Aluminium International Today July August 2023

Volume 36 No. 4 – July/August 2023

Editorial Editor: Nadine Bloxsome

Tel: +44 (0) 1737 855115 nadinebloxsome@quartzltd.com

Assistan Editort: Zahra Awan Tel: +44 (0) 1737 855038 zahraawan@quartzltd.com

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COVER

FAF REVIEW

6 Future Aluminium Forum: Québec City, 2023

13 Tecnar: Real-time monitoring for molten aluminium composition

15 Suspicious minds: Aluminium production in the Amazon

19 ADE Solutions: Smart plants of the future

23 The Haulers’ Evolution

ARTIFICIAL INTELLIGENCE

27 Writing the future of AI to drive digitalisation in the metals industry

THE

31 Aluminium Industry in India

FOCUS

39 India’s potential to increase extrusion production capacity

Cover picture courtesy of PRIMETALS

UK SUPPLEMENT

45 Metals for the future: Creating a circular economy for aluminium

48 50 years of innovation and excellence: Celebrating a milestone anniversary in business

49 BCAST, circularity and aluminium, the upstart competitor

52 Flat Rolling and a 50th Anniversary: Primetals Technologies

ALUMINIUM INTERNATIONAL TODAY is published six times a year by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX, UK. Tel: +44 (0) 1737 855000

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Email: aluminium@quartzltd.com

Aluminium

55 Stress analysis of a structural extruded profile

CRU

60 Sustainability tops the CRU agenda

SORTING

64 Tomra launches Autosort pulse with dynamic LIBS technology

With the recent announcement by Hydro of the world’s first batch of recycled aluminium using hydrogen fuelled production, the shift towards producing carbon-free aluminium is experiencing exciting new developments.

By testing the fuel switch from natural gas to hydrogen and the effects on metal quality, these findings can also be relevant for using hydrogen in primary aluminium casthouses and other high temperature processes, like glass or cement.

Novelis has also recently been awarded £4.6 Million to establish hydrogen burning trials as part of the UK Government’s £55m Industrial Fuel Switching Competition, as part of the £1bn Net Zero Innovation Portfolio (NZIP), and the wider regional HyNet project.

This all ties in nicely with this year’s Greener Aluminium Online Summit which will return on the 7th of September and invites the industry to join virtually to discuss how the industry must continue to adapt, minimising the impacts associated with production of the metal today, while also developing technological pathways for the future.

On the topic of the future, this issue features a collection of articles, kindly contributed by speakers who joined us at the Future Aluminium Forum back in May. There is also a full review of the event and details of how you can be involved in the next Forum, which is planned to take place in Turkey in 2024.

A closer date in the calendar and one that is fast approaching is the UK Metals Expo in September. To celebrate this event being even bigger than last year, there is a full update from the UK sector for you to enjoy!

nadinebloxsome@quartzltd.com

World’s first: Hydrogen fuelled aluminium production

Hydro has produced the world’s first successful batch of aluminium using green hydrogen as an energy source. The test is another step towards carbon-free aluminium.

Carbon-free green hydrogen replaced natural gas as fuel for the recycling of aluminium during the test. The test was carried out at a casthouse in Hydro’s extrusion plant in Navarra, Spain.

“We are excited to be conducting this test and it demonstrates Hydro’s commitment to decarbonization. By removing the car-

bon emissions from the energy source, we will be able to produce carbon-free aluminium from recycling post-consumer scrap,” says Paul Warton, Executive Vice President for Hydro Extrusions.

The test was conducted and led by hydrogen experts from Hydro Havrand, Hydro’s green hydrogen company, in partnership with Fives, an industrial engineering group with expertise in hydrogen burner technology and solutions for the aluminium industry. Fives has contributed with design and

supplying of key components and controls needed to operate safely and effectively.

“This test is part of developing commercial fuel switch solutions and to demonstrate that hydrogen can be used in aluminium production. Green hydrogen can remove hard to abate emissions from fossil fuels, in processes where electricity is not an alternative, both in the aluminium industry and in other heavy industries,” says Per Christian Eriksen, Head of Hydro Havrand.

Novelis to trial use of hydrogen

Novelis Inc have announced that its Latchford plant in the UK has been awarded £4.6 million to establish hydrogen burning trials as part of the UK Government’s £55m Industrial Fuel Switching Competition, as part of the £1bn Net Zero Innovation Portfolio (NZIP), and the wider regional HyNet project.

Novelis joined HyNet in 2017 and has been supporting the development of the regional infrastructure project as well as conducting its own technical feasibility studies

on the use of hydrogen as a direct replacement for natural gas.

“Switching to renewable energy sources is a key initiative to advance on our journey toward carbon-neutral production,” said Emilio Braghi, Executive Vice President, Novelis Inc. and President, Novelis Europe. “Besides decarbonising our own facility, this collaboration drives the industrial decarbonisation of the whole North-West region in UK.”

With the recently awarded grant by the Department for En-

ergy Security & Net Zero, Novelis’ Latchford plant will test the use of hydrogen on one of its recycling furnaces in a demonstration phase in 2024.

“We are proud to be one of the pioneers using hydrogen within the aluminium industry and that these trials at Latchford will additionally advance research on the viability of integrating hydrogen power in our recycling operations around the world,” said Allan Sweeney, Plant Manager, Novelis Latchford.

Hydrogen hype

HAI Group groundbreaking

Rio Tinto to expand smelter

Rio Tinto will invest $1.1 billion (CAN$1.4 billion) to expand its state-of-the-art AP60 aluminium smelter equipped with low-carbon technology at Complexe Jonquière in Canada. The total investment includes up to $113 million (CAN$150 million) of financial support from the Quebec government. This expansion, which will coincide with the gradual closure of potrooms at the Arvida smelter on the same site, will enable Rio Tinto to continue meeting customers’ demand for low-carbon, high-quality aluminium for use in transportation, construction, electrical and consumer goods.

The investment will add 96 new AP60 pots, increasing capacity by approximately 160,000 metric tonnes of primary aluminium per year, enough for 400,000 electric cars. As a result, there will be a total of 134 AP60 pots and a capacity of approximately 220,000 tonnes per annum. Construction will run over two and a half years, with commissioning of the new pots expected to start in the first half of 2026 and the smelter fully ramped up by the end of 2026. Once completed, the expanded smelter is expected to be in the first quartile of the industry cost curve.

This new capacity will offset the 170,000 tonnes of capacity lost through the gradual closure of potrooms at the Arvida smelter from 2024. In addition, Rio Tinto will add 30,000 tonnes of new capacity through the commissioning of the previously announced recycling facility at Arvida in the first quarter of 2025. These facilities will ensure Rio Tinto’s casting facilities at Complexe Jonquière continue to provide value added products that meet customers’ needs, including integrating recycled post-consumer aluminium into primary aluminium alloys.

Alcoa and EGA: Alumina agreement

Alcoa and Emirates Global Aluminium (EGA) have announced a new multi-year agreement for Alcoa to supply EGA with smelter grade alumina.

Over the life of the 8-year agreement, which commences in 2024, volume options will allow EGA to procure as much as 15.6 million metric tons of alumina from Western Australia. The supply agreement will represent a significant portion of Alcoa’s annual third-party alumina sales.

The supply agreement will make Alcoa EGA’s largest third-party supplier of alumina. EGA’s Al Taweelah alumina refinery in Abu Dhabi met 47 percent of EGA’s to-

tal alumina needs in 2022.

“Alcoa operates the world’s largest third-party alumina business with low-carbon processes, and we’re proud to be recognised with this significant additional volume from EGA as a leading global

Alba strengthens ties

Aluminium Bahrain B.S.C. (Alba)’s Chairman of the Board of Directors, Shaikh Daij bin Salman bin Daij Al Khalifa, highlighted the Company’s keenness on strengthening ties with key aluminium producers in the Arab World during a meeting with the Egyptian Minister of Public Enterprises Sector, His Excellency Dr. Eng. Mahmood Kamal Esmat, that was held on 24 May 2023 in Cairo, Egypt.

The meeting – attended by Alba’s Chief Executive Officer, Ali Al Baqali, the Managing Director of the Metallurgical Industries Holding Company Eng. Mohammed Al Saadawy and the Chief Executive Officer of Egyptalum – Egypt’s largest aluminium producer, Dr. Mahmoud Agour – aimed to enhance mutual cooperation and develop potential opportunities for investment in the aluminium

producer,” said Alcoa President and CEO Roy Harvey. “The agreement is the largest alumina supply contract ever signed between Alcoa and EGA will strengthen the long-term supply relationship between our two companies.”

EGA is the largest industrial company in the United Arab Emirates outside of oil and gas, operating smelters in Abu Dhabi and Dubai, an alumina refinery in Abu Dhabi, and a bauxite mine in the Republic of Guinea.

The contract includes options for EGA to choose Alcoa’s low-carbon EcoSourceTM alumina, the aluminium industry’s only low-carbon alumina brand.

Hammerer Aluminium Industries (HAI) has celebrated the official ground-breaking ceremony for the capacity expansion with a 40 MN extrusion line at the Cris site (Romania). The investments in Cris are part of a 125-million-euro investment package for the entire HAI Group.

Automotive part innovation

industry. Alba’s Chairman of the Board of Directors, Shaikh Daij bin Salman bin Daij Al Khalifa, praised the investor sentiment climate in Egypt and welcomed the efforts which will be made on studying the feasibility.

Novelis Inc has announced the start-up of its new roll forming development line. The new development line will help Novelis meet industry demand for a process that can produce large volumes of high-strength aluminium auto parts.

MoU announced

TAHA International has announced it has “deepened” its partnership with Hwarim Tech in signing a Memorandum of Understanding (MOU), aligned with TAHA’s objective of promoting sustainable development within the global aluminium industry and transitioning towards a greener economy.

New UK rolling plant

Diageo has announced that it has provided funding to establish the British Aluminium Consortium for Advanced Alloys (BACALL), a collective of industry experts who will create a circular economy for aluminium in the UK. They will build a plant to roll hundreds of thousands of tonnes of aluminium sheet in the UK, more than enough for over 400 million cans of Guinness and pre-mixed Gordon’s and tonic.

Currently, to recycle and remake cans, the UK is reliant on an energy-intensive supply chain that is based on the unsustainable exporting and importing of aluminium.

The consortium will build an advanced aluminium recycling and manufacturing plant, to establish a new circular economy supply chain for aluminium. This will keep the recycling of aluminium in the UK and cement the UK’s position as a leader in the adoption of carbon reduction and manufacturing.

Once the plant is up and running, the recycled aluminium will significantly contribute to Diageo’s 10-year sustainability action plan by increasing the use of recycled aluminium with Guinness cans made of 100% recycled material reducing the carbon emissions needed to export and import

ASI visits Aludium plant

aluminium sheet reducing the dependency on raw materials needed to create aluminium contributing to a reduction in Diageo’s Scope 3 carbon emissions, as the plant will use 95% less energy in the production of its aluminium sheet versus traditional prime production methods.

SEPTEMBER

13th - 14th

UK Metals Expo

The UK Metals Expo will host the entire industry under one roof. According to Chris McDonald, Chair, UK Metals Council: “Anyone with a career in the metals industry will want to attend, any organisations providing goods or services to this industry will want to be represented.” Held in Birmingham, UK www.ukmetalsexpo.com

OCTOBER

11th - 13th

Inalco 23

During the visit, the Management and Experts of Aludium and ASI discussed and exchanged views about the aluminium value chain’s present and future in the light of sustainable development. Following the meeting and visiting the

plant, Fiona Solomon declared: “The tour provided us with a solid understanding of the processes involved in rolled aluminium production and the aspects of quality and safety that are integrated throughout the facility. The tour has given us valuable insights into the capabilities of the plant and how the policies and processes align with ASI’s goals and certification criteria”. “We were pleased to learn that Aludium has a range of lower-carbon products at levels that are in line with the ASI Performance Standard criteria, and that the company has made transparency of its emissions data a priority. We also appreciated hearing about the company’s setting of targets to reduce average carbon

footprint per ton by 50% by 2025, alongside investments in recycling capacity and efficiency, and plans to increase renewable electricity consumption to 100%,” Solomon added.

On the occasion, Lionel Chapis, Aludium’s CEO, expressed his enthusiasm following the very productive encounter. “We are happy to receive ASI at our plant in Amorebieta. We think it’s important that certification bodies continuously keep contact with the ‘Real Life’. Over the last years we have spent many hours for ASI related aspects and it’s good to see the persons behind this and to have the opportunity for a direct exchange and feedback,” Chapis asserted.

Hydro: Land acquired for recycling plant

Hydro has signed an agreement to purchase land in Torija, Spain, with the aim of constructing a stateof-the-art aluminium recycling plant.The plant will have 120,000 tonnes of annual capacity and around 65 direct employees. The facility will strengthen Hydro’s capabilities to produce low-carbon aluminium and ensure more scrap is kept in Europe.

The agreement has been signed with a subsidiary of the Pulsar Properties Group. The total project

investment is currently estimated to be between EUR 130-140 million, depending on the final facility design, market conditions and macroeconomic development. Hydro aims to make a final investment decision by the end of 2023.

“The European and Iberian market for aluminium continues to

grow. This investment will be an important step towards Hydro’s ambition to recycle more post-consumer aluminium, strengthening our position to capture value from growing demand for greener and circular aluminium,” says Eivind Kallevik, Executive Vice President for Hydro Aluminium Metal.

Organized by the Aluminium Cluster AluQuébec and the Aluminium Research Centre REGAL, this 3-day conference proposes various sessions where the results of recent research activities from all over the world in the field of aluminium constructions are presented.

Held in Québec City, Canada https://event.fourwaves. com/inalco2023/pages

25th - 26th

ALUMINIUM USA

ALUMINUM USA is an industry event covering the entire value chain from upstream (mining, smelting) via midstream (casting, rolling, extrusions) to downstream (finishing, fabrication).

Music City Center, Nashville, Tennessee www.aluminum-us.com

NOVEMBER

7th - 8th

Aluminium Business Summit

The ALUMINIUM Business Summit will be returning for a second round. The event at Altes Stahlwerk in Düsseldorf will be the best place for the aluminium industry to attend keynotes and panel discussions as well as to network. Düsseldorf, Germany www.aluminiumexhibition.com/en-gb.html

For a full listing visit www.aluminiumtoday.com/ events

Future Aluminium Forum: Québec City, 2023

From the UK, Québec is roughly 9 hours and 40 mins away. One attendee told me he flew 20 hours, from China, another flew almost 24 from Australia. The Future Aluminium Forum 2023, held from 10-12th May 2023, welcomed more than 175 delegates from all corners of the globe to Québec City, Canada. Zahra Awan* reports on the event.

Welcomed by the sun, the Future Aluminium Forum opened the doors to its delegates. The forum was structured to begin with an exclusive site visit to the Alcoa Deschambault Smelter.

A select few of the delegates attending the forum were able to visit the site to discover and witness the Alcoa aluminium production process first hand. Visitors to the smelter were invited to walk through all main sectors of the facility, from the anode production plant to the electrolysis area and cast house. Along the route, informative sessions were given to attendees by the smelter

DAY ONE

employees on various topics including maintenance, environment, and energy, as well as shown Alcoa’s Aluminium Center of Excellence. The Deschambault team personally received and directed the tour, allowing for a unique opportunity for the attendees to ask questions. The tour proved successful with the attendee’s feedback being overtly positive, noting the importance of seeing the smelters in the flesh and understanding why conferences and forums are so vital to the industry’s development.

“The Future Aluminium Forum in Québec City was a great meeting. I enjoyed the

presentations as well as the exhibits by pertinent and competent suppliers. The social opportunities allowed me to meet old friends in the industry and meet new, motivated new people with fresh ideas on how to improve our industry. The whole event was well communicated and organized, with an interesting visit to the nearby, impeccable Alcoa plant. Thanks to the organisers for conveying a friendly and positive feel to the activities that made this meeting fruitful for all.” – Pierre Reny Chief Engineer, Hydro.

*Assistant Editor, Aluminium International Today

Following on from the tour was the Future Aluminium Forum Opening Event, hosted by AluQuébec. Located in the centre of the beautiful, historic Eurocentric city, all delegates and associates of the Future Aluminium Form were greeted by Mr Alain Sans Carter, Sous-Minister des Relations Internationales de la Francophonie, who opened the evening with a focus on where the sector now stands: “Aluminium is a metal of the future. It is unique and infinitely recyclable, and it’s been produced in Québec for over 120 years… I’d like to highlight the Québec aluminium development strategy, which enables players in our industry, including the equipment manufacturers here tonight, to accelerate the 4.0 shift, focus on innovation, and showcase our green aluminium.”

Francois Racine, President at AluQuébec followed, stating, “Québec’s aluminium ecosystem is a world-renowned industry known for its expertise and innovations. … The ecosystems biggest strength has resided in its synergy where all sectors work towards a common goal of facilitating aluminium use and promoting it globally.”

After the formalities, the industry reconnected with its experienced members and welcomed its new ones. Anticipating the hubbub, AluQuébec organised a graceful exhibit named the 5th Element. The concept explored nature’s five elements: Water, earth, air, fire, and Québec’s Aluminium!

DAY TWO

With delegates relationships rekindled, and perhaps a bit of fizz to warm the vocal chords, the introductory day set the grounds for a two-day conference. The forum conference focused on the automation and advancement of the aluminium industry.

Opened by Nadine Bloxsome, Editor of Aluminium International Today and Event Organiser for the Future Aluminium Forum, she set the theme which threaded itself throughout the conference sessions: “Sustainability goes hand in hand with efficiency”.

Opening the event were Keynote Speakers from three major aluminium producers in Canada: Rio Tinto, Hydro and Alcoa. The session was opened by Gaby Poirier, Vice President of Operations - North America, Alcoa who discussed the “Spirit of Innovation”, and its importance to the success of the industry in overcoming the challenges we face. He noted that this spirit is one that must continue to grow to progress and succeed beyond company units, and out to the entire industry.

Speaking next was Marie-Eve Pomerleau, Specialist Product Advancement, Rio Tinto, who brought discussions on the circular economy of the industry to the audience, as well as the latest initiatives for Quebec aluminium regarding scrap material and recycling schemes.

Closing the Keynote Session, Pierre Rény, Chief Engineer, Primary Metal, Technology and Operational Support, Hydro Aluminium Canada. He spoke about Hydro’s future for the production of sustainable aluminium, namely on HalZero. HalZero is a new process for the production of primary aluminium. Instead of carbon dioxide, only oxygen is emitted from the process of primary aluminium production, a concept which is in competition with the commonly known ELYSIS.

The next session entitled: Status,

EQUIBRAS

“Everything worked out perfectly, your team is very thoughtful and always available to listen, many thanks!

”

Strategy and Capabilities, started off with a presentation from Jean-Denis Carrier, Global Director - Aluminium, HATCH, who introduced Digital Twins. The use of digital twins also enables the mapping and collection of data, which can be used for future experiments and projects. Quantillion speaker, Hilbrand Kuiken, CEO, noted the importance of data collection with the use of Predictive Intelligence, linking back to the concept of Digital Twins. Quantillion aims to utilise Artificial Intelligence to find the most efficient method for a solution, as well as use the data collect to anticipate and assist in future scenarios.

The third session looked at whether Sustainability & Technology are a ‘Perfect Match’. The speakers for this session were: Adrien Berthier, Decarbonation Project Manager, Aluminium Dunkerque, Linlin Wu, Manager – Statistical Analysis, International Aluminium Institute, and Gunther Schober, Sales Manager, PSI Metals, Non Ferrous GmbH.

Technology, as mentioned by Nadine Bloxsome, goes hand in hand with

sustainability. Adrien Berthier discussed the Carbon Capture Usage and Storage (CCUS), “a breakthrough carbon mitigated for smelters.” Linlin Wu spoke on the possibilities available, across heavy industries, in maximising the use of bauxite residue, in cement. The largest ByProduct presents a huge opportunity for extending the circular nature of aluminium production and sustainable ethics. Finally, Gunther Schober, Sales Manager, PSI Metals, Non Ferrous GmbH, presented on utilising software to optimise efficient energy scheduling to energy availability,

with the target of finding the most optimal solution. All three presenters noted the need for partnership within the industry to address each challenge we face, as well as a partnership with technology.

Closing the day was a session on the Advance of Automation. Technology extends to machinery. This was presented by: Simone Tadiello, Automation Project Engineer, BM Group - Polytec, Malcolm Caron-Boivin, International Business Development Manager, EPIQ Machinery, and Mileidy Hernandez, CPI in Automated Systems - Industrial Computing, WSP Canada. Between the three speakers, they presented the full range of automated machinery available, designed to replace humans in dangerous situations, spoke on how their machinery has transformed to electric vehicles and discussed how autonomous tools, such as WSP’s ADE, is designed to assist the industry shift to Industry 4.0 by providing autonomy to the operation team and centralise all systems into the same interface.

The first day of the conference came to a close, yet the socialising was set to continue. With the sun still shinning, and the balcony doors open, attendees were invited back to the venue for a sit down three-course meal. With opportunities to network throughout the day, the dinner provided downtime and a more casual setting for the industry to unwind.

“The event was well organised, staff were welcoming and dedicated, and the location is perfect!”

THOMAS GARGON, SOFTWARE ANALYST, MAESTRIA

“Overall the event was very good, we had the chance to meet a lot of our business partners”

JEAN- CHRISTOPHE BOUCHEN, BUSINESS DEVELOPMENT, STAS

DAY THREE

We awoke to the final day of the forum on the 12th May.

With a slight change in topic, the forum switched to a focus on Environmental and Social Sustainability. Presenting on Aluminium from the Amazon: Lessons for Sustainability, Simon Lobach, Researcher, Geneva Graduate Institute discussed the need for industries to take more responsibility over their actions. Simon Lobach discussed this in relation to local communities and biodiversity; he called for aluminium industries to change their attitudes towards their impact on native/ indigenous populations and the local environment. The Amazonia presents a number of strengths for the aluminium industry: Aluminium in the Amazonia is fully produced with hydroelectric power and is at the forefront of technological developments for sustainable aluminium, reforestation programmes have been implemented, and the aluminium sector has “significantly improved its relationships in a democratic Brazil.” However, issues as a result of industry still remain a major concern.

The Future Aluminium Forum will be returning in 2024, and will be hosted in Turkey.

Working in collaborating with Turkish Aluminium Association, TALSAD, the event aims to bring together the West and East to discuss and share best practices in automating the industry.

Keep following for more information on how you and your company can take part!

Returning to the topic of automation, was David Roth, Americas Business Representative at RiA Cast House, Andrew Sauerwald, Product Leader - LIBS at Tecnar spoke next on LIBS technology and Jean -Benoit Pineault, MBA CEO at Refraco. Focusing on removing operators from hazardous areas, first mentioned by David Roth, the three discussed how working with automated technology can improve safety of the higher risk areas in a factory.

For example: The implementation of cameras to not only monitor furnace efficiency but also remove an operator from the high temperatures. The implementation of LIBs, which is based on “patented technology from the National Research Council Canada”, to sample metal removes the labour-intensive process, and high-risk factors from an operators role. And automated machinery to remove workers from certain situations.

“Informative speakers, good mix of big industry players, with some smaller businesses too” – George Giles, Regional Sales Manager, Molten Metal Innovation

“

For the first time attending this event and visiting Canada, it was very useful to establish contacts in the industry. Professional, well organised and a well-run event.”

PETER SELBIE, INDUSTRIAL SALES AND MARKETING MANAGER, BRUK TEXTILES.

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950 INSTALLED GLOBALLY

Real-time monitoring for molten aluminium composition

Tecnar is a technology company that takes breakthrough science created in a lab and transforms it into novel industrial products to enhance productivity.

The family-owned company was founded in St. Bruno, Quebec in 1989 by members of Canada’s National Research Council (NRC).

Today, Tecnar still maintains strong ties with the NRC, partnering on new technologies. The company has diversified into four technology divisions: automated pipe and vessel welding, thermal and cold spray sensors, molten metal LIBS analyser and laser ultrasonics. Products based on these technologies can be found in more than 30 countries worldwide among over 500 clients.

The Alulibs advantage

Now Tecnar’s molten metal LIBS analyser division introduces its latest innovation: the Alulibs. This innovation was inspired by the aluminium industry’s need for automated real-time multi-element composition measurements in molten aluminium. The benefits of inline analysis are time savings, efficiency, and worryfree measurements.

All molten aluminium lines must wait for laboratory analysis results before production can continue. Until then, production is idle, increasing downtime. The Alulibs system eliminates the wait for lab results, which can take up to 30 minutes. This saves a plant that conducts around 2,000 analyses annually the equivalent of over 20 days of production each year.

The Alulibs helps increase quality and efficiency by giving operations a better understanding of the melt. For instance, knowing the starting chemistry of a new batch and tracking real-time additions to understand homogeneity time means more efficient material use and less waste due to incorrect additions.

Automating chemistry monitoring virtually eliminates the uncertainty associated with error-prone manual sample measurements. What’s more, automating metal analysis significantly minimises direct contact with molten metal, creating a safer working environment.

The inception of the technology

Tecnar briefly entered the aluminium market in 2007 when it partnered with a primary aluminium company to conduct trials with the Alulibs to automate the chemical analysis of crucibles entering the cast house to quickly sort and direct material. The trial’s goals were to test the validity of the Alulibs in measuring silicon and iron concentrations within a specific range with an accuracy of +/10pmm within two minutes at varying temperatures.

The trial results were successful and achieved all the trial’s goals while proving that measurements were independent of temperature. Discussions turned to a field installation, but the project stalled when operations did not see its value. Tecnar decided not to pursue the project, turning

its focus to the use of the LIBS analyser for galvanizers.

Today, Tecnar has installed over 60 LIBS (Laser Induced Breakdown Spectroscopy) analysers at galvanizers worldwide. We gain knowledge from field experience, improving the design and creating a product trusted for 24/7 operation in the harshest environments. The LIBS is also used in a galvanizing process similar to aluminium production: aluminized galvanizing is 90% Al and 10% Si, with melt temperatures exceeding 700˚C.

Overview of the technology

LIBS is a laboratory method used to determine the quantity of elements in a sample. LIBS is performed by using a laser to produce plasma on a surface and the light produced by the plasma contains

Alulibs-Tecnar

information about the elements present. Collection and analysis of the light and its intensity provide elemental concentration information.

Tecnar’s LIBS design creates the environment for this laboratory analysis to occur beneath the surface of molten metal. This is performed by inserting a ceramic hollow lance attached to our analyser into the melt. High-purity argon is fed through the lance to prevent molten metal from entering the lance and produce a fresh bubbling surface. The analyser then fires the laser down into the bubbles, producing plasma that emits elemental light that travels up the lance to the spectrometer. Tecnar’s software analyses this light, producing a calibrated multielement concentration measurement.

Tecnar’s software has been in development for the past decade, incorporating numerous essential features for raw signal processing. It encompasses data logging functionality and facilitates the assessment of previous events to identify potential production issues. Additionally, the system is compatible with industry 4.0 standards, enabling data transfer from Siemens PLC or Windows industrial HMI. The software operates

on a sequel-server-based PC and can be customised to facilitate data integration with a business network.

Operators have the option to configure a main screen detailing critical elements that need monitoring, along with the desired element concentrations and their acceptable ranges. This main screen also showcases user-configurable historical and future trends, helping operators to understand the evolution of the melt.

The Alulibs has been carefully designed to have a hardware lifespan of 15 years, while the longevity of the overall construction is uncertain but likely to surpass that timeframe, given the existence of operational units. Emphasising durability, the device has been engineered with a focus on minimising the need for preventative maintenance and spare parts, ensuring longevity and reliability.

In field development

In March 2021, Tecnar installed its first new generation Alulibs at a US-based secondary aluminium producer that produces a wide variety of cast alloys. The Alulibs is currently measuring 11 elements at varying concentrations. The system was installed at a bump out of the

furnace and is still operating today. Since it was installed, the system hasn’t required recalibration and still shows the same signal strength as it did at start-up.

This year, another Alulibs installation will be carried out in collaboration with a European aluminium producer. Tecnar has designed a long lance option specifically for this installation, enabling a through furnace wall installation. The extended lance option will be available once field testing is successfully concluded.

In both the in-field installation and the blind experiment, the Alulibs was bench tested against the client’s lab. This comparison allowed us to see how well we were aligned with the current analysis.

Alulibs in the future

As we introduce more Alulibs to the market, we plan to develop more features that will provide the industry with more knowledge about their molten aluminium. In the future, our goal is to expand the concentration ranges for all heavily produced alloys, provide easier calibration with an automatic calibration unit (already developed with Galvalibs) or a single-point calibration and become a certified analyser of quality assurance. �

Suspicious minds: Aluminium production in the Amazon

By Simon Lobach*

The Amazon region in South America extends over nine different countries. It contains vast bauxite deposits, which have been exploited since 1915. During the Second World War, Suriname – then a Dutch colony – was the largest bauxite exporter worldwide, helping the Allied aircraft industry to victory. Aluminium has been produced in the Amazon since the late 1960s, when the first hydroelectric dam was built in Suriname.

In the context of a several-year PhD research project, I have looked at the past and present of aluminium production in the Amazon, and assessed this industry from the perspective of this very fragile and ecologically essential ecological biome. To provide insights into the environmental performance of aluminium production in the Amazon, I performed a SWOT analysis, citing three strengths, three weaknesses, three opportunities and three threats for the industry. This SWOT analysis concerns the full supply chain of primary aluminium, including bauxite mining, alumina production and hydropower generation,

besides aluminium smelting.

Five aluminium smelters exist in the Amazon, but only two are currently active. These two are located in the Brazilian Amazon: Albrás in Barcarena (Pará), operated by Norsk Hydro, and Alumar in São Luís (Maranhão), operated by Alcoa. The aluminium smelter in Paranam, Suriname, is permanently closed, while the two aluminium smelters in Venezuela (Alcasa and Venalum, both in Ciudad Guayana) are only producing a fraction of their original capacity, if they produce anything at all. The SWOT analysis below is therefore primarily concerned with the two active smelters, both in Brazil.

Strengths

� Aluminium in the Amazon is produced with hydroelectric energy. As a result, aluminium production in the Amazon emits much less CO2 than most of the newer aluminium smelters that have been built since the 1990s. And, while early hydroelectric power projects, like Brokopondo (Suriname) and Tucuruí

(Brazil) still had very considerable socioenvironmental impacts, the more recently built Belo Monte hydroelectric dam is designed to have a smaller impact on the environmental functioning of the river and the lands of traditional populations.

� The companies active in the Amazon (Hydro, Alcoa) are among the frontrunners in reducing the environmental footprint of aluminium production. This can be concluded from the reforestation projects that both have implemented at bauxite mining sites, alumina plants, and aluminium smelters, but also from technologies like the dry tailing management implemented in Hydro’s bauxite mine in Paragominas, and the bauxite slurry pipeline running from Paragominas to Barcarena.

� Whereas community relationships of aluminium producers in the Amazon have been heated and difficult in the past, aluminium companies are increasingly taking their responsibility towards affected populations, through social projects and emergency assistance.

*Centre for International Environmental Studies, Geneva Graduate Institute (Switzerland)

Fig 1. Industrial development in the Amazon has chased hundreds of thousands of people from their lands. These people cannot always find another suitable spot to live, farm and fish. Photo: Author, 2023.

Weaknesses

� This relationship with affected communities is also a weakness. Since the beginning of bauxite mining in the Amazon, aluminium companies have ignored property rights of traditional populations. This was possible because property rights in the Amazon function in different, more informal ways, than in the companies’ countries of origin. Thousands of people have been displaced from their ancestral lands where they farmed, fished and lived, in order to make way for bauxite mines, and later for industrial facilities, harbours, and reservoirs for hydroelectric plants. Many of these people are still living close to the production facilities, and if they have not taken up alternative, more polluting activities in order to survive, many of them still claim compensation for what they have lost. Fig 1

� The aluminium sector was one of the ‘first movers’ into the Amazonian space, meaning that the industry built roads and power lines into areas where none of these existed before. While presented as vehicles for progress and development, such roads and power lines also opened forest areas to other sectors, like logging, cattle farming, gold seeking, etc. Especially around the hydroelectric plants that were built exclusively to power aluminium plants,

large-scale environmental destruction can be observed, caused by other actors that were inadvertently given access to these areas. Fig 2

� As the Amazon is a rather flat region, the hydropower produced in the Amazon is not particularly efficient in terms of the amount of territory flooded for each additional unit of electricity. The large reservoirs in the Amazon produce rather small amounts of energy when compared to reservoirs in mountainous regions elsewhere. Furthermore, these reservoirs have flooded extensive forested areas, which functioned as carbon sinks before. Since the forest cover was not removed when the dams were constructed, these rotting forests continue emitting methane, a much more powerful greenhouse gas

than CO2. As a result, one could put some question marks at claims of hydropower in the Amazon being a ‘green’ energy source. Fig 3

Opportunities

� Opportunities abound in the Amazon for companies willing to genuinely improve local environments and living conditions, but they need to adopt a more holistic view to make a positive impact. Amazonian populations are strong and resilient, and their environment provides them with many livelihoods. Their problem is not poverty, but threats to their lands and environmental assets. Insufficient levels of governance, weak institutions and inadequate monitoring play a crucial role herein. Companies that extract riches from the Amazon and wish to return something to the region should not focus on community projects only, but also help improve the overarching institutional structure. This would enable Amazonians to look after their own interests, so they won’t need to depend on charity work any longer. In order to

Fig 2. The hydroelectric plant at Tucuruí was built specifically to power the aluminium smelter in Barcarena. Back then, it was built in the middle of the forest. Currently, the entire area around the reservoir has been deforested, with the exception of two Indigenous reserves. Source: Google Maps, 2022

Fig 3. The rather shallow reservoirs in the flat Amazonian lands cause hydroelectric dams here to be rather inefficient, while the drowned forest continues emitting methane for decades to come. Photo: Ted Sun, 2020.

Fig 4. Amazonian soils provide people with many opportunities for farming, but in order not to exhaust the soil, it is done in a circular fashion. Photo: Author, 2020.

achieve this, aluminium companies in the Amazon should cooperate much more closely together with environmental agencies within governments, and be open to learn from social scientists and research institutions in the region as well as abroad. Fig 4

huge waste problem in the Amazon. This is due to failing waste collection services, while the very substantial rainfall and the fluctuating water levels enable garbage to make its way into ecosystems very quickly. Aluminium, in the form of beverage cans for example, is an important contributor to garbage in the region, but aluminium waste, if collected at all, is currently shipped to far-away recycling plants. Aluminium companies could take up an important responsibility dealing with aluminium and other waste in Amazonian cities.

Threats

� A major threat caused by aluminium production is ‘red mud’ deposition in the alumina production stage. Over the past twenty years, several accidents have occurred with red mud leaking into streams and rivers. The resultant water pollution and loss of soil fertility have direly affected local communities.

� The monitoring of dangerous substances, like red mud, often stops after an industry has left a country. This may not be on anyone’s mind in Brazil today, but sooner or later alumina production will stop here, and it may become unclear who should be responsible for the management of these toxic basins after that, especially if the state lacks the capacity to take this responsibility. The cases of Suriname and Venezuela have taught us that such a moment may arrive sooner than anyone expects. Fig 6

� Finally, the very difficult historical relation between aluminium industry and traditional populations constitutes a major threat. There is a threat in terms of reputation, as affected communities have become increasingly vocal to bring their concerns to local and international audiences. But discontent can also constitute a physical threat, as the Surinamese case shows, where the power lines linking the hydroelectric dam to the aluminium smelter were blown up by a collective of people whose lands had been flooded by the reservoir. Repairing this relationship is an absolute necessity, because, as Elvis Presley sang, “we can’t go on together with suspicious minds”.

� The arrival of foreign companies in the Amazon is normally defended with reference to the supposed ‘progress’ and ‘development’ they would bring. Many Amazonians hope to be employed by these companies. The aluminium industry has not yet fulfilled this promise. A major problem of the aluminium industry is that it is energy-intensive, not labour-intensive, while the Amazon is a region that is poor in energy resources but in need of jobs for the many people who for numerous reasons have been displaced from their lands. For this reason, the aluminium industry could make a difference by not only producing aluminium ingots in the Amazon, but also erecting industries for consumer products. In doing so, a leading principle should be to maximise the number of jobs created, while providing the necessary training so that, rather than attracting more in-migration, an Amazonian workforce can take up these opportunities.

� Another opportunity is linked to the

While security of red mud deposits has improved significantly since then, red mud deposition still needs continued close monitoring to prevent it from threatening local populations again. The Amazonian torrential rains, exacerbated even more by climate change, amplify the risks of basins overflowing. Fig 5

Overall, the aluminium industry in the Amazon is moving towards increasingly sustainable practices. However, challenges remain that are of extreme importance for local populations. There is a dire need for stronger community relations, mitigation of unintended environmental consequences, and responsible waste management. By seizing opportunities to enhance the region’s well-being and livelihoods, the industry can contribute to sustainable development in the Amazon. It has taken the first steps in this direction, but much remains to be done. �

Elements of this research were funded by the European Research Council (grant 950672).

Fig 5. Storm clouds gathering above Hydro’s Albrás-Alunorte complex in Barcarena (Brazil). Heavy rainfall compounds the risk of red mud basins overflowing or leaking into the many river and streams, on which locals depend. Photo: Author, 2022.

Fig 6. The smelter in Paranam, Suriname, owned by Suralco/Alcoa, closed in the early 2000s. Who will take care of cleaning up the rustbelt and the red mud deposits? Photo: Author, 2022.

ADE Solutions: Smart plants of the future

By Mileidy Hernandez*

In 2021, the demand for primary aluminium reached an estimated 68.7 million tonnes, which is an increase of 8% compared to 20201. This growth is part of a larger trend, as world aluminium demand has grown at an average annual rate of 5% between 2012 and 20212 Aluminium smelters must adopt Industry 4.0 to meet demand. The transition to smart manufacturing can be challenging due to complex operations and critical equipment, but integrating advanced technologies and digital solutions can improve efficiency and productivity.

WSP’s Advanced Development Environment (ADE) helps aluminium smelters transition to advanced manufacturing. It provides a comprehensive range of functions for developing, testing, and maintaining automation systems, integrating control, visualisation and communication to improve industrial process efficiency.

ADE is the foundation of a smart plant, offering real-time data analysis that reduces downtime and increases output quality. By logging all actions, ADE enables factories to optimise operations, increase efficiency, and remain competitive.

Learn how ADE can help your aluminium smelter achieve operational excellence and transition to Industry 4.0. Discover key features and real-world examples of improved operations. Become a smart plant, reduce costs, and increase efficiency with ADE.

ADE Solution in terms of industry 4.0

ADE is the foundation of smart plants, enabling aluminium smelters to use new technologies to improve industrial processes while reducing costs and waste. It fills gaps left by humanmachine interface (HMI) software and programmable controllers3, providing a comprehensive solution with added functionalities. ADE offers a structured environment based on a library of “AddOn Instructions,” with corresponding HMI faceplates and objects4

Productivity Aspect

One of the key benefits of ADE is that it reduces the number of alarms,

enhancing normal operations, increasing productivity, and improving efficiency. It also eliminates cascading alarms for quicker problem detection, identification, and resolution. In addition, ADE “ensures complete operator autonomy by providing maximum information on the operator interface5” enabling informed decisionmaking without relying on external sources. This is crucial for aluminium smelters where quick decisions based on real-time data are necessary for a smooth production process. Centralising all systems on a single interface6 with ADE provides a comprehensive overview of operations, simplifies identifying areas for improvement and implementing changes on a single platform for quicker and more efficient processes. This improves overall performance and maintains a competitive edge.

Quality Aspect

ADE’s advanced monitoring and analysis capabilities allow companies to quickly identify equipment failures and other issues, reducing the risk of costly production errors and downtime. ADE’s centralised interface and failure analysis tools provide operators with maximum information and autonomy, enabling them to diagnose and resolve issues more quickly and efficiently. Moreover, the process control PID loop function incorporated in ADE plays a crucial role in delivering high-quality products. Several advanced control features enhance the quality of production, resulting in fewer errors and reduced waste. By reducing waste and enhancing quality, companies can save on raw materials and energy costs, while simultaneously boosting their overall efficiency.

Security Aspect

ADE brings numerous benefits to the aluminium smelter industry in terms of Industry 4.0, not least of which is improved security. ADE employs systemwide global management to ensure that

all actions are secured, and users can only access equipment in read mode when navigating beyond the boundaries of their responsibility7. This is achieved through three concurrent restriction levels:

1. Security based on user group.

2. Security based on sector or department.

3. Security based on operator station. This multi-layered approach provides enhanced protection against unauthorised access and ensures that critical operations are only accessible by authorised personnel.

Sustainability of Industrial Processes Aspect

The ADE’s advanced PID plays a fundamental role in optimising industrial processes. Initially developed to provide advanced process control with Allen-Bradley Control Logix, the PID has evolved to become a standard product with all the functionalities required for different ADE-supported platforms.

The PID’s optimisation capabilities enable industries to maximise the efficiency of their processes while minimising energy consumption. ADE PID features allow for a straightforward and comprehensive handling of cascading loops therefore considering process limits and unusual operating modes. Also, built-in external reset feedback allows for deadtime compensation, optimal loop synchronisation in override control schemes as well as other advanced control strategies. Moreover, an alternate PID algorithm is available to handle intermittent process signals. Increasingly, results from lab testing are used as process variables for closed-loop control which is often essential for advanced product quality control. Such signals are typically updated a few times per day or, at best, a few times per hour and require a dedicated PID algorithm which can be enabled on any PID loop with a single click

* CPI in Automated Systems - Industrial Computing at WSP in Canada

in ADE. By optimising processes, industries can reduce their carbon footprint and contribute to a more sustainable future.

Traceability and Accountability

ADE provides traceability and accountability for industrial settings, particularly factories. Complete records of all actions taken in the factory are logged in ADE to ensure safe and efficient production processes. This includes operator commands, parameter changes, and PLC logic-initiated actions. ADE also logs all alarms and events. This level of traceability helps factories quickly identify and correct issues, and provides valuable data for optimising operations. Analysis of the logged data helps identify areas for process improvement, resulting in increased productivity.

Reducing Cost Aspect

ADE uses advanced technology to provide powerful tools that streamline

operations, reduce costs, and extend the life of factory machinery. This allows factories to avoid purchasing new equipment and save money by optimising and modernising existing machinery using ADE.

ADE’s pre-configured functionalities offer key advantages to factories, including security, navigation, configuration, and more, without requiring additional resources or development time. This streamlines the development process, saves time and money, and includes analog and digital inputs, process control functionalities, group start/stop management, and code generator, all working seamlessly to optimise operations and reduce costs.

The advantage of ADE in terms of cost reduction lies in its ability to allow operators to solve problems independently during production. For instance, if a non-critical

equipment whose process has already been established that it can be bypassed fails overnight, operators can bypass it via the HMI without calling an electrician, ensuring continuous production and saving costs. The next day, electricians can easily understand the bypassed equipment thanks to ADE’s HMI graphics, clearly listed and visually displayed, making a significant contribution to the aluminium smelters’ bottom line.

Real-world applications

ADE provides an efficient approach to Industry 4.0 tech implementation, as demonstrated by in WSP’s project for an aluminium smelter. ADE consolidates the factory’s systems, enabling better communication and memory capabilities. This enables the implementation of IoT, AI, and data analytics, improving efficiency and productivity. ADE streamlines communication to just two channels, providing a solid foundation for future growth and innovation. Figs 1 and 2

The first ADE project was very successful, yielding impressive results such as scan time optimisation, data standardisation, reduction of nuisance alarms and a unique multi-resolution feature that allowed for mobile tracking. These results demonstrated the potential for future implementations. Fig 3

ADE’s recent project for a paper mill factory resulted in decreased downtime, fewer false alarms, improved equipment usage, and extended equipment life. This success highlights ADE’s potential to improve productivity in industrial settings. Moreover, this case study demonstrates the versatility of ADE’s technology, as it can be successfully implemented in several types

1. Natural Resources Canada. (2023, February 24). Aluminum Facts. Retrieved from Government of Canada: https://natural-resources.canada.ca/our-natural-resources/minerals-mining/minerals-metals-facts/aluminum-facts/20510. 2 (Natural Resources Canada, 2023). 3. WSP Canada Inc. (2018). ADE – The Solution for an Integrated System. Brochure. 4. (WSP Canada Inc, 2018). 5. WSP Canada Inc. - Smart Industry. (2018). Advanced Development Environment (ADE). PowerPoint Presentation.6. (WSP Canada Inc. - Smart Industry, 2018). 7. (WSP Canada Inc. - Smart Industry, 2018)

Fig 1. Aluminum smelter Network Architecture prior to ADE

Fig 2. Aluminum smelter Network Architecture with ADE

Fig 3. Case-Study ADE, Logging industry

of factories, regardless of their specific manufacturing processes. ADE’s ability to adapt to different industrial settings and provide exceptional results demonstrates its potential to revolutionise operations across a wide range of industries. Fig 4

Summary

WSP’s ADE is a crucial tool for aluminium smelters shifting to Industry 4.0. It reduces alarms, centralises systems, and ensures complete autonomy which can improve efficiency, boost productivity, and maintain competitiveness.

ADE has advanced monitoring and analysis capabilities to track faulty equipment and improve output quality. It eliminates PLC program interventions, and features advanced security functions to reduce errors and oversights, ensuring reliability and efficiency. ADE also offers real-time data collection and analysis, leading to sustainable industrial processes, improved productivity, reduced downtime, and increased savings. It optimises operations and ensures competitiveness in a dynamic market.

Aluminium smelter factories can benefit from adopting WSP’s ADE for increased efficiency, reduced downtime, and

improved profitability. �

References

Natural Resources Canada. (2023, February 24). Aluminium Facts. Retrieved from Government of Canada: https://naturalresources.canada.ca/our-natural-resources/ minerals-mining/minerals-metals-facts/

Discover

aluminium-facts/20510

WSP Canada Inc. (2017). ADE - The Solution for an Integrated System. Marketing Brochure.

WSP Canada Inc. (2018). ADE – The Solution for an Integrated System. Brochure. WSP Canada Inc. - Smart Industry. (2018). Advanced Development Environment (ADE). PowerPoint Presentation.

Gain a leading edge in aluminum recycling with our in-house developed XRT and Dynamic LIBS sorting technology. Designed to maximize purity and yield, our sorting systems ensure a quick return on investment.

Fig 4. Case-Study ADE, Logging industry

The Haulers’ Evolution

By Malcolm Caron-Boivin*

There are many discussions within the industry regarding the restructuring and establishment of standards to promote the decarbonisation of aluminium production. Important initiatives are deployed to reduce the overall environmental footprint of the industry across the value chain and emerge from close collaboration between smelters, customers, suppliers, equipment manufacturers, employees, and the community.

The enthusiasm that comes with the industrial drive towards net-zero emissions goes to show that aluminium and equipment manufacturers have a pivotal role to play. This is why we, at EPIQ Machinery, decided to develop a new fully electrical motorisation for one of our existing MECFOR tractor model, the MTA30. Timing is right; this initiative is supported by our customers and governments and the prototype is already planned to be tested in real operation environment.

Follow the ‘green’ brick road

The International Aluminium Institute identified three pathways to reduce greenhouse gas emissions (Aluminium Sector Greenhouse Gas Pathways to 2050, 2021):

1. Electricity decarbonisation by using clean energy instead of fossils fuels: The aluminum sector currently produces 1.1 billion tonnes of CO2, and more than 60% of it is from the production of electricity consumed during the smelting process. The opportunity is big there.

2. Direct emissions potential: Emissions from fuel combustion make up 15% of the industry’s emissions. A little bit less then the previous one, but still significant. Of course, this is exactly where the electrification of diesel solutions is going to help.

3. Recycling and resource efficiency: By increasing collection rates to near 100% as well as other resource efficiency progress by 2050 would reduce the need for primary aluminium by 20%.

Aluminium is turning green and big players are leading the way. Many of

our customers have set ambitious goals to achieve net zero emissions by 2050. EPIQ MECFOR has chosen to embrace the challenge and is working in offering equipment to reduce direct emissions.

From Diesel to Electric Hauler

EPIQ MECFOR haulers are criss-crossing halls of primary aluminium smelters for more than 25 years, cumulating over 100,000 hours of operations. With 100+ haulers in operation, hauling different types of trailers with the same attachment system, we figured that our customers already own a lot of spare parts for them, and not to mention that their teams of operators are well-trained making them extremely efficient and accustomed to the way it drives and the way it maneuvers.

Plus, our haulers have gone through several iterations based on customer’s feedback and the expertise developed along the way. It was inconceivable for

EPIQ MECFOR to start designing from scratch. That is why the decision was made to use the same overall design, so most components remain the same (cabin, frame, wheels, operation approach, etc.), except anything related to the motorisation. From the outside, it will be difficult to make the difference; the revolution is from the inside.

This approach will also allow our customers to perform the Anodes or Molten Metal crucibles hauling operations about the same. The vehicle will have the same dimensions and manoeuverability. Pick-up and drop off locations of the payloads can be kept the same. It is an articulated model, it can be coupled to any existing trailers, and future EPIQ MECFOR trailers can be built using the same design, no engineering needed to adapt.

In its portfolio, EPIQ MECFOR has two tractor designs: MTA (narrow) and MTC (large). The Engineering and Design team is currently designing the prototypes of

*Eng., International Business Development Manager, EPIQ Machinery

EPIQ MECFOR Diesel engine powered Anode hauler

the MTE – the electric version – based on the MTA30. The team has started to instrument existing vehicles that are in operation in customers’ plants. Data is collected and analysed to determine the duty cycle of a hauler in operation. That way EPIQ MECFOR can make sure the tractor has the right autonomy and charging time to be integrated in a smelter’s operation seamlessly.

Multifaceted challenges: two key elements to consider

There are multifaceted challenges to this decarbonisation process across all levels. The transition to ‘green’ energy Anode Haulers requires facility modifications (e.g.: charging station) along with new skills for maintenance teams. The same maintenance team that has been working with diesel fleets will now have to develop a brand-new expertise with electric vehicles: maintaining high voltage batteries, electric drives, charging stations, etc.

Hauling anodes may seem simple. However, when we take a closer look at the operating environment of aluminium producers, we quickly come to understand the complex challenges that comes with operating electrified haulers in this environment. The involvement and the cooperation of the end-users, aka the aluminium producers, is necessary.

a. Analysis of vehicle usage

The first key element to consider is the analysis of vehicle usage. This is what we are doing at the moment by instrumenting existing vehicles. However, we cannot use that data for any plant, as every operation is different, from facility to facility, and even from an operator to another.

Type of driving. We have jacks on the articulation that provide steering to the vehicle. This can take a lot of energy. The way you drive, and steer can have a lot of impact on the autonomy.

Acceleration and deceleration. If you have an operator that tends to put the pedal to the floor every time he or she wants to move forward, that’s going to affect and drain a lot more energy than a smooth ramp up. Speed management is important; when and where you are going to reach top speed, optimal speeds in function of distances to travel, etc.

Duty cycle in a shift. Several shifts need to be studied to provide the right solution and maintain the same operation as with a diesel fleet. Operators also need to be prepared to adapt the way they drive. Even with electric city buses, operators need to go to through a whole training to ensure vehicles are operated the same way by different operators. Instrumenting also allows to monitor and log the way it

is being operated.

b. Analysis of work processes and practices

The second key element is the analysis of work processes and practices. A transition strategy needs to be defined to make sure it is seamless, and it doesn’t impact production.

Choice of charging strategy; are we swapping battery packs, having a charger on board, chargers outboard? Where do you put the chargers to optimise operations, at pick-up and drop off locations? How many of them? When are you charging? This needs to be studied at the very beginning of the project and can all be simulated using real operational data from instrumented vehicles to ensure precise results.

Are we switching to a 100% electric haulers fleet or are we doing it gradually? A hybrid fleet might be a good approach for now until battery technology, which evolves extremely rapidly, improves.

Vehicle maintenance plan needs to be considered as it is very different than a diesel fleet: less maintenance, but a different type. Limitations due to space constraints, for charging stations and parking spots need to be well-thought.

The conversion goes further: from electric rigid hauler to AGV

Back in September 2022, EPIQ Machinery announced its partnership with DTA S.A., a Spanish company. DTA’s core business is to deliver heavy-duty and tailored made AGV solutions. EPIQ, in cooperation with, is working on a non-articulated singlehulled electric model. This rigid design could be more easily converted later in AGVs. Our prognostic is that, once the transition to electric equipment is well underway, some producers will be ready to step up with auto guided haulers.

Based on what we’ve seen so far with AGVs in the aluminum industry, customers are not yet ready to go with a fully autonomous solution. The great

thing about the rigid electric design is that it can be converted into an AGV later if wanted.

The cabin can be removed or not to maintain a hybrid operational mode during the transition. Being electric, it has low maintenance, longer lifetime, it is very compact and has innovative traction allowing more flexibility, multidirectional steering allowing crabbing (side movement), which offers great manoeuvrability in limited spaces.

EPIQ and DTA will deliver and put in operations their first rigid electric hauler project by end of this year.

Once the risks mitigated, the industry will be in a reassuring position to shift to full AGV solutions that will allow the optimisation of human resources, which are getting scarcer, towards value added tasks (less repetitive). Also, AGVs will enhance safety in harsh operation environments using natural navigation. This type of navigation prevents from extensive infrastructure modifications (wire, paint lines, heavy-maintenance reflectors, etc.) It is connected to a stateof-the-art fleet management which is fully integrated to the plant management system.

Today’s talk of the town: Industry 4.0 All of this can be fully integrated to the whole 4.0 solution. EPIQ vehicles, autonomous or not, can-do real-time data gathering which includes but are not limited to localisation and traceability of the payload, fleet management, live monitoring of equipment health, predictive maintenance, etc.

The order management of the AGVs would be integrated to the plant control system (MES, ERP, etc.) allowing data gathering and management.

We can also imagine in a near future the ability to treat this data with AI to optimise production. In short, converting heavy-duty mobile equipment from diesel to electric is a step further to a new technological era. At EPIQ, we’re in. �

Battery charging Station

AUTONOMOUS CHARGING & SKIMMING MACHINES

Writing the future of AI to drive digitalisation in the metals industry

Exhibiting at METEC, GIFA, ThermProcess, and NewCast, ABB’s Frederik Esterhuizen** and Tarun Mathur*** spoke with Zahra Awan* on the development of Artificial Intelligence (AI) tools for the metals industry and how they are implemented. The global technology leader also described some of the decarbonisation challenges facing the sector and how they may be overcome by working together.

“Decarbonisation is a target across the whole metals industry, but also within ABB’s manufacturing sites and facilities. We have a responsibility to lead by example, focusing on our customers, our supply chain and ourselves.”

- Frederik Esterhuizen

What is the position of AI in the metals industry, what is the current uses, and how is it beneficial to the industry?

Tarun Mathur (TM): Industry 4.0 is making an impact across many industries, including metals, through aspects of operational excellence, process performance, asset performance, sustainability and connected worker, all underpinned by cyber security. Looking at a customer’s digitalisation journey, big data and AI have become more significant if you look at the maturity of the metals market today. Even five years ago, only 10-20% of the industry was connected. Most producers had some automated systems, but they were working in silos. Since then, there has been a transition where these islands of automation have been broken down, pieced together or replaced to create either an edge or a cloud where all the data can be stored, accessed and shared, enabling gains in productivity, quality and yield. It means that an industry traditionally known as conservative has taken a big and important first step. We have now seen, in the last two years, more AI applications relevant to the industry.

It is still a new area, but the potential is immense. We have more and more unrestricted or available data from across customer sites and the wider industry. Large organisations like ABB can also help to leverage big data from across the many industries we serve, adopting from others and working together. For any organisation, greater certainty of future conditions is valuable and AI can improve that forecasting.

Do you think that AI and automation has a role in combatting industry specific workforce issues?

TM: It’s well known that workers are reaching retirement age and working beyond because companies cannot lose their experienced, knowledgeable people. This is unsustainable and the use of AI and automation can help retain information for the next generations. ABB is exploring the implementation of an app for connected workforces. AI as an assistant can go some way to addressing metals industry challenges.

What does ABB do regarding AI in the metals industry?

TM: ABB is investing in AI applications across many industries. For us, in the metals industry, workforce is one area with tremendous potential to grow. We have built AI packages starting from the upstream stock yards, through pellet plants, into the steel melt shop, and then the downstream rolling mills. The applications will improve the operations or improve the asset reliability or the overall performance of the plants.

Frederik Esterhuizen

Tarun Mathur

At the recent ESTAD conference, which took place in conjunction with the METEC fair, ABB presented on the topic ‘The Role of Artificial Intelligence in Digital Transformation of the Steel Industry’. We outlined some of the tangible ways AI applications can optimise energy purchase and production including at site power plants and turbines. It can lead to more efficient energy use and improved electricity procurement forecasts, with difference of 10-15% compared to alternative solutions. Data and optimisation modelling and rule-based energy management algorithms can lead to optimised energy consumption and energy security in operations.

Frederik Esterhuizen (FE): At ABB, across the process industries, we have examples of customers choosing to use our Collaborative Operations Center, based in India, where we serve our global network 24/7. This deploys AI to help predict any future failures or potential maintenance issues, as well as pinpointing where the initial fault occurred, which makes it easier for the operator to find

Do you have any examples of the implementation of AI in the aluminium industry?

TM: Some of the best examples of AI applications relevant to aluminium are sustainable energy management. To optimise energy use, you need to forecast requirements better. Here, machine learning applications (ML) of AI are much more advanced. Progress is being made, but further work must be completed to gather enough data and measurements from cycles of batches to successfully forecast energy consumption. If you can forecast your energy requirement on the demand side as well as on the supply side, and if you are connected to the electricity market grid, you can have a good decision-making system to optimise your energy purchase and minimise energy consumption.

Before the digital solutions can be added into the process, there must be a solid automation layer. This is where we rely on the constantly evolving ABB Ability™ System 800xA distributed control system (DCS). We know that it has been independently verified as the world’s No. 1 DCS for more than 20 years for its capabilities of networking, controlling and collaborating across plants or enterprises. Now with AI and ML, the massive amounts of data generated by the DCS can be analysed better to help

it. It is about building up a bank of cases and learning from the data over time for process improvements. We can connect multiple locations of the same customer to one set up, enabling improved endto-end production visibility and therefore better decision making.

In metals, we can learn and conduct simulations on different scenarios because we have the ABB Ability™ Data Analytics

Platform for metals in place. It offers plant and enterprise-wide data integration, monitoring, data analytics and optimisation from one feature-rich and fully scalable, vendor neutral platform. It brings together the islands of automation we spoke about earlier and devices into one powerful resource with applications for performance optimisation.

customers to increase production efficiency, predict problems and extend asset life. Process automation and control are key to high-performance metals manufacturing and a prerequisite for digitalised, optimised and sustainable operations. With this in mind, ABB has developed a range of solutions specifically aimed at aluminium manufacturers. Notable examples include ABB’s control loops for eccentricity and hardness compensation at Alunorf’s two-stand aluminium cold rolling mill in Germany. Two further examples of ABB’s commitment to pushing the boundaries of digitalisation and automation in the aluminium space include ABB Manufacturing Operations Management for metals which is being used to connect the mine, refinery, smelter and rolling mill at the world’s largest fully integrated aluminium plant; while the company’s flagship ABB Ability™ System 800xA distributed control system (DCS) is deployed at the record-breaking two-strand vertical continuous caster at Dillinger Hüttenwerke AG in Germany.

The implementation of AI requires a balance between skilled professionals and digital solutions. Do you think some knowledge will ultimately be lost in the industry?

FE: ABB is a technology partner to the metals industry, where you can genuinely make a difference and an impact in the world using the latest digital tools and solutions. To support the industry of tomorrow, covering the need for electrification, automation and digital solutions, we are working with the foremost industrial players to innovate new solutions, as well as in upskilling and talent sourcing. Diverse perspectives and ideas enable us to learn, grow, and reach greater goals. That is why our priority is to provide interesting career opportunities that helps to attract the right talent mix. We are seeking skilled professionals, including the younger generation, with competence in areas such as data science, analytics and sustainability.

Factory acceptance tests (FAT) have been carried our remotely using guidance systems from VR and AR, and with the backup of our experts around the world. Where applicable, this avoids flying workers long distances to isolated locations to reach customers. We have all the data available and access to the FAT on the site. There is an understanding on both sides that the technologies are here for people to work in their preferred location yet impact operations in the mill.

What is ABBs view on the future uses of AI?

TM: AI and ML are under a broad umbrella of physical and virtual technologies. They are only as good as the available data and, in my opinion, some parts of the metals industry are not currently ripe for reaping the benefits. For example,

measuring the temperature of molten metal at such high temperatures cannot be done continuously with the equipment and technologies available today. We must work with a careful blend of digital tools and automated tools, backed by

Do you think there should be limitations/regulations on AI?

TM: People often speak about 100% autonomous factories, but the current reality is we need people, whether that’s on site or in a remote central location. There’s a mutual understanding in the metals industry that technologies can help make the impacts needed for people to reach company goals and global, wider societal

targets around energy and emissions. It’s a balance between accuracy, the product and safety. When you implement AI, you improve the accuracy, but humans have their intuition and deeper expertise on working practices, including safety, which cannot be replicated in AI, yet. AI can, if not adopted well, view

We continually devise solutions for remote operations, and these have the added benefit in sustainability. Experts are now typically available in central locations covering a number of customer mills. Taking ABB Ability™ Performance Optimization Service for cold rolling mills as an example, ABB offers customers an enabler to combine process-specific algorithms with real-time continuous monitoring and remote support from ABB experts. It’s one advanced digital service that shows the direction the industry needs to go to reach new levels of operations.

operators and experts in the field. ABB is focusing on assistive AI, helping the workforce to extract more productivity, quality, yield, and of course data. We can see a future with many more possibilities as we improve together.

production as its only target and disregard safety, relationships in the workplace and social sustainability factors. AI must stay onside as an assistant to humans as every company must consider the purpose behind using these tools, which is often to improve the world for people to live and work in now and in future generations.

India is a powerhouse

The nation has more people than any other country. India is the seventh largest sovereign country by area. It has one of the five largest economies in the world.

India is a major producer and user of aluminium and related products, including the three major aspects of the aluminium industry – bauxite mining, production of alumina, and primary aluminium manufacturing.

The Department of Economic and Social Affairs of the United Nations reported on 24 April 2023 that “...India’s population is expected to reach 1,425,775,850 people, matching and then surpassing the population of mainland China. India’s population is virtually certain to continue to grow for several decades...”

Another international body estimated the nation’s population at a higher level. As of 26 June 2023, The World Bank estimated the population of India at 1,436,510,000 people.

Geographically, India includes more than approximately 3,287,000 square kilometres of territory, according to the World Bank. Only Russia, Canada, the United States of America (USA), China, Brazil, and Australia include more territory than India.

The International Monetary Fund (IMF) projected the Real Gross Domestic Product (GDP) of India will grow 5.9% to (US) $3,740,000,000,000 in 2023. This GDP level would rank India as the 5th largest economy in the world. The only nations with larger economies are projected to be the USA, China, Japan, and Germany.

Consumer Prices in India are projected by the IMF to increase 4.9% in 2023.

According to a report from the United States Geological Survey (USGS), India was the second largest producer of aluminium in 2022. Smelter production was estimated to be 4,000,000 metric tonnes in that year, with smelter production estimated to have been 3,970,000 metric tonnes in 2021.

Whilst these production levels were large, the difference between the amounts of Indian production and production in the largest producer of aluminium was substantial. In 2022, the smelter production of aluminium in China – the largest producer of aluminium globally –was estimated to be ten times higher than that of India.

India was also reported by the USGS as having the second largest amount of aluminium production capacity at the end of both 2022 and 2021; only China had larger capacities at the end of those two years. Year-end capacity in India was

Aluminium Industry In India

By Richard McDonough*

estimated by the USGS to be 4,100,000 metric tonnes of potential aluminium production in 2022, and 4,060,000 metric tonnes of potential aluminium production in 2021.

As for alumina, India was the fourth largest refiner of this compound in 2022, according to the USGS. A total of 7,400,000 metric dry tonnes of alumina was estimated to have been refined in India in that year. This was an increase from the estimated 7,000,000 metric dry tonnes of alumina refined in 2021.

The USGS reported that India was the sixth largest producer of bauxite in 2022. In that year, an estimated total of 17,000,000 metric dry tonnes of bauxite was produced in India. The amount of Indian bauxite produced in that year was lower than the amount produced in 2021; 17,400,000 metric dry tonnes were estimated to be produced in India in that year.

Overall, the USGS estimated that India has the 8th largest reserves of bauxite. The reserves were estimated at 660,000,000 metric dry tonnes as of 2022.

In a report issued by the International

Aluminium Institute in May of 2021, about 68,000 people were employed in the upstream sectors of the aluminium industry in India in 2019. Among all countries surveyed, India was the nation with the second largest employment base in the aluminium industry; only China had larger numbers of people working in its aluminium industries. According to the International Aluminium Institute, “The upstream sector of this study accounts for the aluminium industry’s bauxite mining, refining, and smelting processes.”

According to a news statement issued on 8 May 2023, “Vedanta Limited –Aluminium Business (Vedanta Aluminium), India’s largest producer of aluminium, has achieved the ASI Performance Standard V2 (2017) Certification at its smelter located within the Special Economic Zone at Jharsuguda, Odisha, India. The company was certified for the manufacture of all primary aluminium products in the form of billets, wire rods, primary foundry alloys, ingots, and sow ingots, as well as its ‘Restora’ brand of low-carbon aluminium products.” (Pic 1)

*Do you have questions about the aluminium industry? Governmental regulations? Company operations? Your questions may be used in a future news column. Contact Richard McDonough at aluminachronicles@gmail.com. © 2023 Richard McDonough

(The photograph was provided courtesy of Rahul Shah through Pexels, January 21, 2018.)

Trade

India has been among the top 15 nations for the import of aluminium and related products for a number of years. As for exports, India has increased its ranking to become a top five exporter of these products in 2021.

India was ranked as the 12th largest importing nation of aluminium and related products in 2021. This, according to the International Trade Centre (ITC). Unless otherwise stated, statistics detailing imports and exports of aluminium and articles thereof (hereafter noted as “aluminium and related products”) to and from India are from reports issued by the ITC. In 2020, the country ranked number 14; in 2019 and 2018, India was ranked as number 11; and in 2017, the nation ranked number 12 among countries globally.

The country’s ranking of exports within this category has grown during recent years. In 2021, India was ranked as the 5th largest country globally in exports of aluminium and related products. It was ranked at number 7 in 2020, number 8 in 2019, number 10 in 2018, and number 13 in 2017.

Imports

Whilst imports of aluminium and related products into India increased almost 37% overall from 2017 to 2021, there were decreases in intervening years. From 2018 to 2020, imports decreased, but then increased in 2021.

In 2017, imports of these products amounted to (US) $4,147,450,000; in 2018, (US) $5,506,678,000; in 2019, (US) $4,600,309,000; in 2020, (US) $3,653,533,000; and in 2021, imports of aluminium and related products were valued at (US) $5,679,251,000.

Like most nations, India’s largest source of aluminium and related products imported into the country was from China for the time period from 2017 to 2021.

The rankings of other top sources of these products imported into India varied during this five-year time period. In 2021, the second largest source was the USA, whilst the United Arab Emirates (UAE) was the third largest.

These three together supplied India with about 31.1% of all of its imported aluminium and related products in 2017. Their combined percentage increased to approximately 40.2% in 2021.

Imports from China were:

� (US) $718,913,000 in 2017,

� (US) $1,109,156,000 in 2018,

� (US) $1,037,515,000 in 2019,

� (US) $670,921,000 in 2020,

� (US) $978,449,000 in 2021.

From the USA, imports were

� (US) $189,883,000 in 2017,

� (US) $463,831,000 in 2018,

� (US) $515,552,000 in 2019,

� (US) $476,295,000 in 2020,

� (US) $830,969,000 in 2021.

Imports from the UAE were

� (US) $382,592,000 in 2017,

� (US) $477,718,000 in 2018,

�(US) $310,873,000 in 2019,

� (US) $284,325,000 in 2020,

�(US) $475,117,000 in 2021.

The amount of aluminium and related products imported from the countries ranked as the fourth through seventh largest sources of these imports into India decreased from more than a quarter of all imports in 2017 to approximately onefifth of all imports in 2021.

Imports of these products from the United Kingdom (UK), Saudi Arabia, Malaysia, and South Korea represented about 27.1% of all imported aluminium and related products in 2017. Together, imports from these four nations decreased to about 20.7% in 2021.

In 2017, imports from the UK were

� (US) $315,368,000

� and in 2021,(US) $351,859,000; imports from Saudi Arabia were

� (US) $270,017,000 and in 2021,

� (US) $344,933,000; from Malaysia,

� (US) $357,173,000 in 2017,

� with (US) $253,478,000 in 2021; and from South Korea,

� (US) $181,966,000 in 2017,

� (US) $225,636,000 in 2021.

Other major sources of imported aluminium and related products were from Thailand, the Netherlands, Germany, Singapore, and Bahrain. These five countries represented about 12.4% of all imports of these products into India in 2017; their portion of the import market

for aluminium and related products increased slightly to approximately 13.2% in 2021. Imports from each of these countries, with the exception of Bahrain, increased during this five-year time period. Imports of these items from Thailand were

� (US) $84,038,000 in 2017,

� and (US) $179,156,000 in 2021; imports from the Netherlands were

� (US) $109,069,000 in 2017, and

� (US) $161,217,000 in 2021; imports from Germany were

� (US) $133,344,000 in 2017,

� and (US) $147,771,000 in 2021; imports from Singapore were

� (US) $52,799,000 in 2017,

� and (US) $133,178,000 in 2021; and imports from Bahrain were

� (US) $135,058,000 in 2017,

� and (US) $131,021,000 in 2021.

Three other nations were important sources of aluminium and related products imported into India, including Belgium, Australia, and Qatar. Combined, imports of these items from these countries accounted for about 9.1% of all aluminium and related products imported into India in 2017; the percentage decreased to approximately 6.4% in 2021.

In 2017, India imported

� (US) $47,983,000 in aluminium and related products from Belgium,

� (US) $204,840,000 from Australia,

� and (US) $123,107,000 from Qatar.

Five years later, the amounts were

�(US)$125,938,000,

�(US) $118,265,000, and

� (US) $117,679,000 from Belgium, Australia, and Qatar, respectively.

Overall, imports from these 15 countries represented approximately 79.7% of all aluminium and related products imported into India in 2017, and increased less than

Pic 1. (The photograph was provided courtesy of Vedanta Aluminium.)

one percentage point to about 80.6% of all of these types of imported products in 2021.

Exports

The amount of exports of aluminium and related products from India was almost two-and-a-half times more in 2021 as compared to the amount in 2017. Increases occurred in each of those five years, though the amounts were only modestly higher from previous years in 2018, 2019, and 2020. The increase in 2021 was substantial – approximately 71.5% higher than the amount in 2020.

Aluminium and related products exported from India were valued at

� (US) $3,652,286,000 in 2017, and (US) $9,063,866,000 in 2021. In the intervening years, the amounts were

� (US) $5,170,393,000 in 2018,

� (US) $5,244,321,000 in 2019,

� (US) $5,285,080,000 in 2020.

Key export markets for India included nations in Asia, Europe, and North America.

Exports to South Korea and China – the two largest markets for Indian aluminium and related products – increased from 21.2% of all exports of these products in 2017 to 28.0% in 2021.

The increase in exports to China, in particular, was substantial. Exports of these products from India to China in 2021 was more than 64 times the amount exported in 2017. The largest increases came in 2020 – approximately a 7-fold increase from 2019 – and in 2021 – an about 5-fold increase from 2020.

India exported aluminium and related products to South Korea in the amount of

� (US) $754,859,000 in 2017,

� (US) $515,753,000 in 2018,

� (US) $834,040,000 in 2019,

� (US) $1,089,829,000 in 2020,

� (US) $1,273,871,000 in 2021.

For China, exports of these items from India amounted to

� (US) $19,656,000 in 2017,

� (US) $11,056,000 in 2018,

� (US) $35,068,000 in 2019,

� (US) $245,573,000 in 2020,

� (US) $1,265,429,000 in 2021.

The third and fourth largest export markets for aluminium and related products manufactured in India were the USA and Türkiye. Whilst the amounts of exports of these products to both of these countries grew from 2017 to 2021, the overall percentage of market represented by the two nations decreased one percentage point from about 17.3% in 2017 to approximately 16.3% in 2021.

Aluminium and related products were exported from India to the USA in the amount of

� (US) $536,626,000 in 2017,

� (US) $708,099,000 in 2018,

� (US) $706,634,000 in 2019,

� (US) $484,133,000 in 2020,

� (US) $812,369,000 in 2021.

For exports of these items to Türkiye, the amounts were

� (US) $94,620,000 in 2017,

� (US) $432,800,000 in 2018,

� (US) $95,079,000 in 2019, (US)

� $21,344,000 in 2020,

� (US) $667,616,000 in 2021.

México, Italy, Greece, and Malaysia were the nations that ranked number five through number eight for these items exported from India. Collectively, the actual amounts of exported aluminium and related products increased to these four countries from 2017 to 2021, but their percentage of the export market for India for these items decreased from about 18.9% to approximately 18.0% during this same time period.

Indian exports increased to México from

� (US) $129,312,000 in 2017 to

� (US) $444,587,000 in 2021; to Italy from

� (US) $131,875,000 in 2017to

� (US) $423,148,000 in 2021; and to Greece from

� (US) $57,217,000 in 2017 to

� (US) $396,398,000 in 2021.

Exports to Malaysia, though, declined from

� (US) $371,290,000 in 2017 to

� (US) $363,148,000 in 2021.

Japan, Vietnam, Brazil, Taiwan, and Bangladesh were five other important export markets for aluminium and related products from India. All saw an increase in the amounts of these items exported into

their nations from 2017 to 2021. Together, exports to these five countries increased from about 10.7% of all aluminium and related products exported from India in 2017 to approximately 12.9% of these exports in 2021.

Exports of these products increased to Japan from

� (US) $117,056,000 in 2017 to

� (US) $274,590,000 in 2021; to Vietnam from

� (US) $10,067,000 in 2017 to

� (US) $256,602,000 in 2021; to Brazil from

� (US) $69,256,000 in 2017 to

� (US) $225,865,000 in 2021; to Taiwan from

� (US) $56,737,000 in 2017 to

� (US) $209,910,000 in 2021; and to Bangladesh from

� (US) $136,451,000 in 2017 to

� (US) $200,599,000 in 2021.

Three additional countries were large export markets for aluminium and related products manufactured in India – Spain, Thailand, and the Netherlands. In 2017, exports to these nations amounted to approximately 4.3% of all aluminium and related products exported from India; in 2021, that percentage increased to 6.0%. Aluminium and related products exported to Spain went from

� (US) $55,827,000 in 2017 to

� (US) $190,650,000 in 2021; to Thailand, from

� (US) $50,172,000 in 2017

� to (US) $180,204,000 in 2021; and to the Netherlands, from

� (US) $50,163,000 in 2017 to

� (US) $175,502,000 in 2021.

Overall, exports to these 15 countries represented about 72.4% of all aluminium and related products exported from India in 2017, and approximately 81.2% of all of these types of exported items in 2021. Additional details about production and trade for different portions of the aluminium industry were also provided through the Observatory of Economic Complexity (OEC). The data provided below through the OEC was from the CEPII, also known as the “Centre d’Études Prospectives et d’Informations Internationales” or “Center for International Prospective Research and Data.”

Please note that these statistics may be different from the stats provided through the ITC.

Raw Aluminium

Export markets of raw aluminium manufactured in India in 2021. (Fig 1)

The OEC reported that India was the third largest exporter of raw aluminium in 2021. According to its report, the

OEC indicated that India exported (US) $7,180,000,000 in raw aluminium in that year; this amount represented 9.14% of total exports of this product from all nations. Only Canada and Russia exported more of this product. The UAE and Malaysia were ranked just behind India.

In 2021, the main destinations for raw aluminium produced in India were

� South Korea, (US) $1,480,000,000;

� China, (US) $1,260,000,000;

� Türkiye, (US) $778,000,000;

� México, (US) $406,000,000;

� Malaysia, (US) $362,000,000. Greece was close behind Malaysia in the receipt of raw aluminium exported from India.

Exports to South Korea of raw aluminium represented 20.7% of all such exports from India in 2021. The percentages for the other top five export markets were

� 17.5% for China,

� 10.8% for Türkiye,

� 5.65% for México, and

� 5.04% for Malaysia.

Sources of raw aluminium imported

into India in 2021 (Fig 2).

Imports of raw aluminium into India amounted to

� (US) $584,000,000 in 2021. This included

� (US) $126,000,000 from Malaysia,

� (US) $112,000,000 from Qatar,

� (US) $101,000,000 from the UAE,

� (US) $80,300,000 from Bahrain,

� (US) $55,300,000 from Russia.

Malaysian produced raw aluminium imported into India represented 21.6% of all such imports into India in 2021. The percentages for the other top five import sources were

� 19.1% for Qatar,

� 17.4% for the UAE,

� 13.7% for Bahrain, and

� 9.46% for Russia.

Aluminium Ore (Bauxite)

India was the second largest importer of aluminium ore (bauxite) according to the OEC in 2021. According to its report, the OEC indicated that India imported (US)

$211,000,000 in aluminium ore in that year; this amount represented 3.66% of all of the imports of this product into all nations.

Only China imported more of this product – substantially more. In 2021, China imported 68.4% of all aluminium ore that was imported globally. The UAE, the USA, and Ukraine were ranked just behind India. Other large importing nations were Spain, Ireland, and Germany.

Sources of aluminium ore (bauxite) imported into India in 2021 (Fig 3).

Guinea was the source of (US) $167,000,000 of the aluminium ore imported into India in 2021; this represented 79.4% of all of these imports. Other large suppliers of aluminium ore were

� China, (US) $36,000,000;

� Hong Kong, (US) $4,250,000;

� Guyana, (US) $1,540,000; and

� Trinidad and Tobago, (US) $818,000.

Aluminium ore imported into India from China represented 17.1% of all

Fig 1. Export markets of raw aluminium manufactured in India in 2021. (The image was provided courtesy of the Observatory of Economic Complexity)

Fig 2. Sources of raw aluminium imported into India in 2021. (The image was provided courtesy of the Observatory of Economic Complexity)

Fig 3. Sources of aluminium ore (bauxite) imported into India in 2021. (The image was provided courtesy of the Observatory of Economic Complexity)

Fig 4. Export markets of aluminium ore (bauxite) produced in India in 2021. (The image was provided courtesy of the Observatory of Economic Complexity)

Fig 5. Sources of scrap aluminium imported into India in 2021. (The image was provided courtesy of the Observatory of Economic Complexity)

Fig 6. Export markets of scrap aluminium produced in India in 2021. (The image was provided courtesy of the Observatory of Economic Complexity)

such imports into India in 2021. The percentages for the other top five import sources were all relatively small: 2.01% for Hong Kong, 0.73% for Guyana, and 0.39% for Trinidad and Tobago.

Export markets of aluminium ore –bauxite produced in India in 2021 (Fig 4).

India was a modest exporter of aluminium ore, exporting (US) $16,900,000 of this product in 2021. Its largest export markets in that year included

� Nepal, (US) $6,460,000;

� Slovenia, (US) $4,430,000;

� Kuwait, (US) $1,690,000;

� Oman, (US) $1,310,000;

� Qatar, (US) $673,000.

The percentages of the 2021 export market for aluminium ore produced in India were 38.3% for Nepal, 26.3% for Slovenia, 10% for Kuwait, 7.77% for Oman, and 3.99% for Qatar.

Scrap Aluminium

According to the OEC, India was the largest importer of scrap aluminium in 2021. In that year, the country imported (US) $2,940,000,000 in scrap aluminium; this amount represented 15% of all global imports of scrap aluminium.

South Korea, Germany, Malaysia, and the USA were also among the top five importing nations of scrap aluminium in 2021. The amounts of this product imported to these countries were, respectively,

� (US) $1,760,000,000,

� (US) $1,430,000,000,

� (US) $1,330,000,000,

� (US) $ 1,200,000,000.

In 2021, the percentages of the scrap aluminium imported globally were

� 8.96% for South Korea,

� 7.3% for Germany,

� 6.77% for Malaysia,

� 6.14% for the USA.

China, Italy, and Hong Kong were also large importers of scrap aluminium in that year.

Sources of scrap aluminium imported into India in 2021 (Fig 5).

In 2021, India imported scrap aluminium in the amounts of

� (US) $785,000,000 from the USA,

� (US) $309,000,000 from Saudi Arabia,

� (US) $301,000,000 from the UK,

� (US) $298,000,000 from the UAE,

� (US) $123,000,000 from the Netherlands.

Of all sources from which India imported this product, the percentages for these top five import sources were

� 26.7% for the USA,

� 10.5% for Saudi Arabia,

� 10.3% for the UK,

� 10.1% for the UAE,

� 4.2% for the Netherlands.

Other large sources of scrap aluminium imported into India originated in Australia, Singapore, and Germany in 2021. Export markets of scrap aluminium produced in India in 2021 (Fig 6).

India exported relatively small amounts of scrap aluminium in 2021: (US) $20,300,000 in 2021. Of that amount,

� 71.5% (US) $14,500,000 went to South Korea,

� 10.3%, (US) $2,080,000 went to Thailand,

� 7.4% (US) $1,500,000 went to Malaysia,

� 6.44% (US) $1,310,000 went to Hong Kong,

� 2.04% (US) $415,000 went to Greece.

Aluminium Extrusion

Reflection Window + Wall (RWW) is one of the businesses that utilises aluminium produced and extruded in India. The products are used in commercial highrise buildings, among other structures. The company describes itself as “a fully vertically-integrated façade design, manufacturing, and installation firm.” It is headquartered in Chicago, Illinois in the USA (Pic 2).

“We commission aluminium extrusions produced in various alloys as required for their structural efficacy per engineered standards,” stated Joel Phelps, Chief Operating Officer of RWW and related companies. “Those aluminium extrusions are finished (painted) per AAMA [American Architectural Manufacturers Association] standards and then fabricated in frames.

The frames are then infilled with either vision glass (insulated glass units), or opaque glass, metal panel, stone, terra cotta or other material to make a complete unitised frame.”

“Our customers are typically general contractors, but increasingly we are seeing owner/developer firms source more and more directly to save on time and design costs,” Mr. Phelps continued. “Our sales focus for our Indian-made products is the USA and Canadian markets to end users of high-rise façades.”

He indicated that RWW provided more than 700,000 square feet of highperformance façades through its Indian supply chain for projects in New York, Philadelphia, and Chicago in the USA in 2022. The company valued these contracts at (US) $65,000,000.

“In 2022, our Indian supply chain accounted for nearly 23% sales and backlog,” said Mr. Phelps. He noted that this was “in comparison to 2020 and 2021 where we used only 170,000 square feet of high-performance façade from India or 6% of our total sales and back log.”

The tail end of the COVID-19 Pandemic impacted operations in 2022.

“This resulted in a logistics crisis that plagued the USA and drove container prices from India from (US) $7,000 to over (US) $25,000,” Mr. Phelps explained. “Whilst logistics costs have decreased, they still have not returned to pre-pandemic levels, and likely never will. However, with our partner’s indominable spirit in India, we have overcome those headwinds, by bringing even more value, and innovation to overcome those challenges.”

Market conditions look challenging in the short-term, but long-term growth is anticipated.

Pic 2. Aluminium manufactured in India was utilised by Reflection Window + Wall (RWW) for the façade at 1400 South Wabash in Chicago, Illinois in the USA. According to RWW, this 31-story building is a luxurious apartment complex located in the heart of the South Loop of this American city. (The photograph was provided courtesy of Reflection Window + Wall.)

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“Given the slow-down/recession in commercial construction due to high office vacancies and elevated interest rates, we expect this year and next to be flat,” according to Mr. Phelps. “2025 may also be flat or see modest growth. The global built environment is set to double by the year 2060, and India is expected to

continue to gain substantial market share over other developed and developing manufacturing markets. We expect the Indian supply chain to grow in double digits for at least the next decade.”

“There are positive and negative external forces impacting the business,” Mr. Phelps continued. “There are declining volumes for commercial construction in the shortterm, but we are very bullish beyond as we look forward simply due to the necessity for high-performance, low-cost building products to meet future demand on a global scale. RWW is uniquely positioned to partner with our rapidly maturing Indian supply and manufacturing businesses.”

One of the key aspects highlighted by RWW that propels that outlook is based on the sustainability of the aluminium extrusions manufactured in India.

A representative for the company indicated that “India is producing millions of square feet in low-carbon aluminium for

window frames used in the construction of high-rise buildings. They’re actually on the forefront of significantly reducing the carbon footprint in an industry known to add large amounts of carbon into our atmosphere.”

Mr. Phelps noted that production of aluminium extrusions globally range from 14 kg to 27 kg of carbon dioxide released into the environment for every 1 kg of aluminium extrusion produced. Those emissions are reduced, he stated, because of “…the ubiquitous application of renewable solar installations.” He indicated that for every 1 kg of aluminium extrusion produced, 2.6 kg of carbon is produced at the firm’s partner factories in India.

“This ranges from 83%-90% reduction in carbon emission for our industry,” Mr. Phelps said. “India is a fantastic place for renewable energy, particularly for solargenerated energy products.”(Pic 3) �

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Pic 3. Reflection Window + Wall (RWW) used aluminium produced in India for the façade system at this six-story building of the University of Illinois Hospital and Health Sciences on the near west side of Chicago, Illinois in the USA. (The photograph was provided courtesy of Reflection Window + Wall.)

India’s potential to increase extrusion production capacity

By Pragun Khaitan*

In the ever-evolving global manufacturing landscape, India stands at the cusp of a tremendous opportunity that could redefine its position in the world economy. The downstream aluminium industry is one important yet overlooked sector with immense promise. Backed by abundant resources, a skilled workforce, and favourable market conditions, India can target increasing its aluminium extrusion production capacity from 5% to 25% of the global market. Such a profound shift would boost economic growth and establish the nation’s manufacturing dominance worldwide. The industry offers a wide range of versatility and applications across segments, including construction, automotive, aerospace, defence, and consumer goods.

Driving Forces & Projected Growth

The increasing need for lightweight and durable extruded engineered aluminium products across various sectors is expected to drive the growth of the aluminium extrusion market. Aluminium extrusions are the material of choice for various industries due to a unique mix of lightweight qualities and a high strengthto-weight ratio. Unlike competing materials, aluminium maintains structural integrity under different temperature conditions, adding to its appeal and dependability.

Massive demand from non-fossil-based industries such as solar, wind, hydro, biomass, and nuclear is also driving the rapid expansion of the aluminium extrusion market. These industries require lightweight and long-lasting extruded goods to cater to their ever-increasing demand. Between 2022 and 2030, the global aluminium extrusion market is anticipated to expand with a compound annual growth rate (CAGR) of 7.5%, initially valued at USD 87.84 billion in 2021. In addition, the usage of aluminium in internal combustion and electric vehicles (EVs) across the automotive and

transportation sector will steer the market growth.

This significant growth projection indicates a promising future for the downstream aluminium industry. Realizing this potential, India is ready to cater not only to the domestic markets but also to the global demand as it aims to meet its infrastructure needs. One area where aluminium’s role becomes crucial alongside developing infrastructure is developing public transport systems. As India works to enhance its transportation infrastructure to accommodate the needs of its growing population, the demand for lightweight and durable materials like aluminium becomes imperative. Aluminium’s unique properties make it an ideal choice for various components of public transport systems, including

buses, metro trains, and railways. By incorporating aluminium into these infrastructure projects, it will lead to multiple benefits, including increased fuel efficiency, reduced emissions, and improved overall performance.

India, as the fifth-largest aluminium producer in the world, is well-positioned to capitalize on this upward trend. With a strong emphasis on the construction and industrial sectors and a growing emphasis on EV and the renewable energy sector, the aluminium extrusion industry is poised to play a pivotal role in developing the Indian economy. This surge signifies India’s ambitious drive towards progress and reflects its commitment to sustainability, green energy usage in manufacturing, and fostering innovation. As the world increasingly recognizes the

*Vice Chairman and Managing Director, Jindal Aluminium

urgency of addressing climate change and transitioning to a more sustainable future, India’s emphasis on sustainability in the aluminium sector highlights its proactive approach. By incorporating green energy sources in manufacturing processes and embracing energy-efficient technologies, India is actively reducing its carbon footprint and mitigating environmental impact.

Furthermore, the industry’s emphasis on innovation drives advancements in sustainable practices, materials, and technologies, taking India to the centre stage globally towards sustainable manufacturing. By adopting these approaches, India is bolstering its economy and positioning itself as a leading advocate for environmental stewardship.

Unique Advantages

India has a competitive edge because of its vast resources, ensuring a reliable and sustainable supply chain for the industry’s expansion. Moreover, India boasts a highly skilled and talented workforce with the knowledge and expertise required to excel in the intricate processes of aluminium extrusion. Our unwavering commitment to nurturing and developing talent and substantial investments in innovation

and technological advancements serve as the foundation for India’s burgeoning dominance in this sector.

Embracing a culture of continuous learning and providing our workforce with cutting-edge tools and techniques, we are poised to push the boundaries of what is possible in aluminium extrusion, surpassing international standards and setting new benchmarks for excellence. Our skilled workforce and relentless pursuit of innovation position India as a formidable force in the global aluminium industry, propelling us towards a future of unrivalled success. The government has implemented numerous initiatives to support the sector, recognizing the importance of manufacturing as a driver of economic development.

Together with efforts to enhance the ease of doing business, the “Make in India” campaign has created a favourable environment for domestic and foreign investments. This drive has spurred the establishment of cutting-edge manufacturing facilities, the enhancement of research and development capabilities, and the rapid adoption of innovative technologies.

In conclusion, a surge in aluminium extrusion production would create many

employment opportunities across the manufacturing value chain, stimulating economic growth and improving livelihoods. By incorporating technology adoption, investing in research and development, and fostering innovation, India can bolster its production capacity and enhance the scope of aluminium extrusion utility, opening new consumer segments.

This dynamic combination of increased production, technological advancements, and innovation will meet the infrastructure needs and propel India towards becoming a global leader in the aluminium extrusion industry. The ripple effect of this growth would extend beyond the factory floors, with increased demand for ancillary industries, raw materials, and services. Moreover, India’s enhanced export capabilities would translate into a trade surplus, bolstering its international standing and fortifying the economy. With its unwavering focus on sustainability, green energy usage in manufacturing, and a relentless drive for innovation, India is poised to harness the full potential of aluminium extrusion, ushering in an era of economic prosperity and sustainable development. �

DUOMELT Induction melting furnace

Reaching net zero by 2050 will require a mix of levers within the primary aluminium sector, in the wider aluminium value chain, and in partnership with the power sector

Mission Possible Partnership

ONLINE EVENT

With the recent announcement of the world’s first batch of recycled aluminium using hydrogen fuelled production, the shift towards producing carbon-free aluminium is experiencing exciting new developments.

By testing the fuel switch from natural gas to hydrogen and the effects on metal quality, these findings can also be relevant for using hydrogen in primary aluminium casthouses and other high temperature processes, like glass or cement.

This year’s Greener Aluminium Online Summit invites the industry to join virtually to discuss how the industry must continue to adapt, minimising the impacts associated with production of the metal today, while also developing technological pathways for the future.

Alongside the one-day conference, participants will also be invited to join live discussions and will have the opportunity to network with new contacts, arrange video meetings and exchange resources and information.

STAY UP-TO-DATE WITH SPEAKER ANNOUNCEMENTS, CONFERENCE AGENDA AND REGISTRATION... ALUMINIUMTODAY.COM/GREENER-ALUMINIUM

Zero Outsourced Engineering and Service

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All Granco Clark equipment comes from our 92,000 square foot modern Michigan facility providing the industry’s most innovative custom equipment built with the exceptional quality you come to expect from Granco Clark. Our repeat customers attest to that.

All-inclusive Turn-key System Supplier.

Granco Clark is your all-inclusive turn-key system supplier. Expect superior performance, industry knowledge, unmatched and proven solutions, onsite commissioning, support, and responsive service technicians.

Our industry knowledge and experience are superior and proven, with our custom-engineered equipment delivering the solutions and performance you expect from Granco Clark.

Being a full-service company means we are with you from the initial planning phase of the project through the start of production and beyond. You will have access to unmatched industry service, support and parts. Our global team of trained service technicians are available to keep your production facility always running smoothly and provide on-site service (in most cases, within 24 hours).

Metals for the future: Creating a circular economy for aluminium

By David Sneddon*

As one of the most recyclable materials on the planet, aluminium offers us one of the most direct ways to decarbonise our lives – it is almost infinitely recyclable like gold, without degrading like steel, and in the process of recycling, it can be turned back into useable products with a tiny proportion of the energy of new material, again unlike glass and steel.

However, the UK is currently reliant on an unsustainable material and energyintensive supply chain based on a practise of exporting scrap and slabs and importing huge quantities of sheet and billet.

With manufacturers increasingly concerned about scope 3 emissions and the security of their supply chains, the UK must reconsider its approach to aluminium production and recycling; we must create a closed-loop, circular economy for aluminium sheet in the UK for UK industry and consumers.

We have a solution, and it’s backed by some of the biggest companies in the world. We are the British Aluminium Consortium for Advanced Alloys (BACALL), and we will localise aluminium recycling and manufacture.

The sustainability case

The whole supply chain for prime aluminium production, from bauxite mining to smelter, is a sustainability problem. Alumina production and smelting prime are energy intensive processes with high carbon emissions, particularly where the electricity used in the production comes from fossil fuels.

In addition to this there is little or no visibility of supply chain emissions and accredited material sourcing for end clients. Clients cannot plan when they don’t know how much prime they receive and when.

The UK’s industrial position on aluminium is very vulnerable. Several large and important plant closures over the last 15 years have left the UK dependent on plants either in Europe or further.

The recent interruptions in supply chains amplified this danger. Current figures suggest that approximately 1.2million tonnes of aluminium scrap is imported to the UK whilst 800,000 tonnes of aluminium are exported.

As the industry recycling champions have been repeating for many yearsaluminium offers up to 95% reduction in energy, while maintaining the metal quality through recycling.

engineers, and of metallurgists who have done this job over and over for clients around the world. They have informed the way we move forward and how we can do this for the UK.

Currently, there is no plant in the UK capable of accommodating this model. But there will be. Our unique grouping of industry experts will support the aluminium industry’s transition to a circular economy by building a new, innovative, digital-first facility that will reduce waste throughout the entire product lifecycle.

We will build a plant to roll hundreds of thousands of tonnes of aluminium sheet, in the UK using local material to make sheet for local clients. Local, local, local.

We will apply proven state of the art systems of scrap sorting, casting and rolling, integrating this into a state-of-theart energy efficient plant.

And, through the integration of several processes that are typically dispersed, we can reduce the need for many energyintensive re-melting steps and reducing huge amounts of stock.

Together, this will provide a substantial reduction in associated carbon emissions per tonne of product and provide an exemplar output of ultra-low embedded carbon sheet for UK clients.

Securing the strategic importance of aluminium to the UK.

Making aluminium sheet in the UK, from UK recyclate, would reduce embedded carbon in UK-made cans and vehicles by some 1 million tonnes CO2eq. per annum per 100,000 tonnes recycled.

But in order to fully realise this benefit, reduce manufacturers scope 3 emissions, and help the UK to reach its climate goals, we need to recycle aluminium locally into sheet, so that the finishers of cans and cars have a chance not just to survive but thrive. This means bold thinking and bold action. For this we created the consortium – a grouping of clients, of process and operational experts, of finishers, of

Director of BACALL

The current model - relying on aluminium imports combined with an almost equal surplus of used aluminium end-of-life scrap that is exported for recycling abroad - is not only an environmental issue, but it comes at a substantial economic loss to UK PLC too.

As a sector, aluminium is equally important to the manufacturing economy as steel.

The future of UK car making and packaging lies in the future of ultra-low embedded carbon sheet to be made in the UK. That is tens of thousands of jobs and livelihoods as well as the interests of consumers and households in the UK. This

*Non-executive

is a matter of national industrial strategic importance as much as steel, semiconductors or batteries.

Collecting, processing, and recycling the metal entirely within country will therefore be crucial as we consider its future viability. In doing so, BACALL will create and protect tens of thousands of jobs reshoring vital support engineering services and securing the materials, waste and recycling industries where we are global leaders. It will attract investment in upstream and downstream technologies such as engineering equipment, controls and digital systems, precision engineering of materials sorting and segregation, foundry materials, rolling mill systems, many of which exist in the UK but have hitherto exported to survive.

It is time for the aluminium industry to step up and be counted as a foundation industry of strategic importance to the UK economy, and essential to the futures of the large-scale UK automotive, construction and food and drink industries.

Through the embodiment of sustainable and generative thinking, the BACALL project is a significant step in future-

proofing the sector. So much so, Diageo recently announced its investment.

Diageo invests

Following the announcement by Diageo, life has changed for the project team that has been built up over the last seven years to deliver this most important change in UK metals industry. BACALL has been the brainchild of several members of the aluminium industry who have doggedly stuck to the simple plan to create a closed loop aluminium system in the UK with a recycling dedicated integrated plant to make sheet locally for local clients.

After years of working in confidence, gathering the many experts, advisors, and partner suppliers, it has come as a great relief to be able to talk openly in the industry and market about the plans and years of work, research, modelling and engineering that have led to the announcement. The industry has reacted very positively, for those in the know and to those to whom the announcement has come as a surprise, with many offering their support and engagement in the execution of what will be a complex fast

track build and commissioning exercise. Engineers have been busy across the world preparing for this next stage.

Since, several major players have joined the consortium to ensure the demand is there from day one, and lead by Diageo’s example are readying the process to take the output material for many years.

Diageo hasn’t just bumped into BACALL recently but has been involved for a number of years and was instrumental in supporting BACALL through its feasibility work and in the creation and gathering of the consortium; on top of this it has led the industry not only in publicly nailing its colours to the mast but in putting serious investment behind the project. Preparations are now in full flow. We look forward to sharing more with the industry, soon. �

Something extraodinary is about to happen in the world of furnace engineering

50 years of innovation and excellence:

Celebrating a milestone anniversary in business

Mechatherm International Limited is a supplier of Aluminium casthouse equipment. Established in 1973 Mechatherm began with the ideology to provide bespoke Aluminium Melting and Holding furnaces with robust British engineering and industry leading technologies.

Founded by Bryan Emes, John Gardner and Louis Riley, Mechatherm began in a spare bedroom in Epsom, supplying small furnaces to the UK Aluminium industry. Things began to change in the 1990’s when they completed their first largescale international smelter project, since then the company has continued to grow, installing the largest recycling plant of its kind at JW Aluminium in the US in 2019, establishing the brand as a global leader in Aluminium casthouse equipment.

Among its many achievements, Mechatherm has won the Queen’s Award for Export on three occasions.

The company’s commitment to sustainability has also been a driving force behind its success. Mechatherm has developed innovative solutions to reduce energy consumption, greenhouse gas emissions, and waste generation in the aluminum recycling process. The culmination of this work will see Mechatherm convert the world’s first Aluminium melting furnace for production use in 2024.

Mechatherm Chairman, Andrew Riley - “Mechatherm has come a long way in the last 50 years from my father’s back

bedroom in Epsom, where it all began, to a multinational, award winning, company with its own premises. My Father would be very proud of what everyone has achieved now and will achieve going forward, as am I. The future is bright!”

Mechatherm Director, Chris Emes “I have incredible pride at working for, then running Mechatherm for over 40 years, and now as Mechatherm rise from the ashes of COVID, returning to assist in what has been a record-breaking year in sales.”

To mark this momentous occasion, Mechatherm will be hosting a series of events throughout the year, including a gala dinner and our largest show stand in the US to date at Aluminium USA in October.

To request further information please contact Terri-ann Bethell. �

BCAST, circularity and aluminium, the upstart competitor

“The world of metals is dominated by steel, but the next largest metal in use is probably aluminium. So really, steel is the major metal and aluminium is its upstart competitor.” – Geoff Scamans*

Upstart DEROGATORY

A person who has risen suddenly in rank or importance, especially one who behaves arrogantly.

“The upstarts who dare to challenge the legitimacy of his rule.”

Aluminium has long been held in high regard as the ”magic” metal; its heroic image of being the potential saviour of the heavy manufacturing industries as it leads the way in circular economy and recycling and proves to be the answer for many other industries as it assists in decarbonisation mainly through weight reduction in multiple applications.

However: “Humility isn’t denying your strengths; it’s being honest about your weaknesses.”

-Rick Warren, ‘The Purpose Driven Life: What on Earth Am I Here For?’

“For the aluminium industry, reducing dependence on primary aluminium is absolutely the key…” – Geoff Scamans

Understanding our weakness is something recognised by the industry, but can we address these with the strengths we have? Geoff Scamans spoke with Zahra Awan** on the latest developments seen at Brunel University, Brunel Centre for Advanced Solidification Technology

(BCAST). Geoff Scamans discussed three major topics:

� Whilst there is still a focus on decarbonising primary production, companies are learning to turn towards the more readily available technologies we have for using secondary aluminium.

� In the UK, the ideals of a deindustrialised economy are not as rose tinted as predicted, and are out of step with similar sized developed economies worldwide.

� Transforming users’ attitude towards secondary materials is key to a circular economy.

ALUMINIUM IS OFTEN NAMED AS THE REVOLUTIONARY MATERIAL DUE TO ITS CIRCULAR QUALITIES, COULD YOU ELABORATE ON THE POTENTIAL OF ALUMINIUM, CONSIDERING THIS QUALITY?

Steel dominates the world of metals, but aluminium is probably the next largest metal in use. So really, steel is the major metal and aluminium is its upstart competitor. By 2021, the global cumulative production of steel had reached 62Gt and 1.7Gt for aluminium. It is estimated that more than 75% of these metals are still in existence which should provide the resource bank for future applications and for full metal circulation.

Aluminium has a huge advantage over steel since it has a much lower density. But its Achilles heel is the amount of energy it takes to make aluminium from its oxides (primary aluminium). It takes much less energy to make a kilogram of steel than to make a kilogram of aluminium. So, the problem with aluminium is that it is energy intensive

in its primary form.

This is why, for the aluminium industry, reducing the dependence on primary aluminium is absolutely key, and that’s where all the aspects of circularity are important. This can only be delivered by a systems approach through closing, narrowing and slowing the global flow of metallic materials.

Circularity is important for all metals, but it is particularly important for aluminium.

CIRCULARITY IN CAN PRODUCTION IS A GOOD EXAMPLE OF THE POTENTIAL ALUMINIUM HOLDS. HOW CAN WE USE THIS TO ASSESS OTHER APPLICATIONS OF ALUMINIUM ESPECIALLY IN AUTOMOTIVE?

Aluminium is valuable to the packaging and construction industries, but it is particularly good for anything that moves. Because moving consumes energy, it is most optimal for the vehicle to be of a lower weight, making aluminium a perfect

candidate for this application.

For example, there wouldn’t be an aerospace industry without aluminium. From the earliest days of the Wright brothers up to today and beyond, aluminium continues to play a critical role

as electric aircraft propulsion develops. There was a huge drive for circularity in the automotive industry when electrification [of vehicles] got going. Initially there was a preconception that weight reduction wasn’t going to be as important as it had

*Head of Industrial Research, Brunel Centre for Advanced Solidification Technology (BCAST), Brunel University London and Chief Scientific Officer, Innoval Technology LTD **Assistant Editor, Aluminium International Today

been with internal combustion engine vehicles. The automotive producers thought they could continue to use steel to make electric vehicles; but if you can make a lighter weight car, the range of your battery goes up, or you can put a smaller battery in for the same range. As this is being realised more and more, the pressure on weight reduction to minimise the required volume of battery manufacture increases.

I always thought that the drive for circularity would be led by the automotive industry, and that has certainly been the case for a while. But now, both in the UK and in North America, the drive for circularity is coming far more from the packaging industry than the automotive industry.

For aluminium in construction, weight reduction and longevity are important, particularly for large commercial

WHO ARE THE KEY DRIVERS IN RECYCLING ALUMINIUM?

At the moment the drivers are coming from the major packaging companies. This is because the major drinks companies are pushing forward since they’ve got sustainability targets in their corporate statements. This is changing their outloook on the embedded carbon in their packaging materials, that’s where this recycling drive is coming from.

Beyond these cooperate commitments the recycling drive is coming from consumers, who shouldn’t really be considered as consumers anymore. They’re really custodians of materials who rent/borrow the packaging materials before they are carefully returned for reuse or recycling.

However, the main overall drive is really going to come from the major corporations. They’re signing up to sustainability targets they can’t reach without a serious change of emphasis on the materials they use, and how they look after their materials.

Second to this, I think a customer revolution will be a major driver of industry change.

You’ve only got to look at what’s going on in the oil and gas industry, where the industry is resisting change for as long as it can. I think the world of manufacturing is very much like that, it doesn’t want to lead change until it’s forced to.

structures. Research and investment in the recycling of aluminium use in construction is just as important as for most other industries.

EDUCATING BRITAIN

Today, in the UK there are no undergraduate courses in metals anymore. When we offer positions at BCAST for PhD or postdoctoral positions, we get almost nobody from the UK applying. We get lots of good people applying, but they’re not UK based, and they don’t tend to stay in the UK at the end of their contracts.

The UK has demonstrated that the idea of a post-industrial society promulgated a few years ago is deeply flawed, and we can’t exist by relying just on financial management, and a service based industry. Today, we’re a very unbalanced economy because we don’t have enough manufacturing. Fortunately, this has now been recognised.

COULD YOU PROVIDE A VIEW AND INSIGHT INTO THE PLACE ALUMINIUM HAS IN THE UK AUTOMOTIVE INDUSTRY?

The UK automotive industry is in quite a difficult state because, although it has been important in automotive manufacturing over the years, there’s almost no, or very little, UK-owned automotive manufacturing of volume car production.

There is also almost no autonomy in UK manufacturing. We’ve got lots of speciality niche car makers, but interestingly, they’re not a big part of the circularity argument.

So, you’ve really got to tackle all the large manufacturers, over which the UK doesn’t have significant control.

Jaguar Land Rover were doing remarkably well, and were leading the drive into lightweight aluminium-intensive vehicle structures, but they’ve lost this lead over the last few years. As an example, the Jaguar iPace, is a world leading electric vehicle made in Austria, not the UK.

Then if you talk to the other major OEMs making significant vehicle volumes in the UK, they’ve all been very slow to adopt light weight vehicle structures and are generally still following the ad-on aluminium route for external panels that does not deliver the same benefit as full scale aluminium vehicle structures. They struggle with not having autonomous decision making.

As a metallurgist I think that both steel and aluminium are excellent materials and I think the competition between them is good for both industries.

I started off in steel for my PhD, but I only spent three years in steel research. I’ve now spent nearly 50 years working on aluminium, so obviously my background suits me to argue the case for aluminium, but I have huge amount of respect for the steel industry, and what the steel industry has achieved.

What the steel industry has done in terms of developing advanced steels is just superb and we should use it as a talisman to encourage what we can do to improve the properties of aluminium alloys, to match the steel industry improvements.

I think what we really need is collaboration and cooperation and a joint understanding of the definition of the carbon intensity of materials. Generally, the aluminium Industry does its life cycle analysis in a different way to the steel industry. Unsurprisingly, the way the aluminium industry does it favours aluminium, and the way the steel industry does it favours steel. But to be useful, we need some sort of consistency between the

two industries so that you can compare the two in any specific application.

If you listen to the steel industry, decarbonisation is relatively easy, and zero carbon steel can be produced with no problem. Plus, steel views recycling very differently as it accepts that most of the end of life steel is downcycled, whereas the aluminium industry says we promote high level recycling or even upcycling at the end of component life. So, the actual concepts for the two metals in their recycled states are quite different.

SHOULD THE ALUMINIUM INDUSTRY BE NURTURING BRIDGES WITH THE STEEL INDUSTRY?

The International Aluminium Institute has a discussion document, which is being circulated, to provide details of all the ways of carrying out life cycle analysis for aluminium. They found there’s eight different ways of carrying out life cycle analysis for aluminium and they’ve put in examples of what it means for each of the ways. They have three preferred ways which they think are sensible and so these are out for comment.

I’m of the opinion that it is very clear that the only way that is presently widely

available to make aluminium zero carbon or low carbon is through the circular economy full metal circulation-based route. I think the decarbonisation of primary aluminium production is going to be both incredibly expensive and difficult to implement, despite it having to be done to fill in the gaps where a closed circular loop is not achieved or where production volumes are increasing in a specific application.

I’d rather we try to use the 1.7 billion [1] tonnes of aluminium that has been produced to date; most of it is still around, even if a lot of it’s sitting in landfill. We ought to be happy with what we’ve got and try to use that metal again and keep it in circulation for as long as possible, because recycling, although it’s a huge thing to do, it’s actually the end of the production chain. It’s far more important to have products that last a long time, and can be reused again, than the recycling itself although it is, now, the main recovery technique it should be the last recovery technique.

COULD YOU ELABORATE ON THE BCAST LOW-CARBON ALUMINIUM FOR EVS IN COLLABORATION WITH CONSTELLIUM

BCAST has been running for 20 years now, it was set up by Professor Fan, who is still the leader and its main driving force.

BCAST is based around understanding of nucleation that governs how metals solidify from liquid melts. The main concept is, if you can control nucleation of solidification from liquid metal you can get the right properties built into the cast form and you should get much better properties from casting, semi-fabricated forms like extrusions sheet and from components.

Our latest project with Constellium has focused on making components for electric vehicles, using as much end of life aluminium as possible. We’re exploring what we can do to make extruded sections for automotive and other applications out of recycled end of life aluminium.

At the same time, we’re trying to make high recycled content, low embedded carbon alloys with improved mechanical properties. So, it’s a dual challenge.

WHAT PROJECTS HAVE YOU WORKED ON WITH BCAST?

We’ve had a number of collaborative R&D projects funded through Innovate UK and the Advanced Propulsion Centre, and the latest one is a project called CirConAl which stands for Circular Constant Aluminium which was awarded from the APC 20 competition in 2022. It’s just coming up to the end of quarter three for this project that is focussed on battery enclosures and crash management systems for electric vehicles. Innoval Technology is are providingthe life cycle analysis for this project.

SUPPLY OF ALUMINIUM SCRAP TO/ IN UK DO YOU THINK THAT ELECTRIC VEHICLES (EVS) ARE THE ANSWER TO AUTOMOTIVE DECARBONISATION?

The UK has been very good at exporting its aluminium scrap.

The reason for this is because the aluminium industry in the UK has declined such that there’s no domestic need for it, apart from some casting companies who make shape cast products. Over the last several years, most of the aluminium scrap that would have been available has been exported.

The only way to stop that happening is to develop the demand in the UK for this scrap and this requires new aluminium manufacturing in the UK. To be successful this requires both new extrusion presses and new rolling mills working closely with recycling companies. Unless we build up demand, aluminium scrap will continue to be exported.

I think they’re the best answer we have. I don’t think the other alternatives really solve the problem because hydrogen fuel cells and a dispersed hydrogen supply is extremely difficult.

Unless we move away from the idea of electric propulsion completely and have a different model where people don’t have their own transport, so everyone relies on trains and buses and public transport, EVs are our only viable option.

Look at Scandinavia as a model, where you can see good policies that are working for both aluminium scrap recycling through effective deposit return schemes, and for encouraging the ownership of electric vehicles.

IS THERE ANYTHING YOU WOULD LIKE TO SEE FROM CAR COMPANIES?

I would love to see more support for UK car manufacturing. I think it’s so important that car manufacturing is maintained and expanded in the UK. This would require quite a lot of major decisions on battery giga-factories and investment in UK metal manufacturing., but without this, UK car manufacturing will be left behind.

IS THERE ANYTHING THAT YOU WOULD LIKE TO SAY DIRECTLY TO PRIMARY PRODUCERS/ LARGE COOPERATIONS?

I think the main message is not to be frightened of recycling. Not to be frightened of the impurities that you deal with because you haven’t quite got the correct precise control of composition.

What we’re learning from the BCAST research with Constellium is that for the alloys that we want to make, these highperformance automotive alloys are very tolerant of recycled scrap. They’re very tolerant of impurities, so it’s not the big issue that everybody thinks it is.

We also must consider the expense of striving for perfection, bearing in mind that perfection doesn’t exist. You can’t just keep refining the technology until you get exactly what you want, because that would cost too much. There’s a need for compromise that is well understood by the recycling companies who maximise revenues as much as possible from all the available recyclate streams

[1] https://international-aluminium.org/statistics/ primary-aluminium-production/

Flat Rolling and a 50th Anniversary: Primetals Technologies

Primetals Technologies’ global headquarters is located in Chiswick, London, United Kingdom. The company functions with a strong entity, venturing across continents whilst maintaining leadership, and influence from the UK base.

Zahra Awan* interviewed Grant Shoebridge** on the latest developments and news from Primetals Technologies aluminium business. Meeting at the METEC, GIFA, ThermProcess and NewCast event, where Primetals Technologies were exhibiting, the company hosted several innovative sessions covering topics from green steel, digitalisation and presented technology solutions for the steel and aluminium rolling industries.

Commenting on the event, Mr Shoebridge said: “The event has been incredibly busy this year. We’ve got a large booth dedicated to digitalisation and green metals, primarily focussing on green steelmaking with some aspects of green aluminium production as well.

We are exhibiting both the upstream technologies such as blast furnace, direct reduction, and new advancements, as well as downstream processes including hot rolling and cold rolling for steel and aluminium production.

The market is buoyant at the moment. A lot of clients have been visiting our stand, discussing potential new investments, which is positive.”

COULD YOU GIVE US SOME INSIGHT INTO PRIMETALS TECHNOLOGIES ROLE IN THE ALUMINIUM INDUSTRY?

The Primetals Technologies aluminium business is centred out of the UK and Japan, with a focus on hot and cold rolling. Although our portfolio is quite narrow, we possess a deep understanding of the technology, a broad range of knowledge, and extensive experience in these two areas. Instead of being generalists, we are truly specialists.

We have a huge number of aluminium

references and many of the technologies that are now commonplace in the aluminium industry were initially pioneered by Primetals Technologies or its predecessor companies. These include innovations like the first hydraulic mill and first automated flatness control system and industry leading measurement and control technologies like the ISV spray system and the Air Bearing ShapeMeter.

GRANT SHOEBRIDGE: BIOGRAPHY

With over 20 years of experience in engineering across various industries, Grant joined Primetals Technologies in 2018 to lead the ShapeTech measurement and control product businesses based in Dorset, UK. Earlier this year, Grant took on the role as the Head of the UK Downstream business unit, primarily focussing on supplying aluminium hot and cold mills for steel plate and Steckel mills globally.

*Assistant Editor, Aluminium International Today

**General Manager, Head of Downstream UK, Primetals Technologies

Primetals Technologies booth at METEC

HOW HAS PRIMETALS TECHNOLOGIES BEEN INVOLVED IN THE ALUMINIUM INDUSTRY IN THE UK, AND CAN YOU ELABORATE ON THIS 50TH YEAR ANNIVERSARY?

From the UK side, it’s really interesting. We are seeing a number of investment opportunities, which is excellent because we’ve seen many industries leave the UK in the past 20 years.

In the past, we have been involved in relocating equipment from the UK to India and China, and now we are witnessing the flip side of that with a significant demand for new projects in the UK. There are several UK projects out there currently. Some of which have been announced recently, such as the Diageo/ BACALL project for can production, which will bring a significant new investment to the UK. Primetals Technologies are engaged in supporting these projects and this is fantastic news for the UK aluminium industry.

And it makes a lot of sense. We are

already seeing announcements for battery plants in the UK; every lithium-ion battery requires aluminium foil, and to produce foil, you need foil mills. Currently, there are no foil mills in the UK, so currently this all has to be imported, which isn’t very environmentally conscious.

While everyone talks about the lack of charging points for electric cars, not having enough materials to make the batteries is potentially a more significant issue. Therefore, the entire value chain needs to be connected and sensible. Importing aluminium foil from China to manufacture batteries in the UK makes no sense.

For us, what’s really important is although we do and can supply foil mills, we tend to provide the core technology for foil mills. That includes the automation,

the spray bars and the ShapeMeter. This year marks the 50th anniversary of our Air Bearing ShapeMeter (ABSM) production. We manufacture this in the UK in our Chirstchurch factory, located on the South Coast. We will have our thousandth reference by September this year.

The ShapeMeter is a highly accurate online shape measurement system that has rotor width ranging from 25mm, providing high-resolution flatness measurement across the strip width. This can be remotely located for easy maintenance and maximum equipment reliability. This also continuously measures and provides the most accurate representation of the strip flatness and is ideally suited for the foil mill revamp applications, where the exit side space is restricted.

WITH ALL THESE INDUSTRY INVESTMENTS WITHIN THE UK, IS FINDING A SUITABLE WORKFORCE A CONCERN? HOW CAN AUTOMATION COMBAT THIS CHALLENGE?

It is a challenge that as a business operating five different sites in the UK we face. We are lucky to have a lot of expertise and we’ve worked hard in recent years to protect and grow that knowledge and experience to ensure we have the workforce required for the future. We are big advocates of the modern apprenticeship programs, and we bring in around 5-10% of our workforce from new apprentices. We try and fast track them through the business to become the next experts. That’s how from an engineering point of view, we’re trying to cover that skills gap.

But we also see this issue from the client’s point of view, so how do we address it?

It’s really about the technology. It’s about the automation and about minimising the requirement on the workforce. So we ask, how much can we do with automation to make the rolling operators lives as easy as possible, and to make this process as efficient as possible. How can we guarantee the quality control and the throughput to the maximum possible levels?

This can only be achieved by having the best automation solution and quality control or measuring devices connected

together, all self-learning and constantly improving, to maintain the product quality.

Aside from this, on the maintenance side, it’s about having your asset monitored. Condition monitoring can make the maintenance engineers lives easier and rather than waiting for something to break, it’s about having predictive maintenance to predict, when things will start to wear out so the maintenance budgets can be controlled.

This will mean that sometimes you can employ a lower skilled person. You don’t always have to have the expert.

I think automation is needed because there are not enough people that really have a deep understanding of the aluminium rolling from maintenance side or from production side. It is very limited in the UK and you’re not going to be able to import these people.

So, our aim is to implement the automation system, making the workforce lives easier. We are also very much focused on being a partner with our customers. After we sell a product, we make sure that we support them by providing service contracts and training and by being on the end of the phone etc, when there is a problem.

Flat rolled products, specifically in this sector, have been experiencing an investment cycle for the past two or three years.

We have seen not only the major producers making substantial investments, but medium and lowertier producers have also begun discussing investments in major new equipment.

The aluminium commodity price skyrocketed post covid, stimulating the market for investment. The peak in the early part of last year caused some operators to step back from their grander plans. However, there remains a positive investment cycle within the aluminium industry with many significant projects in discussion around the world.

For the aluminium Industry, it’s a good time. We’re seeing a lot of conversion in end applications from steel to aluminium. Many people talk about aluminium being the metal of the future. It is greener than steel and its lighter weight than steel. It’s infinitely recyclable and can often have the same properties as steel.

It is an interesting material of choice and I think it’s a very good time for us to be in the aluminium business.

FLAT ROLLED PRODUCTS PRODUCERS AND INVESTMENT CYCLES

Foil Mill

WHAT WOULD YOU LIKE TO SEE FROM LEGISLATORS AND GOVERNMENTS ON PROMOTING GREEN-SHORING AND CIRCULARITY WITHIN THE INDUSTRY?

From a policy point of view, it’s difficult. ALFED and its members do a fantastic job in engaging with the government. It’s impressive how we clearly put across our requests, whether that’s for primary aluminium, secondary aluminium, casting, recycling, the UK industry work well together.

It would be nice to see more legislations, but I think we must be realistic. Ultimately, I think the industry must act themselves and it has to make economic sense.

We can talk about grand plans of completely changing the way things work, but realistically it won’t be a drastic change. It has to be a slow change in

ALTERNATIVE FUELS, CCUS ETC, HOW CAN THESE BE IMPLEMENTED IN THE UK?

Mitsubishi Heavy Industries (MHI), our parent company, are hugely involved in green technology developments including research into hydrogen technologies and its applications.

The challenge is the infrastructure for producing and supplying hydrogen in a cost effective and safe way, and this is a global issue. Certainly, there’s a lot of research and development trials ongoing. Primetals Technologies UK is engaged in a hydrogen trial project in the steelmaking sector and we would welcome discussions on similar opportunities in the aluminium sector.

In terms of Carbon Capture, MHI have an established solution in the KM CDR Process™ which is commercially viable in other industries and is currently being trialled in the metals industry ahead of further up-scaling.

Globalisation vs Localisation

A lot of people are talking about turning away from globalisation and becoming more localised. Certainly in the can industry, there is a noticeable trend of localisation in North America. The imposition of tariffs has driven this shift towards local production. India is doing something similar, and China appears to have a more inward-looking approach.

I think it’s positive that maybe, in the UK we’re not completely localised, but we are taking a step back from relying on everything offshored.

We’ve seen the impacts of the Russia and Ukraine war and the global pandemic, and we begin to ask ourselves, what’s next? What’s the next thing we need to prepare for? What is the next disaster?

We are starting to take business contingency planning much more seriously than we ever have in the past.

order for it to be a permeant change. It’s such a challenge.

To celebrate 50 years of our class leading aluminium strip shape measurement technology, Primetals Technologies is partnering with ALFED to host an event that recognises the importance of advanced manufacturing in the UK and specifically in the aluminium flat rolled products market.

The event program seeks to explore the important topics relating to key growth markets such as recycled aluminium sheet used in the beverage can market and where aluminium foil used in car

batteries manufactured in the UK will originate from.

The event will also include a panel discussion on new equipment versus modernising equipment, which is something that we’re quite passionate about even just from a green point of view.

There are lots of mills out there in the world that are not producing to their optimum capacity, so by modernising them you can get very close to the quality and yield that you would get from a new

IF YOU WERE ADDRESSING THE ENTIRE INDUSTRY, WHAT WOULD YOU LIKE TO SAY?

I think as an industry it’s about sharing knowledge and working together. Working in isolation isn’t going to resolve any environmental challenges that we have. The support has to come from the universities, research centres, aluminium producers, equipment manufacturers, and suppliers as well. We all have the same challenge to solve, so we must cooperate where it makes sense to do that.

mill.

So Primetals Technologies will be hosting a panel discussion with some of our people and some customers, on whether you should you buy new or modernise? We will discuss the difference in capital expenditure and the return on that.

The participants will also be given a workshop tour showcasing the advanced shape measurement technologies we manufacture in the UK.

THE ALUMINIUM FEDERATION EVENT

ABSM installed on a foil mill

Hot mill

ABSM Ready for installation

Stress analysis of a structural extruded profile

By Richard Keyte*

In this article I’m going to give an example of how we use finite element analysis (FEA) tools in our work at Innoval Technology. In this case study, our client wanted us to look at how changing the design of some AA6005a extrusions could increase the load carrying capacity of a structure. For us to do this, we needed to carry out a stress analysis.

I will cover some of the designs we explored to increase the load capacity whilst reducing the local stresses to below the softening factor stress. However, we also wanted to include an appropriate safety factor, or safe working limit. The Machinery’s Handbook provides safety factors for design engineers. For this structural application 1.5-2 was appropriate as we are using reliable materials and the environmental conditions were not severe.

The structure.

The structure consisted of three load bearing extrusions, which you can see in Fig 1

There were two vertical uprights bolted to the floor via a welded base plate. Multiple beams straddled the two uprights with bolts through welded end plates keeping them in place. All extrusions were in the T5 condition prior to fabrication.

Some background about structural alloys

Generally, aluminium alloys fall into two categories. Heat treatable alloys can have their properties improved by one or more thermal treatments. On the other hand, non-heat treatable alloys have their properties improved by cold deformation and work hardening.

Structural medium strength extrusions are predominantly made from 6xxx series aluminium alloys that are easy to extrude. This is because they have an elevated temperature flow stress typically less than 20MPa. They are insensitive to corrosion and can be age hardened (heat treated) with comparative ease to raise their mechanical strength. The main alloying elements for this group of alloys are magnesium and silicon (AlMgSi). However, the AA6005a alloy used for this application has additions of manganese and chromium to specifically improve toughness and crack resistance. As a result, it’s one of the main alloys used today for structural extruded profiles.

In addition to the mechanical properties mentioned earlier, AA6005a also offers excellent weldability using either 4000 or 5000 filler wire. However, when aluminium is fusion welded, metal from the individual part melts and re-solidifies

as one piece. The region of metal adjacent to the re-solidified joint is exposed to the heat used in the melting process, creating a heat-affected zone. In this region, the temperature is high enough to cause changes in the alloy microstructure. These can significantly affect the mechanical properties of the metal, reducing the local strength by as much as 50%.

Softening factors

To render these extruded alloys safe to use in welded structural applications BS EN-1999-1 “Design of Aluminium

Structures-General Rules” defines specific softening factors which we must apply to the mechanical properties of the extruded section after we’ve created a fusion joint.

Although this document does not specifically refer to AA6005a-T5, it does reference several AlMgSi alloys. From the values applied to these other alloys it is fair to assume AA6005a-T5 would retain about 48% of its proof stress after welding.

AA6005a 0.2%PS 240 (MPa) x 0.48 = 115.2MPa.

This represents the limiting stress or onset of plasticity which we could expect in the heat-affected zone of a fusion joint if the local stress exceeds 115.2MPa.

*Consultant, Innoval Technology

Fig 1.The basic structure

Fig 2. Linear elastic

Finite Element Analysis (FEA) tools for stress analysis

At Innoval the finite element analysis tools we use are Solidworks Premium and Ansys Mechanical Pro. Solidworks Premium has a linear elastic finite element solver which will determine induced stress within a model based on Young’s modulus. (Fig 2, elastic stiffness). This is 70GPa in our case. Stresses within this model take no account of yield, the onset of plasticity or any associated work hardening that may take place. However, it is suitable for analysis where stresses fall below the yield strength.

Ansys Mechanical Pro has an FEA solver that follows a bi-linear isotropic hardening curve based on uni-axial mechanical data from real tests (Fig 3). This solver follows the true deformation characteristics of the material. Hence, it is the generally accepted method for simulating the plastic deformation of aluminium. We define the rate of change of work hardening by the slope of the true stress, true strain curve within the uniform elongation range. The definition of this range is “post yield up to the onset of necking”. Ansys defines this region as tangent modulus or slope of the curve post yield.

Model development strategy.

At Innoval we model the parts typically at mid-tolerance and build the assembly models within Solidworks. We migrate the files into Ansys as IGES files and we add the appropriate connections, boundary conditions and forces to the structure. For this model the cross members were “bonded” to the end plates where they would actually be welded together (not all the contact faces). However, a “bonded” boundary condition will behave as if welded. We also applied a symmetry condition to the centre line of the cross member to save computation time (Fig 4).

Mesh details.

The FEA set-up will also include mesh refinement within the cross-member end plates (body). It also includes face refinement around the location slots in the uprights to provide greater accuracy within the critical areas (Fig 5). For additional accuracy, we’ve used quadratic tetrahedral elements. A quadratic element has a node in the middle of each side of the element. This additional node allows the element to form a curve between the 3 nodes. This in turn allows the elements to follow the deformed geometry more accurately.

However, it does add computational time. Finally, we have not carried out any simplification of the models. We modeled the extruded profiles according to the die drawings.

Outcome

The individual extruded profiles went through multiple iterations to achieve the final required load state. Using Ansys and Solidworks enabled us to alter the assembly model. We created a new version, then migrated the IGES file into Ansys, updating the geometry and improving set-up time.

During this analysis weight was a major consideration, not only for the cost per metre of the extrusions, but also for shipping costs as well. For the final version (Fig 6) some parts went through 34 iterations to optimise their design! Typically, the weight per metre increased by 20-30%. However, the loading capacity also increased by 30%. Deflections within the cross beam were down, and all welded parts complied with the imposed softening factors. Fig 6 shows the peak stresses in the welded end plate to be 64.5MPa. The softening factor 115.2/64.5 gives a safety factor of 1.78, which complies with Machinery’s Handbook.

How we can help

Innoval has a range of engineering design and simulation tools available to help optimise aluminium component and system geometries. Stress analysis, as demonstrated here, is just one part of this.

Analyses such as these can lead to more efficient, safer and more sustainable products while reducing expensive prototyping stages. Please get in touch with us to find out how we might be able to support your next product development project.

Fig 3. Bi-linear isotropic

Fig 5. Examples of mesh refinement

Fig 6. Optimised design showing reduced deflections and increased load capacity

Fig 4. Analysis conditions

ALUMINUM USA. October 25 – 26, 2023.

America‘s largest aluminum event covering application industries such as automotive, aerospace, construction, packaging and electrical & electronics.

For more info on exhibiting or attending visit: aluminum-us.com

Alumex PLC: Shaping industries with uncompromising quality and sustainability

Maintaining the highest quality standards in construction is crucial. Adhering to stringent measures directly affects the durability, safety, and performance of structures. Structural integrity, resistance to corrosion, and longevity are vital considerations for both residential and commercial applications. By upholding rigorous standards, construction professionals can assure clients that materials exceed industry benchmarks, ensuring lasting projects that meet regulations and deliver optimal value for all stakeholders. Moreover, embracing innovative designs, advanced technologies, and green building practices can significantly contribute to enhancing energy efficiency and promoting sustainability, building a resilient and energy-conscious world.

Alumex is a subsidiary of the Sri Lankan multinational diversified conglomerate; Hayleys Group, which is currently ranked Sri Lanka’s number one corporate. Having pioneered fully integrated aluminium manufacturing in 1986, Alumex has grown to earn its reputation as Sri Lanka’s leading provider of best-in-class and specialised light engineering, residential and commercial architectural aluminium extrusion profiles.

Quality and Sustainability

Quality and sustainability are the driving forces behind Alumex, an industry leader that is revolutionising the aluminium sector. With an unwavering commitment to excellence, they have set the bar high by adhering to the most rigorous standards and certifications in the industry. Their cutting-edge production facility operates at the highest levels of efficiency and has been recognised with esteemed accolades including ISO 9001:2015, SLS, Qualicoat (Sea side), Qualicoat, and Qualanod accreditations from Europe. Moreover, their unwavering dedication to sustainable manufacturing has earned them the prestigious EcoLabel certification by the Green Building Council of Sri Lanka (GBCSL), making them a beacon of responsible business practices in the aluminium extrusion landscape.

But it is not just about certifications and industry accolades for Alumex. They have made significant strides in reducing their carbon footprint through innovative initiatives and investments in cutting-edge technology. By establishing a state-of-the-

art Aluminium recycling plant, they have minimised energy consumption and greenhouse gas emissions, ensuring that their aluminium extrusions are produced with the utmost respect for the planet.

Alumex has gone even further in their pursuit of sustainability by launching the Ozon brand. This brand showcases a range of aluminium products that meet rigorous environmental standards. By promoting sustainability in their product offerings, Alumex actively contributes to a greener future by catering to the needs of customers around the world.

Unlocking Global Trade

Amid a challenging economic environment, Alumex took a strategic approach to prioritize exports as a vital catalyst for Sri Lanka’s sustainable growth and resilience. Spearheading the country’s reach into international markets in 2019, Alumex introduced aluminium extrusions as a new export category.

Commitment to value addition is another aspect that sets Alumex apart in the industry and has helped their transition to cater to global requirements. They offer precision, valueadded products tailored to the specific requirements of their international customers. This customisation capability enhances the competitiveness of their offerings and solidifies their position

as a preferred supplier for diverse industries. With a focus on precision, innovation, and quality, Alumex consistently delivers products that meet and exceed customer expectations.

The company has since experienced a rapid growth and expansion trajectory; currently exporting products to Australia, Bangladesh, Canada, India, Kenya, the Maldives, Nepal, New Zealand, the Seychelles, Switzerland, the United Kingdom, the United States, Germany and Italy and expanding operations across the globe.

Enriching communities

Beyond their commitment to quality and sustainability, Alumex has a deep-rooted dedication to social responsibility. They

Leading with Integrity and Responsibility

As one of the select few aluminium extrusion companies in South Asia to possess a comprehensive range of quality and system accreditations under a single entity, Alumex has solidified their reputation as pioneers of the industry. They understand that upholding the principles of good governance is paramount, and they strive to set a positive example for their peers. With a focus on capacity building, management efficiency, and unwavering accountability, Alumex ensures that every aspect of their operations adheres to legal frameworks and global standards. This unwavering commitment to quality, safety, and security guarantees that their final products are of the highest calibre. In recognition of their transparent operations and ethical

understand that their success is intertwined with the well-being of the communities they operate in. Through strategic investments in education, healthcare, infrastructure development, and environmental conservation projects, they uplift communities, improve livelihoods, and pave the way for a sustainable future for all.

Alumex also prioritises the development of human capital within the industry. One of their most impactful initiatives is their fabricator training programme, which aims to uplift the aluminium fabrication industry in Sri Lanka.

By equipping individuals with advanced skills and knowledge in aluminium fabrication techniques, design, and installation, Alumex fosters innovation, efficiency, and quality within the industry. This programme has empowered numerous professionals and contributed to the overall growth and development of the aluminium fabrication sector in Sri Lanka, a vital part of the ecosystem and very frequently the face of the construction industry to the customer. Their dedication to nurturing talent and uplifting the industry exemplifies their commitment to fostering this talent, nurturing the aluminium ecosystem thus driving societal development.

practices, Alumex has been honored by Transparency International Sri Lanka (TISL). This prestigious recognition underscores their dedication to operating with integrity and fosters trust among their stakeholders. By leading with transparency and setting an exemplary standard for the industry, Alumex is reshaping the aluminium sector and inspiring other companies to follow suit.

A Global Partner for Premium Customised Aluminium Extrusions

Alumex is a trailblazer in the aluminium industry, driven by their unwavering commitment to uncompromising quality and sustainable practices. With their impressive array of certifications and accreditations, they have positioned themselves as industry leaders and champions of responsible business practices.

Its parent company, the Hayleys Group has a rich heritage spanning over 145 years, and has consistently demonstrated a remarkable ability to adapt, innovate, and lead across diverse sectors. Hayleys is currently assigned an AAA (lkr) Stable Outlook rating by Fitch Ratings and is ranked Sri Lanka’s number one corporate.

With a portfolio that encompasses industries such as agriculture, manufacturing, transportation, and leisure, Hayleys Group has established itself as a true titan of the corporate landscape. Guided by a visionary leadership team, Hayleys Group has not only achieved remarkable financial success but has also become a beacon of corporate responsibility and sustainability, as the country’s only 5-time Best Corporate Citizen. Its unwavering commitment to social and environmental causes, coupled with its relentless pursuit of excellence, has earned Hayleys Group numerous accolades and widespread admiration.

Through their low carbon aluminium initiative, launch of the Ozon brand, and investment in social development, Alumex, led by the Hayleys Group, is shaping industries, fostering economic growth, and paving the way for a brighter and more sustainable future.

www.alumexgroup.com

Sustainability tops the CRU agenda

The CRU World Aluminium conference took place between the 16th-18th May 2023. Hosted in the beautiful surroundings of the St. Pancras Renaissance Hotel, London. Zahra Awan* was in attendance.

The 28th World Aluminium Conference was co-hosted, for the first time, by the International Aluminium Institute (IAI) and the Aluminium Stewardship Initiative (ASI). With a heightened awareness and conscious decision to steer topics to the sustainability of the industry, the CRU Group showed their support for global climate goals, whilst maintaining their well-known economic outlook conversations.

CRU commented: “The partnership with IAI and ASI reinforced CRU’s full supply chain focus on delegation and introduced interesting and new content about carbon accounting methodologies and allowed attendees to make valuable connections with industry peers, and build their professional network in a business social environment.” [1]

The CRU Group hosted over 360 delegates, who represented 170+ companies from 42 countries.

Opening the conference, and setting the theme, was Paul Williams, Head of Aluminium, Research Manager, CRU. In his opening comments he acknowledged the importance of “green aluminium and transparency”, as well as the “role of scrap and recycling… and new technology.” The conference covered many topics, but almost always returned to the impact of their actions on the transition to green production.

A second theme, first brought to our attention by Satish Pai, Managing Director, Hindalco Industries, was: “setting a target is the easy part… we are considering how targets are possible. Assessing the technology we have now, and evaluating what is possible with technologies we have in the future.” He raises a key point; it is clear that intentions and ability are two different facts. This lead a thread of thought to run throughout the conference, making the panellists and the audience reevaluate targets with realistic solutions. Unfortunately, reality is not as golden as the common greenwashed descriptions we often get from cooperations who aim to make a profit.

We begin to ask: Is the stark reality

not a part of transparency? Should we be discussing difficult conversations in conferences, or should they be hidden behind greenwashed doors?

The attitude of communities towards the green transition Community, in this instance, refers to the general public and the society within the industry as well as policy makers and governing bodies. Despite their separate categories, challenges, and names, they all are key to the success of sustainable aluminium.

Rachel Wiffen, Senior Process Engineer, Innoval Technology also noted the importance of educating the general public and the need for everyone’s collaboration. Scott Breen, Vice President of Sustainability, Can Manufacturers Institute have agreed with Rachel Wiffen, saying “for the USA, who are slightly less cooperative with recycling. We need to reeducate the public.”

Tolga Egrilmezer, Head of Sales & Marketing, Rio Tinto, commented that the pressures on communities and consumers to use green products should also be applied to governing bodies and policy makers. Sacha Brandtt, Vice President DACH & Head of Sales Extrusion Europe, Norsk Hydro ASA noted; “63% of consumers have changed their behaviour to live more sustainable in the last 5 years.” With the consumer community

demanding sustainable products, he stated the importance of the industry to provide consumers and producers not only the knowledge of green actions, but the materials needed to fulfil this.

For change across the value chain, and for significant change, policy makers are needed. Elaborating on a need for collaboration, Kelly Thomas, Executive Vice President and Chief Commercial Officer, Alcoa, stated “we need to work together, the targets we set have to be achievable but challenging… we need to push one another.”

In the fireside chat, Emilio Braghi, VP Novelis, also called for policy makers and government action to improve the environment aluminium works in, for example, he wishes for aluminium to be listed in the Europeans “critical materials list”. He closed with his statement: “we need primary aluminium to grow and develop the industry, we need recycled aluminium to succeed.”

It came to light that the current aluminium market cannot continue to be veiled under green tinted glasses. The reality of the industry is that it must survive and succeed by producing enough aluminium to fulfil the demand and keep the industry growth upwards. For this to work, the industry is limited to relying on fossil fuels for their base load.

Christian Koulic, Global Market Executive – Metals, TotalEnergies commented:

*Assistant Editor, Aluminium International Today

Photo courtesy of CRU World Aluminium Conference

“renewable energy is cornerstone to the progression the industry.” However, he later admitted that with the unreliable nature of renewable energy, and the need for baseload, renewable energy needs to be complimented with natural fuels. This caused for further discussions as it later became apparent that each society/ community holds differing opinions on the topic.

Later, Fauna and Flora Senior Technical Specialist, Corporate Sustainability, Hafren Williams discussed the impact of the industry on biodiversity, another community that must considered by society. She commented that despite actions and laws in place, a bare minimum is done by companies, governments, and other influential bodies to properly conserve and protect areas. This topic was also discussed at the Future Aluminium forum in mid-May, by Simon Lobach, Geneva graduate institute.

Sam Lacey, Director, Environmental Markets, Nature Metrics, continued the topic of biodiversity and the response from the industry in her session which took place on day two. Sam Lacey said “the importance of biodiversity and the awakening of the industry to the importance of its preservation and their responsibly to its preservation” is vital when fulfilling the title of a sustainable industry. In her discussion she reiterated that awareness of the environment and local communities must be considered by companies.

On the topic of human rights, Neill Wilkins, Head of Migrant Workers Programme, Institute for Human Rights and Business, discussed migrant workers and their importance in the industry. He stated that migrant workers will increase, and that they are needed. Observing the common challenge of an ageing population, Neill Wilkins noted that the industry required a younger workforce, an issue that can only be immediately remedied with migrant workers. He also questioned: “there are new opportunities in response to climate change…but can we managed this [demand for new skill, knowledge and job roles], do we have the work force?” His point stated the importance of migrant communities, and their role in the industry.

Circularity and recycling

Discussing the role of aluminium in the automotive and can industries, it is

apparent that the metal has the trump card. Its circular quality is key to its green metal image. Chris Bayliss noted that recycling must not be confused with circularity, a topic that would emerge in later conversations.

Mark White, Technical Director, Alumobility, spoke on the role of aluminium in the automotive industry, he said “unlike the can industry, the automotive industry is at the other end of the spectrum [the beginning of the journey]. The automotive industry is dominated by steel, whereas the can industry by aluminium. But the place for aluminium in the automotive industry is growing.” This topic of conversation was discussed in the May/June 2023 issue of Aluminium International Today, in an article ‘Steel vs Aluminium: The automotive industry’.

Andy Doran, Senior ManagerSustainability and Recycling Development, Novelis Europe, continued on the topic of circularity. “The story of circularity is still growing; it is still immature.” He also reiterated that circularity doesn’t stop at aluminium, that there is a need for a global mindset change. Complimenting this, Rosa Garcia Pineiro, VP Sustainability, Alcoa and President Alcoa Foundation, stated: “There is a need for change in more than just industry, we need to change the core of what it means to be a business.” She added, making steps to fulfil commitments in the name of sustainability or human right etc “may add complexities, but they hold long term benefits.”

Marlen Bertram, Director – Scenarios & Forecasts, International Aluminium Institute stated, “recycling has to become the heart of the industry.” Alison Conroy, Director, Global Sustainability, Novelis added that the industry must make “challenges into opportunities and make connections and partnerships with other companies.”

Transparency and collaboration

With a society, there is always bound to be competition, as well as need for fairness and collaboration. CRU discussed transparency and collaboration throughout the conference.

Chris Bayliss, Director of Standards, Aluminium Stewardship Initiative, moderated a session on data and transparency, focusing in on the threat of greenwashing in the industry. He reiterated that, “[Climate change] is not

an accountancy exercise, it is a challenge we are experiencing now!” Greenwashing threatens the progress of the industry; in the conferences we have seen this month, despite sustainability being the core topic, it can be interpreted that companies are also blindsiding key Environmental, Social and Governance (ESG) commitments.

Another point discussed on the ASI panel was assurance. It became clear that the industry lacked confidence when it came to data assurance and protection; the panel hinted at the possible business that could arise from this need.

Jean Simard, President & CEO, Aluminium Association of Canada started off the conversation on energy competition, he said “our challenge is ensuring we have renewable energy- we will not have enough [to share] across all industries.” This noted the importance of collaboration in the aluminium industry, as we struggle against other heavy manufacturing industries.

The conference also had a session on Sustainability and its Interconnections – exploring interrelationships between sustainability priorities. Josef Schoen, Corporate Strategy, Audi, who looked at the interconnection of aluminium with other metals questioned why there is such competitiveness, that borders hostility, between the metals industry, namely steel, and questioned the possibilities should there be collaboration. In the automotive industry aluminium leads circularity; Josef Schoen proclaimed that “[all industries] need you [aluminium] to help us all with regards to circularity, but your job doesn’t stop at aluminium, you must help beyond the industry.” It became clear that there needs to be a role model within the heavy manufacturing industries, and aluminium is that role model.

Mahmood Daylami, Secretary General, Gulf Aluminium Council, came forward with the reality behind global targets. He commented, “globally, things are going in a positive direction,” however, developing countries are being made to make changes when the technology they have is not to the standard of the developed countries.”

The decarbonisation target applies to all countries despite their economic and technological differences. Mahmood Daymai called for new technology, “without new technologies, we will not progress.” This called for the collaboration of countries, companies and organisations in the assistance of sustainable change in

Photos courtesy of CRU World Aluminium Conference

countries who have not had the privileges often boasted about in the industry.

Economics in the Aluminium Industry

Throughout the conference, CRU’s well known economic discussions took place. Looking at global trends, it became apparent that the global industry is collectively facing challenges, each depending on the location of the industry. Alex Tuckett, Head of Economics, CRU, provided an economic overview and noted that “headline inflation has come off it’s peak, but core inflation is much too high.”

Chinas market was discussed in day two by Jinny Yan, Chief China Economist, ICBC Standard. She concluded: Confidence across China is needed and that China faces numerous challenges, differing from the west. The key difficulties being: An aging population and lack of growth in the working population. She noted that inflation was not an issue for the Chinese economy. However, it was apparent that the global call for investment in renewable energy, for China, was a key challenge. The Chinas industry appears to have the desire to invest sustainably, but it is hindered by its lack of a youthful work force. With new technology, a growing skilled work force is

required.

The conference observed a shift away from globalisation and towards localisation, as well as the financial burden and strategies needed in place to successfully decarbonise the industry. These were topics left to the audience to think on.

Closing the conference was the session on Bauxite and alumina. The session focused on the supply and demand for bauxite and alumina and a special insight into the Guinean mining sector. Bauxite prices hit 14-year highs in 2022 in response to Guineas growing export levels. The panel discussed the opportunities and threats that come with the growing industry, paying attention to resource nationalism, Environmental, Social and Governance (ESG targets), ocean freight, ore quality, costs, reserves & investments, and government.

Digitalisation and Artificial intelligence

Another topic of conversation focused on Industry 4.0 transitioning. Thomas Quinet, Managing Director, PSI Metals GmbH, who

spoke on the uses of digitalisation tools in improving efficiency through Smart Scheduling and sustainability by transforming management to significantly increase energy efficiency and reduce CO2 emissions. He swiftly returned back to green production stating that “sustainability isn’t a side topic; it needs to be in our everyday lives and activities.”

Julie Al-Saadawi, Director, Industry Monitoring and Analysis for Trade Agreements Policy & Negotiations, International Trade Administration, U.S. Department of Commerce spoke on the new US Aluminum Import Monitoring (AIM) monitoring system, a new aluminium import data collection software.

This topic was also thoroughly discussed the previous week at the Future Aluminium Forum (read more on pages 6-10).

At the end of the conference, CRU announced the World Aluminium Conferences will return in 2024. They will be announcing more details on this event later in the year. �

[1] https://events.crugroup.com/ aluminium/home

Photos courtesy of CRU World Aluminium Conference

Tomra launches Autosort pulse with dynamic LIBS technology

TOMRA celebrates its next milestone in the metal segment by introducing AUTOSORT™ PULSE to the market. Equipped with dynamic LIBS technology for high-precision sorting of aluminium scrap by alloy types, the new sorting system can be used across a wide range of applications to create high-quality secondary metals. TOMRA elaborated on this new technology in an exclusive interview with Aluminium International Today. Speaking with Matthias Winkler* and Tom Jansen**, TOMRA delved into the details with regards to their newest addition.

The AUTOSORT™ PULSE

As the metals industry strives to increase recycling rates to reduce both energy consumption and the use of new materials, the use of best-in-class sorting technology is indispensable. They recover pure mono materials from mixed scrap that can be further processed and turned into virginlike material with high recycled content.

Frank van de Winkel, Market Strategy Segment Manager Metals at TOMRA Recycling Sorting, explains: “Aluminium scrap consists of multiple alloys. Depending on the application, they contain a mix of different alloying metals that define the material’s properties. To recycle a specific alloy without downgrading quality, it must be separated into specific alloy classes – a task that can only be done with the most sophisticated technologies, such as LIBS.

TOMRA’s team of in-house engineers dedicated significant time and efforts in the development of this technology to make it excel in performance. AUTOSORT™ PULSE gives recyclers the means to sort aluminium by alloy classes and produce

furnace-ready products for demanding applications.”

Next-level alloy sorting

AUTOSORT™ PULSE combines leadingedge technology in one machine, enabling high-throughput production of green aluminium. Featuring the patented, dynamic LIBS technology, it delivers outstanding performance in the separation of for example 5xxx and 6xxx aluminium alloys. The machine’s 3D object scanning detects each object regardless of its size and surface while multiple singlepoint scans enable sharper detection of materials in any condition. Thanks to its AI-based object singulation feature, even overlapping and adjacent objects can be accurately separated to maximise yield.

Conventional sorting machines like x-ray fluorescence (XRF) or standard LIBS technologies are limited in maintaining industry-level throughputs when sorting aluminium alloys. AUTOSORT™ PULSE has a combination of the most innovative technologies, leading to peak precision

and high-purity sorting results. Multiple material tests have demonstrated that purity levels of more than 95% can be achieved.

High volume processing

With a bulk infeed system and a processing capacity between 3-7 tons/ hour, operators can create high volumes of recycled content and thereby meet industrial standards across a wide range of applications.

Operators also profit from TOMRA’s proven track record and high safety standards. The AUTOSORT™ PULSE design protects workers from any potentially harmful or penetrating light emissions.

Matthias Winkler, Product Manager at TOMRA Recycling Sorting, states: ”We have a long-standing legacy in the metals segment and our finger is on the pulse of the market. Based on our extensive inhouse knowledge, we started developing the dynamic LIBS technology when we sensed alloy separation could help businesses reduce downgrading material.

*Segment Manager, TOMRA **Product Manager, TOMRA

After an extensive innovation phase, we have now extended our product portfolio with AUTOSORT™ PULSE to complement the new generation X-TRACT™.

Customers testing the machine are impressed by its results and the operational benefits it brings. They can run high throughputs and create highquality products, which gives them access to new material streams and makes them benefit from operational flexibility and a quick return on investment. I strongly believe that AUTOSORT™ PULSE will solve the sorting challenges of tomorrow.”

Data-driven results

The insights generated from sorting operation data play a critical role in facilitating plant operators’ quest to run a profitable business with little to no downtime and maximum output. Available as an additional service for AUTOSORT™ PULSE, the cloud-based data platform TOMRA Insight allows for a data-driven

optimisation of sorting processes through near-live monitoring. As critical sorting data is available anywhere and anytime, operators can anticipate operational issues and future maintenance requirements and be in control of the entire sorting line.

Supporting net-zero Aluminium is a very versatile material that is a highly demanded commodity for the transportation, building and construction and packaging industries, all of which contribute to an unprecedented demand for aluminium.

In Europe alone, demand is expected to grow by 40% from 2018-2050 with no signs of a trend reversal.1 At the same time, the aluminium industry is undertaking considerable decarbonisation efforts to reach worldwide climate goals, such as those set in the EU and US for 2050.

To bridge the gap between supply and demand and support the transition to a

EXCLUSIVE INTERVIEW

What prompted the idea of combining these technologies, where did the idea of LIBs come from?

Matthias Winkler (MWK): LIBS is known in science and material analytics for quite a while. Maybe not in such dynamic/moving solution, but for static or handheld scanners. The technology enables touchless scanning of objects (not direct mechanical interaction with the objects) and provide exact and material characteristic information.

Could you provide us with an indepth explanation on what happens inside LIBs?

MWK: Strong laser pulses create a plasma on the surface of any object. Plasma is a special state of exited matter. The emitted light of the plasma is very characteristic and more or less unique for every element. This has to do with the atomic structure of every element and the way the excited electrons recombine with the atom. Whenever an electron recombines it emits light of an almost exact wavelength. Those wavelength “peaks” is what we need for the analysis. The emitted light of the plasma is short light flashes typically in white/bluish color and a mixture of many wavelengths. In order to detect those characteristic peaks we need a spectrometer to split up the light in its components and transform the spectral information from light to

electrical information which we process in our software.

What else could be sorted by the LIBs? Does this extend to other metals?

MWK: From the technical principle of LIBS there are no limitations. As long as the element/object creates a plasma it contains the characteristic information. There are already scientific solutions for stone analytics (e.g Mars stones), concrete, polymers.

How is this different from other technology, what is the benefit of using LIBS over your other machines (AUTOSORT)?

MWK: From is analytical principle it is similar to AUTOSORT with NIR technology: LIBS is also able to detect the “fingerprint” of any element. Where AUTOSORT with NIR is just able to detect polymers and just able to scan the surface. LIBS offers much more possibilities and it penetrates the surface which means it´s almost independent of the surface quality. But currently, we do not see any benefit of combining LIBS with any other machine because LIBS provides already the most essential master information of every element.

How has working on this new technology been?

Tom Jansen (TJ): On one hand it has

climate-neutral society, the industry resorts to recycled aluminium which comes with a two-fold benefit: on the one hand, recycling aluminium is 95% less energyintense compared to primary production. On the other hand, it prolongs the lifecycle of already produced materials and gives new value to an abundance of scrap.

When it comes to decarbonising aluminium, TOMRA’s extensive knowledge of metal recycling and sorting technology is unmatched. Terence Keyworth, Segment Manager Metals at TOMRA Recycling Sorting, states: “Our intensive and long-term collaboration with some of the world’s largest scrap recyclers and aluminium producers is the foundation of our development process. With AUTOSORT™ PULSE and our new generation X-TRACT™, we provide the technological force in driving the aluminium sector’s net-zero transition as it delivers high-quality alloy scrap fractions for producing low-carbon aluminium.”

been quite challenging. TOMRA has designed the AUTOSORT PULSE from the ground up, implementing our patented dynamic laser technology and other unique features. During this development process, the demand for LIBS sorting was already growing, with high expectations from the market and anticipation from our customers. But now that we are finally here it is very exciting. We have been testing a lot with customers the past year or so, with results extremely promising and exceeding expectations.

How do you see it changing the recycling industry in the next 5 years?

TJ: The LIBS technology of the AUTOSORT PULSE can potentially have a huge impact on the recycling industry, especially for aluminium. Imagine recyclers being able to produce aluminium scrap fractions according to a certain specification or recipe – not only based on the content of heavy metals, which is currently possible with XRT technology but also based on elements such as Si and Mg. This would allow the producers to further increase the amount of scrap they can use on their path of de-carbonisation and would put the recyclers with this technology at a competitive advantage as top tier supplier. We expect that within 5 years the industry will have embraced the technology as the standard. �

Silicon – a ticking clock for Aluminium?

By Jayson Tymko*

Is the clock ticking for aluminium cans and alloy wheels? The answer is yes unless real progress is made on shoring up supply chains for certain critical raw materials and not least supply chains for silicon metal.

The drive to net zero, which necessarily involves a massive increase in electrification of all manner of infrastructure and lightweighting of transport will put unprecedented demands on a range of rare earths and other minerals, most of which are already in short supply and the production of which are restricted to a small number of territories outside of the US and Europe.

To be clear Sinova wholeheartedly supports the energy transition and is building what should be one of the most sustainable quartz mining and silicon metal processing operations in North America.

However, silicon metal isn’t even on the current American critical raw materials list and we are very aware of the misconceptions that abound in relation to this material. It’s essential to a large number of sectors and we are committed to setting the record straight and highlighting the very real risk of supply constraints that will affect industrial applications including aluminium, unless coordinated actions are taken soon to address it.

Quartz, from which silicon is derived, is one of the most abundant minerals on earth, it’s in sand and we all know how much sand there is just laying around for the taking.

However, when you’re talking about silicon metal in particular, quality is king. Refinement gets rid of some impurities but not all – essentially what you put in; you get out.

Additionally, the process to create silicon metal involves temperatures of around 3000 degrees Celsius. Most rocks shatter at 1200 degrees so you need a primary rock source that is both thermo-resistive and low in impurities. That means you can’t just go to the beach with a bucket

and spade to get your quartz. In fact, only a fraction of a fraction of all the quartz that’s out there, is actually usable for silicon metal.

The primary resource is, in fact, scarce and so any uptick in demand is going to be felt by every sector that relies on it.

Enter the drive to net-zero. Any way you slice it, silicon metal is one of the base building blocks that will deliver the energy transition because of its use in solar panels, energy storage, chips and EV batteries. There is no chemical alternative silicon metal for these technologies so competition for the material is going to intensify.

To put this into context in the US already uses twice as much silicon as it produces but by 2030 its demand for silicon will increase:

� x2.6 to supply the energy efficiency sector

� x5 to supply the microchip and semiconductor sector

� x5 to supply the solar power sector

� x100 to supply the grid storage sector

� x400 to supply the EV battery sector

Similar patterns are already playing out in the European and Asia Pacific regions –in fact by 2030 global demand will reach three times supply.

The trend is global. Historically China produced around two thirds of worldwide capacity of silicon metal. However recent issues around quality have seen the country importing silicon metal to mix with their existing stock. China now imports silicon from Brazil and the US just to make polysilicon for solar panels - that is a seismic shift. In fact, China’s five-year plan will see silicon exports going to zero as they struggle to meet their own internal consumption.

The competition for silicon will impact the aluminium sector A decade ago industrial applications made

up about 90% of silicon consumptiontoday they’re less than half.

That shift is not because of solar or microchips – it was the rising demand from the aluminium sector that changed the market. Over the last decade aluminium demand for silicon has increased from 10% to about one third of total consumption.

But over the next five years the energy transition will see aluminium’s share of silicon capacity cut from 32% to 10%and that’s despite the sector’s demand for silicon growing 5-6% per year.

This is because solar and semiconductor demand will grow from 19%-33% and demand from EV manufacturers from 1% to 28%.

Those three products are going to drive competition for supply and when you consider that an EV car requires 140% more aluminium by weight than an ICE vehicle and given the concentration of silicon metal in automotive aluminium is around 10% - ironically, even lightweighting is going to run into problems if supply can’t be secured.

The risk to the aluminium industry is plain to see – the exponential demand from the high-end sectors like solar and EV is going to constrain supply of the highest quality silicon and drive up the cost of lower grade stocks. This will impact all sectors relying on silicon and not least the smelters and producers of aluminium alloys.

There are solutions being built in North America to help plug the looming global supply gap and as a producer of quartz and silicon, Sinova is in active discussions with EU and US clients to supply them with the materials they need. However, the race to meet climate targets risks being lost along with unprecedented supply constraints to the aluminium sector without effective collaboration between governments, suppliers and customers to create supply chains fit to support domestic manufacturing. We need leaders from all sectors, including aluminium, to make this happen. �

*President and CEO of Sinova Global

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Proven to Protect

The benefits of utilising safety cages to protect against falling debris.

Worksite safety plays a big role in refractories, mines, construction worksites and a number of other operations. According to the U.S. Bureau of Labor Statistics, up to 50,000 workers were injured in 2020 when struck by falling debris. Additionally, between 2016 and 2020, there were 1,228 recorded fatalities due to the same safety hazard. Instances that don’t result in major injury or fatality often go unrecorded, which means the true numbers could be – and likely are –much higher.

These statistics are a hard reality and a major motivator for many companies to invest in safety equipment. Along with enhanced training and increased safety procedures, well-designed safety equipment can play a large role in companies’ efforts to protect employees from unnecessary risks. Safety cages are a simple, often overlooked solution that protects workers from falling objects, whether they are working in a kiln, in a mine or on a construction site. But not all safety cages are the same. Here are a few things to consider when looking for a quality safety cage.

Put Your Trust in Quality

The first criterion to consider is the quality of the design and material. Look for a manufacturer that designs its safety cages to meet the most stringent global standards and uses high-quality materials, such as 6061-T6 aircraft-grade aluminum. Well-designed safety cages include an umbrella-type structure to deflect large pieces of coating, rock or debris 360 degrees around the cage. To absorb the initial impact, the roof ribs are designed with “crumple zones,” much like a car, to protect the workers inside.

Another feature to help absorb shock that appears on industry-leading safety cage models is specially engineered legs that contain springs that absorb the remaining impact energy of falling material. The legs are tipped with spikes that dig into the ground to provide extra traction and stability upon impact. To catch smaller debris, well-designed safety cages also feature lightweight stainless steel mesh netting.

However, preventing serious injuries and fatalities is just one part of the safety equation. Ergonomic equipment also prevents physical strain that can cause injury and disability over time. A quality safety cage is constructed from lightweight material that makes it easy for two workers to carry with flip-up handles. A safety cage made from 6061-T6 aircraftgrade aluminum, for example, is just 140 pounds (64 kilograms) – as much as 50 percent lighter than a steel alternative.

Tested and Proven

Lightweight material might seem counter intuitive for safety cages; however, experienced safety cage manufacturers put their designs through various impact tests to ensure the material will stand up to the strain. Look for a manufacturer that implements both computer simulations and intensive destructive testing. Some manufacturers even conduct drop tests at 125% the maximum distance that actual conditions would allow. These tests involve using overweight materials dropped on different points of the cage at different angles to test each safety component. This level of research helps the manufacturer determine the maximum mass and velocity that the product can handle. Some safety cages can withstand up to 250 pounds

By Heather Harding*

(114 kg) falling from a height of 96 inches (2.44 m).

The real test is how the cage performs on the jobsite. A cement plant in Turkey, for example, had an incident where large amounts of coating fell while two workers were inside the kiln. The workers were using a high-quality safety cage that had been rigorously tested, and it handily withstood a greater load than its rating. The workers survived the collapse and escaped without injury.

Invest in Trustworthy Equipment

Keeping employees safe is one of the biggest factors of any jobsite, which is why safety is a subject that keeps industry leaders up at night. Something as simple as the addition of a safety cage to a jobsite can result in lives saved. Investing in a safe, quality product is a great way to protect employees against damages and, in the long run, protect companies from everything from fines to high insurance costs. Ultimately, investments in safety equipment are investments in success. Can you afford not to? �

Contact:

*Bricking Solutions Managing Director

Every step matters on the path to zero

To continue developing modern society, we need more materials, and we need more from our materials, too. What we produce and consume must not only meet the surging demand, but also embody the principles of responsible sourcing, environmental consciousness, and recyclability.

Aluminium, with its infinite recyclability and corrosion-resistant longevity, is already a building block for a low-carbon, circular economy, but production comes with a footprint. Our recycled and low-carbon aluminium products are one step closer to solving that problem, and one step closer on the path to zero.

Choose your materials with the future in mind. Visit hydro.com/path-to-zero to learn more.