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CONTENTS 1
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Volume 30 No. 2 – March/April 2017 Editorial Editor: Nadine Bloxsome Tel: +44 (0) 1737 855115 nadinebloxsome@quartzltd.com
COVER NEWS
2
EXTRUSION
HEAT TREATMENT
LEADER
HISTORY OF ALUMINIUM
2
Consulting Editor: Tim Smith PhD, CEng, MIM Production Editor: Annie Baker
www.aluminiumtoday.com March/April 2017—Vol.30 No.2
THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING
Sales Sales Manager: Anne Considine anneconsidine@quartzltd.com Tel: +44 (0)1737 855139 Sales Director: Ken Clark kenclark@quartzltd.com Tel: +44 (0)1737 855117
NEWS
UPDATES 6 INDIA - Changing the growth route 10 RUSSIA - Russian aluminium industry 15
Advertisement Production
ready for take off GULF - GCC primary aluminium
Production Executive: Martin Lawrence
production
Managing Director: Steve Diprose Chief Executive Officer: Paul Michael
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Circulation/subscriptions Elizabeth Barford Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 email subscriptions@quartzltd.com Annual subscription: UK £231, all other countries £251. For two year subscription: UK £416, all other countries £452. Airmail prices on request. Single copies £42
2 MINUTES WITH... Mahmood Daylami ASSOCIATION - Value Chain Voice: The Aluminum Association Today
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Cover picture courtesy of EGA
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PRODUCTS & PROJECTS
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Supporters of Aluminium International Today
EXTRUSION 21
Announcing the International Fair
Trade Alliance
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27
22
Billet quality and extrusion plant efficiency
27
Premium quality billets for
superior extrusion 30
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 Fax: +44 (0) 1737 855034 Email: aluminium@quartzltd.com
FURNACES 32
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Combustion system retrofits for
aluminium furnaces Fundamentals of gas nitriding
FIRE SAFETY Fire safety solutions
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BUYERS’ GUIDE Taster page
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Effective furnace lining efficiency
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Aluminium International Today (USO No; 022-344) is published bi-monthly by Quartz Business Ltd and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Aluminium International c/o PO Box 437, Emigsville, PA 17318-0437. Printed in the UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent, NP12 2YA, UK
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The power of aluminium
43
HISTORY The “Age of Aluminium” March/April 2017
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2 COMMENT
TOP STORY
AOG and GE agreement Aluminium: The driving force One of my mottos in life is to ‘practise what you preach’, which is how I am justifying my new treat to myself...a shiny Range Rover Evoque, with aluminium lightweighting as standard of course. I’ll forgive the guys at JLR, who tried to rain on my parade slightly by launching the new Velar in the same week! Built alongside the Range Rover Sport and Jaguar F-Pace in the ultra-modern aluminium body and assembly plant in Solihull, West Midlands, JLR insiders are confident that rising demand will drive Land Rover vehicle production to new record levels. It’s an exciting time for the automotive industry and it is good to see that aluminium is continuing its role as the ‘miracle metal’ when it comes to lightweight performance and sheer aesthetic beauty, but then I’m now biased. As always, this issue of Aluminium International Today is packed full of technical articles, with a special focus on extrusion, furnace technology and heat treatment. This issue also sees the introduction of a series of articles looking at the development of the global aluminium industry within its context, showing how from modest beginnings aluminium became ubiquitous and the industry global giant. Read all about it on page 43 I hope you enjoy the issue and please get in touch if you’d like me to make any site visits that require a long drive...! nadinebloxsome@quartzltd.com March/April 2017
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GE and Aluminium of Greece (AOG), a Mytilineos Group subsidiary, have signed a 10-year agreement in Dubai to implement global first-of-their-kind digital smelter solutions for AOG to enhance its aluminium smelting process and contribute to increased operational efficiency and productivity. The digital solutions are a significant step in charting the next generation of smelting operations globally. The agreement was signed by Dimitris Stefanidis, CEO of Aluminium of Greece and Joseph Anis, President & CEO of GE’s Power Services business in the Middle East and Africa, in the presence of senior officials of both companies in Dubai. “As the largest vertically integrated bauxite, alumina and aluminium production and trading unit in the European Union, we are constantly looking at innovative technologies to enhance our performance standards. The ap-
plication of digital industrial solutions is a remarkable opportunity to achieve process optimisation across our operations and to push productivity levels,” said Dimitris Stefanidis. “With GE’s digital smelter solutions, we are setting a global first for the aluminium industry that will contribute to our operational efficiency and set new benchmarks in the sector.” Underlining GE’s strong global collaboration, digital strength and industrial know-how, the digital solutions for smelting operations are being created by a team of engineers and developers based in San Ramon, USA; GE Power’s Digital Smelter Center of Excellence (COE) in Dubai, UAE; and GE’s Global Research Center in Bangalore, India. The project will be executed by the team based at the COE in Dubai, while the facility that the solutions will be implemented at is located in Agios Nikolaos, Viotia, Greece.
“GE has been at the forefront of digitising the future of industry globally and in the region, providing digital industrial solutions for power generation and the LNG industry, among others” said Joseph Anis. “By bringing together the strengths of our multi-locational teams and GE Power’s Digital Smelter Center of Excellence in Dubai, we will collaborate with AOG to create a new chapter in the history of smelting operations as well.” The digital solutions will operate in the cloud, powered by Predix, GE’s operating system for the Industrial Internet. Virtual sensors will facilitate the ongoing evaluation of parameters such as temperature and chemistry that are not ordinarily monitored continuously. This, in turn, will help to anticipate the health and condition of the pot, providing timely monitoring reports on the operations of the plant.
New project: Egypt According to reports, Egypt is setting up a new aluminium factory in Ataqa Industrial Zone, north of the Gulf of Suez. Tarek Kabil, Egypt’s minister of industry and trade, announced that a major Chinese company will
establish the new factory to manufacture aluminium plates that cover building façades. The project will be a joint venture between Egypt, Saudi, and China with a capital of $100m. The factory’s production would
meet a large portion of the local market’s needs and a portion of its production would be allocated for exporting. Approximately 1.6ha have been allocated in the industrial zone in Ataqa to start the factory’s construction.
New online tool from IAI The International Aluminium Institute (IAI), the global association of aluminium producers, has launched a new web-based tool to visualise the aluminium value chain, from bauxite to scrap, including inter-regional trade flows. In a fast changing sector, which has seen new regions of produc-
tion and consumption - led by China - grow at unprecedented rates in recent years, understanding inter-regional flows of raw materials and final products has never been more important. The IAI’s mass flow visualisation, available at www.world-aluminium.org/statistics/massflow,
allows users to manipulate an animated Sankey diagram, showing the production, consumption and trade of bauxite, alumina, ingots (primary and recycled), semis, final products and scrap across nine regions over the period 1962 to 2014.
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INDUSTRY NEWS 3
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Ardagh investment Ardagh Group has announced an important investment in its Rugby manufacturing plant for the purpose of converting its beverage can production capabilities from steel to aluminium. This venture will serve to support committed partnership agreements with some of the most well-established beverage brands in the world. The timeline for the conversion involves project commencement in Q4 2017 and with an anticipated completion in Q1 2018. The investment in the UK plant’s manufacturing capabilities signals a clear intent from Ardagh Group in the continued development of its recently acquired beverage can
business. “We look at this conversion as a key move in furthering Ardagh’s
overall footprint and are confident it will be welcomed by our customers, the Rugby plant and our other key stakeholders,” said Oliver Graham, CEO Ardagh Metal Beverage. The Rugby UK plant was first established in 1989 as a two-line aluminium plant. In 1996, the plant
NEWS IN BRIEF Orbite: 1 tpd HPA was converted to steel to support customer needs at that time. Processes within the plant are currently being optimised via Ardagh’s Wrexham plant and other locations across Europe to ensure that customer expectations continue to be met during the plant’s downtime. Aluminium is a permanent material meaning it can be infinitely recycled without loss of quality. Universally recognised for its protective qualities, versatility and environmental credentials, aluminium has the strongest recycling rates of all packaging materials in Europe, thus effectively contributing to the fundamental principles of a circular economy.
Futura acquisition Bonnell has announced that its parent company, Tredegar Corporation has agreed to acquire 100% ownership of Futura Industries. Upon the closing of the transaction, which is expected by mid-February, Futura will become an operating division of Bonnell Aluminum.
Tenova FAC at Nachterstedt
New rolling mill Danieli Fata Hunter has supplied and installed a cold rolling mill and a tension leveling line at the new Eurometal greenfield plant located in the new Kleszczów Industrial Park in Poland. The cold rolling mill produces 120,000 tpy of aluminium coils, coming from two casting machines, with a thickness of 10 to 6mm and which are rolled down to a minimum thickness of 0.15 mm at a max speed of 1200m/ min., with a max strip width of 2.1m. Equipped with the induction heating system for tight edges
Orbite is approaching 1 tonne per day of HPA production. “We are very pleased with the progress of production, and we are on the doorstep of our intermediate goal of continuous 1 tpd production,” stated Glenn Kelly, CEO of Orbite.
At the end of last year, Novelis Deutschland GmbH gave Tenova the Final Acceptance Certificate for its aluminium automotive Finishing line at the Nachterstedt Plant in Germany. Located adjacent to Novelis’ existing rolling mill and the world’s largest aluminium recycling centre, the $85 million global investment will increase annual production capacity by 120,000 metric tons of automotive sheet and will provide global customers with high-quality automotive sheet of alloys used in lightweight vehicle structures and body panels.
control, a new VOC emission control to guarantee low emissions, and a rolling oil recovery and distillation system, the mill is run by the Danieli FATA Hunter hSystem® to automatically control AGC and AFC and can roll a wide variety of products from foil stock to can body with best-in-the market tolerances and quality. Thanks to Danieli FATA Hunter’s leading leveler technology and design, the tension leveling line can produce quality strip while combining a cleaning section that minimises the use of chemicals employed on conventional lines.
EGA joins ASI Emirates Global Aluminium has become the first Middle East-headquartered aluminium company to join the Aluminium Stewardship Initiative (ASI), which brings the world’s leading mining and metals companies together with household-name aluminium customers to set global standards for governance, environmental and social responsibility. EGA has invested almost $1 billion since 2010 in environmental technologies and facilities to reduce and manage its emissions and waste, and makes important social contributions including creating employment, spurring Aluminium International Today
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broader economic development and focusing on safety and worker welfare. Existing members and supporters of the ASI include mining and metals companies such as Alcoa and Rio Tinto and high profile companies that use aluminium in their products from Apple to Audi, BMW, Coca Cola and Nespresso. Abdulla Kalban, EGA’s Managing Director and Chief Executive Officer said: “Aluminium touches the lives of almost everyone on earth, and the impacts of making aluminium do too. “Being a member of the Aluminium Stewardship Initiative will
enable us to share what we have learned about governance and environmental and social responsibility, as well improve our performance further.” Fiona Solomon, Chief Executive Officer of the ASI, said: “EGA is the largest aluminium producer in the Gulf, which has become an important global centre of aluminium production. “We welcome EGA to the Aluminium Stewardship Initiative and the work we are doing to develop sustainability standards and a certification program for the entire aluminium value chain.”
For up-to-date news & views www.aluminiumtoday.com
March/April 2017
21/03/2017 10:27:46
4 INDUSTRY NEWS NEWS IN BRIEF Craft beer in cans Ball has collaborated with Norwegian craft brewer Lervig Aktiebryggeri, to produce packaging for selected expressions of its craft beer range. This sees Ball extending its cooperation with craft brewers, now manufacturing cans for craft beer in Norway in addition to the UK, Ireland, Germany, Spain and Sweden.
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Hydro: LoI and MOU and witnessed by Hydro’s CEO, Svein Richard Brandtzæg, and Governor of Pará, Simão Jatene. The LoI aims to develop infrastructure and enable the use of natural gas in the region. Hydro Alunorte would be the first significant consumer of gas, and an enabler for establishing new LNG (Liquefied Natural Gas) infrastructure in Pará.
Hydro has signed a Letter of Intent (LoI) with the state of Pará and also a Memorandum of Understanding (MoU) with Shell Brasil Petróleo LTDA, with the aim to replace a major part of its current fuel oil consumption at the Alunorte alumina refinery in Brazil with more environmentally friendly natural gas. The LoI with the Para Government was signed in Belem, Brazil
Recycling congress success Alufoil Winners Bauxite project Rio Tinto says that with the beginning of construction of its $2 billion dollar Amrun bauxite project in Far North Queensland, it will create about 300 jobs for the local people.
Hansens Aluminum The state of Kentucky has approved a grant of about $1 million to Hansens Aluminum, a South African aluminium company that plans to open a plant in Henderson.
The Kentucky Department for Local Government has approved the funding to Hansens Aluminum under Community Development Block Grant programme for the purchase and lease of equipment in order to develop a 75,000-square-foot facility within the Henderson Riverport industrial area.
EGA chooses Fluor Emirates Global Aluminium (EGA) has announced that its subsidiary Guinea Alumina Corporation has awarded an engineering and programme management consultancy contract for its under-construction bauxite mine in the Republic of Guinea in West Africa to Fluor Corporation.
The total value of contracts and purchases to be managed by Fluor is approximately $700 million.
European Aluminium reiterated its commitment to the circular economy at this year’s 14th International Aluminium Recycling Congress. Europe plays a leading role in this debate but will need to cooperate more closely on a global level to close the loop. EU policymakers should ensure equivalent standards for treating exported EU scrap to truly impact the global stage. On 7 and 8 February, over 150 delegates flocked to Manchester from across Europe to participate the 14th International Aluminium Recycling Congress. A biennial event, this edition’s theme was Recycling at its best: the circular economy opportunity. “Europe is creating the basis for the circular economy, but we need to close the loop on a global level,” stated Gerd Götz, Director General of European Aluminium.
“We follow high environmental, health and safety standards in Europe when recycling aluminium scrap. “However, when scrap is exported to other parts of the world it is not required to be treated according to equivalent standards. This skews competition, creating an unlevel playing field with the rest of the world. This is why we call the European Parliament to adopt measures that ensure these standards are enforced.”
In recognition of their packaging excellence six products, which won the prestigious Alufoil Trophy, have been awarded a WorldStar by the World Packaging Organisation (WPO). The winning alufoil products were made by Ampac Flexibles; Ardagh and Amcor Flexibles; Constantia Flexibles; Guala Closures and Huhtamaki Flexible Packaging. Cédric Rauhaus, Manager Communications of the European Aluminium Foil Association, EAFA, said, “Our industry always strives to be proactive and innovative with its packaging solutions. These important WorldStars are proof that our members make both clever and highly practical packs and demonstrate the overall performance and environmental contribution aluminium foil can make to packaging.”
2017 DIARY April 25 - 27 7th International Conference on Electrodes for Primary Aluminium Smelters* As before, the conference topic will include both anodes and cathodes. Held in Iceland. www.rodding-conference.is
May 15-17 Aluminium Middle East* Held in Dubai. www.aluminium-middleeast.com
23 - 24 Aluminium Valley in Business
Located in the heart of the Aluminium Valley; Quebec, Canada. www.valuminium.ca
June 6-8 HARBOR’S 10th Aluminium Outlook Summit* Held in Chicago, USA. www.harboraluminumsummit.com
20 - 24 Aluminium Two Thousand-ICEB/METEF* Conference held in Verona, Italy, alongside METEF, the expo of customised technology for the aluminium and innovative metals industry. www.aluminium2000.com/www.metef.com
*Pick up a free copy of Aluminium International Today at this event For a full listing visit www.aluminiumtoday.com and click on Events Diary March/April 2017
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Aluminium International Today
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6 INDIA UPDATE
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Changing the growth route By Beethika Biswas* The Indian aluminium industry is on the threshold of changing its growth route. While the process started in 2015, efforts are slowly taking concrete shape now. India already has an upper hand in aluminium production due to the presence of high quality metallurgical bauxite ore and an abundance of coal. However, so far, the domestic industry has been referring only to the primary applications of the metal and a handful of downstream applications in the field of casting and extrusion mostly to be used in electrical, construction, automotive and household sector. While the global aluminium industry is shifting its focus to the downstream sector after the primary sector has come to a saturation point, India is also not lagging behind in strategising its moves towards a value added sector that can add value to its aluminium. It is a time when India is poised to become a consumer of aluminium rather than a net exporter of the metal. Raw material security for producers According to the latest report by Geological Survey of India (GSI), India has 306.60 billion tonnes of coal reserves of which Prime coking coal is 5.313 billion tonnes. As per UNFC system, bauxite resources in India are placed at 3,739 million tonnes including 830 million tonnes in reserves. By grades, about 81% resources are of metallurgical grade. Implementation of Mines & Minerals Development and Regulation Act-2015 has paved the way for better raw material security for the metal producers including aluminium by allocating mineral blocks through auction for a longer tenure and reserving mines for specific end uses like alumina and aluminium. The central and the state governments are also trying to find a solution to the bauxite sourcing crisis caused by environmental and tribal issues. On a positive note, the Odisha government and Odisha Mining Corporation entered into a partnership in January 2017, to provide bauxites to the Vedanta Aluminium’s Lanjigarh alumina refinery. Lanjigarh alumina refinery will get bauxite supplies from Kodingamali bauxite mines in Odissa with total reserves of 81 million tonnes.
The refinery has been facing a bauxite shortage after the Niyamgiri bauxite mining project was shut down, following the Supreme Court’s decision and local tribal objections. In an earlier development, central government asked the PSU Nalco to allow Vedanta to participate in Nalco’s tenders for buying alumina.
also call for the use of aluminium in the construction sector. Secondary demand for aluminium consumption is expected to be driven by growth in the automotive sector. As the consumer sentiment improves along with the growing GDP, automobile demand has a very favourable growth outlook for the next five years.
Improved upstream production According to the latest report, bauxite production in India stands at about 22 million tons and production of alumina is about four million tons. The total domestic production of aluminium metal grew by 19.1% YOY, from 2.05 million tonnes in 2014-15 to 2.44 million tonnes in 2015-16, driven by continuous primary metal ramp up by the domestic aluminium producers. Aluminium exports by Indian primary producers also registered a 15% growth YOY, from 0.77 million tonnes in 2014-15 to 0.88 million tonnes in 2015-16. All three major aluminium producers have reported YOY growth through the third quarter of FY-2016-17 and are expecting better production results for the full year.
Downstream focus by primary producers The three aluminium majors in India are currently on a different growth strategy in downstream capacity expansions in order to cut down on import reliance on aluminium products. Hindalco, one of top primary and downstream aluminium makers in India is expected to double its downstream production from 1.3 mtpa to 2.6 mtpa over the next two years. “As the country is growing, demand for downstream products is mounting… demand is rising, from packaging and transportation,” says Satish Pai, MD, Hindalco. Hindalco is planning to expand its downstream brands to leverage on the growing market. In the domestic market, Nalco is focusing on rolling out more value-added products. Under the Make in India initiative, Nalco is planning to take up a joint venture with Indian Defence Ministry’s Mishra Dhatu Nigam Ltd (MIDHANI) MIDHANI to manufacture auto-grade aluminium and other products, which are not manufactured in India. Dr. Tapan Kumar Chand, CMD Nalco said, “51% of India’s aluminium requirements are presently met through imports from China, Middle East and other countries. Of this, a major portion is valueadded products that are not produced in India, and are used by the auto and aero sectors.” The plant will be located in Angul Aluminium Parks, which would be an industrial park by Nalco in collaboration with Odisha Industrial Infrastructure Development Corporation comprising SMEs. Nalco has agreed to supply up to 100,000 tonnes of molten aluminium every year at a discounted price to the downstream units in the park.
Focus on consumption and “Make in India” initiative As forecasted by a 2016 report by Crisil, a research service, aluminium consumption in India would grow from 3.3 million tonne (mt) in 2015-16 to 5.3 mt in 2020-21. Domestic consumption of primary metal also showed a sharp jump of 25.4% YOY, from about 1.58 million tonnes in 201415 to 1.98 million tonnes in 2015-16. Thanks to a series of new initiatives by the government like, Make in India, Smart Cities, rural electrification and housing, indigenisation of defence and freight corridors, there is much more potential for aluminium consumption to grow in the coming time. The power sector is expected to be the prime consumption driver for aluminium, as aluminium is substituting copper at a faster rate as a cheaper, lightweight alternative. The government is set to expand India’s electric transmission and distribution network aggressively in next five years. Faster urbanisation will *Content Head – AlCircle
March/April 2017
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8 INDIA UPDATE
Vedanta owned Bharat Aluminium Company Limited (Balco) resumed sheet rolling operations at its Korba facility in Chhattisgarh, India in July, 2016. This marks the metal major’s comeback in the rolling aluminium products business that was held up about a year ago. The rolled product facility produced 6,100 tonnes of aluminium rolls during the 3rd quarter. The company is also investing in producing special extrusion alloy billets customised for the automotive sector considering the growing demand in India. Jindal Aluminium Ltd (JAL) is the leading aluminium extrusion company in India with an installed capacity of 100,000 tpy. The company produces aluminium flat rolled products like sheets, coils, and chequered sheets and meets 30% of total demand in the country. MIP and Invert Duty structure Domestic aluminium producers are urging Minimum Import Price (MIP) to combat cheaper imports from China and the Gulf countries. They claim that imports which account for 51% of India’s demand and are forcing domestic producers to idle 49% of their rated capacities. Domestic aluminium makers are also concerned
2011-12 2012-13 2013-14 2014-15 2015-16 All figures in kilotonne
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Post-demonetisation, the World Bank has lowered the country’s GDP growth estimate for this fiscal to 7%, from its earlier estimate of 7.6% made in June 2016. According to the data released by the Indian Central Statistics Office, India’s economic growth is estimated to slow to 7.1% in the current fiscal year ending March 31 compared to 7.6% last year. The central economy minister has predicted India’s GDP growth for FY 2017 - 2018 to be upwards of 7% considering the present situation. Notably, key segments of the mines and mineral industries remained unaffected by demonetisation and posted a sharp increase in output in the NovemberDecember period. The latest data from the coal and mines ministries are well supported by a record rise in electricity generation and consumption, indicating there was no slowdown in industrial activities. According to Mines ministry officials, copper and aluminium production continued growing even after demonetisation as SMEs making tubes, wires, plates and other alloys continued driving copper and aluminium demand.
2,473
The auto sector has shown a decline however, this sector is still not the highest demand driver of aluminium in India. The top aluminium producers have recorded substantial growth in the months after demonetisation negating very less impact at the macroeconomic level. Overall, the Indian aluminium industry is in a positive phase looking at further growth in the coming financial year. Although major companies are still awaiting the full year results, the individual forecast is bullish. The effect of demonetisation is gone and the country is on the path of remonetisation. The Government has already provided a modest boost to the economy with a smallish budget deficit. Inflation seems to be under control as the greenback is falling. Even with a 7% growth rate for 201617, India will still be the fastest growing major economy in the world, bypassing China, which is projected to grow at 6.5% in 2016 and this will naturally drive positive growth for the aluminium industry in India. �
2,704.3
2,587.70 2,852.10 3,243.3
Source: Ministry of commerce
over the present inverted duty structure that makes raw materials like caustic soda and aluminium fluoride expensive by adding more import duties. The Aluminium Secondary Manufacturers Association (ASMA) has, however, requested the Finance Minister and Commerce Minister not to impose the MIP on aluminium in order to protect the cause of 3500 Aluminium MSMEs in India. The FY 2017-18 budget has not implemented MIP on aluminium despite the pressure but the issue remains debatable for the time being.
Aluminium consumption in India
Demonetisation and its effects On November 8, Prime Minister Narendra Modi announced the demonetisation of INR 1,000 and INR 500 notes, in order to fight black money, counterfeit currency and terror financing. The demonetization drive and the temporary setback in economic growth have encouraged a number of forecasts about India’s GDP growth and the industrial growth. March/April 2017
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10 RUSSIA UPDATE
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Russian aluminium industry ready for take off While accounting for around 7% of global primary aluminium production, Russian aluminium consumption is as low as 1.6% of the world’s total. This is due to change, though, in the coming years. A recently adopted governmental program to boost demand for high added value aluminium products, efforts undertaken by the Russian aluminium association, establishment of Aluminium Valley in Siberia as well as an overall improving economic outlook for Russia indicate positive prospects for the ‘winged metal’ in the region. By Vera Kurochkina* At present, Russia and CIS countries consume around 1.4 mln tonnes of aluminium annually, with 1 mln tonnes of primary metal and almost 400kt of imported metal and semifinished products. Per capita, aluminium consumption in Russia is just 5.6 kg which is a low level for any industrial country, whereas the world average is 8 kg per capita. Domestic enterprises only supply 65% of domestic demand for semis and aluminium products. The other 35% are imported. This means that the potential for growth for the aluminium industry in Russia is tremendous. Back in 2015, with the aim to create optimal conditions for the development of Russia’s aluminium related industries the Aluminium Association of Russia was established. The Association brings together companies producing aluminium and aluminium-based products, with a total of over 50 members, and had been highly active since its very establishment. One of its major achievements in 2016 was the approval of ‘The Plan of Actions to Stimulate the Demand for High Value Added Aluminium Products’ by Head of the Russian Government Dmitry Medvedev. Speaking at a cabinet meeting in early December 2016, Dmitry Medvedev said: “We expect to see increasingly wide use of aluminium, whether in the construction industry, transport, power generation, or in machine building. Aluminium consumption is forecast to grow in the aircraft engineering and the shipbuilding industries, as well as in rail wagon engineering.” As far as central
and local government procurement and procurement for government companies are concerned, priority should always be given to Russian aluminium products. The plan of actions to stimulate the demand for high value added aluminium products, which is published on the website of the Russian Government, estimates overall growth in demand at 505,000 tonnes by 2020. Despite this being a conservative scenario, the potential of measures suggested on this list is predicted not to end there, with the growth continuing through the following years. The biggest producer of aluminium in Russia and worldwide, United Company RUSAL, believes aluminium consumption
in Russia can grow even higher than that through development in key industries: Automotive (+235ktpa of consumption), construction (+210ktpa), other transport (+400ktpa) and cable industry (+183ktpa) to reach levels of above 2 mln tonnes of consumption per year. Sound foundation already laid In order to support the aluminium consumption growth in Russia, a lot needs to be done. The Russian Aluminium Association is currently working on development of accreditation and certification systems, is involved in discussion on the prospects of aluminium structures use and measures required to remove the restrictions on their use in
*Deputy CEO, UC Rusal March/April 2017
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Aluminium International Today
13/03/2017 14:53:02
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12 RUSSIA UPDATE
the construction sector, the possibility to boost aluminium consumption in the power-generating industry, prevention of counterfeiting and fake product production, and other issues topical for the industry. “The first year of operation of the Aluminium Association has laid sound groundworks for its further operation. One of the goals pursued by the Association is to achieve the worldwide average level of domestic aluminium consumption, meaning that the aluminium products production in Russia will have to expand by a factor of 1.5-2. The 2016 export sales exceeded the import sales with 198,000 tonnes against 160,000 tonnes. The Aluminium Association intends to invest all available resources into maintaining this positive trend in the domestic market in the years to come,” Chairman of the Aluminium Association Valentin Trischenko commented. At the end of last year, the Association signed a cooperation agreement with Association of Railway Equipment Manufacturers that provides for promoting wider use of aluminium in the railway transport engineering – in the building of hopper cars, gondola cars and tank cars. Switching to export-oriented policy As a member of the Association and the leader in the Russian aluminium market, RUSAL also provides its views on the industry trends and forecasts. According to RUSAL’s Head of Russia and other CIS countries Sales Roman Andryushin, the company has improved its 2017 aluminium sales forecast for the Russian and other CIS countries markets and now expects a 10% growth of up to 900,000 tonnes. “These past three years we have been expanding our sales in Russia and other CIS countries – all this quite contrary to the economic trend and despite the drop in consumption. In 2015, the sales had grown by 3.5%, in 2016 we saw a growth of 5%. As for 2017, we have revised our projections. Initially, the planned growth was to reach some 5%, but now our target is 10% as compared to the previous year figure. We have sold 810,000 tonnes of aluminium in 2016; the target for this year is 900,000. This is the fastest growth of the Russian aluminium industry,” Roman Andryushin commented. RUSAL aims at bringing the sales growth in the domestic market up to 1.5 million tonnes by 2021. And yet, Roman Andryushin asserts, this clearly ambitious goal is impossible to attain without boosting the aluminium export from Russia, implementing new technologies and competences, and providing further March/April 2017
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training for employees. “The potential of import phase-out is going to be fully exhausted throughout this and the coming year. During this period we will, of course, be able to substitute the import of some items, but with others this will not be possible, simple as that, because this is where we are obviously anything but competitive,” RUSAL’s top manager explains. In 2013-2014, the total aluminium products imported into Russia and other CIS countries averaged some 700,000 tonnes. Currently, the import volume has dropped to 180,000 tonnes and is represented chiefly by hi-tech goods. The reduction of the import volume was due not as much to import phase-out as to the market squeeze. “We currently estimate the share of import phase-out at 100,000 tonnes; the remaining 400,000 have simply vanished from the market. The potential is presently rather modest, some 50,000-100,000 more can be substituted perhaps, but this is way less than we would like to aim at. Our target figure is hundreds of thousands of tonnes,” the Head of Russia and other CIS countries Sales concludes. “Import phase-out is basically a rather detrimental strategy, if we look at it from the global perspective. It is somehow similar to introducing protectionist measures. All industries, including the aluminium sector, can only develop provided there is healthy competition in both the domestic and the foreign markets, and the goal is to improve and excel in terms of quality and prices alike. And this is quite possible,” he adds. “The capacity of export markets is truly unlimited: every year 60 million tonnes of aluminium are consumed globally, and this figure is forecast to rise up to 80 million tonnes by 2020. What is more, this market is not constrained by either economic factors or possible demand fluctuations. What we have got to do is to identify the niches we could fill successfully and be competitive,” Roman Andryushin said. Beauty comes in aluminium On the eve of the annual meeting of the Aluminium Association, RUSAL announced that it was going to participate in the construction of the first ever aluminium tram interior in the entire history of Russian transport machine building. A tram interior fully made of aluminium would represent a brand new segment of the domestic market, and one with a massive potential for further growth. In the autumn of 2016, TransMashHolding won the tender to supply, in 2017-2019, 300 Vityaz-M trams for Moscow’s public transport system.
The said batch is going to be produced by PK Transportniye Sistemy and supplied by Krasnoyarskiye Mashinostroitelniye Komponenty Ltd. The metal required for the construction of aluminium interiors will be delivered from the Krasnoyarsk aluminium smelter, which is part of RUSAL, to the Krasnoyarsk steel work, where extruded section is produced. Next, aluminium products will be forwarded for recycling to Krasnoyarskiye Mashinostroitelniye Komponenty. According to estimates by RUSAL, supplying 300 trams with aluminium interior will require 500 tonnes of this metal. “Construction of aluminium tram interiors can be seen as a touchstone for wide-scale implementation of aluminium in the majority of transport machine building segments, an example of the growing export potential of Russian producers, and, moreover, as a perfect example of how successful import phaseout can work,” Roman Andryushin summed up. “We are in the middle of negotiations with a number of European tram producers about potential supplies of aluminium interiors.” Yet this is just one of the examples. Back in 2016, RUSAL also signed an agreement with Velomotors, a producer of bicycles and ATVs. The companies agreed to build a facility in Krasnoyarsk to produce aluminium frames for bicycles. The facility is expected to have a capacity of approximately 1 mln frames per year (each frame weighs 3.5 kg and the construction elements add another 1.5 kg). Once the facility becomes operational in 2017 and reaches project capacity, it will be able to annually consume 5,000 tonnes of aluminium. Velomotors plans to purchase an additional 1,000 tonnes of aluminium per year to produce aluminium wheels for bicycles. Together with the Russian ministry of industry and trade, the Russian aluminium association and other parties in 2016 RUSAL has launched over 80 projects which are aimed at increasing domestic demand for aluminium. The most important project initiated by RUSAL is ‘Aluminium Valley’ in the Krasnoyarsk region. This project aims to create a hub of downstream aluminium products production, further strengthening the current market position. All these projects are in line with the strategy to increase aluminium consumption in the domestic market from current levels of 1.4 mln tonnes (primary and imports) to 2 mln tonnes by 2020. With the outlook for the Russian economy improving, these plans have good chances to succeed. � Aluminium International Today
13/03/2017 14:53:02
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GCC UPDATE
15
GCC primary aluminium 2016 production Collectively, the five aluminium primary producers; EGA (UAE), Alba (Bahrain), Ma’aden Aluminium (KSA), Qatalum (Qatar) and Sohar Aluminium (Oman) have produced 5,229,115 tons of primary aluminium in 2016. “During 2016 GCC aluminium smelter and downstream have been going through disciplined productivity improvement and cost cutting initiatives, while maintaining key competitive advantage of having most sophisticated facilities to produce a variety of value added products for local and international market. “At the same time preserving its leadership position of high environmental standards, compared to the rest of the world”, said Mr Daylami, Secretary General, Gulf Aluminium Council. GCC aluminium production constitutes 10% of the total world production and is considered one of the key economic drivers for the Gulf region. Approximately 40% of the total production are utilised by the downstream aluminium industries in the Gulf and 60% exported to different parts of the world. � Contact info@gac.ae
Tonnes 2,471,000 TOTAL PRODUCTION 5,229,115
2,500,000
2 minutes with…
Mahmood Daylami 1) What is something we don’t know about you? I graduated as a Medical Microbiology Scientist and worked for four years at St Thomas Hospital, London. 2) What do you think are the biggest challenges for the aluminium industry? Having a level playing field in the market in different regions and to have universal commitment for sustainability. 3) What is your best piece of advice? Disappointments create disturbance, but our reaction and inability to handle disappointments create chaos in our life. 4) What is the most frequently asked question about your job? I am asked: What does the GAC do? As a business Association in the Middle East and especially in the Gulf, it is a new experience and its role is not fully understood or appreciated by the Business Community or the Governments. As a result, it takes time to have any impact. I am pleased that the GAC has now been recognised by the relevant authorities and the aluminium industry. 5) What are your first and last jobs of the day? My first work at the office is reading all the emails and respond ing to them immediately, if I can. My last job is inconsistent, it all depends what that day brings. 6) What is your proudest moment? When my younger son after receiving his Masters with merits told me, “I would not disappoint you”.
2,000,000
1,500,000
971,420 756,800
1000,000
7) What inspires you? Opportunities to introduce changes and add value.
643,500 386,395
500,000 0 EGA
ALBA
GCC primary aluminium production 2016
MA’ADEN ALUMINIUM
QATALUM
SOHAR ALUMINIUM
8) What was the last gift you gave someone? When someone gives a gift to another person, I am not sure who is the giver and who is the receiver. A gift is a reflection or a response to what a person has already received from another one that made him or her a happier person or made him or her enjoy a better life. � www.gac.ae March/April 2017
2 minutes with.indd 1
20/03/2017 12:40:38
Steinar Iversen.no Foto:HMR Group
www.hmr.no
Focus on the Rodding Shop
AUTOMATED STUD REPAIR LINE Automated Stud Repair Line repairs anode yokes by replacing of worn-out studs with the new pins whilst on the power and free conveyer in the rodding shop. • The operation consists of cleaning, cutting and robot welding of pins; • Completely automated. Requires just one supervising operator; • Efficient, very safe for the floor personnel. Reduces repair down-time to the minimum.
This line has been developed by HMR. HMR’s technology for the smelters has been the reference in the primary aluminium since 1956. HMR is situated in Norway, with the customers all over the world. To stay tuned to the world of modern solution for the rodding shop, meet HMR at 7th International Conference on Electrodes for Primary Aluminium Smelters in Reykjavik, Iceland, 25-27 April 2017.
HMR Group AS, Prestnesvegen 68, N-5450 Sunde, Norway, hmr@hmr.no
ASSOCIATION UPDATE 17 5
www.aluminiumtoday.com
Value Chain Voice: The Aluminum Association Today By Garney Scott*
For more than 80 years, the Aluminum Association has been the leading voice for the North American aluminium industry. With a presence in 35 U.S. states, Canada and Mexico, the 112 Aluminum Association member companies we represent are involved in every aspect of the aluminium value chain – from primary production to value added products to recycling. Collectively, our members make about 70% of the aluminium and aluminium products shipped in the United States and Canada today. The association advocates for the industry on key policy issues, develops product standards, produces business intelligence and provides general industry expertise to member companies, policymakers and the general public. During a time of significant opportunity and major challenge for the industry, our Board of Directors and Committee leadership is collaborating closely to set the agenda – finding key areas of cooperation where the industry can speak with a single voice. Working together, we accomplished a great deal in 2016. One of our signature issues - global aluminium overcapacity - was at the forefront of the national political discussion and even a topic during the final presidential debate. Our work educating policymakers on the benefits of automotive aluminium helped ensure that lightweight materials are central to the on-going conversation around vehicle fuel economy. Our Casthouse Safety Workshop program educated nearly 200 industry employees on safety best practices. An updated edition of Guidelines for
Handling Molten Aluminum added 30% new content to aid the industry in reducing potential hazards. And our market-shaping sustainability research - on auto recycling, green buildings and beverage packaging - drove hundreds of views and downloads by customers and other stakeholders. And we welcome you to the conversation as well – to learn more about joining the Aluminum Association, please visit www.aluminum.org/join Advancing aluminium in the market As the world strives to reduce its overall environmental impact by decreasing the carbon footprint of products of all sizes, aluminium helps drive us toward a more sustainable future. The association plays a key role in educating customers and consumers about aluminium’s positive role by producing credible, peerreviewed research to advance the metal as a sustainable choice for innovative manufacturers. In 2016, the association released research covering three of our major
markets – transportation, building and construction and packaging. A joint effort with researchers at Worcester Polytechnic Institute (WPI) found that the end-of-life recycling rate for automotive aluminium exceeds 90%. This is a key statistic for car companies looking to add aluminium to their material mix. During last year’s Greenbuild Conference, the association released Aluminum in Green Buildings – A Guide to Environmental Declarations, the second in a series of guidelines for the building and construction sector. Environmental declarations are a key component of the U.S. Green Building Council’s Leadership in Energy & Environmental Design (LEED) V4. And finally, the association completed a study with by environmental research firm ICF International that greenhouse gas emissions associated with transporting and cooling aluminium cans are considerably lower than both glass and plastic bottles. Space efficiency and lower packaging weight are the primary drivers of seven to 49% fewer emissions in the product “use phase.”
*Chairman, The Aluminum Association Garney Scott is the President & CEO of Scepter, Inc., a secondary aluminum production company based in Waverly, TN and the Chairman of the Aluminum Association. Aluminium International Today
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March/April 2017
20/03/2017 15:25:45
18 ASSOCIATION UPDATE
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Organisation (WTO), the release of a USITC investigation into aluminium overcapacity this summer and other activity.
By commissioning and promoting this research, the Aluminum Association helps drive market participants toward more sustainable product choices – providing a market advantage for aluminium. Driving aluminium’s future With more than $2.8 billion invested or committed for domestic plant expansions, association member companies are betting big on increasing demand for aluminium in lightweight transportation applications - especially in the auto sector. Current projections suggest that the average aluminium content for a car or truck sold in the U.S. will grow from less than 400 pounds today to more than 500 pounds by 2025 as automakers respond to increasing customer and regulatory demands for more fuel-efficient vehicles. The Aluminum Association’s automotive market committee - the Aluminum Transportation Group (ATG) - pursued a “surround-sound” communications approach in 2016 to educate regulators, NGOs and other third-party influencers about aluminium as part of the solution for car companies looking to drive increased fuel economy. This included influencer events in Washington, D.C., targeted advertising, videos and one-on-one engagement with regulators. As the debate on vehicle fuel economy standards continues, the ATG will continue to advocate for a fact-based discussion on how aluminium can help drive continued efficiency gains, safely and affordably. March/April 2017
Alu Association.indd 2
Industry leadership on international trade In what continues to be a challenging environment for some producers, the Aluminum Association is advocating for a free and fair, rules-based global trading system in which all aluminium producers can compete on a level playing field. Working with the membership and our industry partners, the Association is pursuing a multi-pronged approach to address the on-going problem of Chinese aluminium overcapacity, which is challenging the full value stream in a number of ways. The industry made significant progress in 2016 - moving aluminium overcapacity toward the top of the U.S. - China bilateral trade agenda and initiating an investigation by the U.S. International Trade Commission (USITC). During a hearing last fall, the Aluminum Association and its member companies joined nearly three-dozen industry stakeholders in front of a standingroom only crowd to testify before USITC commissioners. The daylong hearing was part of the investigation initiated by Congress to assess the factors impacting the competitiveness of the domestic aluminium industry. The event received extensive media attention including coverage in The Wall Street Journal, Reuters, Bloomberg, POLITICO and once again shone a bright light on the global challenge of Chinese aluminium overcapacity. The work on trade will continue in 2017 with possible action at the World Trade
Advocating for aluminium country As policy issues from trade to environmental regulations to recycling grow in importance, the association has worked to develop an industry-wide culture of advocacy to engage with key policymakers. Over the past several years, we have developed a significant advocacy infrastructure through efforts like the bipartisan Congressional Aluminum Caucus, the Aluminum Political Action Committee and the Aluminium Nation grassroots advocacy tool - all part of a broad effort to achieve positive policy outcomes for the industry. One key piece of advocacy research last year was the release of a comprehensive economic impact study highlighting the jobs profile of the domestic industry. The study, completed by economics research firm John Dunham & Associates allowed an apples-to-apples comparison between a similar report released in 2013 and detailed a steady increase in downstream jobs, but major job losses in the upstream segment. The Association utilised the new data to highlight the continued importance of the aluminium industry to the national manufacturing economy, but also the real-world consequences of unsustainable aluminium production practices in China. Moving forward The industry still has a great deal of work ahead of it. Aluminium production is a cornerstone of the American manufacturing economy. And as the second largest market for the metal outside of China, we in the U.S. have a leadership role to play. There is no question that segments of the industry are struggling today. Jobs in the primary sector have declined to their lowest levels in decades. Yet many downstream producers are investing and the industry’s overall impact on the U.S. economy grew to $75 billion in 2016 - up 15% from just three years ago. Couple that with a headline demand number that is up for the seventh straight year and we have every reason to expect a bright future. But we need your help. If your firm is eligible for membership in the Aluminum Association but has not yet joined, I encourage you to do so. You can learn how at www.aluminum.org/join. Only by working together, as single industry united in a common purpose, can we tackle the challenges and opportunities ahead. � Aluminium International Today
20/03/2017 15:25:46
PROJECTS & PRODUCTS 19
www.aluminiumtoday.com
The aluminium industry is constantly embarking on new projects and developing new products. In this regular feature, Aluminium International Today presents the latest announcements in these areas. If you’d like the opportunity to be considered for publication, please contact nadinebloxsome@quartzltd.com
Laminazione invests in Achenbach OPTIFOIL® Technology Laminazione Sottile, a major producer of aluminium, located in Caserta, Italy, has just placed an order for a new OPTIFOIL® HeavySlit foil slitting machine, type HGS 18/08 with Achenbach Buschhütten. The objective of this investment is to expand production in the field of finstock products and flexible water pipes. The new foil slitting machine will slit aluminium strip of different alloys, strip widths of up to 1,700mm and strip thicknesses between 50 and 450 µm into narrowest finished rolls. They will not only be used as primary material for starting material for heat exchangers (finstock) but also in the production of flexible, multilayer alu-pex water pipes and for automotive products such as heat shields or internal architectural mouldings. www.achenbach.de
ABB to modernise Alunorf’s cold rolling mill
ABB has received two contracts from Aluminium Norf GmbH (Alunorf) for the modernisation of the KW5 cold-rolling mill with a total contract value of around €2 million. Both contracts represent the first part of a complete four-phase modernisation of the automation and technical equipment at KW5. In doing so, ABB is continuing its almost 20-year cooperation in the lifecycle support of the installation. The first step includes an upgrade of the existing ABB 800xA process control system to
version 5.1, as well as the implementation of an AC800 PEC controller as a master encoder and for drive control in an existing ABB system based on MP200 controllers from the mid-1990s. The AC800 PEC controller is specifically used for the demanding drive-oriented control and regulation tasks in all types of rolling mills. At the same time, the application software has been updated to the latest technology and a current diagnostic system implemented. www.abb.com/metals
New water quench by Smith Aluminium
Electrical Isolation Monitor
Smith-Ferram presented a new type of water quench at ALUMINIUM 2016. This type is suitable for the C36+ cooling process. It is a new type of cooling equipment for extruded profiles, using air, spray or water wave cooling. The system is based on the size of the extrusion press and can be equipped with optional accessories as per customer requirements. This whole equipment and the optional accessories are made of stainless steel. Durability is thus increased. www.ferram-strojirna.cz
VHE‘s Electrical Isolation Monitor is able to measure the electrical resistance between points of different voltage potential. It is designed for aluminium plants to constantly monitor potline resistance to ground. The Electrical Isolation Monitor continuously displays the measured resistance to ground. Should a short circuit occur at some point in the potline then the resistance reading drops. The signal from the monitor may be used to trigger an alarm if the reading falls below a preset level. The device has a very high tolerance for parallel capacitance and noise/spikes in the measurement signal. The monitor is able to measure electrical resistance across a potential difference of up to 2200V DC, plus a 500V AC peak. AC and DC values at the measuring point are also displayed on the front display. The measuring range is set to order during manufacture, usually 0-1 kOhm or 0-10 kOhm. The monitor is simple to operate. An on/off button and a resistance display meter are located on the front panel. The signal is also available from the monitor as 4-20mA, a 0-10V or a serial output. The monitor is permanently connected to either an AC or DC power source VHE‘s Electrical Isolation Monitor is in use at RTA ISAL in Iceland. www.vhe.is
Granco Clark supplies UACJ UACJ of Ludington, MI, has selected Granco Clark to supply log processing/heating and extrusion handling systems. The scope of supply includes; log table/pusher, high efficiency log furnace, hot billet saw, FusionBond, taper quench, high velocity/high impact spray quench, cut on the fly double puller, complete belt/conveyor transfer system, under table cooling, stretcher, auto saw gauge system, off-line precision saw and age oven with powered roll conveyors. Aluminium International Today
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UACJ’s FusionBond system process eliminates ALL two-piece billets. The taper quench unit provides a uniform billet quench and or a longitudinal taper cooling in billets prior to the extrusion process. UACJ’s new Precision Saw has exceptionally close tolerances combined with highest levels of productivity, speed, accuracy, safety and ease of use. www.grancoclark.com
March/April 2017
14/03/2017 08:34:22
Introducing an aluminum mill de-drossing solution that’s versatile, easy to use and reliable Gradall is introducing an XL 4210 V maintenance machine that is the proven solution to efficiently skim dross and maintain the walls and bottoms in aluminum furnaces. With a 49-foot (14.9 m) boom reach and mobile crawler undercarriage, this unique Gradall can quickly and accurately skim the molten surfaces in one or more furnaces while minimizing door opening times. For an actual case study, visit: www.Gradall.com/Novelis Call 330-339-2212 to learn about Gradall metal mill maintenance machines engineered to meet your needs — another reason why nothing works like a Gradall.
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EXTRUSION: IFTA 21 5
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Announcing the International Fair Trade Alliance Aluminium extruders from around the world have formed an alliance designed to promote and defend fair trade practices. The International Fair Trade Alliance (IFTA) is a non-profit organisation created to bring together aluminium extrusion manufacturers and suppliers from across the globe for the purpose of promoting free and fair trade. The Alliance, which began forming earlier this summer, is comprised of aluminium extruders from North and South America, Australia and New Zealand, the Gulf States, and Israel. Jason Weber, Director - International Market Intelligence for Sapa Extrusion North America, and newly elected Chairman of IFTA said: “IFTA believes that a network of market-based aluminium extrusion companies and associations can work together to support, teach, and advocate fair trade practices at a national and international level.” Board members include representatives from extrusion companies and trade associations who will represent their country or region on matters related to fair trade. The newly formed Board of Directors includes: IFTA Chairman International Jason Weber, Director – International Market Intelligence; Sapa Extrusion North America IFTA Board Members U.S./Canada Duncan Crowdis, Past Chairman; Aluminum Extruders Council Colombia Michael Gil Gómez, Chief Financial & Strategy Officer; Alumina S.A. Australia/New Zealand Lewis Saragossi; Australian Aluminum Extrusion Association Gulf States Mahmoud Daylami, Secretary General; Gulf Aluminum Council Ecuador Jochen Münch, Director Comercial Corporativo; Corporación Ecuatoriana de Aluminio Cedal S.A. Israel Roy Shenkar, Business Development Aluminium International Today
extrusion IFTA.indd 1
Manager; Klil Industries Canada Mike Flynn, President; Apel Extrusions IFTA Executive Director Jeff Henderson, President & CEO; The Sanford Organisation The members of IFTA are convinced that non-market based economies are committed to undermining the principles of free enterprise through a variety of illegal and unfair trade practices that must be confronted by individual countries and at the World Trade Organisation. Lewis Saragossi, Chairman and Managing Director of G. James Glass & Aluminum and representing the Australian Aluminum Extrusion Association on IFTA's Board said: "We are all seeing illegal and unfair trade tactics from China being exported to other countries. It is time for our industry to come together as a global community to share data and field intelligence so each of our marketplaces can efficiently and quickly confront these threats.” To date, the International Fair Trade Alliance has recruited new members by invitation and operated on voluntarily donated funds. Extruders and extrusion trade associations are invited to contact IFTA to inquire how to get involved. Jochen Münch, Commercial Director of Ecuadorian extruder Corporación Ecuatoriana de Aluminio Cedal S.A. said, "What we are seeing is the proliferation of Chinese aluminium extrusions throughout South America. As duties, have been imposed by countries like Australia, Canada, and the United States, Chinese extruders are moving into new markets. So, even if you do not feel the threat today, just give it some time and you will." The International Fair Trade Alliance will be managed by The Sanford Organisation (TSO), a fully accredited association management company located in suburban Chicago, Illinois. The Sanford Organisation manages trade associations, professional societies,
and trade shows and is headed by Jeff Henderson. TSO provides administrative oversight for several organisations, including the Aluminum Extruders Council (AEC) and the Aluminum Anodisers Council, which allows TSO to provide efficient collaboration on common issues such as Fair Trade. About IFTA The International Fair Trade Alliance is a non-profit organisation created to bring together aluminium extrusion manufacturers and suppliers from across the globe for the purpose of promoting free and fair trade. The Alliance is guided by a Board of Directors comprised of representatives from aluminium extrusion manufacturers and trade organisations. IFTA's mission is to promote the progress and development of the industry in areas of Free and Fair Trade, cooperate with Government officials and Government agencies on matters affecting the industry, and foster greater and freer networking among global aluminium extrusion industry professionals. For more information about IFTA please visit the website at IFTAonline.trade; or contact IFTA at info@iftaonline.trade �
March/April 2017
13/03/2017 15:02:43
22 EXTRUSION
www.aluminiumtoday.com
Billet quality and extrusion plant efficiency Extruders recognise that billet quality is an important aspect of extrusion plant performance. However, it’s not always easy to prioritise where valuable resources should be focussed when trying to improve the efficiency of an extrusion plant. Dr Gary Mahon* explains
Top level K-Map The K-Map shows where each of the process stages effects the attributes of the extrusion operation. A coloured square indicates where there is an interaction. Colour coding ranks the relative importance of each process stage on each of the attributes. The matrix highlights strong, medium and weak interactions, as indicated in the legend. The K-Map
Stages of billet manufacture There are actually many separate steps which make up the four stages of billet manufacture in our K-Map. However, I’ve grouped them together for simplicity in this example. For a more detailed knowledge-map of extrusion billet, we would break down the stages into steps as follows; � Alloy composition – Si, Fe, Cu, Mn, Mg, Cr, Zn, Ti, trace elements. � Molten metal treatment – degassing, filtration, grain refinement.
Ageing Packing
Forced air cooling Cooling table Stretching Cold saw & stack
Die heating Die change practice Container heating Extrusion cycle Dead cycle Puller Hot saw
Print grid
Die design Die preparation
Fig 1. Generic K-Map for a soft alloy extrusion plant using Innoval Technology’s proprietary software
Billet heating Billet shear/saw
Knowledge map for soft alloy extrusion
DC casting Homogenisation
Stages Alloy composition Molten metal treatment
Knowledge mapping Innoval Technology uses a powerful, yet simple, approach. A matrix identifies the process stages which affect the characteristics (or attributes) of the extrusion operation; Fig 1. This is known as a Knowledge Map (or K-Map). It is built by breaking down the process of extruding into discrete stages on the axis across the top. The other axis lists the important attributes of operating an extrusion plant. These attributes cover the quality of the product as required by the customer, such as dimensions, surface and mechanical properties. They also cover factors which impact the economics of the overall plant operation. For demonstration purposes I’ve kept this list short, but we can add many more attributes if needed. We could also expand the process stages to cover a greater number. However, I’ve kept this example simple in order to focus on the four stages on the left of the list which make up billet supply. These are Alloy composition, Molten metal treatment, DC casting and Homogenisation. This particular K-Map is a generic map appropriate to a gas fired log furnace followed by a hot billet shear or saw. The shear/saw feeds a direct extrusion press producing soft alloy profiles.
sits behind each coloured square, captures and stores this ‘why’ information. In the rest of this post I will concentrate on those billet-related issues that are at least as important as some of the process stages (which are within the control of the extruder).
also captures any disputed or unknown relationships, but these are not required in this example. It is important to realise that, if we look across the rows of the matrix, we can compare the strengths of the relationships. This allows us to assess the relative importance of each process stage on that particular attribute. As you can see, the top level matrix alone is a powerful tool to carry out a structured and repeatable assessment of an extrusion plant. However, the real strength lies in knowing why a particular process stage affects an attribute. We can use this sort of transferable knowledge during a technical audit of an extrusion plant. It can help to identify the specific areas of focus for process improvement activities. The second level of the K-Map software, which
Dimensional accuracy Bow & twist
Attributes
By using knowledge mapping it is possible to clearly understand the impact of billet quality on extrusion plant performance. Then we can focus on evaluating the key aspects of billet quality that can impact plant output and efficiency. I’ll explain the methodology in this article.
Length per cavity Surface pick-up Die lines Surface tearing Tensile strength Die start-up problems Unplanned scrap Scratches & dents Downtime Tonnes per hour
Strong
Medium
Weak
Unknown
Disputed
No relationship
*Director and Senior Metallurgist, Innoval Technology March/April 2017
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FURNACES & CASTHOUSE EQUIPMENT Mechatherm International Ltd is a world leading company of industrial engineering experts specialising in the design, supply and commissioning of furnaces and casthouse equipment for the Aluminium industry. • Casting/Holding Furnaces • Single/Multi Chamber Furnaces • Launder Systems • VDC Casting Machines
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� DC casting – launder materials, casting technology, casting conditions. � Homogenisation – batch or continuous, heating rate, peak metal temperature, time at temperature, cooling rate.
Billet quality: Composition on strength The K-Map (Fig 1) shows that alloy composition has a relatively important effect on several attributes. The strong effect of composition on tensile strength is no surprise. This is the reason why many 6000-series alloy variants exist with their differing levels of Mg and Si. These elements provide strengthening via the volume fraction of fine Mg2Si particles which form during age hardening. One of the key aspects is to achieve consistency of strength which, in part, is about controlling the range of alloying additions made. Although the composition of an alloy can fall within the 6060 composition, the T5 temper UTS can be in the range 150 to 270 MPa. This would clearly be unacceptable for many end-use applications. The effect of Cu, Mn, Cr and other trace elements on strength also emphasises the need for tighter composition tolerances than those shown in the ISO specifications. Typically this needs to be ±0.02 wt.% for the major alloying elements. Billet quality: Composition on surface pick-up The other more important influences of alloy composition are the effects on the surface attributes of the extrusion. In this case, we’re talking about surface pick-up and surface tearing. The extrusion limit diagram in Fig 3 demonstrates these influences. At high billet temperatures and extrusion speeds the surface starts to deteriorate. This is initially because of pick-up, and then via tearing, and eventually surface melting.
Fig 2. A product featuring aluminium extrusions Image courtesy of Norsk Hydro
Moving to a more dilute alloy shifts the limiting conditions to higher speeds, thus increasing tonnes per hour (subject to the other factors indicated in the K-Map). However, there is also an important mechanism caused by the intermetallic particles in the billet which form the β-phase during DC casting. The β-phase can transform to the α-phase during homogenisation. Some of the influences of alloy composition on pick-up are shown in Fig 4. It shows how increasing the Si content of the alloy gives pick-up at lower extrusion speeds. This is as a consequence of Si encouraging the formation of the Sirich β-phase. Fig 4 also shows the effect of increasing Mn on reducing pick-up, even at the highest extrusion speeds. This happens because Mn is an α-phase stabiliser. Typically, it is desirable that at least 70% of the intermetallics are the α-phase. However, as the K-Map shows, there are many other influences on the surface attributes and there is no cut-off below which quality necessarily deteriorates. Billet quality: Homogenisation on surface pick-up The other important influence of billet quality comes via the homogenisation stage. This is a consequence of both the
β to α transformation, and the dissolution and precipitation of the Mg2Si phase. The time and temperature of billet homogenisation controls the extent to which the β-phase transforms to α intermetallics. This in turn affects surface pick-up and surface tearing, as described previously. It is important to measure the consistency of this transformation. It is possible to have significant variation across the billet section and along the length, as shown in Fig 5. Furnace control gives rise to this variability. Furthermore, it can vary significantly between pusher and batch furnaces. Billet quality: Homogenisation on strength Another important influence is on tensile strength. The homogenisation conditions will influence both the extent of dissolution of the as-cast Mg2Si and the re-precipitation of a much finer distribution of Mg2Si during controlled cooling to room temperature. If the billet cools too slowly, the Mg2Si is too coarse to re-dissolve during the extrusion cycle. Consequently, the Mg and Si are not available to take part in the subsequent age hardening stage. An SEM image can show the Mg2Si distribution in the as-homogenised billet (Fig 6) which allows us to easily quantify the particle size distribution. There are other lesser effects caused by both the alloy composition and homogenisation. These are principally a consequence of the effect on flow stress and its associated influence on metal flow through the die during the extrusion cycle. However, as you can see in the K-Map, the effects are only weak in comparison to the other more significant stages within the extrusion plant. As mentioned above, we’d capture the ‘why’ information (as described in the previous four sections) in the Level 2 pages of the K-Map.
125 140
Increasing alloy solidus (dilute alloy)
80 60
Cooling rate during homo
Coarser Mg2Si in billet
40
Surface melting Tearing Pick-up
Inadequate 20 mechanical properties 250
300
350
400
100
450
500
550
600
Billet temperature (°C)
Fig 3. Effect of composition and homogenisation shown on an extrusion limit diagram, after Parson et al, Extrusion Technology 1992
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Exit speed (m/min)
Extrusion speed (m/min)
Low flow stress (dilute alloy)
100
0.09 Mn
Inadequate surface
Insufficient pressure
120
75 0.06 Mn 50 0.03 Mn 25 Pick-up 0 0.40
OK 0.45
0.50
0.55 wt % Si
0.60
0.65
0.70
Fig 4. Effect of Si and Mn on onset of surface pick-up, after Brassard et al, Extrusion Technology 2004
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EXTRUSION 25
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100
Bottom
95
Middle
Top
90 85 % alpha
80 75 70 65 60 55 50 Edge
Mid radius
Centre
Edge
Mid radius Centre
Edge
Mid radius
Centre
Fig 5. Variation in intermetallics through a homogenised 6063 log
Supplier fingerprinting An extrusion plant K-Map highlights the more critical process stages that are within the control of the extruder and their influence on the quality and economic performance of the plant. Billet quality is also an important input that is frequently outside the control of the extruder. Consequently, assessment of billet quality by the extruder is an important control. However, extruders and billet suppliers need to work in partnership to ensure they have systems in
Fig 6. Micrograph showing Mg2Si (coloured red) and Fe-rich (white) intermetallics in billet
place to ensure quality consistently meets extruders’ needs. Independent audits and experimental evaluations are a critical part of that relationship. We offer these services at Innoval Technology. To run an efficient plant extruders should not just rely on the lowest cost suppliers. For the billet suppliers, evidence of high billet quality is a great product differentiator, especially in challenging market conditions. At Innoval we’re able to carry out independent characterisation of billet quality which we term ‘supplier
fingerprinting‘. We can also provide training and mentoring of extrusion personnel. Finally, if you want to make your whole process, from billet storage through to packing, more efficient we can help. Using proven methodology, we will work with your team to analyse what you do and remove the wasteful activities. � Contact www.innovaltec.com
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Some are Born to Lead
C
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Our dedication to making high quality high performance aluminium puts us above our competitors. That’s why our clients trust us to provide the aluminium that will be used in the next generation products. So, whether it’s in aerospace, architecture or IT, our metal is tailor-made for the world we live in. Our products are rated by the US Green Building Council’s Leadership in Energy and Environmental Design (LEED) rating system and the Deutsche Gesellschaft für Nachhaltiges Bauen (DGNB, the German Sustainable Building Council) as suitable for sustainable building practices. Global Excellence in Aluminium
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EXTRUSION 27 5
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Premium quality billets for superior extrusion Having sold an estimated 1.065 million tonnes of primary aluminium billets during 2016, UAE-based Emirates Global Aluminium (EGA) remains the world’s leading producer of billets for extrusion and forging, by volume. The associated 8.2% year-on-year growth in sales for EGA billets confirms the company’s preferred supplier status among customers – both across the globe and in the local downstream sector. According to Walid Al Attar (Chief Marketing Officer), EGA’s billet customers use extrusion processes to produce aluminium items for a range of purposes, including construction (specifically window and doorframes), trains and underground coaches, trucks, trailers and coaches, commercial vehicles, car parts, machine industry and transport facilities. Customers also use forging techniques to transform EGA billets into an array of components for the automotive and transportation sectors. “These diverse applications reflect the advantageous attributes of aluminium – notably aluminium’s unique blend of strength and ductility, its conductivity, its non-magnetic properties and its ability to be recycled repeatedly without loss of integrity,” he says. “These same capabilities not only make aluminium extrusion a viable and adaptable solution for a growing number of manufacturing needs, but also provide business opportunities for EGA.” Al Attar attributes the distinctive differentiation of EGA billets to the manufacturing processes used in the company’s casting operations. “All EGA billets are produced using Airslip technology, homogenized and 100% ultrasound-inspected before delivery,” he explains, adding that continual process improvements, new filtration equipment, many new ultrasonic stations, new batch homogenizers and coolers ensure that the highest quality and purity standards are maintained. Attesting to this, there are eight batch-homogenizing furnaces at EGA’s Jebel Ali smelter operation in Dubai, and two at EGA’s Al Taweelah smelter operation in Abu Dhabi. In-house metallurgy testing laboratories further contribute to the overall quality Aluminium International Today
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of EGA billets by identifying issues, the analysis of which helps EGA’s engineers find and resolve the root causes. To ensure customers get maximum usage of the products and leverage the quality, EGA’s technical experts consult with clients, assess processes and offer recommendations for operational improvements. EGA’s experienced metallurgists also provide specialist guidance on alloys and manufacturing, travelling to individual markets to deliver technical seminars. Tailor-made service solutions can be offered after assessing a customer’s individual requirements. “EGA has more than 40 years of experience producing premium aluminium products,” explains Al Attar. “Our world-class expertise and market insights help customers achieve a competitive advantage in their respective markets.” Niche focused on value-added products, EGA’s major product category is billets for
extrusion and forging, which accounted for 42.6% of sales in 2016 (39.9% in 2015). In anticipation of continued increases in demand, the billet production capacity of EGA’s casting operations in the UAE is set to expand to 1.160 million tonnes per year. This, together with the flexibility offered by EGA’s multiple casthouses, provides the ability to fulfil orders efficiently and expediently. Customised to satisfy customer specifications, EGA billets are produced in common AA alloy series 1000, 3000 and 6000; with a large proportion being cast in high extrudability 6063 alloy. Dimension options include a range of diameters (from 152mm to 406mm) and cut-lengths from 420mm to 7,500mm. Evidencing the strict quality demands that EGA’s metal satisfies, EGA is accredited to ISO/TS16949, the quality management system for the automotive industry supply chain. Moreover sections
March/April 2017
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28 EXTRUSION
extruded from EGA billets are being used in several iconic buildings around the world. Famous landmarks that incorporate EGA’s aluminium products include the Burj Al Arab and Burj Khalifa in Dubai, Etihad Towers in Abu Dhabi, Petronas Towers
US Green Building Council’s Leadership in Energy and Environmental Design (LEED) rating system and the Deutsche Gesellschaft für Nachhaltiges Bauen (DGNB, the German Sustainable Building Council). The accreditation reflects EGA’s
in Kuala Lumpur and the Esplanade in Singapore. Furthermore, EGA billets have been declared suitable for sustainable building practices, as per the criteria defined by the
ambition to produce ‘green metal’ and underscores the company’s corporate commitment to sustainability, specifically the global agenda to protect the environment. It is also a key differentiator,
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given that – as already mentioned – extruders use EGA billets extensively to produce construction components. The largest industrial company in the UAE outside the oil and gas industry, EGA is the largest company that is owned jointly by Abu Dhabi and Dubai. Having produced 2.5 million tonnes in 2016, EGA accounted for approximately 4.3% of the total world aluminium production and almost half of all aluminium production in the GCC. EGA’s two midstream assets in the UAE consistently operate at full capacity, manufacturing to order and delivering direct to over 300 customers in at least 60 countries, predominantly in Asia (37.2%), Europe (24%), the GCC-MENA region (18.4%) and the Americas (20.4%) – based on 2016 data. Both smelter operations are renowned worldwide for using some of the most advanced technologies, many developed in-house, to produce the highest quality products while simultaneously minimising the environmental impact of the production processes. � Contact www.ega.ae
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30 EXTRUSION
The power of aluminium Aluminium extrusions for battery frames in electric vehicles
Battery frames for electric vehicles come in all sizes and shapes. This flexibility is something you get with aluminium extrusions. The main function of battery frames is to hold and protect the battery modules. Protection also means that the frames have to be completely leak-free. If you drive through water, you cannot have water coming in. This would be high-risk. Light weight matters, too, because this is going to affect the performance of the car. Smart designs with aluminium extrusions People want to be able to drive longer distances with their electric cars, and today, this means more battery modules. And a bigger frame. So besides holding the modules in place and protecting them, the battery frame is now having to actually interact with the car body. Big frames can impact the whole architecture of the car body. They have to be integrated in the car structure and interact with the body, to provide the behaviour you want with the whole car. Simplified assembly, more energy absorption Smart designs using aluminium extrusions can simplify the assembly process and fixation of the individual battery modules. They also provide more energy absorption in case of a crash, compared with other materials and processes.
Enclosure using profiles with cooling plate
March/April 2017
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Nadine Bloxsome* spoke to Jonas Bjuhr, Product Development Director, Sapa, to find out more:
Other benefits include: � Cooling - Structural floor panels can be designed to include integrated cooling channels to cool the battery modules. � Strength and stiffness - A frame made from extrusions provides great strength and stiffness to the entire car body while keeping weight to a minimum. � Design flexibility - Modular and scalable frame designs can easily be created cost effectively with extrusions. � Leak tightness - A completely leakfree frame can be achieved using extrusions and the right joining technology, such as friction stir welding. Design flexibility OEMs are looking at different ways to solve these challenges. It depends a little on their philosophy and experience. Other suppliers are working on solutions that use aluminium castings, sheet, even steel. There is a lot of interesting work being done. But the benefits that you get with extruded aluminium, including the design flexibility, make it an alternative that helps OEMs future-proof their battery frames. It is very easy to create modular design with extrusions, and with so much development going on with the electronics and battery modules, the platform concept design becomes relevant. �
Battery packs & enclosures
1) What is your company doing in the area of battery frames for electric vehicles? We have been working with lots of different applications for different customers. Advising them and trying to influence them to use aluminium extrusions. That they get stiffness and strength in the frame. Cooling. The floor. We have manufactured some physical frames on a smaller scale. The interest for extrusions is very high. 2) Are you pulling inspiration from other areas or applications? Yes. First of all, the customer is really doing a fair bit of homework. They are working hard to educate themselves and understand aluminium better. But this is part of the general trend of aluminium in automotive. Aluminium is growing, not just extrusions, and they need lighter and safer. With the battery frame, they need to do more than just protect the electronics. They are becoming so big that they are integrated in the whole car structure. And these philosophies are related to body-in-white manufacturing. Aluminium International Today
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EXTRUSION 31
We take inspiration partly from the rail and marine industry. When we make large panels for the floor, for rail cars or for ships, we use friction stir welding. That works here. We also look at other markets and similar applications for inspiration. We can look at the power electronics industry, where we have done liquid coolers. Then the creativity differs. The fact that the OEMs have different philosophies also has an impact on the design. 3) What issues can an extruded aluminium solution answer? I think we can solve all the issues. The frame has to be leakproof. It needs to hold and protect the batteries inside, and it has to be a solution that eases assembly. Second, the frame needs to interact with the car body – the body in white – so it gives the behaviour you want with the whole car. Not just protection, but energy absorption. Since the frame is a big part, shape and tolerances are very important. It is a very stiff and large component and it can impact the whole chemistry of the whole car body. So shape, form and tolerance are challenges. A benefit of extrusions is that there is so much development going on, the platform concept design becomes relevant for these designs. Carmakers would like to be able to use the same concept for four or five or six different models. And with extrusions, it is very easy to create modular design.
Materials handling solutions for your industry
4) How big are the frames? In some models, almost the whole floor of the car. 5) How do you handle the joining? This is one of the main challenges, trying to match geometrical designs to make it feasible. We talk a lot about friction stir welding, because with the electronics inside, this box needs to be leak-proof, and friction stir welding is a proven technology. For some of the joints, this is really a good option. 6) Do carmakers have different solutions? Yes. They are similar and different, in the same way as with the body in white. Some like castings, extrusions, sheet. The different OEMs sometimes also have different preferences when it comes to preferred joining technologies. 7) What is becoming standardised with e-mobility powertrain systems? I feel that looking now, compared to two years ago, the OEMs seem to be defining their own design philosophies. There is more maturity with what they want. With electronics and the battery modules, the development is going fast. There is a bit more standardisation, such as type of modules or connections. They are planning for the next generation, better batteries, and asking how can they use the same frames. Contact www.sapagroup.com
• Improved storage utilisation • Safer product handling • Increased productivity • Indoor / Outdoor
*Editor, Aluminium International Today March/April 2017
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32 FURNACES/HEAT TREATMENT
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Effective furnace lining efficiency The central processing unit in many refineries and petrochemical plant furnaces consumes more energy than any other piece of equipment, making it essential that all the correct measures are put in place to realise as much energy efficiency as possible. An efficient furnace is key to reducing overall maintenance costs and ensuring that these facilities run smoothly without undue revenue loss caused by downtime. The right refractory materials deliver a protective and insulating layer of heat resistance attached to the inside of the shell, hearth, and tap holes of a furnace. Not only does this protect furnace parts from extreme heat caused by smelting, but it also prevents excessive heat loss and can lead to greater overall energy efficiency. However, identifying the need for new furnace lining and installing the right material, is not an easy task. In order to get this right, we have outlined five top tips for maximum furnace lining efficiency: Use infrared (IR) thermography inspection to evaluate existing lining Ensuring lining quality is critical to protecting the steel from heat and minimising instances of heat loss. Furnaces which have developed cracks over time are prone to leakage. Some may also have design issues that are not visible from the outside, which can cause heat loss issues over time. This is not uncommon with furnaces that have a painted surface. In order to identify hot spots where the unit is leaking or reducing performance, infrared thermography scans are essential. This typically involves pointing an infrared camera at several points on the furnace casing to analyse the external temperature and identify any areas where heat loss is occurring. Although these can be conducted from within the furnace, such scans are more effective when performed from the outside, because this enables engineers to keep the furnace in operation. It is advised that specially trained application engineers carry out any infrared imaging, analyse the scans, and provide recommendations on the most appropriate repair options. Make repairs on-line whenever possible In the instance that an infrared
Refractory engineers remain under constant pressure to increase the performance of furnaces, incinerators and reactors to maximise energy efficiency. Although there are many materials, which can enhance the efficiency of furnaces, many still lose heat when in operation through flue gas, excess moisture in fuel, or continued opening of the furnace door. This is preventing many engineers from realising maximum energy efficiencies, causing businesses to focus their attention on reliable insulation and lining of furnaces from the floor to the stack, to contain as much heat as possible during operation. Companies such as Morgan Advanced Materials are responding to this challenge with a variety of lightweight, energy saving solutions with refractory designs, which minimise heat loss in these units. In this article, Steve Chernack* outlines five top tips for achieving the best furnace lining efficiency.
Furnace and metal waiting to be cast
thermography inspection reveals a need for repair, Morgan always advises that this be done on-line wherever possible. This is the most effective method of maintenance and is reliable, fast and economical, since the unit is still in operation. After all, boilers and process units are constantly generating revenue so any downtime experienced will likely impact a business quite significantly.
Of course, this option does depend on the temperature of the furnace, the difficulty of accessing a particular area, and how large the hotspot is. Morgan’s Superwool® and Kaowool® insulating pumpable solutions can be installed by pumping from the outside of a furnace or boiler, filling cracks and voids caused by deteriorated insulation. Effective and simple to apply, these
*Global Engineering Manager, Morgan Advanced Materials – Thermal Ceramics March/April 2017
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FURNACES/HEAT TREATMENT 33
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products are ideal for providing thermal insulation efficiencies behind boiler tubes in sidewalls, seals and floors. They can also be used to repair ovens, furnaces, and other process equipment. For traditional repairs, the furnace must be shut down and cooled until it is safe for maintenance personnel to enter and repair the lining with fibre blankets, pumping solutions, or monolithics. Consider engineering design carefully In order to realise maximum operating efficiency for the materials specified for furnace relining, it is important to ensure that the engineering design is suitable. Not only must the materials have enough studs to hold them in place, they also require sufficient joints for expansion or shrinkage. If you install a brick lining without adequate expansion joints, the brick can grow so large that it pushes up the entire lining off the furnace wall. This will lead to further inefficiency, requiring the entire process to be repeated. Select the right material for furnace re-builds Some repairs identified by infrared thermology scanning can be too large
DELACQUERING
to address on-line and instead, the unit must be shut down for a furnace reline, or process heater reline. In this scenario, it is important to select the right refractory materials to facilitate a successful furnace rebuild. This will lead to greater efficiency, reliability and lower maintenance costs. The best place to start when selecting this material is by using a heat flow analysis software programme, in which temperature and use factors are inputted to obtain information on the best materials to be used. Properties including hardness, density, mechanical resistance and insulating factor will vary depending upon the furnace application. If your furnace is an older model, it will likely have a different type of insulation to that which is commonly specified today, presenting an ideal opportunity to upgrade when relining the furnace. Products such as Morgan’s Superwool® Plus™ insulating fibre offer up to 20% ßlower thermal conductivity when compared with other products, making it 17% more energy efficient than traditional Refractory Ceramic Fibres (RCF), and Alkaline Earth Silicate (AES) insulations. This is made possible due to maximised fibre material contained
TILTING & MELTING HOLDER
within the solution. Its low bio-persistence also makes it a reliable and effective replacement for RCF insulation. Ensure a successful installation The final point to consider when lining a furnace is to ensure that the installation is completed correctly by somebody who has the required level of skills for the task. The number of products available for furnace lining are vast, and all come with their own unique installation requirements. Getting this wrong will cause inefficient lining, as well as wasting large sums of money. An example of these specific installation requirements can be seen with concrete. If concrete is not mixed with the right volume of water at the correct temperature, the material will not develop properly, it will be difficult to place, and is unlikely to reach expected properties. An ineffective, or inaccurate installation is as bad as not having a good design and not making the right material choice. Get all these points done correctly and you can benefit from an effective and efficient furnace lining for many years to come. � Contact www.morganthermalceramics.com/furnace-lining
SIDEWELL
Engineering & Refractory Delacquering Melters Holders Repair Maintenance
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Combustion system retrofits for aluminium furnaces By Michael Cochran* & Matt Valancius** Changing demands, with respect to productivity, fuel use, and/or emissions requirements, in an aluminium furnace present the operator with a unique challenge to meet the new requirements. Generally, retrofitting an existing furnace with better combustion technology is both cost effective, and minimises downtime. Careful study of the existing equipment and process is crucial in order to affect the proper solution.
and gas pressures may be dramatically different, some pressure switches may require adjustment. Performance Table 1 shows the performance of an actual combustion system before and after a hot air retrofit, paying particular attention to the emissions of CO2 and NOx on both a lb/MMBtu and lb/ hour basis. The required heat did not
Cold air combustion to hot air combustion retrofit For an existing cold air combustion system, the main benefit of converting to a hot air system is lower fuel use because of increased combustion efficiency. Although retrofitting technology has improved dramatically, in many cases minimising the need for modifications to the burner itself, (beware, however, that sometimes the burners themselves may require significant modifications) it is important to evaluate the whole system to account for changes in, for example, flows and pressures. Design Aside from the burner itself, which may require varying degrees of modification (consult the burner manufacturer or another qualified engineering company), a complete combustion system review is necessary, paying particular attention to: � Fan/Blower – Hot air systems generally require lower volume of air, but typically at a higher pressure. � Orifice plates/metering – lower flows may necessitate replacement of metering devices. � Flow control valves – without resising flow control valves, turndown and process control may be more difficult. � Gas regulator – an existing regulator may not function properly at reduced flow. � Pressure switches – because air
14 12 NOx [lb/hr] CO2 [1000lb/hr]
10
8
6
4
Fig 1. Emissions rates for various combustion technologies
2
0
Cold air
Hot air
Cold Air
Hot air low NOx
Regenerative
Hot Air Ultra Low NOx
Required Heat
20
20
Air Preheat
100
800
°F
37.40%
51.10%
HHV
Thermal Efficiency Installed Capacity
MMBtu/hr
53
39
MMBtu/hr
0.138
0.044
lb/MMBtu
Expected NOx Rate
7.4
1.7
lb/hr
Expected CO2 Average
118
118
lb/MMBtu
Expected CO2 Rate
6,310
4,618
lb/hr
Annual Hours
8760
8760
hours
Expected NOx Average
Expected NOx PTE
32.3
7.5
tons/year
Expected CO2 PTE
27,639
20,229
tons/year
Table 1. Expected NOx and CO2 of Cold Air and Hot Air Ultra Low NOx burners
*Marketing Engineer – Combustion Systems **Manager – Marketing & Strategy March/April 2017
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36 FURNACES/HEAT TREATMENT
Cold Air
Hot Air
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Regenerative Ultra Low NOx
Required Heat
20
20
20
Air Preheat
100
800
regenerative
°F
37.40%
51.10%
72.60%
HHV
Thermal Efficiency Installed Capacity
MMBtu/hr
53
39
28
MMBtu/hr
0.138
0.337
0.054
lb/MMBtu
Expected NOx Rate
7.4
13.2
1.5
lb/hr
Expected CO2 Average
118
118
118
lb/MMBtu
Expected CO2 Rate
6,310
4,618
3,251
lb/hr
Annual Hours
8760
8760
8760
hours
Expected NOx Average
Expected NOx PTE
32.3
57.8
6.5
tons/year
Expected CO2 PTE
27,639
20,229
14,238
tons/year
Table 2. Expected NOx and CO2 of Cold Air, Hot Air, and Regenerative Ultra Low NOx Burners
change, but because the combustion efficiency increased noticeably, the fuel use decreased by almost 25%, and thus the emissions rate (lb/hour) decreased dramatically. Assumptions: 2200°F POC Temperature, Natural Gas fuel, 10% Excess air Regenerative retrofits A more dramatic conversion, in terms of both fuel savings and productivity increases, is from cold air combustion to regenerative combustion. Generally, such a conversion will approximately halve the fuel use! (Similarly, it is possible to convert from hot air combustion to regenerative combustion with correspondingly less substantial savings.) Recent innovations in combustion technology mean that significant NOx reductions are possible even though the air temperature increases significantly. Design As with any retrofit, it is crucial to perform a full engineering analysis of the entire combustion system to ensure proper performance after a retrofit. As with a hot air conversion, items such as blowers, regulators, pressure switches, metering devices, and control valves require special attention. Because regenerative systems handle waste gas in an entirely different way, flue modifications are often necessary in applications where furnace pressure is important. Additional cycle valves, a complete exhaust system (including valves and a blower), and cooling air equipment are necessary for any regenerative system. Furthermore, the burner design is completely different and it is never possible to reuse the burner itself. Finally, the regenerative equipment requires significant physical space around the furnace, although there are accommodations including dual headed burners and roof mounted cases if space is extremely limited. March/April 2017
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Performance Current regenerative technology allows for significant reductions in both fuel and emissions on both a lb/MMBtu and lb/hr basis, as shown in Table 2. Fig 1 shows the relative rates of emissions for different direct-fired combustion approaches. It is clear that the proper selection of a combustion system technology can have a dramatic effect on both carbon dioxide and NOx emissions. Assumptions 2200°F POC Temperature, Natural Gas fuel, 10% Excess air Radiant tube retrofit Although conversion of aluminium melting furnaces is probably the most common retrofit project, there are steps in aluminium processing that use indirect heat (radiant tubes). It is also possible to retrofit existing radiant tube burners for efficiency and/or emissions concerns. One of the primary concerns is to ensure that the retrofitted burners are compatible with the existing tubes. Otherwise, the project usually becomes untenable because of the enormous capital expenses associated with replacing all of the tubes and furnace structure. Cold air to cold air low NOx Without making any changes to the capacity of the system, it is possible to Required Heat
Cold Air
see significant decreases in emissions by applying low NOx technology. These kinds of retrofit projects typically have minimal changes to the rest of the combustion system, but, of course, a full system analysis is required. Design The key difference when making a change to a low emissions radiant tube combustion system is an increase in air pressure, typically requiring a new combustion air blower as well as air pressure switches and metering equipment. Because the capacity of the burners does not change, the gas system can usually remain untouched. As long as the design of the burners is done carefully, there should be no changes required to the furnace structure or to the radiant tubes. Performance Table 3 summarises the performance of the retrofitted system on emissions metrics. Here, NOx emissions decreased by almost 40%, although there was no change in fuel use, because this particular retrofit did not include any increase in combustion efficiency. Note that there is no change in CO2 emissions because the capacity of the system did not change. Conclusion Changes in either production requirements or emissions limits can often be accomplished by retrofitting existing furnace equipment and are often economically sound choices. Before undertaking any retrofit, though, it is crucial to define the purpose of the retrofit, as well as the scope. A full engineering analysis of all combustion equipment is required to ensure that the new system will perform appropriately. After identifying the proper approach to a retrofit, careful selection of burner and other combustion components can lead to reduction in fuel use, reduction in emissions or increases in productivity at a minimum of cost and with limited downtime to the process. � Low NOx
0.5
0.5
Thermal Efficiency
41.0%
41.0%
HHV
Installed Capacity
1.2
1.2
MMBtu/hr
Expected NOx Average
0.072
0.044
lb/MMBtu
Expected NOx Rate
0.086
0.053
lb/hr
118
118
lb/MMBtu
Expected CO2 Average
MMBtu/hr
Expected CO2 Rate
142
142
lb/hr
Annual Hours
8760
8760
hours
Expected NOx PTE
0.38
0.23
tons/year
Expected CO2 PTE
622
622
tons/year
Table 3. Expected NOx and CO2 of Cold Air, and Cold Air Low NOx Radiant Tube Burners
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38 FURNACES/HEAT TREATMENT
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Fundamentals of gas nitriding In the business of aluminium extrusion, the extrusion die is arguably the key production tool. If the die does not perform to its optimum, then the efficiency and profitability of the extrusion plant is reduced. Thermserve has been able to make enhancements to the control philosophy and software to provide end users with fully automatically regulated systems. Keith Watkins* explains
Efficiency and profitability are established by continuous extrusion of sections, which are to size specification with acceptable surface finish and fulfil order commitments in the minimum of time. If the die shows premature wear or surface damage then this flow is interrupted resulting in lower plant efficiency. Die reliability is essential. There are a number of factors affecting die performance; some concerned with the quality of the die itself and some concerned with die management and extrusion practices. � Die quality - major factors � Die design � Steel selection – analysis (e.g. H13, H11) � Steel cleanliness � Die bulk heat treatment � Die surface hardening � � �
Extrusion practices major factors Extrusion temperature Extrusion speed
� Die management Including cleaning, correction and die pre heating Die pre heating is an extremely important factor regarding conservation of the quality of the nitride case. Ideally, it should be in a specially controlled atmosphere die oven for a maximum of eight hours. There are many published papers and points of view on all these important factors, and as a supplier to this industry, it is important to have a reasonable understanding of the issues involved in the extruding of aluminium, especially where they impact on the performance of the product supplied. All of the production factors listed above can have dramatic effects upon die performance and many can reduce the effectiveness of any surface
hardening treatment. There are a number of die surface hardening techniques and many have been tried and discarded, while some are still being used. These include hard chromium plating, Ion implantation, TiN and other exotic ceramic combination coatings. However, possibly due to its apparent simplicity, cost effectiveness and robust nature, the gas nitriding process has established itself as one of the most cost effective solutions to increasing die life and performance. It is used extensively as an “in–house” process and there are now several suppliers of such equipment. The understanding of the physics and thermodynamics of the nitriding process
has increased tremendously since its original “discovery”, probably when steel blades were quenched in urine; the blade edge was found to have that something special compared to normal water quenching (possibly the aroma!) due to effect of dissolved Ammonia. Nitriding Nitriding is initiated when gaseous Ammonia is cracked or “dissociated” using a steel surface as the catalyst at about 480°C. Active Nitrogen produced during this reaction moves into the surface of the steel and combines with Chromium and other alloy constituents to form their respective “Nitrides”. These Nitrides are
*RGB Metallurgical Ltd, UK March/April 2017
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extremely hard (1200Hv to 1500Hv) and increase the average hardness of the surface layers of the steel. As a general rule, the processes will double the hardness of the original steel. It is important to understand the basic process before selecting a furnace, which will be a production tool and hopefully a friend for up to 20 years. Plasma nitriding should also be mentioned. It has been around since the beginning of the twentieth century but only lately (last 30 years) with improvements in electronics and power supplies has become a feasible commercial process. The process uses only small amounts of Nitrogen and Hydrogen gas in an approximate ratio of 1:3 and is environmentally friendly. It has had limited success in the aluminium extrusion business as it is a very geometrically sensitive process and can be difficult to control when used on complex shaped extrusion dies. It is also best suited to a very clean working environment. However, some companies are producing very good results. As shown above, the actual chemistry is quite simple and early furnaces were no more than basic stainless steel sealed tubs in which the work was placed and then
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FURNACES/HEAT TREATMENT 39
heated in a suitable brick lined furnace. Ammonia flow was not greatly controlled and temperature approximated at about 500°C. The process was not popular due to the long process times, the quality and reliability of the hard case produced and the smell (Ammonia this time not urine). However, the low or zero distortion characteristics of the process made it ideal for certain applications. Automatic Gas Analysis and Control, by RGB may be using Infrared ammonia analysis or H2 analysis, via a special probe mounted inside the furnace. In gas nitriding the donor is a nitrogen rich gas, usually ammonia (NH3), which is why it is sometimes known as ammonia or gas nitriding. When ammonia comes into contact with the heated work piece it dissociates into nitrogen and hydrogen. The nitrogen then diffuses from the surface into the surface of the material and produces hard Nitrides with alloy constituents such as chromium and aluminium. This process has existed for nearly a century, though only in the last few decades has there been a concentrated effort to investigate the thermodynamics and kinetics involved. Recent developments have led to a
process that can be accurately tailored and controlled. The thickness and phase constitution of the resulting nitriding layers can be selected and the process optimised for the particular properties required. The advantages of gas nitriding over the other surface treatments are: � Uniform nitriding on all surfaces (except those protected by special paints if required) � Large batch sizes possible - the limiting factor only being furnace size. � With modern computer control of the nitriding atmosphere the nitriding results can be closely controlled to give desired case properties. � Relatively low equipment cost - especially compared with other alternatives such as plasma or automated salt/fluid bed. So, to conclude, well controlled, gas nitriding furnaces are produced by RGB Metallurgical Ltd and contain the necessary analysers and software to produce repeatable and consistent results. � Contact www.gas-nitriding.com
March/April 2017
20/03/2017 10:41:21
40 SAFETY
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Fire safety solutions High value and safety critical industries such as aluminium are not strangers to risk. Fire is one such risk. And yet the fire safety is often neglected or misunderstood. Many in fire safety positions do not understand the physical properties of the fire extinguishing systems in place which are installed to put out fires once started. The gases contained in cylinders - the chemicals which put out the fire once the system has been activated – are also misunderstood. This article aims to close gaps in the knowledge about fire safety for those unaware about fixed fire extinguishing systems and to share innovative methods for inspection and continuous monitoring of these systems which even the most experienced may not yet know. Typically, aluminium does not burn, its melts at very high temperatures. The heat is conducted away so the temperature will rapidly increase elsewhere in the vicinity. The need for comprehensive fire safety measures, specifically the fixed fire extinguishing systems in aluminium production and fabrication, in casthouses, foundries, recycling and reclamation plants. The super high temperatures at which aluminium is handled especially at molten points, sow casting and charging. Fine aluminium particles are particularly prone to ignition. Incidences of fire � Devastating fire destroyed a 2800 sqm aluminium plant, which was described as a “total loss”. On December 30th 2016, fortunately there were no fatalities but there were two injured workers. To emphasise how varied the start of fires can be, this plant’s fire was started by the buffing machine used to clean the floors which emitted sparks, resulting in the explosion. (Source: http://aluminiumplantsafety.blogspot. co.uk/2017/01/floor-cleaner-blamed-forexlposion.html). � “A huge fire broke out in an aluminium and lumber factory in the Middle East [sic]. The fire started in the early hours one day during the week of June 28, 2015 PortalevelTM MAX delivers the liquid level content readings and PortasteeleTM calculator converts these to ones of weight and mass
and initial investigations showed that the fire extinguishing system did not work. The sources added that the presence of lumber and diesel tanks in the factory worsened the situation but around 90 firemen, from six fire departments, fought the flames and helped contain the fire in three hours and prevent it from spreading to adjacent facilities. Two firemen were injured in the process and were treated on site.” This incident emphasises “the need to regularly check fire detection and suppressions systems in your plant.” (Source: http://aluminiumplantsafety. blogspot.co.uk/2015/07/the-fireextinguishing-system-did-not.html). Under Pressure! Extinguishing agents CO2, FM-200®, Novec™1230, halons, etc are commonly used agents in the fixed fire extinguishing systems protecting aluminium facilities. Gases under pressure are often considered as passive cylinder columns of solid material from the perspective of their monitoring following installation. However, being under pressure and constantly changing under temperature means the gases should be considered active. Fixed gaseous extinguishing systems These gases leak. It is not a widelypromoted fact in the fire safety industry, except by some experts, and by those who understand the physics behind pressurised gases. If the agent leaks, they may be insufficient gas to suppress a fire in the event they are activated. If there is no agent, the fire will continue to burn and may lead to catastrophe by loss of life, and certain business downtime. They are active and dynamic systems, which require constant monitoring to ensure safety of life, and increase resilience and business continuity. Thus, saving time and
cost long-term by improved monitoring. Constant monitoring Aluminium plants are expensive to build and maintain. It generates significant heat. The value of them are very high but the value of their inability to sustain business continuity is likely to be higher than their physical assets. And yet Insurers are asked to underwrite them and the fire industry to deliver their protection at the cheapest price. Who today would consider installing an alarm system without monitoring its overall daily status - not only on its actuation - and then integrate the alarm system into the building management system, with central monitoring being essential? Who would build plant fitted with power generating auxiliary machinery, without installing emergency power systems or monitoring their condition states? These are basic engineering principles of building redundancy into one’s systems and subsequently monitoring one’s systems. There are clear advantages for the plant and insurers. Business continuity The industry still approaches the installation of a dynamic and pressurised fixed gaseous extinguishing system as if it needs no integration into a BMS/SMS, except alerting on actuation. Nor does it think it needs constant monitoring, lest it reveals the underlying engineering risk of them. Can this be because good engineering is left unrewarded in fire safety matters? Or might it be that the fire industry is more concerned to negate customer awareness of its need lest it reveals that pressurised systems do discharge and leak? These are needless concerns. All good engineering demands the monitoring of dynamic structures and a highly pressurised cylinder is a dynamic structure. It is designed
*Clare Hunter, Head of Marketing & Communications, Coltraco Aluminium International Today
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SAFETY 41
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to protect a critical infrastructure or asset. Without constant monitoring a risk is generated in the very environment for which it is designed to reduce risk. The risk is not only to the asset, but to the people who work in the asset and their ability to enable business continuity in the high value asset under risk. Solution: Continuous monitoring of fire extinguishing systems Ultrasonic solutions are available for the inspection, and now for the continuous monitoring of the contents of fire extinguishing systems. This enables the plants’ facility managers, health and safety managers and fire officers to increase the regulatory annual checks to monthly or even weekly in their plant’s safety management system. Permalevel® Multiplex is the only 24/7, 365 ultrasonic continuous monitoring system of fixed fire extinguishing systems cylinder contents. It can be configured to provide local and remote alarm. Integrated into the existing safety management systems by selected communications capabilities. Available only from Coltraco Ultrasonics, this is leading technology, coming to the market to fulfil the “Ungoverned Space” of fire safety across all industries, especially high value, safety critical ones as aluminium.
Aluminium International Today Buyers’ Directory The Buyers’ Directory is the essential guide to aluminium manufacturers, suppliers of plant equipment and services to the aluminium industry. It provides comprehensive listings, product information and key contact details.
Order your copy now from just £75* Conclusion Coltraco Ultrasonics is a British designer and manufacturer of ultrasonic solutions for improving safety. Coltraco aims to be the lead technical authority in the constant monitoring of liquefied and non-liquefied gaseous extinguishing systems contents during the life of the system once it is installed and commissioned. Coltraco achieve this through 30 years’ experience since inventing the first handheld ultrasonic liquid level indicator Portalevel® - today available in nine models including soon an Intrinsically Safe ATEX Zone 1 variant. Coltraco’s ability to establish the liquid contents of liquefied clean agents – through UL & ABS approved Portalevel™ MAX has led to the research and development into the innovative monitoring system Permalevel™ Multiplex. Once the liquid level is identified, Coltraco can establish the agent’s weight and mass – through Portasteele™ Calculator (the world’s first product capable of this). These Safesite® solutions enable the safety managers to pinpoint exactly when and if a leak in agent occurs – enabling rapid rectification of the issue by organising a refill of agent. Such effective, easy to use, accurate and reliable solutions can improve the facility’s fire safety measures. �
* Free for paid subscribers
For information on how to be listed contact esmehorn@quartzltd.com
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Contact cmehunter@coltraco.co.uk
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7th International Conference on Electrodes for Primary Aluminium Smelters 25 – 27 April 2017, Reykjavik, Iceland ABOUT THE EVENT: The 7th conference will be held on 25-27 April 2017 in Reykjavik, Iceland. The conference has now been firmly established as a platform for development and exchange of ideas in this important and previously neglected field of the aluminium industry. The scope of the conference has now been widened to include cathode rodding. Emphasis will be on environmental issues, increasing productivity and future prospects and challenges in the aluminium industry. More than 100 delegates gathered at the successful 6th conference in 2014 and the organisers are expecting this number to grow in 2017. CONFERENCE PROGRAMME The conference programme is currently being developed and will include international leading experts in this field. Programme announcements will be available online at www.rodding-conference.is EXHIBITION Alongside the conference, a dedicated tabletop exhibition will take place. The exhibition will provide a platform for companies to display their work and products in the primary aluminium industry to an audience of international experts and decision makers.
There is limited space within the exhibition, so don’t miss out; book your space today!
The cost of a tabletop space starts from just £933 and there are sponsorship opportunities available. Contact Anne Considine today to secure your spot: Email: anneconsidine@quartzltd.com Tel: +44 1737 855 139
For all other enquiries, contact Birgir Jóhannesson: Email: Birgirj@nmi.is Tel: +354-522-9174
For conference enquiries, contact Nadine Bloxsome: Email: nadinebloxsome@quartzltd.com Tel: +44 1737 855 115
We look forward to seeing you in Iceland in April 2017!
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HISTORY 43
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The “Age of Aluminium” In this new series, historian Dr Andrew Perchard* provides an oversight of the development of the global aluminium industry within its context, showing how from modest beginnings aluminium became ubiquitous and the industry global giant. Aluminium was inextricably linked to the modern age, and modernism. This was both because of the science and technology with which it was associated, and by design to cultivate markets for the metal and create a mystique around it. The first article in the series (Out of Acorns Grow Big Trees) outlines the scientific discoveries, that were the metal’s midwife, and its early, precious beginnings. Born of the 19th century, it was the twentieth what historian Eric Hobsbawm coined as the ‘Age of Extremes’ - , and especially the two terrible world wars (191418, and 1939-45), that would firmly establish aluminium. These conflicts, the subject of the second article in the series - Le Déluge - would also demonstrate the versatile properties and potential applications of the metal, opening up new and growing markets. In mature industrial economies, the postwar growth of 1950-1975 - the ‘golden years’ or ‘les trentes glorieuses’ - created a boom time for aluminium, as for other sectors. The 1940s and 1950s also witnessed some ruptures in the industry, with challenges to its early ‘first movers’ and leaders. President Richard Nixon's devaluation of the US dollar in 1971, followed by the OPEC crisis of 1973, created challenging political and economic conditions for the global aluminium industry. Aluminium’s exponential growth and smelting capacity, as well as strategic stockpiling by the
United States, resulted in a global glut. The launch of aluminium on to the London Metals Exchange in 1978 contributed to challenging new conditions for the industry. Out of necessity, the industry would become a leader in recycling and in seeking to manage energy consumption and emissions. From the 1980s into the 21st century, the industry underwent profound changes in ownership, structure,
outlook and culture. The period from 1945-present is the subject of the third article, The Age of Light Metal. From the birth of aluminium, national aluminium companies had forged and identified with highly distinctive organisational cultures. Their global reach and networks forging what one historian of the industry has called an Aluminium Civilization, which concludes our series. Steaming into the Modern Age: New York Central’s 20th Century train, c.1938. Much of it built using aluminium. Copyright David A Oram
*Senior Research Fellow at the Centre for Business in Society, Coventry University (UK), and co-founder and director of the History and Strategic Raw Materials Initiative
Out of Acorns Grow Big Trees From the outset, aluminium transfixed audiences. The eminent English Victorian chemist Sir Henry Roscoe, for example, expressed his ‘wonder’ at the ‘silver-white metal’ in 1833. It was an endeavour that attracted the enthusiasm of leading scientists (as well as venture capitalists), such luminaries as Lord Kelvin and Robert Bunsen. If aluminium was a discovery of the 19th century then it was a product Aluminium International Today
History.indd 1
of the enlightenment, and its scientific and technological repercussions. First identified by the English chemist Sir Humphrey Davy (1778-1829) in 1809, further discoveries of the metal were advanced by the Danish and German chemists Christian Oersted (1777-1851) and Friedrich Wöhler (1800-1852), culminating in Henri Saint-Claire Deville’s production of samples of aluminium in
1854. It was the auspicious sighting of Deville’s aluminium ingots at the Paris exhibition of 1855 that attracted the patronage of the French emperor LouisNapoléon III, and piqued the interest of French chemical firm, Produits chimiques d’ Alais et de la Camargue (PCAC). The significance of these connections cannot be overstated in the history of the industry. Napoléon III’s interest in the potential March/April 2017
20/03/2017 09:12:29
22nd
World Aluminium Conference 2017 3-5 May 2017, Marriott London Hotel Grosvenor Square London, UK Sustainability: Exploring the interaction of environmental and economic strategies
Key speakers include:
Reasons to attend:
Michael A. Bless, President, Chief Executive Officer and Director, Century Aluminum
• Hear the latest outlook for price and ingot premiums • Appreciate the market potential for green aluminium products • Understand how susceptible China’s primary aluminium industry is to higher thermal coal prices and environmental pressures • Discuss the role trade defence measures will play in the aluminium market • Benefit from hearing from industry leaders and new and influential players
Lu Dongliang, Executive Director & Senior Vice President, Chalco Sanjeev Gupta, Executive Chairman, Liberty House Group Erika Ahlqvist, Executive Vice President, Communication & CSR, SAPA Göksal Güngör, General Manager, Assan Alüminyum Christopher Robert Smith, President, Ma’aden Rolling Company Andrew Wood, Group Executive Strategy & Development, Alumina Limited Torbjorn Sternsjo, Senior Vice President Technology & Business Development, Gränges AB Senior Executive, Norsk Hydro ASA
The CRU conference is the most important in my annual conference agenda. The content of presentations and the seniority and variety of speakers is high. Taking the conference to different regions takes the discussion to the heart of the matter Will Savage, CEO, Aluminium Federation (ALFED) Supporters
Tolga Egrilmezer, Vice President, Sales and Marketing, Rio Tinto
Register your place today www.worldaluminiumconference.com
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HISTORY 45
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20,000,000 18,000,000
30,000,000 25,000,000
16,000,000 14,000,000
20,000,000
12,000,000
15,000,000
10,000,000 8,000,000
10,000,000
6,000,000
5,000,000
4,000,000 2,000,000
0 1900
1913 1910
1921 1918
1936 1926
1939
1944 1949
1951
1959 1954
1969 1964
1979 1974
1989 1984
2000 1994
Fig 1. Global production of primary aluminium production (metric tons) by selected years (1900-2000). Source USGS
military applications of aluminium was important in transforming its perception as a precious metal of curiosity to a potentially versatile raw material. PCAC’s interest in the metal inadvertently led to the discovery which signalled the birth of the modern aluminium industry. A former PCAC chemist, Paul-Louis Toussaint Héroult (1863-1914) discovered an electro-metallurgical method for reducing aluminium from aluminium powder in 1886. It is indicative of the market for the fledgling metal that PCAC were not supportive of Héroult’s discovery, and indeed abandoned their manufacture of the metal the very same year (only to return to be a market leader). Alfred Pechiney, PCAC’s director, allegedly informed Héroult: “aluminium was a metal… for opera glasses.” On the other side of the Atlantic, US chemist Charles Martin Hall (1863-1914) concurrently discovered a similar process for aluminium reduction. Hall was more fortunate in his industrial backers, the Pittsburgh Reduction Company (subsequently Alcoa) who had the backing of the mighty industrial bankers and venture capitalists, the Mellon brothers. The discovery of the Hall-Héroult process, which continues to be the principal process for aluminium reduction to this day, was not altogether mere serendipity or singular scientific endeavour; it marked a concatenation of events reflecting developments of the second industrial revolution (roughly covering the period 1870-1914) in chemicals and electrical engineering. The aluminium industry also came to benefit from advances in transportation during the period. The French and US chemists’ invention signalled the birth of the modern industry, transforming aluminium production from the chemical process that had predominated to electro-metallurgical production. Previously the chemical reduction of aluminium had combined Henri SaintAluminium International Today
History.indd 2
0 1903 1910 1913 1918 1921 1926 1936 1939 1944 1949 1951 1954 1959 1964 1969 1974 1979 1984 1990
Fig 2. Global consumption of aluminium by selected years (1903-1990) (metric tons). Source: Grinberg and F. Hachez-Leroy,1997
Claire Deville’s method, with that of American chemical engineer Hamilton Castner. The Hall-Héroult process transformed aluminium production from a metal produced in small quantities for luxury products to one that could be produced on a mass industrial-scale. Using the chemical process, aluminium ingot cost as much as $34,000 per tonne as late as 1859 (around $1 million at 2015 prices). Despite improvements in production methods, the chemical production of aluminium remained small and exorbitant. Nevertheless even with the advent of the Hall-Héroult process, aluminium production and consumption was modest, and prices high, prior to the outbreak of WWI (see Figs 1 and 2). As Deville observed in 1900, “Nothing is more difficult than to introduce into the pattern of men’s lives and to get them to accept, a new material, however useful it may be”. Despite his enthusiasm for the metal, Deville further conceded that: “aluminium had not until recently justified its reputation as a metal of the future.” Britain’s main producer, the British Aluminium Company (BACo), struggled in particular. Producers in France, Germany, and US were more fortunate in finding a receptive market for aluminium in the growing automotive sector and the electricity industries. Coupled with a limited market for the metal were the high sunk capital costs involved (then, as now). No producer was self-sufficient in the necessary raw materials, although some (French producers) were better placed than others. In an energy-intensive industry, advances in electrical (and civil) engineering, coupled with the natural capital of water resources, provided the modern industry with its only commercially feasible source of power at the time – hydroelectricity. Nevertheless, in the early 20th century, it required around 30,000 kilowatt hours of electricity to make one tonne of aluminium. With some notable
exceptions, for much of the 20th century, aluminium production would continue to be supplied by hydro-electricity; nearly 60% as late as the 1990s. The aluminium ‘first movers’, AIAG Neuhausen (SwissGerman), the Pittsburgh Company Ltd (subsequently Alcoa), BACo, the French producers (leaders PCAC, Société Electrométallurgique Française (SEMF), and ‘late movers’, l’Aluminium du Sud-Ouest (ASO), La Société Electro-Métallurgie du Sud-Est (EMSE), and the Aluminium Corporation Ltd all relied chiefly on hydro-electric power. This often required them to locate reduction plants in remote locations (for example the Scottish Highlands, Vallée de la Maurienne (France), adding to transportation and habitation costs. The costs are illustrated by BACo’s Highland hydro schemes and reduction works: Foyers, which opened 1896 and closed in 1967; Kinlochleven (opened in 1907, finally closing in 2000); and Fort William (the Lochaber smelter, which opened in 1929 and is still operating, although the smelter has been reconstructed and the power house modernised). By 1898, the construction and modernisation of Foyers had cost BACo £191,000 (£14.2M in 2015 prices). Even before the delays in completion, Kinlochleven was projected to cost the Company £500,000 in 1904 (£48.6M), and by its opening in 1929 (but not the completion of the scheme) Lochaber had cost £2.5M (£137.1M). Construction of these schemes was also labour intensive – with hydro-electric schemes being hewn by rock and explosives out of rugged landscapes – and the human cost of construction was appalling (the tunnel development for the BACo’s Lochaber scheme claimed the lives of 48 navvies alone). Accompanying the development of hydro power were also some of the first environmental battles. BACo (founded in 1894 with the British and Colonial rights to the Héroult process), chose to build their aluminium reduction works in the March/April 2017
20/03/2017 09:12:31
46 HISTORY
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2
3
4
5 1. The Falls of Foyers, c1895. Image courtesy of Glasgow University Archives Service/ CHECK GIVEN NEW OWNERS 2. Blackwater Dam, supplying the Kinlochleven reduction works, being flooded, c.1906. Image courtesy of Robert Cairns 3. Temporary reduction works, Kinlochleven, 1908. Image courtesy of Robert Cairns 4. BACo’s scientific advisor, Lord Kelvin, inspecting intakes at Kinlochleven, c.1906. Image courtesy of Robert Cairns] 5. Interior of Foyers reduction works, opened in 1895, taken in 1920. Image courtesy of Glasgow University Archives Service
Scottish Highlands. The choice of their first plant at Foyers, on the shores of Loch Ness, harnessing the nearby falls made famous in the poetry of Robert Burns and Samuel Coleridge (and a popular tourist spot for wealthy Victorians), was immensely controversial bringing BACo into conflict with a powerful group of opponents, including the then Duke of Westminster, John Ruskin, and the newly formed National Trust. The high costs and low return on investment in the early years of the modern industry claimed its victims; BACo and the Aluminium Corporation (a much smaller British company based at Dalgarrog in North Wales) were forced to recapitalise, and ASO and EMSE went to the wall. Two of BACo’s founding directors, Emmanuel Ristori and Roger Wallace, were bankrupted. This instability in global markets prompted the first two of a series of international aluminium cartels (1901-1908, 1912-1914) controlling production quotas and prices. For much of the industry’s history, the high sunk capital costs, as well as a high degree of oligopolisation within the industry, eliminated new entrants. In 1913, seven companies controlled 94% of global aluminium production. By 1979, six still March/April 2017
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controlled: 54% of bauxite mining; 74% of alumina production; and 62% of primary aluminium production. From a precarious start, and great risk, on the outbreak of the Great War, aluminium was established as a transnational industry. Many of the first movers in the industry, established in the 1880s and 1890s – Alcoa (and its Canadian, the Northern Aluminium Company, Ltd; after 1925, Alcan), AIAG, BACo, PCAC and SEMF, the most prominent – would dominate the industry for much of the twentieth century. The outbreak of the First World War would dramatically change the global aluminium industry; as in so many other aspects of economic and social life, it represented a watershed. A metal that was still an expensive commodity in 1913 ($9,000/ mt; $222,000/mt at 2016 prices) would become recognised as crucial for the conduct of modern warfare and subsequently demonstrate its utility in other areas. The scarcity of supply of other important non-ferrous metals (such as copper, tin, and nickel) further underlined aluminium importance as a strategic raw material. This was also to transform the industry’s relationship with the state in all of the combatant nations for much of the 20th century.
Biography Dr Andrew Perchard is the author of Aluminiumville: Government, Global Business and the Scottish Highlands (Crucible, 2012). For up to 20% off your own copy of ‘Aluminiumville’, use the code ALUM20+ either online: www.carnegiepublishing.com or by calling +44 (0) 0152484011. Some related reading: Grinberg, Ivan (2003), L’Aluminium: Un si léger Métal, Gallimard, Paris. Grinberg, Ivan and Hachez-Leroy, Florence (eds.) (1997), Industrialisation et sociétés en Europe occidentale de la fin du XIXe siècle à nos jours, Armand Colin, Paris. Perchard, Andrew (2012), Aluminiumville: Government, Global Business and the Scottish Highlands, Crucible, Lancaster. _____________ (2011), ‘A “Micawberlike” Undertaking? Innovation, Intrigue, Entrepreneurship and “Dynamic Capabilities” in the Early British Aluminium Industry’, Cahiers d’histoire de l’aluminium / 4 6 - 4 7 (2011), pp.143-155. George David Smith (1988), From Monopoly to Competition: The Transformations of Alcoa, 1888-1986, Cambridge, Cambridge University Press. Aluminium International Today
20/03/2017 09:12:34
BUYERS’ DIRECTORY 47 5
www.aluminiumtoday.com
Aluminium International Today Buyers’ Directory As a leading resource for the aluminium production and processing industries, the Buyers’ Directory reaches the most senior buyers and suppliers in the business. HANDLING & STORAGE
CLAUDIUS PETERS PROJECTS GMBH Schanzenstraße 40 DE-21614 Buxtehude, Germany T: +49 4161 706-0 F: +49 4161 706-270 E: info@claudiuspeters.com W: www.claudiuspeters.com Claudius Peters stockyards, pneumatic conveyors, silos, clinker coolers, grinding mills, and packing systems can be found in Cement, Coal, Alumina, and Gypsum plants across the globe. The group’s other principal Division, Aerospace, manufactures aircraft parts for Airbus. PRIMARY REDUCTION/SMELTER PRIMARY
ALUMINIUM BAHRAIN B.S.C. (ALBA) Building 150, King Hamad Highway Askar 951, Bahrain T: +973 1783 0000 F: +973 1783 0083 E: alba@alba.com.bh W: www.albasmelter.com Aluminium Bahrain has been consistently ranked as one of the largest aluminium smelters in the world and is known for its technological strength and high quality aluminium. FURNACE
HERTWICH ENGINEERING GMBH Weinbergerstr. 6, Braunau, Upper Austria, 5280, Austria T: +43 7722 806-0 F: +43 7722 806-122 E: info@hertwich.com W: www.hertwich.com Hertwich Engineering, a company of the SMS group, is active worldwide with design, supply, construction and commissioning of speciality equipment for the aluminium industry, in particular for aluminium casthouses.
Distributed to more than 50 countries and read by thousands of industry contacts, it contains a comprehensive alphabetical listing of company and contact details. SLITTING
DANIELI FRÖHLING Scherl 12, D-58540, Meinerzhagen, Germany T: +49 2354 7082 0 F: +49 2354 7082 200 E: info@danieli-froehling.de W: www.danieli-froehling.de Danieli Fröhling is synonymous for innovative tailor-made solutions for the aluminium industry. Fröhling customers trust in nearly 70 years’ experience in manufacturing of rolling mills and cutting lines.
EXTRUSION
CASTOOL TOOLING SYSTEMS 2 Parratt Road, Uxbridge, Ontario, L9P 1R1, Canada T: +1 905 852 0121 F: +1 905 852 2300 E: info@castool.com W: www.castool.com CASTOOL Tooling Systems is globally acclaimed as a provider of today’s most technologically advanced production tooling and equipment for the light metal extrusion industry PUBLISHING
ALUMINIUM INTERNATIONAL TODAY Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX UK T: +44 (0)1737 855000 F: +44 (0)1737 85034 E: aluminium@quartzltd.com W: www.aluminiumtoday.com Aluminium International Today is published bimonthly and circulated worldwide alongside foreign languague issues in Chinese and Russian, published twice a year. A weekly newsletter is sent to over 25,000 contacts worldwide.
Here is a sneak peak at some of the listings that will appear in the 2017 Buyers’ Directory.
QUALITY TESTING & MEASUREMENT
POLYTEC GMBH Polytec Platz 1-7, D-76337, Waldbronn, Germany T: +49 7243 6042 36 F: +49 7243 6041 50 E: f.fughe@polytec.de W: www.polytec.de Polytec is the market leader for non-contact, laser based vibration and velocity measurement instrumentation. Our innovative solutions allow our customers to maintain their own technical leadership across many fields. SMELTER PRODUCTION/EQUIPMENT
ROSS CONTROLS 1250 Stephenson Hwy, Troy, Michigan, 48083, USA T: +1 800 GET ROSS F: +1 706 356 3700 E: bob.winsand @rosscontrols.com W: www.rosscontrols.com With more than 90 years of proven design experience, Ross Controls is a global manufacturer of rugged and robust pneumatic solutions for the aluminium industry. Proven potroom performance and safety (LOTO).
It is free to list your company, get in touch today to find out more:
Anne Considine Sales Manager Tel: +44(0)1737855139 Email: anneconsidine@quartzltd.com
Aluminium International Today
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20/03/2017 10:52:26
48 ADVERTORIAL
www.aluminiumtoday.com
BWG answers Nadine Bloxsome* caught up with Stefan Sonntag, Technical Director at BWG, to find out the company’s plans going forward. 1. How are things going at BWG? At the moment things are still going slow. The steel industry is suffering from huge over capacities in China. But BWG could get some small orders for revamps, as well as some midsize orders for quality improvements especially for hot strip after rolling. The big aluminium projects are in a late stage shortly before acceptance or are already finished. 2. What are your views on the current state of the global aluminium industry? After huge investments in China, North America and Europe, also the aluminium industry is cooling down. Currently there are only some projects in Europe and in North America. China is still investing but on a lower scale as the years before. 3. What products are proving the most lucrative? All products around the automotive industry, but also packaging and lithographic products. 4. What are the big trends in technology? BWG is for many years the leading supplier of cleaning and tension levelling lines for lithographic strips. In recent years, we have focused more and more on the complex heat treatment and processing lines for the automotive products. Today we are quite successful in supplying complete high quality heat treatment and processing lines for automotive and aircraft aluminium sheet. 5. Where do you see the most innovation in terms of production technologies – primary, secondary, or further downstream?
Quality of the final product is one of the key issues to be successful. Therefore, all parts of the production processes are involved in innovative production technologies. Nevertheless especially for the automotive industry heat treatment and surface treatment technologies have the driving innovations in the downstream operations. 6. Do you see BWG as an innovator within the industry? Yes, BWG is always searching for innovative solutions for our customers. As one of our most successful innovations, we can name our Pure- Stretch- Levelflex® technology, which became the leading straightening technology for Lithographic printing plates and bright-annealed stainless steel. 7. How do you view BWG’s development over the shortto-mid term in relation to the global aluminium industry? We think our new developments will be a big step forward for better surface quality for automotive aluminium sheets. Midterm we are hoping that this will get standard within the aluminium industry. 8. What does BWG have in store for 2017? We have new developments made in regard of surface treatment for automotive sheets. This development is still treated under confidentiality. Within this year we will be allowed to promote this actively to the market. Nevertheless, our new developments for a high performance flatness-measuring roll and out new joining (clinching) technology will be actively promoted this year. �
BWG Pure- Stretch- Levelflex®, Cleaning and Trimming Line
*Editor, Aluminium International Today March/April 2017
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Aluminium International Today
20/03/2017 09:17:13
Excellence in Strip Processing Technologies
Since 1955.
Quality meets Innovation. We combine solid engineering experience, know-how and innovative solutions for the benefit of our valued customers.
BWG – Your Specialist for Customised Solutions, Processing Lines and Modernisations Since 1955, our name has been synonymous with premium equipment and tech nical solutions which set bench-marks for the metallurgical industry. In addition to the aluminium and non-ferrous metal industries, we have been a reliable partner to the leading steel and stainless steel metal producers for many years, with a focus on:
• Strip processing lines
• Specialty processing equipment • Coil handling equipment
• Modernisation of existing processing plants We have an excellent track record of realising new ideas based on thorough research and development, which have led to significant increases in productivity, product quality, energy efficiency and environmental performance. We look forward to working with you on the implementation of technological solutions that meet the highest standards of quality and innovation.
BWG Bergwerk- und Walzwerk-Maschinenbau GmbH Mercatorstr. 74 –78 47051 Duisburg, Germany Phone: +49 203 99 29-0 Fax: +49 203 99 29-400 E-Mail: info@bwg-online.de
Technology made in Germany. Since 1955. www.bwg-online.de
With aluminium components, cars are lighter, use less fuel and emit less pollution. Put your car on a diet. The planet will thank you – and so will your wallet.
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