FROM RAW MATERIAL RECEIVING UP TO ELECTROLYSIS

PLANTS FOR THE ALUMINIUM INDUSTRY FROM ONE SINGLE SOURCE FROM RAW MATERIAL RECEIVING UP TO ELECTROLYSIS

Coperion is the worldwide market and technology leader in compounding & extrusion, materials handling and service - as well as being a partner for global corporations and small to medium-sized enterprises in the plastics, chemicals, food and aluminium industries offering all business activities along the process chain combined with comprehensive services.

Compounding systems installed worldwide over 10,000 Bulk materials handling systems installed worldwide over 8,000 Employees worldwide 1,900 Network of locations worldwide 29 Plants for the aluminium producing industry - from raw material receiving up to electrolysis Coperion GmbH is the competent partner for all bulk materials

handling solutions around and within the smelter. The company offers solutions to the aluminium producing industry that have proven to be extremely efficient and reliable.

It supports its customers from the first project concept, through a wide range of services to realization and start-up of bulk materials plants such as for example retrofit solutions and provides after-sales support.

Coperion has the necessary expertise for every process stage along the entire process chain in manufacturing of primary alumina. In each process step, the challenges demand plenty of experience, specialist competence and flexibility.

The tasks involved in the design and implementation of a plant from project planning through to installation, and also of individual process stages for handling alumina and petcoke for the

production of primary aluminium, are extremely complex. Therefore, great emphasis is placed on optimization of the interfaces between individual process stages along the entire process chain. This guarantees reliable and economical material flow.

Raw Materials Receiving As large quantities of alumina and petcoke are required for aluminium production, the raw materials are either supplied by ship or rail car. Short ship docking times during unloading are a most important cost-cutting factor. This is something Coperion can guarantee, and at the same time ensure gentle and reliable unloading of the product. The pneumatic Coperion ship unloader features leading-edge technology backed by Hartmann expertise which has proved its efficiency and effectiveness hundreds of times over the years. The decisive

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process components such as filters, rotary valves, blowers etc. are developed and manufactured at the company’s own factory. Speed, reliability and gentle handling of the product during unloading are the first steps towards economical operation of a system. With their experience, pragmatic approach and our innovative technical developments, Coperion experts make sure that the optimum solution is implemented in the shortest possible time.

Reliable and very gentle conveying of the raw materials ensures economical production at a consistently high quality level.

Intermediate conveying After unloading the alumina and

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petcoke, it is transported as quickly and gently as possible to the silos with pneumatic or mechanical conveying systems. To ensure highquality transport, the most suitable conveying mode is selected from a uniquely comprehensive portfolio and customized to suite site conditions and requirements.

Depending on the requirements and the individual situation, Coperion's own pneumatic conveying technologies DUROLIFT, DUROSTAT, DUROSLIDE or mechanical conveying equipment such as belt conveyors, tube belt conveyors and also trough chain conveyors are used. For vertical transport either the DUROLIFT conveying system or mechanical bucket elevators come into use.

MATERIALS HANDLING AND TRANSPORTATION

In-plant storage When charging and discharging alumina silos and also during storage, it is particularly important that a uniform particle distribution is maintained. When handling petcoke the main challenge is to evacuate the product safely.

The company’s know-how guarantees reliable processes for both raw materials. To prevent segratation of the alumina during feeding and discharge, Coperion collaborates with IBAU HAMBURG to implement an efficient antisegregation system. On the silo roof the alumina is distributed from a central transfer point through a system of air-slide conveyors to several optimally arranged filling connections into the silo.

A special discharge system in the silo base permits selective fluidization and sequential discharge of the alumina from individual zones. In this way it is guaranteed that the regular alumina particle distribution is ensured - the most important characteristic for the efficiency of the smelting process. Very robust discharge devices are available and used for discharge of the petcoke.

In-plant conveying Gentle transport and therefore low particle degradation in the alumina enables stable operating conditions and a constantly high quality in the cells. No matter how far storage silos are from the smelter – the product will always reach the "hot spot" in best form. A number of different conveying technologies are offered.

The principle is, however, the same for pneumatic, mechanical or truck transport. Coperion has the know-how needed for all conveying methods to ensure gentle product transport, thereby maintaining the quality of the raw materials.

Distribution to electrolysis cells With the DURODENSE system Coperion offers a very gentle process for charging the electrolysis cells. Slow, continuous, reliable and self-regulating - these are all advantages which really count during this process stage.

The DURODENSE has perfected the technology. With its low alumina flow velocity, the DURODENSE system prevents a scaling effect, providing a sound basis to ensure that primary aluminium manufacturing is reliable and continuous. This system is self-regulating and only requires minimum automation technology which - in light of the large number of electrolysis cells - is not only advantageous with regard to investment and maintenance, but also for operation by personnel. Less is more. This is particularly true in this case.

special knowledge and competence needed for the implementation of both plants and individual process stages.

The global network and the experience of the project managers at all Coperion sites ensure a constant transfer of knowledge which offers customers a host of advantages.

The company provide tailored systems in all sizes, always ensuring deadline compliance and the highest standard of quality.

Local sourcing and cooperation with the global purchasing organization keep costs as low as possible. Coperion’s global assets and project management structure make sure that all processes remain unaffected by frictional losses.

Project management Coperion’s project management team has a wide-ranging scope of engineering skills and know-how at their disposal with all the facets of

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