Aluminium International Today September October 2021 by Quartz Business Media

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www.aluminiumtoday.com September/October 2021—Vol.34 No.5

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www.aluminiumtoday.com September/October 2021—Vol.34 No.5

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

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Stationary Melter Patented Delacquering System

Homogenizing & Cooling Autotapper

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OVER

YEARS

EXPERIENCE IN THE ALUMINUM MELTING INDUSTRY SINGLE CHAMBER/MULTI CHAMBER FURNACES SCRAP DECOATING SYSTEMS TILTING ROTARY MELTING FURNACES SCRAP CHARGING MACHINES LAUNDER SYSTEMS CASTING/HOLDING FURNACES HOMOGENIZING OVENS COOLERS SOW PRE-HEATERS PRE-HEATERS PRE REPAIR & ALTERATIONS

Tilting Melter & Holder

Sow Drying

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314-423 314314 423-9460 423-9460 423

Template SEPT OCT.indd 2

ST. LOUIS, MISSOURI, USA

800-325 800-325 800 325-7075 3257075

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CONTENTS 1

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LEADER

NEWS GREENER ALUMINIUM

The crucial role of aluminium in a sustainable future

Volume 34 No. 5 – September/October 2021

COVER

Editorial Editor: Nadine Bloxsome Tel: +44 (0) 1737 855115 nadinebloxsome@quartzltd.com

INDUSTRY NEWS

reduce carbon emissions?

RECYLING

FURNACE TECHNOLOGY

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

TURKISH SUPPLEMENT

15 18

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

Sales Director: Ken Clark kenclark@quartzltd.com Tel: +44 (0)1737 855117

Advertisement Production Production Executive: Martin Lawrence

is produced

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Hydraulic Free systems are quiet, quick, powerful and boast incredible new features.

Managing Director: Tony Crinion CEO: Steve Diprose

Elizabeth Barford Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 email subscriptions@quartzltd.com Annual subscription: UK £245, all other countries £265. For two year subscription: UK £440, all other countries £480. Airmail prices on request. Single copies £45

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TOMRA machines |

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Sharif Metals interview

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benchmark and circular economy potential

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Cover picture courtesy of GRANCO CLARK

The new life for recycled aluminium,

thanks to Centro Rottami, Indivest and

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Circulation/subscriptions

It matters where and how aluminium

Hydraulic Free : Fully Electric System. A LU M I N I U M I N T E R N AT I O N A L TO DAY S E PT E M B E R / O CTO B E R 2 0 2 1 V O L . 3 4 N O 5

Sales Manager: Nathan Jupp nathanjupp@quartzltd.com Tel: +44 (0)1737 855027

Long-term sustainablity of the aluminium industry

www.aluminiumtoday.com September/October 2021—Vol.34 No.5

Production Editor: Annie Baker

Sales

Can hydrogen and the latest burners

TRANSPORT HANDLING 33

Streamlining the tapping system with more innovative solutions

Supporters of Aluminium International Today

EXTRUSION 37

Mastering challenges in aluminium extrusion through the use of premium steels

FURNACES 40

Autonomous furnace charging for smart cast houses is already a reality

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 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 © Quartz Business Media Ltd 2021

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Aluminium International Today

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Applying ‘through-process’ optical proﬁling

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The beneﬁts of protective clothing

AUTOMOTIVE TURKISH SUPPLEMENT FROM PAGE 59

Improving machining in the automotive industry with the right tools

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Aluminium industry in Turkey

Assan Alüminyum expands further through sustainable investments September/October 2021

16/09/2021 07:28:24

2 COMMENT

TOP STORIES

Éloïse Harvey

Advanced Dynamics and Mecfor form EPIQ Machinery Back in business? Thankfully the term ‘the new normal’ seems to be disappearing (albeit slowly) into Room 101. There are quite a few terms that I will be glad to hear the back of after the last couple of years, but also some changes that I think will actually be beneficial down the line. As travel restrictions start to ease and parts of the world and our lives begin to open up again, it is good to see the majority of people remaining respectful to others and it is also exciting that live events are starting to take place once again. That being said, here at Quartz Business Media, we have been very encouraged by the interaction and engagement we have seen surrounding our virtual events. The future of live events may never be quite what they once were, but hybrid styles and more virtual offerings will open up opportunities that might have once been missed. On this point, the Future Aluminium Forum will return once again on 1st - 2nd December 2021. We have decided to keep this as a virtual event for now, with the hope of re-opening it as a live conference in 2022. This year, we want to encourage discussions on where the gaps are when it comes to realising the value of Industry 4.0 and implementation. Have companies adapted to a change in culture that sees them able to move beyond the proof of concept? Or are there still issues with plants struggling to integrate data and connect across all systems? Join the conversation: futurealuminiumforum.com nadinebloxsome@quartzltd.com September/October 2021

Nadine News sept oct.indd 1

Mecfor and Advanced Dynamics have fully merged their operations. The newly formed company will be known as EPIQ Machinery. Mecfor and Advanced Dynamics, two companies with shared values and complementary expertise, have merged to seize a unique opportunity to make EPIQ Machinery a North American leader in mobile and heavy equipment for the aluminium, pulp and paper, and rail equipment industries. Combined revenues for the two companies will exceed CAD55 million, 75% of which will come from sales outside Canada. Once the merger is finalised,

Éloïse Harvey, who was Mecfor’s President, will officially become CEO of EPIQ Machinery. SeaFort Capital, Mecfor’s majority shareholder for the past three years, will become the majority shareholder of EPIQ Machinery. The balance of shares is held by employees. Éloïse Harvey said: “The announcement is the culmination of several years of fruitful collaboration between our two companies. We’re pleased to be able to create a world-class equipment manufacturer based on shared values. Together, we’ll be able to invest in our growth, our projects, and, above all, our brilliant team to

make Quebec’s industrial equipment expertise shine in the world’s biggest markets.” All current Mecfor and Advanced Dynamics employees will join the new company, which, between its offices and production facilities in Saguenay and Saint-Bruno will have a staff of more than 200. The two organisations will continue to show strong leadership in the development of their own technologies and markets. The Saguenay facilities will be home to the Mobile Equipment and Autonomous Vehicle Center of Excellency as well as the Local Manufacturing Center of Excellency.

LME launches digital provenance register The London Metal Exchange (LME) announced the launch of LME passports, a digital register that stores electronic Certificates of Analysis (CoAs) and sustainability credentials for LME-listed metals. Aluminium will be the first to be issued these passports. The LME passport stores digital versions of the previously paper-based CoAs, which are key specification and quality assurance documents that must accompany shipments of LME metals into and out of warehouses. The first metal to be given access to the digital passport is aluminium. Existing paper and PDF format CoAs can be easily scanned and digitised on the platform, transforming previously unstructured data into information. Metal producers are encouraged to record information in LME passport at the point of production, thereby

reducing the need for downstream stakeholders to access traditional CoA documents. LME passport also enables users to provide disclosures related to metals’ sustainability characteristics on a voluntary basis. Robin Martin, LME Head of Market Development commented on the new passport: “The metals industry is increasingly embracing digital solutions to streamline manual processes for customers across the value chain… LME passport provides substantial benefits for users – not only by automating manual processes and reducing operational risk, but by providing greater transparency and access to provenance data, for which there is growing consumer demand.” Following collaboration with market stakeholders, the LME has developed a sustainability taxonomy, which provides LME passport users with a straightforward cat-

egorisation framework, making it easier to navigate the wide range of sustainability-related focus areas across metals. Georgina Hallett, LME Chief Sustainability Officer, commented: “LME passport will be phased in for all metals that require CoAs, starting with LME Aluminium from 1 October 2021. From this date, all primary aluminium loaded out of LME warehouses will be accompanied by an electronic CoA on LME passport, allowing downstream users ready access to relevant information.” Aluminium International Today

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INVESTMENTS 3

Assan Alüminyum investing in sustainability Assan Alüminyum have announced their latest updates on the companies investments, which claim to have been planned in line with their sense of responsibility towards sustainability. The company announced their 2021 – 2024 road map, which details their intentions to strengthen the ecosystem with investments. According to their claims, this will lead them to achieve their target sustainable goals of 2030. The company previously announced plans to complete a series of investments over the next several years, with a total value

reaching up to 95 million dollars with these investments, they claim their total production capacity will reach over 360,000 tons. With in their plan, they have announced the continuation of their long term collaboration with Achenbach Buschhütten and Novelis PAE, lisiting individual goals and plans which will be completed in collaboration with said companies. The new investments have been said to consist of equipment with state-of-the- art technology, allowing for high energy efficiency and aiming to reduce Assan Alüminyum’s overall carbon foot-

NEWS IN BRIEF

print. Göksal Güngör, General Manager of Assan Alüminyum (pictured above) stated: “We have and we will continue to develop our future plans, based on our vision of reliability, ﬂexibility, innovation and sustainability, while advancing all of our processes based on the sustainability framework set by the Aluminium Stewardship Initiative (ASI) provisional Performance Standard Certificate, … I sincerely believe that we will continue to create long-lasting value for our industry and for our world.”

Novelis expands rolling and recycling capacity in Brazil Novelis has announced the completion of its $150 million investment to expand both rolling and recycling capacity at its Pindamonhangaba, Brazil, plant by 100 kilo tonnes each. Novelis claims that the added capacity will increase to approximately 680 kilo tonnes for aluminium sheet and 490 kilo tonnes for recycling. The expansion is the newest step in support of the company’s sustainability goals to reduce its carbon footprint by 30 percent by 2026 and to be net carbon neutral by 2050.

Steve Fisher, President and Chief Executive Officer, Novelis Inc., commented on the completion of the project: “Recycling and increasing the use of recycled content in our products is the cornerstone of Novelis’ sustainability journey,… We will continue to identify and invest in projects like this expansion in Brazil that will move Novelis toward being a fully circular business.” Novelis also claims that the additional capacity at the South American plant will allow the company to continue to grow alongside its beverage packaging and specialty

customers in the region. The investment also includes the purchase of an additional 380,000-square-meters of land for potential future expansion. Francisco Pires, Senior Vice President, Novelis Inc. and President, Novelis South America, added: “This project reaffirms Novelis’ commitment to serve the growing South American market with high-quality, innovative, low-carbon, sustainable aluminium solutions,… We stand ready to meet our customers’ needs both now and into the future.”

Ball to build new plants Ball Corporation has announced that it is planning to significantly increase its manufacturing capacity, with new cutting-edge facilities in the UK and Russia. With an increasing consumer demand for more sustainable purchasing options and a growing number of new brands and beverage categories choosing cans, the demand for aluminium packaging is rapidly expanding. Ball has claimed that each facility would produce billions of cans a year, after 2023, and provide up to 200 skilled jobs in a fast-growing but Aluminium International Today

Nadine News sept oct.indd 2

stable sector. In the UK, Ball has identified a site at the SEGRO Park Kettering Gateway in Northamptonshire, and has submitted its formal application to the North Northamptonshire Council. The company expect to break ground during 2021, following a period of public consultation. The planned Kettering plant will become Ball’s third beverage can manufacturing facility in the UK, adding capacity to its established plants in Milton Keynes and Wakefield. To serve the fast growing Russian

market, Ball has announced plans to build a plant in Ulyanovsk in Western Russia. Ball Beverage Packaging Naro-Fominsk has signed a cooperation agreement for its construction with the Ulyanovsk Regional Government, who in June also awarded the development ‘Highly Significant Investment Project’ status. The Ulynavosk plant will take the total in Russia to four, with established manufacturing facilities in Naro-Fominsk, Moscow Region; Vesvolozhsk, St. Petersburg Region; and Argayash, Chelyabinsk Region.

Aluminium hits $3,000 Aluminium prices have touched $3,000 a tonne for the first time since 2008, as restrictions on output in China fuelled fears that supply will run short. Prices have leaped 50% this year and nearly 15% in only three weeks as speculators pile into the market. The benchmark contract on the London Metal Exchange (LME) was down 1% at $2,894.50 a tonne at 1600 GMT after touching $3,000. First “High Purity Alumina” project to join Australian Aluminium Council Executive Director of the Council, Marghanita Johnson said: “We welcome Alpha HPA to the Council. We are excited at the prospect of representing a new product which is set to be made in Australia and distributed to the world as part of the evergrowing range of products we will need to meet technology challenges – today and into the future.” Aluexpo 2021 postponed Aluexpo 2021 fair has been postponed to 3 – 5 March 2022 in order to accommodate the increasing number of exhibitors by significantly expanding exhibition area for the coming shows, ensure its stakeholders satisfied and for the fair not to be overshadowed by the pandemic. Gillespie & Powers Inc. purchase Thorpe Holding Company Gillespie & Powers Inc. and Thorpe Technologies Inc. are two strong and successful companies, both with long standing reputations with their customers domestically and internationally. Combining the two entities resources together, the companies aim to elevate the customer experience even further and deliver maximum value with the latest technological advancements.

September/October 2021

21/09/2021 15:11:37

4 ENERGY NEWS

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CPV Power Purchase Agreement for Hydro’s Cressona Operations Competitive Power Ventures has announced a power purchase agreement (PPA) with Hydro. Energy from CPV’s Maple Hill solar facility will power Hydro’s aluminium extrusion facility in Cressona, Pennsylvania. Maple Hill, in Portage Township, Pennsylvania, began construction earlier this year and will start providing power to the Hydro Cressona facility in summer of 2022. The 127 MWdc facility will consist of 237,000 solar panels that utilise the latest bi-facial technology and a single-axis tracking system to maximise energy production. CPV’s PPA with Hydro is the first long-term energy contract signed by Hydro in the U.S. The company has a strong focus on sustainability

Hydro Extrusions Cressona, PA

and recently announced plans to invest $48.3 million in Cressona, Pennsylvania, to support the growing transportation, distribution, and industrial market segments in North America. Mike Hammer, Senior Director of Operations at Hydro Cressona added: “Utilising a renewable energy provider like CPV in the production

of our aluminium products is the perfect complement for Hydro’s sustainability goals, and we’re excited to be the first site in North America to take this step, … The clean, locally-generated energy from CPV’s Maple Hill site makes it an ideal facility to support our investments and world-leading capabilities in Cressona.

IAI data reveals improved energy efficiency New data from the International Aluminium Institute (IAI), claims the IAI, has revealed the aluminium industry’s achievements in reducing energy efficiency in the industry’s continuous sustainability quest. Energy usage accounts for over two-thirds of the industry’s global greenhouse gas emissions. Previous results from the 2020 Global Energy Survey, conducted by the IAI, provided evidence of an industry customising pathways to tackling the problem. The annual survey, which had a 90 per cent response rate across the global industry, demonstrated the use of sustainable production processes and competently managed to reduce its impact on the environment.

The report summarised reports on a reduced energy intensity in both refining and smelting from 2010-20 and an increase in the use of renewable energy.

Commenting on the data, Linlin Wu, IAI’s Manager – Statistical Analysis said: “Our industry has kept the momentum in energy efficiency improvement during the pandemic, with average energy intensity of both smelting and re-

fining improving by about 0.5% compared to the previous year. This is testament to the industry’s commitment to continuous improvement in emissions reduction. It also demonstrates our commitment to providing transparency of footprint across the entire aluminium value chain”. Data from the survey revealed that over the past decade, global production of primary aluminium and metallurgical alumina (aluminium oxide) has increased by 54% and 50%, respectively. Despite this vast production increase, refining energy intensity reduced by 25% and electrolysis energy intensity decreased by 4%. The impact of this 10-year energy saving is the equivalent of 3.2 TeraWatt.

Rio Tinto energy agreement Rio Tinto has signed a power purchasing agreement for a new renewable energy plant to power the operations of its QMM ilmenite mine in Fort Dauphin, Southern Madagascar. The project, which plans to use September/October 2021

Nadine News sept oct.indd 3

solar and wind energy, claims it will significantly contribute towards Rio Tinto’s carbon neutral objective. Rio Tinto aims to reach carbon neutrality by 2023. The project is part of a broader initiative which aims to reduce the ilmenite mine’s

environmental footprint which includes programmes that focus on emissions reduction, waste and water management, carbon sequestration, ecological restoration and reforestation.

2021 DIARY November 2021 14th - 15th 9th BMR Conference The BMR conference provides attendees with industry leaders, networking opportunities, new practices, encourages recycling. With conferences, forums and workshops the BMR aims to share knowledge on the industry, also working with the government to increase the sustainability of the industry. bmr.ae

16th - 18th AZ China * VIRTUAL * AZ China will be holding their next conference virtually. This year the conference brings industry leaders and many sought-after speakers from China and the world to discuss the future of the industry globally. The conference attracts people from all over the world. conference.az-china.com

22nd - 25th The 39th Conference and Exhibition ICSOBA 2021 The 39th Conference and Exhibition ICSOBA 2021 will be be held on 22-25 of November 2021 in Manama, Kingdom of Bahrain, under the Host Sponsorship of Aluminium of Bahrain. icsoba.org/upcoming-icsobaevent-2021/

December 1st - 2nd * VIRTUAL * Future Aluminium Forum At the Istanbul Expo Center, leading local aluminum producers and global supplier companies will showcase their products and technologies to the visitors. futurealuminiumforum.com

March 2022 9th - 10th Sustainable Industrial Manufacturing (SIM) Europe Hosting leaders from the worlds of science, innovation, government, industry, and investment, SIM Europe will provide an opportunity for those at the frontier of energy intensive industrial manufacturing to collaborate and deliver real change. sustainableindustrial manufacturing.com/europe For a full listing visit www. aluminiumtoday.com and click on Events Diary Aluminium International Today

21/09/2021 15:11:41

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CREATING THE FUTURE THROUGH SUSTAINABILITY

Our sustainability vision has been globally recognized We have been entitled to receive the provisional Aluminium Stewardship Initiative (ASI) Performance Standard Certificate which sets the global sustainability framework for the aluminium industry. We are proud that the importance we give to our value of sustainability has been recognized on a global scale. We continue to create value in order to further advance our sustainability.

GREENER ALUMINIUM 7

The crucial role of aluminium in a sustainable future

DI Dr. Markus Schober, MBA. COO HAI Group

Hanna-Mari Soikkeli, MSc (Econ. & Bus. Adm.) Trainee QM & Sustainability at Hammerer Aluminium Industries

This article looks at HAI’s contribution to a greener future and the increasing demand for aluminium. Hammerer Aluminium Industries (HAI) is a family-owned aluminium company with its headquarters located in Ranshofen, Austria. The young and dynamic company has place sustainability into the company values since 2007. Today the company employs 1800 people in four different countries and eight different production locations and has a planned turnover of 520 million euros for 2021. HAI operates within four different business fields: Transport, industry, construction and casting products, offering a true value as well as quality and sustainability regarding the products. The decade of action, towards the net-zero Almost six years ago, around 200 countries made history by adopting the Paris Agreement, the first-ever universal climate agreement, to prevent the rise of global temperatures and at the same time preventing the unreversible impacts of climate change. The European Union’s seventh commission, led by von der Leyen, introduced the European Green Deal to the European Union (EU) in 2019. Following the previous developments, the agreement sets the goal to reach the netzero by 2050. To reach this goal collective actions are necessary. United Nations called the next ten years the “Decade of Action”. Aluminium: unique material with a crucial role in sustainable future The European Commission added, for Aluminium International Today

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the first time, bauxite to its list of critical raw materials in 2020. The list is rewritten every three years and the materials are rated with two main parameters: economic importance and supply risk. Out of 14 industries, 10 rated bauxite as a critical raw material. This highlighted the versatility and importance of the aluminium industry, not only in a European context but worldwide. Aluminium can make a major contribution to a climate-neutral economy as a material that can be infinitely recycled, is light in weight, and can be adapted to different industries from buildings to automotive. According to the International Aluminium Institute (IAI), aluminium is contributing around 2% of total anthropogenic emissions globally. At the same time, the International Energy Agency ranks the aluminium subsector as one of the largest industrial energy demands. The industry wide challenge of “energy intensity” can be addressed by decarbonizing the power supply. With the use of renewable energy, greenhouse gas emissions can be reduced substantially. HAI production sites in Austria and Romania are powered with 100% renewable energy. With the energy, transition to renewable energy the company has demonstrated its commitment to more sustainable business practices. HAI has also contributed to the energy transition in Austria by installing photovoltaic systems on the rooftops of its production facilities. In 2019 an area of 6.300m² of solar panels was built on the

roofs which have expanded in 2021 by an additional 3.000m². Energy transition is not the only field the HAI Group is contributing towards a sustainable future. In the aluminium industry, the material itself has a tremendous impact on the overall carbon footprint of the products. As a recycler HAI has used aluminium scrap in the remelting process, bringing the material back into circulation. The extraordinary high recycling rate of HAI casting division is only possible through investments in production systems, furnace technology, waste material management, and the processing of scrap. This is accompanied by the recycling expertise of the company’s employees and extensive knowledge of the material. Sustainability goes beyond the famous carbon footprint. The casting division of HAI Group has been certified against Aluminium Stewardship Initiatives Performance Standard since 2020. This independent, third party certification program is created to ensure sustainability and human rights principles in aluminium production, use and recycling. The future is looking green The demand for aluminium is increasing constantly due to its unique properties. Now, and in the future, this demand is filled with primary and recycled aluminium. The share of recycled aluminium is now around 30% of the whole market. According to the European Aluminium, secondary aluminium could reach almost September/October 2021

21/09/2021 15:24:08

8 GREENER ALUMINIUM

an equal share of supply of primary aluminium by 2050. The industry must have the legislation and investments that are supporting this target. The industry needs investing in collection and sorting technologies, this way the aluminium is not lost during the circulation and the material can be fully recovered again. By supporting the circularity of aluminium, the industry is not only saving energy in the production process, but the savings are occurring every time the material starts another recycling cycle. For primary aluminium, the future is also looking greener. By 2050, primary aluminium could be 70% less carbon intensive than it is today according to the European Aluminium. With the high recycling rate within the European Union, it is possible to reduce the dependency on imported aluminium, which often has a significantly greater carbon footprint. This development is also in support of the European climate leadership, with global fair-trade conditions. The meaning of low carbon value chains is increasing. It is stated, more than once in different contexts, that cooperation is the key to success. HAI has closed a deal with

its long-standing partners Glencore and Century, regarding 150.000 tons of NaturAl™ aluminium, over the next five years. This low carbon aluminium is made with energy from 100% renewable sources and has a total carbon footprint below four tons of CO2 per ton of aluminium, which is one of the lowest CO2 footprints in the world for primary aluminium. All the endeavours that the HAI Group has taken are founding the reason for our existence: to provide sustainable, high

quality aluminium to our customers. In the year 2021, HAI brought two new alloys to the market, SustainAl 4.0 and SustainAl 2.0., with the value of 4.0 and 2.0 CO2e/ 1t Al, HAI can provide aluminium well below the European average. We are extremely proud to be able to provide sustainable, low carbon options to the market now and in the future. Together we can contribute to a sustainable future. �

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Hydrogen plant

Can hydrogen and the latest burners reduce carbon emissions? Representatives from Air Products presented at the Greener Aluminium Online Summit in June an announced its plans to be the first company in the world to begin building a large-scale green hydrogen production facility. This article looks into the importance of hydrogen for a sustainable future. The risks of climate change need little introduction. The most recent Intergovernmental Panel on Climate Change (IPCC) report delivered the news that we now have less than a 9-year window to act on climate change and limit global warming to 1.5°C. It also stated that limiting warming to 2°C will not be enough to prevent the most serious impacts. To limit global warming to as close as possible to 1.5°C, the most important September/October 2021

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challenge today is the decarbonisation of the global economy and the key to meeting this challenge is to electrify as many economic activities as possible and use hydrogen - primarily made from renewable sources - in other harder-toabate areas. Aluminium – a unique material Due to the unique combination of characteristics of being lightweight, yet durable, and its ease of recyclability,

aluminium has revolutionised industries from construction and transportation to consumer packaging. Its ability to be repeatedly reused - around 75% of all the aluminium ever produced is still in use today – gives it a significant environmental advantage. It is a record unmatched by other materials, and a compelling argument to as to why aluminium will be a hero of the circular economy. Its light weight will also play an important role in enabling other sectors to reduce carbon Aluminium International Today

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emissions – particularly in transportation. However, aluminium production is estimated to generate around 2% of global greenhouse gas emissions. While this may seem small in relation to other sectors - 3% from aviation or 6% from food waste – it is a sector that still needs to take its part in accounting for, and addressing, its contribution to the climate emergency. In 2018, global demand for aluminium was 95 million megatonnes - two thirds of which was met by primary aluminium and one third from recycled aluminium. The International Aluminium Institute (IAI) suggests that due to rapid population and economic growth, between now and midcentury, global demand for aluminium will increase by up to 80% by 2050, including both recycled and primary metal. And despite an increased projected supply of metal coming from recycled sources, the IAI estimates that up to 90 million megatonnes of primary aluminium will still be required per annum by 2050. At the same time, the International Energy Agency’s (IEA) suggests that the industry will need to dramatically reduce Aluminium International Today

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its emissions by 80% by 2050. Carbon pricing as a tool for change For many aluminium production companies, one of the primary considerations for deciding where to locate their smelters is not the carbon footprint of candidate countries’ electricity, but pricing. As a result, China produces over 60% of the world’s aluminium, mostly from coal power. And while one tonne of aluminium produced in Europe creates around five tonnes of carbon dioxide (CO2) emissions, that number rises to 15 tonnes in China. So, there is considerable opportunity for lower carbon fuel solutions. According to analytics and consultancy firm, Wood Mackenzie, to meet the requirements of the Paris Agreement, direct emissions from metals production must halve over the next 20 years. Their view is that the global price of CO2 per tonne should rise dramatically by 2030 in order to keep global warming below 2°C. This would radically change the production economics of emissive industries, like metals production, and

significantly encourage use of renewables as energy feedstock. As aluminium is second only to steel in emissions and competes with nickel for highest levels of intensity, it stands to be considerably affected by carbon pricing so there is now greater impetus for the sector to turn to lower carbon energy sources. According to the IEA’s aluminium tracking report from October of 2020, on the current trajectory, “by 2050, primary aluminium production will be emitting 2.83 billion tonnes per annum, which is the equivalent of over 90% of the CO2 emissions from all of the passenger vehicles in the world today. That doesn’t sit comfortably with the CO2 gains from using aluminium to lightweight vehicles that is being promoted by the industry today”. Reducing carbon and the role of hydrogen It is generally agreed by environmental and energy bodies that a realistic pathway to zero carbon emissions for the aluminium industry needs to be a threefold approach: continuing to reduce energy intensity, adoption of inert anodes, and the shift to using 100% renewably generated power. Low or zero-carbon hydrogen, being produced from renewables, nuclear or fossil fuels with carbon capture, utilisation and storage (CCUS), can help to decarbonise a range of sectors, including long-haul transport, chemicals, iron and steel, where it is proven difficult to reduce emissions. Fuel switching to green hydrogen (defined below) and CCUS offer the most credible pathways. From the position of Air Products, one of the world’s leading industrial gases companies that now regularly supplies hydrogen to environmentally committed aluminium producers, hydrogen can represent just such a carbon emission-free energy source and pathway. Although hydrogen gas has neither color, nor odor, it is now typically identified with a color that associates the gas with the way it is produced, along with the raw feedstock and the emissions emitted in its production. Several colors are used for hydrogen and generally range from grey to blue and all the way to green. Grey hydrogen is mainly produced by the reforming of fossil fuels such as natural gas, LPG, or naphtha via steam methane reforming (SMR) and accounts for about 95% of the hydrogen gas that is produced worldwide today. Grey hydrogen is the lowest cost to produce, requires less equipment and a smaller footprint. Nevertheless, its acceptance is coming under pressure for environmental September/October 2021

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reasons as the SMR process generates CO2 that is vented into the atmosphere. Similarly, blue hydrogen is produced from fossil fuels but with a lower carbon intensity due to sequestration or repurposing of the CO2 emitted. Carbon emissions are reduced through the capture and storage of a portion – up to 90% - of the CO2 produced in the process. The cost of blue hydrogen production depends on feedstock, utilities, the incremental cost involved in handling of the of CO2 (including recovery, compression, storage, transport via pipelines, sequestration), and the availability of carbon credits. Green hydrogen is produced by electrolysis of water using electricity from renewable sources and meets the lowest carbon threshold as clean energy sources are used to separate hydrogen from other compounds such as water molecules. These can include wind, solar, hydro and even geothermal energy. In terms of cost, various factors are involved, with the greatest one being the cost of the actual electrolysis process, but the cost of generating renewable energy has fallen significantly in the past decade. Air Products accelerating the hydrogen economy Air Products has been a supplier of hydrogen since 1975 and was the first liquefier to the US National Aeronautics and Space Administration (NASA). With its long history of expertise in all areas of hydrogen production including SMR, gasification and electrolysis, it now holds a worldwide leadership position in hydrogen production and recovery. Air Products owns and operates over 110 hydrogen plants around the globe and has an established reputation for safe, reliable and cost-effective supply of the gas. In under three decades, it has completed over 250 hydrogen projects in over 20 countries and currently with nearly 9,000 tons per day of capacity. Air Products is a member of the Hydrogen Council, a global CEO-led alliance with a united and long-term vision to accelerate the hydrogen economy. The company has plans to produce 100% green hydrogen from a world-class plant in the high-technology industrial cluster at NEOM in Saudi Arabia. September/October 2021

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In addition to Air Products’ ability to supply hydrogen gas as a fuel for more sustainable aluminium melting, its advanced gas technologies including its innovative transient heating technology and smart process control systems can be used in conjunction with hydrogen or hydrogen fuel blending to boost reverb furnace performance and further minimise carbon emissions. Transient heating oxy-fuel burners with Process Intelligence In both reverberatory (reverb) and rotary furnaces, heat transfer from the flame to the melt charge takes place either directly from the flame to the charge or indirectly from the flame via the refractory walls of the furnace, and then from the refractory walls to the charge. In a rotary furnace, the rotation enables the hot refractory to pass under the metal charge, thereby transferring heat more effectively from refractory to the metal. Therefore, rotary furnaces have very high efficiencies - up to around 90%. Such high efficiency is especially suitable for oxy-fuel combustion as the higher available energy can be more efficiently transferred to the melt. Reverb furnaces are inherently less efficient than rotary furnaces in transferring available energy to the metal.

Due to reverb furnaces being stationary and typically larger - with burners normally mounted horizontally - the heat transfer from the flame to the melt is more limited, with efficiencies of around 65%. Conventional oxy-fuel burners with higher energy levels and heat flux therefore become more difficult if the heat cannot be transferred to the melt effectively. Conventional oxy-fuel burners can present additional challenges in reverb furnaces such as: � Localised overheating due to higher radiation from oxy-fuel burners, especially to the roof; � Non-uniform heat distribution in the furnace due to lack of convection with reduced flue gas volumes and poor furnace pressure control; � Quicker cut back in firing rate of oxyfuel burners due to control thermocouple temperatures reaching set point too quickly from higher radiation; � Yield losses due to non-uniform heat and oxygen distribution close to the metal; and � Higher NOx due to interaction of the oxy-fuel flame with leakage air from the atmosphere or with the air fuel flame in oxy-fuel boost cases, where the flame interaction is not controlled.

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For more effective heat transfer in reverb furnaces, the answer lies in the Transient Heating burner. Usually mounted on the furnace roof, the burner typically has four nozzles directed toward four quadrants of the furnace below. Using proprietary control techniques, coupled with temperature feedback, it can direct heat to any combination of the quadrants, so delivering the efficiency benefits of direct flame impingement, while avoiding overheating by limiting the firing in any one direction. The amount of energy and time spent directing the heat flux towards a particular area of the furnace can be preset to a given frequency or automated by strategically located sensors in the furnace to direct more heat to colder areas and less heat to hotter ones. This results in energy being delivered where and when it is most effective. The heat release profile can also be customized for a specific furnace’s needs, using the burner’s ability to adjust velocity and flame length. Air Products’ patented Transient Heating oxy-fuel burner is the only smart burner technology in the world to incorporate diagnostic sensors and wireless communications to help direct heat down

toward the melt, sequentially to all areas of a reverb furnace. Known as Air Products Process Intelligence (APPI), this smart technology improves monitoring and control of the combustion system, tracks key process parameters, sends alerts and provides remote access to important data. The APPI Process Advisor system can also calculate when the aluminium has reached tapping temperature, helping to predict when the melting process is complete. The combination of the Transient Heating Burner and APPI, has demonstrated up to 40% increase in productivity and fuel efficiency, which is directly converted to CO2 emissions reduction and up to 20% reduction in metal losses in reverb furnaces. Conclusion Aluminium has many environmental benefits, from its ability to be repeatedly reused to enabling other sectors to reduce carbon emissions. At the same time aluminium production generates ~2% of global CO2 emissions, and emissions may increase as demand for aluminium increases. Decarbonizing aluminium production can be accelerated by shifting to renewable energy and reducing energy

intensity. Green hydrogen produced via electrolysis of water using renewable electricity can provide a reliable source of energy for aluminium production while significantly reducing carbon emissions. Likewise, the use of oxy-fuel combustion technologies can improve the energy efficiency of aluminium furnaces. Traditionally, there has been a reluctance to incorporate oxyfuel combustion in reverb furnaces as the technology rarely met the needs of the melting operation. But oxy-fuel combustion technology has made significant progress over the last two decades, with its performance and reliability greatly improved. With the advent of technologies like Air Products’ Transient Heating oxy-fuel burner, real productivity, yield and fuel efficiency have repeatedly shown themselves to be significant benefits to reverb furnace operations. However, it is expected that one of the biggest and most important benefits of using an alternative low-carbon fuel like green hydrogen and optimising furnace performance with the latest burner technology is the aluminium industry’s opportunity to significantly reduce its carbon footprint. �

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Long-term sustainability of the aluminium industry By Pernelle Nunez* In a world where expectations around sustainability are growing, demand for aluminium is also expected to grow. Aluminium is widely recognised as a material that has a role to play in the low-carbon energy transition, with applications across the renewable power sector and in energy storage. Aluminium’s unique combination of properties makes it a valued material across many end-use markets. For example, in the transportation sector, a high strength-to-weight ratio has made it possible for vehicles to be light, strong and fuel-efficient. This will continue to be important with the rollout of electric vehicles which need to be lighter and more efficient. In building and construction, the metal’s durability and formability results in very long lifetimes and enables innovative and energy-efficient buildings. While in the packaging sector, it is the barrier properties of aluminium that reduce wastage and enable food, drink and medicines to be transported across long distances. These sustainability credentials make aluminium a material of choice today and for the future.

Delivering a sustainable future The concept of sustainability has been around for many decades but over the past few years momentum for change has grown in line with evolving societal expectations. The impact of the COVID-19 pandemic has further accelerated society’s sustainability agenda and focused efforts towards rebuilding resilient, green and inclusive economies and communities. Any recovery plans must have sustainability at their core. Sustainability is inherently forward looking. It is a much broader concept that considers impacts across a spectrum – environment, society, the economy; and that long-term holistic approach is crucial to finding a balance between today’s needs and those of the future. While aluminium is part of the solution for a sustainable future, the industry also recognises that it must address its own impacts and act decisively to minimise these to remain aligned with, and deliver on, global sustainability goals. With global demand for aluminium expected to grow by 80% over the next 30 years, the industry must continue to adapt and develop sustainable pathways for the future.

Fig 1. 2018 total aluminium sector emissions (Mt CO2e) heat map by process and source

A growing demand Demand over the next 30 years is expected to be driven by growth across key sectors including consumer durables, which could more than double in size between 2018 to 2050, and transport and electrical enduses which could see growth of over 85% between 2018 and 2050. Overall, demand for semi-fabricated products is estimated to grow from 95 million tonnes in 2018 to about 170 million tonnes by 2050. Recycled metal will form an increasingly important part of supply out to 2050, and because of the energy-saving of almost 95% over the production of primary metal, its use should be maximised. However, the key challenge with recycled metal, is that it is a limited resource – almost 75% of all aluminium ever produced is still in use and so not available for recycling. Fulfilling growing demand for aluminium will therefore still require an increase in primary metal production. A balancing act ahead By 2050, it is estimated that an additional 24 million tonnes of primary production will be needed to meet growing demand. This means an increase in raw material

Fig 2. 2050 total sector emissions under a business-as-usual scenario by source and IEA B2DS Aligned Budget

*Deputy Secretary General, Director - Sustainability, International Aluminium Institute Aluminium International Today

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Such a dramatic decrease in emissions will only be possible with both the widespread deployment of existing decarbonisation technologies and implementation of newer innovations to address emissions along three key pathways (Fig. 3):

Fig 3. Aluminium sector decarbonisation pathways to 2050

inputs with greater tonnages of bauxite and alumina required, as well as an increase in outputs from the processing of these materials. This need for more raw materials will require careful management to mitigate impacts on the environment and local communities. Bauxite residue is a prime example of one of the outputs from the process that will significantly increase during this demand growth period and so will require considered management. For every tonne of aluminium produced, approximately 2.2 tonnes of bauxite residue is generated. Most bauxite residue generated today is stored in specially designed facilities on the refinery site. However, with increased bauxite residue generation out to 2050, innovative solutions such as utilisation in other industries will need to be maximised to reduce pressures on the environment. Another critical output that could increase with growing primary aluminium production is greenhouse gas (GHG) emissions. Climate change is widely considered to be the most significant risk to modern society. Aluminium production is an energy-intensive process however and the energy source used in generating the significant amount of electricity required for electrolysis has a major impact on the total GHGs emitted by the sector. The industry has a long history of managing and reducing emissions directly from its processes. In 2018, total GHG emissions for the sector were close to 1.1 billion tonnes of CO2e (Fig.1) which equates to approximately 2% of global anthropogenic GHG emissions. Electrolysis was the most inﬂuential unit process on the overall sector emissions profile, contributing over 670 million tonnes of CO2e, followed by thermal and direct process emissions which accounted for over 300 million tonnes of CO2e. The industry recognises the importance of aligning its decarbonisation efforts with global climate goals to limit global warming to well below 2 degrees Celsius, compared to pre-industrial levels. September/October 2021

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Aligning with global climate goals Alignment with global climate goals for the aluminium industry requires an understanding of the broader, systemswide context. The International Energy Agency (IEA) acknowledges aluminium’s contribution to a decarbonising society through its use in renewable energy, lightweight electric vehicles and energyefficient buildings. The IEA’s Beyond 2 Degree Scenario (B2DS) and Sustainable Development Scenario (SDS) assign the aluminium sector a GHG budget in 2050 that is greater than zero even though the world would need to be at or near netzero by that time. The International Aluminium Institute (IAI) has modelled a scenario aligned with the IEA’s B2DS (Fig. 2) and estimates that the sector’s emissions would have to be reduced to approximately 250 million tonnes by 2050 compared to 1.1. billion tonnes in 2018 or a Business As Usual (BAU) estimate for 2050 of 1.6 billion tonnes CO2e. This significant shift would require electricity-related emissions to decrease to near zero and all other emissions to reduce by about 50% to 60%.

� Pathway 1: Electricity decarbonisation More than 60% of the aluminium sector’s 1.1 billion tonnes of CO2 emissions (2018) are from the production of electricity consumed during the smelting process. Decarbonised power generation (renewables) and the deployment of carbon capture utilisation and storage (CCUS) offer the most significant opportunity to reduce emissions to near zero by 2050. Improved energy efficiency will also play a role, but incremental improvements and retrofitting are unlikely to see reductions that address more than 10% of these emissions. � Pathway 2: Direct emissions This focuses on the reduction of direct emissions associated with the process and thermal energy. The reduction of these emissions is dependent on technological step changes that can provide heat and steam without the combustion of fossil fuels. Emissions from fuel combustion make up 15% of the industry’s emissions. Here, electrification, fuel switching to green hydrogen and CCUS offer the most credible pathways to achieving the sector’s climate goals. Process emissions make up a further 15% and require new technologies, such as inert anodes. These emissions and those in transport and raw materials will need to be reduced by 5060% from BAU baseline scenario by 2050.

Fig 4. Examples of recent investment and deployment of technology to address sustainability challenges across the sector

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� Pathway 3: Recycling and Resource Efﬁciency Recycled metal will play a greater role in fulfilling future demand for aluminium and if recycling processes and sorting technologies are improved and optimised, there is potential to save approximately 300 million tonnes of CO2e. Increasing collection rates to near 100% as well as other resource efficiency progress by 2050 would reduce the need for primary aluminium by 20% compared to BAU. These three pathways layout a potential way forward for the sector to deliver on society’s climate goals. Different corporate actors will follow different pathways and advance at different rates given the varied starting points, local resources and technologies they have access to. There is, however, promising momentum building throughout the sector and

UAE, waste recycling partnerships with the cement industry have brought GHG savings and reduced other environmental pressures by avoiding further sourcing of new raw materials. The long-term sustainability of the aluminium sector will be dependent on the industry’s ability to adapt and respond to the different challenges ahead. It will also require a holistic approach to sustainability that considers the environment, communities and the economy. Action will be needed from participants across the entire value chain, and technology providers, governments and investors. There is no single solution to the sustainability challenges facing the industry and society as a whole, but one thing is clear, collaboration, innovation and investment will be essential to delivering a sustainable future for all. �

significant progress has already been made in research and development, and technology implementation, across the sector. From increasing solar power usage in the UAE to inert anodes in Canada and fuel switching in Brazil, there are many operations exploring options for decarbonisation already (Fig. 4). Beyond GHGs Other sustainability challenges are also being addressed in parallel with decarbonisation efforts. Key to all these efforts is collaboration, a thread at the core of many new cross-sector initiatives. In recent years, partnerships and investments in technology to maximise the use of industrial wastes and by-products in other industries has enabled the magnification of sustainable practices across different industries. For example, in India and the

AUTHOR BIO: Pernelle Nunez is the Deputy Secretary General and Director of Sustainability at the International Aluminium Institute. She is responsible for the Institute’s broad sustainability work program and has worked on a range of collaborative industry projects including; life cycle impact assessment, environmental footprint analyses, sustainable waste management and GHG emissions accounting. Pernelle was a Lead Author for the Intergovernmental Panel on Climate Change’s (IPCC) 2019 Methodology Report Update to the 2006 National Greenhouse Gas Inventory Guidelines. She is also responsible for the IAI’s work on bauxite mining which encompasses issues such as biodiversity and community engagement. Pernelle holds a MSci Geology (Hons) from the Royal School of Mines, Imperial College London and a Postgraduate Certiﬁcate in Sustainable Value Chains from the University of Cambridge’s Institute for Sustainability Leadership.

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Aluminium is an energy bank. That is one of primary aluminium’s biggest challenges in a climate constrained world due to the amount of energy required to produce the metal. But the energy bank is also one of our metal’s biggest advantages as we can save the energy in the bank by recycling the material again and again without degrading the properties. In comparison with most other materials there is a big difference between the footprint of aluminium based on the source of energy used to produce the metal. It could vary with a CO2 footprint of 4 to 20 kg CO2/kg of aluminium produced from bauxite mine to finished aluminium product. The implication is that we need to produce more aluminium based on renewable energy and we need to recycle more postconsumer scrap as this only requires 5% of the energy used to produce primary aluminium. Recycled aluminium can facilitate Trond Olaf reduction in emissions and a shift Hydro/Nils Vibe-Rheymer to a circular economy in several ways. Our main challenges In short, our industry faces two main challenges: The average value chain emissions are too high, while postconsumer scrap collection is too low. Our metal has a great starting point. Aluminium is a key material in lightweighting vehicles, enabling energy efficient building, construction and infrastructure applications and we have a very strong case when it comes to recycling. However, we believe that it is no longer enough to have a good usercase when it comes to tackling the climate challenge. We also need to face up to the challenges in the production phase of our metal. By this we mean looking at the total emissions for the whole value chain – from bauxite mining and power production all the way to the final product delivered to the end-consumer. Unfortunately, the total global average emissions from aluminium production have increased significantly over the last two decades due to an increase the sourcing of coal fired power to aluminium smelters. In order to remain a part of the solution in the decades to come, we need to significantly reduce emissions by increasing the use of renewable power in primary production. The second challenge we need to tackle is post-consumer scrap collection rates. As mentioned, aluminium is infinitely recyclable - but that can only happen if

It matters where and how aluminium is produced By Trond Olaf Christophersen* we manage to collect post-consumer aluminium. Even in mature aluminium markets such as Europe and the U.S. we have a way to go to improvement collection rates. For an industry with ambitions to be a key part of the green transition, we need to work on getting more end of life aluminium back into the loop. But what happens when recycling is not always cutting emissions? It is easy to agree that recycling and reuse is a great way to avoid extractions of new raw materials. However, to understand if your recycled aluminium is better for the environment, you need to know where the material originally comes from. The higher the recycled post-consumer

content in aluminium, the lower the carbon footprint. When we recycle aluminium from used beverage cans or discarded car parts, its CO2 footprint is close to zero, as recycling aluminium only requires 5% of the energy it takes to produce it the first time around. Postconsumer scrap is therefore the greenest recycled aluminium. Aluminium is also recycled from production waste, or pre-consumer scrap. Nearly all pre-consumer scrap is being recycled today due to the inherent value of the material. However, as this aluminium has never been used in a product and has not had a useful life before, it carries with it the same CO2 footprint as the original aluminium – plus 5% from the recycling process.

*Head of Recycling, Hydro Aluminium Metal September/October 2021

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In short, recycling of pre-consumer scrap is all about resource efficiency while recycling of post-consumer scrap is essential from a climate efficiency perspective. It is recycling of post-consumer scrap where we really need to step up. In Hydro we observe that in the eagerness to deliver on the increase in demand for recycled aluminium, some aluminium companies are importing production scrap from far away sources made with coal power and mix it in the production to claim a high amount of recycled content. It is obvious that this sourcing strategy

“Recycling 1 tonne of aluminium saves 6 tonnes of bauxite and 9 tonnes of CO2 emissions. Globally, the recycling of aluminium saves more than 100 Recycling image Hydro/Halvor Molland

”

million tonnes of CO2 every year

will not cut emissions. However, it can lead to an increase in the CO2 footprint of aluminium as this recycled aluminium is selected over aluminium powered with renewable energy. Where do we go from here? While we do see challenges for our industry, we also see solutions. One important driver to tackle the challenges is the demand from end-consumers for truly sustainable products. This has created a push for our industry to offer greener aluminium solutions to the market. Going forward we should discuss and align on common standards and transparency of the greener offerings so we can simplify the choice for end-consumers when it comes to greener aluminium products. On the market side, we have a job to do together with our customers to design for disassembly. This would simplify the recycling of end of life scrap and really improve the post-consumer scrap collection rates in the decades to come. For our metal to remain part of the solution, and not become part of the problem, we should join forces to make aluminium a symbol of true circularity. �

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Making recycling simple

Rick-Hindley

Rick Hindley* has been a regular face and voice in Aluminium International Today over recent years. Now, in his new role as Executive Director of Podback, he will be turning his attention towards creating a simpler way for UK residents to recycle their coffee pods. Nadine Bloxsome** spoke to him to find out about the ideas behind this new initiative and what drives his passion for advancing the sustainable packaging agenda.

1. What is Podback? Podback is an end-to-end, category-wide recycling programme for coffee pods that launched in April 2021. It was created in partnership with the biggest names in the UK coffee market Nestlé and Jacobs Douwe Egberts (JDE) UK, who between them own Nespresso, NESCAFÉ Dolce Gusto and Tassimo. It aims to provide consumers with simple and easy ways to recycle their coffee pods, whatever the brand, and whether they’re made from aluminium or plastic. 2. Why was Podback created? We wanted people to be able to enjoy the great taste provided by coffee pods, knowing there is a convenient way to recycle them. Consumers are increasingly looking for businesses to take action on recycling and as the two biggest names in the UK coffee pod industry, it was only right that Nestlé and JDE UK joined forces to take the lead. These businesses understood that the key to driving participation is creating a single consumer solution across the category, hence the decision to launch Podback, which strives to make coffee pod recycling simple and clear for each consumer. 3. How does the scheme work? Podback offers consumers two ways of recycling their pods - kerbside collection and Drop Off via Collect+ delivered by Yodel. Collect+ is currently the most widely accessible option. Consumers can order Podback recycling bags alongside their usual coffee pod order from our participating brand websites, fill the bag with their used coffee pods and take it to their nearest Collect+ location for free. We also offer kerbside collection of coffee pods, which allows filled Podback

local authority partners. Podback enables councils to divert valuable resources from residual waste, increase recycling rates and offer residents an extra recycling stream. Crucially, Podback is cost neutral for authorities, meaning all additional costs are covered by the scheme.

Pods being recycled at Tandom Metallurgical Group Ltd. in Congleton, near Stoke-on-Trent

recycling bags to be conveniently collected on a consumer’s normal waste collection day by their local council. This option is currently available in Cheltenham and South Derbyshire covering over 200,000 residents and has also recently launched in Oxford. Chichester District Council is currently trialling the scheme, with at least four other authorities set to join by the end of the summer and even more by the autumn. 4. How is Podback different from other pod recycling schemes? Podback is a simpler solution. It enables consumers to use any participating brands’ pods and recycle them using the same service – reducing confusion and increasing recycling rates. This is also the first-time coffee pods have been incorporated into kerbside collections by UK local authorities. Not only does this increase convenience for the consumer, it also brings benefits for the

5. What happens to the pods after they are collected? They are all given a second life. After collection, the coffee pod materials are separated from the used coffee grounds. Aluminium and plastic pods are recycled separately, with the aluminium pods recycled into beverage cans, car parts and other everyday objects. The plastic pods are recycled into high grade plastic pellets which are then used by manufacturers to produce a variety of plastic products, such as furniture. 6. What are your future plans for the scheme? We are ambitious to grow the scheme much further. We want to make it as convenient as possible for consumers to recycle their pods; so our top priority is bringing kerbside collections to many more locations, and we are in ongoing discussions with local authorities across the UK to make this a reality. We also want as many brands and retailers of pods to join Podback so that the scheme is inclusive of all pods on the UK market. We’re really pleased to have welcomed on board our first associate member, independent coffee brand CruKafe, who joined in May. A further next step for the scheme will be to work with retailers so that consumers can collect bags in-store and also use home delivery as a way for their pods to be collected. This will help us ensure every pod enjoyed, is recycled. �

*Executive Director of Podback, **Editor, Aluminium International Today Aluminium International Today

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The new life for recycled aluminium, thanks to Centro Rottami, Indinvest and TOMRA machines In the province of Latina, a scrap recycler supplies a nearby foundry with recycled aluminium to produce a green billet with 85% recycled content. This is an outstanding example of how to create a quality finished product with lower energy consumption and less pollution. Aluminium is a precious material which, when recycled, maintains its surface characteristics. As a resourse that is 100% recyclable which can and must be enhanced, the recycled alloy offers a 95% savings of the energy that would be needed for the production of primary aluminium from bauxite - with consequent reduction of CO2 emissions. Italy ranks first in Europe in the production of recycled aluminium with 70% recovery, far exceeding the objectives set by the European Union (50% by 2025). Centro Rottami and Indinvest, shining example of recycling from scrap to new product Founded in 1985, Centro Rottami of Cisterna di Latina, Itlaly, has been working with aluminium scrap for 10 years. Gennaro del Prete, technical director of the plant, says: “We started out as a scrap iron shredder.Then five years ago we decided to specialise in aluminium refining. This specialization has been possible thanks to TOMRA’s technologies.” The center processes about 1,500 tons of aluminium and 1,000 tons of ferrous scrap Aluminium International Today

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each month. The incoming aluminium comes mainly from old window profiles. They contain some contaminants such as plastics and rubber, as well as other metal materials like copper, brass, zinc and steel, all of which must be seprated to produce pure aluminium fractions. The company, which has been working with TOMRA for twelve years, currently has three TOMRA FINDER and three TOMRA X-TRACT sensor sorters. Once the incoming material is shredded and presorted by both magnets and eddy current seperators, the material follows two lines. The material is that is dropped by the eddy curret separator is then processed by a FINDER unit, which recovers metals such as stainless steel. Advanced technologies such as SUPPIX® and Z-TECT enable FINDER to detect metal objects with ultraprecision, delivering exceptional purity levels for greater salability. Simultaneously the three TOMRA X-TRACT units purify the aluminium that has been ejected by the eddy current separator. Thanks to advanced X-ray transmission technology, X-TRACT detects

the remaining contaminants and sorts them by their respective atomic density. This way, shredded aluminium is freed from heavy metals, such as copper, brass and cast aluminium with outstanding precision and reliablily, while using little energy and increasing production capacity. Del Prete recounts, “In 2019, we purchased two more TOMRA X-TRACT units because the aluminium market demands ever-increasing quantity and quality. We then combined the three machines into a single line, subdividing the pieces to be screened in order to go into more detail and make the most of the quality of the aluminium recovered from the shredding process. This choice was also made to take advantage of synergies with Indinvest, the aluminium smelter neighboring the company.” Del Prete explains the collaboration with Indinvest: “Relying on a technology that gives a guarantee of a selected and pure aluminium is essential to establish a relationship of trust with foundries, to which it is of utmost importance to continously realise high quality. Thanks September/October 2021

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to TOMRA, we have achieved the highest possible quality: alloy material and zinc and copper meet the requirements for the production of the profiles.” From post-consumer scrap to green billet at Indinvest Indinvest LT is an important company in the production and extrusion of aluminium profiles sector. The company, located next to Centro Rottami, has its own integrated billet foundry with a production capacity of 60,000 tons per year and five extrusion lines with a total capacity of 60,000 tons per year of extruded profiles. Ezio Porreca, Casthouse manager for Indivest LT, says: “For about five years, Indinvest has been buying post consumer scrap from Centro Rottami. Thanks to the use of the TOMRA X-TRACT machines by Centro Rottami, we have been able to significantly increase the use of postconsumer material in the melting furnaces from about 20% of scrap used without their technology to about 40 to 50%. This has not only allowed us to reduce the use of primary material, but also to have energy and gas savings of 5%, which on our volumes is significant.” Indivest LT targets to produce alloys that meet certain specifications. They have developed their own melt recipes to create these alloys by relying on a mixture of three materials: primary aluminium, internal post-production scrap and the post-consumer scrap supplied by Centro Rottami. By making the mix, the reference alloy for the production of the billets is obtained. The higher the quality of the scrap, the less raw material used. Continues Porreca: “By using cleaner recycled aluminium, production has increased significantly. If not properly cleaned, recycled aluminium can still contain some contaminants such as paint, plastic and other material, which, in turn, September/October 2021

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form slag in the furnace. By using the clean material from TOMRA, we have fewer pollutants and can clean the oven less. Cleaning the oven involves opening the door and dropping the temperature from 1100 degrees to 800 to 900 degrees. And getting it back to 1100 degrees takes time, gas and electricity.” Roberto Antichi, President of Indinvest LT, says: “For us, the concept of collaboration is very important of following a path together. We started this project together, using synergies, and can clearly see that it has paid off.” It is a collaboration that has led to the production of excellent and greener aluminium product: “Two years ago, we created a billet called Creal, containing 85% post-consumer aluminium with mechanical and, above all, surface results comparable to those of primary aluminium, created by aluminium manufacturers from bauxite,” Antichi says. Indinvest was able to achieve this incredible results thanks to the selection of TOMRA machines. Otherwise, according to company representatives, the recycled aluminium content could have been as low as 35-40%. Antichi continues: “Recent years have shown us that our recycled aluminium is well received by the market and is increasingly asked for. Especially now, with the 2030 Paris Treaty mandating a reduction in CO2 consumption, all customers are pushing the production of profiles with recycled material.” Aluminium: A growing market Concludes del Prete: “One of the few positive notes of recent years is the growing trend in the aluminium sector. Thanks to the immense availability of recycled material and thanks to its mechanical properties (flexible, resistant, etc.) it will be the material of the future

together with wood and glass. That’s why we have staked everything on recycled aluminium. Many companies approach us because they know the technologies we use, and they know they can count on a recycled product of absolute quality. We already resell our aluminium to companies working in the most important sectors that use this material: automotive and construction. But in the future we reserve the right to explore the rest of the market as well. We have the best team and equipment!” The Case History video is available at this link: https://video.tomra.com/aluminumsorting-centro-rottami TOMRA Sorting Recycling TOMRA Recycling designs and manufactures sensor-based sorting technologies for the recycling and waste management industry. More than 7,400 systems are installed in 100 countries around the world. Responsible for the development of the world’s first infrared sensor for waste recycling applications, TOMRA Recycling is a pioneer in the field and through its sensors recovers high-purity fractions from the waste stream that maximize yield and customer benefits. TOMRA Recycling is part of TOMRA Sorting Solutions, which develops sensorbased sorting and process control systems for the food, mining and other industries. TOMRA Sorting is owned by Norway’s TOMRA Systems ASA, which is listed on the Oslo Stock Exchange. Founded in 1972, TOMRA Systems ASA has sales of approximately €985 million and employs more than 4,300 people. � For more information about TOMRA Sorting Recycling: www.tomra.com/recycling

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Exclusive interview: Sharif Metals With the pandemic halting the face-to-face contact we once took for granted, interviews have taken a new form. Zahra Awan* conversed digitally with Engr. Salam Al Sharif** on the developments and goals of Sharif Metals International. Q1. Your company and plant ethics are centralised around the circular nature of aluminium. With this in mind, how easy is it to source good quality recycled aluminium and what is your main source of secondary aluminium? A1. In fact, Circular Economy is one of our (Sharif Metals Group, referred to hereafter as SMG) main objectives to serve. Aluminium is one of the main commodities we recycle and it has our main focus. Since Aluminium has managed to replace Steel in so many applications that succeeded in reducing more than 50% of automobiles weight which reduces tremendous amount of fossil fuel. For a better environment and less carbon emissions. Preserving natural resources of aluminium bauxite for future generations and saving 95% energy consumption through our aluminium recycling. Being in the recycling business for 4 generations, we have developed our Networking in the Middle East and within our own well located yard facilities throughout the middle east where we have become selective in quality assurance and quality control QAQC . Q2. You mention on your website that you are launching a plant that will have the ability to produce, “under Japanese quality philosophy”, “products to the customer with zero defect each and every time”. Could you elaborate on these statements and philosophies? A2. Our plant is Japanese state of art Aluminium production plant under Japanese quality philosophy “KAIZEN” which means “change for better” or “continuous improvement” Key objectives of Kaizen philosophy include quality control, timely delivery ,standardized work, using efficient equipment and the elimination of waste. Continuous improvement is followed by the “PDCA” cycle (plan-do-check- act). This

fuels, using electric operated equipment or machineries instead of petrol/Diesel engines operated machineries, avoiding usage of unnecessary salts in the process, proper segregation of scrap metals from plastic etc before charging to the furnace. Timely monitoring the emissions and setting up the target to Net zero emissions and taking necessary actions to reach our goal of zero emission progressing. A process which reduces global warming and meets the noble objective of G20 summits.

Engr. Salam Al Sharif

is the brief info about the Japanese quality philosophy which we are implementing. Q3. With regards to this new plant, will any new low-carbon industrial machinery be implemented to reach decarbonisation? And what are your aims to reach Net – Zero? A3. We are using more efficient air pollution control system which will have dual cyclone system, closed loop control system with effective filtration by bag house filters and wet scrubber before releasing to the open atmosphere. As it is understood, carbon emissions can also be reduced by selecting low carbon emission

Q4. Further elaborating on the previous question, what are your future targets for better environmental sustainability? A4. Driven by greater awareness of the harm caused to the environment of relentless consumerism and profitled decision-making, the search for a better way of living and co-existing with the nature and the environment in a sustainable way has gathered pace. Scrap metals are at the heart of a sustainable future: Recycling is a big part of the answer. Environmentally and economically, recycling metal is an extremely effective way of providing the components and products we rely on. Metals such as steel, iron, aluminium, and copper can be recycled an infinite number of times, because their metallic properties do not deteriorate with repeated melting and casting. Metals can be reused, reformed, and re-purposed. There has also been an appreciation that it is, more-often-than-not, easier to recycle existing scrap metal than it is to extract it from virgin ore or find it through mining operations. Due to the inherent economic benefits of metal recycling, it is already a well-established industry, with an existing infrastructure and a clear financial basis that sustains it. Scrap metal from obsolete objects is collected, processed, and returned to commercial supply-chains already.

*Editorial Assitant, Aluminium International Today **Chair, Sharif Metals Group Aluminium International Today

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28 RECYCLING

Q5. Sustainability not only refers to the environment, but also customers and maintaining relationships. What do you as a company do to keep relationships with old and new customers relying on your products? A5. Recycled scrap aluminium is much in demand within various sectors of the industry if not all, i.e. Automotive, Aviation, Construction, Architecture, packaging, home appliances…etc as a sustainable supplier of recycled aluminium scrap SMG caters to the needs of its clients and customers. SMG is a progressive ambitious company, constantly striving to be a better business for clients, employees, communities and the environment. We continue to fulfil a fundamental role in the creation of a circular economy – a world without waste – and whilst recycling itself is an inherently environmentally driven activity. SMG’s commitment to the Circular economy, as part of our environmental, social and governance values, means clients now consider us a critical part of their closed-loop business. Being an active member of BIR, the world recycling federation since 1987, we advocate their noble vision and mission for a better and greener tomorrow. Q6. With your customers in mind, what do your customers use your aluminium for? And where do you see yourself in relation to the aluminium industry, in comparison to other companies, in the Middle East? A6. Our main customers are the leading automakers in Japan, and Asia. Also foundries in our own region who make foundry alloys for structural and fabrication work. Customers who realized that end of Life material is an urban mine for their feed stock instead of relying on primary aluminium which is much more expensive and not environmentally friendly. Handy to meet their production cycle at more affordable prices and logistics chain supply. The Middle East has several recyclers whom we enjoy longer than 4 decades of relationship with. We cooperate and collaborate with each other for a common objective of making our middle east region a major hub in the world. As a matter of fact, I took the honor of being a founding president for BMR, Bureau of Middle East Recycling Association in 2009, we made a robust platform gathering all recyclers under one ﬂag and have 175 members who gather in annual conferences in the Middle East September/October 2021

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to develop the trade and network. Our SMG philosophy is to cooperate with all of them for the sake of a better recycling fraternity. SMG has both backward and forward integration to complete the supply chain and build bridges with our stakeholders for a sustainable future. Q7. Moving forward, with regards to the long and short term, do you have any upcoming investment plans or projects scheduled to develop your company? If so, can you tell us about these? A7. The short term will be to restructure and adapt post covid 19. since covid has expedited virtual administration a decade ahead of time. Long term. I am working on a succession plan for the 4th generation. Already my two sons Mahmoud and Omar have joined the business a few years ago as back-office staff. Recently they have come into front line management. As a matter of fact, I guided them with startup companies to become entrepreneurs and started trading and manufacturing on their own. Each one is holding a board member position at BIR. Passing on my late grandfather & father legacy through me is how we can bridge the old school with the new school of thought in a blend or sync for long sustainability. Q8. On the topic of developments, many companies are now moving in line with the fourth industrial revolution (Industry 4.0), will you be implementing changes to follow suit? If so, for your company, what are the beneﬁts or if not, the concerns of moving to Industry 4.0? A8. Recycling industry is the oldest form of industry and still a few traditional methods are used but technology has

transformed the industry in the past few decades. And a situation like the pandemic was a great lesson and needed to be digitalised to move with the world. Digital tools have transformed the way buying and selling take place. Networking with customers and/or external partners is getting more and more important in the industry. Various digital channels facilitate better integration of customers and suppliers’ network and the entire supply chain. They also help in maintaining better customer relations and retaining customers. The Industry 4.0 applications are primarily deployed in production and R&D, followed by distribution, logistics and the supply chain. At the same time, the company is also focussed on linking up with partners and on mobile devices and cloud computing . Q9. Finally, with all that has happened in the previous year and a half regarding COVID-19, how has the pandemic affected the company and what measures/ changes were made to maintain the company running? How has COVID-19 affected the company as it moves forward? A9. It was a wild ride during the pandemic, and it deeply affected the recycling industry during lockdown, almost 40% of the physical work force was reduced and businesses were affected. Most of the workforce were sent back to their countries until the situation improved. Many of them were given the option to work from home. The main challenges were in supply and manpower. In addition, problems in terms of transportation as day-to-day operations were fully affected because of the limited transport options available. There was a greater need for health and safety and well-being of our staff and workers as employees are our great asset. It was time to be closely connected and understand the human values as families and friends. � Aluminium International Today

16/09/2021 06:40:32

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30 OPINION PIECE

Aluminium recycling: Current industry benchmark and circular economy potential By Dr Subodh Das*

Introduction The global aluminium industry has been at the forefront of criticism by environmentalists because of its energyintensive nature, and for a range of sustainability challenges across the value chain such as bauxite residue, spent pot lining, dross, and saltcake, and end-of-life landfilling. According to the 2019 data from International Aluminium Institute (IAI), the aluminium sector is responsible for 1.05 billion tonnes of greenhouse gas emissions per annum, close to 2% of all global emissions. The data showed about an average of 12.8 tonnes of Co2eq were emitted per tonne of primary aluminium production in 2019 during the electrolysis process. Hence, notwithstanding its green credentials, aluminum has always been struggling with improving its sustainability benchmarks. Aluminium recycling is one of the most economical and sustainable ways to lower the carbon footprint of the global aluminum industry as it generates about 5% of the CO2eq compared to smelting.

A recent data from the International Aluminium Institute (IAI) published in the latest IAI Material Flow Model update showed that the global aluminium industry recycled 20 million tonnes of post-consumer scrap in 2019. This equates to about 60% of the total scrap intake of about 33 million tonnes. The process reduced 300 million tonnes of greenhouse gas emissions by substituting the secondary metal for primary aluminium. Post-consumer scrap availability had surpassed pre-consumer scrap for the first time in 1990, and since then, it has been constantly on the rise. This data conveys a powerful message regarding the impact of end-of-life recycling on improving the sustainability benchmark of the global aluminium industry. Data Source: IAI Image: Phinix LLC

IAI’s material flow analysis for aluminium IAI’s material flow analysis (IAI, 2021a) projected aluminium demand to grow by 80% by 2050 driven by rising demand

from the transport, construction, packaging, and energy sector because of its green credentials. This is where lies the significant role played by recycling

ALUMINIUM INDUSTRY SCRAP INTAKE (‘000 TONNE)

in dramatically changing the industry equations. Currently, the share of recycled aluminium in total production stands at about 34.7% with 64 million tonnes

*CEO, Phinix LLC September/October 2021

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OPINION PIECE 31

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production loop. It is also a part of the manufacturer’s responsibility to design products that are easy to be recycled. Unfortunately, about 7 million tonnes of aluminium end in landfills every year due to collection and processing losses at the end of its life. Recovery of 95% of this material through improved collection, sorting and recycling would reduce primary aluminium consumption by 15% and lead to 250 million tonnes of CO2eq emissions per year.

of primary and 33 tonnes of secondary aluminium production. With collaborative industry efforts, this can be improved to reach a 50/50 balance of recycled and primary metal by 2050. The calculation is based on 2019 collection rates for end-oflife products by IAI. Besides the steady increase in aluminium recycling, what is more significant, is the sharp increase in post-consumer scrap levels. Packaging, transport, and building & construction sector contributed a major part of the post-consumer scrap in 2019. IAI is of the view that with a targeted and aggressive collection of used beverage cans and improved recycling technologies for foils, the industry can increase the recycling rate much higher. The growth so far was possible because the industry has taken serious measures to collect postconsumer aluminium products and put them back to the production chain. The industry needs a steady, clean secondary material stream that can compete with and substitute primary production to achieve the circular economy goals. Substantial progress from this point requires a better coordinated, more cohesive approach to developing and applying advanced collecting, sorting, and recycling technologies. Current and emerging opportunities As shown by the IAI data, pre-consumer scrap remained almost unchanged in Aluminium International Today

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2019 YoY. While about 51% of preconsumer scrap came from sheet and foil, about 27% was from extrusion scrap and the rest were mostly from casting. However, it is post-consumer scrap or end-of-life recycling, which has the maximum potential to change the primary-secondary ratio. As per the IAI data, the packaging and transport sector is the major contributor to post-consumer scrap recycling. In the transport segment, automotive aluminium manufacturers have been able to achieve significant sustainability and economic gains by adapting to a closed-loop-recycling model. Automotive aluminium suppliers such a Novelis, Alcoa and Constellium have been exceedingly successful in expanding their recycling capabilities and establishing a recycling loop with their customers. Novelis boosts 59% recycling input across their product line and managed to bring down their GHG emission by 31% since their baseline average. A well-designed closed-loop model can not only preserve the value of alloys but establish a secure supply chain and save significant costs for customers. On the other hand, aluminium used in packaging has a much shorter lifetime and is more prone to end in landfills, if they are not collected at the end-of-life. In the packaging space, it is the aluminium can, which dominates the recycling performance index. Aluminum beverage cans are the most recycled beverage packaging in the world with a 69% recycling rate compared to 43% for PET and 46% for glass. A UBC that is recycled today can be back on store shelves in just sixty days, proof of the endless recycling and carbon economy potential of a can. Beyond what the major downstream players are doing, a huge volume of aluminium scraps from packaging, transport and building and construction sector are generated every year. The onus lies in manufacturers, consumers, and waste management systems to ensure that scrap is brought back into the

The US scenario The US is one country, where nearly 43% of the aluminum supply is now met through secondary production, up more than 10% since the early 1990s. In 2020, aluminum recovered from scrap in the US was about 3.2 million tonnes and recycled aluminum was equivalent to about 51% of apparent consumption. Notably, after considering sorting and processing losses, about 82% of aluminum UBCs entering the U.S. recycling system are remelted for high-quality closed-loop recycling. US aluminium cans have an average recycled content of 73% and it can go up to 90% with 10% coming from primary aluminium for alloy composition. Notwithstanding that, the annual recycling rate for UBCs hovers around 50%, indicating significant potential for improvement through collection and sorting boost. While the global aluminium industry is constantly working towards curbing its GHG emission in the line with Paris Agreement with the use of green fuels and new smelting technologies, the path remains complicated because of the cost, technology upgrade, commercial viability, and the limited availability of hydropower. Recycling is one tried and tested tool that can expedite this process economically with a planned approach and strategic stakeholder collaboration. �

Reference: 1. IAI MATERIAL FLOW MODEL – 2021 UPDATE (IAI, 2021a) 2. Aluminium Sector Greenhouse Gas Pathways to 2050 3. RECYCLING UNPACKED: Assessing the Circular Potential of Beverage Containers in the United States. By: Can Manufacturers Institute and Metabolic 4. https://www.world-aluminium.org/ 5. https://www.aluminum.org/ (Dr. Subodh Das is a globally recognized expert and consultant in aluminium and light metals and a serial intrapreneur. He is a 45+ year veteran in the global aluminum supply chain from “mine to market” with diversified experiences.) September/October 2021

16/09/2021 06:42:03

Photo: Øyvind Sætre

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TRANSPORT & HANDLING 33

HMR Hydeq offers an efﬁcient vehicle-based tapping system. The tapping vehicle from HMR Hydeq can tap, weigh, transport and discharge molten aluminium in a closed system, which provides energy savings and environmental beneﬁts. (Photo: Halvor Molland/Hydro)

Streamlining the tapping system with more innovative solutions By Endre Røyrvik* HMR Hydeq AS has long been at the forefront of developments of vehiclebased tapping systems. A new generation of vehicles and optimization at all levels makes it possible to perform the job even safer, easier, more sustainable and costeffective. The first of the new MTV-07 and MTV10 tapping vehicle models have already been delivered to Hydro Aluminium. As an immediate neighbour to Hydro’s aluminium plant in Årdal, HMR Hydeq has a unique opportunity to develop solutions that meet customers’ needs. HMR’s alignment with its users is one of the reasons the company has established its position as one of the world leaders in their field. HMR Hydeq works continuously to stay ahead of the industry standards. The new additions are several innovations aiming at increasing efficiency, safety and sustainability: � HMR Hydeq’s customers can now benefit from increased crucible capacity, without affecting axel load limitations. � Even larger proportion of the processes are automated and can be controlled from the cabin. � The operators’ environment is further improved in terms of safety, ergonomics and comfort. � New technology of vehicle-based

metal treatment by fluxing while tapping is being introduced. � All-electric engine solution is being added in response to sustainable development goal. Increased Capacity, Same Weight Class Increased crucible capacity means less cycles to transport the same amount of aluminium, which makes the system more cost effective. For a large smelter, this will lead to a reduced number of tapping vehicles in operation. However, all floors have their axel load limitations. HMR works purposefully to reduce the axel load and the total weight of the new tapping vehicles. The previous generation of what corresponds to the MTV-07 had a capacity of 5.5 tons. This has now been increased to 7.5 tons. Total weight and axel load has been resolved by, among others, right choice of materials and components. The Benefits of Automation and Remote Control HMR Hydeq’s tapping vehicles tap, weigh, treat, transport and discharge liquid aluminium. All operations are carried out by one operator using one machine, instead of overhead cranes, transporters, external weighing, compressors, etc. The fact that molten metal is transported

in a closed system minimises oxidation, reduces heat loss, and increases safety for the smelter operators on the floor. The vehicle driver can control fully automatic crucible cleaning machine, too. It saves both the manpower and delivers the optimal result. Tube cleaning machine, which is a part of HMR’s tapping system has also been upgraded for automated operation. Tapping tubes can be drilled automatically while on a tapping vehicle. Soon it will be also possible to drill discharge tubes and bends in the same way. Greater degree of automation gives optimized results, and the life of the components is extended. This contributes to a more economical and sustainable solution. Automation is a keyword not only when it comes to the tapping operation. Safety systems on all types HMR’s vehicles are steadily improving, too. This applies, among other things, to automatic fire extinguishing and an autonomous electro-hydraulic braking system. Inside a potroom, the dark and reflective surfaces can be a challenge. The goal is to get the sensors to interpret their surroundings correctly, whether it is slowing down or emergency braking if a person enters the blind spot. This is something HMR Hydeq endeavours to improve. Soon, Industry 4.0 will contribute

*General Manager, HMR Hydeq AS Aluminium International Today

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in demand. An example of this is HMR Hydeq’s new method of metal fluxing, which traditionally has been carried out at a fluxing station. Now this process can be completed in on-board crucible while tapping, using special components on the lid. Naturally, it eliminates need of a fluxing station, as well as it reduces the wear and tear of the crucibles. HMR believes that many customers will choose to benefit from this innovation. Electric Anode Transporter The industry is moving towards autonomy and green energy solutions, which customers are willing to take an advantage of. In addition to improvements to existing products, HMR works also on development of a brand-new product: first all-electric anode transporter. The advantages of electrification are many of the same as with electric cars: cleaner and cheaper energy, less noise, fewer moving parts, reduced maintenance costs. But there are several challenges that need to be addressed, including the size of the battery pack against the driving pattern, and charging time, as well as components that cannot be influenced by the magnetic fields. HMR Hydeq’s goal is for the first allelectric vehicle to be ready in 2022. �

The new all-electric e-transporter for HMR Hydeq will be ready in 2022. It will come in several models that can be adapted to the customer’s needs. (Illustration: HMR Hydeq AS)

ABOUT HMR HYDEQ HMR Hydeq AS is a special purpose vehicle designing and manufacturing company, situated in Årdal, Norway, with customers all over the world. The company grew out of a department of the Hydro Aluminium Årdal. It is today a private company, incorporated in HMR Group. For more information about HMR’s smart mobile solutions for the aluminium smelters, please look up www.hmr.no .

to an even greater degree of remote control. HMR Hydeq works on the further development of the software, so that customers can upload all the data from the system to the cloud application. The speed, temperature, pressure, usage patterns and other maintenance and operational statistics can be then analysed and used to perform condition-based

service and maintenance, elongate live of the components, and reduce the risk of accidents. Metal Fluxing HMR Hydeq has always been at the forefront of developments in its ﬁeld. The good dialogue with customers allows HMR to steer innovation towards areas that are

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Aluminium International Today

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Find out more at thermofisher.com/ispark *Based on a data comparison, completed by Thermo Fisher Scientific in 2021, of detection limits for OES systems using data published in specifications and applications notes for ARL iSpark and competitors. ©2021 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified. AD41408 0721

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EXTRUSION 37

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Mastering challenges in aluminium extrusion through the use of premium steels Tool costs and tool life are decisive for the performance of an extrusion line. The pure tool costs are always put in relation to the service life achieved. Furthermore, the use of premium tool steels increases the product quality because the premium grade has a higher strength and toughness. The use of premium tool steel is also more economical because fewer tools have to be changed and thus there is a higher availability of the extrusion press. In addition, premium tool steels enable the production of particularly critical profile geometries. Tool costs of the extrusion tools are determined by the following groups: 1. Extrusion die and mandrel 2. Stem and fixed dummy block 3. Container, inner and intermediate liner as wear parts. For all tool groups, the specific load and, based on this, the desired material properties for the component are derived in this article. Very often premium tool steels from Kind&Co with precisely tailored property profiles that solve the task best and most economically. All premium steels listed here have been developed by Kind&Co and optimised for the respective application. Extrusion dies and mandrels Driven by the electrification of vehicles, there is an increasing trend to use ever lighter aluminium profiles. This trend towards thinner-walled profiles requires higher stability for the die, because higher pressures and temperatures occur in the forming process. This also increases the loads on the die package, which in turn has a negative effect on the service life of the dies and thus increases production costs. To break this negative spiral, Kind&Co has developed premium tool steels especially for these applications. The well-known premium steels TQ1 and HP1 from Kind&Co have been used successfully for years. Aluminium International Today

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Fig 1. High stress on a stem for a 68 MN press.

Well-known aluminium extruders are increasingly using premium steels for dies in the following product groups: � Filigree aluminium profiles (e.g. cooling fin profiles), � Large batches as frequently known from the automotive industry (e.g. bumpers, sills), � Project business, depending on the size and difficulty of the project (e.g. train profiles for the railway). As a result, the extruder achieves twice the tool life at 15-20% higher tool costs by using TQ1 premium steel. A coordinated nitriding cycle also leads to an even better die service life. Premium tool steels can be nitrided together with standard steels. The nitrided layer on premium tool steels provides a much longer tool life than standard steels. As a rule, the service life of the nitrided layer on TQ1 is twice as long as on good standard steels. Kind&Co has assisted many customers in optimising the nitriding process of premium tool steels to the existing plant technology. Stems and fixed dummy blocks Increased extrusion pressures in aluminium extrusion also pose a challenge for extrusion stems and dies. Kind&Co recommends the premium grade CS1 with higher hardness (54-56 HRc). Due to the toughness of this material despite its high hardness, the stem can work longer in the elastic range. The same applies to dummy blocks, which, from a pressure of above 800 MPa, are made of TQ1 (50-

52 HRc). Above a press pressure of 1100 MPa, Kind&Co recommends using stems made of CS1 (54-56 HRc). We observe a trend towards longer stems, which have higher risk of buckling. This must be taken into account when selecting the material. Therefore, we always recommend premium steels from a critical buckling ratio of 1:6 (diameter/length) or higher. (Fig 1). Container, inner and intermediate liners Containers are exposed to the billet temperature and the extrusion pressure. The materials used must have a high heat resistance in order to cope with the high extrusion pressures. A long service life of containers with a consistently good product quality is supported by a temperature management of the recipient that is matched to the product (profile, aluminium alloy). The temperature management of a container consists of heating and cooling (air) and it is the goal to provide a uniform temperature distribution in the extrusion direction. As a result, the bore remains as cylindrical as possible, the dummy block leaves a uniformly good “shirt” and stable production conditions prevail in the extrusion line. Temperature peaks in the centre of the container can be positively influenced by modified heating zones with different heating powers. Intensive temperature differences lead to unstable conditions and to unwanted dimensional changes, e.g. at the shrink fit of each liner. September/October 2021

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38 EXTRUSION

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Fig 2. Modern design for 3-piece container incl. 3-zone cooling system

If modified heating zones are not sufficient, additional air cooling can be installed on the outer diameter of the intermediate liner. (Fig 2 & Fig 3) Different cooling zones in spiral design are aligned in axial direction and fed with cold and dry pressurised air. The greatest cooling effect should be achieved locally where the highest temperature peak is to be expected. By separating the cooling zones from each other, the maximum cooling capacity is applied at this point. Shock-like cooling should be avoided in order to protect the steel of the mantle from cracks. The constructive design of a cooled container involves a certain risk due to the cooling holes to be inserted. This should be consideredagainst the advantages for temperature distribution in each individual case. However, slanted bores must be avoided in any case: Holes should be drilled perpendicular to the container axis to minimise stresses. Kind&Co has developed the premium grade HTR as the carrier material for the air cooling used mainly on the outer diameter of the intermediate liner. This grade has a significantly higher tempering resistance and thermal conductivity compared to standard steels. Both properties extend the service life of the intermediate liner.

Fig 4 & 5. Premium grade HTR for intermediate liner offers higher tempering resistance and thermal conductivity compared to the standard material 1.2367/RPU.

materials laboratory as well as from more than 300 relining services per year. This interaction of theoretical calculations, long time experience and dialogue with extruders leads to an improved service life of containers in the long term.

Fig 3. Optimal temperature management with 4-zone heating system.

(Fig 4 & Fig 5). Kind&Co recommends the premium steel Q10 for inner liners in aluminium extrusion, which is now established in over 50% of all new inner liners. Its very good toughness enables a hardness of 5053 HRc. This keeps sealing surfaces more stable and minimises liner wear on the bore. Generally, the design of the tools is optimised with the help of an FEM analysis. Kind&Co has experience from the many investigations carried out in its own

Conclusion Due to the use of increasingly lighter aluminium profiles, the demand on the quality of materials and tooling technology is growing. In many cases, the standard materials USN/1.2343 or USD/1.2344 are no longer sufficient to meet the demands of the market. For this reason, the use of premium tool steels such as TQ1 for dies is more economical because of its longer service life and better product quality. The demand on quality of the materials for the production of extrusion dies also increases due to higher extrusion pressures. For this reason, Kind&Co recommends the premium tool steel CS1 for extrusion stems. The premium steel HTR is particularly suitable for intermediate liners to achieve better heat resistance and thermal conductivity. Inner liner consisting of the premium steel Q10 have become established in the market because of a better service life. �

The Original.

THE BRIQUETTE.

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Full service for your extrusion tooling For the design of long-lasting containers, we recommend our premium hot-work tool steels TQ1, Q10, CS1 and HTR. These premium grades have proven high performance in many cases. In addition we offer:

∙ Technical support and modification of the container during the entire life cycle

∙ Documentation of the history of each container ∙ Continuous improvement and optimisation in consultation with our customers

∙ Failure analyses in case of excessive wear We are also able to support you with FEM analysis and load simulations for your extrusion tooling.

Kind & Co., Edelstahlwerk, GmbH & Co. KG Bielsteiner Str. 124-130 · D-51674 Wiehl Fon. +49 (0) 22 62 / 84-0 · Fax +49 (0) 22 62 / 84-175 info@kind-co.de · www.kind-co.de

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40 FURNACES

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Autonomous furnace charging for smart cast houses is already a reality RIA Cast House Engineering, based in Leipzig Germany, has supplied over 60 rail mounted precision Furnace Charging and Skimming Machines worldwide, with numerous repeat references. The company was originally founded by Gerald Rockstroh, under the banner of Rackwitz Industrieanlagen in the 1990s. Gerald was the former Technical Director of an Aluminium Plant that is today part

of the Hydro Group. Consequently, all RiA Machines have been Engineered with minimal and ease of Maintenance in mind. RiA equipment is recognised as Sturdy, Durable and Reliable and today capable of Manual, Automatic and now even Autonomous Modes of Operation. Gerald retired in 2018 and his son Michael took over the business and took the decision to develop technology

incorporating Machine Vision Smart Cameras, to make intelligent decisions, optimising Performance and increasing Operator Safety. Since that time, all RIA Charging Machines have been supplied without an Operator Cabin on-board. Instead, the Machines have been supplied with a camera on-board and from a remote location the operator could control all of the movements of the

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FURNACES 41

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Machine based on the images he saw on a monitor from a safe distance, in a Control Room, away from the Furnace. The next step was to introduce air-cooled cameras into the Furnace, capable of operating at high temperatures, to allow the status of the melt to be observed without needing to open the Furnace door. Once the environmental issues had been tackled, the Machine Vision Intelligence was added, enabling the cameras to automatically identify when the melt was ready for the next load, or would benefit from levelling to open the scrap pile increasing melt rates and finally to determine when the cycle was complete and ready for skimming. This fully Intelligent capability is already implemented in several Cast Houses

RiA 15-tonne Furnace Charging Machine in Europe

RiA 11-tonne rotating Furnace Charging Machine in Canada

Worldwide. The cameras can indicate as the melt approaches readiness and the optimum time when to charge. If the Charging Machine has been loaded and released, the Machine will move in front of the required Furnace, open the door, charge the furnace, close the door and then move back to the loading position without any operator interaction. The door opening times are often less than 90 seconds and up to 30 tonnes can be distributed evenly across the hearth during this time. All RiA Machines incorporate accurate Laser position sensors and Laser safety scanners. As they are rail mounted, all Cast House personnel are aware of the possibilities and direction of movements. Even then if a person or an object is in the path of movement, the Machine will slow down and stop without contacting

the object in its path. The benefits of implementation of such technology in your Cast House include: � Increased Melt Rates from even distribution of solids in the Furnace � Increased Productivity and reduced Energy Consumption from shorter Furnace Cycles � Reduced Refractory damage ensuring longer Refractory life and more Furnace uptime � Reduced vehicle movements in the Cast House leading to increased Operator Safety and reduced vehicle maintenance � Removal of Cast House Operators, increasing Operator Safety The vision of a Smart Cast House with Operator Safety a high priority is no longer just a vision for RiA, but already a reality. �

RiA In-Furnace Smart Camera image

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AUTONOMOUS CHARGING & SKIMMING MACHINES

FURNACES 43

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Applying ‘through-process’ optical profiling How to fully understand what is happening in your aluminium CAB furnace…a products eye view! By Dr Steve Offley*

Fig 1. Thru-process temperature profiling system entering a conveyorized CAB brazing furnace measuring radiator and or air temperatures

Introduction – Do you know what truly happens in your furnace? In the global Industrial heat-treating market tens of thousands of products are sent through conveyorized ovens or furnaces each and every day. The thermal processing of these products whether heat treating the core material or even curing a surface coating is often critical to the quality or performance of the finished product. Whether aluminium brazing a radiator or curing paint on a car body, achieving the correct process times and temperatures is essential. Learning what is truly happening to the product inside the black box, that is your furnace, is important and shapes the success of your operation and customer satisfaction. To fully understand the operational characteristics of the heat-treat process an essential technique is that of thruprocess temperature profiling where the environment and product temperature is continuously measured as the product travels through the process. Such technique provides what is referred to as a ‘temperature profile’ which is basically a thermal finger print for that product in that

Fig 2. Typical temperature profile of a continuous aluminum brazing furnace (CAB) showing the critical temperature transitions

particular process. This thermal finger print will be unique and allow understanding, control, optimisation and validation of the heat treat process. As shown in Fig 1 and 2, a temperature profile of a continuous aluminium brazing (CAB) furnace process shows the detailed critical phases of the heat treatment process each contributing to the quality of the final product. Root Cause Analysis – Process Profiling Help The temperature profile of any thermal process is invaluable to get a better understanding how the furnace is working and is a critical tool in fault finding when things go wrong, because they do, and they will! Root cause analysis is a standard tool used in industry to identify the root cause of product or process problems without jumping to conclusions or making knee jerk reactions. In root cause analysis it is important to distinguish between symptoms and problems and drive to find, in the mist of many potential causes, the true root cause. Taking an example of the Aluminium CAB brazing process, the temperature

profile trace may show that the cause of a quality issue is due to the product braze temperature in a particular zone of the furnace being too low. This, although identifying a cause does not necessarily explain the root cause. A low product temperature in a particular furnace zone may be due to many possible different root causes – faulty control thermocouple, burner, recirculating fan or even damage to furnace structure/insulation. The low product temperature may in some

Fig 3: PhoenixTM Optical profiling ‘Optic’ System - Optical Profile View

*Product Marketing Manager, PhoenixTM Ltd Aluminium International Today

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44 FURNACES

circumstances not be detected by onboard furnace controls and will require a deeper dive investigation. Identifying the root cause will require inspection at the source of the problem. This action is referred to commonly as “Going to Gemba” a Japanese word which means ‘the real place’. In this situation going to Gemba means investigating what is actually happening in the furnace in a particular zone, at the point of occurrence. Root Cause Analysis – Continuous Aluminium Brazing (CAB) Example – Automotive Radiator Line

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Fig 4. PhoenixTM Optical profiling system being used in a conveyorized aluminum brazing furnace

4.1 Optical profiling system entering brazing furnace

Symptom High number of radiator rejects identified in QA Problem Poor product quality due to weak braze joints Cause From temperature profiles product braze temperature identified to be too low in Zone 4 Root Cause Recirculating fan fault in zone 4 resulting in poor non uniform heat transfer to radiators Going to Gemba is not always the easiest of tasks especially when considering identifying the root cause of furnace problems. Any task involving the internal inspection of a furnace generally requires that the furnace is switched off, allowed to cool and then dismantled to allow access by operatives. Taking our aluminium brazing (CAB) example, internal inspection of the furnace is not a quick and easy task. Operating at 550°C the cool down period is significant to allow engineers safe access for inspection and corrective action and then further delay to get the furnace back up to a stable operating temperature. Such maintenance action may mean one or two days lost production, from that line, which is obviously detrimental to productivity, meeting production schedules, satisfying key customers and your bottom line. In addition to process temperature problems there are many other production issues that can be faced relating to the furnace operation and safe reliable transfer of the product through the furnace or oven itself. In the CAB process a day to day hazard of the process is the build up of flux debris. Flux materials used to remove oxides from the metal surface and allow successful brazing can accumulate within the internal void of the furnace. These materials are most problematic at the back end of the muffle section of the furnace where due to the September/October 2021

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4.2 Video profile screen shot – exit of muffle furnace showing heavy flux build up

4.3 Video profile screen shot – vacuum brazing furnace showing faulty IR heating element

drop in temperature, entering the cooling zone, materials condense out. Flux build up can create many different process issues including; � Physical damage to the conveyor belt or support structure requiring expensive replacement. � Reduction in belt lubricity creating jerky movement and causing unwanted product vibration. � Lifting of the belt mesh creating an uneven transfer of products causing possible excessive product movement, clumping or clashing. � Reduction in inner furnace clearance creating possible product impingement issues and blockages. To prevent such problems, regular

scheduled inspection and clean out of the furnace is necessary. This is not a pleasant, quick operation, and requires chipping away flux debris with pneumatic tools. Often requiring a furnace down time of 1 to 2 days, this task is only performed when essential. Leaving the clean-up operation too long though can be catastrophic causing dramatic deterioration in product quality or risk of mid production run stoppages. Until now there has been no easy way to see how your product travels through the furnace under normal operation conditions or means by which the need for furnace repair or clean down can be confirmed. A new technology called Optical Profiling changes all this and for the first time gives you the means to see what your product sees in production; a true products eye view! Optical Profiling Optical profiling is a new complementary technique to that of ‘thru-process’ temperature profiling. The new technology allows for the first-time process engineers to view the inner workings of the furnace under normal production conditions. Travelling through the furnace, with the products being processed, the Optic system gives a product’s eye view of the entire heat treatment journey. Employing similar thermal protection technology ‘thermal barrier’ used in temperature profiling, in place of the temperature data logger a compact video camera and torch are used to record a video of what a product would see travelling through the furnace. The principle is just like your car’s dash cam, the only difference being that your journey is being performed in a furnace at up to 550 °C. The resulting video “Optical Furnace Profile” shows process engineers so much about how their process is operating without any need to stop, cool and dismantle the furnace. This allows safe routine furnace inspection without any of the problems of costly lost production and days of furnace down time. Fig.3. Benefits of applying the Optical Profiling principle in conveyorized furnace processes Furnace Condition Check the condition of the internal walls of the furnace to ensure they are fit for purpose; � Damaged or Distorted panels / Sealing gaps / Corrosion � Build-up of dirt/flux/condensate or general processing debris – Contamination risk – identify need for critical cleaning action � Correct alignment adjustment of ducting to allow correct air flow/ Aluminium International Today

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OPTICAL PROFILING “Going to Gemba” New Technology Beneﬁts Instant - View the inner workings of your furnace without need to dismantle the furnace or stop production. � New Understandings – See actual heat treat process if visual changes to product possibly for first time. � Production Conditions - See the operation of the furnace under actual production conditions fully loaded. � Time Saving - No delay to Cool, Disassemble, Reassemble as with normal inspection procedures etc. � Complementary Run video profile simultaneously with temperature profile to combine Thermal and Visual information. The complete Picture of your Heat Treat Process. �

convective heat transfer � Identify ignition events or other safety related issues within the furnace

physically visible; � Brazing – Melt and Flow of filler metal

Product Transfer Check that the product travels safely and smoothly through the process without conflict or obstruction; � Conveyor belts run flat and product orientation is kept constant – No belt damage or distortion � No product vibration of excessive movement which may cause damage to product or affect processing step eg: brazing � Check that product is able to pass through without clashing with furnace furniture or product clumping

Summary ‘Thru-process’ optical profiling is a new revolutionary technique for visually inspecting the condition of and also transfer of product through a continuous furnace. Combining such information with a product temperature profile, process engineers can work with maintenance teams to not only Understand, Control, Optimise and Validate the heat treat process but also Maintain the furnace to protect productivity and quality. Employing the optical profile information preventative maintenance or furnace clean down can be scheduled with confidence, and when problems occur, rapid fault finding is possible. Furnace inspection as part of the production flow at temperature eliminates, days of furnace downtime, lost production and an interrupted product supply chain. PhoenixTM your CAB process to Find, Fix and Forget your furnace problems! �

Condition & Operation of Key Furnace Features Check that key furnace features are working correctly and not damaged; � Fans, Ducting, Control thermocouples, Gas Feed pipes, Zone separation curtains/brushes Thermal Process Observation Check that the process is being performed correctly where heat treatment action is

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HEALTH & SAFETY 47

The benefits of protective clothing

Irrespective of the working environment, it is essential that contractors plan accordingly and protect themselves with the right choice of personal protective clothing (PPE). Reece Safety, a provider of life critical safety products, explains more. Many workplaces require workers and visitors to wear personal protective clothing (PPE) while on worksite premises if there are hazards present in the area, such as open flames or chemicals, which can cause harm. It is important that PPE is always worn correctly whilst in a hazardous area, as this will prevent accidents from occurring and make for a safer work environment. By having PPE in place within the workspace, workers should not have to worry about being safe at work, which therefore reduces the likelihood of workplace injury or short-term/long-term health issues caused by a situation that protective clothing may have prevented. Below, we will discuss the key benefits of PPE in more detail, along with why investing in protective clothing for staff in all hazardous environments should be paramount.

Reduce the risk of respiratory illness Respiratory issues from breathing in smoke, gases or chemicals from contaminated air can be toxic, so respirators are essential to protect your lungs from both long-term and short-term gas-related illnesses. However, on oil and gas sites, it is also important to be fully equipped with eye protection, hearing protection and flame-resistant clothing. If working in oil and gas wells, workers can be exposed to hydrogen sulphide, which can cause irritation and difficulty breathing to some asthmatics. One of the worst gases to inhale is crystalline silica, which is a known

lung carcinogen that can cause silicosis and can, in the worst cases, be fatal. Protect your body from extremes of heat and cold It is imperative to keep workers safe and comfortable, even in uncomfortable and dangerous situations. Protective suits and arc flash clothing from Reece Safety are some great models of how PPE can keep you safe from extreme heat when welding or using electricals for example, as well as extreme cold such as outdoor or underground maintenance work. Multiple layers of PPE are to be worn

Prevent injury from harmful bacteria and corrosives If you are working with chemicals, it is imperative to wear full PPE from goggles to gloves. Harmful and corrosive substances, particularly liquids, can be very dangerous if spilled or leaking occurs; often resulting in splashes which can be life-altering when contact is made with the skin or eyes. When working in an environment that aims to control harmful bacteria such as a clinical lab or a hospital, PPE acts as a barrier between infectious materials that can cause illness and damage to the skin. In these environments, protective clothing is vital. Aluminium International Today

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48 HEALTH & SAFETY

for extreme temperatures, including heatresistant outerwear for hot environments or thermal layers and wicking material to keep you warm in cold environments. Preventing injury Whether it is falling rocks or slipping, make sure you are protected with the right footwear and head and body protection

when you are entering a hazardous area. Boots with good grip and a helmet are examples of much needed essentials to protect yourself from falling and head injuries while on the job; these injuries are some of the most common in the workplace. So, be sure to wear your protective clothing until you are no longer in a hazardous area, particularly in

more dangerous areas such as working underground, on building sites and in damp environments. Top tip: Make sure your PPE is cleaned and locked away securely when not in use to avoid issues like cross-contamination or getting clothing mixed up at work, as each person requires differently sized PPE to fit appropriately. �

WELCOME TO THE WORLD OF PRODUCTIVITY

Pressta Eisele is the number one supplier of high speed and precision saws for the aluminum industry worldwide. We manufacture from simple single station saws to fully automatic cutting lines with loading magazines and handling stations anything a modern production needs to keep up with the steadily increasing market demands.

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AUTOMOTIVE 51

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Improving machining in the auto industry with the right tools The automotive industry faces a dilemma — to save fuel, vehicles must become lighter. At the same time, new components and technologies make them progressively heavier. The solution – components from aluminium. Tool manufacturer Sandvik Coromant shows how special milling cutter designs can be part of the solution.

The automotive industry faces a dilemma – to save fuel, vehicles must become lighter. At the same time, new components and technologies make them progressively heavier. The solution – components from aluminium. Tool manufacturer Sandvik Coromant shows how special milling cutter designs can be part of the solution. A ten per cent reduction in vehicle weight can lead to fuel savings of six to eight percent. That is why manufacturers are increasingly turning to aluminium, one of the most important materials for lightweight construction. But aluminium alloys require complex machining with complex and cost-intensive processes and various tools. In addition to very timeconsuming tool setups, inferior surface finishes, burr formation and inconsistent tool wear are not uncommon. So how can automotive manufacturers achieve shorter lead times, better quality and higher savings? Two-in-one solution For precise, trouble-free and burr-free milling, Sandvik Coromant offers several patented milling cutter designs, including Aluminium International Today

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the M5C90 – the face milling tool was developed for roughing and finishing cylinder heads and blocks as well as solid aluminium parts with long milling operations. It is capable of performing the entire machining process, from roughing to finishing, in just one operation – in many cases with an axial depth of cut of up to four millimeters. This way, tool life can be increased fivefold in some cases while cycle time is reduced by 200 per cent. A key feature of the M5 cutter series is its step technology – the polycrystalline diamond (PCD) inserts are arranged in a spiral and staggered vertically to remove material from the workpiece both axially and radially. The last tooth offers a wiper geometry in order to achieve highquality, flat surfaces. In addition, the fixed position of the wiper cutting edge eliminates the need for time-consuming setups. The M5 series includes also the M5Q90, a tangential milling concept for roughing; the highly stable M5R90 face and shoulder milling cutter, the M5F90, a combination milling cutter for roughing and finishing in smaller dimensions, and

the M5B90 face milling cutter concept for fine finishing. With the M610, the Swedish company also offers a milling cutter solution for the finishing of bimetals or material composites made of aluminium and gray cast iron. The concept, which delivers high feed rates without chipping, burr formation or surface scratches, also requires no setup or adjustment of the inserts. In addition to insert solutions, solid carbide tools are available for both drilling, milling and threading. The CoroMill® Plura range of solid carbide end mills includes tools for roughing to finishing and thread milling. Because aluminium alloys help solve the weight dilemma in the automotive industry, Sandvik Coromant’s complete range of tools for aluminium machining enables companies to successfully meet the demanding requirements in this field. �

Contact www.sandvik.coromant.com

September/October 2021

16/09/2021 07:19:28

52 THE ALUMINA CHRONICLES

Aluminium industry in Turkey By Richard McDonough* “The local primary aluminium production in Turkey has limited capacity (around 80.000 tonnes), therefore the aluminium industry is almost 95% reliant on primary aluminium imports,” stated Ali Kibar, Chairman of the Executive Board of TALSAD – Türkiye Alüminyum Sanayicileri Derneği, founded in 1971, is “…the leading representative of the Turkish Aluminium Industry,” according to a statement from the association. “TALSAD works for sustainable growth and development of the aluminium industry in local and regional markets, development and implementation of new and advanced technologies, implementation of good practices in health, safety and environment and works to develop strong local and international partnerships.” “Turkey is a lot more a customer than a seller considering primary aluminium,” Mr. Kibar said. “The amount of local primary aluminium production is just a small proportion of Turkish primary aluminium consumption. In that regard, we are one of the largest global customers of primary aluminium.” In 2020, Turkey imported (US) $3,407,698,000 in aluminium and aluminium products. This amount is less than the amounts of imports in 2017, 2018, and 2019, but is larger than the

(US) $2,865,841,000 in aluminium and aluminium products imported into Turkey in 2016. The highest amount of these items imported into the country was in 2018; aluminium and aluminium products valued at (US) $3,872,390,000 were imported by Turkey in that year. Unless otherwise noted, statistics detailing imports and exports of aluminium and aluminium products to and from Turkey are from reports issued by the International Trade Centre. The Russian Federation was the largest source of imported aluminium and aluminium products in each of the last ﬁve years, with the exception of 2017. In that year, Malaysia was the largest source of these products. In 2020, approximately one-third of all imported aluminium and aluminium products – (US) $1,055,582,000 – were imported into Turkey from the Russian Federation. Imports from that nation were more than four times the amount imported from the second largest source of these products, Qatar. Turkey also imported aluminium and aluminium products from, in order of valuations in 2020, Kazakhstan, Germany, China, Bahrain, the United Arab Emirates, Oman, Iran, South Korea, and the United States of America (U S). Imports from all

of these countries, with the exception of Germany, were greater in 2020 than five years earlier in 2016. Trade in aluminium and aluminium products not only is focused on imports into Turkey, but also include exports from Turkey that are substantial. In 2020, (US) $3,060,897,000 in aluminium and aluminium products were exported from Turkey to countries throughout the world. The amounts of exports have increased steadily in each of the past five years. In 2016, exports amounted to (US) $2,238,041,000. Germany has been the largest export market for aluminium and aluminium products from Turkey in each year from 2016 through 2020. In 2020, exports to Germany amounted to (US) $477,826,000; in 2016, the amount was (US) $388,899,000. Other large export markets for Turkish aluminium and aluminium products include one nation in North America as well as several countries in Europe and the Middle East. In order of valuations in 2020, the largest export markets for these items were, in addition to Germany, the US, the United Kingdom, Iran, Poland, Italy, France, the Netherlands, Israel, and Egypt. Assan Alüminyum is the largest flat-

*Richard McDonough at aluminachronicles@gmail.com. Do you have questions about the aluminium industry? Governmental regulations? Company operations? Your questions may be used in a future news column. © 2021 Richard McDonough September/October 2021

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Primary aluminium is utilised to manufacture a variety of products in Turkey. (This photograph was provided courtesy of TALSAD, November of 2019.)

Aluminium at Assan Alüminyum in Dilovasi, Turkey. (This photograph was provided courtesy of Assan Alüminyum, January 9, 2019.)

rolled aluminium company in Turkey. “We have a total ﬂat-rolled aluminium capacity of 300.000 tonnes,” stated Göksal Güngör, General Manager of Assan Alüminyum, a subsidiary of Kibar Holding. “We are also the second largest aluminium foil producer in Europe with a production capacity of 100,000 tonnes. We currently have a capacity utilisation of over 90%.” “Assan Alüminyum serves many different sectors, such as transportation, packaging, construction, HVAC, consumer durables etc.,” continued Mr. Güngör. “We work with the most prominent industrial companies in their segments, both in Turkey and in our export markets.” He noted that Assan Alüminyum exports about 80% of total sales: “Our main markets are Western Europe and North America, along with our domestic market, Turkey.” Impact of COVID-19 Pandemic and Trade Tariffs Manufacturing of aluminium products continued at a good pace in Turkey in 2020, even with the impact of the COVID-19 Pandemic. “Although the country is heavily dependent on aluminium imports, there are large-scale industrial manufacturing operations, producing semis and ﬁnal products,” according to Mr. Kibar. “In that regard, aluminium companies in Turkey can be considered as a regional Aluminium International Today

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manufacturing hub for many industrial users located in Europe and other parts of the world. Through the heavy pandemic effect in 2020, Turkish companies were able to sustain the level of manufacturing capacity almost at the same level of 2019 and produced products for exports at a level of 1.0 million tonnes. COVID-19 has serious operational and logistics implications. The heavy part was condensed in the ﬁrst half of 2020, just like many other places in the world, during which companies tried to continue their operations whilst trying to maintain the health and safety of their workers. This was a shift of total focus towards health and safety. The result was a total adaption of the new manufacturing environment combined with improved digital systems, online working, and increased working skills under extreme pandemic conditions.” Assan Alüminyum saw similar impacts in 2020. “There has been a slight (relatively insigniﬁcant) decline in our total sales compared to the previous year, due to the supply chain disruptions due to the COVID-19 pandemic,” noted Mr. Güngör. “The supply chain disruptions arising from the COVID-19 pandemic have certainly been a challenge that we

have worked hard to overcome in 2020. Trade wars are another signiﬁcant issue, as we are an export-oriented company. We have been dealing proactively with these issues and making sure that we are supplying our business partners worldwide, as we always have, in line with our core value of reliability. However, thanks to our effective risk management structure and the outcomes of our supply chain transformation project, which we completed last year, we have managed the pandemic period quite well. We currently continue to produce and serve our business partners worldwide.” Sustainability As is the case in most countries, the sustainability of this metal is a key part of the Turkish aluminium market. Recycling of aluminium products is also an important facet of the industry in Turkey. “Aluminium is preferred for lighter, stronger, more efﬁcient, longer-lasting, and more sustainable products,” said Mr. Kibar. “In this context, we continue to raise awareness for our sector to consider sustainability in a multidimensional way and to make the most effective use of the 100% recyclable feature of the aluminium product we produce, by adopting an ecofriendly production approach. TALSAD is

Aluminium is a major metals industry in Turkey. (This photograph was provided courtesy of TALSAD, November of 2019.)

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preserved in the flora. It is proceeding with determined to emphasise the importance projects every year.” He cited as an example the Assan new plants in 2021 as well.” of the circular economy and sustainability policies for our country and our export- Alüminyum Renewable Energy Power oriented aluminium industry and to guide Plant in Manavgat: “We produce our own Anticipated Growth our association as the representative of clean energy that is almost equivalent to Overall growth in the aluminium the total electrical energy consumption of manufacturing industry is anticipated the industry.” Mr. Kibar indicated that sustainability our production facilities. The acquisition to continue in 2021, though challenges will continue to be important in coming of this renewable energy power plant remain in the marketplace. years and that there are also opportunities was a strategic, sustainability-oriented “The current trend of primary aluminium to increase recycling within the country. investment for us. We obtain International imports has clear indications of an increase He noted that the primary aluminium Renewable Energy Certificates through in primary imports by about 25%,” stated production in Turkey, whilst modest, is our renewable energy production and are Mr. Kibar. “As of the end of May 2021, the based on hydropower resources. “The therefore able to officially offset our scope primary imports of Turkey have increased recycling companies need to improve 2 emissions.” to about 635 thousand tonnes from 515 their operational efficiency, quality thousand tonnes. This reflects just whilst improving the collection and about (US) $2 billion. The trend recovery quantities. We believe the indicates that by the end of 2021, focus is strong and the ability to Turkey is likely to import about 1.5 adapt is high.” million tonnes of primary aluminium As with other aluminium at an anticipated cost of (US) $3.2 businesses in Turkey, sustainability billion.” is a critical component of “The market growth brings operations at Assan Alüminyum. new opportunities for Turkish Mr. Güngör stated that this is one manufacturers, whilst the global of the company’s core values and shift towards decarbonisation that the firm believes “…that all would be the center of focus in individuals and companies need to the Turkish aluminium industry as strive to become more sustainable, well,” Mr. Kibar continued. “This as the future of our world and our new demand cycle, which brings children depend on it. Therefore, new opportunities to the aluminium we are striving to contribute world, would make sustainability and more and more to sustainability low carbon manufacturing the new every year and seeing global center of focus. The governments sustainability principles as the core are likely adapting support systems of our business, as opposed to for greener aluminium, the tariff obligations.” He detailed that Kibar systems would somehow favour Holding has been a signatory of low carbon manufacturing, and United Nations Global Compact for companies who are adapting many years. to this new world would have a “We follow the Aluminium better competitive advantage. The Stewardship Initiative (ASI) Turkish aluminium manufacturing framework to manage all of our companies would be mediating in business processes according to between the strong changes in the global sustainability standards,” demand side whilst shifting to the Mr. Güngör continued. “We low carbon aluminium world.” have been entitled to receive One of the key aluminium Assan Alüminyum operates aluminium production facilities in Dilovasi, the ASI provisional Performance businesses in Turkey, Assan Turkey. Standard Certificate for all of our Alüminyum, also expects growth to (This photograph was provided courtesy of Assan Alüminyum, August, 2018.) flat-rolled aluminium production continue through 2021. and recycling facilities. ASI “As aluminium has many sets the global benchmark for superior qualities such as infinite sustainability in the global aluminium In addition, Mr. Güngör explained that the recyclability, lightness, impermeability, sector, establishing criteria for member firm has implemented several partnerships high-conductivity, it is an essential product companies that address key social, and corporate social responsibility projects for the advancement of many industries governance and environmental issues such on sustainability. “We are particularly proud and technologies,” said Mr. Güngör. as business integrity, transparency, material of the ‘Biodiversity Preservation Project’ “Therefore, as the per capita aluminium stewardship, greenhouse gas emissions, that we have developed in collaboration use increases in all industrialised countries, biodiversity, human and labor rights. The with Kocaeli University,” said Mr. Güngör. the same is happening in Turkey. Therefore ASI Performance Standard aims to provide “We have partnered with the Biology we, as Assan Alüminyum, have made a common, global standard for the Department of Kocaeli University to preserve sustainable investment projects every year aluminium value chain on environmental, and reproduce endemic plants, which are to expand our capacity, as we believe in social and governance performance. facing extinction and to plant them back the bright future of the global aluminium We have met the requirements for these into nature. The project began with the industry. Supply chain disruptions and criteria and we show our commitment to Amsonia orientalis plant, also known as international trade policy measures will global sustainability principles through our ‘Blue Star,’ which has been identified by continue to be important issues for many renewable energy production, integrated the European Commission in 2002 as a industries, including ours. We will continue recycling facility and new energy efficiency plant species that absolutely needs to be to monitor these issues closely.” � September/October 2021

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FOCUS ON TURKEY

Assan Alüminyum expands further through sustainable investments Assan Alüminyum, a subsidiary of Kibar Holding and one of the two largest aluminium foil producers in Europe maintains its position as the fastest growing flat-rolled aluminium producer in Europe, with new sustainable investments. The company aims to reinforce its core value of sustainability through a series of investments worth over 95 million US dollars from 2021 through 2024. The investments will also allow Assan Alüminyum to have the largest continuous-casting capacity in all of Europe and America. Focusing on Sustainability As depleting resources, climate change and widespread social inequalities become a grim reality in today’s world, sustainability becomes ever more crucial for the survival of our future generations. With this awareness, Assan Alüminyum focuses on sustainability as one of its core values and follows the Aluminium Stewardship Initiative (ASI) framework to manage all of its business processes according to global sustainability standards. The company received the ASI provisional Performance Standard Certificate for all of its flat-rolled aluminium production and recycling facilities. ASI sets the global benchmark for sustainability in the global aluminium sector, establishing criteria for member companies that address key social, governance and environmental issues such as business integrity, transparency, material stewardship, greenhouse gas emissions, biodiversity, human and labor rights. The ASI Performance Standard aims to provide a common, global standard for the aluminium value chain on environmental, social and governance performance. The company met the requirements for responsible production, sourcing and material stewardship and shows its commitment to global sustainability principles by focusing on energy and resource efficiency, through its renewable energy production, integrated recycling facility and new energy efficiency projects every year.

roadmap, as he states: “Aluminium is a key contributor to sustainability and circular economy in all aspects. It is not only a sustainable product by nature, but also helps other industries to produce more environmentally friendly, energy

Expansion Through Sustainable Investments Assan Alüminyum’s General Manager and Global Foil Roller Initiative’s (GLAFRI) President Göksal Güngör also draws attention to the significance of sustainability in the company’s future

and resource efficient products using aluminium as a raw-material. We, at Assan Alüminyum aim to build a sustainable ecosystem together with its business partners, while leveraging the eco-friendly advantages of aluminium, such as infinite recyclability, resource efficiency and so

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President Göksal Güngör

on. This is why the sustainability aspect of an investment is crucial as it satisfies economic sustainability requirements through expansion and also has to pave the way to fulfilling the requirements of the European Green Deal. Sustainability is also one of our core values at Assan Alüminyum, along with reliability, flexibility and innovation. We make investments decisions based on these values. This is why the new investments we have planned are critical for our future.” Assan Alüminyum has already completed sustainable investments that amount to almost 60 million US dollars in the last 2 years alone. Despite the slowdown in various sectors due to the pandemic, the company continues to invest further in the aluminium industry in upcoming years. The new investments planned in the 2021 – 2024 period add up to a total of over 95 million US dollars. These include a wide range of investments from a rolling oil recycling facility and new filtration systems for casting lines to the improvement of thin-gauge aluminium foil production capacity, digitalization projects to development of casting capabilities. The most major components of these investments is a state of the art, energyefficient, and modern Achenbach OPTIMILL® thin strip rolling mill and 5 new casting lines by the end of 2024. With a total number of 24 continuous-casting (CC) lines, Assan Alüminyum will have the largest CC capacity in all of Europe and America. The rolling mill is equipped with sophisticated measuring and control systems, which are used to take over the complete control of the rolling process through full automation. With machine learning capabilities, the mill September/October 2021

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helps optimize the rolling process, while increasing the product quality. A part of digital system networking on its innovative platform enables a better traceability of the coil throughout the production process. The mill drive system also comprises of a new generation of AC motors and drive systems with regenerative abilities, reducing the electrical energy consumption. The mill also offers improved production efficiency with its high speed, its highly automated control and modelling system, and Hot Edge Surface (HES) System for flatness control at the strip edges. As an extension of the project, an “airpure” air purification system, which will be installed not only to the new rolling mill, but also to existing cold mills in Assan Alüminyum’s facilities. This allows for the rolling oil to be blown off of the evaporating particles, through the filtration system. Additionally, the new design of the strip blow-off system reduces the oil contamination on the surface of the product, contributing to the production of foil products with higher added value. The wide thickness range of the rolling mill gives the company the flexibility to produce various products for different market segments, ranging from thick coil and sheet products to thin-gauge foil products. Therefore, the company is better able to show its commitment to its core value of flexibility and increase its ability to manage risk more effectively. This new investment is not only forecasted to increase the installed annual production capacity of Assan Alüminyum to more than 360,000 tons, but also aims to enable the company to focus on products with higher added value. The products produced in the new lines will serve various different industries, such as industrial products, consumer durables, automotive, as well as construction. Additional planned investments for the upcoming years include the extension of the casting capacity of Assan Alüminyum and intensive upgrades executed to existing rolling mills, in order to enhance the product quality and increase the installed capacity even further. Eco-Friendly Activities “In addition to the planned future sustainable investments, Assan Alüminyum also has other significant sustainability activities” states Göksal Güngör, “we have also recently installed new filtration systems at our recycling rotary furnaces and induction lines, which bring our emission levels below European norms. We have achieved significant reductions in our greenhouse gas emissions, thanks to September/October 2021

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these investments. Our ‘Biodiversity Conservation Project’, on the other hand, also makes an indirect conribution to sustainability, as the loss of biodiversity is one of the leading causes for climate change. Last year on World Environment Day, we partnered up with Kocaeli University’s Biology Department to support for a project, where they save endemic plants from extinction. This project began with the ‘Amsonia Orientalis’ plant, known as ‘Blue Star’, which has been identified by the European Commission in 2002 as a plant that absolutely needs to be preserved at the flora. This plant has been reproduced in the university’s labs and reintroduced into nature. We firmly believe in the imortance of industry – academia partnerships on sustainability, therefore we plan to continue this collaboration for other projects this year as well.”

Carbon Footprint Reduction Through Renewable Energy Production At a time when resources are becoming increasingly scarce and more carbon emissions arise from excess urbanization and over-consumption, it becomes essential to reduce the dependance on energy produced through fossil fuel resources. Assan Alüminyum produces clean energy at its own renewable energy power plant, at an equivalent rate to its annual electrical energy consumption. The company also obtains I-REC (International Renewable Energy Council) Certificates for its renewable energy production to be used to fully offset its carbon footprint related with scope 2 emissions. The in-house recycling facility also helps reduce the carbon footprint of the company, through increasing the energy

efficiency. The processing of internal and external scrap is much more energy efficient than using primary aluminium. With this facility, the company has achieved a 39% increase in recycled raw-material usage in the last 6 years. Assan Alüminyum aims to use as much recycled aluminium as it could obtain, in its production. However, as the availability of scrap in markets is globally relatively limited, the company aims to avoid long distance transportation of scrap, so that the sustainability of the products is not compromised with elevated carbon emissions related with it. Investing in Corporate Development Projects Assan Alüminyum also aims to improve its economic sustainability by investing in corporate development projects. The company has recently completed its awardwinning Supply Chain Transformation Project, which not only managed to improve the level of service performance given to customers, but also advanced the company’s supply chain efficiency. The transformation proved to be especially useful during the pandemic period, when there have been significant disruptions in the global supply chain, some of which are still ongoing. Risk management is also an area, where Assan Alüminyum claims to have strong muscles and which has served the company well during the pandemic. Corporate risk is managed by a dedicated team at company and group level with activities and applications based on global standards. The company has recently received the TS ISO 31000 Risk Management System Certificate, which is an outcome of the company’s high corporate performance, operational excellence, well-planned and systematic risk management system. The company positions itself as a reliable business partner, that is able to provide customized, flexible solutions for its business partners, while adapting quickly to rapidly changing conditions. Güngör concludes by stating: “Assan Alüminyum believes in the bright future of the aluminium industry, as aluminium is such an essential part of the development and the adaptability to sustainability standards of many different sectors. This is why we will continue to invest further, while improving the sustainability of the ecosystem we create together with our business partners. We export 80% of our total sales, mainly to West Europe and North America. With the dedication and the commitment of our 1500 employees in our core values, we are working very hard to set an example for all of our business partners in becoming more and more sustainable every day.” � Aluminium International Today

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50 years’ story of Turkish aluminium industry

TALSAD, the voice of the Turkish Aluminium Industry for 50 years, continues to advocate for aluminium as a professional industry organization while growing its membersip for wider aluminium industry representation. Turkish Aluminium Industrialists Association (TALSAD), established on March 15, 1971, is one of the oldest industry associations in Turkey. TALSAD celebrating its 50th year had received the right to use the word “Turkey” by the decision of the Council of Ministers in 1989, thus an official representative of the Turkish aluminium industry. Since then, TALSAD has developed its membership by reaching a large base of members and a wider national and international network through its membership of European Aluminium (since 1992), and several memberships of leading national industry organizations. TALSAD aims to assist the growth and development of the aluminium market, to facilitate innovation and advanced technology implementations, to raise awareness and improve health, safety and environment consciousness, and to implement training and education programs to increase the use and applicability of aluminium by organizing fairs and industry events. The ultimate goal is to help to make aluminium as the material of choice, that it deserves, and to increase the share of the Turkish September/October 2021

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aluminium industry in regional and global markets. As a well-established industry organization, TALSAD aims to reach these goals by acting dynamic, reliable, and respected professional organization that

respects ethical values, by developing strong collaborations in national and international fields, closely following all developments based on the sector, sharing the valuable information it has acquired with the society and its members. TALSAD,

today represents 79 leading members of the Turkish aluminium industry. TALSAD has three established technical committees, operating on a functional basis, i.e. Extrusion and Rolling Committee, Recycling and Casting Committee, and Work Health, Safety and Environment Committee. The health and safety committee works to improve work safety, industry standards as well as environmental implementations, while extrusion, rolling, casting and recycling committees are based on the importance we attach to the development and unity of our industry. TALSAD members meet regularly to discuss the problems and needs of the industry and work jointly with members to provide industry-wide solutions and to improve the collective working environment. Alus, a story of 28 years of the aluminium industry’s scientiﬁc and technological symposium TALSAD, together with TUBITAK (the National Scientific and Technological Research Institute) and METEM (Chamber of Materials and Metallurgical Engineers) had initiated a series of the aluminium Aluminium International Today

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Turkey imports 1.6 million tons of aluminium, 1.2 million tons of which is unwrought/primary aluminium

Turkey is one of the largest (# 7th) global primary aluminium importers

Turkey is a net importer of aluminium and aluminium products

Aluminium industry of Turkey is based on value adding processes consisting of wide range of manufacturing technologies

Turkey is a worldwide supplier of wide range of aluminium products

Share of semi products consumption in Turkey

symposium. The symposium was initially held in 1993 as a technical gathering of aluminium scientists and engineers, which then evolved into a series of symposiums. Since 2009 the Symposium has joined forces with the ALUEXPO, International Aluminium Technology, Machinery and Products Trade Fair, as it is the meeting point of Europe, the Middle East and Eurasia. The fair and the symposium have kept growing since then. The symposium is now an international aluminium scientific event, Symposium Proceedings Book receives considerable attention from valuable academicians and members of our industry. ALUS, International Aluminium Symposium of 2019 consisted of 13 sessions, three of which were the Aluminium International Today

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opening panels with the participation of invited distinguished speakers from all over the world, received 103 papers in total, 83 of which were approved and published by the International Scientific Committee. The International Scientific Committee of the 10th Aluminium International Symposium will consist of 25 highly valued academics and experts from 12 different countries. The 10th International Symposium will gather larger participation from all around the world to discuss the recent global transition to a carbon-free world and the role of the aluminium industry. The Green Deal, Net Zero emissions, sustainability will be the key issues of the 10th International Aluminium Symposium, in addition to prominent discussion topics around the

development of new alloys, processing and characterizations of aluminium alloys. Turkish aluminium industry; one of the largest primary importers and a regional manufacturing hub Turkish aluminium industry is one of the largest primary importers globally, even under pandemic conditions Turkey was able to maintain 2019’ level of manufacturing and has imported 1.25 million tons of primary aluminium. Turkey ranks number 7th, globally on the largest aluminium importers after U.S.A., Germany, China, Japan, Malaysia, and Korea. With the addition of around 200 thousand tons of rolled semi’s 180 thousand tons of used aluminium and September/October 2021

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70 thousand tons of various semis and products, the total aluminium imports of Turkey, in 2020, have reached 1.66 million tons (a 6.4% increase compared to 2019). With almost 1.7 million tons of primary and products import market and almost 1.0 million tons of aluminium exports, the Turkish Aluminium industry ranks among the largest global aluminium importers. This large primary aluminium import base is a result of the need for evergrowing manufacturing capabilities of the Turkish aluminium semi and finished products producers. There are large numbers of extrusion plants, around 120 extrusion facilities, ranging from small to large-sized extrusion plants, in addition to some large-scaled rolling plants, many small and medium-sized foundries some are mainly specialized in die- casting in addition to several small to large scale recyclers. The total aluminium processing capability has continuously grown and Turkey has exported around 900 thousand tons of semi and final products in 2020. This is approximately 2.6% less than our exports in 2019. Due to pandemic conditions, this relatively low level of exports reduction is acceptable given the much stronger global market downturn in 2020 due to pandemic. Although the country is more than 95% dependent on primary aluminium to foreign production, Turkey has established an important position in the production of semi-finished and finished products in the aluminium sector. In 2020, the negative impact of the pandemic conditions in many countries in the sectoral sense did not cause a decrease for Turkey, and it continued production by maintaining its place nearly the same as 2019. The export level of Turkey is reached 1.0 million tons and the per capita aluminium consumption has reached the level of 13.6 in 2020. In general, as the attached graphs indicate, the country is a net importer of aluminium by around 500.000 tons, although the share of exports has shown a significant increase over the last years. Turkey has now become a regional hub for aluminium processing, with around 120 extrusion companies, 8 rollers, out of which three are considered to be large-sized rolling facilities, more than 50 casting and foundry units, in addition to several hundred small to medium scale final processing facilities. The longstanding manufacturing experience established quality systems adapted to the needs of global markets, close location to European markets, the ability to trade at a larger scale and ability to adapt to the changes of the market have made the Turkish Aluminium Industry, an important manufacturing base for Europe, Eurasia and North American markets. September/October 2021

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consumption in 2020 was 1.1 million tons. Although our average consumption increase for the last 15 years has slowed down in the 2015-2020 period, it has been around 9% on average. The distribution of aluminium consumption shows that extrusion products and rolled products each constitute about 1/3 of the total consumption, two production techniques representing more than 2/3rds of the total national aluminium consumption.

It is also worthwhile to make a note on the scrap and recycling market of Turkey. The level of scrap imports tends to increase while the local collection of the used aluminium collection is around 300 thousand tons. Combined with used aluminium imports and exports, Turkey is collecting and recycling around 400450.000 tons of scrap, which has shown some increase in recent years, given the increased efficiency and collection rate of aluminium recycling in our country. Turkey’s aluminium consumption has increased significantly and continuously in the last 15 years. Our total annual

Sustainability and circular aluminium, the new strategy for growth Sustainability and the circular aluminium is the obviously new strategy for growth of the aluminium industry. The low carbon emissions due to almost 95% energy savings in aluminium recycling bring even more growth opportunities for aluminium. The inherent full recyclability of aluminium joined with intensive energy savings will bring even more growth opportunities for our material. The new era of the circular world will require more advancements in the area of sorting technologies, improvements in collection efficiencies and melting technologies. As a non-governmental organization, it is our role to bring the industry together and work to support initiatives in sustainability and energy efficiency. Achieving higher rates of recycling would help our goals for a low carbon economy. That will help to improve the share of aluminium against other competing materials towards net-zero emissions. This is why we have initiated a new project competition on recycling of aluminium. One of our ongoing works has emerged

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with the awareness of the necessity of making our industry even stronger in terms of recycling, which is one of the most important areas for the aluminium industry globally in the long run. The project competition is titled “Become a Part of Recycling”, aims to increase efficiency in the area of aluminium recycling, improve collection, sorting, recovery and recycling of aluminium, therefore engaging academicians, engineers and technologists to focus more on the development of aluminium recycling technologies. The project is being supported by the Turkish Ministry of Industry and Technology, the Turkish Ministry of Environment and Urbanization, in addition to leading social and environmental NGO’s. The awards and prizes will be presented with an award ceremony to be held during the 10th International Aluminium Symposium. The carbon emission caused by production in increasingly and growing industrial conditions has drawn attention to the damage it causes to the world and people, and decarbonization actions have been initiated to ensure a sustainable life in this regard. TALSAD plays a very important role in Turkey’s progress and awareness in this field. It organizes webinars on Net

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Zero Emission and the European Green Deal, and project competitions to support recycling. The aluminium industry should play a critical role in the world of communications The new world of digitalization and even faster communication abilities brings new and additional challenges for our industry in connecting to the consumers, business partners and establishing stronger ties with our society. We, therefore, appreciate the importance and value of communication,

as well as the events we carry out and plan. In this sense, the use of social media platforms, which are one of the most effective communication tools of our age, in the best possible way, has become more critical. Industry organizations, companies have to utilize this world of ever-growing digitalization towards connecting with the public. TALSAD appreciates this new growth and places an even stronger emphasis on social media and using digital tools to help our industry. The advancements in the digital world, helping us to establish wider and more effective connection patterns with the target groups. Therefore, in addition to symposiums, our webinar events continue with the participation of many speakers who are competent in their fields and are intertwined with the industry, where current sector issues are discussed. Our latest webinar’s focus was Carbon Border Adjustment Mechanism, the European Green Deal, and the effects of these issues on the Turkish aluminium industry. As TALSAD we acknowledge the importance of these subjects and as the leading organization of the Turkish aluminium industry, we feel obliged to raise more awareness. �

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Board of Directors at TALSAD Chairman of the Board Ali Kibar emphasized the developing importance and value of the Turkish aluminum industry with his words “Turkey’s aluminium industry has now become regional manufacturing base with 1.7 million tons of import and 1.0 million tons of export“.

HALUK KAYABAŞI VICE CHAIRMAN OF THE BOARD

ALI İHSAN YEŞİLOVA CHAIRMAN OF THE BOARD

OSMAN SAHİN MEMBER OF THE BOARD

TALSAD has been successfully representing the Turkish aluminium industry for half a century. Very few NGOs have such a deep-rooted history, well-established and respected presence in manufacturing markets. TALSAD has rightfully earned its position as the main representative of our industry with its valuable contributions, helping it become one of the globally prominent production hubs. As the largest ﬂat-rolled aluminium producer in Turkey, Assan Alüminyum has also been contributing the advancement of our industry, in close collaboration with TALSAD. We are happy to be a part of this history and hope to contribute more by making our industry more sustainable in the near future.

HALF A CENTURY OF EFFORT AND SUCCESS While there is no consciousness of nongovernmental organizations in our country yet, representatives came together to develop the sector and established TALSAD as the ﬁrst sectoral non-governmental organization of our country. TALSAD, has succeeded to be the voice of the industry and has represented the Turkish aluminum industry with great success both at home and abroad. As a result of these efforts made in unity and solidarity, the sector is very developed today, and our country has entered one of the most important aluminum production centers in Europe. We express our gratitude to our industry leaders who saw the value of aluminum and the future of the industry 50 years ago and brought TALSAD to our country.

I sincerely congratulate 50th establishment anniversary of Turkish Aluminum Industrialist Association (TALSAD). Our association has become an exemplary organization with its harmonious, productive and creative works. In addition to being the most effective representative of the aluminum industry in Turkey, it has carried out studies that will take place in the global world in recent years. It played role in growth of the aluminum industry and tried to guide the industry by closely following the growth ﬁgures. Its most important goal is to contribute to development of the export and to support efforts to create value-added products. In this context, I would like to thank everyone who contributed to the works carried out by TALSAD and I am happy and honored to be a part of it.

DERYA HATIBOĞLU MEMBER OF THE BOARD The Turkish Aluminum Industrialists Association (TALSAD) has undoubtedly been a main contributor to the development of the Turkish Aluminum sector for 50 years. Many activities including but not limited to following the industry trends and brieﬁng the members and policy makers, creating progress plans on key issues, collecting and sharing sectoral data, representing the sector in the regional and worldwide organizations, promoting activities and participating in fairs are proudly carried-out. TALSAD, as a nongovernmental organization, signiﬁcantly supported the industry to prepare a sustainable future for our country and industry since its establishment. As Asaş, we are proud to be a part of such an important institution for our industry. Aluminium International Today

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SELDEF BOLGUN MEMBER OF THE BOARD

DR. METIN YILMAZ MEMBER OF THE BOARD

PELIN ARSLAN MEMBER OF THE BOARD

Turkey is able to provide high quality service to all countries in the world due to its production facilities established with high-capacity and high-technology investments and its geopolitical location. Talsad, which is a unifying and informative association in the aluminum industry for 50 years, plays an important role for our industry by closely following all the international associations and organizations that need to be followed, regarding to the legal procedures and technological developments in the world. All studies in this ﬁeld, R&D projects carried out on quality and environmental awareness will enable the Turkish aluminum industry to move forward.

We are honoured and glad to be part of TALSAD, a non-governmental organization catering technological, economic, strategic and political direction for its members and a crucial institution for the developing Turkish Aluminium Sector. The projects related to aluminium are in the pipeline since aluminium has been recognized as the material of the future, it holds a great importance for matters like the population growth, rapid pollution rise and ever evolving world and the EU Green Deal. It is important and signiﬁcant that we work and act together for a better future. We are proud to have been members since the foundation of this association.

We, as TALSAD, shed light on the Future of the Aluminum Industry. Today, we are proud to mark our 50th anniversary under the leadership of the companies in the sector for the development and healthy growth of the aluminum industry in multinational markets. I consider it as a great chance for my industry and myself that my father, Mr. Mehmet ARSLAN, Chairman of the Board of Directors of Arslan Alüminyum A.Ş., which is a well-established company in the aluminum industry for 60 years, is one of the founders of TALSAD. Shedding light on the strong future of the Aluminum sector with its 50-year success story, the TALSAD will continue to act all together with the strong companies in the sector and write a new success story in the upcoming period, as it has done before.

HUSEYIN SEHERLI MEMBER OF THE BOARD Although sales in many sectors around the world were adversely affected during the COVID-19 pandemic, the food and packaging sector, which are the main sectors in which Aluminium products are used, kept its value. With the increase in vaccination in the pandemic, the world economy started to present a more optimistic outlook. There are significant improvements in all our commercial activities, especially in export and production. I congratulate the 50th anniversary of TALSAD, Turkey’s oldest association and the leading non-governmental organization of the Aluminium industry, which has made a significant contribution to these improvements. TALSAD will continue to make significant contributions to Turkish aluminium industry with its professional work and dynamic and effective management style. September/October 2021

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Interview with Ali Kibar, the Chairman of the Board 1. Your comments on the development of the Turkish aluminium industry in recent years and your general assessments of the industry. As a result of the developing technology and industrial growth, one of the important developments in the field of materials engineering has been experienced in the aluminium sector. Aluminium industry has become one of the fastest developing sectors of the 21st century due to its prevailing features such as 100% recyclable and environmentally friendly properties, in addition to its lightweight, high strength, easy formability, ﬂexibility, conductivity, and corrosion resistance. The use of aluminium has continuously been increasing in the automotive, aerospace, defense industries, electrical and electronics industries, advanced chemistry, and ceramics sectors. As a result of these positive market developments, the global consumption of aluminium has displayed a strong and steady upward trend. The average increase in global aluminium consumption during the last 10 years has been around 5% per annum. Parallel to these global developments, the Turkish aluminium sector has also shown strong and steady growth as well. According to data as of 2020, Turkey's import of semi-finished aluminium products has reached 1.7 million tons and our exports were very close to 1.0 million tons. The continuous growth in global aluminium consumption and the versatile set up in Turkish aluminium producers have helped turn our industry into an important manufacturing hub; namely a large-scale primary aluminium importer and also a major regional semifinished goods and parts producer. 2. What is the basis of TALSAD's 50 years of continuity and success as a nongovernmental organization? I believe that the main reason for the success of TALSAD and its 50 yearhistory of successful operation as a

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“In today’s world, the great challenge of climate change and therefore the growing need for sustainability and circular economy provides additional opportunities for growth in our industry. ” ALI KIBAR non-governmental organization is the unity, consistency, and solidarity that our industry leaders have displayed. Since its establishment on March 15, 1971, our association has always been a role model in terms of transparency, objectivity, and consistency in representing our industry’s interests. In addition to closer ties with our international partners, our memberships and networking capability have brought additional success to our association. We are very proud to celebrate the 50th anniversary of TALSAD. This has a special meaning for me, as the Chairman of this Association, as I believe that it would set an example for other industry associations, with its presence in leading the growth of the industry and with the value it creates. 3. What do you think is the position of TALSAD and the Turkish aluminium industry in the field of recycling? Recycling is one of the most important pillars in the future development of our industry. Among consumables, aluminium has a unique place among all materials, as it is 100% recyclable, therefore distinguishes itself with its environmentfriendliness and sustainability. Aluminium products, regardless of their shape and consumption pattern, can easily be recycled and brought back into the economy. The energy saved by recycling, which is about 90%, gives even more incentive to increase collection and recycling rates globally. This is also yet another advantage compared to other materials, especially at a time when the world is moving into “the era of sustainability and circular economy”. The recyclability of aluminium makes it an essential material for our future. TALSAD, as a professional industry organization, has initiated important studies and activities to improve the amount of recycled aluminium in Turkey, intending to support circular economy initiatives as well as to create additional growth and market opportunities in the upcoming years. In addition, we have organized a national competition on aluminium recycling welcoming projects that aim to assist the development of recycling technologies, as well as to improve the national recycling inventory. The project will be called “Be a Part of Recycling” and will aim to emphasize its importance in the sector and to support those working in this field. September/October 2021

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4. With Green Deal’s effects, what kind of changes do you foresee in the short and medium-term in the Turkish aluminium industry? It is very clear that there is a rapid and strong global transition towards a carbonfree economy. EU, once again, is one of the leaders of this transition process and is decisively moving towards a carbonfree economy. Green Deal represents the EU’s comprehensive vision towards this transition. This stance is extremely important against the climate change challenge and is most probably a path that the rest of the world will have to follow with the same level of commitment. This is clearly the challenge of our century. The Paris Agreement, the main principles set out in the policy framework of the Green Deal must be followed joined and taken as a guide by the international business community. We believe, our country also needs to adopt this vision and sectoral collaborations are very valuable in order to adapt to the necessary changes that have to be made accordingly. In this regard, TALSAD is determined to emphasize the importance of circular economy and sustainability policies for our country and our export-oriented aluminium industry and to guide our industry as the main representative in our sector. We also clearly understand that recycling is the main component in the mainframe of circular economy and therefore needs to be developed to further strengthen our industry. As TALSAD we are working to improve national recycling capacity as well to help advance the technological processes on aluminium recycling. 5. What are your comments about the International Aluminium Symposium (ALUS), which has been going on for many years? Does TALSAD have any work to organize events like ALUS in the future, if so, can you elaborate? The Aluminium Symposium, of which our association has been one of the leading organizers since 1993 and which has been held every two years, as a national scientific event along with the international AluExpo fair. The fair and the symposium have successfully grown in size and participation on a regional level, in Eurasia and a need for an international event emerged. Based on these developments, ALUS and AluExpo

have now become an international and regional scientific and technological event. ALUS'10 International Science Board consists of well-known scientists and technology leaders of aluminium from around the world, and the Supporting Organizations of the symposium consists of the most important European and global sector representatives, such as European Aluminium, International Aluminium İnstitute, European Aluminium Foil Association, Global Aluminium Foil Rollers Initiative (GLAFRI), The Aluminum Association, CRU, Aluminium Stewardship Initiative etc., making this gathering an important international event. As TALSAD we value our national and international partners, supporters, and colleagues from respected institutes from all over the world. Along with this symposium, one of our top priorities is to organized new local and international events. 6. Your evaluations for the future of the aluminium industry in the world and Turkey. The aluminium industry continues to be one of the leading and rapidly growing sectors, due to the excellent properties and values inherent to aluminium. In today's world, the great challenge of climate change and therefore the growing need for sustainability and circular economy provides additional opportunities for growth in our industry. Aluminium is clearly the material of the next century and also provides essential input to many other industries to contribute to sustainability. I strongly believe that our industry will play a key role towards reversing the effects of climate change, reducing carbon footprint and improving the circular economy, while maintaining the strong market growth experienced in the last century. Turkish Aluminum Industry is very fast converting itself into convenient requirements of sustainability and also towards the possible requirements for CO2 new taxation laws.Turkey is very much aligned with this vision. While the per capita aluminium consumption of Turkey is equivalent to the world average, the trend is certainly upwards. The Turkish aluminium industry is very ambitious to become one of the regional leaders of the global aluminium industry. �

Aluminium International Today

21/09/2021 12:01:07

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The way to the industrial heat insulation materials and refractories AKM Metalurji offers innovative solutions in terms of industrial insulation with its world leading foreign partners since 1992. With starting to produce monolithic refractories, AKM Metalurji contributes its value-added products to the metallurgical industry. AKM Metalurji provides high temperature insulation materials, refractories and complementary products for metallurgical industry since 1992. With its expert engineering department, competent management approach and employees, AKM offers smart and costeffective insulation solutions to dozens of diverse sectors such as Aluminum, Iron&steel, Energy, Petrochemical, Marine, Ceramic and Glass. AKM offers innovative solutions together with its foreign partners, world’s leading manufacturers in their fields. In terms of these solutions, we supply products that are preferable increasing the quality of the production and contacting the melts directly including aluminium contact refractories, refractory protection and repairing groups, furnace linings and micanite products, cast-house chemicals, element additive tablets, master alloys, Kanthal heating elements, metal cleaning filters, back-up insulation foams, grain refiners etc. AKM Metalurji having a capability of meeting demands instantly thanks to its large a diverse stock capacity, guarantees complete delivery of its products on time with strong supply chain and modern storage unit at its 10.000 sqm modern facilities in Istanbul Tuzla Industrial Zone. Considering increasing demand for monolithic refractories, AKM started to produce its value-added products and put

them into service to the industry in 2020 with license agreement of American based United Refractories Co. AKM has ability to provide wide range of monolithic refractories in diverse ﬁeld of application for aluminum industry including molten metal contacting areas. We believe that this investment supports to the industry with carefully selected raw materials, fully automatized production

process, accuracy in quality control steps. Technology change drives refractory development at a fast pace in today’s high charged manufacturing environment. We focus on this way and develop novel refractory solutions to satisfy customer needs. AKM offers turn-key projects by providing the engineering solutions and the products that are ease of installation and rapid turnaround time. �

www.akm.com.tr September/October 2021

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www.akpaas.com.tr

Technological investments increased efficiency of roduction As one of the aluminum profile and composite panel manufacturers, Akpa Aluminum stands out as the trusted solution partner of the industry that it serves. Akpa Aluminum continues to work on the investment of a new painting facility with an annual capacity of 25,000 tons, in addition to the paint facility operating with an annual capacity of 15,000 tons. Fatih Çalışkan* “With our technological investments, we manage to increase the speed, quality and efficiency of our production” As one of the aluminum profile and composite panel manufacturers, Akpa Aluminum stands out as the trusted solution partner of the industry that it serves. Akpa Aluminum continues to work on the investment of a new painting facility with an annual capacity of 25,000 tons, in addition to the paint facility operating with an annual capacity of 15,000 tons. Stating that the growth momentum continues in 2021, Akpa Aluminum Vice Chairman Fatih Çalışkan said that “We operate with the door-window systems, facade systems, folding door and sliding systems; Office partition systems that we call as aluminium architectural systems; Systems belonging to outdoor solutions which are foldable insulated glass-balcony systems, guillotine sliding systems, shutter systems and lastly aluminum composite panel production which has the most

significant features of lightness, aesthetic appearance, fast and easy assembly, high insulation of heat and sound, a wide variety of colors and flexible project applicability.” Stating that they are exporting to more than 50 countries in 5 continents thanks to their strict adherence to the principles of reliability, flexibility and innovation and their customer-oriented working attitude, Çalışkan said; “We continue to do investments in line with our strategy of growing abroad and becoming a global brand. While maintaining our focus on Europe, we target to strengthen our operations in North America. We aim to focus more on the foreign markets which we are already exist; to increase our reputation in the market even more. As Akpa Aluminum, we can state that we are among the Top 500 Industrial Enterprises of Turkey. In addition, we have been among the Top 1000 Exporters of Turkey since 2004.”

Çalışkan continued his words as; “Our factory has modern equipment with its technology and capacity. Established on an area of 105 000 m²; with 42 000 tons/ year capacity, 6 extrusion presses, 30 000 tons/year capacity anodizing plant, 15 000 tons/year capacity vertical powder coating plant, 1500 tons/year capacity wood transfer paint unit, 4.500.000 m²/year Aluminum composite panel production line included and producing in Sakarya. As Akpa Aluminum; we started to work for a new investment in this year. In addition to our paint facility which operates with an annual capacity of 15,000 tons/year, we continue to work on a new paint facility that can operate with an annual capacity of 25,000 tons/.year. We plan to start operating the new paint facility in the second quarter of 2021, which will have the ability to paint 90kg/ piece of proﬁle with maximum length of 8,100 mm.” �

*AKPA Aluminum Vice Chairman Aluminium International Today

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Al Aluminyum is on the way to becoming a world-renowned aluminium service center Established in 1979, Al Alüminyum is an aluminium manufacturer, wholesale distributor and servicecenter company based in Istanbul, Turkey. With its enhanced network and brand recognition in the sector, it provides high quality and wide range of aluminium products to automotive, construction, defense & aerospace packaging and advertising industries. The product portfolio of the company includes aluminium sheets and coils, proﬁles, composite panels, sandwich panels, trapezoids, ingots, aluminium hemispheres, aluminium granule and pyramids. This family run business is now under the capable leadership of its second generation. Its aim is to become a a world-renowned aluminium servicecenter providing solutions to diversiﬁed industries. The company has already expanded its operations to Europe and planning new investments to increase its capacity to meet the growing demand. The company ethos is to become a longterm reliable business partner for its clients with operational excellence and tailor-

made innovative solutions. For instance, one of the leading technology companies in Turkey recently collaborated with Al Alüminyum to produce aluminium based light-weight electrical scooters in Istanbul. The project will be a pioneering example of collabrative efforts between different industries to create value in an innovative area. Al Alüminyum believes that aluminium is the metal of the future due to its inﬁnite recyclability. In the recent years,

domestically and globally, several companies are increasing recycled aluminium usage where applicable in their production. In this respect, the company is planning to focus on enhancing the capacity of secondary aluminium manufacturing and reducing its carbon footprint in the future. The company has been working with NGOs for recycling technology projects. �

www.alaluminyum.com.tr

The Buyers Guide is the essential guide to furnace manufacturers and suppliers of furnace equipment and services to the industrial heating/process industry. It provides comprehensive company listings, product information and key contact details. SECTION 1 Furnace Industry Index. SECTION 2 Classiﬁed Listings: Company listings by services and products Display advertising and enhancement options are also available for this edition. For details on advertising or for any additional information, please contact Esme Horn esmehorn@quartzltd.com, www.furnaces-international.com

September/October 2021

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Altaş Aluminum, paced up on its efforts to go green Altaş Aluminum is an Irish-Turkish joint venture aluminum extrusion company established in 1990. Headquarter and factory is located in Gebze - Kocaeli, Turkey; 15km from İstanbul, close to major ports and international airports. Main activity areas are; aluminum profile extrusion, machining, powder coating, anodizing. Main markets are EU and North America. The company is IATF 16949 certified by TÜV NORD in 2020. Celebrating 30 years in business, TurkishIrish joint venture extrusion company Altaş Aluminum in Gebze/Turkey, set its strategy to go green faster. Company CEO Taşkın Özkal says; “We always did our best to be environment friendly. It is in fact one of our core values (People, Environment, Respect, Ethics, Justice) since ever. However, the start of pandemic in 2020 and the temporarily shutdowns that came with it, made us see a bigger paradigm shift coming. We’ve set our strategy to be always ahead of requirements of European Green Deal, made our action plan for 3 years and set things in motion. Reducing our carbon footprint, as well as the usage of chemicals and packaging materials; increasing energy efficiency and optimizing all transports are the keystones of this challenge.” So far, the investments Altaş made to go green are also good for improving efficiency and reducing losses. For example, in 2021 overall energy usage per ton is 8% less than 2019. This achieved by; computer-controlled lines, better heat insulation, and reuse of exhaust gases for pre-heating of billets. Considering this, most of the investment will surely pay back in the long run. Officially listed by İstanbul Mineral and Metal Exporters Association, Altaş Aluminum is one of the top 100 exporters of Turkey for non-ferrous metals. Considering 92% of total production sold to export markets (EU, USA and Canada), reducing the carbon footprint is not only a nice gesture for the planet but also a must for the company. According to CSO (Chief Sales Officer) Sinan Gündüz, besides the geographical market demands, also the sectors they serve have had higher requirements to meet as well. He says, “With its 32% share, automotive is the most demanding sector we serve by far.

We are producing many components for Tier1 companies and OEM’s such as FORD, GM, FIAT, CHRYSLER, PORSCHE, BMW; located in Turkey, Germany, Canada, and USA. Serving these customers require constant improvement, even beyond the IATF 16949:2016 certiﬁcation we hold. I believe, they are also quite satisﬁed by our performance. Although automotive have had hard dive because of the pandemic

and the chip crisis added to that, we can say that Altaş Aluminum is minimally/not affected from these setbacks, thanks to solid precautions for employees, strong ﬁnancials, and long-term contracts. Also, increased demand for RV’s helped us a lot in this manner. Compared to 2019, we have managed to keep our sales level in 2020 and even increased by 35% in 2021.” �

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About our magazine WIN&ARTPROJE MAGAZINE It is intended for the PVC construction sector, which includes the Door, Window, Roof, Facade, Glass, Insulation product group. Published every 2 months. The number of prints is 5,000. ALU&ART MAGAZINE It is intended for the Aluminum construction sector, which includes the Door, Window, Roof, Facade, Glass, Insulation product group. Published every 2 months. The number of prints is 5,000. OUR FAIR SPECIAL ISSUE It is specially prepared for Tüyap Window and Germany Fensterbau Frontale fairs. The number of prints is 10,000. Published once a year. Distributed to exhibitors and visitors from our 3 stands at the fair. OUR FAIR ALBUM It is a special work that includes photographs of companies participating/ visiting Tüyap Window and Germany Fensterbau Frontale fairs. The number of prints is 10,000. Published once a year.

Both Win&ArtProje and Alu&Art Magazines reach domestic and foreign companies, architects, civil engineers, large-scale construction companies, construction sites, institutions and organizations (chambers of commerce, chambers of industry, chambers of architects and engineers, etc.) related to the sector, and are also distributed at domestic and international building fairs. WIN&ARTPROJE FOREIGN SUPPLEMENT It is prepared in English language specially for Door, Window, Roof, Facade, Glass fairs held abroad. Published 6 times a year. 5,000 copies are printed. It is distributed both in the fairs where it is prepared and delivered to other companies abroad.

Abroad Fairs to Distribute Our Domestic Issues FENSTERBAU FRONTALE NURNBERG BAU MUNIH ALUMINIUM DUSSELDORF GLASSTEC DUSSELDORF R+T STTUTGART E-MAGAZINE You can view all of our magazines on our websites, Calameo, Turkcell Dergilik, Vodafone Dmags, Türk Telekom E-dergi applications. SOCIAL MEDIA

FAIRS Our magazines are distributed in all door, window, glass, aluminum and building fairs held throughout Turkey. www.winartproje.com www.aluart.com.tr

1-2 DECEMBER DIGITAL EVENT

WHAT’S NEXT FOR INDUSTRY 4.0? Join us for another virtual conference on 1-2 December 2021, to address the challenges behind implementing Industry 4.0 technologies and find out why building digital culture across an organisation is key to a fully digital transformation. Alongside the two-day conference and virtual networking areas, participants will also be invited to join live discussions and will have the opportunity to meet with new contacts, arrange video meetings and exchange resources and information.

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The transformation of the journey that has started with faith into a global actor Having played an important role in the Turkish aluminium industry since 1970, Arslan Aluminium continues to increase its value in the industry with its 3 factories and an annual production capacity of 240,000 tons. Arslan Aüminyum was founded by Mehmet ARSLAN in 1970. The company, which has laid the foundation of its new facilities at the Bilecik Organized Industrial Zone in 1986 and has continued to operate at full pace since then, currently maintains its production activities in 3 factories with a total of 90,000 sqm indoor and 228,000 sqm outdoor area. A total of 62.400 tons/year aluminum proﬁle, 17.400 tons/year anodic oxidation, 18.000 tons/year static powder paint, 4.500 tons/year wooden pattern coating and 180.000 tons/year aluminum billets are produced at Arslan Aluminum facilities which include a mechanical treatment facility, a mold production facility and 8 aluminum extrusion press lines. Thanks to the strong corporate investments that it has made, the company has become one of the leading manufacturers in the aluminum sector in Turkey. As a strong representative and supplier of international markets, Arslan Alüminyum A.Ş. will acquire the title of being the most powerful organization at the top by increasing its total production capacity to 240.000 tons/year in April 2022 through the huge investment in terms of its aluminum casting capacity. As a result of its high production investment and successful initiatives in the national and international arena, Arslan Alüminyum A.Ş. climbed to the 282nd place in the Istanbul Chamber of Industry (ISO)’s Top 500 List in 2019, which measures the largest industrialists in Turkey every year. With its ongoing

investments, Arslan Alüminyum A.Ş. has climbed 20 steps up, rising to the 262nd place in the league of giants in 2020. Arslan Alüminyum A.Ş. has high awareness of new generation carbon emissions as a company that is committed to the sensitivity principles of maintaining clean environments, complying with the green agreement commitments and fulfilling climate and environmental factors at maximum level. It continues to make significant investments in recycling, and succeeds in melting and transforming 72.000 tons/year scrap aluminum into the highest quality primary material by using advanced technology at its facilities. Maintaining its success with substantial growth every year through its professional team of 750 people; Arslan Alüminyum A.Ş. will be the first and only integrated facility that manages to be ranked as one of the Top 120 companies in Turkey by 2022. As the strongest representative of the global aluminum industry thanks to its half-century investment and business journey, Arslan Alüminyum A.Ş. is currently positioned as the most important product supplier for global brands. Thanks to the investments it makes in advanced technology, quality and innovative production approach, the company has become an important supplier and has reached a significant export potential to meet the demands for environmentallyfriendly products derived from recycling, which is a fact that global corporate brands places high priority.

Arslan Alüminyum A.Ş. successfully exports its products to several countries around the world. In 2005, its high quality aluminum raw materials derived from recycling were exported to many countries such as Canada, Mexico, Qatar and Spain. Based on a rational and steady investment/production cycle; Arslan Alüminyum A.Ş. has become a major brand for the national economy, and has succeeded in transforming into a remarkable value in the international markets. As a company that takes confident steps towards the future with its flexible and dynamic management structure that both preserves and strengthens its legacy and fulfills the necessary transformation by quickly adapting to the actual developments and changes; Arslan Alüminyum A.Ş. is able to convert the power of achieving its targets into energy that can be used for new investments. �

www.arslanaluminyum.com

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ASAŞ leads the way in the sector and serving with its strong structure Rising to the 63rd place in the ISO 500 2020 list, ASAŞ, one of Turkey’s leading industrial companies, draws attention with its excellent service quality and state of the art investments. The company, which has made many firsts in its sector, exports to more than 90 countries in 6 continents. Operating with 5 different business units in Sakarya, Turkey, ASAŞ also provides logistics and service support to the European market with the establishment of ASAŞ GmbH located in Neuwied, Germany. ASAŞ has been one of the leading manufacturers in Europe exporting to more than 90 countries across 6 continents since its establishment in 1990. ASAŞ produces Aluminum Extrusion Profile, Aluminum Composite Panel, Aluminum Flat Rolled, PVC Profile and Roller Shutter products in production facilities in Sakarya, Turkey which are located in a total of 923.000 sqm of which 300.000 sqm is enclosed. ASAŞ GmbH, a fully owned subsidiary of ASAŞ, serves as a logistics and service center with 72.793m2 closed area in the city of Neuwied neighboring Koblenz in Germany. ASAŞ is one of the leading manufacturers in Europe, ranking 62 nd among the top 500 companies in the ISO 500 in Turkey in 2020 by climbing an average of 17 steps in 20 years supported by its strong stable financial growth trend. ASAŞ creates solutions and adds value to all sectors in which it operates, with its innovative

products, technology, R&D Center and services that are the ﬁrst in its sector. ASAŞ positions itself as a solution partner with a passion of following the trends based on the industrial innovations and always offering the best solution for its customers by investing in technology. The largest Extrusion Press, the biggest anodizing capacity and the widest foil rolling mill capability in Turkey are among the few that shows ASAŞ’ leadership in technology and investment. The principle of “continuous investment in sustainability, technology, integration and innovation” to always serve its customers better lies at the heart of ASAŞ. Within this perspective, ASAŞ has consistently been the leader in R&D expenditures in non-ferrous sector and product development studies are carried out by the ASAŞ R&D Center the ﬁrst R&D Center in aluminum sector in Turkey. ASAŞ’s production capabilities includes

wide range of value added products for various sectors such as automotive, railway, commercial vehicles, energy, packaging, construction, consumer products, maritime etc. We are partners in many European Union projects in the ﬁeld of product & process development and sustainability. Sustainability is at the core of our business. Sustainability is prioritized over everything else whilst doing business in ASAŞ. We ranked in 7th in Turkey with 11 VAP (Productivity Increasing Projects) projects approved by Ministry of Energy and participated in RetroFeed and Enerman projects which aim to reduce energy use and increase the usage of aluminum scrap under EU Supported Horizon 2020 Program. In the last two years, we have reduced energy consumption per ton by almost 3% and reduce our hazardous and nonhazardous waste by almost 10% �

www.asastr.com

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21/09/2021 12:17:12

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Global leader in continuous cast flat-rolled aluminium Assan Alüminyum, a subsidiary of Kibar Holding, is one of the 2 largest aluminium foil producers and one of the fastest growing flat-rolled aluminium producers in Europe. As a global pioneer in continuous casting technology, Assan Alüminyum continues to invest in further expansions and stays committed to global sustainability principles; managing its processes according to the framework set by the Aluminium Stewardship Initiative (ASI), in line with its core value of sustainability. Assan Alüminyum, a subsidiary of Kibar Holding, is one of the 2 largest aluminium foil producers and one of the fastest growing flat-rolled aluminium producers in Europe. The company has been producing coil & sheet, foil and pre-painted aluminium products since its establishment in 1988, offering its products to a variety of sectors such as packaging, distribution, construction, consumer durables, automotive and HVAC. Assan Alüminyum has an installed annual capacity of 300 thousand tons in its production facilities located in Istanbul and Kocaeli – Turkey and an aluminium foil production capacity reaching up to 100 thousand tons. With a series of investments planned for the years 2021 – 2024, the company aims to reach a total production capacity of over 360 thousand tons and aims to become the largest continuous cast flat-rolled aluminium producer in all of Europe and America, having increased the number of its continuous casting lines to 24. Assan Alüminyum aims to Create the Future Together with its business partners. With its core values of reliability, flexibility, innovation and sustainability, the company

provides customized solutions for its customers. Assan Alüminyum’s vision is based on creating long-term value by being more environmentally, socially and economically sustainable, in line with its motto of “Creating the future without wasting it”. Assan Alüminyum constantly strives to reduce its carbon footprint, through producing clean energy at its renewable energy power plant, recycling inner and outer scrap at its in-house recycling facility and developing new energy efficiency projects every year to reduce its energy consumption per ton of production. The company has received the internationally recognized I-REC certificate with its renewable energy production, through which it is able to fully offset its scope 2 emissions. With the exhaustion of resources, climate change gaining speed and social inequalities becoming prominent, the consept of sustainability is becoming more and more significant every day. Assan Alüminyum focuses on sustainability as one of its core values and follows the Aluminium Stewardship Initiative (ASI) framework to manage all of its business processes according to global

sustainability standards. The company received the ASI provisional Performance Standard Certificate for all of its flat-rolled aluminium production and recycling facilities. ASI sets the global benchmark for sustainability in the global aluminium sector, establishing criteria for member companies that address key social, governance and environmental issues. Assan Alüminyum met the requirements for the ASI performance standards and continues to show its commitment to global sustainability principles. Assan Alüminyum is a global pioneer in the continuous casting technology, developing innovative, tailor-made solutions for its business partners at its officially registered R&D Center. With its global culture, 1500 dedicated employees and its established international locations, Assan Alüminyum exports to more than 70 countries around the world, particularly to West Europe and North America. Kibar Americas, the wholly-owned North American subsidiary of Assan Alüminyum, established in Chicago, aims to perform the ambitious plans for growth. Further sustainable expansion investments are also planned and underway. �

https://www.assanaluminyum.com/en/

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21/09/2021 12:19:35

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Astaş Alüminyum has gained an important place in the Turkish aluminium proﬁle production industry for 46 years As its a well known durable, easily formable metal “Aluminum” is used for many sectors due to its high electrical and thermal conductivity. The trend in the world further develops this orientation and enables us to provide services for new use areas. As Astaş, we have increased our last 5 years export production from 40% to 70% in our yoy revenue amount. We achieved this success by increasing our quality, product and service speed in 1974 with the principle of “Quality Material, Just in Time Delivery”. We carry an annual proﬁle of 20,000 tons with a

350 personnel in our factory located in the Misinli/Çorlu region. This year, we’re planning to increase our investment capacity by 30% with an additional new investment. With our existing lines, we can meet all services from anodizing, powder coating, mechanical manufacturing. We are able to meet all the needs of our customers by providing services in the ﬁelds of anodizing, powder coating and mechanical processing in our existing production lines. We export our production, mainly automotive, solar energy and construction group proﬁles,

around 40 countries all over the world. With our environmental awareness, which has gained an importance especially in recent years, we carry out R&D studies that will develop the understanding of sustainable production in all production stages of aluminum, which is a 100% recyclable material. We aim to increase both our production and our quality in the coming periods, with the studies we have carried out on the compliance of our company with national and international speciﬁcations. �

www.astasalu.com.tr September/October 2021

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21/09/2021 12:51:58

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