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APRIL/MAY 2016

VOLUME 18 | 2

www.goudarefractories.com

n S melter fume treatment plant upgrade by innovatherm n P hotographic review of TMS show n First Words from Prof. Geoff Scamans, Chief Scientific Officer, Innoval Technology n F ives re-melt and casting plant at Garmco n E T 16 at Chicago show preview n A working day in the life of Richard Dean, MQP International, Sales Manager Europe and Middle East and James Parkes, International Sales Manager, Mechatherm International Ltd n R ecent MINO rolling mill modernisations n F eatures on furnaces, gas nitriding and billet heating n N  ews, Contracts & People, Product Information plus the Equipment & Materials Purchasing Guide ISSN 1465-8240

www.mmcpublications.co.uk


EPC solutions for downstream aluminium plants LARGE EXPERTISE IN PROCESS INTEGRATION, PROJECT MANAGEMENT AND EXECUTION — From concept to realization: • Interface management • Global sourcing to select the right suppliers and contractors • Strong commitment to HSE policy — Engineering: • In-house multi-discipline engineering expertise: process, lay-out and general arrangement, civil works, electrical, instrumentation, structural, mechanical and piping • Implementation of the latest 3D design technologies — Process knowledge: • Technology selection expertise • Process guarantees — Life cycle support after commissioning CUSTOMERS BENEFITS — EPC capabilities combined with Casthouse expertise — Optimized CAPEX — Integration of future plant capacity during the initial design — Financial support

60 13

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Experience in the Aluminium Industry

Aluminium-specialized Engineers

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CONTENTS | 1

w ww.mmcpublicat io n s. co . u k 

Regular features

Inside this issue

First Words

04

Professor Geoff Scamans, Chief Scientific Officer, Innoval Technology Limited

News

06

Sapa academy a success; GIFA stays every four years; Karmoy pilot

goes ahead; New extrusion line for Bonnell; Thermserve DC casting cooling water system; Fives Solios at Tomago; Noranda restructures; EGA services contract; FATA Hunter order; Decline in South America; Tall cathode at EGA; TMS photographic review; Jacques heads Rio

Page 33 - Conclusion of the tilting test for a series of GNA 40 t melting furnaces.

Furnaces feature

Tinto; Otto Junker in China; Aluminium takes over

30

from copper at Saudi Electricity and Emiroll plans taking shape

Altek, Fives Solios, Dross Engineering, GNA alutech, Schwartz, Gautschi,

De Winter and Precimeter are highlighted

Company Profile

36

Foundry Ecocer S.r.l based in Ossona near to Milan

Working day in the life of...

39

James Parkes is International Sales Manager for Mechatherm

International Limited

72

Richard Dean is International sales Manager for MQP Limited

Contracts & People

44

Butech Bliss installation; Novelis Europe management changes; Stena

commission Hertwich dross cooler; SMS 160 MN press in production and Becker invests in Georg slitter

Product Information

48

Reduction cell technologies from Hatch; Robust spectrometers; Furnace

door seals; Infrared line cameras; Casthouse consumables; Induction heating systems; Continuous rotary extrusion; Hydrogen analysis; Precast refractories; Slab and billet casting; Stub graphite coating and drying; rolling expertise and ALTEK machine design specialists

Automotive sheet alloy review

Page 43 - At Elval, a view from the operators pulpit into the exit side of the recently upgraded cold rolling mill.

Smelter fume treatment upgrade

16

innovatherm upgrades existing fume treatment centre

Feel the beat at ET in Chicago

19

ET 16 (Extrusion Technology) is held every four years and meets at Chicago

in early May

Induction preheating expertise

25

For almost 50 years Banyard has been a leading name for pre-heating

34

A look at the recent development of commercial automotive sheet alloy

Re-melt expansion project in Bahrain

40

Fives has been awarded an EPC contract at Garmco

An improved refractory for transition plates

38

Foundry Service & Supplies have introduced Ultratemp-Al transition plates

Recent rolling mill modernisations

42

MINO has recently completed rolling mill modernisations in Europe

prior to extrusion

Front Cover

Fundamentals of gas nitriding

As Mechatherm makes strides to extend

26

In aluminium extrusion die reliability is essential and the key production tool

Advanced planning and scheduling success

28

Visual8 bring aluminium plant scheduling into focus

Aluminium Times January/February 2016

its territories worldwide they are pleased to announce the completion of their first reference in the USA. After being awarded a contract to supply 2 x 100T tilting holding furnaces to supply a new continuous redraw rod casting facility at the Noranda Smelter in Missouri. Mechatherm believes this will make their mark for future business in the USA for years to come.


2 | ALUMINIUM TIMES A-Z

www. mmc p ub l i c a ti o n s . co . u k

Companies COMPANY NAME

PAGE NO

COMPANY NAME

PAGE NO

COMPANY NAME

PAGE NO

ABB ............................................................................................................ 50

FATA Hunter ........................................................................................8, 11

Nalco .......................................................................................................... 44

Abtex Corporation..................................................................................... 19

Fives ........................................................................................................... 40

NKM Noell ................................................................................................ 11

Advanced Dynamics ...........................................................................11, 23

Fives India ................................................................................................. 44

Noranda Aluminum Holding Corporation .............................................. 8

AEROBAL ................................................................................................. 12

Fives Solios ..................................................................................6, 8, 30, 44

Novelis .................................................................................................12, 34

Alcoa .................................................................................................6, 14, 44

Foundry Ecocer Srl ................................................................................... 36

Novelis Europe .......................................................................................... 44

Aleris .......................................................................................................... 34

Foundry Service and Supplies ................................................................. 38

Nuova Protecme Srl .................................................................................. 36

ALTEK ...........................................................................................10, 30, 52

Garmco .................................................................................................40, 47

Precimeter AB .....................................................................................10, 32

ALTEK LLC ............................................................................................. 21

Gautschi Engineering GmbH ............................................................11, 33

Presezzi extrusion ..................................................................................... 15

Altus refractories ....................................................................................... 52

Heinrich Georg GmbH ............................................................................. 47

Profile Precision Extrusion ...................................................................... 15

Aluminicaste .............................................................................................. 10

GIFA exhibition .......................................................................................... 6

R&D Carbon ................................................................................................ 8

Aluminum Association ............................................................................. 29

Gillespie & Powers .................................................................................... 11

Retech Systems LLC ................................................................................ 44

Aluminum Extruders Council ................................................................... 6

Glama Maschinenbau GmbH .................................................................. 10

Rex Materials Inc....................................................................................... 11

Aluminium Brazil Exhibition ................................................................... 6

GNA alutech ........................................................................................10, 33

Rio Tinto .................................................................................................... 12

Aluminium Trade Fair, Düsseldorf .......................................................... 6

Gouda Refractories ..................................................................................... 8

L P Royer .............................................................................................10, 11

Aluminium Federation .............................................................................. 6

Granco Clark Inc ...................................................................................... 20

Sapa ............................................................................................................ 12

AMAG ..................................................................................................34, 47

Hatch ....................................................................................................11, 48

Sapa Profiles UK ......................................................................................... 6

AMCOL Corporation ............................................................................... 23

Heat Treatment Australia ........................................................................ 44

Saudi Extrusion ........................................................................................ 15

Asmag GmbH ............................................................................................ 50

Hellenic Aluminium (ELVAL) ............................................................... 42

Schwartz GmbH ........................................................................................ 33

Atema Srl ................................................................................................... 21

Hertwich Engineering GmbH ................................................................. 44

SECO/Warwick Europe............................................................................ 44

Becker Aluminium Service GmbH ......................................................... 47

Hycast ......................................................................................................... 51

Shangdong Wantong Metal Technology Co Limited ............................. 8

Bloom Engineering ................................................................................... 20

Hydro Aluminium ......................................................................6, 8, 13, 34

SMS group ...........................................................................................20, 47

Bonnell Aluminum ..................................................................................... 6

ICME (Institute of Cast Metal Engineers) .............................................. 6

STAS .......................................................................................................... 11

Bosch Rexroth Corporation ..................................................................... 21

Inductotherm Heating & Welding (Banyard) ....................................... 25

Stena Aluminium ...................................................................................... 44

Bridgnorth Aluminium ............................................................................ 42

Innovatherm ........................................................................................10, 16

TMS ............................................................................................................ 10

BUSS AG ................................................................................................... 10

Innoval Technology Limited .........................................................4, 34, 52

TST ............................................................................................................. 50

Butech Bliss .........................................................................................19, 44

Jilin Liyuan Aluminium Company ........................................................ 47

T T Tomorrow Technology SpA ............................................................. 11

Castool Tooling Systems .......................................................................... 19

Otto Junker Metallurgical Equipment ................................................... 13

Thermo-Calc Software AS ....................................................................... 11

Champagne Metals.................................................................................... 44

Kautec Solutions ....................................................................................... 21

Thermo-Scientific ..................................................................................... 12

Cisart Group .............................................................................................. 20

Keit ............................................................................................................. 48

Thermserve Limited .............................................................................7, 26

Combilift USA .......................................................................................... 23

Kelly Control Systems .............................................................................. 19

Turla Srl ..................................................................................................... 19

Constellium .........................................................................................14, 34

Mecfor Inc .................................................................................................. 11

UACJ Corporation .................................................................................... 14

De Winter Engineering ................................................................13, 32, 48

Mechatherm International Limited ........................................1, 11, 23, 38

UC Rusal .................................................................................................... 12

Dias-Infrared ............................................................................................. 48

Melting Solutions Limited ...................................................................8, 44

Venalum ..................................................................................................... 14

Dross Engineering .................................................................................... 33

Metef exhibition .......................................................................................... 6

VeronaFiere ................................................................................................. 6

Emirates Global Aluminium ...............................................6, 8, 11, 14, 23

Metal Packing Europe .............................................................................. 44

VHE ............................................................................................................ 52

Emiroll ....................................................................................................... 15

MINO Group .......................................................................................13, 42

Visual8 ........................................................................................................ 28

Equibras ..................................................................................................... 10

Morgan Advanced Materials ...................................................................... 8

Zhongwang Group ...................................................................................... 6

ET 16 event ................................................................................................ 19

MQP Limited ............................................................................................ 68

Zircar Ceramics ........................................................................................ 50

Advertisers COMPANY NAME

PAGE NO

ALTEK .............................................................................................49 Amcol Corporation .........................................................................24 Bloom Engineering .........................................................................41 Castool Tooling Systems ................................................................22 Combilift Limited .............................................................................5 De Winter Engineering ....................................................................5 Drache GmbH .................................................................................32 Emirates Global Aluminium (EGA) .............................................18 Eredi Scabini ...................................................................................46 Extrutec GmbH ..............................................................................27 Fives ........................................................................................Cover 2 Foundry Service & Supplies ..........................................................41 Gautschi Engineering GmbH ........................................................29 Granco Clark .............................................................................20, 21 Hycast AS ...........................................................................................7

COMPANY NAME

PAGE NO

Inductotherm Heating & Welding Limited .................................22 Innoval Technology Limited .........................................................24 JMC Recycling Systems Limited ..................................................41 Otto Junker GmbH .........................................................................24 Kluber Lubrication .........................................................................13 Mecfor ..............................................................................................29 Mechatherm International Limited ...............................Cover 1, 31 Melting Solutions Limited .............................................................43 Micro-Epsilon ..................................................................................51 MINO SpA .......................................................................................35 MINO Process Control ...................................................................47 MQP Limited .........................................................................Cover 2 Precimeter Control AB ...................................................................17 Salico ................................................................................................45 Sistenm Teknik Industrial Furnaces ............................................53

SMS group .........................................................................................3 Thermo-Calc Software AB .............................................................31 Thermserve Limited .........................................................................9 Wagstaff Inc ...........................................................................Cover 4 Zircar Ceramics Inc ........................................................................13

CLASSIFIED ADVERTISEMENTS ARE ON PAGE 54 AND FEATURE PLANNING PRODUCTION AND SCHEDULING, EXTRUSION EXPERTISE, TEMPERATURE SENSORS AND EXTRUSION LINES FOR SALE.

The following aluminium industry maps and directories are for sale. See www.mmcpublications.co.uk Size of Map is 1000mm x 690mm. Aluminium Extruders Map of Europe (one side) and the World (one side) and Directory (Published January 2016) Aluminium Rolling Mills Map of the World and Directory (Published January 2015) Aluminium Primary Smelters and Refineries Map of the World and Directory (Published July 2015) Aluminium Secondary Smelters Map of Europe and the Middle East and WORLD Directory (Published October 2015) Each Map and Directory £90GBP / e126 euros / $155USA Modern Media Communications Limited, Gresham House, 54 High Street, Shoreham by Sea BN43 5DB United Kingdom Credit Cards welcome Aluminium Times April/May 2016


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4 | FIRST WORDS

www. mmc p ub l i c a ti o n s . co . u k

The story behind REALCAR Volume No: 18 Date: 

Issue No: 02 April-May 2016

Prof. Geoff Scamans of Innoval on the beneficial effect of its collaborative R&D project REALCAR, which is now seeing major returns for key auto makers.

Publisher: John Clarke Editor: Chris Holding BSc BEng Circulation & Subscriptions: info@mmcpublications.co.uk

IT/www Contact: Ceinwen Clarke Managing Director: John Clarke johnclarke@mmcpublications.co.uk

Published by Modern Media Communications Ltd Gresham House, 54 High Street, Shoreham by Sea, West Sussex, BN43 5DB United Kingdom Tel: +44(0)1273 453033 Fax: +44(0)1273 453085 e-mail: info@mmcpublications.co.uk www.mmcpublications.co.uk Distribution: Free to managers, involved in the production of primary or secondary aluminium; or the use of aluminium in the manufacture of semi-finished products; close to form components; or fabrications; or involved in the manufacture of components and structures from magnesium alloys and are involved in the buying process of equipment and materials. All other categories of reader are invited to subscribe at £110.00 to UK addresses and £126.00, €176.00, $220USA overseas. Single copy price £25.00, €35.00 including post and packing. The articles within Aluminium Times are copyright and are the property of the publisher Modern Media Communications Ltd and cannot be reproduced in any media form without permission of the publisher. Application should be made in writing. Reprints of articles and advertisements are

Prof. Geoff Scamans, Chief Scientific Officer, Innoval Technology

It’s crucial that Innoval Technology (Innoval) remains at the forefront of developments in the aluminium industry so that our clients can be confident that our technical knowledge is as up to date as it can be. One of the ways we do this is by being involved, as leaders or partners, in UK-Government funded (via Innovate UK) collaborative R&D projects. We’ve been involved in 20 such projects over the last 10 years and this has strengthened our interactions with both the UK Science base and the OEMs. One of these projects, REALCAR (REcycled ALuminium CAR), has received a lot of publicity recently on account of its success in catalysing the transition from steel to aluminium for Jaguar Land Rover body structures across their whole vehicle range, and we’re proud to say that we played a significant part in the initiation of this project. The project’s success hinges around a significant breakthrough in the cost to use aluminium sheet for automotive structures. Some 10 years ago we had discussions on the imperative for lower cost aluminium sheet with Mark White, Chief Technical Specialist, Light Weight Vehicle Structures at Jaguar Land Rover (JLR). We realised that the only way to get to the JLR cost and sustainability targets was to use as much recycled aluminium as possible and to minimise the use of primary metal. The aim was to effectively treat aluminium in cars in the same way as aluminium in cans by recycling at every stage of production and at end of life. The shorthand notation for this conceived at the time was “Cans to Cars”. The outcome of these discussions was

our formulation and development of the REALCAR project that was funded through a collaborative R&D competition launched by Innovate UK in 2007. The other partners in the project aside from us and JLR (as the project leader) were Novelis, Stadco, Zyomax, Norton Aluminium and Brunel University. Innovate UK contributed approximately 70% of the funding towards the £2 million project. The REALCAR project demonstrated that it was perfectly possible to make the AA5754 structural sheet alloy from segregated and returned press shop scrap without any sacrifice in performance. This version of the alloy is now being promoted by JLR and Novelis as RC5754. The new Jaguar XE was the first vehicle build to use RC5754 and future models like the 2016 XF and F-Pace SUV will also use this alloy. The concept has also been extended by Novelis for the AA6xxx automotive alloys. As JLR generate about 50% of sheet scrap during their pressing operations for vehicle body-in-white manufacture, they ensure that all this scrap is segregated by alloy family type and is directly returned to Novelis for further automotive sheet manufacture. Novelis has set up casting facilities at their Latchford recycling plant in the UK to cast rolling blocks from the returned AA5xxx and AA6xxx press shop scrap essentially as RC5754 and RC6xxx. The value of the press shop scrap is about 90 to 95% of the LME aluminium price and this effectively means that the price paid by JLR for their sheet from Novelis is discounted by a significant fraction of the LME price for every second rolled coil. This significantly reduces the cost of using aluminium sheet for vehicle construction and has made a major direct contribution to JLR’s sheet purchases worth millions of pounds. It doesn’t stop there though. Novelis has since helped Ford develop a similar closed-loop press shop scrap recycling system as that used by JLR in the UK, although with more returning scrap streams. Ford installed US$ 60 million worth of scrap-handling equipment and now trailers full of aluminium scrap are shipped back to Novelis or Alcoa for reprocessing. Through REALCAR, the simple “Cans to Cars” recycling idea has had major global ramifications for both the aluminium industry and major OEMs like JLR and Ford and will continue to deliver major financial benefits for many years to come. We’re proud to have instigated such a successful project which not only enabled two global OEMs to embrace vehicle lightweighting through the use of affordable aluminium sheet (which is also great for our industry), but which also has a significant environmental benefit. www.innovaltec.com/blog

Author: Prof. Geoff Scamans, Chief Scientific Officer, Innoval Technology

available, allow 28 days for delivery. PDF pages available by e-mail. Prices on application to the publisher.

Magazine Production Toni Barrington, The Magazine Production Company Shoreham-by-Sea, West Sussex, BN43 5EG, UK Tel: +44 (0)1273 467579 info@magazineproduction.com

Aluminium Times will be attending the Extrusion Technology Exhibition, ET 16, to be held in Chicago over May 2 – 6. From our booth the latest issues of Aluminium Times will be available as well as the 2016 Extrusion Maps of the World and Europe plus the associated Directory, published in January this year. All our aluminium industry maps and directories are available at www.mmcpublications.co.uk Aluminium Times April/May 2016


|5

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Aluminium Times April/May 2016


6 | NEWS In brief… Fives Solios SA signed a pre-engineering contract with THQ in November 2015 for the Gas Treatment Center and Bath Processing Unit for its greenfield aluminium smelter project in South Vietnam which implements APXe50 technology. Supply of further pieces of equipment was agreed in a contract at the end of 2014.

www. mmc p ub l i c a ti o n s . co . u k

Profile design academy a success

www.aluminium.fivesgroup.com

Alcoa has announced it will delay the curtailment of its Intalco Works smelter in Ferndale, Washington, USA until the end of the second quarter of 2016. The plant was initially scheduled to curtail by the end of the first quarter. Recent changes in energy and raw material costs have made it more cost effective to keep the smelter operating a while longer. www.alcoa.com

ICME and the Aluminium Federation are running a one day training course on Aluminium Casting Metallurgy on Thursday 12 May 2016 at the National Metalforming Centre in the West Midlands, UK. The course covers the technologies of all the stages of production of aluminium castings and their end use. The Tutor is David Harris. www.alfed.org.uk

Thanks to a new partnership with VeronaFiere, the 10th Aluminium Two Thousand International Congress and 6th International Conference on Extrusion and Benchmark (20 - 24 June 2017) will be held along with the Metef Exhibition (21 - 24 June 2017). Aluminium specialists are invited to submit a title for a proposed presentation before 31 May 2016. www.aluminium2000.com www.ice-b.net

The 3rd Aluminium Brazil and the Expo Alumínio will take place together in Sao Paolo, Brazil from 7 - 9 June 2016. At Aluminium Brazil in 2014, there were 43 international companies from Europe, the Middle East and Asia exhibiting, while Expo Alumínio brought together 170 exhibitors and more than 12,000 trade visitors. www.aluminium-brazil.com www.expoaluminio.com.br

Reporting its FY 2015 results, EGA said it produced 2.4 Mt aluminium and generated AED 18.7 bn in revenues in 2015, with more than AED 10 bn committed to a new 2 Mtpy alumina refinery project in Al Taweelah. Two new EGA customer downstream plants (DUCAB 50 kt wire rod plant and TALEX 50 kt extrusion plant) were due in production in 2016. www.ega.ae

Teamwork at the Sapa UK Profile Academy.

Sapa Profiles UK successfully hosted its eighth Profile Academy in November 2015, providing a detailed insight into the world of aluminium for design engineers from around the country. The academy is consistently oversubscribed and this year saw 40 participants from a wide range of industries attend the two-day event. A visit to Sapa’s Futuretools site in Gloucester was added to the itinerary, and participants were able to see the beginnings of the die manufacturing process. This gives an insight into the possibilities when

manufacturing dies, the precision and timescales required in the exacting design process, and the results that can be achieved with extrusion. In addition to demonstrating Sapa Profiles’ aluminium extrusion offering, plant tours and presentations explored the addedvalue services the company offers, including fabrication, finishing, bending/forming, machining and welding, through which customers can reduce transportation costs and lower their carbon footprint. www.sapagroup.com

DOC delay over Zhongwang angers AEC The Aluminum Extruders Council (AEC) said it was disappointed that the Department of Commerce (DOC) decided to delay its decision on the Scope Clarification/ Circumvention filing against Chinese aluminium extruder Zhongwang Group in February. The AEC called for several governments, including the U.S., to investigate a variety of charges levelled against Zhongwang and its U.S. affiliates in the Dupre Report that surfaced last July. According to the evidence provided in the AEC submission to the DOC, Zhongwang, through a series of affiliated exporters and U.S. importers, has poured billions of pounds of aluminium extrusions

into the United States and Mexico in recent years, much of which just sits in warehouses and open fields. The evidence provided in the submission also demonstrates the lengths to which Zhongwang has systematically evaded the antidumping/countervailing duties by exporting extrusions into the U.S. in a variety of forms which have only one thing in common - they have been manipulated solely for the purpose of evading duties and should continue to be subject to the orders. AEC Director of Operations and Fair Trade Committee Director Jeff Henderson has been demanding the DOC launch an investigation into Zhongwang.

The four trade fairs GIFA, METEC, THERMPROCESS and NEWCAST are to be held at the same four-year interval in future and will next be taking place in Düsseldorf from 25 - 29 June 2019. Messe Düsseldorf says it is responding to numerous requests from industrial exhibitors, after it proposed a three year rotation due to shorter innovation cycles. With a global portfolio of 30 events, Messe Düsseldorf has been looking for synergies and optimisation of knowhow. Additional Deputy Directors Gerrit Nawracala and Daniel Ryfisch have recently been appointed. Around 78,000 visitors from over 120 countries came to Düsseldorf in June 2015 for ‘The Bright World of Metals’ and saw 2,214 exhibitors. www.tbwom.com www.gifa.de

New extrusion line at Niles for Bonnell Bonnell Aluminum, a subsidiary of Tredegar Corporation, has announced it will be investing approximately US$ 18 million over the next 12 months to fund an expansion project which will include the purchase of a new state of the art aluminium extrusion line at its AACOA facility in Niles, Michigan. Planned startup is the second quarter of 2017. The new line will be comprised of a 3600-ton extrusion press, housing a 9-inch container, handling systems and ancillary equipment. Capacity is estimated at around 7,260 tonnes (16 Mlb) annually for automotive and speciality applications. The project includes additional floor space to accommodate future value-added fabrication capacity. www.bonlalum.com www.aacoa.com

ALUMINIUM fair on track to emulate 2014

in support from Enova. First metal from the technology pilot is expected during the second half of 2017. The ambition is to reduce energy consumption by around 15 percent per kilo aluminium produced compared to the world average, with the lowest CO2 footprint in the world.

The 11th ALUMINIUM World Trade Fair is scheduled to take place in Düsseldorf from 29 November to 1 December 2016. With eight months still to go before the start of the event, more than 700 exhibitors have already registered, indicating that ALUMINIUM is on track to continue where it left off in a record-setting 2014. ALUMINIUM will occupy six exhibition halls this year (Halls 9 to 14).

www.hydro.com

www.aluminium-messe.com

www.aec.org

Karmøy technology pilot to go ahead Hydro has made a formal build decision for the planned fullscale technology pilot at Karmøy, Norway, aiming to verify the world’s most climate and energy efficient production of primary aluminium. Total costs are estimated at NOK 4.3 billion (US$ 508m), consisting of net project costs of NOK 2.7 billion and around NOK 1.6 billion

GMTN technology fairs keep four year cycle

Aluminium Times April/May 2016


NEWS | 7

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New DC casting cooling water systems Thermserve has recently completed pressure is sensed and an automatic the installation of a water cooling blowdown cycle is initiated. Due to the high cost of potable plant providing cooled treated water to four DC casting machines. The water a reverse osmosis plant has plant installed in the UK consists been installed to soften borehole of a hot receiving well returning water. The plant when fully process water 150 metres to a newly operational will save in excess of constructed complex. Water enters 90% of the potable makeup used a set of two hot-wells where the under the previous system. The water is allowed to reside for up to new system is controlled via an 45 minutes. During this time solids Allen Bradley based PLC control are allowed to settle. The water system mated to a suite of MCC’s. is then pumped via an array of The control system optimises water centrifugal pumps over FM approved usage with an inbuilt recipe function cooling towers. The water is then blending potable, borehole and RO allowed to collect in a set of two softened water. Full PID control cold wells where it is readied to be allows for temperature control of returned to the process. The clean better than +/-1°C and level control cooled water is then returned to better than +/-15 mm. The control system is fully UPS supported elevated storage tanks. The system benefits from the ensuring functionality of critical installation of a bespoke water processes and alarming. The system treatment system controlling is designed in such a way to allow on parameters including pH, hardness, line cleaning, eliminating the need and total alkalinity. Blowdown and to shut down the casting process. The entire system was designed make up are also managed by this system. Filtration of the process and manufactured in-house using water is handled by three unique state of the art hydraulic modelling filters with technolog y more software linked to a 3D CAD typically employed in the oil and package. This process eliminates gas industry, whereby the water issues during start up and enables passes over an organic media the client to fully engage with the before any manufacture takes adsorbing 2015 oily1-2deposits. Once1 18.01.2015 the design Page RAM.01.pdf 20:59:54 media is saturated a high differential place. The plant was installed well

Aerial photograph of typical water cooling plant supplied by Thermserve, showing cooling towers chillers and filtration plant.

within the client’s time frame with the entire tie-in activations being completed in just 10 days. Always keen to use innovative technology, Thermserve continues to be at the forefront of water plant technology, providing water cooling to many of the world’s primary and secondary producers, on an annual basis aiding the production of over 2 million tonnes of aluminium. www.thermserve.com

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Aluminium Times April/May 2016

A Thermserve water cooling plant under construction in the Middle East. The FM approved towers are a key feature.


8 | NEWS In brief… EGA has achieved accreditation of the organisation’s testing and calibration Laboratories to ISO/IEC 17025:2005 in the field of Metallurgical Testing. The certificates were presented to CEO Abdulla Kalban on 18 February 2016. Currently EGA’s Laboratories are in the process of evaluating the Optical Emission Analysis test for the final product.

www. mmc p ub l i c a ti o n s . co . u k

Firing and control system contracts

www.ega.ae

EGA has patented a unique 150 mm “non-contact zone on copper insert” arrangement comprising a groove machined on top of or a hole inside the steel collector bars. The current within the cell can be uneven and copper inserts reduce the voltage drop. The solution could increase the life expectancy of the cell by at least 10 months, an extra 15% pot life. www.ega.ae

Three furnaces in Mexico have recently been installed and commissioned with a new generation of energy saving recuperators designed by Melting Solutions. They are able to pre-heat combustion air to 300 - 325°C. This innovative technology is able to deliver a 20% fuel saving with a low capital investment cost, delivering a very fast payback. www.meltingsolutions.co.uk

Gouda Refractories has developed a special range of AN-Seal series coating products that seal-off and protect a surface from heat, acid and other chemicals. They are either installed on the inner steel shell of the equipment or on the hot face of the refractory lining, and aim to extend refractory life and/or reduce energy consumption. www.goudarefractories.com

The R&D Carbon International Training Course ‘Anodes - From the Raw Materials to the Pot Performance’ is in Thun-Gwatt, Switzerland on 26 - 30 September 2016. R&D Carbon has also appointed JCT Beijing (Jingluhuarui Chem-Tech) as its representative for China (including Taiwan), and Hinditron as its representative for India, as of 1 January 2016. www.rd-carbon.com

Hydro is donating up to NOK 10 million to create a five year professorship at the Norwegian University of Science and Technology (NTNU). The professorship will support the creation of the NTNU Aluminium Product Innovation Center (NAPIC). The vision of the centre is to find new product areas for aluminium. www.hydro.com

Fives Solios firing and control system.

At the end of November 2015, Fives successfully replaced the Level 2 Firing & Control System at Tomago Aluminium’s three Anode Baking Furnaces in Newcastle, Australia. The furnaces were operating with six PCs for the Central Control System, but are now operating only with two. Each furnace is equipped with two monitoring screens instead of

one, thus the daily follow up for the operators is easier. Fives Solios SA also received the industrial completion for the modification of the Firing & Control System on the Anode Baking Furnace at the Trimet’s aluminium plant in St Jean de Maurienne, France in November. www.aluminium.fivesgroup.com

EGA operations support services contract SNC-Lavalin has been awarded an engineering services contract by Emirates Global Aluminium (EGA) to provide operations support services to EGA’s Emirates Aluminium (EMAL) and Dubai Aluminium (DUBAL) smelters. SNC-Lavalin will provide engineering packages and manpower services to DUBAL and engineering and project management services to EMAL Engineering to ensure optimal delivery of a portfolio of projects and operations support. The services shall cover all engineering disciplines and project management areas. Under this new agreement, all engineering work and support services will be executed by SNC-Lavalin employees in the Middle East and by its aluminium smelting and power specialists in Canada and the United States. The mandate covers a period of three years ending in July 2018. www.snclavalin.com

Primary deficit for January to November 2015 The calculated market deficit for primary aluminium for January to November 2015 was 405 kt, which follows a deficit of 589 kt recorded for the whole of 2014, according to WBMS March figures. Demand for primary aluminium for January to November 2015 was 53.13 million tonnes (Mt), 3.686 Mt more than the first eleven months of 2014. Production in January to November 2015 rose by 3.894 Mt compared with 2014. Total reported stocks fell by 139 kt during November to 3.821 Mt, or 26 days demand, compared to 5.020 Mt at the end of 2014. Total stocks held in the four exchanges in London, Shanghai, USA and Tokyo were 3.226 Mt at the end of November 2015, which was 1.219 Mt below the December 2014 total. No allowance is made in

the consumption calculation for large unreported stock changes especially those held in Asia. Overall, global production rose in January to November 2015 by 8 per cent compared with the first eleven months of 2014. Chinese output was estimated at 29.1 Mt and this currently accounts for more than 55 per cent of the world production total. Chinese apparent demand was 15.5 per cent higher than 2014. Chinese net exports were 302 kt in the period. Net expor ts of aluminium semi manufactures from China have soared from 3.154 Mt in January to November 2014 to 3.857 Mt in the first eleven months of 2015, while global demand rose by 7.5 per cent year-on-year.

FATA Hunter announced a contract for the supply of one new hSystem® automation system to Shandong Wantong Metal Technology Co., Ltd. in Shandong Province, China in November 2015. The system will be installed on a 4-high Aluminium Cold Rolling Mill. It will be complete with Automatic Gauge Control (AGC), Automatic Flatness Control (AFC), flatness measurement system, coolant spray bars, thickness measurement system and one integrated Level 2 control system for automatic pass schedule calculation, primary mill data management, and PDA (Process Data Acquisition system). www.fatahunter.com

www.world-bureau.com

Voluntary supervised restructuring for Noranda Noranda Aluminum Holding Corporation announced in February that Noranda and all of its wholly owned direct and indirect subsidiaries have filed voluntary petitions for a court-supervised restructuring process under Chapter 11 of the United States Bankruptcy Code in the U.S. Bankruptcy Court for the Eastern District of Missouri. Noranda has taken this action to have additional time and financial flexibility to evaluate options for its various business operations. Up to US$ 130 million in debtor-in-

Shandong order for FATA Hunter

possession (DIP) financing and up to US$ 35 million in incremental DIP financing was approved by the Court in early March. The company expected to continue operating the single remaining pot line at New Madrid, Missouri until the end of March. The alumina refinery in Gramercy, Louisiana continues to operate at full production levels. The plant completed the expansion of its non-metallurgical or chemical business product capacity by approximately 50% at the end of February. www.norandaaluminum.com/restructuring

Aluminium Times April/May 2016

White paper on trends in aluminium processing Morgan Advanced Materials has published a white paper identifying current trends in primary and secondary aluminium processing, focusing on technology solutions. The paper examines the current state of the aluminium market, which has an average annual growth of 6 per cent with a current total market value of around £45 billion. A summary of market trends is provided. The white paper is available from: www.morganadvancedmaterials.com/ aluminiumWP


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10 | TMS EXHIBITION/NEWS

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TMS hits the right notes The TMS 145th Annual Meeting and Exhibition was held over February 14 -18 at Nashville, Tennessee. The exhibition attracted under 100 booths and included companies GNA alutech, Gillespie & Powers, STAS, Thorpe Technologies, Hycast and NKM Noell. The exhibition

organisers have considered the best way to bring delegates into contact with the exhibitors by holding social events and lunches in the exhibit hall. There were approximately 4,000 delegates attending TMS 2016, of which at least 75% are students, however

the number of executives and managers from the primary sector was perhaps down on previous years due mainly to a quieter market. The next TMS meeting and show takes place in San Diego from 26 Februar y through to 2nd March 2017. Alongside are

two other events, the 3rd PanAmerican Materials Congress a n d E n e r g y M a t e r i a l s 2 017 conference. There now follow photographs taken during the show of exhibitors and visitors. www.tms.org

At the ALTEK stand are from left to right; Alan Peel, Managing Director of ALTEK; Caitlin Detwiler, Sales Engineer, ALTEK LLC with Rick Chandler, President of ALTEK LLC.

Visiting the Royer booth were from left to right; Danny Gagnon, Technical Consultant, Equibras; Diane Dallaire, Director, Equibras and host Jerry Hould, Business Development Manager, ROYER.

Visiting TMS was Joerg Kellermann of Swiss company BUSS AG.

Left is Randall Roush, Area Sales Manager, Precimeter and right is Thomas Jarlsmark, Area Sales Manager, Precimeter based in Sweden.

At the innovatherm booth were from left to right; David Wilburn, Vice President, innovatherm USA; Detlef Maiwald, Managing Director, innovatherm; Anke Di Lisa, innovatherm and Domenico Di Lisa, Sales Director innovatherm.

Gouda Refractories booth was managed by, from the left; Michel Grootenboer, Director Sales & Marketing; Darius Grofik, Sales Manager and right was Frank Constantinesco, Sales Manager.

At TMS were from left to right were David Edgerton, EC&S with colleague Greg Bray and right was Helmut Kurz, Garant Filter, based in Germany.

Left was Ted Phenix, President of GNA alutech Inc based in Canada, with Shaun Hamer, Vice President, Operations and Engineering of Aluminicaste based in Mexico.

Left is Frank Beck, US & Canada Representative of GLAMA Maschinenbau GmbH with Werner Nowitzki, Vice President, Sales of GLAMA Maschinenbau GmbH.

Aluminium Times April/May 2016


TMS EXHIBITION/NEWS | 11

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Left is Giovanni Magarotto, Managing Director of T.T. Tomorrow Technology SpA with Saleh Ahmed Rabba, Vice President Carbon and Port, EGA Operations.

At the Gautschi booth, from left to right were; John Griffin, Gautschi’s North American Representative; Frank Paulus, Sales Manager, Gautschi; Anthony Tropeano, CEO of FATA Hunter; Oliver Moos, Managing Director, Gautschi and right was Robert Voyer, HATCH.

Thermo-Calc Software AS booth was managed by, from left to right; Paul Mason, President, Thermo-Calc Software Inc; Therese Gustafsson, Technical Sales Manager, Thermo-Calc Software AB and right was Georg Schmitz, MICRESS® Global Marketing & Sales Manager, ACCESS e.V.

Attending the Advanced Dynamics booth are, from the left; Kevin Williams, Vice President, Business Development, Advanced Dynamics; David Stephens, Chief Metals Engineer, Penta Engineering and Marty De Goey, Applications Manager, Advanced Dynamics.

Relaxing on the Gillespie & Powers booth are from the left; Jack Gillespie, Project Manager for Gillespie & Powers, Inc; Dan Corley, Sales for Gillespie & Powers, Inc; Jon R. Gillespie, President of Gillespie & Powers, Inc and Skip Anthony, Vice President, Sales & Service for American Pulverizer Company.

At the STAS booth were Pierre Bouchard, President STAS; sitting and right was André Gilbert, Technical Sales STAS. Standing and from the left was Florent Gougerot, Marketing Manager, STAS; Chuck Bestle, Regional Sales Manager, Rex Materials; Louis Bouchard, General Manager STAS; Bob Cravens, Vice President of Sales & Marketing Rex Materials and Pete Forakis, Branch Director, STAS Middle East.

Two casthouse specialist companies were represented at TMS by Jerry Hould, Business Development Manager, of casthouse boot manufacturer Royer with Richard A. Zalzal, on the right side, Vice-President, International Sales for Mecfor specialist in casthouse vehicles.

Attending the NKM Noell stand from left to right were Dominik Berchtold, REEL ALESA, VP Sales; Jonathan Bujold REEL USA Corporation, Vice President; Cedric Schmuck REEL NKM Noell, Director Aluminium and right was Thomas Kunz, REEL NKM Noell Manager Services.

At the Mechatherm International stand were, from left to right; Stuart Allen, Director of Sales; Nigel Walker, Engineering Director and right is James Parkes, Business Development and Marketing Manager.

Aluminium Times April/May 2016


12 | NEWS

Operating results and Rusal’s China review UC Rusal produced 3.6 Mt aluminium in 2015 and 89.1 kt aluminium foil and packaging, and sold 3.64 Mt aluminium in the year. Aluminium production in 4Q15 totalled 878 kt, with sales of 876 kt respectively. The share of value added products (VAP) in the overall aluminium sales portfolio in the quarter was 44% (2015: 43%). The company said in early February 2016 that it does not plan on restarting the aluminium smelters idled in 2013, and is considering further aluminium production cuts totalling approximately 200 ktpy presently. Following several announcements on aluminium capacity cuts in China in 4Q15, with total closures of 4.4 Mt in 2015, aluminium production started to decline in December 2015 (-8.7% MoM), indicating an improving supply discipline in the region. China added 3.7 Mt of new capacity into operation, thus the net operating capacity growth of China in 2015 changed insignificantly. In 2016 it is expected China will ramp up around 3 Mt of new capacity and close around 1.5 Mt, thus capacity growth for 2015-2016 should be much lower compared to the last 5 years. Chinese net semis exports grew by 17.5% in 2015 to 3.7 Mt, but are expected to slow down in 2016 on lower arbitrage and tighter domestic supply. www.rusal.com

High recycled content aluminium alloy Novelis RC5754 alloy, a new automotive product designed to contain up to 75 percent recycled content, has been successfully integrated into the structural components of high volume production passenger vehicles. RC5754 was developed with Jaguar Land Rover and serves as a key component of Jaguar’s REALCAR (REcycled ALuminium CAR) project. First introduced in the new Jaguar XE, the RC5754 alloy will also be featured in all new and legacy Jaguar Land Rover models. www.novelis.com

Sapa injury record Sapa had 132 recordable injuries in 2015. Nearly 100 fewer than in 2014 and the lowest number recorded in company history. Sapa employs around 23,000 employees in 40 countries. www.sapagroup.com

www. mmc p ub l i c a ti o n s . co . u k

ARL easySpark is advanced benchtop analyser

Stable 2015 aerosol can market

A selection of aluminium aerosol cans.

The Thermo Scientific ARL easySpark analyser combines high sensitivity with ease of operation.

Secondary metal processing companies and foundries that require an easy-to-use and highly sensitive solution for the analysis of a wide range of metals can now use a new benchtop optical emission spectrometry (OES) instrument designed to provide fast and accurate results. The Thermo Scientific ARL easySpark analyser first appeared at Pittcon 2016 in Atlanta. It is designed to meet the challenges and demands of small- to medium-sized secondary metal manufacturers that require high-quality, yet cost-

effective OES analyses to produce parts for automotive, aviation, aerospace and consumer products, among other industries. The instrument features a unique multi-grating / CCD (charge-coupled device)-based optical system designed to deliver high spectral resolution and enhanced analytical performances. The analyser is easy to install, use and maintain, making it accessible to non-experts working in OES who require efficiency and productivity in metal and alloy production.

www.aerobal.org

Jacques succeeding Walsh at Rio Tinto

and, with a much lower impact, product regulations. EU elec tricit y price s were estimated to be twice as high as the U.S. or Russia, and 20 per cent higher than China, in 2014. Some European primary aluminium producers either create their own electricity or rely on long-term contracts for purchasing energy signed before the introduction of the ETS, so they are not exposed to its indirect cost (about 90 euros per tonne). As a result, their cumulative regulatory costs represent only 4 -5% of their profit margin. Aluminium producers have had to pay for certain emissions themselves since 2014. The study was based on plant level data and carried out by the Centre for European Policy Studies.

Rio Tinto Chief Executive Sam Walsh will retire from the business on 1 July 2016 and will be succeeded by Copper & Coal Chief Executive Jean-Sébastien Jacques. To ensure a smooth transition, Jean-Sébastien has joined the board and become Deputy Chief Executive with immediate effect. During more than three years on Rio Tinto’s executive committee, Jean-Sébastien has brought greater focus to the copper and the coal businesses. He has delivered a step-change in both safety and cash performance while significantly reducing costs. Sam Walsh leaves Rio Tinto as a much stronger company with a bright future, according to Chairman Jan du Plessis. Jean-Sébastien served as Group Strategy Director for Tata Steel Group from 2007 to 2011. Chris Salisbury is appointed acting Chief Executive of the Copper & Coal product group and will attend the Rio Tinto Executive Committee in this capacity. The rest of the executive team remains unchanged.

www.ec.europa.eu

www.riotinto.com

www.thermoscientific.com/OES

European regulations impact study Several factors continue to hamper the industrial competitiveness of Europe’s aluminium industry. At least eleven of the EU’s 26 primary aluminium smelters have closed since 2003 and not a single new one has opened. A Commission study in 2013 looked at the situation in the aluminium sector and how its competitiveness was affected by EU regulation, and estimated that associated costs were approximately 8% of total costs over a ten year period from 2002 to 2012. For the majority of plants surveyed, EU regulations which caused the highest burden (around 86% of the total burden) were those affecting energy prices, either directly or indirectly through the Emission Trading Scheme (ETS). These were followed by environmental regulations,

The production of aluminium aerosol cans worldwide remained stable at a high level in 2015. The member companies of AEROBAL (International Organisation of Aluminium Aerosol Container Manufacturers) reported total production of 5.4 billion (US$ 530m) aluminium cans and thus a repeat of the previous year’s record result. AEROBAL Secretary General Gregor Spengler said repeating 2014’s record is a good achievement considering the ver y diff icult conditions in 2015 with economic turmoil in China, Russia and some emerging countries, and enduring p ro b l e m s i n o t h e r a re a s . I t demonstrated the strong capabilities of member companies and the aluminium aerosol can’s excellent position in the fiercely competitive global packaging market.

Aluminium Times April/May 2016


NEWS | 13

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Norsk Hydro to continue creating value

JMS Symposium 2016 held in Chengdu

Reporting on 2015, Hydro President and CEO Svein Richard Brandtzæg writes in his letter to shareholders: “The world around us has shifted significantly and fast again. A year ago, we experienced undersupply a nd re c o r d- h i g h al u m i ni um premiums. Shortly after, Chinese oversupply and rising exports pushed aluminium prices to 6-year lows.” Mr. Cesare Pettazzi, the Managing Director of MINO (rolling mills manufacturer), personally attended the JMS symposium.

Otto Junker Metallurgical Equipment (Shanghai) Ltd. (JMS), as the wholly-owned subsidiary of Otto Junker GmbH, has held the JMS Symposium 2016 on 13 January in Chengdu, China. The topic was ‘Advanced Technology of Continuous Annealing Line for Aluminium Strips’. Floater technology and Otto Junker’s advanced quenching system were emphasised. Mr. Cesare Pettazzi, the Managing Director of MINO (rolling mills manufacturer), personally attended the symposium with his colleagues

and gave animated lectures at the meeting. More than 40 participants from 15 companies and potential customers attended the event. Mr. Sebastian Maerz and Mr. Tobias Mertens also made informative presentations. Mr. Neuhaus, Deputy General Manager of JMS, outlined the company structure, products and services as well as the prospects for its development. Otto Junker, through JMS and these regular events, aims to build a solid foundation for the future in Chinese market. www.otto-junker.de

Hydro President and CEO Svein Richard Brandtzæg.

“I am happy to report that Hydro’s improvement efforts have continued independently with undiminished intensity, giving benchmark results and improved ability to stay the course. We have in total delivered NOK 4.5 billion (US$530m) in annual improvements since 2011. That does not mean improvements have come to an end, and we are always seeking the next milestone. On our Capital Markets Day in December we launched a new ambition aiming to realise new annual improvements of another NOK 2.9 billion by 2019.” Hydro is presently a first quartile aluminium and alumina producer with a strong balance sheet. www.hydro.com

De Winter awarded contract De Winter Engineering has been awarded a contract for the turnkey supply of a customised tiltable melting furnace by a Dutch aluminium melting company. The furnace will be assembled as far as possible in the workshop and then transported and lifted into its final location. The furnace will go into production at the end of the year. De Winter has more than 30 years of experience, not only in building customised new furnaces but also in reducing running costs of existing furnaces.

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Aluminium Times April/May 2016


14 | NEWS

Charting the South American production decline With the broader decline in primary aluminium production in South America, a region that was once a major exporter is now becoming increasingly dependent on imports. Leading national producer Brazil’s output has fallen from a peak of 1.67 Mt in 2007 to 962 kt in 2014. The annualised production as of February 2016 (ABAL figures) was 734.4 kt. The shift in trade flows has significant implications for physical delivery premiums into Brazil. When Alcoa announced the full shuttering of the Alumar smelter in Brazil in 2015, it marked the fifth, and largest, Brazilian smelter to be closed since 2009. The first (127 ktpy) potline at the Alumar smelter in the Brazilian state of Maranhao was fired up in 1984. A second (156 ktpy) potline followed in 1986, with a third launched in 1990. Alcoa’s Pocos de Caldas smelter in Minas Gerais (1970) has been fully shuttered since May 2014. The Valesul smelter was closed in 2009, while Novelis closed its Aratu plant in 2010 and its Ouro Preto plant in 2014. Only Hydro’s 460 ktpy Albras and CBA’s 475 ktpy Sorocaba smelters remain operational. To t h e n o r t h , o u t p u t fro m Venezuela’s Venalum (430 ktpy capacity) and Alcasa (170 ktpy) smelters hit a 30-year low in 2014, according to the industry ministry’s annual report. Venalum produced just 90.8 kt primary aluminium in 2015. Elsewhere, the 460 ktpy Aluar smelter in Argentina is reportedly still operating at around 78 per cent capacity. www.reuters.com

Inspection and maintenance innovation at EGA A removable hinged cover that allows for easy wedge insertion and pot inspection activities at the EGA Jebel Ali smelter complex in Dubai is being patented. The invention relates to a particular arrangement of the top cover of the intercalary space between the potshells of two adjacent electrolysis cells, arranged side-byside in a series of electrolysis cells. To avoid uncontrolled heat loss, as well as for practical and safety reasons, the intercalary space is closed by a top structure (slab). To carry out routine operations, maintenance, or in an emergency situation, these heavy concrete slabs may need to be removed by a machine or crane. www.ega.ae

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Developing the tall cathode at EGA

Ibrahim Baggash, Director of Smelter Services at Dubal.

Emirates Global Aluminium (EGA) has, over the past 25 years or so, made substantial investments in developing technologies that ensure continuous improvements in the company’s operations, with energy efficiency being at the top of the agenda. Since 2014, EGA has worked closely with Takamul in developing and submitting the required patent application documentation to protect the company’s inventions. A case in point is a new tall cathode structure that has been developed by a team of engineers at EGA subsidiary Dubai Aluminium (DUBAL, also known as EGA Jebel Ali Operations) to improve energy efficiency in the aluminium production process. A patent application for the invention was filed by EGA in December 2014. Takamul approval for financial support was granted in March 2015. The project, launched in 2011, aimed to identify a structure that provided a barrier to metal flow during the electrolysis process. The targeted result was lower metal velocity, which would help improve electrolytic cell magnetohydrodynamic balance and enable the cell to be operated at a lower voltage. The resulting improved energy efficiency would reduce the operations’ carbon footprint and save on energy related costs. The impor t a nce of e ne rg y efficiency is explained by Sergey

A k h m e t o v, V i c e P r e s i d e n t , Reduction, EGA Jebel Ali Operations, who says, “The energy cost of producing aluminium from alumina is considerable. Typically, 12 kWh to 16 kWh is needed to produce one kilogram of aluminium. Given that the cost of electricity is approximately US$ 0.05 to US$ 0.10 per kWh (equivalent of AED 0.18 to AED 0.36 per kWh), a reduction in energy output can result in significant cost savings. For example, for a plant with an annual production capacity of 1 Mt such as DUBAL, an energy efficiency solution could result in savings of US$ 6 million per year.” Ibr ahim Bag ga sh (Direc tor, Smelter Services) led the project, supported by Alexander Arkhipov (Manager, Modelling) and Sergey Akhmetov. The team began by exploring existing structures in the industry internationally. Following extensive research, the conclusion was reached that a completely new solution had to be developed specifically for DUBAL’s requirements. “Our cell design and anode to cathode alignment is unique, so nothing readily available on the market would suit, so we set out to develop a customised solution for our purposes,” says Baggash. The overall project duration, from concept and construction to testing, took many months. The invention, a taller cathode structure, is still undergoing a lengthy trial process. The tall cathode is successfully reducing metal velocity in the electroly tic cells, enabling a lower operating voltage. The new structure entails replacing one or more standard cathode blocks with taller ones, such that there is no significant change required to the electrolytic cell construction, the cell pre-heating equipment or the cell start-up process. The additional cost in cell construction is marginal, and is more than covered by the returns.

An MoU to expand their existing joint venture (JV) to produce automotive Body-in-White (BiW) sheet in the U.S. has been signed by Constellium N.V. and UACJ Corporation (UACJ) of Japan. The final contract is subject to the board approval of each party. Constellium and UACJ contemplate a joint investment in two 100 kt finishing lines (location to be decided), which would be funded 51% by Constellium and 49% by Tri-Arrows Aluminium Holdings, a U.S. affiliate of UACJ. The agreement would reduce Constellium’s U.S. BiW investments capital requirement from US$ 620 to US$ 340 million. The JV has already invested in a first finishing line located in Bowling Green, Kentucky, which is expected to begin pre-qualification production mid-2016 and ramp-up in 2017 as planned. UACJ was established in October 2013 when Furukawa-Sky Aluminum and Sumitomo Light Metal Industries integrated their business operations, and has over 1 Mtpy capacity for rolled sheet products. www.constellium.com www.uacj.co.jp

New coalition opposes China MES claim

to the company’s history of creating iconic products and its constant focus on the next breakthrough innovation. The future Upstream company will operate under the Alcoa name. The company’s separation into two, independent, publicly-traded companies in the second half of 2016 remains on track.

A group of leading U.S. manufacturing associations today has formed a new coalition, Manufacturers for Trade Enforcement, to oppose China’s designation as a market economy at the end of 2016. China has claimed that it should be automatically accorded treatment as if it were a market economy after the 15th anniversary of its accession to the World Trade Organisation in December 2016. U.S. law requires that the Department of Commerce make a market economy status (MES) determination based on established criteria, which many experts agree that China has not met. Heidi Brock, President & CEO of the Aluminum Association, said “The Chinese economy does not meet the basic requirements set forth by U.S. statutes and the Department of Commerce for a functioning market economy, and we will work together in this coalition to speak loudly to prevent China from gaining a status that it does not yet deserve.” Eight U.S.-based aluminium smelters have curtailed or closed since the beginning of 2015, representing more than 60 percent of U.S. primary aluminium capacity and impacting more than 3,000 workers.

www.alcoa.com

www.aluminum.org

www.ega.ae

Downstream Arconic will add value Alcoa has unveiled the name, logo and tagline of its future Value-Add company: “Arconic. Innovation, Engineered.” The ‘A’ echoes Arconic’s proud Alcoa heritage; the ‘Arc’ represents the arc of progress and the continued pursuit of advancement for customers, employees, shareholders and communities; and ‘-conic’ speaks

Constellium and UACJ expand U.S. BiW partnership

Aluminium Times April/May 2016


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Presezzi to supply Profile with small pipe press Profile Precision Extrusion based in Arizona, U.S. has awarded Presezzi Extrusion with the design and manufacturing contract for a new 11MN front loading press with piercer. The new press will allow PPE to extrude more tight tolerances and the piercer will allow it to extrude small seamless pipes for special markets. This press will be the most technically advanced machine dedicated to the Precision Miniature Extrusion market. Profile was founded in 1994 and acquired the Profile Precision Extrusions in 1997. PPE is a leading manufacturer of small, precision aluminium extrusions and extruded tubing for the medical, aerospace and industrial markets. In addition to extrusions, it offers also CNC machining, anodising and custom cutting fabrication services. www.profileprecisionextrusions.com www.presezziextrusion.com

Emiroll plans taking shape Dubal Holding, Dubai Investments and Singapore-based industrial group MARS are investing US$ 120 million (S$ 162 million) to build an aluminium rolling plant in Abu Dhabi’s Kizad industrial free zone. Emirates Aluminium Rolling LLC (Emiroll), as the joint venture will be called, plans to manufacture 65,000 tonnes of aluminium coils annually and expects to star t up in the third quarter of 2017. Dubal Holding, a unit of sovereign fund Investment Corporation of

Dubai, and MARS will each hold a 35 per cent stake in Emiroll, and Dubai Investments will take the remaining 30 per cent. Construction of the plant will commence soon on 900,000 square feet of land in Kizad. Once operational, Emiroll production will include 45,000 tonnes of cold-rolled and 20,000 tonnes of hot-rolled aluminium for applications in downstream industries, such as automotive body parts, roller-shutters, garage castings, container trays, cans and aerosols.

GCC currently manufactures 4.5 Mtpy of primary aluminium, with UAE’s share about 2.3 Mtpy, and only 10 per cent of this production is used in the downstream industry. As part of the joint venture, MARS has also committed 30% product off-take from Emiroll for application and use across its Middle East operations. The remaining products from Emiroll are expected to be supplied for domestic consumption, as also in other Middle Eastern countries and Europe. www.tradearabia.com

Casthouse Consumables

Auto and power swap copper for aluminium Saudi Electricity Co. said it has already saved 2.4 billion riyals (US$ 640 million) by shifting from copper to aluminium in its medium voltage distribution network. Japan’s Kansai Electric Power last year began replacing 50 year old copper distribution cabling in Osaka prefecture with aluminium. A spokesman said its plans to replace some 140,000 km of copper cabling over 30 years would save tens of billions of yen. The new aluminium wires compensated for the downside of being thicker with a dimpled design that reduces wind pressure and helps repel snow, meaning they can use existing electric poles and lower the risk of cables snapping. Furukawa Automotive Systems, a unit of Furukawa Electric Co, has developed new corrosion-proof terminals for aluminium wires in a harness. Furukawa has been supplying aluminium wire harness systems to Honda’s light vehicles and Toyota’s luxury vehicles, and expects aluminium wire harnesses for use in vehicles will make up about 30 percent of the market in Japan by 2025. Germany’s Leoni started supplying aluminium cables for luxury cars about five years ago. The firm believes a car can be about 1 kg lighter if aluminium cables are used instead of copper, and this difference is expected to climb to 4 kg within five years. www.reuters.com

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16 | PRIMARY

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Smelter fume treatment plant upgrade This article by Detlef Maiwald and Domenico Di Lisa of innovatherm describes a strategy for a Fume Treatment Centre upgrade in an existing smelter in Latin America, which re-uses and integrates major existing components but in parallel enhances the plant by new equipment and process technologies to attain the targets by the most economical solution. The existing Fume Treatment Centre (FTC) had been designed for a nominal exhaust gas volume of 90,000 m3/h and a maximum exhaust gas temperature of 130°C. It was a three chambers bag house filter concept with alumina as adsorbent without cooling tower, due to the low exhaust gas temperatures at the exit of the closed type furnaces. For the higher production of anodes in the new anode baking furnaces, more exhaust gas volume is generated at temperatures up to 220°C, which implies the installation of a new innovatherm FTC to maintain the higher volumes and the higher exhaust gas temperatures. The driving idea for the new FTC design was to keep and use as much as possible from the existing installation to get the best economical concept for minimum CAPEX and still reach the performance and the environmental limits by the following means: • Enlargement of the surface of the filter without addition of new chambers inside the existing baghouse. • High filtration efficiency filtration ratios of < = 1.05 m3/m2 and minute. The new FTC was embedded around the former FTC (baghouse) as shown in Figure 1. The plant was designed to provide ‘ideal’ movement of the gases from the furnace to the stack. Pressure losses were minimised using computer modelling to ensure maximum flexibility even at high baking furnace pressure losses. Three advanced features were implemented in the crude gas channel for operational safety and reliability: 1. The waste gas channel was designed as a special ‘emergency stack’, including an ‘emergency damper’ at the highest point of the gas channel. 2. A diesel generator supplied fan is installed for aspiration of the furnace flue gases in case of power black-out. 3. A spark detection and extinguishing system is installed in the crude gas channel to protect the FTC. A new cooling tower was added as shown in Figure 2. The conditioning cooling tower is designed as a direct current cooler. A special design ensures that the off-gases are treated with atomised water produced by a two-phase nozzle technology in an area where ‘plug-flow’ is reached. The design is optimised with regard to: • Adequate evaporation distance • Avoidance of build-up at the CT inner surface • Dry condition at cooling tower hopper outlet • Discharging of heavy particles at tower hopper.

1 Optimised design of the FTC for low pressure losses.

The off-gas temperature at the conditioning tower outlet is maintained constant at 105°C ±0.5°C by automatic control of the water flow injection. A special surface coating protects the tower against corrosion, acid attack and deposits. The conditioned waste-gases are guided through the lower side conical outlet into the main reactor chamber. Fresh alumina is directly injected after the cooling tower. The injection of fresh alumina early after the cooling tower is a key parameter for the performance of the FTC, especially for the bonding of preliminary phases of acids. Aluminium Times April/May 2016

The enriched waste-gases are guided into individual secondary reactor chambers and finally to the fabric filters. The secondary reactor chambers are also charged using an alumina injector. This injector is fed with re-circulated secondary alumina from the individual fabric filter chambers. The recirculation takes place at high concentrations of alumina, resulting in high adsorption rates for all kinds of pollutants. Due to the long sections of the reactor chambers and intensive mixing of the adsorbent media, the aerosols not only adsorb off-gases, but fines in the media as well and both are extracted at the fabric filter cloth as filtration cake.


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2 The new conditioning cooling tower.

To ensure good alumina transport without sedimentation within the ducts, a minimum flue gas speed of 12 m/s is necessary. During different phases of FTC operation with only one furnace in operation, the minimum flue gas speed has to be maintained. For these dynamic conditions an automatic controlled flue gas recirculation system was designed

and implemented. A further design target was the enlargement of the fabric filter surface within the existing filter chambers. This was achieved by removing the in-built reactor and adding additional filter bags and installation of a pre-collection chamber. High gas flow rates in a range of 18 m/s in the ducts and reactors have to be reduced in steps to less than 1 m/s in the area of the filter bags. The separation of heavy particles (agglomerates) needs to be executed prior to the filtration cake. In this area gas speeds of < 2 m/s are obligatory. The gas flow onto the filter bags has to be oriented in a wide area from bottom to top. Technical solutions which contain a horizontal flow generate an early wear and tear of the fabrics by partial overloads and in parallel inactive areas inside the filter chambers. To ensure the desired flow, 3 new fans with a power of 200 kW each were installed. An

Molten Metal Level Control

operation mode of n-1 is ensured to guarantee the desired performance and reliability.

Attaining performance

After implementation of all design features the desired performance was available. As a positive effect the dosing of fresh alumina could be minimised to 800 kg/h. This corresponds with a fresh alumina load of 7.8 g per Nm3 of flue gas. The fluorides and total dust values were obtained following the US EPA13a method. The condensed soluble tars values were obtained following EPA429 method and correspond with international standard test measurements. For gaseous fluorides, emission values were measured at levels between 0.05 - 0.25 mg/Nm3, whilst for the particulate fluorides the emission values were measured in a range of 0.1 - 0.5 mg/Nm3. The total dust at stack was always in a range below 1 mg/Nm3, while the emissions of condensed soluble tar showed a figure of < 0.008 mg/Nm3. The results presented above show impressively that the upgraded FTC technology even in the given boundary conditions can achieve or far surpass emission values stipulated by international regulations. The project was executed on time and in budget, which finally assured the technological and economical benefits for the carbon plant of the smelter. www.innovatherm.com

Author: Detlef Maiwald and Domenico Di Lisa, innovatherm, Germany

Precimeter‌Worldwide Sweden‌-‌Germany‌-‌USA‌-‌China

‌ •‌Automated‌solutions‌for‌molten‌metal‌casting‌processes

•‌Wide‌range‌of‌products‌within‌molten‌metal‌level‌control

•‌Products‌specially‌designed‌for‌the‌foundry‌industry

•‌Expertise‌to‌assist‌with‌system‌design‌&‌commissioning

sales@precimeter.com

www.precimeter.com Aluminium Times April/May 2016


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Feel the beat at ET in Chicago

ET’16 – The 11th International Aluminum Extrusion Technology Seminar & Exposition – takes place in downtown Chicago, USA from 2 - 6 May 2016. According to the www.et16.org Registration webpage, Individual Early Registration by 8th April 2016 costs US$ 950, rising to US$ 1,150 thereafter. Workshops and Short Courses are US$ 400 each regardless, though numbers may be limited and eligibility criteria applied. Please check details carefully. Overall the ET’16 event includes: • 125+ Technical Seminars representing new and updated research from the brightest minds in the industry

• General Sessions featuring topics and speakers of broad appeal • ET Expo featuring 116+ exhibits from worldwide extrusion industry suppliers • nETworking opportunities to help broaden your industry connections • ET Showcase highlighting the best innovations featuring extruded aluminium • In-conjunction Workshops providing comprehensive education at ET. www.et16.org

Turla Srl Booth 706P – The new 25MN line for NALCO, New Zealand, presents some very innovative features: the latest ECO+LOGIC 2.0 patented solution on the press, the log heater STeP5 and ADAM management system. The ECO+LOGIC 2.0 is a revolutionary hydraulic design that increases the press performances and optimises the electric consumption, showing significant

Castool Tooling Systems

Butech Bliss

recovery, the role of the tooling system is key in achieving these fundamental objectives toward extrusion excellence. Today’s dummy blocks, containers, die ovens, lubrication systems and other related tooling and controls are complex in comparison to earlier examples where their sole function was little more than to push a billet or heat a die. Castool will display its current tooling systems and present 2 papers: Today’s Understanding of the Function and Benef its of Dummy Block Design, and The Design and Benefits of a Thermally Stable Container. It will The heating elements and thermocouple configurations along have many of its sales with best design and operating practices can achieve thermal personnel from around stabilisation. This contributes to both mechanical and thermal container performance, leading to extended container life and the world, technicians and reduced process scrap. designers, and management Booth 311 – As extruders continue onsite to share experience s to optimise productivity by maximising with show delegates and attendees. both equipment uptime and product www.castool.com

Booth 413 – Butech Bliss is a leading innovator providing equipment solutions for coil processing, cold reduction and mill application equipment for over 125 years. Metal producers, service centres and toll processors around the world have relied on the firm to create solutions for their production needs. Butech Bliss builds cutto-length lines, shears, hydraulic levellers, extrusion equipment and scrap choppers. The company’s services include engineering services, manufacturing, field service and shop rebuild services on all types of metal processing equipment. One of the most important a d v a n t a ge s w h e n c h o o s i n g Butech Bliss may be that it provides custom-built equipment to fit your circumstances, not standard designs that may not be the best solution for your particular application. www.butechbliss.com

The Turla 25MN Diana extrusion line.

energy saving (more than 65%), noiseless operation (79 dBA), and a flat front platen (safer working site, less maintenance, higher cooling performances). The STeP5 is the lowest consumption log heater worldwide. www.turla.it

Kelly Control Systems

Booth 202P – At the heart of the Kelly System is a state of the art automation controller exquisitely engineered for simplicity, robustness and performance. The Kelly System can improve and optimise the performance of an extrusion press, significantly improving productivity, quality and reducing downtime. This is achieved by applying proven designs and a wealth of experience to electrical and hydraulic press controls. www.kellysystems.co.uk

Intuitively simple operator controls.

Abtex Corporation Booth 1200 – With the increasing worldwide demand for lighter weight parts in industries like automotive, aeronautics, and medical equipment, light metal manufacturers seek new ways of increasing both productivity and quality. Fortunately, new manufacturing methods are now available for simultaneously

streamlining production and helping manufacturers achieve previously unimagined levels of quality. One of those technologies, the end deburring of aluminium extruded parts, has rapidly advanced to meet and in many cases exceed the demand of the world’s most quality conscious manufacturers. Traditional end deburring, manually holding the end of the extruded part against some kind of sanding media, is rarely used today.

Since 1980, Abtex Corporation has been providing integrated brush/ machine deburring solutions to the North American manufacturing industry. The company supplies filament brushes and custom-designed deburring machines for a wide variety of machined-par t, aluminiumextrusion, fine-blanked, and powdermetal applications. Customers include manufacturers such as automotive tier 2 & tier 3 parts producers. www.abtex.com

Aluminium Times April/May 2016

End deburring of an aluminium extrusion using a nylon abrasive disc brush.


Bloom Engineering Booth 1104 – Bloom Engineering has developed a reputation for quality industrial burners and combustion systems. Its professional staff and years of experience have been the cornerstone of its business. Bloom’s products can be used for a variety of applications and can be operated with a wide array of fuels and capacity ranges. The industrial burners operate with Low to Ultra Low NOx emissions. Bloom Engineering prides itself on having in-depth knowledge of the various heating applications in which its equipment is used. Bloom’s customisable product line, extensive installation list, R&D capability, and on-site field service

1150 Series Ultra Low NOx Lumiflame regenerative burner for aluminium melters.

experience, allows Bloom the ability to provide the best possible solution for each unique situation. Specifically, its 1150 series regenerative burners provide excellent fuel efficiency and production increases in aluminium melting furnaces. www.bloomeng.com

Granco Clark, Inc.

Booth 403 – GRANCO CLARK produces all required equipment to heat, cool, pull, stretch, cut, stack, age, and store aluminium extrusions. Its automated equipment is designed, fully assembled and shop tested to the specific requirements of your extrusion process to deliver exceptional efficiency, productivity and longevity. It is true that GRANCO CLARK has had great success in the North American region, and in other countries as well, in the aluminium extrusion industry, by supplying customers with some of the most advanced, reliable, cutting edge equipment on the market. GRANCO CLARK is a full service manufacturing plant providing to its customers the best possible solution with the right equipment, from initial contact to engineering, to manufacturing, to ser vice and spare parts, continuing the fruitful relations after the sale. Its

Cisart Group Booth 208P – Established in 1973, Cisart has since been supplying customised anodising and powder coating plants to discerning customers around the globe. During these years it has consolidated its reputation as environment friendly quality suppliers dedicated almost exclusively to the aluminium industry. Energy conservation and efficient water management are amongst its top priorities, together with the wellbeing of those who operate its plants. Products range from conventional manual horizontal lines to high productivity vertical ones, both for anodising and powder coating. To those customers who operate mainly in the anodising market for automotive or architectural finishes, Cisart also proposes tanks and equipment for Hard Anodising,

Fully automated anodising plant detail.

Chemical and Electrochemical Brightening, Conventional and Electrochemical Colouring of all types. They also supply Flash Anodising as an alternative to conventional pre-treatment. Final product quality consistency is guaranteed by a sophisticated automation system which controls all main process variables within strict operating limits and assures that productivity targets are met at all times. Cisart is very careful in using the available floor space wisely and ha s developed some unique solutions for its most convenient and efficient utilisation. www.cisartgroup.com

SMS group Granco Clark hot-jet furnace and hot saw shown here in its final testing.

Granco Clark pull-through high-pressure spray quench.

customers, and repeat customers, see firsthand how it works closely with them to have peace of mind that the equipment they purchase is the right solution and will deliver the results they expect for years to come. Visit Granco Clark on booth 403 at ET’16 in Chicago. www.grancoclark.com

Booth 305 – SMS group has with the allnew HybrEx® press a striking technology carrier in the pole position which may change extrusion press technology in future. With radical SMS group HybrEx with integrated housing (2015 German Design Award). new approaches, SMS is setting combined with the novel HMIremarkable benchmarks. While system with joystick controls, are developments in earlier years were highlights of the press. An eyefocussing mainly on optimisation of catching integrated housing, which the extrusion technology, recent includes also a safety concept, brings development steps are targeting contemporary industrial design an increase in energy efficiency and into the press shop. The brandproduction capacity. The minimised new PICOS-TO-GO application, energy consumption and increased which allows for online-monitoring productivity are obvious benefits of the extrusion press by mobile for operating customers. A hybrid devices, comes along with a smart drive concept with highly dynamic platform-independent browserservo drives for fast movements based application. and a unique hydraulic design, www.sms-group.com


KAUTEC SOLUTIONS

ATEMA srl

Booth 1132P – Specialised in the design, manufacture and installation of equipment for aluminium extrusion, KAUTEC SOLUTIONS offers to its customers: all types of equipment for extrusion processes and turnkey projects, ranging from presses of 900 up to 3600 MT force (billet of 5” up to 10” diameter); optimisation and improvements on existing machines (mechanical, electrical, hydraulic); technical assistance; maintenance programs; supply of spare parts; and consultancy services. KAUTEC is currently working simultaneously on several projects in Mexico, India and Serbia. Specifically, KAUTEC is in the process of implementing those projects consisting of the manufacturing, assembly and commissioning of 3 complete

The extrusion die is the heart of every extrusion process. It should be perfectly designed, manufactured and heated prior to extrusion, but it inevitably needs a minor or a major correction. Die correction is a scrupulous and precise process that affects the extrusion result, which in its turn has an overall impact on the company’s activity. Along with the experience of die shop specialists, the tools used for dies correction are of great importance. That is the reason why ATEMA srl, an Italian leading supplier of tools for dies correction, has developed a complete set of tools for the extrusion dies correction field. Co-operation with Italian extrusion companies and dies manufacturers for more than 30 years has allowed ATEMA to make the right choice and offer the market high quality tools and instruments. All products are carefully selected and tested to guarantee long life and high performance. ATEMA supplies all the range of tools for

General view of Kautec workshop.

extrusion plants of 2300 MT force, revamping of an extrusion line and manufacturing of latest technology handling equipment to work hard alloys. To get closer to its clients, KAUTEC is delighted to participate as an exhibitor in ET’16 (booth 1132P) in Chicago from 2-6 May. Visit the booth to take the opportunity to be shown the new products and improvements it is nowadays implementing. www.kautec.net

Bosch Rexroth Corp. Booth 1402 – Bosch Rexroth Corporation offers the world’s broadest range of hydraulics and complete control systems for both new systems and retrofits of aluminium extrusion presses. Visitors to Rexroth booth 1402 can learn how to: • Increase press availability and reduce dead time • Reduce energy consumption and corresponding costs • A chieve greater endpoint accuracy and precision using the latest electrohydraulic control systems. Featured technology will include Rexroth’s A4VSO500 pump - a rugged, low-noise variable pump built to withstand the rigors of industrial 24/7 applications, as well as applications requiring very large volumes. Rexroth will also demonstrate how technologies such as manifolds and proportional valves can streamline system design while improving performance.

Abrasive tools supplied by ATEMA s.r.l. for dies correction departments.

extrusion dies correction, starting from abrasive tools, electric and pneumatic tools, me a suring instruments and milling tools. Among the basic tools every die corrector uses are carbide burrs, diamond files, calipers, edge squares, precision control pins, air grinders, end mills and much more. The catalogue dedicated to dies correction tools is available online. ATEMA is happy to share its vast experience with extruders and die manufacturers. www.atematools.com

Material handling systems

Rexroth’s rugged, dependable, highly accurate, low-noise A4VSO500 variable pump.

For new systems or retrofits, Rexroth’s experts will be available to help customers and press builders optimise performance in their extrusion presses. From pumps, valves and manifolds to press piping and electronic pump and press controllers. www.boschrexroth-us.com

Booth 702P, Advanced Dynamics (ADCL) – With over 50 years of innovation accrued, ADCL delights its global customer base with state of the art material handling systems for carbon plants and cast houses. Its handling technology includes fully automated or semi-automated equipment for anode handling and cleaning, aluminium ingot and T-Bar handling, billet sawing and packaging systems. A DC L i s a one - s top shop fo r yo u r m a t e r i a l h a n d l i n g needs including mechanical and controls engineering, fabrication, assembly, test and commissioning.

Aluminium Times April/May 2016

ADCL fully automated 100% volumetric billet inspection station with test billet stands.

Whether you need a new system or upgrades to existing systems or simply individual pieces of equipment, ADCL can help improve your company’s productivity. Remember to think of ADCL for your next project. www.advanceddynamics.com


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Banyard-Advert-LFI-138x210-trim_Layout 1 12/10/2015 10:21 Page 3

Zero Friction Aluminium Billet Heater Developed specifically for manufacturers of Aluminium micro-tubing and precision extrusions, Banyard’s ZF Series billet heater offers zero friction servo-handling in order to eliminate billet surface damage. l

Eliminates Billet Surface Damage

l

Dynamic and Static Temperature Profiling

l

Zero Carbon Emissions

Banyard….for increased productivity and a higher quality product.

Tel: +44 (0) 1256 335533

www.inductothermhw.com

Email: info@inductothermhw.co.uk

www.castool.com Follow our blog at www.castool.com/blog CANADA

+1-905-852-0121

THAILAND

Castool makes extrusion better

4 individually controlled heating zones EACH with A double acting thermocouple located equidistant between the heating elements and liner

built-in thermal gradient allows heat to dissipate from the liner without using auxiliary cooling or air

+66-38-345188 Visit us at BOOTH # 311 MAY 2 - 6, 2016 Chicago, IL

DUMMY BLOCK maintains a minimal uniform skin of aluminum on the liner ID

PRECISE HEAT CONTROL PREVENTS UNEVEN RUNOUT LENGTHS

REPLACEABLE WEAR RING REDUCES OPERATING COST

NOTE: CASTOOL CONTAINERS AND DUMMY BLOCKS REDUCE SCRAP, extend tooling life AND IMPROVE EXTRUSION QUALITY

In Europe, Middle East and Africa contact: COMEXALE TEL +33-3-83-354649 FAX +33-3-83-355092 WWW.comexale.com P E O P L E

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P L A N E T

CTS.ATimes half pg ad185x128mm.indd 1

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P R O F I T 2016-03-09 10:42 AM

Aluminium Times April/May 2016


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Emirates Global Aluminium

Booth 507 – EGA is owned in equal shares by Mubadala Development Company of Abu Dhabi and Investment Corporation of Dubai. EGA’s core operating entities are Dubai Aluminium (DUBAL or EGA Jebel Ali) and Emirates Aluminium (EMAL or EGA Al Taweelah), whose combined annual production of 2.4 Mtpy ranks EGA among the world’s five largest primary aluminium producers. EGA manufactures high quality primary aluminium products in three main forms - high purity and foundry re-melt products, rolled products, and billets for extrusion and forging. Producing around 1 Mtpy in 2015, EGA is the world’s leading producer of extrusion billets manufactured using Airslip technolog y. All EGA billets are homogenised and

EGA was recognised as the top primary aluminium billet producer in 2014 worldwide.

100% ultrasound-inspected before delivery. Inherently superior in quality and intrinsic purity, a large proportion of annual production is cast in high extrudability 6063 alloy. EGA also produces other specif ications such a s 6061, 60 81, 10 0 0 and 30 0 0 series extrusion billets. EGA billets are rated by the US Green Building Council’s Leadership in Energy and Environmental Design (LEED) rating system and the Deutsche Gesselschaft für Nachhaltiges Bauen (the German Sustainable Building Council) as suitable for sustainable building practices. www.ega.ae

ALTEK, LLC Booth 711 – ALTEK is a technologybased company with specialist expertise in the design, manufacture and installation of aluminium dross and scrap processing systems. ALTEK was formed in the 1980s, inventing the dross press in the early 1990s. Acquiring the TARDIS Dross Press business in 2009, ALTEK combined the two technologies to create the most advanced dross press systems available in the world, the TARDIS Gen II technology. Over 100 presses have been sold since then, adding to the 450+ global press references. In 2009/2010 ALTEK launched their Low Energy,

Air-Cooled Electromagnetic Stirrer which quickly became the benchmark for non-contact furnace stirring technology in the Aluminium Industry, and are the preferred supplier to many high profile companies. Within the US there has been a rapid take up of this technology with many excellent references. A wide array of casting consumables is also available. ALTEK strives to provide its customers with the best technology and knowledge, to meet their needs through a deep understanding of their production processes, operation, equipment and operational cost and profitability requirements. Visit them at Booth 711. www.altek-al.com

The ALTEK product range includes dross & salt slag presses, EMS, TTRF and cast steel castings.

Combilift USA

Mechatherm International Limited Booth 907– UK-based manuafacturer Mechatherm has celebrated its 43rd year since being founded in 1973. Mechatherm concentrates on supplying casthouse furnaces, casting equipment and heat treatment furnaces for the aluminium industry. Mechatherm has supplied many furnaces for melting and holding aluminium for primary smelter casthouses, but at present is supplying more and more furnaces for remelting and recycling clean and contaminated aluminium. Mechatherm can supply complete process lines for remelting and recycling aluminium including charging machines, melting furnaces, transfer launders, tilting holding furnaces, casting launders and vertical direct chill casting machines. The lines also

Mechatherm 80T Melting furnace with 20T rotating charging machine for remelting clean scrap at 22T per hour.

incorporate all necessary ancillary equipment such as degassing and filtering units. T h e M e c h a t h e r m p ro d u c t range also includes an extensive portfolio of reheating and heat treatment furnaces such as slab reheating furnaces, sheet and plate annealing and ageing furnaces, billet homogenising furnaces, solution heat treat furnaces and coil and foil annealing furnaces. The business is looking forward to showcasing its products and services at ET 16 and Aluminium 2016 Conference in Düsseldorf, Germany this year. www.mechatherm.com

Booth 1120 – Combilift USA Ltd will be exhibiting a selection of models from its wide range of customised handling solutions on Booth 1120. Combilift offers 4-way forklifts, narrow aisle trucks and other innovative products for the space saving, safer and productive handling of long length products, containers, oversized loads and pallets. Models range from small pedestrian reach stackers with load capacities of 3,100 lbs up to the Combi-SC Straddle Carrier which can easily lift and transport extreme loads weighing in at as much as 180,000 lbs. Combilift’s 4-way machines work as counterbalance, sideloader, and narrow-aisle forklifts, and their excellent manoeuvrability and versatility means that they can be

Combilift 4-way forklifts are firm favourites in the sector for handling long and awkward loads.

deployed from the initial stages of offloading raw materials, during the manufacturing process, through to the storage and dispatch of finished product. Tailored to suit individual operational requirements, Combilift’s products work inside and out, on semi-rough terrain and in all weather conditions, and are available with LPG, diesel or electric power together with a wide range of options and attachments. www.combilift.com

AMCOL Corporation Booth 103P– AMCOL Corporation has become the recognised global leader in process lubrication systems for aluminium extrusion and fabrication. AMCOL combines high performance lubricants with tailored dispensing systems that cover the

full range from casting to fabrication. Applications include: billet saws, hot log saws, billet ends, dummy blocks, butt discard shear blades, travelling hot saws, finish saws, precision saws, and CNC machining centres. AMCOL has a long list of

products known throughout the industry with tradenames that include CANMIST, DYLUBE, EJECTEZE, and CHARCOOL. The AMCOL slogan says it all: “Proven technology, refined over decades”. www.amcolcorp.com

Aluminium Times April/May 2016

AMCOL combines high performance lubricants with tailored dispensing systems that cover the full range from casting to fabrication.


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TAILOR-MADE INNOVATIONS FOR ALUMINIUM ROLLING MILLS

OTTO JUNKER GMBH Jaegerhausstr. 22 52152 Simmerath Germany

WE

Phone: +49 2473 601-0 | Fax: +49 2473 601-600 E-Mail: info@otto-junker.de

WWW.OTTO-JUNKER.DE

UNDERSTAND METALS

Lubrication Systems for Extrusion, Sawing and Fabrication

Consultancy and technical support to the aluminium industry • Build long-term partnerships with our aluminium experts • Solve your current aluminium production problems • Prepare a downstream business case • Detailed investigation and testing • Product and process training courses • Aluminium industry expertise

AMCOL CORPORATION Hazel Park, MI, USA www.amcolcorp.com 248.414.5700

Tel: +44 (0) 1295 702800

Email: enquiries@innovaltec.com

www.innovaltec.com

Aluminium Times April/May 2016


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Induction preheating expertise For almost 50 years Banyard has been and continues to be the first name for Induction Non Ferrous (and Ferrous) Billet Heaters for pre-heating prior to extrusion, and has maintained its brand presence with numerous references globally. Through the integration into the Inductotherm Group, and specifically Inductotherm Heating & Welding Ltd division in Basingstoke, UK, Banyard has become a global brand and continues to strengthen its engineering and design capabilities. High reliability induction power supplies are a key element in all induction heating and welding applications. Inductotherm Heating & Welding designs and manufactures one of the world’s most extensive ranges of induction power supplies from the UK. These solid state digital power supplies (inverters) are designed to provide precise energy control and eliminate the need for high maintenance switchgear items. In addition to this the global Inductotherm Group has a wide range of medium and high frequency inverters to address a comprehensive range of applications. Working in close partnership with its Inductotherm Group global colleagues provides the opportunity for the customer to have access to local language, personnel and ongoing support. This is a key decision proposition and a major factor of the Inductotherm Group continued successes with Banyard products. In addition, Banyard provides a comprehensive training package, theory and practical classroom training as part of the transfer of ownership early to the customer’s production staff, wherein attention to ease of maintenance and simple operation makes for a straightforward commissioning and faster production start-up. For the heating of large diameter billets, the Banyard latest generation of IGBT low frequency inverters provides greater operating efficiency and significantly faster heating rates. As an example, the LFi 750 IGBT unit is rated to produce a maximum total output power of 750 kW split across up to four independently controlled inverters, each able to output up to 250 kW. This gives the required heating flexibility for a range of billet lengths and the ability to achieve a variable linear temperature taper (gradient) for high quality extruded aluminium product and reduced press die wear.

Billet heating specialism

The accuracy and controllability of induction heating makes it the ideal choice for billet heating applications. Today’s manufacturers demand billets of the highest quality at the press. This can only be achieved by precise control of the manufacturing process. The high repeatability associated with Banyard induction heating equipment satisfies latest industry SPC standards. Reduced grain growth and precipitation of Mg2Si in aluminium alloys improves product quality and anodising finish. Overseen by Inductotherm Heating & Welding today, Banyard designs and

Zero-friction servo handling.

Multi-zone booster heating

manufactures its induction heating equipment for low frequency heating of non-ferrous billets such as aluminium, brass, copper, titanium and exotic alloys. Banyard systems utilise a number of process techniques including billet taper heating, multi-zone booster heating, zero friction servo-handling and aluminium log heating prior to hot shearing. Powered by a Banyard LFi series low frequency IGBT inverter, the Banyard compact multi-zone booster heater can be retrofitted to existing extrusion lines heated by gas. The combination of increased temperature accuracy, with linear temperature taper capability and repeatability results in both increased output and a higher quality product. www.inductothermhw.com

Aluminium Times April/May 2016

Billet taper heating.


26 | EXTRUSION

www. mmc p ub l i c a ti o n s . co . u k

Fundamentals of gas nitriding In the business of aluminium extrusion, the extrusion die is arguably the key production tool. If the die does not perform to its optimum, then the efficiency and profitability of the extrusion plant is reduced. Thermserve has been able to make enhancements to the control philosophy and software to provide end users with fully automatically regulated systems. Efficiency and profitability are established by continuous extrusion of sections which are to size specification with acceptable surface finish and fulfil order commitments in the minimum of time. If the die shows premature wear or surface damage then this flow is interrupted, resulting in lower plant efficiency. Die reliability is essential. There are a number of factors affecting die performance, some concerned with the quality of the die itself and some concerned with die management and extrusion practices. Die quality - major factors: • Die design • Steel selection - analysis (H13, H11) • Steel cleanliness • Die bulk heat treatment • Die surface hardening. Extrusion practices - the two major factors are extrusion temperature and extrusion speed. Die management - this includes cleaning, correction and die pre-heating. In particular, die pre-heating is an extremely important factor regarding conservation of the quality of the nitride case. Ideally, it should be in a specially controlled atmosphere die oven for a maximum of 8 hours. Thermserve designs and manufactures die ovens. There are many published papers and points of view on all these important factors, and as a supplier to this industry, it is important to have a reasonable understanding of the issues involved in the extruding of aluminium, especially where they impact on the performance of the product supplied. All of the production factors listed above can have dramatic effects upon die performance and many can reduce the effectiveness of any surface hardening treatment.

The nitriding option

There are a number of die surface hardening techniques and though many have been tried and discarded, some are still being used. These include hard chromium plating, ion implantation, TiN and other exotic ceramic combination coatings. However, possibly due to its apparent simplicity, cost effectiveness and robust nature, the gas nitriding process has established itself as one of the most cost effective solutions to increasing die life and performance. It is used extensively as an inhouse process and there are now a number of suppliers of such equipment. The understanding of the physics and thermodynamics of the nitriding process has increased tremendously since its original discovery, probably when steel blades were quenched in urine. The blade edge was found

1 Thermserve gas nitrider installed in the USA.

to have that something special compared to normal water quenching (possibly the aroma!) due to the effect of dissolved ammonia. Nitriding is initiated when gaseous ammonia is cracked or “dissociated” using a steel surface as the catalyst at about 480°C. Active nitrogen produced during this reaction moves into the surface of the steel and combines with chromium and other alloy constituents to form their respective nitrides. These nitrides are extremely hard (1,200 Hv to 1,500 Hv) and increase the average hardness of the surface layers of the steel. As a general rule, the processes will double the hardness of the original steel. It is important to understand the basic process before selecting a furnace which will be a production tool and hopefully a friend for up to 20 years. Plasma nitriding should also be mentioned. It has been around since the beginning of the twentieth century but only lately (last 30 years) with improvements in electronics has it become a feasible commercial process. Aluminium Times April/May 2016

The process uses only small amounts of nitrogen and hydrogen gas in an approximate ratio of 1:3 and is environmentally friendly. It has had limited success in the aluminium extrusion business as it is a very geometrically sensitive process and can be difficult to control when used on complex-shaped extrusion dies. It is also best suited to a very clean working environment. However, some companies are producing very good results.

Simple chemistry 2NH3 → N+ + N+ + 3H2 N+ enters steel surface As shown above, the actual chemistry is quite simple and early furnaces were no more than basic stainless steel sealed tubs in which the work was placed and then heated in a suitable brick lined furnace. Ammonia flow was not greatly controlled and temperature approximated at about 500°C. The process was not popular due to


EXTRUSION | 27

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2 Extrusion dies laded into gas nitrider.

the long process times, the quality and reliability of the hard case produced, and the smell (ammonia this time not urine). The low or zero distortion characteristics of the process made it ideal for certain applications. In gas nitriding, the donor is a nitrogen rich gas, usually ammonia (NH3), which is why it is

sometimes known as ammonia or gas nitriding. When ammonia comes into contact with the heated work piece, it dissociates into nitrogen and hydrogen. The nitrogen then diffuses from the surface into the surface of the material and produces hard nitrides with alloy constituents such as chromium and

aluminium This process has existed for nearly a century, though only in the last few decades has there been a concentrated effort to investigate the thermodynamics and kinetics involved. Recent developments have led to a process that can be accurately tailored and controlled. Automatic gas analysis and control by Thermserve may be carried out using infrared ammonia analysis or H2 analysis, via a special probe mounted inside the furnace. The thickness and phase constitution of the resulting nitriding layers can be selected and the process optimised for the particular properties required. The advantages of gas nitriding over the other surface treatments are: • Uniform nitriding on all surfaces (except those protected by special paints if required) • Large batch sizes possible - the limiting factor only being furnace size • With modern computer control of the nitriding atmosphere, the nitriding results can be closely controlled to give desired case properties. • Relatively low equipment cost - especially compared with other alternatives such as plasma or automated salt/fluid bed. To conclude, well controlled gas nitriding furnaces are produced by Thermserve and contain the necessary analysers and software to produce repeatable and consistent results. www.thermserve.com

We stand for Extrusion Technology Log and Billet Storage and Transport Equipment Log Preheating Magazine (Horizontal-/ Vertical Design) Log and Billet Cleaning Devices Gas fired Billet Heaters Gas-/Induction Heater Combination (Inline Solution) Hot Log Shears Hot Log Saws Die Heaters Ageing Ovens Profile Cooling Systems (Air/Water)

extrutec GmbH Fritz-Reichle-Ring 2

D-78315 Radolfzell Tel.: +49 (7732) 9391390 Fax.:+49 (7732) 9391399

E-Mail: info@extrutec-gmbh.de Web: www.extrutec-gmbh.de

Aluminium Times April/May 2016


28 | PLANT SCHEDULING

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Advanced planning and scheduling For aluminium producers in today’s competitive market, Advanced Planning and Scheduling (APS) tools are a necessity, not a luxury. The result of decades of experience in the metals industry, packaged into a single, easyto-use application, Visual8 V8-APS brings aluminium plant scheduling into focus. With depressed prices on finished goods, now is the time to focus on reducing production costs. Visual8 can help by streamlining workflow across your plant operations, creating optimised schedules in minutes. Work in progress, finished goods, and scrap levels are typical areas where significant cost savings can be achieved. These savings, combined with reductions in production lead times and labour costs, can lead to upwards of 10 to 15% increase in profit margin. Visual8 has combined computer simulation algorithms and optimisation models to bring decades of aluminium experience right to the fingertips of production planners and schedulers with V8-APS, a comprehensive planning and scheduling system fully configured to your exact specifications. Founded in 1995 in Ontario, Canada, Visual8 was borne from the idea that detailed process modelling, combined with dynamic visual displays, could provide powerful insight into the many operational and process design challenges faced by companies in the manufacturing and metals industry, and ultimately allow firms to make better, more informed decisions for their business.

Managing in aluminium

Traditional aluminium planning and scheduling tools, such as spreadsheets or high-level capacity-based models, can often be difficult to set up or change and are frequently ineffectual when managing complex production systems. Visual8’s flagship V8-APS framework fuses advanced, highly-detailed production process models, complete with all operational guidelines, rules and constraints, with the latest optimisation techniques, to give producers and fabricators an intelligent, quick and adaptable APS solution tailor-made to meet their business objectives. V8-APS for Aluminum incorporates a suite of modules including everything from capacity planning to slit pattern optimisation, delivering a system which is highly customisable to meet specific plant and process requirements and able to integrate with both legacy and commercial ERP and MES systems. V8-APS makes use of a detailed production model containing all of the plant’s manufacturing rules and constraints that reflect actual operating capacity. This finitecapacity model is used by the production planning and scheduling modules to create accurate and achievable results. The system also uniquely employs dynamic planning points to segment the production process to create a lean manufacturing environment. From re-melt to slitting, across the entire supply chain, V8APS plans production to ensure downstream

demand is met with all the benefits of lean manufacturing including low WIP, flexible supply, and balanced workloads.

Dynamic order allocation

Further, V8-APS fully decouples customer orders from manufacturing orders, giving it the flexibility to maximise production yields and maintain high delivery service levels. The system also maximises coil recovery using an industry-leading 2D slit pattern optimisation routine that combines slit orders onto master coils considering both width and length. Users retain the ability to review order marriages and manually adjust or create new marriages in an easy-to-use graphical interface. Working in conjunction with the detailed production model and process planning points, V8-APS employs intelligent and highly flexible scheduling routines. This permits the system to take into account operating nuances such as: • Warm up coils and special roll requirements on rolling mills • Detailed annealing batching rules and exceptions • Maximising coater throughput by minimising colour changeovers • Breaking coils at any stage of the production process to maximise efficiency. Advanced backward planning generates reroll and materials requirements based on BOMs, current inventories, in-transit supplies, and production requirements. The integrated and modular design of the V8-APS uses vendor-certified interfaces to communicate with all modern commercial ERP systems including SAP and Oracle, as well as shop-floor software for the purposes of both downloading data on a periodic/ polling basis and uploading data on demand. Visual8 consultants also have broad experience interfacing with legacy ERP systems such as JD Edwards and BAAN. The system is based on a modular design principle - a suite of APS modules offers customers the ability to select those that best fit their specific business needs and/or plant data environment. These individual modules are highly configurable and all link to a common database, providing a focused, consistent and scalable planning and scheduling environment. Visual8 is fast developing a reputation for offering exceptional value on the systems they implement without compromising functionality or capability. Every Visual8 system includes a standard warranty period following installation which covers all repairs and incident support. Ongoing software and system maintenance is offered with free upgrades, direct hotline support, full technical coverage and personal end-user assistance. Support requests are handled quickly and efficiently by a team of specialists familiar with the clients’ particular installation, providing outstanding after sales service. Aluminium Times April/May 2016

Diagram of V8-APS high-level system architecture.

Modern and easy-to-use user-interface, with highly visual displays.

Aluminium expertise

In addition to its V8-APS system, Visual8 also offers custom solutions to solve specific operational and supply problems distinct to aluminium processing. With over 20 years of experience across smelting, rolling, extrusion and fabrication, Visual8 has helped customers redesign plants, justify capital expenditures, optimise supply chains, develop long-term capacity plans, and implement lean initiatives, for example: Novelis - Crane & ASRS Study Through a detailed plant simulation model, Visual8 helped to right size materials handling requirements including cranes, forklifts, and a new automated storage and retrieval system to support a major Novelis plant expansion, resulting in millions of dollars in savings. Novelis - Order Allocation System Visual8 implemented a system for CSR’s to optimally allocate customer orders across a group of Novelis light gauge finishing plants. The tool determines the best set of coils to run at each plant to satisfy all orders while considering a number of criteria including capacity, metal recovery, available reroll, and freight costs. Aleris - Plant Capacity Analysis Anticipating an increase in production demand at a key plant, Visual8 developed a capacity simulation for Aleris to analyse and determine melting/casting equipment and storage limitations in order to maximise plant throughput with the new product mix. www.visual8.com


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Aluminium Times April/May 2016


30 | FURNACES

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Something is stirring Since their launch in 2009/2010, ALTEK’s Low Energy, Air-Cooled Electromagnetic Stirrers have become the benchmark for non-contact furnace stirring technology in the aluminium industry(1). The unique inductor design acts as an optimised electromagnet, creating unrivalled stirring efficiency and electromagnetic flow patterns in the molten aluminium at all bath levels. Consequently ALTEK’s EMS can be installed on the bottom, side or back of almost any type of furnace size or shape, and is capable of stirring molten aluminium through all refractory types and thicknesses (currently up to 750 mm). Through its unique features, it is ideal for effective stirring of furnaces when fitted to the side of furnaces, and has many operating references (and possibly the largest side-stirring reference list in the world) for side mounted stirrers applied to low, medium and deep furnace baths. ALTEK designs movement and lifting systems which allow one inductor to travel between t wo furnaces underneath in a b a se m e nt a nd tunn e l se t up. Several of these systems have been successfully installed around the world with each project containing unique features to suit each customer’s cast house layout. ALTEK can also design the control systems to include a ‘switching mechanism’ which allows one control panel to supply two different inductors. This is perfect for customers wanting multi-furnace operation where movement systems are not applicable.

Continuous circulation

It is well known that radiated heat from the burner and hot refractory to exposed scrap is the most efficient

Bottom mounted EMS on trolley and lifting system.

mode of heat transfer. Once the aluminium starts to melt and scrap becomes submerged, this effective heat transfer is replaced with conduction and convection, which is far less efficient. This creates large temperature differences between the top and bottom of the molten aluminium bath, and without continuous circulation melting performance is significantly limited. By its design, ALTEK’s EMS breaks this limitation by circulating the molten bath on horizontal and vertical planes at the same time, improving convection effect, increasing melt rates, and therefore productivity of a furnace. The EMS creates unique flow patterns within the melt whic h signif ic a ntl y improve

alloying operations. Chemical homogenisation can be reached very quickly even with alloys which are difficult to get into solution such as silicon and manganese. Unlike manual stirring, the EMS can be slowly moving the metal during the alloying procedure itself before increasing to the optimal stirring power which is configured during installation.

Dross reduction

The ALTEK EMS has also been proven to significantly reduce the amount of dross produced during the furnace cycle. Using the same principle for improved heat transfer and melt rates from electromagnetic circulation, a company does not have to superheat the surface of

the molten bath in an attempt to melt the submerged scrap through heat convection. The surface is less prone to oxidisation, thus reducing dross generation. The ALTEK EMS is also finely tuned to have a stirring action which is powerful enough to achieve excellent circulation in all areas of the furnace without breaking the oxide skin layer formed at the surface. Other benefits associated with ALTEK’s EMS are significantly reduced gas consumption, excellent accuracy and control in bath temperature during the furnace cycle and when transferring metal, and unrivalled equipment reliability. www.altek-al.com 1

Co-operation with the MHD technology centre in

Krasnoyarsk, Russia.

Fives Solios in the casthouse

More than 50 furnaces have been delivered by Fives Solios over the last 10 years at Alba, Sohar Aluminium, Alcoa Fjardaal, Nordural, Qatalum, Hulamin, Novelis, Ma’aden Aluminium, Emal, and Kitimat, where the

metal capacity up to 169 t. The furnaces are designed in-house using 3D CAD software, with critical elements being verified by finite element analysis. For recent projects, a major focus in the execution was to assemble the furnace structures in workshop conditions with the Fives Solios has delivered more than 50 furnaces over the last 10 years. maximum amount of tilting furnaces are amongst the ancillary equipment pre-fitted, in largest capacity in the world, up to order to minimise subsequent site 135 t nominal capacity with molten installation time. Aluminium Times April/May 2016

Fives Solios has also developed Genios, the latest technology metal moving system, which gives the customer the ability to stir, transfer and cast all from one unit. In addition, Fives Solios proposes EPC solutions for secondary aluminium casthouses, as demonstrated by its latest contract for the new G A R MCO remelt facilit y in Bahrain. As an innovative partner, Fives is continuously developing solutions that combine technology with industrial and environmental performances. www.aluminium.fivesgroup.com


CASTHOUSE TECHNOLOGY

HEAT TREATMENT

RECYCLING

CONTROL & AUTOMATION

Faster melt rates

Improved metal recovery

Lower energy consumption

Advanced technology

Custom designed

Safe & user friendly

Combine your experience with our expertise. Mechatherm International Ltd - Hampshire House, High St, Kingswinford, DY6 8AW, UK t: + 44 (0)1384 279 132 / e: sales@mechatherm.com / www.mechatherm.com


32 | FURNACES

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Industrial furnace technology

New 75T two-chamber furnace: 8 T/hour at <520 kWh/T.

Since its beginning over 30 years ago, DE WINTER ENGINEERING has specialised in customised installations, both for new furnaces and for upgrade and renovation of existing furnaces. For example, a new 75T two-chamber melting furnace designed to have ultralow energy and maintenance costs was built at the end of 2014. This stationary furnace has a proven melting rate of 8 T/hour at <520 kWh/T. This year, DE

WINTER will build a tilting furnace that will be assembled as far as possible in its own workshop and then transported and lifted into its final location to minimise production standstill. Regarding upgrade of existing furnaces, DE WINTER specialises in door sealing and pressure regulation, a relatively small investment which tends to get underestimated. A sturdy pressure regulation system may reduce fuel consumption by 10-15% compared to the same furnace without. DE WINTER has in-house simulation experts to give you accurate ideas of what you may gain by revamping your furnace. Their website carries examples of projects. www.dewinterengineering.com

Improvement of fume extraction of a furnace for contaminated scrap.

Pin position actuators The Precimeter Pin Position Actuator is intended for controlling the level and flow of molten metal through a pin and spout level drop application in any stage of the aluminium casting process. With its compact and robust design this actuator is a perfect choice to operate in the harsh

conditions of a casthouse environment. Application example: When controlling metal flow in a DC slab casting machine the pin position actuators are used to adjust the metal flow rate through the pin and spout setup in the distribution launder/trough. Adjustment is very precise using a stepper motor

to control the pin movement. The PXP-2 is also available as PXP2EM with a fail-safe emergency closing system. It stops the metal flow in any case of power loss or other emergency condition. It is another important feature of the Precimeter actuator. www.precimeter.com

A Precimeter PXP-2EM Pin Position Actuator.

DKS- Drache Calcium Silicate DBN- Drache Boron Nitride Made by Drache.

Casthouse Technology - worldwide.

Tr a n s i t i o n P l a t e s H o t - To p R i n g s

Boron Nitride Coating for Aluminium DC Casting w w w. d r a c h e - g m b h . d e

mail@drache-gmbh.de

Aluminium Times April/May 2016


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Compact secondary aluminium plant

Precast furnace lining

Dross D 305 TRF, 6 t holding furnace and casting machine during installation.

The Dross Engineering Company is in the final stages of commissioning a novel ‘compact secondar y aluminium plant’ at a customer’s site near Paris, France. The plant has a production capacity of 500 tonnes per month and is composed of a 3m3 Tilting Rotary Furnace (TRF) melter, a 6 tonne holding/refining furnace

and an ingot-casting machine. With this particular design of TRF and holder, it is possible to dispense with the need for a filter baghouse as the combustion products from the TRF are ducted at temperature to the holding furnace. The design improves overall energy efficiency and the holding furnace acts as an afterburner chamber. The TRF melts the whole range of commercial secondary aluminium scrap including old rolled, cast, UBC, chips and swarf. The compact plant fits into a foundry 300 m2, has a high degree of automation and only requires 2 operators per shift. www.drossengineering.com

High-efficiency heat treatment schwar tz GmbH is a manufacturer of continuous and batch-type heat treatment systems capable of operating under air or protective atmosphere. Relying on advanced heating solutions, the equipment meets stringent environmental and energy saving Heat treatment system for billets and circular blanks of various sizes for s t a n d a r d s . H e a t installation upstream of a forging press. treatment systems on the basis of proven modules. from schwartz GmbH’s product Schwartz offers local support all por tfolio for the aluminium over the world and professional industry rely on the high convection commissioning and service staff. principle for transferring the heat Established in 1984, schwartz has to the product. Given their low its headquarters in Simmerath, space and energy demand, these Germany a and further three furnaces offer interesting benefits locations worldwide: A production in automotive manufacturing as well facility in Kunshan, China to enhance as in the electrical, construction, the level of service to customers in packaging and aircraft industries. the Asia-Pacific region, a sales office Individual solutions are realised in Beijing, China and a service point to match customer specifications, in Oswego, USA. and custom equipment is built www.schwartz-wba.com

A modern melting furnace comprises many things, including interfaces with peripheral equipment such as a charging machine and stirring equipment. The fundamental furnace design incorporates an energy-efficient combustion system and a PLC based control system with communication capabilities. The equipment configuration is critical to its mission success and nothing is more important than the refractory lining installed in the furnace. The GNA Alutech furnaces shown were lined with precast blocks from Wahl Refractory Solutions. MegaBRIX® is their brand name for any precast furnace lining for new construction or furnace rebuilds. Wahl precast block was chosen for

this project because of the superior refractory properties achieved while minimising installation and dry-out time. Refractory materials are custom formulated in their Ohio plant to ensure proper selection for the application. The use of precast shapes offers improved properties over cast-in-place refractories due to precise water additions, controlled mixing, casting and dryout processes. www.wahlref.com www.gna.ca

Conclusion of the tilting test for a series of GNA 40 t melting furnaces.

Full range up to turnkey

Heat treatment system for billets and circular blanks of various sizes for installation upstream of a forging press.

Gautschi Engineering GmbH has served the Aluminium Industry worldwide for many decades and is a well-known supplier of Cast House and Heat Treatment equipment. Gautschi offers its services for single equipment supplies up to turnkey installations of complete production lines. The wide range of equipment includes, but is not limited to: • Melting and holding furnaces • Horizontal and vertical DC casting systems for billets and rolling slabs

Aluminium Times April/May 2016

• Ingot casting and stacking systems • Pusher type furnaces for rolling slabs • Homogenising furnaces for billets and rolling slabs • Multi-chamber coil furnaces • Single coil annealing furnaces. www.gautschi.cc


34 | ROLLING

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Automotive sheet alloy review Prof. Geoff Scamans of Innoval Technology Limited, Banbury, UK, takes a detailed look at the recent development of commercial automotive sheet alloy classes by several manufacturers. The main alloy used for external panels in the EU is AA6016A, an excess silicon alloy originally introduced to the market by Alusuisse, who were the first company to develop this market in Europe. This alloy has been used for many years by most of the OEMs except for Jaguar, who use AA6111 a stronger version of the family of external panel alloys that was developed by Alcan in Kingston and has been the alloy of choice in North America for many years. AA6111 is basically the alloy AA6082 with a significant addition of copper. The addition of copper enables the alloy to strengthen in the short time available during the bake hardening process used after cars have been painted to cure the paint.

any rectification using mechanical grinding before vehicles are painted, particularly at leading edges that could be damaged by the impact of stones during driving.

well be that deliberate additions of vanadium are not now made to the alloy in its latest iteration. This makes good sense from a recycling point of view and this aspect would certainly appeal to JLR. A yet further complication has been the re-emergence of Alcoa as an automotive sheet alloy supplier in North America to respond to the major sheet supply demands from Ford for their F-150 truck programme. The Alcoa outer panel alloy of choice is AA6022 that was first put on the market in 1996 as an alloy that had the strength of AA6111 with the formability of AA6016A. However, AA6022 is a low copper alloy (<0.11 wt%) and a low iron alloy (<0.20 wt%), making it difficult to make from recycled stock.

Recyclability issue

Supply balance

Jaguar XE chassis.

Heat treatments

In addition to the strong bake hardening response it was also shown that the AA6111 alloy could be made much stronger by combinations of work hardening and precipitation hardening. Alcan developed and patented a range of short pre-aging heat treatments that both stabilised the alloy’s mechanical properties and improved the bake hardening response. AA6016A is a less strong but more formable alloy that has a lower bake hardening response than AA6111 and is used at relatively thicker gauges to get to the same level of dent resistance. The use of AA6111 enabled Jaguar and then Jaguar Land Rover to use thinner panels than most of the German OEMs. AA6016A is available from most of the major aluminium sheet suppliers Novelis, Aleris, Constellium, Hydro and AMAG and, as the alloy specification is very wide, a number of variants are available to provide specific properties like higher strength, formability or hemming quality. These variants appear under a range of trade names. The AA6111 was only available from Novelis, after they were formed from Alcan’s rolling businesses, although they have now moved JLR away from AA6111 to a lower copper containing alloy. Over the past few years Novelis has attempted to rationalise the supply of sheet for automotive panels in Europe to variants of AA6016A, and this has been the alloy supplied for the various Range Rover and Land Rover models that have used aluminium closure panels before Jaguar and Land Rover became part of Tata Steel. AA6016A and AA6111 can suffer from filiform corrosion if mechanical rectification is used before painting. There is some anecdotal evidence that this can occur earlier for AA6111 than for AA6016, which is of concern as it is more likely to occur on AA6111 during the warranty period. The solution to this problem has been to eliminate

Jaguar XF chassis and body.

To make the alloy situation more complicated, Alcan (again in Kingston) developed a compromise alloy AA6451 that combined the best aspects of both AA6111 and AA6016A. Novelis initially marketed this alloy for external panels as Ac600 but have now changed this to Advanz™ e600. The AA6451 is essentially a lower level of copper (<0.4 wt%) version of AA6111, which can have a copper level of 0.5 to 0.9 wt%. Recently Novelis has suggested that AA6451 (Ac600) is the favoured alloy to be made from recycled process scrap. However the situation is further complicated by a second Alusuisse alloy development that started life as a more balanced version of AA6016A (with a lower level of excess silicon and an addition of vanadium rather than titanium) that was carried over from the original development of this alloy as an extrusion rather than a sheet alloy. This alloy, which has been rebranded as Advanz™ e170 when it is used for panel applications, was initially tagged as AA6008. Then for several years it was tagged in Novelis presentations as AA6014. However more recently (as first noted in late 2013) Novelis have started to tag the alloy as AA6005C. The alloy can fit within all three of these alloy specifications which have considerable overlap, except that AA6005C does not allow for a deliberate addition of vanadium, and it may Aluminium Times April/May 2016

For inner panels and structural sheet applications the favoured alloys are AA5182 and AA5754 respectively. Novelis has recently started to supply JLR with RC5754, which has increased allowances for iron, copper and silicon so that the alloy can be made with up to 50% production scrap returned from pressing plants. The supply balance between AA5xxx and AA6xxx alloys is moving progressively towards the AA6xxx alloys as higher strengths are demanded by the OEMs and these properties are more readily realised using the AA6xxx alloys. The AA6xxx alloys represent at least 80% of the presently supplied volumes. Most of the major alloy suppliers are also developing AA7xxx sheet alloys for automotive use prompted by the higher strength demands of the OEMs. These developments are very likely to be unsuccessful due to the higher prices that the OEMs will be expected to pay for these alloys, which have typically been restricted to aerospace and defence applications. The AA7xxx alloys also have both corrosion and stress corrosion issues to overcome, particularly for alloys that are conventionally weldable. So it is expected that the AA6xxx alloys will be the incumbent alloys in automotive applications for many years to come. www.schwartz-wba.com


...since 1840

manufacturer of high performance Hot, Cold and Foil Rolling Mills for Aluminium strip

MINO O S.p.A. SpA Via Torino, 1 – San Michele – 15122 ALESSANDRIA – ITALY x +39 0131 361611 - E-mail: mino@mino.it Tel. +39 0131 363636 Fax

w w w. m i n o. i t


36 | COMPANY PROFILE

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Foundry Ecocer meets global foundry needs Milan-based Foundry Ecocer S.r.l. and Nuova Protecme S.r.l. fulfil a key role in ensuring reliable supply to foundries, smelters and companies involved in the transformation of aluminium alloys and non-ferrous alloys in general. Foundry Ecocer wants to be known everywhere: the constantly evolving range of Foundry Ecocer products is applicable in areas from smelting operations to high pressure and low pressure die casting and permanent mould casting. Foundry Ecocer and Protecme catalogues offer products for all types of foundry - not only aluminium, but also copper, magnesium, tin and zinc.

The Ossona (Milan - Italy) site

Entering Ossona for the first time, it is soon apparent how Foundry Ecocer occupies a prominent position in the locality. Ecocer is expanding its consultancy services in response to customers’ demands: new consultancy offices were opened by the Ossona plant entrance in January 2016. From the main entrance and executive Head Office, it is a short distance to the Quality Control and R&D laboratory area, which is housed in the main building next to the extensive materials storage area. This is very much a quality-based business, so there is an emphasis on product testing. The company has a well-equipped in-house laboratory for developing and testing new formulations of products with qualified technical personnel. Mrs Emanuela Uccellatori is the Research and Development Manager, and she says the company places an emphasis on developing and providing new products and applications. Further collaborative agreements with the Engineering University (Polytechnic University) of Milan (Politecnico di Milano), the largest technical university in Italy, allow completion of product testing. Across a materials transit area is the Lubricants and Greases production unit, making products for high pressure die-casting, billet production, and extrusion presses and lines. Products manufactured here include: • Emulsion mould release agents • Oil-based or dry-type plunger lubricants • Fire resistant hydraulic fluids for high pressure die casting • Lubricants series for all applications in extrusion production • Protective lubricants for moulds in storage. Next to that is the Granulation plant, a very effective operation and a key source of pride (and revenue) for Foundry Ecocer. For example, the ECOSAL AL series of granulated fluxes for covering, drossing, deoxidising, grain refining and modification of aluminium and its alloys is made there. Nearby, the pre-cast shapes are manually made and finished in-house from customer moulds, currently over 1,000 of which are stored on site ready to use. There follows a Baking Oven area.

The Foundry Ecocer plant in Ossona.

Foundry Ecocer R&D quality testing laboratory.

Adjacent to this production zone, Foundry Ecocer operates its own internal sampling system, keeping on average six months’ worth of control samples to address any customer queries which may arise from time to time.

and products. To customers the company offers good prices and rapid delivery across the range, and even has its own lorry transport company to ensure a 7 day week delivery service.

Knowing the detail

The active ingredient

Foundry Ecocer believes it is the only company in Europe that can give 100 per cent of the requirements for aluminium production. The firm closely supports its customers by knowing the detail of what they are making and trying to achieve. It is daily consulted by foundries, smelters or casting / extrusion plants looking to find new suppliers of extrusion machines, furnaces or other equipment. It is a family business but the management team is a very close group. Very keen on continuous improvement, Foundry Ecocer always wants to expand its asset base of people Aluminium Times April/May 2016

Research and Development Manager Mrs Emanuela Uccellatori looks after R&D for the products of the company: “My core work is at the cutting edge of product research and development, but I am responsible not just for products but for all company material needs, including those for marketing and exhibitions. We have a big family of products, including all the fluxes for the treatment of alloys, not only aluminium but also magnesium, copper and zinc. For the various non-ferrous alloys our products require different raw materials, different formulations, different


COMPANY PROFILE | 37

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Foundry Ecocer S.r.l. and Nuova Protecme S.r.l. Key market areas served: • Primary smelters making pure aluminium billets, ingots or slabs from aluminium oxide powder. • Secondary production where ingots go into a foundry or casthouse • Casting (e.g. automotive wheels) to create a final product: GDC, LPDC and HPDC. Some products are used in both primary and secondary applications, but more or less 40 per cent of turnover is in smelters (primary) and 60 per cent in foundry (secondary).

Foundry Ecocer exhibiting (l to r): Ms Carola Barattè, Mrs Emanuela Uccellatori, Research and Development Manager, and Mr Maurizio Sala.

recipes, different temperatures of use. We produce all forms of powder, granulated flux, including a new series called ROCK FLUX. Relatively lower amounts of these reduce oxidation and improve the melting yield, specifically for twin chamber and melting furnaces. We use a special aluminium can packaging, patented in Italy. This is put directly into the melt either manually or automatically by our machines to give a better and more immediate reaction. It has an important safety aspect in that it means no direct contact between operator and active material. Its higher effectiveness requires a smaller equivalent volume than powder or tablets to achieve at least the same result. It is ‘one can, one treatment’. Our dosing machine with a PLC can monitor metal temperature and quantity to manage a melt process with regard to dosing and holding times. Overall the materials, formulations and recipes vary for application with aluminium at 650°C to copper at up to 1,000°C temperature.”

Products

“We are always developing products, and there are many variants, according to customer needs. I test products mostly to address this demand. The best kind of development is when a customer has a production problem, but we do also look at what products work in this market. Research & Development by Foundry Ecocer is always ultimately aimed at meeting customer needs. Coatings for wheel production by low pressure die casting are a success story. The method involves applying a long-life primer with insulating properties. The finish can be fine, satinated or rough. The light-duty surfaces receive one product and the hard-working surfaces receive another. A bigger quantity of wheels can be coated in one series. Other coating solutions are offered for pistons, cylinder heads and other automotive castings and otherwise, for both low pressure and gravity die casting.” However, it is not always plain sailing, says Emanuela:

“We supply a range of master alloys in tablet form for melting and holding furnaces. This is a very competitive and open market in Italy today. The supply of products governed by REACH using EU-priced materials is affected by discounted products from further afield where lower pricing and improved quality supplies are available. The domestic Italian production is therefore eroding. There has also been a lot of ‘copying’ of product formulations.”

Integrated systems

Co-projecting together with three different Italian suppliers, the company offers sophisticated and automated degassing machines with simultaneous grain refining, or modification or cleansing and chemical fluxes addition to the melt, that allow an automatic and repetitive metallurgical practice in the foundry melting shop. It is also producing all consumables, like granulated fluxes, ceramic impellers and special devices to be used with the machines. The same approach has extended its proposals to include building new equipment and control instruments like CCF Heated Filter Box, injection flux machines, complete transfer launders systems, transfer ladles, RPT porosity instruments, automatic coating mixer machines designed to facilitate the consumables’ use.

The multi-national engineering staff are dedicated to giving the highest level of bespoke service to the customer base, which ranges from billets, ingots and slabs producers, to continuous casting foundries and wheels producers, to copper and brass foundries, and all diecasting customers. There is in place a 24/7 service, installation and troubleshooting capability. About the product lines: - Foundry Ecocer lubricating products are designed to prevent the metal from welding onto the mould surface and permit the obtaining of a good surface finish and an easy removal of the castings. - New water-based lubricants for extrusion eliminate the electrostatic dispersion problem with boron nitride powder. They give an indicative blue coating. - The PLASTCOTE protective coatings range for ceramics and refractory surfaces. For GDC and LPDC applications it features a long life primer. For risers and casting launders it has high insulating properties. The standard and tailored low density pre-cast ceramic shapes (ECOISOL and ECOSIL ranges) reduce thermal dispersion in the casting line. - Products for protective coating and treatment of pouring cups can be paints or pastes depending on the application.

Future business

Within Italian non-ferrous are a lot of small, low-overheads foundries and about 25 big foundries. The aluminium casting volume in Italy today is similar to Germany. A new building in Ossona to enable the production of new highest-quality products is planned. Being proactive, the market-oriented firm has established agents worldwide. A future increase in smelting sector supply is likely in both aluminium and copper, because brass is very important in Germany and Italy. Also magnesium use will grow in the future, in new alloys with lower density, perhaps in certain car parts. Foundry Ecocer is continually working with vehicle manufacturers on new products for new alloys. Aluminium Times April/May 2016

Accordingly the company plans to be in 2016 at IIAC in Tehran (Iran), Metalurgia Joinville in Brazil, Targi Kielce in Poland, ALUMINIUM in Germany, Arabal in UAE, and Ankiros Turkey, and the next METEF exhibition in 2017. www.foundryecocer.it www.protecme.com Note: An interview with Mr Maurizio Sala, President and Mr Fulvio Sala, Chief Executive, Foundry Ecocer S.r.l. / Nuova Protecme S.r.l. appeared in Aluminium Times January/February 2016 issue pp42-45.


38 | REFRACTORIES

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An improved refractory for transition plates Over the past 20 years, aluminium billet casters have had limited exposure to alternative refractory materials used in the manufacture of transition plates. This is primarily due to the manufacturer’s lack of incentive to invest in the development, testing and equipment necessary to produce a stronger, more effective and longer lasting product. From a global standpoint only one or two manufacturers have supplied the entire market. This is about to change with the introduction of a new material, manufactured by Johns Manville, named Ultratemp-AL, which is not only ‘the viable alternative’ for existing materials, but its characteristics are proving to be superior to those currently in the marketplace.

Description and function

A transition plate is a refractory component of a major OEM’s billet mould package. Its bottom surface is in contact with the top surface of a graphite ring and is held in place by a threaded hold down ring. A thin layer of either boron nitride or graphitic coating is applied to the mating surfaces to form a seal. The ID of the transition plate is mated to the OD of a refractory cast product called a ‘thimble’. A 1/8” ceramic fibre paper gasket forms a seal between the transition plate and the thimble, typically glued to the ID of the transition plate with glue or gasket cement. The transition plate acts as a conduit to transition molten aluminium from the metal delivery system (refractory) into the mould. In addition, once the mould is filled with aluminium, it stabilises head pressure in the mould package by acting as a baffle. During fill and hold, the transition plate helps insulate from temperature loss. Also, during the run it helps keep the temperature uniform. This is critical to flow and resulting surface quality of the billet produced. Prior to the introduction of Ultratemp-AL as ‘the viable alternative’ for this application, Original Equipment Manufacturers have used existing, proven technology for this application. The OEM’s comfort lies with its repeated performance ensuring minimal variables during start-up and casting. The existing product is an excellent insulator at start-up and during the cast. It helps keep metal molten during the fill and hold. During the cast, it then stabilises molten metal temperature inside the mould so the chill zone produces a uniform and smooth billet surface during the entire length of the cast. This is critical not only for smooth billet surfaces, but helps reduce melt loss that can be very costly.

Existing plate limitations

In the case of the existing OEM product used for transition plates, the downsides include rapid shrinkage and oil absorption. Shrinkage

A transition plate is a refractory component of a major OEM’s billet mould package.

typically occurs after every few casts, requiring the operator to remove the moulds and retighten the plates every time. This can become very costly as the process has to be repeated numerous times throughout production. Incumbent materials shrink during the first few drops after installation of the new plate. It does stabilise after the initial retightening. An operator will know this from experience. In reality, most operators change transition plates as needed, so the re-tightening process is ongoing. The larger the table (number of strands), the bigger the problem. When the user installs all new transition plates in the entire table, it is a real headache to then remove the table from service, remove all of the moulds, and re-tighten every transition plate. Additionally, oil penetration can affect premature failure and early removal and replacement of the transition plate. The porous fibrous body of the plate allows absorption of the oil into its pores rather easily. Over time and temperature, this oil crystallises and becomes brittle, resulting in fracturing to the plate. These are main issues that we have been working to reduce and attempting to eliminate for the past several years. We are virtually at the point where these problems are becoming less and less with the use of Ultratemp-AL transition plates as the ultimate replacement.

to the body, and (as some have reported) “the product does not shrink!” . The lack of shrinkage results in a reduction in surface cracking and, at times, virtually the elimination of fracturing. Additionally and more importantly, increased savings from reduction in scrap losses have been attributed to the Ultratemp-AL transition plates. One customer who had been averaging 2.8% scrap loss is now averaging 0.49%, which is a significant saving. The Ultratemp-AL is described as a carbon fibre reinforced insulating refractory board specifically designed for molten metal applications. Its non-wetting and reduction in shrinkage are functions of its unique chemistry and processing techniques. When machined and installed as a transition plate, it demonstrates operating characteristics far superior to any product currently being sold in the global market. This is supported by over 100 successful applications currently installed and in service during the past year. www.foundryservice.com

Ultratemp-AL transition plates

For the past year, Foundry Service & Supplies in Ontario, California, the distributor of Ultratemp-AL, has engaged in detailed field testing of the product as a transition plate, exposing it to aluminium alloys from 1100 to 8000 series. In all cases, they have recorded, through information received from their customers, increases of plate life of up to 30%, a definite reduction in oil penetration Aluminium Times April/May 2016

Authors: Jay W. Hunziker, Refractory Technology LLC and Joel W. Leathers, Vice President-General Manager, Foundry Service & Supplies


WORKING DAY | 39

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A working day in the life of James Parkes, International Sales Manager, Mechatherm International Working as a travelling Sales Manager in the aluminium industry throws up many challenging situations. One challenge presented itself recently was being asked during the recent TMS conference/ exhibition in Nashville if I would embrace the task of describing a working day in my life of performing my role at Mechatherm. We design, engineer and install furnace and casthouse equipment for the aluminium industry and are based near Dudley in the West Midlands, UK. We all do the day-to-day tasks such as getting up, going to the office, trawling through and answering emails and doing whatever James Parkes is International Sales Manager for Mechatherm International. we do to get our jobs done. Not to mention taking care of family and fitting in social lives as well. My next task is to drag all of our booth materials to the exhibit hall. That means I got to thinking why not be a little different walking a block in what is now freezing rain and describe a day in the life of exhibiting with no coat. I get a few strange looks from overseas and looking at what happens. A 24-hour watch so to speak. the locals wondering what on earth I was Having organised and packed all of doing in such bad weather, but once at the Mechatherm’s sales materials and booth hall I finally start to warm up. Thankfully posters, not to mention my own suitcase for the with this exhibition hall not being one of the week, I’m ready for the long haul journey from larger ones I have encountered, our booth is up Birmingham UK to Nashville, USA - a journey and ready quickly. Some of the bigger shows of 17 hours from house to hotel, with a six require you to be a stand building contractor as hour time difference. On arrival at the airport well as a furnace salesman! All ready now for I face my first challenge, by having an expired the opening day. ESTA to enter the USA! After queueing up for First day of the show, and after suiting up a while, I’m now faced with getting my laptop I’m prepared for severe weather in my new out and going through this lengthy application coat, only to discover it is a nice warm sunny procedure. Still, having got through that I was morning… typical, no coat required. Arriving pleasantly surprised to find an upgrade from at the Mechatherm booth before the doors economy to business class -Result! open, I have time to get familiar with the other Arriving at Nashville airport it’s pretty cold booths. I am generally looking out for our outside, with a bit of snow in the air too, with an competition and key suppliers, wondering outside temperature of -2°C and a bitter wind. what budgets they have spent compared to My worst fear is confirmed when I realise I have ours. It’s not long before I’m greeted by one forgotten to bring a winter coat, or any other of our competitors, who congratulate us on coat for that matter. That’s an extra task to my winning a recent order that we had been list, to buy a new coat. negotiating for on their territory. I could tell My Nashville hotel is next to the Music the congratulation was through gritted teeth, but we too have been there on the losing side, City Centre conference halls and I’m pleasantly so respect to them for saying so! “Smile and surprised to find a new and modern facility. try harder next time” our former Managing A bonus considering some of the hotels Director always used to say. I’ve encountered during my sales travel As the day goes on there is a mixture of visitors around the world over the past fifteen years. ranging from college students right up to CEO’s Good accommodation makes travelling so of some large organisations with whom we do much easier. Aluminium Times April/May 2016

regular business. Events like these are a perfect opportunity to meet and get to know people in the industry on an informal basis. Pre-arranged meetings tend to come with a strict agenda where getting to know the person you are talking to is more difficult. An informal visit to our booth will provide a nice chance to sit and discuss a whole range of things from work to personal life. Sometimes one can pick up by chance comments that maybe will influence a decision making process later, giving you a bit of an extra edge. One thing I always take back from the shows is that there is always something you learn that you wouldn’t have by sitting at your desk back home. Even if no new business opportunities present themselves at the exhibition, just talking to people and networking proves invaluable, as you never know where connections will take you. As the day finally winds down I’m feeling tired from jet lag and head back to my hotel. As I enter the hotel I’m confronted with various business associates welcoming me to have a drink with them. Of course, one drink normally turns into three or four before heading to my room to prepare for dinner out with customers or suppliers. After a good meal I’m either being easily led or leading my guests out for a night cap. Exhibitions are usually held at some fun venues with nightlife so it would be a shame to miss out of the attractions being such a long way from home! After all, entertaining is part of the job right? And Nashville is famous for its country and western music. After taking in live music and sinking another night cap, midnight has fast approached and gone and the country music is starting to wear a bit thin. I’m thinking it’s better to go bed and get ready to do the same all over again the next day and the day after that. I think exhibition hangovers can be the worst, but who needs more than 5 hours sleep anyway? All in all exhibitions and conferences are great, but they are hard work for many different reasons and factors before, during and after. Those who don’t have the opportunity to attend them might say to me they are just a jolly trip. But to those who know, it’s tough both working hard and playing hard! www.mechatherm.com


40 | CASTHOUSE UPDATE

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Re-melt expansion project in Bahrain Garmco’s international aluminium rolling mill is one of the largest downstream aluminium facilities in the Middle East. As part of Garmco’s expansion project, Fives has been awarded an EPC contract for the construction of a new re-melt and casting facility in Bahrain. The project includes the building of a new cast house to enable Garmco to develop its metal recycling capability and lower the cost of producing cast aluminium slabs for rolling. As the EPC (Engineering, Procurement & Construction) contractor, Fives will be fully responsible for the timely and successful execution of the contract. The re-melt facility will be capable of producing 120,000 metric tonnes per year of cast slab product to stringent industrial expectations of metal and casting quality for a varied production campaign of alloys and slab sizes. Fives is responsible for all engineering and project management and construction services associated with the plant and will use the latest 3D engineering tools and project management techniques to ensure the smooth execution of the project. The plant will be located on Garmco’s existing real-estate but is a complete new build incorporating utility and power infrastructures, a purpose built cast house building and all civil works. The challenging ground conditions at the job site, with a very high water table, will need special measures in the civil designs to ensure that the completed civil works remains impervious to water. This includes a sophisticated construction process combining soil reinforcement columns, piling and secant piles. One of the aims of the project is to produce cast slabs in a sustainable way. This will be achieved by incorporating a twin chamber melting furnace capable of melting contaminated scrap from external sources. The ability to recycle scrap metal into useful liquid metal will significantly optimise the operating costs for Garmco. Approximately 50% of the plant metal throughput could be provided by recycling aluminium this way. Associated with the twin chamber furnace will be a chip feeding and submerging system that will process aluminium chips from the downstream processes on the plant and distribute them into the furnace. Automated circulation and metal transferring systems will also be provided. The twin chamber furnace will also have an air pollution control system to manage the furnace emissions to comply with the environmental conditions applicable to the project. Liquid metal from the twin chamber furnace will feed 2 x tilting melter/holder furnaces where the metal will be further refined and mixed to create the necessary alloy mix ahead of casting. The tilting furnaces will be capable of delivering the metal flow at the required tolerances of the casting machine. Two purpose designed charging machines will tend to all the

charging requirements of the furnaces. The project will have a ‘zero chlorine’ policy in the new plant and so the relevant technologies for metal treatment including fluxing, degassing and filtering equipment have been incorporated. The configuration of this equipment will be organised to achieve the specific metal qualities necessary for ensuring good cast products and GARMCO remelt project. The facility will be capable of producing 120,000 metric tonnes per year eventually high quality of cast slab product. aluminium coils. One slab casting machine capable of dropping up to 66 t of cast metal to the required finished quality and tolerances will be supplied. Eventually the project will be a standalone facility and will be capable of maintaining operations independently. All the associated equipment to do this will be supplied such as a casting water cooling system with evaporative cooling Groundbreaking Ceremony marks start of $55 million remelt expansion at GARMCO. towers and a specific water treatment system, a casting machine mould maintenance shop, The Groundbreaking ceremony took process cranes and material handling systems, place on 21 January 2016 in the presence operational tools, all process and motor controls of several high profile guests: the Minister employing a unique configuration devised of Industry, Commerce and Tourism in Bahrain, Mr Zayed Al Zayani and French for this cast house, one fire protection system, Minister of State for Foreign Trade, one plant CCTV system, plant offices and access roads. Mr Mathias Fekl. The construction site One overall control, communication and opened mid-March 2016. data capturing system will be supplied to Fives has a long experience in process enable the operators to monitor equipment integration, project management and operation remotely and transfer production execution combined with in-house multidata to Garmco’s existing plant wide data discipline engineering expertise. Over the handling system. Fives will also assist Garmco past 15 years, Fives has executed several lump with the onsite management of a new band saw sum turnkey contracts in the Middle East installation which is also incorporated into while supplying more than 50 furnaces since the overall design of the cast house. All along 2003 including integrated casthouse solutions. this project execution, Fives will be committed Fives has also demonstrated excellent safety toward Safety. HSE principles are embedded records thanks to its strong and effective at the heart of project management with an HSE policy implemented throughout the objective to achieve zero workplace accidents Group’s companies. www.aluminium.fivesgroup.com in all construction, fabrication and www.garmco.com commissioning activities. Aluminium Times April/May 2016


| 41

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42 | ROLLING 

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Recent rolling mill modernisations Italy’s MINO has recently completed a number of key rolling mill modernisations for aluminium rolling mill clients. In the two case studies below, the business cases were different, highlighting the portfolio of skill, knowhow and expertise in the MINO Group.

Bridgnorth Aluminium

This project involved a radical revamping of a used cold rolling mill which the client had purchased as part of an expansion plan. The mill formerly belonging to a Spanish concern was to form a new production facility to increase capacity at their plant. The mill therefore became a ‘new’ asset but it started life over 25 years ago in another part of Europe. The mill was purchased by Bridgnorth Aluminium (BAL) with the understanding and intention to upgrade and modernise it prior to re-installation at their Bridgnorth site in Shropshire, UK. The mill was dismantled from its original site and transported to the UK for an inventory check and thorough examination. Following invitations to rolling mill equipment suppliers MINO was subsequently awarded the contract to modernise the mill. The original mill stand became the subject of a radical overhaul and re-design. Key sections of the equipment were redesigned or scrapped and replaced. The project was interesting case study for Bridgnorth Aluminium as their alternative option would have been the purchase of a new mill stand. In this case a used mill purchase provided an attractive cost saving alternative to a new mill and a shortcut in lead times and planning. As it proved there was a compelling business case in the ‘new against old’ analysis. After a detailed study by both BAL and MINO, the mill was upgraded and modernised with all new and used parts integrated into a state of the art cold rolling mill fit for purpose in the 21st century. The existing entry and exit equipment of the mill was redesigned, with some sections replaced with new designs. To facilitate the integration and allow a full re-assembly, the original equipment was shipped to MINO’s modern workshop facility in Alessandria, Italy. The new parts were added to the existing mill stand and proof-tested for fit and operation. It was also decided to increase the rolling speed of the mill so several key changes were made in the mill stand, with new bearings, chock assemblies and coolant control systems being part of the upgrade. This would provide higher performance and production in line with expectations and calculations. In general, attention was paid to all aspects of the mill stand with better designs and up-rated components to provide a higher standard of operation and maintenance. The first assembly of the ‘new’ mill was conducted in the MINO workshop where onboard piping, wiring and the new hoods were fitted. This exercise provides a ‘proof fit’ with all the new and used parts assembled

Bridgnorth Aluminium with the ‘new’ MINO cold mill installed.

together. This exercise is regarded as key part of MINO’s knowhow. Another crucial aspect of this part of the project is that the same MINO engineers who do the workshop assembly then attend site to repeat the exercise for real. All agree this is a time and money saving procedure which makes for a smooth transition to the site installation.

Hellenic Aluminium (Elval)

The second case study is the revamping of an existing cold rolling mill which is in production at the Elval production facility in Greece. This contrasts with the Bridgnorth Aluminium project above, where the mill had ceased production and remained dormant in another location. Elval operates a fully integrated plant and within this is one of their key production units, a cold rolling mill facility which has limited time for shutdowns and lost production. This cold rolling mill at Elval is critically important Aluminium Times April/May 2016

to the plant’s output. It forms a crucial link between the up and downstream production facilities. Although working reliably, Elval decided it was time to replace and modernise several aspects of the mill with more up to date technology. The mill was originally installed in the 1970’s and had not received an upgrade for over 20 years. The essence of the project was to replace some ageing technology reaching its obsolescence and improve the process performance of the mill with the best available technology. A better and more advanced new mill stand coolant carryover control and catchment system was also requested in order to improve strip dryness on its exit from the mill stand. MINO was awarded the contract as a recognised and respected supplier for this type of mill equipment. It was also acknowledged that the engineering skills and process control expertise within MINO gave Elval an excellent technology partner for this important project.


ROLLING | 43

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At Elval, a view from the operators pulpit into the exit side of the recently upgraded cold rolling mill.

An additional challenge to both Elval and MINO was the time allowed to stop the mill, remove, replace and re-start the mill with the new equipment. The planning for this involved close collaboration between Elval’s engineering staff and the MINO project team. The mill shutdown time period had to be long enough to allow the extensive upgrade and conversion work to take place, but not too long to cause shortages downstream in the plant. With the mill real estate area compact and

constrained with limited floor space to execute the work, the planning for the conversion required the project teams to co-ordinate all tasks very carefully. This would ensure the sequences of equipment removal, engineering and installation were carefully choreographed. Activity and work programs in such cases can easily overlap causing unforeseen delay. In this case the planning and hard work paid off and the execution of the project proceeded exactly to plan.

Aluminium Times April/May 2016

MINO provided its ‘Avanti’ process control system for flatness and thickness control, coupled with a new high resolution shapemeter roll and roll coolant spray bars. As an addition, MINO’s hot edge spray actuator was included in the package of improvements. Using a high powered, fast acting in-line heating system the MINO hot edge spray system provides a secondary thermal actuator to the conventional roll coolant spray system to apply hot roll coolant oil to the strip edges whilst rolling. The system is integrated into the ‘Avanti’ advanced process control system as an enhanced flatness actuator. ‘Tight edge’ phenomenon is a common problem in the cold rolling of aluminium. Higher tensile stress at the edge margins of the rolled sheet can result in a strip break at high rolling speeds. The hot edge spray actuator can alleviate the condition, reducing tensile stress raisers in strip edges, which in turn will allow higher rolling speeds. The MINO ‘Avanti’ system provides the user with a fully interactive mill control, advanced control strategies and operatorfriendly interfaces. Due to the experience of the MINO engineering staff, Elval enjoyed a fault free and smooth start-up of the mill. Rolling speeds were immediately at their optimum and no time was wasted in calibration or tuning of the control system for their wide range of products. The project has been regarded as a benchmark of how to achieve the desired performance without fuss and delay. www.mino.it


44 | CONTRACTS & PEOPLE In brief… Retech Systems LLC and SECO/WARWICK announced the promotion of Eric Petereit to Managing Director of Retech effective 15 January 2016, when former owner Jim Goltz stepped down after 12 years as President of Retech Systems LLC, remaining as Senior Advisor at Retech and a member of SECO/WARWICK Group’s Supervisory Board. www.retechsystemsllc.com

A leading Mexican secondary aluminium producer supplying automotive die casters has completed a project to install two Melting Solutions 30t Tilting Holding Furnaces feeding a DC rolling slab casting machine. A third 30t capacity Side Well Melting Furnace with Rotary Scrap Submerging System is delivering excellent productivity and recovery rates. www.meltingsolutions.co.uk

Alcoa is permanently shutting down the Warrick Operations smelter in Evansville, Indiana at the end of March, eliminating 600 jobs. The remaining bauxite refining capacity at Point Comfort, Texas will also close, leaving just 60 of the 730 jobs ongoing. Just the Massena West smelter in New York remains operational. www.alcoa.com

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Wide Butech aluminium cut-to-length line

Hertwich dross cooler commissions in Sweden

consumer electronics and appliances industries. the cut-to-length line will feature entry equipment, over and under coil payoff capabilities, a hydraulic crop shear with auto-gap adjustment, side trimmer (up to 8” per side), scrap chopper, hydraulic roller cassette leveller and direct drive flying shear. The new line’s capabilities include the abilit y to process aluminium up to 0.375” thick, 35,000 psi Champagne Metals’ 111” wide aluminium cut-to-length line. yield at a maximum line Champagne Metals aluminium speed of 200 fpm. This multise r vice ce ntre in G le npool, million dollar investment solidifies Oklahoma recently commissioned Champagne Metals’ commitment its new Butech Bliss state of the to the aluminium service centre art 111 inch wide Cut-To-Length market and the continued effort Line at its newly constructed to deliver the high quality services Middlebury, Indiana facility to that their customers have grown satisfy the ever growing demand to expect. for aluminium material from the www.champagnemetals.com marine, commercial transportation, www.butechbliss.com

Stena Aluminium has successfully commissioned the high-speed slag cooler HSC ® supplied by Hertwich Engineering, an SMS group company, at its Ålmhult works in Sweden. The new plant allows Stena to reclaim up to 10 per cent of the metallic aluminium contained in the dross. The HSC® developed by Stena Aluminium and Hertwich Engineering (based in Braunau, Austria) has the capacity to cool up to 5 tons of dross to below 450°C in less than 15 minutes. In other conventional processes this takes several hours. The recovered aluminium is directly recirculated to the smelting process. At dross temper ature s above 450 °C , aluminium contained in dross reacts with the oxygen in the ambient air and will ‘burn’. The resulting loss of aluminium is definitely significant. The new cooler in operation at Stena will markedly reduce the amount of lost aluminium. The cooler has been successfully in operation since August 2015.

Novelis Europe in management team changes

Nalco awarded both Fives India and Fives Solios SA with a turnkey contract to upgrade the Firing and Control system on the Anode Baking Furnaces No.2 at its aluminium smelter located in Angul, India in December 2015. The project consists of the PLC replacement and the installation of new blowing regulation system. www.aluminium.fivesgroup.com

Metal Packaging Europe reports that in 2013 over 3 Mt of steel packaging and aluminium beverage cans were recycled, bringing the recycling rate of rigid metal packaging up 1.1% to a new record of 74.7%. Aluminium beverage cans were recycled at 71.3% and steel packaging at 75.2%. Eunomia made a third party verification of the figures. www.scrapregister.com

Metal Registration Limited was approved by the London Metal Exchange (LME) as Associate Trade Member, Category 5, in March 2016. Londonbased Metal Registration becomes the LME’s first brand certification specialist member. Founder and principal Melanie Wells said it is an honour to be alongside Alcan, Glencore and others. www.metalreg.com

Michael Hahne moves to a VP Automotive role in April.

Marcus Becker takes over as VP Can for Novelis Europe.

Michael Hahne, who previously served as Vice President and General Manager Can in Novelis Europe, will assume the position of Vice President and General Manager Automotive in Novelis Europe effective 1 April 2016. Michael succeeds Pierre Labat, who has been appointed as Vice President, Sales and Marketing Global Automotive and will move to the company’s global headquarters in Atlanta, USA. Hahne joined Novelis in 2008 and served in various management positions, mostly in the company’s Automotive segment. He has led the

Can Value Stream in Novelis Europe since September 2014. M a rcu s B e c ke r, p rev iou s l y Director of Metal Planning and Sourcing at Novelis Europe, will succeed Michael Hahne as the new Vice President and General Manager Can Value Stream in Europe. Marcus Becker joined Novelis in 1999 and has held several leadership positions, including Sales Director Can Europe, Global Can Director for Middle East, Africa and India, and Global Account Director Can. www.novelis.com

Aluminium Times April/May 2016

www.sms-group.com

Continued expansion for Australia’s HTA

Heat Treatment Australia (HTA) s e l e c t e d S E C O / WA R W I C K Europe as their supplier for a FineCarb™ LPC vacuum furnace with 25 bar High Pressure Gas Quench (HPGQ), and two Vacuum Aluminum Braze furnaces. To complete the heat treat cell, SECO/ WARWICK Europe will supply two nitrogen/air tempering furnaces. The 25 Bar HPGQ and one vacuum brazing system will be shipped to the HTA Brisbane, Australia facility and the second vacuum brazing system will be located in their new Los Angeles, California facility. The two 2.0VP-4045/48HVS type furnaces will be designed for the vacuum aluminium brazing process. The 25.0VPT-4035/36NIQ 25 bar VPT-series (HPGQ) furnace going to Brisbane will be equipped with convection heating, low pressure carburising, ability for high pressure gas quenching with argon and nitrogen with pressures up to 25 bar. HTA is the only aerospace heat treater in Australia with AS9100 and Nadcap accreditations. HTA was the winner of the Metal Treating Institute’s 2015 Heat Treater of the year award. www.secowarwick.com www.heat.com.au


www.linkedin.com/company/salico


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Becker invests in Georg slitting line GEORG finishing lines division is to engineer and supply a new line for aluminium slitting, oiling and packing for the recently established Becker Aluminium Service GmbH. The Heinrich Georg GmbH Maschinenfabrik company combines being a renowned supplier of finishing lines to both the steel and the aluminium industry. Becker Steel as a member of the Klöckner Group is investing in the expansion of a new business division located at Bönen. Georg is known as a reliable partner already, as its technology has been in use at Becker Stahl too. The new high-tech installation for possibly the finest aluminium ser vice centre worldwide commences in the middle of 2017. The line is designed for a material width of 2,150 mm and 5 mm strip thickness, and ensures precise slitting, oiling and packing of up to 50 aluminium strands. With its new business division for flat aluminium products for the automotive and

Aluminium Times April/May 2016

After contract conclusion (l to r): Mark Georg, Dr. Thilo Theilen, Alexander Oberg,Karl Standera, Antonio Garcia, René Stäblein, Tom Giebeler, Michael Pöttcker, Stefan Cybulski, Axel Sturm and Franz Steimmel.

metal using industry, Becker Stahl will continue the strategy for increasing the turnover portion in higher value products and services. At the same time Becker will expand its product portfolio with a future oriented material for the automotive industry. Georg finishing lines division will contribute with the new slitting line operating at a maximum line speed of 400 m/ min. For the high line speed, slitting shear and cutter shafts are built in precise geometry. www.georg.com

Automatic flatness control from MINO

www.sms-group.com

Advanced process control from the experts

AMAG rolling GmbH of Austria has placed an order with SMS group for the supply of a cold rolling mill, a heat treatment line with a connected passivation section, a high-bay warehouse and a packaging line, as part of its AMAG 2020 investment project. Commissioning of the new facilities is scheduled for 2017. The six-high cold rolling mill with C VC ® plus technolog y (Continuously Variable Crown) will provide the high degree of flexibility required to handle the extensive range of products, including strip in widths of more than two metres. The rolling mill will come with actuators that ensure production to the required, extremely tight product tolerances.

construction, and stability is increased, whilst reducing the weight. The front-loading press processes billets with a diameter of 720 mm, a length of 2,500 mm and a weight of 2,750 kg. They are used for the production of profiles with widths of up to 800 mm and lengths of up to 35 metres. The 36 MN direct/indirect tube press for seamless tubes allows the processing of billets in high-strength aluminium alloys weighing 300 kg with a diameter of 322 mm and a length of 1,350 mm. In direct extrusion mode, this press can also produce normal profiles.

Contact us for free consultation and quotation for your plant :

SMS to supply AMAG mill and ancillaries

Jilin Liyuan Aluminium Company in Liaoyuan, Jilin Province in China, has granted the SMS group the final acceptance certificate (FAC) for a 36 MN direct/indirect tube extrusion press and a 160 MN front-loading extrusion press just shortly after commissioning. The 160 MN press is the largest extrusion press built by SMS to date. The 160 MN press will be used in particular for the extrusion of large profiles of medium hard aluminium alloys that are used for new high-speed trains and other rail-bound vehicles. Thanks to the large profiles, less welding work is necessary during wagon

Tel: +44 1202 883814

www.garmco.com

Largest front-loading extrusion press built by SMS with 160 MN press force.

www.mino.it

B a h r a i n - b a s e d i n te r n a tio n a l aluminium rolling mill GARMCO has appointed a new General Manager of Operations, Senior Project Manager of the Remelt Expansion Project and Senior Manager, Human Resources and Administration. Mr. JeanBaptiste Lucas, CEO of GARMCO commented “Our strategy this year is to focus on the new Re-melt, operational excellence and investing in human capital development.” M r. M o h a m m e d E s s a h a s been appointed as the General Manager, Operations, after over 30 years of work experience in the company. He joined GARMCO in August 1985, becoming Customer Relations Manager in 2006 and Senior Manager-Technical in 2008. Mr. Fahad Albasam has been appointed as Senior Manager, Human Resources and Administration. He joined the company in 2014 as Manager, Human Resources handling only the HR and training, with new role he will handle all the Admin activity. Mr. Ali A .Mohsen has been appointed as Senior Project Manager of the Remelt Expansion Project. He joined GARMCO in June 1997, was promoted to Quality Control Engineer in 2004, and Cold Rolling Manager in 2012. In his new position, Ali will be looking after the New Remelt Expansion Project from all the aspects and he is representing the company in front of the main EPC contractor.

• Over 35 systems sold since 2011 • Replaces any existing control system • Powerful and fully scalable • Interface with any shape sensor or actuator • Extremely short change-out times • Immediate return to full production

160 MN press at Jilin now in production

New managerial appointments for GARMCO

www.sms-group.com

CONTRACTS & PEOPLE | 47


48 | PRODUCT INFORMATION

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Reduction cell technologies

Hatch Aluminum reduction cell technologies to save power, increase current efficiency and extend potlife.

The Arc-Cast cathode connection reduces current density to reduce MHD instability.

Primary aluminium producers are under continuous pressure to make the most of their existing facilities to save power, increase production, extend potlife and reduce emissions. Hatch of Canada, already known for its project engineering consulting to the Aluminium Industry, has recently introduced novel, patented technologies to upgrade existing aluminium reduction cells. One of these is the use of Anode Nails which form a low resistance steel connection between the cast iron and the anode carbon in an anode assembly. The anode nails are installed in the anode prior to iron casting and are recycled by re m e lting with th e c a s t iron. Hatch claims that recent testing at a primary smelter in Quebec has demonstrated that Anode Nails enable a faster new anode heatup, lower pot noise, lower power consumption and

lower voltage spikes that are associated with generation of perfluorocarbon emissions. Sidewall life and metal pad stability in a reduction cell are also affected by too much or too little frozen bath on the internal potshell walls. These problems are traditionally addressed by the installation of external insulation around the potshell corners and welded steel fins on the potshell’s external sidewalls. Hatch has added high temperature resistant Alnico magnets to high efficiency aluminium cooling fins (MagFin) and to insulation blankets (Mag-Blanket) to enable easy addition or removal of these devices while the reduction cells are in operation. The application of external potshell cooling and insulation enables a better control of the internal frozen bath ledge thickness over the life of the

Robust spectrometers

Keit’s microFTS® is a new Fourier Tr a n s f o r m I n f r a r e d ( F T I R ) spectrometer that is smaller, lighter and more rugged than any current system. Able to perform in many extreme environments, the microFTS was originally designed for s p ace a p p lic ation s. Th e instrument offers a new gold standard for real-time liquid-state analyses, enabling: • Temperature measurement in the 500 - 3,000°C range • Reporting of temperature accurately despite oxide, dross and slag formation on a hot surface. • Detection of CO, CO2 and water vapour emitted from furnace material. The microFTS® has no moving parts, setting it apart from other FTIRs based on the Michelson interferometer. Unlike these devices, which tend to be large, heavy and vulnerable to shock and vibration, the microFTS® is compact, light-weight, and shockand vibration-resistant making it

ideal for use on the production floor. The novel microFTS design eliminates the need for remote sampling or fibre optic cables required in current systems. www.keit.co.uk

Furnace door seals Is your furnace door always completely closed? Most doors remain open! A regular cleaning of aluminium melting or holding furnace door frames prevents a c c u m u l a t i o n o f d ro s s a n d solidified aluminium. This enables an optimal furnace door sealing with such benefits as correct furnace pressure, reduced metal oxidation, shorter melting time and lower fuel consumption. However, in daily practice there is often no time for attention to be paid to sufficient cleaning. To improve this situation, De Winter Engineering has developed a heat-resistant self- adju st able door se aling s y s te m . A d v a n t a ge s of t h e Self-Adjusting Door Seal (SADS) system are:

Anode nails reduce the electrical resistance of anode assemblies and reduce voltage spikes.

reduction cell. These externally mounted devices can provide a midlife change to the thermal behaviour of a potshell in response to desired changes in potline amperage, or to extend the life of a potlining which is experiencing hotspots from worn refractory.

• R educes energy consumption and dross formation - With conventional door seal systems, the door remains a bit open if there is dross accumulation at one point between the door and the doorframe. The SADS system will close this gap and minimise the loss of energy. • The SADS system is designed to operate in the harsh environment of aluminium casthouses with liquid metal, dust, high temperatures and heavy mechanical impacts. • The system can be installed on existing doors. www.dewinterengineering.com

Infrared line cameras The infrared line camera PYROLINE range allows you highspeed non-contact measurement of temperature profiles. The cameras are specially designed for long-term use in fixed-mounted applications. As well as the general purpose spectral ranges of 8 μm to 14 μm and 3 μm to 5 μm, also offered

Aluminium Times April/May 2016

The width of new reduction cell designs, and the amperage increase of existing cells, is limited due to the uneven distribution of electrical current passing through the molten aluminium to the surface of the carbon cathode. The horizontal electrical currents through the aluminium are known to cause magnetohydrodynamic waves in the metal pad, which cause pot noise and which reduce current efficiency. The high current density over the ends of the cathode also accelerates the corrosion of the cathode into aluminium carbide, which is the main cause of cathode wear and eventual failure. Hatch’s Arc-Cast technology for cathode assembly modifies the electrical resistance vertically through the cathode to offset the existing resistance along the horizontal length of the cathode, resulting in near uniform electrical resistance across the top of the cathode. This uniform resistance reduces horizontal electrical current in the metal pad and reduces high current density over the ends of the cathode. Projected benefits include lower metal pad turbulence for improved current efficiency and reduced cathode corrosion for longer potlife. www.hatch.ca

are spectral ranges from 4.8 μm to 5 . 2 μ m (m e a s u r e m e n t o f temperature profiles in glass) and 1.4 μm to 1.8 μm (for metal). With an uncooled infrared linear array (128 or 256 pixels) you can realise non-contact measurement with 256 lines per second (512 lines per second optional) in temperature ranges from 0°C to 1,300°C. The camera comes in an aluminium compact-housing (IP54) or a stainless steel industry protection housing IP65. More housing variants are available. Different lenses with a field of view up to 90° are available. Measurement results can be transferred to your computer with real-time data transmission via fast ethernet with up to 512 lines per second. Stand-alone operation without computer is possible too. Alarm and thresholding monitoring as well as triggered measurements are practicable. PYROLINE has a 2 year Product warranty and customised system solutions with modified hardware and software are offered. www.dias-infrared.com


Air-Cooled, Low-Energy Electromagnetic Stirring

â&#x20AC;&#x153;Providing The Aluminium Industry With The Best Technology And Knowledge To Meet Our Customer Needs Through A Deep Understanding Of Production Processes, Equipment Design And Operationâ&#x20AC;? Dross and Salt Slag Pressing Machinery

www.altek-al.com


50 | PRODUCT INFORMATION

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Protective clothing TST started developing its Heat Protection equipment in 1990. It has thorough experience and a big network which continuously gives feedback on the function of its products. TST listens and keeps developing in order to get better and make work easier for its workwear users. TST offers radiant heat reflective, splash protective, and insulating material-based ranges for head to foot protection. The Marlan® coat is manufactured mainly for the aluminium industry for molten metal splash protection. Molten aluminium does not stick to the fabric surface, and it is heat and flame resistant according to the classification EN 11612 - A1, B1, C2, D3, E3, F1. Marlan® is both soft and moisture-absorbent. It also has good anti-static properties and offers protection from electric arcs, which can reach temperatures of up to 10,000°C. www.tst-sweden.com

Casthouse consumables

New York based Zircar Ceramics manufactures a wide range of engineered high temperature materials. With 39 years’ experience supplying advanced ceramic fibre based thermal, electrical and structural insulation materials, Zircar now offers an extensive lineup of consumable products for continuous aluminium sheet casters. Products include: several varieties of castertip for use on all makes of twin roll casters, for example NKO+ hard caster tip (ma x. profile width 2,362 mm) and ASG soft castertip (with non-reactive Al 2O 3 binder); precision CNC machined baffle and side dam board products; end dams of laminated paper, rigid board or engineered graphite, vacuum formed head boxes, troughs, launders and tundishes; papers for castertip linings or gaskets; several grades of refractory adhesives; graphite release agent; boron nitride coating; CNC machined graphite shafts, rotors and flow control components. www.zircarceramics.com

Induction heating systems Since 1995, Interpower Induction has supplied world class induction mass heating equipment and systems, producing equipment for the forging, automotive, truck

ASCON CRE equipment is utilised in the wire, cable, tube and busbar markets.

and bus, wind turbine, aerospace, military, railroad, handtools, mining, marine, farm machinery, and off road vehicle industries. Interpower is a manufacturing and service business, whose philosophy is to enter into a partnership with customers from the start, and to strive to deliver value from concept through to installation and maintenance. The service division offers full engineering support and breakdown services, spares and repairs, modifications and preventive maintenance. Interpower IGBT-based power supplies are available from 5 to 5,000 kW rating. For billet heating applications, individual Zone Control is offered, coupled with interchangeable coils and optional IR pyrometer monitoring of zone temperature for PLC control. IPC software allows for optimisation of ramp-up and hold patterns. www.interpowerinduction.com

ASCON CRE range ASMAG GmbH has announced that it has further developed its Continuous Rotary Extrusion (CRE) technology to stay ahead of the ever-increasing demands of the global market. As well as copper applications, ASMAG has developed a number of lines specifically for the production of aluminium products, such as solid profiles and sectors, precision

round and multi-void tubes, all of which are proving to be growth applications for the company. ASCON CRE technology has also been instrumental in the extrusion of new complex products using aluminium and copper. The ASCON range of CRE equipment has been developed with a design emphasis on high quality, precision engineered equipment using in-house manufacturing capability, also encompassing excellent user experience to ensure that the equipment is both easy to operate and maintain. With cost of ownership and productivity as the primary drivers in production businesses around the globe, extrusion wheel changes can be completed in under 30 minutes, compared to an industry standard of 2 to 8 hours. ASMAG now offers 3 standard CRE machines in its ASCON range; the ASCON-3, ASCON-4 and ASCON-5, all of which meet relevant international standards and can be bespoke designed to meet customer defined application requirements. www.asmag.at

Hydrogen analysis The AlSCAN TM and AlSCAN TM Argon analysers for hydrogen in liquid aluminium use a technique which is fast and accurate over a broad measurement range and offers outstanding reproducibility.

Aluminium Times April/May 2016

The AlSCAN TM is recognised by the industry with more than 400 units sold worldwide. The hydrogen analyser is portable and designed to survive the severe plant environment. The analyser is automated, easy to use and can be operated by non-technical floor personnel. Once started up, the unit operates autonomously and requires no special attention. The closed recirculation loop is a proven method of directly monitoring hydrogen in liquid aluminium. A small volume of carrier gas, usually nitrogen, is brought in contact with the melt by means of an immersed probe that continuously circulates in the closed loop until its hydrogen content reaches equilibrium with the vapour pressure of H2 in the melt. The H2 concentration in the gas is measured and converted into a reading of the gas concentration in the metal. The amount of H2 in the gas loop of the instrument is determined by a proprietary thermal conductivity sensor which provides high reproducibility and a broad measurement range. The rugged AlSCAN TM probes are available in three different versions, HME0200D for wrought alloys, HME0300D for foundry alloys, and HME1200D for long immersion and strontium modified melts. Longer probes of each model type are also available. www.abb.com/analytical


PRODUCT INFORMATION | 51

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Hydro adjustable flexible moulds project wins award (l to r): Arild Håkonsen, Terje Iveland, Svein Richard Brandtzæg.

Precast refractories Altus Refractories LLC from Pennsylvania, USA specialises in value-added, precast shapes for all industries, with its unique designs and products that help to reduce operating costs in the cement, aluminium, steel, power generation, and other industries. Altus offers a range of precast troughs for the aluminium industry, including Transfer Troughs, which require thermal shock resistance and the ability to withstand erosion and contact with molten aluminium, and Low Flow Troughs, which are generally used in transferring molten aluminium from the holding furnace. The troughs can be made from several different formulas depending on the customer’s need. The troughs are high-impact and low-flow, and are designed for the toughest environments. They are delivered ready to install, and can be supplied with support steelwork. Altus Refractories

Slab and billet casting The Hycast® Adjustable Flexible Moulds (AFM) rolling slab casting technology has been developed to reduce the number of moulds needed to produce ingots with optimised geometry and surface quality. On 10 December 2015, the ‘Adjustable Flexible Moulds (AFM) development and pilot’ won the Hydro President’s Innovation Award in the Products & Processes category. The Award jury found that Primary Metal AFM had shown excellent teamwork developing and implementing new casting technology for sheet ingots. The innovation involves improved safety, cost reductions (in scrap rate and productivity) and improved

market opportunities (new high-margin alloys with volume growth potential). Flexible moulds have been used within Hydro Aluminium for more than a decade. The AFM’s geometry range is 330 - 700 mm in thickness, and the width is 1,100 - 2,500 mm. The adjustable range is 300 mm. For smaller dimensions, flexible moulds with fixed width and moulds with fixed geometry are available. A fully automated casting sequence can be obtained by combining the Hycast AFM with the Hycast® CCS and the Metal Level Control System. High productivity and pit recovery, and excellent and consistent surface quality are obtained. Hycast has also created new casting technology for high quality extrusion billets in the form of Hycast® GC (Gas Cushion) Billet Casting Technology and Hycast® LPC (Low Pressure Casting) technology. The GC billet casting te c hnolog y i s id e a l for the production of high quality extrusion billets with excellent surface quality and extrudability. This system has been proven worldwide over more than two decades in a variety of cast houses. Hycast® LPC Billet technology is ideal for the production of larger diameters and hard alloys. The standard GC diameter range is 127 - 405 mm, and LPC diameter range is 127 - 735 mm. Both the GC and the LPC billet casting technologies have patented dual graphite rings for optimal oil and gas distribution, high pit utilisation due to optimised mould arrangement, and high productivity and pit recovery. A fully automated casting sequence can be obtained by combining the Hycast GC/LPC with the Hycast® CCS.

NON-CONTACT

THICKNESS MEASUREMENT Fast measurement Highest precision with 128,000 readings / sec also against profile tread plates Innovative laser line technology for recognition and compensation of tilting material

Al Fe Cu

All metals without calibration Geometric thickness measurement independent from metal surface type (rough, mirror, oil film...) Fast Return-on-investment Innovative measurement without isotopes or X-rays: no consequential costs

Tel. +49 8542 1680 www.micro-epsilon.com/metal

www.hycast.no

Aluminium Times April/May 2016


52 | PRODUCT INFORMATION

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Stub graphite coating and drying VHE of Iceland manufactures a range of Anode Stub Graphite C o a ti n g Sy s te m s . Pre - b a ke aluminium smelters coat anode stubs (pins) with a thin layer of graphite before sealing them into the carbon anode with molten cast iron. This graphite film significantly reduces the risk of the cast iron fusing into the stub surface, ensuring easy removal of the cast iron ‘thimble’ when the spent anode rod is recycled. In the past, rodding plants often used graphite powder suspended in an organic solvent. This quickly dried at ambient temperatures. Environmental and safety considerations have largely eliminated this practice and today most smelters use an aqueous graphite suspension. The use of water as the diluent means that careful drying is necessary to eliminate the risk of dangerous steam explosions during the anode sealing process. The VHE Anode Stub Graphite Coating System comprises a graphite coating tank and a drying system. The coating tank contains an aqueous graphite suspension and is constantly oscillated to ensure that graphite particles remain in suspension. The tank is elevated to the anode rod by hydraulic or pneumatic rams so that the anode stubs are partially immersed in the graphite mixture. The drying module may be one of several options, including gas burners, high intensity radiant electric heaters, or induction pre-heating, where residual heat in the stubs dries the graphite film. www.vhe.is

VHE’s Graphite Stub dip tank.

The VHE Graphite Coating System with freshly coated stubs.

Hands-on consulting and training from Innoval Technology.

Aluminium rolling expertise Innoval Technology (Innoval) is a unique resource to the aluminium rolling industry. Based in Banbury, UK, this group of experienced consultants has been helping clients to improve products, introduce new ones and optimise their rolling operations for almost thirteen years. Innoval’s experts have worked in aluminium rolling mills all over the world, from large multinational companies to smaller single -site enterprises. This experience means that they are well placed to carry out audits and benchmark a process against operations with similar equipment and against world-class standards. An audit then allows the Innoval team to identify opportunities to improve productivity, yield and product quality which, by working alongside the client’s team, they help to prioritise and implement. There are many ways in which Innoval can help improve aluminium rolling or finishing operations. If there is a problem with the surface, metallurgical or dimensional quality of the strip, or with the performance of the process, they can help solve it and bring about improvements. They can design spray cooling systems for optimum mill control performance, and also reduce the time and energy consumption of large thermal operations such as preheating and annealing. Innoval’s engineers can also give advice on which products can be made with existing equipment, as well as the modifications or investments which are needed in order to manufacture the ones currently beyond the equipment’s capabilities. The Process Improvement team has developed a suite of models

which can optimise almost every aspect of an aluminium rolling process. The models provide information on variables that cannot easily be measured, such as internal process temperatures. Various parameters, which are obtained from machine specifications or operating procedures, are simply entered into the user-friendly interfaces of the models. Effectively, these process models allow the user to ‘see inside’ their process whilst it’s running. Innoval’s Aluminium Rolling Technology Course is the only rolling course specifically for aluminium, and it is now in its tenth year. The course takes place each May and November in Banbury, UK, or it can be delivered at the client’s site. To date, delegates from 59 d i f f e r e n t c o m p a n i e s i n 32 different countries have attended the course. It covers all the key aspects of hot and cold rolling of aluminium flat products. There are several practical workshop sessions, a visit to the Jaguar plant at Castle Bromwich and a programme of social activities. To maximise tutor-delegate interaction, the class size in Banbury is restricted to twelve people. www.innovaltec.com

Anode cleaning machine

VHE’s baked anode cleaning system removes coke from anode holes and cleans all anode surfaces and chamfers. O rigin a ll y in s t a lle d at the former Alcan Aluminium Valais - Steg smelter in Switzerland in 2004, VHE’s anode hole reamer is a pneumatically driven system. The anode is moved to a vertical aspect and the holes are cleaned, the reaming heads automatically locating the holes.

Aluminium Times April/May 2016

VHE Anode Hole Reamer.

The anode is then translated horizontally and pushed through the anode face cleaner by a hydraulic ram where fixed diagonal hardened steel scraper blades clean the major faces. Concurrently, a series of brushes clean the vertical ends and all chamfers. As the cleaned anode exits the scraper area, it is blasted with air to remove all loose coke, before finally exiting the machine on a roller conveyor. Waste coke is discharged to a screw conveyor below the machine. www.vhe.is

Machine design specialists ALTEK has over 25 years’ experience designing, manufacturing and installing machinery for the aluminium cast house. When inventing the dross press in the early 1990s it became a p p a re n t t h a t t h e re w a s a requirement for a new, strong and dur able material to be developed for dross pans and pressing heads. ALTEK went about trying to discover the best material to make a high-quality, reliable and efficient product that would stand the test of time. After a lengthy process the material of choice to ensure best continuous performance and longevity in operation became cast steel. Being sturdy and fit for purpose, having excellent flexibility, and a variety of chemical compositions and heat treatment capabilities made this material stand out from the alternatives such as mild steel and cast iron.


54 | CLASSIFIEDS

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TO ADVERTISE IN THE CLASSIFIED SECTION PLEASE CONTACT JOHN CLARKE ON +44 (0)1273 453033 Want to reduce waste and improve efficiency at your plant? Our planning and scheduling solutions can lower your production costs and increase service levels

Book your Demo Today!

Over 70 Years Combined Aluminium Extrusion Knowledge Tel 01452 423541 Fax 01452 501643

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Eastbrook Rd, Gloucester, GL4 3DB, United Kingdom Service Extrusion Consultants

Advanced Planning, Scheduling & Optimization

www.servexcon.co.uk

www.visual8.com | +1-905-271-3620

Press head and dross pan

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Dross pans

20/01/2016 17:58

The most notable product within ALTEK’s cast steel product range are the dross pan sets. ALTEK has over 40 dross pan set models available varying in height, width, depth, shape, pan capacity and aluminium drain capacity. These also come in single, dual and multichamber designs. Although primarily designed for use in an ALTEK Dross Press, these castings can also be used on their own. Their unique design developed over many years encourages natural aluminium drain into the sow mould below, optimising metal returns from gravity alone. The economic benefit of achieving only 1% extra aluminium recovery over the course of a year pays for the casting itself. This combined with improved operator efficiency and reduced procurement costs make these castings a great investment.

Salt slag bins

Very similar to dross pans in material make up, however additional features have been included to aid in the cooling of the slag. Excellent durability and heat sink qualities make these castings stand out from the competition, which have been known to quickly deform and crack due to the volatility of salt slag. ALTEK has a range of sizes available including high capacity slag bins required to handle large volumes of salt slag produced in a rotary furnace. To be used on their own or in ALTEK Salt Slag Press equipment, these bins can improve cooling time, operation logistics and reduce procurement costs.

For Sale Extrusion Lines 3500 MT SMS 2500 MT SMS 2200 MT SMS 1800MT Lindemann 1800 MT Breda 1650 MT Tecalex 1400MT Tecalex 1160 MT Mingsheng 1000MT Tecalex

11” 9/11” 7” 7” 7” 7” 6” 2 x 5” 5”

Ingot/sow moulds

Manufactured in a cast steel alloy for good heat shock properties and durability at very competitive prices, ALTEK have quickly begun to establish themselves in the industry as a reliable supplier of high quality sow moulds. Special attention around patterns and sand quality have been carried out to ensure an excellent internal face finish. With several standard sow moulds on offer, optional cast feet and bespoke design supply available, ALTEK can meet the requirements of any cast house.

Reed Machinery Ltd has specialised for over 50 years in the supply of good used equipment related to the aluminium industry. REED MACHINERY Ltd., Breton Heights, Layer Breton, Colchester, Essex, UK, CO2 0PS Tel: +44 (0) 1206 331767 E-Mail: reedmachinery@breathe.co.uk Web: www.reedmachinery.co.uk Mobile: + 44 (0) 7785 315415

www.altek-al.com

Aluminium Times April/May 2016


THE BUYERS GUIDE | S1

www.mmcpubl icat io n s. co . u k 

THE EQUIPMENT & MATERIALS PURCHASING GUIDE

Companies who wish to be included within the Equipment and Materials Purchasing Guide and Directory can apply to johnclarke@mmcpublications.co.uk • One entry, with company logo, under the heading of your choice, for one year: (5 issues) is £235.00GBP, €349 euros, $392USA. • One entry, without company logo, under the heading of your choice, for one year: (5 issues) is £150GBP, €210 euros, $265USA Contact: johnclarke@mmcpublications.co.uk telephone +44 1273 453033

A ABB AB Albarrie Canada Limited Aluminum Casting Technology Analytical Reference Materials Int Corp Altek Europe Limited ALTEK L.L.C. Alu1 Arun Technology Ascona GmbH Assimakis S.A. ATEMA srl B BLOOM Engineering (Europa) GmbH Bonetti Cutting Solutions Boreal Laser Inc Bronx International Pty Ltd Buss AG Buss ChemTech AG Butech Bliss BWG Bergwerk-und Walzwerk Maschinenbau GmbH C Castool Tooling Systems A J Charnaud & Co (PTY) Limited Chugai Ro Co., Limited Comexale Combilift, Ireland D Drache Umwelttechnik GmbH Dross Engineering Dynamic Concept

E Ecotherm, Turkey Elite Extrusion Die Limited Eredi Scabini srl Erie Press Systems Eroga Die Company Limited Euroslitter S.r.l. Extrusion Form Tools Limited extrutec GmbH F FATA EPC FATA Hunter Ferram Fives ECL Fives North American Combustion Limited Fives Solios SA Fives Solios Limited Josef Froehling GmbH & Co. KG G Gap Engineering SA Gautschi Engineering Glama Maschinenbau GmbH GNA alutech Inc GORS Limited Gouda Refractories GRAF Technik GmbH Granco Clark H H + H Herrmann + Hieber GmbH Haarslev Industries Press Technology GmbH & Co KG Hengelmolen Engineering Limited Hertwich Engineering GmbH HKO Heat Protection Group HMR Group

Ageing Ovens IUT Industriell Ugnsteknik Sweden AB

Industrivägen 2, 438 92 Härryda, Sweden Tel: +46 301 50 8031 Mob: +46 702 43 48 40 Exch. +46 301 50 80 00 Fax: +46 301 304 79 E-mail: fredrik.berge@iut.se Web: www.iut.se Sales Contact: Fredrik Berge

extrutec GmbH

Fritz-Reichle-Ring 2, D-78315 Radolfzell, Germany Tel: +49 (0) 7732 939 1370 Fax: +49 (0) 7732 939 1399 web: www.extrutec-gmbh.de E-mail: bucher@extrutec-gmbh.de Sales Contact: Ulrich Bucher

Thermserve

Alloys for Foundry Sotrem – Maltech

1685, rue Manic, Saguenay District Chicoutimi (Quebec) G7K 1G8, Canada Tel : +1 418 696-2019 Fax : +1 418 543-0005 E-mail: pdube@sotrem-maltech.com Web:www.sotrem-maltech.com Sales Contact: Patrick Dubé

Anode Paste Kneaders Buss AG

Anode Paste Mixers

CH-4133 Pratteln, Switzerland Tel: +41 61 825 66 00 E-mail: info@busscorp.com Web: www.busscorp.com Sales Contact: Joerg Kellermann

Hohenrainstrasse 12A CH Pratteln 1, Switzerland Tel: +41 61 825 6462 Fax: +41 61 825 6737 E-mail: info@buss-ct.com Web: www.buss-ct.com Sales Contact: Daniel Haeusler

N NKM Noell Special Cranes GmbH Novelis PAE O optimAl Process Technology Limited P Polytec Precimeter Control AB Primetals Technologies Limited Prometal Galvano PSI Metals Non Ferrous GmbH Pyrotek Inc R R&D Carbon Ltd Refratechnik Steel GmbH Remix S.A. Rex Materials Group Riedhammer GmbH L.P. Royer Inc S S + P Samson GmbH Saint-Gobain Industrial Ceramics Limited Salico Sawnode Technologies, Ltd Schwartz GmbH Seco/Warwick Europe S.A. Sistem Teknik Industrial Furnaces SMS Group GmbH Sotrem – Maltech STAS T Techmo Car SpA Thermserve Limited Thermo Scientific T.T. Tomorrow Technology V Vollert Anlagenbau GmbH W Wagstaff Inc Y York Linings Limited

T.T. Tomorrow Technology

Haarslev Industries Press Technology GmbH & Co. KG

Hasteraue 9, D-42857 Remscheid, Germany Tel: +49 2191 20199 10 Fax: +49 2191 20199 29 E-mail: joerg.hoffmann@haarslev.com Web: www.haarslev.com Sales Contact: Joerg Hoffmann

Anode Plant Audit & Process Optimisation R&D Carbon Ltd

Buss ChemTech AG

Halesfield 2, Telford TF7 4QH UK Tel: +44 (0) 1952 684488 Fax: +44 (0) 1952 684489 E-mail: steve@thermserve.com Web: www.thermserve.com Sales Contact: Steven Hodgkiss

K Home International Limited Hotwork Combustion Technology Limited HPI Ges.mbH Hycast AS I IAS GmbH Inductotherm Heating & Welding Limited Innoval Technology Limited Innovatherm, Germany INSERTEC Insulcon BV Interpower Induction IUT Industriell Ugnsteknik Sweden AB J Jasper GmbH K Kautec Solutions S.L. Kelly Control Systems Klüber Lubrication Kone Cranes UK L Lechler Limited Lethiguel SAS LOI Thermprocess GmbH M Major Furnace Australia Pty Limited Marx GmbH & Co.KG Mastec Flexipac AB Mecfor Inc. Mechatherm International Limited Melting Solutions Metalscan Limited MetalTech Limited Metlsaw Inc Micro-Epsilon Messtechnik Mino SpA Mino Automation Mino Press Control August Mössner GmbH + Co. KG MQP Limited

P.O. Box 362, CH-3960 Sierre, Switzerland Tel: +41 27 459 29 29 Fax: +41 27 459 29 25 Email : meier@rd-carbon.com Web: www.rd-carbon.com Sales contact: Markus Meier

Anode Production MECFOR Inc 1788 Mitis Street, Chicoutimi G7K 1H5 (Qc) Canada Tel: +1 418 543 1632 Fax: +1 418 543 4351 E-mail: mecfor@mecfor.com Web: www.mecfor.com Sales Contact: Richard A. Zalzal

Aluminium Times April/May 2016

Via dell’aritgianato 18 I-35020 Due Carrare PD, Italy Tel: +39 049 912 8800 Fax: +39049 912 8888 E-mail: gmagarotto@ tomorrowtechnology.it Web: www.tomorrowtechnology.it Sales Contact: Giovanni Magarotto

Anode Rodding Shop MetalTech Limited

Skogarsel 41-101, Reykjavik IS 109, Iceland Tel: +354 856 2301 E-mail: jhm@metaltech.is Web: www.metaltech.is Sales Contact: Eng. Jon H Magnusson

ONE ENTRY WITH LOGOFOR 5 ISSUES

€349; $392USA; £235GBP

TO ADVERTISE CONTACT JOHN CLARKE: JOHNCLARKE@MMCPUBLICATIONS.CO.UK


S2 | THE BUYERS GUIDE Anodising Plant Design & Production Prometal Galvano Cih San Tic Ltd STi

i.O.S.B. Mah. Milas Cad, Dis. Kapi No 13/A, Ig Kapi No: Z01, Basaksehir 34306, Turkey Tel: +90 212 549 9549 Fax; +90 212 549 9546 E-mail: info@prometalgalvano.com Web:www.prometalgalvano.com Sales Contact: Emin Kalip / Ertan Yuksel

www. mmc p ub l i c a ti o n s . co . u k

HYCAST AS

Carbon Extrusion Presses

Industrivien 49 Sunndalsora 6600, Norway Tel: +47 71 69 38 00 Fax: +47 71 69 00 65 E-mail: hycast@hydro.com Web: www.hycast.no Sales Contact: Jens Meyer-Olsen

Novelis PAE S.A.S.

Apparel A J Charnaud & Co (PTY) Ltd

South Africa Tel: +27 (0) 11 794 6040 E-mail: sales@charnaud.co.za Web: www.Charnaud.co.za Europe Tel: +44 (0) 113 3507 651 E-mail: sales@charnaud.eu Web: www.charnaud.eu Sales Contact: Sales Department

Auto Firing Systems Innovatherm

Centr’Alp-BP 24 F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: pae.autopak@novelis.com Web: www.novelis.com/pae Sales Contacts: Ghislain Le Roy, Antoine Le Tullier, Olivier Schneider

PreciMeter Control AB

Riedhammer GmbH

Fives Solios SA

32 rue Fleury Neuvesel, F-69702 Givors, France Tel: +33 4 72 49 54 54 Fax: +33 4 72 49 54 32 E-mail: fivessolios@fivesgroup.com Web: www.fivesgroup.com

Hornstrasse 19, D-45964 Gladbeck, Germany Tel: +49 2043 9738 0 Fax: +49 2043 4726 8 E-mail: info@glama.de Web: www.glama.de Sales Contact: Werner Nowitzki

HMR Group AS

Carbon Test Equipment R&D Carbon Ltd P.O. Box 362, CH-3960 Sierre, Switzerland Tel: +41 27 459 29 29 Fax: +41 27 459 29 25 Email : meier@rd-carbon.com Web: www.rd-carbon.com Sales contact: Markus Meier

Prestnesvegen 68, N-5460 Husnes Norway Tel: +47 534 82100 Fax: +47 534 82101 E-mail: hmr@hmr.no Web: www.hmr.no Sales Contact: Anna Prestnes

MECFOR Inc

R&D Carbon Ltd P.O. Box 362, CH-3960 Sierre, Switzerland Tel: +41 27 459 29 29 Fax: +41 27 459 29 25 Email : meier@rd-carbon.com Web: www.rd-carbon.com Sales contact: Markus Meier

Casthouse Control 3910 North Flora Road Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person

Automation & PLC Control Systems Klingenhofstrasse 72 D-90411 Nuremberg, Germany Tel: +49 911 5218 0 Fax: +49 911 521 8231 E-mail: thomas.janousch@riedhammer.de Web: www.riedhammer.de Sales Contact: Thomas Janousch

1253 West 12th Street, Erie, PA 16501 USA Tel: +1 814 455 3941 Fax: +1 814 456 4819 E-mail: info@eriepress.com Web: www.eriepress.com Sales Contact: Bob Hirsh, Customer Service

GLAMA Maschinenbau GmbH

Carbon Quality Control & Certification Ostra Hamnen 7 SE-475 42 Hono Sweden Tel: +46 31 764 5520 Fax: +46 31 764 5529 E-mail: marketing@precimeter.com Web: www.precimeter.com Sales Contact: Jonatan Lindstrand

Wagstaff Am Hetgesborn 12, D-35510 Butzbach, Germany Tel: +49 6033 9696 0 Fax: +49 6033 9696 9 E-mail: dmaiwald@innovatherm.de Web: www.innovatherm.de Sales Contact: Detlef Maiwald

Erie Press Systems

Casthouse Vehicles

Kelly Control Systems

Innovatherm

T.T. Tomorrow Technology

Am Hetgesborn 12, D-35510 Butzbach, Germany Tel: +49 6033 9696 0 Fax: +49 6033 9696 9 E-mail: dmaiwald@innovatherm.de Web: www.innovatherm.de Sales Contact: Detlef Maiwald

Via dell’aritgianato 18 I-35020 Due Carrare PD, Italy Tel: +39 049 912 8800 Fax: +39049 912 8888 E-mail: gmagarotto@ tomorrowtechnology.it Web: www.tomorrowtechnology.it Sales Contact: Giovanni Magarotto

Cast House Engineering Services Société des Technologies de l’Aluminium de Saguenay Inc (STAS) Windrush Barns, Church Lane, Corse Gloucester GL19 3BX, UK Tel: +44 (0) 1452 700077 E-mail: mail@kellysystems.co.uk Web: www.kellysystems.co.uk Sales Contact: James Kelly

Carbon Anode Compacting Presses Erie Press Systems

1846 rue Outarde, Chicoutimi Québec, Canada G7K 1H1 Tel: +1 418 696 0074 Fax: +1 418 545 8335 E-mail: marketing@stas.com Web: www.stas.com Sales Contact: Louis Bouchard

Thermserve

Automatic DC Slab Casting

1788 Mitis Street, Chicoutimi G7K 1H5( Qc) Canada Tel: +1 418 543 1632 Fax: +1 418 543 4351 E-mail: mecfor@mecfor.com Web: www.mecfor.com Sales Contact: Richard A. Zalzal

Casting Mechatherm International Ltd

Hampshire House High Street Kingswinford DY6 8AW UK Tel: +44 (0) 1384 279132 Fax:+44 (0) 1384 291211 E-mail: sales@mechatherm.com Web: www.mechatherm.com Sales Contact: Stuart Allen

Wagstaff

GAP Engineering SA

Techno-Pôle 5 CH-3960 Sierre, Switzerland Tel: +41 27 455 57 14 Fax: +41 27 455 57 15 E-Mail: info@gap-engineering.ch Sales Contact: Alfio Schillaci, Valloton Julien

1253 West 12th Street, Erie, PA 16501 USA Tel: +1 814 455 3941 Fax: +1 814 456 4819 E-mail: info@eriepress.com Web: www.eriepress.com Sales Contact: Bob Hirsh, Customer Service

Halesfield 2,Telford TF7 4QH UK Tel: +44 (0) 1952 684488 Fax: +44 (0) 1952 684489 E-mail: steve@thermserve.com Web: www.thermserve.com Sales Contact: Steven Hodgkiss

Aluminium Times April/May 2016

3910 North Flora Road, Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person


THE BUYERS GUIDE | S3

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Casting Equipment Dynamic Concept

2400 rue Alexis-le-Trotteur Jonquiére G7X 0J7, Canada Tel: +1 418 542 6164 Fax: +1 418 542 8720 E-mail: info@dynamic-concept.ca Web: www.dynamic-concept.ca Sales Contact: Patrice Coté

Société des Technologies de l’Aluminium de Saguenay Inc (STAS)

1846 rue Outarde, Chicoutimi Québec, Canada G7K 1H1 Tel: +1 418 696 0074 Fax: +1 418 545 8335 E-mail: marketing@stas.com Web: www.stas.com Sales Contact: Louis Bouchard

Mercatorstrasse 74-78 D-47051 Duisburg Germany Tel: +49 203 99290 Fax: +49 203 9929400 E-mail: bwg@bwg-online.de Web: www.bwg-online.com Sales Contact: Stefan Sonntag

FATA Hunter

Wagstaff

3910 North Flora Road, Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person

Casting Machines (cylinders)

Strada Statale 24, 12 Km I-10044 Pianezza (Torino) Italy Tel: +39 011 96681 Fax: +39 011 9668 355 E-mail: sales@fatahunter.com Web: www.fatahunter.com Sales Contact: Sales Department

SMS group GmbH

Wagstaff

Gautschi Engineering GmbH

Andhauserstrasse 52 8572 Berg TG, Switzerland Tel: +41 71 666 66 66 Fax: +41 71 666 66 77 E-mail: info@gautschi.cc Web: www.gautschi.cc Sales Contact: Sales Department

3910 North Flora Road Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person

Cathode Assembly Systems GNA alutech Inc.,

Eduard-Schloemann-Strasse 4 D-40237 Duesseldorf, Germany Tel: +49 211 881-0 Fax: +49 211 881-4902 E-mail: communications@sms-group.com Web: www.sms-group.com

HPI Ges. mbH

Schloss Strasse 32, A-5282 Ranshofen, Austria Tel: +43 7722 68420 Fax: +43 7722 68805 E-mail: hpi@hpi.at Web: www.hpi.at Sales Contact: Rainer Edtmeier

Novelis PAE S.A.S.

Vollert Anlagenbau GmbH

9495 Trans-Canada Highway Saint-Laurent, Quebec, H4S 1V3, Canada Tel: +1 514 956 1776 Fax: +1 514 956 0562 E-mail: tphenix@gna.ca Web: www.gna.ca Sales Contact: Ted Phenix

Certified Reference Material ARMI-brand metal alloy CRMs from LGC Standards

276, Abby Road, Manchester, NH 03103, USA Tel: +1 603 935 4100 Fax: +1 603 935 4101 e-mail sales@armi.com Web: www.armi.com

Coil Coating Lines

Stadtseestrasse 12 D-74189 Weinsberg, Germany Tel: +49 7134 52 220 Fax: +49 7134 52 222 E-mail: intralogistics@vollert.de Web: www.vollert.de Sales Contact: Oliver Wolschinski

111 Boundary Road, Peakhurst NSW 2210 Australia Tel: +61 2 9534 4233 Fax: +61 2 9534 4732 Email: salesgroup@bronx.com.au Web: www.bronxintl.com Sales Contact: Alan Roberts

Bretton Street, Savile Town Dewsbury WF12 9DB, UK Tel: +44 (0) 1924 506506 Fax: +44 (0) 1924 506311 E-mail: info@hotworkct.com Web: www.hotworkct.com Sales Contact: Denis Hunzinger

Jasper Gesellschaft für Energiewirtschaft und Kybernetik mbH

Bönninghauser Strasse 10 D-59590 Geseke, Germany Tel: +49 2942 9747 - 0 Fax: +49 2942 9747 - 47 E-mail: info@jasper-gmbh.com Web: www.jasper-gmbh.com Sales Contact: Peter Klatecki

Thermserve

Combustion & Burners BLOOM Engineering

(Europa) GmbH Buettgenbachstrasse 14 D-40549 Düsseldorf Germany Tel: +49 211 500910 Fax: +49 211 5009114 E-mail: info@bloomeng.de Web: www.bloomeng.com Sales Contact: Günther Reusch

CHUGAI RO CO. LTD

Bronx International Pty Ltd

Centr’Alp-BP 24 F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: pae.marketing@novelis.com Web: www.novelis.com/pae Sales Contacts: Marc Bosch, Ghislain Le Roy

Heath Mill Road, Wombourne Wolverhampton, WV5 8BD UK Tel: +44 (0) 1902 891200 Fax: +44 (0) 1902 895552 E-mail: fna.sales@fivesgroup.com Web: www.combustion.fivesgroup.com Sales Contact: Ian Ellis

Coil Storage Systems

Hertwich Engineering GmbH

Weinbergerstrasse 6 A-5280 Braunau, Austria Tel: +43 7722 806-0 Fax: +43 7722 806-122 E-mail: info@hertwich.com Web: www.hertwich.com Sales Contact: Elke Deubler

Fives North American Combustion UK Ltd

Hotwork Combustion Technology Ltd

GAP Engineering SA

Techno-Pôle 5 CH-3960 Sierre, Switzerland Tel: +41 27 455 57 14 Fax: +41 27 455 57 15 E-Mail: info@gap-engineering.ch Sales Contact: Alfio Schillaci, Valloton Julien

BWG Bergwerk-und Walzwerk Maschinenbau GmbH

2-4 Chikko-Shinmachi Nishi-Ku Sakai 592-8331 JAPAN Tel: +81-72-247-1440 Fax: +81-72-247-1441 Cell: +81-80-8504-3129 E-mail: Naohiko_Katou@n.chugai.co.jp Web: www.chugai.co.jp/index_e.html Sales Contact: Naohiko Kato

Aluminium Times April/May 2016

Halesfield 2, Telford TF7 4QH UK Tel: +44 (0) 1952 684488 Fax: +44 (0) 1952 684489 E-mail: steve@thermserve.com Web: www.thermserve.com Sales Contact: Steven Hodgkiss

Consultants Aluminum Casting Technology 7 Lone Cedar Way, Old Tappan, NJ 07675 USA Tel: +1 201 767 9044 Fax: +1 201 750 2279 E-mail johnvj@optonline.net Sales Contact: John V. Griffin P.E.

Innoval Technology Ltd

Beaumont Close, Banbury OX16 1TQ, UK Tel: +44 (0) 1295 702800 Fax: +44 (0) 1295 702898 E-mail: enquiries@innovaltec.com Web: www.innovaltec.com Sales Contact: Helen Forrest


S4 | THE BUYERS GUIDE Consumables Drache

Werner-von-Siemens-Strasse 24-26 D-65582 Diez, Germany Tel: + 49 6432 6070 Fax: +49 6432 60752 E-mail: mail@drache-gmbh.de web: www.drache-gmbh.de sales Contact: Frank Reusch

Insulcon BV

www. mmc p ub l i c a ti o n s . co . u k

Cranes & Hoists

HYCAST AS

DC Casting Service & Support Novelis PAE

Fives ECL

100 rue Chalant, F-59790 Ronchin, France Tel: +33 320 88 7070 Fax: +33 320 88 7099 E-mail: fivesecl@fivesgroup.com Web: www.fivesgroup.com Sales Contact: Pierre Escarbelt

Industrivien 49 Sunndalsora 6600, Norway Tel: +47 71 69 38 00 Fax: +47 71 69 00 65 E-mail: hycast@hydro.com Web: www.hycast.no Sales Contact:Jens Meyer-Olsen

Novelis PAE S.A.S.

H + H Herrmann + Hieber GmbH

Centr’Alp-BP 24 F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: pae.autopak@novelis.com Web: www.novelis.com/pae Sales Contact: Ghislain Le Roy, Antoine Le Tullier, Olivier Schneider

Wagstaff Zilverhoek 4 NL-4651 SP Steenbergen, Netherlands Tel: +31 167 565750 Fax: +31 167 566263 E-mail: info@insulcon.com Web: www.insulcon.com Sales Contact: Sales Office

Pyrotek

705 W 1st Ave. Spokane, WA 99201 USA Tel: +1 509 926 6212 Web: www.pyrotek.info E-mail: info@pyrotek.info Sales Contact: Aluminium Sales

Société des Technologies de l’Aluminium de Saguenay Inc (STAS)

Rechbergstrasse 46 D-73770 Denkendorf, Germany Tel: +49 711 93467-0 Fax: +49 711 3460911 E-mail: info@herrmannhieber.de Web: www.herrmannhieber.de Sales Contact: Sales Office

Centr’Alp-BP 24 F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: pae.autopak@novelis.com Web: www.novelis.com/pae Sales Contact: Ghislain Le Roy, Antoine Le Tullier, Olivier Schneider

Kone Cranes UK

Wagstaff

DC Extrusion Billet Casting Industrial Crane Division, 2 Peel Place, College Milton, East Kilbride G74 5LR, Scotland, UK Tel: +44 (0) 1355 220591 Fax: +44 (0) 1355 2636654 E-mail: gordonadie@konecranes.com Web: www.konecranes-uk.com Sales Contact: Gordon Adie

NKM Noell Special Cranes GmbH

3910 North Flora Road, Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person

DC Casting Automation HYCAST AS

1846 rue Outarde, Chicoutimi Québec, Canada G7K 1H1 Tel: +1 418 696 0074 Fax: +1 418 545 8335 E-mail: marketing@stas.com Web: www.stas.com Sales Contact: Louis Bouchard

Continuous Rod Casting Equipment Dynamic Concept

3910 North Flora Road, Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person

Rudolf-Diesel-Strasse, 1 D-97209 Veitshoechheim, Germany Tel: +49 931 40473-0 Fax: +49 931 40473-1000 E-mail: Sales@nkmnoell.com Web: www.nkmnoellspecialcranes.com Sales: Klaus Freitag

DC Casting Dynamic Concept

HYCAST AS

Industrivien 49, Sunndalsora 6600, Norway Tel: +47 71 69 38 00 Fax: +47 71 69 00 65 E-mail: hycast@hydro.com Web: www.hycast.no Sales Contact:Jens Meyer-Olsen

Wagstaff Industrivien 49 Sunndalsora 6600, Norway Tel: +47 71 69 38 00 Fax: +47 71 69 00 65 E-mail: hycast@hydro.com Web: www.hycast.no Sales Contact:Jens Meyer-Olsen

Novelis PAE S.A.S.

3910 North Flora Road, Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person

Degassing & Filtration 2400 rue Alexis-le-Trotteur Jonquiére G7X 0J7, Canada Tel: +1 418 542 6164 Fax: +1 418 542 8720 E-mail: info@dynamic-concept.ca Web: www.dynamic-concept.ca Sales Contact: Patrice Coté

Continuous Strip Casting & Accessories Novelis PAE S.A.S.

Centr’Alp-BP 24,F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: pae.jumbo3C@novelis.com Web: www.novelis.com/pae Sales Contact: Marc Bosch

Drache

2400 rue Alexis-le-Trotteur Jonquiére G7X 0J7, Canada Tel: +1 418 542 6164 Fax: +1 418 542 8720 E-mail: info@dynamic-concept.ca Web: www.dynamic-concept.ca Sales Contact: Patrice Coté

Centr’Alp-BP 24 F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: pae.autopak@novelis.com Web: www.novelis.com/pae Sales Contact: Ghislain Le Roy, Antoine Le Tullier, Olivier Schneider

GAP Engineering SA

Wagstaff

Techno-Pôle 5 CH-3960 Sierre, Switzerland Tel: +41 27 455 57 14 Fax: +41 27 455 57 15 E-Mail: info@gap-engineering.ch Sales Contact: Alfio Schillaci, Valloton Julien

3910 North Flora Road Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person

Aluminium Times April/May 2016

Werner-von-Siemens-Strasse 24-26 D-65582 Diez, Germany Tel: + 49 6432 6070 Fax: +49 6432 60752 E-mail: mail@drache-gmbh.de web: www.drache-gmbh.de Sales Contact: Frank Reusch

HYCAST AS

Industrivien 49, Sunndalsora 6600, Norway Tel: +47 71 69 38 00 Fax: +47 71 69 00 65 E-mail: hycast@hydro.com Web: www.hycast.no Sales Contact: Jens Meyer-Olsen


THE BUYERS GUIDE | S5

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Novelis PAE

extrutec GmbH

Centr’Alp-BP 24 F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: pae.autopak@novelis.com Web: www.novelis.com/pae Sales Contact: Ghislain Le Roy, Antoine Le Tullier, Olivier Schneider

ALTEK LLC

Fritz-Reichle-Ring 2, D-78315 Radolfzell, Germany Tel: +49 (0) 7732 939 1370 Fax: +49 (0) 7732 939 1399 web: www.extrutec-gmbh.de E-mail: bucher@extrutec-gmbh.de Sales Contact: Ulrich Bucher

Société des Technologies de l’Aluminium de Saguenay Inc (STAS)

1846 rue Outarde, Chicoutimi Québec, Canada G7K 1H1 Tel: +1 418 696 0074 Fax: +1 418 545 8335 E-mail: marketing@stas.com Web: www.stas.com Sales Contact: Louis Bouchard

Die Heaters Castool Tooling Systems (Europe)

Comexale: 3 Allée du Pré Ory F-54425 Pulnoy France Tel: +33 3 83 35 46 49 Fax: +33 3 83 35 50 92 E-mail: bach@comexale.com Web: www.castool.com Sales Contact: Emanuel Bach

Castool Tooling Systems (North America)

2 Parratt Road, Uxbridge Ontario Canada L9P 1R1 Tel: +1 905 852 0121 Fax: +1 905 852 2300 E-mail: sales@castool.com Web: www.castool.com Sales Contact: Dan Dunn

IUT Industriell Ugnsteknik Sweden AB

Industrivägen 2, 438 92 Härryda, Sweden Tel: +46 301 50 8031 Mob: +46 702 43 48 40 Exch. +46 301 50 80 00 Fax: +46 301 304 79 E-mail: fredrik.berge@iut.se Web: www.iut.se Sales Contact: Fredrik Berge

Electro Magnetic Stirring ABB AB

Edisonstrasse 5 D-52152 Simmerath, Germany Tel: +49 2473 94880 Fax: +49 2473 948811 E-mail: info@schwartz-wba.de Web: www.schwartz-wba.de Sales Contact: Harald Lehmann

Die Ovens Granco Clark

7298 N. Storey Rd. Belding, MI 48809 USA Tel: +1-800-918-2600 Fax: +1-616-794-2878 Email: gcinfo@grancoclark.com Web: www.grancoclark.com Sales Contact: Michael Werner

IUT Industriell Ugnsteknik Sweden AB

Terminalvägen 24, Västeräs SE 721 59, Sweden Tel +46 21 32 50 00 Fax: +46 21 14 83 27 E-mail: info.metallurgy@se.abb.com E-mail: service.metallurgy@se.abb.com Web: www.abb.com/metallurgy Sales Contact: Olof Sjödén

ALTEK Europe Limited

Lakeside House, Turnoaks Business Park Burley Close, Chesterfield, Derbyshire S40 2UB. United Kingdom Tel: +44 (0) 1246 383737 Fax: +44 (0) 1246 383738 E-mail: alanpeel@altek-al.com Web: www.altek-al.com Sales Contact: Alan Peel

ALTEK LLC

380 Lapp Road, Suite A Malvern, PA 19355, USA Tel: +1-484-713 0070 Fax: +1-484-713 0048 E-mail:jamesherbert@altek-al.com Web: www.altek-al.com Sales Contact: James Herbert

GORS Limited

Industrivägen 2, 438 92 Härryda, Sweden Tel: +46 301 50 8031 Mob: +46 702 43 48 40 Exch. +46 301 50 80 00 Fax: +46 301 304 79 E-mail: fredrik.berge@iut.se Web: www.iut.se Sales Contact: Fredrik Berge

Thermserve

Halesfield 2, Telford TF7 4QH UK Tel: +44 (0) 1952 684488 Fax: +44 (0) 1952 684489 E-mail: steve@thermserve.com Web: www.thermserve.com Sales Contact: Steven Hodgkiss

Dross Management & Handling

K Home International Limited

Ingram House, Allensway, Thornaby Stockton-on-Tees TS17 9HA, UK Tel: +44 (0) 1642 765421 Fax: +44 (0) 1642 760721 E-mail: enquiries@khomeint.com Web: www.khomeint.com

Extrusion Die Cleaning

Schwartz GmbH

Pyrotek

705 W 1st Ave. Spokane, WA 99201 USA Tel: +1 509 926 6212 Web: www.pyrotek.info E-mail: info@pyrotek.info Sales Contact: Aluminium Sales

380 Lapp Road, Suite A Malvern, PA 19355, USA Tel: +1-484-713 0070 Fax: +1-484-713 0048 E-mail:jamesherbert@altek-al.com Web: www.altek-al.com Sales Contact: James Herbert

GRAF Technik GmbH

Max-Eyth-Strasse 23, D-70736 Fellbach Germany Tel: +49 711 633447 0 Fax: +49 711 633447 25 E-mail: info@graf-technik.de Web: www.graf-technik Sales Contact: Heiko Graf

Extrusion Cooling System extrutec GmbH

Fritz-Reichle-Ring 2, D-78315 Radolfzell, Germany Tel: +49 (0) 7732 939 1370 Fax: +49 (0) 7732 939 1399 web: www.extrutec-gmbh.de E-mail: bucher@extrutec-gmbh.de Sales Contact: Ulrich Bucher

Extrusion Die Maker Elite Extrusion Die Ltd

50 Augusta Deglava Str. Riga, LV 1035, Latvia Tel: +371 673 81684 Fax: +371 673 81687 Mobile: +371 295 77455 E-mail: alex@gors-aluminium.com Web: www.gors-aluminium.com Sales Contact: Alex Isidorov

Hurricane Road, Gloucester Business Park, Gloucester GL3 4AQ UK Tel: +44 (0) 1452 618900 Fax: +44 (0) 1452 613444 E-mail: steve@elitedie.eu Web: www.elitedie.eu Sales Contact: Steve Rogers

Fives Solios Limited

Eroga Die Company Limited

Heathbrook House, Heath Mill Road, Wombourne, Wolverhampton WV5 8AP UK Tel: +44 (0) 1902 324000 Fax: +44 (0) 1902 324544 E-mail: fivessolios@fivesgroup.com Web: www.fivesgroup.com

6A Eastbrook Road, Eastern Avenue Gloucester, GL4 3DB, UK Tel: +44 (0) 1452 524039 Fax: +44 (0) 1452 500615 E-mail: alantownsend@erogadie.com Web: www.erogadie.com Sales Contact: Alan Townsend

Engineering Design

ALTEK Europe Limited

FATA EPC

Lakeside House, Turnoaks Business Park Burley Close, Chesterfield, Derbyshire S40 2UB. United Kingdom Tel: +44 (0) 1246 383737 Fax: +44 (0) 1246 383738 E-mail: alanpeel@altek-al.com Web: www.altek-al.com Sales Contact: Alan Peel

Strada Statale 24, Km 12 I-10044 Pianezza (Torino) Italy Tel: +39 011 9668.1 Fax: +39 011 9661.207 E-mail: d.tenivella@fataepc.com Web: www.fataepc.com Sales Contact: Daniela Tenivella

Aluminium Times April/May 2016

Extrusion Form Tools Ltd

Stella Way Malvern View Business Park Bishops Cleeve, Cheltenham GL52 7DQ UK Tel: +44 (0) 1242 673377 Fax: +44 (0) 1242 677711 E-mail: duncan.henderson@ extrusionformtools.com Sales Contact: Duncan Henderson


S6 | THE BUYERS GUIDE Extrusion Equipment

www. mmc p ub l i c a ti o n s . co . u k

Smith Ferram

Marx GmbH & Co. KG

Innovatherm

Assimakis S.A.,

Advanced Machinery for Extrusion Plants P.O.B. 81, Inofita, Viotia, P.C. 32011 Greece Tel: +30 22620 32054 Fax: +30 22620 32250 E-mail: info@assimakis.gr Web: www.assimakis.gr Sales Contact: Maria Assimaki

Våvrovicka 275/89 Opava 74601, Czech Republic Tel: +420 553 608 608 Fax: +420 553 608 609 E-mail: info@ferram.cz Web: www.smithferram.com Sales Contact: David Vecerka

Thermserve

Lilienthalstrasse 6-13 D-58638 Iserlohn, Germany Tel + 49 2371 2105-0 Fax: +49 2371 2105-11 E-mail: info@marx-gmbh.de Web: www.marx-gmbh.de Sales Contact: Christian Eckenbach

Extrusion Roller Tools

Am Hetgesborn 12 D-35510 Butzbach, Germany Tel: +49 6033 9696 0 Fax: +49 6033 9696 9 E-mail: dmaiwald@innovatherm.de Web: www.innovatherm.de Sales Contact: Detlef Maiwald

Albarrie Canada Limited

Furnaces, Ageing GNA alutech Inc.,

85 Morrow Road, Barrie, Ontario, Canada L4N 3V7 Tel: +1 705 737 0551 Fax: +1 705 737 4044 E-mail: extrusion@albarrie.com Web: www.albarrieextrusion.com Sales Contact: Parker Robinson

9495 Trans-Canada Highway, SaintLaurent, Quebec, H4S 1V3, Canada Tel: +1 514 956 1776 Fax: +1 514 956 0562 E-mail: tphenix@gna.ca Web: www.gna.ca Sales Contact: Ted Phenix

Butech Bliss

550 Ellsworth Avenue Salem Ohio 44460, United States Tel: +1 330 337 0000 Fax: +1 330 337 0800 E-mail: sales@butech.com Web: www.butechbliss.com Sales Contact: Al Waigand

Castool Tooling Systems (Europe)

Comexale: 3 Allée du Pré Ory F-54425 Pulnoy France Tel: +33 3 83 35 46 49 Fax: +33 3 83 35 50 92 E-mail: bach@comexale.com Web: www.castool.com Sales Contact: Emanuel Bach

Castool Tooling Systems (North America) 2 Parratt Road, Uxbridge Ontario Canada L9P 1R1 Tel: +1 905 852 0121 Fax: +1 905 852 2300 E-mail: sales@castool.com Web: www.castool.com Sales Contact: Dan Dunn

Granco Clark

Halesfield 2, Telford TF7 4QH UK Tel: +44 (0) 1952 684488 Fax: +44 (0) 1952 684489 E-mail: steve@thermserve.com Web: www.thermserve.com Sales Contact: Steven Hodgkiss

Extrusion Tool & Die Shop TURLA SRL

ATEMA Srl

Via del Pavione 6/8 I-25050 Paderno Franciacorta (Brescia) Italy Tel: +39 030 6857555 Fax: +39 030.6857556 E-mail: i@turla.it Website: www.turla.it Sales Contact: Stefania Venturi

Extrusion Plant Assimakis S.A.,

Advanced Machinery for Extrusion Plants P.O.B. 81, Inofita, Viotia, P.C. 32011 Greece Tel: +30 22620 32054 Fax: +30 22620 32250 E-mail: info@assimakis.gr Web: www.assimakis.gr Sales Contact: Maria Assimaki

SMS group GmbH 7298 N. Storey Rd. Belding, MI 48809 USA Tel: +1-800-918-2600 Fax: +1-616-794-2878 Email: gcinfo@grancoclark.com Web: www.grancoclark.com Sales Contact: Michael Werner

KAUTEC SOLUTIONS S. L.

Ohlerkirchweg 66 41069 Mönchengladbach, Germany Tel: +49 2161 350-0 Fax: +49 2161 350-1667 E-mail: communications@sms-group.com Web: www.sms-group.com

Extrusion Press Container Heating IAS GmbH

c/ del Noc, 24. Pol. Industrial La Farga ES-17820 Banyoles (Girona), Spain Tel: +34 972 584 611 Fax: +34 972 574 174 E-mail: Kautec@Kautec.net Web: www.kautec.net Sales Contact: Roger Blanch

IUT Industriell Ugnsteknik Sweden AB

Via Stella 66 S. Vigilio di Concesio 25062 Italy Tel: + 39 030 2185399 Fax: +39 030 2185371 E-mail: anna.semenkova@atema-utensili.it www.atematools.com Sales Contact: Anna Semenkova

Extrusion Transfer Belts Albarrie Canada Limited

85 Morrow Road, Barrie, Ontario, Canada L4N 3V7 Tel: +1 705 737 0551 Fax: +1 705 737 4044 E-mail: extrusion@albarrie.com Web: www.albarrieextrusion.com Sales Contact: Parker Robinson

Filtration Systems

LOI Thermprocess GmbH

Am Lichtbogen 29, D-45141 Essen Germany Tel: +49 201 1891-1 Fax: +49 201 1891-321 E-mail: loi@tenova.com Web: www.tenova.com Sales Contact: Andrea Kehry (Marketing)

REMIX S.A.

Primetals Technologies Limited

Chiswick Park Building 11 566 Chiswick High Road W4 5YS London United Kingdom Web: www.primetals.com

Fume Treatment Fives Solios SA

Am Grossen Teich 27 Iserlohn D-58640 Germany Tel: +49 2371 43460 Fax: +49 2371 434643 E-mail: sales@ias-induction.com Web: www.ias-induction.com Sales Contact: Gerhard Kleinert

Industrivägen 2, 438 92 Härryda, Sweden Tel: +46 301 50 8031 Mob: +46 702 43 48 40 Exch. +46 301 50 80 00 Fax: +46 301 304 79 E-mail: fredrik.berge@iut.se Web: www.iut.se Sales Contact: Fredrik Berge

25-27 bd de la Paix 78100 ST GERMAIN EN LAYE Tel : +33 1 30 87 45 50 Fax : +33 1 30 87 45 55 E-mail: fivessolios@fivesgroup.com Web: www.fivesgroupcom

Aluminium Times April/May 2016

ul. Poznańska 36 66-200 Świebodzin Poland Tel: +48 68 47 55 400 Fax: +48 68 47 55 404 E-mail: office@remixsa.pl Web: www.remixsa.pl Sales Contact: Rafat Kuznicki

SECO/WARWICK Europe S.A.

ul.Swierczewskiego 76 PL 66-200 Swiebodzin, Poland Tel: +48 68 3819 917 Fax: +48 68 3819 805 E-mail: europe@secowarwick.com.pl Web: www.secowarwick.com Sales Contact: Tomasz Kaczmarczyk


THE BUYERS GUIDE | S7

www.mmcpubl icat io n s. co . u k 

Furnaces, Annealing IUT Industriell Ugnsteknik Sweden AB

Industrivägen 2, 438 92 Härryda, Sweden Tel: +46 301 50 8031 Mob: +46 702 43 48 40 Exch. +46 301 50 80 00 Fax: +46 301 304 79 E-mail: fredrik.berge@iut.se Web: www.iut.se Sales Contact: Fredrik Berge

REMIX S.A.

ul. Poznańska 36 66-200 Świebodzin Poland Tel: +48 68 47 55 400 Fax: +48 68 47 55 404 E-mail: office@remixsa.pl Web: www.remixsa.pl Sales Contact: Rafat Kuznicki

SECO/WARWICK Europe S.A.

ul.Swierczewskiego 76 PL 66-200 Swiebodzin, Poland Tel: +48 68 3819 917 Fax: +48 68 3819 805 E-mail: europe@secowarwick.com.pl Web: www.secowarwick.com Sales Contact: Tomasz Kaczmarczyk

Sistem Teknik Industrial Furnaces

Furnace Charging & Tending Equipment MECFOR Inc

1788 Mitis Street, Chicoutimi G7K 1H5 (Qc) Canada Tel: +1 418 543 1632 Fax: +1 418 543 4351 E-mail: mecfor@mecfor.com Web: www.mecfor.com Sales Contact: Richard A. Zalzal

INSERTEC - Ingeniería y Servicios Técnicos, S.A

Avenida Cervantes nº 6 ES - 48970 Basauri, Spain Tel: +34 944 409 420 Fax: +34 944 496 624 Email: insertec@insertec.biz Web: www.insertec.biz Sales Contact: Javier Cobos

SECO/WARWICK Europe S.A.

ul.Swierczewskiego 76 PL 66-200 Swiebodzin, Poland Tel: +48 68 3819 917 Fax: +48 68 3819 805 E-mail: europe@secowarwick.com.pl Web: www.secowarwick.com.pl Sales Contact: Tomasz Kaczmarczyk

Sistem Teknik Industrial Furnaces

LOI Thermprocess GmbH

Furnaces, Heat Treatment Ecotherm End.Müh.ISI Tekn.Dans. San. Tic. Ltd. Sti

DES Sanayi Sitesi 104 Porsuk Sk. B 10 Blok No:2 Y.Dudullu – Ümraniye Istanbul 34778 Turkey Tel: +90 216 540 34 51 Fax: +90 216 540 34 52 E-mail: info@ecotherm.com.tr Web: www.ecotherm.com.tr Sales Contact: Cenk Yildirim

Am Lichtbogen 29 D-45141 Essen Germany Tel: +49 201 1891-1 Fax: +49 201 1891-321 E-mail: loi@tenova.com Web: www.tenova.com Sales Contact: Andrea Kehry (Marketing)

Mechatherm International Ltd

TOSB-TAYSAD O.S.B, 1.Cadde 14. Sok No.3, TR-41420 Gebze, Kocaeli, Turkey Tel: +90 262 658 22 26 Fax: +90 262 658 22 38 E-mail: info@sistemteknik.com Web: www.sistemteknik Sales Contact: Erdal Sahin

Furnaces, High Temperature Insulation Materials HKO Heat Protection Group

Fives Solios Limited

Heathbrook House, Heath Mill Road, Wombourne, Wolverhampton WV5 8AP UK Tel: +44 (0) 1902 324000 Fax: +44 (0) 1902 324544 E-mail: fivessolios@fivesgroup.com Web: www.fivesgroup.com

Hampshire House, High Street Kingswinford DY6 8AW, UK Tel: +44 (0) 1384 279132 Fax: +44 (0) 1384 291211 E-mail: sales@mechatherm.com Web: www.mechatherm.com Sales Contact: Stuart Allen

REMIX S.A.

Zum Eisenhammer 54 D-46049 Oberhausen, Germany Tel: +49 208 8 59 94-0 Fax: +49 208 8 59 94-70 E-mail: info@hko.de Web: www.hko.de Sales Contact: Sales Office

Furnaces, Holding GNA alutech Inc.,

Gautschi Engineering GmbH

TOSB-TAYSAD O.S.B, 1.Cadde 14. Sok No.3, TR-41420 Gebze, Kocaeli, Turkey Tel: +90 262 658 22 26 Fax: +90 262 658 22 38 E-mail: info@sistemteknik.com Web: www.sistemteknik Sales Contact: Erdal Sahin

Furnaces, Billet Heating Granco Clark

7298 N. Storey Rd. Belding, MI 48809 USA Tel: +1-800-918-2600 Fax: +1-616-794-2878 Email: gcinfo@grancoclark.com Web: www.grancoclark.com Sales Contact: Michael Werner

Thermserve

Andhauserstrasse 52 8572 Berg TG, Switzerland Tel: +41 71 666 66 66 Fax: +41 71 666 66 77 E-mail: info@gautschi.cc Web: www.gautschi.cc Sales Contact: Sales Department

GNA alutech Inc.

9495 Trans-Canada Highway, SaintLaurent, Quebec, H4S 1V3, Canada Tel: +1 514 956 1776 Fax: +1 514 956 0562 E-mail: tphenix@gna.ca Web: www.gna.ca Sales Contact: Ted Phenix

Hengelmolen Engineering Ltd

Halesfield 2, Telford TF7 4QH UK Tel: +44 (0) 1952 684488 Fax: +44 (0) 1952 684489 E-mail: steve@thermserve.com Web: www.thermserve.com Sales Contact: Steven Hodgkiss

Unit 2, Thornleigh Trading Estate Dudley DY2 8UB, UK Tel: +44 (0) 1384 211 183 E-mail: sales@hengelmolen.com Web: www.hengelmolen.com Sales Contact: Andrew Hawkes

ul. Poznańska 36 66-200 Świebodzin Poland Tel: +48 68 47 55 400 Fax: +48 68 47 55 404 E-mail: office@remixsa.pl Web: www.remixsa.pl Sales Contact: Rafat Kuznicki

Schwartz GmbH

Edisonstrasse 5, D-52152 Simmerath, Germany Tel: +49 2473 94880 Fax: +49 2473 948811 E-mail: info@schwartz-wba.de Web: www.schwartz-wba.de Sales Contact: Harald Lehmann

ONE ENTRY WITH LOGOFOR 5 ISSUES

€349; $392USA; £235GBP

TO ADVERTISE CONTACT JOHN CLARKE: JOHNCLARKE@MMCPUBLICATIONS.CO.UK

Aluminium Times April/May 2016

9495 Trans-Canada Highway, SaintLaurent, Quebec, H4S 1V3, Canada Tel: +1 514 956 1776 Fax: +1 514 956 0562 E-mail: tphenix@gna.ca Web: www.gna.ca Sales Contact: Ted Phenix

Furnaces, Homogenising Ecotherm End.Müh.ISI Tekn.Dans. San. Tic. Ltd. Sti

DES Sanayi Sitesi 104 Porsuk Sk. B 10 Blok No:2 Y.Dudullu – Ümraniye Istanbul 34778 Turkey Tel: +90 216 540 34 51 Fax: +90 216 540 34 52 E-mail: info@ecotherm.com.tr Web: www.ecotherm.com.tr Sales Contact: Cenk Yildirim

GNA alutech Inc.,

9495 Trans-Canada Highway Saint-Laurent, Quebec, H4S 1V3, Canada Tel: +1 514 956 1776 Fax: +1 514 956 0562 E-mail: tphenix@gna.ca Web: www.gna.ca Sales Contact: Ted Phenix


S8 | THE BUYERS GUIDE Hengelmolen Engineering Ltd

Unit 2, Thornleigh Trading Estate Dudley DY2 8UB, UK Tel: +44 (0) 1384 211 183 E-mail: sales@hengelmolen.com Web: www.hengelmolen.com Sales Contact: Andrew Hawkes

Hertwich Engineering GmbH

Weinbergerstrasse 6, A-5280 Braunau, Austria Tel: +43 7722 806-0 Fax: +43 7722 806-122 E-mail: info@hertwich.com Web: www.hertwich.com Sales Contact: Elke Deubler

LOI Thermprocess GmbH

www. mmc p ub l i c a ti o n s . co . u k

Schwartz GmbH

Edisonstrasse 5 D-52152 Simmerath Germany Tel: +49 2473 94880 Fax: +49 2473 948811 E-mail: info@schwartz-wba.de Web: www.schwartz-wba.de Sales Contact: Harald Lehmann

SECO/WARWICK Europe S.A.

ul.Swierczewskiego 76 PL 66-200 Swiebodzin, Poland Tel: +48 68 3819 917 Fax: +48 68 3819 805 E-mail: europe@secowarwick.com.pl Web: www.secowarwick.com Sales Contact: Tomasz Kaczmarczyk

Furnaces, Melting Am Lichtbogen 29, D-45141 Essen Germany Tel: +49 201 1891-1 Fax: +49 201 1891-321 E-mail: loi@tenova.com Web: www.tenova.com Sales Contact: Andrea Kehry (Marketing)

Pyrotek

705 W 1st Ave. Spokane, WA 99201 USA Tel: +1 509 926 6212 Web: www.pyrotek.info E-mail: info@pyrotek.info Sales Contact: Aluminium Sales

Dross Engineering SAS

9, rue de la Prairie 77700 Bailly Romainvillers, Marne la Vallée, France Tel: +33 (0) 1 60 42 42 00 Fax: ++33 (0) 60 42 42 01 E-mail: jsimpson@dross-engineering.com Web:www.drossengineering.com Sales Contact: John Simpson

Fives Solios Limited

REMIX S.A.

ul. Poznańska 36 66-200 Świebodzin Poland Tel: +48 68 47 55 400 Fax: +48 68 47 55 404 E-mail: office@remixsa.pl Web: www.remixsa.pl Sales Contact: Rafat Kuznicki

Sistem Teknik Industrial Furnaces

TOSB-TAYSAD O.S.B, 1.Cadde 14. Sok No.3, TR-41420 Gebze, Kocaeli, Turkey Tel: +90 262 658 22 26 Fax: +90 262 658 22 38 E-mail: info@sistemteknik.com Web: www.sistemteknik Sales Contact: Erdal Sahin

ONE ENTRY WITH LOGOFOR 5 ISSUES

€349; $392USA; £235GBP

TO ADVERTISE CONTACT JOHN CLARKE: JOHNCLARKE@MMCPUBLICATIONS.CO.UK

Heathbrook House, Heath Mill Road, Wombourne, Wolverhampton WV5 8AP UK Tel: +44 (0) 1902 324000 Fax: +44 (0) 1902 324544 E-mail: fivessolios@fivesgroup.com Web: www.fivesgroup.com

Gautschi Engineering GmbH

Andhauserstrasse 52 8572 Berg TG, Switzerland Tel: +41 71 666 66 66 Fax: +41 71 666 66 77 E-mail: info@gautschi.cc Web: www.gautschi.cc Sales Contact: Sales Department

GNA alutech Inc.,

Hengelmolen Engineering Ltd

Melting Solutions Limited

Unit 2, Thornleigh Trading Estate Dudley DY2 8UB, UK Tel: +44 (0) 1384 211 183 E-mail: sales@hengelmolen.com Web: www.hengelmolen.com Sales Contact: Andrew Hawkes

Unit E, Dunton Park, Kingsbury Road, Curdworth, Sutton Coldfield B76 9EB United Kingdom Tel: +44 (0) 1675 470 551 Fax: +44 (0) 1675 470 645 E-mail: enquiries@meltingsolutions.co.uk Web: www.meltingsolutions.co.uk Sales Contact: Clive Hall

Hertwich Engineering GmbH

REMIX S.A. Weinbergerstrasse 6 A-5280 Braunau, Austria Tel: +43 7722 806-0 Fax: +43 7722 806-122 E-mail: info@hertwich.com Web: www.hertwich.com Sales Contact: Elke Deubler

INSERTEC - Ingeniería y Servicios Técnicos, S.A

Avenida Cervantes nº 6 48970 Basauri – Spain Tel:+34 944 409 420 Fax: +34 944 496 624 Web: www.insertec.biz Sales Contact: Enrique Uriarte

Jasper Gesellschaft für Energiewirtschaft und Kybernetik GmbH

ul. Poznańska 36 66-200 Świebodzin Poland Tel: +48 68 47 55 400 Fax: +48 68 47 55 404 E-mail: office@remixsa.pl Web: www.remixsa.pl Sales Contact: Rafat Kuznicki

SECO/WARWICK Europe S.A.

ul.Swierczewskiego 76 PL 66-200 Swiebodzin, Poland Tel: +48 68 3819 917 Fax: +48 68 3819 805 E-mail: europe@secowarwick.com.pl Web: www.secowarwick.com Sales Contact: Tomasz Kaczmarczyk

Bönninghauser Strasse 10 D-59590 Geseke, Germany Tel: +49 2942 9747 - 0 Fax: +49 2942 9747 - 47 E-mail: info@jasper-gmbh.com Web: www.jasper-gmbh.com Sales Contact: Peter Klatecki

Sistem Teknik Industrial Furnaces

LOI Thermprocess GmbH

TOSB-TAYSAD O.S.B, 1.Cadde 14. Sok No.3, TR-41420 Gebze, Kocaeli, Turkey Tel: +90 262 658 22 26 Fax: +90 262 658 22 38 E-mail: info@sistemteknik.com Web: www.sistemteknik Sales Contact: Erdal Sahin

Am Lichtbogen 29 D-45141 Essen Germany Tel: +49 201 1891-1 Fax: +49 201 1891-321 E-mail: loi@tenova.com Web: www.tenova.com Sales Contact: Andrea Kehry (Marketing)

Furnaces, Melting, Dross & Scrap Altek Europe Limited

Major Furnace Australia Pty Limited 92 Fairbank Road Clayton, Victoria 3169 Australia Tel: +61 3 8558 1800 Fax: +61 3 8558 1805 E-mail: major@majoreng.com.au Web: www.majoreng.com.au Sales Contact: Andrew North

Mechatherm International Ltd

Lakeside House, Turnoaks Business Park Burley Close, Chesterfield, Derbyshire S40 2UB, United Kingdom Tel: +44 (0) 1246 383737 Fax: +44 (0) 1246 383738 E-mail: alanpeel@altek-al.com Web: www.altek-al.com Sales Contact: Alan Peel

ALTEK LLC 9495 Trans-Canada Highway Saint-Laurent, Quebec, H4S 1V3, Canada Tel: +1 514 956 1776 Fax: +1 514 956 0562 E-mail: tphenix@gna.ca Web: www.gna.ca Sales Contact: Ted Phenix

Hampshire House High Street Kingswinford DY6 8AW UK Tel: +44 (0) 1384 279132 Fax: +44 (0) 1384 291211 E-mail: sales@mechatherm.com Web: www.mechatherm.com Sales Contact: Stuart Allen

Aluminium Times April/May 2016

380 Lapp Road, Suite A Malvern, PA 19355, USA Tel: +1-484-713 0070 Fax: +1-484-713 0048 E-mail:jamesherbert@altek-al.com Web: www.altek-al.com Sales Contact: James Herbert


THE BUYERS GUIDE | S9

www.mmcpubl icat io n s. co . u k 

Altek Europe Limited

Lakeside House, Turnoaks Business Park Burley Close, Chesterfield, Derbyshire S40 2UB, United Kingdom Tel: +44 (0) 1246 383737 Fax: +44 (0) 1246 383738 E-mail: alanpeel@altek-al.com Web: www.altek-al.com Sales Contact: Alan Peel

ALTEK L.L.C.

380 Lapp Road, Suite A Malvern, PA 19355, USA Tel: +1-484-713 0070 Fax: +1-484-713 0048 E-mail:jamesherbert@altek-al.com Web: www.altek-al.com Sales Contact: James Herbert

Ecotherm End.Müh.ISI Tekn.Dans. San. Tic. Ltd. Sti

DES Sanayi Sitesi 104 Porsuk Sk. B 10 Blok No:2 Y.Dudullu – Ümraniye Istanbul 34778 Turkey Tel: +90 216 540 34 51 Fax: +90 216 540 34 52 E-mail: info@ecotherm.com.tr Web: www.ecotherm.com.tr Sales Contact: Cenk Yildirim

Gas Detection Boreal Laser Inc

Lethiguel SAS

12846 - 146 Street, Edmonton, Alberta T5L 2HZ Tel: +1 780 488 5173 Fax: +1 780 488 0780 E-mail: sales@boreal-laser.com Web: www.boreal-laser.com Sales Contact: Hamish Adam

75 Rue Louis Arnal – zac des Prés Secs Lozanne F-69380,France Tel: +33 478 348624 E-mail: contact@lethiguel.com Web: www.lethiguel.com Sales Contact: Guillaume Levacher

Gas Fired Heaters with Hot Saws/ Hot Log Shear Granco Clark

Furnaces Melting Tilting and Rotary REMIX S.A.

ul. Poznańska 36 66-200 Świebodzin Poland Tel: +48 68 47 55 400 Fax: +48 68 47 55 404 E-mail: office@remixsa.pl Web: www.remixsa.pl Sales Contact: Rafat Kuznicki

Furnaces, Open top & closed type for anodes, electrodes and cathodes Riedhammer GmbH

7298 N. Storey Rd. Belding, MI 48809 USA Tel: +1-800-918-2600 Fax: +1-616-794-2878 Email: gcinfo@grancoclark.com Web: www.grancoclark.com Sales Contact: Michael Werner

Graphite Rotors & Shafts Novelis PAE S.A.S.

Centr’Alp-BP 24 F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: brigitte.gout@novelis.com Web: www.novelis.com/pae Sales Contact : Olivier Schneider; Brigitte Gout

Société des Technologies de l’Aluminium de Saguenay Inc (STAS)

1846 rue Outarde, Chicoutimi Québec, Canada G7K 1H1 Tel: +1 418 696 0074 Fax: +1 418 545 8335 E-mail: marketing@stas.com Web: www.stas.com Sales Contact: Louis Bouchard

Insulcon BV

Zilverhoek 4, NL-4651 SP Steenbergen, Netherlands Tel: +31 167 565750 Fax: +31 167 566263 E-mail: info@insulcon.com Web: www.insulcon.com Sales Contact: Sales Office

Induction Heating IAS GmbH

Sistem Teknik Industrial Furnaces

TOSB-TAYSAD O.S.B, 1.Cadde 14. Sok No.3, TR-41420 Gebze, Kocaeli, Turkey Tel: +90 262 658 22 26 Fax: +90 262 658 22 38 E-mail: info@sistemteknik.com Web: www.sistemteknik Sales Contact: Erdal Sahin

Log heaters, gas fired with hot log saws / hot log shears

Am Grossen Teich 27 Iserlohn D-58640 Germany Tel: +49 2371 43460 Fax: +49 2371 434643 E-mail: sales@ias-induction.com Web: www.ias-induction.com Sales Contact: Gerhard Kleinert

Inductotherm Heating & Welding Ltd

Thermatool House Crockford Lane Basingstoke Hampshire, RG24 8NA UK Tel: +44 (0)1256 335533 Fax: +44 (0) 1256 467224 E-mail: WHine@inductothermhw.co.uk Web: www.inductothermhw.com Sales Contact: Wayne Hine

Induction Heating Repairs Interpower Induction

Buss ChemTech AG

Hohenrainstrasse 12A CH Pratteln 1, Switzerland Tel: +41 61 825 6462 Fax: +41 61 825 6737 E-mail: info@buss-ct.com Web: www.buss-ct.com Sales Contact: Daniel Haeusler

32 rue Fleury Neuvesel, F-69702 Givors, France Tel: +33 4 72 49 54 54 Fax: +33 4 72 49 54 32 E-mail: fivessolios@fivesgroup.com Web: www.fivesgroup.com

Fritz-Reichle-Ring 2, D-78315 Radolfzell Germany Tel: +49 (0) 7732 939 1370 Fax: +49 (0) 7732 939 1399 web: www.extrutec-gmbh.de E-mail: bucher@extrutec-gmbh.de Sales Contact: Ulrich Bucher

Log Shears Thermserve

Green Anode Plants

Fives Solios SA

Klingenhofstrasse 72 D-90411 Nuremberg, Germany Tel: +49 911 5218 0 Fax: +49 911 521 8231 E-mail: thomas.janousch@riedhammer.de Web: www.riedhammer.de Sales Contact: Thomas Janousch

High Temperature Insulation Materials

Log Heater

extrutec GmbH

Sistem Teknik Industrial Furnaces

TOSB-TAYSAD O.S.B, 1.Cadde 14. Sok No.3, TR-41420 Gebze, Kocaeli, Turkey Tel: +90 262 658 22 26 Fax: +90 262 658 22 38 E-mail: info@sistemteknik.com Web: www.sistemteknik Sales Contact: Erdal Sahin

Heating Solutions

Unit E, Dunton Park, Kingsbury Road, Curdworth, Sutton Coldfield B76 9EB United Kingdom Tel: +44 (0) 1675 470 551 Fax: +44 (0) 1675 470 645 E-mail: enquiries@meltingsolutions.co.uk Web: www.meltingsolutions.co.uk Sales Contact: David Bell

Insulation Body Soluble Fibres

Halesfield 2, Telford TF7 4QH UK Tel: +44 (0) 1952 684488 Fax: +44 (0) 1952 684489 E-mail: steve@thermserve.com Web: www.thermserve.com Sales Contact: Steven Hodgkiss

Lubricants Castool Tooling Systems (Europe)

Comexale: 3 Allée du Pré Ory F-54425 Pulnoy France Tel: +33 3 83 35 46 49 Fax: +33 3 83 35 50 92 E-mail: bach@comexale.com Web: www.castool.com Sales Contact: Emanuel Bach

Castool Tooling Systems (North America) 2 Parratt Road, Uxbridge Ontario Canada L9P 1R1 Tel: +1 905 852 0121 Fax: +1 905 852 2300 E-mail: sales@castool.com Web: www.castool.com Sales Contact: Dan Dunn

Insulcon BV

Klüber Lubrication

Zilverhoek 4, NL-4651 SP Steenbergen, Netherlands Tel: +31 167 565750 Fax: +31 167 566263 E-mail: info@insulcon.com Web: www.insulcon.com Sales Contact: Sales Office

Geisenhausenerstrasse 7 81379 München, Germany Tel: +49 89 7876-0 E-mail: alu-extrusion@klueber.com Web: www.klueber.com/en/metalworking Sales Contact: Stefan Ott

Aluminium Times April/May 2016


S10 | THE BUYERS GUIDE Marking and Automatic Identification

www. mmc p ub l i c a ti o n s . co . u k

Ascona GmbH

Thermo Fisher Scientific

Karlstrasse 7, D-88074 Meckenbeuren Germany Tel: +49 7542 9464-0 Fax: +49 7542 9464-50 E-mail: info@ascona.de Web: www.ascona.de

Elemental Analysis, En Vallaire Ouest C, 1024 Ecublens, Switzerland Tel: +41 21 694 71 11 E-mail: info.spetrometry@thermofisher.com Web: www.thermoscientific.com/oes Sales Contact: Sales Department

Novelis PAE S.A.S.

S+P Samson GmbH

Industriestrasse 32 D-86438 Kissing, Germany Tel: +49 8233 846-0 Fax: +49 8233 846-299 E-mail: info@sp-samson.com Web: www.sp-samson.com Sales Contact: Stefan Heinzler

Materials Handling

Sales Contact: Alexander Daniker HPI Ges. mbH

Assimakis S.A.,

Advanced Machinery for Extrusion Plants P.O.B. 81, Inofita, Viotia, P.C. 32011 Greece Tel: +30 22620 32054 Fax: +30 22620 32250 E-mail: info@assimakis.gr Web: www.assimakis.gr Sales Contact: Maria Assimaki

Combilift Ltd

Co. Monaghan, Ireland Tel: +353 478 0500 Fax: +353 478 0501 E-mail: info@combilift.com Web: www.combilift.com UK Sales: 07870 976758

H + H Herrmann + Hieber GmbH

Rechbergstrasse 46 D-73770 Denkendorf, Germany Tel: +49 711 93467-0 Fax: +49 711 3460911 E-mail: info@herrmannhieber.de Web: www.herrmannhieber.de Sales Contact: Sales Office

Vollert Anlagenbau GmbH

Stadtseestrasse 12 D-74189 Weinsberg, Germany Tel: +49 7134 52 220 Fax: +49 7134 52 222 E-mail: intralogistics@vollert.de Web: www.vollert.de Sales Contact: Oliver Wolschinski

Measurement & Testing ARMI-brand metal alloy CRMs from LGC Standards

Schloss Strasse 32, A-5282 Ranshofen, Austria Tel: +43 7722 68420 Fax: +43 7722 68805 E-mail: hpi@hpi.at Web: www.hpi.at Sales Contact: Rainer Edtmeier

Micro-Epsilon Messtechnik

Fives ECL

Société des Technologies de l’Aluminium de Saguenay Inc (STAS)

100 rue Chalant, F-59790 Ronchin, France Tel: +33 320 88 7070 Fax: +33 320 88 7099 E-mail: fivesecl@fivesgroup.com Web: www.fivesgroup.com Sales Contact: Pierre Escarbelt

1846 rue Outarde, Chicoutimi Québec, Canada G7K 1H1 Tel: +1 418 696 0074 Fax: +1 418 545 8335 E-mail: marketing@stas.com Web: www.stas.com Sales Contact: Louis Bouchard

NKM Noell Special Cranes GmbH

Koenigbacher Str. 15 94496 Ortenburg, Germany Tel: +49 8542 1680 Fax: +49 8542 16890 Email: info@micro-epsilon.de Web: www.micro-epsilon.com Sales Contact: Achim Sonntag

Polytec GmbH

Rudolf-Diesel-Strasse, 1 D-97209 Veitshoechheim, Germany Tel: +49 931 40473-0 Fax: +49 931 40473-1000 E-mail: Sales@nkmnoell.com Web: www.nkmnoellspecialcranes.com Sales: Klaus Freitag

Metal Circulation Altek Europe Limited

Polytec-Platz 1-7, D-76337 Waldbronn, Germany Tel: +49 7243 6040 Fax: +49 7243 69944 E-mail: info@polytec.de Web: www.polytec.de Sales Contact: Marion Ruzanji

PreciMeter Control AB

Ostra Hamnen 7 SE-475 42 Hono Sweden Tel: +46 31 764 5520 Fax: +46 31 764 5529 E-mail: marketing@precimeter.com Web: www.precimeter.com Sales Contact: Jonatan Lindstrand

Primetals Technologies Limited

276, Abby Road, Manchester, NH 03103, USA Tel: +1 603 935 4100 Fax: +1 603 935 4101 e-mail sales@armi.com Web: www.armi.com

Mechanical Handling

Chiswick Park, Building 11 566 Chiswick High Road W4 5YS London United Kingdom Web: www.primetals.com

Centr’Alp-BP 24, F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: pae.metaltreatment@novelis.com Web: www.novelis.com/pae Sales Contact: Ghislain Le Roy, Antoine Le Tullier, Olivier Schneider

Lakeside House, Turnoaks Business Park Burley Close, Chesterfield, Derbyshire S40 2UB. United Kingdom Tel: +44 (0) 1246 383737 Fax: +44 (0) 1246 383738 E-mail: alanpeel@altek-al.com Web: www.altek-al.com Sales Contact: Alan Peel

Molten Metal Ceramic Materials EREDI SCABINI srl

Via Brallo, 2 – 27010 Siziano (PV), Italy Tel: +39 0382 6671413 E-mail: sales_dept@erediscabini.com Web: www.erediscabini.com Sales Contact: Corrado Scabini

Molten Metal Level Control GAP Engineering SA

Techno-Pôle 5 CH-3960 Sierre, Switzerland Tel: +41 27 455 57 14 Fax: +41 27 455 57 15 E-Mail: info@gap-engineering.ch Sales Contact: Alfio Schillaci, Valloton Julien

Novelis PAE S.A.S.

ALTEK L.L.C. 380 Lapp Road, Suite A Malvern, PA 19355, USA Tel: +1-484-713 0070 Fax: +1-484-713 0048 E-mail:jamesherbert@altek-al.com Web: www.altek-al.com Sales Contact: James Herbertt

Metal Treatment Lethiguel SAS

Centr’Alp-BP 24 F-38341 Voreppe cedex, France Tel: +33 4 76 57 87 00 Fax: +33 4 76 56 65 39 E-mail: pae.autopak@novelis.com Web: www.novelis.com/pae Sales Contact: Ghislain Le Roy, Antoine Le Tullier, Olivier Schneider

PreciMeter Control AB

75 Rue Louis Arnal – zac des Prés Secs Lozanne F-69380 France Tel: +33 478 348624 E-mail: contact@lethiguel.com Web: www.lethiguel.com Sales Contact: Guillaume Levacher

Aluminium Times April/May 2016

Ostra Hamnen 7 SE-475 42 Hono Sweden Tel: +46 31 764 5520 Fax: +46 31 764 5529 E-mail: marketing@precimeter.com Web: www.precimeter.com Sales Contact: Jonatan Lindstrand


THE BUYERS GUIDE | S11

www.mmcpubl icat io n s. co . u k 

Wagstaff Inc

Packaging

optimAl Process Technology Ltd

Assimakis S.A., 3910 North Flora Road, Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person

Molten Metal Pumps Hertwich Engineering GmbH

Weinbergerstrasse 6, A-5280 Braunau, Austria Tel: +43 7722 806-0 Fax: +43 7722 806-122 E-mail: info@hertwich.com Web: www.hertwich.com Sales Contact: Elke Deubler

Molten Metal Equipment Innovations Inc

15510 Old State Road Middlefield, OH 44062 USA Tel: +1 440 632 9119 Fax: +1 440 632 9187 E-mail: info@mmei-inc.com Web: www.mmei-inc.com Sales Contact: Mark Andes

Molten Metal Siphoning Major Furnace Australia Pty Limited 92 Fairbank Road Clayton, Victoria 3169 Australia Tel: +61 3 8558 1800 Fax: +61 3 8558 1805 E-mail: major@majoreng.com.au Web: www.majoreng.com.au Sales Contact: Andrew North

Advanced Machinery for Extrusion Plants P.O.B. 81, Inofita, Viotia, P.C. 32011 Greece Tel: +30 22620 32054 Fax: +30 22620 32250 E-mail: info@assimakis.gr Web: www.assimakis.gr Sales Contact: Maria Assimaki

Rechbergstrasse 46 D-73770 Denkendorf, Germany Tel: +49 711 93467-0 Fax: +49 711 3460911 E-mail: info@herrmannhieber.de Web: www.herrmannhieber.de Sales Contact: Sales Office

Mastec Flexipac AB

Datorgatan 4, SE 561 33 Huskvarna, Sweden Tel: +46 10 218 1350 Fax: +46 36 13 27 80 E-mail: flexipac@mastec.se Web: www.mastec.se Sales Contact: Per Selskog

Vollert Anlagenbau GmbH

3910 North Flora Road Spokane WA 99216 USA Tel: +1 509 922 1404 Fax: +1 509 892 6013 E-mail: info@wagstaff.com Web: www.wagstaff.com Sales Contact: Kevin Person

Dross Engineering SAS

BWG Bergwerk-und Walzwerk Maschinenbau GmbH

Mercatorstrasse 74-78 D-47051 Duisburg Germany Tel: +49 203 99290 Fax: +49 203 9929400 E-mail: bwg@bwg-online.de Web: www.bwg-online.com Sales Contact: Stefan Sonntag

9, rue de la Prairie 77700 Bailly Romainvillers Marne la Vallée France Tel: +33 (0) 1 60 42 42 00 Fax: ++33 (0) 60 42 42 01 E-mail: jsimpson@dross-engineering.com Web:www.drossengineering.com Sales Contact: John Simpson

Fives Solios Limited

Production Management Systems PSI Metals Non Ferrous GmbH

Software Excellence in Metals Campus-Boulevard 57 52074 Aachen, Germany Tel: +49 241 927880-0 Fax: +49 241 927880-20 Web: www.psimetals.com Sales Contact: Volker Vogt

Profile Cooling

Heathbrook House, Heath Mill Road, Wombourne, Wolverhampton WV5 8AP UK Tel: +44 (0) 1902 324000 Fax: +44 (0) 1902 324544 E-mail: fivessolios@fivesgroup.com Web: www.fivesgroup.com

Hertwich Engineering GmbH

Granco Clark Stadtseestrasse 12 D-74189 Weinsberg, Germany Tel: +49 7134 52 220 Fax: +49 7134 52 222 E-mail: intralogistics@vollert.de Web: www.vollert.de Sales Contact: Oliver Wolschinski

Pre-Treatment & Coating Systems Prometal Galvano Cih San Tic Ltd STi

7298 N. Storey Rd. Belding, MI 48809 USA Tel: +1-800-918-2600 Fax: +1-616-794-2878 Email: gcinfo@grancoclark.com Web: www.grancoclark.com Sales Contact: Michael Werner

Project Management

Weinbergerstrasse 6 A-5280 Braunau, Austria Tel: +43 7722 806-0 Fax: +43 7722 806-122 E-mail: info@hertwich.com Web: www.hertwich.com Sales Contact: Elke Deubler

INSERTEC - Ingeniería y Servicios Técnicos, S.A

K Home International Limited

MQP Limited

Wagstaff Inc

380 Lapp Road, Suite A Malvern, PA 19355, USA Tel: +1-484-713 0070 Fax: +1-484-713 0048 E-mail:jamesherbert@altek-al.com Web: www.altek-al.com Sales Contact: James Herbert

Processing Lines

H + H Herrmann + Hieber GmbH

Molten Metal Technology

6 Hallcroft Way,Knowle, Solihull, B93 9EW, UK Tel: +44 (0) 1564 200443 Fax: +44 (0) 1564 200443 E-mail: john.courtenay@mqpltd.com Web: www.mqpltd.com Sales Contact: John Courtenay

Basepoint, Enterprise Way Christchurch BH23 6NW UK Tel: +44 (0) 1202 331640 Fax: +44 (0) 1202 331701 E-mail: john.mason@optimalprocess.co.uk Web: www.optimalprocess.co.uk Sales Contact: John Mason

ALTEK LLC

i.O.S.B. Mah. Milas Cad, Dis. Kapi No 13/A, Ig Kapi No: Z01, Basaksehir 34306, Turkey Tel: +90 212 549 9549 Fax; +90 212 549 9546 E-mail: info@prometalgalvano.com Web:www.prometalgalvano.com Sales Contact: Emin Kalip / Ertan Yuksel

Process Consulting Innoval Technology Ltd

Beaumont Close, Banbury OX16 1TQ, UK Tel: +44 (0) 1295 702800 Fax: +44 (0) 1295 702898 E-mail: enquiries@innovaltec.com Web: www.innovaltec.com Sales Contact: Helen Forrest

Ingram House, Allensway, Thornaby Stockton-on-Tees TS17 9HA, UK Tel: +44 (0) 1642 765421 Fax: +44 (0) 1642 760721 E-mail: enquiries@khomeint.com Web: www.khomeint.com

Recycling Equipment

Avenida Cervantes nº 6 ES - 48970 Basauri, Spain Tel: +34 944 409 420 Fax: +34 944 496 624 Email: insertec@insertec.biz Web: www.insertec.biz Sales Contact: Oscar Iribarren

Mechatherm International Ltd

Altek Europe Limited

Lakeside House, Turnoaks Business Park Burley Close, Chesterfield, Derbyshire S40 2UB. United Kingdom Tel: +44 (0) 1246 383737 Fax: +44 (0) 1246 383738 E-mail: alanpeel@altek-al.com Web: www.altek-al.com Sales Contact: Alan Peel

Aluminium Times April/May 2016

Hampshire House High Street Kingswinford DY6 8AW UK Tel: +44 (0) 1384 279132 Fax: +44 (0) 1384 291211 E-mail: sales@mechatherm.com Web: www.mechatherm.com Sales Contact: Stuart Allen


S12 | THE BUYERS GUIDE Refractories

www. mmc p ub l i c a ti o n s . co . u k

Rex Materials Group

EREDI SCABINI srl

Via Brallo, 2 – 27010 Siziano (PV), Italy Tel: +39 0382 6671413 E-mail: sales_dept@erediscabini.com Web: www.erediscabini.com Sales Contact: Corrado Scabini

Gouda Refractories BV

Goudkade 11 - 16 NL-4191 Geldermalsen GX The Netherlands Tel: +31 182 59 14 00 Fax: +31 182 58 39 59 E-mail: info@goudarefractories.com Web: www.goudarefractories.com Sales Contact: Michel Grootenboer

INSERTEC - Ingeniería y Servicios Técnicos, S.A

Avenida Cervantes nº 6 ES - 48970 Basauri, Spain Tel: +34 944 409 420 Fax: +34 944 496 624 Email: insertec@insertec.biz Web: www.insertec.biz Sales Contact: Oscar Iribarren

Primetals Technologies Limited

Alu 1

Drache

Werner-von-Siemens-Strasse 24-26 D-65582 Diez, Germany Tel: + 49 6432 6070 Fax: +49 6432 60752 E-mail: mail@drache-gmbh.de web: www.drache-gmbh.de Sales Contact: Frank Reusch

Rodding Plants

PO Box 980 5600 E Grand River Avenue Fowlerville Michigan 48836 USA Tel: +1 517 223 3787 Fax: +1 517 223 6822 E-mail: bcravens@rexroto.com Web: www.rexroto.com Sales Contact: Bob Cravens

Saint-Gobain Industrial Ceramics Ltd

Mill Lane, Rainford St Helens WA11 8LP UK Tel: +44 (0) 1744 882941 Fax: +44 (0) 1744 884746 E-mail: craig.d.brennan@saint-gobain.com Web: www.saint-gobain.co.uk Sales Contact: Craig Brennan

INSERTEC - Ingeniería y Servicios Técnicos, S.A

Avenida Cervantes nº 6 ES - 48970 Basauri, Spain Tel: +34 944 409 450 Fax: +34 944 407 201 Email: insertec@insertec.biz Web: www.insertec.biz Sales Contact: Jon Ander Begoña

Lyngás 13, 210 Garðabær, Iceland Tel: +354 522 6800 Fax: +354-522 6810 E-mail: Alu1@Alu1.com Web: www.alu1.com Sales Contact: Eyvindur Guðmundsson

Fives ECL

100 rue Chalant, F-59790 Ronchin, France Tel: +33 320 88 7070 Fax: +33 320 88 7099 E-mail: fivesecl@fivesgroup.com Web: www.fivesgroup.com Sales Contact: Pierre Escarbelt

NKM Noell Special Cranes GmbH

Rudolf-Diesel-Strasse, 1 D-97209 Veitshoechheim, Germany Tel: +49 931 40473-0 Fax: +49 931 40473-1000 E-mail: Sales@nkmnoell.com Web: www.nkmnoellspecialcranes.com Sales: Klaus Freitag

Rolling Mills FATA Hunter

Chiswick Park, Building 11 566 Chiswick High Road W4 5YS London United Kingdom Web: www.primetals.com

SMS Group GmbH

Eduard-Schloemann-Strasse 4 D-40237 Duesseldorf, Germany Tel: +49 211 881-0 Fax: +49 211 881-4902 E-mail: communications@sms-group.com Web: www.sms-group.com

Rolling Mill Automation and Process Control MINO Automation

Elettronica Industriale Via Chiavegoni, 1, I-36040 Brendola (VI), Italy Tel: +39 0444 473 555 Fax: +39 0444 473 573 E-mail: automation@minoautomation.com Web: www.minoautomation.com Sales Contact: Angelo Barosco

optimAl Process Technology Ltd

Refactory Installation Pyrotek

705 W 1st Ave. Spokane, WA 99201 USA Tel: +1 509 926 6212 Web: www.pyrotek.info E-mail: info@pyrotek.info Sales Contact: Aluminium Sales

Strada Statale 24, 12 Km I-10044 Pianezza (Torino) Italy Tel: +39 011 96681 Fax: +39 011 9668 355 E-mail: sales@fatahunter.com Web: www.fatahunter.com Sales Contact: Sales Department

Basepoint, Enterprise Way Christchurch BH23 6NW UK Tel: +44 (0) 1202 331640 Fax: +44 (0) 1202 331701 E-mail: john.mason@optimalprocess.co.uk Web: www.optimalprocess.co.uk Sales Contact: John Mason

Josef Fröhling Gmbh & Co KG

York Linings

MINO Process Control

Insulcon BV

Zilverhoek 4 NL-4651 SP Steenbergen, Netherlands Tel: +31 167 565750 Fax: +31 167 566263 E-mail: info@insulcon.com Web: www.insulcon.com Sales Contact: Sales Office

Millfield Industrial Estate Wheldrake York YO19 6NA UK Tel: +44 (0) 1904 449777 Fax: +44 (0) 1904 449888 E-mail: YorkHQ@capeplc.com Web: www.capeplc.com Sales Contact: Mrs Jill Wales

Robotic Systems ProtoConsul Inc.

MINO S.p.A.

Refratechnik Steel GmbH

Schiessstr. 58 D-40549 Düsseldorf, Germany Phone: +49-211-5858-0 Fax: +49-211-5858-49 Email: aluminium@refra.com Web: www.refra.com Sales contact: Rüdiger Pfaar

Walzwerksmaschinenbau, Scherl 12, D-58540 Meinerzhagen, Germany Tel +49 2354 7082-0 Fax +49 2354 7082-200 E-mail: d.neumann@danieli-froehling.de Web: www.danieli-froehling.de Sales Contact: Detlef Neumann

625 Guimond Blvd Longueuil QC J4G 1L9 Canada Tel: +1 450 651 5875 Fax: +1 450 651 8029 E-mail: info@protoconsul.com Web: www.protoconsul.com Sales Contact: Frederic Villeneuve

Via Torino 1, I-15122 – San Michele (AL), P.O.Box 362 – 15121, Italy Tel: +39 0131 363636 Fax: +39 0131 361611 E-mail: sales@mino.it Web: www.mino.it Sales Contact: Luciano Ceccopieri

Aluminium Times April/May 2016

Unit 5, Gaunts Business Centre, Gaunts, Wimborne BH21 4JT United Kingdom Tel: +44 (0) 1202 883814 / 800799 E-mail: sales@tdh-edm.com Web: www.tdh-edm.com Sales Contact: Neil Hickman

Primetals Technologies Limited

Chiswick Park Building 11 566 Chiswick High Road W4 5YS London United Kingdom Web: www.primetals.com


THE BUYERS GUIDE | S13

www.mmcpubl icat io n s. co . u k 

Rolling Technical Courses

SAWNODE Technologies Ltd

395 Marconi, Quebec City, QC, Canada, G1N 4A5 Tel: +1 418 682 2527 E-mail: egosselin@sawnode.com Web: www.sawnode.com Sales Contact: Edward Gosselin

Slitting & Cut to Length Lines Butech Bliss

South Africa Tel: +27 (0) 11 794 6040 E-mail: sales@charnaud.co.za Web: www.Charnaud.co.za Europe Tel: +44 (0) 113 3507 651 E-mail: sales@charnaud.eu Web: www.charnaud.eu Sales Contact: Sales Department

Hertwich Engineering GmbH

Weinbergerstrasse 6 A-5280 Braunau, Austria Tel: +43 7722 806-0 Fax: +43 7722 806-122 E-mail: info@hertwich.com Web: www.hertwich.com Sales Contact: Elke Deubler

HPI Ges. mbH

Schloss Strasse 32, A-5282 Ranshofen, Austria Tel: +43 7722 68420 Fax: +43 7722 68805 E-mail: hpi@hpi.at Web: www.hpi.at Sales Contact: Rainer Edtmeier

August Mössner GmbH + Co. KG

550 Ellsworth Avenue Salem Ohio 44460, United States Tel: +1 330 337 0000 Fax: +1 330 337 0800 E-mail: sales@butech.com Web: www.butechbliss.com Sales Contact: Al Waigand

Josef Fröhling Gmbh & Co KG

South Africa Tel: +27 (0) 11 794 6040 E-mail: sales@charnaud.co.za Web: www.Charnaud.co.za Europe Tel: +44 (0) 113 3507 651 E-mail: sales@charnaud.eu Web: www.charnaud.eu Sales Contact: Sales Department

1846 rue Outarde, Chicoutimi Québec, Canada G7K 1H1 Tel: +1 418 696 0074 Fax: +1 418 545 8335 E-mail: marketing@stas.com Web: www.stas.com Sales Contact: Louis Bouchard

T.T. Tomorrow Technology

L.P. Royer Inc.

Walzwerksmaschinenbau, Scherl 12, D-58540 Meinerzhagen, Germany Tel +49 2354 7082-0 Fax +49 2354 7082-200 E-mail: d.neumann@danieli-froehling.de Web: www.danieli-froehling.de Sales Contact: Detlef Neumann

EUROSLITTER Srl

712 rue Principale, Lac-Drolet, Quebec G0Y 1C0 Canada Tel: +1 819 549 2161 Ext 665 Fax: +1 819 549 2584 E-mail: jhould@royer.com Web: www.royer.com Sales Contact: Jerry Hould

Smelter Equipment

via G. Marconi 11-13 I-23843 Dolzago (LC) Italy Tel: +39 0341 453511 Fax: +39 0341 451305 E-mail: info@euroslitter.com Web: www.euroslitter.com Sales Contact: Ezio Rinaldo Ribolzi

100 rue Chalant F-59790 Ronchin, France Tel: +33 320 88 7070 Fax: +33 320 88 7099 E-mail: fivesecl@fivesgroup.com Web: www.fivesgroup.com Sales Contact: Pierre Escarbelt

Salico Hispania S.A.

HMR Group AS

c/Mahón, 6-2° Urbanización Parque Rozas ES-28230 Las Rozas, Madrid, Spain Tel: +34 916 305 692 Fax: +34 916 303 670 E-mail: info.spain@salico.net Web: www.salico.net Sales Contact: Cesar Martin

Prestnesvegen 68, N-5460 Husnes Norway Tel: +47 534 82100 Fax: +47 534 82101 E-mail: hmr@hmr.no Web: www.hmr.no Sales Contact: Anna Prestnes

Eduard-Schloemann-Strasse 4 D-40237 Duesseldorf, Germany Tel: +49 211 881-0 Fax: +49 211 881-4902 E-mail: communications@sms-group.com Web: www.sms-group.com

Via dell’aritgianato 18 I-35020 Due Carrare PD, Italy Tel: +39 049 912 8800 Fax: +39049 912 8888 E-mail: gmagarotto@ tomorrowtechnology.it Web: www.tomorrowtechnology.it Sales Contact: Giovanni Magarotto

Spray Bars Lechler Limited

Fives ECL

MECFOR Inc

SELECTOSPRAY® Selective Roll Cooling Systems, 1 Fell Street, Newhall, Sheffield S9 2TP. United Kingdom Tel: +44 (0) 114 2492020 Fax: +44 (0) 114 2493600 E-mail: info@lechler.com Web: www.lechler.co.uk Sales Contact: David Columbine

Primetals Technologies Limited

Chiswick Park Building 11 566 Chiswick High Road W4 5YS London United Kingdom Web: www.primetals.com

Tension levelling Salico Hispania S.A.

SMS Group GmbH

Hohenstaufenstrasse 3 D-73569 Eschach Germany Tel: +49 7175 99806 0 Fax: +49 7175 99806 35 E-mail: post@moessner-kg.de Web: www.moessner-kg.de Sales Contact: Oliver Vogt

Société des Technologies de l’Aluminium de Saguenay Inc (STAS)

A J Charnaud & Co (PTY) Ltd

Granco Clark

7298 N. Storey Rd. Belding, MI 48809 USA Tel: +1-800-918-2600 Fax: +1-616-794-2878 Email: gcinfo@grancoclark.com Web: www.grancoclark.com Sales Contact: Michael Werner

Rudolf-Diesel-Strasse, 1 D-97209 Veitshoechheim, Germany Tel: +49 931 40473-0 Fax: +49 931 40473-1000 E-mail: Sales@nkmnoell.com Web: www.nkmnoellspecialcranes.com Sales: Klaus Freitag

Smelter Boots

Sawing & Cutting BONETTI CUTTING SOLUTIONS

Via Medaglie d’Argento 8, Z.I. NORD 26012 Castelleone (CR) Italy Tel: +39 0374 57203 Fax: +39 0374 350705 Web: www.bonettigroup.eu <http:// www.bonettigroup.eu> E-mail: info@bonettigroup.eu Sales Contact: Rodolfo Bonetti

NKM Noell Special Cranes GmbH

A J Charnaud & Co (PTY) Ltd

Innoval Technology Ltd

Beaumont Close, Banbury OX16 1TQ, UK Tel: +44 (0) 1295 702800 Fax: +44 (0) 1295 702898 E-mail: enquiries@innovaltec.com Web: www.innovaltec.com Sales Contact: Chris Davenport

Smelter & Thermal Socks

1788 Mitis Street, Chicoutimi G7K 1H5 (Qc) Canada Tel: +1 418 543 1632 Fax: +1 418 543 4351 E-mail: mecfor@mecfor.com Web: www.mecfor.com Sales Contact: Richard A. Zalzal

Aluminium Times April/May 2016

c/Mahón, 6-2° Urbanización Parque Rozas, ES-28230 Las Rozas, Madrid, Spain Tel: +34 916 305 692 Fax: +34 916 303 670 E-mail: info.spain@salico.net Web: www.salico.net Sales Contact: Cesar Martin


68 | WORKING DAY

www. mmc p ub l i c a ti o n s . co . u k

A working day in the life of Richard Dean, MQP International Sales Manager Europe and Middle East I’ve been working with molten metals since my first real job when I was 18 years old. Friends or people who I meet who have not had that experience can’t really understand my enthusiasm for it and worry about the dangers involved. My first full time job aged 18 was at Foseco International Limited and the job was as a Metallurgical Technician. My school careers officer had no idea what it was but told me I should go along and find out. Almost from day one I was working with molten metals: copper, iron, steel, zinc and of course aluminium, which became my favourite. The mid Seventies were a great time for innovation and R&D, and having returned to the industry having joined MQP, I see many of the products that were developed at that time: Sivex, Coverals, Insural, Adals and rotary degassing units. It was when I was working for a Japanese graphite producer that I had a chance meeting at an exhibition in Turkey, where MQP was exhibiting, with the MD John Courtenay. We had known each other in Foseco days but had not actually worked together. Sometime during our conversation he basically offered me a job and I accepted. I can honestly say that in the last 14 months there has not really been a typical day, and my first day was not what I expected at all. John asked me to arrive at the office around 9:30 and then the plan was to have some training and induction, but when I arrived I found John rushing backwards and forwards between offices trying to arrange an urgent shipment of Refinal flux to a major European customer. Richard Dean walking in the woods with Nikon ready. They had asked for twenty tonnes to be delivered the next day because the then current supplier had failed to deliver. In the same departure time. It was said to be delayed event MQP delivered the next day. It was at that and so we went for something to eat. When we point I found out how flexible and fast-working returned to the gate we found we had looked at MQP was, and is to this day. the wrong flight. Oh well, another night in The following week was the Aluminium 2014 a hotel. exhibition in Düsseldorf, a show which is the “It must be so wonderful to be able to see major showcase for MQP and its products. After parts of the world most people don’t” is the only a few days working for MQP I was thrust comment I get from people I meet for the first into this limelight as the new International time and they find out what I do for a living. For sure it’s a great experience, but when Sales Manager. you have to wake up a 3:30 am for an early I’ve been travelling really since I started Frankfurt flight to get a connection to wherever working, and as the job title implies most of and end up in a casthouse until 10 pm at night, this is out of the UK. This means trains, planes, the glamour is somehow not there. The inside automobiles and the occasional bicycle! I’m not of most casthouses looks and feels the same and a real fan of flying and have had to experience that’s how I describe it to people. Just pick up several aborted landings and one terrifying your own place of work and put it in another aborted take-off in the course of my travel. In country, somewhere you probably don’t speak all the air miles I’ve done I’ve only ever missed the language, and do your job for a day. This one flight by my own mistake. It was when can be challenging, but also very rewarding returning via Amsterdam (with the boss) that when the job is finished, the trial has been we found two flights back to Birmingham with Aluminium Times April/May 2016

successful and the contract is in your hand. That’s why I do what I do. Working at MQP is like going back in time in terms of the philosophy of the company. This is because the MQP team, which includes John Courtenay, Clive Johnson, Barry Lightfoot, Michael Bryant, and me, all have many years of valuable experience gained whilst working at Foseco. This gives us a real sense of innovation and the need to push the technical boundaries, but mainly to supply our industry with technical solutions that work and make a difference in the casthouse. We are working hard on a new metal filtration product that aims to combine grain refinement and filtration whilst not taking up too much space or holding metal. Our Batchpilot equipment is proving to be a vital tool in the measurement of casting heel and instrumental in providing greater productivity in the casthouse. The introduction of Optifine high efficiency grain refiner into many more casthouses has been one of the most rewarding experiences of my first year. The fact that we have been able to reduce a casthouses’ metal treatment costs, improve the quality of the final casting and, in some cases, allow them to find new markets, has been a real success story. 2015 proved to be a landmark year for MQP when, for the very first time, we exceeded our very optimistic sales targets for two of the main products in the MQP range whilst expanding our customer base into hitherto uncharted regions. When I’m not travelling I can pursue some hobbies that I have, namely walking in our local park (they were once the hunting grounds of King Henry VIII) and now I have my new Nikon D3500 in hand to pursue my photography hobby. At home I like to shut myself away in the music room and try to play guitar. I have an old Fender acoustic and a Strat copy - occasionally the family even recognises the tunes I’m playing! Of course none of this is possible without the support of my family, to whom I’m grateful for putting up with all my time away and all the times I forget to call home. On the plus side, returning home to Sutton Coldfield is always a great pleasure and one that I always look forward to. www.mqpltd.com


Innovative casthouse solutions

From the novel technology of Batchpilot furnace weight measurement to the unique methodology of Opticast grain refiner

optimisation, from Premetz real time web based quality control to Optifilter state of art filtration and from Optifine high performance grain refiners to environmentally friendly Refinal fused refining fluxes, MQP is continuing to advance casthouse melt quality.

Innovative casthouse solutions t +44 (0) 1564 200 443

| info@mqpltd.com

| www.mqpltd.com


Al

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Aluminium Times  

Business to Business magazine for the Aluminium manufacturing industry.

Aluminium Times  

Business to Business magazine for the Aluminium manufacturing industry.