Aluminium International Today March April 2018

ROLLING

ANALYSIS & TESTING

HEAT TREATMENT

FUTURE ALUMINIUM FORUM PREVIEW

www.aluminiumtoday.com March/April 2018—Vol.31 No.2

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

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CONTENTS 1

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2

LEADER

2

NEWS

PRICING UPDATE

6

USA UPDATE 12 Rolled aluminium market

Volume 31 No. 2 – March/April 2018 Editorial Editor: Nadine Bloxsome Tel: +44 (0) 1737 855115 nadinebloxsome@quartzltd.com

ROLLING

ANALYSIS & TESTING

HEAT TREATMENT

FUTURE ALUMINIUM FORUM PREVIEW

FUTURE ALUMINIUM FORUM PREVIEW 19

Production Editor: Annie Baker www.aluminiumtoday.com March/April 2018—Vol.31 No.2

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

Sales

ITALIAN FOCUS 20 CIAL: Aluminium recycling 22 Value-added: Aluminium rod

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ANODE COKE 25 Anode coke: The gathering storm

Advertisement Production

Production Executive: Martin Lawrence Managing Director: Steve Diprose Chief Executive Officer: Paul Michael

FURNACES 29 Investing in furnace technology

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COVER

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HEAT TREATMENT 30 Heat treatment systems for aluminium

forging facilities

Supporters of Aluminium International Today

34

Temperature measurement

developments

29

30

36

PRODUCTS & PROJECTS

ROLLING 38 Case Study: Aluminium rolling mill

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March/April 2018

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2 COMMENT

INDUSTRY NEWS

Trump proposes 10% tariff on imported aluminium

All’s fair in aluminium, or is it?

It’ll come as no surprise that the top story in this issue is the tariffs slapped onto aluminium imports, by the US President.

Opinions across the industry are divided and key commodities have not escaped the fallout of the ‘protectionist’ step, which investors fear may hurt global growth.

Following the announcement on 1st March, 2018, the premium to get immediate delivery on aluminium from warehouses surged to its highest level in three years.

While the attention is focused on China, Canada contributes heavily to a healthy North American sector and President and CEO of the Aluminium Association of Canada, said: “If the United States hits its strategic allies such as Canada with measures, they are missing the appropriate target and they expose their economy to serious adverse effects that are greater than the expected gains.”

There is no denying the US Government is showing commitment to strengthening the industry, but as this issue will be printed before the official decision, just how much of a level playing field will be created remains to be seen...TBC! The rest of this issue brings you technical articles on furnace technology, rolling case studies, and the latest developments in analysis and testing. There is also a focus on anti-corruption efforts, pricing and more.

Enjoy! nadinebloxsome@quartzltd.com March/April 2018

Nadine mar apr.indd 1

US President, Donald Trump, announced that his administration’s response to the findings of the Commerce Department’s Section 232 investigation will be a 10-percent tariff on aluminium imported into the country.

The announcement came after a tumultuous day at the White House on 1st March 2018, which also saw a 25% tariff slapped on steel imports.

In a statement, the US Aluminum Association said: “We appreciate the President’s commitment to strengthening the U.S. aluminium industry. We look forward to working with the President on implementation and to creating a more level playing field.”

The European Aluminium Association has called on the European Commission and EU Member

States to protect the aluminium industry.

Gerd Götz, Director General of European Aluminium said: “We regret President Trump’s decision to impose a tariff on all aluminium imports independent of their country of origin. European aluminium exports to the US, in view of both their quantity and characteristics, do not pose any threat to US national security. Most importantly, this blanket tariff does not address the root cause of the main challenges faced by the aluminium industry today: the unsustainable and steady increase of aluminium overcapacities in China. This global challenge can only be managed effectively through a global and long-term solution based on multilateral rules and common enforcement such as the creation of

a Global Aluminium Forum within G20.”

According to reports, the move sets the US on a collision course with China and will bite the domestic industry. However, the Commerce Department said the tax on imports was necessary as the metal was being sold below cost or with government subsidies - making it impossible for US producers to compete.

Pilot starts production At the end of January, Hydro started producing the first aluminium metal at the technology pilot in Karmøy, marking the start of verifying at an industrial scale the world’s most climate-and energy efficient aluminium technology.

“We’re now producing alu-

minium in the technology pilot, and we are very excited that we can now start to use this technology at an industrial scale,” says Hilde Merete Aasheim, Executive Vice President for Hydro’s Primary Metal business area.

Compared to the world average, the Hydro-developed tech-

nology will use 15 percent less energy in aluminium production and has the lowest CO2 footprint in the world. The low energy consumption, coupled with high productivity, means that Hydro can safely say that the technology pilot in Karmøy will be a world leader.

Next generation pots UC RUSAL has announced the launch of a pilot operation of eight new generation RA-550 pots at the Sayanogorsk Aluminium Smelter.

The investment in the project amounted to USD 30 mln.

The project to develop the technology and launch the RA-550 site at SAZ was implemented within three years.

The key advantage of this new development made by the Technical Directorate of RUSAL is its

high-energy efficiency. RA-550 consumes 10-15% less electricity versus pots of previous generations. Due to design and technological solutions, RA-550 became lighter, more compact, and more environmentally efficient.

Aluminium International Today

08/03/2018 11:21:35

INDUSTRY NEWS 3

UK alloy plant agreed

APPOINTMENTS UC Rusal

The GFG Alliance has welcomed the decision of the Highland Council South Area Planning Committee today (30th January) to grant full planning permission for a new 400-worker alloy wheel factory next to the Liberty British Aluminium smelter at Fort William.

The consent, which comes with a number of standard conditions,

clears the way for the company to begin detailed design on the landmark project to develop the UK’s only large-scale alloy wheel plant, with work hopefully beginning on site later this year.

It is intended that the new plant – part of a £120m investment by GFG at Fort William - will use aluminium from the adjacent

smelter to manufacture up to two million wheels a year for the British car industry, with production beginning in early 2020. The ambitious plans for the site will make Fort William a major centre for the automotive industry, supplying at least one fifth of all the wheels required by UK vehicle manufacturers.

Hydro bids to acquire ISAL Norsk Hydro ASA has made a binding offer to acquire Rio Tinto’s 100% share of Icelandic aluminium plant ISAL. The offer also includes the Dutch anode facility Aluchemie and Swedish aluminium fluoride plant Alufluor.

“The offer demonstrates our strong belief in aluminium, which is seeing the strongest global demand growth among base metals.

Having presence across the value chain is essential to create value from this growth and promote sustainable practices in our global operations,” says Hydro President and CEO Svein Richard Brandtzæg.

Hydro sees synergies with respect to technology creep, opti-

ALBA

misation of anode portfolio and freight and handling. The Icelandic plant runs on the same technology platform as Hydro’s Husnes

plant in Norway, where Hydro recently announced a re-opening and technological upgrade of the plants’ second electrolysis line.

First sealed cathode Aluminium Bahrain B.S.C. (Alba), has announced that its Line 6 Smelter achieved a significant milestone - the First Cathode Sealing Operation - on Wednesday January 31, 2018.

The first cathode is an integral part of the pot lining activities for the new Line 6 pots based on the

UC RUSAL has announced the appointment of Alexandra Bouriko, previously Chief Financial Officer, as Chief Executive Officer of RUSAL. Vladislav Soloviev, who previously held this position, has been appointed CEO of En+. He will also become the President of RUSAL.

Dubal DX Ultra Technology that is being employed at the Line 6 Smelter.

Commenting on this achievement, Alba’s Chief Executive Officer, Tim Murray, said: “We are very much pleased with the overall progress we have made on Line 6 Smelter. The focused-approach

adopted by our team has yielded nicely on the progress of Engineering (79%), Procurement (83%), Contracts (97%) and Construction (17%) simultaneously.

We look forward to the on-schedule completion of Line 6 Expansion Project.”

Aluminium Bahrain B.S.C (Alba) has announced the appointment of Dr. Abdulla Habib Ahmed as the Acting Chief Operations Officer (COO) with immediate effect.

Innoval Technology Ltd Innoval Technology has announced that Dr Mike Clinch will become leader of their Materials Development Group with immediate effect.

As Materials Development Group Leader, Mike will oversee the company’s InnovateUK collaborative R&D projects as well as development work with existing clients. He will also take an active role in creating new business.

New GLAFRI President The Global Aluminium Foil Roller Initiative (GLAFRI) has announced the election of Göksal Güngör as its new President with immediate effect. This follows Oliver Hommel stepping down from his role as he left the aluminium foil industry.

March/April 2018

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08/03/2018 11:21:39

4 INDUSTRY NEWS

www.aluminiumtoday.com

2018 DIARY May 8-9 Future Aluminium Forum*

ElvalHalcor contracts SMS ElvalHalcor has awarded a contract to SMS Group GmbH, to supply a new four-stand tandem aluminium hot finishing mill for its Oinofyta plant, near Athens.

This order is part of a EUR 150 million investment in equipment, technology and infrastructure, announced by the company on the signing of the loan agreement with the European Investment Bank on December 22, 2017, for its financing.

This investment represents the

first phase of the company’s fiveyear plan to more than double its flat rolled aluminium products capacity.

With the new four-stand tandem mill, the future spectrum of hot rolled strips will range from 1.8mm to 12.7mm in thickness and up to 2.6m in width, and will secure ElvalHalcor’s position as one of Europe’s leading producers of wide aluminium sheet.

This investment allows for the increase of ElvalHalcor’s current

presence in aluminium packaging, industrial, transportation and architectural applications and sets the base for expansion in the automotive and aerospace sectors.

The new investment also supports the further modernisation of the plant, introduces the latest industrial technology, increases energy efficiency and improves the environmental footprint.

The new hot rolling line will start production in the first quarter of 2020.

Mecfor poised for growth Benefiting from a major investment by its new Canadian financial partner - SeaFort Capital - and from a strong and unchanged management team, the Quebec-based company has become independent and now wants to double its revenues.

Mecfor is committed to a development plan focused on mergers and acquisitions in the primary and secondary aluminium sec-

tor, innovation and diversification towards rail maintenance equipment and the nuclear sector.

“We are pleased to announce this historic transaction, which gives Mecfor a new financial partner, providing access to capital and resources that will enable us to accelerate our ambitious development plans. We aim to reach new heights by focusing on a bold strategy based on mergers, acqui-

sitions, sustained investment in innovation, and operational diversification,” says Éloïse Harvey, B. Eng. & Mgmt, President of Mecfor.

Through this transaction, which consolidates over 85 jobs at its factory and headquarters in Chicoutimi, Mecfor becomes independent from Groupe Ceger. Mecfor now has the financial resources and the necessary capacity to continue its growth.

European Aluminium awarded European Aluminium received the award for “Best Association Networking Event” and won second place in the “Best Association Publication or Newsletter” category at the 2018 European Association Awards ceremony held in Brussels.

The “Best Association Networking Event” award was for European Aluminium’s public event “Driving Mobility to a Low Carbon Future”, which was held in Autoworld (Brussels) on 27 April 2017. With more than 250 participants and speakers from EU inMarch/April 2018

Nadine mar apr.indd 3

stitutions, industry and academia, the event explored the potential of lightweighting to reduce CO2 emissions in transport through

panel debates, keynote speeches and an interactive Aluminium Playground showcasing the best aluminium solutions in mobility.

What does industry 4.0 mean to the future of the aluminium industry and how can it assist in the quest for greater efficiencies?

Attend the Future Aluminium Forum to join this debate, hear from experts and network with solution providers and industry peers.

Held in Milan, Italy. www.futurealuminiumforum.com

14-18 Rolling Technology Course The Aluminium Rolling Technology Course covers all the key aspects of hot and cold rolling of aluminium flat products. www.innovaltec.com

June 5-7 HARBOR’s 11th Aluminum Outlook Summit Over 500 participants, representing more than 260 companies, meet to network, get industry knowledge and the latest aluminum market intelligence and outlook.

Held in Chicago, USA. www.harboraluminumsummit.com

5-7 Aluminium-21/EXTRUSION The goal of this Forum is to discuss the status and trends in the development of the current market of aluminum extrusions, as well as their application in bridges, construction, transport and power engineering.

Held in Moscow, Russia www.eng.apral.org

July 11-13 ALUMINIUM CHINA Asia’s top aluminium industry platform for the complete aluminium industry supply chain.

Held in Shanghai, China www.aluminiumchina.com *Pick up a free copy of Aluminium International Today at this event For a full listing visit www. aluminiumtoday.com and click on Events Diary Aluminium International Today

08/03/2018 11:21:41

6 PRICING UPDATE

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2018 Aluminium outlook: For once, it’s not all about China Location is everything when it comes to aluminium. A stubborn Chinese surplus depresses local prices whilst an ex-China deficit has driven LME prices to highs not seen since 2011. Regional premiums are also on the rise as trade barriers loom. Near term, we expect pressure from high Chinese semi exports, but further out we see potential for the two worlds to diverge: A more isolated surplus in China versus a tight LME market with a thirst for ingot. For once, it’s not just about China…By Oliver Nugent*

Chinese Semi’s: The SHFE-LME arb is the most supportive for Chinese exports since 2011 and the high January number (+14% yoy) will be the norm for some time We expect aluminium prices could tend down towards $2,000 near term as long fund money retreats from signs that the Chinese surplus is spilling out into the LME domain. But any weakness will be temporary and consumers might look to hedge on these dips. We expect prices to average $2,300 in H2 2019.

Ex-China Deficit: Central to our view is the observation that the ex-China market is in a growing deficit and whilst we do expect this to be even larger than the Chinese surplus it is the ex-china balance that matters most for the LME price.

LME Tightness: The LME is thirsty for ingot. Backwardations are increasingly common at the front of the curve.

This will drive prices higher after the funds retreat. LME stocks are dwarfed by those off-warrant which creates a

China isolation: The fake semi trade has collapsed significantly and trade barriers threaten to displace markets for genuine semi exports. The Chinese surplus will be less able to alleviate the ex-China tightness.

For once, it’s not all about China… (Fig 1).

Near term headwinds Chinese aluminium exports to remain strong for some time The differential between Shanghai and LME is the most supportive for exports of semi’s since 2011. January semi’s exports were up 14% year-on-year and with our 2018 expectations of a 1MT Chinese surplus and 1.7MT RoW deficit we expect the arb to remain supportive for some time. Exports will likely stay high in the coming months especially to the US given the high premiums and ahead of potential trade tariff’s.

The bull case: Ex-China deficit The LME Aluminium price is settled by the willingness of participants to make or take delivery of primary metal in an LME warehouse, ex-China. Chinese primary aluminium is however largely walled off behind a 15% export tax. A widening gap between ex-Chinese smelting capacity and growing demand creates deficits that

$200

2.0 1.5

500

$150

450

$100

1.0 0.5 0.0 -0.5 -1.0 -1.5 -2.0 -2.5

The LME Aluminium price breached $2,200 in December as macro funds broadly allocated to the most liquid commodities on themes of inflation and global growth. Money manager longs rose 13% in the last 2 weeks of December, a similar surge for copper. Even since early Jan profit taking and liquidation was starting to occur which has accelerated amid the equity market sell-off. We expect more liquidation in the coming months amid bearish Chinese trade data and project prices to trend down to $2,000/ mt in Q2. After this we are bullish and recommend consumers hedge at these dips. Fig 2.

structural imbalance between borrowers and lenders. Higher premiums and low warehouse incentives compound the situation

400

$50 $0

350

-$50

300

-$100 -$150

Ex-China post trade China

2012

2013

2014

2015

2016

2017

Fig 1. China and ex-China aluminium balances set to diverge (MT)

2018F

2019F

5

-1

Jan

5

-1

r Ap

15

lJu

250 5

1 ct-

16

Jan

6

-1 pr

O A Semis exports (‘000mt)

7 7 8 7 6 6 17 l-1 -1 r-1 Jul-1 ct-1 an-1 Ju Oct Jan J O Ap China semi’s export Arb ($/mt)

Fig 2. China Aluminium semi exports and arbitrage (‘000mt, $/mt)

*Commodities Strategist, ING March/April 2018

pricing update.indd 1

Aluminium International Today

15/03/2018 15:58:33

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8 PRICING UPDATE

1200 2000 1500 1000 500 0 -500 -1000 -1500 -2000 -2500

2010

2011

2012

2013 2014 Global

2015

2016

2017

2018F

2,000.00 1,900.00 1,800.00 1,700.00 1,600.00 1,500.00

400

2019F

US put antidumping stopped Extrusions from 2011

215 483 440

200

180

0

300 200 100

2018

2019

USA restarts

India

Europe

Middle East/Africa

Contango is positive

0

$2,200

$10 $5

$2,100

Backwardation is negative

2013 2015 2017 South Korea US

Fig 5. China extrusions exports to usual suspects drop in 2017

now far surpass the so-called ‘fake semis’ trade. The shortage of primary metal will drive LME prices higher.

Restarts will fall short of ex-China demand Whilst Chinese smelting production has grown almost 50% in the last 4 years, smelting in the rest of the world is up only 6% and has majorly lagged a 21% increase in demand, putting the ex-china market firmly into deficit.

Since 2015 the ex-China shortage exceeded 1MT but was softened by the fake semi’s flow. Last year it grew to 1.9Mt (pre-trade) and was a still very sizeable 1.75MT after the fake semi’s of primary metal that made its way out of China, bypassing the export tax We expect at least another 2 years of high shortages given just 1Mtpa of supply will be added each of the next two years. Analysts will always disagree on precise numbers but this RoW deficit is universally agreed. We include a generous assumption of restarts in our base case and still find a 1Mt (pre-trade) shortage if demand was flat. At GDP expectations of 3.3% and 4.2% demand growth for ex-China in 2018/19 the ROW deficit is 1.9MT/2.2MT pre-trade and 1.7Mt/2Mt assuming the same fake semi flow.

In fact as China’s aggressive supply reform (capacity swaps, winter cuts, illegal capacity cuts), now slows its capacity growth, the ex-China deficit could even outweigh the Chinese glut. But location is

$2,300

$15

Jan 2016

March/April 2018

35

-117

-200

$0 -$5 -$10 -$15 -$20 2011 Mexico

88

600

$20

2005 2007 2009 Vietnam Vietnam

240

145

Fig 4. Ex-China primary annual production changes (kt),

500 400

299

800

Other

600

(‘000kt)

1000

Ex-China post trade

Fig 3.Global and Ex-China Aluminium Balance(kt),

pricing update.indd 2

2,500.00 2,400.00 2,300.00 2,200.00 2,100.00

Sharp Aug roll drove prices above $2k Prices & spreads correlating $1.7k-$1.9k

$2,000 $1,900 $1,800 $1,700

Feb-March roll $1,600

Nov 2016 Jan 2017 LME aluminium Month 1-2 ($/mt) ($/mt)

$1,500 $1,400

Nov 2017 Jan 2018

Fig 6. Sharp backwardations at the front of the LME curve support prices

key. A mild 250kt global deficit last year pales against the effect of the 1.7Mt exChina inventory drawdown that drove LME prices up 34%. Fig 3. Fig 4.

The growing depth of ex-China deficits far surpass what is possibly alleviated by exports of fake semi’s. We actually believe these ‘fake’ flows are on the decline.

Looking at extrusions and sheet trade flows to the usual suspects we estimate that in 2017 fake semi’s exports dropped by 60% to their lowest since 2010. Given high trade tensions authorities are likely to make it increasingly difficult for repeats of the well-publicised big tonnage flows that went into Vietnam, Mexico etc in previous years.

Given this, any projected stock draws will be far more significantly in the ex-China, LME domain, taking from both on warrant and off-warrant stockpiles. The effect will be to intensify the existing tightness within the LME system, which will see western prices continue outperforming shanghai.

Fig 5.

LME Backwardations and Premiums face off The LME is thirsty for ingot, as evidenced by frequently sharp backwardations in the monthly rolls. December’s long money inflows were a rare sight in a market that has mostly been driven by short covering since it bottomed in Nov 2015. If fund buying stops it will be backwardations and short covering that drives the market

upward once more.

We identify 3 sections to the aluminium rally. From Nov 2015 to August 2016 prices rose 12% but open interest also fell 13% as money manager shorts were squeezed out by over half. Through to H1 2017, short covering drove prices up a further 19% but it was now the producer/ merchants shorts down 11% and a flatter overall open interest as trend following funds added longs, which partly offset the decline. Only since H2 2018 has fund long allocation been the key driver and open interest is up with prices.

LME Aluminium doesn’t trade like the other metals. The sheer masses of inventory hedged/financed globally sees calendar spread trading dominate.

Spreads dictate the cost to roll a position (i.e. keep inventory financed) and while convention is to focus on Cash- 3M most LME positions are on the monthly (3rd Wednesday) prompts. Focusing on these front month spreads we see regular spasms to sharp backwardations near expiry. Around these times open interest dips as the shorts flee pay the cost to roll.

The key price barriers of $1,500, $1,800 and $2,000 were all breached in this way.

Fig 6 The LME tightness is the structural result of the huge financed inventory that dwarfs on warrant stocks by around 5x (ex-China). The price of a spread is the balance between borrowers (rolling a short) and lenders (sell the nearby date Aluminium International Today

15/03/2018 15:58:35

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10 PRICING UPDATE

www.aluminiumtoday.com

Chinese 2017 exports (kt)

India (Foils)

100

Australia (Extrusions)

45

US (PSS +Foils)

670

US (all aluminium articles) European (Extrusions) Total

1000 160 1000-1330

Source: Trademap

Table 1. Highlighted Chinese aluminium exports at risk (kt)

to the borrower in return a further date).

Stock financers are borrowers. They need to roll short hedge forward come the monthly expiry. A natural lender would be a holder of exchange stock outside of a long-term hedge (‘’free-floating’’) because this covers the exposure of the near term sell. Given less free-floating stock, when a mass of stock financing rolls the high demand to buy out the nearby short far outpaces the natural lenders.

The deep backwardations are formed until lenders are incentivised or the shorts squeezed out.

Conventionally backwardations incentivise deliveries, which in turn generate lending but high premiums make this tougher. A stock financer not wanting to pay the cost to roll will weigh the premium he can earn in the spot market against any incentives paid by LME warehouses. Since the LME curbed queues, incentives are down. We hear only $50/mt compared to a US premium at $280/mt and the CME curve expects higher.

Backwardations must therefore pull increasingly hard to offer a time premium that can both compete and more severely push stock financers to liquidate. As shorts are forced out this supports LME prices. In an ex-China primary metal deficit attracting delivered units is set to

March/April 2018

pricing update.indd 3

get tougher still. Until this tightness ends LME price will generally trend up.

Rethinking the China Connection LME Aluminium’s connection with the Chinese market is unlike any other metal.

In its surplus China is a minimal importer so does not pull on LME deliverable material. On the contrary, frequent LME backwardations demonstrate a pull on stock in the other direction but the 15% export tax is keeping most primary metal out the equation.

China’s own market balance only fundamentally connects with the LME through the non-primary semi-fabricated exports that earn a 13% rebate. The most direct means is the fake semi’s (minimally fabricated extrusions/sheet that to be recast into ingot). As discussed these flows have arguably already peaked some years ago and we expect trade tensions to render any significant growth especially tough.

The challenge to fill the RoW deficit therefore depends on genuine semifabricated exports that can displace demand and free up ingot to be delivered on to the LME. Given lengthy supply chains, financing and offtakes we don’t think displacing primary is as immediate an impact as is often assumed but also the required hefty 20% increase in the 4.8MT

export figure is very unlikely considering mounting trade protectionism that will close off customer markets.

The US, India, Australia and Europe are all either investigating or have already imposed restrictions on Chinese products.

The US made up 15% of Chinese exports last year and the 232/ITC investigations looks set to at the least render Chinese foils and common alloys uncompetitive.

These alloys themselves itself made the majority of last years near 0.5Mt of the Chinese-US flat rolled trade and + 170kt of foils (10% of all Chinese semi’s exports). Europe is the largest buyer of china’s aluminium where an investigation on extrusions (160kt) alongside a beefed up methodology that can quicker prove dumping poses further risks. Add in an Indian ban on Foils (100kt), Australia already acting on extrusions (45kt) and you get to sizeable numbers (1Mt+) which will take time to find new markets let alone to grow exports so significantly.

During this time the LME price will be rallying on the said tightness.

The key takeaway is the impact of the Chinese surplus on the rest of world primary balance is neither 1:1 nor immediate. Semi’s exports can only ease LME tightness by re-routing displaced primary. We doubt the scale that this can grow in face of rising protectionism and would further reinforce how lagged the relationship could be. Chinese exports would need to find new downstream customers to the extent it knocks along the supply chain to hit upstream orders of ingot. This needs to accumulate sufficiently to depress spot premiums enough to justify LME deliveries. All the while we are expecting prices to grind higher through 2018 and 2019 on tight spreads and robust fundamentals in the LME’s domain offshore from the Chinese surplus. �

Aluminium International Today

15/03/2018 15:58:35

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12 USA UPDATE

USA Update: Rolled aluminium

By Myra Pinkham*

Overall the U.S. rolled aluminium market has been, and continues to be, quite strong with generally growing demand for its major end-use market sectors.

The largest area of concern is related to imports. Although the domestic industry and the U.S. government have been working to address trade issues – not just with the still pending aluminium Section 232 aimed at the impact of these imports upon U.S. national security but through trade cases against imports of aluminium foil and common alloy sheet from China.

Doug Hilderhoff, team leader for North American aluminium at CRU Group, says he is forecasting a 4.5 percent increase in North American aluminium following a 5.7 percent year on year improvement last year.

He points out, noting that the big driver

of this demand is the transportation sector, particularly automotive. He says that while aluminium rolled products demand for North American transportation equipment is expected to increase 9.6 percent in 2018 on the tail of 13.4 percent growth in 2017, its use in the automotive sector is expected to improve by another 13.2 percent this year after jumping up 23.1 percent last year.

“The automotive sector has clearly been a gamechanger for makers of aluminium auto sheet,” Mike Keown, executive vice president – North America for Aleris International Inc., says, noting that even though North American auto output has peaked, auto aluminium use is still expected to see almost 12 percent compounded annual growth (CAGR) through 2025.

Actually, North American auto production has not just peaked, but has eased slightly, going from a record 17.5 million light vehicles in 2016 to 17.0 million vehicles in 2017 and are projected to fall even further to about 16.5 million vehicles this year, Ganesh Panneer, vice president and general manager – automotive for Novelis Inc. points out. But while it has come down, this is still quite robust and will likely continue to be so in the foreseeable future.

It also helps that more than two-thirds of those vehicles are light trucks – sport utility vehicles, crossover vehicles and pickup trucks – which tend to use much more metal than passenger cars due to their larger size, and, according to Peter Basten, head of the packaging and rolled products unit of Constellium, most experts

*US Correspondent, Information correct at time of print March/April 2018

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Aluminium International Today

15/03/2018 14:56:49

USA UPDATE 13 5

expect that the percentage of light trucks vs. passenger cars will continue to grow, as will demand for hybrids and electrical vehicles, which is currently a small, niche market.

But the growth in automotive aluminium is actually coming more from the amount of aluminium being used per vehicle as opposed to the number or type of vehicles being produced as automakers look for ways to meet the upcoming more stringent fuel efficiency standards coming down the pike. While they have also addressed this by making changes in auto drivetrains, a large percentage of vehicle redesigns have been focused upon reducing weight.

This is frequently being accomplished by adding more lighter weight materials, such as aluminium, per vehicle. “Aluminium is the fastest growing material in North American vehicles today,” Matt Meenan, a Aluminium International Today

update.indd 2

spokesman for the Aluminum Association, maintains.

Based on the latest Ducker Worldwide study conducted for the trade association, it is expected that the aluminium content for the average North American light vehicle will increase nearly 42 percent from about 400 pounds in 2015 to approximately 565 pounds by 2028 and by that time nearly 25 percent of North American vehicles will have at least partially aluminium body-in-white. In fact, Ducker stated in its study that aluminium “is entering its most unprecedented growth phase since we’ve been tracking the shifting mix of automotive materials.”

This is not just being done through the aluminium-intensive vehicle approach like Ford took with its F150 pickup truck several years ago. Many other automakers are engaging in a much more multi-material strategy, increasing the aluminium

intensity of their vehicles largely through using the light metal for more of its closures, such as hoods, doors, trunks, fenders and roofs, Constellium’s Basten points out. Also, expectations for greater sales of electric and hybrid vehicles in the next five to 10 years will also be a plus for aluminium, CRU’s Hilderhoff says, given the need to compensate for the weight of their batteries and the desire for extended range.

While the increase in aluminium intensity has been supported by the recent push to raise the corporate average fuel efficiency (CAFE) to 55.4 miles per gallon by as early as 2025, there currently is some uncertainty whether they will go into effect or if that deadline will be extended given the Trump administration’s push to ease governmental regulations. Meenan notes that as part of the reopened mid-term review on these fuel efficiency standards, the administration has until March 30 to decide whether the current standards will remain in place or be reconsidered. “But consumer demand for lighter, more fuelefficient vehicles won’t go away even if the regulations are relaxed, Mike Southwood, a senior analyst for CRU, points out. Also, given that automakers produce vehicles for global consumption, not just U.S. consumption, and many other countries have even more stringent regulations than are being proposed domestically.

“We believe that we are going to be very capable of producing the aluminium we need to support this additional demand from the automotive sector at least for the next 10-15 years,” Meenan says, noting that the since 2013 the industry has either put in the ground or announced about $2.6 billion worth of investments in U.S. auto sheet plants.

Novelis, for example, is planning to break ground in early spring on a 200,000 metric tonne automotive aluminium sheet manufacturing facility, including a heat treatment and pre-treatment line, in Guthrie, Ky., which it expects to be up in running by 2020. Marco Palmieri, president of Novelis North America, says the pre-treatment line will give aluminium the ability to bond with other materials.

The aluminium coils to be used by the new facility will be supplied by Novelis’ nearby Logan Aluminum Inc. joint venture with Tri-Arrows.

A fledging aluminium producer, Braidy Industries Inc., is also expected to begin construction in the second quarter on the first phase of its mill in Greenup County, Ky., with the aim to produce 370,000 tonnes of high quality sheet, including 200,000 tonnes of automotive sheet, there starting in 2020.

Keown says that last year Aleris invested over $400 million in its sheet facility March/April 2018

15/03/2018 14:57:00

14 USA UPDATE

in Lewisport, Ky., to add automotive capabilities, include three new work centres, two continuous annealing lines and a cold mill and has also opened a research and development centre in Detroit to partner with the auto OEMs on alloy development.

“While I don’t think there is a need for more capacity today, eventually there will be a need for more continuous annealing with pre-treatment (CALP) or heat treatment lines,” Basten says, he and other executives said they would wait to make such moves until they get significant customer commitment.

Meanwhile demand from the very cyclical heavy-duty truck and truck trailer market is expected to have a solid year this year, helped by the tightening of the freight markets, Hilderhoff says. This comes after truck sales had come down from 2016 peak levels, resulting in a pretty significant backlog in heavy-duty truck and truck trailer orders at the end of last year. However, he says that the strong U.S. economy, combined with a shortage of trucks exacerbated by the new electronic logging device mandate that went into effect in December, and expectations of some 2019 and 2020 sales being pulled forward, is expected to bolster demand from this sector this year.

And aluminium content could also increase in areas like chassis and trailer panels, Palmieri says, given that truck and truck trailer makers, like automakers, have become increasingly interested in fuel efficiency, given that the average big rig travels less than seven miles on a gallon of diesel fuel. He says it has been reported that getting just another mile per gallon could help trucking companies save billions of dollars in fuel and operating costs.

“It will also be interesting to see how

update.indd 3

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autonomous and electric vehicles will start to impact this market segment,” Aleris’ Keown says.

While cans are the largest volume market for aluminium, it is a very mature market and one that hasn’t been growing, Hilderhoff says. In fact, he is predicting that the U.S. aluminium can market will see small decreases in demand over the next few years, although that will be offset but increases in Mexico. As result, he expects that overall North American can demand will remain fairly flat. While there is still growth in the United States in the beer segment (especially for craft beer), as well as for sparkling water beverages, iced tea and energy drinks, demand for soft drinks continue to be weak.

“There are, however, early indications of some positive dynamics in the U.S. can market,” Constellium’s Basten says, possibly tightening can sheet supply. In the past year a few new U.S. can lines were announced. In what was the first greenfield facility in the United States for about 20 years, Crown Holdings opened a new beverage can manufacturing plant, last May. Also, Ball Corp. says it will begin construction on a new packaging facility in the second quarter of this year.

U.S. rolled aluminium demand from the building and construction market is expected to grow by 4.5 percent this year, up slightly from 4.1 percent in 2017, when the growth in housing starts, while up, had been a slightly below expectations.

Hilderhoff says.

But this year started off strong, with housing starts jumping 9.7 percent month on month in January to a seasonally adjusted annual rate of 1.33 million units, bringing them within the historical norm of between 1.3 million and 1.5 million homes per year, but still well below the peak of 2 million homes reached prior to

the recession. Keown says that while he doubts that starts will return to that peak, but the dynamics suggest that they will continue to see slow and steady growth, especially for single family homes.

“Housing formations have been growing with millennials getting jobs and moving out of their parents’ homes and baby boomers buying second homes,” he explains. However, the rate of growth continues to be held down by a shortage of skilled laborers. “It isn’t that homebuilders don’t want to build at a greater rate, but they don’t have enough skilled workers to do so.”

Even with the broad-based demand growth across the major end-use markets, imports have been a concern. Meenan observes that at the end of last year the import share of the domestic aluminium sheet and plate market had moved up to 33.6 percent. This came as U.S. import volumes increased 10.6 percent to 1.965 billion pounds.

“We support free and fair trade.

However, in order for the American aluminium industry to compete in highend applications, the United States must ensure that unfair trade does not distort the domestic market for rolled aluminium,” Novelis’ Palmieri declares, adding that the industry is increasingly concerned that developments in China – including higher volumes of low-priced imports of downstream aluminium products – are undermining the ability to obtain a fair return on aluminium investments in the United States.

The final determination in an antidumping trade case filed by the Aluminum Association last year against Chinese aluminium foil imports was announced by the U.S. Commerce Department late in February, resulting in anti-dumping duties of between 48.64 and 106.09

15/03/2018 14:57:05

15

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percent and countervailing duties between 17.14 and 80.97 percent. “We have already seen a positive impact from this trade case,” Meenan says, noting that not only are fewer aluminium foil imports coming into the United States, but Granges AB has announced that it is expanding their foil producing capacity at its Huntingdon, Tenn., facility from 160,000 tonnes to nearly 200,000 tonnes per year.

The next stage in this trade case will be the U.S. International Trade Commission’s final phase determination of whether imports from China are causing material injury or threaten to materially injure domestic producers of aluminium foil that is 0.2mm or less in thickness in reels weighing more than 25 pounds and isn’t backed, etched for use in capacitors or cut to shape. The ITC is tentatively scheduled to vote on that March 15.

Also, in November the Commerce Department self-initiated a trade case against imports of Chinese aluminium common alloy sheet. This was the first time in more than 25 years that Commerce had exercised its right to self-initiate a trade case.

This comes as imports of Chinese common alloy aluminium sheet increased by more than 90 percent between 2014 and 2017.

In mid-January the U.S. International Trade Commission made a unanimous preliminary determination that the Chinese common alloy sheet imports were causing injury to U.S. producers. The preliminary countervailing duty is expected to be announced early in April followed by the preliminary anti-dumping determination in June and final determinations in November. The Commerce Department estimated that the anti-dumping margins would be between 56.54 and 59.72 percent. It also indicated that it will be investigating 26 separate subsidy programs maintained by China’s government.

But when it comes to trade issues, the most attention continues to be on the aluminium Section 232. Following a nine-month investigation, on March 8 Trump signed a proclamation that impose a 10 percent blanket tariff on aluminium imports, as well as a 25 percent blanket tariff on steel imports, to go into effect within 15 days from that date, stating that dumped imports has not only had an adverse impact upon the domestic aluminium and steel industries, but upon U.S. national security.

He did so despite the fact that he has gotten a lot of flak, both domestically and internationally, given the potential that such action could result in unintended consequences, including a possible trade war on both metal and metal-containing finished goods. There have also been concerns voiced that these tariffs could raise prices on not just metal but the finished goods, therefore having a negative impact upon consumers of such products. �

update.indd 4

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ANTI-CORRUPTION INITIATIVE 17 5

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Business-driven integrity in the metals technology sector Nadine Bloxsome* spoke to the market leaders spearheading the fight against corruption.

The Metals Technology Integrity Initiative was formed in early 2013 at a time when the companies were facing an increasingly competitive environment as a result of the decline of the traditional steel producing markets in Europe, and a shift towards emerging markets including the Far East and Indian sub-continent. These new markets presented companies with increased legal and compliance risks, in particular with regard to bribery at a time when law enforcement was on the increase against companies headquartered in OECD countries. For example, the ten highest settlements under the US anti-corruption law (the Foreign Corrupt Practices Act), were all negotiated between 2007 and 2011.

The development of internal compliance programmes and the challenges of the markets where they were operating created the conditions for the senior management of the leading companies in the Metals Technology sector to take a positive step towards establishing industry-specific anti-corruption compliance commitments with a view to raising fair competition standards throughout their sector globally.

The anti-corruption Collective Action initiative brought together key global players in 2013. At the time, they comprised Siemens (now Primetals Technologies

Limited), Danieli & C Meccaniche S.p.A., Primetals Technologies Limited and SMS GmbH, and as from the end of 2017 the newest member, Tenova S.p.A. All of the companies have signed a Memorandum of Understanding (MoU) that they developed over the course of discussions in 2013 and 2014. The MoU sets out the companies’ anti-corruption commitments and proposed actions to implement and promote their anticorruption principles.

Together with the Basel Institute on Governance represented by the International Centre for Collective Action, which acts as facilitator and convener, the companies meet three times per year to address their commitments set out in the MoU. The convener is neutral, has no conflicts of interest and is external to the industry which helps to ensure that no anti-trust issues arise during the meetings.

The members that participate in the meetings are senior legal and compliance officers who are also well aware of the risks of anti-trust issues and this also helps to ensure that the risks are minimised on this front.

What is Anti-Corruption Collective Action?

Anti-corruption Collective Action is ‘a

*Editor, Aluminium International Today

-

World Bank definition

1

-

collaborative and sustained process of cooperation amongst stakeholders.

It increases the impact and credibility of individual action, brings vulnerable individual players into an alliance of likeminded organisations and levels the playing field between Competitors.’1 The Initiative strives to harmonise compliance in order to level the commercial playing field in a particular location or business sector. Regular forums to share experience in implementing the common standard contribute to the creation of communities of practice and enhanced capacity and knowledge across all participants.

The business case for sector-specific Collective Action Setting up an institutionalised form of policy dialogue, with regular meetings of senior company representatives initially means costs incurred by the participating companies. So why do the member companies invest in this collective approach?

In countries where corruption is systemic or entrenched reputational risks for companies can be high. On the one hand, companies have an incentive not to pay when solicited for a bribe, particularly if they are subject to anti-corruption laws

Special thanks to Basel Institute on Governance

“The aim of the collective action is to show the market that the major companies in the metals industry have taken action to combat corruption. Collective actions in other sectors have even drawn common rules, but this is not our case. We basically sent a message to the metals industry, especially in current difficult business environment, that the main players have a

”

tuned approach to compliance.

ANDREA LOVATO, CEO, TENOVA

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15/03/2018 15:25:55

18

“The focus of the initiative is to prevent corruption. Therefore we address all relevant topics to achieve this goal. This contains training and awareness raising in all group entities, how to best deal with gifts and hospitality, donations or public officials but also the prevention of corruption by

”

third parties like agents, consultants or intermediary companies.

MEINHARD REMBERG, EXECUTIVE VICE PRESIDENT, SMS GROUP that are enforced in their home countries.

At the same time, companies fear the loss of business if they fail to pay bribes and risk becoming uncompetitive in emerging markets. In the Collective Action approach, stakeholders work together to lift themselves out of this corruption dilemma.

When companies work together to establish common standards this can lead to a leveling of the playing field as competitors agree not to use improper means to obtain or retain business. A clear industry commitment to clean business as good business can also increase investor and customer confidence and reinforce a positive focus on the companies’ reputation in the wider market. Companies

engaged in Collective Action often find that sharing and benchmarking of internal anti-corruption principles and practices enables peer companies to improve their compliance programme on an ongoing basis and enables companies to work towards establishing best practices in the market.

Active involvement in Collective Action is cited in the UK Ministry of Justice’s Guidance 2010, as being evidence of toplevel commitment to fight bribery within their institution and beyond. Acting collectively has also become a reinforcing pillar of an effective internal compliance management system for the member companies.

Since the Initiative went public in 2016

Molten Metal Level Control

it has attracted the interest of another key market player, Tenova S.p.A., who joined the Initiative in 2017. When asked about the reasons for engaging in a Collective Action Andrea Lovato, CEO of Tenova S.p.A. commented that “all companies in the metals industry face similar corruption risks around the world. We immediately saw the benefits of joining forces with other industry leaders in harmonising our anti-corruption management approach”.

The members are looking forward to the new perspectives Tenova S.p.A. will bring to the table, and fresh impetus for all Initiative members to continuously improve their anti-corruption compliance systems and work towards positively impacting the wider market. �

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anti corruption.indd 2

Aluminium International Today

15/03/2018 15:25:55

www.aluminiumtoday.com

FUTURE ALUMINIUM FORUM PREVIEW 19

The future of aluminium manufacturing Be part of the Future Aluminium Forum and find out what Industry 4.0 means to the future of the aluminium industry and how it can assist in its quest for greater efficiencies.

Aluminium manufacturers and processors are constantly looking to improve the efficiency of their production processes and are relying upon increasingly sophisticated digital technologies to streamline their operations.

In such a fast-moving world, characterised by complex Internetbased manufacturing systems, Future Aluminium Forum 2018 is a must-attend event for aluminium professionals who want to unravel the mysteries and get to grips with the complexities of Industry 4.0.

Taking place on 8-9 May 2018 at the Hotel Michelangelo in Milan, Italy, this global aluminium technology conference will draw upon the unrivalled expertise of industry professionals, production technologists and academics to create an event designed specifically for those seeking a greater understanding of ‘smart manufacturing’.

THE CONFERENCE With the introduction of the new digital economy, companies across the aluminium supply chain are re-imaging their processes, how they manage assets and even how they build lasting customer relationships.

As this ‘new era’ approaches, companies are finding new ways to use data to make smart decisions, allowing them to meet industry regulations while simultaneously saving money through more efficient operations and increasing customer satisfaction. This is just the beginning.

The Forum will provide a platform for a discussion on how and where Industry 4.0 will be applied across the sector and the impacts.

Speakers from academia, across the aluminium supply chain and technology providers will explain key concepts behind the digitalisation of aluminium manufacturing; as well as covering the importance of cyber security, the role of

human beings in the factory of the future, autonomous equipment and the allimportant process safety and control.

DELEGATE REGISTRATION NOW OPEN Register online to subscribe to the Future Aluminium Forum membership package, which will include subscription to Aluminium International Today, the Aluminium International Today Directory, relevant news alerts and admission to the Future Aluminium Forum.

EXHIBITION If you are interested in promoting your products and services to an international audience from across the aluminium manufacturing supply chain, then this is a unique opportunity to position your brand alongside leading experts in this field.

There are very limited opportunities available and these will be allocated on a first-come-first-serve basis.

STANDARD RATE: £990 You can view the full conference programme online:

The Forum will endeavour to answer questions such as: � How can we apply Industry 4.0 across the aluminium value chain? � What areas will see the most innovation? � What will the factory of the future look like? � How can we balance automation and productivity? � What else needs to be done to measure the responsible production and sourcing of aluminium? Can Industry 4.0 help? � Will this idea of smart manufacturing make ‘Closing the Loop’ and reaching a Circular Economy more achievable? � How is the latest technology aiding the move towards a more sustainable aluminium industry?

TABLE TOP EXHIBITION SPACE £1,950

www.futurealuminiumforum.com/conference

Aluminium International Today

FAF preview.indd 1

TO SPONSOR/EXHIBIT: Ken Clark T: +44 (0) 1737 855117

Sales Director E: kenclark@quartzltd.co.uk

John Lane T: +44(0) 1737 855 014

Business Development Manager E: johnlane@quartzltd.co.uk

PROGRAMME DIRECTOR: Nadine Bloxsome T: +44 (0) 1737 855 115

Programme Director nadinebloxsome@quartzltd.com

March/April 2018

07/03/2018 14:18:04

20 ITALIAN FOCUS: CIAL

Aluminium recycling - Italian scenario With the Future Aluminium Forum taking place in Italy, this article looks at the country’s sustainability efforts.

Below is more detailed information on the Italian scenario of aluminium waste recycling, i.e. aluminium of all kinds (not just packaging) that has reached the end of its useful life.

Recycled aluminium is obtained from processed and melted pre-consumer scraps (mainly production waste) and post-consumer waste (i.e. items that have reached the end of their useful life).

It is relatively easy to recycle preconsumer aluminium scraps because they are relatively clean and their composition relatively certain. On the contrary, recycling post-consumer aluminium requires special processes and technologies. Often a careful selection phase is necessary before recycling.

The total quantity of aluminium waste recycled in 2016 was 927 tons.

The total quantities were assessed according to: � Their origin, considering the aluminium from Italy and imported 1,000

materials; � Their belonging to the preconsumer category (scraps from the production system) or post-consumer category (packaging, demolition material, cars, WEEE etc).

With regard to the origin of the processed scraps, data shows that in 2016 the quota from Italy decreased (in terms of percentage as well) compared to the year before, whereas the absolute value of the imported quota was stable (increasing in percentage).

Essentially there has been a decrease in the availability of pre-consumer scraps produced in Italy (with stable exports) whereas imported amounts increased.

This scenario is increasingly characterised by the gradual rationalisation of industrial productions, which tend to reduce the amount of scrap material, combined with the delocalisation of production processes.

909

895

927

48%

52%

56%

1,000

750

909

750

500

The stabilisation of exports is in line with the dynamics described above.

Fig 3 below shows the types of scraps materials recycled in 2016, classified according to the waste classes listed in Italian and European legislation.

Considering that the aims of aluminium packaging recycling are referred to packaging waste generated in Italy, the quantities and types of scraps of Italian origin have been monitored. Special attention was paid to the class of only post-consumer packaging (and declared as such) and the classes of mixed scraps, which contain post-consumer packaging as well.

The results of that analysis on the materials processed in 2016 are shown in fig 4 below. �

927

895

46%

48%

45%

54%

52%

55%

2014 Post consumer

2015

500

250

0

52%

48%

44%

2014

2015

2016

Imported

250

0

National

Fig 1. Place of origin of aluminium scraps 2014/2016

2016 Pre consumer

Fig 2. Place of origin of treated aluminium scraps in 2014/2016

grains/dripping turnings 4% 7%

packaging crushed material

23% 19%

cranckcases/ radiators

26%

sheets/dishware

other 0

10000

30000

50000

70000

90000

100000

130000

4%

22%

Other Packaging Crankcases/radiators Dishware/sheets Turning Crushed material Grains/driping

packaging non packaging

Fig 3. Recycled aluminium scraps and relative packaging content place of origin Italy

March/April 2018

italian cial.indd 1

Fig 4. Types of treated aluminium scraps 2016

Aluminium International Today

16/03/2018 10:03:01

ADVERTORIAL - CIAL 21

www.aluminiumtoday.com

Association update: CiAl CiAl is a non-profit Consortium representing the commitment of Italian manufacturers and users of aluminium packaging to research into new ways of reducing and reusing packaging which reconcile the demands of the market with the need to protect the environment.

The Consortium, the aims of which include guaranteeing collection and recycle of post-consumer aluminium wastes collected by municipalities in Italy, was established in 1997 and has increased the amount of aluminium packaging collected in recent years to meet and even exceed the requirements of European legislation.

The results achieved so far in terms of separate collection, recycling and recovery of aluminium wastes have been very positive, making Italy an example for the rest of Europe.

2015 Facts & Figures for CiAL

But important new goals are already on the horizon, and in order to achieve them CiAl aims to achieve a larger and more conscientious citizens’ involvement, particularly younger citizens, to reinforce today’s awareness of the importance of separate collection and recycling.

� Quantity of aluminium packaging placed on the Italian market: 66,500 tonnes.

Today and in the future, communication will play an essential role in producing positive changes in citizens’ behaviour.

For this purpose CiAl has promoted in recent years a number of projects and campaigns providing in-depth information on aluminium and its countless uses. �

� 203 member companies

� 6,607 Italian municipalities undertaking the recovery of aluminium packaging, with the involvement of over 52 million people. � 455 members, 224 platforms and 11 smelting works that guarantee the collection, treatment, recycling and recovery of aluminium across the entire country.

Visit: www.cial.it/english-posts/

Aluminium International Today

cial to use.indd 1

March/April 2018

16/03/2018 10:26:33

22 ITALIAN FOCUS: VALUE-ADDED

www.aluminiumtoday.com

Aluminium rod A commodity that Properzi Technology is making a speciality product.

Electrical Conductor (EC) aluminium rod, typically defined as 9.5 mm rod with 99.5 – 99.7% Al composition, has been the commodity that has shaped over-head conductors all over the world for many decades.

Recently, alloyed rods are acquiring market share in several different applications.

The market seems hungry for speciality rod: from XTAL and ZTAL alloys for high temperature cables, to 4047 and 5386 for welding wires, to 6063, 5056, 5019 and many other alloys for mechanical uses.

Several Properzi lines totally dedicated to these specialty products are already in production.

In addition to aluminium alloy rod for mechanical applications or welding purposes, special attention is now focused by the automotive industry on specialty aluminium rod for electrical cables for use

March/April 2018

italian properzi.indd 1

in the most modern and future vehicles.

The new Al alloys, independently developed on Properzi Lines by several top producers worldwide like Sumitomo – Furukawa – Midal – Trimet – Alcoa – Alcan and others, contain about 98.5% Al and use Fe as the main alloying element with additions of some Mg and Cu. Some are designated as 8000 series; some as 1000 series; some have proprietary names.

Producing this kind of rod is only the first step. The 9.5mm rod must be drawn to unusual diameters (0.16 – 0.25mm) in multiwire machines. Also, bunching is a delicate operation so the rod quality is fundamental for the productivity of the entire process.

These alloys are very sensitive to produce and therefore the casting parameters must be stable and precisely controlled.

The rolling sequence must avoid even minor surface defects. Only a state-of-the-

art double automatic coiler can provide the drawing shop with undamaged coils of rod weighing 2,000kg or more.

It was clear from the beginning that using the “billet casting and extrusion” method was not economically viable, and it induced problems with coarse Al-Fe compounds making the rod/wire brittle and difficult to process. All rod producers choose the Properzi System and, we can say, more than 90% choose original Continuus-Properzi machinery.

A smooth, consistent and affordable production is based on hundreds of details that only a company with experience spanning 70 years can manage in the most optimal manner. �

Contact www.properzi.com

Aluminium International Today

09/03/2018 10:37:53

PRIMARY AN SECONDARY INGOTS LINES FOR ALUMINIUM PRODUCERS WITH THE TRACK & BELT PROPERZI PROCESS

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ANODE COKE 25 5

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Anode coke: The gathering storm

By John Auers* and Paul Adkins**

Opportunities and challenges come in many sizes. Some are large and may be announced with great fanfare. Responses for these can be carefully evaluated, and there is ample time for preparations.

Other opportunities however, may not be so obvious and can sneak up on you.

These surprises may be the most lucrative simply because the competition may not be ready to react. Being prepared for the next business cycle is often the deciding factor in determining who will be leading the pack.

One such opportunity (or challenge depending on your perspective) is developing around an oil refinery product which gets little attention: Anode Grade Petroleum Coke. This speciality product is of great importance in that it is a critical element in the production of aluminium, since ½ ton of anode grade petroleum coke is required to produce 1 ton of primary aluminium Because global aluminum consumption is rising rapidly while anode coke production is forecast to remain relatively flat, a shortage of this vital product is imminent. Further complicating this outlook will be the actions of the International Maritime Organisation to reduce sulfur levels in bunker fuels in January of 2020. Since there is no alternative production process to produce primary aluminium (unlike steel which can be produced by a variety of different processes) it is intuitively obvious why GPC is such a critical raw material.

Petcoke Production Petroleum coke can be produced in multiple forms depending on the quality of the feedstock and the operating parameters of the coking unit. Anode grade petroleum coke (known in the industry as Green Petroleum Coke or GPC) is low in sulfur and other impurities with a “sponge-like structure” and is suitable for use to produce anodes.

To make an anode, the GPC is calcined (resulting in Calcined Petroleum Coke or CPC), a process which, occurring at over 1000oC in a kiln, drives off the volatiles

Cooling baked anodes, Årdal aluminium smelter, Norway Owner: Hydro Årdal

and moisture in the GPC, and changes the crystalline structure of the carbon from an insulator to a conductive material. The CPC is then mixed with 10-15% Coal Tar Pitch or CTP, and molded into large rectangular blocks weighing a metric ton or more and then baked for hours resulting in a solid block of carbon with small impurities of metals and sulfur (impurities coming from the original GPC and CTP).

To produce primary aluminum, approximately one-half a metric ton of GPC is required to produce one metric ton of aluminum. Since there is no alternative production process to produce primary aluminum (unlike steel which can be produced by a variety of different processes) it is intuitively obvious why GPC is such a critical raw material.

Anode Supply and Demand and the IMO Only about 10% of the U.S. petcoke production is of anode quality, but approximately half of the petcoke

produced in China is used to make anodes. The lower output in the U.S. is reflective of the high degree of processing of very heavy and high sulfur crudes from Venezuela, Mexico, and Canada. A recent study concludes that global anode coke production between 2017 and 2020 will only grow by 2.0%. Through 2025, global output will only increase by 2.6%.

Driven by ever-increasing aluminium consumption, global demand for this material is forecast to increase by 13% between 2017 and 2020. By 2025, demand will rise by a whopping 40%.

This imbalance is expected to bring considerable opportunities and challenges to both the refining and aluminium industries.

Complicating this picture is the impending transition to low sulfur bunker fuel in 2020. When the sulfur cap is reduced from the current 3.5% to only 0.5%, much of the new low sulfur fuel will be produced by blending significant volumes of ultra low sulfur diesel, and

*Turner, Mason & Co **AZ China Ltd Aluminium International Today

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26 ANODE COKE

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low sulfur gas oils to augment the modest levels of lower sulfur resids which can be segregated. This development will initiate a substantial spike in low sulfur bunker prices (being predominantly distillate and gas oil based) and a corresponding sharp decline in high sulfur resid prices. This new pricing structure may also initiate a series of unintended consequences by realigning refining objectives which could also adversely impact the projected anode petcoke balance.

Because the anode coke requirements of aluminium smelters require a lower sulfur content than fuel grade petcoke (many times due to environmental constraints), anode those refiners generating anode grade petroleum coke generally process a lower sulfur crude slate. However, This this also allowsf these refineries to be potential candidates to produce low sulfur bunker fuel. The increase in low sulfur bunker prices could induce some coastal refiners to temporarily (or permanently) shut down their cokers. Coker operations can be difficult for refiners, and while the unit produces higher valued raw gasoline and distillate, these intermediate products must undergo considerable additional processing through reforming, catalytic

cracking, and desulfurisation units.

Petcoke is also becoming increasingly scrutinised globally for a variety of environmental reasons. The opportunity to forgo these issues could become an attractive alternative for numerous coastal refineries.

In addition to the potential of losingloss of existing anode grade petcoke production sites, the post-2020 IMO environment also increases the possibility that some current low sulfur anode grade petcoke producing facilities refineries could decide to sell all or part of their coker feedstock in the low sulfur bunker market and replace it with higher sulfur residual fuel oil which will be plentiful and very inexpensive after the IMO implantation of 2020downgrade petcoke quality.

These lower high-sulfur resid prices could easily induce refiners to purchase incremental higher sulfur resid to fill up any unused coking capacity and degrade the petcoke quality. The expected downturn in high-sulfur resid prices is also expected to widen the light/heavy crude differentials. This could also induce a shift to higher sulfur crudes to optimise refining margins, but also with the result of degrading petcoke quality.

While there is always a high degree of market uncertainty, the forecast of anode petcoke production and demand appears particularly tenuous. The base forecast is troubling enough but many of the unknowns (IMO effects and environmental constraints on petcoke handling and operations) could easily make the situation much worse. If anode grade petcoke prices rise high enough however, new some refiners could be enticed to convert feedstock slates and/ or operations to yield anode quality grade petcoke. This change in operations will not be undertaken lightly and may require additional economic incentives. Whatever actions which can be taken will require time and should optimally be done before the crisis occurs.

These issues are a key component in the new “Anode Coke Supply” study released at the end of February. In addition to supply forecasts by country and refinery, the study also forecasts global consumption requirements and potential solutions to the impending imbalance.

More information on this study can be obtained by visiting the Turner, Mason & Co website at www.turnermason.com or contacting the authors. �

8

ALUMINIUM 2018 12th World Trade Fair & Conference

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Partners

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FURNACES 29 5

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Investing in furnace technology Aludium Amorebieta orders multi chamber melting furnace from Hertwich Engineering.

The long-standing aluminium rolling mill in Amorebieta, Spain, which has been operating under the name Aludium since 2015, has ordered an Ecomelt-PS275 multi chamber melting furnace with preheating shaft for clean and contaminated scrap from Hertwich Engineering, an SMS group company.

This investment sees the plant adapting to the growing amount of recycled material available. The new multi chamber melting furnace will go into operation in spring 2019.

To be able to process the growing amount of return scrap effectively and economically in the casthouse, the melting capacity is increased by investing in a modern multi chamber melting furnace of the type Ecomelt-PS275. The throughput is 275 tons per day. Loose and packaged strip or foil scrap, coils, wire, etc. are melted – each contaminated by oils, lacquers, plastic residues, rubber or other coatings.

Depending on the type and composition of the scrap, Hertwich offers different furnace types within the Ecomelt series.

The PS type furnace ordered by Aludium Aluminium International Today

aludium furnaces.indd 1

Amorebieta is suitable for scrap with the highest contamination rates. It comes with a preheating shaft into which the scrap is fed from above through a material lock. The hot gases flow through the charged material in the shaft from the bottom upwards, and the pyrolysis gases produced thereby are combusted in the main chamber.

By using pyrolysis gases (but also due to the advanced furnace design) the gas consumption can be reduced to some 300 kWh/ton (depending on the scrap input). This reduces operating costs and the minimum emissions (CO2, CO, NOX, dioxins, VOC, no salt) contribute to an environmentally friendly furnace operation.

External after-burning is not necessary as all emerging pyrolysis gases are combusted in the main chamber in a controlled manner.

At the lower end of the shaft, the completely pre-heated and de-coated material is immersed in the melt bath moved by a liquid metal pump and is melted instantaneously with minimal melt loss.

As a further special feature, the melting furnace has a separate feed for scalper chips, which are fed into the furnace immediately after machining of rolling slabs and are also melted using the submersion melting process with the greatest possible yield.

The rolling mill in Amorebieta started the production of rolled aluminium products in 1961. The plant has been continuously expanded and modernised, since 1985 initially as part of the INESPAL group and since 1998 under the direction of Alcoa. Since 2015, the plants in Amorebieta and Alicante, both Spain, as well as Castelsarrasin, France, along with the research site in Cindal, form the Aludium Group, a fully integrated network specialising in the cutting, rolling and refining of aluminium.

The Amorebieta plant includes hot and cold rolling capacities as well as strip processing and a casthouse for rolling slabs. Contrary to the general market trend towards “Automotive” and “Aerospace”, the strategic focus here is on the sectors “Building and Construction”, “Distribution” and “Specialities”. � March/April 2018

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30 HEAT TREATMENT

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Heat treatment systems for aluminium forging facilities Since the foundation of schwartz GmbH in 1984, heat treatment systems for aluminium have featured prominently in the company’s product portfolio. Renowned aluminium processors in Germany, Europe and Asia rely on schwartz GmbH’s heat treatment solutions for their annealing, solution annealing with water quenching, and artificial ageing operations.

Global demand for structural aluminium parts, especially from the automotive industry, calls for highly efficient and economically advantageous solutions adapted to these applications.

Aside from contracts received earlier this year for equipment intended to anneal aluminium billets and structural parts, which are still in the production pipeline, an artificial ageing system delivered in September had to meet stringent requirements related to quality, throughput and, not least significantly, space-saving design.

Artificial ageing, which is necessary after the solution annealing and quench stages, can be performed either continuously, e.g., on conveyor belts, or batchwise in racks.

Continuous-type systems, while achieving fast and uniform heating through an airflow directed straight onto the load, must then include a temperature holding cycle to suit the alloy and part geometry, thereby imposing a substantial equipment width and length.

If the artificial ageing treatment is carried out on parts stacked in racks that are heated in chamber furnaces by a circulating airflow, the heating, soaking and holding times are much longer, involving furnace cycles of many hours’ duration. The space requirement of the necessary chamber furnaces including charging devices is likewise considerable.

The customer’s system specification required fast and uniform heating of each part, a speedy return of parts into the production process and, above all, a very compact furnace design due to limited space availability.

The key technical data for projecting the equipment were as follows: � part weight: approx. 3 kg � cycle time per part: 11 seconds � preheat temperature: 190°C ± 3°C

This photo shows the load / unload end; note the lightweight product carriers, the hydraulic pusher device and the conveying systems.

The gas-heated furnace chamber measures 7.5m in length and can accommodate 37 load racks with 25 parts each, i.e., a total of 925 parts. All parts are uniformly heated by the hot airflow. The air circulation is controlled in 3 zones.

The parts are cooled just as uniformly in the cooling chamber arranged under the furnace, from where the air is discharged to the outdoor environment.

The furnace system is scheduled to be commissioned at the customer’s facility in the PR China in early October. The overall output of 1,000 kg/h was achieved, to the customer’s satisfaction, despite its ultra-small footprint of only 2m (useful width) by 7.5m (useful length).

Exacting specifications regarding product temperature uniformity and a quick return of parts into the production process were fulfilled, as expected.

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In a first operating stage the system was to be loaded and unloaded manually. It is intended to be upgraded to automatic operation later.

To resolve this challenge, an electrically heated system with horizontal airflow and indexing movement of lightweight load racks carrying the parts was projected, proceeding from a system for annealing aluminium castings built by schwartz GmbH as early as in 2003.

A load rack measuring only 200mm in length can accommodate 25 parts weighing approx. 3 kg each. The racks are advanced through the heating chamber on guide tracks by a hydraulically actuated pusher device fitted to the front end of the furnace. The loaded racks are introduced into the furnace and removed at the exit end in a vertical direction using electric motor-powered elevators.

The air cooling zone is fitted underneath the furnace system in a space-saving design. The return of the racks through the cooling zone, back to the load / unload end, is ensured by chain conveyors.

The project management and equipment design, in addition to installation and commissioning support, was provided by Hütte GmbH, a schwartz GmbH subsidiary based in AachenSchleckheim, Germany. �

Aluminium International Today

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HEAT TREATMENT 33 5

The complete artificial ageing system with air cooling zone and electrical equipment, shown fully assembled at the site of the subsidiary, schwartz Heat Treatment Systems Asia, in Kunshan/PR China.

The main components for building the system were supplied to the subsidiary company from Germany.

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34 HEAT TREATMENT

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Aluminium temperature measurement developments Richard Gagg* describes new and enhanced methods of temperature measurement for aluminium extruders.

Previously in Aluminium International Today, Richard Gagg discussed the importance of accurate temperature measurements for modern aluminium extrusions. In this article, he discusses parallel developments, which now enable non-contact temperature sensors to automatically and dynamically track and accommodate physical process changes as they occur. Higher quality extrusions and increased production yields can then be achieved.

The first example is temperature measurement of the extruded profile at the press exit as it exits the die. A noncontact pyrometer is physically aligned to target the extrusion at its optimum measurement position. Traditionally, as die changes occur they would require an operator to verify correct pyrometer alignment and then either physically re-position the pyrometer’s mounting bracket or manually manipulate it using a motorised actuator via a hand-held, remote-control keypad. To simplify and automate this process AMETEK Land has developed an intelligent, motorised actuator that can function independently of an operator.

In that die exit application, a new SPOT actuator is mounted above the press exit, and a SPOT AL EQS pyrometer is attached directly to it. The actuator and SPOT pyrometer share the same low voltage power supply. Both the pyrometer and actuator communicate directly with each other via an Ethernet connection, coordinating together in harmony.

One of the actuator’s selectable modes commands it to automatically align the pyrometer to target the optimum hot spot measurement position on the extrusion.

No operator intervention is necessary as the actuator/pyrometer combination jointly communicate, calculate and rapidly re-adjust to the correct, optimised target alignment.

In other operational modes, the

alignment actuator function can be configured to acquire the extrusion in a repeating, timed interval action. Other options can initiate a scan by a simple signal from a push button. Scans also can be triggered by digital messaging or switch commands from either a PLC or an integrated digital press control system.

Designed from the outset to work together collectively the SPOT AL EQS pyrometer’s tightly focused adjustable optics and rapid 15ms temperature response, combined with the 0.1-degree positioning and fast swivel speed action of the actuator facilitate this precise alignment.

For even faster response speeds the actuator’s arc of movement can be selected to a smaller angular span anywhere within the overall 90-degree range of swivel.

This measurement combination can be very useful at the exit of the quench. In many cases, the extrusion will wander from side to side at this location. In this application, the pyrometer/actuator assembly can rapidly and repeatedly locate, target and measure the laterally shifting profile, producing a valid temperature reading.

If desired the actuator can be configured to scan at user-defined time intervals to re-acquire and measure the extrusion.

After each temperature measurement, the pyrometer reading is held until completion of the next scan, at which time the temperature reading is updated.

In this way a valid temperature value is always received without experiencing any false measurement drops if the profile wanders out of the pyrometer’s view.

Some extruders who employ sophisticated press controls are interested in the billet temperature profile from its head to the tail immediately after the billet has arrived at the side of the press. This profile data can then be communicated to the control system, where it will be used

Pyrometer, actuator combination above the press exit.

to modulate the press speed. In this billet scan mode of operation, the pyrometer/ actuator combination scans along the length of the billet defining the thermal profile prior to it being loaded into the press.

In all actuator modes the SPOT pyrometer’s high brightness, flashing green targeting LED automatically triggers during the scan. The LED exactly defines where the pyrometer is currently aimed together with the diameter of the measurement spot. This makes it easy for an operator to quickly verify the pyrometer’s aim.

Both devices feature integrated digital signal processing, and they communicate directly with each other using Modbus TCP. Each device incorporates a web server, which greatly simplifies configuration. No special tools or cables are required for setup. The user just connects via Ethernet using a standard web browser, enters

*Global Industry Manager, Metals at AMETEK Land March/April 2018

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the IP address of the device to select and change the settings required. The actuator features an integrated network switch and features a gateway setting to enable communications with remote Ethernet devices on different IP addressed network segments.

If the end user’s press control system includes a menu of frequently used dies and their geometries, a unique targeting angle can be communicated directly to the actuator, which will then position the pyrometer for that die’s characteristics.

This has the advantage that every time the same production job is run the pyrometer will target the same physical position on the profile. Fewer variables translate to better repeatability and quality.

For some users, the need for a backup or override method of scanning is desirable, and, for this purpose, an optional handheld remote control is available.

If an optional transmitter is added to the press to measure the speed of the extrusion, then that speed signal can be integrated together with the SPOT AL EQS pyrometer temperature readings coming from both the press and quench exits.

By combining the live temperature readings before and after the quench with

The actuator precisely positions in 0.1 degree increments through a 90-degree swivel movement.

the distance between the two pyrometer locations and the current extrusion speed allows quench rates to be continuously and accurately calculated and displayed.

Fully featured and configurable

software is available to integrate multiple measurement variables, such as temperature, speed and other parameters. In this way customised interactive combinations of signals can be employed for better process control and understanding.

The advent of this new positioning technology allows for more repeatable and reliable temperature measurements to be taken. The ability to integrate these measurements into press and quench controls can further improve product quality, including surface finish and desired metallurgical properties. By measuring these variables and understanding their effects on the process provides extruders with competitive advantages and attracts customers who are demanding the highest quality extrusions. Shorter setup times and increased production rates also improve profit margins. And, for less demanding extrusions, the ability to reduce die wear and increase production speeds results in improved efficiencies from the same press machinery. � Contact www.landinst.com

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mail@drache-gmbh.de March/April 2018

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36 PROJECTS & PRODUCTS

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The aluminium industry is constantly embarking on new projects and developing new products. In this regular feature, Aluminium International Today presents the latest announcements in these areas.

If you’d like the opportunity to be considered for publication, please contact: nadinebloxsome@quartzltd.com

Shape Corp. agrees to acquire aluminium extruder Magnode The deal comes after a successful business relationship between the two companies that included collaboration on engineering projects, as well as shared research and development around lightweighting best practices.

Shape’s global aluminium offerings are immediately elevated by leveraging Magnode’s 70-plus years of aluminum extrusion expertise and their vertically integrated business model. Going forward Magnode will operate as a division of Shape.

Danieli supplies UC Rusal UC RUSAL, Russian Aluminium, contracted Danieli for the supply of a rolling mill specifically for conducting research, to be installed at company’s Engineering and Technology Center in Krasnoyarsk, Russia.

The new rolling mill will allow RUSAL

researchers to perform and accelerate the development of new aluminium alloys and processes in the most comprehensive, efficient and economical way, enabling a lowrisk implementation of the newly developed process knowledge.

Finishing mill in Tianjin Zhongwang’s aluminium hot rolling line expanded by SMS group

Successful line expansion as a secure basis for the production of the complete range of aluminium hot strip grades.

In Tianjin, near Beijing, Chinese aluminium producer Tianjin Zhongwang Aluminium Co. Ltd. operates two high-capacity aluminium hot rolling lines supplied by SMS group. In January 2018, one of the two lines in 1+1+3 configuration, i.e. two reversing roughing stands and a three-stand finishing mill, received a further finishing stand.

SMS group completed the line expansion to 1+1+4 configuration during a shutdown period of only 23 days. The first coil was successfully rolled on January 26, 2018, one day ahead of schedule.

March/April 2018

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Aludium Amorebieta orders multi chamber melting furnace from Hertwich Engineering The long-standing aluminium rolling mill in Amorebieta, Spain, which has been operating under the name Aludium since 2015, has ordered an Ecomelt-PS275 multi chamber-melting furnace with preheating shaft for clean and contaminated

scrap from Hertwich Engineering, an SMS group company. This investment sees the plant adapting to the growing amount of recycled material available. The new multi chamber-melting furnace will go into operation in spring 2019.

Aluminium International Today

08/03/2018 12:02:30

37

Sohar resumes production

Hamed bin Zayed Al Nahyan inaugurates Ducab Aluminium Company in Khalifa Industrial Zone His Highness Sheikh Hamed bin Zayed Al Nahyan, Chairman of the Abu Dhabi Crown Prince’s Court, recently inaugurated Ducab Aluminium Company (DAC) in the Khalifa Industrial Zone of Abu Dhabi (KIZAD) as a joint venture between Ducab, the UAE-based leading manufacturer of high-quality cables and cabling products, and

Senaat, one of the largest holding companies in the UAE’s industrial sector.

The new company is the result of an AED220 million (US$60 million) investment that seeks to strengthen the UAE’s industrial supply chain in line with the UAE strategy to champion industrial investments.

Sohar Aluminium successfully resumed full operations in record time after an unexpected disruption in its normal operations, which led to the complete shutdown of its Potline on August 4th, 2017.

The entire plant was involved in the recovery efforts to ensure the fastest return to full production, while sustaining excellent safety standards. The recovery process was recognised as an important accomplishment within the Aluminium industry.

Renishaw reduces machining time for aerospace impeller manufacturer Honeywell Aerospace, part of global commercial and consumer engineering conglomerate Honeywell, produces a large number of the impellers and blisks used in commercial aeroplanes. The impellers, which are essentially radial and axial compressors, rely on a workpiece datum being maintained throughout the machining process to ensure that they are suitable for use. If the workpiece datum point is not maintained, the impeller will be considered incompatible and will require rework, repair or scrapping entirely.

To help maintain accuracy in the machining process, Honeywell turned to global engineering company Renishaw to supply a RMP600 high-accuracy machine tool probing system and Productivity+™ PC-based inspection software for machining centres. The technology allows Honeywell to take measurements prior to machining and detect any axial displacement early in the process.

Holton Crest Ltd has embarked on a development programme to drive continuous improvements in extrusion processes and lead the technological revolution to bring next generation CRE applications to market.

Potroom Insulation Measurement

At wire 2018, Holton Crest will be showcasing these different machine configurations, along with the latest technology developments to demonstrate how the continuous rotary extrusion industry has progressed over the last two years.

Holton Crest development

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VHE‘s enhanced ohmmeter is able to measure the electrical resistance between points of different voltage potential. Conventional ohmmeters do not have this capability.

Much of the equipment installed in aluminium smelter potroom has significant electrical potential to earth (or ground). The series connection of the pot busbar systems means that pots frequently have a potential to earth of 1500 volts dc, and in the the most recent systems this can exceed 2.000 volts dc. Alumina dust and metallic objects can compromise the installed electrical insulation and it is necessary to monitor insulation performance on a regular basis.

Traditional instruments for this purpose have been large and cumbersome. VHE‘s enhanced ohmmeter is portable, lightweight and fitted with comfortable shoulder straps, freeing both hands to use the measuring probes. The instrument has a clear digital display and works just like any other ohmmeter but with the added ability to measure live conductors.

An earlier version of VHE‘s ohmmeter has been in use at RTA ISAL in Iceland since 1997.

08/03/2018 12:02:36

38 ROLLING

Case Study:

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Aluminium rolling cut-to-length line

mill replaces and leveler

Martinrea Honsel required a new cut-to-length line with a working width of 300–1,250mm, as well as a cut length of 300–3,500mm. The required strip thickness was 0.3–2.2mm, with a maximum stacking height of 750mm. Moreover, the cut-to-length line needed to satisfy the tolerances for aluminum and aluminum alloy strips, sheets and plates defined in DIN EN 485.

Source: Burghardt + Schmidt GmbH

Fewer rejects in light metal production – Custom-built cut-to-length line guarantees evenness, narrow tolerances and high surface quality.

Martinrea Honsel Germany GmbH in Meschede is known as a specialist for outstanding mechanical properties, surface qualities and narrow tolerances in aluminium processing. Seeking to satisfy the rising requirements of the industry, the company replaced its outdated cut-to-length line in late 2017 and commissioned Burghardt + Schmidt GmbH with the production of a tailormade line with a Schnutz leveler.

The new system satisfies the requirements defined by Martinrea Honsel regarding evenness, operating speed and surface critical processing. It guarantees leveling quality according to DIN EN 4854 and evenness according to DIN EN ISO 9445. Moreover, the new cut-to-length system ensures 97% availability.

“The range of products manufactured at our plant extends from coils and sheets to stamped blanks for trim parts in the automotive industry or sheet formed parts to decorate automobile interiors, to name just a few,” says Dipl.-Ing. Thomas Rünker, project manager at Martinrea Honsel March/April 2018

Rolling Burghardt and schmidt.indd 1

Schnutz fitted quick-change leveling cassettes to speed up inspection and replacement of the leveling cassettes.

This shortened downtime and ensured improved machine availability. Source: Burghardt + Schmidt GmbH

Germany GmbH. “The maintenance requirements for our previous system were rising continuously, and the procurement of spare parts was becoming increasingly difficult by the day.”

It had become necessary to maintain the old system in painstaking, increasingly short intervals in order to continue ensuring high quality – and in emergencies it was even necessary to commission external providers with cut-to-length services. System availability was therefore no longer guaranteed.

“We had already collaborated with Burghardt + Schmidt GmbH in recent years on several projects which demonstrated their technical competency,” says Rünker.

“Another decisive aspect for placing the order was the expertise at Schnutz GmbH, as their levelers had been picked as core components of the new cut-to-length system.”

The Siegerland-based leveler machine specialist has supplied roll levelers since the early 20th century and are therefore among the world’s oldest manufacturers Aluminium International Today

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Burghardt + Schmidt equipped the system with an integrated swing arm stacking machine to protect the surface of the sheets. It has special swing arms that are powered by highly dynamic three-phase servomotors with controlled force-velocity curve. Source: Burghardt + Schmidt GmbH

“It’s our experience that the leveling unit defines the quality of each individual system. Good, reliable and regular maintenance of the leveling cassettes is essential to satisfy our requirements,

”

as it is the only dependable way to avoid downtime,

explains Dipl.-Ing. Thomas Rünker (on the right), project manager at Martinrea Honsel Germany GmbH. (On the left is Alexander Niessen, technical director at Schnutz.) Source: Martinrea Honsel Germany GmbH

in this field. In fact, Schnutz has built its first leveler in 1882. This experience was crucial to the production of a tailor-made system by Burghardt + Schmidt and its subsidiary Schnutz according to strict specifications.

Aluminium International Today

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Custom cut-to-length system guarantees evenness Cold-rolled, wrought aluminium alloys are cut to length in the Martinrea Honsel plant in Meschede. These anodised and non-anodised aluminium strips are destined for the automotive, furniture

and suitcase industries. A key requirement was the production of particularly even aluminium strips that guarantee troublefree downstream processing. An unwinder is used to remove the strips from the coil and feed them into a leveler that uses 23 leveling rolls to ensure absolute evenness.

March/April 2018

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adjustment for varying material properties are perfectly obvious,” Rünker explains. “It cuts tooling times and the cost of auxiliary process times, while also allowing quick intervention during production in case of any deviation from the customary quality standard. Corrections can be initiated immediately. It also significantly extends the life cycle of the cutting tools.”

Additionally, the modern electronics in the drum shear and B+S’s proprietary software guarantee the narrow length tolerances requested by Martinrea Honsel.

“We equipped the system with a drum shear to speed up the operating process,” reports Thomas Baral, managing director at Burghardt + Schmidt GmbH. “Its advantage is that the material runs continuously and therefore without a looping pit.”

Source: Burghardt + Schmidt GmbH

Martinrea Honsel requires a working width of 300–1,250mm, as well as a cut length of 300–3,500mm. The strip thickness was between 0.3 and 2.2mm. Moreover, the cut-to-length line needed to meet the length and form tolerances according to DIN EN 485 for aluminium and aluminium alloy strips, sheets and plates. The cutto-length line is designed for up to 40 cuts per minute. “We manufacture those lines as a tailor-made solution in order to meet the conditions and specifications on site,” explains Thomas Baral, managing director at Burghardt + Schmidt GmbH. “The system only needs slight technical modifications to handle steel and stainless steel, as well as other metals.” Burghardt + Schmidt designs each system individually to meet the customer’s expectations and hence accommodates a broad application spectrum while still enhancing the quality of the results.

Quick change cassettes improve machine availability “It’s our experience that the leveling unit defines the quality of each individual system,” says Rünker. “Good, reliable and regular maintenance of the leveling cassettes is essential to satisfy our requirements, as it is the only dependable way to avoid downtime.” The leveling tools need to be reworked from time to time, and the Burghardt + Schmidt GmbH subsidiary Schnutz can handle this task as an after-sale service at its own factory in Siegen. Continuous quality and extremely short delivery times are guaranteed if the leveling cassettes need to be completely March/April 2018

Rolling Burghardt and schmidt.indd 3

replaced.

Schnutz developed quick-change leveling cassettes so that inspection and replacement of the leveling cassettes can speeded-up. “These leveling cassettes improve accessibility and therefore the maintenance can be reduced,” says Baral. “During maintenance, the operator removes the cassette completely from the leveler and positions it on a rack which is enclosed on a robust welded steel frame.

Lifting gear is then used to simply pick up the cassettes from there, inspect them, and then rework them if necessary.” This leads to minimal downtime and improved machine availability.

Drum shears accelerate operating process Once it has been unwound and leveled, the strip is then cut crosswise into metal plates. “We equipped the system with a drum shear to speed up the operating process,” reports Baral. “Its advantage is that the material runs continuously and therefore a looping pit is not needed.”

Not only does this make the system more compact, but it also reduces the cost of the footings. Setting the blade clearance for the drum shear is fully automatic.

This means that the clearance between the two blades is adjusted automatically depending on the material strength and thickness. Material data are entered at the main operating console, and the drum shear adjusts to the right clearance. This prevents unnecessary user errors while also speeding up the operating process.

“The benefits of quick and individual

Swing arm stacking machine protects the product surface Once cut, the metal plates need to be stacked to ensure smooth downstream processing. But this can damage the surfaces if the plates are deposited improperly. “Our workpieces need to satisfy strict decorative standards, so an impeccable surface is essential,” explains Rünker. “This means they must not be scratched during stacking, and the edges have to be absolutely flush.”

This prompted Burghardt + Schmidt to equip the system with a swing arm machine to stack the sheets up to a height of 750 mm including pallet, without damaging their surfaces. The stacker has special swing arms with powered transport rollers in order to transport the sheets. Highly dynamic, three-phase servomotors with controlled force-velocity curve are used for the swivel and deposit movements.

This ensures extremely precise swing movements. “In earlier iterations, these movements were powered pneumatically, but air is an extremely expensive medium,” says Baral to explain the motorization.

“That’s why we now use energy-efficient servomotors.”

Punctual delivery enables quick commissioning Each of the system’s manufacturing stages was completed on schedule, so Burghardt + Schmidt GmbH was able to deliver a turnkey cut-to-length system with protective fencing to Meschede as early as November. The system will be in the startup phase until January. “Although we rescheduled the delivery date, Burghardt + Schmidt still helped us by ensuring punctual delivery and in doing so enabled quick replacement of the systems in our rolling mill,” says Rünker, looking back.

“We are therefore confident that our customers will benefit from the improved quality of our new machine from January onward.” � Contact www.schnutz.com www.b-s-germany.de www.martinrea-honsel.com

Aluminium International Today

07/03/2018 15:25:45

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42 ROLLING

www.aluminiumtoday.com

Cold rolling mill revamp SMS Group reported that at its site in Slovenska Bistrica, Impol Group Slovenia has successfully rolled the first aluminium strip on the cold rolling mill, which was recently modernised by SMS group.

In the summer of 2016, Impol Group Slovenia awarded SMS group Technical Services Ltd. the contract to revamp its over 40-year-old cold rolling mill.

With this upgrade, Impol Group Slovenia has invested in the future viability of the cold rolling mill and has brought about significant improvements.

The range of coil dimensions has been extended, including larger coil diameters and increased width, with maximum coil mass doubled. Higher strip tensions now allow thicker strip to be rolled.

What’s more, the strip quality conditions, particularly the thickness and flatness results, have been improved.

Last but not least, strip drying has been optimised resulting in an enhanced strip surface quality.

To achieve these improvements, SMS group has modified the foundations and replaced the complete entry and exit equipment. The new pay-off and tension reels are fitted with mandrels with outboard bearing supports to ensure safe handling of the larger and heavier coils.

Thanks to the new change-speed gear units at the drives in the entry and exit

sections and at the main drive, thickergage material can now be rolled with higher torques. Also new strip threading equipment has been installed.

The pay-off reel features a strip centering system from EMG Automation GmbH, a company of SMS group. This allows the rolling process to be optimally controlled. The aluminium strip can be guided through the rolling mill perfectly centered, a key requirement for a stable and precisely wound coil.

Along with the rearrangement of the tension reel on the exit side, a belt wrapper was integrated. The design of the belt wrapper allows strip coiling with the strip being fed from above or below.

While improving coiling of the rolled strip, this design also provides higher flexibility in the production of treadplate.

Integrating thickness gages at the entry and exit side of the mill has improved the quality of strip gage control. New spray headers for work roll cooling and a new flatness measuring roll provide enhanced flatness and quality control. A DS system arranged in the exit section of the four-high mill stand reliable removes

any residual oil from the strip surface.

This ensures that the strip surface is of a very good quality, a key requirement for successful downstream processing of the aluminium strips.

The revamp also included the installation of new ancillary coil handling equipment and utility systems. This involved the integration of new coil cars, a pallet conveyor system for coils complete with a strapping station, and media supply systems for the hydraulic and pneumatic equipment.

In this revamping project, the main challenge for SMS group was to design the new components and plant units in such a way that they would fit into the existing configuration, while ensuring that the revamped equipment would comply with the latest European machinery safety standards. Last but not least, the good cooperation between all involved was key to the success of the project. The aluminium cold rolling mill of Impol Group Slovenia is now fit for the challenges of the future and certainly stands comparison with the performance of a brand new plant. ďż˝

The project team is glad about the successful revamp of the aluminium cold rolling mill, which is all set for more challenging rolling tasks

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07/03/2018 15:28:02

ADVERTORIAL - DANIELI FROHLING

Automotive applications drive cutting technology After aluminium became the major casting material for chassis frames or motor parts, today we are also facing a change within the material application of aluminum in car body construction.

Analysts expect that aluminium sheet demand for auto body and closures parts will double within the coming seven years. Both additional production capacities and adapted technologies are required to cope with the increasing demand and rising quality requirements. Based on the unique Danieli Fröhling high-speed trimming and precision pit slitting line technology, sophisticated solutions for the aluminum automotive industry have been developed and introduced into the market.

For the final customer, the slitting process may still be considered as the finishing part of the cold rolling process, but it can also be seen as the first downstream step after cold rolling and levelling where the “virgin” material has to be converted and tailored for the next stage. Wherever you want to situate the slitting process it is definitely the point where all the efforts of the upstream production process concentrated on achieving the perfect strip material condition should be finished and not downgraded.

One main category of technological requirements for slitting lines depends on the condition of the material entering the slitting process, and the goal is to maintain these material features. For automotive applications we can point out the following two issues in this category, both of which are essential to consistently produce the complex geometry of auto body panels with the highest tolerances: The strip quality (includes scratch free surfaces and closest strip tolerances) and the strip formability to preserve the desired material microstructure received in upstream processes. All this has to go along with increase of line production, energy efficiency and reduction of scrap.

Several new lines dedicated to automotive strip production have been supplied by Danieli Fröhling recently and all are characterized by an optimized line layout maintaining the formation behavior of the aluminum strip for the downstream forming process steps. Clearly, there are also benefits for associated industries such as the aviation and shipbuilding industries.

But there are no “one-size-fits-all solutions” in this new growth field either. Danieli Fröhling’s know-how and capability to customise line concepts and designs are important to fulfill individual product mixes and the material flow requirements of aluminium producers, as well as provide both economical and sustainable technologies.

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44 ROLLING

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Providing a process solution for Bridgnorth Aluminium Ltd As the UK’s only manufacturer of lithographic printing plate material, for Bridgnorth Aluminium Ltd, producing high quality products efficiently and effectively is paramount. Based in Shropshire, Bridgnorth Aluminium Ltd has a purpose built rolling mill and stretch levelling line, allowing the company to specialise in hot and cold aluminium rolling, annealing and levelling. Following a period of sustained growth for the business, an expansion of its facility led to the installation of two additional hot water boilers as part of its new litho finishing line, with a payback period of just two years.

For the company’s lithographic material, it is critical that the material’s surface remains unmarked and unblemished when a finishing chemical is applied. To achieve this, a hot degreassant, which is heated using industrial hot water boilers, is applied to the surface, giving the plates a flat surface for printing.

As with any new manufacturing process, efficiency in terms of both time and cost was a key consideration. However, coordination, trust and flexibility played a vital role in the successful installation and, following a competitive tender process, Bridgnorth Aluminium Ltd opted to work with Bosch Commercial and Industrial.

Providing efficiency It was agreed that Bosch Commercial and Industrial would be able to provide not only the products necessary for the expansion but also the support structure needed to cope with the logistical and organisational demands of the project.

In order to increase capacity for the site, while maintaining high efficiency standards, two UNIMAT UT-M 1,400kW

Rolling bridgnorth.indd 1

hot water boilers were installed to heat a primary circuit which raises the temperature of both the chemical treatment and hot water rinse.

Bosch’s flue gas heat exchanger allows heat from the flue to be returned to the system, saving energy and increasing efficiency by 2% – an efficiency measure which equates to a saving of up to £18,000 a year.

Planning for success One of the challenging aspects of this installation was that the boilers had to be married up with the rest of the manufacturing line’s creation. To reduce energy-losses, short pipelines were designed as part of the system, which made access to the site difficult.

Additionally, the commissioning timings of the different components within the line had to align, in order to minimise the line’s downtime and test periods.

To combat these logistical challenges, Bosch took a flexible approach and worked closely with other site suppliers in order to achieve a joined-up installation within

both time, space and budget constraints.

In a project that totalled 12 months to complete, the installation and commissioning of the boilers themselves took just 2-3 months.

The verdict Simon Edwards, Mechanical Maintenance Manager at Bridgnorth Aluminium Ltd, commented: “This was a complex project and we needed a hot water boiler supplier that we could discuss all our needs with, which would be on hand post-installation as well as pre.”

Rob Brown, Special Projects Sales Manager, at Bosch Commercial and Industrial, commented: “We are delighted we have been able to help a leading UK manufacturer continue to expand and develop. The UNIMAT UT-M hot water boiler was perfectly suited to the site due to its flexibility and energy efficient characteristics.” � Contact www.bosch-industrial.co.uk

07/03/2018 15:30:29

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07/09/2017 12:44

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It provides precise measurements, allowing metals producers to correctly lubricate their metal sheet and put an end to costly oil spillages on the warehouse floor. Take control of your process and of your strip.

PROSIS coating weight sensor Highly sophisticated technology for thin and ultra thin coatings

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09/03/2018 18:08

ANALYSIS & TESTING 47

An overview of aluminium surface analysis

Fig 1. The Reichert-Jung Ultramicrotome

By Peter Andrews* The aluminium surface is very important.

What goes on there can impact upon future performance, such as bond durability, corrosion resistance, paint / lacquer adhesion to mention but a few.

In this blog I’ll describe how we use ultramicrotomy with transmission electron microscopy (TEM) to really understand the aluminium surface.

Why do we need understand the aluminium surface?

There are many questions involving the aluminium surface which we need to answer if we want our product to perform as it should. Is the surface clean? This means there are no disturbed layers.

A disturbed layer incorporates residual oxides and metal from thermo-mechanical processing. Is the pretreatment the correct thickness and of uniform coverage? Is there even a pretreatment present?!

Unlike the more macro surface issues such as dents, scratches and metal cracking, the ones above occur on the

micro / sub micro scale. Because of this, we often choose ultramicrotomy with transmission electron microscopy (TEM) as a means of analysis.

Ultramicrotomy Ultramicrotomy is a technique involving cross-sectionaly ‘slicing’ very thin (~100nm, so it is electron transparent) sections with a diamond knife from an interface. As a result, the sections should incorporate bulk metal, surface oxides or pretreatment, and possibly an overlayer of lacquer or paint.

The slices produced are not only thin but their dimensions rarely exceed 1500 x 500 µm. Consequently, handling can be quite difficult. Fig 1 shows an ultramicrotome.

Sample preparation You can see the process steps we go through to create a slice for TEM observation from a bulk metal sample in Fig 2.

First of all we remove a small sample (~ 3 x 9 mm max) from the bulk material,

generally with a jeweller’s saw. We sputter it with a very fine gold layer which helps define the outermost surface and aids focussing. We then mount the sample in a two part epoxy resin. This offers rigidity to the sample and enables us to section material as thin as foils. After this, we produce the samples as described in Fig 2.

We use a 3mm diameter copper grid to collect the slices from the water. It’s possible to capture up to 50 slices on the grid. As a result, we should uncover an ideal interface section. We then place the grid in the TEM for observation.

Ultramicrotomy is a technique I have been practising for around 30 years. I was told it was a science when I first started, but I quickly found it’s a bit of a ‘dark art’. Repeating the same method doesn’t always result in usable samples.

In addition to cutting speed, water

*Peter Andrews, Surface Scientist, Innoval Technology Ltd, www.innovaltec.com Aluminium International Today

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48 ANALYSIS & TESTING

meniscus level and cutting thickness, air temperature and humidity also play a part in how well a sample will cut. Some days nothing works, so you just have to go home and try again the next day!

Invaluable observations Over the years we’ve found these types of observations to be invaluable. As well as allowing us to monitor coatings, they also give us a deeper understanding of the interface and why it might fail.

Furthermore, most TEMs are equipped with an EDX (energy dispersive x-ray analysis) facility offering elemental identification. Understanding where certain elements end up in and around an interface can really add to the story.

Whilst the technique requires a lot of patience and can be very frustrating at times, the results are often extremely rewarding. Here at Innoval we have several people who are now accomplished in the dark arts should you need an examination of an interface.

Over the years we have been involved with monitoring pretreatments and surface quality for many industries. Products have included automotive aluminium, internal and external architectural panels, food and drink containers and packaging, and various anodised products. In fact, just March/April 2018

Analysis innoval - Copy.indd 2

Surface

Resin embedded sample shaped to a four sided pyramid

Tip microtomed back to form flat face incorporating resin and sample

Embedded sample

Microtomed face from which samples are collected

Embedded sample

Near surface region ~1µm

Region of interest at epoxy/metal interface

Sample is cut by static diamond knife

Some examples of what we can see The images shown below are typical of the type of interfaces we monitor.

Fig 3 shows a thick porous anodic film with nickel deposits down the pores (adjacent to the barrier layer).

Light reflections cause, in this instance, the material to have a grey finish. The thickness and uniformity of the deposited nickel is critical to the colour.

Fig 4 shows a typical chrome phosphate pretreatment film. It displays a uniform 30 nm thickness with continuous coverage.

When a surface isn’t cleaned properly it can leave disturbed layers (Fig 5) consisting of rolled in oxides, fine grains and lubricants. This type of surface is quite reactive and is therefore a poor recipient of pretreatments or films.

Partial cleaning can open up a surface resulting in voids and cracks. As Fig 6 shows, a pretreatment film can penetrate down into the surface.

Fig 7 shows a thick Si based pretreatment film on a poorly cleaned surface. In this case, subsequent adhesion and durability may be a problem.

When everything goes right with the processing and sample preparation, it’s possible to obtain an image such as the one in Fig 8.

It shows a clean surface and a good anodic film with a fine layer of sputtered gold attached to the bonding media.

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Copper grid

Bulk micro-structure

Pivoting arm moves sample over diamond knife cutting slices <100mm thick Water bath

Fig 2. Preparation technique

Fine gold layer

Lacquer

Pre treatment layer

Disturbed layer

Fig 3. An anodic film with Ni in the pores (arrow)

Fig 4. A 30 nm thick chrome/phosphate pretreatment

Fig 5. Poorly cleaned AA5754

Fig 6. Poorly cleaned with sub-surface pretreatment

Fig 7. Silica based pretreatment on a poorly cleaned surface

Fig 8. DC H3PO4 anodised film

about anything involving an aluminium surface!

You can find more information about what we do here. Finally, if you’d like to read a brief overview of aluminium pretreatments, have a look at this blog.

Thumbnail and snippet (what appears in Google) The state of an aluminium surface affects the performance of many products. This blog explains how ultramicrotomy & TEM analysis help us to understand how. � Aluminium International Today

07/03/2018 15:33:55

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ANALYSIS & TESTING 51 5

Real-time feedback of oil ďŹ lm consumption

By Christopher Burnett*

Aluminium sheet is bent and formed into a wide variety of shapes, and is the material of choice for manufacturing beverage cans and many other consumer goods. As mechanical engineers design these products and their subcomponents, they focus not only on the mechanical properties of the final part, but consider the stresses associated with the fabrication of the parts themselves. The stamping and punching operations of aluminium sheet require a specific coefficient of friction as the sheet is drawn and formed to its final Absorbance 100%

shape. Lubrication oils are commonly used to assure the surface of the aluminium behaves consistently during this process.

When the oils are applied in excess, they can pool in the die and cause problems in the stamping operation. If they are not present, the sheet may tear, heat up too much, or cause the punch press to jam.

Each of these scenarios is undesirable and can lead to production delays. Therefore, measurement of the oil becomes critical to the process.

Aluminium is truly one of the most

versatile materials available to modern designers. It is used in nearly every aspect of our world, all manner of engineers across transportation, housing, communication, food and beverage, defense and recreation all use aluminium in their products. As the applications for aluminium increase, the forming, bending and shaping of raw aluminium products expands as well. For example, a flat sheet of aluminium could literally end up in over a million end uses, and as it is recycled, a million more.

Fig 1. Schematic of IR absorbance by CH molecules CH- absorption

More oil

Less oil Clean surface

Wavelength

Fig 2. Thermo Scientificâ&#x201E;˘ PROSIS measuring head

Measurement channels

*Marketing Manager, Flat Sheet Gauging, Thermo Fisher Scientific Aluminium International Today

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52 ANALYSIS & TESTING

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Noise in coating weight measurement (averaging time: 0.1 s)

Scanning from left to right

2 second integration time:

Scanning from right to left

Scanning from left to right

0.1 second integration time

Scanning from right to left

Mean: -0.06, Std-DevP 0.008

0.06

Measurement deviation from mean value

Coating profile with oil gap

0.04 0.02 0 -0.02 -0.04 -0.06 0 1000

Fig 3. Impact of integration time on determining the location of a clogged nozzle

9000 10000

Fig 4. Typical statistical noise observed for IR sensor measurement of oil coatings

Light intensity change with distance

1

3000 7000 5000 No of measurement

14

0.9

Correlation of measurement to LabValue for model 2

12 10

0.7 Measured value

Relavitve light intensity

0.8 0.6 0.5 0.4 0.3

6 4

0.2

Dist. 45mm

2

0.1 0 0

8

Dist. 29mm 5

10

15

20

25

30

35

40

0

0

2

4

Distance to sensor in mm

Fig 5a. IR light intensity as a function of sample position

Component manufacturing lines that produce hundreds of thousands of stamped parts per day rely on uniform distribution of oil across the strip. The presses and stamping operations that transform the flat sheet would overheat and bind up without the benefit of a thin layer of lubricant on the aluminium.

To prevent these unplanned line stoppages, lubricants are often applied in excess, reducing profitability, creating slip hazards in the coil storage areas and generating an additional waste stream to manage. Traditional methods developed to measure the amount of oil require cutting samples, punching out coupons of exact diameters and precisely weighing the sample before and after stripping the oil from the surface.

While generally accepted, this process reduces yield by taking from the finished coil and takes place after the components have been made, too late to make any changes.

A robust sensor that employs infrared light to determine the amount of oil online is essential, thereby allowing sheet suppliers to provide assurances to component manufacturers that the critical oil layer is thick enough to guarantee consistent production, but not too excessively thick to cause waste or pooling in their dies.

March/April 2018

TESTING thermo 2.indd 2

10

6 8 Lab value

12

14

Fig 5b. Accuracy at 29mm and 45mm of height

Oil weight measurements Oil is applied in very thin coatings ranging from 50 to 1500 mg per square meter, or 0.055 to 1.65 microns in thickness assuming an oil density near 0.9. Traditional destructive techniques based on the Weigh-Strip-Weigh (W-S-W) process described in ASTM A90 or ISO 1460 to verify coating thickness require hyper-precise scales to achieve accurate results. Sample coupons that are roughly 75cm in diameter will have less than 1 mg of coating on them. If a scale is accurate to +/-0.1 mg this could result in an error that is 20 % or more of the coating amount. To counter this dilemma, larger coupons can be used, but this too has its drawbacks.

Infrared spectrum based sensor overview Infrared (IR) light is ideal for measuring hydrocarbon based lubricants. Just below the energy of visible light, IR light is defined as light with wavelengths between 0.7 and 1000 microns. Subdivided into three sections based on wavelength, IR light has many practical applications outside of the coil coating line. The sensor presented here primarily uses light in the Near IR range to take advantage of the fact that the molecular bonds of most hydrocarbons absorb specific wavelengths of infrared light in that range. (See Fig

1) By positioning an IR light source and detector on the same side of the coated product, a system of optics can be used to measure the intensity of a specific wavelength of reflected light relative to a reference wavelength. By comparing the ratio of the two intensities, a relative measurement of the coating thickness can be made. In general terms, the thicker the coating, the more absorption will occur at the measured wavelength in relation to the reference wavelength and the larger the observed ratio.

Rudimentary sensors designed to measure only two channels can provide erroneous measurements when certain production parameters change. Therefore, the most appropriate sensor is one that measures a wide spectrum of infrared light. When configured to measure wavelengths associated with an entire range of hydrocarbon bonds, an infrared sensor can accurately measure coating weights for nearly every type of coating.

Additionally, by using optical light, the sensor is immune to background interference due to air temperature changes between the sensor and the strip. By synchronising the source lamp emissions with detector sampling, the sensor will eliminate background light variations and sheet flutter. (See Fig 2).

For example, as the light intensity varies Aluminium International Today

07/03/2018 15:41:42

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54 ANALYSIS & TESTING

1.8

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consumed into heat, so often less than 5% is converted to light. Additionally, higher power lamps cost more and have a reduced lifetime.

The use of reflectors, lenses and light guides are more effective at reducing signal noise. Again, like the incandescent light bulb, the source of the IR light emits in all directions. For the IR spectrum sensor, the IR light is only needed on the strip side, so a parabolic reflector can be used to direct all the light forward on to the coated strip. The net result will significantly multiply the number of photons used in the measurement without the need for temperature control and complex cooling circuits.

For the IR spectrum sensor, typical noise observed on the oil measurement over an averaging time of 100 milliseconds is less than +/- 0.02 gram per square metre (See Figure 4). When compared to the W-S-W coupon this is less than 0.09 milligrams of oil mass on the sample, which is only possible with expensive high precision scales mounted on special vibration limiting tables with enclosed measuring environments.

precision of the laboratory method used.

In order to minimise the random errors of the W-S-W process, multiple samples are required. As the number of samples used in the calibration increases, the overall error of least squares fit through the samples decreases. As stated earlier, the laboratory method directly measures the oil weight using a scale. The list of possible sources of error in this process extends well beyond the precision of the scale. Oil coatings can be accidentally wiped off during handling, or residual oil can stick to the balance surface. Determining a repeatability and reproducibility test is difficult as samples are destroyed during the process and sample-to-sample consistency is not guaranteed. With care and disciplined laboratory practices, adequate samples can be collected. The process will take time, but the time investment will be rewarded with an accurate, reliable calibration that will last the lifetime of the sensor and beyond. Additionally, in order to cover the full production range of minimum to maximum oil thickness, samples should be provided from at least 10% below the minimum coating to 10% above the maximum coating. Extending the calibrated measuring range beyond the normal production range will prevent extrapolation and assure meaningful measured values that will guide out of control situations back to normal production processes.

Typical IR spectrum based sensor accuracy is depicted in Figure 6. This data was collected on seven oil-coated samples, plus one sample of the bare substrate, ranging from 0.13 to 1.6 gsm (0.14 micron to 1.8 micron at a density of 0.9). Nine measurements were made on each sample, over an area of 100 square centimetres. A simple least squares fit through the data resulted in a two-sigma accuracy of less than +/- 0.03 gsm.

Passline variation As discussed above, well-designed optics can decrease the statistical noise on the measurement. They can also be positioned and focused to direct the light in a manner that minimises sensitivity to passline.

The sensor response can be virtually immune to typical variations in passline, maintaining accurate measurements over a span of +/- 8 mm (Figs 5a and 5b).

The intensity of the detected IR light will vary by a factor of 3 across this range, but by considering the relative absorption of wavelengths across the whole spectrum, the system is still able to provide accurate measurements.

Summary Online measurement of oil coatings is becoming essential as metals component manufacturers work to eliminate costly delays in their process, save raw materials, reduce rework and improve product quality. The infrared spectrum technology described in this article addresses the typical influences present in a rolling mill and provides reliable measurements for oil coating thickness in real-time. This method results in significant benefits associated with improved coating uniformity, reduced re-work and elimination of delays while destructive tests are made by sheet suppliers. ďż˝

Observed accuracy of oil coatings The accuracy of any non-contact sensor will depend heavily on the accuracy and

Contact Thermo Fisher Scientific www.thermofisher.com/gauging

Regression: RV = (-0.0011) * MV2 + (1.0019) * MV + (-0.0004) Correlation: R= 0.99954; R2 = 0.99907

1.6 Measured and corrected value

1.4 1.2 1 0.8 0.6 0.4 0.2 Fig 6: Predicted versus actual lab measurements

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across the spangle of a zinc coating, older sensor design would falsely interpret that as a coating change, whereas the spectrum based detector monitors the influence on the entire spectrum in one single measurement location and is thereby immune to any variation.

Technical performance Statistical noise As with all measurements, there is a base level of sensitivity or ultimate limit to the precision of any single measurement. In the case of infrared light, the detector signal is proportional to the number of light photons collected in a unit time. For any consecutive measurements on a single sample, the number of photons detected will vary in a statistical distribution and result in slightly different measurements even though the sample is exactly the same. This variation is called statistical noise. To minimise the noise, the unit time over which the data is collected can be increased. This will decrease the per cent of variation and result in a more precise measurement. However, when considering an online sensor, it is preferable to collect the data as quickly as possible to allow for process control actions as changes are observed. In Figure 3, the impact of increasing the averaging time is seen. As a sensor is scanning across an area on the sheet where a spray nozzle might be clogged, the location of the gap will erroneously be skewed depending on the direction of scan.

As an alternative to increasing the averaging time, the number of photons for the same unit time can be increased.

This can be accomplished by using a higher power IR Lamp, or optimising the geometry between the source and detector to capture the most light. While using a higher power lamp seems to be an obvious solution, there are limitations due to heat build-up and thermal stability. IR lamps, like incandescent light bulbs, convert the majority of the energy

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ANALYSIS & TESTING 55 5

www.aluminiumtoday.com

LIBS: The tool of choice for analysis Laser induced breakdown spectroscopy (LIBS) is now the leading technology for analysing aluminium. LIBS utilises a laser to create a plasma on the aluminium and is inherently good at light elements such as Mg, Si, and Li. These elements radiate brightly making them easy to measure at low levels; ideal for analysis of aluminium.

LIBS measurements are instantaneous and the laser can burn through contamination allowing measurements to be made with minimal sample prep. TSI has several LIBS solutions that provide fast measurements in your hand or on the line.

TSI’s Chemlite™ handheld instrument IDs in 1 second and sorts alloys XRF cannot.

The ChemLine™ In-Line Metal Analyser is a LIBS laser-based sensor that operates even faster at pieces moving as fast as 3 m/s. These LIBS solutions are being used in the industry for both QC and scrap sorting applications.

QC Applications: Trust but verify LIBS instrumentation is being used throughout the aluminium manufacturing process as a QC check. Incoming materials can be checked easily on the dock with the Chemlite handheld analysers. Scrap loads can be quickly and accurately sampled and verified. The Chemline In-Line process sensor can be installed throughout the manufacturing process to verify the material automatically.

Automating the ID process will easily provide 100% inspection of the manufacturing process.

Scrap sorting The Chemlite handheld and Chemline In-Line process sensor are being used extensively for scrap sorting applications.

The accuracy, speed and ease of use make these solutions a great tool for sorting scrap, including Mg from Al, wrought from cast or separate alloy families, like 5XXX from 6XXX.

The Chemlite is the only LIBS instrument that is a Class 1 (Eye Safe) laser product.

With this, there are no additional safety regulations required, no radiation glasses, no laser safety officer or laser safety training required. This makes it the only regulation free analyser in the industry.

The Chemline is designed for automatic aluminium scrap sorting systems and has an industrial sensor designed for 24x7 operation. This sensor is customisable for specific applications and utilises a high power, high rep rate laser that makes fast accurate measurements on a stream of material. TSI can provide full turnkey scrap sorting systems or sensors customised to your application.

LIBS works for the aluminium market and TSI’s handheld and installed LIBS solutions are the answer. � Contact www.tsi.com

Fast, Safe, Regulation-Free Metals Analyzers ChemLite™ and ChemLine™ metals analyzers precisely identify metal alloys. Better than XRF. No regulation worries. No OSHA fines. Just fast, accurate sorting.

ChemLite™ Handheld The “Green Gun” + ID in 1 second + Eye-safe laser—no regulations + Sorts alloys XRF can’t

ChemLine™ In-Line Metal Analyzer + LIBS laser-based sensor for fast scrap sorting + Sort Mg from Al + Wrought from cast Al + 5XXX from 6XXXX Al + Sensor only or complete turnkey solution

Schedule A Demo Today 800.874.2811 — www.tsi.com

LIBS That Work — Assembled in the USA

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March/April 2018

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Limited delegate spaces remaining – register for your pass now

8-9 MAY • HOTEL MICHELANGELO MILAN • ITALY

Applying Industry 4.0 to the aluminium industry Taking place on 8-9 May 2018 at the Hotel Michelangelo in Milan, Italy, this global aluminium technology conference will draw upon the unrivalled expertise of industry professionals, production technologists and academics to create an event designed specifically for those seeking a greater understanding of ‘smart manufacturing’.

Commercial packages to promote your brand, products and services

Subjects include: The Digital Revolution Plant Security and Safety Striking a Balance with Automation and Productivity The Innovation Hub: European Aluminium Panel Smarter Manufacturing for a Streamlined Supply Chain The Smelter of the Future Key Market Opportunities

There are very limited opportunities available and these will be allocated on a first-come-first-served basis. Please note bespoke packages can also be created for you if you have something specific you want to achieve.

Register online to subscribe to the Future Aluminium Forum membership package which will include subscription to Aluminium International Today, the Aluminium International Today Directory, relevant news alerts and admission to the Future Aluminium Forum, 8-9 May, Hotel Michelangelo, Milan, Italy.

Included in the delegate fee is the Networking Dinner which will take place on Tuesday 8 May. This intimate gathering provides a perfect opportunity to interact with all delegates, speakers and exhibitors attending the event.

If you are interested in promoting your services and products to an audience interested in increasing efficiencies within their aluminium manufacturing facilities, then this is a unique opportunity to position your brand alongside leading experts in this field.

Sponsorship opportunities include: Delegate Bags Badges & Lanyards Conference Programme Delegate Lunch Networking Dinner Coffee Breaks GET IN TOUCH TO FIND OUT MORE: Ken Clark International Sales Director +44 (0) 1737 855 117 kenclark@quartzltd.com John Lane Business Development Manager (Europe) +44 (0) 1737 855 014 johnlane@quartzltd.com

Standard Rate: £990 + VAT View the full conference programme and register for your pass here: www.FutureAluminiumForum.com Official Media Partner

Organised by:

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@alu_forum

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Proven energy saving from 15-60% Typical heat dross reduction about 20% Low NOx/reduced CO2 emissions High bath coverage Custom configuration Tel: +41 (0) 71 649 20 90 contact@hotwork.ag www.hotwork.ag

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Sponsors

World Aluminium Conference 2018

Supporters

23-25 April 2018 • Jumeirah Carlton Tower, London, UK

Key themes the conference will explore: • • • • • • • •

Primary aluminium - looming shortages, or long-term surplus?

The renaissance of the US aluminium industry European aluminium industry - the phoenix from the ashes?

Chinese strategy – to buy or build outside China?

Shifting paradigms for carbon products The sustainability differentiator Electric vehicles – in demand Price and premiums outlook

Includes a pre-conference workshop: Aluminium Demand – Opportunities and Threats “The contacts that I met here were beneficial to my role overall and my region... the conference has been great” Melissa Wonderling, Senior Manager Procurement, Packaging, Coca Cola

For more information, or to book your place, visit: www.worldaluminiumconference.com

“Gives us the information we need as business leaders” Tim Murray, CEO, ALBA

#CRUaluminium

58 PACKAGING

The Advanta advantage As the Government continues to strive for a zero waste economy, where all resources are financially and environmentally valued, it is time for businesses to consider the materials they choose and how they handle waste. Aluminium packaging manufacturer, Advanta, has always believed aluminium should be the first choice material for packaging manufacturers and has always minimised the waste produced in its own processes.

Advanta is a leading aluminium packaging manufacturer based in Cannock, Staffordshire, UK. Its purposebuilt headquarters is at the heart of the global foil packaging industry. With loyal customers all over the world, Advanta offers the largest manufacturing capacity in Europe, and, with optimal production conditions, Advanta can produce a mammoth half a million trays in just an hour. The company also boasts the widest product portfolio in the industry.

Through organic growth and acquisition, this company has become one of the largest producers of foil packaging in Europe.

History Advanta, previously known as Nicholl Food Packaging, was set up in the UK

by Mr Nicholl in 1989. Over the next 13 years, Nicholl acquired companies across Europe, including the United Kingdom, France, Belgium and Germany. By 2007, the Nicholl Group had also set up sales and distribution centres in America, South Africa and Australia.

In 2012, the Nicholl Group was acquired

by Bawtry Investment. This meant Nicholl group joined the umbrella company of Bawtry Carbon International, a niche carbon supplier to primary aluminium smelters. The following two years were a time of great change for the business, March/April 2018

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including rebranding, international expansion and new product innovations.

This is when Miguel Campos joined Nicholl Food Packaging as the export sales manager.

It was also at this time that Nicholl Group was given a fresh new identity with the new company name; Advanta.

This encompassed all subdivisions of the Nicholl Group of companies. This new name represented the forward thinking nature of the business.

“It has been a pleasure to be a part of Advanta’s transformation,” said Campos.

“I joined a company that has a lot of history behind it, but this new rebranded identity signified a new chapter in the story. These days, I am responsible for the three operations across three continents, which can be demanding. It gets a bit complicated sometimes, but I’ve got a great workforce behind me - as well as all that history and knowledge.”

Environmental responsibility As a founding member of the Aluminium Packaging Recycling Organisation, AluPro, Advanta has a deep commitment to protecting the environment and promoting aluminium as a permanent, sustainable and endlessly recyclable material choice for food packaging.

Recycling aluminium saves 95% of the energy that it takes to source primary

aluminium. This equates to a massive 97% reduction in carbon dioxide emissions.

With this in mind, Advanta exceeds the statutory requirements in reducing aluminium waste, ensuring every ounce of aluminium that enters the Advanta headquarters, either leaves as an end product or goes on its way to be recycled.

Advanta won the AluPro awards in 2001 and 2007 for innovation in waste reduction. These were awarded for extremely efficient use of aluminium with minimal wastage. This came down to the company’s technical consideration and efficiency when using the material, demonstrating an unrivalled ability to get the most out of a given amount of metal.

“When people buy food in a foil tray that was manufactured by Advanta, they are helping in three ways,” said Campos.

“Firstly, they are helping the environment as aluminium is a 100% recyclable packaging material. Secondly, they are helping British families to put food on the table everyday because this material is manufactured in the UK. Finally they are helping themselves because the consumer experience when a ready-to-cook meal is made in a foil tray is like homemade food prepared from the scratch. It tastes awesome.”

The right tools for the job To serve more than 400 customers in over Aluminium International Today

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PACKAGING 59 5

“It gets a bit complicated sometimes, but I’ve got a great workforce behind me - as well as all that history

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and knowledge.

20 countries, the company relies on 65 power presses, almost 500 customised tools and 140 employees. The presses manufacture the 700 different products in the Advanta catalogue. Various, bespoke tools are used on these presses to shape the foil to a specified design brief.

“The tools themselves are huge facilitators of what we do,” said Campos.

“Each tool is unique to each product.

Once we’ve finalised our customer’s design, it can take 14 to 16 weeks to get a bespoke tool from the tool maker. Some of our tool are made in Switzerland by people as skilled as Swiss watch makers, it’s a real craft.

“As these tools are made out of the best quality steel, they last decades. To put that in perspective, a tool needs to endure up to 80 blows a minute, in almost continuous operation. Some packaging manufacturers will select cheaper tools, which may only last a few years or even just months.

“We have tools that we purchased in 1991 that are still working, showing the quality and longevity that they bring to Advanta and our customers. These are investments that pay for themselves and mean clients can rely on us to continually manufacture a product they need for years. As it is a metal against metal process when these tools are pressed onto the aluminium, and the tools need Aluminium International Today

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to handle up to 80 blows a minute, we need to get it right.”

In addition, all the tools and presses are serviced in-house by the Advanta tool maintenance team, so any potential downtime is kept to a minimum.

Setting the standard Advanta was the first company to develop the plain silver smooth wall tray that we’re all so used to buying our oven ready meals in. Before Advanta created this product, a plain silver smooth wall option wasn’t available without the addition of an expensive lacquer layer. This was because the lacquer provided the necessary lubrication to aid the manufacturing of the smooth wall tray. However, reliance on this priced a lot of food manufacturers out of using the product.

By working closely with metal suppliers, Advanta developed the effective process that enabled the team to bring a smooth walled tray in plain silver to market, totally removing the need for spending extra on lacquer. This was an important milestone for the industry and Advanta, as a lacquered smooth wall tray can be up to 100 per cent more expensive.

The smooth wall trays from Advanta are temperature resistant from minus 40 up to 400 degrees celcius and incorporate ribbed walls and an embossed base for added strength and sturdiness. This

product launch has continued to be a very popular option with customers for aesthetic, practical and financial reasons.

As well as bringing innovative off-theshelf products to market such as the plain silver smooth wall trays, Advanta also works closely with customers’ to meet design specifications and timeline requirements, no matter how unusual or testing.

“We’ve had many weird and wonderful requests from customers over the years,” said Campos. “However, the trickiest part is always going to mass production. When you start manufacturing a new product to that level, there’s a lot at stake. It doesn’t happen often, but if a machine does go down, we have the ability in-house to just deal with it. It helps that we don’t work on next day deliveries, but instead strategically factor in aluminium delivery and our client’s production forecast.”

The company doesn’t consider any product to be the best seller. While there is plenty of interest for new product launches, and a high demand for poultry trays at Christmas, the best selling product is the service. The brand, the reputation and the direct work with customers all makes Advanta a leader in the industry.

With the team’s imagination, innovative thinking and technical ability, all products are created with the end user in mind.

The future looks prosperous for the company, with plans to expand into new markets and further increase its global footprint. Ultimately, the aim is to continue to be leading voice for aluminium recyclability and foil innovations.

As all industries work towards a zero waste economy, Advanta, alongside its work with AluPro, will continue to promote aluminium as a financially and environmentally wise material of choice and make sure they support their customers in meeting their own goals to reduce their carbon footprint. � March/April 2018

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60 BUYERS’ GUIDE TASTER

www.aluminiumtoday.com

BUYERS’ GUIDE TASTER As a leading resource for the aluminium production and processing industries, the Buyers’ Directory reaches the most senior buyers and suppliers in the business.

HANDLING & STORAGE

CLAUDIUS PETERS PROJECTS GMBH Schanzenstraße 40 DE-21614 Buxtehude, Germany T: +49 4161 706-0 F: +49 4161 706-270 E: info@claudiuspeters.com W: www.claudiuspeters.com Claudius Peters stockyards, pneumatic conveyors, silos, clinker coolers, grinding mills, and packing systems can be found in Cement, Coal, Alumina, and Gypsum plants across the globe. The group’s other principal Division, Aerospace, manufactures aircraft parts for Airbus.

PRIMARY REDUCTION/SMELTER PRIMARY

ALUMINIUM BAHRAIN B.S.C. (ALBA) Building 150, King Hamad Highway Askar 951, Bahrain T: +973 1783 0000 F: +973 1783 0083 E: alba@alba.com.bh W: www.albasmelter.com Aluminium Bahrain has been consistently ranked as one of the largest aluminium smelters in the world and is known for its technological strength and high quality aluminium.

FURNACE

HERTWICH ENGINEERING GMBH Weinbergerstr. 6, Braunau, Upper Austria, 5280, Austria T: +43 7722 806-0 F: +43 7722 806-122 E: info@hertwich.com W: www.hertwich.com Hertwich Engineering, a company of the SMS group, is active worldwide with design, supply, construction and commissioning of speciality equipment for the aluminium industry, in particular for aluminium casthouses.

March/April 2018

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Distributed to more than 50 countries and read by thousands of industry contacts, it contains a comprehensive alphabetical listing of company and contact details.

SLITTING

DANIELI FRÖHLING Scherl 12, D-58540, Meinerzhagen, Germany T: +49 2354 7082 0 F: +49 2354 7082 200 E: info@danieli-froehling.de W: www.danieli-froehling.de Danieli Fröhling is synonymous for innovative tailor-made solutions for the aluminium industry.

Fröhling customers trust in nearly 70 years’ experience in manufacturing of rolling mills and cutting lines.

CARBON ELECTRODES

R&D CARBON PO Box 361, Sierre 3960, Switzerland T: +41 27 459 29 29 F: +41 27 459 29 25 E: rdc@rd-carbon.com W: www.rd-carbon.com R&D Carbon provides expertise for the worldwide metal, oil and coal industry through R&D studies,onsite audits and process optimisation, carbon test equipment, quality control, certification and training courses.

Here is a sneak peak at some of the listings that will appear in the 2018 Buyers’ Directory.

SAFETY

AJ CHARNAUD & COMPANY (PTY) LTD Tel: RSA +27 11 794 6040 T: +27 11 794 6040 EU: +44 (0) 1133 507651 E: aj@charnaud.co.za W: www.charnaud.net With over 40 years of experience AJ Charnaud & Company (Pty) Ltd. has been at the forefront of the development and manufacturing of specialized personal protective clothing. With a complete head-to-foot range of certified products, supported with advanced professional and technical assistance.

SHEET CASTING CONSUMABLES

ZIRCAR CERAMICS INC 100 N. Main St Florida, NY USA T: +1 845 651 6600 E: sales@zircarceramics.com W: zircarceramics.com ZIRCAR Ceramics, Inc. is a US based manufacturer and international marketer of castertips, graphite release agent, boron nitride coating, vacuum formed, and pre-cast refractory products for use on all makes of continuous aluminum sheet twin roll, belt and block casters.

QUALITY TESTING & MEASUREMENT

POLYTEC GMBH Polytec Platz 1-7, D-76337, Waldbronn, Germany T: +49 7243 604-0 F: +49 7243 69944 E: info@polytec.de W: www.polytec.de Polytec is the market leader for non-contact, laser based vibration and velocity measurement instrumentation. Our innovative solutions allow our customers to maintain their own technical leadership across many fields.

It is free to list your company, get in touch today to find out more: Anne Considine Sales Manager Tel: +44(0)1737855139 Email: anneconsidine@quartzltd.com

Aluminium International Today

07/03/2018 15:47:46

Together we bring your aluminum vision to life

Achieving production excellence is more than using quality materials and advanced industrial machines and controls. It goes beyond equipment and plant investment.

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