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THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

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INDUSTRY NEWS

GREENER ALUMINIUM

RECYCLING

ROLLING TECHNOLOGY

The benefits offered by Total www.aluminiumtoday.com May/June 2021—Vol.34 No.3

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

ANAC INDUS

A L U M I N I U M I N T E R N AT I O N A L T O D AY M AY/J U N E 2 0 2 1 V O L . 3 4 N O 3

Aluminum Processing Fluids

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• Air-wash scrubber oils General maintenance lubricants and greases.

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CONTENTS 1

www.aluminiumtoday.com

Volume 34 No. 3 – May/June 2021

COVER

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

INDUSTRY NEWS

GREENER ALUMINIUM

RECYCLING

LEADER NEWS

ROLLING TECHNOLOGY

2 The benefits offered by Total

Support and partnership

A major player With our production, supply chain and commercial presence in more than 150 countries, we deliver a full range of lubricants.

Thanks to local technical presence, we provide a high level of service to optimize your

Total cost of Ownership.

Production Editor: Annie Baker www.aluminiumtoday.com May/June 2021—Vol.34 No.3

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

ANAC INDUS

A L U M I N I U M I N T E R N AT I O N A L T O D AY M AY/J U N E 2 0 2 1 V O L . 3 4 N O 3

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

This service provides you a full range of lube oil analysis, to allow you to anticipate and diagnose anomalies in the equipment. This solution is both preventive and corrective.

Aluminum Processing Fluids

Thanks to ANAC INDUS, you: Reduce your operating costs. Anticipate and plan maintenance operations to perform them at the best time.

Optimize drain intervals and extend the lifetime of your equipment.

Advertisement Production

Improve the reliability and performance of your equipment.

Production Executive: Martin Lawrence Managing Director: Tony Crinion CEO: Steve Diprose

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

Renowned rolling oils:

ROLLING COMPETENCE CENTER (RCC)

• NOA and TANDEMOL SERIES are hot rolling oils from Total sold to aluminum rolling companies for more than 30 years. • LUBRILAM SERIES are premium cold rolling oils produced and sold by Total to aluminum rolling companies.

The RCC is composed of TOTAL’s international team of metal rolling experts, working together to:

Total Lubrifiants cooperates

with equipment manufacturers to create

Innovation & Research

high-technology products for optimal performance and production of your machinery.

• Provide a unified, consistent and superior platform of rolling fluid technologies to customers worldwide, including product development of tailor made formulations.

Total invests in biotechnologies to find the most suitable components to reach

energy efficiency Quality and environment

GREENER ALUMINIUM Specialty products dedicated to the Aluminum Industry: • Compatible hydraulic oils: VITAL FLUID SERIES, NOALUBRIC SERIES • Low-Stain oils

• Deliver high level on-site technical support and problem solving

• Drive and create value for TOTAL customers through integration of best product with best practice for each process

through formulations designed in our Research Centers.

Total Lubrifiants ISO 9001 and 14001 certifications are the guarantee of a long term commitment to quality and environment. From the initial design stage, our R&D teams seek to develop products that minimize toxicity risks and environmental impact.

Billet heating and its impact • Air-wash scrubber oils

General maintenance lubricants and greases.

on the environment

lubricants.total.com

Total Industry Solutions

Sustainability quantiﬁed

The Dawn of the Age of Aluminium

Safety Data Sheets are available at sdstotalms.total.com

ms.metalworking@total.com ms.industry.lub@total.com

RECYCLING

Cover picture courtesy of Total Lubricants

A UNIQUE PRODUCT PORTFOLIO

Aluminium Industry in Iceland

Aluminium recycling: Is there still magic?

From scrap to oven-ready aluminium:

Supporters of Aluminium International Today

The new recycling plant in Deral Spa 29

Innovative approach for recycling

SECONDARY 35

Technologies for production wastes driving the circular economy

38 ALUMINIUM INTERNATIONAL TODAY is published six times a year by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX, UK. Tel: +44 (0) 1737 855000 Fax: +44 (0) 1737 855034 Email: aluminium@quartzltd.com Aluminium International Today (USO No; 022-344) is published bi-monthly by Quartz Business Ltd and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Aluminium International c/o PO Box 437, Emigsville, PA 17318-0437. Printed in the UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent, NP12 2YA, UK © Quartz Business Media Ltd 2021

How dross recovery is playing a role in the shift to sustainable technology

ROLLING

52 43

The calculation of rolling force

A closer look at the aluminium welding wire industry

SEARCH FOR ALUMINIUM INTERNATIONAL TODAY

ROD REPAIR 49

Focus on: Storvik ILRR

HANDLING ISSN1475-455X

Aluminium International Today

Contents Template.indd 1

Combilifts are a highlight for HAI May/June 2021

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01/2021 -TOTAL Lubrifiants SA 552 006 454 RCS Nanterre - Photos: 123RF. Design:

Sales

A P

THE ALUMINA CHRONICLES References & OEMs

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

2 COMMENT

New series of global events launched to help hard-to-abate sectors reach carbon neutrality

Supporting the hardto-abate sectors I’m apparently writing this column on ‘Earth Day’. It’s not a day I usually celebrate or know much about, but Google alerted me to the fact and then I fell down a virtual rabbit hole, looking at all of the other annual celebratory days that have worked their way onto our calendars. It seems fitting as once again, this issue’s news pages are filled with stories of new sustainable technolgies, low carbon announcements and commitments to net-zero targets. As industries become more accountable for their environmental impact, at Quartz Business Media (QBM) we are working to develop more programmes, events and platforms where the aluminium industry can share best practices and also gain insight from other hard-to-abate sectors. Our upcoming Greener Aluminium Online Summit (2nd - 3rd June) will challenge how far we are on the road to decarbonisation and if we’re going in the right direction. And, in an effort to draw on our experience at QBM, across the aluminium, glass and steel sectors, in 2022, we will launch the Sustainable Industrial Manufacturing (SIM) Global Event Series. No other event in the world will bring together senior executives from across all hard-toabate sectors, so keep following on our online and social media channels to find out more about this exciting new project. I hope you enjoy this issue and as always, I welcome any comments or feedback! nadinebloxsome@quartzltd.com May/June 2021

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Organisers of a new industry platform for manufacturers within hard-to-abate sectors have announced details of Sustainable Industrial Manufacturing (SIM) - set to be Europe’s largest showcase of solutions in sustainable manufacturing, when it opens at Brussels Expo in Belgium from 9-10 March 2022. The EU has committed to carbon neutrality by 2050 and it wants industry to “pave the way”. With heavy industry responsible for 30% of carbon emissions worldwide, a transition towards net zero emissions is no longer optional for those in-charge of heavy industrial sectors. Nadine Bloxsome, Editor of Aluminium International Today, and Event Director of SIM comments: “To deliver change at the speed required, manufacturers must urgently accelerate and embrace sustainable technologies to future-proof their competitiveness, viability, and protect the other industries that they support. SIM has been created to help address this challenge and encourage a collaborative approach. By working together to conserve resourc-

es and deliver change, industrial manufacturers can ensure a sound future for generations to come.” Curated by a coalition of industry experts, SIM is a global series of events supporting and facilitating the transition towards cleaner manufacturing around the world and will focus on five hard-toabate sectors: Steel, Cement, Glass, Aluminium and Chemicals. Hosting leaders from the worlds of science, innovation, government, industry, and investment, SIM Europe will provide the first opportunity for those at the frontier of energy intensive industrial manufacturing to collaborate and deliver real change. The SIM agenda is being driven by a steering committee of international experts in the fields of industry, academia, R&D, media and investment and includes: Geoff Matthews, Modulation Specialist, EnergyFlex Pty Ltd; Pernelle Nunez, Deputy Secretary General and Director – Sustainability, International Aluminium Institute; Oscar Verheijen, Chairman of the GlassTrend Board, and Melanie Williams, CEO and Sustaina-

bility Consultant. SIM Europe will be the first of four regional events planned for 2022, with other editions to be hosted in the United Arab Emirates, United States and China. The cornerstone of every SIM event is a trio of exhibition and conference zones entitled ‘Energy’, ‘Evolve’ and ‘Environment’ that together, deliver end-to-end sustainable manufacturing opportunities. Zones will include solutions for providing cleaner energy, new technologies to enable plants to evolve, and a collaborative approach to protecting the environment and the future of industrial manufacturing businesses. Organised by Quartz Business Media, SIM has been curated by a team that is combining more than 90 years of experience of facilitating business for the manufacturing industry. Owners of market-leading trade journals, exhibitions, conferences, and digital content solutions for the steel, glass and aluminium industries, each year QBM products reach more than 85,000 manufacturing professionals around the world.

ELYSIS selects Alma smelter for prototype cells ELYSIS has announced it has selected the Alma smelter, operated by Rio Tinto in Saguenay-Lac-SaintJean, Quebec, for the first installation and demonstration of its inert anode technology at a commercial size of 450 kiloamperes (kA), which is a common capacity for modern, full-scale smelters. ELYSIS is a joint venture company, led by Alcoa and Rio Tinto, that is working to commercialise a new technology to make aluminium that eliminates all direct greenhouse gases (GHGs) from the traditional smelting process and instead produces oxygen.

As part of its technology development and scale-up, ELYSIS will install industrial inert anode prototype cells at the end of an existing potline at the Alma smelter to demonstrate the technology’s effectiveness at a commercial scale in an industrial operating environment. This will build on ongoing work at the nearby ELYSIS Industrial Research and Development Cen-

tre, also located in the Saguenay region of Quebec. ELYSIS plans to commercialise its breakthrough technology in 2024, for use in retrofitting existing smelters and installation in new facilities. The 450 kA cells at Alma will be supported by a $20 million CAD investment from the Government of Quebec to help bring forward the start of work at the site and to further strengthen the capability of manufacturing businesses in the region to supply specialised equipment required for the ELYSISTM technology. Aluminium International Today

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GREEN NEWS 3

Hydro to explore hydrogen opportunities Hydro is exploring the potential for developing and operating hydrogen facilities to meet large internal demand as well as serving an external market, leveraging the company’s industrial and renewable power expertise. “We see a substantial potential for industrial hydrogen consumption. Taking a developer and operator role in the hydrogen sector represents an opportunity for Hydro to reduce industrial CO2 emissions and develop a profitable and sustainable business based on hydrogen,” says Hilde Merete Aasheim, President and CEO in Hydro. Hydro has set out a clear stra-

tegic direction toward 2025 and aims to strengthen its position in low-carbon aluminium, while exploring new growth opportunities in recycling and new energy. “Hydro has unique capabilities that set us apart from other industrial players due to our own renewable power positions and competence, and large internal demand for gas that can be replaced by green hydrogen solutions. We can therefore build and develop a complete value chain for green hydrogen in Norway,” Aasheim says. A developer and operator role for Hydro is in line with the com-

pany’s internal pipeline of possible hydrogen projects and would likely entail a full or partial switch from gas to hydrogen in plants in several locations. A probable start to this process would be to switch from gas to hydrogen at some of Hydro’s aluminium plants in Norway. “We have large internal demand for gas used for heating in our casthouses and anode production, and a hydrogen production facility could be placed near the consumption. For Hydro it would contribute to our target of reducing our own CO2 emissions by 30% by 2030,” Aasheim says.

Novelis commits to Net-Zero carbon emissions by 2050 Novelis Inc., has announced that it will further its longstanding sustainability commitment by becoming a net carbon-neutral company by 2050 or sooner and reducing its carbon footprint 30 percent by 2026. Novelis also commits to becoming a fully circular business, along with a more diverse, inclusive and safe workplace. “Our ambition is to be the world’s leading provider of low-carbon, sustainable aluminium solutions that advance our business, industry and society toward the benefits of a circular

economy,” said Steve Fisher, President and Chief Executive Officer, Novelis Inc. “As the world’s largest recycler of aluminium, sustainability has been paramount to our business and these new commitments will further ensure the health and well-being of the environment, the safety of our people, and the long-term success of the communities in which we live and work.” With its new environmental targets, Novelis commits to: � Net carbon-neutrality by 2050

� 30% reduction in CO2

by 2026

� 20% reduction in waste

to landfills by 2026 � 10% reduction in energy

intensity by 2026 reduction in water consumption by 2026 � 10%

The company will continue increasing the use of recycled content in its products and engaging with customers, suppliers, and industry peers across the value chain to drive innovation that improves aluminium’s overall sustainability.

AMAG and Audi Hungaria collaborate to close the loop A supply contract was recently signed with AUDI HUNGARIA Zrt to expand resource saving closed loop relationships. In the future, production waste generated at the Audi plant in Györ will be delivered to AMAG in Ranshofen in the form of sorted aluminium sheet scrap. AMAG recycles it into new aluminium sheet leading to a closed material cycle. This conserves valuable resources and saves energy.

“Recycling is one of AMAG’s

core competencies. The closedloop concept is an effective and sustainable recycling concept that goes beyond our corporate boundaries. Many years of experience, our know-how and the use of state-of-the-art recycling technology allow us to provide our customers with the best possible support in terms of CO2-optimised products and processes”, says AMAG CEO Gerald Mayer.

NEWS IN BRIEF Gränges to invest USD 33 million to increase aluminium casting capacity in the US Gränges will invest USD 33 million to expand its aluminium casting operations in Huntingdon, Tennessee, to meet the growing demand from North American customers. This investment follows the previous and successful investments in new rolling capacity at the sites in Huntingdon and Newport, Arkansas. The expansion includes investment in buildings and a new casting line. When completed, the casting capacity in Huntingdon will increase by about 25 ktonnes per year and will enable higher capacity utilisation in the downstream rolling and slitting operations. Metso Outotec completes divestment of its Aluminium business Metso Outotec has completed the divestment of its Aluminium business to REEL International, headquartered in France. The divestment to REEL was announced on December 28, 2020. The divested business comprises equipment and plant solutions to green anode plants, anode rodshops, and casthouses used in aluminium smelters, as well as the related services. Metso Outotec will continue to serve its customers in certain other parts of the aluminium value chain, such as alumina refinery and petroleum coke calcination technologies. En+ Group Director Alexey Spirin joins ASI board En+ Group has announced that its Director of Environmental and Climate Risk Management Department, Alexey Spirin, has joined the Board of the Aluminium Stewardship Initiative (ASI). Alexey, whose term of office is two years, succeeds Tolga Egrilmeizer, Vice President of Sales & Marketing at Rio Tinto Aluminium.

Aluminium International Today

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4 INDUSTRY NEWS

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IAI releases global aluminium industry 2050 climate pathways The International Aluminium Institute (IAI) has published the most comprehensive greenhouse gas emissions reductions pathways available to the aluminium sector over the next three decades. The pathways are based on the IAI’s unrivalled data and leading analysis of the global industry. The new report, Aluminium Sector Greenhouse Gas Pathways to 2050, sets out three credible and realistic approaches to emissions reductions for the aluminium industry, in line with the International Energy Agency’s Beyond 2 Degree Scenario. While the industry works to re-

duce its emissions by about 80%, demand for aluminium products is also predicted to grow. Over the coming decades, global demand for primary aluminium will

increase by up to 40% and recycled aluminium from post-consumer scrap will more than triple through to 2050, as economies

grow, urbanise, and build up their infrastructure. “Emissions reduction is a challenge for every sector. It is, however, a challenge that the aluminium sector is poised to address. Over the last two years, a Greenhouse Gas Pathways Working Group made up of IAI member companies and regional associations has been working to articulate credible ways to achieve global climate goals. This collaboration is what has resulted in the industry’s most comprehensive pathways, which we have published today,” said Miles Prosser, the IAI’s Secretary General.

Alcoa Completes Divestiture of Warrick Rolling Mill to Kaiser Alcoa Corporation has completed the sale of the rolling mill and associated assets near Evansville, Indiana, held by Alcoa Warrick LLC, to Kaiser Aluminum Corporation. The sale closed on March 31, 2021. In accordance with the previously announced sale agreement, Alcoa Corporation received total consideration of approximately $670 million, including the assumption by Kaiser of related other postretirement employee benefit (OPEB) liabilities.

Alcoa retains ownership of the 269,000 metric tons of smelting capacity at the Warrick smelter, the Warrick electric generating units, and land holdings in Warrick County, Indiana. As part of the sale, Alcoa has entered into a market-based metal supply agreement, a long-term ground lease, and a transition services agreement with Kaiser. Alcoa employs approximately 660 people at the smelter and the power plant at the Warrick site.

Ramp-up of Husnes B-line – halfway milestone reached Cell number 100 has now been restarted at the Husnes B-line in Western Norway, meaning that the halfway mark on the way back to full capacity for the aluminium production plant was crossed. The journey back to full production at Hydro Husnes started on November 24, 2020 when the first of 200 electrolysis cells was restarted - after being idled for more than ten years as a result of the financial crisis. As of today, Hydro Husnes proMay/June 2021

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duces about 95,000 tonnes of aluminium annually via the A-line. This will gradually increase to around 195,000 as the 200 electrolysis cells in the one-kilometer-long B-line are restarted. “I am happy that the first 100 cells have been successfully restarted and I am impressed by the whole organisation that have managed this in a safe and controlled way. We are now focusing on the remaining 100 and we aim to be at full capacity by the end of

June,” says Plant Manager at Hydro Husnes Johan Berg. The restart of the B-line at Hydro Husnes represents a NOK 1.5 billion investment in upgrades and the production line holds world-class standards in climate, environmental and operational performance. In addition to doubling the production of aluminium based on renewable energy, the restart of the B-line contributes to almost a hundred new jobs.

2021 DIARY June 2nd - 3rd Greener Aluminium Online Summit * VIRTUAL * Bringing together aluminium manufacturers and environmental solutions providers, the Summit will present the main issues, investments, technologies, and best practice examples from across the supply chain. www.aluminiumtoday.com/ greener-aluminium

8th - 10th NorCast 2021 The Nordic Aluminium Casthouse Conference returns. Held in Norway www.norcast-seminar.com

10th - 12th METEF Expo of customised technology for aluminium, foundry castings and innovative metals Held in Bologna, Italy www.metef.com

September 1st - 2nd ALUMINUM USA A weeklong leading industry event covering the entire value chain from upstream (mining, smelting) via midstream (casting, rolling, extrusions) to downstream (finishing, fabrication). Held in Kentucky, USA www.aluminum-us.com

14th - 15th Future of Furnaces * VIRTUAL * This online event will unite the glass, aluminium and steel sectors to discuss overcoming heat treatment challenges and present a collaborative approach to bring the Furnace of the Future to life. www. aluminiumtoday.com/ furnaces/future-of-furnaces

22nd - 24th 6th GLAFCO The most important worldwide gathering of the aluminium foil production sector. Held in Istanbul, Turkey www.global-alufoil.org For a full listing visit www. aluminiumtoday.com and click on Events Diary Aluminium International Today

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Aluminium Industry In Iceland Overall Aluminium Industry Iceland is one of the most important nations producing aluminium. The country is a critical element in the global economy for this metal. Alcoa, Century Aluminum, and Rio Tinto – three major international manufacturing corporations – operate aluminium smelters on this island. Renewable energy resources provided the bedrock for the creation of the aluminium industry in Iceland. Energy costs remain critical to the industry. “The hot metal production was 831 thousand tonnes aluminium in 2020,” stated Mr. Pétur Blöndal, Managing Director of Samál, Icelandic Association of Aluminium Producers. “In a normal year, the production is around 870 thousand tonnes. The main reason for lower production can be traced to Rio Tinto only producing with 85% capacity. It was negotiating energy prices with Landsvirkjun, the state energy company, and maintained the price was not competitive.” As noted below, a new energy contract was signed between the two firms in February of 2021. Mr. Blöndal indicated that an increase in aluminium production is likely at the ISAL smelter of Rio Tinto, but “…besides that, there are no foreseeable increases in production.” While countries throughout the world import aluminium from Iceland, most exports of aluminium from Iceland go to nations within the European Economic Area, consisting of the member nations of the European Union and three countries of the European Free Trade Association. European Aluminium, a trade organisation that includes more than 80 businesses and national organisations involved in the aluminium industry, confirmed that “Norway and Iceland, while being part of the economic area with the European Union, are the largest exporters of primary aluminium to the European Union.” The value of aluminium exports from Iceland was (US) $1,802,062,000 in 2019, according to the International Trade Centre. The Netherlands was by far the largest importer of aluminium from Iceland; imports to the Netherlands amounted to (US) $1,074,160,000 in 2019. Spain, which imported (US) $301,384,000; the United Kingdom, which imported (US) $104,090,000; Germany, which imported Aluminium International Today

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The Northern Lights seen over the ISAL aluminium smelter of Rio Tinto in Iceland. (This photograph was produced by and provided courtesy of Bragi Kort through bkort at Flickr, 21 January 2016. The photograph should not be printed or resold for any purpose.)

(US) $99,844,000; and France, which imported (US) $77,581,000 worth of aluminium from Iceland rounded out the top five export markets for Iceland. These five nations collectively imported more than 90% of all of aluminium exported by Iceland. Other top importers of aluminium from this North Atlantic nation included Hungary, Canada, China, Belgium, and Australia. These five countries collectively imported about (US) $98,000,000. With the exception of exports to Spain, the value of aluminium exported from Iceland decreased to all of its top ten export markets from 2018 to 2019. During the time period from 2015 to 2019, the value of aluminium exports from Iceland decreased to Belgium, Germany, Hungary, and Spain; the value of the exports to the other six countries increased from 2015 to 2019. While Iceland is a major exporter of aluminium, the nation also imports aluminium. In 2019, the value of imports of aluminium into Iceland was (US) $137,507,000, according to the International Trade Centre. More than forty-five percent of those imports came from two countries, Italy and the Russian Federation. More than two-thirds of all aluminium imports into Iceland came from those two nations plus Canada, Denmark, and Germany. Sustainability is key to aluminium

production in Iceland. “Aluminium is produced in Iceland with renewable resources and has one of the lowest CO2 footprints in the world,” explained Mr. Blöndal. “All three aluminium producers in Iceland brand their aluminium as low carbon.” Recycling is also part of those sustainability efforts. European Aluminium issued a report on 16 December 2020 on recycling rates of aluminium beverage cans overall and in individual countries in 2018. According to that report, overall recycling rates of aluminium beverage cans “…rose by more than 2% from 2017 (74.5%), to reach an all-time record of 76.1% in 2018. The total amount of aluminium recycled increased by 37,000 tonnes to an impressive 457,000 tonnes…” In Iceland, European Aluminium indicated that the recycling rate for aluminium beverage cans was 87% in 2018. Energy Electricity is critical – in terms of accessibility, stability, and cost – to the production of aluminium. Iceland excels in all three areas. “Iceland is one of the lowest carbon countries in the world,” stated David Samuel, Senior Hydropower Sector Analyst at the International Hydropower Association. “The electricity mix is almost 100% renewables, relying mainly on hydropower. In 2019, 70% May/June 2021

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THE ALUMINA CHRONICLES

www.aluminiumtoday.com

Fljótsdalsstöð is the largest power plant operated by Landsvirkjun in Iceland. (The photograph was provided courtesy of Landsvirkjun.)

An aerial view of the Norðurál aluminium smelter in Grundartangi, Iceland. (The photograph was provided courtesy of the United States Geological Survey, 2020.)

of electricity generated came from hydropower (13.3 TWh), and 30% from geothermal, according to International Energy Agency figures. It has remaining economic potential of hydropower of around 37 TWh, annually. Iceland is also looking at developing green hydrogen, produced from electricity based largely on hydropower.” “As a comparison, in total across the Organisation for Economic Co-operation and Development, hydropower supplied 14% of electricity,” Mr. Samuel continued. “There are several other countries where hydropower supports a similar share of electricity supply in 60-70% range, e.g. Austria, Canada, Colombia, Brazil, New Zealand, and Costa Rica, among others. Countries with levels around 90-95% are Norway, Tajikistan, Kyrgyzstan, Nepal, and Paraguay. Note there are other countries which produce high amounts of hydropower, e.g. China, Turkey, US [United States], Japan, Russia, India, France, Sweden, among others. But the share of the electricity mix is not so high when also considering other fuel sources.” Iceland – as a nation – owns Landsvirkjun, an energy company that generates electricity from hydropower as well as from geothermal energy and wind. The 2020 Annual Report of Landsvirkjun confirmed that “Iceland generates almost 100% of its electricity from renewable energy resources. Landsvirkjun produces 75% of this energy.” The annual report also stated that most of the energy generated by Landsvirkjun was sold to customers in the aluminium industry, including all three of the large aluminium smelters in the country. “Fljótsdalsstöð is our largest power plant, with 690 megawatts of installed capacity and can generate 4,800 gigawatt hours of electricity per year,” according to a statement from Landsvirkjun. “The powerhouse of Fljótsdalsstöð is located underground, inside Valþjófsstaðafjall and is accessed by a special 800 meter long access tunnel. From the station’s May/June 2021

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An aerial view of the Alcoa Fjarðaál aluminium smelter in Reyðarfjörður, Iceland. (The photograph was provided courtesy of the United States Geological Survey, 2020.)

reservoir, Hálslón, the water flows through almost 40 kilometers of headrace tunnel to the station, but the total drop of the water is over 600 meters. Two-thirds of that drop is in a 400 meter high and almost vertical drop tunnel at the station. In the powerhouse, the water propels six powerful turbines and then flows through drainage tunnels and ditches into Jökulsá in Fljótsdalur, east of Valþjófsstaður, at 26 meters above sea level.” The 2020 Annual Report of Landsvirkjun included note of the views of an aluminium expert at a research company that “…stated that the aluminium industry in Iceland certainly has access to competitive electricity prices. Still, this advantage decreases when overall costs are compared with aluminium smelters worldwide. However, the operation of Icelandic smelters was more efficient than two-thirds of the smelters worldwide.” Norðurál Norðurál is one of three large aluminium companies operating in Iceland; the firm is owned by Century Aluminum. “Norðurál produces pure aluminum and aluminum alloys to meet the needs of the most demanding customers,” according to a

statement from the firm. A news statement issued by Norðurál on 10 February 2021, announced that Gunnar Guðlaugsson, the Chief Executive Officer of Norðurál, had been appointed to manage all of the smelters of Century Aluminum. As Executive Vice President of Global Operations, Mr. Guðlaugsson is responsible for the operation of the smelter in Grundartangi, Iceland, as well as the three smelters owned by Century Aluminum in the U S. The news statement detailed that Mr. Guðlaugsson has been CEO of Norðurál since 2019 and would continue in that role in addition to his expanded responsibilities. According to a filing with the U S Securities and Exchange Commission (SEC) by Century Aluminum, the Americanbased firm indicated that the actual production at its smelter in Iceland was 313,000 tonnes of aluminium in 2020. “Grundartangi is currently in the process of a multi-year expansion project that has brought the annual primary aluminum production capacity to current capacity of approximately 317,000 tonnes and is expected to ultimately increase annual production capacity at Grundartangi to approximately 325,000 tonnes,” Aluminium International Today

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9 A major highway leads to the Rio Tinto ISAL aluminium smelter (back center in this photo) in Hafnarfjörður (Straumsvík), Iceland. (The photograph was provided courtesy of Mannvit, 20 October 2020.)

The Alcoa Fjarðaál aluminium smelter is located in Reyðarfjörður, Iceland. (The photograph was provided courtesy of Mannvit, 8 July 2008.)

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

stated the company in this SEC filing. “Grundartangi produces standard-grade aluminum ingot and a primary foundry alloy product, which is a value added product that is sold at a premium to standard-grade aluminum.” Fjarðaál “The Alcoa Fjarðaál smelter in Reyðarfjörður started operations in 2007,” according to a statement from Alcoa. “Fjarðaál is one of the most modern and technologically advanced smelters in the world and is a model in terms of environmental protection. The smelter is the largest in Iceland, with a production capacity of up to 360 thousand tonnes of aluminum per year.” Alcoa has an agreement with Landsvirkjun to supply competitivelypriced electricity to the company’s smelter in eastern Iceland, according to the 2020 Annual Report of Alcoa. That report indicated that the energy agreement is a 40-year power contract, with an expiration date “in 2047 with price renegotiation effective from 2027.” ISAL Rio Tinto operates the ISAL smelter in Aluminium International Today

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Hafnarfjörður (Straumsvík), Iceland. The acronym comes from its original name as “The Icelandic Aluminium Company (ISAL).” Approximately 500 people work at this location, according to the company. This smelter was the first of the three aluminium smelters to be built in Iceland; the plant began operations in 1969. In a news statement dated 15 February 2021, Rio Tinto announced that it had “reached agreement on an amended power contract that will allow the ISAL aluminium smelter in Iceland to continue operating with an improved competitive position. The agreement with power supplier, Landsvirkjun, will deliver a more competitive power price and energy flexibility that is mutually beneficial for both ISAL and Landsvirkjun.” Rio Tinto had spent much of 2020 conducting a “strategic review” that considered “all options including curtailment and closure” of the ISAL smelter. The company had indicated that its operations in Iceland were “… unprofitable and cannot compete in the challenging market conditions due to its high power costs…” With the new agreement, Alf Barrios, Chief Executive Officer of Rio Tinto

Aluminium, stated that “We are pleased to have reached an agreement on a power price that, coupled with improved efficiencies we have delivered at the site, makes ISAL more competitive. This provides a stronger footing to continue operations at the smelter and gives increased security for the team at ISAL, who have been doing an outstanding job in challenging conditions. We will continue to work to strengthen ISAL’s future in order to keep supplying low carbon aluminium to customers…and making a significant contribution to Iceland’s economy.” The company reported that all of the aluminium produced at ISAL is sold to buyers in Europe. Rio Tinto noted that a number of different products are made from its Icelandic aluminium, “…including plates for aluminum cladding, sheets for Audi and Rover car bodies, printing plates for the lithographic industry, aluminium foil for packaging, and sheets with high shine for use in reflectors.” Summary With the expansion of production expected at the Rio Tinto ISAL smelter, leaders in the aluminium industry anticipate aluminium exports from Iceland to increase during 2021. The renewable energy resources and competitive pricing in the electricity market will likely continue to be critical aspects of the aluminium industry in Iceland. � May/June 2021

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Billet heating and its impact on the environment As the world’s focus shifts to the impacts of climate change and the environment, industry is taking note. Reactive measures are being put in place in almost every facet of human life and how we as a collective can curb the rate of climate change; from banning of use of fossil fuels to increased taxes on emissions. The metal forming industry is no exception with steps already being taken in an eco-friendly direction, but with many more steps until a ‘green industry’ can be established. Realistically, a ‘green industry’ relies on a multitude of factors that stretch far beyond, and can’t be easily influenced by, any given sector. This being said, small changes at the foundations can enact massive movement in the overall state of the environment. This article sets out to highlight some of the key factors of environmental impact and ways they can be combatted within the scope of billet heating. By Thomas Postins, B.Eng.* The Environment The ferrous and non-ferrous metal sectors account for 8% of global greenhouse gas emissions, more than 4 times more than that of the aviation sector1. The leading factor causing climate change is the release of greenhouse gasses2. Greenhouse gasses are named as such owing to the greenhouse effect they cause. An insulating layer of these gasses such as Carbon Dioxide (CO2), Methane (CH4) etc. cause an excess build-up of heat in the atmosphere hence causing a sealevel rise through the melting of sea-ice. It is said that by 2050, given the current rate of temperature rise, the earth will be 3°C hotter than pre-industrial levels. ‘The 2050 Scenario’ sets out that such a rise in temperatures would lead to approximately 3 meters of sea-level rise by 2100 – a rise that would see countries such as the Netherlands largely submerged3. A perhaps more alarming scenario is that of the ‘Hothouse Earth’. This hypothesises that if temperatures rise 2°C beyond preindustrial levels, the effects are irreversible – there are no measures that can be taken to stop sea-level rise and irrevocable damage to ecosystems. This 2°C figure was therefore set as the baseline for the Paris Agreement4 . Methods of Billet Heating The heating of ferrous and non-ferrous billets is an energy-intensive process. Most

SPECIFICATION

NATURAL GAS-FIRED HEATER

INDUCTION HEATER

AL 6063

MATERIAL SPECIFIED TEMPERATURE BILLET DIAMETER BILLET LENGTH

500°C

Φ152 mm

550 mm

1000 kg/h

ADJUSTED POWER†

1056.5 kWh

750 kWh

POWER PER TONNE

1056.5 kWh

224 kWh

BILLET THROUGHPUT

† 1m3 Natural Gas is approximately 10.28kW assuming 100% efficient burn.

Table 1. Specification of comparable heaters

commonly, billets are heated using either gas furnaces or through an induction heating process. Each method is industry proven over many decades of extrusion and each method has practical benefits. In order to feasibly make a comparison, one gas-fired heater and one induction heater both providing nominally similar temperatures and mass-throughput rates were selected. Gas & Induction Historically, the use of gas-fired heaters are generally more commonplace in the industry. They tend to have marginally lower capital equipment costs and, depending on country of use, a lower running cost. As of 2020 Q3, the average cost per kWh of gas in the United Kingdom was £0.180. The average cost of electricity per kWh by the same metric is £0.8105. These lower running costs are seen as

attractive in the short term. However, The Climate Change Committee estimates that these prices will change dramatically by 2030. Predictions suggest an increase of 100% in the price per kWh of natural gas by 2030, compared to a 42% rise per kWh of electricity in the large manufacturing sector6. This disparity is highlighted further in other European countries. Gas furnaces require a period of preheating to achieve a set temperature before billets can be heated. This time is wholly dependent on the size of the furnace as well as suitable thermal insulation. For this reason, gas furnaces tend to be “powered on” at the desired temperature for long periods of time using energy regardless if billets are being heated or not. Alternatively, when utilising induction, energy is only expended when actively heating a billet and essentially no energy is used when a

*Inductotherm Heating and Welding Aluminium International Today

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billet is not undergoing the heat process. This is sometimes seen as a more flexible method for operators of press lines, as supply of heated billets can be altered to match press throughput rates more easily without wasting energy. A positive element of gas-fired heating is the simplistic design. This can allow for easier installation and operation by plant employees. This is often seen as a key benefit as to why a business may choose a gas-fired heater over a more technologically advanced alternative. As billets pass through the heater, they will homogenise at the set temperature throughout. This will take considerably longer than induction and can often cause scaling on the billet exterior, which can affect the final extrusion quality. The biggest advantage of using induction is that it can allow for taper heating. Taper heating is utilised to achieve a gradient across the length of a billet – a key factor in reducing press die wear as well as offering isothermal extrusion at full press speeds. The design of gas furnaces incorporates a kiln lining that will need replacing periodically; this can lead to extended down-times on press lines. Similarly, induction coils will also need replacing, although this can take as little as thirty minutes. There have been advances in technology in recent years to the systems surrounding flue-gas recovery and CO2 flue scrubbers. These allow for a higher efficiency and lower emissions respectively. Other Methods Methods of billet heating are not limited to the two aforementioned processes. Magnetic heaters and the use of superconductors are starting to become effective in the sector. Both of these methods rely on electricity as opposed to fossil fuels to operate. Environmental Impact Both methods of billet heating discussed in the article will cause a detrimental May/June 2021

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Fig 2. Above: CO2 Released Per Tonne Fig 3. Above right: CO2 Emissions over time

Fig 4. Right: Expected 10-year emissions

environmental impact due to the release of greenhouse gasses. In the case of gas heating, the CO2 is released at the manufacturing facility. Induction relies entirely on each nation’s energy grid and therefore the local energy mix. Using Table 1, it is possible to establish the potential CO2 emissions for each instance. The burning of natural gas releases 0.185 kg/kWh of CO2 while electricity production in the United Kingdom produces 0.256kg/ kWh7. The large difference between the two methods is closely attributed to the ‘power on’ times of each system – induction only uses power on a per-billet basis. As the UK moves its focus towards renewable energy sources, the 0.256 kg/kWh CO2 emissions is expected to drop to 0.100kg/kWh by the year 20308. As is shown in Fig 3, the expected CO2

emissions are set to drop under the UK’s ‘Net Zero by 2050’ climate approach. Using the values determined in Figures 2 and 3 it is possible to return an expected CO2 emission over a 10-year period. The data in Fig 4 assumes 1000kg/h throughput, 16 hours a day, 5 days a week, 52 weeks per year. These values alone aren’t especially quantifiable from one’s personal perspective. It can be more easily visualised as follows. A fully-laden Boeing 747-400 emits approximately 90 kg/h of CO2 per hour of flight per passenger 9. The 10-year plant emissions from a relatively small gas-fired billet heater as specified in Figure 1 are approximately the same as flying a Boeing 747 from Heathrow to JFK – 34 times. Or driving an Aston Martin DB9 to the moon and back – 27 times. This level of environmental impact is not sustainable. The Future The ferrous and non-ferrous extrusion market is expanding. Current figures estimate a compound annual growth rate (CAGR) of 3.8% between 2021 - 202710 for aluminium extrusion. This predicted CAGR would see a market revenue forecast increase from $57.3 billion to $91.67 billion by 2027. This is inevitably going to cause a greater and greater impact to the environment as the sector expands. Aluminium International Today

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The UK government has recently rolled out an initiative to large industry offering grants that will help increase energy efficiency and lower carbon-footprint. Phase 1 is providing up to £40 million for “projects deploying technologies that improve the energy efficiency of industrial processes” & “feasibility and engineering studies into energy efficiency and deep decarbonisation measures for industrial processes”11. Other countries, such as Norway, have recently invoked a price increase per tonne of CO2 emitted fourfold12. Further development into flue-gas recovery and CO2 scrubbers for gas-fired

furnaces are helping to increase efficiency and reduce CO2 emissions. Reactive measures are what we as a society have relied on, but it’s no more than a sticking plaster. We need to turn reactive into proactive. Actively making changes that are better for the environment. On an individual basis it’s easy to remove oneself from the decisions being made with regard to the environment. We can take the easier or cheaper option because it’s exactly that, easier and cheaper. What isn’t as easy to stomach is the damage that we have caused, are causing, and will continue to cause our planet. But changes

can be made to halt this harm. Humanity faces a climate crisis. It can be stopped. �

References 1.https://ourworldindata.org/emissions-by-sector#direct-industrial-processes-5-2 2.https://www.metoffice.gov.uk/weather/climate-change/causes-of-climate-change 3. https://www.breakthroughonline.org.au/papers 4.https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6099852/ 5.https://www.gov.uk/government/statistical-data-sets/prices-of-fuels-purchased-by-manufacturing-industry#history 6.https://www.theccc.org.uk/wp-content/uploads/2017/03/Energy-Prices-and-Bills-Committee-on-Climate-Change-March-2017-Annex.pdf 7.https://bulb.co.uk/carbon-tracker/#:~:text=The%20UK%20government%20report%20on,kg%20per%20kWh%20of%20gas. 8.https://www.carbonbrief.org/analysis-uk-low-carbon-electricity-generation-stalls-in-2019 9.https://www.carbonindependent.org/22.html 10.https://www.grandviewresearch.com/industry-analysis/aluminum-extrusion-market 11. https://www.gov.uk/government/publications/industrial-energy-transformation-fund-ietf-phase-1-spring-2021-how-to-apply 12.https://www.reuters.com/article/us-climate-change-norway-idUSKBN29D1BD

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Sustainability quantified - The key environmental indicators in sustainable material selection

Sustainability is increasingly becoming a central aspect of our world, particularly within the materials industry. Multiple sustainability indicators within environmental, economic and social schemes are specifically sought to ensure sustainable production, use, reuse and disposal of products and materials. However, the challenge lies in the quantification of these indicators and finding the best methods for measuring and reporting their impacts. Here, Samir Jaber*, explores the most common environmental sustainability indicators in a materials selection process and how they are quantified. As defined in the Brundtland Report in 1987, “sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs.” Today, sustainability has long passed the mere association with minimising carbon and greenhouse gases. Discussions about sustainability are concerned with various matters of the environment, the economy, and the society. These are commonly known as the “three pillars of sustainability,” as they all demand consideration and proper management to ensure a sustainable future. But one question remains: How can we properly measure sustainability, quantify its impacts, and set meaningful and appropriate goals? Well, measuring sustainability is no easy task. It is a multifaceted process that involves dozens of considerations and indicators. As more ambitious sustainability targets are being set by governments, organisations and companies alike, the challenge of measuring the impacts and meeting demands has become increasingly difficult yet ever important. No matter what industry you are in, sustainable material selection has become a fundamental course of action in your work scheme. Here are some of the key and most common environmental

sustainability indicators that can go into the material selection process. Carbon footprint The carbon footprint of a material refers to the total greenhouse gas (GHG) emissions produced throughout the different stages of the material’s lifecycle, including production, processing, use and end-oflife. Over the whole lifespan, several GHGs can emanate, including carbon dioxide, methane and nitrous oxide. Such gases have different heat-trapping capacities that contribute to the overall global warming phenomenon. These are measured as global warming potentials (GWPs) in units of carbon dioxide equivalents (CO2e). This allows for straightforward comparison of carbon footprints of different materials accounted for by single units. As climate change has become one of the world’s major challenges, mitigating GHGs and adapting to climate change are now of paramount importance. Initiatives targeted at alleviating GHGs primarily depend on emission quantification, monitoring, reporting and verification. For that, the International Organisation for Standardisation (ISO) issued the ISO 14060 family of standards that not only offers a clear and consistent approach to the measures mentioned above but also enhances the environmental integrity,

credibility and transparency of these measures. Other indicators under the umbrella of carbon footprint include carbon reduction, carbon offset and carbon neutrality. While carbon reduction is, as its name implies, the reduction of carbon emissions, carbon offset is that reduction made particularly to counterbalance emissions produced somewhere else. The ideal result from carbon offsetting is known as carbon neutrality, which is net zero carbon emissions. Embodied energy The embodied energy of a material is the sum of the direct and indirect energy inputs involved in resource extraction, transportation, production, processing and delivery of the material. Embodied energy can also be defined in a way that incorporates the whole lifespan of the material. However, such a measurement is relatively complex to calculate as it depends on the product the material was used to make. Either way, it is crucial to reduce the embodied energy of a material or product as much as possible to minimise its environmental impact. Such a sustainability indicator is most commonly found around applications of building and construction, but it is also utilised in other application areas. It is expressed in units of megajoules

*Content Writer at materials database Matmatch May/June 2021

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(MJ) or gigajoules (GJ) per unit weight (kg or tonne) or per unit area (m2). In construction applications, this characterises the measurement of nonrenewable energy input per unit of building material or system. Embodied energy should not be confused with what is known as embodied carbon. Embodied carbon is, basically, the carbon footprint of the material, but it differs based on which part of the material’s lifecycle is considered. It is important to distinguish it from embodied energy as it indicates the carbon emissions involved not the energy. Recycled content Also known as recycled material input, recycled content represents the proportion of material in a product that has been redirected from the solid waste stream. This can happen in two different stages, leading to two different categories of recycled content. One is pre-consumer recycled content, also known as post-industrial. This is when the material is redirected during manufacturing, before it reaches the consumers. The other one is postconsumer recycled content (PCR), which refers to materials recycled after consumer use. Recycled content is generally expressed as mass fraction in percent. Common materials that incorporate recycled content include plastics (PET, PP, HDPE, ABS), metals (aluminium, steel), and glass. The process of recycling materials, whether they fall under post-consumer or post-industrial, plays a significant role in promoting sustainability practices and attaining sustainable materials. It effectively helps in reducing energy consumption and depletion of nonrenewable resources. Given all these metrics, they can all be put together into what we call as an environmental sustainability index (ESI), which is a measure of the overall progress Aluminium International Today

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towards environmental sustainability. This composite index presents a combination of environmental, socioeconomic and institutional indicators that have quantifiable impacts on environmental sustainability at a national level. At Matmatch, we have begun to incorporate sustainability indicators in our materials database to help engineers make more sustainable choices. We put together a guide to sustainable materials selection and we are currently collecting data from materials suppliers to make some of the indicators mentioned in this article searchable. For example, leading aluminium producer Nature Alu is committed to producing fully environmentally

friendly and contributing to sustainable development. Its high-purity aluminium (P0101 up to 4N+) has a very low carbon footprint, but it is also designed with the health and safety of employees in mind and the needs of the client in mind. Similar suppliers can be found on our database. By finding the most sustainable materials and identifying their environmental impact, we can contribute to more environmentally friendly and economically viable production. Aspects such as the carbon footprint, embodied energy and recyclability of a material are all very important considerations for any engineering project that is concerned about the wellbeing of the society and the planet at large. � May/June 2021

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The Dawn of the Age of Aluminium

Jock Armstrong, Principal Consultant, Bauxite and Alumina, Worley

Every jump in our evolution has been underpinned by metals The Copper, Bronze and Iron Ages have each allowed humanity to develop and achieve new technological advancements like never before. We’re intrinsically linked to the earth’s materials, and it’s naïve to think that metals won’t support our next evolutionary jump. Pressure is mounting for green Aluminium The 2015 Paris Agreement and decarbonization commitments from countries and companies around the world are softening the curve, but with CO2 emissions still increasing, there’s a long way to go. Perfect for lightweight electric vehicles, infinitely recyclable, and corrosion resistant, Aluminium can help meet these emissions targets as well as society’s transport, construction and electronics needs while remaining compatible with a circular economy. However, aluminium production requires a lot of energy. The conundrum is that despite being a metal of choice, as we transition to new energy systems, aluminium’s current carbon footprint is incompatible with our climate change targets. Green aluminium currently produced by hydro-powered smelters is a relatively new and already differentiated product Aluminium International Today

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in the market. Proving to be a potentially valuable solution, customers are increasingly prepared to pay for ethical, low-carbon products. As decarbonizing options accelerate, the reality is that refineries and smelters need reliable, large-scale power supply, and alumina refineries need heat, so variable renewable electricity does not provide a simple solution. For example, the recently installed 100-megawatt Tesla battery pack in South Australia would only allow a typical smelter to operate for eight minutes. The right approach depends on local conditions and access to energy forms. Hydropower may work for some. But solar or wind power with thermal or liquid air storage and ultimately hydrogen may work better for others. Megatrends are reshaping the aluminium industry Geopolitics and aluminium market imbalances The first megatrend to consider is geopolitical influence on markets. Government subsidies underpin energy projects, which help to support local production independence. However, the extent to which subsidies are applied varies from country to country. As regulations and policies vary

regionally, some countries still produce most of their energy from coal. And where there’s cheap energy, there’s cheap aluminium. These distortions have had a dramatic impact on the industry’s carbon footprint. Smelter power demand increased its carbon footprint globally from 7 kilograms CO2 equivalent per unit kilogram of aluminium (kgCO2-e/kg Al) in 2010 to over 10kg CO2-e/kg Al in 2018. To progress as an industry, we must pivot in direction to ensure lower carbon intensity when it comes to aluminium production can be achieved in a less carbon intensive way. The energy transition The industry can’t stick with coal to compete in a decarbonized future. And nor will it want to as new energy alternatives and technologies change the way alumina and aluminium is manufactured. The levelized cost of energy from photovoltaics and onshore wind already matches the cost of energy generated from coal. As the cost of renewable energy continues to fall, it becomes a matter of understanding how to keep these energy intensive aluminium plants running when the wind’s not blowing and the sun’s not shining. Good news – we can see some economically attractive solutions taking shape already! May/June 2021

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18 GREENER ALUMINIUM

How to Reduce Alumina and Aluminium Carbon Footprint? Just add a pinch of salt and Voila! Molten salt energy storage technology offers a more immediate solution because it takes technology that is ready now, supported by renewables, which can then be applied to the alumina industry. It can act as a large-scale thermal storage, allowing for the integration of renewables by smoothing out fluctuations in supply. Heat is initially generated by low-cost transient renewable power. Raising the molten salt temperature to 500-600°C provides the energy to raise steam for the refinery while also producing reliable power for both the refinery and smelter and valuable grid firming services. This is something Worley is already demonstrating successfully in Concentrated Solar Power with over 100 projects under our belt. Indeed, Worley is Owner’s Engineer for the largest hybrid solar energy project in the world, the current NOOR project in the UAE. Thermal energy storage is transferrable, known technology. Because of this, costs and risk can be minimized. There are potential retrofitting opportunities for existing utilities facilities to use molten salt rather than having to build new assets. Using molten salts allows access to low-cost renewables, tapping into wind and solar technology, or by building concentrated solar thermal plants. Utilising stored heat energy at the refinery improves efficiencies. Decarbonizing Aluminium Molten salts are only one piece of the puzzle. Technology-driven efficiencies always need to be progressed in a competitive market. There is potential to balance electricity demand with stabilization mechanisms, such as shell heat exchange technology for smelter power modulation. Pumped hydro storage and liquified air are also compelling options for large scale energy storage. Aluminium smelters will likely exist in more complex power networks, where energy comes from multiple sources at different times, with increased modulation. The anticipated commercialisation of carbon free anode technology will also be a major step forward for the industry.

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Alumina Refinery Decarbonization Pathways Other opportunities for refinery decarbonization innovation could be � Electrification through mechanical vapour recompression, a process used to recycle waste heat, and an electric calciner. � CO2 capture in residue. � Green hydrogen, if costs fall sufficiently, to create a viable bridge between variable renewable energy supply and base load refinery demand. Worley has invested in developing an alumina decarbonization roadmap. Each site’s circumstances are unique. Different pathways will take shape dependant on local factors. ONE SMALL STEP FOR SUSTAINABILITY, ONE GIANT LEAP FOR ALUMINIUM! Businesses need to start paving their route to decarbonization now or they will struggle to maintain their social licence to operate. Through decarbonization, Aluminium will find its place in a more sustainable world. As we look to take a step closer to the Age of Aluminium, it is the boldest, not the biggest, that will transform the aluminium industry of tomorrow. �

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RECYCLING 21

Fig 2. The US is well on track to a second trillion loss of UBCs

Aluminium recycling: Is there still magic? By Prof. Geoff Scamans* In this blog I’m going to focus on aluminium recycling and the aluminium “magic” description by Thomas Canby from almost half a century ago. Does this concept still apply today, specifically in the metal’s end-of-life recycled embodiment? The Magic Metal In an article “Aluminum the Magic Metal”, published by National Geographic in 1978, its author, Thomas Canby, approved the societal vision expressed by Nobel Prize-winning chemist Glenn T Seaborg, a former chairman of the US Atomic Energy Commission. He proposed that “the present materials situation is literally reversed: all waste and scrap – what are now called secondary metals – become our major resources, and our natural, untapped resources become our backup supplies.” Canby predicted that when this day comes, versatile aluminium would play a major role. Can deposits kick-start aluminium recycling In 1978 aluminium recycling from endof-life products was in its infancy. The annual US primary aluminium production was 5.4 million tonnes. However, they threw away three billion pounds (1.36

Fig 1. An early Eddy current separator.

million tonnes) of aluminium each year. This was equivalent to the total US primary production twenty years earlier. The largest single scrap aluminium source was the beverage can. Reynolds, well before Alcoa consumed them in 1999, reportedly “plunged” into can recycling offering 17 cents a pound (about 23 cans in 1978). Consequently, in 1977 they recycled 2.9 billion UBCs (Used Beverage Containers). This equated to 48% of the total collected across the US, and the company paid out $20 million. However, it proved that cash payment incentivised can recycling, whereas petrol coupons or charitable endeavours did not. Straight cash payments of 10 cents a

pound ($220/tonne) eventually established the can recycling habit. Money was the vital incentive. However, individual recyclers also felt that they were playing a role in improving the environment. Brewing companies like Coors and the Energetic Pearl Brewing company became the major can collectors. They shipped most of what they collected to Alcoa for remelting and can body sheet manufacture. Separating the scrap In 1977 the payment scheme resulted in more than 6 billion cans returned for recycling. In addition, technologists developed new ways to retrieve aluminium from urban waste. Eddy currents, created by magnets, separated the aluminium from the waste stream. Fig 1 shows an early Eddy current separator developed by Raytheon under test at the US Bureau of Mines. This device, known as the “aluminum magnet”, repulsed shredded aluminium scrap and conveniently separated it from the waste stream. A plant in Ames, Iowa, was the first US urban recycling facility to use this type of separation. Further plants soon followed in New Orleans and Milwaukee.

*Chief Scientific Officer, Innoval Technology Aluminium International Today

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Barriers to UBC recycling In 2013 Andres Tominaga Terukina, studying at the NTNU in Trondheim, presented his thesis “Barriers and solutions for closed-loop aluminium beverage can recycling” for a Masters in Industrial Ecology degree. His work concluded that the main barrier to reaching the high recycling targets set by the aluminium industry in the US remained the low recovery of UBCs. Almost 50% were still lost to landfill or incineration facilities, much the same as in 1978. His results also showed that the surplus of alloying elements and the entry of impurity elements provide a limiting factor for the recyclability of cans in the future. This is due to the can body sheet alloy’s sensitivity to the entry of impurities. Unfortunately, this runs counter to the widespread “infinite” recyclability claims without caveats. He surmised that, to reach a 100% recycling rate, we would need a better UBC recovery supply chain, further technological developments for reprocessing aluminium cans and improved production yields.

Deposit schemes lead to high recycling rates In 2017 the CRI reported that the aluminium UBC recycling rate in the US was 46.1%, except for the states where deposit schemes were in operation. In those states the rate leapt up to 82.5% showing the dramatic effect of these schemes. Generally, the US UBC recycling rates vary between lows of 40% and highs of 60% on an annual basis. This makes 50% a good estimate of the return rate. In the period 1996 to 2006 the US was selling about 100 billion cans/year and recovering between 40 billion and 60 billion UBCs. This is directly in line with the recycling percentages. On average, during this period, each person in the US both recycled and wasted about 200 cans. Recycling rates in states that require a 5¢ or 10¢ deposit on beverage containers range from 70-95% for the ten states that have these deposit schemes. Huge losses a blow to aluminium recycling Between 1972 and 2005 the US had wasted more than 1.1 trillion cans. Since

then we can estimate that a further 700 billion UBC’s have been landfilled, incinerated or littered. This puts the US well on track to a second trillion loss. Another way of looking at this is that more than 27 million tonnes of aluminium cans, with a value of more than $30 billion, now lie buried and waiting for recovery. According to the CRI one trillion cans, lined up end to end, would stretch to the moon and back almost 160 times. What’s more, they could encircle the earth more than 3000 times. A dull glow? It is clear to me that the magic of aluminium has not shone as brightly as was predicted fifty years ago. However, there has never been a better time, or a more urgent need, to deliver on that magical vision through exploiting the closed loop recycling of end-of-life aluminium. In a future blog I will look at the situation in the UK over a similar time frame. Finally, you may find another blog of mine interesting; Aluminium can recycling and the landfill debacle. �

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RECYCLING 25

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From scrap to oven-ready aluminium: The new recycling plant in Deral Spa

From left to right Vincoli and Cibaldi

Starting from aluminium scrap Deral Spa produces high quality billets for the national and international market. To ensure high production quality, the material loaded into the ovens must be carefully treated from any impurities. For this reason, the company has its own grinding and selection plant, recently upgraded by Panizzolo Recycling Systems with a new Mega 1100 hammer mill and new separation systems. Aluminium International Today had the pleasure of interviewing Mauro Cibaldi and Pietro Giulio Vincoli, respectively President and CEO of the Italian foundry DERAL S.p.A. Good morning Mr Cibaldy. How was Deral born? Cibaldi: Deral was born in 1986 in Manerbio, in the province of Brescia, initially dealing with scrap discarded from extrusion production cycles and from which we produced new billets. Over the years, the evolution of production has led us to expand the range of incoming aluminium, reaching today to be able to Aluminium International Today

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insert material from the demolition of windows and profiles into the melting cycle. This evolution has introduced greater attention to the quality of recycling and enhancement of the raw material from scrap. In 2015 this process saw the replacement of the old line with a first Flex 1000 mobile durm plant in Panizzolo complete with eddy current. Over the years we have also implemented an x-ray selector, allowing us to effectively identify and separate the secondary alloys from the primary aluminium ready for use. In Deral today we are structured for a production of about 40-45,000 tons / year of finished product and we expect, for the next ten years, a production growth of the company both thanks to the new Mega 1100 and to a booming Italian market. Can you give us some numbers on your staff and your business? Cibaldi: To date, the staff consists of 35 employees and 5 directors, we occupy an area of approximately 28,000 square meters of which 4,000 square meters

are dedicated to production in a covered warehouse and 600 square meters of offices. By 2030 we expect to be able to expand production with an additional furnace and a new line for casting billets. As regards the flow we can say that we receive on average about 40 / 45,000 tons of materials divided between scrap, pure aluminum ingots and, to a minimum, alligants. The output is mainly in the form of an aluminium billet and a small part of waste which is defined as slag. All our waste, slag or waste that comes out of the shredding system that is not correct for us, has an economic value and is therefore recovered. How did you get to know Panizzolo recycling systems? Vincoli: I went to a customer of yours to see a Panizzolo recycling plant at work, in particular on the crushing process of electric motors. I immediately liked the basic idea: More compact mills with a more than adequate investment and management cost, compared to a market that generally sees large machinery with May/June 2021

28/04/2021 06:57:06

26 RECYCLING

considerable costs. An example? The maintenance of a 100 Kg hammer is not that of a 22 Kg one and with the Flex 1000 mobile drum we have processed 10,000 tons of material for 3-4 years. How does the Panizzolo plant make your treatment cycle more efficient? Vincoli: At the beginning of the business we worked with shear presses and a manual selection for the cleaning phases. In particular, our double shaft shredder produced a very large piece of aluminium (50-60 cm) and forced us to slow down our productivity. Furthermore, the quality of the product was not perfect, with clear repercussions at the time of casting. For this reason, in recent years we have opted for complete and more effective systems such as the Panizzolo line, up to the new x-ray selection. One of the first Panizzolo machines installed, due to timing reasons, was the hammermill Flex 1000 mobile drum, started up in a very short time while now we have switched to a stationary hammermill Mega 1100. Our first need was to increase the production capacity of the grinder and from the first accounts of the new production cycle we have already seen a clear improvement. With the grids set for our scrap we have calculated a productivity of about 15/16 tons per hour. A high level of control is important in a good car. We want to support the operators with new technologies for monitoring production, so that the plant operates every day at its maximum potential. The new software, which also works with artificial intelligence, will analyse all the operating data of the machine and will bring us the necessary feedback to understand where we are going and how we can improve. What prompted yu to choose Panizzolo recycling systems as a technology supplier? Mr Vincoli: Surely one of the reasons is that Mauro Panizzolo has a long experience with grinding and hammer mills. He has used them personally, has noted strengths and weaknesses and created a product based on his own experiences. There are other hammer mills of this size but they are not up to the processing of our ferrous scrap. I also found Panizzolo’s technical office to be very prepared and professional. The structure of the Panizzolo hammer mill at the carpentry level is very good. I have visited the factory where all the machines are built, noting that the carpentry is also part of an international content of high quality in railway supplies. This is further confirmed by the fact that our Flex 1000 Mobile had no problems, May/June 2021

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even though it worked for many years under intense production regime. What also distinguishes their recycling plants is both its simplicity and low operating costs, avoiding the need for highly specialised or constantly present personnel. Following the simple routine maintenance, the Panizzolo hammermill does not give any problems, with undoubtedly lower costs than the doubleshaft hydraulic shredders on the market. There are other models on the market as well, but normally they are mills of 1,000 horsepower and up. Unlike, I was looking for a medium-sized mill and in Italy the high-quality medium-sized mill is located in Panizzolo. In my opinion it is counter-productive to treat scrap like ours with high power systems. The Flex 1000 Mobile drum has allowed us to operate with a much less demanding system and with a productivity, in two working shifts, of between 100 and 150 tons of processed material. How important is the patented interchangeable cradle in hammer mill processing? Vincoli: The interchangeable cradle has a simple and effective engineering that allows for really fast maintenance. Not only the extraction of the cradle, but also the extraction of the rotor itself is very practical. In a large mill, maintenance of

the hammers would normally require a production stop of at least one day. Unlike in Panizzolo machines, it only takes a few hours if you do not have a spare rotor. With the Flex 1000 Mobile they had two rotors and therefore set off in less than half an hour. Returning to the crib I think its sizing is ideal, so much so that I am sure I will retire before having to replace it! Seeing the side walls and the reinforcements below I don’t think it will be subject to wear for at least 10 years! What hourly productivity do you expect from the new plant? Vincoli: We will certainly produce at least 12 tons per hour, but already from the recent processing tests we have calculated that we are around an average of 15/16 tons per hour. How is your commercial presence distributed between Italy and abroad? Cibaldi: Mainly with regard to input, we have to make two major distinctions. Scrap is predominantly Italian, with a quantity of less than 10% coming from abroad. Conversely, the pure aluminium ingots are all produced outside the EU. As regards our sales process, 60% of our turnover is directed to our parent company Estral. The remaining 40% is almost all destined for the Italian market, Aluminium International Today

28/04/2021 06:57:18

RECYCLING 27

Panizzolo hammermill - the interchangeable cradle

where there is the presence of about 45 extruders and a small part for the European market (about 2-3%). Do you undertake any environmental policies at Deral? Cibaldi: We are ISO 9001 and ISO 14001 certified and we have the 333 certificate of 2011 which certifies the transformation of our waste into secondary raw material. In addition, in December 2020 we also received the environmental assertion validation certificate. Our company’ sensitivity to the environment is growing and this constantly leads us to apply what are called the “best available technologies” to the ovens, as well as to maximise the use of energy from renewable and natural sources. In June 2020 the new B.A.T. for the metallurgy sector, providing for a continuous monitoring system for emissions. For this reason we have installed on all our fireplaces special detectors that analyse the outgoing emissions every 5 seconds. As for the energy aspect, together with our parent company, we have an energy manager with whom we plan the use of renewable energy. In addition, in 2020 our parent company completed a 1 megawatt solar panel system and therefore many machines can benefit from self-produced energy. Aluminium International Today

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How is the aluminium market structured abroad? Cibaldi: Italy is the European leader in the field of extrusion both in terms of production and quality and in this panorama Deral is among the five main national billet production foundries. The strong propensity for recycling has allowed Italy to develop more than other European countries where, unlike, the creation of a few large foundries has been favored. Italy therefore has a very large production and quality capacity with an export trend that is growing every year. As regards the final purchase area of our products, we can say that the German automotive sector is the master. Many German vehicles are structured with Made in Italy aluminium. What are your sources on market trends? Cibaldi: We are operators who are constantly active on the market, interacting with many subjects. This allows us to find news on the trend day by day, together with the classic information channels such as sector publications. We are also part of the CENTROAL trade association, of which I am also president, because we believe that associations help individual realities. If there are regulatory problems, which in some way can have an impact, going it alone makes no sense. What is your opinion on the changes in the sector in the coming years? Vincoli: Major changes are taking place in our industry. In the next 10/15 years there will be more and more structured

companies with complete systems that carry out the total enhancement of the material internally. In this process, the figure of the mere scrap dealer will disappear. In order to face the near future, companies must therefore structure or deconstruct themselves. An example? As a foundry, we collect demolition material or ready-made material, there is no more middle ground. In Deral, thanks to the very strong demand for aluminium and the regulations aimed at reducing CO2, we are considering making an additional investment in the treatment plant. This is why I think that the 1100 Mega Panizzolo mill has considerable success possibilities for the treatment of aluminium. With the same machine it is possible to work both the profile and the aluminium casing and also other types of aluminium. However, it remains a machine with a decent size at low cost. Cibaldi: At a European and national level, we see a whole series of incentives flourish on products and materials that have particular value within the circular economy. Among these materials, aluminum plays one of the most important roles. Aluminium is 100% recyclable, its recycling process requires 1/20 of the energy that would be used starting from the raw material. It is used more and more due to its lightness and strength and involves very little CO2 emissions during melting. All these are elements on which we are focusing predominantly and will ensure that aluminium will become the material of the near future. � May/June 2021

28/04/2021 06:57:33

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RECYCLING 29

Fig 1. Dynamic concept high performance scrap preheating system

Innovative approach for recycling Context of the Industry The situation in terms of global climate and greenhouse emissions represents a big challenge for our modern society – which requires real actions and new solutions. More and more groups and companies participate in this worldwide effort to bring new opportunities. Aluminium recycling is one piece of the puzzle to achieve the goal of ensuring a greener economy. Meanwhile, responsible companies integrate aluminium recycling into their marketing strategy. Customers in general are more sensitive to this aspect. So, this is why we observe that these direct customer suppliers ask their suppliers to increase the recycling of their contents in their products. This is how the value chain is solicited. Availability of Scrap The availability of post consumer scrap has always been a challenge. In some regions, this type of scrap used to betransported away to be recycled elsewhere. The trend is to minimize transportation and CO2 emissions through local recycling. The Aluminium International Today

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result is that more scrap is available in some markets, as we can see in North America. Closed Loop Economy In many processes, an efficient way to recycle is to recover scrap generated in the same value chain. For example, an aluminium slab supplier can recover scrap from its own customers and subcustomers to cast new slabs. The advantage in this is the compatibility of the products in terms of alloys and other characteristics. The required equipment is simpler, and the constant supply of scrap is easier to guarantee. Dynamic Concept’s Approach Dynamic Concept has been involved in many projects in both process engineering support and adapted equipment solution for casthouses around the world. We can confirm that there is no unique solution in the implementation of recycling. It is a case by case approach. For any adapted solution regarding scrap handling, scrap pre-treatment, melting and metal transfer

system, several factors must be taken into account: � Type of scrap to process � Existing constraints (for example, room available in existing building) � Actual/existing metal transfer system or metal route � Products/requirements of metal to cast � Configuration of existing casting machine � Etc. We propose a flexible approach in terms of design and configuration that would support the customers in all steps of a project. For recycling project, study all those parameters in order to fit the best solution and configuration is the key for success. Then, we support the client for the further steps project implementation either with our adapted equipment and/or other supplier equipment. The idea is to provide the client the best available solution on the market and implement the best configuration for his needs. May/June 2021

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30 RECYCLING

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Fig 3. Dynamic concept automated remove tap hole opening/closing system

Fig 2. Dynamic concept furnace to furnace metal transfer siphoning system

Solutions and Options to Consider For scrap handling, changing, treatment and melting, many options are possible depending on the type of material to be recycled. Some require sorting and pre treatment; others can be loaded directly. Many melting solutions are to be considered such as a rotating furnace, a multi chamber furnace, fume post burning requirement, level of automation, preheating requirements, etc. Fig 1 Metal transfer is a key factor in the recycling configuration. In some existing plants, crucibles are already used for molten metal transfer or route. So, many options are possible: � Gravity pouring � Gravity tap out � Gravity siphoning � Aspiration (vacuum/pressure) siphoning � Pressure siphoning � Mechanical pump Dynamic Concept has direct experience with most of these systems. There is no one system that is better, only preferred systems for specific requirements and May/June 2021

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configurations. Fig 2/Fig 3/Fig 4 To select the right equipment for any specific application, we use a PUGH Matrix, which takes into account several factors such as dross generation level, reliability/complexity, maintenance cost, investment, safety, degree of automation, metal level dependency and process requirements. Conclusion Our experience has shown that it is very important to analyse the technical requirements according to the existing constraints of the existing production line and the building. Starting with a good analysis of the possible options will guarantee a good project and process efficiency that c/w with a good return on investment. Dynamic Concept can support the plants in all the steps to implement higher contains of recycling in their production. � Contact www.dynamicconcept.com patrice.cote@dynamicconcept.com

Fig 4. Dynamic concept metal pump (Mg pump on picture)

Aluminium International Today

27/04/2021 12:44:17

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ONE MACHINE, ONE LINE, MANY SOLUTIONS – METAL SORTING WITH THE MOST ADVANCED COMMERCIALLY AVAILABLE SORTING SOLUTIONS FROM REDWAVE R EDWAVE XRF/C FOR NONFERROUS METALS – ONE MACHINE IS ALL YOU NEED As a shredder operator, success is based on keeping your customers happy and your margins as wide as possible. Today much attention is focused on new systems to upgrade the nonfer-rous product produced. The future of every operation depends on how well a system can effectively deal with constantly changing export markets, customer requirements and new mixes of materials available. The best processor is the one that can create furnace ready scrap that commands the best prices from the widest variety of customers. Today there are many options for getting a clean sorted product (see comparison table). But if you need a simple system with the flexibility for new sorting scenarios and capability to grow with new business all backed by the experience of the world leader in advanced nonferrous sorting, then the REDWAVE XRF/C is the only system designed for you. Many equipment suppliers develop systems to fit a specific step in the recovery of high value materials from nonferrous mixes; depending on who you talk to they recommend some combination of induction, XRT, camera and XRF systems. But when a plant requires multiple sorting processes, the best solution is one that can do the most with the least and that is when REDWAVE comes into play. 13 years ago, REDWAVE invented the X-Ray Florescence (XRF) based sensor sorters for the recycling industry. At that time, the sorter was developed to effectively separate heat resistant glass and leaded glass in an input of mixed container glass. In collaboration with leading scrap recyclers, REDWAVE adapted the XRF system for the metal recycling industry to be able to do what no other sensor sorter could. With combination of XRF and camera technology in a compact industrial grade housing and using a free-fall concept rather than a conveyor belt, the sorted

metal grades produced can reach purity levels high enough to sell directly to furnaces and refiners. It´s an industry goal to cover the shredder’s operating costs by the revenue generated from the nonferrous output. But in a competitive market where every dollar counts, a fully sorted Zorba package can be worth up to 60% more than the val-ue of the Zorba alone. The REDWAVE XRF/C has a compact footprint of only 10 square me-ters allowing integration into almost any existing plant. Moreover, operating only with one machine and a single vibratory feeder, repair and maintenance needs are minimal in com-parison to belt type machines or multiple machines. Depending on the international market and other factors, the price of mixed nonferrous metals like Zorba, Zebra and Zurik can suffer a drop of over 50% in value in a matter of months. The price of Zorba historically has experienced swings from the low 20’s up to near €1 per pound. Sorted materials like aluminum twitch, die cast zinc and copper products tend to trade in tighter bands with their pricing linked to the prices of virgin metals on the LME markets. Sorting these materials with a REDWAVE XRF/C can greatly increase nonferrous revenues and allow a business to grow as can be seen in the graph. Global Sales Manager Martin Weiss says: “REDWAVE is proud to be the pioneer of advanced metal sorting using XRF. With more than 100 XRF-based sorting machines worldwide in operation we are the world market and technology leader for XRF-based sorting machines.” The REDWAVE worldwide customer base ranges from familyowned shredder yards to mul-tinational corporations and each one has fulfilled their specific needs in nonferrous sorting with the REDWAVE XRF/C.

REDWAVE – COMPANY DETAILS: REDWAVE is your reliable partner for profitable solutions in the recycling, waste management and mining industry. It supplies groundbreaking and economic sorting plants for recyclables as well as turnkey waste treatment plants. Furthermore, REDWAVE is a leading manufacturer of sensor-based sorting machines with a sturdy industrial design which achieves high performance and quality recovery of materials. REDWAVE does not stop at the sensor level but provides the complete machine taking the responsibility for the sorting result. It also focuses to have its own software and hardware knowledge in house as this gives their clients the required flexibility and allows them to continuously develop their products and react quickly on market and customer needs. REDWAVE operates worldwide and is headquartered in Austria. It maintains branch offices in Germany, China, Singapore and the United States.

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Aluminium International Today

28/04/2021 06:59:35

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SECONDARY 35

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Altromex

1. Nigel Seddon, CEO of Ultromex 2. Michael Glass, Ultromex Projects Director 3. Chris Goddard, SPL Project Manager

2 3

Technologies for production wastes driving the circular economy Reflections on a year at Ultromex. There is no doubt that sustainable metals production can become a cornerstone of the circular economy. Ultromex, based near Liverpool in the UK together with its new operations in France, is determined to ensure that it plays a major part in propelling the aluminium sector to the front and centre of circular manufacturing with its technologies for creating valuable secondary resources from aluminium smelting wastes. Nigel Seddon, the CEO of Ultromex has been reflecting on what has been an extraordinary year for Ultromex. “The pandemic has been a defining feature of 2020 affecting most people’s lives and businesses all around the world. We had only just shipped an ALTROMEXTM plant overseas to process dross when the UK and much of the world went into its first lockdown. Fortunately, we at Ultromex Aluminium International Today

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managed to stay safe and after this lockdown, to carry on working. It’s just as well because we have never been busier.” Ultromex was also awarded a major contract with Rio Tinto to remediate a salt slag landfill in France. All the required permit and planning applications have now been granted, the whole site scheme has gone through HAZOP and detailed design, and currently all the plant equipment is in manufacture. The whole plant will be built in fully integrated modules, each about the size of a shipping container. Each module will be piped, electrically wired, commissioned and factory acceptance tested here in the UK, prior to transhipment to France. Once on site, the modules can be rapidly connected and installed for operational use - plug and play in action! When the project is complete, the plant can be

rapidly disassembled and moved to start the next project. Leading this project is Alban Le Bret, a talented French engineer, recruited to head up Ultromex’s French operations. Currently he is overseeing site preparations and recruiting the rest of the team in readiness for plant commissioning later this year. In parallel with working on the Rio Tinto project during 2020, Ultromex has built and commissioned a SALTROMEXTM (salt slag treatment) plant at its Bromborough site. Through operation, the organisation has been able to design out minor bottlenecks and increase its throughput from 1 tonne per hour to 1.5 tonnes per hour. Michael Glass, Ultromex Projects Director, explains, “By previously investing in pilot scaleup facilities, we were able to test out all aspects of our process and equipment May/June 20201

27/04/2021 12:46:58

36 SECONDARY

www.aluminiumtoday.com

Saltromex

options before designing and building this optimised plant. Now we are reaping the benefits as this fully automated plant runs very reliably. Our unique slag process generates no toxic gases so that we have a clean, safe working environment, and the process is so simple and compact that it will fit in to almost any available space on a foundry’s site.” SALTROMEXTM plants incorporate a number of key Ultromex innovations which completely change the economics of processing salt slag and can be built to any scale. The same SALTROMEXTM equipment forms the main body of the company’s 15+ tonnes per hour French plant. Alongside SALTROMEXTM at Bromborough, Ultromex has also built a multi-purpose ALTROMEXTM plant which can raise the metal quality of dross by removing oxide without losing metal yield, and it can also break up salt slag without damaging its delicate aluminium particles thereby enabling the process to recover much more aluminium from salt slag than any other current means. Michael adds, “Typically, we have found that we recover around 3% more aluminium than other salt slag processing plants. 2021 looks set to be even busier than 2020 at Ultromex. We are now in the middle of building a Spent Pot Liner (SPL) pilot plant.” For a long time, Ultromex has had a process for treating SPL, a major hazardous waste stream produced during primary aluminium smelting. Just like slags and drosses, SPL has components which, with the right chemical treatment, can make a contribution to the circular economy. According to Michael, SPL has been waiting for a good recycling solution for years. To accelerate development of their SPL offering, Ultromex has appointed Chris May/June 2021

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Goddard; a highly experienced chemical engineer with a background in managing hazardous chemical manufacturing facilities and leading a hazardous chemical remediation business. Chris heads up a focused SPL team, drawing resources from across Ultromex’s laboratory and engineering teams to push their technology and knowhow for SPL to get to market readiness. Chris comments, “Last year was a really exciting time to land at Ultromex. There is a real buzz about the place with the success of the dross and slag technologies, and I am relishing the challenge to emulate this for SPL.” On behalf of a range of primary smelters, the team has been working on SPL treatment processes for both fresh arisings of first and second cut SPL, SPL stockpiles, and landfilled mixed SPLs. One-by-one, significant solutions have been developed

for each of SPL’s many challenges. First cut SPL is extremely hard and has a reputation for being very difficult to crush, but Ultromex’s unique technology for downsizing ceramic materials successfully recovers any aluminium that is left in bath residues or trapped within fissures. Rather than model this treatment process on any existing methods Ultromex, as ever, has chosen to start afresh with the aim of eliminating hazards at their source rather than by adding ever more complex plant and equipment to deal with the consequences of upstream process steps. Thus, as a first step, the company’s chemistry eliminates the risk of hazardous gas generation and destroys any cyanides present. Chris says, “We can make SPL safe to store, handle and transport.” Treatment processes are only useful if they are economically viable and so process efficiency is the central focus. The team has developed a means of fluoride extraction that is quicker and more cost effective than established approaches. Over time, they have optimised the process conditions to make it a highly resource efficient one. For the circular economy, the value of the components of SPL waste depend on their end uses and a deal breaking contaminant for one industry can be a valuable input for another. Chris continued, “What has been developed over the last 12 months is really impressive. From SPL, we can now selectively derive a range of valuable products, and we seek to optimise our process according to local priorities and opportunities. The aim is to maximise recycling at the minimum of cost but, of course, there is a trade-off between valuecreation from material recoveries and the degree and cost of processing required.”

Saltromex

Aluminium International Today

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SECONDARY 37

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Metal recovered

Ultromex has also been working hard to connect industries. The circular economy is more than just recycling and recovery technologies, processes and equipment. It is all about pairing the creators of treated and recovered outputs with potential users. Chris revealed that as the company has been developing the SPL processes, it has also been keeping close to a number of key primary aluminium smelters, so that Ultromex can ensure the solutions meet the smelters’ requirements technically with sound economics, which are also aligned with their sustainability objectives.

The right relationships combined with Ultromex’s technologies will enable the type of industrial symbiosis that drives the circular economy. The engine for the innovations being made at Ultromex is definitely the discovery team in the laboratory. The team is a blend of young talented chemistry and chemical engineering graduates and seasoned professionals, who have spent a lifetime both developing new treatments, and operating chemicals and hazardous waste processing facilities. Chris reports, “We are close to completing a flexible SPL pilot plant at our Bromborough site which will enable us to perform the new processes in bulk to enable us to uncover and resolve any potential teething problems, using equipment that can be scaled-up with confidence. Indeed, we have plans to upscale to a small commercial sized plant very soon after that”. With an eye to the future, Nigel concludes that the company sees huge potential for its SPL technologies. In addition to helping smelters at the point of production, the organisation has been developing the processes to treat mixed land filled SPL

In the lab

wastes and has a number of feasibility projects in progress at various stages. There are many such SPL landfills around the world, created before regulations changed but which now require making safe. He adds, “Whatever the next 12 months bring, we will continue to build a high performing organisation. This will ensure that the work we do at Ultromex will help both our aluminium industry customers and the circular economy; we will be playing our part in building back better”. �

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How dross recovery is playing a role in the shift to sustainable technology

By James Herbert*

Sustainability is one of the biggest buzzwords across numerous industries today. As more data comes to light about climate change, there is a large emphasis on implementing environmentally friendly practices and working toward zero waste. New technologies are being developed at a rapid pace to meet consumer demand for eco-conscious products made through green manufacturing methods. For every industry, how this will look in practice will be different, but one of the main ways that aluminium organizations can shift toward more sustainable practices is by

focusing efforts on dross recovery. State of dross recovery today Dross is an unfortunate byproduct of the aluminium melting process and is predominantly a mixture of aluminium and aluminium oxides, as well other minor constituents which arise from the combustion of organics and compounds formed when the trapped aluminium reacts with nitrogen and carbon dioxide within the air. Unlike many processes in the casthouse, dross practices vary significantly across the

industry and especially across geographic locations. While many within the industry understand the value of dross and the importance of dross management, for some, dross is perceived as a nuisance and an afterthought, often falling into the “out of sight, out of mind” category. And who can blame them – dross management is one of the least exciting and unattractive aspects of the aluminium manufacturing process. Having said this, dross should be seen as an opportunity and a valuable resource that can be exploited if managed correctly.

*Global Sales Director, ALTEK May/June 2021

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SECONDARY 39

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y James Herbert

Above: ALTEK Latest generation dross press technology Below: ALTEK Melting Solutions tilting rotary furnace technology

Aluminium International Today

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Metal loss is usually one of the highest individual cost items in a casthouse. While a great deal of emphasis is typically given to the metal losses associated with dross generation, often, the losses associated with inadequate preservation of the metal trapped within the dross is overlooked. It is estimated that as much of 50% of the three million tonnes of aluminum dross generated globally each year is still disposed of in landfills. This is an alarming number and a huge opportunity for the industry to act and prevent so many valuable metal units being lost forever from the value chain, as well as reduce the carbon footprint of a facility and the material. As the demand for aluminium continues to grow and the climate continues to be impacted by human activity, the aluminium industry has a critical role to play in both reducing waste generation and extracting value from waste streams. Importance of dross recovery Today, with more focus on sustainability and the ever more stringent environmental legislation being implemented around the world, many in the industry are reevaluating their approach to handling dross and other waste streams. Typically, environmental initiatives provide no commercial benefit and have a negative impact on the bottom line. However, projects associated with dross not only meet many environmental objectives but can also provide a relatively quick and significant return on investment. There are a variety of technologies that have been developed to try and address both the economic and environmental issues associated with handling dross. Whatever the technology, typically, the approach is to cool the dross as quickly as possible. This approach allows the oxidation of trapped metal to be minimized, thereby maximizing the available aluminum to be recovered downstream. The rapid cooling of the

dross also minimizes the amount of emissions generated. The most efficient method for recycling dross is a tilt-type rotary furnace which – if operated with salt and in conjunction with an appropriate cooling technology mentioned above – can provide the highest metal recoveries. The downside of this approach is that the byproduct of this process is salt slag, which in many parts of the world, is classified as a hazardous waste by environmental protection agencies. Salt slag therefore must be dealt with appropriately and in accordance with local regulations. While this has historically been a concern and challenge to the industry, in recent years, new technologies have been developed to economically recycle the slag at the generators facility, enabling further metal units to be recovered along with the salt that can be reused in the rotary furnace process. The byproduct of this process is predominantly aluminum oxide, which can be used in a variety of value-add products. The approach outlined not only maximizes metal recoveries, but also eliminates the need to ship waste to landfills. This ultimately reduces the carbon footprint of the aluminum production process. Today, becoming equipped to meet the technological advancements and environmental needs of the future is a necessity, not a nice-to-have. Every casthouse is an opportunity for innovation, and the next step in improving operations is the movement towards green aluminium via metal recoveries. Improving dross recovery Taking ownership of dross and its management gives an organization greater control over the production process. By doing this, organizations can realize the true value trapped in the dross and slag and achieve the highest efficiencies. But in too many instances, organizations do not have the access to proper sustainable technology to recover the metal units properly or do not understand how much of the dross can be recycled in the first place. As an example, those that outsource dross recovery may only be attaining 45 percent recovery. If this process were managed properly and occurred in-house, metal recovery could be significantly higher and potentially closer to 70 percent. The material and its management can also be seen as a key recovery tool for the postpandemic world, as companies look to take control of their own destinies and prevent production disruptions down the line. During the 2009 stock market crash, and again at the onset of the coronavirus May/June 2021

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40 SECONDARY

Metal recovered from dross

pandemic, organizations were forced to cancel projects and unnecessary costs, many of which included sustainability efforts and other corporate social responsibility (CSR) initiatives. However, those organizations that chose to weather the storm and moved forward with previously outlined plans are those who came out on top once the market leveled out and the economy returned. They were better poised to take advantage of the benefits of their investment in sustainability, with no time to “catchup” needed. Although it is difficult for an organization to spend precious funds on green initiatives when productivity is low,

it is predicted that when the economy bounces back, as it always does, those organizations are going to be better off in the long run. In the end, one of the most important principles for a business in this industry is self-reliance. The pandemic has helped organizations take more control over their own destinies, as they became less reliant on external operations and established themselves as more resilient in the face of future economic disruptions. For example, a secondary dross processor or salt slag processor is a critical part of the aluminium production chain. If such an operation were to shut down,

depending on the geographic location, it can have a huge impact as they may not have an alternate outlet to process their materials, or if they do, the economics may not be attractive. This waste stream will not go away any time soon, as aluminum production increases around the word, so too will the amount of dross. As the industry continues to shift towards sustainable technologies, the financial impacts of aluminum loss cannot be overlooked. Dross recovery is as profitable as it is sustainable, and the current methods of recovery must be evaluated. �

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Time to advance We have continued to push boundaries and look at our industry with fresh eyes, resulting in new and advanced solutions across the entire casthouse that are transforming the aluminum industry. Underpinning this methodology, and at the center of our brand, sits ALTEKAdvance, the four pillars of our repositioned brand architecture – ALTEKadvance Partnering: taking partnering to a new level ALTEKadvance Thinking: using our knowledge, skills and experience to offer ﬁrst class consultancy advice ALTEKadvance Insight: a bi-annual magazine that shares insights and trends across our entire industry ALTEKadvance Solutions: our leading-edge technology that is the foundation for the change we are making to our industry With a vision to shape the casthouse and aluminum industry of the future, we are the only global partner providing commercially viable and scalable end-to-end solutions for sustainable aluminum production. Isn’t it time we advanced together?

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42 ADVERTORIAL: STEINERT

Greater operational reliability and more sorting options in scrap and aluminium recycling with STEINERT XSS® T EVO 5.0 In situations, for example, where recovered, recycled aluminium is being used to produce new products, aluminium manufacturers need their secondary raw materials to display consistently high levels of purity. This is one of the challenges solved by sorting technology. For the new “EVO 5.0” generation of machines, STEINERT also provides a 4-year warranty on the x-ray source and x-ray sensors. What’s more, customers also benefit from continuing software and hardware updates. Dry density sorting using x-ray transmission is a proven method that is used by hundreds of metal recycling firms around the globe. Simply considering processors of the high-performance material aluminium, the sorting machine is used to separate free heavy metals, aluminium compounds, free magnesium and wrought and cast aluminium parts. STEINERT’s ongoing development work now ensures specific benefits for the sorting process. The EVO 5.0 generation with new functions Thanks to Multilayer Data Evaluation (MDE), the sorting machine is able to use even more distinguishing criteria for detection thanks to high-resolution object recognition and by undertaking classification in parallel. Complex sorting tasks, such as magnesium detection are solved easily. Automatic x-ray monitoring and calibration (AXM) of the x-ray sensors help achieve consistently high detection and sorting quality. The hardware has also been improved. The high-resolution valve pitch of 6.25 mm enables even more efficient sorting of fine material down to 5 mm. The x-ray scan area is cleaned automatically in the new generation of machines. This vastly reduces the amount of manual cleaning needed and maintains a consistently high level of detection quality. The 4-year warranty for the x-ray source and sensors provides operational reliability and keeps operating costs low.

Downloadable e-book for guidance on sorting options A so-called solution guide can be downloaded as an e-book (download: https://steinertglobal.com/metalrecycling/aluminium-recycling/) to provide an initial overview of the opportunities provided for sorting aluminium scrap and other materials. Although aluminium scrap comes from different sources like profiles and plates, incineration bottom ash, shredder systems or Dense Media Separation (DMS), the rough stages of the sorting process are similar: recovering non-ferrous metals and upgrading the recovered metals, in other words, producing pure metal types. The e-book provides insight into both the heart of the systems – the STEINERT XSS T EVO 5.0 – as well as the upstream magnet technology and downstream fluorescence technology; of benefit to operators of aluminium shredders, secondary smelters or processors of waste incinerator ash. The downstream fluorescence technology produces pure heavy metal fractions such as copper, brass and zinc. Given that aluminium is increasingly replacing conventional materials, such as steel, and can be 100% recycled, this metal has a very promising future. What’s more, using secondary aluminium, also known as green aluminium, cuts energy use in production by up to 90% compared with virgin material. STEINERT’S key technology for saving energy is therefore an investment in a better future.

https://steinertglobal.com/metal-recycling/aluminium-recycling/

May/June 2021

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STEINERT provides a warranty on the x-ray source and x-ray sensors for the new “EVO 5.0” generation of machines; giving recyclers peace of mind for 4 years.

The new e-book on aluminium sorting outlines the solutions and can be downloaded.

New software: Multilayer Data Evaluation provides even more distinguishing criteria and the automatic x-ray monitoring and calibration of the x-ray sensors help achieve consistently high levels of detection and sorting quality. The high-resolution valve pitch of 6.25 mm enables even more efficient sorting of fine material down to 5mm

Aluminium International Today

27/04/2021 14:17:51

ROLLING 43

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The calculation of rolling force By Timothy Clemson*

When manufacturing sheet products it’s important to understand the rolling force. This is because you need it to set the appropriate roll gap on the mill, accounting for the stretch of the stand. The prediction of rolling force can be challenging due to the large number of inter-connected process variables involved. However, many years of experience working with rolling mills has allowed us to create the Innoval Rolling Model which gives accurate rolling force predictions.

of the thermal history and resulting metallurgical properties is imperative to the prediction of yield strength. Friction We can calculate the resulting pressure on the rolls from the deforming material once we’ve calculated the flow stress at a given point within the roll bite. However, the friction between the two surfaces also plays a part, especially in cold rolling.

Factors which influence the rolling force Yield strength The main factor influencing the rolling force required to reduce the thickness of strip in a rolling mill is the yield strength of the material being rolled. The calculation of yield strength depends upon a wide range of factors. These are: � composition � previous work done � thermal history � speed of rolling � change in thickness

on the material

Fig 1. Diagram of rolling pressure through the bite for cold rolling of aluminium sheet

Consequently, we must understand the microscopic interactions between the lubricant, rolls and material. This means knowing about the roughness of the surfaces and the temperature-viscosity relationship of the lubricant. Neutral Point Fig 1. In standard cold rolling, pressures developed within the bite increase towards the middle of the bite from the entry and exit. They peak at a point known as the neutral point, where the speed of the rolls is precisely matched by the speed of the material. The location of this point determines the total rolling force and is strongly influenced by the tension on the strip either side of the bite. To find its location, we need to calculate the rolling pressures from the entry and exit until their values match at some point within the bite. At very thin gauges the neutral point becomes spread out into a neutral zone and the roll is flattened into a more complex shape, requiring alternative calculations. At very thick gauges, the

We use what’s known as a constitutive equation to calculate the material’s yield point, or flow stress. There are many forms of these equations in the academic literature, and physical metallurgy is the basis of most of them. However, in general these equations all have a similar form: Yield stress = (Strain hardening factor) x (Strain rate hardening factor) x (Thermal softening factor) In the rolling of aluminium, it is strain hardening which typically dominates at low temperatures. On the other hand, strain rate and temperature are more important in hot rolling. The alloying elements and the state in which they exist within the material influence each of these factors. Therefore, a good understanding

Fig 2. Simulation of horizontal stresses during rolling of an ingot 400mm thick.

*Senior Engineer, Innoval Technology Aluminium International Today

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situation is different too. The effects of the through-thickness flow become more important and require a third approach to rolling load calculations. Fig 2 Further learning In summary, the calculation of rolling force is a complex and multi-disciplinary calculation. Changes to one process variable inevitably influence others, and the effects can often be counter-intuitive. For these reasons, the Innoval Rolling Model is an invaluable tool in our day-today consulting business. It is also available to purchase, enabling the refinement of process schedules and the simulation of potential new products and equipment. We discuss all of these topics, and much more, on our Aluminium Rolling Technology Course. Participants of the course take part in an insight-packed two weeks of lectures from our highly experienced team of rolling consultants (Fig 3). �

ALUMINIUM ROLLING TECHNOLOGY COURSE - Innoval Technology, Banbury, April 2021

MONDAY 19th 13:30 Start 13:30

Introduction and meet the lecturers

14:15

The Business of Rolling BREAK

15:00 15:15

13:30

14:30 14:45

BREAK Machinery and Process Overview Group Discussion and Questions

MONDAY 26th 13:30 Start 13:30

16:00 16:15 17:00 17:15

BREAK

14:30 14:45

15:30 15:45

Group Discussion and Questions

13:30

Finishing Overview BREAK

14:30 14:45

BREAK Control Workshop

BREAK

Group Discussion and Questions

BREAK Process Metallurgy Workshop

15:45 16:00

Group Discussion and Questions

17:00 17:15

WEDNESDAY 28th 13:30 Start 13:30

Mill Vibration 17:00 17:15

THURSDAY 22nd 13:30 Start

Process Metallurgy 17:00 17:15

14:30 14:45

Introduction to Control 15:45 16:00

Data Workshop Group Discussion and Questions

14:15 14:30

Introduction to Control

Surface Defects 15:45 16:00

13:30

Mechanics of Rolling Workshop

13:30

14:30 14:45

WEDNESDAY 21st 13:30 Start

Process Metallurgy

TUESDAY 27th 13:30 Start

Surface Generation

17:00 17:15

Machinery and Process Overview

Mechanics of Rolling

Aluminium Casting Overview

16:00 16:15 17:00 17:15

TUESDAY 20th 13:30 Start

16:00 16:15 17:00 17:15

13:30

Thermal Aspects of Rolling BREAK

BREAK

13:30

BREAK

14:30 14:45

Automatic Gauge Control Workshop Automatic Gauge Control BREAK

15:45 16:00

Automatic Gauge Control 17:00 17:15

BREAK Mechanics of Profile and Flatness BREAK

15:45 16:00

Thermal Aspects of Rolling Workshop Group Discussion and Questions

Aluminium Rolling Lubrication

14:30 14:45

Thermal Aspects of Rolling

Mechanics of Profile and Flatness

17:00 17:15

THURSDAY 29th 13:30 Start

Automatic Gauge Control

Group Discussion and Questions

FRIDAY 23rd 13:30 Start

FRIDAY 30th 13:30 Start 13:30

Profile Measurement and Control BREAK

14:30 14:45

Profile Measurement and Control

15:30 15:45

BREAK

Automatic Flatness Control BREAK Automatic Flatness Control Workshop BREAK Automatic Flatness Control

Profile Measurement and Control Workshop Group Discussion and Questions

Group Discussion and Questions

17:00 17:15

Group Discussion and Questions

Fig 3. Aluminium Rolling Technology Course timetable

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ROLLING 45

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A closer look at the aluminium welding wire industry The combination of Properzi hot-rolling and cold-rolling technology revolutionises the production of aluminium welding wire alloys. By Giuseppe E. Marcantoni*

Revolutionary technology and innovation are no stranger to Continuus-Properzi, S.p.A. In the late 1940s ContinuusProperzi pioneered the continuous casting and rolling of nonferrous wire rod. This disruptive technology totally altered the industrial process of wire rod production throughout the world. Since that time numerous patents and innovative technologies within the nonferrous industry have been brought to the market by Continuus-Properzi. This article will focus on the aluminium welding wire industry and how the Properzi (hot and cold) rolling technology has changed and improved the manner in which aluminium welding wire alloys are produced. Various industries, especially automotive and transportation, require more aluminium sheet, rod, and other aluminium parts to reduce the weight of anything that moves on roads, rails, rivers, etc. As these industries increase their usage of the light metal, this also drives the demand for aluminium welding wire alloys. Continuus-Properzi has been providing equipment for the continuous casting and rolling of aluminium wire rod for more than 70 years and the highest quality 4000 and 5000 series welding wire alloys (see table below) have been produced using Properzi technology and equipment for many decades. The Properzi methodology processes molten aluminium through a wheel & belt casting machine yielding a cast bar which is fed directly into an in-line hot-rolling process in order to produce wire rod. The most widely produced aluminium wire rod diameter is 9.5 mm, equivalent to 3/8”. The traditional production process for aluminium welding wire alloys consists of several independent operations. It starts from the procurement or production of 9.5 mm rod, followed by subsequent wire drawing to smaller diameters, to other intermediate operations such as

ALLOYS USED FOR Mig WIRES & Tig FILLER ROD Alloy Rod designation

Applications field

Purposes

Typical composition

4003

Automotive/Aerospace

Melting temp

Si 4.5-6.0

Recreation/Containers

& fluidity

Automotive

Melting temp & fluidity

Shipbuilding/Recreation

Work hardening

4047 5183 5356

Si 11.0-13.0 Mg 4.3 - 5.2

Transportation/Containers

Mn 0.5 - 1.0/Fe 0.4/Si 0.4

Automotive/Aerospace

Mg 4.5-5.5/Fe 0.4/Si 0.35

Shipbuilding/Defense

Work hardening

Recreation/Transportation/Containers 5554

Automotive/Shipbuilding/Transportation

Work hardening

5556

Containers

Work hardening

5654

Containers

Work hardening

normalization, drawing, intermediate annealing, shaving, and additional drawing, in varying order depending upon the different alloys and producers, and then on to finishing operations such as cutting and packaging. Since Properzi’s founding, their rolling technology was based on a three-roll concept in order to contain the spread of the metal under the rolling forces much better than a two-roll concept and this is especially important when temperature, type of alloy and/or roll surfaces change. Based on their vast experience in the continuous casting and hot-rolling arena, in 1980 Properzi finalized and introduced their Microrolling® technology. This concept made possible the replacement of conventional wire drawing operations for ‘hard-to-draw’ alloys. This greatly reduced, and in some cases even eliminated, the need for intermediate annealing steps. This allowed the aluminium welding wire producers to cold-roll from a 9.5mm diameter wire rod

Mg 5.0-5.5 Mg5.0-5.5 Mn 0.6-1/Fe 0.4/Si 0.25 Mg 5.0-5.5 Man 0.6 -1/Fe 0.4/Si 0.25

inlet size down to wires in the 2mm range while avoiding the intermediate annealing steps! The aluminium welding wire alloy manufactures around the world quickly recognized the potential benefits of the Properzi Microrolling® technology and began to adopt it. Today, all of the major aluminium welding wire manufacturers utilize the Properzi Microrolling® coldrolling mill in their production scheme. In the late 1990s, Giulio Properzi (President and CEO of ContinuusProperzi) proposed yet another innovative concept to the aluminium industry for the production of difficult aluminium mechanical alloys. This concept was driven by four major considerations: 1. Mechanical alloys are required in relatively small quantities when compared to electrical alloys 2. A small dedicated system to produce continuously cast wire instead of rod will facilitate savings in both CAPEX (Capital Expenditures) and OPEX (Operational Expenditures)

*General Manager, Properzi International Aluminium International Today

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3. A cast bar having a smaller cross section will render the production of mechanical alloys much easier 4. The alloy producer’s expense for intermediate annealing can be significantly reduced

The CCW Line at the Continuus-Properzi factory - 1997

A key point of this idea for a Continuous Cast Wire (CCW) Line was the Microrolling® machine’s ability to roll down to a diameter of 3.2mm directly from molten aluminium. Knowing that the market would be reluctant to leap into this new revolutionary concept, Properzi decided to invest in a prototype CCW Line in order to demonstrate it to the market. This prototype CCW Line was installed at the Continuus-Properzi factory in 1997 during the Wire Association’s International Technical Conference (ITC) that was held in Stresa, Italy. The operation of the CCW line was demonstrated to more than 110 of the conference attendees, mainly American and European, that opted to make the journey from Lake Maggiore to the Properzi factory located on the outskirts of Milan in Sordio, Italy. A fully operational CCW Line was presented to the attendees. The 1997 CCW version was equipped with: a 6 ton reverberatory furnace; a 1.5 tph casting machine; and a Microrolling® Mill that converted the 620mm2 cast bar into 3.20 mm wire with a maximum exit speed of 20 m/sec. It was evident from the first cast that having a smaller cast bar cross section was extremely beneficial in controlling the solidification parameters especially with alloys containing Mg in the range of 5% or Si in the range of 6 to 12%. In hindsight it is evident that the attendees, and therefore the market in general, did not realise the full potential

Partial view of a modern CCW Line with bar straightener, scalping machine and induction heater

May/June 2021

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Aluminium International Today

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WELCOME TO THE WORLD OF PRODUCTIVITY

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The future is now when it comes to furnace technology Manufacturing industries are already seeing the results of the ‘Furnace of the Future’ in reducing CO2 emissions and producing cleaner, more sustainable materials. But how can energy-intensive manufacturers work towards making this future a reality? Are we already seeing the benefits of adopting smarter and more sustainable technologies within furnaces? Could we be doing more? This online event will unite the glass, aluminium and steel sectors to discuss overcoming heat treatment challenges and present a collaborative approach to bring the Furnace of the Future to life.

www.furnaces-international.com

Topics will focus on: Industry 4.0 (the Furnace of the Future) Furnace Maintenance Heat Treatment Energy Efficiency Testing & Measurement Retrofitting Emerging Technologies Operations & Productivity

ONLINE EVENT 14-15 SEPTEMBER REGISTER TODAY

Alongside the two-day virtual conference, participants will also be invited to join live discussions and will have the opportunity to network with new industry contacts, arrange video meetings and exchange resources and information.

FROM THE PRODUCERS OF

IN ASSOCIATION WITH

ORGANISED BY

48 ROLLING

Tight coil of 6 mm diameter wire continuously cast on the CCW Line

of this innovative concept targeted for the production of mechanical alloys. After the inauguration, the Properzi team operated the CCW Line from time to time for more than two years conducting numerous tests on different mechanical and welding alloys. Despite its promotion through several technical papers and advertisements, as well as endorsements from the Italian Welding Association, the reaction of the market was virtually zero and the line remained idle for some years.

2.15 mm Wire being spooled at 25 m/sec

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This prompted Giulio Properzi to simply state, “Sometimes if you are too far ahead, you stand alone.” Bringing innovative technology to the market, before the market can understand and appreciate its advantages, is an occurrence that has repeated itself throughout ContinuusProperzi’s history. Never resting on their laurels, and firmly believing in the merits of the CCW concept, the Properzi organization decided to combine these two methods. In 2018 Properzi married the Microrolling® process conceived in the early 1980s with the CCW process that was developed in the late 1990s in order to significantly streamline the production of aluminium welding wire alloys and provide an advantageous alternative production method for these specialty alloys. As mentioned previously, the major aluminium welding wire producers throughout the world have already opted to replace the traditional rod breakdown process with Properzi Microrolling® in order to avoid the intermediate annealing steps. Now they have the ability to utilize the latest technology to even further optimize the aluminium welding wire production process. This revolutionary Properzi process utilises both the CCW technology and the Microrolling® technology. It starts by

melting ingots and preparing the alloy in a continuous or batch mode. The molten aluminium is fed to the modern CCW Line where it is continuously cast with a wheel & belt machine and the cast bar is directly hot-rolled through a special 2-stand roughing mill and an 8-stand finishing Microrolling® mill to produce 6mm wire/ rod. Between the casting machine and the rolling train, the modern CCW Lines are equipped with a rotary bar shear, a bar straightener, a bar scalping (milling) machine and a bar induction heater, items that were not present on the 1997 CCW Line prototype. Partial view of a modern CCW Line with bar straightener, scalping machine and induction heater The CCW Line exit diameter of 6 mm was selected for two reasons. First, the larger exit diameter reduces the exit speed thereby simplifying the continuous automatic coiling operation. Second, it facilitates the use of an almost identical 8-stand Microrolling® mill in the coldrolling operation. The 6mm diameter produced by the modern CCW Line is coiled with a double automatic take-up into standard 2-ton tight coils. Tight coil of 6mm diameter wire continuously cast on the CCW Line The first Microrolling® mill is an 8-stand hot-rolling mill that is the finishing mill within the CCW Line. The second Microrolling® mill is an almost identical 8-stand cold-rolling mill that replaces the traditional breakdown drawing machine. In this manner the two rolling mills enjoy commonality of parts with the only exception being the work rolls. The 6mm wire enters the Properzi coldrolling mill with about 20% elongation and exits at 25 m/sec with approximately 3% elongation and a diameter of 2.15mm. 2.15mm Wire being spooled at 25 m/sec After this, the only annealing operation of the entire process, if necessary, takes place before the final draw and any other required operations such as shaving, cutting, packaging, etc. This modern CCW integrated process is flexible, appropriately sized, energy efficient, and controllable from molten metal to the final product. It has been supplied to three different welding wire producers in China that are manufacturing technologically advanced products from raw metal to top quality aluminium welding wire alloys with full control of the process while obtaining consistent energy and process savings. Utilisation of the Properzi CCW Line in conjunction with the Microrolling® machine is the optimal process for highly specialised production plants making aluminium welding wires and mechanical alloys. � Aluminium International Today

28/04/2021 10:05:37

ROD REPAIR 49

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Focus on: Storvik ILRR In Line Rod Repair for automatic robotized repair on anode yokes. By Dag Sverre Sæsbøe*

Storviks automatic welding of anode stubs installed in Mosjøen

Storvik has served the aluminium industry from the onset in Norway and has contributed to the development

of this industry for more than 60 years. Based on our experience, expertise, and multidisciplinary approach we are today

proud of presenting the ILRR (In Line Rod Repair). Storvik has in close cooperation with

*Managing Director Storvik AS and Head of Sales and Marketing in Storvik Group Aluminium International Today

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May/June 2021

28/04/2021 10:16:50

RODDING

IN-LINE ROD REPAIR

ROD REPAIR

A typical layout in a 3D feasibility study performed by Storvik.

Robotic welding of anode studs

The recently installed automatic repair of anode yokes installed in Protech, Sunndalsøra. Protech is a daughter company of Storvik Group

FEATURES n n n n n

Cost-effective Reliable

Scalable

Industry 4.0

Low space requirements

BENEFITS n n n

Fewer rods and trolleys needed Increased rod efficiencies Redundancy

Industriveien 13, N-6600 Sunndalsøra Phone: +47 71 69 95 00 Email: storvik@storvik.no

www.storvik.no May/June 2021

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selected partners customised the robot concept for inline identification (Vision), cutting and welding of anode yokes (studs). The new anode conveyor line is an integrated solution in the rodding shop (factory). Yokes (studs) which need to be repaired are identified and guided in to the ILRR, while anode hangers inside the acceptance criteria will continue along the main conveyor line. As the quality of repair is high and reliable, we recognise the biggest achievement is reduced manual work and down-time, and improved HSE. By utilisation of the ILRR we have reduced a numerous of handling and man-hours involved. Hardware components in the concept is hanging conveyer, vision system, band saw, welding machines, welding- and handling robots, and a lathe machine (offline) for preparing of welding groove. The ILRR is proven technology since 2016 and is currently operating at an impressing overall efficiency in Mosjøen and in Sunndal. System integrator Before implementing an automatic process line for repair of anode studs it is required with a feasibility study. The study is performed in close interaction between Storvik and the customer and will identify and propose technical solutions. An evaluation of the interfaces and adaptation to the existing organisation is also an essential part of the feasibility study. Our complex ILRR is installed and operated by Storvik personnel, which ensures proper ownership, competence, maintenance and reliability which is needed for such a critical operation at the aluminium smelter. Customers of Storvik are typically top tier aluminium producers with the highest standards and most challenging criteria’s to amongst others consistency in quality of anode yokes as well as the capacity, reduced waste and logistics, efficiency and automation in operations with limited need for personnel and as little need as possible for maintenance and manual work. Storvik has the highest standards for its products and deliverables, where the ILRR is no exception, we put our honour always to deliver on agreed time and budget with the desired capacity, redundancy, and quality. �

Aluminium International Today

28/04/2021 10:16:55

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14/04/2021 08:34

52 HANDLING

www.aluminiumtoday.com

Combilifts are a highlight for HAI

Hammerer Aluminium Industries (HAI) employs a workforce of 1,600 at its eight sites in Europe, and the company’s activities include supplying high-tech aluminium profiles and finished components as well as employing highly efficient recycling processes. It is now using three multidirectional forklifts from the Irish manufacturer Combilift, which ensure the safer and more efficient handling of extrusion billets at the company‘s HQ in Ranshofen, Austria. The trucks have been in operation for about 6 months now, replacing the previous sideloaders, which, according to Christian Ertl, Group Manager of transport logistics casting “had not exactly impressed us with their track record of reliability.” Ertl and some of his team from HAI’s finishing and loading division visited a steel processing plant in another part of Austria where Combilifts had been in operation for some time to check out their capabilities and get the drivers‘ opinions. “We like to involve those who will actually operate the trucks in the decision making process”, said Ertl, “and after seeing them in action we all agreed that Combilift’s products fitted the bill perfectly. The advantages of the 4-way concept that combines front and side loading May/June 2021

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technology are significant compared to conventional forklifts. The ability to turn the wheels with just the touch of a button to change the direction of travel is of great benefit, particularly in the packing station, where space is pretty limited.” Two 14t capacity C14000 models and an 8t C8000 truck, all diesel powered, were chosen as the best solutions for the tough operational requirements at HAI. The 7500mm long and 1200mm deep bundles of billets, which can weigh up to 7000kg, need safe and efficient handling inside in the production area and packing station as well as stable transportation to the interim storage area outside. They also need to be able to cope with an intensive 4-shift schedule and clock up operational hours of around 3,000 a year per truck. Space is not only at a premium in the packing station but elsewhere on the premises, including the outdoor storage area, where the billets are stored on cantilever racking up to a height of 3m, as well as the HGV loading zone. To maximise the available space, a guided-aisle system was implemented between the racking, enabling operational aisle widths to be narrowed down to just 3620mm. Telescopic forks, which can reach across the whole of the trailer bed, were fitted

to the C14000 models to enable loading from just one side, once again enabling best use of space. One of Combilift’s acknowledged strengths is its ability to customise its products according to specific individual requirements, and this was the case at HAI too, to make the daily tasks of the drivers as straightforward as possible. Features included in HAI’s fleet include a reversing and fork camera, air conditioning, handsfree phone and an air-suspension comfort seat. The high cab position guarantees maximum safety as it offers a clear overview of the load, the forks and the direction of travel. Ertl sums up: “These robust and powerful trucks from Combilift now ensure an efficient and more cost effective operation. Thanks to the co-operation with the manufacturer as well as the excellent advice from Wiener Staplerund Fördertechnik, we were able to find a handling solution that meets all of our requirements.” �

Contact www.combilift.com www.hai-aluminium.com

Aluminium International Today

27/04/2021 12:59:58

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Photo: Getty/iStock - Azure-Dragon

Know the actual environmental impact of recycled aluminium Aluminium is an ideal material for the circular economy because of its recyclability. But not all recycling is equal. To understand if your recycled aluminium is better for the environment, you need to understand what kind of aluminium scrap the recycled aluminium is made from. Therefore, Hydro offers customers full transparency into the content and carbon footprint of our recycled aluminium products: Recycled aluminium made from disposed beverage cans or discarded car parts starts its second life. This material is called post-consumer scrap. The carbon footprint is close to zero. This is the greenest type of recycled aluminium. Recycled aluminium made from production waste is different. The waste is called pre-consumer scrap since it has not been used in a product before. It typically bears the carbon footprint from its original production.

Learn more at hydro.com/recycling