aluminium world journal 2013

TECHNOLOGY

2013 EditionGlobal Media Communication Ltd.

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3AWJ 2013

Foreword By Christopher Fitcher-Harris

Aluminium World Journal 2013 features editorials, case studies, company profiles, and product reviews.

The publication is divided by industry sector sections to ensure ease of navigation.

The information contained in each section provides readers with the tools to reduce operating costs, increase productivity, and increase the life cycle of technology.

This edition contains a special feature report produced by Siemens Metals Technologies entitled "The benchmark in aluminium rolling - Effective Project management brings a lifetime of benefit for aluminium producers".

I take this opportunity to thank the participating companies for providing Aluminium World Journal 2013 with editorial, company profiles, advertisements and corporate sponsorship.

Aluminium World Journal 2013 is available for you to read online, download, and in print format. Visit us online at: www.globalmediacommunication.com

If you should wish to discuss with me anything concerning the content of this edition, do not hesitate to contact me.

Hope you enjoy the read!

Christopher Fitcher-Harris

Managing Director

Managing Director Christopher Fitcher-Harris, Production Manager Sofia Henriksson Sales Manager Peter Jones Production Design: row1graphics

Published by: Global Media Communication Limited Telephone: +44 208 579 0594 E-mail: [email protected] Website:globalmediacommunication.com The opinions and views expressed in the editorial of content in this book are those of the authors alone and do not necessarily represent the views of any organisation with which they may be associated. Material in advertisements and promotional features may be considered to represent the views of the advertisers and promoters. The views and opinions expressed in this book do not necessarily express the views of the publisher. While every care has been taken in the preparation of the book, the publishers are not responsible for such opinions and views or for any inaccuracies in the articles or advertisements.

©2013 The entire contents of this publication are protected by copyright. Full details are available from the publishers. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior knowledge of the copyright owner.

Cover illustration: ABB Switzerland Ltd.

Aluminium World Journal 2013Global Media Communication Ltd.

ON-LINE DEFECT DETECTION,IDENTIFICATION AND REPORTING

For further information visit www.cognex.com/sisd email [email protected] or call:US +1 508 650 4141 Europe +49 721 66390China +86 21 63517377Japan +81 35977 5400

REAL TIME INSPECTION OF ALUMINIUM ENABLES FASTER PROCESS CORRECTION AND BETTER YIELD OPTIMIZATION.

Surface Vision

Surface Vision Ad A4.indd 1 09/10/2012 17:15

AWJ 2013

INDEX

Special Feature p. 7-14

EPC and Industry Projects p. 15-20

Bauxite Mining To Alumina p. 21-24

Primary Smelting and Processes p. 25-34

Anode Plant Technology p. 35-56

Materials Handling And Transportation p. 57-74

Company Profiles p. 75-85

Advertiser and Web Index p. 86

ON-LINE DEFECT DETECTION,IDENTIFICATION AND REPORTING

For further information visit www.cognex.com/sisd email [email protected] or call:US +1 508 650 4141 Europe +49 721 66390China +86 21 63517377Japan +81 35977 5400

REAL TIME INSPECTION OF ALUMINIUM ENABLES FASTER PROCESS CORRECTION AND BETTER YIELD OPTIMIZATION.

Surface Vision

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6

During the past five decades we have supplied hundreds of new and modernized mills setting the benchmark for producing quality strip in an efficient manner. The market is ever changing and demands highest yield and tolerances while minimizing environmental impact. Siemens VAI is at the forefront of this challenge.

As a total solution provider the Dynamic Shape Roll DSR© has been developed as a variable force distribution actuator, replacing a conventional solid back-up roll,Improving mill productivity and reducing operating costs.

The DSR© enables you to meet market challenges of today and the future. Your mill will produce a harder, wider and thinner product portfolio ensuring product flatness, increase your schedule flexibility, reduce material breakages and roll changes.

The Intelligent flatness control algorithm uses feedback from the shape roll to generate signals to vary the force distribution across strip width.

The DSR©’s performance is impressive; eliminating undesirable roll contact and stress peaks. The control range is considerably larger than 6hi and contoured roll

Answers for industry.

siemens-vai.com

Focus on Precision, Yield and Green

design mills. True dynamic control is achieved by fast response of the pads to changes in the force distribution reference.

DSR© Benefits:

Yield Savings – Achieves target flatness quicker and retains longer during tail out.

No warm-up coils required during mill start-up or width change.

Rolling passes reduced.

Rolling speed increased.

Productivity increased (product mix dependant).

Number of Back Up roll changes reduced.

Retrofitting of DSR© requires minimal downtime and recommissioning.

Be the leader in the field – with SIROLL ALU solutions fromSiemens VAI, a global supplier and your local partner.

Set the benchmark in Aluminum Rolling!

7AWJ 2013

SPECIAL FEATURE

Siemens Metals TechnologiesThe Benchmark In Aluminium Rolling p. 8-12Effective Project Management p. 13-14

During the past five decades we have supplied hundreds of new and modernized mills setting the benchmark for producing quality strip in an efficient manner. The market is ever changing and demands highest yield and tolerances while minimizing environmental impact. Siemens VAI is at the forefront of this challenge.

As a total solution provider the Dynamic Shape Roll DSR© has been developed as a variable force distribution actuator, replacing a conventional solid back-up roll,Improving mill productivity and reducing operating costs.

The DSR© enables you to meet market challenges of today and the future. Your mill will produce a harder, wider and thinner product portfolio ensuring product flatness, increase your schedule flexibility, reduce material breakages and roll changes.

The Intelligent flatness control algorithm uses feedback from the shape roll to generate signals to vary the force distribution across strip width.

The DSR©’s performance is impressive; eliminating undesirable roll contact and stress peaks. The control range is considerably larger than 6hi and contoured roll


siemens-vai.com

Focus on Precision, Yield and Green

design mills. True dynamic control is achieved by fast response of the pads to changes in the force distribution reference.

DSR© Benefits:

Yield Savings – Achieves target flatness quicker and retains longer during tail out.

No warm-up coils required during mill start-up or width change.

Rolling passes reduced.

Rolling speed increased.

Productivity increased (product mix dependant).

Number of Back Up roll changes reduced.

Retrofitting of DSR© requires minimal downtime and recommissioning.

Be the leader in the field – with SIROLL ALU solutions fromSiemens VAI, a global supplier and your local partner.

Set the benchmark in Aluminum Rolling!

8 GLOBAL ISSUES

siemens-vai.com

Focus on Precision, Yield and GreenSet the benchmark in Aluminum Rolling!


We know what we’re talking about when it comes to aluminum rolling.

During the past five decades we have supplied hundreds of new and modernized mills that set the benchmark for producing quality strip in an efficient manner. The market is ever changing and now demands highest yield and tolerances while minimizing environmental impact. Siemens VAI is at the forefront of this challenge.

On the basis of immense process know-how and engineering experience, Siemens VAI works with our customers to meet their targets for productivity, quality, yield and flexibility.

As a total solution provider, maximum mill performance is assured with the latest equipment design, advanced technological packages, sophisticated electrical, automation, environmental systems, and a

full range of vertically integrated supply packages. With specialized technologies for thickness, profile and flatness control, the strictest quality and tolerance demands are met for all downstream product requirements.

At every stage of a mill’s productive lifetime, we have the right solution to ensure that your mill performs at its peak level. Our portfolio includes:

New plants and mill modernizations

Complete equipment supply

Electrical and automation systems

Consultancy services and mill audits

Customized mill products

Worldwide, around-the-clock services

Be the leader in the field – with SIROLL ALU solutions from Siemens VAI, a global supplier but your local partner.

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9AWJ 2013

The Benchmark in Aluminium Rolling

Siemens Metals Technologies is a global leader in the Metals Industry, supplying the world’s metal producers and processors with world class equipment and services.

Metals Technologies (MT) in the UK is the global Centre of Competence (CoC) for aluminium and Rolling Mills with responsibility for the engineering, supply, installation and commissioning, and technological development and innovation on a worldwide scale.

Siemens MT was established in the United Kingdom 170 years ago and is made up of a merger of a number of companies, namely Loewy Robertson, Davy Corporation, Davy International, Kvaerner Metals and most recently Voest-Alpine Industrieanlagenbau (VAI).

The UK team is made up of over 260 highly qualified people with many years of experience based on a strong heritage dating back through the mergers and acquisitions mentioned above. With our sophisticated know-how and our deep experience in aluminium, ranging from hot rolling to the finished product, including cold rolling and foil mills, Siemens MT can meet both upstream and down-stream demands and build the mill that fits the client’s requirements.

• Our solution has everything to bring aluminium rolling mills up to speed. This includes:-

• The most powerful roll drives for higher throughput

• State of-the-art mechanical and hydraulic solutions to optimize performance and operational efficiency

• Online process models and neural networks will enable you to produce more accurately than ever before

• Proven automation solutions to maximize your plant’s end-to-end consistency

• Reliability and security for the future

Siemens MT is the only mill builder with in-house capabilities to bring together the mechanical and electrical technologies in one package.

Strategy

We use a wide range of specialised technologies such as SIROLL DSR® (Dynamic Shape Roll), SIROLL SmartCrown®, AGC, automatic profile and AFC flatness control along with in-house technological instrumentation to achieve highest product quality.

Key to the companies’ success is the Project Management and Quality Management systems which are used within Siemens MT. The systems are based on many years of experience gained from the application in numerous projects and are relevant for both small and larger projects. Project Management ensures for the customer, not only conformity with our quality standards but also that delivery and commissioning take place on schedule, while Siemens MT benefit from the cost and quality control.

Siemens MT sources equipment from the global market, whilst ensuring that our quality systems are adhered to by the suppliers. Equipment classed as Intellectual Property (IP) is made exclusively in our own workshops. These manufacturing centres are based in Montbrison, France, Shanghai, China and in Worcester, USA. All these specialised shops build the mills components and provide global support for the mill business.

Core Competence

Siemens MT supply a range of aluminium rolling mills for hot rolling, cold rolling and foil rolling in various roll configurations and for all strip widths.

The full range of cold rolling mills including breakdown mills, tandem mills with two, three, four or five stands and thin strip mills for light gauges including foil roughing are also available. The mill stands are of 4-high or 6-high design and provide the flexibility to cover the complete range of alloys over a wide gauge range. Strip widths are ranging up to 2,100 mm, and future expectations are of widths up to 3,000 mm.

Latest references include:-

• Three Single-stand foil mills for Shanghai Shenhou in 2006

• Single-stand cold rolling mill for Chinalco Henan in 2011

• Single-stand cold rolling mill for Chinalco South West Aluminium in 2011

• Three-stand hot finishing mill for Chinalco Ruimin in 2011

• Three-stand hot finishing mill addition for Novelis Korea in 2011

• Single-stand 4 metre wide plate mill for Aleris-Dingsheng in 2011

• Single-stand hot reversing mill for Chinalco Nela in 2012

In addition during the last 5 years we have supplied over 200 foil mill Technological Control Systems (TCS) for thickness and flatness control, over 50 system’s were supplied to Dingsheng Aluminium alone.

The Chinese market continues to grow and is a key market for Siemens MT; this is why Siemens MT has developed a range of foil mill configurations based on a standard design for each mill providing economical solutions, fast delivery and minimised production start-up.

10

Key Technologies

SIROLL Dynamic Shape Roll (DSR®)

The SIROLL DSR® has its origins back in the paper industry with the NIPCO roll from Sulzer Escher Wyss. Paper mills have always tended to be much wider than mills in the metals industry and problems of stability occur at widths above 1,800mm. The SIROLL DSR® was developed to give improved control under these conditions. Siemens MT have now taken this technology and extended it into the metals rolling field.

SIROLL DSR® replaces the top solid backup roll usually employed in 4-high stands. It provides improved flatness control, especially in the critical areas at the head and tail ends of the strip. This allows for significant improvements in overall coil yield. Currently the company considers the SIROLL DSR® to be the only truly online dynamic actuator that can enable symmetric and asymmetric changes to the roll gap profile during ongoing production.

Operational benefits of the SIROLL DSR® include:-

• Head and Tail Flatness – improved yield by achieving flatness guarantees quicker than conventional roll

• Overall Flatness – flatness guarantees of less than 3 I units have been achieved with the SIROLL DSR®

• Width Changes - with the SIROLL DSR® it is possible to switch rolling widths by considerable amounts (in excess of 600mm) and to still achieve excellent flatness without any warm-up (transition) coils

• Cold Starts - these are particularly impressive with a SIROLL DSR®, body of coil flatness of 8 I units

after just over 90 metres rolled have been achieved after a prolonged stop-page of sixteen hours on 0.447mm strip at 1,870mm strip width

Based on a review of a typical new large cold mill producing around 100,000 tonnes per annum Siemens MT have estimated potential benefits in the order of millions of dollars per year. This of course does depend on the product mix. The savings are approximately evenly divided between the benefits from improvements to the head and tail performance and the ability to minimise out of specification material at width changes.

SIROLL DSR® Sectional Diagram

SPECIAL FEATURE

Cold Aluminium DSR® Mill at Chinalco Henan

11AWJ 2013

SIROLL Air Bearing Shapemeter Roll Section

SIROLL Air Bearing Shapemeter Roll

With over 500 references worldwide the SIROLL Air Bearing Shapemeter roll is Siemens MT principle technology for the on-line measurement of flatness for both the Aluminium and Steel sheet and foil applications.

The SIROLL Air Bearing Shapemeter roll comprises a series of hardened, precision ground rotors, supported by air film bearings on a stationary stainless steel arbor. This design results in low inertia rotating elements with negligible frictional resistance usually inherent in air bearings, thereby eliminating the need for helper drives. Connected by a detachable pneumatic umbilical cord the electronics are mounted remotely from the roll for easy access and protection from harsh mill environments.

An array of jets supplies each rotor with air from a common plenum chamber in the centre of the arbor. The differential pressure measured between the top and bottom of the inside of each bearing is proportional to the load applied to the rotor. Hence, the tension is calculated at each rotor position across the width of the strip to provide the tension profile or ‘shape’ of the rolled strip.

Each differential pressure output is measured by means of a high integrity pneumatic transducer, which is remotely located in the transducer

housing attached to the end of the shapemeter arbor. Each measuring channel has a single moving part, the rotor. All other parts are stationary, including the measurement and signal transfer elements. The signal outputs provide continuous readings that are independent of mill speed allowing a fast signal response and high accuracy even at low rolling speeds.

Key benefits of the SIROLL Air Bearing Shapemeter include:-

• Lower Cost Solution – Solid type rolls more expensive

• Very Low Inertia Rotors – No drive system required

• Very Compact Design – Greater installation flexibility

• Simple Design – Low maintenance, can be serviced on site by customer

• No Electric's in Roll – Pressure Transducers etc mounted in remote Transducer box

• Signal Output – Continuous & independent of mill speed

SIROLL Integral Solenoid Valve Sprays (ISV)

The SIROLL ISV Sprays is one of the metal industries leading spray valves, with over 300 references worldwide the SIROLL ISV Sprays have been supplied to the rolling industry for over 25 years. Proven extensively in both steel and aluminium industries, the SIROLL ISV Sprays are suitable for all mill types, from hot mills through to aluminium foil mills.

SIROLL ISV Sprays

Chinalco Southwest Aluminium Mill

12 SPECIAL FEATURE

The SIROLL ISV Sprays system is designed to apply zone cooling and lubrication to the work rolls. The system removes residual flatness errors and controls the bulk temperature of the mill during the rolling process. Temperature control is achieved by modulating the coolant through individual ISV valves thereby controlling the thermal profile of the work rolls. Nozzle configurations are specifically designed, using advanced thermal modelling, to optimise the spray patterns and coolant flow rates to suit the requirements of the process.

Schneider® Coolant Filtration

Schneider® Coolant Filtration

Coolant filtration is an essential element in the rolling and forming of all metals. Since 2004 Siemens MT has supplied the Schneider® Coolant Filtration system for aluminium hot and cold mills, steel, stainless steel, copper/brass mills and for 2-piece can making plants.

The market leader in the design, supply and operation of mineral oil and emulsion coolant filtration systems, Schneider Filtration ‘know-how’ from Siemens MT will improve performance and product quality throughout the rolling and forming process.

The very high levels of filtration achieved for both mineral oils and emulsions when using the Schneider® Coolant Filtration system maintains the coolant in ‘as-designed’ condition. The system extends the life of the coolant providing an exceptional sheet surface and foil quality. Specific system design features and auxiliary components are unique to the technology. Today’s modern semi-synthetic coolants require a different approach to coolant handling and filtration. Traditional methods do not meet the new demands for cleaner low smut sheets and for the conditioning of the emulsion to keep the coolant to its original design specification. Filtration to and below the oil drop-

By doing this, the optimal thermal performance may be achieved for each and every application regardless of the rolling duty or individual pass schedules.

As a complement to the SIROLL ISV Sprays and to minimise shape errors at the strip edge, Siemens MT also offer an integrated Hot Edge Spray System to spray hot coolant outboard of the strip edge to reduce work roll thermal gradients.

Key benefits of the SIROLL ISV Sprays include:-

• Easy Maintenance

• Universal Valve for all Mill Types

• Robust Design

• Small Installation Envelope

• High Reliability

• Advanced Thermal Modelling

• Stainless Steel Valve

let size is easily accomplished with specially designed filter cloth media for depth filtration using multiple layers of different media.

Over 1400 Schneider® Coolant Filtration systems are being used today to roll, Aluminium, Steel, Stainless Steel, Copper/Brass, Titanium, Zinc and similar metals. The Schneider® system has become the industry standard in the rolling and can industry.

Key benefits of the Schneider® Coolant Filtration include:-

• Improved Filtration Performance – less than 10μm

• Improved Product Quality

• Patented Green Filter Media - safe to handle, no dust hazard

• Reduced Waste Streams - zero waste available

• Eliminates Coolant Dumps

• Low Operating Costs

• Improved Process Performance – increased roll life

13AWJ 2013

Effective project management brings a lifetime of benefits for aluminium producers

Author; Albert Renshaw – Senior Project Manager and PM@Siemens UK Champion (RPP), Siemens VAI Metals Technologies

For aluminium producers, when building or modernising a production line, the investment amount required is not the only issue to be considered. Any delays to a modernisation or the belated commissioning of a new line means loss of production and financial revenue. Therefore, choosing the right partner for a project is as important as choosing the right technology. A partner capable of providing effective management from conception to production ensures that an aluminium plant is built on-time and according to specification. This is the basis for maximising value. Professional project management provided on a global stage is a core competence of Siemens and a vital success factor for our customers.

Project management is the process by which projects are defined, planned, monitored, controlled and delivered such that the agreed benefits are

achieved. In general, more than 50% of Siemens global sales is project-related. In 2001, Siemens embarked upon the global project management programme “PM@Siemens” to support the continuous and sustainable improvement of project management processes in all of its business activities worldwide. The aim was to establish best practice through the application of knowledge, skills, tools and techniques in order to ensure business excellence. Siemens employs more than 15,000 project managers, all working in accordance with the company values of “excellence, innovative and responsible.”

The philosophy is simple; there are clearly defined roles and responsibilities for all those involved in a project. The programme ensures that state-of-the-art processes, methodologies and tools are applied in ways appropriate to the complexity of the tasks. By undertaking both comprehensive training and an internal certification process, Siemens safeguards that its project managers are trained and qualified such that they are able to manage a project

On-Going Service & Support

Service to existing aluminium producers and new customers is critical to capture new business, customers continue to request the following studies:-

• Plant and Mill Studies – studies to investigate ways to increase plant productivity or change specific mill or product parameters which can help clients choose the most cost effective investment route for future plant modernisation

• Mill Performance Optimisation Studies – advice from rolling

process experts on how to improve and optimise mill productivity within the constraints of the existing equipment

• Mill Alignment and Condition Studies – measurement and analysis of the status of existing equipment with corresponding report and recommendations

• Spares, Service and Training Support – existing Siemens clients can be offered complete product life cycle services including spares, product training and site support from Siemens service engineers

Siemens MT engineering offers the full range of studies as described above and has a number of technological tools and instruments available to provide complete plant analysis, fault identification, FE analysis, and sophisticated reporting.

Author: G.Garfitt, BEng (Hons), MIET, CEng, MBASales Manager Plate and Aluminium MillsContact Information: Siemens plc Metals TechnologiesE- mail: [email protected]

professionally. Siemens project managers are empowered to do the right things in the right way and at the right time to accomplish the project goals. As a global partner, this means globally uniform procedures that are always executed in a systematic and professional manner by appropriately trained and qualified staff.

As a result of the PM@Siemens programme, Siemens was the first corporate company to have its project management programme accredited by the Association for Project Management (APM), itself one of the largest professional bodies of its kind in Europe.

The need to find the right partner for a project has already been emphasised. Siemens VAI Metals Technologies is a life-cycle partner for the metals industry. Its UK headquarters, located in Sheffield, incorporates the plate and aluminium rolling mills businesses, including the associated engineering and technology. Mark Chatterton, Director of the Siemens VAI Aluminium Business, sees many advantages in leveraging the engineering and project

14 SPECIAL FEATURE

management experience gained by both the Plate and Aluminium Business areas during the recent boom years in the metals market. “Siemens global project management experience is one of our core strengths, which differentiates us from our competitors. The company is driven to ensure that our project management skills are ‘best practice.’ As part of the company-wide, global project management programme, both plate mill and aluminium mill project teams have demonstrated these skills through the completion of many complex metallurgical infrastructure projects during the last fve years”.

These are exciting times for the Siemens VAI Aluminium Business, as a number of high-profile projects have recently been commissioned and put into full operation. The following examples show the typical breadth and complexity of projects delivered by the Siemens VAI Aluminium group:

This project comprises the supply of a single-stand aluminium rolling mill for Aleris Dingsheng Aluminium (Zhenjiang) Co. Ltd in Jiangsu Province, China. The rolling mill is designed to produce 250,000 tons per annum of heat-treated and non-heat-treated sheets and plates in widths of up to 4.1 meters. It is the first aluminium plate mill ever to be implemented by Siemens. Commissioning was completed in early 2013. The Siemens supply scope included mechanical and electrical equipment for the four-high rolling stand, a hydraulic shear and the roller tables for the new rolling mill.

New 3-stand aluminium finishing mill for Novelis Korea Ltd.

For this project a new three-stand finishing line was added to the existing rolling mill that was originally supplied by Siemens in 1993. The project boosted capacity and enables future production of high-grade aluminum strip for the automobile and beverage can industries. Siemens supplied the mechanical and electrical equipment for this tandem rolling mill, including a coiler and a coil-handling system. Lightweight cropping shears are installed in the entry section of the finishing line. The first coil was rolled in June 2013. The extended hot rolling mill will greatly increase annual capacity and will be capable of rolling strip up to 2,250 millimeters wide with a thickness spectrum from 1.8 to 6 millimeters.

Novelis Korea Ltd. is a subsidiary of Novelis Inc. based in Atlanta, Georgia, USA, a leading producer of aluminum and aluminum products. Novelis Inc. operates around 30 production facilities worldwide. The company is the global leader for rolled aluminum products and in aluminum recycling.

Recently commissioned projects in China include the 1+4 hot mill at Chinalco Ruimin, the 1+1 hot mill at Chinalco North East Light Aluminium, the cold mill with Dynamic Shape Rolls (DSR) at Henan Zhongfu Aluminium, and the cold mill with DSR at Chinalco Southwest in Chongqing, China.

These projects are currently setting the benchmarks for aluminum rolling

plants and demonstrate the benefits to be gained from a partner who can offer excellence in project management across all sectors of the industry.

Contact Information:

Siemens plcE-mail: [email protected]

Follow us on Twitter at: www.twitter.com/siemensuknews

The Siemens Industry Sector (Erlangen, Germany) is the world's leading supplier of innovative and environmentally friendly products and solutions for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the Sector enhances its customers' productivity, efficiency, and flexibility.

With a global workforce of more than 100,000 employees, the Industry Sector comprises the Divisions Industry Automation, Drive Technologies and Customer Services as well as the Business Unit Metals Technologies.

For more information, visit http://www.siemens.com/industry

Aleris Aluminium Plate Mill

Novelis

15AWJ 2013

EPC AND INDUSTRY PROJECTS

ABB SwitzerlandRio Tinto Alcan ISAL Smelter in Iceland Expansion Project p. 16-20

16 EPC AND INDUSTRY PROJECTS

Rio Tinto Alcan ISAL Smelter in Iceland Expansion Project

Introduction

The power intensive industry, which is characterised here as manufacturersneeding more than 7 MWh/t of theiroutput product, is highly dependent on the technological development of the manufacturing companies in the areas of products conveying, transforming, switching and controlling power at medium and high voltages.

It is of mutual benefit to these companies to cooperate for continuousimprovements of quality and efficiency of their products and processes. For Rio Tinto Alcan (RTA), HSE (Health-Safety-Environment) aspects of their equipment and production processesare paramount in their evaluationfor construction and operationpotential.

The engineering and production technique of ABB in the field of SF6 insulated switchgear, has presently reached such a level that smelters

with high HSE-demands combined with high demands of availabilityand reliability of equipment, cantake confidence in choosing medium voltage switchgear.

The specific properties of SF6 are further outlined below.

Electrical Properties

The excellent dielectric properties of SF6 are attributable to the electronegative character of its molecule. It has a pronounced tendency to capture free electrons forming heavy ions with low mobility, making the formation of electron avalanches very unlikely. The dielectricstrength of SF6 is about 2,5 times higher than that of atmospheric air under the same conditions, and this leads to space demand of only 1/10th of conventional air insulated switchgear. This fact is decisive for

economical considerations in many cases for voltage levels of 33 kV and higher.

Chemical Properties

SF6 can be heated to 500°C without decomposition in the absence of catalytic metals. SF6 is non-flammable. Therefore, the risk of ignition caused by an SF6 switchgear malfunction is practically zero, as well as the risk of damage caused by an external fire is as limited as possible. The fault current interruption capability of SF6 is excellent. In its pure state, SF6 is nontoxic, and this is regularly confirmed on new gas prior to delivery, by placing mice in a gas mixture of 80 % SF6 and 20% oxygen for a period of 24 hours (biological test recommended by IEC 376).

220kV AIS Footprint

17AWJ 2013

Operation and Maintenance

The temperature within an arc in the interruption chamber can be 15 000K. However, only minor decomposition remnants are present after each interruption. CIGRE WG 23.10 is working on an SF6 recycling guide, covering purity criteria for SF6 SWG. Criteria for handling of SF6 are based on IEC 376 Standards for safety of personnel and environment.

These factors contribute in minimizing emissions to the atmosphere. The normal leakage rate of HV Switchgear can be expected to be 0,1 % - 0,5 % per year.

Only authorised personnel are entitled to work with SF6 in Iceland and other EEA (European Economic Area – an outer Layer of the EU) countries, as mandated by an EU directive. Two electricians of our substation staff have passed through tests after theoretical and practical training of SF6 Gas Treatment with ABB nearMannheim in Germany.

RTA ISAL have acquired special equipment which is dedicated for the sampling, testing, emptying and refilling purposes.

RTA ISAL keeps track of its mass of gas by annually weighing the reserve gas and by having SF6 gas detectors in the switchgear room and in the cable cellar connected to the alarm system of the substation. The pressure gauges of each gas compartment are read off once a week. They are also equipped with a warning and alarm/trip level.

Environmental Aspects

SF6 does not contribute significantly to stratospheric ozone depletion, as it contains no chlorine, which is the main agent in ozone catalysis, nor to the Greenhouse effect, because the quantities present in the atmosphere are very small.

SF6 has infrared absorption characteristics and is considered a minuscule Greenhouse gas, due to its very long lifetime in the atmosphere. It's contribution to global warming however is very small, due to the extremely low concentration of SF6 in the atmosphere.

Assessment on Engineering:

The experience of most, if not all, users of SF6 switchgear, for a wide range of operating conditions, is that this technology has brought advantages in performance, size, weight, global costs and reliability.

However, for this endeavour to be implemented, it is necessary to perform a rigid risk analysis. This is carried out jointly by knowledgeable consultants with experience on operation, the operators and maintenance staff of the owner, and the manufacturer. The findings of such risk analysis and an SQRA (Semi Quantitative Risk Analysis) shall form the basis for the engineering of the switchgear.

The modern SF6 Switchgear, as for instance manufactured by ABB in Germany, is an extremely safe equipment against Arc Flash. In spite of this, the standard policy of RTA ISAL is to control it remotely from the control rooms.

Switchgear Room:

The IPU project (ISAL Production Upgrade) needed space for the installation of 13 bays of 60 kV Circuit Breakers on double busbar. Due to the limited space available near the seaside, accommodating an air insulated switchgear would not have been possible without costly landfill. The gas-insulated switchgear (GIS) technology offered a feasible solution on the available land. It was therefore decided to construct a concrete building beside the two 220/60 kV, 200 MVA, bays for the Step-down transformers feeding each half of both 60 kV busbars. The link from the

ABB’s latest development in GIS has been to reduce the overall footprint drastically

Out of the total contribution of allagents, the contribution of SF6 (lessthan one part in ten thousand, 0,1promille) is negligible.

secondary of these Step-downs is an SF6 insulated busbar.

18 EPC AND INDUSTRY PROJECTS

degree of precision in the civil part and in installation of transformers and switchgear. Avoiding cable connection here, offers the possibility of undistorted condition analysis of the transformers among otherbenefts.

On the GIS, the local manoeuvring cubicles have indicators for the position of the respective switches.However, for safety reasons, normally the manoeuvring of the switches takes place at the substation’s SCADA system, or in one of the two new Control Rooms constructed by IPU.

The GIS-room is fitted with an overhead crane. This was integrated with the installation of the switchgear, and can be utilized in repair of the switchgear if required.

The GIS is not particularly maintenancedemanding, but ISAL intends toincorporate it in its switchgear maintenance scheme, recording the pattern of the control circuit of the trip coils, the pattern of the main current under the interruption period and to record the length of the total interruption period.

Control System

ISAL‘s main substation is supervised by an Allen-Bradley Control Logix controller, SuperMaster, that monitors the status of high voltage and auxiliary equipment, interfaces with Landsnet, the national grid operator, and controls transformer cooling, filter banks and collects usage data (energy, water consumption, etc.). Landsnet can enforce automatic curtailment of plant load remotely from their National Control Centre. The required load reduction is divided among the potlines and adjusted for plant power variations by the SuperMaster.

The new high voltage (HV) equipmenttransformers, 220kV air-insulated switchgear (AIS) and 60kV gas-insulated switchgear (GIS) are controlled and supervised by ABB Relian protective relays. A communication gateway, ABB COM600, passes information between the protective relays (status, process values, commands, etc.) and SuperMaster, as well as the InTouchSCADA system. In case of failure of the plant‘s SCADA system, the COM600 can be used for supervision and control of the HV equipment.

Each of the potlines is controlled,

protected and supervised by its respective potline current controller. PL1 and PL2 are controlled by state ofthe art A-B Control Logix controllers and PL3 by an ABB Controller (PSR). The existing diode rectifer units of PL1 and PL2 are directly controlled by their potline controllers, but rectifier units of potline 3 are each controlled by anABB PSR. In case of a potline master controller failure, all rectifier units can be operated manually in stand-alone mode.

The new rectifier units are each controlled by a specialized ABB AC800 PEC rectifier controller. The new units fulfill the same requirement, as the existing ones, of being able to provide current to their potline in the absence of a potline controller, in a stand-alone mode.

Communications:

As the IPU project was one of integrating new equipment with existing equipment, several communication paths had to be developed.

• SuperMaster / COM600 communicate through a serial link using the IEC 60870- 5-101 protocol. A ProSoft module for the Control Logix platform is used

This technique demanded a high

19AWJ 2013

and software was developed to pass information and commands back and forth.

• InTouch SCADA / COM600 as well as Relian / COM600 communicate over Ethernet using the IEC 61850-8-1 protocol. Paths 1) and 2) are completely independent, allowing the SuperMaster to supervise operation and to generate redundant alarms/ warnings in case of break down of COM600 / SCADA communications.

• SuperMaster / PML power monitoring devices ION 7600 communicate through an RS-485 link using the Modbus RTU protocol. A ProSoft module for the Control Logix platform is used and software was developed to collect data from the intelligent power meters. Supervision and redundant control of plant power transformer OLTC voltage regulators (21 kV) is also done via a Modbus link.

• InTouch SCADA / PML power monitoring devices communicate over Ethernet. A proprietary Schneider Electric (ex. Power Measurement Limited of Canada) ION Enterprise system collects detailed data from the ION 7600 meters, transients, sag/swell, power quality and historical data into a MS SQL database.

• Potline Controllers PL1 and PL2 / AC 800 PEC rectifier controllers communicate over Ethernet using the EtherNet/IP protocol. The interface on the PEC side is an Anybus module developed by HMS Industrial Networks. As the EtherNet/IP Anybus module‘s implementation allows only point to point communication, gateways were required for the swing units

S1 and S2, as they can be connected to any potline and therefore have to be able to communicate with all the potline controllers. The seamless integration of the PEC controllers of the rectifier units makes them appear as Allen-Bradley equipment to the rest of the world (SCADA, MES, potline controllers, etc.)

• Potline Controller PL3 PSR / AC 800 PEC rectifier controllers S1 and S2 communicate over an ABB proprietary PowerLink using an ABB PSR-PSR protocol.

• The four AC 800 PEC controllers communicate with each other through a dedicated redundant PowerLink.

In Conclusion

As demonstrated by the Rio TintoAlcan Isal Smelter Production Upgrade project, GIS can be integrated into existing facilities to support expansion and power supply for smelters with high energy and health and

safety requirements. SF6 insulated switchgear is an enviromentally friendly and safe technology, with excellent operational capacities.

An upgrade can be fully tailored through engineering solutions to work with, and around, existing technologies, even where space restrictions may need to be considered.

Futhermore, the communication and control systems are designed to integrate seamlessly with existing ones, to provide flexibility and economical advantages, while securing optimal performance.

Authors: Bjarni Jonsson, RTA ISALLeader of the Electrical Services,Haflidi Loftsson, Staki ehfChief Engineer and Max Wiestner, Head of the Aluminium business within ABB

20 SURFACE INSPECTION

ABB’s history of powering primary aluminium plants started 45 years ago. Since then, we have supplied complete electrification solutions and substations to more than 60 aluminium smelters worldwide. The modernization of an existing plant to the latest standards and production and efficiency levels – performed while it is still in operation – requires a different set of skills and competencies than building a green-field plant. ABB has in-depth knowledge of the aluminium production process and the experience necessary to execute complex projects – always with the objective to keep your production running day and night. For more information, visit us at www.abb.com/aluminium

Keeping your production running day and night?

Certainly.

Global Product Group Aluminium5405 Baden 5 Dättwil, [email protected]

21AWJ 2013

ABB’s history of powering primary aluminium plants started 45 years ago. Since then, we have supplied complete electrification solutions and substations to more than 60 aluminium smelters worldwide. The modernization of an existing plant to the latest standards and production and efficiency levels – performed while it is still in operation – requires a different set of skills and competencies than building a green-field plant. ABB has in-depth knowledge of the aluminium production process and the experience necessary to execute complex projects – always with the objective to keep your production running day and night. For more information, visit us at www.abb.com/aluminium

Keeping your production running day and night?

Certainly.

Global Product Group Aluminium5405 Baden 5 Dättwil, [email protected]

BAUXITE MINING TO ALUMINA

UC Rusal

About UC Rusal p. 22 Recycling Red Mud p. 23-24

22

About UC RUSAL

UC RUSAL is a leading, global producer of primary aluminium and alloys with a particular focus on the production and sale of value-added products and one of the world's major producers of alumina.

The company’s current capacity means it is able to produce 4.7 million tonnes of aluminium, 11.5 million tonnes of alumina and 80 thousand tonnes of foil per annum. In 2012 RUSAL accounted for approximately 9% of global production of aluminium and 8% of alumina.

RUSAL operates in 19 countries on 5 continents. The company employs 72,000 people across the globe. RUSAL’s assets include 15 aluminium smelters, 12 alumina refineries, 8 bauxite mines, 3 aluminium powder plants, 3 silicon factories, 3 secondary aluminium plants, 4 foil mills, 2 cryolite and 2 cathode plants.

Within its upstream business, UC RUSAL is vertically integrated to a high degree, having secured substantial supplies of bauxite and alumina production capacity.

The Company’s core smelters, located in Siberia, Russia, benefit from access to stranded low-cost hydro generated electricity enabling it to be a low-cost producer of aluminium, with its principal Siberian facilities in close proximity to important European and Asian markets.

The Company’s key sales markets are Europe, Russia and the CIS countries, North America, South-East Asia, Japan and Korea. The major end users consist of over 700 companies representing transport, construction and package industries.

RUSAL has a strong growth potential – around 1 million tonnes of attributable aluminium capacity are currently under construction (equivalent to 25% of the current Company’s production volume):

- The BEMO Project, which involves the construction of the 3,000 megawatt BEMO HPP and BEMO aluminium smelter in the Krasnoyarsk region of Russia with a design capacity of 588 thousand tonnes of aluminium per annum;

- The Taishet aluminium smelter in the Irkutsk region of Russia has a design capacity of 750 thousand tonnes of aluminium per annum.

The company was founded in 2000 and, following its merger with SUAL and the alumina assets of Glencore, became the global aluminium industry leader in 2007.

RUSAL has a 27.8% interest in Norilsk Nickel, the world’s largest producer of nickel and palladium and one of the largest producers of platinum and copper.

Together with Kazakhstan’s National Welfare fund “Samruk-Kazyna” RUSAL is developing the Ekibastuz coalfield in Central Asia.

RUSAL is currently focusing on strengthening its competitive advantages, including low production cost, considerable raw material base, proprietary R&D capabilities and proximity to key markets. RUSAL owns proprietary smelting technologies (RA-300, RA-400 and RA-500) and is developing new ones, including a revolutionary inert anode technology.

RUSAL’s ordinary shares are listed on The Stock Exchange of Hong Kong Limited (Stock code: 486). Global depositary shares representing UC RUSAL’s ordinary shares are listed on the professional board of NYSE Euronext Paris (RUSAL / RUAL). Russian depositary receipts representing RUSAL’s ordinary shares are listed on the Moscow Exchange (RUALR /RUALRS ). RUSAL's shareholders are En+ (48.13%), ONEXIM Group (17.02%), SUAL's shareholders (15.80%), Glencore's subsidiary Amokenga Holdings (8.75%) and RUSAL's management. There is a 10.03% free-float.

Official website: www.rusal.com

UC RUSAL is a leading global aluminium producer.


23AWJ 2013

Recycling red mud

Annual world aluminium production is expected to break the 50,000,000 tonnes barrier this year. Making one tonne of aluminium requires about two tonnes of alumina. The production of two tonnes of alumina creates from two up to four tonnes of red mud or bauxite residue, presently waste from the Bayer process and a potentially valuable resource.

The total amount of bauxite residue produced in the world annually is estimated at around 200 million tonnes. Red mud is a mineral residue left after the extraction of alumina from bauxite in the course of the Bayer Process, the principal industrial method of processing bauxite ores into alumina.

Bauxite is one of the most complex industrial ores, containing almost all elements of the periodic table in different quantities with alumina being the predominant component (making some 30 to 60% mass of all ore components). Other major oxides

With todays technology, alumina and sometimes gallium are the only commercial products being extracted from bauxite ores.

constituting industrial bauxites are Fe2O3 (from 5 to 25% mass, SiO2 from 1 to 9 %, TiO2 from 1 to 7 %). Like most ores and soils, bauxite can also contain trace quantities of metals such as beryllium, cadmium, chromium, lead, manganese, arsenic, mercury, nickel and naturally occurring radioactive materials. To achieve extraction of the main components, more advanced technologies are to be evolved.

With today’s technology, alumina and sometimes gallium are the only commercial products being extracted from bauxite ores. Correspondingly, bauxite residue is primarily composed of the insoluble in the alkaline Bayer liquors fraction of the bauxite ore, and some Ca and Na aluminosilicates formed in the process as secondary reactions.

At present, the amount of bauxite residue being processed is limited. Alumina production waste is mainly disposed of in special facilities known as bauxe residue disposal areas (BRDAs). Due to the Bayer process, red mud has residual alkalinity. The pH level of the

residue is generally up to 13 or higher in some cases, due to the presence of alkaline sodium compounds, such as sodium hydroxide. Because of the very small sizes of bauxite residue particles (less than 100 microns) it can be easily carried by wind over fairly long distances from BRDAs.

To prevent the red mud from being carried out from BRDAs and causing harm to the environment or people, different methods are being used such as construction of new BRDAs with special membranes and protective layers, dry disposal, 'sloped deposition' etc. With regards to RUSAL, the company pays very special attention to the environmental safety at all of its operations and constantly monitors the situation at each of its BRDAs.

Treatment methods include reducing pH by carbonation, washing with large quantities of seawater adding gypsum, other amendments such as bitterns, (all of which replace sodium with more favourable elements such as calcium and magnesium) as well as increasing

24

Chinese national governments. For instance, RUSAL's recycling project was supported by the Ministry of Science as a next-generation technology. RUSAL's involvement in the red mud recycling project is one of the main focuses of the company in the sphere of environmental stewardship. RUSAL’s Engineering and Technology Centre is the project's engine, which is supported by a think-tank, consisting of major Russian technology andengineering partners.

The Chinese government has set a target of recycling 10% of all of its red mud by 2015, and our Chinese colleagues from Chalco have already introduced several solutions taken from the iron and rare-earth metals extraction industry, to use the residue for the steel and concrete industry. The recent memorandum between UC RUSAL and Chalco foresees joint R&D projects, and we hope that together we can find ways to solve the red mud problem.

At present, the recycling of alumina production waste is a global challenge. The maximum recycling rate is about 30% for an individual plant. Worldwide bauxite residue processing does not exceed 5 million tonnes per year, which means that less than 1/40th of the amount produced is currently recycled. The industry targets regarding the red mud problem are quite ambitious. The International Aluminium Institute predicts that at least 25% of all red mud will be recycled by 2025. This means that a comprehensive technology for complete bauxite residue processing to marketable value-added products is required to be developed.

Bauxite is one of the most complex industrial ores, containing almost all elements of the periodic table.

organic matter content by mixing in organic waste or establishing grass pasture to initiate the nutrient cycle. This is the case of Queensland alumina refinery (QAL) in Australia (RUSAL owns a 20% stake in the refinery), where red mud is neutralized with seawater.

One way or another, the major problem is that there is no established bauxite residue processing technology that would be able to be applied at all the alumina refineries in the world because the bauxite composition (depending on the deposit) differs greatly. Finding a way to utilize the red mud in other industries, instead of disposing it in BRDAs, could develop as the best solution moving forward.

Today bauxite residue can be used in the steel industry as an iron-containing raw material, in cement production, road construction as well as in agriculture. A part of the bauxite residue is used as an absorbent of industrial gas, to treat industrial and municipal wastewater, as a reductant for soil, absorbent of heavy metals

and other harmful substances, as a coagulant, pigment, catalyst and ceramic.

RUSAL, which is one of the world’s largest alumina producers, is now building a pilot recycling plant at the Ural aluminium smelter (UAZ), Russia with an annual capacity of 40,000 tonnes looking to expand it up to 200,000 tpa. According to our analysis, the demand for red mud and its byproducts stands at 3 million tonnes per annum from Russian enterprises only, which can easily generate a return on planned investments. The main consumers of the plant in Russia will be the iron and steel industry and the construction sector.

Following the launch of this facility, UAZ will establish red mud treatment operations, -creating a new niche on the market- furthering the potential to implement the technology in other RUSAL plants.

Red mud recycling technologies are being cultivated by the Russian and


Bauxite residue can be used in the steel industry as an iron-containing raw material.

Through MÖLLER® technology, FLSmidth® specializes in design, engineering, procurement, erection and commissioning of pneumatic material handling systems for turnkey projects and components for the alumina industry. For more than 75 years the MÖLLER brand has stood for high quality standard systems with more than 5.000 references world wide.

MÖLLER Alumina handling systems - High performance, high efficiency.

For further information please contact us at:FLSmidth Hamburg GmbHHaderslebener Str. 7 25421 Pinneberg Germany Tel: +49 4101 788-0 Fax: +49 4101 788-140 [email protected]

www.flsmidth.com

higher performance

MÖLLER® Alumina handling systems deliver

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FLS Moeller_Aluminium Ad_back cover_13_06_1.indd 1 23.05.2013 11:30:56

FLSmidth is your expert in handling of fresh alumina, reacted alumina, crushed bath

and aluminiumfluoride

Large capacity storage silo including anti-segregation filling and discharge

MÖLLER airlift conveying

Pressure vessel dense phase conveying either with MÖLLER Turbuflow® or

standard conveying pipe

Truck/wagon loading and unloading stations

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MÖLLER Fluidflow® pipe air slide conveying systems

MÖLLER direct pot feeding systems

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FLSmidth Hamburg GmbHTel: +49 4101 788-0 [email protected]

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25AWJ 2013

PRIMARY SMELTING AND PROCESSES

STAS Inc.THE STARprobe™ p. 26-27

ECL The ECL™ New Concept Furnace Tending Assembly p. 28-31

FLSmidth MÖLLER Alumina Handling Systems p. 32-33

RiedhammerCarbon Baking Technology p. 34

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26 PRIMARY SMELTING AND PROCESSES

The STARprobe™A new technology allowing simultaneous measurements of four cryolitic bath properties in only four minutes

1- Cart2- Reusable probe tip3- Probe4- Electronic probe head5- Interface computer6- Power unit7- Battery pack8- Telescopic towing arm

During the last 10 years, Alcoa has developed a new device called the STARprobe™ [1, 2, 3]. This technology, now available through STAS, is a portable device that takes real time measurements of four bath properties in electrolysis cells:

Superheat

Temperature

Alumina concentration

Ratio (excess AlF3)

(STAR)

This synchronicity of measurements is the most important step forward in improving the control and efficiency of electrolysis cells.

Figure 1 shows one STARprobe™. The device kit consists of a mobile cart and two probes, one communication panel, one interface computer, one power unit, one battery pack and a telescopic towing arm in the front.

How it works

The probe concept consists in making a Differential Thermal Analysis (DTA), which is a proven method [4], on a bath sample and a reference. The reusable

Figure 1: STARprobe™ device kit

probe tip (Figure 2) includes two high-precision type K thermocouples, dynamically paired for compatibility.

The thermocouple on the left records the cooling rate of the bath sample, while the thermocouple on the right records the cooling rate of the reference. During the cooling process – the bath sample liquidus temperature – cryolite starts to solidify, which slows the bath sample cooling rate even further. At the eutectic temperature of the bath cryolite-alumina phase diagram, the alumina starts to solidify as well. Finally, at a much lower temperature -that has reduced down to the eutectic temperature of the bath cryolite AlF3 phase diagram (Figure 1 of [1]) -the excess AlF3 finally solidifies.

The reference temperature is selected as the X coordinate instead of the time, so the analysis results of the bath sample are not affected by fluctuating ambient conditions [1]. In fact, the shape of the curve depends on two things only: the design of the probe tip and the composition of the bath sample. This means that for a given probe tip design, the shape of the curve is solely dependant on the composition of the bath sample.

The correlation algorithm is very fast,and the calculated results are equivalent to the XRD analysis, as presented [1] and as independently verified on many occasions so far by the author in demonstrations performed in smelters all around the world (for example, see[5]).

How it is used in the potroom

The reusable, consumable probe tip can take around 100 measurements. It is connected to the probe head through a probe lance, as seen in Figure 3. An operator can use two of those assemblies to measure cells simultaneously. That way, a trained operator can obtain an average time of just under 4 minutes per measurement.

Figure 3: Probe assemblyThe probe head includes a very high resolution electronic thermocouple reader that reads the thermocouples and transmits data via Wifi to the tablet PC running the STARprobe™ application.One tablet PC can simultaneously process the data from the two probe heads. After a few seconds, the results are displayed on the tablet screen (left side of Figure 4), stored in a file on the tablet and can be transmitted automatically to the plant database and/ or to the pot control system.

Figure 4: STARprobe™ application displaying the results

ONE STEP AHEAD

3

12

27AWJ 2013

1 Sample cup Contains bath sample

2 Reference side Provides a reference cooling curve

3 Thermocouple connectors Measures temperatures

Figure 2: Reusable probe tip

Potential of process control improvements using the STARprobe™

The conventional way to control the bath ratio and the temperature is to regularly take bath samples and measure the bath temperature. Most of the time, bath sampling is not synchronized with bath temperature measurement. In any case, due to the delay in getting the bath sample analyzed, the cell controller typically never receives new temperature and ratio data at the same time. This lack of synchronicity between the bath ratio and bath temperature data and the lag in getting the ratio data can be totally eliminated by using the STARprobe™ to measure both parameters at the same time and by immediately transmitting the results to the database and to the pot control system via Wifi .

Furthermore, a typical bath ratio control logic uses the data for both the bath temperature and bath ratio in order to control the bath ratio by adjusting the amount of AlF3 added to the cell, assuming a given and constant cell superheat. As presented in [7], any inconsistencies between the target bath ratio and the target bath temperature can create instabilities in the feedback control loop.

Since the STARprobe™ also measures the bath superheat, the bath ratio control and the bath temperature control – or rather the bath superheat control – can

be decoupled. The bath ratio can be controlled by adjusting the amount of AlF3 and the bath superheat by adjusting the target cell pseudoresistance independently [8].

Improvements have already been achieved in more than 10 of Alcoa’s plants in terms of process control. In parallel with the development of the STARprobe™, Alcoa has developed a new cell controller called QLC which takes full advantage of its STARprobe™ bath properties measurement technology. The QLC automatically acquires the results of STARprobe™ measurements in real time via Wifi [1,6].

The gains guaranteed by Alcoa [6] are the following:

• 0.5% current efficiency (proven) • 35 mV voltage savings (proven) • 5% AlF3 savings (proven) • 100-150 day potlife improvement (still to be established) • One time capital cost saving (X-ray equipment) (proven) • Labor savings for sampling/ analysis (proven) • Improved understanding by operators (proven)

The STARprobe™ technology is a new way to control electrolysis cells. Other companies around the world have already taken advantage of this new opportunity.

STAS is the exclusive supplier for theSTARprobe™ technology and offers demonstrations upon request:

www.stas.com/en/starprobe

References[1] Xiangwen Wang, Bob Hosler and Gary Tarcy, Alcoa STARprobe™, Light Metals, (2011), 483-489.[2] Bob Hosler, Xiangwen Wang, Jay Bruggeman and Patrick O’Connor, Molten Cryolytic Bath Probe, US patent no. 2005/0069018 A1.[3] Xiangwen Wang, Bob Hosler and Gary Tarcy, Systems and Methods Useful in Controlling Operation of Metal Electrolysis Cells, US patent no. 2007/0295615 A1.[4] R.C. Mackenzie, Differential Thermal Analysis, Academic press London, 1970.[5] M. Dupuis, P. Bouchard and J.-P. Gagné, Measuring bath properties using the STARprobe™ , 19thInternational ICSOBA Symposium (2012).[6] Wang, X., Tarcy, G., Batista, E. and Wood, G. Active pot control using Alcoa STARprobe™, LightMetals, (2011), 491-496.[7] M. Dupuis, Excess AlF3 concentration in bath control logic, National Conference on Advancements in Aluminium Electrolysis, Indian Institute of Metals, Angul Chapter, (2006).[8] M. Dupuis and J-P. Gagné, Testing a new STARprobe™, ALUMINIUM 89 (2013) 1/2, 76-79.


Pierre Bouchard, Eng., M.Sc. - President Telephone Office: + 1-418-696-0074 ext. [email protected]

Jean-Pierre Gagné, Eng., M. Eng. – Technical Manager, Electrolysis and Carbon Technologies : Telephone Office: + 1-418-696-0074 ext. [email protected]

28

Innovation in motionInnovation is in everything we do and in all the equipment we design and build.

For over 60 years, ECL™ has been the benchmark for reliable, high quality and cost-effective equipment for aluminium smelters, for all technologies.

We will maintain that focus now and in the future.

www.ecl.fr

29AWJ 2013

The ECL™ New Concept Furnace Tending Assembly:Focus on safety, productivity and operational costs savings

Since the first Furnace Tending Assembly (FTA) commissioned by ECL™ in 1963 in Slatinia, Romania, the design and tasks of this machine have evolved. For the first time in industry history, ECL™ has performed a total rethink of the FTA, based on:

• A modular structure providing higher performances in terms of: safety, shorter commissioning time, productivity, quality and operational cost savings.

• A streamlined architecture - providing significant weight and height reductions.

• Better, faster and more efficient coke suction flow rates and enhanced speed in tool movement.

• The possibility to have one or two grabs and/or one or two filling pipes on the crane.• An evolutionary design greatly improving maintenance access, costs and ergonomics.

ECL™ has focused its efforts in safety, productivity and operational costs-savings in order to deliver a new concept FTA achieving maximum availability and reliability.

A modular and streamlined structure

Most FTAs consists of a twin girder cross travel structure supporting a tools trolley. Each machine is tailor-made for the smelters following the specific requirements and technical imperatives of the production technology used.

The ECL™ New Concept FTA is based on a modular structure, that offers several advantages over conventional designs. It’s lighter than a regular crane. As the FTA is the main piece of equipment supported by the baking furnace building’s rails, this weight reduction has a direct impact on their design and cost requirements.

The modular concept leads to a simplification of the FTAs overall structure. Each of the crane’s constituting elements and the links between them (pneumatics, electrics and optical) have gone through a total rethink that makes them individual modules rather than imbricated elements. The resulting crane is faster to commission and easier to maintain. Furthermore, the location of the FTA tools (dedicated for working on the pits) has been modified to greatly improve the operator’s visibility. Consequently the accuracy of tools’ movements is improved, - reducing the potential of damage on the tools and flue walls.

The modularity of the cranes also allows flexibility with regard to implementing upgrades. A second grab and/or a second filling pipe, can be installed on a machine to facilitate a possible increase in anode production. Whereas the design of all FTAs is made according to the customer’s requirements, the ECL™ New concept FTA leaves room for further enhancements and future developments.


Environment, Health and Safety first

In harsh environments with heat, gas, and dust; it is essential to prioritize environment, health and safety for the smelter and above all the operators. The Research & Development department of ECL™ had a strong focus on providing an ergonomic cabin, paying special attention to air quality and temperature control, visibility, safety and reliability.

To minimize the safety risks (falling, pinching, crushing, suffocation) ECL™ has equipped its crane with the following safety features:

• Retractable step ladder with guardrail to access the crane.

• An emergency evacuation access - whatever the position of the main trolley - in case of power cut or damages on tools in the furnace.

• Higher number of emergency stops and push buttons.

• Improved lighting - accomplished by relocation of floodlights to minimise shade interference.

Further, the cabin itself has been subject to many changes and transformed into a shell around the operator. The cabin is more spacious: its size increased by 75%. The new size of the cabin brings many advantages. The operator benefits from a 70% wider window area, providing a brighter environment and better visibility. With a visibility range of 10 metres under the cabin, the operator is now able to see the bottom of the pit which makes the operation of coke filling and sucking much easier. 2 to 3 people can fit in the cabin simultaneously, which offers a great opportunity for training and management purposes. The seats have been rethought and are now motorized - enabling cross travel movements to facilitate and guarantee seat position accuracy perfectly in front of the tools. The seat

includes height adjustment as well as air and mechanical suspension, arm support and body fixation for greater ease and flexibility. As an additional option cameras can be installed on the suction pipe, which will eliminate back bending and improve the overall safety observation. The operator can also adapt the control units (joystick) according to his morphology. The smooth driving of the FTA is therefore facilitated and fatigue of the driver considerably reduced.

An easy maintenance, safer and cheaper

By redesigning its FTA, ECL™ has significantly improved the working environment for the operator, as well as enabled maintenance works to be carried out - which was previously problematic due to the difficult access to key areas of concern. The New Concept FTA is now equipped with several onboard platforms and access points, including:

New cabin; more spacious, better visibility and improved ergonomy

31AWJ 2013

• A complete upper platform giving full access to the grab hoist unit, the top of the storage hopper (sucking pipe elbow) and the top of the filter hopper to perform filter bags changing.

• Maintenance platform, which provides access to the valve situated between the cyclone and the filter hopper as well as the valve used to control the de- dusting sucking during the pit filling phase.

• A platform situated at the top of the sucking pipe.

• Direct access point to the 25 metric tons hoist, situated above the main trolley.

• Direct access point situated between the top of the FTA girder and the long travel maintenance platform.

• Lifting points and lifting rails - installed directly on the crane - to facilitate dismantling of the heavy components that are not directly a accessible (moto-reducer, air condition unit, hoist unit).

No effort has been spared in ensuring the safety for both the operator and the maintenance staff. The large number of onboard platforms puts an end to having to rely on any cumbersome external mobile platform, which is usually unavailable when required.

A New Concept FTA combining reliability and greater performance

A double filling pipe

The new architecture of the FTA is based on a double filling pipe assembly that can be used individually or simultaneously. This system of double filling pipe compared with a conventional FTA (1 filling pipe, 1 grab and 1 sucking pipe) allows an increase of almost 10% of the FTA utilization

rate and therefore productivity. FTA utilization rate is carefully computed by ECL™ engineers to match the customer’s production needs, while ensuring a minimum 25% backup capacity. This approach ensures that the FTA is not oversized (which would result in over pricing) and that the anode production requirement is met.

ECL™ engineers also worked to make the filling pipe more resistant to shocks, coke temperature variation as well as decreasing the risks of pipe blocking and falling.

A powerful sucking pipe

From a rate of 65 m3/h to a rate of 110m3/h: this is the new suction capacity of the sucking pipe set up in the FTA which almost doubles suction speed. Moreover, the sucking pipe is

equipped with a new shock absorption system which assists in avoiding the risk of crushing for the pipes.

Conclusion

Here is the reality: produce more, faster, at a lower cost in a safer way. The New Concept FTA helps to achieveall this.

Author: Anne-Gaëlle Hequet, Communication Manager with ECL, fully part of Rio Tinto Alcan.

Double filling pipe system


About FLSmidth

FLSmidth® is a market-leading supplier of equipment and services to the global minerals and cement industries. FLSmidth supplies everything from single machine units to complete minerals and cement flow sheets including associated services.

With more than 15,000 employees, FLSmidth is a global company with headquarters in Denmark and local presence in more than 50 countries including project and technologycentres in Denmark, India, USA andGermany.

FLSmidth has over the past 131 years developed a business culture based on three fundamental values: competence, responsibility and cooperation.

It is FLSmidth’s vision to be the customers’ preferred full-service provider of sustainable minerals and cement technologies. This is reflected in focused research and development efforts aimed at fulfilling customers’ future needs in terms of innovative technical solutions, high reliability and availability, minimum environmental impact, and the lowest possibleproduct lifecycle costs.

The FLSmidth in-house resources are primarily engineers who develop, plan, design, install and service equipment, with most of the manufacturing being outsourced to a global network of subcontractors. This has proven to be both a robust and sustainable business model. FLSmidth therefore has a flexible cost structure, which makes it possible to plan and adjust resources to prevailing market conditions.

FLSmidth is a learning organization, and our people are our most valuable resource. FLSmidth’s strategy entails strong emphasis on selecting, attracting and retaining the right people who can support value creation in FLSmidth.

FLSmidth in the alumina business

FLSmidth first entered the alumina industry more than 100 years ago. Today FLSmidth has an experienced team of engineers and support staff with extensive alumina experiencelocated in offices around the world – and offers the latest equipment for most areas of an alumina plant.

Red side, white side and alumina handling

Based on the Bayer process, invented by the Austrian chemist Josef Bayer, the alumina production process can be split into a ‘red side’ and a ‘white side’.

Red side solutions

FLSmidth offers equipment for the complete bauxite handling, storage,crushing and grinding flowsheet, complementing the digestion or dissolution of bauxite in hot causticliquor. This is followed by the complete Settler-Washer train flowsheet for Red Mud using the leading technology acquired from Dorr-Oliver Eimco.

White side solutions

FLSmidth offers white side equipment, covering the complete flowsheet after the hydrate precipitation process, including MÖLLER equipment technology for alumina handling and load-out.

Overall, FLSmidth equipment covers more than 50 percent of the equipment needs of a complete alumina plant, from the bauxite mine to the above refinery equipment. In addition, FLSmidth also offers all equipment for alumina handling in the smelters.

MÖLLER Technology

Through MÖLLER® technology, FLSmidth specializes in design, engineering, procurement, erection and commissioning of pneumatic material handling systems for turnkey projects and components for the alumina

industry. Our capabilities of handling fresh alumina, reacted alumina, crushed bath and aluminiumfluoride comprise of:

• Large capacity storage silo (up to 85.000 t realized) including anti- segregation filling and discharge• MÖLLER airlift conveying systems (up to 6oo t/h realized)• Pressure vessel dense phase conveying either with MÖLLER Turbuflow® or our standard conveying pipe• MÖLLER screw pump conveying systems• Truck/wagon loading and unloading stations• Dosage systems• MÖLLER Fluidflow® pipe air slide and rectangular air slide conveying systems• MÖLLER direct pot feeding systems either with 100 % MÖLLER Fluidflow pipe air slide conveying technology or as a hybrid of MÖLLER Turbuflow conveying pipe and MÖLLER Fluidflow pipe air slide• PTM filling stations• Modular designed systems – plug and play -

For more than 75 years the MÖLLER® brand has stood for high quality standard systems with more than 5000 references worldwide.

Actual contracts under execution for Emirates Aluminium Smelter (reacted alumina silos, MÖLLER direct pot feeding system, PTM filling stations, fresh alumina truck unloading stations and pressure vessel dense phase conveying systems for a mix of crushed bath/alumina oxide) and for UC RUSAL/RusHydro’s Boguchansky Aluminium Smelter (MÖLLER direct pot feeding system) prove the strong position of FLSmidth in the global aluminium smelter industry.

FLSmidth Hamburg GmbHHaderslebener Strasse 725421 Pinneberg, [email protected]: +49 4101 7880

MÖLLER Alumina Handling Systems - High performance, high efficiency.

33AWJ 2013

FLSmidth is your expert in handling of fresh alumina, reacted alumina, crushed bath

and aluminiumfluoride

Large capacity storage silo including anti-segregation filling and discharge

MÖLLER airlift conveying

Pressure vessel dense phase conveying either with MÖLLER Turbuflow® or

standard conveying pipe

Truck/wagon loading and unloading stations

Dosage systems

MÖLLER Fluidflow® pipe air slide conveying systems

MÖLLER direct pot feeding systems

PTM filling stations

Modular designed systems - plug and play -

FLSmidth Hamburg GmbHTel: +49 4101 788-0 [email protected]

www.flsmidth.com

Alumina handlingExpertise in

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FLS Moeller_Aluminium Ad_right hand_Expertise_13_09.indd 1 23.05.2013 11:22:20

35AWJ 2013

ANODE PLANT TECHNOLOGY

Fives SoliosReal Time Central Control For Anode Baking Furnaces p. 36-39

STAS Inc. World Class Electrolysis Equipment p. 40-41

Brochot Group Advanced Technology From Brochot p. 42-45

Innovatherm Upgrade Of Existing Fume Treatment Plants p. 46-51

Alstom Novel Anode Bake Furnace Gas Cleaning p. 52-55

36 ANODE PLANT TECHNOLOGY

Qatalum is operating one of the most efficient and most environmentally- friendly aluminium smelters in the world.By implementing the best available technology in terms of Firing & Control Systems and Fume Treatment Centers on the Anode Baking Furnaces, Qatalum ensures that the operation of its furnaces is safe and that the stack emissions of condensed and volatile tars, dust and hydrogen fluoride are kept under the most stringent environmental levels.Thanks to its long experience both in Firing & Control Systems and Fume Treatment Centers, Fives Solios offers additional synergies as part of an integrated FCS/FTC design to further improve emissions, OPEX, working and safety conditions for a more reliable Anode Baking Furnace.

Fives Solios, designing today the plants of the future

What about the compliance of your Anode Baking Furnace?

Qatalum selected Fives Solios’ solutions for its Anode Baking Furnace to comply with the highest standards in terms of safety and emissions

Driving progresswww.fivesgroup.com

37AWJ 2013

HELIOSRT - REAL TIME CENTRAL CONTROL FOR ANODE BAKING FURNACES

Summary

For more than 20 years, the mobile ramps composing the fires of the Firing and Control system (FCS) have been controlled and monitored by redundant computers (Central Control System). The master computer makes calculations based on data collected from each ramp through the communication network. The ramp PLCs have no other functions than applying the commands sent by the master computer. (See figure 2).

In the last ten years, the CAPEX and OPEX of the control system architecture have increased with no significant improvements regarding the anode baking process, day to day operation and maintenance. Indeed, the main changes were only to replace the wired network by an Ethernet Wireless one and to fulfil the new safety requirement, the PLC became Safety Integrated PLC (SIPLC).

Fives Solios has developed HeliosRT, an innovative solution based on a Real Time Ethernet Network that allows entrusting the entire FCS control to the Central Computers only, without distributed PLC. The control system architecture is greatly simplified:

it uses only one Real Time Central Controller and remote Inputs/Outputs for each mobile piece of equipment. (See figure 3).

The robustness and reactivity of the control as well as the required safety loops are preserved. The maintenance and day to day operation are simplified.

Furthermore, Real Time Network and accurate time synchronisation between the ramps open new perspectives to improve the Baking Process management and to enhance Safety.

Simplified Day to Day Operation

HeliosRT is fully automatic: less intervention is required from the operator.

All the operator action and follow-up are done using only Real Time Supervisory Human Machine Interface (RTS-HMI – Control Screens). Indeed, the ramp screens and their dedicated HMI are replaced by the RTS HMI displayed on screens located on each side of the Anode Baking Furnace

(ABF) and on WiFi tablet PC for a local control close to each ramp for unusual or maintenance operations.

Industrial, Open and Well-Proven Technology

HeliosRT is a modern solution based on an open and well-proven technology in many industries: Ethercat technology [2] is used for the Real Time Network along with Twincat from Beckhoff as Real Time Controller.

Reliable Network

Earlier, WiFi Networks have simplified the conventional infrastructure, but they are more difficult to install, to configure and to maintain because they can be disturbed by other Wireless Networks or radio users (such as meteorological and army radars) [1]. Moreover, the WiFi infrastructure increases the latency time that is already present in the communication on any TCP/IP Ethernet network. This can become an issue with SIPLC that required for their safety data to be updated regularly. It also forbids the development of new control principles based on an enhanced synchronization of the ramp actuators.

HeliosRT Ethercat Network is a wired Class C Ethernet Network that uses dedicated hardware on the slave device side and a dedicated process data protocol transported directly in the Ethernet Frame to ensure high performance. The dedicated components simplified the network implementation and unlike a WiFi Network, the Ethercat Network has predictable and steady performances

Enhanced Safety

To achieve the same level of Safety as expected by most users and as promoted by Fives Solios, reliable

Figure 1 – Anode Baking Furnace


continuous communications between the pieces of equipment are mandatory and modern conventional architectures required SIPLCs on the key ramps (Auxiliary Equipment, Exhaust Ramp & Heating Ramp) are required for managing independent safety loops in addition to the Process Safety handled by the Process Controller.

HeliosRT Safety is enhanced compared to a modern conventional architecture using SIPLC but without the cost impact of the SIPLC technology.

The safety loops, that were managed by several SIPLCs, tasks are now managed by only one dedicated Safety Controller. The testing maintenance and traceability of the safety program, which are key points of the standard IEC 61508, are easier as there is only one safety program to manage.

The safety loops are more robust and the reactivity of the system is improved as there are no perturbations due to any communication latency time.HeliosRT technology allows reliable

and accurate localization of the ramp on the furnace. With the generalisation of the WiFi Network, unless costly systems were integrated, the system was depending on the operator inputs to know on which section the ramp was localized. This could have consequences on the Process follow-up and on the Safety.

Because the Real Time Controller is running on an Industrial Computer, the great calculation power available allows increasing the accuracy of some Safety Modules developed by Fives Solios such as the blocked flue wall detection.

Robustness Improved

By design, HeliosRT architecture is simple to understand and to maintain. The hardware is reduced, and has less active components to be programmed before change-over (no WiFi Network with very specific settings, no Ethernet component switches or others to be programmed, no complicated IP address plan to be set, no firmware

to be updated on all the components, so they can be compatible with each other, and so on).

Moreover, by reducing the number of components on the ramps, their electrical cabinets are simplified and their sizes are reduced along with the solicitations for the air-conditioning system.

The Ethercat Network is a redundant wired network. The Communication is more reliable than on a WiFi Network because it cannot be disturbed by external phenomena. Of course this Network could suffer from the same problems as other Wired Networks such as plugs, sockets and cables that are cumbersome and cannot endure cyclic change-over. For that reason, specific cables and plugs were tested to be more resistant and easy to change. Backup solutions such as additional cables and plugs are part of the design so that process continuity is always ensured.

Figure 2 - ABF Control System Architecture

39AWJ 2013

Anode Baking Process Improvement

HeliosRT “Injector Matrix Control” specific algorithm combines the temperature set points set by the operator and the temperatures read for each flue wall with other measurements such as CO, air flow inside the flue wall and so on, to calculate the optimal injector sequencing.

The Real Time Network and accurate time synchronization between the ramps allow an accurate sequencing of the injection, to optimise the air consumption inside each flue wall along with the fuel flow across each Heating Ramp. Flooding situations are avoided. A complete combustion and a homogenous injection flame are preserved.

The advanced injection management leads to significant gain on the overall fuel consumption and a reduction of the unburnt fuel residues along with

an improvement for the homogeneity and consistency of the baking level -inside and across- the various pits.

HELIOSRT

HeliosRT reduces the investment cost (CAPEX) of the FCS and provides several operation benefits: improved safety, less maintenance, lower energy consumption, and fewer unburnt emissions.

HeliosRT is an innovative solution to a more efficient FCS based system on a well proven technology in many industries. A first industrial reference on anode baking furnaces for the aluminium industry will start operation in 2013.

References

1. Nicolas Fiot, Christian Coulaud, “Wireless communication for secured Firing and Control Systems in Anode Baking Furnaces”, TMS2011.

2. Ethercat Technology Group – General presentation.

3. Nicolas Fiot, Xavier Genin “New Central Control System Architecture for Anode Baking Furnaces”, TMS2012.

By Nicolas FIOT, Solios Carbone, 32 rue Fleury Neuvesel, BP24, 69702 Givors Cedex, France

Figure 3 – New ABF Control System Architecture


WORLD CLASS ELECTROLYSIS EQUIPMENT FROM STAS

CAT / Covered Anode Tray

STAS has developed new technologies dedicated to the potrooms and the rodding shop, among which the AAPS / Automatic Anode Positioning System and the CAT / Covered Anode Tray, which are used in the potroom to improve operational and safety aspects of the anode changing process, and the EIC / Electrically Isolated Platform which provides a fully safe environment for the operators working above the pots. On the existing conveyor system of the rodding shop plant, STAS provides an Anode Butt Inspection System (ABIS) and also an Anode Stub Inspection System (ASIS) to perform the automatic inspection of anode butts and stubs.

The Automatic Anode Positioning System

In modern aluminium smelters, huge amounts of prebaked anodes need to be replaced continually and properly positioned in electrolysis cells. However, manual positioning methods – even with the best trained operating crews – are quite conducive to variability and a lack of consistency, exposing operators to safety hazards.

The Automated Anode Positioning System, or AAPS, is a fully automated system developed by Alcoa Canada & STAS which can be implemented on existing or new Pot Tending

Machines (PTMs) to ensure optimal anode positioning. Based on laser measurements using the anodic beam as a reference, the AAPS also relies on load sensing devices to avoid positioning errors related to mechanical play.

With the AAPS, the duration of the anode replacement cycle can be reduced by up to 25%. The system is also designed to minimize the period of time between the removal of the anode butts from the electrolysis cell and their storage in the transport tray. The system therefore contributes in improving the health and safety conditions for floor operators by reducing their exposure to HF emissions, gases and particulates.

Using the AAPS in combination with the Covered Anode Tray (see below), the anode butts can be quickly loaded into closed containers, which further reduces HF emissions in the potroom.

The Covered Anode Tray

Once the used anodes (anode butts) are removed from the cells, they are usually placed on anode trays for transportation and cooling, a process during which Hydrogen Fluoride (HF) – a particularly toxic gas for the environment and human beings – is generated in large quantities.

Manufactured by STAS, the Covered Anode Tray, or CAT, is a specifically designed container that confines the cooling anode butts in an enclosed container shortly after their removal from the cells in order to reduce HF emissions from the anode butts by up to 50% [1].

The panels of the closed container are automatically activated by the movement of the anodes when they are inserted or removed. The CAT features a patented mechanism used to seal the gap around the anode rod and to ensure optimum confinement while minimising downtime and maintenance costs. The geometry of the containers can be easily adapted for use with any plant anode trays and transport vehicles.

The Electrically Isolated Platform

Live parts up to 2 KV are within reach in certain layouts of a Hall-Heroult potroom, special tools are required during operation and maintenance activities to protect workers against electrical hazards.

Thanks to its triple level of isolation, the Electrically Isolated Platform or EIP virtually eliminates electrical hazards by preventing the circulation of an electric current between the live parts and the ground, thus ensuring the safety of the operator.

STAS uses industrial boom lifts and modifies them with very specific electrical insulation material at the first joint hinge, which eliminates the possibility of short circuits if a boom lift were to come into contact with two different electrical potentials in the potroom. An important feature of the STAS EIP is its Realtime Isolation Supervisory System (RISS) that validates the insulation of the boom lift in real time, using STAS’ proprietary instrumentation. If for any reason the electrical insulation is broken, the platform operator, while still protected against electrical shocks, is immediately informed by an alarm that an insulation barrier is non-functional

ONE STEP AHEAD

41AWJ 2013

and that maintenance is required.

STAS Anode Butt Inspection System and Anode Stub Inspection System

At the end of their life cycle, anode butts need to be cleaned from the bath residue before recycling the residual carbon. Inadequate cleaning leads to high sodium levels in the residual carbon (which is reused in the anode fabrication process), causing problems such as cracks in the anodes and shortened life expectancy of the anode baking furnaces.

In addition, abnormal shapes (defects) could indicate the need to adjust process parameters such as the thickness of the carbon that remains underneath the cast iron thimbles, which gives information on the anode cycle, etc. Such process data provides relevant information for optimizing the fabrication of new anodes and the electrolysis process.

Typically, only a few anode butts are manually inspected, and limited useful information is available from such an inspection scheme.

After the removal of residual carbon and cast iron thimbles, the stubs of each anode rod assembly also have to be carefully inspected to determine if the assembly can be used again or if it needs to be routed to the repair area. Stubs tend to deform and corrode in the

EIP / Electrically Isolated Platform

cells, and such defects can reduce the efficiency of, or jeopardize the anode assembly process, or cause major downtimes when faulty stubshave to be removed.

To take all these problems into consideration, STAS supplies two automated systems based on high-resolution artificial vision: the ABIS / Anode Butt Inspection System [2] and the ASIS / Anode Stub Inspection System [3].

The ABIS measures a certain number of geometrical characteristics of the anode butts and is easily integrated into the conveyor system of the rodding shop. The ABIS measures and analyses all the anode butts processed at the rodding shop, identifies a certain number of defects, and performs the monitoring of anode butt cleanliness with regard to the residual bath remaining on the surface.

The ASIS measures more than 30 geometrical parameters associated to the anode rods and stubs. These measurements are used to route rod assemblies through the repair area or to the equipment used to align up the external stubs if repairs are needed. The measured parameters are stored in the plant database. The characteristics of each anode rod can be followed up, and statistical analyses are made available for process control.

The ABIS and the ASIS are available separately but can be combined to ensure the best possible performance regarding anode cycle optimization.

About STAS

STAS Inc. (www.stas.com) is a well established company and a recognised leader in its innovative abilities to develop, fabricate and commercialise new technologically advanced equipment for the aluminium industry.

STAS is serving a global market place on a custom-made basis, with quality specifications that comply with world standards.

Founded in 1989, STAS employs more than 150 persons, including 80 engineers and technicians with broad expertise in process and design. STAS’ headquarters are in the heart of Quebec, Canada, where about 2.5 million tonnes of aluminium are produced by some of the world’s most technologically advanced plants. STAS holds licenses with Rio Tinto Alcan and Alcoa.

References

[1] Jean-Pierre Gagné et al, HF Emission Reduction from Anode Butts Using Covered Trays, Light Metals, (2012), 557-560.[2] Jean-Pierre Gagné et al, ANODE BUTT AUTOMATED VISUAL INSPECTION SYSTEM,Light Metals, (2008), 895-898.[3] Jean-Pierre Gagné et al, ANODE STUB INSPECTION SYSTEM, Light Metals, (2007),1021-1024.Contact Information:Jean-Pierre Gagné, Eng., M. Eng. – Technical Manager, Electrolysis and Carbon Technologies : Telephone Office: + 1-418-696-0074 ext. [email protected]

ASIS / Anode Stub Inspection System

ABIS / Anode Butt Inspection System


BROCHOT, YOUR PARTNERIN THE LIGHT METAL INDUSTRY

ALUMINIUMPotrooms• Electric pot ramming machines with paste feeding

machines and/or data box• Anode raising beam

On a single machine delivery or on a turnkey basis :

Carbone plant • Full anode handling system and rodding shop

equipment• Anode slot cu ng machine

Cast house• Cas ng and stacking lines (Aluminium and alloys)• Aluminium oxyde-free ingot cas ng wheel• Ladle skimming, ladle cleaning• Water cooling system

AFTER-SALES SERVICES• Exper se, follow up, improvement• Maintenance and training• Spare Parts

SIMULATIONTaylor made simula onof all processes on demand

Special vehicles• Furnace charging and tending machine• Transport of bath or alumina• Anode pallet transport vehicle• Ladle transport vehicle• Til ng ladle transport vehicle

BROCHOT - 52, avenue Marcel Paul93297 Tremblay en France Cedex www.brochot.frTel: +33 (0)1 49 63 74 00

Fax: +33 (0)1 49 63 74 [email protected]

For any informa on, please contact us

Design, Manufacture, Supply, Installa on at site on a turnkey basis

Brochot_Pub-LightMetal-A4-V2.indd 1 29/08/13 10:31

43AWJ 2013

ADVANCED TECHNOLOGY FROM BROCHOTA PROVEN SOLUTION FOR ANODE SLOT CUTTING

The French based company :

Brochot is a well-established supplier of production process equipment to the non-ferrous metals industry. The company is represented on a worldwide basis with offices in Canada, China, Russia and Middle-East and 3 workshops in Quebec, France and China. The company’s portfolio is extensive and increasing, in particular with the addition of recent equipment supply to the copper and zinc industries by the Brochot Hydromet division. Brochot’s principal activity remains the design, development, manufacturing and supply of equipment for the primary aluminium sector. In this sector Brochot is well known for supply of individual machines and complete turnkey projects for anode rodding shops and anode handling installations.

A recent successful installation is the supply of an anode slot cutting machine to the NALCO plant in Angul, India. This machine is part of an on-going development of the Brochot anode slot cutting design, which seeks to improve and adapt the design to the

varying criteria of individual smelter sites. Brochot continues to invest in the development of new and revised designs for its slot cutting machine, and future orders will incorporate a number of improvements to cycle times and adaptations to client slotting requirements

Advantages of slotted anodes

The use of slotted anodes is now well established in aluminium smelter pot lines. The slotting of anodes is known to give improvements in pot efficiency by reducing the formation of bubble films (which create higher electrical resistance), reducing anode cracking and allowing use of increased pot currents. The cost of aluminium production is highly dependent on the cost of energy used in the reduction process and efficiency gains from slotted anodes have a direct cost benefit.

Studies have shown that a large part of the gases (mostly carbon dioxide and carbon monoxide) generated by the reduction process are formed on the underside of the anode block and

Brochot anode slot cutting machine during workshop testing

the build-up of a layer of gas increases the cell resistance. The distance needed by a gas bubble to escape from the underside of the anode is a determining factor in the development of the layer thickness and basically, the shorter the escape distance the lower the resistance created by the gas layer will be. As anode sizes grow, the problem of the gas layer increases.The introduction of slots into the anode therefore simulates, for as long as the slot exists, the effect of using a smaller anode by providing an escape path for the gas bubbles formed on the underside of the anode.

Slot configurations

Anode slotting arrangements have existed in two configurations – lengthwise slots and transverseslots. These slots can be formed in two ways – by moulding during the formation of green anodes orby machining the slots in baked anodes. It is accepted that the longitudinal slot configuration delivers the greatest benefit and the Brochot slot cutting machine produces slots in this direction.

The use of moulded slots has a number of disadvantages compared to machined slots. Slot forming plates introduced in green anode moulds can affect the paste distribution and compaction around the slots. The slots are wider than machined slots and they can become clogged with packing coke at the anode baking stage. The wider slots also reduce the overall mass of carbon consequently reducing the life of an anode. Such slots create more fragile green anodes and increase rejection rates during the green anode forming, cooling and transportation stage. These problems are exacerbated with increases in the slot depth which would be potentially useful in maintaining the slot through a greater part of the anode life.

Brochot slot cutting unit

44

Machine installation and construction

The Brochot slot cutting machine is intended to be used as an integrated part in the anode handling system. The machine is integrated into the anode conveying lines, receiving anodes from the baked anode storage areas and cutting the slots before transfer to the anode rodding shop. At NALCO the Brochot machine was integrated as a retrofit into the existing conveyor line just before feeding the anode rodding station. The machine installation was adapted to the existing slope of the conveyor and the machine integrates the possibility of changing its configuration to allow a ‘pass through’ condition. Space restrictions in this plant do not allow the use of a by-pass conveyor.

The basic elements of the machine are a strong, rigid frame which supports an anode transport carriage and anode lifts, a powerful gearmotor which directly drives the shaft mounted cutting tool discs, entry and exit roller conveyors, and a fully enveloping enclosure to retain carbon dust within the machine, whilst assuring operator safety.

Slot parameters

The machine delivered to Nalco can cut a variety of slot configurations, including horizontal slots and sloped slots up to 450mm deep. In this machine the slot cutting unit is in a fixed mounting configuration. Brochot, as mentioned below, can deliver other slot dimensions as well. This simple and robust solution. is well adapted to the clients needs. Brochot can also offer machine configurations with mobile slot cutting unit mountings, where the position of the cutting discs can be raised or lowered. The position of the slots in the anode is normally predefined by the client, but nevertheless, the distance between the slots may be modified by changing the disc mounting spacers. To aid the exit of gas bubbles from the slots, the top of the slot is often inclined. This parameter can be quickly and easily changed in the Brochot machine by the addition or removal of spacers on the anode support pads of the transport carriage. This operation inclines the anode, relative to the machine chassis, so that the depth of cut is greater at one end of the anode than at the other.

We emphasize that Brochot is manufacturing its own in-house blade, which is designed for the specific application of each customer.

The stability of the slot cutting discs is very important for reliable operation of the slot cutting machine. Disc diameters for deep slots become very large compared to the disc section. One of the objectives of slot cutting is to create a significantly smaller slot than in a moulded anode. The disc stability is related to its thickness, materials, detail design and fixing arrangements.

Any run-out in the cutting discs will cause premature wear to cutting tools, creates localised tool heating and slots that are wider than desired. The design of the Brochot disc ensures excellent stability of the disc with respect to the mechanical loads and the thermal variations caused by cutting anodes which are still at a high temperature, particularly in the core of the anode. For NALCO, Brochot has produced tooling which produces an 11.5mm inclined slot with two slots per anode. Brochot can also offer machines with slot capacity up to 450mm with small slot widths.

The machine offered by Brochot is a fully automated process machine where the type of product to be treated is defined by the requirement of a particular smelter or anode production unit. Within the limitations of the machine sizing determined at the outset, the machine can be adapted to accommodate changes in slot dimensions (depth, length, slope, fully traversing or partially traversing slots, distance between slots) when production parameters change.

Anode slot cutting in progress


Brochot anode transport carriage

45AWJ 2013

Tooling life

Operating costs of slot cutting machines are largely related to the life of the cutting tools. Brochot has worked over a number of years to choose and refine the specification of the cutting tools in order to achieve long life and reliability. A single set of tool tips can reliably achieve a life of 40000 anodes (Customer reports achievement of 45000 anodes) and by indexing the tool tips the life of the tools can be doubled. The Brochot tooling design uses special tool holders carrying diamond tip tools which are alternately mounted on either side of our tool carrying discs. Brochot supplies the complete machine and tooling package with after sales service, giving full support for supply of consumables and replacement parts.

In any slotting operation the rigid mounting of the anode is essential to avoid problems of vibration during the machining operation. The Brochot machine has a rigid anode transfer carriage equipped with strong pneumatic anode clamps. The anodes are delivered to the machine by a motorised roller conveyor and placed above an anode lift. The lift raises the anode allowing the transfer carriage to position itself around the anode. The lift retracts lowering the anode onto the anode support pads, and the carriage anode clamps fix the anode securely in place. The carrier advances the anode and the discs cut the slots in the anode as the carriage advances. After exiting the cutting, the anode clamps are released and the exit lift lowers the anode onto the outlet roller

conveyor. During the cutting, a new anode is loaded and lifted ready for the return of the anode carriage. The slot inclination and the orientation of the slot are determined by the height of the anode support pads, the anode being inclined in the carriage during the slotting operation.

The quality of the cutting operation and the control of vibration are well understood by Brochot, allowing reliable calculation of the parameters for disc rotation speed and anode advance. This ensures good prediction of cycle times for new projects, which is essential to the sizing of equipment in new and existing installations.

Dust control

One constraint of the slot cutting method is the creation of carbon dust during the process. To control the dust, Brochot supplies a complete dust extraction and filtration system along with the slot cutting machine and works together with our clients to create the best package for the site installation. A fully enclosing housing is supplied for the machine providing dust control and safety protection. The housing is in two parts, retractable to allow maintenance access into the machine. The lower part of the machine is formed by a dust collection hopper which feeds a screw conveyor. During the cutting, the larger carbon particles fall into the hopper and are extracted by a screw conveyor to a collection bin. Periodically this bin is emptied to the carbon recycling system.

Ongoing developments

Capitalising on our experience at NALCO and at other sites, current design developments at Brochot are focused on providing cost optimised designs with higher capacity, and reducing cycle times whilst simultaneously increasing the depth of slot. New designs optimise the use of the cutting unit (discs

and drive system) to allow multiple anode slotting with a single cutting unit. Other improvements include new dust collection and extraction systems, tool life optimisation and automation of pass-through systems to facilitate anode transfer without slotting. The reliability of the equipment is of primary importance, since downtime of the slot cutting machine can quickly lead to supply problems for the rodding shop operations. The current Brochot slot cutting machine delivers a reliable performance at around 45 anodes/hour depending on anode dimensions. The next generation of equipment will maintain current reliability levels while increasing this to a rate of around 60 anodes/hour.

Backed up by its commercial and engineering resources across several continents, Brochot is already replying to client requests for the next generation of slot cutting machines and has the intention to remain a leading player in this market.

Brochot slot cutting machine during installation at Nalco

Author: Philip Dunabin, Brochot Engineering Department Manager


Introduction

Aluminium Smelters are designed and built for a nominal start-up capacity. Once the ramp-up of all pots is finished, the production output is raised by continuous increase of the amperage. Other facilities of the Smelter, like the anode plant, have to adsorb these changes in production. Higher aluminium production output enforces higher production of anodes. Usually, the green anode plant is designed with some spare or extra capacity for maintenance purposes. In addition, the baking furnace can adsorb some geometrical changes of the anode, and with the help of a state-of-the-art system, higher production rates are possible by shorter fire cycles or implementation of a fourth burner ramp.

What is most often not considered is the performance of the fume treatment plant. Existing plants have been designed for a nominal exhaust

gas volume and a target exhaust gas temperature. Future expansion of the FTC is not foreseen. To accommodate higher production of anodes, an increase in exhaust gas volume is necessary.

The specific volume per ton of produced anodes is in the range of 5.200 Nm3/t. The exhaust volume can not be boosted at will, as the main fans are designed for 100 % capacity. Other parts of the fume treatment plant also become affected. These effects and possible solutions will be outlined in this paper.

General

FTCs are designed for a maximum flow rate of the exhaust gases. The flow rates are limited by design, the gas speeds are in the range of 15 to 20m/sec. Higher flow rates can be temporarily realized by the use of stand-by fans, or over drive of the existing frequency driven fans. These

flow rates lead to higher gas speeds. The high gas speeds increase the entire pressure drop of the FTC. The effective pressure and volume flow for the anode baking furnace is realized by a much higher energy input at the fans. Higher maintenance, and a potential risk of production loss, are the logical consequence. Figure 1 shows a typical FTC in operation.

The situation will get worse, if the produced gas volume is just sufficient for the production of anodes, but the remaining oxygen is not sufficient for the efficient combustion of the volatiles. The result will be more deposits of unburned tars and volatiles in the ducts. This will be the starting point of a vicious cycle, where the pressure drop continues to rise, and the effective gas volume continues to decrease. Eventually the FTC enters into a dramatic situation of operation. The operation needs to be extended for continuous supervision and extensive maintenance sessions, which will not

Fig. 1: FTC in operation

Upgrade of existing Fume Treatment Plants to cope with higher anode production requirements

47AWJ 2013

improve the situation, and can only achieve a temporary stabilization.

Consequences for the Cooling Tower

The cooling tower is designed as a direct current cooler. The off gases are guided to the top of the cooling tower (gas inlet) and leave the cooling tower at the bottom. Water spray lances are installed in the top level of the cooling tower. Most cooling towers in older plants have only 1 to 3 water lances and are equipped with less water nozzles. Based on today’s knowledge the generated drops of water are too big. Figure 2 shows a typical cooling tower arrangement.

The cooling tower uses the principle of the enthalpy of water evaporization. The design criteria include a dedicated exhaust gas volume and a target “cooled” outlet gas temperature. This finally results in the size of the cooling tower due to the stretch necessary

for evaporization. If the exhaust volume now increases above the design values, the cooling tower will become overloaded. Under normal operation conditions, production staff will not recognize it, because the outlet temperature of e.g. 105 °C is still reached by the controls.

The evaporization itself is a non-stationary process, which needs time in relation to the size of the droplets.

For higher exhaust gas volumes, the average dwell time within the cooling tower decreases significantly and as a result, the off gases at the outlet of the cooling tower are chilled, but no longer dry.

For the lifecycle of the FTC, this is of vital significance. The high kinetic energy of the non-evaporized water droplets at the outlet leads to wet walls and ducts.

This is the cause for:

• Deposits, which grow at the walls• Formation of heavy corrosion by acids of SO3 and Fluor

Finally the pressure drop of the cooling tower, and consequently for the whole FTC, starts to increase continuously.

Consequences for the fabric filter

Fabric filters are designed and calculated through the so called “filter surface load”. The value of the filter surface load should be favourable in a range of < 1,0 m3 / m 2 and minute. For maintenance purposes, the filter can be operated in a (n-1) chamber mode. During this period, the value will be in a range of 1,5 or up to 2,0 for a short period of time.

This implicates that the fabric filters are designed on a conservative level, and are consequently more robust in overload situations compared to the cooling tower or the fans. The cooling tower and fans reach their technical limits at a very early stage, and are therefore unable to facilitate futher volume flow increases.

The fabric filters allow the precipitation of the adsorbant alumina including all attached pollutants, even in an over load situation. But due to the described bottlenecks in the furnace and the cooling tower, the exhaust gases start becoming loaded with higher concentrations of pollutants, such as soot and condensed tars. The resulting situation can only be compensated by higher throughput capacity of alumina, which will exponentially increase the abrasive wear of the FTC.

The increased volume flow implies further disadvantages. The pressure loss between the inlet and the outlet of the fabric filters is increased quadratic

Fig. 2 Cooling tower arrangement


Fig. 3 Used and destroyed filter bags


and further feeds the vicious cycle with regard to all influences caused by reduced volume flow. The differential pressure value of the fabric filter moves fast towards the threshold limit, for the pulse cleaning system of > 22 mbar. The filter bags are physically stressed and start to burst partially. When the pulse cleaning system is no longer able to fully clean the filter bags and the differential pressure stays at high values, the technical limit is exceeded. As a final consequence, the filter bags have to be changed in much shorter time intervals where nominative usage rates are in the range of 3 years plus. Figure 3 shows the used and destroyed filter bags.

Consequences for the filtration of harmful components

The continuous overload of the FTC by exceeded volume flows finally results in a negative overall situation for the main task of the FTC, which is the efficient cleaning of the exhaust gases. Exceeded volume flows reduce the average reaction time between the adsorbant alumina and the pollutant. Some important adsorbant reactions have to take place in intermixed reactor chambers prior to the final precipitation in the filtration cake. Especially the probability of contacts between the aerosols -conditioned in the cooling tower- and the alumina will be reduced intensively due to insufficient dwell times. Some unsteady adsorbtion processes are not yet finished, while the fume gases already penetrate into the filtration cake.

As already mentioned earlier, this can also be compensated by higher throughput capacities of alumina,

which will further increase the abrasive wear of the FTC.

Consequences for the fans

The FTC will now operate at much higher pressure losses. The fans can only compensate this with a decreased volume flow. To ensure the desired flow, spare fans or spare capacities have to be operated in parallel to reach the necessary volume flow. An operation mode of n-1 is no longer

possible, and every subsequent malfunction disturbs the furnace production immediately.

Systematic maintenance, including turn-down of fans becomes impossible.

Figure 4 shows a fan system in operation.

Fig. 4 Fan system in operation

Fig. 5 Dual phase spray nozzle system

Fig. 7 Condition of a duct system with accumulated deposits

49AWJ 2013

Solutions for a solid state upgrade

Main targets for a solid state upgrade of an FTC are:

1. A maximum reliability to operate 24-7-365 without any major interruptions.

2. Spare capacity and redundancy for maintenance works to be performed without production stop, operation with n-1 chambers to ensure 1.

3. A continuous high qualityperformance of anode production with minimum energy consumption and minimum emission.

It is also essential to perform a complete combustion of the volatiles inside the furnace. This can be ensured by an advanced state-of-the-art firing system, providing the FTC can provide the adequate volume and flow for all operation situations at the furnace.

Cooling tower

The cooling tower has to contain the stretch necessary for evaporization. Existing cooling towers have to be checked to establish if this stretch is available. Sometimes it is possible to increase the performance of evaporation by upgrading the lance system to a dual-phase nozzle technology with finest droplets.Figure 5 indicates such a spray nozzle system, consisting of 5 nozzles per lance.

In other cases, it might be advisable to renew the cooling tower by size and technology to eliminate the first major bottleneck.

Duct systems and Dampers

The duct system guides the gases through the FTC. Existing Duct Systems and Dampers have to be checked carefully. Non-optimized

layouts with multiple bends and elbows lead to high pressure losses. The same applies for special types of dampers. A proper design of the duct system is the basic task to minimize these pressures losses. A redesign of the damper system, can improve the performance of the FTC tremendously. Figure 6 shows a “symmetrical” design to optimize flows and pressure losses.

Finally, in existing plants the duct system has to be inspected for

Fig. 6 “Symmetrical” design of the duct system

ANODE PLANT TECHNOLOGY50 ANODE PLANT TECHNOLOGYANODE PLANT TECHNOLOGY

Fig. 5 Dual phase spray nozzle system

deposits. A complete cleaning of the duct system, dampers, and the cooling tower will also minimize pressure losses and improve the flow rates and performance of the FTC. Figure 7 shows the condition of a duct system with accumulated deposits.

Filter chambers

The adaptation of existing filter chambers is strongly dependant on the existing infrastructure and the existing design. The process requirements for a redesign of an existing filter chamber are easy to formulate, but not as easy to realize. The future value of the filter surface load should be favourable in a range of <1,0m3/m2 and minute. High gas flow rates in a range of 18 m/s in the ducts and reactors should be reduced in steps to less than 1 m/s in the area of the

filter bags. The separation of heavy particles (agglomerates) needs to be executed prior to the filtration cake. In this area, gas speeds of < 2m/s are obligatory.

The gas flow onto the filter bags should be in a wide area from bottom to top. Technical solutions which contain a horizontal flow generate an early tear and wear of the fabrics by partial overloads, and in parallel inactive areas inside the filter chambers.

As a first approach, disturbing installations should be eliminated. Second, the filter chamber should be fully furnished with a maximum possible amount of filter bags. In addition, a pre-separation chamber should be designed and installed to ensure the staggered deceleration of the gas speed.

In other applications it is possible to raise the filter chambers, and to prolong the filter bags. The maximum length is limited by the efficiency of the pulse jet cleaning system, and the maximum physical load on the filter bags during the cleaning cycle. Filter bags of up to 6m are feasible, longer bags need to be examined with care. Figure 8 shows the inner part of the filter chamber.If all these solutions are not viable, the amount of filter chambers has to be increased.

In general 2 main topics have to be considered:

• Production must be possible even with n-1 chambers in operation, meaning with 1 chamber isolated.

• The change of one complete set of filter bags for one chamber should be possible during one production shift.

Conclusion

If all these aspects are technically realized the desired performance for higher production will be available. As a positive outcome, the dosing of fresh alumina can now be tuned and minimized. If the right balance is found between fresh and recirculated alumina, the wear and tear in all aspects of the FTC will be minimized and the adsorbtion ratio, respectively the cleaning effect is maximized. This leads to minimum emissions in the clean gases which are vented to the atmosphere. At the end, a detail assessment will be conducted to show, if or how, a retrofit or partial renewal of equipment is feasible.

Fig. 8 Inner part of the filter chamber

AuthorsDipl.-Ing. D. Maiwald;Dr.-Ing. F.Heinke;Dipl.-Ing.(PE) D. Di Lisa;InnovathermProf.-Dr. LeisenbergGmbH & Co KG,Butzbach, Germany

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Novel Anode Bake Furnace Gas CleaningBy Bo Herrlander, Alstom

Introduction

In November 2011 Alstom started the novel gas cleaning plant for anode bake furnace at Alcoa Mosjøen, Norway. This Fume Treatment Centre (FTC) comprises a new gas cooling principle replacing the conventional conditioning tower with a heat exchanger. The “AHEX” heat exchanger has the dual purpose of cooling the flue gas and simultaneously works as a reactor for capturing tar and hydrogen fluoride (HF) on alumina. The heat exchanger is integrated into the filter and will thus constitute a very compact FTC design.

The novel Fume Treatment Centre concept

Even though improved state-of-the-art firing technologies on today’s open anode bake furnaces have significantly reduced the emissions, there is still a need for further gas cleaning to meet regulations. The main furnace emissions are compounds in the flue gas such as PAH (Polycyclic Aromatic Hydrocarbons), HF, SO2 and carbon particulate. HF emissions originate

from the recycled butts used in the anode production and PAH from the green anode material. There are PAHs known for their carcinogenic, mutagenic and teratogenic properties such as benz[a]anthracene*, chrysene*, benzo[b]fluoranthene*, benzo[j]fluoranthene, benzo[k]fluoranthene*, benzo[a]pyrene*, benzo[ghi]perylene, dibenz(a,h)anthracene* and indeno(1,2,3-cd)pyrene* (*classified by the US EPA as probable human carcinogens). Some of these compounds are subject to emission levels set by government authorities. These are typically expressed as subsets of the various PAH’s such as PAH-16 and OSPAR 11, which includes 16 or 11 different PAH. The abatement of PAH is temperature dependent in such a way that the removal efficiency increases by lowering the flue gas temperature.(see fig.1)

This novel FTC with AHEX solves a number of problematic issues related to the traditional conditioning tower-filter combination. The conditioning towers evaporative cooling principle increases the flue gas moisture

Fig.1 The integrated Alstom AHEX FTC

content, typically by some 6 - 7 %, to reach the acceptable operation temperature levels around 100 – 110 oC. However, a drawback of this method is that the increased moisture content may cause corrosion in the conditioning tower and hydrolysis of the bag polyester material in the fabric filter. By contrast the gas cooled in the AHEX avoids this humidity increase and thus prevents the above problems. In order to prevent these from fouling the AHEX tubes, alumina is injected upstream. Through this measure there is a controlled condensation of tar on the alumina. Since the tar will end up on the alumina there is no need for disposal of hazardous material. Conventional conditioning tower cooling may occasionally see wet bottom and tar rich effluents, and it will inevitably result in tar deposits in the ducts connecting to the filters, from where it must be removed and and safely disposed of as hazardous material. With AHEX no such ducts are required, as AHEX is integrated in the fabric filter.

This novel FTC with AHEX is built on Alstom’s DDS (Distributed Dedicated Scrubber) concept. The DDS is based on the well proven Abart dry scrubbing technology, which features a two stage counter current gas cleaning process. It is developed for green field as well as for retrofit/modernization projects, applications where space is limited, or where it is desired to keep the resources used for site installation/erection to aluminium. The DDS invention has been granted a patent in all major aluminium producing countries. The DDS integrates fresh alumina storage and is equipped with an internal alumina handling system powered by one high pressure fan. Enriched alumina from the DDS is distributed back to the pots via Alstom’s Alfeed system. There is one exhaust fan per filter compartment, which operates on medium voltage (440 V). This allows full flexibility

53AWJ 2013

for tuning the DDS for optimal performance. The DDS is supplied in modules, which makes the DDS easy to transport and install. The DDS may be fully shop-manufactured, as the size of a DDS compartment meets road transportation requirements. Shop fabrication ensures a uniformly high quality of work. Several DDS can be erected simultaneously and independently. The DDS system may integrate a SO2 scrubber on the top, which enables it to comply with more stringent emission limit values. The available reagent choice is between an alkaline solution or seawater. This DDS/SO2 technology will be in operation in 2013 at a smelter in Europe. (see fig.2)

The AHEX is integrated to the DDS, upstream of the filter stage. The hot gas, containing the condensable fumes, is cooled inside multiple water cooled steel tubes in the AHEX and enters the cooling tubes from the top. The fumes are mixed with alumina in the plenum upstream of the tubes inlets. The hot fumes include condensable tar components, which condense on the alumina surface during the gas

Fig.2 The Årdal DDS

cooling. Simultaneously HF and to some extent SO2 is adsorbed. Due to the efficient mixing of alumina and gas inside the heat exchanger tubes, more than 95% of the HF and tar is being adsorbed on the alumina inside the tubes. The efficient collection of tar aerosols on the alumina particles reduces the risk for tar depositing on the heat exchanger surfaces. In addition, the injected alumina will clean the surfaces from possible deposits as demonstrated in the earlier trials in the Middle East, which were the basis for this patented design. Control or elimination of heat exchanger surfaces fouling has been the main driver behind Alstom’s development of this new fire tube heat exchanger. Alstom has long-term experience with fire tube heat exchangers on similar or more difficult flue gases, such as from Fe/Si- and Si-metal furnaces. Over the last 3 years this technology has also been proven for potgas in full-size demonstration units (EHEX, MHEX, IHEX) at Alcoa Mosjøen in Norway.The adsorption process is enhanced by the even gas/particle distribution, relatively long retention time and short mixing length within the confined

space of the multiple parallel tubes. The dry process of the novel AHEX FTC, allows the gas to be cooled to temperatures below 105°C, possibly even below 80°C. This allows for further condensation of PAH and improved cleaning efficiency. After leaving the heat exchanger the cooled gas enters directly into the dry scrubber where the main part of the injected alumina is separated into the filter hopper and re-circulated directly back to the heat exchanger inlet. Primary alumina is injected in the filter compartment, and collects on the bags in a final polishing stage, to adsorb any trace components of tar fumes and HF. The re-circulated or spent alumina leaves the system through an overflow device inthe filter hopper to be sent to the pots. The new AHEX FTC can efficiently handle a larger variation of the flue gas flow than today’s systems. There is no need for gas re-circulation, which is common for the conditioning tower based FTC.

The heat energy recovered in the AHEX may be used or disposed into the environment. One example of efficient use of the heat energy is


the use in district heating, another to use it for seawater desalination. Electricity production is also possible by deploying an Organic Rankine Cycle (ORC) machine. For the AHEX plant at Mosjøen, the hot water will be used for both district heating and for driving an ORC for electricity production. During the cold season, an extension from the plant’s (and thus also the town’s) district heating system to the AHEX is planned.

Validation of the novel AHEX FTC concept

The full scale AHEX concept is demonstrated at the existing Alcoa Mosjøen FTC delivered by Alstom. This includes six filter compartments downstream the conditioning tower. One compartment is retrofitted with the AHEX heat exchanger. Thus the gas bypasses the existing conditioning tower and flows directly into the top of the heat exchanger and further on to one filter compartment, which operates on gas from the heat exchanger only. This compartment is therefore conveniently benchmarked with the other five compartments running on flue gas from the conditioning tower. The measurements on the gas from these compartments are references in the full scale validation of the AHEX

performance. The ingoing water temperature to the AHEX is usually 60°C and the outgoing is 80-90°C. The inlet gas temperature normally varies between 160 to 190°C and the corresponding outlet gas temperature reads 90-100°C. (see fig.3)

The heat recovered in the AHEX heats up the 50% glycol water mixture to about 90°C. This fluid flows in a closed loop between the AHEX and the heat delivering heat exchanger. Here it is normally cooled down to about 60°C. The heat flow is calculated from measuring the fluid mass flow and corresponding temperatures in and out of the AHEX, deploying a specific heat value of approximately 3300 KJ/kgK for the heat transfer fluid. The heat transferred to the fluid is in the range of 0.8 to 1 MW. This indicates a total heat recovery potential of about 5 MW for the complete anode bake plant at Alcoa Mosjøen. (see fig.4)

A fifty percent higher gas flow is estimated to flow through the AHEX compartment, compared to the remaining compartments. The reason for the higher gas flow to the AHEX compartment is the lower pressure drop across the AHEX compared to the conditioning tower. The gas flow is estimated within +/-10% accuracy

Fig.4 AHEX The combined heat exchanger and tar condensation system

assuming a gas specific heat value of about 0,37 Wh/Nm3. This is based on the fact that the heat absorbed in the fluid will be equal to the heat recovered from the gas (neglecting the small heat loss to the environment). The total gas flow to the remaining compartments is measured in a venturi duct.

To validate that there is no excessive dust deposits on the AHEX tubes, a heat transfer coefficient is calculated from the measured data and divided by a theoretically calculated heat transfer coefficient from the literature. The stable quota curve indicates that the heat transfer coefficient is not degrading due to e.g. excessive dust deposits. Even if there are some fluctuations in the measured pressure drop, it is evident that the pressure drop is not increasing over time. This is also verified by several visual inspections of the heat exchanger surfaces. It demonstrates that the heat exchanger is clean and not fouled by tar residue.

Extractive PAH samples from the flue gas were collected with standard methods from the inlet to the conditioning tower, and from the AHEX compartment outlet as well as from the other compartments outlets.

55AWJ 2013

Fig.3 The installed full scale demo AHEX FTC at Alcoa Mosjøen

Based on these measurements the removal efficiency is calculated. During the measurements, the outlet gas temperature from the AHEX was set identical to the conditioning tower outlet temperature, to simplify the comparison of the AHEX concept with a conventional filter compartment. The measured removal efficiency of the AHEX can therefore be considered to be conservative, since more PAH will be collected in an AHEX FTC, should it be operated at the lowest gas temperatures possible. An external laboratory analyzed the samples for the different PAH compounds (Gas chromatography–mass spectrometry method). It is evident that the AHEX compartment has similar or better removal efficiency compared to the reference compartment. Overall the removal efficiency for the PAH-16 gas compounds was 18% higher for the AHEX compartment. As the gas flow through the AHEX compartment is in the order of fifty percent higher compared with the reference compartment, the AHEX compartment collects about 70% more PAH (kg/h) than the reference compartment. An ocular inspection of the enriched alumina from the AHEX compartment revealed a much darker color compared with the reference compartment. As the primary alumina

flow to all of the compartments is identical, it supports the higher collection efficiency. HF emissions from the filter compartments were measured by portable HF analyzer. It showed that the HF emissions from the AHEX compartment were significantly lower than from the reference compartment.

Conclusion

A novel Fume Treatment Centre (FTC) concept has been developed. The core of this concept is the integrated heat exchanger reactor combination, simultaneously cooling the flue gas and adsorbing PAH, condensed tars and HF on alumina. This novel FTC concept is a further development of the Alstom’s DDS (Decentralized Dedicated Scrubber) Technology. This new AHEX concept integrated into the filter eliminates the need for a conditioning tower with water injection. All the operational challenges related to the conditioning tower (corrosion, tar deposits, bag hydrolysis) are reduced or removed. The fumes flow directly into the filter, without the need for a duct from the conditioning tower to the filter. The AHEX concept allows cooling the gas to below 100°C without the risk of corrosion of the duct and the filter. The improved cooling of the

gas will allow for even higher removal efficiency. The AHEX offers recovery of approximately 1 MWth heat per compartment.

The concept has been validated on a full scale demo-plant at Alcoa Mosjøen, which has been in operation since November 2011. The performance of the compartment with AHEX has been compared with another compartment running on conditioning tower at the same gas temperature. The emission measurements show that the AHEX has an improved removal efficiency, compared to the compartment with the conditioning tower. This higher efficiency is achieved even though the AHEX compartment handles fifty percent more gas compared with the compartment downstream of the conditioning tower.

The novel AHEX FTC is more compact, compared with a conditioning tower cooled FTC, and allows for improved removal efficiency, reducing emission of carcinogenic tars and gaseous fluorides. It recovers heat which when used reduces the carbon footprint of the smelter. It eliminates handling of carcinogenic residues from tar drop outs in conditioning towers and ducts, and it adds “renewable” energy to the smelter. It secures lower operational and capital costs compared with the conventional conditioning tower cooled FTC. AHEX is flexible, allows integration in existing FTCs and will add many benefits, both to greenfield and brownfield smelter projects.

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Pot feeding systemsPneumatic ship unloadersTruck and railcar loading stationsSilo storage systemsHarbour facilitiesHigh capacity pneumatic conveying systems

ISO 9001ISO 14001OHSAS 18001

Global leader in materials handling systems

For over forty years Alesa has been supplying aluminium smelters with systems to handle and convey bulk materials such as fresh and reacted alumina, crushed bath, coke and � uoride.

Why?

Our knowledge goes beyond materials handling. Being an aluminium producer we understand how our systems impact your process. Alesa is a full service technologies supplier that also offers automation, pot controls systems and reduction technologies.

Trusted by more smelters than any other.

RTA Alesawww.rta-alesa.comT+41 44 435 33 33

109028-Pub_RTA-Alesa_2011_full.indd 1 11/09/02 9:47 AM

Pot feeding systemsPneumatic ship unloadersTruck and railcar loading stationsSilo storage systemsHarbour facilitiesHigh capacity pneumatic conveying systems

ISO 9001ISO 14001OHSAS 18001

Global leader in materials handling systems

For over forty years Alesa has been supplying aluminium smelters with systems to handle and convey bulk materials such as fresh and reacted alumina, crushed bath, coke and � uoride.

Why?

Our knowledge goes beyond materials handling. Being an aluminium producer we understand how our systems impact your process. Alesa is a full service technologies supplier that also offers automation, pot controls systems and reduction technologies.

Trusted by more smelters than any other.

RTA Alesawww.rta-alesa.comT+41 44 435 33 33

109028-Pub_RTA-Alesa_2011_full.indd 1 11/09/02 9:47 AM

57AWJ 2013

MATERIALS, HANDLING & TRANSPORTATION

Coperion GmbHHow Should A State Of The Art Vacuum Ship p. 58-61Unloader Look Like?

Vigan Engineering Expertise In Alumina Unloading p. 62-63

Siwertell Technology That Delivers On All Counts p. 64-67

Neuero Developments In Alumina & Pet Coke Ship Unloaders p. 68-69

SMVFresh Thinking For A Better Working Environment p. 70-72

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How Should A State Of The Art Vacuum Ship Unloader Look Like?

Introduction

Coperion is a leading supplier of pneumatic vacuum ship unloaders for unloading of Alumina and Petcoke from seagoing vessels. In 2007 Coperion incorporated the Hartmann company, acquiring with it, the experience of more than 100 years in the field of pneumatic unloading.

The design of the vacuum ship unloader will be adapted to the climatic conditions of the operation place. Coperion has proven to have the right technical solution with its references reaching from hot areas in the Middle East, to very cold areas in Canada.

Coperion can adapt the unloading

capacity of its vacuum ship unloader from 150 t/h up to 1.200 t/h. The capacity design is done considering a specified max. berthing time and/or the capacity of already existing down stream conveying equipment.

Single Or Double Boom

The distinctive attribute of a vacuum ship unloader is the number of unloading nozzles and conveying pipes. Usually there are 1 or 2 pipes and each one is arranged on one boom. Hence there are single or double boom unloaders.

A single boom design has its advantages in a minimum amount of equipment and a lighter steel structure due to one single point for the force introduction. The lower

amount of equipments reduces the maintenance costs of a single boom compared to a double boom. (see fig.1)

The double boom design is more flexible and the unloading process can also take place in two separate hatches. Another big advantage is the high availability of the system, due to the fact that the unloading can also take place with one boom in case of any technical break down of the other one. Also the resting process is faster with a double boom design and therefore reduces the berthing costs of the ship.(see fig.2)

Conveying line

The conveying line of the vacuum

Figure 2: Coperion double boom vacuum ship unloader

MATERIALS HANDLING AND TRANSPORTATION

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ship unloader has various special equipments which will be described in the following part.

A proper adjustment of the product fluidisation and the conveying air at the product pick-up point is necessary to achieve smooth product conveying. Coperion has designed a special suction nozzle with adjustable setpoints for the false air, ie. the air that will be aspirated in addition to the mixtureof bulk material and air at the nozzle inlet.

This leads to an optimized, stable and safe aspiration process at the nozzle inlet and consequently to a stable and reliable pneumatic conveying process in the pipe.

The telescopic vertical suction pipe is needed to reduce the lifting height during lifting of the boom and to adapt the pipe length to the tide height of the ship. After the vertical suction pipe the 90° bend is needed to guide the product flow. On this 90° bend the product flow impacts directly and wears the lining of the bend. To ensure a high life time these bends are lined with basalt or ceramic. Another important feature after the 90° bend is a pipe prolongation with the same lining as used for the 90° bend to reduce the wear of the first part of the horizontal suction pipe where the product stream is still a strand on the pipe top.

The horizontal pipe can be executed as a fixed or a telescopic pipe. Whereas the fixed pipe has less investment cost and less maintenance cost, the movable pipe is more flexible for positioning the vertical suction pipe in the hatch. Without a telecopic device at the horizontal pipe, often the entire ship unloader has to be moved for placing the suction nozzle in a desired position.

A highly efficient pre-separation of the bulk material from the conveying air is necessary in order to protect the filter bags of the vacuum filter and to extend the lifetime of the latter. Therefore, Coperion has designed a filter with a pre-separation of bulk material and air. As a result Coperion can optionally use filter cartridges instead of filter bags, thus enabling downsizing of the filter housing. The Coperion filter specialists are continuously working to Improve the performance of the filter and to deliver to our customers the state-of-the-art technology or to update the existing filters.

Coperion has two different systems for the airlock beneath the filter. Both airlocks are based on the rotary valve design, which assures continuous discharge. The first air lock system is the Coperion rotary belt discharger. The rotary belt discharger has belts for sealing the rotor and for minimizing wear on the housing of the rotary valve. This solution is a well proven and economically beneficial technology.(see fig.3)

The second solution is the Coperion ceramic lined rotary valve. This valve has a ceramic lining in the housing and tungsten carbide welding on the tip ends of the rotor in order to have

a much higher wear resistance than the economic construction materials like mild steel or cast iron. This solution has a very long lifetime and is economical due to the savings achieved from lower maintenance costs.(see fig.4)

For discharging the product from the rotary valve to the jetty conveyor Coperion offers different solutions depending on the bulk material. These solutions are:

• Coperion Duroslide (Air gravity conveyor). This is the most economical solution for the conveying of Alumina, if the difference in height of the ship unloader and the Jetty belt conveyor allows the installation of a sloping air gravity conveying.

• Belt conveyor. This is the most economical solution, if Petcoke and Alumina have to be conveyed. In addition, this technology allows the installation of a belt scale for controlling the total unloaded mass.

• Through chain conveyor. The through chain conveyor is a totally enclosed and robust system for the conveying of Petcoke and Alumina.

Figure 1: Coperion single boom vacuum ship unloader

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To generate the vacuum in the conveying system Coperion uses its own rotary piston blower or a fan. Each of the two principles has its advantages in different application sizes.

Two stage fans will normally be used in vacuum ship unloaders with high capacities (>300 t/h) in one conveying line. Fans have the advantage of low investment costs. Furthermore, the efficiency is higher in the nominal operating range. During the resting process the transported capacity of bulk decreases and the conveying velocity would increase if not adjusted accordingly. The conveying velocity has a direct impact on the wear aspect. In a fan application the air flow can be reduced easily with a flap.

Below a conveying capacity of 300 t/h the rotary piston blower has proven to be the best technical and economical solution.(see fig.5)

Steel structure

Beside the process equipment in the pneumatic conveying line there are different mechanical aspects that make a Coperion vacuum ship unloader unique. The slewing mechanism for the boom can be located directly below the booms, so only the boom is slewing. Another solution is to locate the slewing mechanism under the filter housing, which means the entire upper part of the unloader including all equipment like filter, rotary valve and the rotary piston blower/fan are moving with the boom.

The first solution applies for double boom vacuum ship unloaders and the second solution

will be used for single boom vacuum ship unloaders, with the aim to use the filter and the other equipments as a counterweight to the long and heavy boom. Then no additional counterweight is necessary and the gravity centre can be lowered as much as possible.

In general it is necessary to reduce the steel weight to a minimum and to design the unloader to have the gravity centre as close to the ground as possible. One advantage of the lower gravity centre is the resistance against earthquake forces that have to be considered and that would lead to instability in case of a high gravity centre. The second advantage is the reduced cost of steel/steel assembly and therelated costs for the grounding and rails. Another important point regarding the loads on the quay is the amount of the wheels and how they distribute the loads to the rail.

The most convenient solution for the steel structure can only be provided with the choice of the beststeel structure concept and the application of modern FEM design tehniques.

Modernization, Refurbishment

Beside new vacuum ship unloaders

Coperion is engaged in engineering studies and revamping projects of vacuum ship unloaders for example on the following items:

• Exchange of the bogies

• Boom exchange

• Filter refurbishment

• Exchange of the control system

• Throughput increase

Summary

Before designing and installing a new ship unloader, many different parameters have to be considered, reaching from the environmental data (temperature, wind forces,

MATERIALS HANDLING AND TRANSPORTATION

Figure 3: Coperion rotary belt discharger without cover

Figure 4: Ceramic rotary valve in a vacuum ship unloader

Figure 5: Coperion rotary piston blower

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earthquake forces) to the individual requirements of the customer (max. loads on the jetty, unloading capacity, resting process).

As shown, there are many technical solutions available for each part of the pneumatic unloading process, for the supporting steel structure and for the motion of the ship unloader.

Only with the profound know-how of an experienced specialist like Coperion, that has available the entire range of technologies for each process step, it is possible to design the optimized technical and economical solution that fulfils the project and customer specific requirements.

>>Why we enjoy an unloading challenge. Because time is money and this is also very true when it comes to alumina and petcoke unloading. With our Vacuum Ship Unloader VSU, fea-turing leading-edge technology and our deep process know-how, we can guarantee short ship lay times and ensure gentle and reliable unloading of your product. That’s what we mean when we say „confi dence through partnership“ . >>www.coperion.com

> For unloading capacities up to 1.000 t/hr

> Double or single boom technology

>compounding & extrusion >materials handling >service

VSU_210x148.indd 1 20.11.2012 13:57:38

Authors: Frank Speck (Head of Sales, Aluminium & Minerals Industry) and Bertram Bartsch (Sales Manager, Aluminium Industry)

62 MATERIALS HANDLING AND TRANSPORTATION 71

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VIGAN EXPERTISE IN ALUMINA UNLOADING

Alumina's characteristics as a white powder, very free flowing but also quite abrasive make its handling rather complex in order to achieve optimum performances in terms of quantity to be conveyed but at the same time to avoid dust and spillage.

Most frequently, alumina is unloaded from sea vessels into a special conveying system to the storage facilities, or into a hopper from which it is downloaded into trucks but it can also be directly packed on the quays, into 1 or 2- ton big bags for instance, to be transported later on to smelting plants.

The traditional unloading method is done by grabs and simple hoppers on the quay. The hoppers can be integrated with weighing scales and filling equipment for large-size bags.

Two major concerns with grabs:

• DUST pollution is a serious problem, mainly in urban areas. Any moderate breeze will blow away the alumina, thus contaminating the air and surrounding areas which must be continuously cleaned.

• SPILLAGE: 0.2 to 0.5 % of such a valuable product as alumina. The use of hoppers with dust suppression devices like fans and air filters is feasible. Nevertheless, the investment cost is relatively high and can reduce operational flexibility, with quite large size and heavy port equipment to be displaced along the ships.

VIGAN pneumatic unloaders

Pneumatic unloading is a most convenient way for handling alumina. Its free flowing characteristics make its suctioning very easy and because the product is conveyed in a totally enclosed system, pollution by escaping dust and spillage is almost totally eliminated.

VIGAN expertise in alumina unloading includes up-to-date technologies such as:

- Optimized design of the suction line and with unique high wear-resistant alloys.

- State-of-the-art know-how for separating the alumina from the conveying air without any airlock: maintenance free.

- Special filter conception and filtering material to guarantee dust-free air exhaust.

Frequency converters, also called speed variators or an inverter, allow continuous and precise controls of the suction pattern with most significant energy consumption savings.

Self-propelled on rails or on rubber wheels for instance, VIGAN unloaders are able to move easily along the ship and no additional equipment (such as hoppers) are required to ensure quick and reliable unloading operations.

With equipment for alumina unloading already commissioned in several countries such as Finland, France, Poland, China and Iran, VIGAN has gained a large amount of experience regarding this raw material handling in bulk.

This cost-effective technology for alumina unloading is a most promising alternative for many ports and the alumina processing industry.

Up-to-date handling technologies for alumina are a major concern in many ports not only to achieve low operational costs but also for minimizing environmental impact.

64 MATERIALS HANDLING AND TRANSPORTATION

A wide range of benefits, including dust-free operations, high handling rates and minimal material losses, ensure that Siwertell technology delivers excellent commercial and environmental credentials.

Cargotec’s totally-enclosed Siwertell unloading and loading systems have put the brand at the forefront of environmentally considerate dry bulk handling for decades, well before many operators or legislators gave much thought to the issue. As a result, Siwertell technology was perfectly positioned for the onset of local, national and international regulations designed to improve the industry’s environmental credentials. Current product lines maintain this position and easily meet and exceed all existing environmental standards.

“This market leading environmental position is no accident,” says Juha Huovilainen, Sales Director for Siwertell at Cargotec. “It is a natural outcome of developing and employing

Totally-enclosed Siwertell technology delivers on all counts

sophisticated, reliable, efficient machinery capable of handling almost any type of dry bulk material, normally without any modification or adjustment."

“When, as in this case, the technology and philosophy are fundamentally sound, the benefits can be widespread, and that is certainly true when Siwertell equipment is employed for handling alumina in bulk.”

Considering the unloading operation, the clean discharge delivered by a Siwertell totally-enclosed screw-type unloader delivers important economic benefits in addition to providing a safe, dust-free environment for the personnel directly involved and for those in the wider local environment.

The absence of dust and the elimination of spillage mean that there is no expenditure on cleaning the vessel and the port facilities. Furthermore, all of the cargo contained within the vessel is

delivered to the aluminium production plant; the amount of cargo that can be lost using other discharge methods may come as some surprise.

A practical demonstration

In 2012 Siwertell conducted a test at the port of Hamina in Finland, which imports about 500,000 tonnes of alumina per annum, from around 60 vessels, each of about 8,500 dwt. Normally the port employs conventional grab cranes, unloading directly into railway wagons.

A 15 000 S Siwertell road-mobile unloader was used to provide a real world comparison between the open and enclosed unloading systems.

“The unloading area was completely clean during and after the test with the Siwertell unloader,” notes Mr. Huovilainen. "This was in marked contrast to the standard grab crane operations when the port area was completely covered in white alumina

65AWJ 2013

powder. Annual material losses using grab cranes amount to about 1.57 percent. On Hamina’s annual throughput this equates to 7,850 tonnes of lost cargo; at an average price of 400 US$/tonne this translates to US$ 3,140,000. On these figures, payback time for the road-mobile unloader would be less than nine months.”

This test supports the benefits identified by earlier case studies (see box).

Performance on all levels

It is not only important to unload all the shipped cargo without loss; the condition of the cargo as delivered can have a big impact on the production process. Alumina can be a delicate cargo, in particular the ‘sandy’ type of alumina particles display a higher tendency for crushing in the transport process than the ‘alpha’ type of alumina with rounder particles. But regardless of type, alumina requires

gentle handling because crushing and the consequent generation of ‘fines’ has an adverse effect on the aluminium production process. The higher the percentage of fines, the slower the electrolytic process and the greater the energy consumption.

“Siwertell’s screw-type unloaders have a very light touch on the bulk material passing through them,” he says “Typically, alumina cargoes handled by Siwertell machinery will have around 0.1 percent fines. Pneumatic transportation, in contrast may well show a value of five percent fines.”

In addition to these benefits, Siwertell systems are also cost-effective. The well-proven screw conveying system ensures continuous, high capacity operation, but there is more to it than that.

“While a high rated capacity is important, it is the average, through-ship capacity that tells the full story.

Siwertell defines unloader efficiency by comparing rated capacity with average capacity; all its unloaders score highly by this measure. Furthermore, Siwertell unloaders are very energy efficient; for example a Siwertell mobile ship unloader consumes only 0.18 litres fuel or 0,5KwH per tonne during a cement handling operation; the figure for alumina would be similar .”

Aside from the road-mobile range, Siwertell unloaders are categorised in three types, F, M and D, reflecting the size of ship to be handled, the required rated unloading capacity and the commodity to be handled. The main difference between the groups relate to the supporting steel structures carrying the conveyors and the arm system.With the exception of the road-mobile products, all Siwertell unloaders and loaders are tailor-made to suit the particular requirements of the operator and any constraints imposed by the proposed location for the system.


Once again, these unloaders are very energy efficient and typically Siwertell will guarantee the power consumption for a ship unloader.

To meet the range of market requirements, Siwertell has developed ship loaders using three different conveying technologies: screw, aero slide and belt. The choice of conveying method depends on factors including local site conditions and the cargo or cargoes to be handled. As with the unloaders, the totally-enclosed technology delivers exceptional environmental performance.

Local service on a global scale

Operators must have confidence in the quality, performance and reliability of the equipment they purchase; not just at commissioning,

but throughout its working lifetime. Siwertell machinery employs patented, proven technologies and engineering philosophies developed by a world-leading company; hundreds of installations have demonstrated their effectiveness in decades of operation.

Long term viability is ensured by extended support from the manufacturer. As a Cargotec brand, Siwertell has access to a global service organisation, through which it offers service solutions on a planned, on-demand and emergency basis. Planned maintenance agreements, in the form of Siwertell Care agreements (STCs), are tailored to meet an operator’s specific needs and ensure reliable, safe operations that maintain the equipment’s original design capacity.

Case studies demonstrate Siwertell advantages

Customer: ALUMINIJ MOSTARLocation: Port of Ploce, CroatiaReason: Client operation; alumina from Sicily.Date: 1997-2006Capacity: 150t/hEquipment: Siwertell 5000 S /+ 3 x 18m mobile screw conveyor, road-/port-mobileResult: Very positive. Fully dust and spillage free operation. Screw technology worked extremely well. High efficiency, cargo breakage calculated at about 0.1 percent. No screw conveyor wear due to very low turning speed.Plans and targets: Continuation of environmentally friendly, high-efficiency unloading. Reports are available.

Customer: FREMANTLE PORT AUTHORITYLocation: Kwinana AustraliaReason: Full scale test with the Ports. Siwertell test arranged by Cargotec together with SGS. Alumina from ALCOA.Date: end 2006Capacity: 1,300t/h for sulphur and fertiliser, about 650t/h for alumina.Equipment: ST640-D, full-bodied rail-travelling Siwertell unloader for Panamax vessels.Result: Extremely low degradation: “There was no significant difference between particle size distributions before and after being handled by the unloader”. Dust and spillage free operation. Screw technology worked very well.Plans and targets: To prove to new customers that degradation with a Siwertell unit for handling of alumina is close to zero. Full SGS report is available.

“Siwertell support goes beyond simply maintaining equipment in good condition,” says Mr. Huovilainen . “ As technology develops and operational requirements and regulations change, Siwertell systems can be modernised and upgraded to take full advantage of any new developments.”

For more information on Siwertell systems, please send an email to:

[email protected]

or call +46 4285800

Official website: www.siwertell.com

67AWJ 2013

This demonstrates how much spillage you get with a Siwertell ship unloader.

www.siwertell.com Siwertell is a Cargotec brand


MARKET REVIEWDevelopments In Alumina & Pet Coke Ship Unloaders

MARKET SITUATION - CHARACTERISTICS

Unloading Alumina is a small niche because the amount of installations needed worldwide is limited. They are typically required with a new smelter or to solve logistical or environmental problems in existing operations.

The biggest aluminium market players have a company in-house that supply them. This makes it challenging for other suppliers to position this special type of equipment in the market. It is difficult to compete because of the logical consequence of internal preferences and the available and emerging opportunities being awarded accordingly.

In the past a tender came out with high execution costs, calculation, drawings, trips and even Bid Bond were requested, all without any guarantee of a fair decision after technical equalisation. This lack of competition however does nothing to motivate innovation and ultimately pushes costs upwards. New Chinese, Indian and Russian players are changing this situation and actual plants like Vedanta in India and Rusal in Russia have opened opportunities for suppliers to showcase new developments in the market.

In the market you can find 2 different types of alumina shipunloaders. These are called single boom and dual boom systems. The advantage of the dual boom system remains its capability to split the load and give redundancy. This is not always compensated in a technical / economical comparison. Being the more expensive option in execution, and the fact that it is not a complete redundant system can make marketing harder. The single boom unloader has the advantage of being less expensive, which is due to the boom having a natural counterweight of the machinery house with the blower inside.

However 2 unloaders with smaller capacity (for example 400t/h) are not more expensive than a single machine with double capacity. The extra operational cost involved can be reduced by using automation in cases where "manpower" cost is high. The redundancy and unloading efficiency is achieved. At clean-up the unloading capacity is reduced because the material needs to be pushed to the nozzle, therefore using one smaller

machine instead of a bigger one is more effective. EXCEPTIONAL WORKING RANGE AND SIMPLE DESIGN AT THE FOREFRONT

We provide a clean design with a horizontal telescopic conveying line, and a simple airlock for the separation of Air / Product. The horizontal boom can be equipped with a fixed point. Equipping the boom with a fixed point saves money in investment and maintenance cost but can make operation difficult depending on the other equipment on the quay or the ships gears or both factors taken together.

The horizontal telescopic conveying line facilitates manoeuvres and reaches the hatch without travelling, which is essential in case of a need to use stationary equipment. This is particularly important when the ship is effected by interferences such as cranes or other devices along it that force manoeuvres to occur.

One conveying line with one simple rotary airlock simplify the system. With such a solution there is no need for special requirements like changing from alumina to pet coke for example. Worth considering is that unloading pet coke is also often needed for aluminium plant operations. NEW M400AL UNLOADER

Neuero's new M400AL unloader supplied to an Aluminium discharging port at Kakinada Port not only

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achieved the contracted performance requirements but surpassed them. The capacity in the peak is about 500t/h and the power consumption approx. 600kWh. The short delivery time also helped to make the investment more attractive.

This unloader is mounted on rails, however a similar version on rubber tires is available as well as a set with its own power generation capability. STATIONARY – ON RAILS or ON RUBBER TIRES

Several references of ship unloaders for different products and in different environments open up options to choose from depending on use. The use of equipment on rubber tires makes it possible to solve problems even in ports where no permanent position for placement is possible. An unloader equipped with its own power generating unit is truly independent of local power supply in cases where this is not available or is insufficient. The alumina can be delivered directly to trucks, to mobile conveyors or to big bag stations. NEUERO - A SPECIALIST COMPANY

Focusing on Ship unloading and Ship loading gives us the advantage of learning effectively with each and

every installation and provides space for the ongoing development of the key components used such as Turbo Blowers, Airlocks, Winches and Conveying pipes.

Project management with worldwide experience with quality and our safety certifications (in accordance with the ISO 9001:2008 and OSHAS 18001:2007) highlight this expertise and knowledge. Training, technical assistance, and after sales service gives the necessary client support for this important piece of equipment.

OUR IN-HOUSE COMPONENTS DESIGN AND MANUFACTURING

Direct turbo blowers – Simple design with effective vibration and temperature controls, essential for any ship unloader. Our blowers are the result of more then 40 years of continuous development.

Belt Rotary Airlocks - Have been perfected, although not yet reached the

optimum as development is on-going. The other competitors alternatives are not superior considering the slide gates for this product.

Conveying pipes – Now made of Hardox 450 and completely avoiding cross-seam welding. Unbeatable in the market.

Winches – To get over control of roughness work in this type of equipment our own winches were developed adequate for this outside operation and controlled by a central PLC.

IN CONCLUSION

Even in the most difficult environments it is possible to supply simple and efficient equipment solutions as well as to continue fostering ongoing equipment development to meet future challenges. Neuero has the necessary know-how and resources to provide Alumina and Pet Coke Ship Unloading equipment and solutions to the aluminium industry with innovation and flexibility as our guiding principles.

Contact Information:Eng. Andreas HaeuserEmail : [email protected] : http://www.neuero.de

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FRESH THINKING FOR A BETTER WORKING ENVIRONMENT AND IMPROVED EFFICIENCY

The most important element for smelters around the world today is qualified personnel.

Today a modern smelter has a high focus on security and good working conditions for their employees. Further, there are several other areas which can be improved with regard to safety, the working environment and process performance. SMV has worked in close co-operation with our customers for more than 55 years and have developed concepts which have contributed to achieving these improvements.

As a supplier it is essential that we remain conscious about the developments that are taking place, and continue to actively contribute with good solutions to the challenges emerging from an ever evolving market. As an example for this, I would like to mention one project we had some years ago.

A customer contacted us and wanted to discuss how they could improve upon one specific type of pot room vehicle they were using in their operation. With regard to this vehicle, they were weighed down with heavy

maintenance costs as well as a higher incidence of sick leave compared to operators on other vehicles. Together with our customer we discovered the areas with potential for improvement by using the maintenance log. We made a new design to accommodate the working tools more efficiently and focused on improving the ergonomic factors the client was having issues with.

The modifications we made on the vehicle, for delivery to the client, were:

Installing hydraulic suspension on all the wheels,

Equipping the cabin with an air suspended operator chair mounted on a hydraulic rotating table to ensure correct orientation towards the working area.

After some months of operating the upgraded vehicle we delivered, it was discovered that sick leave related to neck, shoulder and back problems had been more than halved. After one year in operation the findings demonstrated that the maintenance costs were also more than halved.

The strong focus given to these important factors contributes to a better working environment, as well as enabling the investment made to pay it itself off in a short amount of time. In the last few years we have seen a considerable extent of involvement from the people involved in executing the day-to-day tasks, such as maintenance, vehicle and process operators. This change has been very positive and we can conclude that it contributes to better products from us, and a greater sense of ownership from the customers side.

In the following I will present some of our concepts that have been developed very much in the same way with good customer involvement, combined with the creativeness of our skilled staff.

Reduce HF and improve working Conditions with the Hot Bath Crushing system (HBC)

In aluminium production hot baths are produced through the operation of changing anodes. Most smelters today focus on how to reduce HF emissions, improve working conditions, effective utilization of the buildings areas and effective logistics. SMV Hot Bath Crusher is designed to receive grabbed bath from the anode changing operation.

The first two hours are are especially important with regard to HF emissions, and it is critical to bring the bins with hot bath to the HBC as soon as possible after anode changing.

Hot Bath Crushing System


Once the bins with hot bath are tilted into the HBC the process starts automatically, the fumes are extracted into the suction/scrubber system, the material is crushed down and distributed onto a covered cooling conveyor. The length of the cooling conveyor is determined depending on the capacity needed and what temperature the second stage fine processing can handle.

This system is suitable for reducing fluoride emissions, substantially reducing the amount of bins in circulation, freeing up expensive cooling areas for bins as well as reducing the need for handling equipment and operators in the recycling process.

Improve Anode Consumption with the Hot Anode Milling machine

In Aluminium plants with pre-bake technology, peaks can occur under the anodes in different conditions. This can occur on start-up of the pots, thus lowering anode quality and having an adverse effect on the operation and tuning of the pots. The resulting deviations can present as

"mushrooms" or peaks in appearance, or as a generally uneven surface on the anode blocks underside. In both cases these deformations disturb the electrolysis and should be removed.

Normally the troubled anode is taken out and replaced, or the anode is taken out and an attempt is made to remove the deformation by dragging it over the floor, usually with limited success.

To secure optimal utilization of the carbon block, SMV have designed the Hot Anode Milling Machine, and since 1985 we have delivered over 32 machines. The principle of operation is that the machine is moved to the pot where the troubled anode is, and the anode is placed into the milling area of the machine by crane or anode changer vehicle. The milling operation takes approx. 4-6 min, after this the anode is put back with a clean and uniform surface. The total time outside the pot should not be more than 10-15 min. and the disturbance of the process and heat loss is minimal for the pot.

The operator is sitting inside the cabin with full overview of the milling and with no exposure to the fumes and heat.

Safe and efficient Service - Inspection on pots and pipes with SMV Service Wagon

At the top rack over the pots, there are several components which need to be inspected or replaced regularly. Further, most smelters also employ the feeding of oxide trough wall mounted pipes which have to be cleaned or replaced.

The SMV Service Wagon is a small and flexible vehicle and can be operated by one operator. The service wagon is equipped with a operator basket and a service crane. The platform is

raised and aligned to face the pot, and the crane enables lifting components from the floor/ vehicle to the top of the pots.

All movements of the crane and platform are performed from the remote controlled panel. It is designed for effective and secure performance and gives the operator a chance to execute the work in a safe way.

Reduce voltage drop with an Effective Anode Beam Repair System

After some time as the contact surface between the anode beam and anode stem becomes damaged, it is most important to have a smooth surface to avoid voltage drop. SMV have developed a system for the milling and welding of anode beams. The work can be performed inside pot rooms or in the service area for cell reparation.

The system is tailor-made for each customers needs and can be equipped with one or two milling heads, for dual milling/welding or single milling/welding operation. The equipment is hooked onto the anode beam with a crane or a forklift, and is operated from a remote control panel.

Before milling

After milling

SMV service wagon

Anode milling machine

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Efficient Logistics with SMV Anode transporters

Considerable masses of new anodes and used butts are transported. For most aluminium plants these operations represents high costs due to the wear and tear of the flooring.

SMV’s Anode Transporters are easily maintained, and their advanced suspension system reduce the damage on floors. The anode transporters consists of a standardized truck with a tailor-made trailer for different customers. The operator has full control with a direct view to the loading/unloading of pallets. If required the wagon may be equipped with covers.

By Lars Hovda, SMV A/S

COMPANY PROFILE

SMV was founded in 1958 and has a wealth of experience as a supplier to a variety of markets. What began as a company supplying the local market in the Sunnhordland region in Norway, has now grown to encompass a range of products and services provided to the local, national and international markets.

Today, SMV is a multi-disciplined company working within the field of industrial mechanics. Our various departments - including development and construction, machining, installation, testing, surface-treatment and service -, make it possible for us to provide packages covering everything from entire projects to smaller, individual sections.

By using modern design and construction programs our engineers perform design of vehicles, stationary machines for Potrooms, and rodding and bath recycling solutions created especially for the aluminium industry.

SMV has long experience with training, start ups, maintenance and preventive service on electro hydraulic machines / equipment. This work is performed both in-house at SMV or on site at Customer facilities (incl. mechanical, electrical, hydraulics, pneumatics). SMV has a number of strategic business partners that complement us in areas such as prefabrication of steel, automation and material transportation.

The company is ISO 9001-2000 Certified.

SMV Technology

• Product Development

• Engineering Services

• Project Development and

Management

• Spare Parts

• Machine Safety CE

• Safety Solutions and Products

SMV Production

• Machining

• Special Welding

• Installation

• Testing

• Surface-Treatment

SMV Service

• Service of Industrial Machines

• Service of Hydraulic Components

• Preventative Maintenance

• Renovation of Machinery


Lars Hovda

Managing director

Telephone Office : +47 53771200

Telephone Direct : +47 53771202

Telephone Mobile: +47 90840855

E-mail : [email protected]

Martin Fitje

Technical Manager

Telephone Office : +47 53771200

Telephone Direct : +47 53771206

Telephone Mobile: +47 90840853

E-mail : [email protected] : www.smv.as

74

Stressometer® Systems. From hot to cold.

The long standing problem of flatness measurement and control in aluminum hot rolling mills is now solved by ABB. Achievements in the field show yield improvements of 2 % and rolling speed improvements of 10%. Altogether this corresponds to millions of dollars on the bottom line. One reason for this is, as one of our customers put it, ”Good tail-out from the hot rolling mill results in high quality head-in to the cold rolling mill”.

The range of applications where the Stressometer system sustainably improves your business includes all kinds of cold rolling mills; and now also aluminium hot rolling mills. www.abb.com/pressductor

ABB ABForce MeasurementPhone: +46 21 32 50 00

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Stressometer® Systems. From hot to cold.

The long standing problem of flatness measurement and control in aluminum hot rolling mills is now solved by ABB. Achievements in the field show yield improvements of 2 % and rolling speed improvements of 10%. Altogether this corresponds to millions of dollars on the bottom line. One reason for this is, as one of our customers put it, ”Good tail-out from the hot rolling mill results in high quality head-in to the cold rolling mill”.

The range of applications where the Stressometer system sustainably improves your business includes all kinds of cold rolling mills; and now also aluminium hot rolling mills. www.abb.com/pressductor

ABB ABForce MeasurementPhone: +46 21 32 50 00

Since January 2013 the IST Industrieofen +Stranggieß-Technik GmbH is a member ofthe KUTTNER Group. The company isoperating with the brand name “ISTTechnology” and is a part of the businessunit of “Non ferrous Industries” of theKUTTNER Group.

Founded in 1949, the worldwide operatingKuttner Group designs and builds turnkeyplants for the iron, steel and non-ferrousmetal industry, as well as in the field ofenergy and environmental technology. Therange of services covers all stages of aproject starting with expert advice,individual planning, design, delivery ofmechanical and electrical equipment andsteel construction, installation andcommissioning of complete plants withcontrol systems and data processing. TheKÜTTNER group today employs over 650people.

Under the direction of Dipl.-Ing. ChristianHamers, KÜTTNER expanded the productrange of the business unit "Non FerrousIndustries" with technologies for thealuminum industry. The experts from IST willprovide their know-how for the melting andcasting of aluminum into the Kuttner Groupas the “Aluminum Division”. For existingcustomers of IST, the consolidation meansthat not only individual components can beprovided, but also complete plantscomposed by turnkey construction of thecharging, industrial furnace, heat recovery,off gas cleaning and automation.Furthermore, plants for the production ofaluminum from secondary materials cannow be realized. In addition to newconstruction, individual solutions foroptimization and modernization of facilitiesare also offered.

Consolidating the existing market presenceof both companies in their respective field ofactivities now allows serving a larger andeven more international circle of customers.

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Your full-line partner worldwide!

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Competence in Aluminum Melting

An extract of our references:

Volkswagen, Kassel WorksShaft Furnace

KUMZ Kamensk Uralsky Metallurgical WorksMelting and Pouring Furnace

Henan Zhongfu IndustrialTwin-Chamber Furnace (under construction)

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COMPANY PROFILES

Rolling MillABB Force Measurement p. 76-77

Cast House Hycast p. 78-79Kuttner p. 80-81Jasper GmbH p. 82-83

Heat Treatment Seco/Warwick p. 84-85

76 COMPANY PROFILES

Making your processes measure up

ABB Measurement ProductsForce MeasurementVasteras, Sweden

At the heart of ABB technology is the understanding that flatness, tension, pressure, position and dimension can be sensed accurately, reliably and repeatedly on a continuous basis. The data generated by such sensing devices can then be used to control external equipment in such a way that process parameters are kept constant. And as a result, operators can increase productivity and achieve higher levels of consistency in product quality. Our products not only measure the forces within a process, they help make sure that production measures up to expectations. Using state-of-the-art technology, ABB provides purpose built solutions for your force and dimension measurement needs. Making it possible for your production output to accurately match the most varying and demanding requirements.

Stressometer Flatness Control System installed in an aluminium rolling mill.

We are helping thousands of clients all over the world to boost their productivity and yield

Challenge the hidden potential within your application with the leading measurement technologies:

Pressductor® Technology

ABB’s well-known Pressductor® Technology is a measurement principle based on the magneto-elastic effect – the magnetic properties of a metal are influenced by the mechanical force applied to it. Because the signals produced are not reliant upon physical movement or deformation, the load cells combine sensitivity with extraordinary tolerance to overloads and virtually no built-in limit to the number of load cycles.

ABB’s Pressductor® transducer stands for unbeatable load cell performance, thanks to its unique combination of accuracy, overload capacity and ability to withstand harsh environments. By using this technology you will achieve higher quality and reliability, especially under demanding conditions.

Pulsed Eddy Current Technology

ABB has developed a completely new way of performing measurements with eddy current technology. It is a method that makes it possible to measure, in real time and in line, dimensions and other attributes with exceptional accuracy.

The new ABB technology is based on measurements of the voltage pulse induced in the coil when the current is suddenly interrupted. By measuring this value at three different times three parameters can be derived; the distance, the electrical resistivity and the thickness.

Since this is a non-contact technology it eliminates the drawbacks of common systems based on X-ray or isotope contact measurement.

Flatness Measurement & Control

Based upon our experience from more

AWJ 2013 77

ABB’ Millmate Thickness Gauging System installed in an aluminium rolling mill.

than 1200 installations of flatness measurements and flatness control systems worldwide we continuously develop new generations of the market leading flatness system – the Stressometer® System FSA.

This system will not only make your mill more competitive today, it will also provide you with tools and methods to ensure that you keep in front of your competition in the future. Internet technology gives you a non-proprietary platform - independent way of expanding the system functionality and the CPU power when your needs are growing.

Advanced control methods, such as the Extended Singular Value Decomposition (ESVD), bring rewards to our customers exceeding 100,000 USD per year.

Some of the benefits with the Stressometer® System are:

• Improved yield out of each coil• Improved strip quality• Shorter production cycles• Reduction of number of strip breaks• Reduction of cost for process development• Reduction of cost for maintenance

Lab accuracy in the mill

The Millmate Thickness Gauging Systems (MTG), utilizing the Pulsed Eddy Current Technology, open up a new dimension in metal strip gauging with superior features:

• Contact-free and yet material independent gauging for non-ferrous metals• Robust and completely insensitive for conditions in the measuring gap, such as oil, water, coolants, steam, etc.• Accuracy to a level of 0.1%• Poses none of the risks associated with X-ray or isotope gauges• Measures as accurately in production as in the laboratory

A non-contact, non-optical measurement system

The Millmate Strip Scanner System determines the edge position of a metal strip in a rolling mill down to millimeter resolution. High, consistent quality is always the aim when producing steel, aluminum or copper strip. This is equally true in rolling mills and process lines.

Modern rolling mills often use a variety of measurement and control facilities. One of the most important parameters is the position of the strip. If this is not correctly measured, there is a great risk of rolling the strip under incorrect presumptions. This leads to poor flatness, especially at the edges, and to a final product of inferior quality or even strip breakage. In addition to this, the strip width must be kept within the specified tolerances – essential for good economy of production.

Millmate Strip Scanner System installed in a rolling mill.

HycastGame Changer Casthouse Solutions

®

78 COMPANY PROFILES

In 1990 Hycast AS was established by Hydro to be a commercial manufacturer and market organisation for casthouse technology developed in-house at Hydro’s R&D centre at Sunndalsora. The first product was an inline degasser but shortly casting technology for extrusion ingots, and stations for pot line metal fluxing followed. Most of the Hycast products have been captive during these two decades.

Today the Hycast product portfolio covers the whole casting centre and includes;

RAM – Removal of Alkaline Metals

SIR – Inline Melt Refining Hycast Launder Systems and Grain Refiner Rod Feeders

CMV – Casting Machine Vertical for extrusion ingot and sheet ingot casting

GC – Gas Cushion / LPC – Low Pressure Casting, extrusion ingot casting technologies,

AFM – Adjustable Flexible Moulds / FM – Flexible Moulds and, sheet ingot casting technologies,

CCS – Casting Control SystemsHycast Services, Knowledge and Competence

The business model of Hycast is to be an engineering company for aluminium casthouse projects. Manufacturing is done by a limited number of qualified suppliers. Innovation is a highly prioritized task and new product development is done in close collaboration with Hydro’s R&D and production systems, technology partners, customers and suppliers. The core competence of Hycast is actually multi-disciplinary. Aluminium metallurgy knowledge

HYCAST PROFILE

is the basis for all our products and services but process understanding, mechanical and electrical engineering, automation and project execution are equally important competences at Hycast. Over the years a substantial number of small and large projects have been completed in most corners of the world. The largest project so far for Hycast has been Qatalum. Here melt treatment in crucible, vertical DC casting machines, inline melt refining, launders, rod feeders, casting tables for extrusion ingot, casting control systems and more were delivered. In addition to this several vertical casting machines, casting tables for sheet ingot, launder systems, rod feeders and automation systems are delivered around the globe.

HES have been the back-bone of Hycast from day one. Since the start in 1990, no Hycast employee has been injured at work! No fatality related to the operation of Hycast equipment has ever been reported. Hycast was the first to deliver a technology portfolio that eliminated the need for Chlorine in the cast house. This was made possible by combining the AIF3 pot line fluxing (RAM) with the SIR inline melt refining unit. The casting processes delivered by Hycast are highly automated and minimize the need for operators to be in close proximity to the casting pit during all phases of the cast. The Hycast Safety Philosophy is embedded in the automation system, including hardwiring of all emergency functions.

In the last two year’s Hycast has introduced two new technologies to the market. In 2012, Hycast introduced the Adjustable Flexible Moulds (AFM) for sheet ingot casting. The new AFM technology is based on the proven Hycast flexible mould technology a unique and patented technology that ensures optimal sheet ingot geometry from start to end, and for

varying casting speeds. Additionally the AFM reduces the number of mould sets needed in the casthouse as the technology has an adjustable range of up to 400mm depending on the mould width. During NorCast 2013, Hycast presented the Low Pressure Casting (LPC) casting technology for extrusion ingot casting; the foundation of the new technology is based on proven Hycast GC technology. LPC is a new direct chill casting technology for applications where surface quality matters. It’s also ideal for the production of larger diameters and hard alloys. The LPC provides a new standard in surface quality as well as a thinner inverse segregation zone compared to other technologies.

Service and support is a challenge when working globally. To meet this challenge Hycast is staffed with highly skilled, experienced and mobile service engineers. In addition, in many cases customer assistance may be done from the Hycast office by accessing the cast house systems online for investigations and trouble-shooting. Hycast supports customers to constantly achieve better quality at lower operation cost and thereby increases the competiveness of its customers.

For more information see; www.hycast.noContact: [email protected]

AWJ 2013 79

80 COMPANY PROFILES






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AWJ 2013 81

Metal Treatment

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AlloyingAdditive injectionVortex stationsDegassingLadle & lid heating

Casting Machines

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Metal transferLaunder systemsVertical DC casting machine

Ingot castingSlab & billet caster�

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Auxiliary Systems

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BurnersRecuperative / regenerativeAir & oxygen models

Primary and secondarydedustingHeat recoveryProcess control

Küttner GmbH & Co. KG, Essen/GermanyAluminium Division

+49 (0)201 7293 [email protected]�

www.kuettner.com

Competence in Aluminum Melting

An extract of our references:

Volkswagen, Kassel WorksShaft Furnace

KUMZ Kamensk Uralsky Metallurgical WorksMelting and Pouring Furnace

Henan Zhongfu IndustrialTwin-Chamber Furnace (under construction)

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82

Foundation

The engineering office Jasper was founded in Geseke, Germany in the year 1983 by Robert Jasper. First business operations happened in the field of planning and advertisement of energy plants. Following the entry of Hans Dieter Jasper in 1988, a clear expansion in business activities took place, and the engineering office was changed into a GmbH.

Since the beginning of the company 30 years ago, Jasper GmbH is now operating in the fields of thermal process engineering, building of industrial furnaces and electrical engineering. Today Jasper GmbH is able to combine all these capabilities and supply these services as an "all in one solution" from one source.

Currently Jasper GmbH employs approximately 40 employees, majority of whom are certified engineers, at the three sites located in Geseke (close to Kassel), Remscheid (close to Cologne) and Quickborn (close to Hamburg).

Due to our international activities we have offices and cooperation partners

Jasper GmbH, Company Profile

all over the world. As consulting, analysis and project engineering of such plants requires outstanding knowhow, we support all our customers from the responsible offices.

Industrial furnaces and combustion systems

In the field of industrial applications, for melting, smelting, homogenizing of metals, glass processing, process engineering and thermal residue elimination, we plan and build industrial furnaces and combustion systems. We provide maintenance, repairs, and retro-fitting of suchplants. Complete aluminium casting lines, (charging, melting, holding, casting, and homogenizing) are also available.Some of our products offering are listed below,

Special Furnaces and Combustions Systems with highly efficient heat recovery capacity

• MultiMelter - Melting of different kinds of aluminium-scrap without salt, use of regenerator systems including reduction of Dioxin

• EcoMelter - Shaft melting furnace with regenerator systems

• EcoSpan - a concept for highly efficient cleaning and drying of swarf, with reduction of Dioxin

Optimised burner systems with highly efficient heat recovery capacity

• PulsReg® - classic regenerator

• PulsReg®Zentral - further development of the classic PulsReg®-system, with multiple burner heads

• PulsReg®Medusa, with multiple burner heads

• EcoReg® - rotating, continuously operating regenerator, with multiple burner heads.

The EcoReg® is available from Jasper GmbH exclusively.

Since the development of the EcoReg®-system (in 1995) we offer a heat recovery system with high efficiency, which avoids the disadvantages of conventional pulsed regenerators. A preheating of the combustion air up to 1400°C can be achieved in special applications. Energy savings of up to 50% (compared to cold air burner systems) are possible, providing the benefit of simultaneous production increase.A suitable regenerator is available for nearly every application imaginable.

Engineering and building of plants for economical and eco-friendly energyconsumption

Our main principle is the use of energy in a reasonable and economical way, adapted for environmentally friendly functioning. Following this guiding principle often leads to surprising solutions. In this regard we are

AWJ 2013 83

JASPER

Gesellschaft für Energiewirtschaft und Kybernetik mbH / Bönninghauser Str. 10 / D-59590 GesekeTelefon: +49 2942 9747 0 / Fax: +49 2942 9747 47 / www.jasper-gmbh.com / [email protected]

Setting The Standards For HighestEfficiency In Thermal ProcessingSetting The Standards For HighestEfficiency In Thermal Processing

EcoMelter©, 105t per day, cont. 35tPulsReg® Medusa RegeneratorEcoMelter©, 105t per day, cont. 35tPulsReg® Medusa Regenerator

active in the following special fields, complementary to each other:

• Energy - Engineering

• Engineering and building for economical and environmental energy consumption

How energy is used, how heat is recovered, and how it is provided again to the process. All these are important questions for consideration within the framework of process engineering, where economical energy system solutions are necessary.

Process control techniques for measuring and controlling software

No industrial plant can be operated today without control- and managing-systems which embed the plant

seamlessly into complex systems and procedures. Therefore, we cross-linkcontrols and systems (from our own and outside products) on all hierarchical levels of control engineering. In this area, we mainly use the Siemens SPS (S7), a well proven industrial standard. However, custom-built controls are also configured and documented correspondingly.Besides the standard furnace systems we also offer highly optimised installations, with special process technology, for a wide range of different applications.

Today

In recent years there has been a clear increase in the demands for energy optimised furnace systems in both national and international markets. Due to our longstanding experience

of 30 years, we are able to fulfil the energy and economical demands of our customers, while respecting their environmental requirements.

Jasper GmbHInnovations and developments for industrial furnaces.

[email protected]

Boenninghauser Str. 10D – 59590 GesekeGermany+49 2942 9747 0

84 COMPANY PROFILES

The SECO/WARWICK Group

The SECO/WARWICK Group is a public limited company which is listed on the Warsaw stock exchange. In 2012 the Group made a sales of 497 mZł (approx. 158 mUS$ or 120 m€), employed about 1000 people worldwide and is one of the biggest heat treatment and processing equipment manufacturers worldwide. The company is organized in five business segments,

• VAC | Vacuum Furnaces• ATM | Atmosphere Furnaces• AP | Aluminum Process Equipment• CAB | Controlled Atmosphere Brazing Equipment • VME (RETECH) | Vacuum Metallurgy Equipment

with production sites in Poland, USA (2), India, China and Brazil. Sales, service and spare parts offices are located in Russia, Belarus and Germany.

Our advanced, energy-efficient and environmentally friendly heat treatment and thermo-process equipment with guaranteed process technology is operated in aerospace, power generation, tools & dies, medical, machine and automotive industries, in commercial and in-house heat treatment plants, HVAC production, steel plants, metallurgy and all other industries, that require heat treatment and heat process equipment.

The business segment VAC (Vacuum Furnaces) supplies horizontal and vertical vacuum furnaces for annealing, brazing, sintering, gas and oil quenching, vacuum carburizing and nitriding (LPC & LPN) and other processes.

The business segment AP (Aluminum Processes) furnaces are applied for Aluminum processes such as: melting, holding, preheat processes,

homogenizing, annealing solution heat treatment and artificial aging. Furnace types available include: walking beam furnaces, roller hearth furnaces, tower furnaces, drop bottom furnaces, pusher furnaces, pit furnaces, batch systems with cold and hot cars.

The business segment ATM (Atmosphere Furnaces) offers carburizing, nitriding, hardening, annealing, tempering and special process (like spherodizing annealing) atmosphere furnaces. Types offered are batch furnaces (chamber, pit, tip-up, bell, bogie hearth), semi-continuous furnaces (multi-chamber furnaces, automated linked process lines), continuous furnaces (belt, pusher, walking beam, roller, rotary hearth, rotary retort), auxiliary systems (washers, quench tanks, cooling chambers, hoppers, feeders, conveyors, load storages, feeding systems of any type).

The business segment CAB (Controlled Atmosphere Brazing) supplies controlled Atmosphere Brazing (CAB) equipment, using a noncorrosive flux. This is the preferred process for aluminum heat exchangers in the automotive branch. A CAB furnace system includes a thermal degreaser, a fluxer unit, a dry off oven, and the CAB furnace. Types offered are radiation (CAB R), convection/radiation (CAB CR), convection continuous (CAB C), Active Only® semi-continuous and chamber furnaces with vacuum purging for heat exchanger prototypes (R&D).

The business segment RETECH/VME (Vacuum Melting Equipment) supplies advanced process technologies and equipment - including Plasma Arc (PAM) and Electron Beam Cold Hearth Melting (EB), Vacuum Induction Melting (VIM) and Vacuum Arc Remelting (VAR) used for melting, refining, atomizing of casting reactive

and refractory metals, super-alloys as well as rare earth metals.

SECO/WARWICK Aluminium Process Business Unit offers advanced products, allowing for the reduction of cycle times and energy consumption, as well as improvement in cooling rates.

Our Furnaces are applied for a wide range of processes, such as:

• melting and holding• preheat processes• homogenizing• annealing• solution heat treatment• artificial aging

Our five basic product groups include coil/foil annealing, solution heat treatment and ageing, log and slab homogenizing, ingot heating, and melting and holding furnace systems. They are operated in: aviation, automotive and machine, power, metallurgy and other aluminium industries, for single batch and mass production. Furnaces with control and material handling systems are offered in configurations to suit every type of production including: walking beam furnaces, roller hearth furnaces, tower furnaces, drop bottom furnaces, pusher furnaces, pit furnaces, and batch systems with cold and hot cars. With our experience, we are the single source for all your aluminium process furnace system needs and we guarantee the best performance of our equipment.

SECO/WARWICK Europe S.A.Polandul. Swierczewskiego 7666-200 SwiebodzinTel.+48 683819800Fax. +48 [email protected]

AWJ 2013 85COMPANY PROFILES






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86

COMPANY WEB ADDRESS PAGE No.ABB AB Force Measurement www.abb.com/measurement 74

ABB Switzerland Ltd. www.abb.com/aluminium 20Brochot Group www.brochot.fr/1.aspx 42Cargotec/Siwertell www.siwertell.com 67Cognex Surface Vision www.cognex.com/sisd 4Coperion www.coperion.com 61ECL www.ecl.fr 28Fives Solios www.fivesgroup.com 36FLSmidth www.flsmidth.com 33Hycast A/S www.hycast.no 79Innovatherm www.innovatherm.de 51Isravision Parsytec www.isravision.com 2Jasper GmbH www.jasper-gmbh.de 83Küttner GmbH & Co. KG www.kuettner.com 81Neuero Industrietechnik www.neuero.de 70Riedhammer GmbH www.riedhammer.de 34RTA Alesa Ltd. www.rta-alesa.com 56Seco/Warwick www.secowarwick.com 85Siemens Metals Technologies www.industry.siemens.com 6SMV A/S www.smv.as 71Stas Inc. www.stas.com 26/40UC Rusal www.rusal.ru/en/ 22Vigan www.vigan.com 62

Advertisers and Web Index

AWJ 2013 8771

Through MÖLLER® technology, FLSmidth® specializes in design, engineering, procurement, erection and commissioning of pneumatic material handling systems for turnkey projects and components for the alumina industry. For more than 75 years the MÖLLER brand has stood for high quality standard systems with more than 5.000 references world wide.

MÖLLER Alumina handling systems - High performance, high efficiency.

For further information please contact us at:FLSmidth Hamburg GmbHHaderslebener Str. 7 25421 Pinneberg Germany Tel: +49 4101 788-0 Fax: +49 4101 788-140 [email protected]

www.flsmidth.com

higher performance

MÖLLER® Alumina handling systems deliver

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aluminium world journal 2013

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