Aluminium World Journal 2012

Industrieofen + Stranggieß - Technik GmbH
2012 Edition
Aluminium Melting Furnace after Revamping
150 to/day melting capacity
83 to content
8 MW EcoReg (r)
Photo credit: Jasper GmbH
Global Media Communication Ltd.

2
Flexible solutions for aluminium
Whether you need to move long materials, sheet metal or coils – Demag Cranes & Components supplies you with
complete and integrated solutions for efficiently handling aluminium. Demag cranes provide for gentle material
handling, precise positioning and efficient order picking, as manually operated cranes and automated crane
installations with an integrated warehouse management computer. Demag cranes accelerate your processes and
provide improved reliability and productivity.
Demag Cranes & Components GmbH · Phone +49 (0) 2335 92-7296 · info@demagcranes.com · www.demagcranes.com

3
Foreword By Christopher Fitcher-Harris
Aluminium World Journal aims to provide
solutions available to increase productivity and reduce
costs of operation within aluminium production and
processing facilities. The publication aims to increase
awareness of the significant technology and strategies
of companies operating globally within the aluminium
industry.
This edition of Aluminium World Journal major focus is
on materials handling and transportation. Contained in
the major focus is indepth case studies and technology
reviews produced by leading companies such as
COPERION, FROMM Packaging and CARGOTEC.
I take this opportunity to thank the companies providing
editorial, advertisements and corporate sponsorship
support.
Feel free to visit us online to view industry related news,
reports, and updates of the Aluminium World Journal
2013 edition confirmed editorial. Find us online at:
www.globalmediacommunication.com.
We are pleased to receive proposals from companies,
and professional bodies wishing to provide technical
papers on the latest developments, for publication in
future editions.
I hope you enjoy this edition of Aluminium World Journal.
Should you have any comments concerning the content
of this edition or would like to discuss participation in a
future edition, please contact us.
Christopher Fitcher-Harris
Managing Director
Managing Director
Christopher Fitcher-Harris,
Production Manager
Sofia Henriksson
Sales Manager
Peter Jones
Production Design:
row1graphics
Printing:
CBF Group
Published by: Global Media
Communication Limited
Telephone: +44 208 579 0594
E-mail: gmcproduction@gmx.com
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.
©2012 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: Jasper GmbH
Aluminium World Journal 2012
Global Media Communication Ltd.

4
To power your operation while lowering consumption we provide you with stable, highly
efficient electrical energy systems and products for all power conversion and distribution
applications. To increase productivity and engineering efficiency, ensure environmental
compliance and maintain product quality, apply our automation, optimization and expert
solutions. To improve dynamic performance and reduce power losses, we provide drive
systems based on direct torque control technology. Maximize the return on project
investment through our vast know-how and extensive experience. Using ABB quality
products helps you achieve industry leading productivity. www.abb.com/aluminium
Lower plant investment and operation costs?
ABB Switzerland Ltd
5405 Baden 5 Dättwil
Phone: +41 58 586 84 44
Fax: +41 58 586 73 33
E-mail: minerals@ch.abb.com
Certainly.

5
INDEX
Global Issues p. 6-14
Materials Handling and Transportation p. 15-31
Surface Inspection p. 32-40
Primary Smelting and Processes p. 41-47
Cast House p. 48-61
Heat Treatment p. 62-66
Rolling Mill p. 67-69
Advertiser and Web Index p. 70

6
UPCYCLING WITH UNIQUE TECHNOLOGY
Alufluor is one of the world’s leading producers and suppliers of aluminium fluoride.
From the very start, in 1973, we have been driven by our commitment to high quality and
efficiency and low environmental impact. We believe that business and environmental
values go hand in hand. The aluminium fluoride produced at our site in Helsingborg,
Sweden, is based on upcycled fluorine-containing by-products from industry, rather than
on diminishing raw material, virgin fluorspar.
and consistent quality. The high purity aluminium
fluoride also enables usage in various applications
in the chemical, ceramic, glass and metal
industries.
Our unique technology has been the core of our
business since the start in 1973 and we refine and
develop it continuously.
For more information visit us on www.alufluor.com
Fast Facts Alufluor AB
Founded 1973
Location Helsingborg, Sweden
Employees 45 Employees
Production Capacity 24,000 tons/year
Ownership Jointly owned by Rio Tinto Alcan and Yara
Aluminium fluoride (AlF ) is a crucial component in
aluminium production. It lowers the melting temperature
in the pot, enabling higher electrical efficiency through
the production cell. It enables aluminium producers to
cut energy use, streamline production, cut production
costs and ensure a pure end product.
What makes our process unique is that it reclaims the
value within the by-products and use them to produce
aluminium fluoride with the highest available purity
3

7
GLOBAL ISSUES
Emal/Dubal
The Current Situation And Future With Regards To
Aluminium Production In The Middle East p. 9-11
Rusal
The Past Present And Future Of
The Aluminium Industry p. 12-14

8 GLOBAL ISSUES
Pot feeding systems
Pneumatic ship unloaders
Truck and railcar
loading stations
Silo storage systems
Harbour facilities
High capacity pneumatic
conveying systems
ISO 9001
ISO 14001
OHSAS 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 fluoride.
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 Alesa
www.rta-alesa.com
T+41 44 435 33 33

9
THE CURRENT SITUATION AND FUTURE WITH REGARDS TO
ALUMINIUM PRODUCTION IN THE MIDDLE EAST
In a little over 40 years the
Middle East has become a major
global hub in the primary alumin-
ium industry. Five smelters have
been established within the Gulf
Co-operation Council (“GCC”) re-
gion, this year boasting a collec-
tive capacity of 3.6 million tonnes
per annum — approximately 13.2
per cent of total world production.
With aluminium consumption in the
GCC being approximately 606,000
metric tonnes per annum, more
than 3 million tonnes of primary
aluminium are exported across the
world. A wide variety of product-
types is produced, from standard,
sow and T-ingots, through billets,
to sheet ingot and rolling slab; plus
anode- and busbars.
Two GCC smelters — Aluminium
Bahrain (“ALBA”) and Dubai Alu-
minium (“DUBAL”) — have been
in operation since 1971 and 1979
respectively. The others are new-
comers: Oman’s Sohar Aluminium
began operating in 2008; while
commissioning of both Emirates
Aluminium Company Limited
(“EMAL”) and Qatar Aluminium
(“Qatalum”) began in 2009. A sixth
smelter — Ma’aden — is under
construction in Saudi Arabia which,
together with planned expansions
at the existing smelters, will lift the
GCC’s annual production capacity
to almost 5 million tonnes by 2015.
The two smelters in the United
Arab Emirates (“UAE”) — DUBAL
and EMAL — will account for ap-
proximately 50 per cent of this
volume. An entirely state-owned
enterprise, DUBAL operates a one
million tonne per annum primary
aluminium smelter (1,573 reduction
cells) at Jebel Ali, Dubai — one of
the largest single-site operations of
its kind in the world — and in 2011
produced 1,014,795 tonnes of hot
metal. The complex also comprises
a power plant (2,350 MW at 30°C),
a large carbon plant, the world’s
largest aluminium casting opera-
tions, a 30 million gallon per day
desalination plant, plus a com-
prehensive auxiliary and support
infrastructure. DUBAL is renowned
internationally for its premium
purity, high quality products and
services; and its commitment to
sustainable development through
conscious efforts to maximize the
health and safety people, reduce
the impact of its operations on
the environment, and invest in the
social and economic development
of the community. Dedicated pro-
grammes support the Emiratization
goals of the UAE, including target-
ed recruitment, skills development,
management training and strategic
career planning. Approximately 92
per cent of DUBAL’s annual produc-
tion is exported globally. More than
300 customers in over 50 countries
worldwide are served, the compa-
ny’s key markets being Asia, Eu-
rope, the Middle East North Africa

10 GLOBAL ISSUES
(“MENA”) region and the Americas.
Evidencing DUBAL’s determina-
tion to develop its own smelting
technology, in-house experts
have successfully developed DX
Reduction Technology — which
offers enhanced energy efficiency
and productivity levels yet lower
environmental emissions than
comparative technologies. A dem-
onstration line of 40 DX Reduc-
tion Technology pots at DUBAL’s
Jebel Ali site started-up in February
2008. Since then the amperage
has gradually increased from 340
kA to 380 kA with stable results,
demonstrating capability to operate
at high amperage. Subsequently,
DUBAL’s DX Technology cells have
been redesigned to operate at
even higher amperages. Five new
generation cells, built in a pilot line,
have been operating at 420 kA. The
improved technology — known as
DX+ Reduction Technology — is un-
derpinned by the inherently robust
DX Reduction Technology.
A green-field development at
Al Taweelah, Abu Dhabi, EMAL
is owned jointly by DUBAL and
Mubadala Development Company
(in equal shareholding). Energiz-
ing of the 756 reduction cells (in
two potlines) at EMAL Phase I took
place between 1 December 2009
and 31 December 2010. Full pro-
duction capacity of 750,000 tonnes
per annum was reached within
three years of the project’s incep-
tion (four months ahead of sched-
ule). The company, which currently
serves over 150 customers, already
enjoys a strong reputation for
sound safety management, well-
being programmes for employees
and adopting global best practices
to minimize its environmental
footprint — the latter entrenched
through the implementation of
DUBAL’s DX Reduction Technology.
Initiatives are also in place to har-
ness Emirati talent through job-cre-
ation, engaging the community in
corporate activities and celebrating
the cultural heritage of the UAE.
In July 2011, EMAL announced
Phase II of its planned develop-
ment. The EMAL Phase II project
will entail the construction of a new
potline within the EMAL complex.
The line will comprise 444 DX+
Reduction Technology cells, pow-
ered by increasing the onsite power
plant capacity to 3,000 MW. This
will yield boost annual production
capacity by 520,000 metric tonnes.
Simultaneously, the technology
installed in EMAL Phase I is up-
graded, increasing the production
yield from the existing 756 cells to
800,000 tonnes per annum. Thus,
on completion of EMAL Phase II
in 2014, EMAL’s annual production
capacity will be around 1.3 million
tonnes, making EMAL one of the
largest single-site primary alumini-
um producers in the world.
In the meantime, questions are
being asked regarding the impact
of this year’s political turmoil in
the Middle East on the regional
aluminium industry. Reflecting the
inherent stability of the GCC, only
Bahrain and Oman were involved
— and in both cases the situation
was well-contained. The bulk of the
unrest has been in North Africa,
plus Syria and Yemen.
Naturally, the instability introduced
new challenges to the regional
industry. For example, a minimal
loss in demand (about 0.1 per cent)
has been experienced; and the cost
of business has risen slightly due
to the increased political risk and
associated rise in freight insurance.
There have also been minor logisti-
cal issues and investor confidence
in the region may have declined
temporarily.
On the up-side, the crisis has cre-
ated opportunities as a result of
the accelerated implementation
of social and infrastructural de-
velopment projects in the region.
Published figures indicate US $985
billion in infrastructure investment
within the GCC between 2010 and
2015, including large-scale proj-
ects such as the GCC rail network,
which will lead to increased metal
demand and thus greater growth
potential than previously predicted.
Within the UAE alone, demand for
aluminium is expected to reach 9
per cent over the next five years.
This will be driven by the develop-
ment of a long-term sustainable
downstream industry, an initiative
promoted strongly by both EMAL
and DUBAL the latter, is fully
aligned with the Abu Dhabi Eco-
nomic Vision 2030 to diversify the
economy. The Khalifa Industrial
Zone Abu Dhabi, where EMAL is
located, will play a key role. One of
the world’s largest industrial zones,
the 417 square kilometer KIZAD
is attracting downstream semi-
fabricated aluminium producers to
avail liquid metal or value-added
products from EMAL. Indeed, sev-
eral agreements have already been
signed.
These developments, together with
the anticipated growth in annual
global demand for aluminium from
the current 42 million tonnes to 70
million tonnes by 2020, bode well
for the rapidly growing, internation-
ally acclaimed Middle East sector.
Especially given the ideal strategic
location of the region “in the centre
of the world”, which ensures easy
access to both established and
emerging markets. As such, the
outlook for the Middle Eastern alu-
minium industry is very positive.

12
THE PAST PRESENT AND FUTURE OF THE ALUMINIUM INDUSTRY
Today it is impossible to imagine
our life without aluminium. The
light and soft white metal, with
a frosted silver tint is virtually
everywhere.
But there was a time when
aluminium was more precious than
gold. Contrary to popular belief,
aluminium mines do not exist, and
only certain minerals and rocks
containing aluminium are suitable
for industrial production. The latter
only started at the end of the 19th
century when ways to produce
aluminium through electrolysis
were discovered, and only in the
period between the two World
Wars, the extent of its potential was
more widely recognised.
GLOBAL ISSUES
Increasingly employed by the
transport and construction sectors,
aluminium production boomed
following World War II. Whilst only
8,000 tonnes of aluminium were
produced in 1900, a century later,
its production volume had reached
over 40 million tonnes.
Aluminium’s outstanding
properties explain why, in terms of
application in various industries,
it is nowadays second only to
iron. Aluminium is forgeable and
malleable. Its oxide film makes it
resistant to corrosion and means
the life span of aluminium goods
is very long. In addition, it has a
high electrical conductivity, is non-
toxic and is easily reprocessed.
These properties go some way to
explaining aluminium’s importance
in the world economy.
The aluminium industry is the
largest non-ferrous metal industry
in the world economy. It is highly
competitive and characterized
by high concentration. The six
largest producers of aluminium
account for more than 40% of the
global primary aluminium output.
This is mostly due to high entry
barriers relating to the specifics
of the aluminium production
process, which includes bauxite
mining, alumina refining and
production of aluminium itself. It
is no wonder that industry leaders
are large, vertically integrated
companies, managing all stages of
aluminium production. More than
that, aluminium production is very
energy-intensive; therefore access
to cheap energy resources is key to
becoming an industry leader.
Currently, there are two primary
technologies to produce
aluminium: Soederberg and
prebake. Soederberg uses a
continuously created anode made
by addition of ‘pitch’ to the top of
the anode. The lost heat from the
smelting operation is used to bake

13
the pitch into the carbon form,
required for reaction with alumina.
Prebake technology is named after
its anodes, which are baked in large
gas-fired ovens at high temperature
before being lowered by various
heavy industrial lifting systems
into the electrolytic solution. In
both technologies, the anode,
attached to a very large electrical
bus, is slowly used by the process.
Prebake technology tends to be
more efficient, but is more labor
intensive.
Prebake is becoming preferred in
the industry because of the various
pollutant emissions related to the
creation of the anode from liquid
pitch.
As already mentioned, aluminium
production process is very power-
intensive. Hydropower has always
been and continues to be the most
important source of electrical
energy for the aluminium smelting
process. More than 55% of the
world’s primary aluminium is
produced using hydro-electric
power which is clean, CO2 free and
renewable. From an environmental
standpoint, different energy
sources have different impacts,
releasing the same amount of
energy. For instance, the carbon
dioxide emissions impact of
producing 1 MWh from coal has
a different environmental (CO2
emissions) impact to that of
hydroelectric power production.
The high share of hydropower in the
electricity mix and the reductions
of direct and indirect greenhouse
gas emissions have resulted in a
decrease from 12 to 10 tonnes of
CO2 equivalents for every tonne of
aluminium produced since 2000.
The improvement of the aluminium
production process, aimed at
increasing production efficiency
and lessening the environmental
impact, is a key challenge for
the industry. RUSAL, the world’s
largest aluminium producer, is
using a three-pronged approach
to address this : modernisation
of the existing facilities (e.g the
Krasnoyarsk aluminium smelter),
equipping greenfield projects with
the best available technologies and
equipment (e.g the smelters in
Khakassia, Taishet and Boguchany)
and, finally, a gradual
of obsolete capacities with the
modern ones.
Within this approach,
RUSAL is developing new
advanced aluminium production
technologies, reduction pre-
bake technologies, such as RA-
300, RA-400 and RA-500, is
improving Soederberg technology
(“Clean Soederberg”), and finally,
developing a revolutionary
inert anode technology,
which will significantly reduce
energy consumption and
eliminate emissions producing
environmentally safe products –
aluminium and oxygen.
replacement

14 GLOBAL ISSUES
Meanwhile, the future of the
aluminium industry remains bright.
The industry itself has solid growth
potential, supported by booming
emerging economies. Consumption
and demand in emerging
economies are expected to more
than double in the coming years
on par to the level of consumption
in developed countries. Today,
China alone consumes over 40%
of current global aluminium
output. It is estimated that this
figure will exceed 50% by 2025
due to continued urbanization and
industrialization of the country. At
the moment, in China, per capita
consumption of primary aluminum
is 10kg, whereas consumption
in the developed countries
consumption is 15-30kg, so the
potential for growth is tremendous.
Another reason to be confident
in this light weight metal’s
prospects, is that aluminium
is part of the solution for a
sustainable future. Approximately
75% of all aluminium produced
is still in productive use, having
been through countless loops
of its lifecycle. Recycling saves
almost 95% of the energy
needed to produce aluminum
from its original source, bauxite
ore. Aluminium is a recyclable
material, bringing substantial
energy savings and green gas
reduction. The aluminium
industry has taken a leading role
by establishing a uniform global
monitoring approach to energy and
greenhouse gas emission reduction
goals.
It is now almost 200 years since
aluminium’s first appearance. This
metal has changed many aspects
of the world in which we live in. The
success of this lightweight metal
has earned it the name of “metal
of the future.” Starting out as a rival
to silver and platinum, aluminium
gradually took on a new role and
won over ground from iron, steel
and plastic. While consumption of
aluminium continues to grow, it
looks like the future belongs to the
thirteenth element.
UC RUSAL
13/1, Nikoloyamskaya str.,
Moscow,
109240,
Russia
Phone: +7 (495) 720-51-70
+7 (495) 720-51-71
Fax: +7 (495) 745-70-46
www.rusal.com

15
MATERIALS HANDLING AND TRANSPORT
Coperion
Plants For The Aluminium Industry From One Single
Source From Raw Material Receiving Up To Electrolysis p. 16-19
Cargotec
One Of The Worlds Largest Alumina Producers Opt
For Environmentally Friendly Siwertell Ship Loader
From Cargotech p. 20-23
FROMM Packaging
The Fromm Group-Latest Technology Has Reached
Around The World p. 24-26
SMV AS
Fresh Thinking For A Better Working Environment
And Improved Efficiency p. 27-29
Jungheinrich
Forklift Drive Systems – Between The Hype And Reality p. 30-31

16
Personal contact is an essential step
for us to create confidence.
>>That’s why we form the basis for your success. Because Coperion
conveys what you need to produce primary aluminium: alumina
and petcoke. From unloading to feeding of the electrolysis cells,
pneumatically or mechanically. Reliable, safe, gentle to the prod-
uct, economical and, above all, individually adapted to meet your
requirements. Our experts plan and implement complete plants or
individual process steps up to commissioning. We build plants and
process components for the market. We produce confidence for our
customers. Confidence through partnership is our assurance that you
can rely on. >>www.coperion.com
>compounding & extrusion >materials handling >service

17
Coperion is the worldwide
market and technology leader
in compounding & extrusion,
materials handling and service
- as well as being a partner for
global corporations and small
to medium-sized enterprises in
the plastics, chemicals, food and
aluminium industries offering
all business activities along the
process chain combined with
comprehensive services.
Compounding systems installed
worldwide over 10,000
Bulk materials handling systems
installed worldwide over 8,000
Employees worldwide 1,900
Network of locations
worldwide 29
Plants for the aluminium
producing industry - from
raw material receiving up to
electrolysis
Coperion GmbH is the competent
partner for all bulk materials
handling solutions around and
within the smelter. The company
offers solutions to the aluminium
producing industry that have
proven to be extremely efficient
and reliable.
It supports its customers from the
first project concept, through a
wide range of services to realization
and start-up of bulk materials
plants such as for example retrofit
solutions and provides after-sales
support.
Coperion has the necessary
expertise for every process stage
along the entire process chain
in manufacturing of primary
alumina. In each process step,
the challenges demand plenty of
experience, specialist competence
and flexibility.
The tasks involved in the design
and implementation of a plant
from project planning through to
installation, and also of individual
process stages for handling
alumina and petcoke for the
production of primary aluminium,
are extremely complex. Therefore,
great emphasis is placed on
optimization of the interfaces
between individual process stages
along the entire process chain. This
guarantees reliable and economical
material flow.
Raw Materials Receiving
As large quantities of alumina
and petcoke are required for
aluminium production, the raw
materials are either supplied
by ship or rail car. Short ship
docking times during unloading
are a most important cost-cutting
factor. This is something Coperion
can guarantee, and at the same
time ensure gentle and reliable
unloading of the product. The
pneumatic Coperion ship unloader
features leading-edge technology
backed by Hartmann expertise
which has proved its efficiency
and effectiveness hundreds of
times over the years. The decisive
PLANTS FOR THE ALUMINIUM INDUSTRY FROM ONE SINGLE SOURCE
FROM RAW MATERIAL RECEIVING UP TO ELECTROLYSIS

18
process components such as filters,
rotary valves, blowers etc. are
developed and manufactured at
the company’s own factory. Speed,
reliability and gentle handling of
the product during unloading are
the first steps towards economical
operation of a system. With their
experience, pragmatic approach
and our innovative technical
developments, Coperion experts
make sure that the optimum
solution is implemented in the
shortest possible time.
Reliable and very gentle conveying
of the raw materials ensures
economical production at a
consistently high quality level.
Intermediate conveying
After unloading the alumina and
petcoke, it is transported as quickly
and gently as possible to the silos
with pneumatic or mechanical
conveying systems. To ensure high-
quality transport, the most suitable
conveying mode is selected from a
uniquely comprehensive portfolio
and customized to suite site
conditions and requirements.
Depending on the requirements
and the individual situation,
Coperion's own pneumatic
conveying technologies DUROLIFT,
DUROSTAT, DUROSLIDE or
mechanical conveying equipment
such as belt conveyors, tube belt
conveyors and also trough chain
conveyors are used. For vertical
transport either the DUROLIFT
conveying system or mechanical
bucket elevators come into use.
In-plant storage
When charging and discharging
alumina silos and also during
storage, it is particularly important
that a uniform particle distribution
is maintained. When handling
petcoke the main challenge is to
evacuate the product safely.
The company’s know-how
guarantees reliable processes for
both raw materials. To prevent
segratation of the alumina during
feeding and discharge, Coperion
collaborates with IBAU HAMBURG
to implement an efficient anti-
segregation system. On the silo
roof the alumina is distributed from
a central transfer point through a
system of air-slide conveyors to
several optimally arranged filling
connections into the silo.
MATERIALS HANDLING AND TRANSPORTATION

19
A special discharge system in
the silo base permits selective
fluidization and sequential
discharge of the alumina from
individual zones. In this way it
is guaranteed that the regular
alumina particle distribution is
ensured - the most important
characteristic for the efficiency of
the smelting process. Very robust
discharge devices are available and
used for discharge of the petcoke.
In-plant conveying
Gentle transport and therefore low
particle degradation in the alumina
enables stable operating conditions
and a constantly high quality in the
cells. No matter how far storage
silos are from the smelter – the
product will always reach the "hot
spot" in best form. A number of
different conveying technologies
are offered.
The principle is, however, the same
for pneumatic, mechanical or
truck transport. Coperion has the
know-how needed for all conveying
methods to ensure gentle product
transport, thereby maintaining the
quality of the raw materials.
Distribution to electrolysis cells
With the DURODENSE system
Coperion offers a very gentle
process for charging the electrolysis
cells. Slow, continuous, reliable
and self-regulating - these are
all advantages which really count
during this process stage.
The DURODENSE has perfected
the technology. With its low
alumina flow velocity, the
DURODENSE system prevents a
scaling effect, providing a sound
basis to ensure that primary
aluminium manufacturing is
reliable and continuous. This
system is self-regulating and only
requires minimum automation
technology which - in light of
the large number of electrolysis
cells - is not only advantageous
with regard to investment and
maintenance, but also for operation
by personnel. Less is more. This is
particularly true in this case.
Project management
Coperion’s project management
team has a wide-ranging scope of
engineering skills and know-how at
their disposal with all the facets of
special knowledge and competence
needed for the implementation of
both plants and individual process
stages.
The global network and the
experience of the project managers
at all Coperion sites ensure a
constant transfer of knowledge
which offers customers a host of
advantages.
The company provide tailored
systems in all sizes, always
ensuring deadline compliance and
the highest standard of quality.
Local sourcing and cooperation
with the global purchasing
organization keep costs as low as
possible. Coperion’s global assets
and project management structure
make sure that all processes
remain unaffected by frictional
losses.

Dry bulk handling systems
that you can truly rely on
Cargotec’s land-based Siwertell ship unloaders and loaders are designed to suit each terminal’s specific requirements.
Siwertell systems use unique enclosed screw conveyor technology to ensure that dry bulk cargo operations are
environment-friendly and efficient.
Let the dry bulk handling experts design a custom-made answer to your particular needs.
Siwertell ship loader
at Alunorte, Brazil
SIWERTELL IS A CARGOTEC BRANDwww.cargotec.com • www.siwertell.com
20

21
ONE OF THE WORLDS LARGEST ALUMINA PRODUCERS OPT FOR
ENVIRONMENTALLY FRIENDLY SIWERTELL SHIP LOADER FROM CARGOTECH
Environmental benefits and
efficiency were two key factors
in Alunorte’s decision to replace
its belt-type ship loader with
a totally enclosed Siwertell
alumina ship loader from
Cargotec Sweden.
The new system has been operating
since the summer of 2010.
Company Alumina do Norte do
Brasil S.A. (Alunorte) was created
in 1978 to take advantage of the rich
bauxite deposits in the Brazilian
state of Pará.
Following a series of expansion
projects, Alunorte now operates the
world’s largest alumina refinery.
Annual production has increased
from 1.6 million tonnes in 2000
to the current production capacity
of 6.26 million tonnes per year,
representing 7% of the world’s
alumina production.
In 2006 the company identified
the need to replace its existing
belt-type ship loader because of
problems related to the high dust
emissions it created and the need
to increase the loading capacity.
Cargotec was contracted to design
and provide a modern, efficient,
environmentally friendly solution
from its Siwertell ship-loader
brand.
The brief was for a system designed
to load Kamsarmax-size vessels up
to 80,000 dwt, to be located at the
production plant in Barcarena, Pará,
in Northeast of Brazil.
Mr. Douglas Wichers, Sales
Manager, Cargotec Sweden said
Alunorte’s new Siwertell ship
loader was built on a different
design concept to the older one.
“The new design is based on a
totally-enclosed aero slide system
and a Cleveland cascade-type
vertical telescopic loading spout.
In combination with two dust
collectors at the transfer points,
this is a very efficient loading
system when it comes to the
elimination of dust emissions into
the environment.”
The loader is based on a travelling
gantry design with one horizontal
arm capable of slewing and
luffing motions and is fitted with a
vertically adjustable loading spout.
The operator cabin is located on an
arm which extends over the ship’s
hold to give the operator the best
possible view of loading operations,
adding significantly to efficiency
and safety.
Mr Wichers noted that although the
designed loading capacity of the
new Siwertell system is 2,500t/h,
in practice this has been reduced to
about 2,000t/h in order to match
the current feeding capacity of the
existing shore side tube conveyors.
“The loader can obviously not
process more than the incoming
material flow. If Alunorte decides
to increase the tube conveyor’s
capacity, then the Siwertell loader

22 MATERIALS HANDLING AND TRANSPORTATION
is already prepared for such an
increase.
Cargotec’s involvement does
not stop when the equipment
is delivered, installed and
commissioned, said Mr Wichers.
“Quality service combined with
comprehensive long-term support
is as essential to our customers
as quality products. From the first
contact through the entire lifetime
of an installation, Cargotec provides
the services and products needed
to ensure cost-effective, efficient,
safe operations. It is this sort of
quality and commitment that
means that one of the first Siwertell
ship unloader delivered in 1975
is still unloading over one million
tonnes of cargo per year”.
Considering the wider scope of
Cargotec’s Siwertell range, Mr
Wichers says the company has
developed loaders employing three
different conveying technologies
to best meet varying market
demands; namely screw, aero slide
or belt conveying. The choice of
conveying technology is influenced
by a number of factors including
the on site conditions and the cargo
or cargoes to be handled. “Siwertell
ship loader products offered by
Cargotec exploit technologies
carefully developed over a long
period, benefitting from a world
leading company’s accumulated
experience. In developing the most
operationally efficient and safe dry
bulk handling equipment, Cargotec
emphasises the importance
of optimising the loader in
environmental terms as well as in
maximising its performance.
In addition to the loader, the
Siwertell brand also includes
ship unloaders where Cargotec
for years has been the company
that has delivered most continous
unloaders worldwide. A Siwertell
ship unloader is totally enclosed
from the pick-up point in the
hold, which is below the cargo
surface, to the transfer point at
the jetty conveyor. This attention
to detail delivers a cleaner,
safer environment through the
elimination of spillage and dust.
The Siwertell unloader programme
is divided into four groups. The
appropriate group is determined by
the size of ships to be handled, the
required unloading capacity and
the commodity to be handled.
In addition to loading and
unloading systems, Cargotec
can also provide bespoke bulk
terminals incorporating Siwertell
ship unloaders and/or loaders with
mechanical or pneumatic conveying
systems to suit the particular
requirements of bulk terminal
projects, whether for import,
export, or cargo transhipment.
For ports and harbour that do not
have or need permanent bulk
handling facilities, Mr Wichers says
Cargotec offers the ultimate
in flexibility with its Siwertell
mobile unloaders, designed to
be completely autonomous in
operation without the need for any

23
other dockside equipment such as
an auxiliary crane.
Mounted on a semi-trailer,
Cargotec's mobile unloaders are
based on Siwertell’s unique screw
technology and can be operational
very soon after arriving on site.
Typically it takes between 30
and 45 minutes to complete the
unfolding operation.
Like the Siwertell ship unloaders,
the mobile unloaders have a
totally-enclosed conveying line
that delivers environmentally
friendly, cost effective operation
and typically consuming only 0.18
litres fuel/tonne during a cement
handling operation .
Three different models are
available with unloading capacities
of up to 500t/h and vessels size
up to 20,000 dwt. In addition to
Alumina, the mobile unloaders,
together with the other types
of Siwertell ship unloaders, are
suitable for handling other free-
flowing dry bulk cargoes such as
cement, sulphur (when equipped
with a Siwertell sulphur safety
system), grain, feedstuffs, biomass
and fertilisers.
The other types of Siwertell ship
unloaders can be designed to
unload vessels of up to 200,000
dwt and for none free flowing
materials such as coal.
The totally enclosed system
eliminates costs associated with
loss of material and clean-up
operations when unloading is
complete.
Maintenance and spare part
costs are kept to a minimum, for
the mobile unloaders since they
generally incorporate only standard
components, easily sourced
worldwide at any time. Personnel
costs are low as only one person
is required to operate the unit and
perform the folding and unfolding
procedures.
By Douglas Wichers, Sales
Manager, Dry Bulk Terminals,
Cargotec
and Jörgen Ojeda, Director
Mobile Unloaders, Cargotec
Cargotec Sweden AB, Bulk
Handling
Visit us at: www.siwertell.com
e-mail us on:
blksales@siwertell.com
Tel: +46 42 858 00, Fax: +46
42 858 99
Images of Siwertell ship loader
at Alunorte, Brazil. It has a
loading capacity of 2500 t/h of
Alumina.

FROMM Holding AG | Switzerland | Tel. +41 (0)41 741 57 41 | Fax +41 (0)41 741 57 60
www.fromm-pack.com
Strapping equipment
Keep an eye on your maintenance
and downtime costs!
Strapping equipment in the aluminium industry is subject to
high wear and tear. High downtime and excessive maintenance
affect your costs. Next time you select your strapping equip-
ment check us out. FROMM stands for high reliability equip-
ment, first class service and low maintenance costs. A full
range of quality strapping tools and machines backed up by a
worldwide network of sales- and service engineers can be a
valuable alternative to the equipment you might be using today.
Call us – our FROMM representative will be happy to tell you
more about the benefits of our strapping products!
Benefit from our experience!

25
THE FROMM GROUP-LATEST TECHNOLOGY HAS REACHED
AROUND THE WORLD
Fromm automatic strapping
machines and strapping tools are
designed for highly demanding
applications in the aluminium,
non-ferrous metals and steel
industries. The company’s state
of the art technology is backed up
by worldwide customer service
and support
FROMM’s new MH610 strapping
heads and P330 strapping tool,
designed by the company’s R&D
centre in Germany, are almost
equally capable of producing
the highest strapping tension.
The P330 is believed to be the
strongest mobile strapping tool
on the market today and allows
all heavy steel strapping sizes
to be replaced by 25mm/1 inch
polyester strapping. Polyester
strapping is more economical than
steel strapping and savings can be
substantial. Polyester strapping
pulled to its optimal working
range ensures tight straps and safe
transport of products.
MH610 PET strapping heads
Loose straps can damage products
during shipping and pose a threat
to safety. Therefore Fromm
strapping machines with MH610
heads have been designed to
produce a strapping tension of
7000N, the highest achieved by any
PET strapping head on the market.
This ensures that products remain
safely secured until they reach their
destination. The machines and
heads are built to strap aluminium
ingots, billets, slabs, coils and
sheet materials efficiently using
25mm/1-inch and 32mm/1.25 inch
wide and 1.35mm/0.055 inch thick
PET strapping.
All head components are produced
on ultra modern machining centres
at Fromm manufacturing facilities.
The well-designed, ruggedly built
head offers high reliability even
when used around the clock,
minimising both maintenance costs
and downtime.
Combined with a service
contract and regular preventive
maintenance by Fromm’s well
trained, local service engineers, the
machines have a long working life.
P330 PET strapping tool
The P330 portable plastic
strapping tool can produce a
tension of up to 6000N, which
permits the processing of plastic
straps up to 25mm/1 inch in width
and 1.53/0.062 inch thick. The
heavy polyester straps provide a
problem –free replacement for
traditional steel straps, resulting
in considerable cost savings. The
ergonomically designed handle,
the new push-button arrangement
and simple operation ensure a
high degree of user-friendliness
and rational working methods.
The high quality manufacture and
well known operating safety and
reliability of the tools are reflected
in very low maintenance costs, even
when used for extended periods.
Fromm tools provide the highest
level of safety in the manual
packaging of ingots, slabs, billets
or sheet materials.
Strapping tool for round
applications
The Fromm Group has just
started to launch the world’s
first pneumatic strapping tool
for round applications and small
surfaces called P380. The patented
technology allows the customer to
convert the existing steel strapping
applications locked with steel
seals. The P380 is applicable on a
minimum surface of 80mm and a
minimum diameter of 240mm. The
new combination tool outperforms
separate tensioner and sealer
operation giving the user higher
work efficiency.
Automatic ingot strapping
machine
The Fromm automatic strapping
machine model PM 200002
has been developed to strap
packs of ingots securely using
PET strapping. The heart of the
machine is the high tension
MH610 strapping head applying
automatically two to three straps
per pack of 25 x 1mm (1 x 0.040
inch) PET strapping. The savings
in material costs mean that the
payback on the investment in an
automatic polyester strapping
machine or in a retrofit solution is
achieved relatively quickly.
Strapping head retrofits
– a case study
The Fromm company in Australia
have been offering industry a
retrofit solution to minimise the
cost of changing to Fromm’s
plastic strapping system. Last year
a four machine retrofit replacing
existing PET strapping heads was
undertaken at one of
Australia’ largest Aluminium Ingot.
Whilst the project was without
difficulties the end result of the
customer is, new strapping heads
lower cost of strap and much lower
spare parts and service costs.
With cost of ownership much
more considered that in the past,
people are looking for cheap
to own not cheap to buy. Using
19mm x 1.27mm Fromm strap,
the Fromm company have been
able to improve the customers
pack integrity by strapping much
tighter. The ingots transport better
to Asian destinations meaning
less breakages and happier end
customers.
Down in Australia there is quite
some interest at the remaining
ingot producers to move to the
Fromm solution and the affiliate
company AWS is guiding them
accordingly.

Turnkey end-of-line
solutions
The Fromm Group can
provide turnkey end-
of-line solutions using
its automatic strapping
lines, strapping tools and
polyester strapping, backed
up by an efficient after-sales
service. Fromm packaging
experts are available to
customers to analyse their
existing packaging facilities
and advise on how their
packaging budgets can be
reduced.
About the Fromm Group
The Fromm Group through
its parent company Reinhard
Fromm Holding AG in
Switzerland was established
in 1647. The family-owned
business employs over
8000 people throughout
the world. Its 34 subsidiaries
in Europe, the USA, South
America, India, Asia, South
Africa and Australia and over
50 partners and distributors,
guarantee efficient customer
service and support. The
Fromm corporate policy
is based on continuity,
independence, reliability
and quality products.
Numerous world-leading
aluminium manufacturers
put trust in Fromm products
and solutions.
Contact information
FROMM Holding AG
Hinterbergstrasse 26
CH-6330 Cham,
Switzerland
Phone: +41 / 41 741 57 41
Fax: +41 / 41 741 57 60
Website:
www.fromm-pack.com
MH610 PET strapping head and P330 PET
strapping tool
– the strongest combination
Technical data for strapping head MH610
Suitable strapping qualities: StarStrap Polyester (PET)
Strapping dimensions: widths
thicknesses
25.0 – 32.0 mm / 1 – 1 1
/4¨
0.40 – 1.35 mm / .016 - .055¨
Average seal strength: up to 85% of strap breaking strength
(dependent on strap quality)
Sealing method: friction welding
Strap tension: 7000N adjustable
Feed/retract speed: 5.3 m/s / 17.4 ft/s
Tension speed: 105 mm/s / 4 1/8 ft/s
Package size: min. W150 x H180 mm W 5 9/10 x H 7”
max. W3000 x H3000 mm W 9.84 x H 9.84 ft
Power supply: 400V – 3PE – 50Hz
230V – 3PE – 60Hz
Consumption: 1.1KW
Control Voltage: 24V DC
Dimension: L 615 x W 307 x H 446 mm / L 24 x W 12 x H 17.5¨
Weight: 115 kg/118 kg / 253/260 lbs
Technical data for strapping tool P330
thicknesses
19.0 – 25.0 mm / 3
/4 – 1¨
0.60 – 1.53 mm / .025 – .062¨
Average seal strength: up to 85% of strap breaking strength
(dependent on strap quality)
Sealing method: friction welding
Strap tension: 300-6000N adjustable
Battery: 28 VDC/3.0 Ah Lil
Weight: 7 kg/ 15.4 lbs
Technical data for strapping tool P380
thicknesses
13.0 – 19.0 mm / 1/2 – 3/4¨
0.40 – 1.35 mm / .016 – .053¨
Weight incl. suspension bracket 6.8kg / 15 lbs
Tool sizes with suspension bracket L39O x W135 x H305 mm / 15.4¨ x 5.3¨ x 12.0¨
Average seal strength: up to 75% (dependent on strap quality)
Type of seal Friction weld sealing
Strap tension: 600-1800N / 135-405 lbs (adjustable)
Tensioning speed: 120-260 mm/s / 47-10.2 inch/s
Max air pressure: 60 bar / 87 psi Type of seal
Min. package size Flat packages: 80 mm / 3.1¨
Round packages: 2 x 70 mm / 2.7¨
or 1 x 240 mm / 9.4¨

27
FRESH THINKING FOR A BETTER WORKING ENVIRONMENT
AND IMPROVED EFFICIENCY
The most important element for
smelters around the world today
is qualified personnel.
A modern smelter today has a
high focus on security and good
working conditions for their
employees. At the same time
there are still several areas which
can be improved in portion to
safety, working environment and
process performance.
SMV have worked close together
with our customers for more than
53 years and have developed
concepts which have contributed
to this improvement.
As supplier to this market it is
of high importance that we are
conscious about the changes
happening and contribute actively
with good solutions.
As an example for this, I would
like to mention one project we had
some years ago. One customer
contacted us and wanted to
discuss how to improve one type
of pot room vehicles. They had
heavy maintenance costs on
these vehicles and also higher
appearance of sick leave compared
to operators on other vehicles.
Together with our customer we
exposed the areas of improvement
by using the maintenance log, we
made a new design for the working
tools, and at the same time we
had a high focus on ergonomic
issues. When we delivered the
vehicle it was equipped with
hydraulic suspension on all
wheels, the cabin was equipped
with an air suspended operators
chair mounted on a hydraulic
rotating table, this was to ensure
correct orientation towards the
working area. After some months in
operation it was exposed that sick
leave related to neck, shoulder and
back problems had been more than
halved.
After one year the maintenance
costs also was more than halved.
A strong focus on these
important issues contributes to
a shorter payback time for the
investment and to a better working
environment.
The latest years we have seen a
considerable extent of involment
from the people executing the
tasks on a daily basis, such as
maintenance, vehicle and process
operators. This change have been
very positive and we can conclude
that it contributes to better
products from us, and greater grade
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 involment
and the creativeness of our skilled
staff.
Reduce HF,
improve working conditions
Hot Bath Crushing system (HBC)
In aluminium production hot bath
are produced through the operation
of changing anodes. Most smelters
today have focus on how to reduce
HF emissions, improve working
conditions, effective utilization
of building area and effective
logistics.
SMV hot bath crusher is designed
to receive grabbed bath from the
anode changing operation.
The first two hours are critical
related to HF emission, and it is
important to bring the bins with
hot bath to the HBC as soon as
possible after anode changing.
When 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
depends on the capacity needed
and what temperature the second
stage fine processing can handle.
This system is suitable in order
to reduce emissions of fluoride,
but it also reduces substantial

the amount of bins in circulation,
liberate expensive cooling areas for
bins and also reduce the need of
handling equipment and operators
in the recycling process.
Improve Anode Consumption
Hot Anode Milling machine.
In Aluminium plants with pre-bake
technology, there can occur peaks
under the anodes under different
conditions. This can occur under
startup of pots, lower anode quality
and how the pots are operated and
tuned. The deviance can occure
as “mushrooms” or peaks, but
also as unevenness surface of the
anodeblock 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 the
deformation is attempt i.e removed
by dragging it over the floor 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 30 machines.
The principle of operation is that
the machine is moved to the pot
where the troubled anode is, 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.
and 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 pot and pipes
SMV Service wagon
At the top rack over the pots, there
are several components which
need to be inspected or replaced
regularly. Most smelters also
have 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
operator basket and a service crane.
The platform is raised and faced
with the pot, and the crane helps with
lifting components from the floor/
vehicle to the top of the pots. All
movements of crane and platform
is done 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.
Before Milling
After Milling
Reduce voltage drop
Effective Anode Beam Repair
System
After some time the contact surface
between the anode beam and
anode stem is damaged, it is most
important to have a smooth surface
to avoid voltage drop.
SMV have developed a system
for 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 need 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 crane or forklift,
and it is operated from a remote
control panel.
Efficient Logistic
SMV Anode transporters
Considerable masses of new
anodes and used butts are
transported. For most aluminium
plants these operations represents
high costs due to tear and wear of
the flooring. SMV’s
Anode Transporters are easily
maintained, and their advanced
suspension system reduces the
damage on foors.
The anode transporters consists
of a standardized truck with tailor
made trailer for different customers.
The Operator has full control
with direct view to the loading/
unloading of pallets. If required
the wagon may be equipped with
covers.
By Lars Hovda, SMV A/S

29
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 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, Rodding and bath
recycling for the Aluminium
Industry especially.
SMV also 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 (mechanical,
electrical, hydraulics, pneumatics).
SMV also has a number of
strategic business partners that
complement us in areas such as the
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
Contact Information:
Lars Hovda
Managing director
Telephone Office : +47 53771200
Telephone Direct : +47 53771202
Telephone Mobile: +47 90840855
E-mail : lars.hovda@smv.as
Web : www.smv.as
Martin Fitje
Technical Manager
Telephone Office : +47 53771200
Telephone Direct : +47 53771206
Telephone Mobile: +47 90840853
E-mail : martin.fitje@smv.as
Web : www.smv.as

The search for alternative drive
systems is nothing new: back
in 1900 Ferdinand Porsche
introduced the electric Lohner
Porsche with wheel hub motors,
followed in 1902 by a hybrid
vehicle.
Faced with rising oil prices,
tight budgets and concerning
environmental developments,
manufacturers of forklift trucks are
coming up with ever more efficient
and environmentally friendly drive
systems, both IC motor and electric.
But which systems best meet the
customer’s requirements?
Back in 1900 Ferdinand Porsche
launched the highly regarded
electric Lohner Porsche with wheel
hub motors at the World Exhibition
in Paris. A racing version followed
and by 1902 there was even a
hybrid vehicle.
Public interest is focused on
alternative drive technologies
depending on oil prices. A hype
cycle represents phases of public
receptiveness to new technologies.
Due to the climate debate and
rising energy costs we are now in a
cycle of maximum receptiveness to
alternative drive systems.
With lift trucks however, drive
technologies and energy efficiency
for optimum customer intralogistics
solutions have always been at the
heart of research and development.
This applies especially to in-
house, battery powered warehouse
vehicles.
Multi-shift operation with a single
battery charge, avoiding battery
replacement and simply reducing
battery sizes have immediate cost
implications for our customers.
Energy recovery in braking and load
lowering, efficient AC threephase
drive systems and state-of-the-art
charging technologies have long
been standard at Jungheinrich,
developed over many years.
With IC motor trucks fuel costs
account for over one third of total
costs. With its latest hydrostatic
truck generation (keyword: state-
of-the-art TDI motors) Jungheinrich
is again one step ahead of the
competition. This has been borne
out time and again in independent
comparative tests. As a result we
offer a product range that is already
extremely attractive from a carbon
footprint perspective.
The choice of drive system
technologies depends on the
customer
New drive systems must always be
judged by how much they improve
customer advantage. And customer
requirements are becoming
increasingly complex.
They include above all
• Energy efficiency,
• Low / zero emissions
• Short fuel times,
• High capacities,
• A positive carbon footprint and
above all,
• A low total cost of ownership
And this is where the wheat is
separated from the chaff in the
drive systems currently being
debated. Although hybrid and fuel
cell systems meet the criteria for
FORKLIFT DRIVE SYSTEMS – BETWEEN THE HYPE AND REALITY

31
short fuelling/charging times and
improve the carbon footprint, in
terms of total cost of ownership
these technologies are simply
uneconomical for customers. In
the foreseeable future fuel cell
technology is unlikely to make the
leap to economic efficiency, despite
rising energy costs.
Energy costs will continue to rise
as new technologies decrease
in cost. This applies in particular
to lithiumion batteries, should
these gain a foothold in the
automotive industry in future. If
costs fall significantly as a result of
automated production, lithium ion
batteries could fully exploit their
advantages over lead acid batteries.
• Three times the storage capacity
with the same weight,
• Higher currents and hence
performance for the same size,
• Better efficiency for the same
charge and discharge
performance,
• Shorter charging times,
• Considerably higher number of
charge/discharge cycles,
• Greater use of capacity - lead acid
batteries are generally only 80%
discharged by the time the
voltage fails,
• Reducing the useful life
significantly.
Lithium-ion technology is
becoming an alternative to lead
acid batteries
The combination of lithium-ion
technology with efficient electric
motors can therefore be used
initially in smaller vehicles.
However, with appropriate
investment it could increasingly
be used with larger vehicles as
an economic alternative to the
traditional lead acid accumulator. At
the moment we cannot accurately
predict when this will be. It
depends largely on developments
in the automotive industry.
But what about the much-debated
hybrid drive system in industrial
trucks? A factual assessment of
this not exactly new technology
requires the right comparisons to
be made. If you compare outmoded
technology from a previous
generation with the latest hybrid
technology, there is indeed a
reduction in consumption in excess
of 40%. It is misleading to publish
such figures. If you compare
Jungheinrich’s latest generation of
energy-efficient trucks with hybrid
technology, the potential for a
reduction in consumption through
hybrid systems reduces drastically.
It’s the same with the car industry.
Modern diesel vehicles have
virtually the same consumption
levels as hybrids. If you factor in
the additional technical cost, the
carbon footprint equation may even
be negative.
According to Marek Scheithauer,
Head of Product Management for
IC motor trucks at Jungheinrich’s
Moosburg plant, there are only
a small range of applications
where the hybrid systems can be
used effectively. The additional
technology required is only
worthwhile on highly intensive
operations and even then only if
diesel and LPG prices increase by a
further 50%.
Conclusion:
Electric mobility and hybrid
technology have been around for
over 100 years. Fuel cell technology
has also been known for decades
and was used back in the 60s as
an energy source for the Apollo
missions. The real challenge lies
in developing the technology
specifically to optimise costs taking
into account all application factors.
The automotive industry must
play its role
The time is right to introduce a new
technology when its application
advantages outweigh those of
the old technology. Wide-ranging
public interest in new drive
technologies should not distract
our attention from the main focus.
According to a VDMA study, over
the next ten years 56% of efficiency
improvements will come from
existing technologies. In addition
lithium-ion technology has great
prospects for finding its way into
industrial trucks. Not least, the
industrial truck sector is dependent
on the support of the automotive
industry to force through the
enormous amount of investment
required for cost-effective battery
production.
Jungheinrich will continue to
actively develop alternative drive
technologies without losing
its focus for improving existing
technologies. This will allows us
to provide trucks that meet criteria
for efficiency and a good carbon
footprint. When the opportunity
arises to achieve a greater customer
advantage through lithium-ion or
hybrid technology, Jungheinrich
will offer its customers these
trucks.
by Peter Dibbern

32 SURFACE INSPECTION
On-line
Defect Detection,
identificatiOn
anD reporting
for further information visit www.cognex.com/sisd
email SmartView@cognex.com or call:
US +1 508 650 4141
Europe +49 721 66390
China +86 21 63517377
Japan +81 35977 5400
real time inspection of aluminium enables faster
process correction anD better yielD optimization.
surface Vision

33
SURFACE INSPECTION
Isra Vision Parsytec
Surface Master-Breaking The Limits Of Aluminium
Surface Inspection. p. 34-37
Cognex
Complete Process Vision Improves Product Quality
And Process Efficiency With Rapid Roi p. 38-40
COGNEX
Official Sponsors Of This Section
ISRA VISION PARSYTEC
Official Sponsors Of This Section

www.parsytec.com www.isravision.com
Ingot Hot Rolling Cold Rolling Annealing Coil Treatment Coating Finishing Packaging Automotive
End Markets
„Ensure Higher Quality, Increase Productivity & Improve Process with SURFACE MASTER“
Non-Ferrous
Ferrous
Aluminium
MASTERSURFACE
Yield Optimization! … Beyond Inspection!
ISRA VISION Provides the Key to Productivity: 25 Years of Experience with Thousands of Installations in
More than 20 Countries around the Globe. Always close to You with our Customer Support & Service Team.
V I S I O N
ISRA
Partner With The Global Leader In Surface Inspection.
Get MORE Out Of YOUR Production.
34

35
Increased customer demands and
a competitive market in today’s
aluminium strip production have
made it critical to continuously
work on improving efficiency in
the manufacturing process and
the overall quality of the final
product.
Automatic surface inspection is
the status quo in many production
steps. SURFACE MASTER
defines the top in terms of image
acquisition and classification, but
the key for the successful use of
surface inspection systems is the
inspection performance.
What does inspection performance
mean? Even the best images will
not help improving the process or
making precise quality decisions
without a system selecting the
relevant information from the huge
amount of data. Beside proper
detection of surface defects,
classification is the key to the
most important step: creating
data quality. SURFACE MASTER
filters and aggregates the defect
information to support your
decisions in process optimization,
material grading and downstream
optimisation.
Inspection Performance
The goal using surface inspection
systems is creating the base
for confident quality decisions.
The major aspect to allow this
is Inspection Performance that
means getting exactly the data
which is needed for the decision.
This includes sharpest images,
confident detection and exact
classification of the relevant
defects.
It starts with image acquisition:
The broad experience of ISRA
VISION PARSYTEC with all
SURFACE MASTER-BREAKING THE LIMITS OF ALUMINIUM SURFACE INSPECTION
SURFACE MASTER DEFINES INSPECTION PERFORMANCE IN A NEW WAY
kinds of production lines in the
aluminium manufacturing process
is condensed into a portfolio
of SURFACE MASTER Sensor
configurations, well adapted to the
individual line types, thus providing
optimum image acquisition during
the aluminium manufacturing
process. SURFACE MASTER
guarantees highest resolutions,
even on fast production lines by
using the most advanced cameras.
For most complex inspection
tasks on lines with a great variety
of material – from bright to
dark and from shiny to dull - the
DUAL SENSOR™ creates best
image quality by combining one
sensor with diffuse illumination
and one sensor with direct light.
The following figure illustrates
the advantage of the combined
approach.
After detecting the defects
within an image, it’s necessary
to classify them according to
the defect type and grade to
prepare quality decisions. The
hierarchical classifier approach
using specialized classifiers, e.g.
for shells or for scale, allows a
differentiation at a classification
rate far beyond what’s possible
using just a single classifier and
is the precondition to create data
quality. It allows filtering the data
according to the different tasks.
To protect a tension leveller, only
information about holes and edge
cracks is necessary. To inform the
melt shop about quality problems
regarding the casting, only non-
metallic inclusions may be relevant,
whereas for process improvements,
a lot of defects may be interesting.
Applications
SURFACE MASTER’s outstanding
inspection performance allows a
variety of (semi-)automatic appli-
cations for immediate reaction on
surface quality issues.
Tension Leveller Protection
One example is ISRA VISION
PARSYTEC’s Tension Leveller
Protection. Tension levelling lines
have to deal with strip breaks. The
costs of strip breaks are high, taking
time to get the mill up and running
again, additional costs arise due to
INSPECTION PERFORMANCE = PERCENTAGE OF CORRECT QUALITY DECISIONS
DUAL SENSOR™ unique with ISRA VISION PARSYTEC
DUAL SENSOR™ : all 8 real
defects

roll shop cost, material loss, and
overall attention to this problem.
As strip breaks due to material
defects often form the majority
of strip breaks, eliminating those
allows putting a clear focus on the
operational issues. Based on the
highest inspection performance,
SURFACE MASTER offers a
unique and innovative tension
leveller or cold mill protection
solution, scale perfectly applies
to tension leveller in aluminium.
Severe surface defects can
cause strip breaks in a tension
levelling line, leading to loss of
material and machine downtimes.
Identifying these defects in-time
for immediate process reaction
provides significant yields in terms
of runability and throughput.
Harmful defect (hole) at a tension
levelling line
Ensuring Highest Quality
Standards: Defect Marking (fig.1)
Aluminium producers that are
simultaneously supplier to further
processing industries such as can
manufacturers have been asked
to physically mark defective strip
areas .
This allows discharging marked
areas of the strip in the end-users
manufacturing process. Hence, the
highest possible quality standard
of the produced material can be
assured.
During production, critical defects
will be detected automatically for
the marking process. Immediately
after the recognition, the relevant
defects can be marked. On top, if
there is sufficient time between the
defect recognition and the required
action of marking, a review by the
operator of the defects which are
going to be marked can be addi-
tionally included in the procedure.
This overall process is based on a
rule set which is defined and adjust-
ed according to the requirements of
each end-user.
This defect marking solution helps
providing material of a constant
high quality. The interactive ap-
proach supports the decision-mak-
ing process of the inspector
Automatic Sorting (fig.2)
If the time for an inspector’s
review is too short, there is also
the possibility for fully automatic
operation. One very effective
application is the Automatic
Sorting, e.g. for coated Litho
sheets.
The strip is cut into sheets, but
not all of those sheets are of the
same high quality. Sorting the
sheets automatically according to
their quality can be enabled by an
inspection system, specially trained
for triggering this sorting process.
Advanced System Characteristics
To Create Benefits
Inspection performance is the key
for confident decisions but there
are other characteristics making
an inspections system breaking
today`s limits.
Image Processing Power
To get the best detection
performance on high resolution
images, even at highest speed,
the inspection system needs
sufficient Image Processing
Power to precisely analyse each
and every image taken from the
surface. SURFACE MASTER allows
adjusting this power exactly to the
specific needs.
Fast Start-Up
The best inspection system will not
create benefit if the commissioning
takes too long. SURFACE MASTER
contains easy to use tools to
setup the system in shortest time.
SURFACE MASTER comes with an
instant classifier and pre-settings
which allow starting the payback
within one month.
(fig.1) Defect Marking

37
Highest System Availability
SURFACE MASTER is designed to
guarantee 100% inspection. The
system utilizes standard hardware
that can be exchanged in shortest
time. The cameras are pre-
calibrated, so that even a change
can be done within shortest time.
For even higher availability
redundancy packages are available.
(fig.2) Automatic Sorting
Auditability
Today’s customers are more and
more interested in the used quality
management. Your customer
will trust you because SURFACE
MASTER offers tools and reports
for best auditability. This starts with
a comprehensive system diagnosis
and a long term analysis of the
system performance and ends with
a System Performance Indicator for
each produced coil.
Conclusion
We can conclude that surface
defects make surface inspection
indispensable for each and every
aluminium manufacturer. Surface
Inspection Systems enable the
detection of surface defects and
thereby give the possibility to
repair defects where possible
or to eliminate their causes. To
get the full benefit out of the
surface inspection results, only
the relevant information must
be filtered out from the vast
data. Hence, SURFACE MASTER
with its outstanding inspection
performance contributes to the
enhancement of the produced
material by reducing downtimes of
the system due to fewer coil breaks,
by producing less scrap and thus
lowering the manufacturing costs,
and by finally gaining high-quality
aluminium. Surface inspection
should be an integral part of the
production process chain in the
aluminium industry as it guarantees
a high level of surface quality.
ISRA VISION PARSYTEC
Auf der Hüls 183
52068 Aachen
Germany
Superior Quality and Optimum Yield: SURFACE MASTER in Action
Online view on the running coil and all defect images•
Coil reports to travel with the coil•
Width measurement report•
Web reports make the quality visible on the intranet•
Shift reports to examine the shift performance•
Process and Product Analysis
SURFACE MASTER offers flexible reporting and analyzing tools for
operators, quality engineers and controller. Examples are:

COMPLETE PROCESS VISION IMPROVES PRODUCT QUALITY
AND PROCESS EFFICIENCY WITH RAPID ROI
Goal: maximize product quality
and yield, and reduce production
costs.
Today’s leading aluminum
suppliers strive to continuously
improve their rolling processes
to maximise product quality and
yield, and to minimise production
costs. For example, in the
extremely competitive aluminum
can business, producers seek to
obtain the highest level of quality
at the lowest price. For this reason,
any technology that enables a
supplier to produce the desired
product with greater efficiency and
yield—in other words at a lower cost
would be highly desirable. With
lower production costs, suppliers
can achieve greater flexibility by
balancing their sales price and
sales volume to stay competitive.
Even incremental improvements
in process efficiency and yield can
markedly impact profitability.
Detecting and identifying defects
prior to value-added downstream
processes is one important way to
reduce cost and ensure product
quality. Ideally, the line supervisor
would like to quickly identify
where a defect originated within
the process, or determine if the
defect was actually created in a
prior process. When production
line problems are solved rapidly,
downtime and scrap are minimised,
and yield is maximised.
In many situations, new worker
safety requirements and machine
guarding prevent operators from
manually inspecting the strip while
the line is in operation. As such,
another way to reduce cost is to
address the inspection challenges
created when employees are
physically isolated from machines.
Enhancing manual inspection
processes with vision technologies
not only improves operator safety, it
also frees employees from tedious
tasks.
Aluminum manufacturers also
seek new aluminum applications.
One such opportunity is the
substitution of steel with
specialized or premium quality
aluminum to enable manufacture
of lighter weight vehicles. For this
application, end users require a
more optically uniform, defect-free
strip. To produce such a strip often
requires next-generation inspection
techniques.
Though surface inspection systems
are commonly used to examine
metal strip, there is a critical need
for advanced vision technologies
that can pinpoint the exact location
of an upstream process problem
with greater speed and accuracy. Of
course, any new vision technology
chosen to address these trends is
expected to produce a rapid return
on investment (ROI).
Current approach
To achieve these goals, many
aluminum suppliers have adopted
surface inspection systems. These
vision systems routinely and
reliably detect surface defects
and irregularities using various
camera and lighting configurations
including collimated, diffuse, or
side lighting depending on the
application. With collimated light,
two sets of cameras capture the
material surface from different
angles thus enhancing defect
detection. In real time, experienced
operators can use the resulting
images to aid in troubleshooting
line problems.
Engineering and quality
departments aggregate and
analyze the defect information
in support of their longer
term-process improvement
recommendations and decision-
making. Customer service and
order fulfillment departments
often use the information to grade,
allocate and price the product to
the appropriate use and end-user.
Advanced systems, such as
SmartView® Metals with patented
SmartLearn® Multi-Step Classifier,
automatically classify defects and
irregularities to give the operator
more insight about the overall
quality of the coil. However, even
when using advanced systems,
confirming the “why and where”
of the problem can be a time-
consuming and imprecise task.
When small defects occur in a very
large strip, finding the source of
the problem can be as difficult as
“finding a needle in a haystack.”
As a result, these defects can shut
down a production process for
hours. Though millions of miles of
metal strip have been successfully
examined by surface inspection
systems, there remains a need
to automatically, and thus more
rapidly, pinpoint the exact location
of an upstream process problem.
A better solution: complete
process monitoring speeds
problem resolution
The solution to the problem lies in
the integration of high-resolution
surface inspection at the line
exit, with video cameras that are
synchronized and strategically-
placed throughout the line. To
create this solution, software
(SmartSync) is used to link high-
resolution surface inspection
(SmartView) and web-based
monitoring (SmartAdvisor™).
The combination of capabilities
produces a comprehensive view
of the entire rolling process in
which the visual synthesis of
upstream and downstream events
captured on video enable the

39
operator to rapidly determine the
root cause of defects and take
immediate corrective action. With
the combined solution, process
problems are resolved more rapidly
enabling the supplier to minimize
if not eliminate defects, and to
increase yield and efficiency.
Though this combined solution
is new to the metals industry, it
is based on proven technology
leveraged from other continuous-
strip applications where hundreds
of similar systems are installed
worldwide. The technology
has been specifically adapted
to metals, using early-adopter
feedback from the world’s largest
aluminum manufacturers.
The SmartAdvisor process
monitoring system uses a series
of cameras to monitor multiple
user specified points along a
production line simultaneously.
Patented line-synchronization
technology integrates all the
images together into one fully-
visualized process flow. Because
the cameras are automatically
synchronized to continuous metal
processing, it tracks and pinpoints
where a defect or problem in
the process occurred, from root
cause to failure, more accurately
and efficiently than single-point
surface inspection. Operators are
also able to determine if the defect
originated in the current process or
if the defect was already present in
the raw material. Its cameras can be
configured to focus very closely on
the strip, or further away to capture
the overall work environment.
The flexible front-end of the
design ensures that the complete
rolling process from entry to
exit can be scaled up to provide
synchronized vision and process
control across the entire production
line. Critical defects and process
upsets automatically trigger a
video of the defect on the strip as
it passes each camera’s vantage
point. The SmartSync software
combines video and defect
classification information into an
integrated composite quality map.
Its database allows reporting of all
visual anomalies.
The SmartAdvisor system can
also function as a standalone
inspection and diagnostic tool.
Aluminum suppliers currently
use its video and defect detection
information to inspect the bottom-
side of their slabs. Because it is
portable, the solution can be used
to troubleshoot almost any process
including slitters and cut-to-length
lines. Repeating defect detection
algorithms have been specifically
designed to find defects such as
roll marks.
Results obtained
Using this technology, aluminum
processors are already increasing
their quality and yield, and reducing
unscheduled downtime.
Time is no longer wasted
troubleshooting or performing
maintenance on the wrong
machine or the wrong process.
By eliminating manual inspection
and other costs such as material
handling and unnecessarily
scrapping good material, they
are also realizing substantial cost
savings.
Fig. The integrated combination of surface inspection and process monitoring platforms provides a
comprehensive view of the complete process.

For one of the industry’s largest
aluminum suppliers, the cost
savings realized surpassed the cost
of their system --$100,000 US-- in
less than one month. This rapid
ROI was achieved due to a marked
improvement in the supplier’s
ability to:
• Track down the root-cause or
origin of defects by “rewinding”
images from each location on the
line.
• Determine whether a defect
originated from an upstream line,
for example the hot strip mill or
occurred on the current line, the
cold mill.
• Immediately identify and confirm
welding defects before they
became much larger, more costly
problems downstream.
Though these results are quite
remarkable, with the cost savings
achieved, users can expect a typical
system to pay for itself in nine
months or less.
Jason Zyglis, Strategic Marketing
Manager, COGNEX Corporation
A repeating defect classified at the rolling mill exit was also seen as it
entered the rolling mill.
Real-time and historic video from each process monitoring camera

41
PRIMARY SMELTING AND PROCESSES
ECL
New Anode Rodding Shop Solutions p. 42-44
FLSmidth
Moller® Technology: Advanced Solution
For Direct Feeding Of Electrolytic Cells p. 45-47

42
Driven by Innovation
Innovation 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 and in all
sectors.
We will maintain that focus now
and in the future
www.ecl.fr

43
NEW ANODE RODDING SHOP SOLUTIONS
1970, Eastalco, State of Maryland,
USA: ECL commissioned his first
complete anode rodding shop,
from loading/unloading station to
casting station. 40 years later, ECL
has gained an extensive know-how
and unrivalled experience with
more than 40 smelters equipped
with ECL machines across 6
continents. Able to offer from
single machines to turnkey rodding
shops for all types of anode (2, 3, 4
or 6 tubs) including engineering of
the building (Alba Line 5 – 2003,
Jonquière – 2009, Balco – 2010)
and construction of the building
(Emal Phase 1, 2010); ECL has
designed and set up more than
280 machines, constituting the
largest worldwide installed base in
the primary aluminium industry.
Rodding shop design through
flow management
Needless to say that the anode
rodding shop is a complex system
playing a major role
in the smelter efficiency and
productivity. Its performance can
dramatically influence reduction
line operation but also the lifetime
of Anode Baking Furnaces flue
walls. The reduction line must
be constantly supplied with new
anodes whereas spent anodes are
taken out of the pots. Hence the
rodding shop has some absolute
imperatives: quality, productivity
and reliability. It’s why ECL attaches
considerable importance to the
first phase of the rodding shop:
DESIGN. As a start, ECL always
considers first the smelter’s targets
in terms of production quality
and productivity. This includes
identifying solutions to reduce
operating cost and increase
capacity. The type and quantity of
stations needed is only a part of the
equation. To help it in this task,
ECL employs a highly specialized
software (Witness®) commonly
used in the automotive industry to
organize and simulate the anode
flow, taking into account the cycle
times, reliability and availability
rates of machines, anode buffer
sizes between machines, conveyors
speed and machines locations.
Various solutions are simulated to
determine the best set of machines
and rodding shop organization.
This allows ECL to guarantee
an efficient solution with given
production performance for single
machines or complete shops.
To ensure the optimum productivity
of the shop, a global flow,
production and maintenance
management system can also
be put in place. To this end
ECL provides a level 2 solution
giving access to a large amount
of information regarding each
station and the whole rodding
shop operation. The centralized
computer receives from each
station several information such
as Input, Output, Alarms status,
fault status and operator’s
shifts changes. The computer

Cast iron thimbles
rejection
Butt
entry
Stem Exit
Carbon
rejection
44 PRIMARY SMELTING AND PROCESSES
analysis helps determine for each
machine the availability rate, the
breakdown statistics and therefore
its reliability and productivity. The
level 2 solution allows the total
optimisation of the rodding shop.
It can also assist in determining
which station needs to be doubled
or replaced for a possible smelter
expansion. As a reference, at Alba
smelter only 9 shifts per week have
been determined as necessary to
produce the anode assemblies
required for the 336 pots (AP35
technology) whereas 12 shifts were
specified originally.
When designing rodding shop
equipment, ECL also focuses on
environment, health and safety.
Special features, unique technical
solutions and extensive safety
systems have been designed to
control the dust created by the
spent anodes cleaning process
and the high noise levels in order
to help our customers in their
HSE efforts and ensure a safe and
clean working environment for the
workers.
Innovation, around specific
customer requirement
ECL is constantly investing for the
future, continuously innovating
and continually partnering with its
customers for win-win solutions
no matter is the project: complete
turnkey system for Greenfield
smelters or retrofit project within
an existing plant. ECL delivers
improvements in operational
efficiency while always adding
value to its customer’s assets.
For instance, we can underline the
high level of ECL innovation with
the 2-in-1 station. Even if each
station is assigned to a specific task
in the cleaning or rodding process,
ECL designated and commissioned
in 2009 during EMAL‘s phase 1
the Butt & Thimble Stripping
Machine. It combines the butt
stripping and thimble breaking
functions which brings remarkable
savings in capital investments but
also significant reduction of the
total cycle time. Special jaws are
placed around the anode stubs,
protecting them from bending.
They are equipped with knives on
the underside that break the carbon
block when it is pushed against
them by the breaking tool coming
from below. Once the carbon is
removed, the same tool continues
its upward movement to push the
thimbles against the lower surface
of the jaws, until the bottom of the
anode stub reaches the level of the
jaw. Both carbon and iron pieces
fall on the same conveyor. They are
separated for recycling by pushers
on a sorting table. The total cycle
time is lowered down to less than
50 seconds per anode, against 88
seconds for separate stations.
We can also mention the anode
cooling tunnel, one of the last
but not least functional machines
developed by ECL engineers and
recently installed at Emal as well.
This system ensures the heat
treatment of spent anodes after
the hot bath removal facility. The
cooling tunnel use blowers to force
ambient air or outside air into the
tunnel while drawing heated air
from the anodes out after filtering.
These results in significantly faster
cooling times: the air volume
blown in tunnel is calculated to
lower down anode’s temperature of
200°C (392° Fahrenheit) in an hour,
against 80 hours without cooling
system whereas the butt conveyor
length is reduced by 15% compared
to a natural cooling solution.
By manufacturing and
commissioning 28 complete anode
rodding shops, ECL has been able
to constantly optimize the design of
each station, increase dramatically
the reliability and to create some
innovative new ones to meet
with customer’s requirements.
ECL is committed to reach the
performance required to feed
smoothly the potrooms with sealed
anodes of the highest quality,
in the safest and most reliable
environment as well as the lowest
operation costs.

¨
45
Introduction
It is a long way to the aluminium,
beginning with mining of the
clay-like ore called “bauxite”, and
finalised with the electrolysis of
alumina in the electrolytic cells.
However the goal to realise the
final step inside the electrolytic
cell of this 24 hr smelting process
in an environmentally friendly way
with the highest level of reliability
is extremely dependent on the
method chosen for the feeding of
electrolyte cells. Self-regulating
and continuous feeding of the ore
bunkers of the electrolytic cells,
absolute dust free operation, no
generation of fine particles, no
segregation, no scaling, minimised
energy consumption as well as
minimised maintenance work,
these are the indispensable
characteristics of an advanced
solution of a MÖLLER® Direct Pot
Feeding System.
General Description
The secondary oxide (fluorinated
alumina), produced in the gas
treatment centres (GTC) will be
stored in silos, near by the GTC.
This fluorinated alumina will
be taken from the so-called
fluorinated alumina silos and will
be transported directly by the direct
pot feeding system to each of the
electrolytic cells. This pneumatic
transport ensures a continuous
fluorinated alumina feeding to
each of the electrolytic cells. The
MÖLLER® Direct Pot Feeding
System works independently
from the pot room cranes, fully
automatically and completely
dust free. Because of the design,
maintenance work as well as
the amount of spare parts are
minimised.
Furthermore, the MÖLLER® Direct
Pot Feeding System has been
designed to work with highest
possible reliability under strongest
winter summer and tropical
conditions.
MOLLER®
TECHNOLOGY: ADVANCED SOLUTION FOR DIRECT FEEDING OF ELECTROLYTIC CELLS
Functional Description
One of the main requirements
for the direct pot feeding is the
smooth bulk material transport
to the electrolytic cells. Bulk
characteristics as grain size
distribution are unchanged.
Generation of fines (attrition),
scaling as well as segregation
is prevented by lowest possible
conveying velocities (< 0.1 m/s) and
minimised fluidising air amount.
The fluorinated alumina will be
taken from the fluorinated alumina
silo at the gas treatment centre and
will be transported to the so-called
main bins, normally one main bin
for each half of a pot room.
The pneumatic transport to the
main bins (near by the pot room
walls) as well as the transport
along the two pot room walls
will be realised by the MÖLLER
FLUIDFLOW pipe air slide system.
According to client requirements,
different kinds of feeding systems
to the electrolytic cells are
available. The so-called 'Single-
Feed', the 'Double-Feed' or even
'Multi-Feed' systems can be
foreseen.
'Single Feed System'
The main MÖLLER FLUIDFLOW
pipe air slide along the pot room
feeds directly each of the MÖLLER
FLUIDFLOW pipe air slides on
top of the superstructure of the
electrolytic cell.
'Double Feed System' or
'Multi Feed System'
The main MÖLLER FLUIDFLOW
pipe air slide along the pot
room feeds distribution bins.
Each of those distribution bins
are connected with two or more
electrolytic cells via MÖLLER
FLUIDFLOW pipe air slides on
electrolytic cells.
All necessary venting is realized via
venting domes which are connected
to the gas duct of the GTC.
The MÖLLER Direct Pot Feeding
Figure 1: Fluorinated alumina silo, MÖLLER FLUIDFLOW®
pipe air slide to the pot room wall, main bins and
MÖLLER FLUIDFLOW® pipe air slide along the pot.

46
System is working fully
automatically and is more or less
100% filled with Alumina all the
time.
The different customer
requirements in view of free access
to crust breakers, dosing devices
and the possibility for removing
the ore bunkers during operation,
influences the final design of the
MÖLLER FLUIDFLOW pipe air
slide on top of the superstructure
of the electrolytic cell. When the
bunker of an electrolytic cell is
full and the bulk material cone
level has reached the filling spout
discharge opening of the MÖLLER
FLUIDFLOW pipe air slide, the
mass flow of alumina is blocked
automatically. When fluorinated
alumina oxide is removed from
the ore bunker of the electrolytic
cell, the pneumatic transport starts
again automatically and a constant
and reliable mass feed rate to the
pots is ensured. The fluidising of
the fluorinated alumina inside the
MÖLLER FLUIDFLOW pipe air slide
works permanently to ensure a
constant bulk density.
Due to the material cone level in
the ore bunker of an electrolytic
cell, the self-closing filling spout
allows a self-regulating and
continuous re-filling of the ore
bunkers during operation of the
smelting plant. The self-closed
filling spout and the filling process
of the ore bunker are shown in
figure 2/3.
Furthermore, no pressure tight
sealing of the electrolytic cell is
necessary, because of the low
(over) pressure in the MÖLLER
FLUIDFLOW pipe air slide.
The fluidisation air for the MÖLLER
FLUIDFLOW pipe air slide along
the pot room will be supplied by
rotary piston blowers or fans. The
fluidisation air for the MÖLLER
FLUIDFLOW pipe air slide on
electrolytic cells will be supplied by
Figure 2/3: Self-closed filling spout and
filling process of the ore bunker of the
electrolytic cell.
fans in order to reduce the energy
consumption during operation to
the necessary minimum amount.
Conclusion
The direct feed of the electrolytic
cells is a fully integrated part of the
electrolysis of Alumina.
Highest possible quality of the
aluminium as well as reliability of
the smelting process cannot be
achieved with any equivalent direct
pot feeding system.
The MÖLLER Direct Pot Feeding
System satisfies highest possible
requirements in view of reliability,
smooth materials transport with
unchanged bulk characteristics,
dust emission and energy
consumption. Variable design
on top of the cell combined with
single-, double- or multi-feed
solutions meets all possible site
requirements.
Furthermore, this system is
working fully self regulating and
maintenance free.
Figure 4: MÖLLER FLUIDFLOW® pipe air slide on top of the superstructure
of the electrolytic cell.
PRIMARY SMELTING AND PROCESSES

47
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 13,000 employees,
FLSmidth® is a global company
with headquarters in Denmark and
local presence in more than 50
countries including project and
technology centres in Denmark,
India, USA and Germany.
FLSmidth® has over the past 130
years developed a business culture
based on three fundamental
values: competence, responsibility
and cooperation.
The Group’s 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 proved to be both a robust
and sustainable business model.
FLSmidth®, therefore, has relatively
few tangible assets and fixed costs
leading to a flexible cost structure,
which makes it possible to plan and
adjust resources.
FLSmidth® is a learning
organization, and our employees
are our most valuable asset. As
we continue to evolve, we will
place even greater emphasis on
performance and on attracting,
developing and retaining people
who can enhance our high-
performance culture.
FLSmidth® carries out a focused
effort in the area of research and
development aiming at fulfilling
customers’ future needs in terms of
innovative technical solutions, high
reliability and availability, minimum
environmental impact and the
lowest possible product lifecycle
costs.
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 experience located 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 caustic liquor. 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® specialises 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 primary
alumina, secondary alumina,
crushed bath and aluminium
fluoride comprise
• 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® 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 5.000 references worldwide.
Actual contracts under execution
for Emirates Aluminium Smelter
(secondary alumina silos, MÖLLER
direct pot feeding system, PTM
filling stations, primary alumina
truck unloading stations and
pressure vessel dense phase
conveying systems for a mix of
crushed bath/alumina oxide),
for UC RUSAL/RusHydro’s
Boguchansky Aluminium Smelter
(MÖLLER direct pot feeding
system) and C.V.G. ALCASA
(MÖLLER direct pot feeding
system) prove the strong position of
FLSmidth® in the global aluminium
smelter industry.
MÖLLER Alumina Handling
Systems - High performance, high
efficiency.
FLSmidth Hamburg GmbH
Haderslebener Strasse 7
25421 Pinneberg, Germany
hamburg@flsmidth.com

48
Novelis PAE Expert in
Casthouse Equipment
Using our technical expertise and experience,
we engineer, build and commission complete
CC and DC aluminium casting lines.
Continuous strip roll casters JUMBO 3C
- 3CM
DC slab and billet casters, AUTOPAK
automation system
In-furnace metal treatment system IRMA
In-line metal treatment units ALPUR, JETCLEANER, PDBF, CFF
After-sales services
Novelis PAE
Centr’Alp • BP 24
38341 Voreppe cedex
France
Tel +33 4 76 57 87 00
Fax +33 4 76 56 65 39
pae.marketing@novelis.com
www.novelis.com/PAE
Certified by Bureau
Veritas Certification
ISO 9001 • ISO 14001
OHSAS 18001
novelis.com/PAE

49
CAST HOUSE
Hycast AS
Hycast Profile p. 50-51
Jasper GmbH
More Than 25 Years Of Optimised
Thermal Technology p. 53
SMS Siemag AG
A Fixed Quantity For Aluminium Rolling Mills p. 54-57
IST GmbH / Kuttner
International Success For Kunttner Ist p. 59-61
¨
SMS SIEMAG Official Sponsors Of This Section
¨

50
Innovative Casthouse Solutions that Perform
Hycast AS
Industriveien 49 / P.O. Box 225
N-6600 Sunndalsøra, NORWAY
Phone: +47 71 69 38 00
Fax: +47 71 69 00 65
E-mail: hycast@hydro.com
Web: www.hycast.no

Aluminium World Journal 2012

Recommended

Recommended

More Related Content

What's hot

What's hot (13)

Viewers also liked

Viewers also liked (8)

Similar to Aluminium World Journal 2012

Similar to Aluminium World Journal 2012 (20)

Recently uploaded

Recently uploaded (20)

Aluminium World Journal 2012