Novelis, a world leader for surface-finished and coil-coated aluminium products, presents innovative surfaces and fascinating facades at the BAU 2017 fair in Munich. One example: the corporate headquarters of the Belgian mechanical engineering group, Cockerill Maintenance & Ingénierie in Seraing (see photo), blossoms through its attractive three-dimensional aluminium façade of 6,500 square metres. The Paris’ architects Reichen et Robert Associate chose Novelis J57S due to its outstanding consistency of colour and gloss level. The combination of glass elements and 2 mm thick batch-anodized aluminium in a golden champagne colour shade provides a lively play of light and shadow. The most striking façade element is a golden metal net that unfolds around the building. The second layer of suspended, 3 mm perforated aluminium plates with rectangular cutouts provides a visual highlight and an extraordinary atmosphere.
In recognition of their packaging excellence six products, which won the prestigious Alufoil Trophy, have been awarded a WorldStar by the World Packaging Organisation (WPO). The winning alufoil products were made by Ampac Flexibles, Ardagh and Amcor Flexibles, Constantia Flexibles, Guala Closures and Huhtamaki Flexible Packaging.
Five WorldStars were received by Alufoil Trophy winners in the food category. Ampac were given the award for its Marinade Pouch, an innovative, 3-side-sealed pouch with a special zipper solution, which contains 200 ml of sauce, to marinate fresh meat within 30 minutes.
Magna International, in cooperation with the US Department of Energy (DOE) and partners FCA US and Grupo Antolin, has developed a new, ultralight door architecture that achieves the project objective of 42.5% mass savings compared to an average current production door. Making the announcement at the Detroit Auto Show, Magna and its project partners presented a solution to further help global automakers meet emissions standards and reduce fuel consumption through lightweighting. The door-in-white assembly makes extensive use of aluminium, which achieves around half of the total mass reduction of the door assembly.
The Ceratizit Group has acquired the German company Becker Diamantwerkzeuge, a producer of extremely wear resistant tools for the automotive, mechanical engineering, medical technology and aerospace industries. Becker tools are used when it comes to materials that are exotic and difficult to machine, such as aluminium, carbon fibre reinforced plastics or high alloy steel. In order to minimize the wear while machining, the cutting edges of the carbide tools are reinforced with diamonds or boron nitride.
Over the next five years, the automobile industry will be undergoing greater changes than over the past hundred years, and these changes will be worldwide. Megatrends such as growing urbanization with new business models of urban mobility, the spread of interconnectivity and the greater and greater use of electro-mobility – these are transforming our world. Rheinmetall Automotive CEO Horst Binnig commented on the occasion of the Detroit Auto Show starting on 9 January: “The auto industry is facing the greatest upheaval in its history. It must rise to the challenges if it is to continue to play a key role in the mobility of individuals. And this is only possible through a concerted effort by all concerned.”
Kobelco Aluminum Products and Extrusion, Inc. of Bowling Green, Kentucky has selected Granco Clark to supply a complete billet/log processing and extrusion handling systems for their new press line. The scope of supply includes Granco Clark’s next generation high efficiency log furnace, hot billet sawing, a billet taper quench system, eight IR die ovens, a high performance / high impact spray quench, 24’ air quench, cut-on-the-fly double puller system, high velocity cooling ducts, stretcher, a complete belt/conveyor system, ECS (Extrusion Cutting System) and gauge with scrap handling, age oven, extrusion stacking system, age oven rack stacking, powered roll rack conveyor with lift/transfers, and age oven rack de-stacking. This project will also have Granco Clark’s SCS Extrude software that provides powerful diagnostics with system diagrams, step-by-step troubleshooting instructions and graphics.
Danieli Fröhling’s new high-speed trimming line installed at Henan Zhongfu’s Gongyi plant in the Henan province, is in full production, processing 250,000 tonnes a year of aluminium strip. The strip thickness of the main product is 0.1 to 0.8 mm, with widths in the range of 900 to 2.150 mm, for a maximum coil weight of 30 tonnes. The line’s maximum strip-cutting speed is 1,500 m/min, producing primarily alloys of series 1xxx, 3xxx, 5xxx, and 8xxx.
Danieli supplied mechanical and process technologies for the entire system, including coil entry side, in-line coil preparation, electrostatic oiling, side trimming, scrap suction and high-speed recoiling, as well as the auxiliary systems and electrics/automation. Special technological features are also included in the package, such as in-line preparation with a drum shear (head end cropping) at a speed of 200 mpm, CNC trimming shear for fully automatic adjustment of width, knife immersion and cutting gap, and a reliable scrap suction and removal system, including a wet washer unit.
Primetals Technologies has been awarded an order from Jiangsu Dingsheng Aluminium (Dinsheng) in China to supply 60 sets of Air Bearing Shapemeters, ISV Spraybars, Magnescale Transducers and four packages of spare parts. The equipment is part of Dingsheng’s foil rolling mill expansion project taking place on three sites: the new Tong Liao site in Inner Mongolia and the two existing sites Zhengjiang in Jiangsu Province and Hangzhou in Zhejiang Province. First deliveries were made in October 2016 and final deliveries will be made in February 2019.
Emirates Global Aluminium (EGA) has announced that the first bauxite bulk sample shipment from its mine under development in the Republic of Guinea has left from the port of Kamsar, bound for bauxite customers in China. The shipment of 55,000 tonnes is a milestone in EGA’s programme to unlock Chinese and other markets for Guinean bauxite.
First-tier auto-industry supplier Rheinmetall Automotive is emphasizing at the North American International Auto Show in Detroit (8-22 Jan 2017) its extensive capabilities for engines with present and future drive systems. The main topics are lightweight engineering, thermal management, friction and emission reduction, downsizing and turbo-charging as well as the electrification of auxiliary units.
Novelis has published its fiscal year 2016 sustainability report, detailing significant progress toward increasing the use of recycled aluminium and minimizing the use of natural resources. Recycling aluminium produces 95% fewer greenhouse gas (GHG) emissions and requires 95% less energy than primary aluminium production, enabling Novelis to achieve lower GHG emissions despite increasing global production capacity. At the end of fiscal 2016, Novelis achieved an average of 53% recycled aluminium inputs, up 23 percentage points from the baseline averages of fiscal years 2007 to 2009. Novelis also reduced its GHG emissions by 19% for the same baseline years.
ASAS Aluminium, which ranks No 91 among the top 500 industrial enterprises in Turkey and is a leading aluminium semis producer in Europe, attracted applause at its ALUMINIUM 2016 Stand in November in Düsseldorf, where it presented a number of works of art. The motto of the ASAS Stand: Art Meets Industry.
General manager Bülent Atabay stated: “ASAS is an exporter with an average annual growth rate of 26% over the last 15 years. In addition to being a big industrial enterprise that employs over 2.150 people, our target is to grow and develop the company by achieving competency that will create more added value for our country and by participating in social responsibility projects.”
ALUMINIUM China is Asia’s leading aluminium industry platform for the complete aluminium industry supply chain, bringing together leading industry figures, state-of-the-art technologies and advanced applications. In July 2016 some 19,530 visitors and delegates from 75 countries and regions worldwide attended the 3-day event with its more than 400 exhibitors. Around one third of the visitors were related to automotive manufacturers, one tenth to packaging and transport sectors, respectively. The organizer of the Show, Reed Exhibitions, reports that more than 80% of the visitors play an important role in purchasing decisions.
ALUMINIUM China 2017 will take place from 19 to 21 July at Shanghai New Intl Expo Centre.
KS Huayu AluTech GmbH, a joint venture between Rheinmetall Automotive and Huayu Automotive Systems, is currently enjoying a constant growth in new business. Order influx for die castings in aluminium is such that KS Huayu urgently needs to expand its capacities. Concurrently, this castings specialist, which is based in Neckarsulm, Germany, is venturing more and more into new types of products without, however, neglecting its traditional engine block business. Whereas at present only around 12% of sales is generated by components outside the power train, plans are for the proportion to triple over the next decade. Besides the original additions to the portfolio of lightweight components, such as transverse links and rear subframes, orders for other parts in aluminium, e.g. suspension-strut mounts, have also been booked.
Aluminium producer UC Rusal and Elka-Cable signed an agreement in December to create Bogoslovsk Cable Plant, a jointly owned facility producing cables and wires. The partners will have an equal number of shares in the joint venture and the total investment is estimated at USD19 million. The new facility will be set up within the site currently occupied by Rusal’s Bogoslovsk Aluminium Smelter (BAZ). Once the new plant reaches its full capacity, it will be making 4,300 tonnes of aluminium products annually, in terms of the metal used, including oil-submersible cables, flexible cables and displaceable wires and self-supporting insulated wires – all these for Russia and the CIS market.
Novelis has been awarded the prestigious European Aluminium Award at the ALUMINIUM 2016 trade fair. The award honouring efficient and forward-thinking uses of aluminium was bestowed upon Novelis for its work in automotive aluminium innovation on the REALCar (REcycled ALuminium Car) project. Launched in 2008 by Jaguar Land Rover, the REALCar programme is a multi-stakeholder initiative established to create a closed-loop vehicle production model that recycles automobiles at the end of their lifecycles. Through this dedicated closed-loop recycling system, Jaguar Land Rover was able to recover over 50,000 tonnes of press shop aluminium scrap in 2015.
From primary to recycling, the total demand for aluminium is increasing by an average of 2% each year. These figures released at the ALUMINIUM 2016 trade fair in Düsseldorf, Germany, confirm aluminium to be the material of choice for a broad range of strategic applications. Gerd Götz, director general of the European Aluminium (EA) association said: “Our forecasts for 2016 and 2017 show steady growth in both production and demand across the aluminium value chain in Europe. Clearly aluminium is the preferred material for applications with strategic value for a sustainable economy, such as transport, packaging and buildings.”
The aluminium company Hydro has signed a cooperation with Austin AI Inc. (AAI), Texas, on the joint development of advanced technology to sort automotive aluminium alloys. New developments can bring a step change to efficient, robust recycling of manufacturing scraps and later on used cars. The automotive industry boosts the use of aluminium to build lighter cars that emit less CO2. Their press shops are stamping different sheet components mostly made of 5xxx or 6xxx alloys. This requires separation of production scrap and makes recycling complex both for production remains and at the end-of-life phase.
Developments in business activity in the German aluminium sector have been mixed so far this year. Producers of semi-finished aluminium products in-creased production by 6.1% during the period January to September 2016, but aluminium producers (-0.5%) and converters (-1.8%) reported declines. The expectations for 2017 tend to be positive. According to Christian Wellner, ex-ecutive member of the board of GDA, the German Aluminium Association: “Although the economy is currently characterised by considerable uncertainty, the business outlook for the coming year is nevertheless positive. Demand for aluminium worldwide will continue to increase, in Germany as well. Further-more, the past has shown that the German aluminium industry can assert itself very well despite increasingly more intensive competition and cooling demand. This good performance by German companies is largely attributable to their high innovation potential and good competitive position.”
At this year’s ALUMINIUM trade fair in Düsseldorf from 29 November to 1 December, Achenbach Buschhütten and Goebel IMS will present their joint development: the NovaSlit S – a next-generation aluminium foil slitter for the processing of both hard rolled and soft annealed aluminium foils. Precise cutting of foil thicknesses from 6 to 50 µm into slitting widths starting from 25 mm is guaranteed with this innovative machine. The finished roll diameter ranges up to 800 mm in slitting operation and maximum 1,000 mm for re-reeling operation on the bottom rewinder.
Rio Tinto has reached an agreement to sell its assets at Lochaber, Scotland, to Simec for consideration totalling USD410 million (£330m). The agreement comprises the sale of Rio Tinto’s 100% shareholding in Alcan Aluminium UK Ltd which includes the operating smelter, the hydroelectric facilities at Kinlochleven and Lochaber as well as all associated land. Rio Tinto Aluminium CEO Alf Barrios said: “This is a value-creating sale for Rio Tinto and represents another example of refining our portfolio to focus on our suite of tier one assets. At the same time, our priority has been to ensure a long-term sustainable future for Lochaber and economic benefit for the wider Fort William community. There was significant interest in the assets, but Simec is committed to continuing operations at the smelter and working with the community on further economic development.” Simec’s intention is that the smelter will be operated by the Liberty House Group, its sister company within the international GFG Alliance. The sale is expected to close mid-December 2016.
Super Alloy Industrial Co. Ltd. (SAI) from Taiwan has placed an order with Hertwich Engineering for the supply of a compact remelt plant for aluminium billets in sizes up to max. 305 mm diameter and 7,000 mm length. The plant is designed for a capacity of 40,000 tonnes a year and shall be commissioned in September 2017.
The company Aluminium Konin / Impexmetal in Poland has recently commissioned a high-performing cut-to-length line from Georg GmbH for the processing of coils out of thin and soft aluminium. That the company relies on high-tech from Georg is no novelty: already since 2005 there is a cut-to-length line from Georg in operation.
Russia’s aluminium flagship UC Rusal has completed the sale of a 100% stake in Alumina Partners of Jamaica (Alpart) to the Chinese state industrial group Jiuquan Iron & Steel Co. Ltd (Jisco) for a USD299 million cash consideration. The divestment of Alpart does not affect Rusal’s 100% self-sufficiency in alumina. Vertical integration into efficient upstream assets remains one of the key pillars of the company’s strategy.
Emirates Global Aluminium, the largest industrial company in the UAE outside the oil and gas industry, is to supply high quality UAE-made aluminium to BMW for use in the manufacture of some of the German car group’s engines. Although EGA has supplied aluminium to the automotive parts industry for decades, the deal with BMW is the first directly with a major automotive group. EGA will supply BMW with aluminium under the deal for the next three years.
As part of its realignment and restructuring, Stockach Aluminium GmbH in Dachau, Germany, is concentrating on wrought alloys and will be discontinuing the production of casting alloys at the end of the year. This decision was made by the management and shareholders of the company. Some 25,000 tonnes of casting alloys capacity is being shut down. The decision was made against the background of the enormous oversupply on the market, which no longer allows for production at sufficient margins. In future, the production of casting alloys will be concentrated at the locations of the sister company Oetinger Aluminium in Weißenhorn and Neu-Ulm.
Russia’s aluminium producer UC Rusal has announced Q3 2016 figures. Revenue in Q3 amounted to USD2,060m, up 3.9%. Adjusted Ebitda increased by 22.4% to USD421m, and adjusted net profit quadrupled to USD181m. All in comparison with the previous quarter. Compared with the year-ago period, revenue, adjusted Ebitda and adjusted net profit were on the same level.
Aluminium segment cost per tonne declined by 7.6% to USD1,330 in Q3 2016 as a result of efficiency measures, cost reduction initiatives and external factors such as fluctuation of Russian Ruble to the US dollar and decrease of raw materials price.
Four renowned extrusion plant operators could be convinced that exceptionally high temperature control accuracy, maximum flexibility plus energy savings are possible, all at the same time. Billet heating systems relying on combined gas and induction heating have now been successfully commissioned at these customer’s sites in Austria, Finland, Canada and the Czech Republic, respectively.
Alcoa spin-off Arconic has announced a multi-year contract with Airbus for the supply of aluminium sheet and plate. This USD1 billion contract is the first to include material from the company’s new thick plate stretcher in Davenport, Iowa. Arconic’s most significant share gain in the contract is in the A320 family of aircraft, which is Airbus’ highest growth programme. The multi-year agreement will start in January 2017 and makes Arconic sole supplier to Airbus for specific applications, including some wing, fuselage and structural components. In addition, Airbus planes will feature Arconic plate products on every platform, used in key applications such as wing ribs, fuselage frames and other structural parts of the aircraft.
Super Alloy Industrial CO. Ltd. (SAI), located in Dou-Liu City, Taiwan, has placed an order with Hertwich Engineering for the supply of a compact remelt plant for aluminium billets. The plant is designed for a capacity of 40,000 tonnes a year and shall be commissioned in September 2017.
The international journal for industry, research and application of aluminium is published monthly. It provides information on all topical issues concerning the material, its production, processing, recycling and application. Furthermore, economic topics and ecological consequences of aluminium application are discussed. Thirty percent of all articles in the journal are written in English.
The trade journal is the leading title in the whole German-speaking area. It provides information on material-specific characteristics of aluminium, latest processing technologies and innovative applications in various branches and sectors of industry.