Slide 1: Alunorf: A true world leader
Alunorf: A true world leader Thomas Geupel Commercial Managing Director (1)
Slide 2: Welcome to Alunorf
Welcome to Alunorf The world’s biggest aluminium rolling and casting plant (2)
Slide 3: Hjertelig velkommen til Alunorf!
Hjertelig velkommen til Alunorf ! Thomas Geupel, Dr. Holger Voss Commercial Managing Director Unit Manager Hot Mills Dr. Hans Peter Kneijnsberg, Herman Koss, Technical Managing Director Unit Manager Remelt
Slide 4: Unique «Aluminium triangle» utilizing logistical, cost and process synergies
Unique «Aluminium triangle» utilizing logistical, cost and process synergies (4)
Slide 5: Aluminium Norf GmbH
Aluminium Norf GmbH • Founded 1965 • Energy consumption − 1 400 GWh natural gas • Owners − 600 GWh electricity − 50% Hydro Aluminium Rolled Products GmbH • Capacities − 50% Novelis Deutschland GmbH − 1 000 kmt remelt • Capital intensive operation with − 1 800 kmt hot mills replacement value much hig
Slide 6: Production equipment
Production equipment • Remelt • Hot mills − 13 melting / casting units (DCs) − HM 1: − 2 recycling furnaces − 23 Soaking pits − 10 sow dryers − Breakdown mill − 10 induction furnaces − 3-stand tandem mill − 3 scalpers − 2 edge scalpers − HM 2: − 3 saws − 6 pusher furnaces − Breakdown mill • Cold mil
Slide 7: Alunorf Process Steps
Alunorf Process Steps Alunorf / partner scrap, pigs, Melting furnace Holder / casting furnace Melt treatment, casting hardeners + recycling Ingots from Alunorf Sawing of ingot butts Scalping of ingot surfaces Soaking pits / pusher furnaces remelt & smelters homogenization / preheating Length 4,500 /
Slide 8: Product mix for Hydro in %
Product mix for Hydro in % (Volume shares 2014; total 708 kt) Others, 4% Shate, 6% Litho stock, 31% Automotive, 14% Foil stock, 19% Beverage can body stock, 14% Can end/lid stock, 12% (8)
Slide 9: Alunorf’s contribution to Hydro’s aspiration
Alunorf’s contribution to Hydro’s aspiration (9)
Slide 10: Better: Safety is our No 1 priority
Better: Safety is our No 1 priority Accident rates (per 200 khrs) 7 6 5 4 3 2 1 0 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 Target 2015 RC-rate LT-Rate (10)
Slide 11: Better: Continuous improvements
Better: Continuous improvements 460 1650 1600 450 Productivity in kg / total worrked hours Sales in thousansd tonnes per year 1550 440 1500 430 1450 420 1400 1350 410 1300 400 1250 390 1200 380 1150 2008 2009 2010 2011 2012 2013 2014 Plan 2015 (11)
Slide 12: Bigger: Past and present
Bigger: Past and present 1969 Annealing furnaces Recycling Centre 2011 (12)
Slide 13: Bigger: Hot mill production development
(13) 200 400 600 800 1000 1200 1400 1600 1800 0 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 HM 1 1991 1992 HM 2 1993 Bigger: Hot mill production development 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 20
Slide 14: Bigger: Hot mill developments
Bigger: Hot mill developments New HM 1 screw-down New HM 1 edger (14)
Slide 15: Greener: Efficient and continuously improving processes
Greener: Efficient and continuously improving processes PPP district heating Heat from waste air saves Neuss and Alunorf 20,000 t CO2 per year Freq.-controlled motors Process-adapted lower speed saves motor energy Regenerative burners New furnaces and burners reduce gas input and increase capacity C
Slide 16: Greener: specific energy input reduced
Greener: specific energy input reduced kWh/t • New pusher furnaces, new melting furnaces 10% • Refurbishment soaking pits 5% Savings so far: • District heating, use of waste gas 0% Power + gas -5% 907 mill kWh/y • Enhanced energy saving programme -10% CO2 224,000 t/y • Optimization of compressed air
Slide 17: Greener: Double award winner
Greener: Double award winner 2014 German Energy Award 2014 Energy Efficiency Award (17)
Slide 18: Infinite Aluminium Hydro
INFINITE ALUMINIUM HYDRO