Norsk Hydro Asa · OSL:NHY
Norsk Hydro Asa — Technical Presentation (2015)
39 slides from Norsk Hydro Asa's technical presentation, 2015
Slide 1: Grevenbroich: Industry benchmark and platform for excellence
Grevenbroich Industry benchmark and platform for excellence Dr Stefan Kästner Plant Manager (1)
Slide 2: Mastering safety means to master processes
Mastering safety, means to master processes We continuously improve HSE • Focus on high risk incidents, awareness Hydro TRI Rate and employee involvement 30 • Special attention on contractor 25 management and involvement • Key tools: near-miss reporting, training, 20 WOC*, LOTO** and auditing 15 10
Slide 3: We campaign to raise awareness and establish safe standards
We campaign to raise awareness and establish safe standards • Safety at work info event for >1300 colleagues • Annual Health and Safety week: Event with lots of info stations, tests, exercises, practising etc. • Special courses, e.g. for drivers of forklift trucks • Eye Catcher Campaigns for > 200 c
Slide 4: Continuous Improvements
Continuous Improvements (4)
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Slide 6: Unique Aluminium triangle utilizing logistical, cost and process synergies
Unique «Aluminium triangle» utilizing logistical, cost and process synergies (6)
Slide 7: Grevenbroich: the largest finishing plant in the world
Grevenbroich: the largest finishing plant in the world Building our future on four strong pillars • Quality and technology leadership with strong cost focus Litho Foil • Selective growth in future-oriented products Safety Quality Production Performance Cost Focus Can Automotive (7)
Slide 8: Grevenbroich plant balance the factors of excellence
Grevenbroich plant balance the factors of excellence People / Know-How Processes • highly educated • mastering complex production processes operators and • highest standards for operational maintenance technicians procedures and quality • skilled engineers in Operations • process innovations product
Slide 9: Our products span worldwide
Our products span worldwide Sales in thousand tonnes Sales per incl. Norf-deliveries region in %* 8% Europe 12% South America 608 8% North America 591 593 589 4% 68% Middle East 584 583 580 578 Asia / Pacific 552 555 Sales per market segment in %* 19% Packaging & Building 32% Automotive 5% Lithograp
Slide 10: Selective growth in future-oriented products
Grevenbroich Plant Selective growth in future-oriented products Sales Litho sheets in kt Sales aseptic liquid Foil in kt 185 +4% 50 +7% 175 45 165 40 155 35 145 30 2008 2009 2010 2011 2012 2013 2014 2008 2009 2010 2011 2012 2013 2014 Sales Can End in kt Sales Automotive in kt 105 100 95 -4% 80 85 60
Slide 11: Intimate cooperation with European industry leaders
Intimate cooperation with European industry leaders Most of these are served from our Grevenbroich base Our products Our customers Our position Litho World market leader Global reach Foil Can Leading position in Europe Auto European reach Leading position in Europe GE/ Building (11)
Slide 12: Grevenbroich Plant – The Business System
Grevenbroich Plant – The Business System Creates culture and generate benefits Financial benefit > 270 trained + contributing! Prepare for Cont. Improvement > 650 trained + ~250 in participating! all departments teamwork! involved! (12)
Slide 13: Continuous improvement of KPIs in Grevenbroich
Continuous improvement of KPI’s in Grevenbroich …supported by a structured Business System approach Productivity in kg/manhour +12% 2009 2010 2011 2012 2013 2014 Claim rate in % Delivery performance in % -5% +21% 2009 2010 2011 2012 2013 2014 2009 2010 2011 2012 2013 2014 (13)
Slide 14: Grevenbroich: the largest finishing plant in the world
Grevenbroich: the largest finishing plant in the world Building our future on four strong pillars • Quality and technology leadership with strong cost focus Litho Foil • Selective growth in future-oriented products Safety Quality Production Performance Cost Focus Can Automotive (14)
Slide 15: World class know-how in foil production
World class know-how in foil production Leading global supplier for aseptic liquid foil • More than 90 years of experience • First liquid packaging foil in the world and first to make it 2 m wide • First computer-integrated manufacturing foil line • Strong focus on resource efficiency (15)
Slide 16: Foil production line
Foil production line Rolling, cutting and annealing (16)
Slide 17: Improving our resource efficiency in foil production
Improving our resource efficiency in foil production Rolling oil consumption in tonnes Specific power consumption in MWh/mt (17)
Slide 18: Setting a new industry benchmark in energy efficiency
Setting a new industry benchmark in energy efficiency First catalytic waste air purification on final annealing furnaces in the world (18)
Slide 19: Lithography production line
Lithography production line Rolling, stretching and degreasing (19)
Slide 20: Strengthening Litho
Strengthening Litho Global market leader through technology lead and high efficient production • First dedicated litho line in the world installed 1985, expansion lines built 1992 and 2005 • Hydro produced first aluminium lithographic sheet in the world and is market leader ever since • State-of-the
Slide 21: Strengthening Can
Strenghtening Can Global leader in quality & performance for end stock • Strengthening product focus and process chain including “aluminium triangle” Grevenbroich-Rheinwerk-AluNorf • Greening up our profile: • New UBC line to raise recycled content and improve metal base Product innovation • Hydro´s
Slide 22: Packaging and building production line
Packaging and building production line Lacquering and cutting (22)
Slide 23: Boosting Automotive
Boosting Automotive Leadership through innovation, service & quality • First investment in automotive BIW capacity in 2008 • Joint effort of Sales, Production, R&D and Technical Customer Service enabled smooth ramp-up • Excellent technology platform built up • Hydro today positioned as preferred par
Slide 24: Automotive production line
Automotive production line Rolling, cutting, annealing and stretching (24)
Slide 25: Automotive Line 3 Investment
Automotive Line 3 Investment (25)
Slide 26: Automotive line 3 contributing to our aspiration
Automotive line 3 contributing to our aspiration «AL3» will become benchmark in the aluminium world Capacity boost to 200,000 tpy Significant reduction of C02 emissions (26)
Slide 27: Aluminium sheet for cars reduces energy consumption and CO2 emissions
Aluminium sheet for cars offers reduction of energy consumption and CO2 emissions Lighter cars are more fuel efficient • For 10% reduction in vehicle weight, car manufacturers achieve a 5-7% fuel saving • Each 1 kg of aluminium replacing mild steel, cast iron or high strength steel in cars saves bet
Slide 28: Significant reduction of specific energy consumption through new AL3 line
Significant reduction of the specific energy consumption through new AL 3 line Current AL3 Gas consumption [kWh/t] 600 435 -27,5 % Electricity consumption [kWh/t] 334 214 -36,0 % Sustainable reduction of the carbon footprint (28)
Slide 29: Investing in developing our value chain
Investing in developing our value chain • Automotive line 3 «AL3» world class • Capacity increase to 200,000 tpy • Investment of €130 million • 55 employees on the new line • Ground-breaking in January 2015 • Production start 2nd half 2016 (29)
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Slide 32: Dimensions and process speed
Dimensions and process speed: Main building: Annealing line: Skin pass mill: 210m long, 45m width 140m long, 18m high 30m long, Speed max. Speed max. 100m/min 400m/min Auxiliary buildings Annealing line Skin pass mill Scrap Conveying line Surface treatment line Auxiliary buildings High- High-Bay Bay
Slide 33: Electric discharge texturing (EDT) line
Electric discharge texturing (EDT) line 400 m/min Recoiler Quality of surface Skin pass mill Uncoiler inspection Pinch roll unit Cross cut Leveller shear Drum shear Trimming shear Scrap box Scrap box (33)
Slide 34: Surface topography of automotive sheet
Surface topography of automotive sheet Mill Finish EDT - Electro Discharge Texturing Advantages of EDT topography for car body sheets: stochastic & isotropic > appearance after painting closed structure > improvement of tribological properties 100 µm 100 µm isotropic > same forming properties in all
Slide 35: Annealing line
Annealing line 140 m/min Water / Air quench area Furnance area Dancer Tension roll bridle Delivery side strip accumulator Entry side strip accumulator Drum shear Recoiler Uncoiler 1 Pre-Bake furnance Leveller 1 Uncoiler 2 Levelflex Scrap box Leveller 2 Strip joiner (35)
Slide 36: Coating line
Coating line 100 m/min Entry side strip accumulator Exit side strip accumulator De- Acid / ionised No- Oiling alkaline Desmutting rinsing Drum shear cleansing Rinsing 1-3 Rinsing 4-5 Rinse No-Rinse Uncoiler 1 Coater furnance Recoiler Leveller 1 Uncoiler 2 Tension Cooling bridle roller Scrap box 1&2
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Slide 38: Men of steel drive cars of aluminium.
Men of steel drive cars of aluminium.
Slide 39: Infinite Aluminium Hydro
INFINITE ALUMINIUM HYDRO