"The AL-EMS solution ensures stability, and higher reliability for our aluminium furnace operations while maintaining homogeneity, alloy composition, and overall efficiency,” said Mr. Junjiang Yu, Equipment Manager, Casting Plant, Nanshan.
| Customer: |
Shandong Nanshan Light Alloy Co, Ltd. |
| Requirements: |
Improve furnace efficiency and productivity |
| Application: |
Aluminium furnace |
| ABB scope: |
AL-EMS equipping 25+ furnaces |
| Customer benefits: |
- Rapid chemical and temperature homogenization
- Increased melt rate and furnace efficiency
- Safer working conditions
- Reduced energy consumption
|
| Commissioning: |
2004-2021 |
“We have been using ABB’s electromagnetic stirring technology for aluminium furnaces (AL-EMS) for over twenty years, which has enabled us to homogenize the temperature and chemical composition of the molten aluminum, increase melt rate, reduce energy consumption, and improve furnace efficiency,” said, Mr.Yu, Nanshan. “Without an EMS, you need to manually stir the melt with a rake. This task may involve some risks for people working in production and can damage the furnace lining. By removing the need for manual stirring, ABB's solution has contributed to a safer working environment.”
Aluminium manufacturer Shandong Nanshan Light Alloy Co,Ltd. (Nanshan), located in Longkou, Yantai City, Shandong Province, China, primarily produces alloy ingots, hot-rolled and cold-rolled products, and aluminum foils. Their products are mainly used in packaging and aviation materials as well as hard alloy, automobile sheets which are distributed to domestic and overseas markets.
Nanshan chose ABB’s solution due to three key aspects: stability and higher reliability of aluminium furnace operations while maintaining homogeneity and alloy composition, including timely service.
“Firstly, from a performance perspective, melt homogeneity is good when using ABB’s electromagnetic stirring (EMS) technology,” said, Mr. Yu. “Secondly, in terms of reliability, the overall EMS operation is stable with a low failure rate. The aftersales service ensures any problems are resolved quickly.”
Melt homogeneity is vital to consistently achieving accurate alloy compositions necessary to produce material with specific properties and performance requirements such as Nanshan’s aluminium foils, which must be strong yet flexible.
From being the first customer in China to install the EMS technology in 2004, Nanshan has gone on to equip more than 25 furnaces with the solution. “The equipment provided by ABB is of good quality overall and user friendly. We are maintaining a strong communication and collaboration,” said Mr. Yu.
Unlocking higher levels of furnace efficiency
Two decades ago, in consideration of the potential challenges that would arise during the aluminum process, leaders at Nanshan decided to select ABB’s AL-EMS solution，which today equip more than 400 aluminium furnaces worldwide, and effectively mix the entire melt for aluminium furnaces with capacities of up to and exceeding 200 tons.
“ABB’s decades of experience in supplying electromagnetic stirring technology to aluminium producers was an important factor in choosing to install the solution,” said Mr. Yu.
“Nanshan has been a repeat customer for us; hence our team understands the furnace requirements very well,” said HanYu Pan, Area Sales Manager for Metallurgy Products at ABB. “We are very pleased that Nanshan continues to choose ABB to provide AL-EMS technology. Together, we continue to make real progress towards more resource-efficient metals manufacturing.”
ABB's AL-EMS product range includes air and liquid-cooled, and side and bottom-mounted stirrers, and ensures cost and energy efficiency by enhancing productivity and quality for aluminium melting, holding, and refining operations while increasing yield. The solution typically delivers up to 25% higher productivity, 15% lower dross generation, 10% less energy consumption, and a payback within 6-12 months.
Equipment Manager, Casting Plant at Nanshan