- Aluminum furnace builder GNA alutech will use four ABB electromagnetic stirrers in its project
- New melting and casting complex in U.S. is set to become a beacon for reshoring, recycling and sustainable practices
- ABB technology will increase productivity, lower energy consumption and help to reduce operating costs
ABB has won an order from world-leading aluminum furnace builder GNA alutech, an Ebner® Group member. Four electromagnetic stirrers (AL-EMS) will contribute to a major expansion for a U.S. aluminum manufacturer. The producer runs the only aluminum mill in the country that focuses exclusively on common alloys, materials vital for the aerospace, automotive and electronics industries, and is now constructing a new melting and casting complex.
The aluminium producer has ambitions to increase its capacity from a current 325,000 tons per year and supply U.S.-manufactured high-quality common alloy aluminum coil across North America, with a focus on reshoring, recycling and sustainability at every stage. As part of GNA’s build, ABB’s water-cooled AL-EMS will contribute to safer, more consistent and repeatable aluminum furnace operations following commissioning at the site in late 2024.
The technology has proven to increase productivity by up to 25 percent, lower energy consumption by 10 percent and reduce dross generation by 15 percent in more than 400 aluminum furnace installations worldwide. The end-customer can expect to increase aluminum yield, record rapid chemical and temperature homogenization and achieve return on investment within six to twelve months. The water-cooling will allow the stirrer coils to operate at a lower temperature, protecting the windings from wear and tear, resulting in longer-lasting equipment and lower maintenance requirements. This method makes up most of ABB’s extensive installed base of electromagnetic stirring and braking devices in steel and aluminum production processes and has been deployed safely by customers for more than 80 years.
ABB metallurgists predict and commercially ensure electromagnetic stirring force and related improvements for each furnace project. Image ABB 
ABB's water-cooled electromagnetic stirrers will contribute to safer, more consistent and repeatable operation of four GNA alutech furnaces. Image GNA alutech
“Aluminum alloys will continue to be essential for a wide range of engineering and manufacturing applications, with many modern consumer products, transportation and buildings reliant on these strong, lightweight materials,” said Ted Phenix, founder of GNA alutech. “Our customers therefore rely on certainty in the design, construction and operation of furnaces and equipment for the aluminum industry, and by working together with ABB, we are stronger. The combination of technologies will serve this aluminum manufacturer for years to come.”
“This is an exciting project in the US with customers that are serious and ambitious about reaching their own sustainability objectives and meeting the expectations of the wider world,” said Joel Hatfield, Area Sales Manager, North America at ABB Metallurgy. “ABB’s electromagnetic stirrers will enable the desired levels of repeatability and efficiency in the aluminum furnace process while increasing yield too. All partners recognize the challenge of optimizing and reducing energy in aluminum melting, and that we can achieve results using technologies that exist today.”
ABB also offers an exclusive performance guarantee; a team of in-house metallurgists that uses fluid flow calculations of electromagnetic stirring force for every furnace to predict performance improvements which are commercially ensured for each installation.
GNA alutech is a recognized world leader in the design and construction of furnaces and equipment for the aluminum industry, especially melting and holding furnaces; homogenizing, annealing and heat treatment furnaces; cathode sealing equipment and associated machinery. It provides equipment and services for primary and secondary aluminum producers around the world. GNA alutech focuses on advanced design, control systems and construction techniques for long service life and class-leading efficiency and reliability, all with operator safety and user-friendly features built in.
ABB offers the world’s most comprehensive range of water and air-cooled EMS systems for both steel and aluminum production processes, delivering metallurgical improvements that are proven to increase productivity, end-product quality and reduce operating costs for electric arc, ladle and aluminum furnaces, as well as thick and thin slab and billet and bloom casters.
A complete range of products, services and end-to-end solutions that improve productivity, quality, safety and energy efficiency in iron, steel, aluminium and other metals production processes are available through ABB contributing to saving cost per ton of metal. Across the whole metals value chain, ABB demonstrates a commitment to optimize operations with high performance products, automation, electrification and digital solutions.
ABB’s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market. With its ~20,000 employees, leading technology and service expertise, ABB Process Automation helps customers in process, hybrid and maritime industries improve performance and safety of operations, enabling a more sustainable and resource-efficient future. go.abb/processautomation
ABB is a technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on more than 140 years of excellence, ABB’s more than 105,000 employees are committed to driving innovations that accelerate industrial transformation.www.abb.com
