An introduction to the Future Aluminium Forum, highlighting all the key themes that will be covered over today's conference sessions.

A brief introduction from our partners TALSAD before the forum kicks off.

Turkish aluminium industry; global trade trends and transition towards greener aluminum.

20 years of change (the past), the new look of the present (old world, new world, global relocation), what is the Future?

What does the future look like, what is driving change?

Energy, carbon, ESG, industrial efficiency, technology advance.

Success needs engagement with governments, communities, research partners, suppliers.

Investing for the future: slow speed, high speed, right speed?

Aluminium manufacturers face a range of challenges from a volatile and uncertain world and changing customer, employee and stakeholder expectations. AI is bringing change to all industries and companies are working to understand the benefits and risks and how to stay ahead of the curve. Successfully navigating this changing world will depend heavily on driving efficient and sustainable operations and on having reliable data. An integrated digital platform can help companies make the right decisions about new markets to enter, keeping assets in shape, reaching customers more profitably and improving efficiency and sustainability. This session will discuss examples of industry leaders who are using digital technology including Business AI and analytics to innovate and grow including how to:

• Reduce risk and improve supply chain agility using digital technologies such as Business AI, Machine Learning and IOT

• Establish a transparent and auditable enterprise system of record for corporate carbon accounting

• Benchmark operations and value chains to find areas for optimization and sustainability, using more granular data and predictive technologies

• Collaborate within and across industries to better use data as we move to a circular economy

• Sell to new markets using an integrated digital commerce platform

GHG emissions have been the central focus of the aluminium industry’s sustainability ambitions for a number of years. Aluminium production can be emissions intensive because of the high electricity and thermal energy requirements during the smelting and refining process and climate change remains a priority issue globally. It is increasingly clear though, that in order to produce truly sustainable metal, a holistic and integrated approach, beyond GHG emissions, is essential. Today, the industry is working actively to demonstrate its sustainability ambitions across all major ESG issues alongside ramping up critical decarbonisation action at a pivotal moment in global climate efforts.

This presentation will focus on the sustainability challenges and opportunities for the aluminium sector over the coming years as both demand and societal expectations grow. The industry will have to overcome significant sustainability challenges to maintain the sector’s social licence to operate and its position against other competing materials. Aluminium has an important role to play in many energy transition technologies and it is integral in modern societies – it is essential that the industry continues to take action across the value chain to maximise opportunities for improvement and continue to position aluminium as a sustainable material of choice for the future.

Hammerer Aluminium Industries (short: HAI) is a supplier of complete solutions to the aluminum industry, from recycling to high-tech aluminum profiles and finished components. It caters its aluminum products to various end-user industries, including transportation, building and construction, the industrial sector, and others. Hammerer Aluminium Industries is headquartered in Ranshofen, Austria, and operates seven other locations in Germany, Romania, and Poland. Besides being a key player in the aluminum industry, it is a member of associations such as the Aluminium Stewardship Initiative, Aluminium Deutschland, Bureau of International Recycling (BIR), and European Aluminium underscoring its commitment for a more sustainable aluminum industry. SustainAl is the brand name of Hammerer Aluminium Industries' low-carbon aluminum product. This product line is especially climate-friendly by using up to 80% recycled material, while the primary aluminum is generated entirely with electricity from renewable sources. With a casting capacity of around 250,000 tons and extrusion capacity of 120,000 tons, the company boasts a large consumer base globally.

An exceptionally high recycling rate, such as that offered by HAI, is only possible thanks to a wide range of processed scrap types, extensive knowledge of materials, production processes as well as many years of recycling expertise of our employees. To ensure optimal use of scrap, considerable investments have been made in plant engineering, furnace technology, residue management and scrap processing in recent years. The two HAI foundries are among the most modern and flexible ones in Europe.

The goals of the Paris Agreement on climate protection are clear: by 2050, the industry must be CO2-neutral. This also increases the pressure on supply chains and, as a result, customer demand for low-CO2 products. Since HAI has already been dedicated to sustainability and circular economy for years, bringing new, more sustainable products to the market was an obvious choice. We see the industry's commitment to climate targets as an immense opportunity.

In 2021, HAI launched its low-carbon product lines, the SustainAl 2.0 and SustainAl 4.0 alloys, to offer customers a transparent contribution to sustainability. With our high recycling competence and selected partners, we now offer high quality alloys with one of the world's lowest footprints in the market. SustainAl 2.0 has a carbon footprint of only 2 tons CO2 per ton aluminum and SustainAl 4.0 has a carbon footprint of 4 tons CO2 per ton aluminum. This is well below the European average of 6.7 tons and the global average of 18 tons. Sustainable corporate governance, aluminum recycling, green sourcing and green energy as well as environmentally friendly processes are the pillars for this. All company divisions are involved in the project, as it affects the entire process chain.

The SustainAl family is available in the 6xxx aluminium class. This alloy series is known for its above-average strength, corrosion resistance, good machinability and is used in a wide range of industries from construction to automotive.

Since the launch, three years ago, acceptance in the market has grown rapidly. In the meantime, we have a solid share of SustainAl alloys throughout all market segments.

Customers have realized that by using HAI’s CO2 reduced alloys, they can easily and significantly cut their carbon emissions. At the same time, ambiguity with respect to the importance of recycling rates, different methodologies used in determining the carbon footprint, available data and certifications are big topics. HAI Group can address these questions with its extensive expertise, ensuring transparency and authenticity without greenwashing.

Founded in 1913 by Nils Storvik, a visionary farmer, Storvik began as a local smithy on the Sande farm, focusing on producing and repairing agricultural tools. This origin grounded Storvik in principles of sustainability, emphasizing durable, high-quality products designed for longevity and repairability. Over the years, this philosophy has not only remained central to our operations but also evolved to address the pressing needs of environmental responsibility in the aluminium industry.

By 2020, Storvik undertook a significant transformation to formalize our sustainability approach, establishing clear goals and a comprehensive strategy aimed at minimizing our environmental impact. A cornerstone of this initiative is our pursuit of Science-Based Targets (SBT) approval, underscoring our dedication to actionable and measurable environmental responsibility.

Our commitment extends beyond mere operational adjustments; it encompasses a thorough examination of our carbon footprint since 2021, including a detailed product-level analysis across our cast product line. This introspective approach enables us to identify key areas for innovation, ensuring that both our processes and products actively contribute to a more sustainable environment.

However, our vision extends beyond our immediate operations. We recognize the profound impact that our products and solutions can have on the global stage. By focusing on helping our clients and partners reduce their carbon footprint, we contribute to a larger, collective effort to mitigate CO2 emissions worldwide. Through advanced aluminium production technologies and a steadfast commitment to quality and sustainability, we offer solutions that not only meet the industry's current needs but also forge a path toward a greener future.

Among our notable contributions are:

• The development of PjN-G, a proprietary iron quality structure that significantly extends the lifespan of furnace tending tools, enhancing sustainability in aluminium production.
• The pioneering Cathode Potshell Reset Project in Norway, offering a sustainable alternative by repairing and resetting worn-out cathode potshells instead of producing new ones, thus markedly reducing the carbon footprint.
• ICON, an innovative method for removing alkaline metals during liquid metal tapping, developed in cooperation with Hydro Sunndal, Europe’s largest primary smelter. This technique stands as a testament to our commitment to reducing CO2 emissions through collaborative innovation.

As Storvik gears up for the Future Aluminium Forum, we're focused on highlighting our role in advancing sustainable aluminium production. Our efforts are driven by a belief in collaboration and innovation as key drivers of industry-wide change, promoting sustainable practices that will help secure aluminium's role in a global green economy. As a central supplier to both primary aluminium production and recycling plants, our efforts are critical in the collective push towards net-zero emissions by 2050.

Each step we take is a testament to our commitment to forging a greener future, demonstrating that every contribution, no matter the size, is vital in our shared environmental responsibility.

The aluminium industry is witnessing a notable shift towards automation, aimed at optimising processes and boosting efficiency. Flexible operational designs are essential for seamlessly integrating automation in aluminium smelters. In this presentation we emphasise on the crucial link between flexibility and successful automation implementation, underscoring the pivotal role of agile operational frameworks in navigating this transformation.

Flexibility, in this context, refers to the capacity to swiftly adjust to changes in demand, production requirements, operational environment, and external variables. A flexible operational environment accommodates dynamic shifts without compromising operational efficiency. It establishes the groundwork upon which automation can flourish, ensuring the integration of automated technologies is smooth and efficient. Moreover, a flexible operational framework enables dynamic decision-making, ensuring that automation strategies align with ever-changing demands.

The integration of automation in aluminium smelters is not a standalone initiative; it is intricately linked to the flexibility of operations. By nurturing adaptability, responsiveness, and resource optimization, flexible operations pave the way for aluminium smelters to unlock the full potential of automation, ushering in a new era of operational efficiency and competitiveness.

Artificial Intelligence (AI) used in the industrial context has special requirements above smart tools known from the internet and the press. Existing systems such as Manufacturing Execution Systems (MES) need to converge with AI. In the special process-oriented production of aluminum, AI became an important force in driving operational excellence and transforming manufacturing strategies. By utilizing AI's predictive capabilities and qualitative labeling, MES can anticipate potential production disruptions, thereby enabling timely process intervention, reducing quality failures and minimizing downtime.

The collaboration between the MES and AI frameworks represents a significant step towards achieving Industry 4.0 principles. By harnessing the strengths of both technologies, aluminum producers can achieve unprecedented levels of operational excellence, quality, and responsiveness, positioning themselves for sustainable success in the ever-evolving manufacturing landscape. Obtain significant productivity enhancements through the combination of PSI Metals and PSI Qualicision AI, thereby enhancing financial viability.

The aluminum industry is undergoing a significant transformation, propelled by the advent of Industry 4.0. This paradigm shift is characterized by the integration of advanced digital technologies to enhance manufacturing processes. Central to this transition is implementing innovative technologies and methodologies reshaping production landscapes. DTE's ground-breaking solutions are at the forefront of this change, providing real-time compositional analysis of molten aluminum, coupled with advanced data analytics. These solutions facilitate unparalleled process improvements and decision-making. The ability to analyze molten metal in real time opens numerous opportunities for process improvements, allowing for immediate adjustments and optimization of the production process, boosting efficiency and throughput.

DTE‘s solutions are engineered to withstand challenging industrial conditions while providing precise, consistent and repeatable results. Due to DTE‘s proprietary technology, the solution offers unprecedented stability of results, minimizing need for calibration or standardization. Maintenance of the solution is minimal as no disposable or consumable components are needed, offering the customer a complete piece of mind.

DTE's solutions are highly configurable and can be integrated into various process points throughout a plant. This flexibility ensures that they can be adopted in different setups, from smelters to secondary processing facilities. The configurable nature of DTE's solutions means they can be tailored to fit the unique requirements of different facilities, from large-scale smelters to specialized secondary processors. This adaptability is key in a diverse and evolving industry. DTE offers solutions that can monitor melt composition at all process points, in smelter potrooms, transfer crucibles, furnaces and launders, both in primary and secondary processing.

DTE’s solutions unlock new optimization possibilities. Leveraging previously unavailable real-time data into actionable intelligence, efficiency can be increased at every process point. DTE’s solutions can therefore enhance decision making throughout the entire process from tapping, to batching and casting in primary production, ensuring that the production is always within specification and eliminating the need for over-processing and guaranteeing efficient use of valuable resources. In secondary processing such as recycling, the technology aids in better scrap and resource utilization and overall process efficiency, increasing the scrap content in finished products and allowing for optimal batching for every single batch. By eliminating waste in the production process, DTE’s solutions can help to reduce the carbon footprint, a critical factor given the increasing focus on environmental sustainability in manufacturing.

DTE's next-gen analytics and real-time molten metal analysis represent a significant advancement in aluminum production. By offering a solution that enhances efficiency, improves product quality, and reduces environmental impact, DTE is not only contributing to the evolution of the aluminum industry, but also ensuring its sustainability.

In the pursuit of sustainable practices and resource conservation, aluminium recycling plays a crucial role. The success of recycling programmes heavily relies on maximising recovery rates, which necessitates the selection of appropriate technologies. This presentation, titled "Maximising Recovery Rates: Choosing the Right Technology for Aluminium Recycling," aims to address key factors that contribute to enhanced recovery rates and the implications of improper choices.

The session begins by exploring methods to optimise recovery rates, discussing definitions and precautions to be taken into account. The presentation emphasises three essential factors to consider when selecting a melting furnace, as this choice significantly influences the overall efficiency of the recycling process.

Additionally, attendees will gain insights into the consequences of exceeding 1% VOCs (volatile organic compounds) in reverberatory furnaces, shedding light on potential challenges and environmental concerns. Moreover, distinguishing between clean scrap and contaminated scrap becomes imperative to achieve higher recovery rates and maintain the quality of recycled aluminium.

Join this informative session to understand the intricacies of aluminium recycling technology selection and discover how to make conscious decisions to maximise recovery rates while upholding sustainability and environmental responsibility.

In short and mid-term aluminium recycling is the most reliable tool to reach zero carbon targets for the aluminium industry. But, in secondary aluminium production we have also many problems. Mainly scrap availability, scrap quality, scrap sorting, metal efficiency, solid wastes (dross/salt cake) generation, carbon and equivalent emissions, and metal refining and secondary metal quality.

In this paper we have studied for solutions and try to create “digital eco-system” in aluminium recycling plant by using digital tools, models and processes like AI applications, furnace monitoring, robotization and lesson learned system based on data mining.”

AI, the more popular acronym cousin to AL. These acronyms AI - artificial intelligence and AL - aluminium are destined to be synonymous with our global aluminium industry, but this session will showcase the potential and challenge this possibility, all at the same time.

Historical trends around the limited digital advancements in our industry have often left innovators wanting more. Still, there have been some notable adoptions of AI in our ALuminium domain in recent times. In our field, we are positioned to learn from the successes and failures of several other similar and allied industries around the applications of AI and leapfrog to greater success rates. What does AI mean for us and our industry - bigger, better, faster, safer, and cleaner? Or will it bring more than what is visible to the eye?

The workshop-style format of this session will discuss the role of AI in our aluminium value chain and in particular, delve deeper into its applications to accelerate our journey to net zero. With a single focus agenda of sustainability for our global aluminium family, AI could hold the answer to many of our Scope 1, Scope 2, and Scope 3 emissions. Interactive tools throughout the session will allow participants to engage and opine on the benefits and not-so-positives of AI for our AL industry and also imagine the endless possibilities that AI can open up for aluminium, our industry, our people, and our products.

Automation of the scrap Charging and Skimming operations, with Fioscope air-cooled In-Furnace Smart Camera systems gives advantages that are unique, in an environment where keeping well trained operators in the Cast House is difficult.

Maximum scrap loads and short cycle scrap Charging of the Furnace with the utilization of Smart In -Furnace camera systems, with melt status analysis for optimum Charging times, can reduce melt cycles by more than 50% and save as much as 30% of the energy consumed in melting. This has a large impact on CO₂ generation, whilst keeping operators safe and improving productivity.

Automated skimming has a significant impact on overall dross recovery, energy use and the final amount of salt cake waste created. Taking the skimming out of the hands of the operator, makes total dross removal a thorough, efficient and repeatable practice every time. Automation of the process allows for complete skimming, eliminating the generation of more dross due to dross remaining on the bath and lowering the next melt’s recoveries. Precise skimming operations keeps the molten and alloyed aluminum in the furnace where it belongs. A thorough skimming process also keeps the free aluminum in the furnace where it belongs and not being removed in a wave action because of untrained operators or uneven floors, or simply trying to beat the clock.

All advantages of these areas will be discussed in detail this paper.

In the aluminium industry, the rapid advancement of digital technologies has presented both significant opportunities and daunting challenges. Chief among these challenges is the issue of data connectivity: the ability to seamlessly integrate and utilize data from a multitude of disparate sources across the business. Traditional methods of managing this data have often led to siloed information systems, impeding operational efficiency and flexibility.

The introduction of the Unified Namespace (UNS) as a centralized data management framework offers a solution to these challenges by standardizing data access and representation across all levels of operation. The UNS operates by creating a single source of truth that spans the entire business. It incorporates real-time data from various sources, such as PLCs, SCADA systems, MES, and ERP systems, into a common data model with intuitive naming conventions. While the concept of a single source of truth is not new, what sets the UNS apart from earlier approaches is its open architecture that's rooted in modern IT best practices.

The presentation will start by highlighting the data connectivity issue within the aluminium industry, pinpointing the challenges of integrating disparate data sources. It then proposes the Unified Namespace (UNS) as a solution, avoiding technical jargon for clear understanding. The session concludes with practical steps on implementing a UNS at your plant, providing a straightforward roadmap for post-conference action. This approach aims to equip attendees with the practical knowledge of how a modern data infrastructure can enable digital transformation at their company.