Bulk materials handling for the production of primary aluminium. How you can safeguard reliable materials handling from raw materials supply through to electrolysis – with a universal approach.

>compounding

& extrusion

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handling

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03 >>Why you need what we convey. Aluminium has

a bright future. The growing number of possible ­applications for this promising material has resulted in higher quality requirements, and demand is on steady increase. For the production of primary ­aluminium, reliable and economical raw materials supply is the first main requirement to be met – irrespective of whether you are modernizing an existing plant or designing a new one. We convey alumina reliably, gently and economically, from raw materials receiving through all stages of handling up to electrolysis. This is what you need to safeguard the success of your operations. The complexity of bulk materials handling for the primary production of aluminium Raw Materials Receiving

Intermediate Conveying

In-Plant Storage

In-Plant Conveying

Distribution To Electrolysis Cells

Project management – The competence to manage complexity and integrate processes Concept Development Planning

Engineering & Design

Manufacturing & Procurement

Your high demands regarding economy and quality can only be satisfied by a plant in which all links along the entire process chain are optimally managed, no matter whether you are handling alumina or petcoke. With our experience, know-how and our project management expertise we are proficient in the transport of raw materials down to the last detail. This expertise has made us the global leader in the installation of customized bulk materials systems. More than 8,000 successfully completed projects all over the world speak for themselves.

Qualitiy & Logistics

Construction & Site Management

Commissioning & Training

With us as your partner, you can be sure that your plant will start operation right on time and that it is ideally designed for your individual needs and site conditions. We provide solutions for your applications quickly and professionally. In addition to our engineering proficiency and expertise, there is one other skill we are proud of – we listen very carefully to our customers. This is why our materials handling systems for primary aluminium are always tailored to your needs. That’s what we mean when we say “confidence through partnership”.

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>>Why we deal with complexity in an individual

way. The tasks involved in the design and implemen­ tation of a plant from project planning through to ­installation, and also of individual process ­stages for handling alumina and petroleum coke, are extremely complex. However, our experts master these with ease. With their experience, pragmatic approach and our innovative technical developments, they make sure that the optimum solution is elaborated for you in the shortest possible time. You can rely on us to further your complex interests with ­tailored concepts.

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Alumina PetCoke

Alumina As soon as we have worked with you to clarify the specifications and requirements of your plant or individual process stages, we pull out all the stops to make our know-how in handling alumina and petcoke work for you. As a result you can be sure that you get just what you need to produce primary aluminium to a consistently high quality standard – a plant which is designed fully in line with your specifications. This already starts with vacuum ship or wagon unloading with track-proven

Hartmann know-how, continuing with intermediate conveying, in-plant storage and in-plant conveying through to charging the electrolysis cells. We also place great emphasis on optimization of the interfaces between the individual process stages along the entire process chain. This guarantees reliable and economical material flow. As the world market and technology leader in materials handling, we deal with alumina and petcoke just the way you need it – in a simply first-class manner.

Raw Materials Receiving

Intermediate Conveying

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>Raw Materials Receiving

Why we enjoy an unloading challenge. Because time is money, and this is also very true when it comes to alumina and petcoke unloading. As large quantities of alumina and petcoke are required for aluminium production, the raw materials are either supplied by ship (A) or rail wagon (B). Short ship lay times during unloading are a most important cost-cutting factor. This is something we can guarantee, and at the same time ensure gentle and reliable unloading of your product. The pneumatic ­Coperion ship unloader features leading-edge technology backed by

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­ artmann expertise which has proved its efficiency and effecH tiveness hundreds of times over the years. The decisive process components such as filters, rotary valves, blowers etc. are developed and manufactured at our own works. Speed, reliability and gentle handling of the product during unloading are the first steps towards economical operation of your system. This is what we offer – offload your work on to us!

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02a | BELT SEALED ROTARY VALVE 02b | WEAR PROTECTED ROTARY VALVE 03 | SUCTION BLOWER 04 | TROUGH CHAIN CONVEYOR

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In-Plant Storage

Alumina PetCoke

Alumina

In-Plant Conveying

Distribution To Electrolysis Cells

Raw Materials Receiving

Intermediate Conveying

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> Intermediate Conveying

Why we overcome any distance quickly and directly for you. After unloading the alumina and petcoke, we transport it as quickly and gently as possible to the silos with pneumatic or mechanical conveying systems. To ensure high-quality transport, we select the most suitable conveying mode from our uniquely comprehensive portfolio and customize it to suit site conditions and requirements. Depending on the requirements and the individual ­situation, we use Coperion’s own pneumatic conveying technologies

and also trough chain conveyors. For vertical transport we use either the DUROLIFT conveying system or mechanical bucket

DUROLIFT, DUROSTAT, DUROSLIDE or mechanical conveying equipment such as belt conveyors, tube belt conveyors

elevators. We select the optimum technology for you – we have them all at our fingertips.

05 | TUBE BELT CONVEYOR

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06 | BELT CONVEYOR

08 | AIR LIFT – DUROLIFT

07 | AIR-SLIDE CONVEYOR – DUROSLIDE

09 | BUCKET ELEVATOR

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In-Plant Storage

Alumina PetCoke

Alumina

In-Plant Conveying

Distribution To Electrolysis Cells

Raw Materials Receiving

Intermediate Conveying

>In-Plant Storage

Why powders can be buffered. When charging and discharging alumina silos and also during storage, it is particularly important that a regular particle distribution is maintained. When handling petcoke the main challenge is to evacuate the product reliably. Our know-how guarantees reliable processes for both raw materials. To prevent segregation of the alumina during feeding and discharge, we collaborate with IBAU HAMBURG to implement an effective anti-segregation system. On the silo roof the alumina is distributed from a central transfer point through a cleverly devised system of air-slide conveyors to several optimally arranged filling connections into the silo. A special discharge system in the

10 | Silo DISTRIBUTION SYSTEM 11 | DISCHARGE SYSTEM 12 | MECHANICAL DISCHARGE DEVICE

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silo base permits selective fluidization and sequential discharge of the alumina from individual zones. In this way we can guarantee that the regular alumina particle distribution is ensured – the most important characteristic for the efficiency of the smelting process. Very robust discharge devices are available and used for discharge of the petcoke. We know what really counts.

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In-Plant Storage 06

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Alumina 11

PetCoke

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Alumina

In-Plant Conveying

Distribution To Electrolysis Cells

Raw Materials Receiving

Intermediate Conveying

>In-Plant Conveying

Why our gentle systems ensure raw materials ­quality. Gentle transport and therefore low particle degradation in the alumina enables stable operating conditions and a constantly high quality in the cells. No matter how far your storage silos are from the smelter – your product will always reach the “hot spot” in best form. A number of different conveying technologies are at your disposal. The principle is, however, the same for pneumatic, mechanical or truck transport. Coperion has the know-how

13 | Maxi CONVEYor 14 | Dense Phase CONVEYING – DUROSTAT 15 | TRUCK LOADING SYSTEM

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needed for all conveying methods to ensure gentle product transport, thereby maintaining the quality of the raw materials.

Alumina

In-Plant Storage

In-Plant Conveying PetCoke

A | Mechanical Transport

Alumina 05

PetCoke

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Alumina PetCoke

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Alumina

B | Pneumatic Transport Alumina

Alumina

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C | Truck Transport

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Distribution To Electrolysis Cells

Raw Materials Receiving

Intermediate Conveying

>Distribution To Electrolysis Cells

Why slow speeds boost production. With our ­DURODENSE system we offer a very gentle ­process for charging the electrolysis cells. Slow, continuous, reliable and self-regulating – these are all ­advantages which really count during this process stage. Our ­DURODENSE ticks all the right boxes as a perfected technology. With its low alumina flow ­velocity, the DURODENSE system prevents a scaling effect, providing a sound basis to ensure that primary aluminium manufacturing is reliable and continuous. This system is self-regulating and only requires minimum

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automation technology which – in light of the large number of electrolysis cells – is not only ­advantageous with regard to investment and maintenance, but also for operation by your personnel. Less is more. This is particularly true in this case.

In-Plant Storage

Alumina

In-Plant Conveying

Distribution To Electrolysis Cells

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PetCoke

Alumina

17 >> Why powder is not just powder. Professional

handling is essential – especially when transporting raw materials in powder form. We have the necessary experience and know-how on our side.

Our technical centre holds an archive of the properties of more than 10,000 bulk materials with all their conveying characteristics. More are added almost daily, as our customers trust us with their new developments and innovations. As a result we can show you the optimum solution for all conveying and handling stages for your production line. In addition, we have also installed more

than 8,000 ­materials handling systems around the world. This is why we know how to convey products with care and reliability, to maintain their quality and produce optimum results without wasting a pinch of powder. This also applies to alumina and petcoke. We are not the global market and technology leader in the bulk ­materials handing sector for nothing!

01 | TEST SET-UP 02 | BULK MATERIALS ANALYSIS 03 | BULK MATERIALS ARCHIVE

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18 >>That’s why we are the basis of your success. We

regard each customer individually and are unique on a global scale. For the market we produce systems and process components; for our customers we produce trust and confidence – and have been doing so for more than one hundred years. We can also design a customized plant or individual process stages to suit your own special requirements. Confidence through partnership is our promise that you can rely on.

Coperion GmbH Competence Center Materials Handling Niederbieger Straße 9 88250 Weingarten, Germany Tel.: +49 (0) 751 408-0 Fax: +49 (0) 751 408-200

Coperion GmbH Offenbach Office Heinrich-Krumm-Straße 6 63073 Offenbach, Germany Tel.: +49 (0) 69 829775-0 Fax: +49 (0) 69 829775-50

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& extrusion

Coperion GmbH Competence Center Compounding & Extrusion Theodorstraße 10 70469 Stuttgart, Germany Tel.: +49 (0) 711 897-2301 Fax: +49 (0) 711 897-3963 [email protected] Coperion GmbH Competence Center Materials Handling Niederbieger Straße 9 88250 Weingarten, Germany Tel.: +49 (0) 751 408-0 Fax: +49 (0) 751 408-200 [email protected] Coperion GmbH Competence Center Service Theodorstraße 10 70469 Stuttgart, Germany Tel.: +49 (0) 711 897-2206 Fax: +49 (0) 711 897-3920 [email protected] [email protected] www.coperion.com

>materials

handling

>service

EN_01_0908 Subject to changes.

>compounding

>Europe

>Asia

>America

Germany Coperion GmbH Offenbach Office Heinrich-Krumm-Straße 6 63073 Offenbach, Germany Tel.: +49 (0) 69 829775-0 Fax: +49 (0) 69 829775-50

China Coperion (Nanjing) Machinery Co. Ltd. No. 59, West Tianyuan Road Jiangning District Nanjing, 211100, PR China Tel.: +86 25 5278-6288 Fax: +86 25 5261-1 1 88

USA, Canada, Mexico, NAFTA Coperion Corporation 663 East Crescent Avenue Ramsey, NJ 07446, USA Tel.: +1 201 327-6300 Fax: +1 201 825-6494

Coperion GmbH Germany West Office Industriestraße 71a 50389 Wesseling, Germany Tel.: +49 (0) 2232 20700-10 Fax: +49 (0) 2232 20700-11 Belgium, Luxembourg, Netherlands Coperion N.V. Industrieweg 2, 2845 Niel, Belgium Tel.: +32 3 870-5100 Fax: +32 3 877-0710

Coperion International Trading (Shanghai) Co. Ltd. Coperion Machinery & Systems (Shanghai) Co. Ltd. Bldg. No. A2, 155 Dong She Road Song Jiang Industrial Zone (Dong Jing Branch) Dong Jing Town, Songjiang District Shanghai 201619, PR China Tel.: +86 21 6767-9505 Fax: +86 21 6767-9198

Sweden, Denmark, Finland, Norway Coperion AB Sjödalsvägen 42 14124 Huddinge, Sweden Tel.: +46 8 608-1818 Fax: +46 8 608-0868

Coperion Representative Office 2F, Tian Fu Ge, Tian He Square No. 268 Zhong Shan Da Dao Tian He District, Guangzhou 510660 Guangdong, PR China Tel.: +86 20 8230-7248 Fax: +86 20 8230-2606

France Coperion Sarl 13 Chemin du Baudy 69260 Charbonnières-les-Bains France Tel.: +33 478 4426-97 Fax: +33 478 8784-78

Singapore Coperion Pte. Ltd. 150 Beach Road #08-01/04 Gateway West Singapore 189720 Tel.: +65 641 88-200 Fax: +65 641 88-204

United Kingdom Coperion Ltd. Victoria House, 19–21 Ack Lane East Bramhall, Cheshire, SK7 2BE United Kingdom Tel.: +44 161 925-6910 Fax: +44 161 925-6911

Taiwan Coperion Pte. Ltd. Taiwan Branch Office 9F-2 No. 30 Chung San North Road, Sec. 3 Taipei, Taiwan Tel.: +886 225 9150-51 Fax: +886 225 9153-04

Italy Coperion S.r.l. Via Calvino 32 44100 Ferrara, Italy Tel.: +39 0532 7799-11 Fax: +39 0532 7799-80 Coperion S.r.l. Milan Office Via Milanese 20 20099 Sesto San Giovanni (MI) Italy Tel.: +39 02 241049-01 Fax: +39 02 241049-22 Spain, Portugal Coperion, S.L. Balmes, 73, pral. 08007 Barcelona, Spain Tel.: +34 93 45173-37 Fax: +34 93 45175-32 Russian Federation, CIS Coperion OOO ul. Pravdy 26, 127137 Moscow Russian Federation Tel.: +7 495 72558-93 Fax: +7 495 64895-45

Coperion Corporation Wytheville Office 285 Stafford Umberger Drive P.O. Drawer 775 Wytheville, VA 24382, USA Tel.: +1 276 228-7717 Fax: +1 276 228-7682 Coperion Corporation Houston Office 3955 World Houston Parkway Suite 190 Houston, TX 77032, USA Tel.: +1 281 449-9944 Fax: +1 281 449-4599 South America Coperion Ltda. R. Dona Germaine Buchard 418 05002-062 São Paulo-SP Brazil Tel.: +55 11 3874-2740 Fax: +55 11 3874-2757

Japan Coperion K.K. Kotobuki-Bldg.-9F 3-18, Kanda-Nishikicho, Chiyoda-Ku Tokyo 101-0054, Japan Tel.: +81 3 5217-1050 Fax: +81 3 5217-1055 India Coperion Ideal Pvt. Ltd. Ideal House, A-35, Sector 64 201307 Noida (U.P.), India Tel.: +91 120 24016-86 Fax: +91 120 24016-91

For more information about the worldwide Coperion network, visit www.coperion.com