SICK ALUMINUM - SENSOR SOLUTIONS FOR THE ALUMINUM INDUSTRY User guide

INDUSTRY GUIDE

ALUMINUM

SENSOR SOLUTIONS FOR THE ALUMINUM INDUSTRY

2 Aluminum | SiCK 8026472/2021-03-22

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TABLE OF CONTENTS

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Aluminum | SiCK

Aluminum | SiCKmF 3

Tasks

Tasks in the aluminum industry 4

Applications in focus

Ingot casting system 9

Secondary aluminum and recycling 15

Alumina production 23

Primary aluminum 39

Off-gas system 55

Products

Product overview 72

General information

Company 106

Industries 108

SICK LifeTime Services 110

Versatile product range for industrial automation 112

Industry 4.0 – digitization and networking 116

Industrial communication and sensor integration 118

Services 123

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BERGBAU

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TASKS IN THE ALUMINUM INDUSTRY

In the end, the quality has to be right. To achieve this, some critical details

need to be observed. Monitoring the ow and dosing of bulk materials op-

timizes the throughput and reduces maintenance times. This also includes

the correct positioning and alignment of semi-nished and nished prod-

ucts on roller tables and the optimal distance between nished products

in order to avoid damage and compromising quality. Flexible processes

and interactions between humans and machines require safety technol-

ogy. The regulations for emission monitoring and data transmission to

the authorities are becoming increasingly stricter; this also applies to the

aluminum industry. SICK delivers sensor solutions for almost every appli-

cation so that reliable aluminum products are produced.

More information g www.sick.com/metal_and_steel

Emission monitoring

Measurement systems either check to see if emission stan-

dards are reached and complied with or only report limit viola-

tions. Operators in aluminum mills trust the expertise of SICK

when choosing appropriate solutions for gas ow and dust

concentration measurement as well as gas analysis.

Material ow optimization

2D LiDAR sensors and ow sensors measure volume ow on

conveyor belts. Level sensors monitor the contents of silos

and material discharge hoppers. Encoders and sensors for de-

tection control the dosing processes. Even material manage-

ment benets from sensor technology from SICK: production

efciency increases.

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TASKS IN THE ALUMINUM INDUSTRY

Quality control

The product quality must be consistently ensured in the pro-

duction chain. Solutions from SICK ensure that the required

quality level of nished products is achieved – from measuring

sheet thickness to checking the ingot dimensions, from prol-

ing and adjustment to warpage detection.

Security and protection

It is not just the protection of people that is important. Equally

important is the protection of the plant and its machines from

damage and loss. SICK offers solutions for collision protection,

access control in risk zones and accident prevention within

and outside of the production building.

I2 Aluminium

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Applications in focus

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Applications in focus

Ingot casting system 9

Secondary aluminum and recycling 15

Alumina production 23

Primary aluminum 39

Off-gas system 55

I3 Masselngießanlage

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Applications in focus ALUMINUM

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ALUMINUM Applications in focus

9

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Ingot casting system

Focus 1 10

Casting wheel

Focus 2 12

Ingot casting belt and chute system

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Focus 1: Casting wheel

INGOT CASTING SYSTEM

2

3

1

Speed measurement of casting

wheel for casting process

monitoring

For optimal lling of ingot molds, it is

essential to synchronize the speed of

the casting wheel with the speed of the

ingot casting conveyor. This requires

precise measurement of the speed of

the casting wheel. The AFS/AFM60 Inox

absolute encoder performs this task re-

liably and, thanks to its high resolution,

with maximum accuracy too. Its rugged

design enables it to be used in the

harsh environment of aluminum casting.

AFS/AFM60 Inox g p. 92

2

Speed measurement of ingot

casting belt

To ensure the empty ingot molds arrive

at the casting wheel at the right time

and can be lled, it is essential to syn-

chronize the speed of the ingot casting

conveyor with the speed of the casting

wheel. This requires precise measure-

ment of the speed of the ingot casting

conveyor. The DBS36 Core incremental

encoder performs this task reliably in

the harsh environment of aluminum

casting.

DBS36 Core g p. 93

3

Presence monitoring of

casting molds

In an ingot casting plant, the casting

conveyor comprises individual ingot

casting molds that are connected to a

chain. At the casting wheel, it must be

ensured that no molten aluminum runs

out freely due to a missing mold. The OD

Value displacement measurement sen-

sor therefore checks for the presence of

the casting molds before the aluminum

is poured by the casting wheel.

OD Value g p. 96

4

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Focus 1: Casting wheel

INGOT CASTING SYSTEM

1

4

Level monitoring of ingot casting mold

Perfect ingots are only possible if the

casting mold is lled correctly and

enough molten aluminum is always

available. The DT1000 long range

distance sensor measures the level of

the molten aluminum precisely in the

distribution unit upstream of the casting

wheel as well in the casting molds down-

stream of the casting process.

This works with molten aluminum

despite its reective surface and its

temperature of more than 600 °C both

up- and downstream from the casting

process. The measurement ensures that

there is always sufcient aluminum avail-

able and every mold can be uniformly

lled. The sensor immediately detects

deviations from the target values.

Dx1000 g p. 97

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Focus 2: Ingot casting belt and chute system

INGOT CASTING SYSTEM

1

Access monitoring and protection

of casting system

A casting system for aluminum ingots

has various dangerous parts, such as

the rotating casting wheel, conveyor

belts, as well as automated grippers

or robots. The molten metal and hot

surfaces also pose a hazard. A combina-

tion of several safety sensors and MOC

Motion Safety Drive Monitor ensure

safe machine standstills. The DFS60S

Pro safety encoder safely monitors the

machine speed. One and more TR110

Lock safety locking devices ensure that

no personnel can enter the hazardous

areas while the machine is running. The

conveyor belts are also protected by

safety light curtains.

Flexi Soft g p. 78

TR110 Lock g p. 77

DFS60S Pro g p. 93

2

Presence monitoring of ingots after throw-out

The ejection of ingots from the casting

mold must be monitored. The position of

each ingot on the casting conveyor is de-

cisive. The position is important in order

to prepare for downstream processes,

e.g. gripping and stacking of the ingots.

In addition, the exact shape of each in-

got must be recorded for quality control

of the casting process. The Ranger3

streaming camera generates 3D data of

the shape and dimensions of each ingot.

This data can be compared with the

target values in a separate image pro-

cessing system. This enables deviations

to be detected and countermeasures to

be initiated.

Ranger3 g p. 94

3

Monitoring of ingot mold to ensure

ingot was thrown out

In an ingot casting plant, the casting

conveyor comprises of individual ingot

casting molds that are connected to a

chain. Once the molten aluminum has

fully solidied in the mold, it is dis-

charged onto a conveyor belt. An OD Val-

ue displacement measurement sensor

checks whether the ingot has released

from the mold.

OD Value g p. 96

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Focus 2: Ingot casting belt and chute system

INGOT CASTING SYSTEM

1

2

3

4

Collision warning on manned forklift trucks

The Visionary-B 3D vision sensor is used

as an active driver assistance system to

reduce the risk of collisions during turn-

ing and reversing maneuvers of manned

forklift trucks. Its congurable 3D detec-

tion zones can be tailored to the specic

blind spots of the vehicle. The vehicle

operator maintains an overview of the

situation via a live image. The sensor is

also equipped with an intelligent object

detection capability.

For example, the vehicle operator only

receives a visual or acoustic warning

signal if absolutely necessary.

Visionary-B g p. 95

I3 Sekundäraluminium und Recycling

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Applications in focus ALUMINUM

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ALUMINUM Applications in focus

15

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Secondary aluminum and recycling

Focus 1 16

Slag preparation

Focus 2 18

Chip drying

Focus 3 20

Furnaces

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Focus 1: Slag preparation

SECONDARY ALUMINUM AND RECYCLING

1

2

3

1

Protection of slag preparation

machine

The recycling process for aluminum in-

cludes treating any slag, also referred to

as dross, produced during the smelting

process. This still contains a signicant

quantity of aluminum that is worthwhile

recovering. This slag treatment occurs

in rotary kilns that are fed by conveyor

belts. The DFS60S Pro safety encoder

safely monitors the machines when they

are idle. They ensure that the access

points can only be accessed when the

machine is stationary.

DFS60S Pro g p. 93

2

Monitoring of conveyor belt operation during slag preparation

The Bulkscan

®

LMS511 ow sensor is

ideally suited for measuring the through-

put of bulk materials on conveyor belts.

The Bulkscan

®

LMS511 continuously

determines the volume of aluminum slag

or chips on conveyor belts. The system

operator therefore always knows the vol-

ume of bulk materials being transported

in his systems. Overlling can thereby be

reliably avoided.

The multi-echo technology of the

Bulkscan

®

LMS511 ensures reliable

sensor operation, even when dust,

steam or rain are present.

Bulkscan

®

g p. 103

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Focus 1: Slag preparation

SECONDARY ALUMINUM AND RECYCLING

3

Protection of slag preparation system

Moving machinery such as slag process-

ing plants always pose a risk to person-

nel. A combination of several safety sen-

sors and the MOC Motion Safety Drive

Monitor ensure a safe standstill of the

slag processing plant. The DFS60S Pro

safety encoder monitors the machine

speed. One or more TR110 Lock safety

locking devices ensure that no person-

nel can enter the hazardous areas while

the plant is in operation.

Flexi Soft g p. 78

TR110 Lock g p. 77

DFS60S Pro g p. 93

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Focus 2: Chip drying

SECONDARY ALUMINUM AND RECYCLING

3

1

Monitoring of fuel stores

Use of aluminum chips in a furnace

means they must rst be thermally pre-

treated. Rotary kilns heat up the chips

to remove not only moisture but also any

contaminants, such as lubricating oils,

grease, lacquer or paint residues. These

kilns are usually red by fossil fuels. Var-

ious sensors can be employed at their

supports to monitor ll levels, pressure

and, in particular, the protective gas

atmosphere. A variety of sensors, such

as TRANSIC100LP are available for use

in explosion-hazardous areas.

TRANSIC100LP g p. 79

3

Gas analysis for process control and optimization in drying ovens

Aluminum chips are a byproduct of the

procedure when further processing

semi-nished products. The chips can

contain signicant organic contaminants

in the form of paints, lacquers, grease

and other impurities. Therefore these

impurities must be thermally treated

and dried before being melted. This

heating of the chips creates poisonous

exhaust gases which are destroyed

during post-combustion.

The METPAX300 process gas analysis

system monitors the exhaust gas from

the drying kilns thereby ensuring an opti-

mal combustion of poisonous gases.

FLOWSIC500 g p. 86

FLOWSIC600-XT g p. 87

2

Flow measurement of fuel at

drying oven

Rotary kilns dry aluminum chips to

remove moisture and contaminants.

The kilns are generally red by natural

gas. To ensure optimal and efcient

operation of the kilns’ burners, it is

necessary to precisely measure the gas

ow per unit of time. The FLOWSIC500

and FLOWSIC600-XT ultrasonic gas

ow meters guarantee high precision

measurement.

METPAX300 g p. 79

This graphic is not presented in the overview.

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Focus 2: Chip drying

SECONDARY ALUMINUM AND RECYCLING

2

4

5

4

Exhaust gas monitoring downstream of drying oven

Aluminum chips are produced as a

byproduct of the process when further

handling semi-nished products. Chips

can contain signicant amounts of

organic contaminants. The chips

therefore must be thermally treated and

dried before being melted. This creates

exhaust gases that are subject to emis-

sion limits, which must be continuously

monitored.

This monitoring includes gas analyses,

dust concentration measurements, and

measurement of the exhaust gas volume

ow. The FLOWSIC100 gas ow meter is

ideally suited for these purposes.

FLOWSIC100 g p. 86 DUSTHUNTER SP100 g p. 82

5

Monitoring of dust emissions in

drying oven

Aluminum chips are produced when fur-

ther processing semi-nished products.

They can contain signicant amounts

of organic contaminants. The chips

therefore need to be thermally treated

and dried before being melted. This

creates exhaust gases that are subject

to emission limits and must continuous-

ly monitored. The DUSTHUNTER SP100

dust measuring device is particularly

suited for dust concentration measure-

ments.

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Focus 3: Furnaces

SECONDARY ALUMINUM AND RECYCLING

1

Speed measurement of rotary

drum furnace

The aluminum recovered from recycling

of aluminum waste is rst placed in a

furnace, usually a rotary drum furnace.

The rotation of the furnace chamber

ensures a perfect mixing of the input

materials and accelerates the smelting

process. For optimal process control,

the speed of rotation and rotational

position of the rotary drum furnace

needs to be monitored and measured.

The AFS/AFM60 Inox absolute encoder

performs this task even under harsh

conditions.

AFS/AFM60 Inox g p. 92

2

Position determination of

oven door

The aluminum recovered from recycling

of aluminum waste is rst placed in a

furnace - often a rotary drum furnace

with a hinged door is used. An IMB

inductive proximity sensor monitors

the position of this door. Ensuring that

the door is properly closed guarantees

that the burner built into the door is not

put into operation unless the door is

fully closed.

IMB g p. 74

3

Tilt measurement at rotary drum

furnace

Rotary drum furnaces are often used as

smelting units when recycling aluminum

waste. The furnace drum can rotate, the

door opens and closes, and the entire

unit tilts. The latter mentioned move-

ment is necessary in order to tilt the

furnace to the rcorrect angle and in the

correct direction for loading the waste

and tapping the molten aluminum. The

TMS/TMM88 inclination sensor precise-

ly measures this tilt in two axes.

TMS/TMM88 g p. 94

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SICK ALUMINUM - SENSOR SOLUTIONS FOR THE ALUMINUM INDUSTRY User guide

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