SICK ALUMINUM - SENSOR SOLUTIONS FOR THE ALUMINUM INDUSTRY User guide

Category
Measuring, testing & control
Type
User guide
INDUSTRY GUIDE
ALUMINUM
SENSOR SOLUTIONS FOR THE ALUMINUM INDUSTRY
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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
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
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 sufcient 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
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

Category
Measuring, testing & control
Type
User guide

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