ABB Secures Order to Advance Sustainable Production at US Aluminum Alloys Facility

ABB, a Swedish-Swiss multinational corporation headquartered in Västerås, Sweden, and Zürich, Switzerland, has secured an order from GNA alutech, a member of the Ebner® Group and a prominent aluminium furnace builder. The order entails the supply of four electromagnetic stirrers (AL-EMS) to support a significant expansion project for a leading U.S. aluminium manufacturer. This manufacturer operates the sole aluminium mill in the nation dedicated exclusively to common alloys, crucial materials for industries such as aerospace, automotive, and electronics. Currently, the company is in the process of constructing a new melting and casting complex to bolster its operations.

With aspirations to elevate its capacity from the current 325,000 tons per year, the aluminium producer aims to supply high-quality common alloy aluminium coil manufactured in the U.S. across North America. This strategic initiative emphasizes reshoring, recycling, and sustainability at every phase of production. As part of GNA's development, ABB's water-cooled AL-EMS will enhance safety, consistency, and repeatability in aluminium furnace operations. These electromagnetic stirrers are slated for commissioning at the site by late 2024.

The adoption of this technology has demonstrated remarkable benefits, including up to a 25 percent increase in productivity, a 10 percent reduction in energy consumption, and a 15 percent decrease in dross generation across more than 400 aluminium furnace installations worldwide. The end-customer can anticipate enhanced aluminium yield, accelerated chemical and temperature homogenization, and a return on investment within six to twelve months. The water-cooling feature enables the stirrer coils to operate at lower temperatures, safeguarding the windings from wear and tear, thereby extending equipment lifespan and reducing maintenance needs. This approach constitutes a significant portion of ABB's extensive installed base of electromagnetic stirring and braking devices in steel and aluminium production processes, ensuring safe and reliable operation for over 80 years.

Aluminium alloys remain indispensable for a wide array of engineering and manufacturing applications, serving as crucial components in modern consumer products, transportation, and construction. Given the significance of these materials, customers place utmost importance on the design, construction, and operation of furnaces and equipment within the aluminium industry. Collaborating with ABB empowers these stakeholders, ensuring robust solutions tailored to their specific needs. This project in the U.S. underscores the commitment of the involved parties to sustainability objectives, aligning with global expectations.

ABB's electromagnetic stirrers will facilitate optimal levels of repeatability and efficiency in the aluminium furnace process, concurrently boosting yield. All stakeholders acknowledge the imperative of optimizing energy usage in aluminium melting, recognizing the potential of existing technologies to deliver tangible results.

Additionally, ABB offers an exclusive performance guarantee, supplemented by a team of in-house metallurgists. These experts utilize fluid flow calculations of electromagnetic stirring force for each furnace to forecast performance enhancements, commercially guaranteed for every installation.

GNA alutech stands as a renowned leader in the design and construction of furnaces and equipment for the aluminium industry, specializing in melting and holding furnaces, homogenizing, annealing, and heat treatment furnaces, as well as cathode sealing equipment and associated machinery. The company's focus on advanced design, control systems, and construction techniques ensures extended service life, unparalleled efficiency, and reliability, coupled with operator safety and user-friendly features.