Outokumpu Technology offers you tailored solutions to meet your

specific needs. Our aluminium expertise is a powerful combination of

innovative proven technologies. Co-operation and a team approach
enable us to provide you with the best possible service – and vast
expertise in alumina refining, paste plant and rodding shop as well as
casthouse machinery.

Alumina and aluminium

technologies

stainless | copper | technology

 Together we are stronger
The Outokumpu
factor
The Outokumpu factor is the
competitive advantage we give our
customers by helping them enhance
the performance of their processes,
products and services. It is a factor
our customers rely on to help them
overcome even the most demanding
challenges; a hidden asset that helps
them win.
2
Over the past few years, Outokumpu
Technology has successfully
implemented a strategy of growth
and transformation which has made
us stronger and more competitive,
helping us maximize value to our
customers. To this end, we have also
unified all our businesses under one
brand. Outokumpu Technology, with
the combination of Lurgi Metallurgie,
KHD and AISCO, is among the most
important technology providers for the
aluminium industry.
As one of the world’s leading
developers and suppliers of technology,
Outokumpu Technology designs and
delivers plants, processes and equipment
tailored to each customer’s specific
needs. We also provide engineering,
project and support services for the
minerals processing and metallurgical
industries globally. Environmental
awareness and protection are important
features of all our technologies.
Best technology from
a single partner
In the global aluminium industry,
Outokumpu Technology provides total
business solutions for the treatment of
alumina and aluminium. We offer you
proven expertise in alumina refining,
paste plant and rodshop, and casthouse
machinery. Today, our circulating
fluidized bed (CFB) technology for the
calcination of alumina is the industry
standard.
Early choice of a single technology
partner, who can manage production
processes and design through the entire
operation, saves time and money.
Without bottlenecks, plant operation is
smooth, and profits accrue quickly. We
continuously develop both processes
and equipment for our customers’
production plants.
Committed to your Alumina refinery
business Grinding As your partner, we offer:
Digesting
As your partner, Outokumpu Settling Close co-operation
Technology offers comprehensive Filtration Innovative technologies
engineering and project implementation Calcination Engineering and project
services as well as worldwide customer implementation
support. We have qualified and Aluminium smelter green Trouble-free commissioning
experienced field personnel to ensure anode plant
Worldwide service and
trouble-free commissioning. Every Paste plants
customer support
plant is unique and, therefore, processes Pitch handling facilities
always need to be modified to meet Preheaters
specific requirements. Anode formers
Our long-term commitment and Butt and carbon scrap recycling
extended customer service minimize
operating risks throughout the life of Aluminium smelter rodding shop
the plant. Co-operation can begin with Complete rod shops
a feasibility study leading to a lump- Bath removal
sum turn-key delivery and, ultimately, Thimble stripping & cleaning
to a long-term partnership. We help Butt stripping
you enhance your production processes Anode casting & mating
– and take care of the whole delivery. Rod reconditioning
Carbon block handling
Comprehensive Bath treatment plants
aluminium technologies
Casthouse
Our solutions for the aluminium
Sow casters
industry cover proven technologies.
Ingot casters
Furthermore, we offer professional
Automatic billet handling and
engineering and project management
saw lines
services based on extensive R&D
resources as well as comprehensive
Other services
technological and business knowledge
SPL treatment technology
of metals production. Our global sales
Capital investment and plant-
and service network is always close at
operation-related services
hand when an expert is needed.
R&D resources
 Alumina calcination with
the CFB technology
Outokumpu Technology developed
the circulating fluidized bed (CFB)
technology for the calcination of
alumina, the final step in the alumina
refining process. From the early 1960’s
onwards, CFB technologies have been
applied to the calcination of alumina.
Since then, this technology has gained
wide acceptance and become recognized
as the standard process for alumina
calcination.
Uniform product quality
Uniform product quality is the major
benefit of the CFB technology. The
operators can adjust the process
conditions, such as temperature and
retention time in the reaction system,
and keep them constant in all parts of
the reactor. If product requirements
change, the process conditions can easily
be adjusted to meet the new product
4
specification. The CFB offers you a
very compact design, which reduces
capital investment costs considerably
compared to classical process
alternatives, such as rotary kilns.
Advanced technology
The CFB system is especially suited
to all kinds of exothermic and
endothermic reactions of fine-grained
solids. We are one of the front-runners
in applying this technology to different
metallurgical processes and have put
considerable effort into the research for
this process.
Outokumpu Technology has
continuously improved the process
and added further developments to it
in order to increase energy efficiency
and optimize process control. This
has allowed us to maintain a leading
world-market position, with roughly
one third of the world’s production of
alumina being processed in CFB plants
built by us.
Key features of the CFB
With Outokumpu Technology as your
partner, you benefit from a variety of
outstanding features of our calcining
plant technology:
Very stable plant operation
Very uniform product quality with
low fines fraction
High availability and low maintenance
Less vulnerability to power failures;
quick re-start possible
Excellent overload performance
Favorable partial-load behavior
High flexibility of plant with respect
to product quality and plant capacity
Low emissions of NOx and CO
Low specific energy consumption
Long-term experience in
green anode plants

The production of carbon anodes and Our special equipment for green anode
electrodes requires special expertise and plants includes vibrocompactors for Heavy-duty custom-
tailoring in the primary aluminium and the forming of green anodes, cathode designed equipment
other metals industries. Outokumpu blocks and electrodes, with more than tailored to the rough
Technology has a tradition and 90 units in operation. service conditions in green
experience of more than 50 years in the anode plants, including:
design and supply of complete carbon Full project
plants.
Solid pitch storing and
responsibility
melting
We can provide you with the full span Liquid pitch unloading
Design and supply of
of project services. These include initial and storing
green anode plants
studies, basic and detailed engineering, Petroleum coke unloading
Outokumpu Technology’s aluminium project management as well as plant and storing
operations specialize in plant and and equipment supply. In addition, we
Screening and crushing
equipment for the production of offer installation and commissioning of
Grinding of petroleum coke
carbon anodes and electrodes required plant and equipment, training of your
in the primary aluminium and other personnel and customer service after Proportioning of dry-mix
metals industries. In this, we have taking over. Preheating and mixing
provided services and supplies to all By working in co-operation with Anode forming and cooling
the major aluminium producers our customer, we plan and propose Pitch fume dry scrubbing
throughout the world. We service the solutions to meet our customer’s HTM system
aluminium industry with: expectations. Our process engineers are Butts and reject anode
Specialist engineering staff responsible for defining the plant and crushing
Long-term worldwide activity and equipment design criteria, and they
experience work in close contact with our design
Proprietary process equipment department and suppliers. They also
Single-source responsibility train the customer’s personnel and are
Modernization, upgrade and available for temporary production
capacity enhancement projects assistance.
Ongoing customer service

Legend:
Raw Material and Product

Utilities and Off-Gas

Green anode plant flow diagram.

Major equipment for green
anode plants

Today, our vibrocompacting Anode vibrocompactors

technology is the market leader. As
Outokumpu Technology is a specialist
our customer, you can rely on our
in vibrocompactors for forming of green
proven technology. More than 90
anodes, cathode blocks and electrodes.
vibrocompactors have been supplied to
Based on your needs, we offer the design,
customers in 25 countries, and further
supply, installation and commissioning
units are currently being manufactured.
of new vibrocompactors as well as
The technology of vibrocompacting of
retrofit and modernization of existing
carbon blocks has found full acceptance
machines. Different machine types
in the industry and completely
can be offered to meet your individual
replaced hydraulic press molding.
requirements with regard to dimensions,
shape and weight of carbon blocks, as
well as output in blocks per hour.
In the vibrocompactor, a batch
Benefits of
of carbon paste composed of a pitch
vibrocompacting:
binder with an aggregate of particles
Homogeneous anodes and dust is contained in an anode
Consistent anode height mold. This mold is subjected to strong
Fewer rejects vertical vibrations. During the vibration
Prediction of green process, a weight load is put onto the
paste batch providing the compaction
apparent density
of the paste to a dense block. This
Production quality control
process is enhanced by the application
of vacuum to the mold.

Densitrol® - cycle chart.

6
Our aim is to continuously improve
the product quality (anode properties)
as well as the reliability and availability
of the equipment. Further, we work to
reduce the impact on the workspace
and plant environment, considering
factors such as fume collection, noise
level and vibration transmitted to the
foundations.
Outokumpu Technology is the
market leader in designing and
supplying vibrocompactors for the
production of carbon blocks.
More than 90 units supplied to the
aluminium and carbon products
industries
Sliding table type / turntable type
models available depending on
production requirements
Operation with vacuum system
VIBROPLUS® (“precompressed
cover weight”) for enhanced green
anode density
DENSITROL® on-line green anode
density monitoring system
Hydraulic anode crusher.
Preheating screws
Preheater screws are used for the
continuous thermal treatment of coarse
or fine-grained bulk materials, such as
anode dry aggregate. To this effect, the
product is steadily conveyed through
the preheater by means of counter-
rotating hollow screws, through which
the heat-transfer agent flows.
Intensive heat exchange
Gentle product conveyance;
no product breakdown
Very high availability
Compact design, low space requirement
Well proven
Hydraulic anode
crushers
The hydraulic anode crusher was
designed to suit the requirements of
the aluminium industry for a primary
reject anode and butt crusher.
Product 85 % less than 150 mm
Minimal fines generation
No dynamic forces transmitted to
foundations
Low headroom
Simple mechanical construction
7
Advanced rodding shops

Outokumpu Technology’s rodshops contracts to support your internal

combine the expertise gained from resources. A project team is assigned to
more than 25 years of servicing the supervise your project through design,
aluminium industry. Our cost-effective manufacturing, commissioning, training
solutions bring improved productivity, and ongoing service support.
and our leading-edge technology
results in reduced maintenance and Fast track project
contributes to a safer workplace. execution
In addition to vast experience in process
Engineered solutions
and plant design, we offer modern tools
Outokumpu Technology’s engineered and concepts for project execution.
solutions are designed to suit We ensure smooth integration of new
your plant layout and operational processes into existing facilities by
requirements. We design the system 3-dimensional software tools, early Worldwide experience
to incorporate the components best involvement of local suppliers and including:
suited to your operation, including partners at the project development 2 pin – Century Aluminum,
preferred brand-name components for phase, and worldwide sourcing. USA
increased compatibility and simplified
maintenance, spares, inventory and
3 pin – Comalco Boyne
training. Island, Australia
All our systems are shop-tested 4 pin – Noranda Aluminum,
prior to delivery to ensure trouble-free USA
commissioning. After start-up, our 6 pin – Alcan Alma, Canada
service is available for maintenance

Typical rodding shop layout.

MCC &
CAST IRON CLEANING SYSTEM ELECTRICAL
CONTROL
ROOM

STUB STRAIGHTENING STUB CUTOFF SAW

MACHINE BUTTS / RODDED ANODE
ROBOTIC PALLET STORAGE
THIMBLE STUB WELDER
STUB SHOTBLAST STUB COATING
STRIPPING MACHINE
PRESS MACHINE ANODE MATING
STATION

BAKED
ANODES
FROM
NEW RODDED
STORAGE
ANODES OUT
STEM BRUSH
MACHINE
ANODE CLEANING UNHOOKING STATION
SYSTEM

CARBON BUTTS IN
RECYCLING

TO BATH
PLANT

BUTT STRIPPING BUTT SHOTBLAST

PRESS MACHINE PALLET DUMP HOOKING STATION
BATH REMOVAL
SYSTEM
Complete range of
equipment
Our aluminium smelter rodshop
machinery covers:
Automatic load / unload systems
Butt bath cleaning systems
Butt shotblast machines
Butt stripping presses
Thimble stripping presses
Combination butt & thimble
stripping presses
Stub shotblast machines
Anode rod assembly & casting systems
Semi-automatic iron pouring systems
Anode rod brushing systems
Cast-iron thimble cleaning systems
Automatic stub cut & weld systems
Complete rodshops

Combination butt and thimble stripping press.

A full line of casthouse machinery

Outokumpu Tehcnology sets new new or upgraded casting systems.

In 2000, we supplied the standards for superior casthouse The equipment is custom-designed
single largest automated performance with proven, automated to suit the required ingot shape and
sow casting system in the casting, stacking and handling systems. bundle configuration. Ingot handling
world, comprising: Our machines are built to last; high equipment can be integrated into
machinery reliability together with existing machinery, or the bundle of
Fully automatic pouring
low operating and maintenance ingots can be removed off line from
Natural convection cooling
costs contribute to rapid return on the existing equipment for strapping
of sows investment. and weighing. The bundle would
Automatic demolding, then be returned to the accumulation
tracking, marking & Leader in aluminium conveyor.
stacking casthouse Our billet saw lines combine
high production rates, low labour
Outokumpu Technology is a leading
requirements and reliable operation to
company in the design, fabrication
provide the highest billet processing
and supply of casthouse machinery
efficiency available. The rolling slab
appropriate to today’s competitive and
and T-bar saw lines that we offer are
quality-driven aluminium industry.
designed to meet your specific needs.
Our experience in the research, testing,
Our easily integrated systems provide
design, operation, installation and
maximum productivity and safety.
service of ingot and sow casters is your
guarantee of quality.
We provide ingot stacking,
strapping and weighing equipment for

T-bar saw-handling system.

 Our extensive line
also covers:
Foundry ingot casting
Jumbo sow-casting
water-cooled
air-cooled
Saw lines
billet
rolling slab
T-bar
Billet homogenizing

Outokumpu Technology possesses an

unparalleled wealth of alumina and
aluminium production and processing
knowledge. With our powerful
combination of proven technologies, we
help you enhance the performance of
your processes. We relish a challenge
and can apply our know-how, together
with the determination we are renowned
for, to meet your requirements
reliably and cost-effectively.

Billet saw line.

 3004EN. Libris, Helsinki, Finland. February 2004.

Outokumpu is a dynamic metals and

technology group. Focusing on our core
competences, that is, extensive knowledge of
metals and metals processing, we aim to be
leaders in all of our key businesses: stainless
steel, copper and technology. Customers in a
wide range of industries use our metals, metal
products, technology and services worldwide. E-mail: info.technology@outokumpu.com

www.outokumpu.com