STEEL BELT CONVEYORS FOR SEVERE CONDITIONS since 1929

NOVELIS SHEET INGOT GmbH

THE CHALLENGE

In June 2015, Novelis Sheet Ingot GmbH awarded Magaldi a contract for a turnkey installation of a complete Hot Shred Conveying System able to handle the hot shredded recycled aluminum from the rotary de-coaters to the melting furnaces in the most reliable and simplest way, while ensuring the lowest temperature drop.
Since December 2015, two complete lines equipped with the Magaldi Ecobelt® technology have been handling hot shred aluminium in the world’s largest aluminum recycling plant, with a continuous total production of 75 t/h for the can & flex lines.

 

THE CUSTOMER

Part of the Indian multinational Aditya Birla Group, Novelis Inc. is the global leader in aluminum rolled products and the world’s largest recycler of aluminum. It supplies premium aluminum sheet and foil products to the transportation, packaging, construction and electronics markets throughout North America, South America, Europe and Asia.
The Nachterstedt Recycling Center in Germany is the world’s largest and most technologically advanced aluminum recycling center, processing up to 400,000 metric tons of aluminum scrap annually.  The facility features innovative technology for aluminum scrap sorting, de-coating, melting and casting while limiting the environmental impacts of its operations.

 

THE SOLUTION

For its Nachterstedt Recycling Center, Novelis was looking for a different technology able to improve all aspects related to safety, reliability, process capability and spare parts demand, in order to replace the original conveyors not performing well.
Magaldi agreed to simulate the operational conditions of the aluminum recycling plant so to better customize its well-proven capabilities in bulk material handling. 
After receiving aluminium samples, the Magaldi R&D dept. started the test protocols to define the Ecobelt® features based on the material behaviour.

Once successfully completed the erection of the first Ecobelt® conveyor (out of total 8 Magaldi conveyors), Novelis realized that it was the right choice and awarded Magaldi an additional contract for replacing the other Apron-based conveyors and providing a tailored diverter valve for a correct aluminum distribution in the different furnaces.
The Magaldi Ecobelt® system entered in full operation in November 2015 (for the Flex Line) and December 2015 (for the Can Line).
Currently 2 separate conveying systems are installed:

The conveyed material is post and pre-consumer scraps as used beverage containers (UBC), automobile radiators, taint/tabor, painted sheet and other type of aluminum scraps.
The bulk density varies from 120 kg/m3 (as minimum) up to 1.200 kg/m3 and the temperature is above 500 °C.
The great synergic efforts between Novelis and Magaldi has contributed to increase the plant throughput up to the design capacity in less than 6 months. In fact, Magaldi was able to design, manufacture, delivery and install the first Ecobelt® conveyor in less than 2 months from the purchase order.
Working on three shifts, under severe conditions and high temperatures, the Ecobelt® technology has proven to be the best available solution also for aluminum recycling plants.

 

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