Of key strategic importance to Constellium will be a fully integrated DC casting
and extrusion laboratory, which is planned to include a full-size 1600ton extrusion press complete with support facilities and full automation.
By introducing a semi-automated and semi-manual dam-lifting system, mould-filling in the DC casting
area can be managed by a single operator instead of two, as was previously the case.
However, the new EMAL Aluminium Smelter project currently under construction in Al Taweelah, Abu Dhabi, will feature - among other state-of-the-art equipment - two new vertical DC casting
machines, which will increase our capacity by 50% once the plant is commissioned in 2010.
These proceedings from the conference in September 2005 include industry trends and profiles in Russia and the Middle East as well as such topics as safety and the environment (including molten metal splash testing of protective clothing and new ways with rotary furnaces), reduction/cast house interface (the potroom/casthouse interface and integrating planning and scheduling), DC casting
(structure features related to hot tears during direct chill casting and slab casting improvements), ingot casting and foundry alloys (development of an ingot caster filling system and using alloys), furnace technology including several new designs, degassing, and filtrations and inclusions including a new filter technology.
In a mix of practice-oriented and technical/scientific papers focusing on operations worldwide, coverage includes topics such as environmental regulations and performance, PFC emissions, fugitive fluoride emissions, cell development and operations, pot control, emerging technologies, aluminum melting (strategies, sourcing, furnace design, and refractories), DC casting
(melt flow and cooling, microstructure and hot tearing), and extraction of value added products from aluminum dross material to achieve zero waste, among other topics.