Multi-million furnace makes all the difference for Speira

Aluminium producer Speira says its new ‘transparent’ melting furnace is boosting capacity while improving its recycling performance.

The aluminium player has invested EUR 6.5 million in the furnace at its plant in Hamburg, Germany. The new furnace replaces the oldest model in the plant which dates back to the 1970s. This will help to ‘future-proof’ the facility, Speira says.

More capacity, more efficiency

Speira currently recycles up to 650 000 tonnes of aluminium per year. With a melting capacity of 60 tonnes per batch, the new furnace increases annual aluminium production by 7 500 tonnes.

Introducing an electromagnetic stirrer and state-of-the-art burner technology has improved energy efficiency by 15% and significantly reduced CO₂ emissions.

‘This new furnace is of great importance to us,’ says Alexander Dörsel, head of the specialties business unit at Speira. ‘It increases the performance and output of the foundry in Hamburg and helps us to optimise the metal flows and recycling options.’

Cutting-edge tech

One special feature is the integration of Industry 4.0 technologies with oven being the company’s first fully ‘transparent’ oven. Innovative sensor and camera technology provides real-time insights into all furnace processes. The data obtained ensures continuous optimisation of the operation and burner control, adapted to the mix of scrap and primary metal used.

For example, based on the constant monitoring of the melt and supported by artificial intelligence, the operator is given the ideal times for alloying or dross removal. The parameters also allow the hydraulic components to be used with less wear and tear. This enables targeted predictive maintenance, reduces downtime and improves plant efficiency.

‘Great signal’

The new furnace in Hamburg follows two other plant upgrades Speira completed in Germany this summer. It installed new furnaces at its plants in Grevenbroich and Töging to boost recycling of ‘low-grade’ highly contaminated fractions.

‘By introducing state-of-the-art process control and further improving energy efficiency, we are setting new standards for our customers,’ adds Hamburg plant manager Danny Kelm. ‘This is also a great signal for our colleagues.’