Exlabesa, a prominent player in the aluminum extrusion industry, is set to enhance its recycling operations at its facility in A Coruña, Spain. The company is collaborating with Hertwich Engineering, a subsidiary of SMS group, to install a state-of-the-art continuous homogenizing furnace. This new addition includes an air cooling station, a long-billet stacker, and a semi-automatic PET strapping system, all aimed at improving the production of recycled aluminum sourced from post-consumer scrap. This expansion reflects Exlabesa's commitment to sustainability and its goal to meet the rising demand for high-quality recycled aluminum products.
The new continuous homogenizing plant will increase Exlabesa's recycling capacity by an additional 30,000 metric tons annually, bringing the total capacity to approximately 80,000 metric tons per year. This facility is designed to work alongside the second melting furnace that was previously installed, which focuses on producing high-quality recycled billets from aluminum scrap that has reached the end of its lifecycle. By enhancing its recycling capabilities, Exlabesa aims to reduce its dependence on primary aluminum sources, thereby conserving valuable resources and minimizing environmental impact.
The continuous homogenizing furnace from Hertwich Engineering represents a significant advancement in aluminum processing technology. It is specifically designed for aluminum billets with diameters ranging from 178 to 406 millimeters and lengths of up to 7.0 meters. The furnace allows for uniform heat treatment of the billets at temperatures reaching up to 590 degrees Celsius. This precise temperature control ensures that the billets achieve a consistent microstructure, which is essential for maintaining high metallurgical quality. The efficient heating process also contributes to energy savings, making the operation more sustainable.
Hertwich Engineering has a history of successful collaboration with Exlabesa, having previously supplied a second continuous homogenizing plant and a multi-chamber melting furnace in 2018. The ongoing partnership is built on a shared commitment to sustainability and innovation in aluminum production. Gerold Keune, CEO of Hertwich Engineering, emphasized the importance of tailored solutions for their clients, stating, “Our expansion of continuous homogenization operations at the Exlabesa plant fits perfectly into the existing production environment. This endeavor underscores our commitment to long-term cooperation and partnership.”
The expansion of the casthouse with the new continuous homogenizing facility will significantly enhance Exlabesa's ability to process production scrap. This capability aligns with the principles of the circular economy, promoting a cleaner and more efficient industry. By utilizing recycled aluminum, Exlabesa not only reduces CO2 emissions associated with primary aluminum production but also meets the growing market demand for sustainable materials. The investment in this technology positions Exlabesa as one of the most advanced foundries in the world, reinforcing its leadership in the aluminum sector.
At the end of the production line, the newly homogenized billets will be stacked and strapped with plastic straps, ready for further processing or delivery. The innovative design of the continuous homogenizing system ensures that the billets maintain high quality throughout the production process, which is crucial for meeting the stringent requirements of various industries that rely on aluminum components.
Hertwich Engineering, based in Braunau am Inn, is recognized as a global leader in the aluminum industry, specializing in the engineering, design, and manufacture of machinery and equipment for aluminum processing. With a market share of around 90% in the continuous homogenization of aluminum extrusion billets, Hertwich is well-positioned to support Exlabesa's ambitious expansion plans. The collaboration between Exlabesa and Hertwich Engineering exemplifies the potential for innovation and sustainability in the aluminum recycling sector, paving the way for a more sustainable future.
