“Transparent” melting furnace increases production output and energy efficiency

• Speira invests 6.4 million euros in Hamburg plant
• New furnace with 7,500 tons more production capacity
• Cutting-edge technology saves 15 percent energy and improves process control

Speira’s new “transparent” melting furnace delivers more capacity, more recycling, precise insights and data collection in all process steps with 15 percent less energy. The aluminum roller and recycler is investing around 6.4 million euros in the new furnace, thus preparing the Hamburg plant for the future. The unit, known internally as “Furnace 6”, replaces the oldest model in the plant, which dates back to the 1970s – a project that was successfully handled without any accidents during ongoing foundry operations.

Increase in production capacity and energy efficiency

With a melting capacity of 60 tons per batch, the new furnace enables an increase in aluminium production of 7,500 tons per year. The use of an electromagnetic stirrer and state-of-the-art burner technology has improved energy efficiency by 15 percent and significantly reduced CO2 emissions.

“This new furnace is of great importance to us. It increases the performance and output of the foundry in Hamburg and helps us to optimize the metal flows and recycling options at Speira,” explains Alexander Dörsel, Head of the Specialties business unit at Speira. “By introducing state-of-the-art process control and further improving energy efficiency, we are setting new standards for our customers. This is also a great signal for our colleagues and therefore for Speira’s future in Hamburg,” adds Danny Kelm, the new plant manager in Hamburg since October.

With sensor and camera technology and AI to the “transparent” oven

One special feature is the integration of state-of-the-art Industry 4.0 technologies: The oven is the company's first fully “transparent” oven. Innovative sensor and camera technology provide real-time insights into all furnace processes, and the data obtained in this way enables continuous optimization of the operation and burner control, adapted to the mix of scrap and primary metal used. 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, for example. The measured parameters also allow the hydraulic components to be used with less wear and tear, enable targeted predictive maintenance and thus reduce downtimes and further improve plant efficiency.