Tenova, one of the leading suppliers for heat treatment systems as well as for recycling plants of contaminated aluminium scrap, has received a new order from the Belgian E-MAX group.

The contract includes engineering, supply, erection and commissioning of a twin-chamber melting furnace (TCF) and a melting and casting furnace (MCF) for the production upgrade and modernisation of the E-MAX Kerkrade plant. The existing plant equipment was supplied and installed by LOI Thermprocess in 1990 and it is still operating with reliable performances.

E-MAX Profiles delivers sustainable, high-quality aluminium profiles to various sectors of the aluminium market. The Dutch branch E-MAX Billets in Kerkrade was established in 1990 and is the central operation plant in the E-MAX group for the production of extrusion billets. One of the main targets of this project in addition to the increased production is the sustainability of the process, with a minimisation of environmental impact.

The new TCF will have an annual production capacity of 50,000 tons of liquid aluminium based on a scrap charge mix with organic contaminations. The furnace is equipped with LOI’s regenerative heat recovery system CCR, an electromagnetic stirrer for metal circulation and an automatic charging machine.

A fume treatment plant, transfer launders and other equipment are also included in the scope of supplies. In addition, the order comprises a tiltable MCF with an annual production capacity of 25,000 tons of liquid aluminium and related equipment.

As a new technology, this MCF can melt scraps with light contaminations of organics. Special processing ensures less metal loss and reduces overall emissions.

Compared with former installations, the efficiency of the modern TCF® technology allows for the treatment of higher contaminated scraps. At the same time, the consumption of natural gas and the metal loss are reduced by 50%. The plant commissioning is scheduled for beginning of 2022.

E-MAX Billets project manager Carlos Kampen said: “With the development of low carbon X-ECO alloys which are produced with up to 85% scrap charge in the new furnaces, we realise minimisation of environmental impact and sustainability of the process.

“We selected Tenova LOI Thermprocess thanks to their innovative technology and the reliability of the furnaces supplied in 1990. We look forward to starting the operation of the first new furnace in the beginning of 2022.”

Hartwig Thie, Tenova LOI Thermprocess sales manager light metals, said: “We are very pleased about this new order which confirms the trust in this leading Tenova technology and underlines our long term strategic partnership with E-MAX.

“The upgraded plant will ensure the highest quality and environmental standards that our customer is aiming for.”