ABP combines innovation and experience in aluminum processing

In this interview, Alexander Keller, Head of System Sales, explains ABP‘s ideas for the industry of the future

The current megatrends, in particular decarbonization and digitalization, mean that fundamental processes in the metalworking industry need to be considered and changed. The melting process of die casting, semi-finished product production and recycling in the aluminum sector has also come into focus, as high CO2 emissions are generated here, considerable energy consumption is required and there is a considerable loss of material. This calls for innovative solutions – which Alexander Keller, Head of System Sales at ABP Induction, sees in particular in the conversion from traditional natural gas furnaces to induction melting furnaces, as he explains in an interview.

Induction furnace technology in the aluminum environment – where do you see the advantages?

Alexander Keller: The use of induction technology in conjunction with renewable energy sources enables virtually emission-free production. Compared to gas furnaces, our induction technology offers numerous advantages: a considerable reduction in CO2 emissions of up to 94%, significantly higher energy efficiency and much lower material losses. At 440 kWh/t, the energy balance of induction melting furnaces, for example, is significantly more favorable compared to gas furnaces. Heat recovery can further increase the savings effect by up to 20 percent. In addition, the operating costs of using induction technology are already lower in the short to medium term, especially when taking into account the prices for CO2 certificates and energy.

Aluminum processing is still an energy-intensive industry – how do you deal with energy costs and availability?

Alexander Keller:  Induction furnaces from ABP not only boast low energy consumption, but can also be used as energy storage units – meaning that furnace operation can be adjusted to the prevailing electricity price. This means that when electricity is cheap, you use the large buffer in the furnace, which can cover up to four hours of production. This production method can be advantageous not only from an economic point of view, but also with regard to the “global footprint of product”.

So it‘s about the carbon footprint of the product in question?

Alexander Keller:  Exactly, if you melt down aluminum as scrap, the global carbon footprint of the product improves. A great deal of energy is required in the production of primary aluminum. But if scrap is melted down in an induction plant, the carbon footprint is reduced considerably. A significant example comes from the automotive industry, where parts made from recycled aluminum are processed using an induction furnace as a melting unit. The direction is right if the carbon footprint is close to zero.

How much restructuring is required in foundries, especially when switching from a gas furnace to an induction furnace?

Alexander Keller: We are in direct dialog with our customers: The operation of ABP induction channel furnaces in aluminium foundries is logistically optimized together with the customer and adapted to existing processes. In practice, you can imagine it like this: containers with the metal to be processed are simply brought to the furnace by forklift and the furnace is loaded directly. This means that no major changes to the material flow, system operation or maintenance are required, which is an important advantage for ABP customers. We provide customers with intensive support throughout the entire journey of switching from one technology to another – be it through process consulting, training or technical support.

How are the processes changing? The technology has proven itself…

Alexander Keller: That‘s right, we refer to our induction channel furnaces as „proven technology“. Our experience with this technology goes back to 1903, to our predecessor companies such as ASEA. And although hardly any new induction furnaces for aluminum have been installed in the last 30 years, the existing systems are still in operation. During this time, many optimizations were carried out together with the customers and development continued. Close cooperation with other industry players such as die casting machine manufacturers and suppliers is important to us, especially with large customers who operate many aluminum foundries, in order to understand their requirements and processes. The result is a combination of decades of experience, proven technology and new innovations. 

Can you provide any real-life examples?

Alexander Keller: Of course, this can be seen in the daily production process, for example: normally, aluminum has a melting loss of over 2%, which limits the recycling cycles to around 50. However, the melting loss in efficient ABP systems is well below 1%, which at least doubles the number of recycling cycles. This underlines the fact that ABP is also extremely familiar with induction furnace technology in the aluminum sector – with advantages for users in particular.

But induction furnace systems are more expensive to buy than gas-powered systems, for example…

Alexander Keller: At first glance – yes. But it turns out that induction melting technology is not only more environmentally friendly, but also more cost-efficient. Savings through lower operating costs and an independent energy supply secured by renewable energy sources position induction technology, which has been continuously developed and perfected by our engineers, as a superior alternative in modern die casting and other aluminum foundries. Thanks to the efficiency properties described above, the additional costs of purchasing an induction furnace system pay for themselves within around two years thanks to the lower energy consumption, heat recovery, lower melting loss and the fact that no CO2 certificates are required. As already mentioned, induction furnaces can also be used to store energy – a valuable feature, especially with a view to the future of energy-intensive industry. This highlights how switching to innovative technologies can offer both environmental and economic benefits, making it an important consideration for the future of the manufacturing industry.

Do you also want to start installing new furnaces again?

Alexander Keller: Definitely! Induction furnace technology is perfect for aluminum processing under today‘s conditions. And our engineers and designers are currently developing a new furnace for large machines, known as GiGA Casting, which can produce half a car with a single press. This development project is well advanced and the furnace is expected to be available in summer 2025. This also shows that ABP can consistently adapt its own systems to new trends and industry requirements.