Computer integrated manufacturing technology for optimisation of aluminium recycling

Akan Rolled Products UK, Rogerstone Works Remelt Plant produces approximately 90 000 tonne/annum of aluminium sheet ingot in a wide variety of alloy types. This paper describes the implementation and experience of computer integrated manufacturing in that plant which has resulted in major direct and indirect benefits. The system is based around on-line reel-rime control of raw materials inventory and the use of advanced furnace charge optimisation technology The relative proportion of recycled strap consumption has been increased with a corresponding reduction in the consumption of virgin materials from about 15% down to about 4% which has resulted in a major reduction in costs. Control of raw materials stocks and movements has been dramatically improved. In addition to the significant effects on product qualify arising from the improvement of composition control throughout the process, there have also been consequential gains in productivity and energy efficiency. The paper considers some of the factors which have contributed to the success of this highly successful project since ifs inception.