Speira launches new melting furnace

Speira’s new “transparent” melting furnace offers higher capacity, more recycling, accurate knowledge and data collection at every step of the process, with energy savings of 15 %.

The aluminum manufacturer and recycler is investing around €6.4 million in this new furnace, thus preparing the Hamburg plant for the future. The unit, known internally as “Furnace 6”, replaces the plant’s older model, which dates back to the 1970s. This project was completed successfully and accident-free, despite being carried out during continuous smelter operations.

With a melting capacity of 60 tons per batch, the new furnace enables an increase in aluminum production of 7,500 tons per year. Thanks to the use of an electromagnetic stirrer and advanced burner technology, energy efficiency has been improved by 15 % and CO2 emissions have been significantly reduced.

This new furnace improves the performance and output of the Hamburg foundry and helps to optimize metal flows and recycling options at Speira. By introducing state-of-the-art process control and further improving energy efficiency.

A special feature is the integration of advanced Industry 4.0 technologies: the furnace is the company’s first completely “transparent” furnace. Innovative sensor and camera technologies provide real-time information on all furnace processes, and the data obtained allow continuous optimization of the operation and control of the burners, adapting to the mix of scrap and primary metal used.

Thanks to constant melt monitoring and artificial intelligence support, the operator is provided with the ideal times to perform tasks such as alloying or slag removal. The measured parameters also allow hydraulic components to be used with less wear, enable targeted predictive maintenance and thus reduce downtime and further improve plant efficiency.