Highlights of Aluminum Scrap Forum at AICE 2025

On April 18, the AICE 2025 SMM (20th) Aluminum Industry Conference & Expo, hosted by SMM Information & Technology Co., Ltd. (SMM), co-organized by Zhongyifeng Jinyi Technology (Suzhou) Co., Ltd. and Lezhi County Qianrun Investment Promotion Service Co., Ltd., and sponsored by Shangli County Keyuan Metallurgical Materials Co., Ltd., Press Metal International Ltd., Delta Metal (Holdings) Limited, Jinqiao Light Alloy Technology (Jiangmen) Co., Ltd., and other entities as forum title sponsors, Sunstone Development Co., Ltd. and Shanghai Jialang Industrial Co., Ltd. as forum co-organizers, and supported by various specially invited supporters, conference supporters, conference acknowledgment units, and media partners, successfully concluded at the Suzhou International Expo Center in Jiangsu!

The summit featured multiple sessions, including the Alumina and Aluminum Raw Materials Forum, Aluminum Melting and Casting Technology Forum, Aluminum Die Casting Industry Development Forum, Supply and Demand Exchange - Domestic and International Aluminum Scrap Supply and Demand Forum, Aluminum Plate/Sheet, Strip and Foil Industry Development Forum, Main Forum, Aluminum Industry Chain Sustainable Development Forum, Global Secondary Aluminum Industry Development Forum, and Industrial Aluminum Extrusion Forum. As the annual pinnacle event for the global aluminum industry, this conference, with the strategic pillars of "Global Vision, Industry Insights, Green Future," brought together over a hundred international authoritative experts, academic giants, leading entrepreneurs, and government representatives to build a platform for intellectual exchange. The conference focused on core topics such as aluminum market trend analysis, price trend forecasting, supply-demand pattern dissection, business opportunity matching, and cutting-edge technology exchanges, conducting in-depth discussions from multiple dimensions to set the direction for industry development. Attendees directly addressed industry pain points, explored paths for industrial innovation, and unlocked new paradigms for clean and sustainable development around key themes such as green and low-carbon transformation and intelligent upgrading. Through innovative drive and cross-industry thinking collisions, the conference fostered consensus, integrated resources, and actively responded to global climate change and environmental governance challenges. This event established a high-end dialogue and resource integration platform, empowering industrial upgrading with wisdom and injecting strong momentum into the high-quality development of the global aluminum industry, jointly drawing a new blueprint for the industry's future.

In addition, SMM meticulously prepared roundtable interview sessions across multiple forums, inviting many renowned industry experts and corporate executives to engage in intense intellectual collisions on various hot topics, including the green transformation of the aluminum industry - the development and outlook of the low-carbon aluminum market, internal and external challenges - exploring new paths for aluminum plate/sheet, strip and foil enterprises in the fog, roundtable interview: discussing new models for integrated die-casting cooperation from a supply chain perspective, China's aluminum industry from a global perspective, analysis of factors influencing aluminum prices in 2025 and market forecasts for the second half of the year, building a global green aluminum ecosystem (ESG aluminum prices, CBAM), and the market business models and overseas investment opportunities of global secondary aluminum.

Forum on Supply and Demand of Aluminum Scrap at Home and Abroad

Aluminum Melting and Casting Technology Forum

Speech Topic: Research on Cracking Behavior of Extra-Large 2024 Aluminum Alloy Flat Ingots

Guest Speaker: Wang Guojun, Chief Expert and Secretary General of Chalco Group and Advanced Aluminum Alloy Collaborative Innovation Alliance

Process Optimization of Large 2024 Flat Ingots Based on Numerical Simulation

(I) Background ► Application of 2024 Alloy in Aerospace: High-strength and tough 2xxx aluminum alloys, with advantages such as low specific gravity, high strength, good fracture toughness, and corrosion resistance, are widely used in the aerospace field. Among them, the first-generation AA2024 aluminum alloy remains an important material for commercial aircraft transports due to its excellent damage tolerance and high resistance to fatigue crack propagation under aging conditions, primarily used for lightweight components in fuselages and wings.

► The first process for wrought aluminum alloy is Direct-Chilling casting.

► With the increasing size of large structural components in China's aerospace industry, aluminum alloy ingots are also developing towards ultra-thick and ultra-wide dimensions.

► Due to the large solidification range and high cracking tendency of 2024 aluminum alloy, an increase in ingot size leads to more severe cracking phenomena.

(II) Model Establishment

► (1) Basic Assumptions: Under the premise of ensuring the computational accuracy of the model and considering computational efficiency, the main assumptions of this model are as follows:

► This model ignores the influence of minor fluctuations in the liquid surface during the casting process on the solidification process of DC casting, simplifying the crystalliser liquid surface to a wall.

► Radiation heat transfer from the crystalliser liquid surface is ignored.

► The influence of solute segregation on the solidus and liquidus of the aluminum alloy melt is ignored, with the solidus and liquidus taken as fixed values.

► The heat transfer processes in the primary and secondary cooling zones are simplified, and the heat transfer on the surface of the cast slab is described using a comprehensive heat transfer coefficient.

► The direct influence of ingot deformation on melt flow is not considered.

(2) Model Establishment: Through the parametric modeling of Chalco's digital model, one-click numerical simulation calculation was achieved, significantly reducing modeling time and improving work efficiency.

(3) Analysis of Cracking Causes

Relationship between Stress Direction and Crack Direction: Cracking occurs along the direction of maximum principal stress. The primary cause of cracking: excessive thermal stress during the casting process. Optimization direction: reduce thermal stress.

Influence of Casting Speed

From the temperature field distribution at different casting speeds, it can be observed that due to the application of a scraper at the lower edge of the crystalliser, the temperature of the casting ingot surface rebounds. As the casting speed increases, the temperature rebound on the casting ingot surface becomes higher, and the increase in casting speed shows a linear trend.

From the stress field distribution at different casting speeds, it can be seen that as the casting speed increases, the stress in the casting ingot tends to decrease. Increasing the casting speed can reduce the tendency of internal cracking in the casting ingot. The larger the casting ingot specification, the slower the change in casting ingot stress with casting speed.

Speech Topic: Common Knowledge in Melting and Casting

Guest Speaker: Lei Li, General Manager of Shangli County Keyuan Metallurgical Materials Co., Ltd.

Speech Topic: Thoughts on the Development of Melting and Casting Technology in the Secondary Aluminum Industry

Guest Speaker: Bolin Zhang, Professor at Nanchang University

Speech Topic: Causes and Prevention of Molten Aluminum Explosions in Semi-Continuous (Deep Well) Casting of Aluminum and Aluminum Alloys

Guest Speaker: Yingquan Zhou, Senior Engineer and Resident Expert at Suzhou Emergency Management Bureau

Speech Topic: Research and Application of High-Efficiency Dust Removal and Energy-Saving Systems in the Aluminum Industry

Guest Speaker: Zhejiang Lanwei Environmental Protection Technology Equipment Co., Ltd.

1. Industry Background

With the tightening of global environmental regulations and the rise of environmental awareness, traditional dust removal and environmental protection equipment for aluminum melting furnaces still face problems and challenges.

Existing Problems: High energy consumption and inefficient operation, inflexible equipment adjustment, untimely status monitoring, and high equipment maintenance costs.

2. R&D Team

Zhejiang Lanwei Environmental Protection Technology Equipment Co., Ltd., in collaboration with innovation teams from renowned universities such as Zhejiang University City College and Hangzhou Dianzi University, has conducted research and application breakthroughs on high-efficiency energy-saving dust removal systems for aluminum melting furnaces, achieving notable application results.

Speech Topic: Common Problems and Solutions in Metal Liquid Refining Treatment in Aluminum Melting and Casting

Guest Speaker: Yueteng Xue, China Product Line Manager - Non-Ferrous Metal Liquid Treatment, Vesuvius Foundry Technology (Jiangsu) Co., Ltd.

Speech Topic: Safety Hazards and Dual Prevention Mechanisms in Aluminum Processing

Guest Speaker: Zhiqiang Ying, Certified Expert of China Nonferrous Metals Think Tank, Chief Engineer and Senior Engineer of Anhui Guangsheng Meichen New Materials Technology Co., Ltd.

3. Detailed Explanation of Dual Prevention

Dual prevention refers to the dual prevention mechanism of safety risk classification control and hidden danger investigation and management.

This mechanism is the foundation and important guarantee of enterprise safety management. The following is a detailed explanation of dual prevention:

1. Safety Risk Classification Control

Safety risk classification control is the first line of defense in the dual prevention mechanism. Its main contents include:

a. Risk Identification: Identify the hazardous substances and energy present at risk points, and the circumstances under which these hazardous substances and energy may cause accidents.

b. Risk Assessment and Classification: Use risk assessment criteria to evaluate the identified risks, and classify the risks into different levels based on the evaluation results, such as extremely high safety risk, high safety risk, relatively high safety risk, and general safety risk (usually corresponding to red, orange, yellow, and blue color codes).

C. Risk Control: Personnel at different levels control the classified risks to ensure that the safety control measures at risk points are intact and effective.

2. Hidden Danger Investigation and Management

Hidden danger investigation and management is the second line of defense in the dual prevention mechanism. Its main contents include:

a. Hidden Danger Investigation: Conduct a comprehensive investigation of the control measures at risk points to promptly identify potential hidden dangers.

b. Hidden Danger Management: Timely manage the identified hidden dangers to ensure they do not evolve into accidents. Hidden danger management requires the implementation of "five implementations," namely responsibility, measures, funds, time limits, and contingency plans.

3. Purpose and Significance of the Dual Prevention Mechanism

The purpose of building a dual prevention mechanism is to address prominent issues in the field of safety production, emphasizing the forward shift of safety production from hidden danger investigation and management to safety risk control. This mechanism helps enterprises fully implement their main responsibility for safety production, improve the effectiveness of accident and disaster prevention, reduce the losses caused by accidents and disasters, and thereby promote social stability and economic development. In addition, the dual prevention mechanism emphasizes the strict control of two key points: first, the risk control point, insisting on the key control of major risks; second, the hidden danger management point, insisting on the time-limited management of major hidden dangers. Through the working mechanism of dual prevention, every type of risk is effectively controlled within an acceptable range, every hidden danger is managed at its formation stage, and every accident is eliminated in its embryonic state.

In summary, the dual prevention mechanism is an important part of enterprise safety management. It emphasizes starting with risk identification, using risk control as a means to control risks before they form hidden dangers, and ensuring enterprise safety production through hidden danger investigation and management.

4. Main Examples of Aluminum Processing Hazards

1. Focus on Key Areas of Safety Prevention. Highlight safety supervision of high-risk operations such as melting furnaces, deep well casting, dust explosion, and confined space operations. Deeply analyze the jurisdiction, target efforts, overcome difficulties, and resolutely prevent and curb major and above accidents. Urge enterprises to study and formulate practical hard measures for safety basic management based on their own characteristics, and strictly implement them to reduce sporadic accidents.

Speech Topic: Technical Challenges and Solutions for Lining Technology of Different Types of Secondary Aluminum Dual-Chamber Furnaces - Promoting Green and Efficient Development of the Industry

Guest Speaker: Xuebin Song, Chairman and President of the Enterprise Research Institute, Jiangsu Ruifuda High-Temperature New Materials Co., Ltd.

Speech Topic: Innovation and Application of Short-Process Technology in Aluminum Processing

Guest Speaker: Xiangwen He, Chief Engineer of the Process Department, China Nonferrous Metals Processing Technology Co., Ltd.

01 Overview of Short-Process Technology in Aluminum Processing

1.1 Overview of Short-Process Technology in Aluminum Processing

Definition of Short-Process Technology: Short-process technology refers to the process of directly producing the required products from molten aluminum, omitting some intermediate steps in traditional processes, such as directly casting and rolling molten aluminum into thin plates, reducing energy consumption and production time. The process is characterized by short flow, low energy consumption, and high production efficiency, meeting the requirements of modern aluminum processing industry for high efficiency, energy saving, and environmental protection.

Advantages of Short-Process Technology: Reduced Energy Consumption: In traditional aluminum processing, molten aluminum needs to be cooled and reheated multiple times, resulting in high energy consumption. Short-process technology reduces these steps, directly producing products from molten aluminum, significantly reducing energy consumption.Improved Production Efficiency: By omitting intermediate steps, the production cycle is shortened, and production efficiency is increased, enabling faster response to market demands.

Current Application Status of Short-Process Technology: Currently, the application of short-process technology in the aluminum processing industry is gradually increasing, particularly in the production of thin plates, strips, and other products, where it offers significant advantages. For example, some enterprises have adopted short-process technology to produce automotive aluminum sheets, foils, and general-purpose 1-series, 3-series, and 8-series aluminum sheets, which not only enhances production efficiency but also reduces costs.

The short-process technology discussed in this context primarily focuses on the production of plate and strip materials, as their production processes generally involve the longest workflows, highest energy consumption, and largest investments in aluminum processing production.

1.1 Main Short-Process Technologies in Aluminum Processing

Twin-roll casting and rolling process, Micromill continuous casting and rolling process, Hazelett continuous casting and rolling process

1.2 Main Equipment for Short-Process Technology

02 Innovation and Development of Twin-Roll Casting and Rolling Process

2.1 Typical Casting and Rolling Production Line

Twin-roll casting and rolling machine: The twin rolls solidify the molten aluminum into cast-rolled strips. Generally, the common thickness of cast-rolled strips is 5-12mm (for rapid cast-rolled strips, it is 3-8mm), and the common alloy series are 1XXX, 3XXX, 8XXX, and some 5XXX.

2.1 Main Layout Methods of Casting and Rolling Production Line

Mirror Layout of Adjacent Casting and Rolling Machines: Advantage: One team can manage two adjacent casting and rolling lines, reducing the number of personnel required.

Same-Direction Layout of Adjacent Casting and Rolling Machines: Advantage: Equipment components of the casting and rolling machines can be standardized, reducing the number of spare parts needed.

2.2 Classification of Aluminum Melting Furnaces/Holding Furnaces

2.3 Innovative Technologies in Casting and Rolling Process

►Innovation in Casting and Rolling Roll Technology: The application of new-type casting and rolling roll materials and surface treatment technologies has improved the service life of casting and rolling rolls and the quality of cast-rolled coils. For example, casting and rolling rolls made from nanocomposite materials or copper roll shells exhibit higher thermal conductivity and wear resistance.

►Innovation in Casting and Rolling Process Control Technology: The application of automated control systems in the casting and rolling process enables precise control over the casting and rolling process. Through sensors and computer technology, parameters such as molten aluminum temperature, composition, and casting and rolling roll speed are monitored in real-time and automatically adjusted to ensure stable quality of cast-rolled coils.

►Innovation in Molten Aluminum Purification Technology: Advanced molten aluminum purification technologies, such as electromagnetic stirring, ultrasonic treatment, and fine filtration, effectively remove impurities and gases from the molten aluminum, improving the purity of cast-rolled coils while also altering the grain size during casting and rolling. The application of these technologies significantly enhances the mechanical properties and surface quality of cast-rolled coils.

Speech Topic: Production Practices in the Melting, Casting, and Homogenization Processes of 3003 Alloy

Guest Speaker: Lu Jianjun, Chief Engineer of Shaanxi Xincai Dingsu Technology Co., Ltd.