Edition 2 I 2009

>> INFOCUS – the Coperion Service Newsletter.

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An Eye on Every Detail: Service at Coperion

Top performances called for – Coperion implements primary aluminium conveying system for Qatalum

4,900 tons of material delivered, 400 people working on site, 8 months assembly time – those are some of the basic data for our challenging task at the construction of the world’s biggest aluminium plant. This is currently being built in the Arabian Emirate of Qatar. Its name: Qatalum, a joint venture between the Norwegian company Norsk Hydro ASA and Qatar Petroleum, the state mineral oil and natural gas producer.

Qatalum contracted Coperion as general project manager for the turnkey construction of the entire primary aluminium conveying system – from raw materials receiving, in-plant storage and conveying to loading of the trucks. Coperion planned, delivered and installed the complete pneumatic conveying system and, in addition to the engineering and design, was in charge of material procurement and site management.

First, our responsible team of experts divided up the whole project into large subcontractor packages. Suitable subcontractors were chosen and evaluated; we assigned the subcontracts exclusively to companies in the Persian Gulf region. That was the way to ensure trouble-free construction of the plant in the short time available.

“For this project we benefit from our long years of activity in the primary metals and minerals industry,” says Jörn Matzke, Head of the Site Management Division at Coperion, Weingarten. “By combining our broad experience in plant engineering with our know-how in project management, we are able to offer our customers an all-round trouble-free package in the implementation of conveying systems – from minor plant modifications to lump-sum turnkey plants.“

Your contact:
Joern Matzke, Tel.: +49 (0) 751 408-683, email

At a glance
Production volume of 585,000 tons/year planned
2 electrolysis halls each measuring 1,150 meters in length
1,100 employees
Start of aluminium production before the end of 2009
Full operation of the facility in 2010

Service in Focus: Compounding & Extrusion

Increased throughput as a retrofit? With the ZS-EG side devolatilization from Coperion

The only prerequisites: You need enough space available around your ZSK extruder’s processing section. An open vent barrel must be replaced by a combi-barrel, the ZS-EG twin-screw side degasser needs to be installed. And you‘re benefiting from throughput increases already.

Step by step: The performance capability of the ZSK series with a conventional top vent barrel can be limited in many cases especially in the extrusion of low-viscous, thin-bodied melts and high gas volumes.

The ZS-EG twin-screw side degasser provides the remedy. With its large free cross-section for devolatilization it keeps the melt in the processing section without product escape, even at the extruder’s maximum specific torque. Fumes or gases are extracted safely by the axially open screw channels. Increased throughputs of up to 30% together with an improvement in the product quality are possible.

Your contact:
Ulf Wittmann, Tel.: +49 (0) 711 897-2583, E-Mail

At a glance
Advantages of the ZS-EG side devolatilization from Coperion:
Increases in throughput of up to 30%
Maximum operating safety up to a vacuum of 50 mbar
Simple handling thanks to quick-release locks for assembly and disassembly
Maximum economy
ZS-EG side degassing of Coperion

Service in Focus: Materials Handling

Efficient use of energy – with tailor-made solution concepts from Coperion

Our sights are set on a clear goal for our customers: We implement plant technology for maximum product quality and cost effectiveness – with maximum energy efficiency. With our long years of experience as a system supplier we execute project-integrated and separate analyses of your plants and work out individual energy saving solution concepts for you.

In the minerals industry, for example, we not only achieve lower maintenance efforts by replacing screw pumps by wear-protected cellular wheel sluices but also reduce energy consumption by up to 97%.

We can achieve energy savings of up to 92% in pneumatic conveying systems by modernization measures. The important thing here is our EnergyPro software tool with which the energy consumption of air generators can be calculated among other things

Our Bulk-X-Change® heat exchanging component is used increasingly in thermal processes because of its statically simple structure. In comparison with complex units such as fluidized beds or drums it only uses a fraction of the energy at the same heat transmission rate.

Your contact:
Carsten Packeiser, Tel.: +49 (0) 751 408-619, E-Mail

Pneumatic conveying systems from Coperion
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