Located in Northern France, the Aluminum Dunkerque plant was founded in 1991. It is the largest primary aluminium smelter in Europe, specialising in the manufacture of aluminium slabs and ingots with over 99% purity, which have a high level of demand across a range of value added applications in the transport, automotive, aerospace, packaging, building and construction industries.
The site has three major manufacturing areas, which include anode production, electrolysis and foundry.
The anode production section manufactures the anodes used on site during the electrolysis process. Materials used include pitch and coke as well as recycled anodes. This department consists of:
The electrolysis department produces the primary aluminium that is formed into slabs and ingots. The aluminium is produced in two 850 meter long electrolysis halls, into 264 reduction cells.
The reduction pots are connected in series to the substation. As soon as a pot is switched on and supplied with alumina, it produces metal continuously. The pots are controlled by microcomputers that measure the voltage individually, control and monitor the supply of alumina into each pot and adjust the distance between the anodes and the metal automatically.
Each tonne of primary aluminium on site is manufactured through the use of:
The foundry department receives the liquid aluminium from the electrolysis department and casts both slab, using the DC casting method for the rolling industry, or alloys and cast foundry ingot for use in the automotive sector.
Foundry - Key figures :
Liberty Aluminium Dunkerque also has a maintenance department, which is responsible for all equipment on site and ensures the smooth running of the operation. The maintenance team is responsible for: