Special Focus:  Top five equipment manufacturers for the aluminium industry in Quebec, Canada

Equipment manufacturers and technology suppliers are an integral part of any industry and metal industry is no exception. The aluminium industry value chain is one of the most widely spread ecosystem that covers participants from the ore to the end user segments. The entire range of operations starting from mining to final processing of end –products requires highly effective technology and fixed and mobile equipment. The technology and the equipment also need to be upgraded from time to time in order to keep pace with changing needs of the industry, market and environment.  This reinforces the significant role played by the equipment suppliers in the aluminium industry value chain.

Quebec, being at the center of Canada’s aluminium industry with the presence of Alcoa, Rio Tinto Alcan and Alouette, three major aluminium players producing 2.9 million tonnes of primary aluminium, has catalysed the growth of group of equipment and technology providers who not only supplies to the industry in Quebec and North America but export to some of the largest aluminium makers all over the world. 

Having been working with the aluminium smelters and processing plants in the province from the initial days and developing hands on expertise in building, maintaining and operating and supporting the plants, these companies are now sharing their expertise to similar plants globally.

As cited by AluQuébec, the co-ordinating and supporting body for the Québec aluminium industry, equipment suppliers from Quebec are mainly active in three areas of the aluminium industry:

1. Primary production
2. Secondary production and remelting
3. Processing (casting semi-finished aluminium products)

The mapping of the Québec aluminium processing industry done by AluQuébec lists 53 equipment suppliers of aluminium smelters and 43 businesses whose expertise supports aluminium processing activities. Here, we are listing down five major equipment suppliers in the Quebec region that have built a trusted client base in America, Europe and Asia. The sequence is not necessarily in descending order and is based on their market reach, client base and product relevance for the aluminium value chain.

1. STAS

STAS has been an equipment manufacturer for the global aluminium industry for 30 years now. STAS Inc. specializes in the development, fabrication and commercialisation of process equipment for the aluminium industry.

Despite having the headquarters in faraway Québec, Canada; STAS has clients in Russia, India, North America, and Middle East. The company has a dependable network of well-known associates around the globe to manage their sales operations along with overseas offices.

STAS’s various equipment is designed to improve productivity and the quality of molten aluminium not only in the primary smelters but also in secondary smelters and also in rolling mills and aluminium extruding plants as well. STAS’s team of engineers and technicians has a broad expertise in processes and engineering.

STAS supplies to five main segments of the aluminium industry.

Equipment for Smelting technologies includes the STARProbe, the Pot Ramming Machine, fume hoods to reduce HF emissions, anode positioning systems, anode stub inspection systems and anode butt inspection systems.  Crucible cleaners, siphon tube cleaners and crucible preheating systems are used for molten metal handling. Equipment like Aluminium Compact Degasser, Inert Gas Dross Cooler, Treatment of Aluminium in Crucible etc. cater to the Casthouse technologies and molten metal filtration.

Automation technologies include programming, process control, plant support, training etc. Engineering segment covers feasibility studies, design/detail/installation engineering, project management, safety and ergonomic reviews, design of custom-made equipment, R&D in new technologies, etc.

2. Mecfor

Mecfor is a supplier of both fixed and mobile equipment to the aluminium value chain. They operate from Quebec Canada and supplies to many brownfield plants in North America and other parts of the world. Mecfor has been a leading solution provider for the aluminium value chain for the past 20 years, starting from alumina refining to processing to secondary smelting. 

Mecfor not only develops new technologies from scratch, but also adopts new technologies through acquisition. For example they have acquired technologies through different companies like Vallée, Inventium, and Brochot over the years and constantly upgraded their portfolio of products.

Mecfor is the leading supplier of their specialised vehicles (haulers and casthouse vehicles) in North America with more than 85% of the market in the primary smelters and growing share in the secondary smelters. Anode slot cutting machine is popular equipment in terms of number of equipment in operation worldwide.  Through the acquisition of the aluminium and magnesium Brochot line of products, they have become a world leader in pot ramming machines with the largest number of installed equipment worldwide. Other than that, they have crucible skimming stations, specialised finished goods trailers, complete rodding shops and ingot casting line for the aluminium sector.

Mecfor exports more than half of its sales volume outside North America (Canada and the USA) for the past 10 years. 85% of their activities are with brownfield plants. They have installed more than 670 equipment or process lines (rodding) worldwide in 35 different countries.

3. Advance Dynamics

Advanced Dynamics is an equipment supplier that focuses on engineering, designing and manufacturing custom, heavy-duty material handling systems. The Management owned company, established in 1965 currently has over $25 million annual sales revenue.  Located in St. Bruno, near Montreal, Quebec, Canada, Advanced Dynamics has easy access to all major shipping modes and exports to a global customer base in North America, Europe, Asia and the Middle East.

Advanced Dynamics employs a group of skilled professionals in project management, engineering, production, sales and administration. The company has integrated, end-to-end capabilities enabling them to deliver the highest value to global clients.

In the Aluminium and primary metals industry the company designs, manufactures and supplies Ingot handling systems,  Billet sawing systems,  Sow Casting systems ,  Anode handling systems,  Rod and tube processing systems,  Furnace and casting systems,  Coil handling systems,  Industrial control systems etc.

In addition to designing and supplying systems, the company is also involved in upgrading to a single piece of equipment in an existing production line according to customer requirement.

They even offer to assess their current handling systems performance and layouts to identify opportunities to increase automation, and increase their ROI and povide turnkey installation service to maximize installation efficiency and effectiveness.

4. Dynamic Concept

Dynamic Concept is an equipment supplier, which provides specialized custom-fit production equipment for the aluminium and magnesium industries catering to the specific conditions of each process line.

The company has a team of experienced people with expertise of the aluminium and magnesium industries, as well as technicians and engineers well connected to the latest technologies.

The company is involved in single product supply as well as turnkey solutions. Since, many aluminium and magnesium producers choose to do business with a single supplier for the entire project when procuring new equipment, Dynamic Concept also offers turnkey solutions, covering all steps of a project.

The company offers assistance in all stages of a project, from preliminary studies to start up, including design, engineering, fabrication, testing, erection of equipment, and the supervision of commissioning and start up. The company provides equipment and technology in the field of DC Casting, Continuous Casting, Metal Transfer Systems, Process Automation, Furnaces and Preheating Systems and Carbon Sector.

Some of their leading equipment include Casting tables, Slab, T-bar and billet moulds, Tilting and rolling carriage system, Bar and rod handling equipment, Siphoning crucibles, Transport crucibles, Remelt and holding furnaces, Preheating systems etc.

5. Equibras

Since its creation at the beginning of the 21st century Equibras is operating into the designing, optimization and adaption of the equipment, tools and work methods that are directly or indirectly used in the field or electrolysis of aluminium. Their equipment is used in Pots conductors, Potlining and Potdelining, Cathode rodding and Crucible cleaning segment.

"Photo machine Alba 2017"is the last equipment Equibras developed, which is called "Next generation multipurpose machine for electrolysis cell lining’’.The company’s services mainly cover the design and conceptualization of new equipment and tools;   the enhancement of existing equipment and tools and technical support.

Other than these domestic companies there are a number of companies that are headquartered in other countries but have actively operating branches in Quebec. Fives Group remains one such leading equipment manufacturer. 

Fives Group

Fives Group is an industrial cluster that designs and supplies machines, process equipment and production lines for a number of industrial sectors in the world.  Located in over 30 countries and with nearly 8,400 employees, Fives is known for its technological expertise and competence in executing international projects. The Aluminium business line is specialized in the design and supply of process equipment and the management of complete installations in the three sectors of the aluminium industry: carbon, reduction and casthouse.  Fives works with aluminium producers to supply latest technology solutions suitable for the large capacity smelters equipped with high amperage pots in order to cut costs and facilitate smooth operations.

Fives Solios Inc. in Montreal and Fives Services inc. in Quebec, are a part of Alu Quebec and have been operating actively supplying to domestic and international aluminium producers.

Fives designs and supplies and installs high capacity Green Anode Plants for the manufacturing of pre-baked anodes along with designing Fume Treatment Centers to treat fumes coming from the Anode Baking furnaces as well as Firing and Control Systems. Fives also designs Gas Treatment Centers.  From full EPC contracts to equipment supply, Fives provides complete solutions dedicated to primary and secondary aluminium casthouses.

Being located in the heart of the Aluminium Valley in Quebec surrounded by primary and secondary smelters and processors, these equipment manufacturers and suppliers had the opportunity to develop products based on the first hand inputs from local clients. The equipment and technology are applied, tried and tested in the Quebec plants before exporting, adding to their credibility. Such practical method of product development with support from major local players like Alcan (Rio Tinto) years ago, and then Alouette and Alcoa, have helped the equipment manufacturers built a legacy of their own in the international market.

Along with that, initiatives taken up by the Quebec government in bringing together the equipment producers under the Québec Aluminium Cluster along with the primary aluminium producers and the transformers have added more credibility to the equipment suppliers in the international scenario.

(The article is a part of a special coverage feature series by AlCircle on the Quebec Aluminium Industry. AlCircle Content Head Beethika Biswas went to Quebec as a visiting journalist, met some of the major industry players and explored the aluminium cluster in the region while visiting plants and offices around Montreal, Saguenay, Chicoutimi and Sherbrooke.)