Pressure | Temperature | Level | Force | Flow

Measurement technology forthe aluminium industry

Alexander Wiegand,
Chairman and CEO, WIKA

About usAs a family-run business acting globally, with over 10,000
highly qualified employees, the WIKA group of companies
is a worldwide leader in pressure and temperature measurement. The company also sets the standard in the measurement of level and flow, and in calibration technology.
Founded in 1946, WIKA is today a strong and reliable partner
for all the requirements of industrial measurement technology, thanks to a broad portfolio of high-precision instruments and comprehensive services.
With manufacturing locations around the globe, WIKA

2

ensures flexibility and the highest delivery performance.
Every year, over 50 million quality products, both standard
and customer-specific solutions, are delivered in batches of
1 to over 10,000 units.
With numerous wholly owned subsidiaries and partners,
WIKA competently and reliably supports its customers
worldwide. Our experienced engineers and sales experts are
your competent and dependable contacts locally.

Contents
Aluminium industry

04

Safety and configurability

18

Alumina refinery

06

Internet of Things

20

Anode carbon plant

08

Engineered solutions

22

Primary aluminium smelter

10Casting house

12

Calibration & service centre

14

WIKA – Your partner in thealuminium industry
To increase productivity and product quality in primary metallurgy, WIKA supports you with a comprehensive portfolio ofprocess instrumentation that enables flexible operation andcomplete process monitoring.
Our robust and reliable measuring instruments have beendeveloped on the basis of many years of application experience and can withstand even extreme process conditions.
Customers trust our instrumentation solutions for measurements under high-pressure conditions up to 10,000 bar orat extreme process temperatures up to 2,000 °C, e.g. forthe melting of metals or in applications with highly abrasive
process media.

With WIKA's product portfolio, from innovative force, pressure,temperature, level and flow instrumentation to calibration
technology and service offerings, your equipment canoperate more efficiently and produce high-quality products
while increasing profitability and flexibility.
Whether standard products or custom designs: Working withyou we'll find the right concepts for your requirements.

3

Aluminium industry
Today, aluminium is the second most-frequently used metalin the world. This is because aluminium has a unique combination of attractive properties - light weight, high strength,very easy to mould and excellent corrosion resistance are
only the most important ones.
Aluminium is one of the materials of the future. In the longterm, the global trend in primary aluminium is very positive.
According to forecasts, demand is expected to increase by
50 percent by 2050 and reach well over 100 million tons.

1

4

Aluminium features very good recyclability and is one of themost commonly recycled metals. Energy consumption during
aluminium smelting is only five to ten percent of the energy
used in new production.

Aluminium industry

1
2
3
4
5

Alumina refinery
Anode carbon plantPrimary aluminium smelter
Casting house
Calibration & service centre

3

4

2

5

Detailed information
can be found online

5

Alumina refinery
for the highest demands

Globally, most commercial alumina refineries use theBayer process to refine aluminium oxide from bauxite ore.
Extraction of aluminium from its ore and subsequent processing into finished products takes place in a series ofsuccessive operations that are largely independent of eachother. The process conditions within the alumina refinery caustic concentration, temperature, pressure, flow and level- are set depending on the properties of the bauxite ore.The
most significant risk in an alumina refinery is the mechanicaloverpressure of a digester.

There, bauxite ore reacts with caustic soda under highpressure and high temperature. In the past, major explosions
have occurred due to failures of process instrumentation
devices and pressure relief systems, resulting in major
damage to vessels and equipment.
The optimal use of raw materials, energy and process steam
can be guaranteed by the use of reliable and accurate flow,pressure, level and temperature measuring instruments from
WIKA to ensure strict process control.

Detailed information
can be found online
6

Product recommendation
Alumina refinery

PSM-700

TC80

UPT-20TR10-F

Temperature

F1136

F3831

CPH7000

CPH7650

CPH7650Force

CPH7650

DPT-10 with 990.27 and 990.29

Pressure

TG54

BZG

F1211

FLC-COFLC-CO

BNA

Level

DMA

Flap indicators
Flow

OLS

FLC-WG

Wedge flow meter

CTR3000 with CTS3000

CTR3000
Calibration

7

Anode carbon plant
Ensuring the quality of anodes

After the mixture of petroleum coke, resin, aggregates andrecycled used anodes, the mass is shaped (“green anodes”).
In the anode furnace, the green anodes are gradually heatedto the range of 1,100 to 1,120 °C and slowly cooled again.
The entire heating cycle can take 16 to 28 days.

For the anode furnaces, WIKA offers a range of accurate,
reliable and robust measuring instruments designed tocontrol high temperatures, ultra-low pressures and primary
flow elements to optimise the anode baking process, significantly reducing the risk of low-quality anodes.

The goal of firing the green anode is to produce properties
such as sufficient mechanical strength, thermal shock, highelectrical conductivity, and low chemical reactivity.
One of the main requirements of anode baking is that allanodes, regardless of their location, are exposed to the same
temperatures.

Detailed information
can be found online
8

Product recommendation
Anode carbon plant

CPT-21

A2G-90A2G-50TC80-H

F3831

F2802

FLC-HHR-FP

Pressure

F9302

Force

CTR2000

CPC 6050

Calibration

T32

Temperature

FLC-2300

Flow

TR10-CFLC-CO

CPH7000-Ex

9

Primary aluminium smelter
Productivity and cell efficiency
The bath temperature is one of the most-important parameters for achieving optimum cell operation. It is necessary tomeasure the bath temperatures as frequently and as accurately as possible.

Precise temperature control is crucial for the efficiency ofaluminium plants. Our experience in manufacturing andcalibrating temperature measuring instruments enables you
to meet your exact requirements and standards.

Thus, abnormalities in the cell can be detected and necessary measures taken to achieve a stable cell operation(e.g. addition of bath additives). WIKA offers a variety ofsolutions for reliable temperature measurement in aluminium
reduction cells.

Detailed information
can be found online
10

Product recommendation
Smelter

UPT-20

F1136

Pascal 100

IS-3

Pressure

F4812

Force

PGS43.100

F1211

CTH7000

Calibration

TC80-H

FLC-HHR-PP

TC40

Temperature

FLC-HHR-FP

Flow

TC59

FLC-COCTD9300

11

Casting house

High reliability for high availability
Low weight with high strength, high load capacity andextreme flexibility – these are the characteristics of modern
sophisticated aluminium alloys. The use of aluminium in theconstruction of modern transportation can save up to a thirdof the weight – and thus fuel.
In the age of mobility, aluminium is the material of choice.
The efficiency of a casting house is measured in cost per
ton of aluminium produced. To increase this, it is essential tomonitor the temperature of liquid aluminium.

The flow temperature of the hot metal is determined while it
flows through the channels.
For the temperature measurement of molten aluminium,
immersion thermocouples from WIKA are durable andextremely precise.

Detailed information
can be found online
12

Product recommendation
Casting house

A-10

TR10-F

F3831

CPG1500

612.20

PSM-700

TC40

TC80

F2301

F2802

Pressure

Temperature

Force

CTD9100-110

Calibration

GLS-1000

FLC-2200P

RLT-1000

OLS-H

FLC-HHR-FP

FLC-CO

Level

Flow

CPH700013

Calibration & service centre

Consultation, design, implementation � all from one source
Precise calibration instruments are the starting point forresolving your test requirements. However, they only form
one part of a high-performance calibration system. From
our extensive product range, we can design a complete andindividual solution for you which contains all the relevant
components: with adaptability for test items, pressure andvacuum supply, components for pressure control and fineadjustment, through to voltage supply and multimeters for thecalibration of electrical test items.

Our particular strength lies in the project planning, development and the building of complete, individual, application-specific systems – from simple manual work stations
through to fully automated test systems in production lines.

Complete test assembly forpressure, temperature and electricalmeasurands

Detailed information
can be found online
14

Calibration & service centre

Versatile support
Our worldwide laboratories are accredited in accordancewith ISO 17025. We perform our own research and actively
contribute our experience in DKD/DAkkS working groups andstandards committees.
The calibration, maintenance and repair of your measuring
instruments is carried out in full consideration of the latest
national and international standards in our own WIKA calibration laboratory or on-site with you.
Should your measuring instrument not meet the required
specifications, the deficiencies identified are immediately
corrected.
As an independent service provider, naturally, we offer ourservices for measuring instruments from all manufacturers.

Pressure controller CPC4000

CPH7000-Ex

Precision thermometer
CTR3000 and multiplexer CTS3000

Precision thermometer CTR3000 with Multiplexer CTS3000
15

Calibration service

Manufacturer-independent calibration – fast and precise for ...
Pressure■ -1 bar … +8,000 bar (to +9,500 bar
possible with factory calibration)■ Calibration using working standards(precise electrical pressure measuring
instruments) or high-accuracy reference
standards (pressure balances)■ With an accuracy of 0.003 % … 0.01 %of reading■ In accordance with the directives
DIN EN 837, DAkkS-DKD-R 6-1 or
EURAMET cg-3

Force

Temperature

Current, voltage andresistance■ -196 °C … +1,200 °C■ DC current from 0 mA ... 100 mA■ Comparative calibration in calibration
baths and tube furnaces with an accuracy of down to 1.5 mK■ Calibration at the fixed points of the
ITS90 with the smallest-possible measurement uncertainties (mercury, water,
gallium, tin, zinc, aluminium)■ In accordance with the appropriate
DKD/DAkkS directives

Length■ 2.5 N … 6 MN

■ Factory calibration■ With a system accuracy of up to 0.01
% with pressure loading or 0.02 % withtensile loads■ Calibration of special-purpose gaugesin accordance with customer drawings■ Factory calibration■ In accordance with directive DIN EN
10204

16

■ Replacement of the measuring device
if required■ Calibratable measuring devices- Calliper gauges to 800 mm- Testing pins up to 100 mm- Ring and plug gauges up to 150 mm- Tapered thread gauges up to 150 mm- Others on request■ DC voltage from 0 V ... 100 V■ DC resistance from 0 Ω … 10 kΩ

■ In accordance with the directives VDI/
VDE/DGQ/DKD 2622

Calibration service

Materials
For high-pressure measurement, high-strength stainlesssteel is used, while for pressure measurements at elevated temperatures, temperature-resistant stainless steel isneeded. For processes involving highly aggressive media – in
combination with diaphragm seals/gauges with diaphragmfor pressure measurement, or thermowells for temperature
measurement – an extensive range of chemically resistantmaterials is available. In this case, all wetted parts are madeof this special material.
Diaphragm seals are manufactured from 316L stainlesssteel (1.4404/1.4435) as a standard. If diaphragm seals
are required with wetted parts in special metals, then theseare „metallically bonded“ using one of WIKA’s patented
procedures. The junction between the diaphragm and thediaphragm seal body is designed to be diffusion-tight,
vacuum protected and tear-resistant, and also resistant to all
extremes of temperature to which the diaphragm seal might
be exposed.
With pressure and differential pressure measuring instruments using diaphragm elements, wetted parts can be manufactured in the widest range of special materials. Measuringsystems for Bourdon tube instruments are manufactured in
316L stainless steel (1.4404) as standard. All pressure-bearing materials used can be supplied with a 3.1 sub-suppliercertificate.

Large range of special materials and coatings
Stainless steel

NickelDuplex 2205

Gold

Hastelloy B3

Platinum

Hastelloy C22

Tantalum

Hastelloy C276

Titanium

Incoloy alloy 825

Zirconium

Inconel alloy 718

Ceramic

Duratherm

Polytetrafluorethylene PTFE

Monel alloy 400

Perfluoroalkoxy PFA

Mounting arrangements
WIKA is happy to support you in the selection of the correct components for yourapplication. Alongside the extensive selection of instrumentation valves and accessories, WIKA also offers qualified assembly of different individual components
into a complete measuring arrangement (“hook-up”). In addition to the valves andprotective devices described here, combination with diaphragm seal systems is
also possible.

17

Certified safety
Quality assurance
In aluminium production, extensive quality standards are
stringently specified. WIKA ensures this through an effective
quality assurance system.

Safety integrity level
The safety integrity level (SIL) of a component is certified
through a manufacturer's declaration on the basis of an
FMEDA (failure modes, effects and diagnostic analysis).
The FMEDA is a systematic evaluation of the random failure
behaviour of the component.

With this, the statistical values ​​of individual components andtheir functional correlations are jointly assessed. The results
are quantified data on the probability of failure and the reliability of the components.

International approvals/certificates
High-quality components are essential for safe and reliable
production processes. They are a precondition for highly
efficient processes, helping to avoid danger to people, environment and property. Rigorous testing of the instruments

18

used, by national and international authorised bodies, results
in reliability and stable workflows. WIKA instruments offer awide range of approvals and certificates worldwide.

Safety and configurability

Electrical
output signals
Bus technology

Standard output signals

The general trend towards using digital bus systems insteadof the conventional field instruments with an analogue output
signal is also being seen in the aluminium industry. Advantages:

Based on the variety of output signals available our measuring instruments can be easily integrated into any plant
concept. Among others, the following standard output signals
are available:■ Higher accuracy■ Analogue (e.g. 4 … 20 mA, 0 … 10 V)■ Reduced wiring requirements■ Possibility of parameterisation■ Analogue 4 ... 20 mA, design per ATEX Ex II 2G Ex ia IIC
T4/T5/T6■ Improved process monitoring■ PPROFIBUS® PA■ Extended diagnostics of field instruments■ Reliable digital signal transmission■ 4 … 20 mA with a superimposed HART® protocol■ FOUNDATION™ Fieldbus

To plant managers this means a cost reduction and an increased availability of their plants.

Interoperability

Internal and also external
tests certify the compatibilityof our transmitters withalmost all open software andhardware tools.

19

Time for networking
Internet of Things

Wireless sensors are no longer simply suppliers of measured
values. Rather, the sensors can, in addition, be combinedwith extensive intelligence, so their performance is multiplied.

Autonomous wireless platform
Temperature sensors with SAW technology for
low-voltage and medium-voltage switchgear
The robust, wireless, fully passive sensors operate maintenance-free in high electromagnetic fields and in high current
and voltage environment (e.g. 20 kA, 545 kV). This enables
direct measurement on the inside of this critical industrial
equipment.
The unique temperature sensor has been designed for
critical applications in power plants. SAW temperature
sensors can be connected directly to the conductors, nobattery or power source is required. They feature easy
installation and maintenance. For new plants, they are alsoavailable as a retrofit solution.

20

Internet of Things

Easy accessto precise measured data
Do you have to react quickly and flexibly to requirements?
WIKA offers you a versatile digital pressure gauge with datalogger for long-term monitoring.
The accuracy of digital measurement technology and thesimplicity of an analogue gauge are brought together in this
digital pressure gauge CPG1500, which in terms of performance, ease-of-use, and instrument features, is unmatchedin the pressure measurement market.

When monitoring plants from remote locations or mobile
units that cover long distances, a variety of protocols areavailable, such as LoRaWAN™, Sigfox, NB-IoT, LTE, CAT-M1
and Bluetooth, depending on the availability in each country.
Wireless networks and wireless process instrumentation
require great know-how and careful planning. At WIKA, we
are pleased to support you in this.
Talk to us.

21Engineered solutions
Miniature multipoint thermometers
In principle, miniature multipoint thermometers are made from individual measuringprobes with low diameters, which measure the temperature at different positions orheights. Each individual probe is protected with a sheath from either stainless steel
or a special alloy. The individual thermocouples can be combined within a single
thermowell. This design is used where the generation of a temperature profile isrequired, but the weight or size of the multipoint thermometer is limited. Thesedesigns are available in a number of variants.

Temperature measurement in pilot plants
For research and development, processes are often built in pilot plants. Since
the measurement of temperature data for the understanding of a new or modified
process is of utmost importance, the thermocouple must be designed and manufactured carefully. Since the operation of pilot plants is on a smaller scale, thesensors must be scaled down, so as not to influence the processes taking place.
At the same time it is important that the measured temperatures are correct. These
factors are of utmost relevance and must already be taken into account during
design.

Diaphragm monitoringfor critical processes

Chemical & petrochemical industries

Diaphragm monitoring fordiaphragm seals

WIKA's patented double-diaphragm design is the solution for critical processes where neither the medium should find its way into the environment, norshould the system fill fluid find its way into the product (patent no. Germany:
DE102016015447, China: CN108240885, Netherlands: NL2019251, USA:
US2018180505).
In the event of a diaphragm rupture, a second diaphragm in the diaphragm seal
system ensures the reliable separation of the environment and the process.
The measuring task can still be performed. Time to act – without any risk for theprocess.
You can choose between the following basic models:■ Double-diaphragm system with flange connection andall-welded, flush diaphragm■ Double-diaphragm system with threaded connection andinternal, all-welded diaphragm

22

Extensive information can be found in theflyer “Diaphragm monitoring” at www.wika.
com

Engineered solutions

Diaphragm seals
Diaphragm seals are always used when the conditions at the
point of usage deviate from the permissible specifications forthe pressure measuring instrument. These are, for example:■ Too low or too high temperatures of the media■ Aggressive media■ Particle-laden media (also where there is scale formationin the hot-water systems)■ Abrasive media■ Highly viscous media
A further application is the connection of the measuring pointwith a remotely mounted pressure measuring instrument.

Pressure gauges

Diaphragm seals are delivered by WIKA as ready-to-use,
filled systems. These consist of the diaphragm seal itself (theprocess connection), the mounting element and the pressure
measuring instrument. All components are perfectly matchedto one another.
The combined systems can withstand a pressure of 10 mbar
up to 3,600 bar at extreme temperatures (-130 … +400 °C)
and with a wide variety of media, thus enabling accuratepressure measurements under extreme conditions.
Our programme is rounded off by test certificates andapprovals for specific applications.

Pressure sensors

Direct mounting

Diaphragm seals with threaded connection

Cooling element

Process transmitters

Pressure switches

Capillary

Diaphragm seals with flange connection

23

WIKA worldwide
EuropeAustria
WIKA Messgerätevertrieb
Ursula Wiegand GmbH & Co. KG
Tel. +43 1 8691631
info@wika.at / www.wika.at
Benelux
WIKA Benelux
Tel. +31 475 535500
info@wika.nl / www.wika.nl
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Tel. +359 2 82138-10
info@wika.bg / www.wika.bg
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Tel. +45 4581 9600
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Tel. +358 9 682492-0
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info@wika.fr / www.wika.fr

North America

Asia

Africa/Middle East

Romania
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Tel. +40 21 4048327
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Canada
WIKA Instruments Ltd.
Tel. +1 780 4637035
info@wika.ca / www.wika.ca

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WIKA Instrumentation Suzhou Co., Ltd.
Tel. +86 512 6878 8000
info@wika.cn / www.wika.com.cn

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Instrumentos WIKA S.A.U.
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WIKA Alexander Wiegand SE & Co. KG
Alexander-Wiegand-Straße 30 | 63911 Klingenberg | Germany
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You can find further
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14349875 04/ 2023 EN

www.wika.com