AL-EMS electromagnetic stirring for aluminium furnaces

Maximize productivity, reduce dross, and cut energy costs

Overview

ABB’s AL‑EMS electromagnetic stirring technology ensures rapid melt homogenization for aluminium melting, holding and alloying furnaces, delivering consistent, efficient, and sustainable operations. With over 430 installations worldwide, in-house metallurgical expertise, and global lifecycle support, this non-contact solution provides long-term reliability while improving process repeatability, reducing resource use, and enhancing safety in the aluminium casthouse.

Typical benefits

Increase productivity by 25%

Faster melting and alloy dissolution shorten cycle times and boost throughput

Reduce dross by 15%

Lower surface temperature and improved melt homogenization minimize oxidation losses

Cut energy use by 10%

Better heat transfer and closed-door stirring reduce gas and electricity consumption

Increase aluminium yield

Elimination of manual stirring, door-opening and lower oxidation mean more metal per batch

Improve process repeatability

Consistent temperature and chemical homogeneity enable stable, predictable operations

Typical payback under 12 months

Rapid ROI thanks to combined savings in energy, yield, and productivity

Features

Explore the core design and control capabilities that make ABB AL-EMS the right choice, from predicted savings to non-contact installation and full-bath stirring, to automated control and expert global support, these features ensure reliable performance and long-term value for aluminium melting, holding, and alloying furnace operations.

  1. Non-contact installation for maximum reliability and safety

    ABB AL-EMS has no physical contact with the molten aluminium, minimizing wear and maintenance. This design ensures long service life and reduced downtime while eliminating the need for manual stirring and frequent door-opening. The result is safer, more efficient furnace operation with improved working conditions and reduced heat loss.

  2. Full-bath stirring for homogeneous melt

    The ABB AL-EMS creates a powerful electromagnetic force that stirs the entire aluminium melt bath, eliminating dead zones and hot spots. This accelerates scrap melting, improves temperature and chemical uniformity, and supports consistent alloy quality.

  3. Flexible installation options for all furnace types and sizes

    Designed for both retrofits and new furnace projects, with bottom or side-mounted stirrers for melting, holding, and alloying furnaces; air- or water-cooled models for capacities up to 200 tons, ABB AL-EMS even includes a multi-coil concept for cost-effective operation of multiple furnaces with shared auxiliary equipment.

  4. Automated control for safer, more repeatable furnace operations

    AL-EMS Control is an optional add-on that integrates with the furnace system to deliver automated stirring profiles and step-specific adjustments for melting, alloying, and holding. This supports repeatable operations, improved process safety, and optimized energy use.

  5. Proven technology with largest global installed base

    Typical improvements with ABB AL-EMS are backed by more than 430 installations worldwide, over 80 years of electromagnetic innovation, and a performance guarantee that ensures results. ABB has the largest installed base for this technology globally, giving aluminium producers confidence in proven reliability and long-term value.

  6. Expert global support and metallurgical know-how

    ABB's Metallurgy team includes in-house metallurgical expertise and a dedicated aftersales team offering lifecycle services and support worldwide. from commissioning to optimization, you can benefit from tailored support that maximizes performance and ROI.

EXPLORE OUR EXPERT INSIGHTS

Sustainability in motion: what lifecycle assessments reveal about modern aluminium manufacturing

Despite its reputation as a 'green metal', aluminium generates 2-3% of global CO2 emissions. Understanding the environmental impact across the lifetime of products like AL-EMS is crucial to decarbonizing production.

Engineering that helps aluminium producers scale up with confidence

Explore how ABB is innovating to enable consistent and efficient performance to support aluminium producers in meeting growing demand and sustainability goals.

Reshoring, recycling and efficiency pave the way for increased capacity

Explore reshoring and recycling trends and the role of technology in enabling competitive, sustainable aluminium production - with a particular spotlight on North America.

How to improve aluminium melting and product quality

Gain insights from our metallurgical experts on how electromagnetic stirring and liquid aluminium measurement technologies can elevate aluminium casthouse production.

Achieving consistent melt quality through optimized electromagnetic stirring

Learn about the effect of electromagnetic stirring on heat and mass transfer in melting and holding furnaces, and its impact on energy use, dross generation, and overall melt quality.

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