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A new research centre being launched in Auckland is the first in the world to offer a full suite of leading-edge light metals research and development activities within the one facility, its founders said today at the opening of the Light Metals Research Centre, The University of Auckland.
"By bringing together acknowledged research world leaders in a state-of-the art facility, the Light Metals Research Centre, The University of Auckland provides a new critical mass of expertise," the Centre's Director Designate Dr Mark Taylor said.
"For us, the launch of the Centre is a very exciting development, and follows many years planning. Up til now clients needing environmental research, or energy efficiency gains, or answers to supply problems have had to go to separate research institutions or university faculties: the Centre provides a one stop shop.
"More importantly, our team, spanning all relevant disciplines, can focus on a range of client issues in the context of solving a business problem. "
Dr Taylor said the Centre offers services such as research, training, troubleshooting and testing of materials delivered to the highest standard.
"International research is focusing on a reduction in the cost of metal production and the enhancement of its quality. In meeting these needs we aim to be the supplier of choice," he said.
The Centre's depth of resources also meant it could focus on delivering solutions to long term challenges such as the enhancement and protection of the environment, health and safety and the amelioration of greenhouse gases.
Dr Taylor has taken up his position after 19 years in the aluminium industry with Comalco Australia. He was most recently General Manager of the Boyne Island smelter in Queensland, which has become the world's fifth largest single site smelter in recent years.
During an earlier posting as Technical Manager of the NZAS Smelter at Tiwai Point, Invercargill, New Zealand, Dr Taylor said he developed first-hand knowledge of the big gains that could be achieved when industry and academia worked together.
In the early 1990's, research led by Professor Emeritus Barry Welch, who has been recognised as the pre-eminent world expert in the aluminium smelting industry for many years, Professor Jim Metson of the Department of Chemistry, in the Faculty of Science at The University of Auckland, and Professor John Chen and Dr Margaret Hyland, both of the University's Department of Chemicals and Materials Engineering in the School of Engineering - in collaboration with Comalco Research Centre and Dr Taylor's own staff opened the way for NZAS to achieve very significant energy and production efficiencies. Between 1994 and 1996 Dr Taylor managed the implementation of the subsequent smelter upgrade that achieved an energy saving of 450 GWh per year for the same productivity, a $NZ 40m increase in export sales and a reduction of CO2 emissions equivalent to 100,000 tonnes per year.
Dr Taylor said the scientists and engineers who helped achieve those gains have distinguished international reputations spanning more than 20 years that have established them at the forefront of the light metals development.
"I am thrilled the Centre can draw on the research leadership and special skills of Professors Chen, Metson, Welch, and Dr Margaret Hyland as well as other staff of The University of Auckland, "Dr Taylor said.
"Following global restructuring in the industry and the strong potential for light metals to play a key role in advancing new environmental quality standards, the timing is right for this Centre," he said.
Professor Metson said that in the last five years China had dominated growth in magnesium production using the so-called Pidgeon process which is unacceptable in other parts of the world. "The Centre has skills to help develop better understanding of magnesium production and materials applications of magnesium and its alloys so that both production and environmental goals can be met," he said.
"The timing for this Centre is also ideal for the aluminium industry, as company mergers and other factors have reduced international research capacity and technical support for many operators," Professor Welch said.
"We see significant research opportunities in helping develop inert anode technology. The academic skill base is there. Now the Centre provides the structure to develop an integrated approach in providing solutions that can produce environmental gains," Professor Welch said.
The Centre is installing specialised new computing facilities for mathematical modelling of complex metallurgical processes. A purpose-built laboratory for simulating process conditions and testing new materials is also under development. The Centre's launch marks the return from sabbatical of Professor Metson and Dr Hyland.
Auckland UniServices Limited, the company founded to manage and develop The University of Auckland's commercial activities, has invested significantly in the development of the Centre.
The University of Auckland has long ranked as one of the top aluminium smelting metals research institutions in the world. Based on this reputation, the Centre has signed contracts to undertake research for companies in Germany, France, and Norway and has been approached by a number of overseas companies to undertake consulting and testing work. The Centre is now finalising a cooperative agreement with a major Chinese research institute and refractories manufacturer.
The Light Metals Research Centre, The University of Auckland also has a global educational role, Dr Taylor said.
In co-operation with the University of New South Wales, the Centre offers both a Certificate and a post-graduate Diploma specialising in Aluminium Smelting, and has enrolled students from Norway, Germany, France, Argentina, Bahrain, Dubai, Australia, Holland, South Africa and Iceland.
Some teaching will be done on site at NZAS Tiwai Pt, and at Boyne Island.
Professor Metson said the co-operation and support industry management has shown for the training the Centre will offer has been much appreciated by the Centre and underlines the need felt by many companies to develop a larger international skill base.
Professor Metson said the Centre will maximise opportunities in advancing research in magnesium smelting and surface protection technologies; high intensity energy conversion systems; environmental enhancements and process energy efficiencies, including heat recovery.
John Kernohan, UniServices' CEO, said the Centre had been established to help the sector meet considerable potential for further growth.
"The Centre builds on the recognition that scientists and engineers at the University have earned. The depth of resource and expertise the Centre now makes available will enable it to take a leading role in meeting global need for environmentally sustainable processes and products," he said.
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