Italy-India co-operation on eco-metallurgy: an interview with Mario Bodini, CEO of Sideridraulic

Finding a balance between markets and the aluminium and steel production sectors, this is the main statement that Mario Bodini, CEO of Sideridraulic, has made to Al Circle. Since the post-war period, this Italian company has been a pioneer in metal development, with its innovative products in the hydraulic automation and water purification sectors. It takes its place alongside Danieli, which accompanied the company’s growth in steel, as well as other groups like Lucchini, Techint, Dalmine, Thissen Group and many others around the world.

AlCircle: What do you think of the cooperation between Italy and India in the field of air and water purification in the metallurgy sector?

Mario Bodini: It will be a crucial sector for the development of both countries, the first in the role of integrator of technologies, the other in the role of receiving these technologies and as a large user base.

AlCircle: How much is the Italian and Indian steel market worth compared to aluminium?

Mario Bodini: In Italy, almost 25 million tons of steel in 2017 is a significant result. If we increase that soon, thanks to an agreement with the Indian group Arcelor Mittal, we will be able to add ILVA's production, a plant that is currently far below its standard. Thanks to another large Indian group – JWD of the Jindal family – Italy will be able to increase the capacity of the Piombino plant, formerly Lucchini, one of Europe’s largest producers of track for rail.

In Italy last year we had steel production equal to 24 ML t/y compared to an aluminium production of about 2.4 ML t/y; so, we’re talking about a ratio of 10 to 1. Moreover, in India it is even higher: with steel at 100 ML t/y compared to an aluminium production of 5 ML t/y; a ratio between steel and aluminium production of 100 to 5.

AlCircle: What do you think about the aluminium market in India?

Mario Bodini: I would like to take advantage of the AlCircle context to point out that India has produced around 3.42 ML t/y of primary aluminium in 2018. Furthermore it imports aluminium scrap equalling 1.12 ML t/y for a total of around 4.5 ML t/y. Meanwhile, India’s factories use only 2 ML t/y of aluminium for domestic production and sell the remainder.

So, it’s evident that the Downstream sector India has low consumption. And, as can be seen from the graph, it is centred in the aluminium cables sector, with plants present in the vicinity of smelters, and with an unspecified quota spread across Extrusion, Die-casting and Lamination in the transport sector.

It is very important to talk about aluminium in India if we consider its natural reserves. India has 593 million tons of bauxite reserves and is naturally endowed with large deposits of gibbsitic bauxite. According to the Indian Bureau of Mines, there are a reported 152 mines, of which 134 operate in the private sector and 18 mines in the public sector.

AlCircle: In your opinion will there be a growing need for air and water purification in both the aluminium and the steel sectors?

Mario Bodini: Italy is one of the great conglomerates of world metallurgy. Our experience in ferrous and non-ferrous metals is unique in the world.

In the near future we will see a growing refinement of environmental safety criteria in metallurgy. The comparison will be made with the emerging countries that care the most about job security like India, South East Asia, Taiwan, South Africa, and also the relaunch of Russia and the whole of North America. We would also like to point out the importance of Mexico, where Sideridraulic has just acquired a very important contract.

The European standards are the most rigorous and selective and will have the effect of becoming the benchmark for plant control in various countries.

AlCircle:  What are the special features of water purification for the non-ferrous sector?

Mario Bodini: In the non-ferrous sector, mainly in aluminium, economic savings can occur. Of course the reduction of CO2 emissions is also an important area of expertise, therefore in terms of this we have the Italian experience in filtering. For example, some filters in the aluminium downstream sector will be increasingly replaceable, washable. You will be able to recover the lubricant, which can then be reintroduced. This means that the mechanical / electronic parts will last longer, favouring a constant evacuation of the pollutant. In addition, the total absence of vibrations attributable to the installed air purification system guarantees the precision of the parts produced.

AlCircle: How did Sideridraulic develop as company over time?

Mario Bodini: Well, up until the end of the 1990s it continued working in the hydraulic sector, becoming the main partner of all of the major steel-plant builders. Then there were about 10 to 15, now they’ve been consolidated into the four major companies that everyone knows.

AlCircle: How much of the Sideridraulic Group business is still in the hydraulics sector?

Mario Bodini: It still makes up about 30% of our turnover. We’re working with plant designers, and hydraulics have a major effect on the performance of equipment in every rolling mill, extrusion press, or continuous casting facility, so there is still a substantial market for us. In addition, in these types of plants there is also a need for lubrication, and we offer other systems for providing and maintaining lubrication.

AlCircle: During the boom of the 1980s there were fewer companies working in your industry, was it more or less competitive than it is now?

Mario Bodini:  Back then there were just a few companies that specialized in working on very large projects; that said, it was still a competitive market.

AlCircle: Can we take a moment to discuss the topic of training, especially knowledge transfer as it relates to plants established in places like India? How does Sideridraulic approach training in ferrous and non-ferrous production plants?

Mario Bodini: Just this year In India we’ve hired 4 new operators and 5 new technicians (including engineers). Often we’ll call in our recently retired personnel to do the training so that current workers don’t lose time in training and the new workers can benefit from the extensive experience of these ex-employees. We are also connected with Technical Institutes and Universities in Brescia and Milano. In Brescia the job-market is highly competitive and many companies want to snap-up the top talent. For our Water Division, we have offices in Milan and hire personnel from that area.

AlCircle: Sideridraulic’s sister Company, Ekoplant, is now involved in new projects relative to the Aluminium Processes. Can you describe the latest developments in this area?

Mario Bodini: Ekoplant can apply its expertise in different and complementary markets.  We have now a partnership with JS Group, that is a very skilled team in the direction of metals and mainly in aluminium.

At Ekoplant the continuous improvement in air filtration techniques, and consequent enhanced bag cleaning efficiency, means that the EKO e3 technology produces superior efficiency and increases the lifetime of filter bags while reducing energy consumption. Process filtration has shown a dynamic development in recent years and particularly in non-ferrous industries like aluminium where the applications are in the areas of alumina calcination, anode baking, potlines (electrolysis), shredding, de-lacquering and melting. The innovation is related to a much shorter valve opening time and reduced inertia of the valve elements, which lead to significant improvements in terms of cleaning efficiency, energy consumption, and long-term reliability.

Disclaimer: “The interview is published in AlCircle in collaboration with Indo-Italian MilanHUB. The information presented herein is neither intended nor implied to be a substitute for professional advice. The views and opinions shared in the interview section of www.alcircle.com are unique to the interviewees and do not necessarily reflect the viewpoint of www.alcircle.com."