SIEMENS VAI Company profile

GLOBAL MEDIA COMMUNICATION LTD. 2

Siemens VAI Metals Technologies

SIEMENS VAI COMPANY PROFILE3

Index

Your challenge 4

Roughing mill 5

Our solution 6

Our portfolio at a glance 7-8

Hot rolling mills 9-10

Cold rolling mills 11-12

Foil rolling mills 13-14

Life-cycle management 15-16

Mill modernization 17-18

Special products 19-20

Drive solutions 21-22

Automation solutions 23-24

Process optimization 25-26

Aluminium Portfolio 27


Your challenge:

A growing need for plant productivity and quality rolled products

Growing markets

Driven by Asia’s economic growth, the market for alumin ium strip and foil continues to grow. China’s aluminium demand exceeds that of all other countries and will continue to do so in the coming years. Such steady growth means plants must continually optimize aluminium rolling processes in order to stay competitive. Increased rolling speeds and increased plant productivity are key factors for securing your position in the market.

It’s all about quality

Although being able to increase quantity is important, the key factor is quality enhancement. The ability to provide aluminium strip and foil in customized qualities is becoming increasingly crucial. Your customers in aerospace, automotive, commercial transportation and packaging as well as construction require even tighter tolerances. To meet these demands, you need a flexible, easily adaptable rolling setup.

Flexibility is a must

As your customers’ market needs change, your plant must be capable of adapting. Short delivery times and fast production changeover are key criteria when end customers decide where to place orders. Dealing with prod uct changes is therefore a vital factor in the economics of aluminium rolling. Logistic design has to be part of the plant solution, too.

The need to drive costs down

Rising raw material costs also have to be considered. In recent years, the price of aluminium has risen sharply. This means waste reduction is an important target.

High plant availability

Plant operations need to be optimized to increase capacity and improve quality while decreasing operating costs. Easy maintenance is also important for improving plant availability and strengthening long-term performance. With ever greater demands for aluminium strip and foil, the need for better product quality, mill productivity, availability and reliability continues to grow as well.


Roughing Mill

You expect:

• Leading process technology that delivers high-quality products

• Fast rolling speed and flexible production processes

• Tailored and comprehensive solutions that accommodate the increasing quality demands for aluminium products

• Expandable solutions that protect your investments into the future

• High plant availability that lowers operations costs

• Long-term performance with services that meet your needs


Our solution:

Cutting-edge technologies for aluminium rolling millsThe answer for the aluminium industry:

SIROLL ALU

Our solution has everything to bring aluminium rolling mills up to speed. This includes the most powerful roll drives for higher throughput. State of-the-art mechanical and hydraulic solutions optimize performance and operational efficiency. Online process models and neural networks will enable you to produce more accurately than ever before, and our proven automation solutions maximize your plant’s end-to-end consistency, reliability end-to-end consistency, reliability and security in the future.

Increased production

With our decades of experience, Siemens Metals Technologies has a deep understanding of processes in the aluminium industry. Through the seamless integration of technology, mechanics, automation and electrical engineering, our solutions can help your plant achieve its highest level of productivity.

Improved quality

We use a wide range of specialized technologies like SIROLL DSR® (Dynamic Shape Roll), SIROLL SmartCrown®, SIROLL SIFLAT noncontact shape measurement, AGC, automatic profile and flatness control and more to achieve highest product quality.

Efficiency from mill stands to production planning

Our automation technology allows you to respond quickly to your customers’ requirements and achieve market- driven, flexible production. A modular strategy, open communications and transparent automation architecture ensure that the solution fits your needs, whether you’re building a new plant or modernizing an existing one.

Through the intelligent distribution of functionality, application-specific solutions and globally proven drive concepts, SIROLL ALU guarantees reliable plant operation through out the entire production process. While maintaining the highest product quality and maximum plant availability, you’ll lower your operating costs significantly.

Customized production

Customers today want aluminium strip and foil to meet different sizing specifications. They also want small batches and good prices. That means you need fast and flexible production processes that produce higher yield through reduced cropping, trimming and off-length losses.

Our solutions minimize scrap from trimmed edges to help you achieve unrivalled cropping and width optimization.

Our services ensure your success

Our professional services are aimed at helping your plant achieve top performance throughout its entire life cycle. Customized preventive and predictive strategies let you minimize unplanned downtime and reduce your costs on maintenance, spare parts and personnel.


Tandem cold rolling mill

Cold rolling mill

Automatic high-bay store

Foil mills

Bright finishing mill

Slitting line

Cut-to-length lineTension leveling line Packaging line

Strip caster Combined strip caster and hot rolling mill Hot-strip rolling mill Finishing standRoughing stand Roughing stand with edgerHot-strip rolling mill Tandem finishing train

Our portfolio at a glance

Siemens Metals Technologies offers the full range of aluminium mill solutions

As your life-cycle partner, we’ll team with you to meet all your needs, including investment planning, operating concepts and layout, and modernization, to ensure that your plant is always using the latest technology. With a proven track record for conducting integrated rolling complex projects and supplying process equipment, we can also define, supply and install auxiliary

Contents

Aluminium Mills

Hot Mills 9-10

Cold Mills 11-12

Foil Mills 13-14

Supplies and Services

Life-cycle management 15

Our Services 16

Modernization 17-18

Special products 19-20

Drive solutions 21-22

Automation solutions 23-24

Process optimization 25

Innovation 26


Tandem cold rolling mill

Cold rolling mill

Automatic high-bay store

Foil mills

Bright finishing mill

Slitting line

Cut-to-length lineTension leveling line Packaging line

Strip caster Combined strip caster and hot rolling mill Hot-strip rolling mill Finishing standRoughing stand Roughing stand with edgerHot-strip rolling mill Tandem finishing train

facilities including roll shop, annealing, finishing and packaging equipment as well as identifying building and civil engineering costs associated with different layouts or planning for future plant expansion for increased production.

Service is another key element that Siemens Metals Technologies delivers.

Main benefits:

• Decarburizing heats with higher carbon levels

• Steel can be heated during RH treatment

• Quick skull removal using burner function

• Low investment and maintenance costs

From the training of operating and maintenance personnel to the supply of knowledge and total plant maintenance service, Siemens Metals Technologies has the expertise to meet your requirements.


Hot rolling millsAdvanced technology for high-quality products

These include:

• Reversing roughing mills

• Tandem mills

• Twin-coiler mills

• Plate mills

• Minimills

With our flexible mill configuration, you can roll high quality strips in capacities from 100,000 to 800,000 t/a, depending on the installation.

Product technologies are focused on achieving the highest-quality products. Siemens Metals Technologies provides advanced mechanical actuators, electrical and automation control systems and applied process know - how to deliver gauge, profile/flatness, temperature and surface quality with the highest level of consistency.

Advanced roll stack actuators such as SIROLL SmartCrown® and SIROLL DSR® can be custom-selected according to your specific mill design.

Features:

• Our mill stand equipment is designed for the highest rolling loads and main drive torques, which ensures the correct development of material property and maximized throughput.

• Hydraulic systems to provide controllable, responsive, precise, safe and efficient operation. These include hydraulic edger, HGC, work roll bending and shifting, side guides and shears.

• SIROLL SmartCrown® roll contour guarantees enhanced flatness control.

• For perfect cooling and contour control we provide pulse- modulated work roll spray bars.

Chinalco Ruimin – mill build

SIROLL ALU features a full range of aluminium hot rolling mills for both new and revamp projects.

• An accurate mill setup is crucial for meeting the demands for quality. SIROLL ALU features physically based analytical online models supported by neural networks to achieve tight tolerances right from head end.

• Common technological solutions to enhance performance, operability, maintenance, safety and environments are utilized across the hot mill, such as strip coolant blow-offs, fume hoods and fume extraction.


Main benefits:

• Flexible, low-cost rolling of a wide range of products, even for small order lots

• Tightest strip thickness, profile flatness tolerances

• Maximum yield due to hydraulic edging with automatic width- control functions

• High surface quality

• Most advanced and innovative automation

• Integrated health and safety concepts

Selected references:

Alcan, Pindamonhangaba, Brazil

Alcasa, Puerto Ordaz, Venezuela

Alumax, Texarkana, USA

Alunorf, Neuss, Germany

Chinalco Ruimin, Fuzhou, China

Chinalco NELA, Harbin, China

Compania Valencia de Aluminio (CVA), Segorbe, Spain

Novelis Korea, Ulsan, South Korea

Southwest Aluminium, Chongqing, China

TLM, Sibenik, Croatia


Cold rolling millsSolutions for high-precision rolling

6-high millstand

The cold mills supplied by Siemens Metals Technologies offer a unique blend of innovative design and proven technology, allowing strip to be produced at very tight tolerance and productivity levels.

Our mills provide both breakdown and finishing capability, offering flexibility for the production of a wide product range from a single mill configuration.

The fully integrated automation and drive system enables automated equipment sequencing for efficient mill operation. Process control, which uses the latest Siemens Metals Technologies automation technology, assures the online control of strip flatness and gauge and allows for the production of high-quality products such as can stock, lithographic sheet and foil stock.

Our SIROLL ALU portfolio includes:

• Breakdown mills

• Thin-strip mills

• Tandem mills (2 and more stands)

The cold rolling process can be assigned to different process applications, each suited to the material finish requirements.

Breakdown mills are available as the more conventional process option. These mills can be supplied as 4-high or 6-high design and provide the flexibility to operate on the complete range of alloys, over a wide gauge range of around 10 mm – 0.05 mm. Capacities of up to 150,000 tonnes per year are achievable with this process.

Tandem mills with 2, 3 or 5 stands can be used to extend the throughput capacity to 300,000 tonnes per year and more.

Thin-strip mills of 4-high design allow for a finishing capacity on light gauges of down to around 0.02 mm. This mill type can be used for foil roughing applications. Capacities vary and depend on the application, but are usually in the order of 30,000 tonnes per year.

Features:

• To ensure an accurate mill setup, our cold rolling mills are based on physical online process models. This plus our fully integrated process control, automation and drive systems using the industry-standard SIMATIC platform allow for optimum rolling results at any time.

• We offer a range of mill stand technologies to suit the part- icular requirements of your project. Options include SIROLL DSR® backup roll technology, SIROLL SmartCrown® roll technology and 6-high stand design.


• SIROLL Edge Wipe technology enhances the Siemens Metals Technologies‘ strip drying sy- system, addressing the edge bead issue common on open gap passes.

• The SIROLL ALU Vapor Shield fume cleaning and oil recovery system ensures environmentally friendly operation and the efficient collection and retrieval of rolling oil.

• The appropriate choice among a range of flatness sensors is available: SIROLL SIFLAT, a non-contact flatness sensor, ideal for surface critical applications SIROLL Air Bearing Shapemeter roll, particularly suited to thin- gauge finished products.

• The Schneider roll coolant filter, manufactured and supplied under license by Siemens Metals

Technologies, is the market leading filter, enabling high levels of filtration and long cycle times with its Acticel R filtration media.

Main benefits:

• Highest production rates

• Optimized yield

• Flexible production

• Tight tolerances for strip thickness, flatness, and high surface quality

• Low costs for operation, maintenance, and minimum downtimes


Alcoa, Samara, Russia

Alcoa (KAAL), Moka, Japan

Alcoa Bohai, Qinhuangdao, China

Aluar, Abado, Argentina

Aluminium Konin, Konin, Poland

CBA, Sorocaba, Brazil

Chinalco Henan, Zhengzhou, China

Chinalco NELA, Harbin, China

Comital, Volpiano, Italy

Elval, Inofyta, Greece

South West Aluminium, Chongqing, China

Louisville Thin Strip Mill, United States of America

High levels of filtration: Schneider roll coolant filter


Foil rolling mills

Foil mill, Shanghai Shenhuo, Shanghai, China

Best quality at the lowest cost

Siemens Metals Technologies‘ range of high-performance foil mills combines the latest developments in measure-ment, computing and control with innovative mill design to enable you to produce the best-quality foil at the lowest cost.

The mills feature a number of automated systems for coil, spool and scrap handling as well as high-speed work roll change. The design puts you in sync with the market trend toward larger coil weight combined with wide strip to maximize yield and productivity.

The fully integrated automation and drive system enables automated equipment sequencing for efficient mill operation. Process control, which uses the latest Siemens Metals Technologies automation technology, ensures the online control of strip flatness and gauge and allows for the production of high-quality products.

Features:

Our state-of-the-art high-speed foil mills (all types) have a number of specific features:

• Operation and drive-side work roll latching allows for thermal expansion of the rolls to the operator side.

• Accommodated by bearing clear- ances, this eliminates potential thrust forces on the mill spindles and work roll bend rams during long passes.

• Operation and drive-side backup roll latching similarly eliminates potential thrust forces on the roll load cylinder during long passes.

• An optimized mill bearing design with specifically tailored tolerances enhances high-speed operation.

Foil mill, Shanghai Shenhuo, Shanghai, China


Foil mill line and coil yard

• Oil circulation lubrication to the backup roll bearings maintains bearing temperatures within their operating range and allows for the use of synthetic oils, which have a better load carrying capability.

• A work roll and backup roll bearing temperature measurement function ensures precise monitoring of the bearing temperatures.

• A constant-force ironing roll permits consistently higher coiling speeds.

• Spindle piloting eliminates potential roll vibration by providing a positive location of the roll neck in the spindle end.


Northwest Aluminium, LongXi, China

Shanghai Shenhuo, Shanghai, China

Varopakorn, Bangkok, Thailand

Main benefits:

• High production rates

• Flexible production

• Tight tolerances for strip thickness and flatness

• Low costs for operation and maintenance, and minimum downtimes

RecyclingModernization

New investmentOperation

• Investigation/inspections & feasibility study• Design• Layout• Construction• Installation• Commissioning

• Service contracts • Spare parts and components • Consulting and training • Online and offline

maintenance • Maintenance contracting

• Migration packages • Upgrading and

modernization


Life-cycle managementPartnership never ends

Siemens Metals Technologies‘ life-cycle services

As a plant operator, you have conflicting needs. On the one hand, your perfor-mance is measured each quarter against short-term profitability expectations. On the other hand, you have to think on a totally different timescale compared with the capital market.

Depending on the lifetime of your plant, you have to take 15 years or more into account. At the very least, that’s 60 full quarters. But thanks to our comprehensive expertise and integrated approach to solutions, you benefit both short-term and long-term from our life-cycle services.

In the short term:

Backed by our extensive experience with many reference plants, we provide you with the certainty of fast, dependable production start-up and shorter amortization periods.

In the long term:

Our master plan guarantees competitive performance for your plant in every phase of its life cycle. Whether we’re providing 24/7 technical support, optimizing maintenance, or making permanent plant improvements, we are always working to ensure the cost-effective operation of your plant.


Our servicesBest performance throughout your plant‘s lifetime

Siemens Service Engineer

Features:

• Dedicated spare parts service from small proprietary items to major assemblies

• Stock control and distribution database

• Standard packages with measu- rable client benefits

• Dynamic spare parts and material management system

• Material information system

• Substitution of parts including re-engineering

• Service for electrical equipment and automation

Best performance throughout your plant‘s lifetime

You want your plant to produce at competitive costs over its entire life cycle, and always have state-of-the-art technology. That‘s why you make an investment. For this investment, you should expect an effective life-cycle concept from your plant manufacturer.

Services offered by Siemens Metals Technologies range from planning, consulting and engineering to supply of both individual components and complete production lines, including safe and rapid start-up. Whether we’re constructing new plants or modernizing existing capacities, our own training specialists make sure that your personnel know how to handle the process and technology safely and efficiently.

Our offerings include …

• Presale studies – from design, engineering and feasibility studies to improvement studies

• Start-up support – from on-site training to accelerated start-up programs

Spare parts and components supply

Our spare parts service specializes inthe engineering and supply of spare and wear parts, technological components and systems. Professional handling ensures that you receive the right part in the shortest time possible.

The maintenance of your production facilities and equip ment is a significant cost factor for you. Yet unplanned process downtime greatly affects the earnings of the entire company. Risks must be minimized, as must the costs for keeping those risks small.


Mill modernizationKeeping your production up-to-date

Novelis Utinga, Santo Andre, Brazil: before ...

To remain competitive as an aluminium producer, you need the latest and most advanced technologies that ensure the best product quality and output. This is particularly true in the field of rolling mill modernization, where complex mechanical and hydraulic equipment components must be integrated with sophisticated process control systems in order to respond to market demands.

Drawing on the SIROLL ALU concept, Siemens Metals Technologies provides solutions that can be implemented through a phased upgrade with a minimum of downtime in ongoing plant operations.

This approach allows the mill to improve its production output, maintainability, machine access and product quality, helping you to remain competitive and successful.

The solution may be purely electrical, automation, mechanical or a combination thereof, and can be carried out in one or more steps during a plant shutdown.

Siemens Metals Technologies‘ experience minimizes downtimes and ensures fast start-up and top quality.

A successful modernization project starts with the selection of one of three types of modernization strategies:

• Type 1: Mill modernization via ongoing and continuous improvements and investments

• Type 2: Mill modernization via one or two major modernization steps

• Type 3: Mill modernization via relocation and improvement of an existing mill

Type 1: Mill modernization via ongoing and continuous improvements and investments

The 5-stand and tandem mill at Novelis Rogerstone was installed in the late 1940s and has undergone many upgrades over the last forty years. The latest of these has included quality and productivity improvements of the last stand and exit table. Modernized at the end of 2006, the upgraded mill is now realizing its performance targets and beyond.

Type 2: Mill modernization via one or two major modernization steps

For keeping their process automation up-to-date, Alunorf, Neuss, decided to modernize the rolling 4-stand finishing mill with a state-of-the-art Level 2 and HMI system. Modernization was done while the mill was running (shadow mode).


... and after foil mill modernization

That meant no additional standstill of the mill was necessary. The first strip with the new Level 2 system has already reached targeted figures. With the new Level 2 system, Alunorf is well prepared to roll a wider range of new, sophisticated material in the future. The final acceptance by the customer took place as scheduled in December 2004.

Type 3: Mill modernization via relocation and improvement of an existing mill

The relocation and modernization of a hot reversing mill and 3-stand tandem mill from Scotsboro, USA, to Bohai, China, refocuses production in the rapidly expanding Chinese market. A general refurbishment of the equipment took place before installation in 2008.


Alcoa, Samara, Russia

Alcoa Bohai, Qinhuangdao, China

Alcoa Europe, Kofem, Hungary

Aleris, Koblenz, Germany

Alunorf, Neuss, Germany

Hindalco, Renukoot, India

Hydro Aluminium, Grevenbroich, Germany

Kumz, Kamensk-Uralsky, Russia

Logan Aluminum, USA

Nikkei Siam, Bangkok, Thailand

Novelis Korea, Yeongju, South Korea

Novelis Packaging, Bridgnorth, United Kingdom

Novelis UK, Rogerstone, United Kingdom

Novelis Utinga, Santo Andre, Brazil


Special productsUnique solutions to improve the performance of your mill

SIROLL SIFLAT – flatness measurement and control

One of the strengths that sets Siemens Metals Technologies apart from the competition is our decades of experi-ence, both in machine engineering and automation. Our special products combine expertise from both areas to create unsurpassed solutions. Proven mechanical designs, optimized control technology and clearly defined interfaces deliver a solid foundation for flexibly expanding existing aluminium rolling mills or constructing new plants from a single source. And these solu-tions are modular in design, making them ideal for efficiently modernizing plants in easy-to-manage projects.

SIROLL DSR® – Dynamic Shape Roll

The SIROLL DSR® system from Siemens Metals Technolo gies is a key technol-ogy for enhancing the performance of cold rolling mills. SIROLL DSR® re-places the top solid backup roll usually employed in 4-high stands. It provides improved flatness control, especially in the critical areas at the head and

tail ends of the strip. This allows for significant improvements in overall coil yield. (Currently, SIROLL DSR® is the only truly online dynamic actuator that can enable symmetric and asym-metric changes to the roll gap profile during ongoing production.)

The dynamic control range of the SIROLL DSR® is considerably larger than any other rolling mill actuator in the market place. True dynamic control is achieved by the fast response of the pads to the changes in the force distribution refer-ence. DSR® eliminates undesirable roll contact and stress peaks.

SIROLL SmartCrown work roll contour

Work rolls are equipped with SIROLL SmartCrown (patent pending), a new type of roll contour introduced by Sie-mens Metals Technologies.

Employing work rolls shifting in con-junction with specially profiled work rolls significantly increases the flatness

control range. SIROLL SmartCrown® is usually installed in combination with work roll bending to enable profile and flatness control. With SIROLL Smart-Crown’s large adjustment capability, only one grind is needed to replace all roll grinds for conventional rolls.

SIROLL SIFLAT

SIROLL SIFLAT helps you achieve greater precision and productivity in flatness control. This contactless system is based on the principle of periodically exciting the strip and measuring the excitation amplitudes across the strip width. In practice this means:

• High resolution of measurement

• Independence from strip speed

• Elimination of the need for special coating or surface treatment

• Maintenance that can be performed by your maintenance staff

• Elimination of the need for spare device


SIROLL ISV spray systems

Flatness package

Our flatness solution includes all re-quired mechanical actuators and mea-surement and control systems to ensure the highest flatness performance. De-pending on the mill type and product mix, the mill stands feature:

• Work roll bending

• Multizone cooling SIROLL ISV Sprays - enabling local corrections

• Hot-edge sprays – addressing tight-edge issues

• SIROLL DSR® – giving fully dynamic control

• SIROLL SmartCrown® – allowing for continuous crown adjustment

These actuators work in conjunction with a range of flatness sensors, including:

• Air bearing shape roll – high sensitivity, particularly suited for foil production, but also available in a cold mill, heavy duty version

• SIROLL SIFLAT – noncontact

measurement for highest surface demands

• SIROLL Placinim® shape roll – robust, solid roll available for hot and cold applications

AGC packages

Siemens Metals Technologies auto-matic gauge control (AGC) packages combine the hydraulic capsules, servo- valves, transducer and control system to create a comprehensive solution. Mass flow control ensures thickness precision to within a few thousandths of a millimeter.

Our REC (roll eccentricity compensa-tion) system also allows for improved thickness performance, especially for modernizations.

Coolant collection and filtration systems

Siemens Metals Technologies offers a selection of rolling oil treatments, including:

• Schneider Filter – a multiplate filter designed and made under license by Siemens Metals Technologies, providing microfiltration

• SIROLL ALU Vapor Shield fume cleaning and oil recovery system, providing effective emission control and recycling of recovery rolling oil Further products offered bySiemens Metals Technologies:

• SIROLL Edge Wipe – removes the coolant edge bead prevalent in cold rolling, thereby improving exit coil dryness

• Constant-force ironing roll – with optimized geometry and servocontrol to maintain straight coil buildup throughout the coil Scratch brushes – work roll chockmounted, with precise hydraulic loading


Drive solutionsMoving the aluminium industry

In aluminium rolling, interruption-free processes and high-quality end products are important. The crucial demands placed on drive technology are therefore high-dynamic response of the control system and brief overload capability, smooth running, maximum availability, service friendliness and seamless integration into higher-level automation systems.

For over two decades, Siemens has pioneered synchronous main drive technology for rolling mill applications. With an installed base of AC main drives with a combined capacity exceeding 1 GW (1,000 MW), Siemens has extensive experience in delivering reliable, high quality main drives for demanding rolling mill applications.

Siemens’ synchronous motors – the most powerful available – have established themselves as an economical, versatile solution. With low maintenance and great efficiency they offer everything you need for minimizing life-cycle costs.

The right way to get your aluminium mill rolling

Based on our low-maintenance and reliable cylindrical rotors we are able to offer the most attractive synchronous motors for main drive systems.

• High availability and low maintenance

• Compact design without fixing elements and screw connections

• Fewer electrical connections

• Vacuum impregnation of whole rotor

• Extremely rigid and robust design

• Optimal to withstand extreme forces

Power needs control

Based on a single platform, Siemens SINAMICS drives combine to form a complete and consistent drive family that spans the entire performance range in terms of flexibility, functionality and engineering design.

The selection criteria for the right drive include:

• Application requirements• Network conditions• Economical aspects• Operational issues

The control system fits seamlessly into the SIMATIC automation environment ensuring standardized interfaces and standardized engineering environment. A sole control system covers every application area from low-power units into the medium-voltage upper megawatt range. And with our high-end control units we provide the latest, state-of-the-art drive control as well as the right choice for all technological challenges.

Voltage source converter

From standstill to top speed, the SINAMICS voltage source converter is a highly dynamic, responsive device even with regenerative feedback into the line supply. Minimum line harmonics, outstanding torque smoothness and

Reliable and high quality synchronous main drives for very demanding applications


the highest degree of efficiency of the entire drive/energy system distinguish our multilevel converter with fully adjustable line power factor.

Upgrading motors and drives

Most aluminium hot mills being considered for an upgrade are equipped with DC main motors since their construction predates modern synchronous motors. A requirement for higher torque, better control and increased operating efficiency leads naturally to a synchronous motor solution. The virtuous circle of market need driving technical development means that the aluminium industry can now call on motor configuration that can be adjusted to fit existing foundations, that can be installed quickly and that require a minimum of maintenance.

Compared to DC machines synchronous motors deliver more than simply increased torque at low speed. Because the limitations of commutation

are eliminated, the cut-off at field weakening range can be increased by up to 50%. For heavy reversing duty, the cylindrical or nonsalient pole configuration is ideal, being both compact and robust as well as maximizing dimensioning torque through the use of the greatest number of poles possible.

But you may need to upgrade more than motors and drives. The need for increased torque may require a revamping of the transmission as a whole. Spindle design and selection also may need attention, and a simple size increase in the joints is seldom straightforward, because the roll neck size and separation is usually constrained. Electrical and mechanical engineering design issues frequently must be closely combined in mill upgrade projects.

For foil mill applications utilizing extremely small tensions and at the same time wide tension ranges, Siemens has already successfully implemented AC drive systems.

Features:

• Common software tools for engineering and commissioning all Siemens drives

• IGCT/IGBT frequency converters and integrated vector control

• Operator panel with self- explanatory texts

• Upgrading of DC drives to the technical level of AC drives – through subsequent digitalization

Main benefits:

• Constant strip tension even in highly critical sections

• Smooth strip flow in all operational states with nearly maintenance-free operation – throughout the entire service life

• Quick responses to changes in load – reliable prevention of strip damage

Maintenance-free cylindrical rotor


Automation solutionsComplete process control at every level

Mastering production processes requires fully understanding and mapping them in physical-metallurgical models. Modeling allows you to identify the effects of individual parameters on the entire process. Good models are therefore critical for the precise control of the plant.

Realistic physical models

Siemens Metals Technologies relies on more than 30 years of experience in the development of physical models for rolling processes. Thanks to our continuous collaboration with our customers, universities and metallurgical research institutions, we now have detailed models for the entire rolling process. These provide a solid foundation for our leading automation solutions, especially in the area of aluminium technology.

Pass schedule calculation and mill setup

Based on ingot or strip data and customer target specifications for the finished product, our process control system ensures that your production is fast and efficient. We achieve this through fully automatic pass schedule calculations and intelligent plant setups that are self-adjusting on the basis of measured process data. Such features allow you to avoid production bottlenecks and maximize plant throughput. You achieve shorter production cycles and outstanding material quality right from the very first strip.

Automation Pulpit

A case in point:Perfect temperature control in hot mills

Our sophisticated temperature model takes all physical effects into account, including heat conduction into the work rolls, frictional heating, deformation heating and convective and radiative heat transfer into the atmosphere and cooling water. An intelligent adaptation algorithm refines the heat transfer coefficients (rather than simply applying a correction factor to the final result).

The model takes into account the actual physics of rolling heat transfer through adaptation, results of which can be applied across different plants.


Another example:

Setup calculation for strip threading in cold mills In a cold mill, the phase when the strip is threaded and the mill is accelerated to the desired speed is particularly critical. A wrong initial setting can lead to strip breaks or cause poor mill acceleration.

The setup calculations based on our mathematical models help circumvent this by precalculating the mill setting just before the actual strip is threaded, based on the current mill status.

All necessary aspects such as the roll wear and temperature, initial roll profile and incoming strip profile are taken into account by means of our sophisticated mathematical models. The online adaptation is performed by means of neural-network technology.

Profile and flatness control

Strip geometry involves not only width and thickness, but also profile and flatness measures. To meet the specifications of the market, our profile and flatness control system builds on sophisticated physical models. A roll temperature model, for example, analyzes the asymmetrical conditions on the roll surface, while a material flow model calculates the roll pressure distribution as well as the strip flatness after each pass. Based on this data, the profile and flatness control system makes sure that the finished strip has the desired profile or contour and flatness.

The profile and flatness controllers fully incorporate and exploit the capabilities of available actuators such as SIROLL SmartCrown®, roll bending, SIROLL DSR® and roll cooling.

Custom control systems

MES solution

Siemens Metals Technologies includes a MES (manufacturing execution system) solution specially developed for rolling mills. The MES assists you in aligning production targets with available resources, while simultaneously documenting the production process reliably and completely.


Process optimizationSpecific solutions for your entire plant

Our process optimization, process control and basic automation technology guarantees stable processes and greater system reliability, as well as custom solutions to meet your needs right from the design phase.

Scalable solutions

The Siemens Metals Technologies‘ solutions for the entire automation and drive system are scalable to your specific requirements. Solutions can range from simple pass schedule storage to a complete pass schedule optimization and setup system that includes the generation of all relevant production result data for product quality tracking and analysis.

Automation system

The SIMATIC process control system is based on a unique combination of international industry-standard hardware and software components and expertise in aluminium rolling that has been acquired through decades of experience in mill automation. It provides excellent quality tolerances together with easy service and spare part access and maintenance. The remote access features give you access to support from our specialists no matter where you are.

Technological controls

We offer the full range from AGC/AFC packages to fully integrated mill automation and drive systems. SIROLL ALU includes a complete set of sophisticated control algo rithms for hot, cold and foil applications. All features are carefully integrated with the related drive system and mechanical equipment to enable optimum results.

HMI and diagnostics

The SIROLL automation system provides easy-to-understand HMI (human-machine interface) screens and features targeted diagnostics to provide excellent operator guidance.

Hydraulic AGC: First application on an aluminium mill

SIROLL Edge Wipe: New device to improve strip dryness in cold mills

SIROLL SmartCrown: New actuator for profile and flatness control

SIROLL Heavy Duty Shapemeter:High load bearing capacity for cold mills.

Vidimon air bearing shape roll: Pioneer in use of flatness measurement

RSV sprays: Pioneer in flatness control actuators

Advanced mass flow control

Novel profile and flatness control algorithm for hot mills

SIROLL ISV Sprays: Introduction of pulse-width-modulated sprays

AC main drives in hot mills

Neural networks for process automation

SIROLL SIFLAT: New, noncontact sensor for flatness measurement

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2003SIROLL DSR®: New dynamic flatness control actuator

SIROLL ALU Vapor Shield: Introduction of environmentally friendly technologies


InnovationWe’ve been working to build your future

We’ve pioneered innovation for 100 years and are constantly driving de-velopment forward. For the greatest quality, from the first coil. For ever-thinner foil and higher- quality prod-ucts. The basis for our innovation is the systematic linking of our exper-tise in rolling technology, electrical engineering, automation, IT, process technology and operation. It is our common knowledge base – yours and Siemens’.

Expanding technological leadership - our goal, your advantage.

Stay at the top. Our research and development budget – which is 8% of our annual revenues – is a clear signal that we want to remain your partner for innovation. Our own R&D department, together with the R&D resources of Siemens and the cooperation with leading universities and aluminium manufacturers, helps us further develop innovative solutions that meet our customers’ future market requirements.


SIROLL ALU - Siemens VAI comprehensive Aluminium Portfolio

Hot Rolling - Aluminium our competences along the entire value chain

Innovation DSR® – Powerful Dynamic Mill Actuator

SIROLL ChatterBlock – vibration elimination

Cryogenic Cooling – eliminate kerosene

Energy & Environment VaporShield – VOC collection and recovery

Schneider Filter – No.1 filter technology

SIROLL Green Button

Service Know-how consultancy

Spare and wear parts

Hardware and system software upgrades

Modernization Hydraulic Screwdown / AGC

DSR® Conversion – Quality & Yield Optimisation

SIROLL Roll Eccentricity Compensation

Electrics, Automation & IT Process optimization and technological controls

Efficient mill drive solutions

SIROLL TCS: Technological Control System

Aluminium Hot Mills

Reversing Roughing Mills

Tandem Mills

Twin-Coiler Mills

Plate Mills

Mini-Mills

Aluminium Cold Mills

Single Stand Breakdown Mills

Multi-Stand Tandem Mills

Thin Strip Mills

Aluminium Foil Mills

Roughing Mills

Intermediate Mills

Finishing Mills

Universal Mills

Bright Finish Mills

Innovation SIROLL Smart Crown: Technology Package

Profile / Flatness Control

Automated Roll Bite Assistance

Energy & Environment Roll Coolant Conditioning & Filtration

SIROLL Green Button

Service Know-how Consultancy

Spare and wear parts

Condition monitoring system (CMS)

Hardware and System Software Upgrades (Retrofit)

Modernization Hydraulic Screwdown / AGC

Surface Quality Control

Edger and Heavy Duty Shear

Electrics, Automation & IT Single Source Control, PLC, MCC, Drives, Motors

Efficient mill drive solutions

Comprehensive Temperature Models

Online Level 2 Process Models (hybrid models)

Cold & Foil Rolling - Aluminium our competences along the entire value chain

Records Wide Plate Mill – 4.5m

Wide Twin Coiling Mill – 3m

Excellent results 3 stand FM

Records DSR® - Maximised Yield

Benefits – 1800mpm

Air Bearing Shapemeter – over 1000 sold

Life Cycle Services


During the past five decades we have supplied hundreds of new and modernized mills setting the benchmark for producing quality strip in an efficient manner. The market is ever changing and demands highest yield and tolerances while minimizing environmental impact. Siemens VAI is at the forefront of this challenge.

As a total solution provider the Dynamic Shape Roll DSR© has been developed as a variable force distribution actuator, replacing a conventional solid back-up roll,Improving mill productivity and reducing operating costs.

The DSR© enables you to meet market challenges of today and the future. Your mill will produce a harder, wider and thinner product portfolio ensuring product flatness, increase your schedule flexibility, reduce material breakages and roll changes.

The Intelligent flatness control algorithm uses feedback from the shape roll to generate signals to vary the force distribution across strip width.

The DSR©’s performance is impressive; eliminating undesirable roll contact and stress peaks. The control range is considerably larger than 6hi and contoured roll

Answers for industry.

siemens-vai.com

Focus on Precision, Yield and Green

design mills. True dynamic control is achieved by fast response of the pads to changes in the force distribution reference.

DSR© Benefits:

Yield Savings – Achieves target flatness quicker and retains longer during tail out.

No warm-up coils required during mill start-up or width change.

Rolling passes reduced.

Rolling speed increased.

Productivity increased (product mix dependant).

Number of Back Up roll changes reduced.

Retrofitting of DSR© requires minimal downtime and recommissioning.

Be the leader in the field – with SIROLL ALU solutions fromSiemens VAI, a global supplier and your local partner.

Set the benchmark in Aluminum Rolling!

Visit us at: Aluminium 2014 Messe Dusseldorf, Hall 9, Booth 9E40

ALuminium Dynamic Shape Rolling 2014 V1.indd 1 14/04/2014 14:58


Published by: Global Media Communication Limited t: +44 208 579 0594 e: [email protected] w: globalmediacommunication.com

Siemens VAIMetals Technologies GmbHP.O. Box 4, Turmstr. 444031 Linz, AustriaPhone: +43 732 6592-0siemens-vai.com

Date post:	31-Jul-2015
Category:	Technology
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