AWJ13: Siemens VAI Metals Technologies by GMC Online

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Focus on Precision, Yield and Green Set the benchmark in Aluminum Rolling! siemens-vai.com

We know what we’re talking about when it comes to aluminum rolling. During the past five decades we have supplied hundreds of new and modernized mills that set the benchmark for producing quality strip in an efficient manner. The market is ever changing and now demands highest yield and tolerances while minimizing environmental impact. Siemens VAI is at the forefront of this challenge.

full range of vertically integrated supply packages. With specialized technologies for thickness, profile and flatness control, the strictest quality and tolerance demands are met for all downstream product requirements. At every stage of a mill’s productive lifetime, we have the right solution to ensure that your mill performs at its peak level. Our portfolio includes: New plants and mill modernizations

On the basis of immense process knowhow and engineering experience, Siemens VAI works with our customers to meet their targets for productivity, quality, yield and flexibility.

Complete equipment supply

As a total solution provider, maximum mill performance is assured with the latest equipment design, advanced technological packages, sophisticated electrical, automation, environmental systems, and a

Worldwide, around-the-clock services

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Electrical and automation systems Consultancy services and mill audits Customized mill products

Be the leader in the field – with SIROLL ALU solutions from Siemens VAI, a global supplier but your local partner.

Answers for industry.

Core Competence

The Benchmark in Aluminium Rolling Siemens Metals Technologies is a global leader in the Metals Industry, supplying the world’s metal producers and processors with world class equipment and services. Metals Technologies (MT) in the UK is the global Centre of Competence (CoC) for aluminium and Rolling Mills with responsibility for the engineering, supply, installation and commissioning, and technological development and innovation on a worldwide scale. Siemens MT was established in the United Kingdom 170 years ago and is made up of a merger of a number of companies, namely Loewy Robertson, Davy Corporation, Davy International, Kvaerner Metals and most recently Voest-Alpine Industrieanlagenbau (VAI). The UK team is made up of over 260 highly qualified people with many years of experience based on a strong heritage dating back through the mergers and acquisitions mentioned above. With our sophisticated knowhow and our deep experience in aluminium, ranging from hot rolling to the finished product, including cold rolling and foil mills, Siemens MT can meet both upstream and down-stream demands and build the mill that fits the client’s requirements. • 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 to optimize performance and operational efficiency • Online process models and neural networks will enable you to produce more accurately than ever before

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• Proven automation solutions to maximize your plant’s end-to-end consistency • Reliability and security for the future Siemens MT is the only mill builder with in-house capabilities to bring together the mechanical and electrical technologies in one package. Strategy We use a wide range of specialised technologies such as SIROLL DSR® (Dynamic Shape Roll), SIROLL SmartCrown®, AGC, automatic profile and AFC flatness control along with inhouse technological instrumentation to achieve highest product quality.

Siemens MT supply a range of aluminium rolling mills for hot rolling, cold rolling and foil rolling in various roll configurations and for all strip widths. The full range of cold rolling mills including breakdown mills, tandem mills with two, three, four or five stands and thin strip mills for light gauges including foil roughing are also available. The mill stands are of 4-high or 6-high design and provide the flexibility to cover the complete range of alloys over a wide gauge range. Strip widths are ranging up to 2,100 mm, and future expectations are of widths up to 3,000 mm. Latest references include:• Three Single-stand foil mills for Shanghai Shenhou in 2006 • Single-stand cold rolling mill for Chinalco Henan in 2011

Key to the companies’ success is the Project Management and Quality Management systems which are used within Siemens MT. The systems are based on many years of experience gained from the application in numerous projects and are relevant for both small and larger projects. Project Management ensures for the customer, not only conformity with our quality standards but also that delivery and commissioning take place on schedule, while Siemens MT benefit from the cost and quality control.

• Single-stand cold rolling mill for Chinalco South West Aluminium in 2011

Siemens MT sources equipment from the global market, whilst ensuring that our quality systems are adhered to by the suppliers. Equipment classed as Intellectual Property (IP) is made exclusively in our own workshops. These manufacturing centres are based in Montbrison, France, Shanghai, China and in Worcester, USA. All these specialised shops build the mills components and provide global support for the mill business.

In addition during the last 5 years we have supplied over 200 foil mill Technological Control Systems (TCS) for thickness and flatness control, over 50 system’s were supplied to Dingsheng Aluminium alone.

• Three-stand hot finishing mill for Chinalco Ruimin in 2011 • Three-stand hot finishing mill addition for Novelis Korea in 2011 • Single-stand 4 metre wide plate mill for Aleris-Dingsheng in 2011 • Single-stand hot reversing mill for Chinalco Nela in 2012

The Chinese market continues to grow and is a key market for Siemens MT; this is why Siemens MT has developed a range of foil mill configurations based on a standard design for each mill providing economical solutions, fast delivery and minimised production start-up.

Key Technologies SIROLL Dynamic Shape Roll (DSR®) The SIROLL DSR® has its origins back in the paper industry with the NIPCO roll from Sulzer Escher Wyss. Paper mills have always tended to be much wider than mills in the metals industry and problems of stability occur at widths above 1,800mm. The SIROLL DSR® was developed to give improved control under these conditions. Siemens MT have now taken this technology and extended it into the metals rolling field. SIROLL DSR® replaces 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 the company considers the SIROLL DSR® to be the only truly online dynamic actuator that can enable symmetric and asymmetric changes to the roll gap profile during ongoing production.

Cold Aluminium DSR® Mill at Chinalco Henan Operational benefits of the SIROLL DSR® include:• Head and Tail Flatness – improved yield by achieving flatness guarantees quicker than conventional roll

SIROLL DSR® Sectional Diagram

• Overall Flatness – flatness guarantees of less than 3 I units have been achieved with the SIROLL DSR® • Width Changes - with the SIROLL DSR® it is possible to switch rolling widths by considerable amounts (in excess of 600mm) and to still achieve excellent flatness without any warm-up (transition) coils • Cold Starts - these are particularly impressive with a SIROLL DSR®, body of coil flatness of 8 I units

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after just over 90 metres rolled have been achieved after a prolonged stop-page of sixteen hours on 0.447mm strip at 1,870mm strip width Based on a review of a typical new large cold mill producing around 100,000 tonnes per annum Siemens MT have estimated potential benefits in the order of millions of dollars per year. This of course does depend on the product mix. The savings are approximately evenly divided between the benefits from improvements to the head and tail performance and the ability to minimise out of specification material at width changes.

SIROLL Air Bearing Shapemeter Roll With over 500 references worldwide the SIROLL Air Bearing Shapemeter roll is Siemens MT principle technology for the on-line measurement of flatness for both the Aluminium and Steel sheet and foil applications. The SIROLL Air Bearing Shapemeter roll comprises a series of hardened, precision ground rotors, supported by air film bearings on a stationary stainless steel arbor. This design results in low inertia rotating elements with negligible frictional resistance usually inherent in air bearings, thereby eliminating the need for helper drives. Connected by a detachable pneumatic umbilical cord the electronics are mounted remotely from the roll for easy access and protection from harsh mill environments. An array of jets supplies each rotor with air from a common plenum chamber in the centre of the arbor. The differential pressure measured between the top and bottom of the inside of each bearing is proportional to the load applied to the rotor. Hence, the tension is calculated at each rotor position across the width of the strip to provide the tension profile or ‘shape’ of the rolled strip. Each differential pressure output is measured by means of a high integrity pneumatic transducer, which is remotely located in the transducer

SIROLL Air Bearing Shapemeter Roll Section housing attached to the end of the shapemeter arbor. Each measuring channel has a single moving part, the rotor. All other parts are stationary, including the measurement and signal transfer elements. The signal outputs provide continuous readings that are independent of mill speed allowing a fast signal response and high accuracy even at low rolling speeds.

Key benefits of the SIROLL Air Bearing Shapemeter include:• Lower Cost Solution – Solid type rolls more expensive • Very Low Inertia Rotors – No drive system required • Very Compact Design – Greater installation flexibility • Simple Design – Low maintenance, can be serviced on site by customer • No Electric's in Roll – Pressure Transducers etc mounted in remote Transducer box • Signal Output – Continuous & independent of mill speed

Chinalco Southwest Aluminium Mill

SIROLL Integral Solenoid Valve Sprays (ISV) The SIROLL ISV Sprays is one of the metal industries leading spray valves, with over 300 references worldwide the SIROLL ISV Sprays have been supplied to the rolling industry for over 25 years. Proven extensively in both steel and aluminium industries, the SIROLL ISV Sprays are suitable for all mill types, from hot mills through to aluminium foil mills.

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SIROLL ISV Sprays

The SIROLL ISV Sprays system is designed to apply zone cooling and lubrication to the work rolls. The system removes residual flatness errors and controls the bulk temperature of the mill during the rolling process. Temperature control is achieved by modulating the coolant through individual ISV valves thereby controlling the thermal profile of the work rolls. Nozzle configurations are specifically designed, using advanced thermal modelling, to optimise the spray patterns and coolant flow rates to suit the requirements of the process.

By doing this, the optimal thermal performance may be achieved for each and every application regardless of the rolling duty or individual pass schedules.

Key benefits of the SIROLL ISV Sprays include:-

As a complement to the SIROLL ISV Sprays and to minimise shape errors at the strip edge, Siemens MT also offer an integrated Hot Edge Spray System to spray hot coolant outboard of the strip edge to reduce work roll thermal gradients.

• Robust Design

• Easy Maintenance • Universal Valve for all Mill Types

• Small Installation Envelope • High Reliability • Advanced Thermal Modelling • Stainless Steel Valve

Schneider® Coolant Filtration Coolant filtration is an essential element in the rolling and forming of all metals. Since 2004 Siemens MT has supplied the Schneider® Coolant Filtration system for aluminium hot and cold mills, steel, stainless steel, copper/brass mills and for 2-piece can making plants. The market leader in the design, supply and operation of mineral oil and emulsion coolant filtration systems, Schneider Filtration ‘know-how’ from Siemens MT will improve performance and product quality throughout the rolling and forming process. The very high levels of filtration achieved for both mineral oils and emulsions when using the Schneider® Coolant Filtration system maintains the coolant in ‘as-designed’ condition. The system extends the life of the coolant providing an exceptional sheet surface and foil quality. Specific system design features and auxiliary components are unique to the technology. Today’s modern semisynthetic coolants require a different approach to coolant handling and filtration. Traditional methods do not meet the new demands for cleaner low smut sheets and for the conditioning of the emulsion to keep the coolant to its original design specification. Filtration to and below the oil drop-

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Schneider® Coolant Filtration let size is easily accomplished with specially designed filter cloth media for depth filtration using multiple layers of different media.

Key benefits of the Schneider® Coolant Filtration include:-

Over 1400 Schneider ® Coolant Filtration systems are being used today to roll, Aluminium, Steel, Stainless Steel, Copper/Brass, Titanium, Zinc and similar metals. The Schneider® system has become the industry standard in the rolling and can industry.

• Improved Product Quality

• Improved Filtration Performance – less than 10μm • Patented Green Filter Media safe to handle, no dust hazard • Reduced Waste Streams - zero waste available • Eliminates Coolant Dumps • Low Operating Costs • Improved Process Performance – increased roll life

On-Going Service & Support Service to existing aluminium producers and new customers is critical to capture new business, customers continue to request the following studies:• Plant and Mill Studies – studies to investigate ways to increase plant productivity or change specific mill or product parameters which can help clients choose the most cost effective investment route for future plant modernisation • Mill Performance Optimisation Studies – advice from rolling

process experts on how to improve and optimise mill productivity within the constraints of the existing equipment • Mill Alignment and Condition Studies – measurement and analysis of the status of existing equipment with corresponding report and recommendations • Spares, Service and Training Support – existing Siemens clients can be offered complete product life cycle services including spares, product training and site support from Siemens service engineers

Siemens MT engineering offers the full range of studies as described above and has a number of technological tools and instruments available to provide complete plant analysis, fault identification, FE analysis, and sophisticated reporting. Author: G.Garfitt, BEng (Hons), MIET, CEng, MBA Sales Manager Plate and Aluminium Mills Contact Information: Siemens plc Metals Technologies E- mail: aluminiummill.metals@ siemens.com

Effective project management brings a lifetime of benefits for aluminium producers Author; Albert Renshaw – Senior Project Manager and PM@Siemens UK Champion (RPP), Siemens VAI Metals Technologies For aluminium producers, when building or modernising a production line, the investment amount required is not the only issue to be considered. Any delays to a modernisation or the belated commissioning of a new line means loss of production and financial revenue. Therefore, choosing the right partner for a project is as important as choosing the right technology. A partner capable of providing effective management from conception to production ensures that an aluminium plant is built on-time and according to specification. This is the basis for maximising value. Professional project management provided on a global stage is a core competence of Siemens and a vital success factor for our customers. Project management is the process by which projects are defined, planned, monitored, controlled and delivered such that the agreed benefits are

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achieved. In general, more than 50% of Siemens global sales is projectrelated. In 2001, Siemens embarked upon the global project management programme “PM@Siemens” to support the continuous and sustainable improvement of project management processes in all of its business activities worldwide. The aim was to establish best practice through the application of knowledge, skills, tools and techniques in order to ensure business excellence. Siemens employs more than 15,000 project managers, all working in accordance with the company values of “excellence, innovative and responsible.” The philosophy is simple; there are clearly defined roles and responsibilities for all those involved in a project. The programme ensures that state-of-the-art processes, methodologies and tools are applied in ways appropriate to the complexity of the tasks. By undertaking both comprehensive training and an internal certification process, Siemens safeguards that its project managers are trained and qualified such that they are able to manage a project

professionally. Siemens project managers are empowered to do the right things in the right way and at the right time to accomplish the project goals. As a global partner, this means globally uniform procedures that are always executed in a systematic and professional manner by appropriately trained and qualified staff. As a result of the PM@Siemens programme, Siemens was the first corporate company to have its project management programme accredited by the Association for Project Management (APM), itself one of the largest professional bodies of its kind in Europe. The need to find the right partner for a project has already been emphasised. Siemens VAI Metals Technologies is a life-cycle partner for the metals industry. Its UK headquarters, located in Sheffield, incorporates the plate and aluminium rolling mills businesses, including the associated engineering and technology. Mark Chatterton, Director of the Siemens VAI Aluminium Business, sees many advantages in leveraging the engineering and project

management experience gained by both the Plate and Aluminium Business areas during the recent boom years in the metals market. “Siemens global project management experience is one of our core strengths, which differentiates us from our competitors. The company is driven to ensure that our project management skills are ‘best practice.’ As part of the companywide, global project management programme, both plate mill and aluminium mill project teams have demonstrated these skills through the completion of many complex metallurgical infrastructure projects during the last fve years”. These are exciting times for the Siemens VAI Aluminium Business, as a number of high-profile projects have recently been commissioned and put into full operation. The following examples show the typical breadth and complexity of projects delivered by the Siemens VAI Aluminium group:

Aleris Aluminium Plate Mill This project comprises the supply of a single-stand aluminium rolling mill for Aleris Dingsheng Aluminium (Zhenjiang) Co. Ltd in Jiangsu Province, China. The rolling mill is designed to produce 250,000 tons per annum of heat-treated and non-heat-treated sheets and plates in widths of up to 4.1 meters. It is the first aluminium plate mill ever to be implemented by Siemens. Commissioning was completed in early 2013. The Siemens supply scope included mechanical and electrical equipment for the four-high rolling stand, a hydraulic shear and the roller tables for the new rolling mill.

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New 3-stand aluminium finishing mill for Novelis Korea Ltd.

plants and demonstrate the benefits to be gained from a partner who can offer excellence in project management across all sectors of the industry. Contact Information: Siemens plc E-mail: aluminiummill.metals@siemens. com

Novelis For this project a new three-stand finishing line was added to the existing rolling mill that was originally supplied by Siemens in 1993. The project boosted capacity and enables future production of high-grade aluminum strip for the automobile and beverage can industries. Siemens supplied the mechanical and electrical equipment for this tandem rolling mill, including a coiler and a coil-handling system. Lightweight cropping shears are installed in the entry section of the finishing line. The first coil was rolled in June 2013. The extended hot rolling mill will greatly increase annual capacity and will be capable of rolling strip up to 2,250 millimeters wide with a thickness spectrum from 1.8 to 6 millimeters. Novelis Korea Ltd. is a subsidiary of Novelis Inc. based in Atlanta, Georgia, USA, a leading producer of aluminum and aluminum products. Novelis Inc. operates around 30 production facilities worldwide. The company is the global leader for rolled aluminum products and in aluminum recycling. Recently commissioned projects in China include the 1+4 hot mill at Chinalco Ruimin, the 1+1 hot mill at Chinalco North East Light Aluminium, the cold mill with Dynamic Shape Rolls (DSR) at Henan Zhongfu Aluminium, and the cold mill with DSR at Chinalco Southwest in Chongqing, China. These projects are currently setting the benchmarks for aluminum rolling

Follow us on Twitter at: www.twitter.com/siemensuknews The Siemens Industry Sector (Erlangen, Germany) is the world's leading supplier of innovative and environmentally friendly products and solutions for industrial customers. With end-to-end automation technology and industrial software, solid verticalmarket expertise, and technologybased services, the Sector enhances its customers' productivity, efficiency, and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Divisions Industry Automation, Drive Technologies and Customer Services as well as the Business Unit Metals Technologies. For more information, visit http://www.siemens.com/industry