Siemens VAI Company Profile

Siemens VAI Metals Technologies GLOBAL MEDIA COMMUNICATION LTD.

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Index

3

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

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SIEMENS VAI COMPANY PROFILE

Your challenge: A growing need for plant productivity and quality rolled products

Growing markets

Flexibility is a must

Driven by Asia’s economic growth, the market for alumin­ium 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.

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 prod­uct changes is therefore a vital factor in the economics of aluminium rolling.

Logistic design has to be part of the plant solution, too.

It’s all about quality

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.

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.

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The need to drive costs down

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.

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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

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SIEMENS VAI COMPANY PROFILE

Our solution: Cutting-edge technologies for aluminium rolling mills The 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.

Through the intelligent distribution of functionality, application-specific solutions and globally proven drive concepts, SIROLL ALU guarantees reliable plant operation through­out 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 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.

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.

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.

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Our portfolio at a glance

Strip caster

Combined strip caster and hot rolling mill

Hot-strip rolling mill

Tandem cold rolling mill

Cold rolling mill

Foil mills

Automatic high-bay store

Bright finishing mill

Contents Aluminium Mills Hot Mills Cold Mills Foil Mills

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9-10 11-12 13-14

Supplies and Services Life-cycle management Our Services Modernization Special products Drive solutions Automation solutions Process optimization Innovation

Siemens Metals Technologies offers the full range of aluminium mill solutions 15 16 17-18 19-20 21-22 23-24 25 26

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 SIEMENS VAI COMPANY PROFILE

Roughing stand

Finishing stand

Hot-strip rolling mill

Roughing stand with edger

Tandem finishing train

Slitting line

Tension leveling line

Cut-to-length line

Packaging line

Main benefits: 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.

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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.

• Decarburizing heats with higher carbon levels • Steel can be heated during RH treatment • Quick skull removal using burner function • Low investment and maintenance costs

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Hot rolling mills Advanced technology for high-quality products

Chinalco Ruimin – mill build

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

These include:

Features:

• Reversing roughing mills

• 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.

• 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.

• 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.

• 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.

• 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 know­how to deliver gauge, profile/flatness, temperature and surface quality with the highest level of consistency.

• SIROLL SmartCrown® roll contour guarantees enhanced flatness control.

• For perfect cooling and contour control we provide pulsemodulated work roll spray bars.

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

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Main benefits:

Selected references:

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

Alcan, Pindamonhangaba, Brazil

• Tightest strip thickness, profile flatness tolerances

Alumax, Texarkana, USA

• Maximum yield due to hydraulic edging with automatic widthcontrol functions • High surface quality • Most advanced and innovative automation • Integrated health and safety concepts

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Alcasa, Puerto Ordaz, Venezuela

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

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Cold rolling mills Solutions 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.

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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 particular requirements of your project. Options include SIROLL DSR® backup roll technology, SIROLL SmartCrown® roll technology and 6-high stand design.

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High levels of filtration: Schneider roll coolant filter

Selected references:

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

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

Alcoa, Samara, Russia

Main benefits:

Aluar, Abado, Argentina

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

• Highest production rates

Aluminium Konin, Konin, Poland

• Optimized yield

CBA, Sorocaba, Brazil

• Flexible production

Chinalco Henan, Zhengzhou, China

• The appropriate choice among a range of flatness sensors is available:

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

Chinalco NELA, Harbin, China

SIROLL SIFLAT, a non-contact flatness sensor, ideal for surface critical applications

• Low costs for operation, maintenance, and minimum downtimes

Elval, Inofyta, Greece

SIROLL Air Bearing Shapemeter roll, particularly suited to thingauge finished products.

Alcoa (KAAL), Moka, Japan Alcoa Bohai, Qinhuangdao, China

Comital, Volpiano, Italy

South West Aluminium, Chongqing, China Louisville Thin Strip Mill, United States of America

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

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Foil rolling mills Best quality at the lowest cost

Foil mill, Shanghai Shenhuo, Shanghai, China

Features: Siemens Metals Technologies‘ range of high-performance foil mills combines the latest developments in measurement, 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 highspeed 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.

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 clearances, 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

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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.

Main benefits:

Selected references:

• High production rates

Northwest Aluminium, LongXi, China

• Flexible production • Tight tolerances for strip thickness and flatness

Shanghai Shenhuo, Shanghai, China Varopakorn, Bangkok, Thailand

• Low costs for operation and maintenance, and minimum downtimes

• 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.

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Life-cycle management Partnership never ends

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

• Service contracts • Spare parts and components • Consulting and training • Online and offline maintenance • Maintenance contracting Operation

t stmen inve New

Recycling

tion rniza Mode

• Migration packages • Upgrading and modernization

Siemens Metals Technologies‘ life-cycle services

In the short term:

In the long term:

As a plant operator, you have conflicting needs. On the one hand, your performance 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.

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.

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 costeffective operation of your plant.

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 shortterm and long-term from our life-cycle services.

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Our services Best performance throughout your plant‘s lifetime

Siemens Service Engineer

Best performance throughout your plant‘s lifetime

Our offerings include …

Features:

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

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

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

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

• Stock control and distribution database

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.

Spare parts and components supply

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Our spare parts service specializes in the 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 equip­ment 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.

• Standard packages with measurable client benefits • Dynamic spare parts and material management system • Material information system • Substitution of parts including re-engineering • Service for electrical equipment and automation

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Mill modernization Keeping 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.

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

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

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

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 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 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).

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... 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.

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Selected references: Alcoa, Samara, Russia Alcoa Bohai, Qinhuangdao, China

Novelis Packaging, Bridgnorth, United Kingdom

Alcoa Europe, Kofem, Hungary

Novelis UK, Rogerstone, United Kingdom

Aleris, Koblenz, Germany

Novelis Utinga, Santo Andre, Brazil

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

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Special products Unique 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 experience, 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 inte-­ rfaces deliver a solid foundation for flexibly expanding existing aluminium rolling mills or constructing new plants from a single source. And these solutions are modular in design, making them ideal for efficiently modernizing plants in easy-to-manage projects.

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 asymmetric changes to the roll gap profile during ongoing production.)

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

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 reference. DSR® eliminates undesirable roll contact and stress peaks.

SIROLL SIFLAT

SIROLL DSR® – Dynamic Shape Roll

SIROLL SmartCrown work roll contour

The SIROLL DSR® system from Siemens Metals Technolo­gies is a key technology for enhancing the performance of cold rolling mills. 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

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

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Employing work rolls shifting in conjunction with specially profiled work rolls significantly increases the flatness

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

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SIROLL ISV spray systems

Flatness package measurement for highest surface demands

Our flatness solution includes all required mechanical actuators and measurement and control systems to ensure the highest flatness performance. Depending on the mill type and product mix, the mill stands feature:

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

• Work roll bending

AGC packages

• 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

Siemens Metals Technologies automatic gauge control (AGC) packages combine the hydraulic capsules, servovalves, transducer and control system to create a comprehensive solution.

Mass flow control ensures thickness precision to within a few thousandths of a millimeter.

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

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

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

Coolant collection and filtration systems

• SIROLL SIFLAT – noncontact GLOBAL MEDIA COMMUNICATION LTD.

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 by Siemens 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

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Drive solutions Moving the aluminium industry

Reliable and high quality synchronous main drives for very demanding applications

In aluminium rolling, interruptionfree 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.

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The right way to get your aluminium mill rolling

The selection criteria for the right drive include:

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

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 highend control units we provide the latest, state-of-the-art drive control as well as the right choice for all technological challenges.

• 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.

Application requirements Network conditions Economical aspects Operational issues

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 SIEMENS VAI COMPANY PROFILE

Maintenance-free cylindrical rotor

Features: 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

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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.

• Common software tools for engineering and commissioning all Siemens drives • IGCT/IGBT frequency converters and integrated vector control • Operator panel with selfexplanatory 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

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Automation solutions Complete process control at every level

Automation Pulpit

Pass schedule calculation and mill setup 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.

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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.

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.

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Custom control systems

Another example:

Profile and flatness control

MES solution

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.

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.

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.

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.

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

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Process optimization Specific 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.

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Automation system

Technological controls

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.

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 algo­rithms 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 (humanmachine interface) screens and features targeted diagnostics to provide excellent operator guidance.

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Innovation We’ve been working to build your future

1973

1996

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

Neural networks for process automation

1978 RSV sprays: Pioneer in flatness control actuators

1958 Hydraulic AGC: First application on an aluminium mill

1960

1970

1980

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

SIROLL SIFLAT: New, noncontact sensor for flatness measurement

2001

2009

SIROLL SmartCrown: New actuator for profile and flatness control

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

1991

2003

SIROLL DSR®: New dynamic flatness control actuator

SIROLL ALU Vapor Shield: Introduction of environmentally friendly technologies

1990 1989

1985

1999

AC main drives in hot mills

2000 1996

SIROLL Edge Wipe: New device to improve 1988 Advanced mass flow control strip dryness in cold mills

2010

2004 Novel profile and flatness control algorithm for hot mills

Expanding technological leadership - our goal, your advantage.

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

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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.

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SIROLL ALU - Siemens VAI comprehensive Aluminium Portfolio

Aluminium Hot Mills

Aluminium Cold Mills

Aluminium Foil Mills

Reversing Roughing Mills

Single Stand Breakdown Mills

Roughing Mills

Tandem Mills

Multi-Stand Tandem Mills

Intermediate Mills

Twin-Coiler Mills

Thin Strip Mills

Finishing Mills

Life Cycle Services

Plate Mills

Universal Mills

Mini-Mills

Bright Finish Mills

Hot Rolling - Aluminium our competences along the entire value chain Records Wide Plate Mill – 4.5m

Innovation

SIROLL Smart Crown: Technology Package

Wide Twin Coiling Mill – 3m

Profile / Flatness Control

Excellent results 3 stand FM

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 DSR® - Maximised Yield

Innovation

DSR® – Powerful Dynamic Mill Actuator

Benefits – 1800mpm

SIROLL ChatterBlock – vibration elimination

Air Bearing Shapemeter – over 1000 sold

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

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SIEMENS VAI COMPANY PROFILE

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

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

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.

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.

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.

Rolling passes reduced.

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

Number of Back Up roll changes reduced.

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

Rolling speed increased.

Productivity increased (product mix dependant).

Retrofitting of DSR© requires minimal downtime and recommissioning.

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

Answers for industry.

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Siemens VAI Metals Technologies GmbH P.O. Box 4, Turmstr. 44 4031 Linz, Austria Phone: +43 732 6592-0 siemens-vai.com

Published by: Global Media Communication Limited t: +44 208 579 0594 e: gmcproduction@gmx.com w: globalmediacommunication.com 1

SIEMENS VAI COMPANY PROFILE