Leading Partner in the Fascinating World of Aluminium

Transcription

1 Flat Rolling Plants Aluminium Plants Leading Partner in the Fascinating World of Aluminium Aluminium Rolling Plants, Technology and Services

2 Leading Partner in the Fascinating World of Aluminium Contents Experts in Aluminium Solutions from one source... 4 Partnership and Full Service A perfect symbiosis... 6 Digitalization and Automation The road to a learning aluminium mill... 8 Striving towards superior and consistent quality From isolated applications to a single data warehouse Sustainable Production with Ecoplants Multi-Plate filters and Airwash TM systems Integrated Plants Example Tianjin Zhongwang, China Plate Mills Example Tianjin Zhongwang, China Reversing Hot Strip Mills Example Guangxi Alnan, China Tandem Hot Strip Mills Example Ma aden Aluminium, Saudi Arabia Combo Cold Rolling Mills Example AMAG Austria Metall AG, Austria Tandem Cold Rolling Mills Example Shandong Nanshan, China Mill Modernizations Example ALUNORF, Germany Mill Expansions Example Tianjin Zhongwang, China Aluminium Rolling One Step Ahead: Latest Developments Nexcast Our vision for a next generation minimill Anti Chatter Device ACD Record of Success References Built-in Aluminium Expertise Leading partner in the world of metals

3 Leading Partner in the Fascinating World of Aluminium Experts in Aluminium Solutions from one source Leading partner in the world of metals SMS group is a global, leading partner in the metals industry. As a family-owned business headquartered in Germany, quality and innovation are in our roots. We are committed to the success of our customers and strive to add value along the entire value chain of the global metals industry. The full range from one source The fascinating world of aluminium is part of this. We supply a large range of machinery and plant for producing, processing and refining aluminium and aluminium products. Customized to your requirements, our solutions are designed for efficiency and resource saving. Across-the-board service for integrated systems and components Harmonized mechatronic systems Engineering, production and installation Immediate start-up through plug-and-work solutions Training and after-sales services Upgrading and modernization Financial services Rolling Plants Plate Rolling MIlls Hot Strip Rolling Mills Cold Rolling Mills EDT Rolling Mills Melting and Casting Plants Horizontal and Vertical Casting Plants Single and Multi Chamber Melting and Casting Furnaces Furnace Charging Machines Ultrasonic Testing Equipment Continuous and Batch Homogenizing Plants Sawing, Stacking and Packaging Plants Rolling Ingot Preparation Sawing Lines Scalping Lines Brazing Lines Chip Handling Logistic Systems High-Bay Coil Storage Systems Horizontal Coil Storage Systems Automatic Conveying Vehicles Packaging Equipment Presses Extrusion Presses Forging Presses Plate Processing Sheet and Plate Stretchers Plate Handling Equipment Strip Processing Lines Heat and Chemical Treatment Lines Color Coating Lines Anodizing Lines 4 5

4 Leading Partner in the Fascinating World of Aluminium Partnership and Full Service A perfect symbiosis Financial services SMS group service doesn t start after commissioning. It s much earlier than that. Our experience and reputation mean that we stand by our customers providing financial services helping to open up chances for new investments or modernization projects. Turnkey expertise Either as general contractor or as leading partner in a consortium, SMS group builds turnkey solutions combining innovative plant technology with building and infrastructure, tailor-made logistics and all auxiliary equipment. TECademy Our partnership goes beyond plants and machines. SMS group also cares about your workforce. With the services offered by SMS TECademy, we aim to strengthen you in your expertise as plant owner. Modern and practice-proven training programs are employed in which the focus is clearly on practical benefits. In addition to the standard training courses, the SMS TECademy specialists can also tailor an individual training concept specially geared to your needs, on request. Expanding, consolidating and above all safeguarding know-how is the motto here. Technical service across the process chain The Technical Service Division of SMS group is equipped at 50 locations around the world to offer you customized service packages, in order to boost the productivity of your plant, to reduce downtimes and to ensure the lasting value of your production facilities. The key service highlights are: Spare Parts and Logistics Maintenance and Repairs Upgrades and Modernizations Consulting and Training Aluminium Rolling Plants Financial services Turnkey expertise TECademy Technical service 6 7

5 Leading Partner in the Fascinating World of Aluminium Digitalization and Automation Digitalization and Automation The road to a learning aluminium mill The digital transformation of process automation AluControl AluControl comprises proven modules of the X-Pact electrical and automation systems and is especially dedicated to the process of aluminium production. Digital commissioning of the automation system is already done during the Plug & Work test. The simulation model the digital twin of the plant allows pre-commissioning under realistic conditions. During the training of the customer s staff at the SMS group test field, the reality of working in a real plant is replicated. All operation modes and processes are simulated in real-time and are visualized on the customer s systems by using X-Pact Vision. The innovative X-Pact Vision HMI-concept, its forwardlooking interactions, structures and communication channels within the plant automation ensure safe operator guidance and offer comprehensive tools for system maintenance, diagnosis and trouble-shooting. The vision of a learning aluminium mill, enabling intelligent and largely autonomous production sets the direction into the future. That s why AluControl focuses on the following aspects: Flexible production planning with variable batch sizes meeting production deadlines Intelligent process and production analysis along the entire value added chain Continuously meeting the most stringent product quality demands and at the same time achieving maximum yield Maximization of plant service life with minimum maintenance requirement and low capital tie-up For further information on AluControl take a look at the SMS group website X-Shape precise flatness measurement Core component of the X-Shape flatness measurement and control system is the X-Shape flatness measurement roll, developed by SMS group. It is mainly characterized by the following features: Measurement roll with four bore holes according to the best available technology Mark-free measurement by closed roll shell Maintenance-free signal and power transmission technology Free configuration of sensor arrangement and selection of width of measuring zones Model based evaluation of X-Shape analyzer raw data Measurement zone up to 3000 mm width max. 96 sensors AluControl Digital Transformation Digital Twin Learning Aluminium Mill Production Planning Product Quality Plant Condition Machine Learning Leading Automation Expertise Artificial Intelligence X-Shape flatness measurement roll. Since 2009, SMS group has supplied more than 100 X-Shape measurement rolls to customers in the entire world. 8 9

6 Leading Partner in the Fascinating World of Aluminium Digitalization and Automation Digitalization and Automation Striving towards superior and consistent quality Advanced production planning with X-Pact MES 4.0 X-Pact MES 4.0 is a state-of-the-art, intelligent planning tool for manufacturing execution based on optimization algorithms and artificial intelligence. Combined with SMS group domain know-how, it helps customers create optimized production processes that boost their business success. Today s generally centralized and inflexible medium to long-term production planning will in future be replaced by the learning aluminium mill with real-time, self-optimizing production planning. X-Pact MES 4.0 offers the dynamic optimization of production planning processes in respect to four key performance indicators: output, delivery performance, product in stock, and cost efficiency. The core features also include the X-Pact Business Intelligence application with interactive analysis options and an extensive, advanced web reporting system. This provides a very clearly structured and comprehensive dashboard visualization of the production processes and the use of associated inputs, in addition to processing the information to the desired level of detail. PQA Product Quality Analyzer PQA has been set up as advanced process and quality assurance software by MET/Con, a member of SMS group. PQA perfectly combines the comprehensive process know-how of MET/Con experts with efficient quality assurance software particularly adapted to the needs of the metallurgical sector, to create powerful technology for the aluminium industry. PQA documents quality data and quality relevant process parameters for all products along the process chain from aluminium casting up to the finished product and analyzes them continuously. Among other things measured values and results as well as complex criteria for the analysis are included. Should deviations in quality standards occur, PQA gives advice on corrective action. Clear instructions enable you to take appropriate countermeasures in good time. The key features of PQA are: Data recording of all relevant process systems (Level 2, Level 3 etc.) and storage in a central data base Automatic quality check of products and report generation (quality monitor) Automatic rejection of substandard coils Generation of quality and approval certificates The substantial advantages are immediate detection and elimination of quality defects, improved process stability and yield increase as well as improved customer acceptance, due to continual documentation of the entire production process. Production Report with X-Pact Business Intelligence PQA Product Analyzer For further information on X-Pact PQA take a look at the SMS group online magazine

7 Leading Partner in the Fascinating World of Aluminium Digitalization and Automation Digitalization and Automation From isolated applications to a single data warehouse Smart Maintenance Relating to the subject of digitalization and maintenance there are different approaches, software products and solutions. We help you to follow the path that s right for you. Our concept aims to merge all information from isolated applications to a single data warehouse. SMS group s Smart Maintenance Solutions will link the recorded production data with the actual machine status. Relevant criteria will not only be registered but also identified and analyzed. Due to the modular system, both worlds operator and OEM are united. They are combined in one single data warehouse. Digitalizing plant maintenance schedules step by step. Your benefits: Analysis of software tools, data bases and plant maintenance processes Recommendations for relevant data and potential for improvement Provides basis for informed decision making Plant Monitoring with Genius CM The SMS group Genius Condition Monitoring System is a modular, online plant monitoring system. The system monitors and documents the current condition of components susceptible to malfunction and wear. The advantage over traditional inspection and maintenance methods lies in the continual monitoring of plant components. Smart Maintenance Solutions Operators are kept informed on the current situation and are alerted where critical situations arise. Genius CM opens up completely new dimensions in optimizing quality and reliability. In contrast to other analysis systems, the Genius CM compares the acquired measured values with process data. EDI Customer ERP-System Interface ERP 4.io Smart Parts IMMS Data Mining Service In-depth Reporting ERP Level 1+2 Plant Automation IMMS Centric Integrated Maintenance Management System PDW Product Data Warehouse edoc Electronic Documentation and Spare Parts Catalogue EDI Supplier ERP-System Interface Process Monitoring Genius Analytics In-depth Reports GENIUS CM Condition Monitoring Virtual Training Center Maintenance Training CRM Customer Relation MES 4.0 Level 2 Virtual Field Service Support Remote AR Support REX Reliability Engineering Consulting Webshop Repair Services SMS group Workshops PQA Quality Monitoring Management my.sms-group.com TOS Technical Outsourcing 3D-Print Additive Manufacturing Methods Remote Support These results are checked against tolerances and an alarm is triggered when a limit value is exceeded. Considerable damage due to overloading, or incalculable consequential damage is thereby prevented. Relevant online Genius CM modules for aluminium rolling mills: MDVA Condition monitoring system for bearings and gearboxes MiDaS Chatter monitoring for fast operating cold rolling mills TmM Temperature monitoring Customer premises Smart Maintenance SMS group premises 12 13

8 Leading Partner in the Fascinating World of Aluminium Sustainability Sustainable Production with Ecoplants Multi-Plate filters and Airwash TM systems Spiraling energy costs, government restrictions on emissions, and limited resources: Going green makes business sense. The SMS group s answer is the ecoplants label. It indicates especially environmentally -friendly solutions. It shows exactly how thoroughly we are behind the concept of sustainability as a key growth factor - not only for ecological reasons but for economic ones too. Looking at the process of aluminium rolling, SMS group offers proven solutions that help to keep the process clean and efficient by reducing operating media consumption and emissions, increasing the recycling potential. Multi-Plate filter for rolling oil cleaning Benefits Efficient cleaning of contaminated rolling oil, up to 0.5 μm Compact modular design, fully pre-assembled and tested Very good accessibility and maintainability of all components Automatic filter cake removal Airwash TM systems for exhaust air cleaning Benefits Scrubbing of oil contaminated exhaust air by means of washing oil in an absorption process Rectification of contaminated washing oil and recovery of rolling oil Continuous & closed circuit operation Recovery of oil: > 90% Payback period < 2 years For further information on Airwash systems take a look at our brochure on Ecoplants solutions, p. 20/21. For further information on MultiPlate filter systems take a look at our Newsletter 2016/01, p. 59. Airwash TM System 14 15

9 Leading Partner in the Fascinating World of Aluminium Expertise Integrated Plants Example Tianjin Zhongwang, China System supplier One of China s largest production facilities for rolled aluminium products has been built in Tianjin. It has been realized in two construction stages, being put into operation in 2015 and SMS group was involved as an integrated supplier for mechanical equipment, electrical and automation systems and utility systems for complete aluminium production facilities. Integrated plant means flexible production Tianjin Zhongwang Aluminium Co. Ltd. is able to serve all market requirements where high quality rolled aluminium products are demanded. In addition to the hot and cold rolling mills, SMS group supplied several ingot scalpers, plate stretchers, strip processing lines and high bay storage systems. Rolling mills of the first construction stage Hot rolling mill (HSM 1) Capacity > 500,000 t/y 2 Single stand cold rolling mills (CRM 2 & 3) Capacity > 250,000 t/y Rolling mills of the second construction stage 1+5 Hot rolling mill (HSM 2) Capacity > 1,000,000 t/y 2 Three-stand tandem cold mills (TCM 1 & 2) Capacity > 600,000 t/y 2 Single stand cold rolling mills (CRM 4 & 5) Capacity > 400,000 t/y For further information on the Tianjin Zhongwang project take a look at our video. Aluminium flat production complex of Tianjin Zhongwang

10 Leading Partner in the Fascinating World of Aluminium Expertise Plate Mills Example Tianjin Zhongwang, China Technical data Aluminium plate mill No. 1 Technical data Aluminium plate mill No. 2 The growing demand for ecological and economical transportation heightens the need for durable lightweight material. The designers of aircrafts, ships, trains or trucks are increasingly seizing the opportunities that wide aluminium plates and sheets offer. Tianjin Zhongwang have established a production facility for extra wide plates of up to 4.3 metres to serve local and international markets. The hot rolling line No. 1 supplied by SMS group offers great flexibility by featuring two plate rolling mills in one line. Both plate mills can be operated separately or in combination. Material Plate width Ingot thickness (entry) Aluminium and aluminium alloys AA 2xxx, AA 5xxx, AA 6xxx, AA 7xxx 1,240 4,300 mm mm Material Plate width Ingot thickness (entry) Aluminium and aluminium alloys AA 2xxx, AA 5xxx, AA 6xxx, AA 7xxx 1,300 2,900 mm mm Plate thickness (exit) Capacity mm 275,000 t/y Capacity 60,000 t/y (plate/shates) 215,000 t/y (hot strip) Plate mill No. 1 in 4-high design is mainly producing aluminium plates for advanced applications

11 Leading Partner in the Fascinating World of Aluminium Expertise Flexible for hard aluminium alloys For rolling aluminium plates, the preheated ingots are inserted into plate mill No. 1. It is possible to turn and centre the ingots for widening before the first pass. Even wide aluminium plates can be produced on plate mill No. 1. In reversing mode, the aluminium plates are rolled down to deliver thicknesses from 260 to 8.0 millimetres and widths up to 4,300 millimetres. Between the reversing passes, the plates are cropped to ensure optimum quality. Finally the plates are lifted off by a gripper. Automated flexibility In fact, the plate production at Tianjin Zhongwang is very flexible. After cutting daughter plates off, different target thicknesses can be rolled. Narrower plates can be produced by a combined use of both plate mills. The X-Pact AluControl electrical and automation systems by SMS group make sure that the challenging production process runs completely automatically. The quality of the plates is outstanding. This is especially true for those in hard aluminium alloys, being specifically for applications in railway and commercial vehicles, aerospace and ship industries. Exit side view on plate Mill No. 1. Entry and exit side are equipped with strong side guides

12 Leading Partner in the Fascinating World of Aluminium Expertise Reversing Hot Strip Rolling Mills Example Guangxi Alnan, China A reversing hot finishing mill is the most economical hot rolling mill solution for low or medium size outputs. It can be built as a Hot Compact Mill, where the roughing and the finishing rolling passes are all performed on one mill stand. For higher output and flexibility a separate roughing mill is located in front of the reversing finishing mill and only the typically 3 or 5 coiling passes are rolled here employing two strip coilers. The hot rolling mill at Guangxi Alnan Aluminium Fabrication Co., Ltd., supplied by SMS group, is one of the most efficient facilities worldwide for producing special rolled aluminium products mainly for applications in the shipbuilding, container, automotive and aircraft industries. New rolling stand with innovative technology It is designed as a hot rolling mill, which means it consists of a plate/roughing stand and a finishing stand. SMS group equipped the hot rolling line with X-Pact AluControl electrical and automation systems, including the level 1 process controls as well as the technological models of level 2. The plate/roughing stand is equipped with one of the most powerful drives worldwide for aluminium mill stands and is able to produce plates with widths of up to 3,800 millimetres in a thickness range between 8.0 and 260 millimetres and a maximum length of 38 metres. High-quality aluminium plates and strips The reversing finishing mill comes with proven CVC plus technology. The finishing stand is able to produce up to 2,900 millimetre wide coils with a final strip thickness between 2.2 and 12.0 millimetres. The maximum coil weight is 31 tons. An edger, two dividing shears and an automatic plate piler able to move plates from 4 to 38 metres in length and a weight of up to 31 tons supplement the rolling line Finishing mill of Guangxi Alnan Hot mill configuration ( ) SMS group is a world-class company. It is highly reputed, has an excellent design team and outstanding manufacturing facilities. Second, SMS group has a quality management system for the complete manufacturing process. This combination of rolling-technological know-how and sophisticated manufacturing possibilities creates plants enabling us to satisfy our demands on the production of high-quality products. Yulin Zheng, President of Guangxi Alnan Aluminium 22 23

13 Leading Partner in the Fascinating World of Aluminium Expertise Tandem Hot Strip Rolling Mills Example Ma aden Aluminium, Saudi Arabia A multi-stand hot finishing mill is the ideal tool to produce can body stock with the most suitable metallurgical properties for high yield (low earing ). At the same time, the tandem mill is flexible enough for producing all other grades including automotive sheet of the finest quality, at high output levels. One of the most ambitious Greenfield projects was realized in Ras Al Khair, Saudi Arabia by a joint venture between US aluminium producer Alcoa and the Saudi Arabian Mining Company, known as Ma aden. Today, the company is operating under the name Ma aden Aluminium. Intelligent configuration and automation SMS group was a major supplier of flat rolling and strip processing equipment. The hot rolling mill configuration comprises a roughing stand and a four-stand finishing mill. The roughing mill operates in reversing mode with a maximum speed of 270 metres per minute. Between the passes, the deformed strip head and tail ends are cropped by a heavy hydraulic shear for quality reasons. After the final roughing pass, the strip end cropping is performed by a light shear. Now, the strip is ideally prepared for the finishing mill. Main technical data Roughing mill Material Ingot width Ingot thickness Ingot length Aluminium and Aluminium alloys: AA3xxx and AA5xxx series 1,050 2,100 mm mm 5,000 9,000 mm Ingot weight Roll force Rolling speed Transfer bar length Transfer bar thickness max t max. 40 MN max. 270 m/min. max. 200 m min. 33 mm View from the exit end on the hot rolling line

14 Leading Partner in the Fascinating World of Aluminium Expertise The state-of-the-art adjustment systems are responsible for the strip profile and for the constant strip flatness and gauge within the narrowest tolerances. All four finishing mill stands at Ma aden Aluminium, and also the roughing stand, are equipped with hydraulic gap adjustment and work roll bending systems. The finishing stands also have the proven CVC plus technology with axial work roll shifting. The finish-rolled hot strip is edge-trimmed and then carefully coiled with the help of a belt wrapper for thin strips. The hotrolled strip can now be further processed into can stock or automotive grades via the production routes with either a four-stand tandem cold mill or a single stand cold rolling mill with combined heat treatment and chemical coating line, all supplied by SMS group. Main technical data Finishing mill Roll force max. 40 MN per stand Rolling speed max. 600 m/min. Strip width 1,050 2,100 mm (trimmed) Strip thickness mm Coil weight max. 32 t X-Pact AluControl AluControl is the digital centerpiece of the X-Pact electrical and automation system for aluminium rolling mills. It comprises operating and sequence controls as well as controls for ancillary components such as rolling oil system, low-pressure and high-pressure hydraulic units. With its proven Plug & Work method for testing and optimizing the complete automation technology including all operating modes in cutting-edge test environments and simulations prior to shipment, SMS group is clearly ahead of its time. Work Roll Brush for excellent strip surface quality The work roll brushes keep the rolls free from aluminium oxide pick-up. This ensures excellent strip surface quality and longer-lasting work rolls under the given surface finish requirements. The brushes oscillate across the work roll barrel and guarantee uniform cleaning of the roll surface. Due to a special low-vibration design, the work roll brushes achieve an excellent cleaning effect. Benefits of the work roll brush: Hydraulic oscillating drive Contact force and position control Long brush lifetime Compact arrangement Arrangement of work rolls fitted with work roll brushes. Main pulpit of the finishing mill

15 Leading Partner in the Fascinating World of Aluminium Expertise Combo Cold Strip Rolling Mills Example AMAG Austria Metall AG, Austria AMAG has expanded its Ranshofen headquarters to one of the most advanced locations of the European aluminium industry. Europe s most advanced cold rolling facility AMAG is focusing on increasing market requirements for high tech materials and grades for special industrial applications, such as automotive body parts or aircraft industries. SMS group supplied major production equipment including cold rolling mill, heat and chemical treatment line, high-bay store and packaging line. Since April 2017, the CVC plus 6-high cold rolling mill has been operating. It is designed to serve the highly flexible production strategy of AMAG. The mill is able to roll the entire spectrum of aluminium grades and aluminium alloys in widths up to 2400 millimetres and final gauges down to 0.2 millimetres. Apart from SMS group s most modern actuators for roll gap setting, the mill is fitted with some ground-breaking technologies setting new standards in the cold rolling of aluminium. One of Europe s most advanced aluminium cold rolling mill is operating in Austria

16 Leading Partner in the Fascinating World of Aluminium Expertise EDT Rolling Inductive Heating Dry Strip System (DS system) Inline Inspection SMS group developed the plant s combined reduction and EDT rolling in order to meet car manufacturer s requirements. Highly formable 5xxx-series alloys, being mainly used for inner car body parts and 6xxx-series, primarily for exposed external parts can be processed in one and the same mill. In EDT mode an isotropic strip surface with approx µra roughness is produced by transferring the roughness of EDT-machined work-rolls onto the strip surface during a soft reduction pass using lower rolling forces. The combo mill can be flexibily operated either in heavy-force reduction modes or in lightforce EDT mode. The innovative inductive edge heating system is SMS group s most efficient solution for preventing tight edges occurring during the cold rolling process of aluminium. Benefits Highly-accurate heating of work rolls in the strip edge area Sufficient heating effect, even at high work roll temperature Significant reduction of energy consumption compared to conventional Hot Edge Spray System (HES) In order to dry the strip surface as thoroughly as possible after rolling, a DS system is installed on the exit side of the mill stand. Conventional blowoff systems are very noisy and use large amounts of compressed air. SMS group optimized the design of the DS system. Benefits Reduction of residual fluid on the strip surface Minimization of staining and therefore reduced number of downgraded strips High resource efficiency of operation Significantly reduced noise level Increased yield Top blow-off system The production process of valuable high-grade aluminium strips requires fast response times where tolerance limits are reached to prevent downgrading of coils. SMS group provided AMAG s cold rolling mill with the latest inline inspection system, equipped with innovative features and several benefits: Positioning of the strip samples by fully automatically operating manipulators for inspection of the upper and the lower side of the finished strip Fast surface inspection in order to detect surface faults as soon as possible Operation either stand-alone or in combination with a conventional offline inspection Coolant-separating and return-line Bottom blow-off system Design of the inline inspection system featuring fully automatic sample handling. Roughness transfer onto the strip surface after EDT rolling pass. Inductive heating of the work roll barrel. Exhaustion (vacuum system) Basic design of the DS system by SMS group. For further information on recent inline inspection sys-tems take a look at our video details from 01:41 to 01:57. AMAG s Continuous Heat and Chemical Treatment Line supplied by SMS group

17 Leading Partner in the Fascinating World of Aluminium Expertise Tandem Cold Rolling Mills Example Shandong Nanshan, China Chinas first three-stand tandem cold mill The first three-stand tandem cold mill (TCM) for aluminium ever installed in China has been operating successfully at Shandong Nanshan Aluminium Company since June 2012 in Yantei, province of Shandong. SMS group supplied the TCM which means a capacity boost of 340,000 tons per year thus helping to increase the market share of one of China s leading Aluminium producers, especially in can stock. Capacity boost The aluminium strips are up to 2,100 millimetres wide and are rolled down to final gauges of 0.15 millimetres. To ensure top strip quality and optimized yield, the TCM is provided with the full range of modern actuators, adjusting elements and technical controls. All three 6-high stands incorporate CVC plus technology by SMS group. Coil preparation station, coil inspection line and pallet conveyor system complete the rolling line. Innovative filter and exhaust-air purification systems guarantee that the highest environment protection standards are met and resources are saved. Furthermore, the TCM is fitted with four Multi-Plate filters for optimal rolling oil cleaning plus a powerful Airwash TM exhaust air purifications system. Exit side view on China s first three-stand TCM

18 Leading Partner in the Fascinating World of Aluminium Expertise High Efficiency Cooling (HEC) Cold rolling of aluminium strips in Nanshan s multistand tandem mill is performed by using rolling oil as lubricant, which is characterized by its flammability, causing limitations in productivity. In order to overcome these limitations, SMS group developed an innovative inter-stand cooling system, called high-efficiency cooling (HEC), providing high strip cooling and therefore greatly reducing the risk of ignition. The system comes with special features and benefits: Addition of a strip channel with counter-flow of rolling oil to facilitate convection cooling Significant increase in rolling speeds Up to 20 % increase in productivity Double Ironing Roll An important quality feature of the cold rolled strip is the shape and the stability of the coil and the coiling accuracy. Therefore SMS group equipped the tension reel with a double ironing roll. During the winding process the double ironing roll ensures the finished strip is being wound precisely and tightly, i.e. without any air trapped causing non-uniform coiling. Benefits of this exit side feature are: Strip surface protection during winding Stable coil eye and coil stability right from the beginning of winding Providing best coiling quality for downstream processing All TCM stands are designed as 6-high featuring CVC plus technology. High efficiency cooling (HEC) equipment. Coiling process supported by double ironing roll. Ensuring accurate winding and preventing air inclusions

19 Leading Partner in the Fascinating World of Aluminium Mill Modernization Mill Modernizations Example I ALUNORF, Germany Aluminium Norf GmbH (ALUNORF) is operating one of the world`s largest integrated aluminium smelter and rolling mills at a single site in Neuss, Germany. Expanding market opportunities Hot rolling line 1, supplied by SMS group started production in ALUNORF defined a modernization agenda in order to increase capacity and improve quality standards and to make production planning more flexible. ALUNORF engaged SMS group as supplier. Three modernization steps were carried out, each with well-defined performance targets. The modernization started in 2012 and was completed in Three steps into a bright future Step 1 Upgrade of the roughing mill Significant increase in the roll gap adjustment traversing speed from 32 to 56 mm/sec. Shortening of reversing sequences Increase in roll force from 30 to 45 MN Increase in production of up to 4.5 % per year Step 2 Replacement of edger mill Roll force increased to 12 MN Significantly reduced rolling ingot transport distances and operating cycles through new edger mill attached to the roughing mill Step 3 Extension of the finishing mill New powerful first mill stand featuring e.g.: 4-high design, HGC, positive and negative work roll bending, Sieflex -HT gear-type drive spindles. Thus extending the 3-stand mill into a 4-stand finishing mill. For further information on the ALUNORF project take a look at our video. Benefits of the modernization Identification and exploitation of hidden potential of a 50 year old hot strip mill Significant increase in production capacity Elimination of bottlenecks Prepared to meet toughest future strip quality requirements Modernization process Step 1 Step 2 Step 3 Upgrade of the roughing mill Shut-down time 8 days Replacement of the edger mill Shut-down time 21 days Extension of the finishing mill Shut-down time 19 days 36 37

20 Leading Partner in the Fascinating World of Aluminium Mill Expansion Mill Expansions Example I Tianjin Zhongwang, China Chinese aluminium producer Tianjin Zhongwang Aluminium Co. Ltd. is operating two high-capacity hot rolling lines supplied by SMS group. Expanding market opportunities In 2018, one of the two lines in configuration, consisting of two reversing roughing stands and a threestand finishing mill, received a further finishing stand. SMS group completed the line expansion to configuration during a shutdown period of only 23 days. Ready for the complete range of aluminium hot strip grades Being in the first position of the finishing train, the new, high-performance stand does a major part of the forming work. Therefore the new stand F1 is provided with upto-date rolling technologies by SMS group, featuring the latest actuation and control systems, such as: CVC plus (Continuously Variable Crown) roll shifting technology X-Pact AluControl electrical and automation system Hydraulic actuation systems and cooling, lubrication, measuring and cleaning systems Modification of related auxiliary equipment Especially for low-temperature rolling, a newly developed blow-off and suction system has been installed in the exit section of the finishing mill. Benefits of the expansion The newly added finishing stand provides: Rapid start-up and regular three-shift production within only three days after commissioning High flexibility needed to roll the complete range of aluminium hot strip grades in widths of up to 2,900 millimetres and thicknesses between 2.2 and 12.0 millimetres Modernization process Operating phase 1 23 days Operating phase Configuration High-speed Modernization Additional Finishing Stand Configuration Mission completed. The successful modification is the result of well-coordinated teamwork between Tianjin Zhongwang Aluminium Co. Ltd. and SMS group. Positioning of the completely preassembled and wired module of the mill stand platform

21 Leading Partner in the Fascinating World of Aluminium Digitalization and Automation Aluminium Rolling One Step Ahead: Latest Developments Nexcast Our vision for a next generation minimill Conventional mill Nexcast Cost benefits Conventional mill equipment Nexcast equipment We strive to be the leading partner in the fascinating world of aluminium. This is why we provide you with the world s most advanced aluminium production equipment. Continuous improvement of plants, technologies and processes as well as developing new ideas is a genuine part of our business. We are constantly working on ways to simplify process routes and to improve product quality and yield to make your business more profitable. The following examples reveal latest highlights of what our research and development experts are creating for you. Plant layout of the compactly designed nexcast minimill. The length of the complete line is only 125 meters, whereby the width is only 55 meters. SMS group s minimill concept is the next generation of the successful block caster. It has the potential to revolutionize the aluminium industry. The next minimill generation comes with stunning advantages. Competitive costs Low investment and conversion costs for medium size outputs. Suitable for market entry and expansions. Flexible production Output and product specification adjustable to dynamic market conditions. Short lead time from order to coil shipping. Reliable operation Application of a successful process. Upscaling to modern product dimensions and process speeds. Wide product portfolio Transparent HT and NHT alloys close to DC product characteristics. Provision for future progressive alloys. Capex per ton 0-40 % Annual output (kt/a) CAPEX-comparison between conventional mill with Nexcast. Efficient solutions The combined casting and rolling of aluminium strip has the potential to substantially enhance efficiency in aluminium production. Basically the nexcast minimill concept comprises strip caster, hot rolling mill and downcoilers. One of the advantages is the compact design. The length of the entire casting/rolling line is only 125 metres, and therefore 25% compared to the total size of a conventional hot rolling mill. DC casters Block caster Ingot saw - Ingot scalper - Reheat furnaces hot mill 2-stand hot mill Auxiliaries Auxiliaries Nexcast saves approx. 40% of capital cost per ton of installed casting/hot rolling capacity compared to conventional DC mills. Nexcast provides > 25% direct conversion cost savings (depending on alloy and overall process) for the production of hot rolled strip. Nexcast basic line concept Caster Block re-cooling Cooling block Tundish Nozzle Tip Cooling block carrier with chassis Design of the strip caster

22 Leading Partner in the Fascinating World of Aluminium Digitalization and Automation Latest Developments Anti Chatter Device ACD Active vibration damping in cold rolling mills In cold rolling mills chatter vibration can interfere with strip quality parameters such as thickness, shape, surface quality and others. Since vibration can occur at higher speeds, in most cases the rolling speed in particular of multi-stand mills has to be limited. The most critical vibration issues when running cold rolling mills are the 3rd octave chatter (100 Hz 160 Hz) and the 5th octave chatter (> 600 Hz). Looking at the 3rd octave chatter, several characteristics have to be mentioned: Process instability mainly in the last mill stand Self-exciting Vertical roll stack and entry strip tension vibration Strip exit thickness fluctuation This is why SMS group has developed a chatter management system, which consists of two key features. An automatic chatter detection and slow-down function, carried out by the Genius CM Chatter Plus Monitoring. After the 3rd octave chatter is detected by the monitoring system, the motor speed is decreased by the automation system within a reaction time of less than 100 milliseconds. The second feature of the anti-chatter device ACD is to apply a counteracting vibration using piezo actuators with the same frequency but with a 180 degree phase shift in relation to the undesired chatter vibration. This provides effective damping. A pilot installation using the new active damping technology was initiated in 2017 on an operating 4-stand Aluminium Tandem Cold Mill built by SMS group. Operational results taken in July 2017 show a significant reduction in acceleration amplitudes in the chatter frequency range using the anti-chatter device. The pilot installation shows an increase in the chatter-limit speed by more than 300 m/min., which creates a significant production increase for the reference mill. 3 rd octave chatter Anti Chatter Device F w Control system Sensors h 0 v0 h 1 v 1 z 1 Signal processing z 0 Actuators box with force measurement l 0 F w Actuator box during operation test in the SMS group workshop in Hilchenbach (Germany). Actuator box Anti chatter device with piezo actuators and vibration control

23 Leading Partner in the Fascinating World of Aluminium Record of Success References 16 Marketleader Plate and Roughing Mills 13 Marketleader Hot Reversing and Tandem Finishing Mills New and modernized plants References since 2005 As of June Marketleader Tandem Cold Rolling Mills Marketleader Single-Stand Cold Rolling Mills and EDT Mills Media and Environmental Systems 44 45

24 Leading Partner in the Fascinating World of Aluminium Built-in Aluminium Expertise Leading partner in the world of metals Aluminium Rolling Plants Integrating the mill builder s know-how into the controls Supplying aluminium rolling mills for more than 50 years Widening your view with Industrie 4.0 solutions Committed to engineering and manufacturing excellence Producing quality all along the line Let our X-Pact automation system take over control. For consistent product quality. Let know-how advance your expertise. The TECademy offers expert training courses tailored to your needs. Let X-Pact MES 4.0 support you in planning and managing production orders, plants and processes. Let the quality of custom-built aluminium plants convince you and your customers. Let yield be increased and rejects be minimized PQA analyses your product quality along the process route

25 SMS group GmbH Flat Rolling Plants Aluminium Plants Michael Schäfer Wiesenstraße Hilchenbach, Germany Phone: Fax: Internet: W E SMS group GmbH Published on Circulation 1,000 MM Printed in Germany Ky The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may changes as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.