modernization of cold rolling mills

EXTRACTS FROM VARIOUS NEWSLETTERS

MODERNIZATIONOF COLD ROLLING MILLS

CONTENTS SMS group Extracts from various newsletters

2

SMS Siemag is the right partner for modern-izations of cold rolling mills. This has been proved by numerous references during the last few years, some of which are shown in this magazine.

14 Bilstein Four-stand tandem mill modernized

16 Rasselstein Tailor-made modernization

17 Rasselstein, Andernach Modernization of tandem mill

18 Ilva, Cornigliano Continuous exit section installed

19 Ilva, Novi Ligure Higher drive power

20 TKS, Dortmund Modernization of PL-TCM

4 Intelligent solutions for cold rolling mills

6 CARBON STEEL

8 OAO Severstal Higher yield and better quality

10 Ruukki Tandem mill to receive

upgrade

11 ArcelorMittal Brasil Expansion of cold strip capacity

12 Bilstein Smart upgrade concept

21 Rasselstein, Andernach Relocation and revamp

21 ArcelorMittal, Genk Revamping of reversing mill

22 Wickeder Westfalenstahl Fire damage remedied as fast as possible

24 International Steels Limited Increasing annual

capacity by 40 percent

25 KYCR Coil Industries Expansion of reversing

cold mill

Contents

CONTENTS

3

33 ThyssenKrupp Nirosta Düsseldorf For quality and stainless-steel strip

34 ArcelorMittal, Genk Revamp of “CRM 4” completed

36 Theis Kaltwalzwerke A world’s first: CVC plus® in multi-roll stands

37 ThyssenKrupp Nirosta Dillenburg Higher productivity

38 Register

26 STAINLESS STEEL

28 Outokumpu Prepared for new requirements

29 VDM Werdohl Large product unit

30 Revamps in Torshälla, Terni and Krefeld Experience that counts

32 ThyssenKrupp Nirosta Düsseldorf Smooth modernization

IMPRINTPublisher SMS group

Corporate Communications

Eduard-Schloemann-Straße 4

40237 Düsseldorf, Germany

www.sms-group.com

Cover photo Bilstein GmbH & Co KG,

Germany. Operator controls mill

operation of the comprehensively

modernized tandem cold mill.

Order PDF version under [email protected]

Digital reading

COLD ROLLING MILLS SMS group Extracts from various newsletters

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“Rotary Inspect“ inline inspection station. Bending and shifting systems.

Automatic work roll change device.

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INTELLIGENT SOLUTIONS FOR COLD ROLLING MILLS

After the global steel boom of recent years, the market is going through a phase of consolidation. Now is the right time to bring old plants

up to the state of the art to prepare for future tasks and challenges.

As a supplier of plant and equipment, SMS Siemag offers its customers not only integrated and new plants, but of course also intelligent solutions for the modernization of existing works. For this, our portfolio includes exten-sive technology packages as well as extra facilities for mechanical equip-ment, utilities, electrics and automa-tion – all from a single source. With

the right partner for modernizations:

Preparation of tailor-made modernization concepts Competent project teams Decades of experience in the con-struction and modernization of cold rolling mills Exact planning over the entire project handling time Extensive pre-assembly plus test-ing in our shops Assignment of experienced erection and commissioning teams

iSMS SIEMAG

Hydraulic valve stand module.

reference to some recent examples, we would like to present various solu-tions for different types of plants.

The modernization of cold rolling mills necessitates concepts that are exactly tailored to the plant and to the needs and requirements of the cus-tomer. Therefore, we team up with our customers to develop modernization solutions. Not only do our activities ac-count for the technological and design requirements, but as early as in the project planning phase we draw up and implement exact and detailed schedules for manufacture, erection and commissioning.

Our customers benefit from our long-standing experience in the vari-ous fields of cold rolling mill equip-ment and technology. Besides a large number of new plants built worldwide, we have modernized over 40 cold roll-ing mills in a whole range of different designs since 1995. Here are some ex-amples.

COLD ROLLING MILLS

6

CARBON STEELSMS Siemag’s portfolio for carbon steel rolling comprises reversing

cold mills, compact cold mills and tandem cold mills, as well as skin pass mills for tempering. Customers can rely on high quality equipment

and tailor-made solutions.

8

Russian steel producer OAO Severstal placed an order with SMS Siemag in February 2014 for modernization of the 4-stand tandem cold mill 1700 at Cherepovets works in northwest Rus-sia. With replacement of the tandem cold mill in 4-high design, operating since 1963, annual production will be increased by 200,000 t up to 1,300,000 t. The modernization includes the oppor-tunity of later coupling of the tandem cold mill with a new pickling line. Thereby OAO Severstal will be prepared

HIGHER YIELDAND LESS OPERATION COSTSSMS Siemag modernizes 4-stand tandem cold mill 1700 at OAO Severstal in Russia. This will enlarge the product range, improve quality and increase the annual production.

for increasing material requirements of the customers, especially of the au-tomotive industry.

SMS Siemag has supported numer-ous customers in adopting tandem cold mills technologically to current and future market demands. This ex-perience combined with the expertise as system supplier of mechanical, electrical and automation systems has essentially contributed to OAO Sever-stal choosing SMS Siemag as supplier.

SMS Siemag is going to replace the

four mill stands and the entry section completely. On the entry side, a double expansion head pay-off reel with strip centering device and equipment for strip head end preparation as well as a roller press are installed. The roller press helps to increase strip tension prior to the first mill stand, especially when rolling thicker strips, which is beneficial to rolling of high strength grades. The entry side coil car will be additionally equipped with new hy-draulic controls.

The four-stand tandem cold mill at OAO Severstal gets an all-around revamp.

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PRECISE AND EFFICIENT ROLLING

The core of the tandem cold mill is built by four new mill stands in 4-high design, providing the latest rolling technology by SMS Siemag for precise and efficient rolling. The technical configuration comprises hydraulic gap and wedge ad-justment, CVC® plus as well as positive and negative work roll bending. In the last stand strip, quality is optimized by multizone cooling and DS system. SMS Siemag has optimized the roll and inter-stand cooling according to up-to-date findings, allowing high reductions.

Automatic work roll change devices enable fast work roll change, whereby idle times will be reduced. Especially when looking on the intended later coupling of the TCM to a pickling line, realizing continuous operation, it is important to keep production on a high level. The back-up roll change will be assisted by a new semi-automatic change device.

NEW AUTOMATION SYSTEM

The first mill stand drive will be com-pletely modernized with drive system, motor and feeding by a medium volt-age electronic frequency converter. The remaining stands will be equipped with new drive spindles. The existing Leonard-converter as the gear of mill stands 2 up to 4 as well as of the ten-sion reel will be provided with a new field weakening by SMS Siemag.

The tandem cold mill gets the latest generation X-Pact® level 1 and level 2 automation. In addition, the techno-logical measuring systems for strip thickness, strip tension and rolling speed will be exchanged. This com-plete solution provides for significantly reduced thickness tolerances and off-gauge lengths at the strip head and tail ends, by setup value calculation on the basis of the process model and the mass flow control, both developed by SMS Siemag.

Together with OAO Severstal a tai-lored operating concept was realized. The electric lines will be supplied in dust-proof containers. This simplifies the integration into the existing sur-roundings and reduces efforts for the customer.

Apart from the existing tension reel, the exit section of the tandem cold mill will be exchanged. To fulfill challeng-ing demands on strip flatness, behind stands one and four highly precise X-Shape flatness measuring systems are to be installed.

REDUCED EMISSIONS

The tandem cold mill will receive a modern mill stand cladding with a most efficient fume exhaust system, keeping the environment for the mill operators free from emission. The mill stand platform with hydraulic valve stands allows good accessibility for

maintenance. Further, SMS Siemag is going to install new high- and low- pressure hydraulic systems and to modernize the existing emulsion plant. New feed line filters and chain-type magnetic separators clean the emul-sion in an efficient way from the con-tamination of the rolling process. By this emulsion consumption and opera-tional costs are reduced.

For the challenging modernization there is only one main shutdown of two and a half month being scheduled. By this revamp, OAO Severstal gets a state-of-the art tandem cold mill, able to meet given targets to the full extent and being characterized by low main-tenance, resource saving and efficient operation. (Newsletter 1/15)

FACTS & FIGURES

Year of commissioning 2016

Annual production 1,300,000 t

Strip thickness 5.5 – 1.5 mm (entry)

3.2 – 0.4 mm (exit)

Rolling speed max. 1,500 m/min.

Material grades carbon steel and

high-strength,

micro alloyed Si-steel

i

SMS Siemag is modernizing the tandem mill of the Finnish steelmaker Ruukki at its Haemeelinna location. The cold rolling mill is being equipped with high-precision adjust-ment systems.

The four-stand quarto tandem mill has been in operation since 1972 and is the central facility for cold strip produc-tion at Ruukki. Here, carbon steel strips with widths rang-ing from 540 to 1,575 mm and maximum entry gages of up to 6.30 mm are rolled down to final gages as thin as 0.30 mm. The annual capacity amounts to 1,250,000 t.

Before the contract was awarded, investigations were performed by SMS Siemag with the aim of defining mea-sures by means of which the quality level, productivity and economic efficiency of the plant can be increased step by step. In addition, Ruukki wanted to enlarge the portion of high-strength grades in the product mix. On this basis, a modernization concept was prepared in cooperation with the customer.

TANDEM MILL AT RUUKKI TO RECEIVE UPGRADE

Tailored modernization concept

In 1998, SMS Siemag had already equipped mill stands 1 and 2 with state-of-the-art hydraulic adjustment systems. Within the scope of the current order, mill stands 3 and 4 are now being provided with hydraulic adjustment systems which are characterized by high positioning accuracy, pre-cise roll gap adjustment and good accessibility as well as serviceability. Thus, performance and reliability of the tan-dem mill are again significantly improved.

All quality-relevant components are manufactured and subjected to extensive tests in the SMS Siemag workshop in Hilchenbach. This ensures smooth installation at Ruukki, so that after just one short revamping shutdown period, the plant can resume operation at the end of July 2013. (News-letter 1/13)


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Sophisticated modernization concepts by SMS Siemag help the customer attain maximum improvement of the plant performance at minimum effort and costs. The experience of numer-ous business departments of SMS Siemag have been incorporated in the customized concept for modernization of Ruukki’s tandem mill. Another essential factor is the close coopera-tion and coordination with the custom-er throughout all project phases.

iEXPERIENCE COUNTS

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THE SUCCESS STORY CONTINUES

ArcelorMittal Brasil extends cold-strip capacity to 1.4 million tons per year

ArcelorMittal Brasil contracted SMS Siemag to extend the cold rolling mill in São Francisco do Sul in the state of San-ta Caterina, Brazil, so as to be able to boost the annual ca-pacity of the PL-TCM to 1.4 million t. Situated on an island, the complete cold strip complex was built by SMS Siemag in 2003, under the name of Vega do Sul, responding to an order by Usinor (now ArcelorMittal) and CST, Brazil.

The Vega plant had originally been designed so as to per-mit capacity to be increased after successful placement of the products on the Brazilian market. Today, the former Vega do Sul ranks among Brazil’s leading producers of high-quality hot strip. With the contract now awarded to SMS Siemag, ArcelorMittal Brasil is implementing the orig-inal plan for mill extension. In keeping with the order, the four-stand pickling line/tandem cold mill (PL-TCM), which currently operates in semi-continuous mode, will be equipped for fully continuous rolling. With this measure, ArcelorMittal wants to boost annual production from cur-rently 900,000 t to some 1.4 million t.

SECOND REEL, NEW PINCH ROLL UNITS AND DRUM-TYPE

SHEAR, EXTENSION OF SIDE TRIMMER, MORE DRIVE POWER

For fully continuous operation, we will supply and install a second tension reel, a drum-type shear and pinch roll units. The new reel will be identical in design to the existing ten-sion reel. The drive rating of the first stand of the tandem mill will be doubled by the provision of a second motor. In the exit section, the baseframes, the fume exhaust system

and the coil handling systems will be modified accordingly. The side trimmer in the pickling line will be extended by two knife heads and two scrap choppers. In addition, the emul-sion system and the acid regeneration plant will be adapted to the new situation.

REVAMPING IN JUST TWO WEEKS

All revamping work will be completed during a two-week main shutdown of the mill. Then, in October 2010, the mill will produce the first strip in fully continuous operation. (Newsletter 2/09)

Production data

Material deep-drawing steels, higher-strength steels

Strip width 750 to 1,875 mm

Strip thickness

ingoing 1.2 to 4.8 mm

outgoing 0.4 to 2.0 mm

Coil weight max. 40,000 kg

Technical data

Stand type four-high stands with CVC® plus

Rolling speed max. 850 m/min

Rolling force 30,000 kN adjusting force per stand

Capacity 1,400,000 tpy

The four-stand tandem cold rolling mill in figures

Four-stand tandem mill before extension (entry side).

Cold-strip complex of ArcelorMittal Brasil S.A., São Francisco do Sul.

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REVAMP OF BILSTEIN’S TANDEM COLD ROLLING MILL

Smart upgrade concept for minimum production losses

SMS Siemag has developed a new revamp and moderniza-tion concept which, unlike conventional procedures, guar-antees plant users significantly less production losses, shorter commissioning, steeper ramp-up curves and thus faster Return-on-Investment. For modernizing the four-stand tandem cold rolling mill of Bilstein GmbH & Co. KG, Germany, SMS Siemag is implementing this concept in a way that is tailored to the specific needs of the customer. The essential steps of the concept are: inventory of the ac-tual situation, engineering, installation of a process-IO server (PIOS), integration test, revamp and optimization.

STARTING SITUATION

Supplied by SMS Siemag in 1969, the four-stand tandem cold rolling mill to be modernized has meanwhile under-gone several expansions. It rolls a wide spectrum of 400,000 t of cold-strip products per year in widths between 320 and

670 mm and thicknesses of 7.5 to 0.3 mm. The starting ma-terial is slit hot strip which, owing to different wedge pro-files, poses high demands on the cold rolling process. The modernization mainly aims at enhancing the plant’s avail-ability, boosting production by 60,000 tpy, improving prod-uct quality and increasing the degree of automation.

The revamp activities are to be carried out during regu-lar shutdowns. Three standstill periods of five weeks in to-tal are available.

SMART UPGRADE CONCEPT

FOR MINIMUM PRODUCTION LOSSES

Inventory of the actual situation. All mechanical and elec-trical components, all functions, processes and sequences as well as the operating philosophy of the mill will be checked and documented in the customer’s works.

Engineering. The engineering and subsequent manufac-

Plug&Work test. The tandem cold rolling mill at Bilstein.


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Time

Mechanically caused conversion times

Mod

erni

zatio

n st

eps

atS

MS

Dem

agin

the

pla

nt

Pro

duct

ion,

% 115100

Inventoryof situation

Electronic terminalboard “PIOS“.Monitoring on old plant

Conversion andoptimizing phases(stepwise)

Operation withnew plant

Engineering Integrationtest

Time

ture will be based on the exact data provided by the inven-tory and a description coordinated with the customer of new functions, modified process sequences and the new operating philosophy.

PIOS, the “electronic terminal board”. Almost simulta-neously with the preparation of the engineering, a process-IO server (PIOS) will be installed in the customer’s existing plant during scheduled maintenance shutdowns. Repre-senting the “heart” of an automation system – a kind of electronic terminal board with software switch – it permits to run the system in the shadow mode and to implement step-by-step changeover to the new signal paths and/or the new automation system. Operation in parallel with the old automation system allows switchback to the old automa-tion in case of deficiencies or problems. In this way, pro-duction is safeguarded!

Integration test. The complete hard- and software will be installed in SMS Siemag’s test field, and will then be tested and preset under realistic conditions by means of a simula-tion system. The simulation includes the existing mechani-cal components and those plant elements whose kinematic behavior and dimensions were assessed in the inventory. At the same time, Bilstein’s operating and maintenance crews will be trained on the new system before it is started up.

Revamp and optimization. During revamping and subse-quent optimization, the mechanical equipment as well as the new functions and controls will be switched on, tested and optimized, either completely or in part. Digital change-over at the PIOS makes it possible to restore the original state and condition of the plant very quickly. After the new functions have been thoroughly tested and optimized, the “old” automation components will be removed for the new systems to take over.

Old New

PPS / L3

Process models / L2

Process control / L1 Process control / L1

Remote IO´s

PIOS

PIOS(Process IO Server) =“electronic terminal board”

Process models / L2

M

The most important mechanical modernization measures include:

Entry-end pinch roll set Fitting all the stands with hydraulic adjusting systems New gear wheel sets Dry-Strip system in the exit section Swingable bridle roll set in the exit section

A major part of the existing electrics and automation will be replaced with new systems:

Multi-drive converter with modern synchronous motors for stands and tension reels, and with asynchronous motors for payoff reels, pinch roll units and bridle rolls Main control pulpit, operating stations and visualization system Integrated automation system for sequence controls and technological controls Model-based level-2 system for setpoint calculation for the entire mill

iFACTS & FIGURES

Process-IO server. Modernization time schedule.

Thanks to this modernization concept, both Bilstein, the plant user, and SMS Siemag can be absolutely sure that revamping will go smoothly and that the goals pursued with the modernization will be achieved within the specified time. (Newsletter 2/07)

PROJECTS SMS group newsletter 02 / 2013

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At Bilstein GmbH & Co. KG in Hagen-Hohenlimburg, Ger-many, SMS Siemag comprehensively modernized the four-stand cold rolling mill supplied by SMS Siemag in 1969. The project involved the installation of new mechanical, electri-cal and automation equipment in several stages. The dis-continuous rolling mill plays a key role in cold strip produc-tion at Bilstein, a company with a long-standing tradition. In December 2010, Bilstein granted us the FAC for the com-plete revamp.

HIGHER CAPACITY, BETTER QUALITY

The main objective of the tandem mill modernization at Bil-stein was to keep the plant at the latest state of the art and boost annual production. Further targets were to improve plant availability, increase the degree of automation and re-duce the number of plant operators. In addition to these aspects, the revamp was intended to safeguard and further improve the product quality, especially in terms of gage tol-erances and straight-edge coiling. A distinct improvement was needed due to the fact that hot strip slit into two or three bands with different taper is used as input material. This posed a special challenge to our cold rolling experts. The existing electrical and automation equipment was large-ly replaced by new systems as part of the modernization.

MODERNIZATION PROJECT IN FOUR CONSTRUCTION STAGES

SMS Siemag implemented the smart modernization project in four stages to have only short shutdown periods. First, the new controls for the media systems were installed.

HIGHER CAPACITYSMS Siemag modernized a four-stand tandem mill for Bilstein, Germany.

Bilstein benefits from better quality and closer gage tolerances.

During the two-week shutdown, preparatory work for the installation of the mechanical equipment could already be accomplished. The next phase of the project involved the installation of new hydraulic adjusting systems and the stand drives during a seven-day standstill.

CHANGEOVER OPERATION SAFEGUARDED PRODUCTION

A highlight of the second construction phase was the instal-lation of the process-IO server (PIOS), which we refer to as our “electronic terminal board”. Being the “heart” of the au-tomation system, it permitted to run the system in the shad-ow mode and to change over step by step to the new auto-mation system. The old automation system was kept live and running in parallel. This allowed switchback to the old system at any time. During a further regular standstill of two weeks, the mechanical portion of the project was large-ly completed. It involved the installation of the entry-side pinch roll units for stabilizing strip guiding, the exit-side

SMS Siemag specifically supplied the following features from level-0 up to the level-2 system:

Multi-drive converters with modern synchronous motors for the mill stands and tension reel, and with asynchronous motors for the payoff reel, pinch roll units and bridle rolls Main control pulpit, operation stations and visualization system Integrated level-1 automation system Model-based level-2 system for setpoint calculation for the entire mill

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bridle roll set and the payoff reel motors. During the last phase, the new automation system could be completed.

Also during this phase, the operation in the changeover mode ensured that, depending on the production require-ments, it was possible to switch between the old and the new automation system. This safeguarded production of the four-stand tandem mill, having a key function within the customer’s process chain, at all times, also during ramp-up for commissioning.

INCREASE OF ROLLING FORCE AND ROLLING SPEED

The installation of new hydraulic long-stroke cylinders achieved a significant increase in rolling force by 30 % per stand. The stand drives were refurbished with new gear-wheel sets for raising the maximum rolling speed by 25 %. The former DC drives have been replaced with modern AC drive technology. This brings down the maintenance effort significantly and improves control dynamics. In addition, the existing operating concept based on local control sta-tions was substituted by a central, ergonomically designed control room.

AUTOMATIC THREADING ASSISTANT TRC®

Moreover, we developed an automatic threading assistant TRC®, which is active during threading and unthreading. It takes into account the wedge formation and the thickness deviation at the strip head and tail, and ensures strip flat-ness and centered strip material travel. It controls the roll-ing force and corrects the roll-gap setting as a function of the material properties, and helps reduce off-size strip lengths by up to 50 %.

For improved strip drying, we installed a Dry-Strip sys-tem on the stand exit side. The stand exit area was comple-mented by a swingable bridle roll set for stabilizing the strip tension there.

ECONOMIC EXPANSION OF THE PRODUCT PORTFOLIO

The new level-2 automation provides the customer with the possibility of expanding the product range in an economic

way. As the pass schedules can be pre-calculated with high accuracy, rolling trials for new products can be largely dispensed with.

TRAINING OF THE OPERATING

PERSONNEL

We instructed the operating personnel of Bilstein during a four-week training course on SMS Siemag’s rolling simu-lator to familiarize them with the new automation. This was one reason why the modernization measures could be implemented so smoothly. Through the simulation they understood how the functions of the plant work, how to handle them under realistic operating conditions and how to control virtual production processes.

SUCCESSFUL REVAMPING

As a result of the revamp, Bilstein has been able to boost both production and the yield of the plant and adjust the product quality to specific customer requirements. The new automation systems in level 1 and level 2 not only optimized threading and unthreading performance but the entire process control, enabling reorganization of the shift crews. The future-oriented mod-els in level 2 provide Bilstein the nec-essary basis for short-term expansion of the product range to include new materials. We owe the successful completion of this modernization proj-ect not least to the excellent coopera-tion with the teams of Bilstein. (News-letter 2/11)

iBILSTEIN – a name that stands for cold strip.

Bilstein GmbH &

Co. KG located in

Hagen-Hohenlim-

burg produces cold

strip in a wide range

of materials and

products. The spec-

trum ranges from

standard grades,

case-hardening

and special steels

through to micro-

alloyed, high-

strength steels.

The company is

renowned as a

supplier of highly

specialized niche

products.

The automatic threading assistant reduces off-size lengths.

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Andernach-based Rasselstein GmbH, a subsidiary of ThyssenKrupp Steel Europe, is Germany’s only producer of tinplate. Rasselstein and SMS Siemag can look back on over 50 years of co-operation covering both the installa-tion of new plants and the moderniza-tion of existing equipment. Since 1959, SMS Siemag has implemented a total of twelve successful projects with Ras-selstein. In his paper, Paul Michels, General Manager Tinning 1 at Rassel-stein, reports about two demanding revamp projects of the recent past. One covered the two-stand DCR (Double Cold Reduction) rolling mill and the other one the five-stand tandem mill.

REVAMP OF THE DCR ROLLING MILL

Rasselstein had commissioned SMS Siemag to relocate a DCR mill from Dortmund to Andernach and to mod-ernize this mill. The first step was to dismantle the old components in Dort-mund and to inspect them for their re-usability. It was found that some of the components indeed could be reused. But at the same time, new equipment had to be designed and manufactured for integration into the overall concept.

Key mechanical equipment such as roll stands, bending systems, and work and backup roll chocks were rema-chined and pre-assembled in the Hil-chenbach shops of SMS. SMS Siemag was responsible for the sophisticated project logistics relating to both the old and the new mill components. Finally,

LONG-STANDING PARTNER-SHIP WITH RASSELSTEIN

Success through tailor-made modernizations

the revamped combined DCR mill was installed and successfully put into op-eration in Andernach, Germany.

TOP QUALITY AND REDUCED OFF-GAGE

LENGTHS

The modernized mill meets highest quality demands in terms of strip thickness, flatness, roughness, clean-ness and surface dryness. Productivity was improved through reduction of off-gage lengths. Extensive online measuring systems plus the increased degree of automation ensure stable and reliable process control and top strip quality.

UPGRADE OF THE TANDEM MILL

Put on stream in 1960, the five-stand tandem mill produces cold strip in widths from 600 to 1,080 mm and final thick-nesses ranging from 0.10 to 1.20 mm at rolling speeds of up of 1,830 m/min.

The tandem mill at Rasselstein after modernization.

The focus of the 2008 modernization was on the entry area of the rolling mill and the mill stands. The entry ar-ea received a new walking-beam sys-tem, a lowering station and a payoff reel. The roll stands were equipped with new hydraulic adjusting systems, new stand platforms and a new enclo-sure. The SMS Siemag package also included a new fume exhaust system with scrubber system as well as equip-ment for the HP and LP hydraulic sys-tems including associated piping.

The mill was shut down at the be-ginning of September 2008 and went back into operation already four weeks later, followed by quick ramp-up and successful availability tests. Thanks to the measures implemented, strip thickness tolerances and flatness were improved while off-gage lengths were diminished. (Metec Newsletter 2011)


COLD ROLLING MILLS – CARBON STEEL

17

The site of TKS Rasselstein in Andernach. Rasselstein’s tandem cold mill (TCM) after revamping.

Rasselstein GmbH, Andernach, Germany

The scope for this modernization job comprised the entry section of the tandem mill, new hydraulic adjusting sys-tems, a new stand platform and stand enclosure, a fume exhaust system as well as HP and LP hydraulic systems including associated piping.

The new concept for the entry section was developed in no more than two months through in-depth discussions with the customer. Both project teams contributed their ex-periences to achieve an optimal configuration because the prevailing local conditions such as foundations and bay col-umns, and the equipment to be newly designed had a con-siderable impact on the new entry section. All of these as-pects could be considered as early as in the project planning phase. Already at this point, the equipment groups to be pre-assembled were defined, later significantly reducing erection time during mill shutdown.

PRE-ASSEMBLY AND FUNCTION TESTS

In the course of project implementation, SMS Siemag car-ried out extensive pre-assembly work and function tests. All hydraulic adjusting cylinders were completely assem-bled in our shops and subjected to various standard func-tion tests on our testing stand. In addition, some of the cylinders were tested using the original control system.

Furthermore, all new platform components including valve stands, piping and cabling as well as parts of the in-terconnecting piping in the area of the platform were com-pletely assembled in our workshops. Upon completion, all parts were disassembled suitable for final erection and were delivered in due time for field installation.

The re-designed entry section in-cluding walking beams, coil lowering station, payoff reel and entry group was likewise pre-assembled and func-tion-tested. Being an innovation, the lowering station was additionally started up in the SMS workshops us-ing the original control system.

Thanks to these measures, excel-lently coordinated sequences and highly motivated project teams, the mill could go back into production on schedule as early as the end of Sep-tember 2008, after a shutdown of four weeks. By the end of 2008, following specified ramp-up and successful completion of the availability test, the mill achieved Rasselstein’s demanded capacity and performance. (Newslet-ter 2/09)

Modernization of five-stand tandem mill

iBenefits of manufacture and function-testing by SMS Siemag:

Components manu-

factured in the SMS

Siemag workshops

in Hilchenbach

are subjected to

extensive function

tests. This ensures

equipment quality

and quick start-up.

If so requested by a

customer, the scope

of function-testing

can be extended to

include testing of the

functions of com-

plete units including

their hydraulics and

automation.

PREPARED FOR THE FUTURE

SMS Siemag installed a continuous exit section of the tandem mill at Ilva Cornigliano, Italy.


18

As part of the modernization of the five-stand tandem cold rolling mill No. 1 of its Genoa Cornigliano Works, Ilva placed an order with SMS Innse for the supply, installation and commissioning of the new continuous exit section. This measure is one step to allow the mill to be operated as a PL-TCM.

After a project handling time of only 16 months, erection of the new continuous exit section started with the shut-down of the mill in December 2008. The new carousel ten-sion reel had been designed, manufactured and supplied in a mere 14 months, and was pre-assembled on the new foundation during ongoing production.

The reel is able to wind coils with a weight of 45 t and a maximum diameter of 2.5 m. Upon completion, the coils are transported to the downstream production facilities by the new coil handling system.

Further extensive preparation work in this area was like-wise carried out while production continued. This included foundation work, pre-cabling, pipe routing and installation of hydraulic valve stands.

The modernization scope included the complete new exit equipment behind stand 5 such as rotary shear, car-rousel tension reel, coil car, strapping and marking ma-chines as well as a high-speed coil car for transport of the finished coils.

The close cooperation with the customer was the key to the success of this project. Through this modernization step and further revamps still pending, Ilva will receive a modern PL-TCM and will be well prepared for the future. (News-letter 3/09)

New continuous exit section. The new carousel tension reel.

19

SMS Innse recently completed mod-ernization work on the five-stand tan-dem mill at Ilva’s Novi Ligure opera-tions. The upgrade was carried out in two steps. First, in April 2009, the sec-ond stand of the tandem mill received a new drive. In August 2009, modern-ization was completed with the instal-lation of new drives on stands No. 3 and No. 4. In addition, SMS Innse equipped the mill with a new entry group which is located upstream of the PL-TCM and is connected with the en-try looper via a bridge.

Today’s cold rolling mills operate within a wide speed range and at high rolling speeds. Increasing demands are being made on the performance and capacity of tandem mills and, con-sequently, also on the stand drives. This was the main reason why Ilva de-cided to revamp the work-roll drives of its four-high cold rolling mill.

SMS Innse’s package covered the design, supply and installation of all mechanical drive components for the three central roll stands of the tandem mill, including the pertaining central oil lubrication system. The mechanical drive components included: - Sieflex motor couplings- spur-gear mill pinion gears - drive spindles

HIGHER DRIVE POWERSMS Innse modernized a five-stand tandem mill at Ilva, Novi Ligure.

Ilva now is able to roll wider strip and therefore a broader product mix.

Combined spur-gear mill pinion gears in Ilva’s tandem mill.

The Sieflex motor couplings and spur-gear mill pinion gears were manufactured in the Hilchenbach workshops.

Ilva is highly satisfied with the suc-cess of this measure because mill ca-pacity could be increased. Plus, the higher drive power now available en-ables the product spectrum to be ex-tended. In its Novi Ligure operations, Ilva can now roll wider strip as part of a broader product mix. (Newsletter 1/10)


20


20

ThyssenKrupp Steel, Dortmund, Germany

ThyssenKrupp Steel in Dortmund was keen to revamp its semi-continuous PL-TCM to continuous operation to boost capacity and improve product quality.

To enable continuous operation, the exit section was re-designed and equipped with a double-reel unit and a coil handing system tailored to the situation in the works. For quality con-trol, SMS Siemag also integrated its innovative “Rotary Inspect” inline in-spection station. This ensures reliable strip quality control.

As a result of these measures, pro-duction capacity rose from 165,000 t to 192,000 t per month. Another benefit was that spare-parts stockkeeping was facilitated because all key compo-nents of the new exit section corre-spond to those of the TAKO “sister mill” which SMS Siemag had built at ThyssenKrupp Steel’s Duisburg loca-tion in 2000.

INSTANT HELP AFTER

HEAVY FIRE IN NOVEMBER 2003

On November 26, 2003, the tandem mill was seriously damaged by a major fire. Thanks to the tireless efforts of all

staff involved in the project, both on the side of the customer and of the supplier, and active involvement of the SMS work-shops, the shutdown could be reduced

from a planned four months to six weeks. As early as December 31, 2003, the mill was back in production, rolling the first strip. (Newsletter 2/09)

Modernization of five-stand PL-TCM

Strip turning for inspection of top surface and underside by means of “Rotary Inspect“.

Modular-design double-reel exit section in SMS Siemag’s Hilchenbach shops.

Dismantling of old foundations in the area upstream of the double-reel exit section.

The modernized tandem mill with new double-reel exit section.

21

Rasselstein GmbH, Andernach, Germany

ArcelorMittal Genk Stainless Europe, Belgium

At its location in Andernach, Germany, Rasselstein GmbH, a company be-longing to ThyssenKrupp Steel, pro-duces tinplate material for the pack-aging industry. Due to the shutdown of various production units at the Dort-mund location, the production capacity in Andernach had to be increased.

Rasselstein GmbH took this step to safeguard its market leadership in tin-plate production and to cover the packaging industry’s current and fu-ture demand for tinplate material. So the two-stand DCR mill was relocated from Dortmund to Andernach, and on this occasion was extensively upgrad-ed by SMS Siemag.

Back in 1988, SMS Siemag had built a CVC® four-high reversing cold rolling mill for the production of low-carbon steel strip at Arbed in Dudelange, Lux-embourg.

In December 2006, ArcelorMittal Genk Stainless Europe contracted SMS Siemag to extensively revamp the “CRM4” cold rolling facility on the occa-sion of its relocation to Genk, Belgium, and to make it fit for a new job and func-tion, i.e. the rolling of stainless steel. The mill in Genk made it possible for

Relocation and revamp of two-stand DCR mill

Revamping of single-stand reversing mill

Reversing cold-rolling mill at ArcelorMittal Genk Stainless Europe.

the customer to cut production costs and to increase the future production capacity for stainless-steel strip.

The use of this reversing cold-roll-ing stand turned out to be economi-cally very advantageous for the cus-tomer because the mill stand, major parts of the mechanical equipment and of the auxiliary and the secondary facilities could be retained. ArcelorMit-tal Genk Stainless Europe now has a powerful stainless-steel mill in four-high design. (Newsletter 2/09)

Following dismantling of the com-plete plant, key components such as the mill stand, the bending system as well as the work- and backup roll chocks were remachined in the SMS shops. Then, these facilities were pre-assembled together with newly sup-plied parts. Finally, the equipment was supplied for final erection in the field.

Two-stand DCR Double Cold Re-duction mills combine reduction in the first stand with tempering (or skin-passing) in the second stand. This is ideal for precisely setting the material properties required for further pro-cessing. (Newsletter 2/09)

Retaining and re-using components of the old mill Change of rolling direction Processing of wider strips Increase of coil weights Short coil cycle times

i CUSTOMER BENEFITS

Relocated from Dortmund to Andernach: the DCR mill No. 4.


“Fortunately it happens rarely – but sometimes it does. A seemingly unim-portant mistake during ongoing pro-duction has disastrous consequences, and a rolling mill catches fire. Keeping the adverse effects for the plant user as small as possible requires a lot of experience. With its expert knowledge and organizational skills SMS Siemag was able to actively support Wickeder Westfalenstahl GmbH, Germany, and led a challenging repair to speedy suc-cess,” Klaus Grimm, the responsible

FIRE DAMAGE REMEDIED AS FAST AS POSSIBLE

After fire damage at the reversing cold mill of Wickeder Westfalenstahl GmbH, SMS Siemag took on the restoration of the heavily damaged plant.

Project Leader Cold Rolling Mill Divi-sion, puts his experience in a nutshell. The four-high reversing cold rolling mill had been supplied to Wickeder Westfalenstahl by the former SIEMAG. It commenced operation in 1969 and has repeatedly been modernized since then. It is a multitalent, rolling a wide material range from soft to highest-strength grades and clad material in the medium strip-size area of up to 700 mm width to a minimum final thickness of 0.15 mm.

PROJECTS SMS group newsletter 02 / 2013

22

Shining in new splendor: the reversing mill after restoration.

During ongoing production, a hy-draulic pipe at the coiler had been damaged. Oil had emerged from the pipe and caught fire. The flames had quickly spread to the mill stand and the drive side. The fire and fire-fighting activities had both caused heavy dam-age to the vapor exhaust system in-cluding stack, mechanical and electri-cal equipment as well as to media and measuring systems in the mill stand area and on the drive side.

FACTS & FIGURES

MILESTONESOrder placement September 1, 2012

First coil March 18, 2013

Acceptance by Wickeder April 17, 2013 Westfalenstahl

As early as by the date of acceptance, the mill had met the specified produc-tion data like minimum final thickness at maximum speed for different grades. Thus, the plant could be re-integrated in the production process without delay.

i

[email protected]

The four-high reversing cold mill stand is ready to resume operation.

»OUR AMBITION WAS TO RESTORE THE ROLLING MILL WITHIN A MINIMUM OF TIME:

SMS SIEMAG GAVE ITS BEST SUPPORT TO ACHIEVE THIS GOAL.«

Andreas Wellié, Manager Technical Services, Wickeder Westfalenstahl

After the loss had been verified, Wickeder Westfalen stahl entrusted SMS Siemag with the restoration of the plant and the coordination of the complete project which involved sev-eral suppliers. SMS Siemag supplied the mechanical equipment and was responsible for coordination of the overall plant assembly.

INEVITABLE EXCHANGE

The measuring devices close to the mill stand and the hydraulic valve stands on the drive side had been seri-ously damaged by the flames and also the extinguishing agents had partly to be repaired or replaced. Mechanical


equipment such as the gear unit, drive spindles, hydraulic adjustment system and work roll bending system were in-spected in the Hilchenbach workshop of SMS Siemag. Seals and wear parts were renewed. The complete hydraulic piping in the mill stand area and on the drive side had to be exchanged.

Just slightly affected by the fire were the coil preparation station, car-ousel reel and recoiling line. In this area, hydraulic valves and cylinder seals were replaced as a preventive measure. All components in the oil cellar, such as the central oil lubrica-tion system and oil-film-bearings lu-brication system, were not directly concerned, but were inspected as a precaution and could resume opera-tion after they had been thoroughly cleaned.

The greatest challenge for SMS Siemag was to meet the very tightly calculated schedule of the project in order to restore the operational state of the reversing mill as early as possi-ble. Another challenge was the exist-ing documentation. During the many years of its existence, the plant had been modified several times. Some documents had to be reconstructed in

cooperation with the project team of Wickeder Westfalenstahl. Thanks to an intensive and well coordinated co-operation between all participants, the problems could be mastered in time, and the reversing mill could resume operation according to schedule. (Newsletter 2/13)

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24

PLUS 40 PERCENTIn February 2014, International Steels Limited (ISL), Pakistan,

selected SMS Siemag to extend its Reversing Cold Mill (RCM). The two-stand Compact Cold Mill (CCM®)

will increase the annual capacity by 40 percent.

The four-high RCM of CVC® plus de-sign by SMS Siemag is the first cold rolling mill of its kind in Pakistan. Since 2011, ISL has been producing high-quality cold strip with widths ranging from 700 to 1,250 mm and fi-nal thicknesses of minimum 0.25 mm on this RCM. The annual capacity is 250,000 t. Precautions were made al-ready in the planning phase of the RCM to permit economical extension of the plant to a two-stand CCM® later on. These concerned primarily the lay-out of the foundations and media sys-tems. ISL recently exercized its option and awarded SMS Siemag the order for an extension which will increase the annual capacity by 40 percent.

NO CAPACITY ADAPTATIONS

SMS Siemag will supply the second mill stand which is of identical design to the existing one, as four-high stand with hydraulic adjustment, CVC® plus and work roll bending system. The supply package of the second stand furthermore includes the X-Shape flatness measuring system. As the capacity of the emulsion system has been designed for two-stand opera-tion right from the beginning, capacity adaptation is not required. The only thing to do is replace the exit-side equipment such as tension reel and coil car to permit installation of the second mill stand. Torsten Seeger,

www.sms-siemag.com/ cold-rolling-mills

Project Manager of SMS Siemag, comments: “The plant extension schedule was made to keep the down-time as short as possible. ISL will be able to start production on the CCM® in mid 2015.”

Due to the geographical proximity to ISL in Pakistan, Esmech Equipment Pvt. Ltd., SMS Siemag’s Indian joint-venture partner, will supply further plant components, including equip-ment for roll changing, the interstand area, enlargement of the mill stand platform and stand enclosures as well as valve stands for the LP hydraulic system. (Newsletter 2/14)

iCCM®

Compact Cold Mills

(CCM®) efficiently

close the capacity

gap between single-

stand reversing mills

and tandem cold

mills. In the range

up to 800,000 t per

year, they optimize

investment and

operational costs.

The RCM at ISL will be supplemented by a second mill stand to come as CCM®. The second mill stand will be installed on the left side.

PROJECTS SMS group Extracts from various newsletters

25

EXPANSION CONCEPTKYCR, Bangladesh, enlarges its cold rolling mill, which SMS Siemag

supplied in 2002. Annual production is increased to 170,000 t.

PROJECTS

KYCR will expand its RCM to a compact cold mill.

KYCR Coil Industries Ltd., Bangladesh, placed an order with SMS Siemag for the expansion of their existing CVC® plus six-high reversing cold mill to become a compact cold mill (CCM®). Since 2002, the single-stand reversing cold mill (RCM), which had been supplied by SMS Siemag to KYCR Coil Industries Ltd. in Chittagong, has been producing cold strip with widths between 600 and 1,050 mm and final thick-nesses of minimum 0.9 mm. Accordingly, this plant with CVC® plus technology had been specifically designed to roll thin strip which includes operation with thin work rolls hav-ing a minimum diameter of 200 mm for high reduction. The existing RCM will be expanded to a two-stand CCM® with CVC® plus in both mill stands. Thus, KYCR will increase its annual production capacity to approx. 170,000 t. (Newsletter 2/14)

www.sms-siemag.com/cold-rolling-mills

26

STAINLESS STEELThe portfolio of SMS Siemag for stainless steel rolling comprises single-stand 20-roll mills in mono block and split block design. The CVC® plus 18 HS design

can be applied in single-stand mills as well as in tandem cold mills.

Still in good shape after 45 years: the mill stand door. But it’ll be also renewed.

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Modernization at Outokumpu Nirosta

Outokumpu Nirosta in Krefeld, Ger-many, has awarded to SMS Siemag, Germany, an order to modernize the 20-roll cold mill “SG3” of type MB 21BB-61“. The order was placed at the beginning of September 2014, with the aim of technically updating the 45-year-old cold rolling stand and pre-paring it to deal with demanding new rolling tasks.

The 20-roll cold rolling mill of stand type Monoblock MB 21BB-61“ had been supplied in 1969 by SMS Siemag (previously Demag). It was modernized in 1991. Following the closure of the Outokumpu works at the Düsseldorf-Benrath location, the production previ-ously carried out there, for example thin mirror-finish material, is being transferred to the Krefeld works.

REVAMP OF THE COLD ROLLING MILL

The “SG3” 20-roll cold mill, with a strip width of 1,570 millimeters, and strip gages of max. 10.00 millimeters in the entry section and min. 0.50 mil-limeters in the exit section, will con-tinue to be used for the production of high-grade special-steel strips made of austenitic, ferritic and martensitic

materials. The mill’s future rolling tasks will include, in particular, thin-gage ferritic strips in high-gloss qual-ity (2R bright-annealed). The cold rolling mill needs to undergo a cer-tain amount of conversion work in or-der to satisfy the preconditions for manufacturing mirror-finish materi-al. The SMS Siemag supply scope comprises changes to the entry and exit sides and on the millstand itself.

To achieve the desired strip surface quality, the existing squeezer system is to be converted to a dual-cassette wiper system, including changing de-vice, which can be operated with vari-ous types of coated wiper rolls. One of the aims of the conversion work is to enable the entire thickness range to be rolled at maximum rolling speed. The existing strip cooling system will be equipped with a volume control so as to allow pre-setting of different rolling-oil quantities, depending on the pass schedule. The axial shifting system of the first intermediate rolls is to be renewed in the millstand. The plant is also to be provided with a new millstand door and new exhaust hoods. The pinch roll situated at the

entry end will be replaced by an ad-justable, swiveling pinch roll. This will make it easier for the strip to be threaded into the stand. The exit end too will be provided with a bending and pinch roll. Furthermore, new car-ry-over tables will ensure that the strip head end can be inserted direct-ly into the reel slot. The above work will help to achieve safe, gentle and

A sprightly 45 - ready for new challenges. SMS Siemag revamps 20-roll cold mill.

The “SG3” 20-roll cold mill of Outokumpu Nirosta in Krefeld is being revamped.

29

Revamp of 20-roll cold mill

rapid threading and tailing-out of the strip and thus ensure the efficient op-eration of the rolling mill also in the future.

Besides the equipment described above, the SMS Siemag supply scope also comprises the dismantling of the components to be replaced, the per-formance and supervision of erection of the new equipment items, and the commissioning of these items. A tight time schedule has to be observed

In April 2014, VDM Metals GmbH, Ger-many, commissioned SMS Siemag to upgrade its 20-roll cold mill for high-performance materials. The split-block rolling mill of size SB 33-30” was supplied by SMS Siemag and has been in operation since 2002. On this mill, VDM Metals rolls a broad material spectrum of nickel-based and high-al-loy special stainless steels from a width range between 350 and 750 mil-limeters down to foil thickness with a minimum final gage of 0.02 millime-ters. The revamp will include modifica-tions in the entry and exit sections and in the flatness control system area.

VDM Metals, Germany

The split-block 20-roll cold mill of VDM Metals will undergo slight modification.

here, since the commissioning of the modernized mill is to take place al-ready in July 2015, following a revamp shutdown of 21 days.

This is already the fourth order within a period of a few years for the revamping of a 20-roll cold mill, awarded to SMS Siemag by custom-ers in Germany, and is powerful proof of the confidence in the ability of SMS Siemag to carry out modernization work. (Newsletter 1/15)

Mill stand type MB 21BB-61“

Material Martensites, austenites, ferrites

Strip width 1,570 mm

Strip thickness Max. 10.00 mm (ingoing)Min. 0.50 mm (outgoing)

Coil weight Max. 26 t

Rolling speed Max. 500 m/min.

Facts + Figures

COLD ROLLING MILLS

30

EXPERT SINCE 1950SMS Siemag has more than 50 years in experience

of installing 20-high cold rolling mills. Three modernization examples prove the know-how.

31

20-high cold rolling mills have been part of SMS Siemag’s product portfolio since the 1950s. Right from the beginning, SMS Siemag has constantly optimized many of the technical details of these rolling mills to better measure up to the needs and requirements of cold-strip producers. The achieved key developments contribute to higher productivity and significantly improved product quality.

These developments are not only suited for new plants, but are also used to modernize existing facilities. The installa-tion of individual systems, for example new rolling-oil wipers, is just one of many modernization solutions. As can be seen from the following examples. (Newsletter 2/09)

Example 1: Revamp of MB23-56“ mill at Outokumpu Nyby

The 20-high cold rolling mill at Outokumpu Nyby in Tor-shälla, Sweden, was modernized to give it more reliability in meeting the thickness tolerances and to improve the strip flatness. Supplied by SMS Siemag back in 1956, the rolling mill rolls stainless-steel hot and cold strip of the AISI 300 and AISI 400 series in widths between 700 and 1,400 mm and a final gage of minimum 0.2 mm.

Mill modernization was implemented in several steps. First, the stand was dismantled in just three days. On this, it was mechanically overhauled and equipped with modern actuators for roll and crown adjustment in our workshops. Finally, it was re-installed and put back into service. Thanks to our tailor-made revamping schedule, production losses could be minimized. While the stand was being modernized in our shops, the entry and exit areas were revamped in the customer’s works so as to enable the handling of coils with larger diameters. In addition, a new hydraulic station was provided. Due to the narrow space conditions, it had to be located on top of a steel structure.

In the second revamping phase, SMS Siemag modern-ized the axial shifting system of the inner intermediate rolls. The new hydraulic adjusting system featuring automatic coupling of the rolls is ideally suited for highly dynamic in-fluencing of the strip flatness.

Example 2: ThyssenKrupp Acciai Speciali Terni MB22-49“

This mill, originally built in 1957, was installed in Terni in 1974. For modernization, SMS Siemag made provisions to enable the handling of larger coils (higher coil weight, larger coil diameter), and equipped the rolling mill with a new rolling-oil filtering system and modern strip-thick-ness control systems. The electrical equipment was up-graded while retaining the main drive ratings. Today, this rolling mill produces stainless-steel cold strip and, due to its modular design and drive rating, is particularly suited for the rolling of titanium strips.

Example 3: Revamp of MB22-52“ mill (SG 2) at ThyssenKrupp Nirosta, Krefeld

The size MB22-52“ (Mono-Block) mill built by SMS Siemag in 1963 was originally equipped with all then-modern adjusting or control elements. Our key revamping measures included the provision of a new hydraulic adjusting system, a crown adjusting system, an axial shifting system in push-push de-sign, a new media platform with hydraulic controls, new roll-ing-oil wipers as well as thickness and flatness measuring systems including control. The goal was to bring productivity and especially product quality up to current standards.

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Just 18-day downtime – Smooth modernization at ThyssenKrupp Nirosta

SMS Siemag extensively modernized the 20-roll cold mill, size MB21BB-64”, which had been erected in the Düssel-dorf-Benrath works of ThyssenKrupp Nirosta in 1976.

The modernization focused on the area of the mill stand which was equipped with a hydraulic roll adjusting system, an axial shifting system for the inner intermediate rolls, and a new media platform.

Advantages of the high-tech components. The hydraulic roll adjusting system permits closest strip thickness toler-ances to be met. The crown adjusting system serves to adapt the roll gap to the entering strip and thus attain top

strip flatness. The axial shifting system of the inner inter-mediate rolls helps perfect the rolling result right up to the strip edges and facilitates roll changes. The all-in-one me-dia platform is characterized by easy maintenance.

The new stand components were completely manufac-tured, pre-assembled, and tested in the SMS Siemag work-shop in Hilchenbach. Thus, final installation could be ac-complished within a single plant downtime of just 18 days. Commissioning progressed as scheduled and was com-pleted 17 days ahead of the contract deadline by granting the FAC on February 6, 2012. (Newsletter 3/12)

First strip rolled on January 7, 2012, after a conversion period of just 18 days.

“FITTED WITH THE NEW HIGH-TECH COMPONENTS BY SMS SIEMAG, THE 20-ROLL COLD MILL IS PERFECTLY PREPARED TO MEET THE RISING DEMANDS

OF OUR CUSTOMERS, ESPECIALLY IN RESPECT OF THE STRIP QUALITY.”

Peter Großmann, Manager Production at ThyssenKrupp.

COLD ROLLING MILLS – STAINLESS STEEL

33

High-tech stand components for ThyssenKrupp Nirosta, Düsseldorf

For quality and stainless-steel strip

ThyssenKrupp Nirosta GmbH, Germa-ny, contracted SMS Siemag in Febru-ary 2011 for the upgrade of the 20-roll cold rolling mill “SZ 1600” of its Düs-seldorf-Benrath works.

Once again, TKN counts on SMS Siemag competence in the modernization of this type of mill. The SMS Siemag Mono-Block of size MB21BB- 64“ has been in operation since 1976.

Modernization of the stand area. The upgrade measures will focus on the mill stand which will receive a hy-draulic roll adjusting system for clos-est strip thickness tolerances, a hy-draulic crown adjusting system and a hydraulic axial shifting system for the inner intermediate rolls.

Crown control. Hydraulic crown ad-justment is implemented through ser-vo-controlled adjusting cylinders en-suring good flatness and optimal adaptation of the roll gap to the mate-rial profile.

Axial shifting of the inner interme-diate rolls. Hydraulic axial shifting of the inner intermediate rolls allows to achieve a perfect rolling result right up

to the strip edges. Axial shifting of the inner intermediate rolls is accom-plished by means of a push-pull sys-tem. This facilitates roll changing be-cause the inner intermediate rolls no longer have to be uncoupled by hand.

New media platform. The “SZ 1600” will also receive a new media platform in All-In-One design. Our media plat-form is characterized by a compact modular design and maintenance ease. The valve units for control of the hydraulic functions will be integrated together with the piping.

Manufacture with pre-assembly plus testing. All new components of the stand will be manufactured in the Hil-chenbach workshops, and pre-assem-bled and tested including their piping. Thanks to pre-assembly and testing in our shops, the time and work needed for final installation and commissioning in ThyssenKrupp’s Benrath works will be reduced to an absolute minimum. As a result, TKN will be able to roll the first strip already at the beginning of Janu-ary 2012 after a mill stoppage of just 17 days. (Newsletter 3/11)

Stand type Size MB21BB-64“

Material Austenitic, ferritic,

martensitic strip


Strip thickness

Ingoing 2.0 to 8.0 mm

Outgoing 0.5 to 6.0 mm

Technical data

of our stand components

Better dynamics of the actuators and adjusting elements Improved positioning accuracy, hence better reproducibility of product quality Greater adjusting precision Less wear Closest strip thickness tolerances and minimum off-gage lengths Closest strip flatness tolerances Easier roll changing

iADVANTAGES

Pre-assembled mill stand in the Hilchenbach shops of SMS Siemag.

34

Relocated and modified RCM.

Device for automatic and fast work roll change.

REVAMP OF “CRM 4” IN GENK COMPLETED

ArcelorMittal Genk Stainless Europe issues PAC

On September 19, 2008, Arce lor Mittal Genk Stainless Europe granted SMS Siemag the PAC for the revamping of the “Cold Reversing Mill CRM 4” at its location in Genk, Belgium. The project is now in its final stage. The first coil had already been rolled in April 2008 after a short erection time.

REVAMP WITH A MOVING HISTORY

The mill stand now revamped had been in operation at ArcelorMittal (previously Arbed) in Dudelange, Lux-emburg, since 1988. Supplied by SMS Siemag, it originally was a CVC® four-high reversing cold rolling mill for the rolling of low-carbon steel strip. Arce-lorMittal then decided to relocate this mill stand to its operations in Genk. In December 2008, ArcelorMittal Genk Stainless Europe (formerly Ugine & ALZ) contracted us to extensively re-vamp the “CRM 4” reversing mill and to make it fit for a new job and func-tion, i.e. the rolling of stainless steels.

COSTS DOWN, CAPACITY UP

The facility in Genk makes it possible for ArcelorMittal Genk Stainless Eu-rope to cut production costs and in-crease the future output of stainless steel strip which is used, for instance, in industrial applications, for the man-ufacture of household goods and in the automotive industry.

THE REVAMPING MEASURES

For the revamp, the existing CVC® plus shifting systems were modified to make them more compact. On the stand entry and exit sides, we provided holddown rolls, pinch rolls, leveling and bending rolls as well as an oil wip-er unit. In addition, the mill received new reversing coilers, two coil cars and two coil deposits.

MODIFIED ROLL CHANGING EQUIPMENT

Normally, stainless steel strips are rolled in multi-roll cold mills. The use of a four-high reversing mill for this task necessitates a suitable roll-changing system. That’s why the roll changing facilities had to be modified so as to enable automatic roll chang-ing. The roll changing car now has two cassettes which can accommodate a total of four roll pairs. The number of rolls on the car was thus doubled compared to the conventional design.

The revamping measures were completed by the installation of an au-tomatic oil-air coupler and a paper winder. The hydraulic systems and the safety equipment were adapted to the new local conditions. All new equip-ment was supplied and installed with-in 12 months. (Newsletter 3/08)

Material Austenite, in the

future also ferrite


Strip thickness,

Ingoing max. 5.0 mm

Outgoing min. 0.6 mm

Coil weight max. 36 t

Technical data

Stand design Four-high CVC® 4-HS

Rolling speed max. 800 m/min

Rolling force 22,000 kN

Drive rating 11,500 kW

Reversing coiler No. 1 1,775 kW (2x)

Reversing coiler No. 2 1,775 kW (2x)

Backup roll drive 2,200 kW (2x)

Rolling capacity 200,000 tpy

Technical data


35

A WORLD’S FIRST: CVC® PLUS IN MULTI-ROLL STANDS

For quality and stainless-steel strip

NEW APPLICATIONS

Theis Kaltwalzwerke GmbH in Hagen produces cold-rolled quality and stain-less-steel strip in widths of up to 650 mm on a tandem cold rolling mill which has recently been modernized. SMS Demag – for the first time ever – successfully installed the CVC® plus technology in this mill’s four-high stands which use changeable multi-roll inserts.

Work-roll diameters of 85 to 100 mm in multi-roll operation. The con-ventional four-high tandem mill allows the rolling mode in mill stands 3 and 4 to be varied by adopting so-called

The tandem cold mill.

multi-roll inserts. Unlike the conven-tional four-high mode which uses work rolls with diameters of 275 to 310 mm, the multi-roll mode employs work rolls with diameters of just 85 to 100 mm which are laterally supported by means of rollers. This allows the spectrum of rollable final gages to be expanded, especially for higher-strength steels.

CVC® plus technology as a flexible control element. This necessitates a strip-flatness control element (actua-tor) with a flexibility as ensured in par-ticular by the CVC® plus technology. For each of the two operating modes a

CVC® plus roll contour was determined which covers the entire roll crown range for the respective mode. While in four-high operation the work roll is used as CVC® plus roll, this job or func-tion is taken over by the driven inter-mediate roll in the multi-roll mode.

All flatness requirements met. wWhen using the proven CVC® plus technology in combination with roll bending, all flatness requirements can now be satisfied reliably and reproduc-ibly. This applies to soft IF grades as well as to austenitic stainless steels with strip widths between 320 mm and 650 mm. (Newsletter 2/07)

36

37

High-performance oil wiper unit for ThyssenKrupp Nirosta Dillenburg

In cooperation with Voith GmbH, SMS Siemag developed a new squeegee-roll system for 20-high cold rolling mills and put it through a first series of tests in ThyssenKrupp Nirosta’s works in Düsseldorf-Benrath, Germany.

Won over by the excellent test re-sults, the customer decided to have the new Nipco™ oil wiper unit installed in one of ThyssenKrupp’s other cold rolling mills.

In May 2011, ThyssenKrupp Nirosta GmbH commissioned SMS Siemag to supply our Nipco™ unit for its German Dillenburg works to replace the exist-ing entry- and exit-side oil wiper sys-tems of the 20-roll stainless-steel cold mill. The package comprises the sup-ply of equipment, supervision of erec-tion, commissioning, and trial opera-tion. The revamp will increase the mill’s productivity significantly.

THE NIPCO™ OIL WIPER UNIT

WITH SQUEEGEE ROLLS

Our new high-performance Nipco™ oil wiper unit perfectly adapts to any and all boundary or operating conditions. It ensures a uniform contact pressure through individual hydrostatic support elements which are exactly set to suit the width of the strip to be rolled. This prevents any deflection of the squee-gee rolls which often occurs in con-ventional wiper systems.

The Nipco™ oil wiper unit ensures a uniform wiping effect across the full width of the strip and hence a uni-form distribution of residual oil on the strip surface. As opposed to conven-tional wipers, it reduces the amount of residual oil on the strip by 30 to 60 percent. While other types of oil wip-ers often limit the rolling speed, the Nipco™ oil wiper unit enables a speed increase. (Newsletter 3/11)

Separately adjustable hydro-static support elements.

resulting from the Nipco™ oil wiper unit

Higher rolling speed Less residual oil on the strip Less cooling lubricant being carried along Longer service lives of the squeegee rolls Short revamping time

iADVANTAGES

Revamp matter and mill feature ReferenceActuators Outokumpu Nyby

Theis Hagen TKS Nirosta Krefeld TKS Nirosta Düsseldorf AM Genk Stainless

Automation system Bilstein OAO Severstal

Carousel reel Ilva CorniglianoChain-type magnetic separator OAO SeverstalCoupling of TCM with pickling line (PLTCM) Ilva Cornigliano

OAO Severstal (preparation)Drive system Bilstein

Ilva Novi LigureDS System BilsteinEntry side equipment Rasselstein

Bilstein AM Genk Stainless OAO Severstal

Exit side equipment Ilva Cornigliano AM Brasil TKS Dortmund AM Genk Stainless ISL Pakistan TKS Acciai Speciali Terni

Extension Theis Hagen ISL Pakistan KYCR Bangladesh

Filter system TKS Acciai Speciali Teerni (rolling oil)Fire damage Wickeder Westfalenstahl

TKS DortmundFlatness measuring system KS Nirosta KrefeldHydraulic adjusting system, Hydraulic gap control system Rasselstein

Ruukki Bilstein OAO Severstal TKS Nirosta Krefeld TKS Nirosta Düsseldorf

Media platform, cladding and exhaust system Rasselstein OAO Severstal TKS Nirosta Düsseldorf

Mill relocation Rasselstein AM Genk Stainless

Mill stand replacement OAO SeverstalNipco™ oil wiper system TKN Nirosta DillenburgPaper winder AM Genk StainlessPIOS (Process-IOServer) BilsteinPlug & Work BilsteinRotary Inspect TKS Dortmund

Training Bilstein (Operating personnel)TRC© threading assistance system Bilstein

Register


38

PUBLICATIONS

Nipco®

INNOVATIVE WIPER SYSTEMFOR COLD ROLLING MILLS

METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY

Innovative wiper system

SMS SIEMAG

W6-309E_Nipco.qxp_Neutral 14.01.14 10:48 Seite 1

COLD ROLLING MILLSFOR STAINLESS STEELCOLD ROLLING MILLSFOR STAINLESS STEEL

Modernizationconcepts for abright future


Cold Rolling Mills

SMS SIEMAG

W6-307E_Kaltwalzanlagen_Edelstahl.qxd_Edelstahl 18.12.13 11:46 Seite 1

All publications of

the SMS group

can be ordered via:

www.sms-group.

com/en/print_mate-

rial.php

ONLINE

Published in German and English Order No.: W6/309D or E

Published in German and English Order No.: W6/307D or E

Our new brochures at a glance

are available from our

ordering service

Further publications

REVERSING COLD MILLSREVERSING COLD MILLSReferences

Cold mills

FLAT ROLLING MILLS

SMS SIEMAG

W6-304E_Reversierwalzwerke.qxp_Reversier-Kaltwalzwerke 14.01.14 10:53 Seite 1

Published in German, English or Russian Order No.: W6/304D, E or R

SKIN-PASS MILLSSKIN-PASS MILLS for a perfect finish


Flat-product rolling mills

SMS SIEMAG

W6+7-304E_Dressierwalzwerke.qxd_Referenzen 14.01.14 10:57 Seite 1

Published in German and English Order No.: W6+7/304D or E

SMS SIEMAG AG

Flat Rolling Plants Division

Wiesenstrasse 3057271 Hilchenbach, Germany

Phone: +49 2733 29-1800Telefax: +49 2733 29-1782

E-mail: [email protected]: www.sms-siemag.com

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“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 change 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.”

MEETING your EXPECTATIONS

modernization of cold rolling mills

Documents