SOLUTIONS FORALUMINIUM ROLLING MILLSTECHNOLOGY, MECHANICALENGINEERING, AUTOMATION AND
ELECTRICAL ENGINEERING FROMA SINGLE SOURCE – CUSTOMIZEDSOLUTIONS THAT FIT YOUR NEEDS

primetals.com

YOUR CHALLENGEA GROWING NEED FOR PLANT
PRODUCTIVITY AND QUALITY ROLLED
PRODUCTSYOU EXPECT• Leading process technologythat delivers high-quality
products• Fast rolling speed and flexible
production processes• Tailored and comprehensive
solutions that accommodate
the increasing quality demands
for aluminium products• Expandable solutions that
protect your investments into
the future

GROWING MARKETSFLEXIBILITY IS A MUST

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

As your customers’ market needschange, your plant must be capable ofadapting. Short delivery times and fast
production changeover are key criteria
when end customers decide whereto place orders. Dealing with productchanges is therefore a vital factor in
the economics of aluminium rolling.
Logistic design has to be part of theplant solution, too.

IT’S ALL ABOUT QUALITY
Although being able to increase
quantity is important, the key factor
is quality enhancement. The ability
to provide aluminium strip and foilin customized qualities is becoming
increasingly crucial. Your customers
in aerospace, automotive, commercial
transportation and packaging as wellas construction require even tighter
tolerances. To meet these demands,
you need a flexible, easily adaptablerolling setup.

2With ever greater demands foraluminium strip and foil, the needfor increased mill productivity andavailability, better product quality andenhanced reliability continues.

• High plant availability thatlowers operations costs• Long-term performance withservices that meet your needs

THE NEED TO DRIVE COSTS DOWN
Rising raw material costs also haveto be considered. In recent years, theprice of aluminium has risen sharply.
This means waste reduction is an
important target.
HIGH PLANT AVAILABILITY
Plant operations need to be
optimized to increase capacity andimprove quality while decreasing
operating costs. Easy maintenanceis also important for improving plant
availability and strengthening longterm performance.

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OUR SOLUTION
CUTTING-EDGE TECHNOLOGIES FORALUMINIUM ROLLING MILLSADVANTAGES OF
PRIMETALS TECHNOLOGIES• Universal partnership –Primetals Technologies isyour single-source supplier
for mechanical, electrical andautomation equipment• Top quality – our cuttingedge technologies help you
improve quality significantly• Greater efficiency – modular
automation packages
allow you to fine-tune yourprocesses to fit your current
needs

THE ANSWER FOR THE ALUMINIUM
INDUSTRYEFFICIENCY FROM MILL STANDS TO
PRODUCTION PLANNING

Our solution has everything to bringaluminium rolling mills up to speed.
This includes the most powerful roll
drives for higher throughput. Stateof-the-art mechanical and hydraulicsolutions optimize performanceand operational efficiency. Online
process models and neural networks
will enable you to produce moreaccurately than ever before, and ourproven automation solutions maximize
your plant’s end-to-end consistency,
reliability and security in the future.

Our automation technology allows you
to respond quickly to your customers’
requirements and achieve market
driven, flexible production. A modular
strategy, open communications andtransparent automation architecture
ensure that the solution fits yourneeds, whether you’re building a
new plant or modernizing an existingone. Intelligent application-specificsolutions and globally proven drive
concepts, guarantee reliable plant
operation throughout the entire
production process. Maintaining thehighest product quality and ensuresplant availability, you’ll lower youroperating costs significantly.

INCREASED PRODUCTION
With our decades of experience,Primetals Technologies has a deep
understanding of processes in thealuminium industry. Through theseamless integration of technology,
mechanics, automation and electricalengineering, our solutions can help
your plant achieve its highest level ofproductivity.
IMPROVED QUALITY
We use a wide range of specialized
technologies like DSR® (Dynamic
Shape Roll), SmartCrown®, Noncontact shape measurement,
Automatic Gauge control (AGC),
automatic profile and flatness control
and more to achieve highest productquality.

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Our experience ranges from hot
rolling to the finished product. This
allows us to meet the demands both
upstream and downstream – and tobuild the mill that perfectly fits yourrequirements.

• Higher yield – intelligent
process control helps you
reduce waste significantly• Optimum reliability –comprehensive maintenanceand service offerings ensure
the highest availability of yourplant

CUSTOMIZED PRODUCTION
Customers today want aluminium
strip and foil to meet different sizing
specifications. They also want small
batches and good prices. That means
you need fast and flexible production
processes that produce higher yieldthrough reduced cropping, trimmingand off-length losses. Our solutions
minimize scrap from trimmed edges tohelp you achieve unrivalled cropping
and width optimization.
OUR SERVICES ENSURE YOUR
SUCCESSOur professional services are aimed
at helping your plant achieve top
performance throughout its entire
life cycle. Customized preventive andpredictive strategies let you minimize
unplanned downtime and reduce yourcosts on maintenance, spare parts andpersonnel.

5OUR PORTFOLIO
AT A GLANCE

Strip caster

Combined strip caster and hot-rolling millHot-strip rolling mill

Roughing standFinishing standHot-strip rolling mill

Roughing stand with edger

Tandem finishing train

Tandem cold-rolling millSlitting line

Cold-rolling millTension levelling line

Cut-to-length line

Packaging line

Foil mills

Bright finishing mill

CONTENTS
Aluminium mills
Hot mills
8–9
Cold mills
10–11
Foil mills
12–13

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Automatic
high-bay store

PRIMETALS TECHNOLOGIES` OFFERS THE
FULL RANGE OF ALUMINIUM MILL SOLUTIONS
Supplies and services
Life-cycle management
ServiceModernization
Special products
Drive solutions
Automation solutions
Process optimization
Innovation
Selected references

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16–17
18–19
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22–23
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26–27

As your life-cycle partner, we’ll team with you to meet all
your needs, including:• investment planning,• operating concepts and layout

building and civil engineering costs associated withdifferent layouts or planning for future plant expansion
for increased production. Service is another key elementthat Primetals Technologies` delivers. From the trainingof operation and maintenance personnel to the supply ofknowledge and total plant maintenance service, Primetals
Technologies` has the expertise to meet your requirements.

• modernization
We ensure that your plant is always using the latest
technology. We have a proven track record for conducting
complex integrated rolling complex projects and supplying
process equipment. We can also define, supply and install
auxiliary facilities including roll shop, annealing, finishingand packaging equipment. In addition, we can identify

7HOT ROLLING MILLSADVANCED TECHNOLOGY FOR
HIGH-QUALITY PRODUCTS

Chinalco Ruimin – mill build

Our portfolio features a full range of aluminium hot rollingmills for both new and revamp projects.
These include:• Reversing roughing mills• Tandem mills• Twin-coiler mills• Plate mills

Tandem mill window

Novelis 3 Stand Hot MillFEATURESTYPICAL PRODUCT RANGE

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

Strip thickness: 		Strip width: 		
Coil weight: 		Spec. coil weight:
Alloys: 			

• Alcan, Pindamonhangaba, Brazil• Hydraulic systems to provide controllable, responsive,
precise, safe and efficient operation. These include
hydraulic edger, Hydraulic Gauge Control (HGC), work rollbending and shifting, side guides and shears.

1.5 – 8.0 mm
600 – 2,600 mm+30 t+15 kg/mm
1xxx – 8xxx grade• Alcasa, Puerto Ordaz, Venezuela• Alumax, Texarkana, USA• Alunorf, Neuss, Germany

MAIN BENEFITS• Chinalco Ruimin, Fuzhou, China• Flexible, low-cost rolling of a wide range of products,
even for small order lots

• Chinalco NELA, Harbin, China• Mini mills• SmartCrown roll contour guarantees enhanced flatness
control.

With our flexible mill configuration, you can roll high quality
strips in capacities from 100,000 to 800,000 tonnes perannum, depending on the installation. Product technologies
are focused on achieving the highest-quality products.
Primetals Technologies provides advanced mechanicalactuators, electrical and automation control systems
and applied process knowhow to deliver gauge, profile/flatness, temperature and surface quality with the highest
level of consistency. Advanced roll stack actuators such as
SmartCrown and DSR can be custom-selected according to
your specific mill design.

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

• Maximum yield due to hydraulic edging with automatic
width-control functions• An accurate mill setup is crucial for meeting the demands
for quality. Our range features physically based analyticalonline models supported by neural networks to achieve
tight tolerances right from head end.

• High surface quality• TLM, Sibenik, Croatia• Most advanced and innovative automation• Furukawa Sky, Rayong, Thailand• Integrated health and safety concepts• China Steel Aluminium, Kaohsiung, Taiwan

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

• Tightest strip thickness and profile flatness tolerances• Compania Valencia de Aluminio (CVA), Segorbe, Spain• Novelis Korea, Ulsan, South Korea• SouthWest Aluminium, Chongqing, China• Nanshan Aluminium, Nashan, China• Aleris, Zhengjiang, China

9COLD ROLLING MILLSSOLUTIONS FOR HIGH-PRECISIONROLLING

Henan Cold Mill, China

CBA, Sorocaba, Brazil

Heavy Duty, Standard and Light Duty Shapemeter Rotors

6-high millstandThe cold mills supplied by Primetals Technologies offer aunique blend of innovative design and proven technology,
allowing strip to be produced at very tight tolerance andhigh productivity levels.

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

MAIN BENEFITSSELECTED REFERENCES• To ensure an accurate mill setup, our cold rolling mills are
based on physical online process models. This plus our
fully integrated process control, automation and drive
systems allow for optimum rolling results at any time.

• Highest production rates• We offer a range of mill stand technologies to suit theparticular requirements of your project. Options include
DSR backup roll technology, SmartCrown roll technology
and 6-high stand design.

• Tight tolerances for strip thickness, flatness, and highsurface quality

Our mills provide both breakdown and finishing capability,
offering flexibility for the production of a wide productrange from a single mill configuration. The fully integrated
automation and drive system enables automatedequipment sequencing for efficient mill operation. Processcontrol, which uses the latest Primetals Technologies
automation technology, assures the online control of strip
flatness and gauge and allows for the production of highquality products such as can stock, lithographic sheet andfoil stock.
Our portfolio includes:• Breakdown mills• Thin-strip mills• Tandem mills (2 and more stands)

Breakdown mills are available as the more conventional
process option. These mills can be 4-high or 6-high design
and provide the flexibility to operate on the complete
range of alloys, over a wide gauge range of around 10 mm– 0.05 mm. Capacities of up to 150,000 tonnes per year areachievable with this process.
Tandem mills with 2, 3 or 5 stands can be used to extend
the throughput capacity to 300,000 tonnes per year and
more.
Thin-strip mills of 4-high design allow for a finishingcapacity on light gauges of down to around 0.02 mm.
This mill type can be used for foil roughing applications.
Capacities vary and depend on the application, but areusually in the order of 30,000 tonnes per year.

• Edge Wipe technology enhances the Primetals
Technologies‘ strip drying system, addressing the edge
bead issue common on open gap passes.

• Optimized yield• Flexible production• Low costs for operation, maintenance, and minimum
downtimes
SELECTED REFERENCES• Alcoa, Samara, Russia• The Vapour Shield fume cleaning and oil recovery system
ensures environmentally friendly operation and theefficient collection and retrieval of rolling oil.

• Alcoa (KAAL), Moka, Japan• The appropriate choice among a range of flatness
sensors is available:• Aluar, Abado, Argentina• Alcoa Bohai, Qinhuangdao, China• Aluminium Konin, Konin, Poland- A non-contact flatness sensor, ideal for surface
critical applications• CBA, Sorocaba, Brazil- Air Bearing Shapemeter roll, particularly suited tothin-gauge finished products.

• Chinalco NELA, Harbin, China• The Schneider roll coolant filter, manufactured andsupplied under license by Primetals Technologies, is themarket leading filter, enabling high levels of filtration andlong cycle times with its Acticel R filtration media.

• Chinalco Henan, Zhengzhou, China• Comital, Volpiano, Italy• Elval, Inofyta, Greece• South West Aluminium, Chongqing, China• Furukawa Sky, Rayong, Thailand• China Steel Aluminium, Kaohsiung, Taiwan• Mitsubishi Aluminium, Mishima, Japan

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FOIL ROLLING MILLSBEST QUALITY AT THE LOWEST COST

Foil mill, Shanghai Shenhuo, Shanghai, China

Foil mill, Novelis, Bridgnorth, United Kingdom

Foil mill line and coil yard

Primetals Technologies range of high-performance foil
mills combines the latest developments in measurement,
computing and control with innovative mill design toenable you to produce the best-quality foil at the lowest
cost.

The mills feature a number of automated systems for
coil, spool and scrap handling as well as high-speed
work roll change. The design puts you in sync with themarket trend toward larger coil weight combined withwide strip to maximize yield and productivity. The fully
integrated automation and drive system enables automatedequipment sequencing for efficient mill operation. Processcontrol, which uses the latest Primetals Technologies
automation technology, ensures the online control of strip
flatness and gauge and allows for the production of highquality products.

FEATURES

MAIN BENEFITS

Our state-of-the-art high-speed foil mills (all types) have anumber of specific features:• High production rates• Operation and drive-side work roll latching allows forthermal expansion of the rolls to the operator side.
Accommodated by bearing clearances, this eliminates
potential thrust forces on the mill spindles and work rollbend rams during long passes.
• Operation and drive-side backup roll latching similarly
eliminates potential thrust forces on the roll load cylinder
during long passes.
• An optimized mill bearing design with specificallytailored tolerances enhances high-speed operation.

• Flexible production• Tight tolerances for strip thickness and flatness• Low costs operation, maintenance, and minimum
downtimes
SELECTED REFERENCES• NorthWest Aluminium, LongXi, China• Shanghai Shenhuo, Shanghai, China• Varopakorn, Bangkok, Thailand• Oil circulation lubrication to the backup roll bearings
maintains bearing temperatures within their operating
range and allows for the use of synthetic oils, which havea better load carrying capability.
• A work roll and backup roll bearing temperature
measurement function ensures precise monitoring of the
bearing temperatures.
• A constant-force ironing roll permits consistently higher
coiling speeds.
• Spindle piloting eliminates potential roll vibration by
providing a positive location of the roll neck in thespindle end.

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LIFECYCLE MANAGEMENTPARTNERSHIP NEVER ENDSOUR SERVICESBEST PERFORMANCE THROUGHOUTYOUR PLANT‘S LIFETIMENEW INVESTMENTOPERATION

MODERNIZATION• Investigation/
inspections &feasibility study• Servicecontracts• Migration
packages• Spare parts andcomponents• Upgrading andmodernization• Design• Layout• Construction• Installation• Commissioning• Consulting andtraining• Onlineand offline
maintenance• Maintenancecontracting

PRIMETALS TECHNOLOGIES LIFECYCLE SERVICES
As a plant operator, you have conflicting needs. On the one
hand, your performance is measured each quarter against
short-term profitability expectations. On the other hand,
you have to think on a totally different timescale comparedwith the capital market. Depending on the lifetime of yourplant, you have to take 15 years or more into account. At
the very least, that’s 60 full quarters.
But thanks to our comprehensive expertise and integrated
approach to solutions, you benefit both short-termand long-term from our life-cycle services. In the short
term: Backed by our extensive experience with manyreference plants, we provide you with the certainty of fast,
dependable production start-up and shorter amortization
periods.

SERVICE FOR ELECTRICAL EQUIPMENT AND
AUTOMATION

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

The maintenance of your production facilities andequipment is a significant cost factor for you. Yet
unplanned process downtime greatly affects the earningsof the entire company. Risks must be minimized, as mustthe costs for keeping those risks small.
Services offered by Primetals Technologies range fromplanning, consulting and engineering to the supply ofboth individual components and complete productionlines, including safe and rapid start-up. Whether we’reconstructing new plants or modernizing existing capacities,
our own training specialists make sure that your personnel
know how to handle the process and technology safely andefficiently.

OUR OFFERINGS INCLUDE …
• Pre-sale studies from design, engineering and feasibility
studies to improvement studies• Start-up support from on-site training to accelerated
start-up programs
FEATURES• Dedicated spare parts service from small proprietary
items to major assemblies• Stock control and distribution database• Standard packages with measurable client benefits• Dynamic spare parts and material management system• Material information system• Substitution of parts including re-engineering

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

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MILL MODERNIZATIONKEEPING YOUR PRODUCTION
UP-TO-DATEOUR EXPERIENCE IN MODERNIZATION PROJECTS• Evaluation ofequipment andoperationalbottlenecks• Clarificationof operational
practice• Analysis of current
performance andavailability• Simulate possible
mill modifications
based on ROI• Presentation of
possible revamp
concepts• Verificationof possible
equipment
upgrades• Develop revamp
roadmap• Definition of final
revamp solution• Installation andcommissioning• Smooth transition
with minimum
production impact• Documentation ofcurrent status

Key to success: ANALYSIS + REVAMP CONCEPT• Global networkof experienced
personnel• Extensive
experiencethrough numerous
references• Throughput
simulation• Competitive
solutions withshort-term return• Local partners• Scheduledstart-up with top
product quality
right from the
beginning

Systematic approach for target-oriented modernizations

Novelis Utinga, Santo Andre, Brazil after foil mill modernisation

SELECTED REFERENCES• Novelis Packaging, Bridgnorth, United Kingdom• Alcoa, Samara, Russia• Novelis UK, Rogerstone, United Kingdom• Alcoa Bohai, Qinhuangdao, China• Novelis Utinga, Santo Andre, Brazil• Alcoa Europe, Kofem, Hungary• Garmco, Bahrein• Type 1: Mill modernization via ongoing and continuous
improvements and investments• Aleris, Koblenz, Germany• Alcoa Europe, Spain• Type 2: Mill modernization via one or two major
modernization steps• Alunorf, Neuss, Germany• AMAG, Austria• Hindalco, Renukoot, India• Novelis Oswego NY, USA• Hydro Aluminium, Grevenbroich, Germany• Novelis Ulsan, South Korea• Kumz, Kamensk-Uralsky, Russia• Novelis Pinda, Brazil• Logan Aluminum, USA• Constellium Singen, Germany

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

Primetals Technologies experience minimizes downtimes
and ensures fast start-up and top quality.

Primetals Technologies provides solutions that canbe implemented through a phased upgrade with aminimum of downtime in ongoing plant operations. Thisapproach allows the mill to improve its production output,
maintainability, machine access and product quality,
helping you to remain competitive and successful. The
solution may be purely electrical, automation, mechanicalor a combination thereof, and can be carried out in one ormore steps during a plant shutdown.

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A successful modernization project starts with the selectionof one of three types of modernization strategies:• Type 3: Mill modernization via relocation andimprovement of an existing mill

• Nikkei Siam, Bangkok, Thailand• Novelis Korea, Yeongju, South Korea

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SPECIAL PRODUCTSUNIQUE SOLUTIONS TO IMPROVE THE
PERFORMANCE OF YOUR MILL

Dynamic Shape Roll (DSR®)

Non-contact – flatness measurement and control

ISV spray systems

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

SMARTCROWN® WORK ROLL CONTOURFLATNESS PACKAGE

AGC PACKAGESWork rolls are equipped with SmartCrown® (patentpending), a new type of roll contour introduced byPrimetals Technologies. Employing work rolls shifting in
conjunction with specially profiled work rolls significantly
increases the flatness control range. SmartCrown is usually
installed in combination with work roll bending to enableprofile and flatness control. With SmartCrown’s large
adjustment capability, only one grind is needed to replace
all roll grinds for conventional rolls.

Our flatness solution includes all required mechanicalactuators and measurement and control systems to ensure
the highest flatness performance. Depending on the milltype and product mix, the mill stands feature:• Hot-edge sprays – addressing tight-edge issues

Primetals Technologies’ automatic gauge control (AGC)
packages combine the hydraulic capsules, servovalves,transducer and control system to create a comprehensive
solution. Mass flow control ensures thickness precision towithin a few thousandths of a millimetre. Our REC (rolleccentricity compensation) and CECO (coil eccentricity
compensation) system also allows for improved thickness
performance, especially for modernizations.

• Induction heating - addressing tight-edge issues

COOLANT COLLECTION AND FILTRATION SYSTEMSDSR® – DYNAMIC SHAPE ROLLNON-CONTACT FLATNESS MEASUREMENT SYSTEM
This non-contact system helps to you achieve greater
precision and productivity in flatness control. It is basedon the principle of periodically exciting the strip andmeasuring the excitation amplitudes across the strip width.
In practice this means:• Hot-edge sprays - addressing tight-edge issues

Primetals Technologies offers a selection of rolling oil
treatments, including:

The DSR® system from Primetals Technologies is a key
technology for enhancing the performance of cold rollingmills. DSR® replaces the top solid backup roll usuallyemployed in 4-high stands. It provides improved flatness
control, especially in the critical areas at the head and tailends of the strip. This allows for significant improvementsin overall coil yield. Currently, DSR® is the only truly
online dynamic actuator that can enable symmetric andasymmetric changes to the roll gap profile during ongoingproduction.

• High resolution of measurement• Independence from strip speed• Elimination of the need for special coating or surface
treatment• Maintenance that can be performed by your maintenancestaff• Elimination of the need for spare devices• Work roll bending• Multizone cooling ISV Sprays – enabling local corrections• DSR® – giving fully dynamic control• SmartCrown® – allowing for continuous crown adjustment
These actuators work in conjunction with a range offlatness sensors, including:• Air bearing shape roll – high sensitivity, particularly suitedfor foil production, but also available in a cold mill, heavy
duty version• Non-contact measurement for highest surface demands• Placinim® shape roll – robust, solid roll available for hot
and cold applications• Schneider Filter – a multiplate filter designed and madeunder license by Primetals Technologies, providing
microfiltration• Vapour Shield fume cleaning and oil recovery system,
providing effective emission control and recycling ofrecovery rolling oil
Further products offered by Primetals Technologies:• Edge Wipe which removes the coolant edge beadprevalent in cold rolling, thereby improving exit coildryness• Constant-force ironing roll with optimized geometry andservocontrol to maintain straight coil build-up throughout
the coil• Scratch brushes that are work roll chockmounted, with
precise hydraulic loading

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SPECIAL PRODUCTSUNIQUE SOLUTIONS TO IMPROVE THE
PERFORMANCE OF YOUR MILL

Edge Wipe – Coolant Bead removal system

VPT3 - Mill Position Transducer

Integral Solenoid Valve Spray Bar

Air Bearing Shapemeter Roll

COOLANT CARRY OVER CONTROLVPT3 MILL POSITION TRANSDUCERSISV SPRAY TECHNOLOGYSHAPE MEASUREMENTThe Primetals Technologies Edge Wipe, is designed towork in conjunction with conventional mill strip drying
equipment in order to specifically address the problem of
coolant edge bead carry over.
Coolant edge bead is caused by the open gap in the roll
bite outside of strip width. The coolant bead on the strip
edge, if then not removed, contaminates the finished coilby coolant ingress into the coil body.

A range of mill position transducers specifically designed
for the harsh environment of the rolling mill. Mounted tothe hydraulic capsule and offering self-aligning capability
and zero backlash due to the unique mounting system.

The ISV spray technology is a well proven system forapplying roll coolant to flat product rolling mills. With
over 350 references worldwide the ISV is one of the mostversatile spray systems available today.

The air bearing shapemeter roll was first introduced in theearly 1970s just as shape control on flat product mills was
being introduced. Now available in a range of 3 diameters
and with rotor widths available from 25mm wide, the rolls
may be configured to suit any application.

The unit is designed to be mounted in the mill exit table,
close to the mill bite and features the following:• High resolution measurement

BENEFITS• Self-aligning mounting arrangement• No sliding parts in valve

BENEFITS• No bellows• Compatible with kerosene and water based Coolants• High sensitivity• No compression springs• Excellent tolerance to mill contaminates• Continuous output• Incorporates either Magnescale or Temposonictechnologies• Stainless Steel Valve construction• Low inertia – No drive• Front access to valve / solenoid• Simple on-site maintenance• Strokes available from 25mm upwards• Pulse Width Modulated (PWM) capability providing
10:1 flow level turndown• Compact design• Independently indexing heads• Infra-red edge tracking system• Self-adjusting carry over plates
BENEFITS
Controlling edge bead coolant provides the following
benefits:

BENEFITS• Specifically designed for rolling applications• All stainless steel construction

Suitable for all rolling applications from hot mills to foil mills
its simple design ensures reliability whilst advanced thermal
modelling ensures correct nozzle selection for each andevery application.

The air bearing is one of the most sensitive shape sensors
available and can now be offered with Automatic Trend
Alignment which further increases its accuracy andserviceability.

• Large reference list

• Improved coil stability and telescoping• Reduced material staining• Reduced operating and external environmental
contamination

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SPECIAL PRODUCTSUNIQUE SOLUTIONS TO IMPROVE THE
PERFORMANCE OF YOUR MILL

Automatic Trend Alignment

Hot Edge Spray Header

AUTOMATIC TREND ALIGNMENTHOT EDGE SPRAYS

Alignment is particularly important on any flat productrolling mill and failure to maintain alignment can cause strip
and shape problems both online and downstream.

The Primetals Technologies unique solution to applying
hot coolant outboard of strip edge is centred around two
position controlled individual hot coolant spray headers.
This gives the maximum amount of flexibility as to where
the hot coolant is sprayed for optimum results.

The air bearing shapemeter roll in particular benefits fromcorrect alignment both in terms of overall sensitivity andreduction of wearing components. Even a perfectly aligned
mill can produce thrusting emanating from the material
being rolled.
The Automatic Trend Alignment (ATA) for air bearing
shapemeter applications is the ultimate solution to ensure
the highest sensitivity of shape measurement together withimproved reliability. The ATA is available not only on all new
applications but may also be retrofitted onto existing.

Benefits include the reduction of the work roll thermal
gradient at the strip edge to eliminate inboard pockets andtight edges.
BENEFITS• Infinitely adjustable position• Proprietary spray nozzles• Compact design

BENEFITS• Bottom or top spray bar mounting• Automatic operation• More controllable strip edge shape• Thrust sensing• Increased mill speeds• Improved sensitivity• Reduced component wear

Schneider Filter

SCHNEIDER FILTRATIONBENEFITS

Coolant filtration is an essential element in the rolling andforming of all metals. Primetals Technologies supplies theSchneider Coolant system for all rolling applications.

• Improved filtration performance

Offering very high levels of filtration for both mineral oils
and emulsions, it maintains the coolant in “as designed”
condition, extending the life of the roll coolant.

• Improved product quality• Patented green filter media is safe to handle,
no dust hazard.
• Reduced waste streams, zero waste available• Eliminate coolant dumps• Low operating costs• Improved process performance

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DRIVE SOLUTIONSMOVING THE ALUMINIUM INDUSTRY

Reliable and high-quality synchronous main drives for very demanding
applications

Maintenance-free cylindrical rotor

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

MAIN BENEFITS
Primetals Technologies provides the full range of main
drives and auxiliary drives systems. Our expertise covers
the entire range from the power supply to the motor, thus
we can ensure a fully integrated solution to achieve thehighest quality and reliability.

For over two decades, Primetals has pioneered main
drive technology for rolling mill applications. With an
installed base of AC main drives with a combined capacity
exceeding 1 GW (1,000 MW), Primetals has extensive
experience in delivering reliable, high quality main drives
for demanding rolling mill applications.
INTEGRATED DIGITAL DRIVE SYSTEMS
Fully digital, integrated systems with full diagnostic
performance have been designed for drive control withhigh speed multi-microprocessors.
Flexible applications range from single drives with pinion
gears to integrated drive systems for twin-drive andtandem-drive, from DC converters to AC cyclo-converter
drives and AC multilevel drives, covering a wide rangeof power and voltage ratings. Comprehensive softwaredevelopment tools and libraries are supplied as part ofthe system. Diagnostic capabilities with local display of
messages, operator control and monitoring are included in
the applications.

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AUTOMATION SOLUTIONSCOMPLETE PROCESS CONTROL AT
EVERY LEVEL
ERP

MES

Automation

Power, drives, and infrastructure
Process

Leading automation solutions on all plant levels – from the field up to the management level

MODERN AUTOMATION CONCEPT FOR IMPROVED
PRODUCT QUALITY
Technological controls and process models are thecore of any modern automation concept with the goalof maximizing utilization of the mechanical, electrical,
hydraulic and other controlled equipment. The control
concepts have evolved with the increasing performanceof the equipment and increasing demands in terms oftolerances of the final product - from simple analogue
PI controllers to highly complex and interlinked control
systems. These controls and process models are nowadays
integrated and the added value is well visible in the rolled
strip.
These added values are:• improved gauge tolerances,• less off-gauge material,• Perfect profile and flatness to meet growing demands
worldwide.
• Maximum throughput
REALISTIC PHYSICAL MODELS
Primetals Technologies relies on more than 30 years ofexperience in the development of physical models forrolling processes. Thanks to our continuous collaboration
with our customers, universities and metallurgical research
institutions, we now have detailed models for the entire
rolling process. These provide a solid foundation for ourleading automation solutions, especially in the area ofaluminium technology.
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PASS SCHEDULE CALCULATION AND MILL SET-UP

ANOTHER EXAMPLE

MANUFACTURING EXECUTION SYSTEM (MES) SOLUTION

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

Setup calculation for strip threading. In a cold mill,the phase when the strip is threaded and the mill is
accelerated to the desired speed is particularly critical.
A wrong initial setting can lead to strip breaks or cause
poor mill acceleration. The setup calculations basedon our mathematical models help circumvent this byprecalculating the mill setting just before the actual strip
is threaded, based on the current mill status. All necessary
aspects such as the roll wear and temperature, initial roll
profile and incoming strip profile are taken into accountby means of our sophisticated mathematical models. The
online adaptation is performed by means of neural-network
technology.

The Production Management Systems support the
Optimization of the entire supply chain from the receipt
of a customer order through to final product delivery.
Aluminium producers must cope with increasing
complexity in product and order mix. Tight due dates
for product delivery, influenced by last-minute-changes
by customers makes just in time production inevitable,
resulting into high planning and logistics requirements. The
Primetals Technologies’ Production Management Systems
overcome these challenges. The solutions consist of a set ofmodular components, configurable to customer’s specificrequirements. Covering manufacturing execution, stockyard
logistics, quality management & control, advanced planning& scheduling.

A CASE IN POINT
PERFECT TEMPERATURE CONTROL IN HOT MILLSOur sophisticated temperature model takes all physicaleffects into account, including heat conduction into thework rolls, frictional heating, deformation heating andconvective and radiative heat transfer into the atmosphereand cooling water. An intelligent adaptation algorithm
refines the heat transfer coefficients (rather than simply
applying a correction factor to the final result). The modeltakes into account the actual physics of rolling heat transfer
through adaptation, results of which can be applied acrossdifferent plants.

PROFILE AND FLATNESS CONTROL
Strip geometry involves not only width and thickness,but also profile and flatness measures. To meet the
specifications of the market, our profile and flatness control
system builds on sophisticated physical models. A rolltemperature model, for example, analyzes the asymmetricalconditions on the roll surface, while a material flow model
calculates the roll pressure distribution as well as the strip
flatness after each pass. Based on this data, the profile andflatness control system makes sure that the finished strip
has the desired profile or contour and flatness. The profileand flatness controllers fully incorporate and exploit thecapabilities of available actuators such as SmartCrown, rollbending, DSR and roll cooling.

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

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PROCESS OPTIMIZATIONSPECIFIC SOLUTIONS FOR YOURENTIRE PLANT
Process automation

Level 3:primary data

Operator:
manual input

Tables:strategy values

Rolling strategy
Setup calculation(precalculation)

Process control models

EXPERTISE FROM EXPERIENCESELECTED SUCCESS STORIES INALUMINIUM ROLLINGHIGH PRODUCTION, HIGH QUALITY
Customer. Chinalco Ruimin, Fuzhou, China
Plant type. Hot rolling mill
Our solution. 3-stand tandem finishing millTechnical data. Width 1,050 – 2,250 mm; thickness 2.5 – 10.0 mm
The result. Production of 370,000 t/a of high quality hot rolled strip from 2010

Postcalculation

Physical models
Neural networks
to adapt physicalparameters

Adaptation

Measurement
data collection

Basic automation

Our process optimization, process control and basic
automation technology guarantees stable processes andgreater system reliability, as well as custom solutions tomeet your needs right from the design phase.
SCALABLE SOLUTIONSThe Primetals Technologies solutions for the entire
automation and drive system are scalable to your specificrequirements. Solutions can range from simple passschedule storage to a complete pass schedule optimizationand setup system that includes the generation of all
relevant production result data for product quality tracking
and analysis.

Measuring
devices

ALWAYS AT THE LEADING EDGE
Customer. Chinalco Northeast Light Alloy, Harbin, China
Plant type. Hot rolling mill
Our solution. Twin Coiler finishing millTechnical data. Width 900 – 1,850 mm; thickness 2.5 – 18.0 mm
The result. Production of 210,000 t/a of high quality hot rolled strip from 2012

TECHNOLOGICAL CONTROLS
We offer the full range from AGC/AFC packages tofully integrated mill automation and drive systems.
The technological controls includes a complete set ofsophisticated control algorithms for hot, cold and foil
applications. All features are carefully integrated with therelated drive system and mechanical equipment to enableoptimum results.
HMI AND DIAGNOSTICS
The automation system provides easy-to-understand HMI(human-machine interface) screens and features targeted
diagnostics to provide excellent operator guidance.

UP TO A QUARTER-MILLION TONNES – RIGHT FROM THE START
Customer. SouthWest Aluminium, Chonqing, China
Plant type. Cold rolling mill
Our solution. 4-high breakdown mill with DSR®
Technical data. Width 800 – 1,800 mm; thickness 0.15 – 6.0 mm
The result. Production of 250,000 t/a of high-quality cold-rolled strip from2009

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

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SPEEDING INTO THE FUTURE
Customer. CBA, Sorocaba, Brazil
Plant type. Cold rolling mill
Our solution. 4-high breakdown mill with DSR®
Technical data. Width 1,000 – 2,100 mm; thickness 0.075 – 4.0 mm
The result. Production of 50,000 t/a of high quality cold rolled strip from 201029

A QUANTUM LEAP IN QUALITY
Customer. Huta Konin, Konin, Poland
Plant type. Cold rolling mill
Our solution. 4-high thin-strip mill with VC rollTechnical data. Width 900 – 1,650 mm; thickness 0.04 – 1.5 mm
The result. Production of 40,000 t/a of high-quality cold-rolled strip since
2006

FOILS FOR THE FUTURE
Customer. Shanghai Shenhuo, Shanghai, China
Plant type. Foil rolling mill
Our solution. Foil roughing mill, foil intermediate mill, foil finishing mill, all with
VC rolls
Technical data. Width 1,000 – 1,920 mm; thickness 0.006 – 0.6 mm
The result. Production of 25,000 t/a of high-quality foil since 2006

MOVING THE ALUMINIUM INDUSTRY IN CHINA
Customer. Alcoa Bohai, Qinhuangdao, China
Plant type. Mill modernization
Our solution. Relocation and upgrade comprising a 4-high roughing mill and a
3-stand tandem finishing millTechnical data. Width 1,016 – 2,023 mm; thickness 2.0 – 8.0 mm
The result. Production of 150,000 t/a of high-quality hot-rolled strip from 2008

Customer. Chinalco Henan (Henan Zhongfu), China
Type. Cold Rolling MillOur Solution. 4-High breakdown mill with DSRTechnical Data. Width, 900 - 2,100 mm, thickness 5.5 mm - 010 mm
The result. High speed rolling up to 1800m/min, 120,000 tpy production
capacity

Customer. Aleris - Dingsheng, Zhenjiang, China
Plant Type. 4.0m Plate MillOur Solution. Single Stand Plate MillTechnical Data. Width 1,070 - 3,800mm, Thickness 6-250mm
The Result. 250,000 tonnes per annum of heat treated and non-heat treatedsheets and plates

Customer. Novelis Korea, Ulsan
Plant Type. 3-stand Hot Mill
Our solution. 3 Stand hot finishing mill, expansion to existing single stand twin
coiler hot mill to increase throughput
Technical Data. Width 2200 mm (untrimmed - 2150 mm (trimmed), Entry
thickness 60 mm - 25 mm, Exit thickness 6 mm - 25 mm
The result. Improved product quality and mill throughput.

RAZOR-SHARP PRECISION
Customer. Novelis Packaging, Bridgnorth, United Kingdom
Plant type. Mill modernization
Our solution. Extensive upgrade of a 4-high foil finishing millTechnical data. Width 825 – 1,650 mm; thickness 0.0055 – 0.76 mm
The result. Production of 12,000 t/a of high-quality foil since 2003

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Primetals Technologies Limited
A joint venture of Mitsubishi Heavy Industries and partners

Sheffield Business Park
Europa Link | Sheffield, S9 1XU
United Kingdom
primetals.com
Brochure No.: T07-0-N023-L4-P-V3-EN
Printed in Austria© 2020 Primetals Technologies Ltd. All rights reserved
The information (including, e.g., figures and numbers) provided
in this document contains merely general descriptions or
characteristics of performance based on estimates andassumptions which have not been verified.
It is no representation, does not constitute and/or evidence a
contract or an offer to enter into a contract to any extent and is
not binding upon the parties. Any obligation to provide and/or
demonstrate respective characteristics shall only exist if expressly
agreed in the terms of the contract.
These estimates and assumptions have to be analyzed on acase-to-case basis and might change as a result of further
product development.
Primetals Technologies excludes any liability whatsoever underor in connection with any provided information, estimatesand assumptions. The provided information, estimates andassumptions shall be without prejudice to any possible futureoffer and/or contract.
Any use of information provided by Primetals Technologies
to the recipient shall be subject to applicable confidentiality
obligations and for the own convenience of and of the sole riskof the recipient.
Primetals is a trademark of Primetals Technologies Ltd.