W2-303E SectionBillet Mills

SMS metallurgy Conference 2007
Session 2
HOT ROLLING MILLS
Hot rolling, cold rolling and strip
processing
Introduction and market overview
Dieter Rosenthal
Member of the Managing Board
SMS Demag AG
Düsseldorf, Germany
Hot rolling, cold rolling and strip processing
Introduction and market overview
Dieter Rosenthal
The economic situation of the steel in- On the occasion of the METEC 2007
dustry continues to develop very posi- more detailed information and operating
tively. In many regions of the world in- results will be presented within the frame
vestments are made into new plants, ex- of the SMS metallurgy Conference.
isting plants are replaced or modernized.
Due to the introduction of new steel Passion for Metals, documented by a
grades the attractiveness of steel as a multitude of new technologies, equip-
material has been and will further be ment units and services.
steadily enhanced.
The companies of the SMS metallurgy

support the steel industry as partners
through new technologies, the supply of
the most modern mechatronic systems
as well as by providing a multitude of
services in order to further improve eco-
nomic efficiency, productivity and prod-
uct quality of the individual companies.
In the recent years a large number of

new technologies as for example
CVC plus®, T-roll® or CVGL were devel-
oped and refined to operational maturity
in the Hot Rolling, Cold Rolling Mills and
Strip Processing Lines Divisions. Power-
ful mechanical systems, newly devel-
oped and customized modernization
concepts as well as the most up-to-date
mechatronic systems complete the prod-
uct range of the Divisions.
Technology for the whole world of metals
Market requirements for technology supplier
▬
▬ New
New process
process technologies
technologies
▬
▬ Advanced
Advanced and
and reliable
reliable mechatronic
mechatronic systems
systems
▬
▬ Wide
Wide range
range of
of engineering
engineering and
and services
services
▬
▬ Realization
Realization of
of complete
complete plants,
plants, including
including turnkey
turnkey
▬
▬ Project
Project solutions
solutions with
with aa fast
fast ROI
ROI
▬
▬ Environmental
Environmental technologies
technologies

Examples of new products and developments
Tribological roll
Uni plus coiler gap process CVC plus®
model
STEEL INDUSTRY
Technologies for pipe-, DP-,
multiphase grades CVGL
Shears and leveler for

plates Level-2 models CSP®: Extended product mix
Electrics and automation from the technology supplier
Techno-
logical
process
models
Techno-
logical Power
control distribution
systems Special
Special
equipment
equipment
and
and
functions
functions
HMI &
basic Drives
automation
Field
devices

Wide range of services from the technology supplier
Erection and Integrated Maintenance

commissioning Management System
(IMMS®)
Maintenance Technical
outsourcing assistance
Customized
Service
Training Inspection
Repair
Teleservice/ Spare Parts

Hotline Service
Main greenfield references worldwide since 2000
Hot rolling mills, cold rolling mills, strip processing lines
10 Hot rolling mills

8 CSP® plants (Number of stands: 51)
11 Plate mills (Width: 3.2 m to 5.5 m)
8 PLTCMs (Pickling Line/Tandem Cold Mills)

12 RCMs (Reversing Cold Mills)
12 Multi roll mills
14 CGLs (Continuous Galvanizing Lines)

11 PLs (Pickling Lines)
5 CALs (Continuous Annealing Lines)
7 Si-Lines
98 New plants total
Longtime partner for the steel industry
BENEFITS
... for steel producer ... for plant builder
▬ Short project implementation time ▬ Efficient coordination during projects

and fast start-up ▬ Precise and direct customer feedback
▬ Best cost efficiency ▬ Joint development of processes and
▬ Joint development of process know-how technologies
▬ Mechatronic supply from one partner ▬ Customer relationship
▬ Full range of services ▬ Continuous service and
spare parts business

New developments in plate
rolling and plate processing
Dipl.-Ing. Gerhard Horn

General Manager – Technical Sales Hot Rolling Mills Division
Dipl.-Ing. Manfred Dingenotto

Deputy General Manager – Project Planning Hot Rolling Mill
Dipl.-Ing. Peter Schmitz

Senior Project Manager – Hot Rolling Mills Technical Sales
SMS Demag AG
Düsseldorf, Germany
New developments in plate rolling and plate processing
Gerhard Horn, Manfred Dingenotto, Peter Schmitz
Given the high demand for heavy plate For the development of the optimum
worldwide, capacities for plate produc- plant layout, vast experience and close
tion are currently greatly extended. Since cooperation with the customer are of vi-
2000, new plants with an output of tal importance. The layout mainly de-
approx. 8.5 million t have started opera- pends on the production specifications of
tion, and by 2010 more than 20 million t the customer and the site premises
will have been added to this capacity. which is why the arrangement of the
The typical heavy plate mill remains the various plant sections rather often differs
prevailing type of plant as it combines greatly.
high productivity with an excellent prod-
uct quality and a large range of steel To enable the demanded large range of
grades and dimensions. products with a great proportion of high-
strength plates to be produced, new mills
With a market share of more than 50 %, are designed for a great variety of pro-
SMS Demag is definitely the leader of duction technologies. In addition to this,
the market in the heavy plate sector. unrestricted compilation of the rolling
Since as recently as 2005, five heavy- campaigns is called for with great varia-
plate mills supplied by us have been tions in terms of thickness, width and
commissioned, and another six are un- steel grades from one plate to the next
der construction and will start production without negative effects on the productiv-
by 2010. The users of all new mills have ity (schedule-free rolling). Prime quality
awarded contracts to us for the supply of in terms of thickness, width, profile, flat-
the entire process line from the mill ness, rectangularity and a homogeneous
stands to the plate finishing section. The microstructure are likewise expected
scope of supply of some contracts also with all steel grades and even extreme
included the furnaces, equipment for dimensions.
heat treatment and roll shop. An increas-
ing number of the contracts equally in- The production of high-strength plates
clude the electrical equipment and all has implications for all sections of a
automation systems like for the already heavy-plate rolling mill. Mill stands and
completed plant at Xiangtan (China) and plate cooling systems as well as all
the two most recent contracts for MMK in downstream mill sections have to be de-
Russia and Yingkou in China. signed such that high-strength plates
can be produced and processed to ob-
tain top-quality final products. This is
why SMS Demag has improved rolling, 550 mm have already been built several
cooling, leveling and shear technologies times. For even larger roll gaps, a
with a view to achieving highest quality CVC plus® system has been developed
standards. with vertical movement of the shifting
system with the work roll.
The basis for reproducible production
processes and a high production rate is Mill housings in multi-part
a high degree of automation. and bolted design
SMS Demag as system supplier pro-
vides integrated solutions including me- For construction of a new heavy-plate
chanical, electrical and automation mill, procurement of the mill housings
equipment and hence the conditions for may be a bottleneck given the currently
optimum process control. extremely heavy work loads of foundries.
This is why SMS Demag offers multiple-
CVC plus® part bolted mill housings in addition to
well proven single-part mill housings and
In the mill stand sector, the use of the the multiple-part welded design concept.
CVC plus® technology is certainly the Only on site the finish-machined mill
most important development. CVC plus® housing yokes and posts are connected
is an integrated system and based on by strong tension rods. This approach
the combination of work roll bending, axi- simplifies casting of the mill housing,
al shifting of the work roll with the special cuts delivery times and makes shipment
CVC contour as well as technological to the site easier. At the same time, con-
process model (PFC Profile and Flat- trolled preloading of the tension rods en-
ness Control). For each pass, bending sures minor deformation of the mill hous-
and shifting position are reset under con- ing under load and hence very good
sideration of the roll force such that pro- plate travel and excellent plate geo-
file and flatness can exactly be trimmed. metry.
CVC plus® allows higher drafts during
the last passes which altogether implies Cooling system
that a smaller number of passes is re-
quired and therefore productivity is Further development of the material
higher. In addition, CVC plus® makes properties of high-strength plates is one
flexible production possible due to free of the major trends in the heavy-plate
compilation of a rolling campaign. market. Energy producers demand ever
higher strengths and toughness for pipe
The advantages of the CVC plus® tech- grades in order to make the transport of
nology can also be applied for mill energy over very long distances profit-
stands with a large roll gap. Mill stands able. By combining newly developed
with CVC plus® and a roll gap up to spray cooling with the proved laminar
cooling in a cooling system, SMS Demag Cold plate leveler
has developed a crucial metallurgical
tool. In the spray cooling section up- Also for cold leveling, the combination of
stream of the laminar cooling section, a a mechanical solution with an efficient
high-performance high water pressure leveling model has resulted in substan-
station together with special cooling tial improvement. Each leveling roll of
ramps enable very high cooling rates to the patented 9/5 cold plate leveler has a
be reached. This allows accelerated separate hydraulic adjusting system and
cooling and direct quenching for wide, individual drive apart from the hydraulic
thick and thin sheets. With a view to main adjusting system. In conjunction
achieving good flatness despite the high- with the latest-state leveling models, it is
rate cooling, the rolling stock is guided possible to set the ideal curving for each
between pinch rolls in the spray cooling plate and to thus reduce residual stress.
section. The cooling model is based on Individual adjustment of the leveling rolls
the mapping of physical processes and allows operating the cold plate leveler in
controls the cooling process such that the nine-roll and five-roll mode. The lev-
the metallurgical properties are precisely eling range is thus extended up to maxi-
obtained. mum plate thickness of 50 mm and the
leveler has practically the capacity of two
Shear technology levelers.
Accurate cutting of a plate to the re- Summary

quired dimensions is a key quality fea-
ture for the final customer. SMS Demag The presented further and new develop-
has improved the shear technology in ments are the result of close cooperation
such a way that even high-strength between SMS Demag and the rolling mill
plates of a thickness up to 50 mm can be operators, aiming to increase the heavy-
accurately cut. Cropping and dividing plate quality and achieve a high capacity
shears are of the closed-housing design utilization of the installations. The
type. Due to the high rigidity of the struc- CVC plus® technology, multiple-part and
ture, the cutting accuracy and edge qual- bolted mill housings, combined spray
ity can be improved. This design concept and laminar cooling as well as the inno-
and its combination with the rolling cut vations in the shear and leveling technol-
principle applied by all SMS Demag ogy make SMS Demag the forerunner in
heavy-plate shears make it possible to the development of heavy-plate rolling.
cut the plates accurately and with These innovations improve the entire
straight edges. production process from rolling to plate
finishing and have allowed further devel-
oping the material properties and en-
hancing the plate quality.
New developments in plate rolling and processing
Extension of the heavy-plate capacity since 2000

30,000,000
Total capacity
25,000,000 Conventional mills
Plate/Steckel mills
Capacity rise [t/a]
20,000,000
15,000,000
10,000,000
5,000,000
0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Year
SMS metallurgy Conference 2007 1
Latest references of SMS Demag
No. Start-up Customer Width Capacity Stands Remarks

[mm] [Mio. t]
1 2009 Yingkou, China 2.0 2 w. compl. automation systems
2 2009 MMK, Russia 5,000 1.5 1 w. furn., heat treatm't, roll shop, E/A.
3 2008 Pudong, China 4,300 1.6 2
4 2008 Anshan, China 5,500 / 5,000 1.8 2 widest mill stand of latest design
5 2007 Baotou, China 3,800 1.4 2
6 2007 Ural Steel, Russia 2,800 1.15 2

7 2006 Shougang, China 4,300 1.2 1 multiple-part, bolted mill housing
8 2005 Xiangtan, China 3,800 1.4 2 w. compl. automation systems
9 2005 Abu Zaabal, Egypt 3,800 0.12 1 w. furnaces, heat treatm't, roll shop
10 2005 Xinyu, China 3,800 0.8 1

11 2005 Baosteel, China 5,000 1.4 2 roughing stand in 2008

Two-stand heavy plate mill

Minmetals Yingkou Medium Plate Co., Ltd./China
Production capacity 2 million t/year

Commissioning 2009
Slab/ingot block weight, max. 80 t
Plate length, max. 56 m
Total plant length 1,600 m
Total weight of all equipment units 46,000 t
Mill stand area Heavy plate line Heat treatment Painting line
Slab furnaces Roll shop Cooling beds Shearing line Finishing line
Single-stand heavy plate mill

Magnitogorsk Iron & Steel Works (MMK)/Russia
Production capacity 1.5 million t/year

Commissioning 2009
Slab furnaces Mill stand Heavy plate Shearing line Finishing

area line line
Roll shop Cooling beds Heat treatment

Heavy-plate manufacturing program
Plate width [mm]
4250
1250
3500
3750
4000
4500
4750
5000
5250
1500
1750
2000
2250
2500
3000
1000
2750
3250
5
6
7
8
10
12
15
20
30
TM
Plate thickness [mm]
40
50
60
70
80
90
100
120
140
N
160
180
NQ
200
220
240
260
280
300
320
340
360
380
400 TM Thermomechanical rolling
420
N Normalizing rolling
NQ Normalizing rolling and quenching

Source: Dillinger Hütte GTS
Requirements to be met for heavy plate production
▬ Production
Advanced production technologies
(thermomechanical rolling, direct quenching)
Schedule-free rolling
High output (up to 2 million t/year)
Reproducible processes due
to high degree of automation
Economic efficiency
▬ Product
Large range of products, e. g. high-strength low
alloyed steels, shipbuilding steel, structural
steel, pipe grades (up to API X80)
Longitudinal-profile plates
High product quality (thickness, width, profile,
flatness, rectangularity, microstructure)
Reproducible mechanical properties

Latest innovations for the entire process
▬ Increasing requirements to be met by product and production

▬ Growing importance of thermomechanical rolling: more stringent
requirements to be met by the equipment over the entire process line
▬ CVC plus® ▬ 9/5 cold plate leveler

for high-strength plates
▬ Multiple-part mill housing
▬ New, closed-housing
▬ Spray cooling shear design concept
▬ System supplier SMS Demag:

Integrated solutions including mechanical, electrical and automation
CVC plus® as integrated system
CVC
CVC plus®
plus WR
WRshifting/bending
shifting/bendingsystem
system Automation
Automationsystem
system
Process model
PFC
Physical
Patent EP0294544
know how
s
plulus ®
Work roll
crown
VCC p
(Ref. width)
CCV
▬Plate
Plateprofile
profile
® C Shifting
CV
ClV
C position
(Crown)
(crown)
iicca
ssss
l
cclaa ▬Flatness
Flatness

CVC plus®
Most important advantages

▬ Increase in productivity
▬ Extension of product range ("longer, thinner, harder")
▬ Improvement of plate quality in terms of thickness, profile & flatness
▬ Greater flexibility by free compilation of the rolling schedule
▬ Longer roll hours run due to "schedule free rolling"
Relative reduction Production increase (example)

Plate size: 10.0 x 3,250 x 52,000 mm
35
Plate size: 10.0 x 3,250 x 52,000 mm
30 270
Draft [ %]
25
Production [ t/h]
260
+ 12.6%
20
250
15
240
10
without CVC 230
5
with CVC
0 220
1 2 3 4 5 6 7 8 9 10 11 12 13 w. CVC®
Pass w/o CVC®
CVC plus® and work roll bending for mill stands with
different roll gaps
Gap up to 320 mm Gap up to 550 mm Gap above 550 mm

▬ CVC plus® with displaceable ▬ CVC plus® with fixed bending ▬ CVC plus® with vertically
bending blocks blocks and mobile guides for displaceable shifting
the work roll chocks cylinders
▬ References: SSAB, Baotou,
MMK ▬ References: Baosteel, ▬ Recent development
Anshan, Pudong, Yingkou

Mill housing: Multi-part, bolted design concept
▬ Multi-part, bolted mill housing as

alternative design for heavy mill
housings
▬ Housing yokes and housing
posts connected by tension rods
Benefits
▬ Lower casting weights, shorter
delivery times, lower
transportation costs
▬ Less deformation of housing
under load
Expanded concept for plate cooling with spray cooling
Requirements
▬ Increase of cooling rate for further development of high-strength steel
grades
▬ Optimum flatness
Design of spray cooling system

▬ Spray cooling and laminar cooling integrated in one cooling system
▬ Powerful nozzles for very high cooling rates
▬ Pinch rolls between the cooling headers
Pre-leveler Spray Cooling System Laminar Cooling System

(SCS) (LCS)

Spray Cooling System (SCS)
Benefits
▬ Higher cooling rates
▬ Extended thickness range
▬ Enhanced flatness
▬ Flexible cooling strategies
▬ Less alloy charging
▬ Improved weldability
(reduced carbon equivalent)
▬ Homogenous microstructure
References
MMK, Russia(2009)
Pudong, China (2008)
Anshan, China (2008)
Rautaruukki, Finland (2007)
Baosteel, China (2005)
Closed-housing design concept of the rolling-cut dividing

and cropping shears
Conventional C-type New closed-type
Benefits
▬ Higher rigidity of the structure
▬ Greater cutting accuracy
▬ Improved edge quality
▬ Less shear wear
▬ Short cutting times
▬ High plate length accuracy by moveable end stop
▬ Automated shear change
Cold plate leveler

Features
▬ High leveling force (up to
35 MN)
▬ Solely hydr. adjusting system
▬ Individual leveling roll
adjustment
▬ Nine- and five-roll mode with a
single roll cassette
9-role mode
▬ Benefits
▬ Extended leveling range ▬ Less residual stress
9-5 - concept conventional
neutral fibre
5-role mode
Summary
▬ Ongoing further developments of SMS Demag improve the process and

allow high productivity and first-grade product quality:
Four-high stands with CVC plus® and work roll bending
(also with greater roll gap)
Multiple-part bolted mill housing with controlled preloading
Combination of spray and laminar cooling for an extended cooling
technology
Closed and optimized housing design of rolling cut type cropping and
dividing shear for optimum cutting quality
Cold plate leveler with 9/5 mode and individual adjustment of all
leveling rolls for high-strength plates with stringent flatness
requirements
▬ SMS Demag as system supplier offers optimized packages including
mechanical, electrical and automation equipment.

Hot rolling technology for
future mill concepts
Dipl.-Ing. Stephan Krämer

Executive Vice President – Hot Rolling Mills Division
Dipl.-Ing. Stefan Berger

General Manager Technical Sales – Hot Rolling Mills Division
Dipl.-Ing. Kurt Eckelsbach

Vice President – Hot Rolling Mills Division
SMS Demag AG
Hilchenbach, Germany
Hot rolling technology for future mill concepts
Stephan Krämer, Stefan Berger, Kurt Eckelsbach
Looking back on the development of the the two plant types is the coilbox which,
steel industry over the last 15 years, a in compact hot mills, is installed between
major characteristic is beside the posi- the roughing and the finishing mill. It
tive overall economic trend the unex- equalizes the transfer bar temperatures
pected renaissance of the hot rolling mill. to the effect that with as few as six finish-
Out of the about 180 million t of hot strip ing stands final gages of 1.2 mm can be
capacity newly installed worldwide since achieved. The output capacity of a com-
1990, about two thirds were produced by pact hot mill is in the range of
way of conventional hot strip mills. In the 3.5 million t/year, high-performance mills
process, the Asian growth markets were achieve up to approx. 5.5 million t/year.
the most important regional focus for
new plants, both for conventional hot In recent years, the market did not only
strip mills and for thin slab mills: Firstly develop in terms of quantity but also in
China and for some time now India and terms of quality. What is of decisive im-
South Korea. In newly industrializing portance for owners of hot strip mills to-
countries such as the Near East and day is a broad range of products as well
Southeast Asia, new plants were erected as meeting high product quality with re-
in correlation with industrial-political gard to geometrical tolerances and me-
strategies. The third growth region was chanical properties. At the same time,
North America. Here, the mill owners the intensive competition increases the
counted above all on the thin slab tech- necessity for economically efficient pro-
nology which proved to be a suitable duction.
plant type in the strongly changing mar-
ket. Also in Western Europe, this tech- To meet these increased requirements,
nology played an important role in the state-of-the-art plants are rated with
modernization of the steel industry. much higher drive powers, roll forces
and torques, more efficient cooling sys-
For conventional hot strip mills as well as tems and stronger coilers than former
for thin slab mills, SMS Demag is the un- ones. This advancement of plant tech-
challenged market leader. In the next nology becomes apparent in the large
two years alone, six new hot strip mills variety of decisive innovations by
will go on stream with SMS Demag tech- SMS Demag. They improve the hot strip
nology. Among the new plants, there are quality, enable narrower tolerances and
high-performance and compact hot rol- an enhanced dimension range or sup-
ling mills. The main difference between port the development of new steel
grades. Moreover, the innovations aim at eliminated and transfer bar camber is
improving the economic efficiency of the prevented.
rolling process, for example by higher
plant availability and better process sta- Microstructure model
bility.
Another development focus is on the
Characteristic of the most recent innova- modeling of microstructure characteris-
tions is an optimized, well tuned rating of tics. For this purpose, powerful micro-
mechanics, electrics and automation. structure models were developed, con-
This is the prerequisite for further devel- sidering the temperature and deforma-
opments in process control as well as a tion curves and the recrystallization be-
more efficient plant rating. Another ad- havior which allow a precise prediction of
vantage of a close linking between me- the material properties. This enables
chanics, electrics and automation as monitoring and influencing of the me-
supplied by SMS Demag is that for every chanical product characteristics and an
problem the most efficient solution can optimization of the process control for
be found by a combination of the me- steel grades difficult to roll. Moreover,
chanical design and the automation the microstructure models cut the devel-
technology. opment times for new products.
Camber-free rolling The benefit of the microstructure model

becomes apparent for example in rolling
An example of such a solution is cam- micro-alloyed steels. They are character-
ber-free rolling which was successfully ized by a highly complex, temperature-
introduced by SMS Demag. Camber in dependent recrystallization behavior in
the transfer bar resulting from asymme- longitudinal and crosswise directions. If
tric heating of slabs or thickness wedges the work hardening and softening fronts
in the slab is one of the main causes for relocate from the inter-stand area into
reduced stability of the rolling process in the roll gap, the rolling behavior be-
the finishing mill. The combination of comes instable and often results in cob-
strong hydraulic side guides and the bles. The microstructure model can be
automated Roll Alignment Control (RAC) used to optimize the reduction distribu-
largely avoids the formation of camber. tion and temperature control in such a
The heavy side guides actively counter- way that the critical work hardening and
act the formation of strip camber. The softening fronts are under the common
RAC keeps the roll gap perfectly in par- scatter of the process conditions always
allel and thereby enforces a mass flow between the stands.
crosswise to the direction of rolling in the
stock. In this way, wedge formation is
UNI plus coiler ment costs, speed up commissioning
and simplify maintenance.
Currently the modernization of coiler sys-
tems is on the agenda of many owners An example of this development is the
of hot strip mills. This is due to the ever modularization of the mill-stand hydrau-
increasing requirements for coiling high- lics. All hydraulic controls are located in
strength tube grades in ever increasing a media platform on the stand and con-
thicknesses and widths which are more nected via pre-fabricated pipework mod-
and more demanded by the power sup- ules with the hydraulic actuators. Here
pliers. To meet these demands, many each hydraulic function (e. g. hydraulic
well-known mill owners count on the adjustment systems, work roll bending)
UNI plus coiler. It is based on a coiler is implemented in a dedicated module.
design which has proven its worth in The different modules are combined in a
over 100 applications. The further devel- compact column design and accommo-
opment to the UNI plus coiler is charac- dated in the media platform separately
terized by the reinforced mandrel for a for the drive and operator sides.
long service life and the highly dynamic
and precise setting of the position and The advantage of this design is that the
the pressing forces of the wrapper rolls. system's susceptibility to failure is very
The UNI plus coiler thus ensures an ex- low due to protected installation of all
cellent coiling quality also for higher- elements. The hydraulic supply is easy
strength materials in large widths and to service and accessible even in ongo-
thicknesses. ing operation. Moreover, the complete
hydraulic system is pre-assembled in our
An example of this trend is the new shops and tested before installation
UNI plus coiler for Arcelor Bremen which which results in shorter commissioning
will soon go into service and is one of periods.
the most powerful coilers in the world. It
is rated for coiling tube grades with a Plant and process monitoring
maximum thickness of 25.4 mm and a
strip width of 2,100 mm at low strip The Plant and Process Monitoring Sys-
head-end temperatures. tem (PPMS) is focused on maintenance
optimization and avoiding production los-
Modularization ses. It enables a state-orientated mainte-
nance which is a function of the plant's
For improving the economic efficiency in actual condition and is therefore the
any phase of a plant's life cycle, most cost-effective kind of maintenance.
SMS Demag implemented modulariza- The PPMS system is based on three
tion of the hot strip mill to a large degree. main modules: control circuit monitoring,
This concept is able to cut the invest- drive monitoring and alarm analysis. The
control circuit monitoring uses simple Conclusion
characteristic variables for monitoring
the performance of the control circuits These examples show how the proven
and makes tools available for a detailed concept of the conventional hot rolling
analysis of performance deviations. In mill has been complemented by a large
the field of drive monitoring, the PPMS number of technological innovations
includes systems for measuring and leading to major improvements of prod-
analyzing torque, bearing temperature uct quality, productivity and economic ef-
and frequency. The alarm analysis ficiency. As system supplier,
evaluates the warning signals of the SMS Demag offers technologically and
automation system. In that way it points economically optimized overall packages
out weak points and operating errors at of mechanical equipment, electrical and
an early date and enables successively automation systems which ensure that
improving plant operation. the hot rolling mill will continue to be one
of the most important and powerful tools
for producing high-quality hot strip.
Expansion of hot rolling capacities since 1990
160
Hot strip mills Today
140
New capacity in Mio. t/a Thin slab plants
120
100
80
60
40
Under
construc-
20 tion
0
1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010
Year
▬ Worldwide hot rolling capacity: approx. 475 million t (2006)

▬ Thereof thin slab plants: approx. 60 million t
SMS Demag: New plants for hot strip production since 1990
Hot strip mills

CSP® plants

Compact hot strip mill
Roughing stand with edger Coilbox
Compact hot strip mill: annual capacity up to 3.5 million t/year
Finishing mill Laminar strip cooling Downcoiler
Demands on new hot rolling mills

▬ Large product mix
New steel grades
Wide range of product sizes (thinner, thicker, wider, harder)
Future potential (new steel grades)
▬ Tight geometrical tolerances

Thickness, width, profile, flatness
▬ Fit-to-purpose mechanical properties

Strength, formability, surface quality
▬ Economic efficiency
Maximum yield, high process efficiency, reduced downtimes

Dimensioning of new hot rolling mills
Demands Consequences for mill layout
▬ Increased reductions Larger work roll diameter in first mill

stands (F1 - F4)
▬ Lower final gages Smaller work roll diameter in last mill

stands (F5 - F7)
▬ Rolling of high-strength Higher motor power

materials Higher rolling torques
Higher rolling forces
▬ Flexible cooling Installation of higher water quantity in

strategies laminar cooling
More effective cooling devices
(compact cooling)
▬ Enlarged product Larger coiling capacity

spectrum
Important innovations in hot strip production over

the past 20 years
UNI plus coiler
Camber-free rolling
Microstructure model
Plant and process monitoring
Modularization
Compact cooling system

Looper technology (DTL + TML)
CVC plus®
Mandrel-less coilbox
Edge masking
Cooling model based on physical relations
Slab sizing press
Profile and flatness control
Work roll and strip cooling
Hydraulic loopers
CSP® -technology
Hydraulic downcoiler with Step control
CVC®
1985 1990 1995 2000 2005

Integrated solutions by SMS Demag
Optimized, coordinated layout of mechanics, electrical and

automation systems
▬ Further development of process technology requires a profound

knowledge of plant technology
▬ Knowledge of plant technology is basis for an optimum plant layout
▬ Determination of most effective solution for every problem possible
Roughing mill camber-free rolling
Problem
▬ Transfer bar camber due to temperature or
geometrical wedge
Solution
▬ Camber-free rolling as combination of
strong side guides and automated Roll
Alignment Control (RAC)
AS
F1 F2
- -
Thickness wedge σ0 σ1 Camber-free transfer bar
+ +
Direction of rolling BS Material flow

Camber-free rolling
Slab after Slab after

first pass last pass
Measurement of transfer bar camber
transfer bar
length [m]
Modeling of strip microstructure
Targets
▬ Influence on and pre-setting of
mechanical properties
▬ Support for development of new
products
▬ Optimization of the process control
for demanding steel grades
▬ Optimum plant layout
Benefits
▬ Increased rolling stability
▬ Reduced downtimes
▬ Increased yield
▬ Short development time for new
materials

Example: Strain hardening and softening of micro-alloyed

steel
AS Edge waves Edge waves
Move of hardening and
softening front into roll gap
Unstable rolling condition

σF2_1 σF4_0
BS σF3_0 σF3_1
Hardening/
F2 F3 softening front F4
AS σF3_0
σF2_1 σF3_1 σF4_0
Hardening and softening front
well defined between stands
Stable rolling condition
BS
Hardening/
softening front
Stable rolling conditions due to optimization of draft distribution
Developments in coiler technology

Trends
▬ Development of high-strength steel
grades (e. g. pipe grades)
▬ Enlarged dimensions (thicker and wider
strips)
UNI plus Coiler
▬ Reinforced design for thick and wide
high-strength strips
▬ Retention of approved design principles
(more than 100 references)
▬ Long service-time of mandrel
▬ Highly dynamic and precise adjustment of
position and coiling forces
▬ Excellent coiling quality
▬ High reliability and availability

References UNI plus Coiler

▬ Example: UNI plus Coiler for Arcelor Bremen, one of the most
powerful coilers worldwide
Mod.
Target New
▬ Expansion of the product spectrum to high-strength

pipe grades
Requirements to be met by UNI plus Coiler
▬ Material: X 70
▬ Strip width: 2,100 mm
▬ Strip thickness: 25.4 mm
▬ Strip temperature at the head: 470°C
Seven more orders for UNI plus Coiler are placed at present
Modular design
Example: hydraulic system

▬ Modular-design valve stands
▬ Pre-manufactured pipe modules
▬ Pre-assembly and testing in
SMS Demag shop
▬ Protection of all sensitive hydraulic
parts
Benefits
▬ Fast erection on site
▬ Easy maintenance
▬ High availability

Plant and process monitoring in rolling mills
Maintenance strategies
Cost efficiency
Event Time State
orientated orientated orientated
Plant and Process Monitoring System (PPMS)
Control Drive monitoring Alarm

monitoring analysis
Torque
monitoring
Performance Alarm
monitoring Temperature evaluation
monitoring
Inspection
Alarm reporting
tool Vibration
analysis
Conclusion
▬ The hot rolling mill continues to be one the most powerful tools for the
production of high-quality rolled products
▬ SMS Demag improves plant and process technology by means of
continuous innovations
Camber-free rolling
Microstructure model
UNI plus Coiler
Modularization
Plant and process monitoring
▬ SMS Demag as system supplier offers optimized packages of
mechanics, electric and automation

Interactive processes to
develop tailor-made modernization
solutions
Dipl.-Ing. Stefan Berger

General Manager – Technical Sales
Dipl.-Ing. Frank-Günter Benner

Executive Vice President
Dipl.-Ing. Detlef Ehlert

Senior Specialist – Plant Technology
SMS Demag AG
Düsseldorf, Hilchenbach, Germany
Interactive processes to develop tailor-made modernization solutions
Stefan Berger, Frank-Günter Benner, Detlef Ehlert
SMS Demag develops tailor-made mod- Short project time:

ernization concepts which in an interac- The overall project time is to be as short
tive process together with its customers as possible to allow the improvements
are pushed ahead to produce a success- resulting from the modernization project
ful solution. Existing hot strip mills that to become effective as soon as possible.
are suitably modernized can satisfy mar-
ket requirements as much as latest- Short shutdown times:
generation mills. A very important factor is the minimiza-
tion of downtimes. It is the plant de-
Depending on the environment and con- signer's and builder's job to come up with
figuration of any mill, a number of rea- intelligent mechanical solutions that en-
sons may speak for a modernization. sure short installation times.
In most cases these can be summarized
in the categories shown in figure 1. The Use of scheduled maintenance down-
foremost aim in every project is to main- times:
tain or improve competitiveness. A plant owner can be helped best by
carrying out the revamping job during
In the case of comprehensive modern- scheduled maintenance downtimes. De-
ization projects, plant designers and pending on the extent of the project, this
builders are faced with two main chal- cannot however always be accomplished
lenges. It is their job to identify the new without additionally scheduled downtime
equipment plus the one to be modern- days.
ized, to dimension it and to thus suggest
a technical solution which satisfies the Avoiding additional interruptions of pro-
stricter requirements. At the same time a duction:
revamping concept has to be drawn up Of special importance is the reliability of
for the suggested technical solution the revamping projects designed by us.
which takes into account the specified Once the parties have agreed on specific
boundary conditions (figure 2). revamping times, causing additional in-
terruptions of production must definitely
be avoided. Otherwise the customer may
be faced with significant disturbances in
the downstream process chain.
Steep start-up curves:

Planning is designed such that the mill The results of the study will be incorpo-
reliably re-achieves the status it had be- rated in the initial concept. Together with
fore the revamp. Then the new functions the customer this concept is developed
are optimized. further to a joint concept in several
rounds of discussions. The following
Low investment cost: describes in more detail the process
In every cost/benefit consideration of a stages until the joint concept is available.
project it is, of course, important that the
relating investment cost does not prefer- The analysis of the customer require-
ably exceed the planned budget. ment comprises the items described in
figure 4.
In establishing the need for moderniza-
tion, owners take different approaches, Studies give both partners an impression
figure 3. Some of them use analyses to of the actual capability of an existing mill,
define which components of a mill are to figure 5. They essentially include the fol-
be replaced, added or improved. In this lowing work:
case enquiries with mill designers and
builders include specific requirements Fact-finding of the existing mill serves
for, e. g., new or reinforced plant compo- to record the performance parameters of
nents. Other owners specify their targets the existing mill. The information thus
(increase in production; quality improve- obtained is incorporated in the offline
ments, etc.) and leave it to the plant de- simulation of the mill.
signer's/builder's discretion to work out a
suitable modernization concept as part The analysis of the product mix and of
of a study. production yields findings about the re-
quirements which plant components
From the definition of targets to the must satisfy and about bottlenecks of the
finished concept, several stages of pro- mill which prevent an increase in produc-
cessing are passed which again and tion or a specific extension of the product
again require coordination between the range.
mill owner and the mill designer and
builder. With the help of strength analyses of
the critical components the statical
The first phase is the analysis of the tar- and dynamic stressing of critical mill
gets. Where we have already executed components is investigated. It is found
similar projects for comparable mills, an out to which extent the findings derived
initial concept can be presented to the from the production analysis must be
customer shortly after the analysis. In satisfied by the existing mill components
many cases the analysis of targets is as- in terms of the necessary rolling forces,
sociated with the preparation of a study. moments, etc.
Dynamic simulations, e. g. of drive All steps mentioned above will become
trains in conjunction with measured data part of the integrated sequence chart for
from the mill, provide information on the civil work, mechanical equipment, electri-
behavior in extreme load situations. cal equipment and automation systems.
As a result of this study it will be speci- To avoid any surprises during the down-
fied which forces, moments and setting times, risks are minimized, figure 7. New
ranges are needed to fulfill the customer- equipment can be fully assembled and
defined objectives. Solutions for modern- piped in our workshops. All mechanical
ization activities to be implemented are movements are first performed with hy-
then derived from the above in a dialog draulic power. In many cases the auto-
with our customers. mation system is already tested in the
workshop and control parameters are
The implementation of modernization optimized. Further "shadow mode" tests
projects, figure 6, requires maximum ex- will follow after the components have
perience in this field as well as close co- been set up at the customer in parallel
operation with all parties involved. An ex- with the production line.
perienced project management team en-
sures the quality of implementation of Preparatory work during regular mainte-
the project stages and adherence to the nance downtimes and the installation of
scheduled deadlines. A continuous dia- new or existing equipment during longer
log between the customer's and the sup- downtimes (e. g., summer shutdown) will
plier's project teams allows potential be carried out according to detailed time
problems to be recognized at an early schedules.
stage and counteracted in good time.
Our automation systems, figure 8, are
Draft solutions are based on work that completely tested by a simulation of the
has already been successfully performed customer's mill. In reality this means that
in the past. In addition, the effort needed a much lower testing effort will be re-
for adapting to the specific project situa- quired on site during the shutdown. After
tion will be considered. the components have been installed, the
mill may be restarted very quickly. We
The designs will take into account exist- therefore call this function "Plug and
ing foundations which are analyzed with Work".
the help of three-dimensional CAD.
Along with other suitable activities this
will allow the effort required and the
downtimes for the installation of equip-
ment to be established very accurately.
Another activity to ensure short revamp- drive with the drive spindles and the
ing times is the parallel operation of our rolls. The revamping concept that was
automation systems next to the mill. This eventually implemented is described in
means that the new automation system figure 10.
is installed in parallel with the existing
automation system. A software switch is Depending on the boundary conditions
available to change over between the as imposed by the project situation, we
existing and the new automation system. have in the past implemented a variety
of different concepts. Figures 11 to 13
Prior to the start of every major shut- show a few examples ranging from the
down, all boundary conditions are re- revamping of individual components up
checked and in case of possible varia- to the installation of prefabricated equip-
tions from the time schedule, action ment areas on mobile foundation blocks.
plans are worked out together with the
customer. In all examples shown we ensured the
integration of the revamp of the mechan-
Using a few examples from successfully ical equipment, electrical equipment and
implemented modernization projects, we automation system through clearly de-
would like to demonstrate how we have fined steps, figure 14.
developed optimal solutions in an inter-
active process with our customers. The essential factors for successful mod-
ernization jobs (figure 15) are long years
of experience gained in this field and
In the first example, the customer re-
creativity in the development of individu-
quired, figure 9, the installation of a new
al solutions on the basis of vast know-
drive unit to raise the drive torque for a
how and close interaction of all parties
reversing stand. Two independently
involved.
variable drive units for the top and bot-
tom roll were specified. New products to
be rolled required a larger lift of the roll
gap. Bigger work rolls were needed to
transmit higher rolling torques. The avail-
able downtime was not allowed to ex-
ceed 20 days.
The first version produced a twin drive

with a motor power of 2 x 7,000 kW at
30 min-1. Such huge motors, with a
power like this and a speed as low as
this, have never been built before. The
3-D view shows the draft of the twin
Reasons for modernizations
▬ Increase of production
▬ Increase of productivity
▬ Extension of product mix
▬ Improvement of product quality
▬ Replacements
Target: Maintain and strengthen the competitiveness
Conditions for modernizations
▬ Short project time
▬ Short shutdown times
▬ Use of scheduled maintenance downtimes
▬ Avoiding additional interruptions of production
▬ Steep start-up curves
▬ Low investment costs

From the inquiry to the final concept
Customer
Partners SMS Demag
Definition of targets Analysis of the targets

(perhaps study)
Elaboration of first
Common phase of concepts
optimization
- Targets and options -
Draft of a common
concept
Final commitment;
dimensioning
Commonly agreed concept

Proposal/Contract
Analysis of the customer requirements
Analysis of the inquiry
▬ Checking the availability of all required information
▬ Plant survey
▬ First technical discussions and clarifications with the customer for

agreeing on the next steps
▬ Correlation of customer requirements with successfully performed

projects

Performance of studies
▬ Fact-finding of the existing mill
▬ Analysis of product mix and

production level, and identification of
bottlenecks
▬ Strength analysis of critical

components
▬ Dynamic simulation
Results:
Determination of the required forces,

torques, control ranges and consumptions
Elaboration of the modernization concepts
▬ Drawing up of design drafts or adaptation

of reference designs
▬ Analysis of existing conditions, e. g.

foundations, using 3D-CAD
▬ Adaptation of standard mechanical design

to existing conditions
▬ Elaboration of an integrated modification

concept for mechanics, electrics and
automation

Short shutdown and commissioning periods
Measures to ensure very short shutdown and

commissioning periods
▬ Assembly and piping of the Minimizing the

new equipment in our production risk
workshop
▬ Functional test (mechanics, Minimizing the

electrics and automation) commissioning risk
in our workshop
▬ Pre-assembly and test parallel

to the production line (shadow Minimizing the erection
mode) and commissioning risk
Automation systems
Measures to ensure very short shutdown and

commissioning periods
Plug and Work

Test of the automation system
by simulating the mill
Plant in the Loop Test
Parallel operation
Assembly and test of new automation
systems parallel to the existing automation; old new old
Switching between old

Software new
and new automation signal
Software
acqui-
switch
sition

Development of tailor-made modernization solutions
Example of the interactive process to develop the optimal

solution for our customer
Customer requirements:
▬ New reversing-stand main drive
▬ Increased torque
▬ Independent drives for top and bottom roll
▬ Shutdown ≤ 20 days
1st Version
Twin drive with a power
of 2 x 7,000 kW, 30 RPM
Development of tailor-made modernization solutions

Applied concept
▬ Twin drive with two reduction gears in one housing
▬ Pre-assembly of the gearbox and the motors on a new

foundation block
▬ Test of the complete unit incl. oil lubrication system followed by

shadow mode test
▬ Disassembly of the old drives incl.

foundation followed by the
insertion of the foundation block
with the new drive system
▬ Start-up of the mill within 24 h to

the usual daily production level

Modernization options
Exchange of individual components by disassembly of the old

equipment and assembly of the new equipment in the mill
Example:
ThyssenKrupp Steel
Side guides and HGC
for R1
Shutdown
10 days
Disassembly of the old equipment and installation of the

completely assembled new equipment in the mill
Example:
Salzgitter
Roughing stand with
attached edger
Shutdown
18 days

Disassembly of the old equipment and installation of the

completely assembled equipment on a movable foundation
block
Example:
Outokumpu
Three finishing stands
Shutdown
5 ½ days

▬ Parallel switchable operation of old and new automation

system
▬ Commissioning of the old mill with the new automation

system
▬ Integration of the new mechanical equipment
▬ Commissioning of the new mill with the new automation

system

Successful modernizations
Essential factors for a successful modernization:
▬ Long-term experience
▬ Creativity
▬ Extensive know-how and close cooperation of
Project management
Planning of the buildings and civil structures
Mechanical design
Electrics and automation
Process technology
Good cooperation with the customer
▬ Good cooperation with the customer

Evolution of CVC plus®
technology in hot rolling mills
Dipl.-Ing. Hartmut Hof

General Manager
Hot and Cold Rolling Mills/Plant Technology
Dipl.-Ing. Jürgen Seidel

Deputy General Manager Hot Rolling
Dipl.-Ing. Peter Sudau

Vice President Research and Development
SMS Demag AG
Evolution of CVC plus® technology in hot rolling mills
Hartmut Hof, Jürgen Seidel, Peter Sudau
Growing quality requirements and a con- As early as 1980, the CVC® basic prin-
tinuously increasing number of newly de- ciple (Continuously Variable Crown) had
veloped higher-strength steel grades been invented as a perfect addition to
characterize the market for hot rolled the already well-established work-roll
steel. Together with the obligation to pro- bending system, figure 2. Through axial
duce at low costs and in a flexible man- shifting of work rolls with special con-
ner, plant and process technology have tours, it is possible to continuously influ-
to face ever more exacting standards. ence the resulting crown of the rolls and,
Here, ensuring sufficiently high rolling consequently, also the roll gap profile.
stability and, consequently, high plant Parallel to the first practical use, a per-
availability is an essential precondition taining technological process model
for economical production, in particular, (PFC) was developed on the basis of
of high-strength hot thin strips. physical-mathematical methods. This
process model calculates, among others,
The SMS Demag technology concept, the setting values for the CVC® shifting
comprising various interlinked technolo- and work roll bending.
gy modules, constitutes a comprehen-
sive basis for satisfying these require- In the years that followed, the CVC® sys-
ments. Figure 1 shows some examples tem came to be popularly used in the
of such technology modules from the most different types of hot rolling mills
mechanical control elements, control thanks to its simple and efficient operat-
systems and process models. CVC plus® ing principle combined with a robust and
as an effective profile final control ele- reliable mechanical system. The diverse
ment in conjunction with a state-of-the- tasks in the different implementations to-
art process model are indispensable gether with the feedback about practical
modules of this technology concept. The results have led to a continuous further
following pages show how the profile development, with regard to the types of
and flatness control element CVC® has grinding to be used as well as the strate-
evolved into the technology package gies stored in the process model. Today,
CVC plus® through consistent further de- the name CVC plus® comprises the re-
velopment. The efficiency of this technol- sults of these developments as compo-
ogy is recorded on the basis of current nents of a comprehensive technology
operating results. package, figure 3. The classical CVC®
solution with a standard crown setting plate mill stands. This type of stand is
range of, for example, +/- 0.5 mm and characterized by the fact that relatively
cylindrical backup rolls is sufficient for small plates have to be rolled with ex-
the requirements of most hot strip mills. tremely large roll barrel lengths. It is
known that with such geometrical condi-
Modern hot wide strip mills are often tions, the effectiveness for narrow plates
subject to high loads and have to cover a is severely restricted due to the parabolic
vast range of products. Depending on effect of the CVC plus® and work roll
these requirements, the need arises ever bending control elements. As a reaction
more frequently for extremely large set- to this problem, a CVC plus® grinding of
ting ranges of the CVC plus® system es- a higher order was developed, figure 5.
pecially in the first stands, figure 4. By
applying a compensating CVC plus® Compared with the standard grinding of
grinding to the backup roll, it is possible the third order, the equivalent roll crown
today to achieve a crown setting range in the CVC plus® grinding of the fifth
of, for example, -1.3 to +1.1 mm without order shown is extremely enlarged espe-
the symmetrical contact load between cially in the case of narrow plates, with-
the backup roll and the work roll taking out having to increase the difference in
on inadmissibly high values. Of course, it diameter. All products and rolling pro-
must also be borne in mind here that grams are rolled only with one
with the use of modern roll grinding ma- CVC plus® contour. Compared with a
chines today, considerably steeper classical CVC plus® grinding of the third
grinding contours can be ground without order, the effect of the CVC plus® grind-
any errors. ing of the fifth order at the roll gap profile
when shifting from -150 to +150 mm is
The CVC plus® grinding shown in fig- more than 70 % greater depending on
ure 4 has been in operation since Sep- the plate width, figure 6. CVC plus®
tember 2006 in the stands F1 to F4 of grindings of this type have, for example,
the new hot wide strip mill No. 2 at successfully been in use in the plate mill
WISCO. The contour of the CVC plus® stands at Oxeloesund in Sweden and
grinding is described here by a poly- Baoshan in China.
nomial of the third order. Due to the
maximized crown setting range, it is pos- The latest development from the field of
sible to set the customarily required strip CVC plus® technology is the intelligent
profiles for the entire product mix and all shifting strategy with CVC plus® work
operating conditions with only one rolls. According to the state of the art,
CVC plus® contour.
A completely different area of application

for the CVC plus® system are very wide
CVC plus® rolls with large setting ranges rolling program. The work roll bending
are used in the first stands of a hot strip system takes over the responsibility for
mill to set the strip "body" profile, fig- ensuring strip flatness for which almost
ure 7. the entire setting range available is used.
In the rear stands, so-called shape-opti- Towards the end of the rolling program,
mized cyclical shifting strategies with the cyclical strategy is interrupted by the
conventional work rolls are used to im- process model. This prevents the wear
prove the strip contour and to extend the contour from being pushed too far into
times between regrinds. The disadvan- the strip range through further shifting
tage here is the need to provide for dif- and inadmissible strip contours and flat-
ferent sets of work roll grindings adapted ness deviations of a higher order from
to the different types of rolling programs. occurring in the strip edge area. On the
The intelligent shifting strategy with the whole, the desired effect of a relatively
CVC plus® work rolls combines the ad- smoothly descending wear edge on the
vantages of the CVC plus® technology work rolls is attained as a result of the
with the advantages of the shape-opti- cyclical shifting.
mized cyclical shifting strategies in the
rear stands of the hot strip mills. Here, all In the case of work rolls that have not
rolling programs are rolled with only one been shifted, distinctly more unfavorable
CVC plus® contour in the last stands. wear contours are attained under the
same boundary conditions. Normally, the
To explain the operating principle, the passages in one strip width in the rolling
cyclical shifting of work rolls with conven- program have to be reduced accordingly
tional crowns is compared with the cycli- due to the reinforced formation of profile
cal shifting of CVC plus® rolls, figure 8. anomalies in the strip edge area as a re-
This is based on a rolling program for sult of the unfavorable wear contours.
conventional deep-drawn steel with
approx. 40 coils in one width (1,230 mm The intelligent shifting strategy with
x 2.8 mm) prior to roll change. CVC plus® rolls is shown on the right-
hand side of the figure. The process
The left half of the figure shows the clas- model has cyclically shifted the
sical cyclical shifting strategy in which CVC plus® work rolls so that the work roll
the work rolls are shifted from coil to coil bending moves in a defined middle oper-
by a certain dimension to even out the ating range. The automatically ensuing
work roll wear. The work rolls are pro- change in the roll gap profile when shift-
vided with an optimized crown for this ing the CVC plus® rolls is compensated
by changing the setting range for the also available for a precise setting of
work-roll bending system in the opposite these final control elements.
direction. At the end of the roll campaign,
this too results in a wear contour with The comparison of rolled hot strip pro-
smoothly descending edges. files before and after the installation of
CVC plus® technology at the hot strip mill
Ever since the revamp carried out by of Salzgitter Flachstahl shows a marked
SMS Demag, the hot strip finishing mill improvement in the results, figure 13. In
at Salzgitter Flachstahl has CVC plus® addition to the narrower profile toler-
systems in the stands F2 to F7, figure 9. ances, the number of work roll crowns
In addition to the rolled strip profiles C25, has been considerably reduced, bringing
figures 10 to 12 also show some mea- about advantages in terms of roll man-
sured strip transverse profiles for three agement and operating costs.
characteristic rolling programs:
CVC plus® provides us with a proven
▬ Thin sheet and well-known technology package for
▬ Micro-alloyed steel influencing profile and flatness in hot
▬ High-carbon steel strip mills, figure 14. More than 20 years
of experience in practical applications
In an impressive manner, it is demon- have been invested in the ongoing fur-
strated how satisfactory strip profiles are ther development of this technology. The
generated by employing the CVC plus® CVC plus® technology has the potential
technology despite the partially extreme to adapt itself also in the future to the
boundary conditions. continuously growing demands made on
process and plant engineering.
The rolling of high-carbon steels with
long passages of the same strip width
deserves special mention here. A certain
restriction regarding the attainability of
the relevant target profiles arises due to
the fact that the conventional work roll
crowns in stand F1 (which has not been
revamped) will not necessarily always be
in optimum condition. For such sophisti-
cated rolling programs, reproducible pro-
cess stability, in particular with regard to
strip flatness, is an important precondi-
tion. This can only be guaranteed if in
addition to effective profile final control
elements, an efficient process model is
Introduction
Market requirements: Requirements of hot strip producers:
▬ New materials with short cycles of development ▬ High rolling stability and mill availability with
▬ (e. g. HSLA-, multiphase-, C-steels,) restricted tolerances for profile, thickness, width
Introduction/ ▬ Short delivery times
History ▬ Closer tolerances (e. g. profile and thickness) => flexible programming of the rolling sequence
▬ High surface quality (e. g. wheel rim industry) with small lot sizes
Components
CVC plus®
Technological modules of the hot rolling
CVC plus® concept (selection)
setting range
Physical process parameters
CVC plus®
higher order Pass schedule Mass flow Cooling Profile and
model control model flatness (PCFC)
Shifting
strategy
Control systems
Operational Width Mass flow Leveling Flatness
results control control control control
Summary
Mechanical control elements and measuring systems
Hydraulic roll Looper,
Slab sizing CVC plus®
gap adj. differential
press and bending
systems tension looper
History Main steps of CVC® CVC plus® development
1980 Invention of CVC® roll contour

Introduction/
History
1984-85 Installation of CVC system in THYSSEN-HSM 2
(CVC in F3 to F5 and WR bending in F3 to F7)
Components
CVC plus® 1983-88 Development and commissioning of the online Profile
and Flatness Control (PFC)
CVC plus®
setting range 1991 Assignment of CVC® and PFC for Steckel and
aluminum mills
CVC plus®
higher order 1991-93 Extension of the online process model for Profile,
Contour and Flatness Control (PCFC)
AW-Crown
Shifting 1997 Application of CVC plus® for heavy-plate mills
strategy (Application of CVC® -contour 5th order)
Convent.
Operational 1997-05 Successive optimization of PCFC set-up model
results
C Shifting 2005 Intelligent shifting strategies
CV position
Summary

Main components of CVC plus® technology
Introduction/
▬ Optimized mechanical design of the
History shifting/bending system
Components ▬ CVC plus® on work and backup rolls

CVC plus®
▬ CVC plus® grinding of higher order
CVC plus®
setting range ▬ Special CVC plus® grinding for specific
applications
CVC plus®
higher order ▬ Optimized wedge part of CVC plus® grinding
Shifting ▬ Shifting of CVC plus® rolls during rolling
strategy process
Operational Physical
process model ▬ Intelligent shifting strategies
results PCFC
▬ Process model for Profile, Contour and
Summary Flatness Control (PCFC)
CVC plus® on work and backup rolls
cylindrical setting range CVC plus® on

backup roll backup roll
Introduction/ 1.50
History
CVC classic
CVC plus® 1.00
equivalent WR-crown [mm]
Components classical CVC® CVC plus®

CVC plus®
0.50
CVC plus®
setting range 0.00
CVC plus® -0.50

higher order
-1.00
Shifting stand F1 - F4
strategy
-1.50
contact load
contact load
asymmetrical symmetrical
-150 -100 -50 0 50 100 150
Operational
results CVC position [mm]
Summary
▬ Maximized CVC plus® setting range with symmetrical contact load

▬ Example WISCO HSM2, F1 to F4: -1.3 mm +1.1 mm
▬ Efficient profile control for the whole product mix with only one CVC plus® contour

CVC plus® work roll contour of higher order

Extension of equivalent work roll crown
Example: 5.0-m heavy-plate mill
Classical CVC plus® contour CVC plus® contour of higher order
Introduction/ R(x) = R0 + a1x + a2x2 + a3x3 R(x) = R0 + a1x + a2x2 + a3x3 + a4x4+ a5x5
History
shifting + 150mm shifting + 150mm
Components upper roll upper roll
CVC plus®
strip strip
bottom roll bottom roll
CVC plus®
setting range shifting + 150mm shifting + 150mm
equal diameter difference

CVC plus®
higher order equivalent work roll crown equivalent work roll crown
(based on strip width) (based on strip width)
Shifting
strategy 0.8 0.8
0.7 0.7 e.g. BAOSTEEL
Operational 0.6 0.6
results
CR [mm]
CR [mm]
0.5 0.5
0.4 0.4
Summary 0.3 0.3
0.2 0.2
0.1 0.1
0.0 0.0
-3000 -2000 -1000 0 1000 2000 3000 -3000 -2000 -1000 0 1000 2000 3000
CVC plus® work roll contour of higher order

Extension of equivalent work roll crown
Example: 5.0-m heavy-plate mill
Introduction/ 2.50
History
115 %
Components 2.00
CVC plus® 135 %
setting range [mm]
CVC plus® 1.50

setting range 152 %
CVC plus® 1.00

higher order 165 %
Shifting 0.50
173 %
strategy
0.00
Operational
results 1600 2400 3200 4000 4800
product width [mm]
Summary
classical CVC plus® grinding
CVC plus® grinding of higher order

Intelligent shifting strategy with CVC plus® rolls
State of the art:

Introduction/
History
▬ CVC plus® in front stands for adjustment of strip body profile
Components
CVC plus®
▬ Shape-optimized cyclical shifting of work rolls
with conventional work roll crowns
CVC plus®
setting range
=> Improvement of strip contour, minimization of profile anomalies
CVC plus® ▬ Many different work roll crowns necessary for different rolling
higher order programs in last stands
=> Extensive work roll handling
Shifting
strategy
Operational
results
New intelligent shifting strategy in last stands:
Summary
Shape-optimized cyclical shifting of
CVC plus® work rolls
Intelligent shifting strategy with CVC plus® rolls

Comparison of different shifting strategies in the last stands
Cyclical shifting of conventional WRs Cyclical shifting of CVC rolls

Introduction/
History shifting in positive direction
Components
CVC plus®
CVC plus® effect of

setting range contour model
CVC plus® shifting in negative direction

higher order
bending in positive direction

Shifting
strategy
Operational bending used for flatness

results
Summary
work roll wear stand F6 work roll wear stand F6
upper roll
Oberwalze upper roll
bottom roll bottom roll

Operational results of CVC plus® technology

Salzgitter finishing mill with CVC plus® and
work roll bending in last stands F2 to F7
Introduction/
History
Components
CVC plus®
CVC plus®
setting range
CVC plus®
higher order
Shifting
strategy
Operational
results
Summary
Stands F2 to F4: Stands F5 to F7:
▬ Steeper CVC plus® grinding, ▬ Flat CVC plus® grinding
▬ Shifting stroke : ± 120 mm ▬ Shifting stroke: ±150 mm
▬ Setting range : -0.45 mm +0.55 mm ▬ Setting range: -0.10 mm +0.35 mm
▬ Work roll bending : 1,200 kN ▬ Work roll bending: 1,350 kN

Rolling of thin sheet
SALZGITTER
strip thickness [mm]
FLACHSTAHL
6,5 Ein Unternehmen der Salzgitter Gruppe
5,5
Introduction/
4,5
History
3,5
Components 2,5
CVC plus® 1,5
0 20 40 60 80 100 120 140 160
CVC plus®
setting range 1700
strip width [mm]
1600 thickness: 1.52 mm

1500 width: 1,180 mm
CVC plus® 1400 material: S235J
higher order 1300
1200
thickness: 2.01 mm
1100 width: 1,521 mm
Shifting 1000 material: DX51A
strategy 900
0 20 40 60 80 100 120 140 160
Operational
strip profile C25 [μm]
70
results
60
50
Summary 40
30
20
10
0
0 20 40 60 80 100 120 140 160
Number of coils


Rolling of micro-alloyed steel
SALZGITTER

6,5 FLACHSTAHL
thickness: 2.54 mm thickness: 2.04 mm Ein Unternehmen der Salzgitter Gruppe
5,5 width: 1,435 mm width: 1,364 mm

material: 420MC material: PSK38
Introduction/
4,5
History thickness: 1.89 mm thickness: 1.89 mm
3,5 width: 1,307 mm width: 1,071 mm
material: PSK34 material: PSK38
Components 2,5
CVC plus® 1,5
0 20 40 60 80 100 120
CVC plus®
setting range 1700
strip width [mm]
1600
1500
CVC plus® 1400
higher order 1300
1200
1100
Shifting 1000
strategy 900
0 20 40 60 80 100 120
Operational
70
results
60
50
Summary 40
30
20
10
0
0 20 40 60 80 100 120
Number of coils

Flexible rolling 60 km equal strip width
SALZGITTER
6,5 FLACHSTAHL
Ein Unternehmen der Salzgitter Gruppe
5,5
Introduction/ 4,5
History
3,5
Components 2,5
CVC plus® 1,5
0 20 40 60 80 100 120 140 160
CVC plus® measured profiles:
setting range 1700 thickness: 2.03 mm
thickness: 3.03 mm width: 1,235 mm
strip width [mm]
1600 width: 1,235 mm

1500 thickness: 2.53 mm thickness: 2.03 mm
width: 1,250 mm width: 1,235 mm
CVC plus® 1400
higher order 1300
1200
1100 60 km equal width
Shifting 1000 micro-alloyed steel
strategy 900
CK55 CK75 (82 km)
0 20 40 60 80 100 120 140 160
Operational
70
results
60
50
Summary 40
30
20
10
0
0 20 40 60 80 100 120 140 160

Operational results Salzgitter AG:

Strip profile C40 and work roll handling
Before modernization After modernization, with CVC plus® in
(June 2001) F2 to F7 (June 2004)
60 60
SALZGITTER SALZGITTER
FLACHSTAHL FLACHSTAHL
Introduction/ Ein Unternehmen der Salzgitter Gruppe
50
Ein Unternehmen der Salzgitter Gruppe
50
History
Frequency [ % ]
Frequency [ % ]
40 40
Components
CVC plus® 30 30
CVC plus® 20 20
setting range 10,523 strips
10 10
CVC plus®
higher order 0 0
-60 -40 -20 0 20 40 60 80 100 120 -60 -40 -20 0 20 40 60 80 100 120
-40 -20 -0 20 40 60 80 100 120 140 -40 -20 -0 20 40 60 80 100 120 140
Shifting Profile classes [μm] Profile classes [μm]
strategy
Number of different WR crowns: Number of different WR crowns:
Operational ▬ 6 (7) grinding groups at 7 stands ▬ 3 different work roll crowns at F1
results
▬ Total: 16 different grindings ▬ Steep CVC plus® at F2 to F4
▬ Flat CVC plus® at F5 to F7
Summary ▬ Total: 5 different grindings
Conditions: Conditions:
▬ Complicated work roll handling ▬ Less grinding loss
▬ Unscheduled intermediate work roll ▬ Flexible work roll handling
changes can cause a work roll bottleneck ▬ Longer rolling campaigns
▬ Reduced operating costs
CVC plus® technology Conclusion
Customer advantage from

Introduction/ CVC plus® technology:
History
Proven technology
▬ High rolling stability
Components
CVC plus®
in more than High mill availability
CVC plus®
370 hot rolling stands and Extension of product range
setting range (wider, thinner, harder)
54 PCFC models
Flexible programming of the
CVC plus®
higher order
rolling sequence
▬ Reproducible flatter strip profiles
Shifting (e. g. slit strip, Ck67)
strategy
▬ Simplified roll handling
Operational
results
Summary

Softening kinetics of micro-alloyed high-strength steel grades
during hot forming
Dr. Carl-Peter Reip, Dr. Jens Kempken, Stephan Krämer
Compact Strip Production CSP® cast microstructure into a preferably en-

tirely recrystallized austenitic microstruc-
The CSP® technology is typically charac- ture. This requires certain minimum de-
terized by the following three major pro- grees of deformation at temperatures
cess stages: above recrystallization stop temperature.
If the critical degree of deformation
▬ Casting of near-net-shape slabs which is required for dynamic recrystalli-
▬ Temperature homogenization of the zation is reached during this process,
directly charged thin slabs post-dynamic recrystallization processes
▬ Rolling of the thin slabs to obtain the such as meta-dynamic recrystallization
specified hot-strip final dimensions between the passes may become effec-
and defined cooling and coiling of the tive. Meta-dynamic recrystallization,
hot strip. which takes place at a much faster rate
than static recrystallization, is therefore
The special feature of the classical fun- of particular importance in case of micro-
damental thin-slab technology concept is alloyed steel grades with sluggish re-
the coupling of the casting and rolling crystallization properties.
process stages which in the conventional
process are discontinuous. Requirements to be satisfied by
higher-strength line-pipe steel grades
The metallurgical phenomena which are for low-temperature applications
of importance in the various process
stages of the CSP® technology differ Line pipes of steel have proven since
greatly from those taking place in con- long ago to be extremely suitable for the
ventional hot strip production. Due to di- transport of fossil fuels. Depending on
rect charging, the austenitic microstruc- the location of use and the load and ser-
ture resulting from cooling of the thin vice conditions, different requirements
slabs delivered by the caster is main- have to be met in terms of service prop-
tained until rolling. As a result, rolling op- erties. As a rule, steel materials are de-
eration in the first finishing mill stands manded which, in addition to a high
has to transform the relatively coarse enough strength, are sufficiently tough,
have good welding properties and are Selected development steps will now be
resistant to corrosive fluids. Line-pipe presented, for instance:
steel grades for low-temperature applica-
tions as well as use involving exposure ▬ the characterization of the softening
to sour gas are a particular challenge in behavior during the deformation out
the development of steel. of the casting heat
▬ modeling of the microstructure by us-
Requirements to be met especially in ing a recrystallization model
terms of chemical analysis, tensile- ▬ the performance of field trials in a
strength test values and toughness prop- CSP® plant.
erties are compiled in the API stand-
ard 5L. In addition, other requirements Simulation of the deformation out of
specified for instance in specifications the casting heat by means of Gleeble
and supply agreements with customers tests
have to be taken account of.
In analogy with the near-net-shape CSP®
Development of hot strip produced at casting process flow, plane strain upset-
near-net shape with a strength equiv- ting samples were partially liquefied in a
alent with API X65 to X80 Gleeble machine and, after solidification
and controlled cooling, were deformed
A development project was carried out directly out of the casting heat. The hot
with the objective to describe near-net- load-strain curves after temperature and
shape hot strip of strengths ranging from friction correction allow characterizing
500 to 700 MPa and sufficient toughness the softening kinetics of micro-alloyed
even at temperatures as low as -60 °C. higher-strength steel grades in depen-
dence of the steel analysis, temperature,
The toughness properties are consider- deformation rate and deformation histo-
ably determined by the microstructures ry.
in the finished hot strip. It was therefore
a particular metallurgical challenge to Precipitation processes may impair the
define an optimum pass schedule and sequence of static recrystallization. By
cooling strategy in order to achieve suffi- optimizing especially the temperature
ciently fine-grained microstructures, giv- control and also the extent of deforma-
en the demanded hot strip thickness and tion during the first passes in the hot rol-
considering the limited overall degree of ling simulation, it is possible to obtain
deformation.
softened fractions above 80 %. Obvious cro-alloyed versions. The sulfur and
softening particularly over very short pe- nitrogen content could be limited via the
riods of time suggests that dynamically selected charge materials (e. g. scrap,
or meta-dynamically recrystallized struc- DRI, HBI) used in electric steelmaking as
ture portions have formed. well as ladle treatment measures.
Modeling of the microstructure during It was possible to optimize both the mi-
thermo-mechanical rolling crostructure homogeneity and the pre-
cipitation behavior for the CMn (VNb)
In order to design an optimum pass grade. The results are yield point and
schedule and to define the cooling strat- strength values in the range of an X80.
egy, it is necessary to take the metallur- Even higher strength values were ob-
gical phenomena which take place for tained for the Mo-alloyed grade, given
recrystallization, grain coarsening, trans- the greater proportion of granular bainite.
formation as well as the precipitation be- Another result are yield point conditions
havior into consideration. A microstruc- < 0.90.
ture model has been developed for this
on the basis of the known theoretical in- The temperature dependences of the
terrelationships. shear fracture portions determined in the
DWTT (Drop Weight Tear Test) allow to
The grain size resulting from static as derive a Fracture Appearance Transition
well as dynamic and meta-dynamic re- Temperature (FATT) for instance for a
crystallization can be computed succes- shear fracture portion of 85 %. For the
sively for each roll pass on the basis of CMn (VNb) grade, transition tempera-
an initial grain size to be defined as well tures of approx. -50 °C result. In order to
as the respective pass reduction and obtain these transition temperatures, the
rate of deformation. Grain coarsening slab thickness to hot strip thickness
starting in intervals between passes, as ratios must be about 7.
well as an accumulation of deformation
during partial static recrystallization are Outlook
taken into account.
Future activities will be oriented towards
Production of API line pipe steel the description of sour-gas-resistant API
in a CSP® plant grades.
Low-carbon steel grades with limited

amounts of manganese and silicon were
selected as a basis for the experiments.
The CMn (VNbTi), CMn (VNb) and
CMn (VNb)-Mo grades were used as mi-
Softening kinetics of high-strength steel grades
Development task
▬ Pipe steels API X65 X80 with sufficient low temperature

toughness
Challenge for CSP®: Reduction ratio
Caster Soaking furnace Mill and cooling section
Success factors for process strategy
Standard API 5L
Tensile Alloying concept

properties
+ CMn(VNbTi)
Charpy + CMn(VNb)
Chemistry
toughness + CMn(VNb)-Mo
API X
DWTT Customer Action plan

toughness demands
+ Laboratory testing
Others + Micro-structural modeling

+ CSP® processing

Laboratory testing
Gleeble simulation for CSP®

▬ Melting
▬ Solidification
▬ Hot deformation
Estimation of flow curves

Analysis of softening kinetics
CMn(VNb) (500, 710)
200
975°C
180
160 1000°
140 1020°C
1020°C
Flow stress in MPa
120
100
1050°C
1020/975°C
80
1070°C 1050/1000°C
60 1070/1020°C
40
20
0
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3 1,4 1,5
Reduction Ξ
Analysis of softening kinetics
Dynamic/meta-dynamic Delay of static recrystallization

recrystallization by precipitates
Optimization
Softening in %
increased strain lower strain
Interpass time in s
► Optimization of alloying concept and pass schedule

Micro-structural modeling
Hot rolling
Initial grain size Strain ε Dynamic/meta-dynamic recrystallization
Strain rate έ
Calculation of critical strain εc for DRX of

the actual deformation pass
Start of grain
Start of dynamic growth
recrystallization
ε < εc ε > εc Transition to meta-dynamic
recrystallization
Dynamic/meta-
Static
dynamic
recrystallization
recrystallization
SRX
DRX/MRX
Static recrystallization
Calculation of
▬ recrystallized fraction
▬ grain size after recrystallization
Start of static Start of grain
▬ grain coarsening recrystallization growth
▬ strain accumulation
CSP® processing
Concept: CMn(VNbTi)
CMn(VNb)
CMn(VNb)-Mo
Slab thickness: 60 mm
Hot strip thicknesses: 6 to 12 mm
► Production of API grades by CSP® technology

Optimization of microstructure
Initial: CMn(VNbTi)
▬ polygonal ferrite with dav= 6.1 μm
▬ portions of IF with B/AF (7 Vol. % )
Strength increase,
homogenization of
microstructure
CMn(VNb)
▬ small portions of IF with B/AF (2.5 Vol %)
▬ more homogeneous microstructure
▬ fine VN precipitates
Further increase of
CMn(VNb)-Mo strength
▬ portions of granular bainite (29 Vol. %)
Fine ferritic-pearlitic microstructure Alloy CMn(VNb)

Multi-micro-alloying precipitates: Alloy CMn(VNb)

EFTEM analysis of carbon extraction replicas
Nb-Map Ti-Map
7
nm
25
nm
VN
(NbVTi)(CN)
Multi-micro-alloying
precipitates
Fine VN <10 nm
(NbVTi)(CN) 20-70 nm V-Map N-Map
► Strength increase by precipitation hardening of fine VN
Tensile strength vs. yield strength
higher portion of granular bainite
more homogeneous microstructure

reduced grain size
fine VN-precipitates
► High-strength values of up to API X80 and low yield strength ratios

Tensile and toughness properties of CSP® pipeline

steel grades
DWTT:
FATT(85%SA):
-50°C
► Fracture appearance transition temperatures of -50 °C
Current and future activities
Development HIC-resistant grades
Start production X70 on CSP® plants
Test production of high toughness X70/80
Start production X52/60 on CSP® plants
Use of TMCP on CSP® plants
1st trials for TMCP on CSP® plants
Start-up of CSP® plants
► Prospect: Pipe steel for sourgas application

A new strong heart for the
aluminum production at
Aleris Aluminum Koblenz
Dipl.-Ing. Eckehard Jung Dipl.-Ing. Ralf Ohrndorf

Senior Projekt Manager Project Director
Product Sector Aluminum Product Sector Aluminum
Dipl.-Ing. Hendrik Langer Dipl.-Ing. Michael Schäfer

Deputy General Manager General Manager
Design Aluminum plants Product Sector Aluminum
SMS Demag AG
A new strong heart for the aluminum production
at Aleris Aluminum Koblenz
Eckehard Jung, Hendrik Langer, Ralf Ohrndorf, Michael Schäfer
Aleris Aluminum Koblenz is one of the These aims can be attained for the air-
world's leading manufacturers of high- craft builders by reducing the number of
quality aluminum rolling products. The components. Structures which until re-
Koblenz aluminum works founded in cently consisted of several individual
1964 has been part of the American parts are to be replaced by compact
Aleris Group since 2006 and produces structural components which are milled
158,500 t of aluminum strips, sheets and from a thicker plate. At the same time,
plates per year, in particular for the air- there is a trend towards using bigger and
craft, shipbuilding and automotive indus- wider components, for example, when
tries, for tooling and mold making and for building the fuselage, thereby further re-
the manufacture of coolers and heat ex- ducing the number of elements.
changers.
It is therefore important for manufactur-
Aleris Aluminum Koblenz supply around ers of aluminum plates to prepare them-
27 % of their production to the aircraft in- selves for these developments now. With
dustry. Due to the positive growth pros- the existing 148" hot mill stand, Aleris
pects, it is considered one of the most Aluminum Koblenz were able to expand
important future markets for the alumi- their product range to include thicker,
num industry. Experts forecast that by wider and longer plates only to a limited
2025 air traffic will more than double and extent. In order to roll thicker plates, the
thus anticipate that there will be a need mill stand has to meet particularly high
for more than 20,000 new planes. Cur- requirements because high drafts have
rently, the aircraft industry is developing to be performed to ensure a uniform
new model series with lower fuel con- thorough deformation of the material with
sumption and greater passenger and low porosity. For this purpose, the rolling
cargo capacity in order to improve the mills require high rolling forces as well as
profitability and environmental compati- a high rolling torque and sufficiently large
bility of air traffic. At the same time, the work rolls for reliable initial pass. A pre-
manufacturers are striving to reduce cise analysis of the required force and
their manufacturing costs. torque for the rolling of thicker plates
showed that both, the drive train as well work to be performed. All other activities
as the housing window of the 148" mill, have been planned in such a way that
were suitable only to a limited extent for they can take place during ongoing pro-
an increase in the drive power and rol- duction or during regular shutdown peri-
ling forces. Hence Aleris Aluminum Ko- ods for maintenance.
blenz decided to replace the old facility
by a new 160" stand with a new drive. The revamps in Koblenz began in
May 2006 with the preliminary work for
The new mill is designed in such a way the installation of motor and gear unit.
that it produces considerably higher rol- Without disrupting production, a founda-
ling forces at 60 MN (previously 45 MN) tion trough was provided downstream of
and has more than twice the main drive the old drive in which the new motors
power with 2 x 7,000 kW. With the 160" and gear unit were mounted on a mov-
roughing mill, Aleris Koblenz will in- able foundation block. At the beginning
crease capacity by approx. 10,000 annu- of December, the installation work was
al tons and produce plates with a maxi- completed and the new drive was tested
mum width of 3,800 mm at a later date. in parallel to the existing drive in shadow
The new mill will give Aleris Aluminum mode.
Koblenz a clear edge over their com-
petitors. The main shutdown period for the first
phase began on December 20, 2006,
The detailed planning of the individual and lasted 18 days. First of all, the old
steps is of particular importance for such drive unit was removed and the founda-
a revamp project. To reduce the down- tion adapted accordingly. The new drive
times to a minimum, the implementation was then shifted with the foundation
has been divided into two phases. In the block to its position at the location of the
first phase in 2006, the new drive was former motor. The drive spindles were
assembled, new side guides and roller then installed and the new main drive
tables installed and the foundations of was put into operation with the old stand.
the mill stand reinforced. The installation Already one day before the end of the
and commissioning of the new 160" planned plant shutdown, Aleris Alu-
stand will take place in 2007. minum Koblenz was able to go into oper-
ation again.
The two main operations, i. e. the as-
sembly of the drive and the installation of During the same shutdown period, the
the new stand, had been scheduled at foundation in the mill stand area was re-
Aleris Aluminum Koblenz for the custom- inforced by means of a special high-
ary annual shutdown periods over pressure injection procedure. For this
Christmas. They were extended by a few purpose, liquid concrete was injected at
days due to the extensive scope of the high pressure into prepared boreholes
and reinforced with a steel core. Since The second 21-day shutdown period be-
the old roller tables had to be dismantled gins at the beginning of December with
to perform this work, the opportunity was the dismantling of the old mill stand.
used to install new roller tables and new After adapting the foundations, the new
side guides. They had been installed be- stand will be pushed into rolling position
forehand parallel to the mill line and test- over a stretch of around 20 m. The entire
ed. new mill is to be put into operation on
New Year's Eve 2007.
Even for the second revamp phase, the
work is already in full swing. In the sum-
mer of 2007, the new 160" stand will be
fully pre-assembled in the workshop of
SMS Demag in Hilchenbach, Germany.
In September 2007, the stand will be set
up directly next to the mill line and oper-
ated parallel to the existing stand in
"shadow mode" to be able to check all
functions before hot commissioning.
New roughing mill stand for Aleris Koblenz
Aleris Koblenz
▬ Production capacity
158,500 t/year
Aircraft
Coolers/
Heat
exchangers
Automotive
Miscellan-
eous
Ship-
building Mold Construction Sales markets of
making
Aleris Koblenz
Market trends in aircraft industry
▬ Air traffic will more than double by 2025

▬ Increase in air cargo
▬ Growing demands for economic efficiency and
environmental compatibility
▬ Strong growth in aircraft construction
Number of commercial airplanes wordwide
40,000
33,500
7,200
30,000 New Airplanes8,760

for
Replacement
Retained Fleet
++16,400
16,400
Growth airplanes
New planes for
20,000
addit. growth + 22,600
17,100
++7,200
7,200
10,000
Replacements
Replacements
Replacements
9,900
9,900
Retainedfleet
Retained fleet
0
2005 2025
Source:
Source
Airbus
: Airbus

Market trends in aircraft industry
▬ Airbus and Boeing develop a new generation of passenger

planes
▬ Demands on new airplane generation

Higher cargo
Reduced fuel consumption
Cost-efficient production
Trends in aircraft construction
Source: Airbus Source: Airbus
▬ Reduction in number of components

▬ Larger and wider components
▬ Components with optimized structure

Consequences for the production of aluminum plates
Source: Aleris Koblenz
▬ Wider and longer plates and sheets to reduce the number of

components
▬ Thicker sheets for milled structural components
▬ Thicker sheets with uniform or improved deformation as well
as lower porosity
Consequences for the rolling process
Rolling of thicker plates with Rolling of thicker plates with

smaller work roll diameter larger work roll diameter
F
F
R
R
M M
R R
Final
Final
M Product M product
product
Product with
with
casting R completely
completely
R casting F
F deformed
deformed
structure
structure R
R
▬ High drafts required for complete deformation of thick plates

▬ High drafts require high rolling torques and forces

Aleris Koblenz: State prior to revamp
Technical data of 148 roughing mill stand

Rolling force max. 45,000 kN
Work roll diameter 920 mm
Back-up roll diameter 1,525 mm
Rated power 2 x 3,300 kW
▬ Available rolling torques insufficient

▬ New drive system necessary
Analysis of need for modernization
▬ Determining the required rolling forces and torques

Calculation of crucial pass schedules
Determination of drive power and rolling force
▬ Analysis of mechanical components
1. Drive spindle
2. Work roll necks
3. Housing window and mill housing

Results of analysis
▬ Increase of rolling torques necessary

larger work roll diameter
higher drive power
new, stronger drive train
▬ Higher rolling forces necessary

new, stronger housings
▬ Increase in production desired

Wider mill stand (160)
New 160 roughing mill stand

Technical data of new roughing mill stand (160)
Rolling force max. 60,000 kN

Work roll diameter 1,175 mm
Back-up roll diameter 1,750 mm
Rated power 2 x 7,000 kW

Revamp concept
Phase 1
▬ Assembly of new motors and gearbox offline
▬ Pre-commissioning of drive and shadow rolling
▬ Installation of new drive system
▬ Reinforcement of foundations in mill stand area
▬ Installation of new roller tables and side guides
▬ Preparations for installation of new roughing mill stand
Implementation Phase 1
▬ Installation of new drive
2006 2007
01 02 03 04 05 06 07 08 09 10 11 12 01 02 03
Production and downtimes
Construction of foundation with movable block
Assembly of gears and motor
Shadow mode 10 days
Demolition of old drive, adaptation of foundations
Relocation of new drive
Completion and commissioning

Implementation Phase 1:
Reinforcement of foundations in millstand area
▬ Preparation of foundation reinforcements in the millstand

area by means of HDI columns (high-pressure injection
process)
Preparation Injection of concrete Completion of

of a borehole with high pressure HDI columns
Foundation work at
Aleris Koblenz
Revamp concept
Phase 2
▬ Pre-assembly of new roughing mill stand
▬ Renewal of complete automation system
▬ Pre-commissioning of new mill stand and shadow rolling
▬ Installation of new roughing mill stand

Revamp Phase 2
▬ Installation of new roughing mill stand
2007 2008
01 02 03 04 05 06 07 08 09 10 11 12 01 02 03
Production and downtimes
Preassembly of stand in workshop
Transport and installation on site
Cold commissioning
Parallel mode
Tearing down of old stand
Adjustm. of foundation
New stand in position, commissioning
Results
▬ Enlargement of product size (wider, thicker, longer

sheets), by means of
higher rolling forces
higher rolling torques
▬ Increase of production by 10,000 t/year
▬ Revamp with minimal downtimes

MEETING your EXPECTATIONS
SMS DEMAG AG
250/05/07 . WW . Printed in Germany
Hot Flat Rolling Mills Division

Wiesenstrasse 30
METEC 2007 · Session 2 E
57271 Hilchenbach, Deutschland

Phone: +49 (0) 2733 29-1616
Telefax: +49 (0) 2733 29-2832
E-mail: hot.mills@sms-demag.com
Internet: www.sms-demag.com

W2-303E SectionBillet Mills

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SMS metallurgy Conference 2007

The companies of the SMS metallurgy

In the recent years a large number of

SMS metallurgy Conference 2007

Market requirements for technology supplier

SMS metallurgy Conference 2007

Shears and leveler for

SMS metallurgy Conference 2007

Electrics and automation from the technology supplier

SMS metallurgy Conference 2007

Erection and Integrated Maintenance

Teleservice/ Spare Parts

SMS metallurgy Conference 2007

Main greenfield references worldwide since 2000

Hot rolling mills, cold rolling mills, strip processing lines

10 Hot rolling mills

8 PLTCMs (Pickling Line/Tandem Cold Mills)

14 CGLs (Continuous Galvanizing Lines)

... for steel producer ... for plant builder

▬ Short project implementation time ▬ Efficient coordination during projects

SMS metallurgy Conference 2007

Dipl.-Ing. Gerhard Horn

Dipl.-Ing. Manfred Dingenotto

Dipl.-Ing. Peter Schmitz

Gerhard Horn, Manfred Dingenotto, Peter Schmitz

Accurate cutting of a plate to the re- Summary

Extension of the heavy-plate capacity since 2000

SMS metallurgy Conference 2007 1

New developments in plate rolling and processing

Latest references of SMS Demag

No. Start-up Customer Width Capacity Stands Remarks

3 2008 Pudong, China 4,300 1.6 2

5 2007 Baotou, China 3,800 1.4 2

6 2007 Ural Steel, Russia 2,800 1.15 2

8 2005 Xiangtan, China 3,800 1.4 2 w. compl. automation systems

10 2005 Xinyu, China 3,800 0.8 1

SMS metallurgy Conference 2007 2

Two-stand heavy plate mill

Production capacity 2 million t/year

SMS metallurgy Conference 2007 3

New developments in plate rolling and processing

Single-stand heavy plate mill

Production capacity 1.5 million t/year

Slab furnaces Mill stand Heavy plate Shearing line Finishing

Roll shop Cooling beds Heat treatment

SMS metallurgy Conference 2007 4

Heavy-plate manufacturing program

Plate width [mm]

NQ Normalizing rolling and quenching

SMS metallurgy Conference 2007 5

New developments in plate rolling and processing

Requirements to be met for heavy plate production

SMS metallurgy Conference 2007 6

Latest innovations for the entire process

▬ Increasing requirements to be met by product and production

▬ CVC plus® ▬ 9/5 cold plate leveler

▬ System supplier SMS Demag:

New developments in plate rolling and processing

CVC plus® as integrated system

SMS metallurgy Conference 2007 8

Most important advantages

Relative reduction Production increase (example)

SMS metallurgy Conference 2007 9

New developments in plate rolling and processing

8 PLTCMs (Pickling Line/Tandem Cold Mills)

14 CGLs (Continuous Galvanizing Lines)

Conventional C-type New closed-type

Roughing mill camber-free rolling