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CCM ® – Compact Cold Mills References

CCM ® – Compact Cold Mills References

CCM ® – Compact Cold Mills References
CCM ® – Compact Cold Mills References
CCM ® – Compact Cold Mills References
CCM ® – Compact Cold Mills References
CCM ® – Compact Cold Mills References

COLD ROLLING MILLS

Contents

Introduction 4
Introduction
4
Steel Dynamics Inc. USA 1 0
Steel Dynamics Inc.
USA
1 0
Magnitogorsk Iron & Steel Works Russia 12
Magnitogorsk Iron & Steel Works
Russia
12
Jinan Iron & Steel China 14
Jinan Iron & Steel
China
14
Zhejiang Southeast Metal Sheet China 18
Zhejiang Southeast Metal Sheet
China
18
Jinan Iron & Steel China 14 Zhejiang Southeast Metal Sheet China 18 Jindal South West Steel
Jindal South West Steel Limited India 20
Jindal South West Steel Limited
India
20
Abul Khair 22 Bangladesch KYCR 24 Bangladesch International Steel Industries Pakistan 26 Nam Kim Steel
Abul Khair 22 Bangladesch
Abul Khair
22
Bangladesch
KYCR 24 Bangladesch
KYCR
24
Bangladesch
International Steel Industries Pakistan 26
International Steel Industries
Pakistan
26
Nam Kim Steel Vietnam 28
Nam Kim Steel
Vietnam
28
Hoa Sen 30 Vietnam
Hoa Sen
30
Vietnam

COLD ROLLING MILLS

CCM ® – Compact Cold Mills Latest references

Latest references for two-stand reversing mills

The new concept for two-stand reversing cold rolling mills – Compact Cold Mills (CCM ® ) for short – is a creation of SMS group. What's special here is that we designed this two-stand type specifically for the production volume of minimills arranged downstream of CSP ® plants.

It achieves capacities of 500,000 to 900,000 t of sheet per year, so that this plant type closes the gap between single-stand reversing mills and four-stand tandem mills.

Included in a CCM ® are two roll stands in four-high or six-high technology with variable, process-optimized work- roll diameters as well as state-of-the-art thickness and flatness control systems. Depending on requirements, the stands come with work-roll, intermediate-roll, or backup- roll drive. Another useful feature of CCM ® is that you can change from polished to rough-surface rolls in the final pass. To ensure perfect crown correction, our CVC ® systems have been working effectively for years.

RCM Up to 500,000 tpy

CCM ® 500,000 to 900,000 tpy

TCM Over 900,000 tpy

RCM Up to 500,000 tpy CCM ® 500,000 to 900,000 tpy TCM Over 900,000 tpy
RCM Up to 500,000 tpy CCM ® 500,000 to 900,000 tpy TCM Over 900,000 tpy
RCM Up to 500,000 tpy CCM ® 500,000 to 900,000 tpy TCM Over 900,000 tpy

Cost-optimized production capacity.

TCM Over 900,000 tpy Cost-optimized production capacity. The CCM ® principle, reference plant at Abul Khair,

The CCM ® principle, reference plant at Abul Khair, Bangladesh.

Your advantage: high cost-effectiveness

Investment and operating costs are optimized for the capacity range of the CCM ® and markedly lower than for reversing stands or tandem mills. The CCM ® by SMS group features compact design, which benefits in reduced investment costs of the infrastructure and in high yield.

Flexible applications The CCM ® is sufficiently flexible to meet a whole range of market
Flexible applications The CCM ® is sufficiently flexible to meet a whole range of market

Flexible applications

The CCM ® is sufficiently flexible to meet a whole range of market requirements. Due to free selection of the number of passes, it offers a wide spectrum of pass strategies and proves highly versatile for all customary materials such as sheet, ultra-thin sheet, stainless steel, and Si strip.

Scope for further expansion

Upgrading an existing single-stand reversing cold mill into a CCM ® is not only possible but also affordable at mini- mum effort with our flexible expansion strategy. It’s a budget-friendly solution which, especially in recent years, has been in strong demand from customers in young, emerging markets.

COLD ROLLING MILLS

Our solution

Also available is the option of converting your reversing CCM ® into a tandem mill right up to fully continuous PLTCM using our intelligent concept and durable plant technology. Yet SMS group supplies smart technology not just for any production capacity, but also for impressive product variety.

Especially for rolling a very broad product portfolio ranging from IF grades to high-strength steels including stainless steels, SMS group has developed the CVC ® plus M 18/4 multifunctional stand type that can even be integrated into existing stands. It features easy and rapid-change pack- ages with roll sets in CVC ® plus four-high and 18-high design. Consequently, you can expand your product spec- trum at low cost to supply even small batches that cannot be produced profitably on specialized mills. Switching between the mulit-roll mode and the 18-Its mode is per- formed during a regular roll change.

Proven technological control elements and measuring systems

The tried-and-tested technological control elements we install in our X-Roll ® cold mills guarantee high production, stable and resource-saving operations, as well as excellent strip quality in terms of thickness, flatness, and surface quality.

Included here are:

Hydraulic Roll Adjustment (HGC)thickness, flatness, and surface quality. Included here are: CVC ® plus roll shifting system Positive and

CVC ® plus roll shifting system ® plus roll shifting system

Positive and negative work roll bending, and – depending on the stand type – intermediate roll bendingRoll Adjustment (HGC) CVC ® plus roll shifting system HS Horizontal stabilization Edge Drop Control (EDC

HS Horizontal stabilizationdepending on the stand type – intermediate roll bending Edge Drop Control (EDC ® ) Multizone

Edge Drop Control (EDC ® ) ® )

Multizone coolingHS Horizontal stabilization Edge Drop Control (EDC ® ) Dry Strip system (DS system) EDC ®

Dry Strip system (DS system)Edge Drop Control (EDC ® ) Multizone cooling EDC ® minimizes the typical thickness reduction in

EDC ® minimizes the typical thickness reduction in the strip edge area, reducing trimming losses. We also ensured our DS system is the ideal contact-free way to remove the

our DS system is the ideal contact-free way to remove the rolling emulsion from the strip.

rolling emulsion from the strip. It uses a controlled airflow that also dries the strip surface.

You benefit because DS systems from SMS are both ener- gy-saving and low-noise. T-roll ® process technology precise- ly records the processes in the roll gap. This enables you to configure more energy-efficient cold rolling, thanks to exact advance calculation of rolling temperature, rolling force, lubrication behavior, and surface roughness. As a result, you can reduce friction in the roll gap by precisely adjusting the application of cooling lubricant.

Principle of a highly efficient CCM ® in CVC ® plus six-high design. Shown without
Principle of a highly efficient CCM ® in CVC ® plus six-high design. Shown without

Principle of a highly efficient CCM ® in CVC ® plus six-high design. Shown without housing.

Innovative, high-precision measurement systems such as our X-Shape flatness measuring roller and our system for measuring residual oil on the strip guarantee the strip quality or help you save operating materials.

Effective mechatronic systems

Using our holistic system expertise in mechanics as well as electrics and automation, we develop for and with you flexible, cost-competitive, tailor-made solutions.

Key elements are:

X-Pact ® modular automation packages ® modular automation packages

Plug & Work testsKey elements are: X-Pact ® modular automation packages Energy distribution and drive systems Hardware design

Energy distribution and drive systemselements are: X-Pact ® modular automation packages Plug & Work tests Hardware design Central control stations

Hardware design® modular automation packages Plug & Work tests Energy distribution and drive systems Central control stations

Central control stationsX-Pact ® modular automation packages Plug & Work tests Energy distribution and drive systems Hardware design

COLD ROLLING MILLS

COLD ROLLING MILLS Our latest developments keep you at the cutting edge As a plant operator,

Our latest developments keep you at the cutting edge

As a plant operator, you face high competitive pressure that demands the most efficient, flexible production possible.

SMS supports these requirements through constant improvement of our well-known, proven X-Roll ® technology. Now there is a new generation of X-Roll ® cold mills offering numerous optimizations and innovations.

Assistance systems for yield increase

Yield Optimizer

Simplifies the strip threading process for the manually preset roll gap

Technical features

Consideration of the hot strip profileprocess for the manually preset roll gap Technical features Easy strip threading into the roll gap

Easy strip threading into the roll gapTechnical features Consideration of the hot strip profile Prevention of marks on the strip surface Stable

Prevention of marks on the strip surfacethe hot strip profile Easy strip threading into the roll gap Stable tension build-up Setup tables

Stable tension build-upinto the roll gap Prevention of marks on the strip surface Setup tables or Level 2

Setup tables or Level 2of marks on the strip surface Stable tension build-up Exit side cameras Advantages Strongly reduced off-gauge

Exit side camerassurface Stable tension build-up Setup tables or Level 2 Advantages Strongly reduced off-gauge weight up to

Advantages

Strongly reduced off-gauge weight up to 1.5 %Setup tables or Level 2 Exit side cameras Advantages Increase of yield Fast, stable and reliable

Increase of yieldAdvantages Strongly reduced off-gauge weight up to 1.5 % Fast, stable and reliable threading process Low

Fast, stable and reliable threading processreduced off-gauge weight up to 1.5 % Increase of yield Low investment costs No lead strip

Low investment costsof yield Fast, stable and reliable threading process No lead strip and therefore no additional welding

No lead strip and therefore no additional welding equipment requiredstable and reliable threading process Low investment costs Total Roll Gap Control (TRC ® ) Assistance

Total Roll Gap Control (TRC ® )

Assistance system for automatic strip threading into the preset roll gap

Technical features

Automatically strategy adaption on thickness, material and respectively to operator demandstrip threading into the preset roll gap Technical features Close to target strip thickness already at

Close to target strip thickness already at head endon thickness, material and respectively to operator demand Direct roll gap measurement or installation of load

Direct roll gap measurement or installation of load cells under wedge adjustment systemdemand Close to target strip thickness already at head end Level 2 automation Exit side cameras

Level 2 automationor installation of load cells under wedge adjustment system Exit side cameras Advantages Highest savings in

Exit side camerasload cells under wedge adjustment system Level 2 automation Advantages Highest savings in off-gauge wight Increase

Advantages

Highest savings in off-gauge wightsystem Level 2 automation Exit side cameras Advantages Increase of process stability No lead strip and

Increase of process stabilityside cameras Advantages Highest savings in off-gauge wight No lead strip and therefore no additional welding

No lead strip and therefore no additional welding equipment requiredsavings in off-gauge wight Increase of process stability The yield optimizer significantly increases the yield of

strip and therefore no additional welding equipment required The yield optimizer significantly increases the yield of

The yield optimizer significantly increases the yield of batch mills.

Ideally used in new mills for standard productsoptimizer significantly increases the yield of batch mills. Interesting for modernizations with limited budget TRC ®

Interesting for modernizations with limited budgetbatch mills. Ideally used in new mills for standard products TRC ® is part of the

products Interesting for modernizations with limited budget TRC ® is part of the level 2 automation.

TRC ® is part of the level 2 automation. For the first time it was installed in Bilstein’s tandem cold mill as part of a revamp.

Ideally used in new mills for high-grade productsin Bilstein’s tandem cold mill as part of a revamp. Interesting for modernization with complete exchange

Interesting for modernization with complete exchange of the level 2/level 1 automationit was installed in Bilstein’s tandem cold mill as part of a revamp. Ideally used in

Emulsion Compact Unit (ECU)

Emulsion plant in very compact design with only small space requirements

Technical features

Multi-level installationdesign with only small space requirements Technical features Reuse of heat from the rolling process Reduced

Reuse of heat from the rolling processrequirements Technical features Multi-level installation Reduced piping Advantages Considerably reduced space

Reduced pipinginstallation Reuse of heat from the rolling process Advantages Considerably reduced space requirements (up to 40

Advantages

Considerably reduced space requirements (up to 40 %)of heat from the rolling process Reduced piping Advantages Reduced energy consumption Lower investment level Sieflex

Reduced energy consumptionConsiderably reduced space requirements (up to 40 %) Lower investment level Sieflex ® -HT gear type

Lower investment levelspace requirements (up to 40 %) Reduced energy consumption Sieflex ® -HT gear type drive spindle

Sieflex ® -HT gear type drive spindle

Transmission of high rolling torques even at small work roll diameters

Technical features

Improved tooth rim designtorques even at small work roll diameters Technical features Material of higher wear resistance Enlargement of

Material of higher wear resistanceroll diameters Technical features Improved tooth rim design Enlargement of alignment range up to 3.5 degree

Enlargement of alignment range up to 3.5 degreeImproved tooth rim design Material of higher wear resistance Advantages Smaller work rolls Lower rolling force

Advantages

Smaller work rollsEnlargement of alignment range up to 3.5 degree Advantages Lower rolling force Reduced operating costs More

Lower rolling forcerange up to 3.5 degree Advantages Smaller work rolls Reduced operating costs More compactly designed new

Reduced operating costs3.5 degree Advantages Smaller work rolls Lower rolling force More compactly designed new mills Increased capability

More compactly designed new millswork rolls Lower rolling force Reduced operating costs Increased capability of existing plants Optimal for product

Increased capability of existing plantsReduced operating costs More compactly designed new mills Optimal for product mix including high and ultra-high

Optimal for product mix including high and ultra-high strength gradesdesigned new mills Increased capability of existing plants DS System Cost efficient strip blow-off system by

DS System

Cost efficient strip blow-off system by reduced com- pressed air consumption

Technical features

Optimal combination of stationary and moveable sealing elementsby reduced com- pressed air consumption Technical features Contact- and wearless sealing of the work roll

Contact- and wearless sealing of the work roll barrel by the COANDA-nozzlecombination of stationary and moveable sealing elements Targeted and perfectly balanced blow-off and exhaustion

Targeted and perfectly balanced blow-off and exhaustion areassealing of the work roll barrel by the COANDA-nozzle Advantages Reduced noise emission 50 % reduced

Advantages

Reduced noise emission

Reduced noise emission

50 % reduced maintenance costs

50

% reduced maintenance costs

More than 60 % reduced energy costs

More than 60 % reduced energy costs

80 % less rejected coils because of emulsion residues

80

% less rejected coils because of emulsion residues

on the strip

rejected coils because of emulsion residues on the strip ECU-concept for a pickling line tandem cold
rejected coils because of emulsion residues on the strip ECU-concept for a pickling line tandem cold

ECU-concept for a pickling line tandem cold mill with separate emulsion plants for rolling stands 1-4 and 5.

with separate emulsion plants for rolling stands 1-4 and 5. Drive train with Sieflex ® -HT

Drive train with Sieflex ® -HT gear type drive spindle for a cold rolling mill with work roll drive.

drive spindle for a cold rolling mill with work roll drive. Exit side installation of blow-off

Exit side installation of blow-off system in the last stand of a cold rolling mill.

COLD ROLLING MILLS

Steel Dynamics Inc., Butler, USA

World's first CCM ® plant

The Compact Cold Mill for Steel Dynamics Inc. (SDI) in Butler, USA, is designed to roll all hot-strip grades pro- duced on the upstream CSP ® plant. That means it is capa- ble of processing SAE 1006 to 1030 including HSLA steels. This input material goes to make cold strip in widths of up to 1,575 mm and minimum thicknesses of 0.38 mm.

The mill consists of two four-high CVC ® roll stands, a gear- type payoff reel, and two direct-driven reversing reels in the entry and exit sections (high-tension reels). The small- est work-roll diameter is 400 mm.

reels). The small- est work-roll diameter is 400 mm. To meet the high requirements here, the

To meet the high requirements here, the backup rolls are supported in oil bearings. This allows the rolls to be ground in the neck sleeves for maximum true-running accuracy. Also contributing to top product quality are the state-of- the-art thickness and flatness control systems.

Housing window of the four-high roll stands.

quality are the state-of- the-art thickness and flatness control systems. Housing window of the four-high roll
quality are the state-of- the-art thickness and flatness control systems. Housing window of the four-high roll
View of the entry side with 2 reels. CVC ® -4 Reversing cold rolling mill,
View of the entry side with 2 reels. CVC ® -4 Reversing cold rolling mill,

View of the entry side with 2 reels.

CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned in 1997)

Production data

Technical data

Technical features

Material

SAE 1006 to 1030,

Stand design

CVC ® -4

Axially shiftable work rollsMaterial SAE 1006 to 1030, Stand design CVC ® -4

incl. HSLA,

Rolling speed

max. 1,350 m/min

(for CVC ® control)

CQ 50 %, DQ 30 %

Rolling force

max. 22,000 kN

Positive and negative work-rollCQ 50 %, DQ 30 % Rolling force max. 22,000 kN

Strip width

915 to 1,575 mm

Capacity

approx. 850.000 tpy

bending

Strip thickness

DS system (Dry Strip)Strip thickness

ingoing

2.03 to 3.96 mm

Direct-driven tension reelsingoing 2.03 to 3.96 mm

outgoing

0.38 to 2.18 mm

Oil bearings (BUR bearings)outgoing 0.38 to 2.18 mm

Coil weight

28 t

Payoff reel and reversing reel.

Coil weight 28 t Payoff reel and reversing reel. Run-up curve. 100 75 50 25 0

Run-up curve.

100 75 50 25 0 1 2 3 4 5 Months after commissioning Production [%]
100
75
50
25
0
1
2
3
4
5
Months after commissioning
Production [%]

COLD ROLLING MILLS

COLD ROLLING MILLS Magnitogorsk Iron & Steel Works Magnitogorsk Iron & Steel Works, Russia Tailor-made design

Magnitogorsk Iron & Steel Works

Magnitogorsk Iron & Steel Works, Russia

Tailor-made design for special products

Originally, the SMS-patented Compact Cold Mill (CCM ® ) design was developed for the cost-optimized production of cold-rolled material in a typical minimill. Yet, due to its great flexibility, the two-stand reversing cold rolling mill is also recognized as a tailor-made design for manufacturing special products in an integrated metallurgical complex – such as Magnitogorsk Iron & Steel Works (MMK).

This project represents a key milestone for MMK in improving its competitiveness in cold-rolled products. Opting for CCM ® paid off for MMK in terms of an opti- mum balance between investment and yield.

Operating results

We preassembled many of the units in the stand and interstand areas as well as in the entry and exit sections in our Hilchenbach workshop.

That ensured a short erection phase and commissioning. As a result, the first strip in saleable quality rolled off the line straight away. Fully operational from the start were all technological controls including the shifting and bending system.

Then, over the following weeks, we optimized the process controls and boosted the yield.

There were words of praise from our customer when the plant surpassed the contractually agreed performance guarantees for strip thickness and flatness tolerances as well as off-size lengths. Today, the system achieves excel- lent quality results in all operating modes.

Housing window.

lengths. Today, the system achieves excel- lent quality results in all operating modes. Housing window. Exit

Exit side.

lengths. Today, the system achieves excel- lent quality results in all operating modes. Housing window. Exit
Overall view of the mill. CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned
Overall view of the mill. CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned

Overall view of the mill.

CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned in 2002)

Production data

Technical data

Technical features

Material

LC, HSLA

Stand design

CVC ® -4

Axially shiftable work rollsMaterial LC, HSLA Stand design CVC ® -4

Strip width

800 to 1,650 mm

Rolling speed

max. 1,350 m/min

(for CVC ® control)

Strip thickness

Rolling force

max. 22,000 kN

Positive and negative work-rollStrip thickness Rolling force max. 22,000 kN

ingoing

1.5 to 5.0 mm

Capacity

approx. 800,000 tpy

bending

outgoing

0.35 to 3.0 mm

Multizone coolingoutgoing 0.35 to 3.0 mm

Coil weight

max. 35 t

DS system (Dry Strip)Coil weight max. 35 t

Coils ready for dispatch.

35 t DS system (Dry Strip) Coils ready for dispatch. Run-up curve. AIO (All-in-one) modular design

Run-up curve.

AIO (All-in-one) modular designsystem (Dry Strip) Coils ready for dispatch. Run-up curve. Direct-driven tension reels Oil bearings (BUR bearings)

Direct-driven tension reelsfor dispatch. Run-up curve. AIO (All-in-one) modular design Oil bearings (BUR bearings) 100 80 60 40

Oil bearings (BUR bearings)AIO (All-in-one) modular design Direct-driven tension reels 100 80 60 40 20 0 1 2 3

100 80 60 40 20 0 1 2 3 4 5 Months after commissioning Production
100
80
60
40
20
0
1
2
3
4
5
Months after commissioning
Production [%]

COLD ROLLING MILLS

COLD ROLLING MILLS Jinan Iron & Steel Group Corporation, China Low operating costs thanks to X-Pact

Jinan Iron & Steel Group Corporation, China

Low operating costs thanks to X-Pact ® automation

Jinan Iron & Steel Group Co. of Shandong Province in China contracted SMS group in September 2003 to sup- ply a CCM ® (Compact Cold Mill) and a single-stand skin- pass facility complete with all electrical systems and automation.

We built the two-stand reversing cold rolling mill in CVC ® plus four-high design including oil bearings. Capable of producing carbon and low alloyed carbon steels, the plant can roll strip to a minimum thickness of 0.3 mm and a maximum width of 1,650 mm. It achieves an annual pro-

duction of 840,000 t. Included here are axially shiftable work rolls for high production flexibility. Our proven DS (Dry Strip) system ensures optimal strip drying.

The first strip was rolled in December 2005.

We ran an extensive integration test to thoroughly check the X-Pact ® Level-2 system. Equally important for smooth commissioning was intensive support of the customer by our experts. This formed the basis for a steep run-up curve.

Preparation of a work-roll change.

This formed the basis for a steep run-up curve. Preparation of a work-roll change. The X-Pact

The X-Pact ® automation.

This formed the basis for a steep run-up curve. Preparation of a work-roll change. The X-Pact
This formed the basis for a steep run-up curve. Preparation of a work-roll change. The X-Pact
Overall view of the mill. CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned
Overall view of the mill. CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned

Overall view of the mill.

CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned in 2005)

Production data

Technical data

Technical features

Material

LC, HSS, HSLA

Stand design

four-high stand

Axially shiftable work rollsMaterial LC, HSS, HSLA Stand design four-high stand

Strip width

900 to 1,650 mm

with CVC ® plus

(for CVC ® plus control)

Strip thickness

Rolling speed

max. 1,350 m/min

Positive and negative work-rollStrip thickness Rolling speed max. 1,350 m/min

LC steels

Rolling force

max. 22,000 kN

bending

ingoing

1.8 to 5.0 mm

Capacity

approx. 840,000 tpy

DS system (Dry Strip)ingoing 1.8 to 5.0 mm Capacity approx. 840,000 tpy

outgoing

0.3 to 2.5 mm

Oil bearings (BUR bearings)outgoing 0.3 to 2.5 mm

HS and HSLA steels

 

X-Pact ® -Automation ® -Automation

ingoing

2.7 to 5.0 mm

(including Level 2)

outgoing

0.3 to 2.5 mm

AIO modular designoutgoing 0.3 to 2.5 mm

Coil weight

30 t (max. 35 t)

0.3 to 2.5 mm AIO modular design Coil weight 30 t (max. 35 t) Control stand

Control stand with X-Pact ® automation.

COLD ROLLING MILLS

SMS group as a systems supplier including automation

COLD ROLLING MILLS SMS group as a systems supplier including automation 16
17
17

COLD ROLLING MILLS

COLD ROLLING MILLS Zhejiang Southeast Metal Sheet, China Excellent mill setup with X-Pact ® level 2
COLD ROLLING MILLS Zhejiang Southeast Metal Sheet, China Excellent mill setup with X-Pact ® level 2

Zhejiang Southeast Metal Sheet, China

Excellent mill setup with X-Pact ® level 2

This was an order from Zhejiang Southeast Metal Sheet that SMS group build a Compact Cold Mill. The two-stand reversing cold mill is featuring six-high stands and CVC ® - plus technology. Here is what our customer gained above all: increased plant flexibility in terms of the grades and qualities to be rolled.

Furthermore, SMS group supplied the entire electrical equipment and X-Pact ® automation system for the mill, which was integrated into a new complex.

Comprehensive integration tests

Exclusively available from SMS, the X-Pact ® Level-2 sys- tem ensures an excellent mill setup. Our services also involved extensive integration testing that ensured smooth commissioning and a steep run-up curve.

The mill rolls strip with a maximum width of 1,350 mm from a maximum ingoing thickness of 4.0 mm down to a minimum final thickness of 0.2 mm. It achieves an annual production rate of some 500,000 t and can handle coils weighing up to 28 t.

A processor of high-grade material, Zhejiang has attracted

a number of major orders. They include steel structures and cladding for sports arenas for the 2008 Olympic Games and for the new airport in Guangzhou.

What clinched the decision in favor of SMS technology was the ideal combination of cost-effectiveness and attainable product quality.

View of the drive side with fume exhauster.

and attainable product quality. View of the drive side with fume exhauster. Control stand for coil

Control stand for coil feeding.

and attainable product quality. View of the drive side with fume exhauster. Control stand for coil
Overall view of the mill. CVC ® -6 Reversing cold rolling mill, CCM ® (Commissioned
Overall view of the mill. CVC ® -6 Reversing cold rolling mill, CCM ® (Commissioned

Overall view of the mill.

CVC ® -6 Reversing cold rolling mill, CCM ® (Commissioned in 2006)

Production data

 

Technical data

Technical features

Material

LC, HSLA

Stand design

six-high with

Axially shiftable intermediate rollsMaterial LC, HSLA Stand design six-high with

Strip

width

600 to 1,350 mm

CVC ® plus

(for CVC ® -plus control)

Strip thickness

 

Rolling speed

max. 1,200 m/min

Positive and negative work-roll andStrip thickness   Rolling speed max. 1,200 m/min

ingoing

1.8 to 4.0 mm

Rolling force

max. 18,000 kN

intermediate-roll bending

outgoing

0.2 to 2.0 mm

Capacity

approx. 500,000 tpy

DS system (Dry Strip) on both standsoutgoing 0.2 to 2.0 mm Capacity approx. 500,000 tpy

Coil weight

max. 28 t

X-Pact ® automation (including Level 2) ® automation (including Level 2)

DS system (Dry Strip) on both stands Coil weight max. 28 t X-Pact ® automation (including

COLD ROLLING MILLS

COLD ROLLING MILLS Jindal South West Steel Toranagallu, India First CCM ® in India Here, in

Jindal South West Steel Toranagallu, India

First CCM ® in India

Here, in the Indian province of Karnataka, SMS group built the sub-continent's first CCM ® . This was after Jindal South West Steel Ltd. (JSW) contracted us in 2005 to supply a Compact Cold Mill (CCM ® ) as well as a skin-pass stand. The skin-pass stand can process not only cold strip, but also hot-rolled and pickled strip.

These plants are part of a new cold rolling complex JSW erected in Toranagallu.

62 t coil weight

The high-capacity cold rolling mill is designed for an annu- al production of 850.000 t. It’s equipped to handle coils weighing up to 62 t and strip of up to 1,650 mm wide. Naturally, the CCM ® rolls standard products, but it can also produce carbody sheets for the automotive industry. That demands extremely high strip quality and flexibility of the CCM ® . To meet these requirements, the CCM ® is engineered as a six-high stand and fitted with our patent- ed CVC ® plus six-high technology.

Preassembly of the mill stands in our workshop.

ed CVC ® plus six-high technology. Preassembly of the mill stands in our workshop. Overall view

Overall view of the mill.

ed CVC ® plus six-high technology. Preassembly of the mill stands in our workshop. Overall view
Operator side of the raised mill. CVC ® -6 Reversing cold rolling mill, CCM ®
Operator side of the raised mill. CVC ® -6 Reversing cold rolling mill, CCM ®

Operator side of the raised mill.

CVC ® -6 Reversing cold rolling mill, CCM ® (Commissioned in 2007)

Production data

 

Technical data

Technical features

Material

LC, HSLA, IF

Stand design

six-high with

Axially shiftable intermediate rollsMaterial LC, HSLA, IF Stand design six-high with

Strip

width

800 to 1,650 mm

CVC ® plus

(for CVC ® -plus control)

Strip thickness

 

Rolling speed

max. 1,350 m/min

Positive and negative work-roll andStrip thickness   Rolling speed max. 1,350 m/min

ingoing

1.8 to 6.0 mm

Rolling force

max. 22,000 kN

intermediate-roll bending

outgoing

0.3 to 3.0 mm

Capacity

approx. 850,000 tpy

DS system (Dry Strip) on both standsoutgoing 0.3 to 3.0 mm Capacity approx. 850,000 tpy

Coil weight

max. 62 t

Flatness control and multi-zone cooling on both standsCoil weight max. 62 t

both stands Coil weight max. 62 t Flatness control and multi-zone cooling on both stands Hydraulic

Hydraulic systems.

COLD ROLLING MILLS

Abul Khair, Bangladesch

Best flatness results of thin strip rolling at high rolling speeds

It was in 2012 when ABUL KHAIR Strip Processing Ltd. awarded SMS group a contract for a Compact Cold Mill (CCM ® ). Completed just three years later, the mill started its ultra-thin strip production in 2015, and is now the main production plant at the Abul Khair facility in Chittagong.

The CCM ® is a flexible plant type that enables Abul Khair to meet a whole range of market requirements. Fundamen- tal to the CCM ® design developed by SMS group are two reversing mills with a CVC ® plus six-high configuration, provided with small work rolls of minimum diameter of 260 mm. Regarding production capacity, the CCM ® closes the gap between the single-stand reversing mill (RCM) and the multi-stand tandem mill (TCM). What also made it an attractive alternative for Abul Khair were the low invest- ment and operating costs.

The CCM ® processes pickled hot strip in widths of up to 1,250 mm and entry gages of up to 4.0 mm. It rolls a major part of the strips down to a minimum final thickness

Enter side pay-off seel.

down to a minimum final thickness Enter side pay-off seel. of 0.09 mm. For this reason,

of 0.09 mm. For this reason, it is the first CCM ® world- wide rolling to such small final gage. The quality-determin- ing plant components were all made in SMS group's own workshops. Equally effective are CVC ® plus technology combined with work roll and intermediate roll bending, multi-zone cooling at the entry and exit ends, as well as our Dry Strip system because they ensure all strip quality requirements are met. SMS group equipped the CCM ® with a payoff reel and two tension reels. Related to this particular product mix the annual production capacity is 185,000 t.

Also included in the SMS group supply scope were the emulsion plant with a capacity of 8,000 liters per minute. This unit features a chain magnet separator and vacuum filter for efficient rolling emulsion cleaning. Plus there are speed-controlled pumps that feed the required quantity of emulsion for especially low-energy operation. That means the CCM ® is not only flexible, but also saves resources.

The first strip was rolled on April 23, 2015.

That means the CCM ® is not only flexible, but also saves resources. The first strip
That means the CCM ® is not only flexible, but also saves resources. The first strip
Mill stand in proven CVC ® plus six-high design: the slender work rolls achieve high
Mill stand in proven CVC ® plus six-high design: the slender work rolls achieve high

Mill stand in proven CVC ® plus six-high design: the slender work rolls achieve high reductions.

CVC ® plus 6 Reversing cold rolling mill, CCM ® (Commissioned in 2015)

Production data

Technical data

Technical features

Material

LC

Stand design

six-high with

Axially shiftable intermediate rollsMaterial LC Stand design six-high with

Strip width

650 to 1,250 mm

CVC ® plus

for CVC ® plus control

Strip thickness

Rolling speed

max. 1,500 m/min

Positive and negative work roll andStrip thickness Rolling speed max. 1,500 m/min

ingoing

1.00 to 4.00 mm

Rolling force

max. 12,000 kN

intermediate roll bending

outgoing

0.09 to 1.20 mm

Capacity

approx. 185,000 tpy

Multizone cooling on both standsoutgoing 0.09 to 1.20 mm Capacity approx. 185,000 tpy

Coil weight

max. 25 t

DS system (Dry Strip) on both standsCoil weight max. 25 t

on both stands Coil weight max. 25 t DS system (Dry Strip) on both stands Plant

Plant overview: opeerator side.

COLD ROLLING MILLS

KYCR,

Bangladesch

Cost-effective expansion concept

Bangladesh is a developing country with a continually expanding economy and steadily growing industrial sector. Leading by example is the young company KYCR Coil Industries Limited.

KYCR is a subsidiary of KDS Steel, which makes it a mem- ber of the KDS group. Taking a major step forward, the company built its modern cold rolling complex in Kumira, 25 kilometers from Chittagong, in 2000. Right at the heart of the production facility is the reversing cold mill (RCM) from SMS group in six-high design with CVC ® plus. It has been in operation since 2002. Also fully operational are the pickling line as well as a slitting and wrapping line. KYCR further processes the strip it produces here in a continu- ous galvanizing line and a color coating line.

Initially, the RCM produced high-quality cold strip in final thicknesses of down to 0.10 mm. To achieve this level of performance, the plant was designed with CVC ® plus tech- nology specially for rolling thin strip. Crucial here were very small work rolls with a diameter of 200 mm for high reduc- tions per pass. Then, after more than ten years of success- ful plant operation, KYCR decided to expand the power and capacity of its RCM using a tailor-made package from SMS group. That's why, in May 2013, the company contracted SMS group to upgrade its existing RCM into a Compact Cold Mill (CCM ® ).

It was a huge advantage that SMS group had planned the RCM right from the start with the option of subsequent expansion. Now the existing plant was converted into a two-stand CCM ® with CVC ® plus in both mill stands. Taking this step meant KYCR increased its annual production capacity from 100,000 to approx. 170,000 t.

Included in our scope of supply was the SMS group X-Pact ® electrics and automation system. As part of the plant expansion, the electrical and automation systems for both the new and the old plants were enhanced.

This involved new, highly dynamic regulation and controls based on state-of-the-art target and guide value technolo- gy. There were even more extras in the package, such as user-friendly process visualization and control.

Not only responsible for the core mill stand equipment, SMS group also expanded the high and low pressure hydraulics as well as the emulsion plant. That required enlarging the basement equipment, another component of the advance planning.

Conveniently located near to our customer, the Indian Joint Venture partner of SMS, Esmech Equipment Pvt. Ltd., also supplied further plant equipment.

What clearly benefitted KYCR was that the foundations had been designed with such foresight because the second mill stand could be installed at little cost and effort. This meant only the exit-side equipment such as coiling reel, coil trans- fer car, and belt wrapper had to be moved. Holistic plan- ning ensured the necessary plant standstill time was as short as possible.

It was a big day on August 16, 2015 when KYCR rolled the first strip on its new CCM ® . The plant produces very thin strip for the regional market in widths of 600 to 1,050 mm and final thicknesses of down to 0.09 mm.

Helmut Klatt, Technical Project Manager at SMS group, says: “Apart from CVC ® plus, the CCM ® features a new, modern regulation and control system with modern target and guide technology. All this guarantees a cost-effective production process plus high product reliability and quality. And that helps KYCR further enhance its market position.”

CCM ® : Entryside. CVC ® plus 6 Reversing cold rolling mill, CCM ® (Commissioned
CCM ® : Entryside. CVC ® plus 6 Reversing cold rolling mill, CCM ® (Commissioned

CCM ® : Entryside.

CVC ® plus 6 Reversing cold rolling mill, CCM ® (Commissioned in 2015)

Production data

Technical data

Technical features

Material

carbon steels

Stand design

six-high with

Axially shiftable intermediate rollsMaterial carbon steels Stand design six-high with

Strip width

600 to 1,050 mm

CVC ® plus

(for CVC ® plus control)

Strip thickness

Rolling speed

max. 1,000 m/min

Positive and negative work-roll andStrip thickness Rolling speed max. 1,000 m/min

ingoing

1.60 to 3.00 mm

Rolling force

max. 10,000 kN

intermediate-roll bending

outgoing

0.10 to 0.50 mm

Capacity

approx. 170,000 tpy

X-Pact ® electrics and automation ® electrics and automation

Coil weight

max. 22 t

The RCM prior to expansion.

automation Coil weight max. 22 t The RCM prior to expansion. The KYCR CCM ® during

The KYCR CCM

® during the commissioning phase.

automation Coil weight max. 22 t The RCM prior to expansion. The KYCR CCM ® during

COLD ROLLING MILLS

International Steel Industries, Pakistan

First CCM ® for an integrated cold rolling complex in Pakistan

A renowned Pakistani company, International Steels Limit- ed (ISL) awarded SMS group a contract in February 2014

to expand its reversing cold mill (RCM).

This RCM in CVC ® plus four-high design was the first of

its type in Pakistan. Ever since 2011, ISL had been using

it to produce high-quality cold strip in widths of 700 to

1250 mm and final thicknesses of down to 0.25 mm. The plant's annual capacity was 250,000 t. Now our customer could reap the full benefit of the initial planning. That's because the RCM was designed with the option of low- cost future expansion into a two-stand CCM ® already built in. Most important here was the preparation of the foun- dations and media systems. So, when ISL was ready for the next stage, it placed the order with SMS group. Equipped with the two-stand Compact Cold Mill (CCM ® ), ISL has increased its annual capacity by 70 percent.

SMS group supplied the second mill stand in identical design to the existing stand in a four-high version with hydraulic roll adjustment, CVC ® plus, and work roll bend- ing. Included in the scope of supply for the second mill stand was also an X-Shape flatness measuring and con- trol system from SMS group.

There was no need to expand the capacity of the emul- sion system because it had been designed for two-stand operation right from the start. It was sufficient to move the exit-side equipment such as tension reel and coil cars to make room for the second mill stand.

Esmech Equipment Pvt. Ltd., the Indian joint venture part- ner of SMS group, supplied further plant components. Specifically, they contributed equipment for roll changing, the interstand area, the stand platform and housing, as well as valve stands for the low-pressure hydraulics.

As early as July 26, 2015, the first coil successfully rolled off the Compact Cold Mill (CCM ® ) of International Steel Limited (ISL).

The X-Shape flatness measuring roller from SMS group is sturdy and works with precision.

The X-Shape flatness measuring roller from SMS group is sturdy and works with precision. The RCM

The RCM prior to expansion.

The X-Shape flatness measuring roller from SMS group is sturdy and works with precision. The RCM
CCM ® after revamp. CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned in
CCM ® after revamp. CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned in

CCM ® after revamp.

CVC ® -4 Reversing cold rolling mill, CCM ® (Commissioned in 2015)

Production data

Technical data

Technical features

Material

CQ, DQ, DDQ

Stand design

four-high with

Hydraulic roll adjustmentMaterial CQ, DQ, DDQ Stand design four-high with

Strip width

700 to 1,250 mm

CVC ® plus

Axially shiftable work rollsStrip width 700 to 1,250 mm CVC ® plus

Strip thickness

Rolling speed

max. 1,200 m/min

(for CVC ® plus control)

ingoing

1.60 to 5.00 mm

Rolling force

max. 15,000 kN

Work-roll bendingingoing 1.60 to 5.00 mm Rolling force max. 15,000 kN

outgoing

0.25 to 2.00 mm

Capacity

approx. 425,000 tpy

X-Shape flatness measuring rolleroutgoing 0.25 to 2.00 mm Capacity approx. 425,000 tpy

Coil weight

max. 25 t

tpy X-Shape flatness measuring roller Coil weight max. 25 t View of the entry side of

View of the entry side of the CCM ® .

COLD ROLLING MILLS

Nam Kim Steel, Vietnam

Step-by-step production expansion

Nam Kim Steel Joint Stock Company ranks among Viet- nam's leading suppliers of surface-treated cold strip. Teaming up with SMS India Pvt. Ltd., Indian joint venture partner and member of SMS group Esmech Equipment Pvt. Ltd. supplied the electrics and automation for a high- performance reversing cold mill (RCM) with proven SMS rolling technology for Nam Kim Steel. The plant success- fully went on stream in April 2015. Immediately, with the RCM alone, Nam Kim Steel set new standards in cold strip quality on the local market.

Yet, to further boost its production, Nam Kim Steel con- tracted SMS group in April 2015 to supply a two-stand Compact Cold Mill (CCM ® ). That is the second time Nam Kim Steel is relying on Esmech Equipment Pvt. Ltd. for the mechanical equipment featuring SMS rolling technology and core components from SMS group Germany, as well as the ancillary plants. Here again, as with the RCM, the electrics and automation come from SMS India Pvt. Ltd.

CVC ® plus six-high mill stand.

SMS India Pvt. Ltd. CVC ® plus six-high mill stand. What the six-high CCM ® means

What the six-high CCM ® means for Nam Kim Steel is a boost to its annual capacity for high-quality cold strip by 435,000 t and an even stronger position on the regional market.

Equipped with CVC ® plus in combination with positive and negative work-roll and intermediate-roll bending, the CCM ® achieves a very wide range of settings for the roll gap. Together with the X-Shape flatness measuring and control system, that guarantees a precision rolling result with top strip flatness.

The two belt wrappers on the tension reels ensure dam- age-free coiling of the finished strip. Also contained is equipment for fast work-roll and intermediate-roll chang- ing. That reduces idle times and boosts plant productivity.

Commissioning is scheduled for the end of 2016.

Drive-side view of a similar CCM ® .

boosts plant productivity. Commissioning is scheduled for the end of 2016. Drive-side view of a similar
boosts plant productivity. Commissioning is scheduled for the end of 2016. Drive-side view of a similar
Nam Kim Steel is increasing production not by expanding the new RCM, but by adding
Nam Kim Steel is increasing production not by expanding the new RCM, but by adding

Nam Kim Steel is increasing production not by expanding the new RCM, but by adding a complete CCM ® .

CVC ® plus 6 Reversing cold rolling mill, CCM ® (Commissioned end of 2016)

Production data

Technical data

Technical features

Material

LC

Stand design

six-high with

Axially shiftable intermediate rollsMaterial LC Stand design six-high with

Strip width

650 to 1,250 mm

CVC ® plus

(for CVC ® plus control)

Strip thickness

Rolling speed

max. 1,400 m/min

Positive and negative work-roll andStrip thickness Rolling speed max. 1,400 m/min

ingoing

1.6 to 4.5 mm

Rolling force

max. 12,000 kN

intermediate-roll bending

outgoing

0.2 to 2.0 mm

Capacity

approx. 435,000 tpy

X-Pact ® electrics and automation ® electrics and automation

Coil weight

max. 25 t

X-Shape flatness measuring rollerCoil weight max. 25 t

Coil weight max. 25 t X-Shape flatness measuring roller Yield optimizer Design of a similar CCM

Yield optimizerand automation Coil weight max. 25 t X-Shape flatness measuring roller Design of a similar CCM

Design of a similar CCM ® .

COLD ROLLING MILLS

Hoa Sen, Vietnam

Plant concept ideal for growth market Vietnam

In spring 2016 the Vietnamese Hoa Sen Group placed an order with SMS group for the complete supply of a twin- stand CCM ® in the context of further expansion of the facilities nearby Ho Chi Minh City. By this order, Hoa Sen group confirms trust in the plant technology of SMS group. Such as the successful previous supply of a reversing cold mill (RCM), which went into operation in 2015, the mechanical equipment will be delivered by joint-venture partner Esmech Equipment Pvt. Ltd. from India. Core components of the rolling technology are provided from SMS group in Germany. In contrast to the previous order, this time the X-Pact ® electrical and automation systems are part of the contract as well. The CCM ® will be also equipped with the advanced X-Shape flatness measure- ment and control system.

The CCM ® is designed for the rolling of low carbon steel strips with maximum width up to 1,250 millimeter and min- imum final gages down to 0.11 millimeters. The annual pro- duction capacity adds up to 350,000 tons. The CVC ® plus technology by SMS group in combination with other proven rolling technologies ensures the high-grade strip quality. The rolling stands in 6-high design are provided with small work rolls, by what high pass reductions can be realized. Rolling takes place with maximum rolling speed up to 1400 meters per minute. The CCM ® is provided with a pay- off and two reversing reels, so the finished coils can be removed from entry and exit side as needed. The reversing reels are designed to wind up finished strips to coils with a maximum weight of 27 tons. Further both are equipped with belt wrappers for easy coiling of thin strips onto the sleeves. Work and intermediate roll change work automati- cally.

In 2015, the reversing cold mill by SMS group has started operation at Hoa Sen.

SMS group supplies the complete electrical equipment and the automation system including Level 1 and 2. Physically defined adaptive models, e.g. to describe plastic yielding, roll gap and roll setting, are precondition for optimized pass schedule arrangement as well as for the ideal preset- ting of the process parameters for thickness, tension and flatness control. Thereby it is possible that the mill reacts very flexibly on changes of the rolling process and achieves reliably the product quality required. Excellent flatness results are ensured by the X-Shape flatness measurement and control system. Part of the supply scope are an entry and an exit side X-Shape flatness measurement roll by SMS group, which are characterized by their robust design and at the same time highly precise measurement accura- cy and trouble free signal transmission.

Also included in the supply are fluid and media plants, like high and low pressure hydraulic as well as the emulsion plant.

included in the supply are fluid and media plants, like high and low pressure hydraulic as
Design concept of a similar CCM ® . CVC ® plus 6-Reversing-cold mill, CCM ®
Design concept of a similar CCM ® . CVC ® plus 6-Reversing-cold mill, CCM ®

Design concept of a similar CCM ® .

CVC ® plus 6-Reversing-cold mill, CCM ® (Commissioned in autumn 2017)

Production data

Technical data

Technical features

Material

LC

Stand design

6-high stands with

Axially shiftable intermediate rollsMaterial LC Stand design 6-high stands with

Strip width

650 - 1,250 mm

CVC ® plus

(for CVC ® plus control)

Strip thickness

Rolling speed

max. 1,400 m/min.

Positive and negative work- andStrip thickness Rolling speed max. 1,400 m/min.

ingoing

1.60 – 4.00 mm

Rolling force

max. 12,000 kN

intermediate roll bending

outgoing

0.11 – 1.20 mm

Capacity

350,000 tpy

X-Pact ® electrics and automation ® electrics and automation

Coil weight

max. 27 t

X-Shape flatness measuring rollCoil weight max. 27 t

Yield optimizer350,000 tpy X-Pact ® electrics and automation Coil weight max. 27 t X-Shape flatness measuring roll

© SMS group GmbH · Published on 01.10.2016 · Circulation 1000 · Printed in Germany · Ky

W6-305E

SMS group GmbH Cold Rolling Mills Division

Wiesenstrasse 30

57271 Hilchenbach, Germany Phone: +49 2733 29-1800

Fax:

E-mail: cm-csteel@sms-group.com

Internet: www.sms-group.com

+49 2733 29-1782

“The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.”