aluminum- strip processing lines - sms · pdf filesms siemag aluminum strip 2 high-quality...

ALUMINUM-STRIP PROCESSING LINESALUMINUM-STRIP PROCESSING LINESExtensive know-how and process understanding

METALLURGICAL PLANTS and ROLLING MILL TECHNOLOGY

Strip Processing Lines

SMS SIEMAG

W7-308E_Alu-Bandanlagen_Bandanlagen 09.11.12 09:00 Seite 1

Aluminum stripSMS SIEMAG

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HIGH-QUALITY ALUMINUM STRIPHIGH-QUALITY ALUMINUM STRIP

Extensive know-how and process

understanding about aluminum strip

processing lines

As a global leader in metallurgical plant and rolling mill technology, SMS Siemag also knows all there is to know about constructing and installing aluminumstrip processing lines, plus the processes involved.

A special thing is our ability to supply the modulardesigned lines completely from a single source –including highly advanced process components, powerful and eco-friendly furnace technology, reliablemechanics, as well as electrics and automation. Youcan use our innovative process lines and componentsto produce a broad spectrum of high-quality aluminumalloy strip and plate for a wide variety of applications –efficiently and cost-effectively.

There are multiple uses for the final products, aboveall in fields such as the automotive and aerospaceindustries. Increasingly successful in recent years,SMS Siemag has built several new aluminum stripprocessing plants as well as performing complexrevamps. Furthermore, SMS Siemag attracted neworders for all the major types of processing lines.

Included in our scope of supply are color coatinglines, combined annealing and passivation lines, andanodizing lines.


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Contents

Line designs 4

Process components 6

Coater systems 8

GATV convection furnaces 10

Henan Zhongfu – color coating line 12

Ma’aden-Alcoa Joint Venture – annealing and passivation line 14

Coil GmbH – anodizing line 15

ASAS Alüminyum – color coating line 16

Amag Cold Rolling – annealing line 16

Madar Coil Coating – color coating line 17

Since 2000, SMS Siemag has attracted orders for20 lines. Among our customers were for exampleASAS Alüminyum, Turkey, Corus Aluminum, Bel-gium, Amag Cold Rolling, Austria, Hydro Aluminium,Germany, or Madar Coil Coating, Syria. Also new onour books are for example another anodizing line forCoil GmbH, Germany, plus an annealing and passiva-tion line for Ma’aden-Alcoa Joint Venture, Saudi Ara-bia. A further new order includes a color coating linefor can material for Henan Zhongfu, China.



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Tension leveling

Annealing

Pre-cleaning Entry

Entry

Entry

Chem coating

Exit

Cleaning

Cleaning Etching Neutralization Anodizing

LINE DESIGNSLINE DESIGNS

All aluminum strip processing lines from SMS Siemag are tailor-made to your requirements and modular in design. Depending on the aluminum alloys and qualities as well as the strip dimensionsyou want to produce, your plant comes equipped with the right technologies and components.

Color coating lineThese lines apply a high-quality coating to the strip so that it can be directly processed into end products.That saves costly process stages. As a rule, the color coating consists of several layers. First in line is a chem-coater which applies a conservation layer, followed by drying. Next, a primer-coater adds an adhe-sion agent, and finally one of two integrated finish-coaters applies the top coat.

Anodizing lineAnodizing is an electrochemical process that creates a transparent, colorless protective oxide layer onthe strip surface. This significantly increases corrosion resistance and surface hardness. What is more,the strip is positively charged (anode) and discharged in an electrolyte bath. Subsequently it is colored,with the color penetrating deep into the surface pores. Finally, the color pigments are permanently fixedin a sealing bath.

Annealing and passivation lineDuring cold rolling, the aluminum strip solidifies and must be annealed to regain its formability for furtherprocessing. These lines also homogenize and solution-anneal alloys that can solidify due to special inter-metallic precipitates. To achieve the microstructure necessary for the desired mechanical properties, thematerial is heated to as much as 600 degrees Celsius, then rapidly cooled in a controlled way. It is imper-ative that the sensitive surfaces are not supported by rolls during heating, which is where convection


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Tension leveling Cleaning

Overaging

Cooling

PassivationExit

Exit

Curing

Curing

Primer coating

Finishcoating

Coloring Sealing

Typical plant parameters:Strip thickness: 0.15 – 2.0 mmStrip width: 700 – 2.100 mmCapacity: up to 150,000 t/a

Typical plant parameters:Strip thickness: 0.5 – 3.5 mmStrip width: 800 – 2,300 mmCapacity: up to 50,000 t/a

Typical plant parameters:Strip thickness: 0.3 – 6.0 mmStrip width: 700 – 2.650 mmCapacity: up to 200,000 t/a

Service lines such as slitting, cross-cutting, and tension leveling plants for furtherprocessing the refined strip complete our product range.

strip floatation furnaces come in. The strip travels through themcontact-free in a sinus shape. Furthermore, the strip receives a pas-sivation in these lines that prepares the surfaces for subsequentpainting. The material produced in this way is used for instance inthe automotive and aerospace industries.

The layers of primer and finish paint are each dried separately in a high-performance convection oven (catenary or floating type). Integrated inthe plant is an energy-efficient exhaust air cleaning and energy recircula-tion system that treats the exhaust air.

The resulting color coating is UV-proof and durable. Wherever esthet-ically pleasing, non-corrosive strip material with a long service life isrequired (e.g. in architecture), this type of aluminum plate is the idealsolution.


Aluminum strip

PROCESS COMPONENTS

SMS SIEMAG

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PROCESS COMPONENTS

Vital to the high performance of ouraluminum strip processing lines arethe process components for clean-ing, alkaline pickling, neutralizing,and anodizing the strip surfaces. Allthe elements are designed for excel-

lent surface qualities at minimummaterial consumption. You benefitfrom our many years of experiencebecause the components aresophisticated, with a high degree ofautomation.

Tension leveling lines

You use these machines to makesure the strip is perfectly flat. That is usually a top priority. The tensionleveler removes any unflatnesssuch as waves, cambers or longitu-dinal bows and crossbows. Alsoincluded in the tension leveling lineis cleaning the strip surfaces, whichinvolves stripping them of rolling oil,

abrasions from the rolling process,and other contaminants. The alka-line cleaning phase finishes withrinsing and hot-air drying. It is impor-tant that the strip edges are straightand the strip is cut to the rightwidth. This is where the integratedside trimmer comes in.

Spray cleaning and cascade rinsing in analuminum strip processing line.

Even more, SMS Siemag knowseverything about the process tech-nology and operation of these plantparts that are often crucial to sur-face quality and production costs.

Further components are coilers andshears in the entry and exit areas aswell as a stitcher to join the coils.


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TENSION LEVELERTENSION LEVELER

Typical of our efficient mechanicalequipment is the tension and bend-ing leveler. It applies strip tensionsof up to 50 t to achieve the speci-fied strip flatness.

The machine consists of an array ofbending and correction rolls as wellas an upstream and a downstreamset of S-rolls to create the tension.What happens here is that the com-bined effects of tensioning andbending exceed the yield strengthof the strip as it passes through therolls. As a result, the fiber lengthsacross the entire strip width areequalized and the internal stress inthe material relaxed – for absolutelyflat strip. There are various straight-ening cartridges and operatingmodes available to suit differentmaterial properties and dimensions.That means the tension and bend-ing are always set optimally for

your requirements. Integrated in the machine is a Level 2 automationsystem that adjusts the roll positionand sets the necessary extension.The leveler can be used both dryand with minimal lubrication toavoid pick-ups and material adhe-sions. To allow the stitched seamthat joins the aluminum strips to

pass through, the tension levelerfeatures a rapid-opening system.

For sensible surfaces and specialstrip dimensions the machine canbe operated in pure stretch modetoo. Then the strip is elongatedwithout frequent bending.

Flatness is set in the tension leveler to meet the highrequirements of the aluminum strip.

Tension leveling lines adjust the flatness,clean the strip surfaces, and trim the stripedges.



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COATER SYSTEMSCOATER SYSTEMS

Uniform and high-precision strip coating with roll coaters

Roll coaters in aluminum strip processing lines apply various coats to the strip surfaces. Specifically,several rotating rolls on both sides transfer the medium evenly from a trough onto the surfaces. Now,depending on the intended use of the strip, the machine applies chemical passivating layers, primer, orpaint coatings to one or both sides.

Efficient control

technology and low

consumption

All SMS Siemag roll coaters comewith efficient control technologythat guarantees a uniform and pre-cise coating result in the requiredlayer thickness at low medium consumption. Built in is a hydraulicrapid-opening function to makesure the coater can be opened orclosed within two seconds. That ensures smooth passage ofthe stitched seams. Accommodat-ing different strip speeds is easyusing designs with different rolldiameters.

Exact control of the

coating process

To achieve the required coatingresult, a database is linked to theLevel 2 automation system. It pro-vides information for adjusting theroll speeds and positions as well asthe pressing forces. Electric drivesensure uniform roll rotation. Theposition of the rolls is adjusted withhigh precision in a linear way by anelectric motor system using spindlelifting elements.

The exact position is automaticallycontrolled or fine-tuned via thepressing forces. Crucial to the effec-tiveness is the coating thickness. To prevent deviations, a sensor continuously measures the coatingresult so that the settings can bemanually adjusted.

Chem coaters

The chem coater applies a thin,even passivating layer. It containstwo coater decks, each with anapplication and a pick-up roll. There are also several automatedcirculation systems for rapid coatingchangeovers. They ensure the rolls,troughs, and media systems can beautomatically cleaned within twominutes for product changes.

Primer coaters

Some products require a primercoat between strip passivation andcolor coating. This is where primercoaters come in. Ideal for coatingboth sides of the strip simultane-ously are S-roll coaters. A scrapersystem and solvents continuouslyclean the guide roll.

Medium

Strip side

Type

Figures

Application

That eliminates deposits of coatingmedium which would cause flaws.Whenever necessary for mainte-nance or adjustment purposes, thecoater deck can be moved back onrails.


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Chem coater Primer coater Finish coater 1 Finish coater 2

Chemical passivation agent Primer Paint Paint

Both sides Both sides Top side Both sides(optionally one side) (optionally one side) (optionally one side)

Vertical coater S-roll coater U-roll coater (one S-roll coater(two coater decks (two coater decks coater deck with (two coater decks with two rolls each) with two rolls each) three rolls) with three or two rolls)

Annealing and passivation Color coating lines for Color coating lines Color coating lines as well as color coating lines e.g. architecture grades for e.g. can material and for e.g. can material and

architecture grades architecture grades

Finish coaters

As a rule, two coaters are used forthe color coating stage itself. First,the strip runs through a U-coater(only the top side) and then throughan S-coater (both sides). That’s whytwo coaters are installed for coating

the top side, making rapid productchanges possible. The coater decksfor coating the top side feature 3 rolls. You have the option of 2 or 3 rolls for the underside. If youchoose a 3-roll coater deck, you canvary the roll positions depending onthe product application (V position,

inline, or only 2 rolls). Whatever finish coater you decide on, theguide rolls are continuously cleaned,while the underside coater deck ofthe S-roll coater can be moved outat the back.

S-roll coaters apply a color coating to thestrip with high precision. (Rolls adjustedhere to V position).



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GATV CONVECTION FURNACESGATV CONVECTION FURNACES

Modular and compact in design, high-performance convection furnaces standout for even heating and cooling performance as well as exceptionally highefficiency and eco-friendliness. All this requires ideal setting and control of theprocess parameters, ensured with a mathematical model. One highlight hereis the floatation furnace, used especially in annealing and passivation lines aswell as in color coating lines.

Floatation furnace

Nozzles in the floatation furnaceensure the strip travels contact-freethrough the furnace and air cooler ina sinus shape. This is possiblebecause, throughout the furnacelength, hot-air nozzles heat the stripevenly and keep it afloat on an aircushion. The elimination of mechani-cal contact in the furnace translatesinto a fault-free strip surface.

Furthermore, the low, even tensionrules out heat creasing or dishingcaused by excessive tension. Modu-lar in design, the furnaces featureseveral heating zones that use tur-bines to generate an air channel con-sisting of top and bottom airflows.That makes them easy to control.The air is heated by burners thatwork with combustion air pre-heatedto as much as 450 °C, yet require avery low energy input..

Annealing with high

cooling capacities for

automotive and aero-

space qualities

The furnaces feature excellent tech-nologies for stress-relieving anneal-ing, homogenizing, and solutionannealing in annealing and passiva-tion lines. Even heating and coolingover the length and width of thestrip creates uniform hardness andgrain size – and high material quality.

As a rule, floatation furnaces heatthe strip to temperatures of up to600 °C, depending on the materialgrade. Crucial here is that the tem-perature is achieved throughout the strip. This annealing processrestores the formability of the alu-minum alloys. Finally, the strip iscooled.

It is vital in annealing lines for automotive or aerospace materialsto achieve high cooling rates. This is why we supplement air cooling in our lines with a powerful water cooling system. Our GATV furnacesfeature cooling technologies for allalloys including 6xxx and 7xxxseries.

Contact-free heat treatment in theGATV floatation furnace.


A mathematical model with its own database controls the thermal process and guarantees highprocess reliability and material quality.

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Autothermal drying and

curing of coatings

Convection ovens are also used fordrying and polymerizing coatings onaluminum strip. Then there are colorcoating lines, where solvents areevaporated at 230 to 260 °C to fusethe paint molecules and harden thepaint.

You benefit because we analyze your product range and mix, then calculate the energy consumptionand cost-effectiveness to determinethe best type of heating for yourovens. Finally, after extraction, theflue gases are burned in an afterburn-ing system (regenerative thermal oxi-dizer) with a thermal effectiveness of up to 98%. Depending on the sol-vent content in the exhaust air, theafterburning system can be operatedwithout additional energy input.

This also applies to the ovens if anenergy recirculation system is addedto the configuration. We have alreadyimplemented strategies with auto-thermal oven mode for a large prod-uct spectrum.

Mathematical model

The entire thermal process is con-trolled by a mathematical modelthat calculates the treatment curveand target value parameters, ensur-ing high process reliability withexcellent material quality.

The model draws on an extensivedatabase and its own software,applying different calculation meth-ods depending on the applicationrequired. It can be controlled bothinline using the Level 2 automation,or offline by data input. All you haveto do is enter the material data (typeof alloy, dimensions) – for color coat-ing also the paint data (solids con-tent, density, necessary tempera-ture) – and the model delivers theappropriate process param eters.The GATV database contains thedetails of more than 350 solventswith the corresponding processparameters.

A high-performance water cooling system achieves the rapidcooling rates necessary in annealing lines for materials such asautomotive or aerospace grades.

Drying oven for color coating with hot air and exhaust air channels, water cooler, squeeze rolls, and air-knife.



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HENAN ZHONGFU HENAN ZHONGFU Color coating line for aluminum can material

Everything from

one source

This is a project where SMS Siemagis responsible for the engineeringand manufacturing as well as thesupervision of assembly and com-missioning. We are also supplyingnot only the mechanical equipment,process technology components,and the furnaces, but also theelectrics and automation. The mate-rial to be produced in Gongyi City,Henan Province in the mid-east ofChina is destined primarily for pro-cessing into beverage cans. How-ever, the line can also produce alu-minum strip for architecturalapplications.

Pretreatment with

sulfuric acid pickling and

chemical coating

First, the strip surface is pre-cleaned.Then the strip passes through a ten-sion leveler to achieve the requiredflatness. Just as importantly forcolor coating, the surface must bescrupulously clean. The alkalinecleaning stage is followed by pick-ling with sulfuric acid. Finally, aftercascade rinsing, a chem coaterapplies a preparing chemical to both sides which is then dried in a vertical furnace.

High-quality color

coating and energy-

efficient curing

Integrated for the color coatingstage are two extremely precise rollcoaters. The strip can be coated onone or both sides, while rapid paintchangeovers are possible. Next, the solvents are evaporated contact-free in the GATV floatation oven andburned in a regenerative afterburn-ing system with a high degree ofthermal efficiency. This is how alarge range of products can be ther-mally treated without any externalenergy input.

High speeds, high-quality coatings, thin strip, and energy-efficient operation – the HenanZhongfu color coating line. The entry and exit areas are arranged side by side in the line,making for simpler coil transport.

Contracted by Chinese aluminum producer Henan Zhongfu (Henan Zhongfu Industrial Co,Ltd.), SMS Siemag is building a color coating line for aluminum strip to supply the can indus-try. This very energy-efficient line will coat 70,000 t of aluminum strip per year with a high-quality color coating. Another standout feature is the impressive processing speed of theextremely thin material. Furthermore, the compact design means the plant is only 230meters long. Moreover, it is possible to bypass the color coating section to produce onlychemically coated material.


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Technological details Commissioning 2014 (planned)Annual production 70,000 tStrip width 850 – 1,900 mmStrip thickness 0.15 – 1.0 mmEntry speed 300 m/minProcess speed 250 m/minExit speed 300 m/minMaterial grades Aluminum and aluminum

alloys (1xxx and 3xxx seriesas well as 5052 and 5182)

The entire thermal process is con-trolled by a mathematical modelbased on a database that containsthe process parameters for morethan 350 solvents.

Post-treatment of

the surfaces with wax

and oil

Now, the processed strip can becoated with wax. That’s why the linealso features a vertical roll coaterwith heated rolls. The wax coatingprotects the material and improvesits deep-drawing capability. There isalso a DUMA oiling machine in theexit area which can apply a thin filmof oil to the surfaces in an electro-static process.

Chemical coating in the vertical chem coater and colorcoating with two S-roll coaters.



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MA’ADEN-ALCOA JOINT VENTUREMA’ADEN-ALCOA JOINT VENTUREAnnealing and passivation linefor automotive qualities

SMS Siemag is supplying all the plant components, complete with the electrics and automation,for the new annealing and passivation line at Ma’aden-Alcoa Joint Venture. Included in the orderis the design, manufacturing, assembly supervision, and commissioning of the plant in the newfacility in Ras al Khair, Saudi Arabia. Technological highlights of the line are the GATV strip float-ing furnace, the tension leveler, and the chem coater. All this is high-quality equipment that, after its installation, will enable Ma’aden-Alcoa Joint Venture to tap into the market for aluminumautomotive plate. Starting in 2014, the line is to produce 50,000 t of annealed, cleaned, andchemically treated material per annum in a quality that is easy to form and paint.

Technological data Commissioning 2014 (planned)Annual production 50,000 tStrip width up to 2,100 mmStrip thickness 0.8 – 3.5 mmStrip speed- Entry 60 m/min- Process 30 m/min- Exit 60 m/min

Material Aluminum alloys(5xxx and 6xxx series)

Annealing and passivation line for aluminumautomotive plates for Ma’aden-Alcoa JointVenture.


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COIL GMBHCOIL GMBHAnodizing line

It was a logical choice for Coil GmbH in Bernburg, Germany. Pleased with the good performance of theanodizing plant SMS Siemag installed in 2005, Coil decided to once again rely on the extensive techno-logical know-how, process expertise, and vision of SMS Siemag for its planned capacity expansion. In particular, the competence in the special chemical treatment of the strip distinguishes SMS Siemagas preferred supplier for this kind of plant. The new line is the first of its kind able to process aluminumstrip in widths of up to 2,000 mm and thicknesses of up to 3.5 mm. These record dimensions will giveCoil GmbH the capacity to expand its market. Another special feature of the line is the electrolytic paintbath developed jointly by SMS Siemag and Coil. The new line, with an annual capacity of 15,000 t, will be erected next to the old plant and is scheduled to go into production in 2013.

Technological data Commissioning 2013 (planned)Annual production 15,000 tStrip width 600 – 2,000 mmStrip thickness 1.0 – 3.5 mmStrip speed- Entry 30 m/min- Process 15 m/min- Exit 30 m/min

Material Aluminum alloys(1xxx, 3xxx and 5xxx series)

Sealing section.(Pictures of the first plant for coil).

Anodizing section.



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ASAS ALÜMINYUMASAS ALÜMINYUMColor coating line foraluminum and steel

On December 15, 2010, SMS Siemag received an order from ASAS Alüminyum Sanayi ve Ticaret A.S. in Istanbul, Turkey for a color coating line for aluminum alloys, and galvanized steel strip. This line appliesa high-quality color coating that eliminates the need for costly process stages downstream. Today'smodern coating systems mean one-side coating and fast color changovers are possible. Also included in the order are two slitting lines and one cut-to-length line.

AMAG ROLLINGAMAG ROLLINGAnnealing line

SMS Siemag also supplied a continuous annealingline to AMAG Rolling in Austria. Included in the supplypackage for this line were a coil payoff section, a ten-sion leveler, a side trimmer, inspection equipment,and a coiling and strapping station.

Apart from the mechanical equipment, SMS Siemag issupplying the electrics and automation for the plants.They will go on stream in 2013 in the ASAS works nearAkyazi in the Turkish province of Sakarya – some twohours' drive from Istanbul.

Technological data Commissioning 2013 (planned)Annual production 50,000 tStrip width 900 – 2,100 mmStrip thickness 0.2 – 2.0 mmStrip speed- Entry 160 m/min- Process 80 m/min- Exit 160 m/min

Material Aluminum alloys (1xxx, 3xxx, 5xxx, 6xxxand 8xxx series) and galvanized steel

A finish coater applies the paintcoating to the prepared strip.

In the entry area, a stitcher joins the strips into one endless strip.


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MADAR COIL COATINGMADAR COIL COATINGAluminum and steelcolor coating line

SMS Siemag also supplied a color coating line to Madar Coil Coating in Damascus, Syria.The plant went into production in 2005. Included here are chem-, primer-, and finish-coaters as well as a floating furnace with air and water cooling.

Technological data Commissioning 2005Annual production 30,000 tStrip width 210 – 1,250 mmStrip thickness 0.16 – 1.0 mmStrip speed- Entry 130 m/min- Process 70 m/min- Exit 130 m/min

Material Aluminum alloysand galvanized steel

Technological data Commissioning 2007Annual production 20,000 tStrip width 900 – 1,700 mmStrip thickness 0.2 – 3.5 mmStrip speed- Entry 60 m/min- Process 45 m/min- Exit 60 m/min

Material Aluminum alloys (2xxx, 6xxx and 7xxxseries)


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MEETING your EXPECTATIONS

W7/308E

2000/09/12 .Ky . Printed in Germany

SMS SIEMAG AG

Strip Processing Lines Division

Walder Strasse 5340724 Hilden, Germany

Phone: +49 211 881-4618Telefax: +49 211 881-4212

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

“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 thesecharacteristics 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 willnot have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.”


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