Constellium, a global leader in the development and manufacturing of high value-added aluminum products, plays a crucial role in enhancing the world around us, making it lighter, safer, and cleaner. The company designs, develops, and engineers advanced solutions for a wide range of industries. To support their growth objectives, Constellium trusted Primetals Technologies to increase production volumes, improve product quality, and expand into new markets, with a particular focus on the automotive sector.
Challenge
Constellium Rolled Products Singen GmbH selected Primetals Technologies to revamp both the 4-high, 2-stand aluminum tandem cold rolling mill and the 4-high, 3-stand aluminum tandem cold rolling mill at Singen, Germany.
As a major global supplier of aluminum flat rolled products, the main aims of this investment for Constellium were to:
- Increase production volumes
- Improve product quality
- Penetrate new markets, particularly automotive
- Ultimately exceed the demands of the expanding aluminum market
Edgewipe
New exit equipment
New ironing roll
Solution
Primetals Technologies was successful in securing this project after demonstrating that:
- The entire project, from engineering design, equipment manufacture, supply, and installation, could be achieved within a ten-month timeframe.
- Only a 10-day outage period was required, which greatly minimized any disruption to production.
- Primetals Technologies could deliver the engineering design, manufacture, supply, and installation of the equipment on a turnkey basis.
- The mill enhancements would deliver increased production volumes, improved quality, and greater yield.
- The newly installed Level 2 automation system would reduce off-gauge length.
- In addition to its technical competence and world-class automation system, Primetals Technologies has significant experience in the successful delivery of modernization projects.
Scope of Supply
2-Stand Aluminum Cold Tandem Mill
Project management, design, and supply of key equipment for:
- Entry temperature measurement system
- Automatic coil centering system
- Primetals Technologies ISV Spraybar solution
- Primetals Technologies Edgewipe solution
- Interstand strip cooling system
- Exit temperature measurement system
- Mill hydraulic system pipework
- Mill coolant pipework
- New shear
- New carryover tables
- New ironing roll
- New outboard bearing support arm
- New offline inspection system
- Mass flow thickness control
- New ET200 process interfaces
- New HMI
- New roll coolant controls
- New stand controls
- New Level 2 automation incorporating math models for automated mill setup calculation
3-Stand Aluminum Cold Tandem Mill
Project management, design, and supply of key equipment for:
- Entry temperature measurement system
- Entry bridle
- Entry X-ray gauge
- Work roll offset solution
- Work roll bending and backup roll balance system
- Roll coolant system
- Backup roll (BUR) chock modification
- Interstand ironing roll
- Interstand strip cooling system
- Exit temperature measurement system
- Mill hydraulic system
- Mill coolant pipework
- Mass flow thickness control
- New ET200 process interfaces
- New HMI
- New roll coolant controls
- New stand controls
- New pulpit
- New Level 2 automation incorporating math models for automated mill setup calculation.
- ISV roll coolant spray bar
New exit equipment
Edgewipe
New ironing roll
Benefits
- Only a 10-day outage period was required on each mill, which greatly minimized any disruption to production.
- Mill enhancements delivered increased production volumes, improved quality, and greater yield.
- Newly installed Level 2 automation system reduced off-gauge length.
- New ISV spray bar improved flatness control.
- Reduction in off-gauge material length has improved coil yield.
Conclusion
- Constellium sought to increase production volumes and improve product quality.
- Primetals Technologies Edgewipe system installed to remove edge beading and improve surface quality.
- Mill exit structure replaced, including new equipment to improve the process and inspection of rolled products.
- Fully integrated electrical and automation system, including AFC/AGC/L2 control, has greatly improved mill availability.
