To meet end-market demands, Shanghai Shenhuo Aluminum Foil Co Ltd. required a partner with a proven track record that could supply them with three aluminum foil mills capable of producing thinner and wider aluminum foil at high production volumes. They put their faith in Primetals Technologies, confident that its foil mill technology would give them the edge in delivering high productivity and outstanding product quality to satisfy the needs of both their domestic and international markets.
Challenge
As the demands for aluminum foil applications in terms of quantity and quality have increased, so have the demands on the equipment that produces the foil. Today’s rolling mills are, therefore, expected to produce foil thinner than 6 microns, in widths exceeding 2 meters, and to be capable of speeds in excess of 2,000 meters per minute. Primetals Technologies was tasked with supplying three foil mills capable of producing 25,000 tonnes per year and rolling material 2 meters wide.
High quality aluminum foil
Solution
The Shanghai Shenhuo foil mills are amongst the most advanced foil rolling mills in the world today. The three wide, high-speed foil mills were supplied to Shanghai Shenhuo Aluminium Foil Co. Ltd. as part of the foil plant development in Pudong Kangqiao Industrial Zone, Shanghai. The aim is to produce in excess of 25,000 tonnes of thin foil per year.
The three mills include a range of state-of-the-art rolling features, including numerous design features specifically for high-speed operation. Primetals Technologies provides process support on every new foil mill project, which ensures the smoothest start-up and quickest production build-up. For Shenhuo, the start-up of the mills was achieved in record time for a new foil mill project.
The specific demands of wide, high-speed foil mills relating to product quality and mill operation are catered for with a range of proven mill design features. The world-leading technological process control system from Primetals Technologies provides online control of strip flatness and gauge, producing finished foil of the highest quality.
Comprehensive data logging, reporting, and diagnostic features form an integral part of the control package, maximizing the operating efficiency of the mills.
High quality aluminum foil
Results
The first coil rolled on each mill was of saleable quality. The foil roughing mill achieved rolling speeds greater than 1,750 meters per minute (mpm) at start-up + 20 days. The foil intermediate mill achieved a rolling speed of 1,000 mpm on the first coil, rolling speeds greater than 1,800 mpm at start-up + 7 days, and foil thickness of 7.5 microns at start-up + 16 days. The foil finishing mill also achieved 7 microns within the first week of rolling. Usual industry guarantees were met and exceeded for thickness flatness, surface quality, coil build-up, strip breaks, and productivity.
Shnaghai Shenhuo's aluminum foil rolling mill's equipment data
Benefits
- The first coil rolled on each mill was of saleable quality.
- Usual industry guarantees were met and exceeded for thickness, flatness, surface quality, coil build-up, strip breaks, and productivity.
- Three foil mills produce in excess of 25,000 tonnes of thin foil per year.
Conclusion
- The customer had a need to produce foil thinner than 6 microns, in widths exceeding 2 meters, and at speeds greater than 2,000 meters per minute.
- Primetals Technologies supplied three wide, high-speed foil mills as part of the foil plant development.
- The start-up of the mills was achieved in record time for a new foil mill project.
