SIEMENS VAI Company profile Aluminium Industry

GLOBAL MEDIA COMMUNICATION LTD. 2
Siemens VAI Metals Technologies

SIEMENS VAI COMPANY PROFILE3
Index
Your challenge 4
Roughing mill 5
Our solution 6
Our portfolio at a glance 7-8
Hot rolling mills 9-10
Cold rolling mills 11-12
Foil rolling mills 13-14
Life-cycle management 15-16
Mill modernization 17-18
Special products 19-20
Drive solutions 21-22
Automation solutions 23-24
Process optimization 25-26
Aluminium Portfolio 27

Your challenge:
A growing need for plant productivity and quality
rolled products
Growing markets
Driven by Asia’s economic growth, the market for aluminium
strip and foil continues to grow. China’s aluminium demand
exceeds that of all other countries and will continue to do
so in the coming years. Such steady growth means plants
must continually optimize aluminium rolling processes in
order to stay competitive. Increased rolling speeds and
increased plant productivity are key factors for securing
your position in the market.
It’s all about quality
Although being able to increase quantity is important,
the key factor is quality enhancement. The ability to
provide aluminium strip and foil in customized qualities is
becoming increasingly crucial. Your customers in aerospace,
automotive, commercial transportation and packaging as
well as construction require even tighter tolerances. To
meet these demands, you need a flexible, easily adaptable
rolling setup.
Flexibility is a must
As your customers’ market needs change, your plant must be
capable of adapting. Short delivery times and fast production
changeover are key criteria when end customers decide
where to place orders. Dealing with product changes is
therefore a vital factor in the economics of aluminium rolling.
Logistic design has to be part of the plant solution, too.
The need to drive costs down
Rising raw material costs also have to be considered. In
recent years, the price of aluminium has risen sharply. This
means waste reduction is an important target.
High plant availability
Plant operations need to be optimized to increase capacity
and improve quality while decreasing operating costs.
Easy maintenance is also important for improving plant
availability and strengthening long-term performance. With
ever greater demands for aluminium strip and foil, the need
for better product quality, mill productivity, availability and
reliability continues to grow as well.

Roughing Mill
You expect:
• Leading process technology that
delivers high-quality products
• Fast rolling speed and flexible
production processes
• Tailored and comprehensive solutions
that accommodate the increasing
quality demands for aluminium products
• Expandable solutions that protect your
investments into the future
• High plant availability that lowers
operations costs
• Long-term performance with services
that meet your needs

Our solution:
Cutting-edge technologies for aluminium rolling mills
The answer for the aluminium industry:
SIROLL ALU
Our solution has everything to bring aluminium rolling mills
up to speed. This includes the most powerful roll drives
for higher throughput. State of-the-art mechanical and
hydraulic solutions optimize performance and operational
efficiency. Online process models and neural networks will
enable you to produce more accurately than ever before,
and our proven automation solutions maximize your plant’s
end-to-end consistency, reliability end-to-end consistency,
reliability and security in the future.
Increased production
With our decades of experience, Siemens Metals Technologies
has a deep understanding of processes in the aluminium
industry. Through the seamless integration of technology,
mechanics, automation and electrical engineering, our
solutions can help your plant achieve its highest level of
productivity.
Improved quality
We use a wide range of specialized technologies like SIROLL
DSR® (Dynamic Shape Roll), SIROLL SmartCrown®, SIROLL
SIFLAT noncontact shape measurement, AGC, automatic
profile and flatness control and more to achieve highest
product quality.
Efficiency from mill stands to production
planning
Our automation technology allows you to respond quickly to
your customers’ requirements and achieve market- driven,
flexible production. A modular strategy, open communications
and transparent automation architecture ensure that the
solution fits your needs, whether you’re building a new
plant or modernizing an existing one.
Through the intelligent distribution of functionality,
application-specific solutions and globally proven drive
concepts, SIROLL ALU guarantees reliable plant operation
throughout the entire production process. While maintaining
the highest product quality and maximum plant availability,
you’ll lower your operating costs significantly.
Customized production
Customers today want aluminium strip and foil to meet
different sizing specifications. They also want small batches
and good prices. That means you need fast and flexible
production processes that produce higher yield through
reduced cropping, trimming and off-length losses.
Our solutions minimize scrap from trimmed edges to help
you achieve unrivalled cropping and width optimization.
Our services ensure your success
Our professional services are aimed at helping your plant
achieve top performance throughout its entire life cycle.
Customized preventive and predictive strategies let you
minimize unplanned downtime and reduce your costs on
maintenance, spare parts and personnel.

Tandem cold rolling mill
Cold rolling mill
Automatic
high-bay store
Foil mills
Bright finishing mill
Strip caster Combined strip caster and hot rolling mill Hot-strip rolling mill
Our portfolio at a glance
Siemens Metals Technologies
offers the full range of
aluminium mill solutions
As your life-cycle partner, we’ll team with
you to meet all your needs, including
investment planning, operating
concepts and layout, and modernization,
to ensure that your plant is always
using the latest technology. With a
proven track record for conducting
integrated rolling complex projects and
supplying process equipment, we can
also define, supply and install auxiliary
Contents
Aluminium Mills
Hot Mills 9-10
Cold Mills 11-12
Foil Mills 13-14
Supplies and Services
Life-cycle management 15
Our Services 16
Modernization 17-18
Special products 19-20
Drive solutions 21-22
Automation solutions 23-24
Process optimization 25
Innovation 26

Slitting line
Cut-to-length lineTension leveling line Packaging line
Finishing standRoughing stand Roughing stand with edgerHot-strip rolling mill Tandem finishing train
facilities including roll shop, annealing,
finishing and packaging equipment
as well as identifying building and
civil engineering costs associated
with different layouts or planning for
future plant expansion for increased
production.
Service is another key element that
Siemens Metals Technologies delivers.
Main benefits:
• Decarburizing heats with
higher carbon levels
• Steel can be heated during RH
treatment
• Quick skull removal using
burner function
• Low investment and
maintenance costs
From the training of operating and
maintenance personnel to the
supply of knowledge and total plant
maintenance service, Siemens Metals
Technologies has the expertise to meet
your requirements.

Hot rolling mills
Advanced technology for high-quality products
These include:
• Reversing roughing mills
• Tandem mills
• Twin-coiler mills
• Plate mills
• Minimills
With our flexible mill configuration,
you can roll high quality strips in
capacities from 100,000 to 800,000
t/a, depending on the installation.
Product technologies are focused on
achieving the highest-quality products.
Siemens Metals Technologies provides
advanced mechanical actuators,
electrical and automation control
systems and applied process know-
how to deliver gauge, profile/flatness,
temperature and surface quality with
the highest level of consistency.
Advanced roll stack actuators such as
SIROLL SmartCrown® and SIROLL DSR®
can be custom-selected according to
your specific mill design.
Features:
• Our mill stand equipment is
designed for the highest rolling
loads and main drive torques,
which ensures the correct
development of material
property and maximized
throughput.
• Hydraulic systems to provide
controllable, responsive, precise,
safe and efficient operation. These
include hydraulic edger, HGC,
work roll bending and shifting,
side guides and shears.
• SIROLL SmartCrown® roll contour
guarantees enhanced flatness
control.
• For perfect cooling and contour
control we provide pulse-
modulated work roll spray bars.
Chinalco Ruimin – mill build
SIROLL ALU features a full range of aluminium hot rolling mills for both new and revamp projects.
• An accurate mill setup is crucial
for meeting the demands for
quality. SIROLL ALU features
physically based analytical online
models supported by neural
networks to achieve tight
tolerances right from head end.
• Common technological solutions
to enhance performance,
operability, maintenance, safety
and environments are utilized
across the hot mill, such as strip
coolant blow-offs, fume hoods
and fume extraction.

Main benefits:
• Flexible, low-cost rolling of a wide
range of products, even for small
order lots
• Tightest strip thickness, profile
flatness tolerances
• Maximum yield due to hydraulic
edging with automatic width-
control functions
• High surface quality
• Most advanced and innovative
automation
• Integrated health and safety
concepts
Selected references:
Alcan, Pindamonhangaba, Brazil
Alcasa, Puerto Ordaz, Venezuela
Alumax, Texarkana, USA
Alunorf, Neuss, Germany
Chinalco Ruimin, Fuzhou, China
Chinalco NELA, Harbin, China
Compania Valencia de Aluminio (CVA), Segorbe, Spain
Novelis Korea, Ulsan, South Korea
Southwest Aluminium, Chongqing, China
TLM, Sibenik, Croatia

Cold rolling mills
Solutions for high-precision rolling
6-high millstand
The cold mills supplied by Siemens
Metals Technologies offer a unique
blend of innovative design and proven
technology, allowing strip to be
produced at very tight tolerance and
productivity levels.
Our mills provide both breakdown
and finishing capability, offering
flexibility for the production of a
wide product range from a single mill
configuration.
The fully integrated automation and
drive system enables automated
equipment sequencing for efficient mill
operation. Process control, which uses
the latest Siemens Metals Technologies
automation technology, assures the
online control of strip flatness and
gauge and allows for the production of
high-quality products such as can stock,
lithographic sheet and foil stock.
Our SIROLL ALU portfolio includes:
• Breakdown mills
• Thin-strip mills
• Tandem mills (2 and more stands)
The cold rolling process can be assigned
to different process applications,
each suited to the material finish
requirements.
Breakdown mills are available as the
more conventional process option.
These mills can be supplied as 4-high or
6-high design and provide the flexibility
to operate on the complete range of
alloys, over a wide gauge range of
around 10 mm – 0.05 mm. Capacities
of up to 150,000 tonnes per year are
achievable with this process.
Tandem mills with 2, 3 or 5 stands
can be used to extend the throughput
capacity to 300,000 tonnes per year
and more.
Thin-strip mills of 4-high design allow
for a finishing capacity on light gauges
of down to around 0.02 mm. This mill
type can be used for foil roughing
applications. Capacities vary and
depend on the application, but are
usually in the order of 30,000 tonnes
per year.
Features:
• To ensure an accurate mill setup,
our cold rolling mills are based on
physical online process models.
This plus our fully integrated pro-
cess control, automation and drive
systems using the industry-stand-
ard SIMATIC platform allow for
optimum rolling results at any
time.
• We offer a range of mill stand
technologies to suit the part-
icular requirements of your pro-
ject. Options include SIROLL
DSR® backup roll technology,
SIROLL SmartCrown® roll tech-
nology and 6-high stand design.

• SIROLL Edge Wipe technology
enhances the Siemens Metals
Technologies‘ strip drying sy-
system, addressing the edge
bead issue common on open
gap passes.
• The SIROLL ALU Vapor Shield fume
cleaning and oil recovery system
ensures environmentally friendly
operation and the efficient colle-
ction and retrieval of rolling oil.
• The appropriate choice among a
range of flatness sensors is
available:
SIROLL SIFLAT, a non-contact
flatness sensor, ideal for surface
critical applications
SIROLL Air Bearing Shapemeter
roll, particularly suited to thin-
gauge finished products.
• The Schneider roll coolant filter,
manufactured and supplied un-
der license by Siemens Metals
Technologies, is the market leading
filter, enabling high levels of filtra-
tion and long cycle times with its
Acticel R filtration media.
Main benefits:
• Highest production rates
• Optimized yield
• Flexible production
• Tight tolerances for strip
thickness, flatness, and high
surface quality
• Low costs for operation,
maintenance, and minimum
downtimes
Alcoa, Samara, Russia
Alcoa (KAAL), Moka, Japan
Alcoa Bohai, Qinhuangdao, China
Aluar, Abado, Argentina
Aluminium Konin, Konin, Poland
CBA, Sorocaba, Brazil
Chinalco Henan, Zhengzhou, China
Chinalco NELA, Harbin, China
Comital, Volpiano, Italy
Elval, Inofyta, Greece
South West Aluminium, Chongqing,
China
Louisville Thin Strip Mill, United
States of America
High levels of filtration: Schneider roll coolant filter

Foil rolling mills
Foil mill, Shanghai Shenhuo, Shanghai, China
Best quality at the lowest cost
Siemens Metals Technologies‘ range of
high-performance foil mills combines
the latest developments in measure-
ment, computing and control with
innovative mill design to enable you
to produce the best-quality foil at the
lowest cost.
The mills feature a number of
automated systems for coil, spool
and scrap handling as well as high-
speed work roll change. The design
puts you in sync with the market trend
toward larger coil weight combined
with wide strip to maximize yield and
productivity.
The fully integrated automation and
drive system enables automated
equipment sequencing for efficient mill
operation. Process control, which uses
the latest Siemens Metals Technologies
automation technology, ensures the
online control of strip flatness and
gauge and allows for the production
of high-quality products.
Features:
Our state-of-the-art high-speed foil
mills (all types) have a number of
specific features:
• Operation and drive-side work
roll latching allows for thermal
expansion of the rolls to the
operator side.
• Accommodated by bearing clear-
ances, this eliminates potential
thrust forces on the mill spindles
and work roll bend rams during
long passes.
• Operation and drive-side backup
roll latching similarly eliminates
potential thrust forces on the
roll load cylinder during long
passes.
• An optimized mill bearing design
with specifically tailored tolera-
nces enhances high-speed oper-
ation.
Foil mill, Shanghai Shenhuo, Shanghai, China

Foil mill line and coil yard
• Oil circulation lubrication to the
backup roll bearings maintains
bearing temperatures within their
operating range and allows for
the use of synthetic oils, which
have a better load carrying
capability.
• A work roll and backup roll bea-
ring temperature measurement
function ensures precise monit-
oring of the bearing temperat-
ures.
• A constant-force ironing roll
permits consistently higher
coiling speeds.
• Spindle piloting eliminates
potential roll vibration by
providing a positive location of
the roll neck in the spindle end.
Northwest Aluminium, LongXi,
China
Shanghai Shenhuo, Shanghai, China
Varopakorn, Bangkok, Thailand
Main benefits:
• High production rates
• Flexible production
• Tight tolerances for strip thickness
and flatness
• Low costs for operation and
maintenance, and minimum
downtimes

Recycling
Modernization
New investment
Operation
• Investigation/inspections & feasibility study
• Design
• Layout
• Construction
• Installation
• Commissioning
• Service contracts
• Spare parts and components
• Consulting and training
• Online and offline
maintenance
• Maintenance contracting
• Migration packages
• Upgrading and
modernization
Life-cycle management
Partnership never ends
Siemens Metals Technologies‘
life-cycle services
As a plant operator, you have conflicting
needs. On the one hand, your perfor-
mance is measured each quarter against
short-term profitability expectations.
On the other hand, you have to think on
a totally different timescale compared
with the capital market.
Depending on the lifetime of your plant,
you have to take 15 years or more into
account. At the very least, that’s 60
full quarters.
But thanks to our comprehensive
expertise and integrated approach
to solutions, you benefit both short-
term and long-term from our life-cycle
services.
In the short term:
Backed by our extensive experience
with many reference plants, we
provide you with the certainty of fast,
dependable production start-up and
shorter amortization periods.
In the long term:
Our master plan guarantees competitive
performance for your plant in every
phase of its life cycle. Whether we’re
providing 24/7 technical support,
optimizing maintenance, or making
permanent plant improvements, we
are always working to ensure the cost-
effective operation of your plant.

Our services
Best performance throughout your plant‘s lifetime
Siemens Service Engineer
Features:
• Dedicated spare parts service from
small proprietary items to major
assemblies
• Stock control and distribution
database
• Standard packages with measu-
rable client benefits
• Dynamic spare parts and material
management system
• Material information system
• Substitution of parts including
re-engineering
• Service for electrical equipment
and automation
Best performance throughout
your plant‘s lifetime
You want your plant to produce at
competitive costs over its entire life
cycle, and always have state-of-the-
art technology. That‘s why you make
an investment. For this investment,
you should expect an effective
life-cycle concept from your plant
manufacturer.
Services offered by Siemens Metals
Technologies range from planning,
consulting and engineering to supply
of both individual components and
complete production lines, including
safe and rapid start-up. Whether
we’re constructing new plants or
modernizing existing capacities, our
own training specialists make sure that
your personnel know how to handle
the process and technology safely and
efficiently.
Our offerings include …
• Presale studies – from design,
engineering and feasibility studies
to improvement studies
• Start-up support – from on-site
training to accelerated start-up
programs
Spare parts and components
supply
Our spare parts service specializes in
the engineering and supply of spare and
wear parts, technological components
and systems. Professional handling
ensures that you receive the right part
in the shortest time possible.
The maintenance of your production
facilities and equipment is a significant
cost factor for you. Yet unplanned
process downtime greatly affects the
earnings of the entire company. Risks
must be minimized, as must the costs
for keeping those risks small.

Mill modernization
Keeping your production up-to-date
Novelis Utinga, Santo Andre, Brazil: before ...
To remain competitive as an aluminium
producer, you need the latest and most
advanced technologies that ensure
the best product quality and output.
This is particularly true in the field
of rolling mill modernization, where
complex mechanical and hydraulic
equipment components must be
integrated with sophisticated process
control systems in order to respond to
market demands.
Drawing on the SIROLL ALU concept,
Siemens Metals Technologies provides
solutions that can be implemented
through a phased upgrade with a
minimum of downtime in ongoing
plant operations.
This approach allows the mill to
improve its production output,
maintainability, machine access
and product quality, helping you to
remain competitive and successful.
The solution may be purely
electrical, automation, mechanical
or a combination thereof, and
can be carried out in one or more
steps during a plant shutdown.
Siemens Metals Technologies‘
experience minimizes
downtimes and ensures fast
start-up and top quality.
A successful modernization project
starts with the selection of one of three
types of modernization strategies:
• Type 1: Mill modernization via
ongoing and continuous
improvements and investments
• Type 2: Mill modernization via one
or two major modernization steps
• Type 3: Mill modernization via
relocation and improvement of an
existing mill
Type 1: Mill modernization
via ongoing and continuous
improvements and
investments
The 5-stand and tandem mill at Novelis
Rogerstone was installed in the late
1940s and has undergone many
upgrades over the last forty years. The
latest of these has included quality and
productivity improvements of the last
stand and exit table. Modernized at
the end of 2006, the upgraded mill is
now realizing its performance targets
and beyond.
Type 2: Mill modernization
via one or two major
modernization steps
For keeping their process automation
up-to-date, Alunorf, Neuss, decided to
modernize the rolling 4-stand finishing
mill with a state-of-the-art Level 2 and
HMI system. Modernization was done
while the mill was running (shadow
mode).

... and after foil mill modernization
That meant no additional standstill
of the mill was necessary. The first
strip with the new Level 2 system has
already reached targeted figures. With
the new Level 2 system, Alunorf is well
prepared to roll a wider range of new,
sophisticated material in the future.
The final acceptance by the customer
took place as scheduled in December
2004.
Type 3: Mill modernization via
relocation and improvement
of an existing mill
The relocation and modernization
of a hot reversing mill and 3-stand
tandem mill from Scotsboro, USA, to
Bohai, China, refocuses production
in the rapidly expanding Chinese
market. A general refurbishment
of the equipment took place before
installation in 2008.
Alcoa, Samara, Russia
Alcoa Bohai, Qinhuangdao, China
Alcoa Europe, Kofem, Hungary
Aleris, Koblenz, Germany
Alunorf, Neuss, Germany
Hindalco, Renukoot, India
Hydro Aluminium, Grevenbroich,
Germany
Kumz, Kamensk-Uralsky, Russia
Logan Aluminum, USA
Nikkei Siam, Bangkok, Thailand
Novelis Korea, Yeongju, South Korea
Novelis Packaging, Bridgnorth,
United Kingdom
Novelis UK, Rogerstone, United
Kingdom
Novelis Utinga, Santo Andre, Brazil

Special products
Unique solutions to improve the performance of your mill
SIROLL SIFLAT – flatness measurement and control
One of the strengths that sets Siemens
Metals Technologies apart from the
competition is our decades of experi-
ence, both in machine engineering
and automation. Our special products
combine expertise from both areas to
create unsurpassed solutions. Proven
mechanical designs, optimized control
technology and clearly defined inte-
rfaces deliver a solid foundation for
flexibly expanding existing aluminium
rolling mills or constructing new plants
from a single source. And these solu-
tions are modular in design, making
them ideal for efficiently modernizing
plants in easy-to-manage projects.
SIROLL DSR® – Dynamic
Shape Roll
The SIROLL DSR® system from Siemens
Metals Technologies is a key technol-
ogy for enhancing the performance
of cold rolling mills. SIROLL DSR® re-
places the top solid backup roll usually
employed in 4-high stands. It provides
improved flatness control, especially
in the critical areas at the head and
tail ends of the strip. This allows for
significant improvements in overall
coil yield. (Currently, SIROLL DSR® is
the only truly online dynamic actuator
that can enable symmetric and asym-
metric changes to the roll gap profile
during ongoing production.)
The dynamic control range of the SIROLL
DSR® is considerably larger than any
other rolling mill actuator in the market
place. True dynamic control is achieved
by the fast response of the pads to the
changes in the force distribution refer-
ence. DSR® eliminates undesirable roll
contact and stress peaks.
SIROLL SmartCrown work roll
contour
Work rolls are equipped with SIROLL
SmartCrown (patent pending), a new
type of roll contour introduced by Sie-
mens Metals Technologies.
Employing work rolls shifting in con-
junction with specially profiled work
rolls significantly increases the flatness
control range. SIROLL SmartCrown® is
usually installed in combination with
work roll bending to enable profile and
flatness control. With SIROLL Smart-
Crown’s large adjustment capability,
only one grind is needed to replace all
roll grinds for conventional rolls.
SIROLL SIFLAT
SIROLL SIFLAT helps you achieve greater
precision and productivity in flatness
control. This contactless system is based
on the principle of periodically exciting
the strip and measuring the excitation
amplitudes across the strip width. In
practice this means:
• High resolution of measurement
• Independence from strip speed
• Elimination of the need for special
coating or surface treatment
• Maintenance that can be perform-
ed by your maintenance staff
• Elimination of the need for spare
device

SIROLL ISV spray systems
Flatness package
Our flatness solution includes all re-
quired mechanical actuators and mea-
surement and control systems to ensure
the highest flatness performance. De-
pending on the mill type and product
mix, the mill stands feature:
• Work roll bending
• Multizone cooling SIROLL ISV
Sprays - enabling local corrections
• Hot-edge sprays – addressing
tight-edge issues
• SIROLL DSR® – giving fully dyn-
amic control
• SIROLL SmartCrown® – allowing
for continuous crown adjustment
These actuators work in conjunction
with a range of flatness sensors,
including:
• Air bearing shape roll – high
sensitivity, particularly suited for
foil production, but also available
in a cold mill, heavy duty version
• SIROLL SIFLAT – noncontact
measurement for highest
surface demands
• SIROLL Placinim® shape roll –
robust, solid roll available for hot
and cold applications
AGC packages
Siemens Metals Technologies auto-
matic gauge control (AGC) packages
combine the hydraulic capsules, servo-
valves, transducer and control system
to create a comprehensive solution.
Mass flow control ensures thickness
precision to within a few thousandths
of a millimeter.
Our REC (roll eccentricity compensa-
tion) system also allows for improved
thickness performance, especially for
modernizations.
Coolant collection and
filtration systems
Siemens Metals Technologies offers
a selection of rolling oil treatments,
including:
• Schneider Filter – a multiplate
filter designed and made under
license by Siemens Metals
Technologies, providing
microfiltration
• SIROLL ALU Vapor Shield fume
cleaning and oil recovery system,
providing effective emission
control and recycling of recovery
rolling oil
Further products offered by
Siemens Metals Technologies:
• SIROLL Edge Wipe – removes the
coolant edge bead prevalent in
cold rolling, thereby improving exit
coil dryness
• Constant-force ironing roll –
with optimized geometry and
servocontrol to maintain straight
coil buildup throughout the coil
Scratch brushes – work roll
chockmounted, with precise
hydraulic loading

Drive solutions
Moving the aluminium industry
In aluminium rolling, interruption-
free processes and high-quality end
products are important. The crucial
demands placed on drive technology
are therefore high-dynamic response of
the control system and brief overload
capability, smooth running, maximum
availability, service friendliness and
seamless integration into higher-level
automation systems.
For over two decades, Siemens has
pioneered synchronous main drive
technology for rolling mill applications.
With an installed base of AC main drives
with a combined capacity exceeding 1
GW (1,000 MW), Siemens has extensive
experience in delivering reliable, high
quality main drives for demanding
rolling mill applications.
Siemens’ synchronous motors – the most
powerful available – have established
themselves as an economical, versatile
solution. With low maintenance and
great efficiency they offer everything
you need for minimizing life-cycle
costs.
The right way to get your
aluminium mill rolling
Based on our low-maintenance and
reliable cylindrical rotors we are able to
offer the most attractive synchronous
motors for main drive systems.
• High availability and low
maintenance
• Compact design without fixing
elements and screw connections
• Fewer electrical connections
• Vacuum impregnation of whole
rotor
• Extremely rigid and robust design
• Optimal to withstand extreme
forces
Power needs control
Based on a single platform, Siemens
SINAMICS drives combine to form a
complete and consistent drive family
that spans the entire performance range
in terms of flexibility, functionality and
engineering design.
The selection criteria for the right drive
include:
• Application requirements
• Network conditions
• Economical aspects
• Operational issues
The control system fits seamlessly into
the SIMATIC automation environment
ensuring standardized interfaces and
standardized engineering environment.
A sole control system covers every
application area from low-power
units into the medium-voltage upper
megawatt range. And with our high-
end control units we provide the latest,
state-of-the-art drive control as well as
the right choice for all technological
challenges.
Voltage source converter
From standstill to top speed, the
SINAMICS voltage source converter is a
highly dynamic, responsive device even
with regenerative feedback into the
line supply. Minimum line harmonics,
outstanding torque smoothness and
Reliable and high quality synchronous main drives for very demanding applications

the highest degree of efficiency of the
entire drive/energy system distinguish
our multilevel converter with fully
adjustable line power factor.
Upgrading motors and drives
Most aluminium hot mills being
considered for an upgrade are
equipped with DC main motors since
their construction predates modern
synchronous motors. A requirement
for higher torque, better control and
increased operating efficiency leads
naturally to a synchronous motor
solution. The virtuous circle of market
need driving technical development
means that the aluminium industry
can now call on motor configuration
that can be adjusted to fit existing
foundations, that can be installed
quickly and that require a minimum
of maintenance.
Compared to DC machines synchronous
motors deliver more than simply
increased torque at low speed. Because
the limitations of commutation
are eliminated, the cut-off at field
weakening range can be increased
by up to 50%. For heavy reversing
duty, the cylindrical or nonsalient
pole configuration is ideal, being
both compact and robust as well as
maximizing dimensioning torque
through the use of the greatest number
of poles possible.
But you may need to upgrade more
than motors and drives. The need
for increased torque may require a
revamping of the transmission as a
whole. Spindle design and selection
also may need attention, and a simple
size increase in the joints is seldom
straightforward, because the roll
neck size and separation is usually
constrained. Electrical and mechanical
engineering design issues frequently
must be closely combined in mill
upgrade projects.
For foil mill applications utilizing
extremely small tensions and at the
same time wide tension ranges, Siemens
has already successfully implemented
AC drive systems.
Features:
• Common software tools for
engineering and commissioning
all Siemens drives
• IGCT/IGBT frequency converters
and integrated vector control
• Operator panel with self-
explanatory texts
• Upgrading of DC drives to the
technical level of AC drives –
through subsequent digitalization
Main benefits:
• Constant strip tension even in
highly critical sections
• Smooth strip flow in all operat-
ional states with nearly maint-
enance-free operation – thro-
ughout the entire service life
• Quick responses to changes in
load – reliable prevention of strip
damage
Maintenance-free cylindrical rotor

Automation solutions
Complete process control at every level
Mastering production processes requires
fully understanding and mapping
them in physical-metallurgical models.
Modeling allows you to identify the
effects of individual parameters on
the entire process. Good models are
therefore critical for the precise control
of the plant.
Realistic physical models
Siemens Metals Technologies relies
on more than 30 years of experience
in the development of physical
models for rolling processes. Thanks
to our continuous collaboration
with our customers, universities and
metallurgical research institutions, we
now have detailed models for the entire
rolling process. These provide a solid
foundation for our leading automation
solutions, especially in the area of
aluminium technology.
Pass schedule calculation and
mill setup
Based on ingot or strip data and
customer target specifications for the
finished product, our process control
system ensures that your production
is fast and efficient. We achieve
this through fully automatic pass
schedule calculations and intelligent
plant setups that are self-adjusting
on the basis of measured process
data. Such features allow you to avoid
production bottlenecks and maximize
plant throughput. You achieve shorter
production cycles and outstanding
material quality right from the very
first strip.
Automation Pulpit
A case in point:
Perfect temperature control in
hot mills
Our sophisticated temperature model
takes all physical effects into account,
including heat conduction into the work
rolls, frictional heating, deformation
heating and convective and radiative
heat transfer into the atmosphere
and cooling water. An intelligent
adaptation algorithm refines the heat
transfer coefficients (rather than simply
applying a correction factor to the final
result).
The model takes into account the actual
physics of rolling heat transfer through
adaptation, results of which can be
applied across different plants.

Another example:
Setup calculation for strip threading
in cold mills In a cold mill, the phase
when the strip is threaded and the mill
is accelerated to the desired speed
is particularly critical. A wrong initial
setting can lead to strip breaks or cause
poor mill acceleration.
The setup calculations based on our
mathematical models help circumvent
this by precalculating the mill setting
just before the actual strip is threaded,
based on the current mill status.
All necessary aspects such as the roll
wear and temperature, initial roll profile
and incoming strip profile are taken into
account by means of our sophisticated
mathematical models. The online
adaptation is performed by means of
neural-network technology.
Profile and flatness control
Strip geometry involves not only
width and thickness, but also profile
and flatness measures. To meet the
specifications of the market, our profile
and flatness control system builds on
sophisticated physical models. A roll
temperature model, for example,
analyzes the asymmetrical conditions
on the roll surface, while a material
flow model calculates the roll pressure
distribution as well as the strip flatness
after each pass. Based on this data,
the profile and flatness control system
makes sure that the finished strip has
the desired profile or contour and
flatness.
The profile and flatness controllers fully
incorporate and exploit the capabilities
of available actuators such as SIROLL
SmartCrown®, roll bending, SIROLL
DSR® and roll cooling.
Custom control systems
MES solution
Siemens Metals Technologies includes a
MES (manufacturing execution system)
solution specially developed for rolling
mills. The MES assists you in aligning
production targets with available
resources, while simultaneously
documenting the production process
reliably and completely.

Process optimization
Specific solutions for your entire plant
Our process optimization, process
control and basic automation
technology guarantees stable processes
and greater system reliability, as well as
custom solutions to meet your needs
right from the design phase.
Scalable solutions
The Siemens Metals Technologies‘
solutions for the entire automation and
drive system are scalable to your specific
requirements. Solutions can range
from simple pass schedule storage to
a complete pass schedule optimization
and setup system that includes the
generation of all relevant production
result data for product quality tracking
and analysis.
Automation system
The SIMATIC process control system
is based on a unique combination
of international industry-standard
hardware and software components
and expertise in aluminium rolling that
has been acquired through decades
of experience in mill automation. It
provides excellent quality tolerances
together with easy service and spare
part access and maintenance. The
remote access features give you access
to support from our specialists no
matter where you are.
Technological controls
We offer the full range from AGC/
AFC packages to fully integrated
mill automation and drive systems.
SIROLL ALU includes a complete set of
sophisticated control algorithms for hot,
cold and foil applications. All features
are carefully integrated with the related
drive system and mechanical equipment
to enable optimum results.
HMI and diagnostics
The SIROLL automation system provides
easy-to-understand HMI (human-
machine interface) screens and features
targeted diagnostics to provide excellent
operator guidance.

Hydraulic AGC: First
application on an
aluminium mill
SIROLL Edge Wipe:
New device to improve
strip dryness in cold mills
SIROLL SmartCrown: New actuator
for profile and flatness control
SIROLL Heavy
Duty Shapemeter:
High load bearing
capacity for cold
mills.
Vidimon air bearing shape roll:
Pioneer in use of flatness measurement
RSV sprays: Pioneer in
flatness control actuators
Advanced mass flow control
Novel profile and
flatness control
algorithm for hot
mills
SIROLL ISV Sprays: Introduction of
pulse-width-modulated sprays
AC main drives in hot mills
Neural
networks
for process
automation
SIROLL SIFLAT: New, noncontact
sensor for flatness measurement
1960 1970 1980 1990 2000 2010
1958
1973
1978
1991
1996 1999
1996
2001 2009
1988
2004
1985
1989
2003
SIROLL DSR®: New
dynamic flatness
control actuator
SIROLL ALU Vapor
Shield: Introduction
of environmentally
friendly technologies
Innovation
We’ve been working to build your future
We’ve pioneered innovation for 100
years and are constantly driving de-
velopment forward. For the greatest
quality, from the first coil. For ever-
thinner foil and higher- quality prod-
ucts. The basis for our innovation is
the systematic linking of our exper-
tise in rolling technology, electrical
engineering, automation, IT, process
technology and operation. It is our
common knowledge base – yours and
Siemens’.
Expanding technological
leadership - our goal, your
advantage.
Stay at the top. Our research and
development budget – which is 8%
of our annual revenues – is a clear
signal that we want to remain your
partner for innovation. Our own
R&D department, together with the
R&D resources of Siemens and the
cooperation with leading universities
and aluminium manufacturers, helps
us further develop innovative solutions
that meet our customers’ future market
requirements.

SIROLL ALU - Siemens VAI comprehensive Aluminium Portfolio
Hot Rolling - Aluminium our competences along the entire value chain
Innovation DSR® – Powerful Dynamic Mill Actuator
SIROLL ChatterBlock – vibration elimination
Cryogenic Cooling – eliminate kerosene
Energy & Environment VaporShield – VOC collection and recovery
Schneider Filter – No.1 filter technology
SIROLL Green Button
Service Know-how consultancy
Spare and wear parts
Hardware and system software upgrades
Modernization Hydraulic Screwdown / AGC
DSR® Conversion – Quality & Yield Optimisation
SIROLL Roll Eccentricity Compensation
Electrics, Automation & IT Process optimization and technological controls
Efficient mill drive solutions
SIROLL TCS: Technological Control System
Aluminium Hot Mills
Reversing Roughing Mills
Tandem Mills
Twin-Coiler Mills
Plate Mills
Mini-Mills
Aluminium Cold Mills
Single Stand Breakdown Mills
Multi-Stand Tandem Mills
Thin Strip Mills
Aluminium Foil Mills
Roughing Mills
Intermediate Mills
Finishing Mills
Universal Mills
Bright Finish Mills
Innovation SIROLL Smart Crown: Technology Package
Profile / Flatness Control
Automated Roll Bite Assistance
Energy & Environment Roll Coolant Conditioning & Filtration
SIROLL Green Button
Service Know-how Consultancy
Spare and wear parts
Condition monitoring system (CMS)
Hardware and System Software Upgrades (Retrofit)
Modernization Hydraulic Screwdown / AGC
Surface Quality Control
Edger and Heavy Duty Shear
Electrics, Automation & IT Single Source Control, PLC, MCC, Drives, Motors
Efficient mill drive solutions
Comprehensive Temperature Models
Online Level 2 Process Models (hybrid models)
Cold & Foil Rolling - Aluminium our competences along the entire value chain
Records Wide Plate Mill – 4.5m
Wide Twin Coiling Mill – 3m
Excellent results 3 stand FM
Records DSR® - Maximised Yield
Benefits – 1800mpm
Air Bearing Shapemeter – over
1000 sold
Life Cycle Services

During the past five decades we have supplied hundreds of
new and modernized mills setting the benchmark for
producing quality strip in an efficient manner. The market
is ever changing and demands highest yield and tolerances
while minimizing environmental impact. Siemens VAI is at
the forefront of this challenge.
As a total solution provider the Dynamic Shape Roll DSR©
has been developed as a variable force distribution
actuator, replacing a conventional solid back-up roll,
Improving mill productivity and reducing operating costs.
The DSR©
enables you to meet market challenges of today
and the future. Your mill will produce a harder, wider and
thinner product portfolio ensuring product flatness,
increase your schedule flexibility, reduce material
breakages and roll changes.
The Intelligent flatness control algorithm uses feedback
from the shape roll to generate signals to vary the force
distribution across strip width.
The DSR©
’s performance is impressive; eliminating
undesirable roll contact and stress peaks. The control
range is considerably larger than 6hi and contoured roll
Answers for industry.
siemens-vai.com
Focus on Precision, Yield
and Green
design mills. True dynamic control is achieved by fast
response of the pads to changes in the force distribution
reference.
DSR©
Benefits:
Yield Savings – Achieves target flatness quicker and
retains longer during tail out.
No warm-up coils required during mill start-up or width
change.
Rolling passes reduced.
Rolling speed increased.
Productivity increased (product mix dependant).
Number of Back Up roll changes reduced.
Retrofitting of DSR©
requires minimal downtime and
recommissioning.
Be the leader in the field – with SIROLL ALU solutions from
Siemens VAI, a global supplier and your local partner.
Set the benchmark in Aluminum Rolling!
Visit us at:
Aluminium
2014 Messe
Dusseldorf, Hall
9, Booth 9E40

Published by: Global Media Communication Limited
t: +44 208 579 0594
e: gmcproduction@gmx.com
w: globalmediacommunication.com
Siemens VAI
Metals Technologies GmbH
P.O. Box 4, Turmstr. 44
4031 Linz, Austria
Phone: +43 732 6592-0
siemens-vai.com

SIEMENS VAI Company profile Aluminium Industry

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