EXTRACTS

FROM VARIOUS NEWSLETTERS

MODERNIZATION
OF COLD ROLLING MILLS
CONTENTS 
Contents
SMS Siemag is the right
partner for modern-
izations of cold rolling
mills. This has been
proved by numerous
references during the
last few years, some of
which are shown in this
magazine.
4 Intelligent solutions
for cold rolling mills
6 CARBON STEEL
8 OAO Severstal
 Higher yield and better
quality
10 Ruukki
Tandem mill to receive
upgrade
11 ArcelorMittal
Brasil
Expansion of cold strip
capacity
12 Bilstein
Smart upgrade concept
2
SMS group Extracts from various newsletters
14 Bilstein 21 Rasselstein,
Four-stand tandem mill
Andernach
modernized
Relocation and revamp
16 Rasselstein 21 ArcelorMittal, Genk
Tailor-made modernization Revamping of reversing mill
17 Rasselstein, 22 Wickeder
Andernach Westfalenstahl
Modernization of tandem mill  ire damage remedied as fast
F
as possible
18 Ilva, Cornigliano
Continuous exit section 24 International
installed
Steels Limited
 Increasing annual
19 Ilva, Novi Ligure capacity by 40 percent
Higher drive power
25 KYCR
20 TKS, Dortmund Coil Industries
Modernization of PL-TCM
Expansion of reversing
cold mill
CONTENTS

26 STAINLESS STEEL 33 ThyssenKrupp

Nirosta Düsseldorf
28 Outokumpu For quality and stainless-
Prepared for new steel strip Digital reading
requirements
34 ArcelorMittal, Genk Order PDF version under
29 VDM Werdohl Revamp of “CRM 4” completed coldrollingmills@
sms-siemag.com
Large product unit

36 Theis
30 Revamps in Kaltwalzwerke
Torshälla, Terni A world’s first: CVC plus®

in multi-roll stands
and Krefeld
Experience that counts
37 ThyssenKrupp
32 ThyssenKrupp Nirosta Dillenburg
Higher productivity
Nirosta Düsseldorf IMPRINT
Smooth modernization Publisher SMS group

38 Register Corporate Communications

Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
www.sms-group.com

Cover photo Bilstein GmbH & Co KG,

Germany. Operator controls mill
operation of the comprehensively
modernized tandem cold mill.

3
COLD ROLLING MILLS  SMS group Extracts from various newsletters

Automatic work roll change device.

“Rotary Inspect“ inline inspection station. Bending and shifting systems.

4
COLD ROLLING MILLS
INTELLIGENT SOLUTIONS
FOR COLD ROLLING MILLS
After the global steel boom of recent years, the market is going through
a phase of consolidation. Now is the right time to bring old plants
up to the state of the art to prepare for future tasks and challenges.
As a supplier of plant and equipment,
SMS Siemag offers its customers not
only integrated and new plants, but of
course also intelligent solutions for
the modernization of existing works.
For this, our portfolio includes exten-
sive technology packages as well as
extra facilities for mechanical equip-
ment, utilities, electrics and automa-
tion – all from a single source. With
Hydraulic valve stand module.
reference to some recent examples,
we would like to present various solu-
tions for different types of plants.
i SMS SIEMAG
The modernization of cold rolling
the right partner for
mills necessitates concepts that are
modernizations:
exactly tailored to the plant and to the
needs and requirements of the cus-  reparation of tailor-made
P
tomer. Therefore, we team up with our modernization concepts
customers to develop modernization Competent project teams
Decades of experience in the con-
solutions. Not only do our activities ac-
struction and modernization of cold
count for the technological and design rolling mills
requirements, but as early as in the Exact planning over the entire
project planning phase we draw up project handling time
and implement exact and detailed Extensive pre-assembly plus test-
ing in our shops
schedules for manufacture, erection
Assignment of experienced erection
and commissioning. and commissioning teams
Our customers benefit from our
long-standing experience in the vari-
ous fields of cold rolling mill equip-
ment and technology. Besides a large
number of new plants built worldwide,
we have modernized over 40 cold roll-
ing mills in a whole range of different
designs since 1995. Here are some ex-
amples.
5
 CARBON STEEL
SMS Siemag’s portfolio for carbon steel rolling comprises reversing
cold mills, compact cold mills and tandem cold mills, as well as
skin pass mills for tempering. Customers can rely on high quality equipment
and tailor-made solutions.

6
7
The four-stand tandem cold mill at
OAO Severstal gets an all-around revamp.
HIGHER YIELD
AND LESS OPERATION COSTS
SMS Siemag modernizes 4-stand tandem cold mill 1700 at OAO Severstal in Russia.
This will enlarge the product range, improve quality and increase the annual production.
Russian steel producer OAO Severstal
placed an order with SMS Siemag in
February 2014 for modernization of the
4-stand tandem cold mill 1700 at
Cherepovets works in northwest Rus-
sia. With replacement of the tandem
cold mill in 4-high design, operating
since 1963, annual production will be
increased by 200,000 t up to 1,300,000 t.
The modernization includes the oppor-
tunity of later coupling of the tandem
cold mill with a new pickling line.
Thereby OAO Severstal will be prepared
8
for increasing material requirements
of the customers, especially of the au-
tomotive industry.
SMS Siemag has supported numer-
ous customers in adopting tandem
cold mills technologically to current
and future market demands. This ex-
perience combined with the expertise
as system supplier of mechanical,
electrical and automation systems has
essentially contributed to OAO Sever-
stal choosing SMS Siemag as supplier.
SMS Siemag is going to replace the
four mill stands and the entry section
completely. On the entry side, a double
expansion head pay-off reel with strip
centering device and equipment for
strip head end preparation as well as a
roller press are installed. The roller
press helps to increase strip tension
prior to the first mill stand, especially
when rolling thicker strips, which is
beneficial to rolling of high strength
grades. The entry side coil car will be
additionally equipped with new hy-
draulic controls.
PRECISE AND EFFICIENT ROLLING
The core of the tandem cold mill is built
by four new mill stands in 4-high design,
providing the latest rolling technology by
SMS Siemag for precise and efficient
rolling. The technical configuration
comprises hydraulic gap and wedge ad-
justment, CVC® plus as well as positive
and negative work roll bending. In the
last stand strip, quality is optimized by
multizone cooling and DS system. SMS
Siemag has optimized the roll and inter-
stand cooling according to up-to-date
findings, allowing high reductions.
Automatic work roll change devices
enable fast work roll change, whereby
idle times will be reduced. Especially
when looking on the intended later
coupling of the TCM to a pickling line,
realizing continuous operation, it is
important to keep production on a high
level. The back-up roll change will be
assisted by a new semi-automatic
change device.
NEW AUTOMATION SYSTEM
The first mill stand drive will be com-
pletely modernized with drive system,
motor and feeding by a medium volt-
age electronic frequency converter.
The remaining stands will be equipped
with new drive spindles. The existing
Leonard-converter as the gear of mill
stands 2 up to 4 as well as of the ten-
sion reel will be provided with a new
field weakening by SMS Siemag.
The tandem cold mill gets the latest
generation X-Pact® level 1 and level 2
automation. In addition, the techno-
logical measuring systems for strip
thickness, strip tension and rolling
speed will be exchanged. This com-
plete solution provides for significantly
reduced thickness tolerances and off-
gauge lengths at the strip head and
tail ends, by setup value calculation on
the basis of the process model and the
mass flow control, both developed by
SMS Siemag.
Together with OAO Severstal a tai-
lored operating concept was realized.
The electric lines will be supplied in
dust-proof containers. This simplifies
the integration into the existing sur-
roundings and reduces efforts for the
customer.
Apart from the existing tension reel,
the exit section of the tandem cold mill
will be exchanged. To fulfill challeng-
ing demands on strip flatness, behind
stands one and four highly precise X-
Shape flatness measuring systems
are to be installed.
REDUCED EMISSIONS
The tandem cold mill will receive a
modern mill stand cladding with a
most efficient fume exhaust system,
keeping the environment for the mill
operators free from emission. The mill
stand platform with hydraulic valve
stands allows good accessibility for
maintenance. Further, SMS Siemag is
going to install new high- and low-
pressure hydraulic systems and to
modernize the existing emulsion plant.
New feed line filters and chain-type
magnetic separators clean the emul-
sion in an efficient way from the con-
tamination of the rolling process. By
this emulsion consumption and opera-
tional costs are reduced.
For the challenging modernization
there is only one main shutdown of two
and a half month being scheduled. By
this revamp, OAO Severstal gets a
state-of-the art tandem cold mill, able
to meet given targets to the full extent
and being characterized by low main-
tenance, resource saving and efficient
operation. (Newsletter 1/15)
i FACTS &
FIGURES
Year of commissioning  2016
Annual production  1,300,000 t
Strip thickness  5.5 – 1.5 mm (entry)
 3.2 – 0.4 mm (exit)
Rolling speed  max. 1,500 m/min.
Material grades  carbon steel and
high-strength,
micro alloyed Si-steel
9
COLD ROLLING MILLS 
TANDEM MILL AT RUUKKI
TO RECEIVE UPGRADE
Tailored modernization concept
SMS Siemag is modernizing the tandem mill of the Finnish
steelmaker Ruukki at its Haemeelinna location. The cold
rolling mill is being equipped with high-precision adjust-
ment systems.
The four-stand quarto tandem mill has been in operation
since 1972 and is the central facility for cold strip produc-
tion at Ruukki. Here, carbon steel strips with widths rang-
ing from 540 to 1,575 mm and maximum entry gages of
up to 6.30 mm are rolled down to final gages as thin as
0.30 mm. The annual capacity amounts to 1,250,000 t.
Before the contract was awarded, investigations were
performed by SMS Siemag with the aim of defining mea-
sures by means of which the quality level, productivity and
economic efficiency of the plant can be increased step by
step. In addition, Ruukki wanted to enlarge the portion of
high-strength grades in the product mix. On this basis, a
modernization concept was prepared in cooperation with
the customer.
10
SMS group Extracts from various newsletters
In 1998, SMS Siemag had already equipped mill stands 1
and 2 with state-of-the-art hydraulic adjustment systems.
Within the scope of the current order, mill stands 3 and 4
are now being provided with hydraulic adjustment systems
which are characterized by high positioning accuracy, pre-
cise roll gap adjustment and good accessibility as well as
serviceability. Thus, performance and reliability of the tan-
dem mill are again significantly improved.
All quality-relevant components are manufactured and
subjected to extensive tests in the SMS Siemag workshop
in Hilchenbach. This ensures smooth installation at Ruukki,
so that after just one short revamping shutdown period, the
plant can resume operation at the end of July 2013. (News-
letter 1/13)
i EXPERIENCE
COUNTS
Sophisticated modernization concepts
by SMS Siemag help the customer
attain maximum improvement of the
plant performance at minimum effort
and costs. The experience of numer-
ous business departments of SMS
Siemag have been incorporated in the
customized concept for modernization
of Ruukki’s tandem mill. Another
essential factor is the close coopera-
tion and coordination with the custom-
er throughout all project phases.
 Cold-strip complex of ArcelorMittal
Brasil S.A., São Francisco do Sul.

Four-stand tandem mill before extension (entry side).

THE SUCCESS STORY

CONTINUES
ArcelorMittal Brasil extends cold-strip capacity to 1.4 million tons per year

ArcelorMittal Brasil contracted SMS Siemag to extend the and the coil handling systems will be modified accordingly.
cold rolling mill in São Francisco do Sul in the state of San- The side trimmer in the pickling line will be extended by two
ta Caterina, Brazil, so as to be able to boost the annual ca- knife heads and two scrap choppers. In addition, the emul-
pacity of the PL-TCM to 1.4 million t. Situated on an island, sion system and the acid regeneration plant will be adapted
the complete cold strip complex was built by SMS Siemag to the new situation.
in 2003, under the name of Vega do Sul, responding to an
order by Usinor (now ArcelorMittal) and CST, Brazil. REVAMPING IN JUST TWO WEEKS
The Vega plant had originally been designed so as to per- All revamping work will be completed during a two-week
mit capacity to be increased after successful placement of main shutdown of the mill. Then, in October 2010, the mill
the products on the Brazilian market. Today, the former will produce the first strip in fully continuous operation.
Vega do Sul ranks among Brazil’s leading producers of (Newsletter 2/09)
high-quality hot strip. With the contract now awarded to
SMS Siemag, ArcelorMittal Brasil is implementing the orig-
inal plan for mill extension. In keeping with the order, the
The four-stand tandem cold rolling mill in figures
four-stand pickling line/tandem cold mill (PL-TCM), which
Production data
currently operates in semi-continuous mode, will be
Material deep-drawing steels, higher-strength steels
equipped for fully continuous rolling. With this measure,
Strip width 750 to 1,875 mm
ArcelorMittal wants to boost annual production from cur-
rently 900,000 t to some 1.4 million t. Strip thickness
ingoing 1.2 to 4.8 mm
SECOND REEL, NEW PINCH ROLL UNITS AND DRUM-TYPE outgoing 0.4 to 2.0 mm
SHEAR, EXTENSION OF SIDE TRIMMER, MORE DRIVE POWER Coil weight max. 40,000 kg
For fully continuous operation, we will supply and install a Technical data
second tension reel, a drum-type shear and pinch roll units. Stand type four-high stands with CVC® plus
The new reel will be identical in design to the existing ten- Rolling speed max. 850 m/min
sion reel. The drive rating of the first stand of the tandem Rolling force 30,000 kN adjusting force per stand
mill will be doubled by the provision of a second motor. In Capacity 1,400,000 tpy
the exit section, the baseframes, the fume exhaust system

11
COLD ROLLING MILLS 
REVAMP OF BILSTEIN’S
TANDEM COLD ROLLING MILL
Smart upgrade concept for minimum production losses
SMS Siemag has developed a new revamp and moderniza-
tion concept which, unlike conventional procedures, guar-
antees plant users significantly less production losses,
shorter commissioning, steeper ramp-up curves and thus
faster Return-on-Investment. For modernizing the four-
stand tandem cold rolling mill of Bilstein GmbH & Co. KG,
Germany, SMS Siemag is implementing this concept in a
way that is tailored to the specific needs of the customer.
The essential steps of the concept are: inventory of the ac-
tual situation, engineering, installation of a process-IO
server (PIOS), integration test, revamp and optimization.
STARTING SITUATION
Supplied by SMS Siemag in 1969, the four-stand tandem
cold rolling mill to be modernized has meanwhile under-
gone several expansions. It rolls a wide spectrum of 400,000 t
of cold-strip products per year in widths between 320 and
Plug&Work test.
12
SMS group Extracts from various newsletters
670 mm and thicknesses of 7.5 to 0.3 mm. The starting ma-
terial is slit hot strip which, owing to different wedge pro-
files, poses high demands on the cold rolling process. The
modernization mainly aims at enhancing the plant’s avail-
ability, boosting production by 60,000 tpy, improving prod-
uct quality and increasing the degree of automation.
The revamp activities are to be carried out during regu-
lar shutdowns. Three standstill periods of five weeks in to-
tal are available.
SMART UPGRADE CONCEPT
FOR MINIMUM PRODUCTION LOSSES
Inventory of the actual situation. All mechanical and elec-
trical components, all functions, processes and sequences
as well as the operating philosophy of the mill will be
checked and documented in the customer’s works.
Engineering. The engineering and subsequent manufac-
The tandem cold rolling mill at Bilstein.
 Old New

PPS / L3
Mechanically caused conversion times
115

Production, %
100
Process models / L2 Process models / L2

Time
Process control / L1 Process control / L1

Inventory
of situation

in the plant
Remote IO´s

Modernization steps
PIOS Electronic terminal Conversion and
board “PIOS“. Operation with
optimizing phases new plant
Monitoring on old plant (stepwise)

SMS Demag
PIOS Integration
(Process IO Server) = Engineering

at
test
“electronic terminal board”
M
Time

Process-IO server. Modernization time schedule.

ture will be based on the exact data provided by the inven-

tory and a description coordinated with the customer of
new functions, modified process sequences and the new
i FACTS & FIGURES
operating philosophy.
PIOS, the “electronic terminal board”. Almost simulta- The most important mechanical modernization
neously with the preparation of the engineering, a process- measures include:
IO server (PIOS) will be installed in the customer’s existing
 ntry-end pinch roll set
E
plant during scheduled maintenance shutdowns. Repre-
Fitting all the stands with hydraulic adjusting systems
senting the “heart” of an automation system – a kind of
New gear wheel sets
electronic terminal board with software switch – it permits Dry-Strip system in the exit section
to run the system in the shadow mode and to implement Swingable bridle roll set in the exit section
step-by-step changeover to the new signal paths and/or the
new automation system. Operation in parallel with the old A major part of the existing electrics and automation
automation system allows switchback to the old automa- will be replaced with new systems:
tion in case of deficiencies or problems. In this way, pro-  ulti-drive converter with modern synchronous motors
M
duction is safeguarded! for stands and tension reels, and with asynchronous motors
Integration test. The complete hard- and software will be for payoff reels, pinch roll units and bridle rolls
installed in SMS Siemag’s test field, and will then be tested Main control pulpit, operating stations and visualization
system
and preset under realistic conditions by means of a simula-
Integrated automation system for sequence controls and
tion system. The simulation includes the existing mechani- technological controls
cal components and those plant elements whose kinematic Model-based level-2 system for setpoint calculation for
behavior and dimensions were assessed in the inventory. At the entire mill
the same time, Bilstein’s operating and maintenance crews
will be trained on the new system before it is started up.
Revamp and optimization. During revamping and subse-
quent optimization, the mechanical equipment as well as
the new functions and controls will be switched on, tested
and optimized, either completely or in part. Digital change-
over at the PIOS makes it possible to restore the original Thanks to this modernization concept, both Bilstein, the
state and condition of the plant very quickly. After the new plant user, and SMS Siemag can be absolutely sure that
functions have been thoroughly tested and optimized, the revamping will go smoothly and that the goals pursued with
“old” automation components will be removed for the new the modernization will be achieved within the specified
systems to take over. time. (Newsletter 2/07)

13
PROJECTS 
HIGHER CAPACITY
SMS Siemag modernized a four-stand tandem mill for Bilstein, Germany.
Bilstein benefits from better quality and closer gage tolerances.
At Bilstein GmbH & Co. KG in Hagen-Hohenlimburg, Ger-
many, SMS Siemag comprehensively modernized the four-
stand cold rolling mill supplied by SMS Siemag in 1969. The
project involved the installation of new mechanical, electri-
cal and automation equipment in several stages. The dis-
continuous rolling mill plays a key role in cold strip produc-
tion at Bilstein, a company with a long-standing tradition. In
December 2010, Bilstein granted us the FAC for the com-
plete revamp.
HIGHER CAPACITY, BETTER QUALITY
The main objective of the tandem mill modernization at Bil-
stein was to keep the plant at the latest state of the art and
boost annual production. Further targets were to improve
plant availability, increase the degree of automation and re-
duce the number of plant operators. In addition to these
aspects, the revamp was intended to safeguard and further
improve the product quality, especially in terms of gage tol-
erances and straight-edge coiling. A distinct improvement
was needed due to the fact that hot strip slit into two or
three bands with different taper is used as input material.
This posed a special challenge to our cold rolling experts.
The existing electrical and automation equipment was large-
ly replaced by new systems as part of the modernization.
MODERNIZATION PROJECT IN FOUR CONSTRUCTION STAGES
SMS Siemag implemented the smart modernization project
in four stages to have only short shutdown periods. First,
the new controls for the media systems were installed.
14
SMS group newsletter 02 / 2013
SMS Siemag specifically supplied the following
features from level-0 up to the level-2 system:
 ulti-drive converters with modern synchronous motors
M
for the mill stands and tension reel, and with asynchronous
motors for the payoff reel, pinch roll units and bridle rolls
Main control pulpit, operation stations and visualization
system
Integrated level-1 automation system
Model-based level-2 system for setpoint calculation for
the entire mill
During the two-week shutdown, preparatory work for the
installation of the mechanical equipment could already be
accomplished. The next phase of the project involved the
installation of new hydraulic adjusting systems and the
stand drives during a seven-day standstill.
CHANGEOVER OPERATION SAFEGUARDED PRODUCTION
A highlight of the second construction phase was the instal-
lation of the process-IO server (PIOS), which we refer to as
our “electronic terminal board”. Being the “heart” of the au-
tomation system, it permitted to run the system in the shad-
ow mode and to change over step by step to the new auto-
mation system. The old automation system was kept live
and running in parallel. This allowed switchback to the old
system at any time. During a further regular standstill of
two weeks, the mechanical portion of the project was large-
ly completed. It involved the installation of the entry-side
pinch roll units for stabilizing strip guiding, the exit-side
 The automatic threading assistant
reduces off-size lengths.

bridle roll set and the payoff reel motors. During the last way. As the pass schedules can be
phase, the new automation system could be completed.
Also during this phase, the operation in the changeover
mode ensured that, depending on the production require-
pre-calculated with high accuracy,
rolling trials for new products can be
largely dispensed with.
i
ments, it was possible to switch between the old and the
BILSTEIN –
new automation system. This safeguarded production of TRAINING OF THE OPERATING
a name that
the four-stand tandem mill, having a key function within the PERSONNEL stands for cold
customer’s process chain, at all times, also during ramp- We instructed the operating personnel strip.
up for commissioning. of Bilstein during a four-week training
course on SMS Siemag’s rolling simu- Bilstein GmbH &
INCREASE OF ROLLING FORCE AND ROLLING SPEED lator to familiarize them with the new Co. KG located in
The installation of new hydraulic long-stroke cylinders automation. This was one reason why Hagen-Hohenlim-
achieved a significant increase in rolling force by 30 % per the modernization measures could be burg produces cold
stand. The stand drives were refurbished with new gear- implemented so smoothly. Through strip in a wide range
wheel sets for raising the maximum rolling speed by 25 %. the simulation they understood how of materials and
The former DC drives have been replaced with modern AC the functions of the plant work, how to products. The spec-
drive technology. This brings down the maintenance effort handle them under realistic operating trum ranges from
significantly and improves control dynamics. In addition, conditions and how to control virtual standard grades,
the existing operating concept based on local control sta- production processes. case-hardening
tions was substituted by a central, ergonomically designed and special steels
control room. SUCCESSFUL REVAMPING through to micro-
As a result of the revamp, Bilstein has alloyed, high-
AUTOMATIC THREADING ASSISTANT TRC® been able to boost both production and strength steels.
Moreover, we developed an automatic threading assistant the yield of the plant and adjust the The company is
TRC®, which is active during threading and unthreading. It product quality to specific customer renowned as a
takes into account the wedge formation and the thickness requirements. The new automation supplier of highly
deviation at the strip head and tail, and ensures strip flat- systems in level 1 and level 2 not only specialized niche
ness and centered strip material travel. It controls the roll- optimized threading and unthreading products.
ing force and corrects the roll-gap setting as a function of performance but the entire process
the material properties, and helps reduce off-size strip control, enabling reorganization of the
lengths by up to 50 %. shift crews. The future-oriented mod-
For improved strip drying, we installed a Dry-Strip sys- els in level 2 provide Bilstein the nec-
tem on the stand exit side. The stand exit area was comple- essary basis for short-term expansion
mented by a swingable bridle roll set for stabilizing the strip of the product range to include new
tension there. materials. We owe the successful
completion of this modernization proj-
ECONOMIC EXPANSION OF THE PRODUCT PORTFOLIO ect not least to the excellent coopera-
The new level-2 automation provides the customer with the tion with the teams of Bilstein. (News-
possibility of expanding the product range in an economic letter 2/11)

15
COLD ROLLING MILLS  SMS group Extracts from various newsletters

LONG-STANDING PARTNER-
SHIP WITH RASSELSTEIN
Success through tailor-made modernizations

Andernach-based Rasselstein GmbH,

a subsidiary of ThyssenKrupp Steel
Europe, is Germany’s only producer of
tinplate. Rasselstein and SMS Siemag
can look back on over 50 years of co-
operation covering both the installa-
tion of new plants and the moderniza-
tion of existing equipment. Since 1959,
SMS Siemag has implemented a total
of twelve successful projects with Ras-
selstein. In his paper, Paul Michels,
General Manager Tinning 1 at Rassel-
stein, reports about two demanding
revamp projects of the recent past. One
covered the two-stand DCR (Double
Cold Reduction) rolling mill and the
other one the five-stand tandem mill.
REVAMP OF THE DCR ROLLING MILL
Rasselstein had commissioned SMS
Siemag to relocate a DCR mill from
Dortmund to Andernach and to mod-
ernize this mill. The first step was to
dismantle the old components in Dort-
mund and to inspect them for their re-
usability. It was found that some of the
components indeed could be reused.
But at the same time, new equipment
had to be designed and manufactured
for integration into the overall concept.
Key mechanical equipment such as
roll stands, bending systems, and work
and backup roll chocks were rema-
chined and pre-assembled in the Hil-
chenbach shops of SMS. SMS Siemag
was responsible for the sophisticated
project logistics relating to both the old
and the new mill components. Finally,
the revamped combined DCR mill was
installed and successfully put into op-
eration in Andernach, Germany.
TOP QUALITY AND REDUCED OFF-GAGE
LENGTHS
The modernized mill meets highest
quality demands in terms of strip
thickness, flatness, roughness, clean-
ness and surface dryness. Productivity
was improved through reduction of
off-gage lengths. Extensive online
measuring systems plus the increased
degree of automation ensure stable
and reliable process control and top
strip quality.
UPGRADE OF THE TANDEM MILL
Put on stream in 1960, the five-stand
tandem mill produces cold strip in widths
from 600 to 1,080 mm and final thick-
nesses ranging from 0.10 to 1.20 mm
at rolling speeds of up of 1,830 m/min.
The tandem mill at Rasselstein
after modernization.
The focus of the 2008 modernization
was on the entry area of the rolling
mill and the mill stands. The entry ar-
ea received a new walking-beam sys-
tem, a lowering station and a payoff
reel. The roll stands were equipped
with new hydraulic adjusting systems,
new stand platforms and a new enclo-
sure. The SMS Siemag package also
included a new fume exhaust system
with scrubber system as well as equip-
ment for the HP and LP hydraulic sys-
tems including associated piping.
The mill was shut down at the be-
ginning of September 2008 and went
back into operation already four weeks
later, followed by quick ramp-up and
successful availability tests. Thanks to
the measures implemented, strip
thickness tolerances and flatness
were improved while off-gage lengths
were diminished. (Metec Newsletter
2011)

16
COLD ROLLING MILLS – CARBON STEEL

The site of TKS Rasselstein in Andernach. Rasselstein’s tandem cold mill (TCM) after revamping.

Rasselstein GmbH, Andernach, Germany

Modernization of five-stand tandem mill

The scope for this modernization job comprised the entry The re-designed entry section in-

i
section of the tandem mill, new hydraulic adjusting sys- cluding walking beams, coil lowering
tems, a new stand platform and stand enclosure, a fume station, payoff reel and entry group
exhaust system as well as HP and LP hydraulic systems was likewise pre-assembled and func-
including associated piping. tion-tested. Being an innovation, the
The new concept for the entry section was developed in lowering station was additionally Benefits
of manufacture
no more than two months through in-depth discussions started up in the SMS workshops us- and function-
with the customer. Both project teams contributed their ex- ing the original control system. testing by
periences to achieve an optimal configuration because the Thanks to these measures, excel- SMS Siemag:
prevailing local conditions such as foundations and bay col- lently coordinated sequences and
umns, and the equipment to be newly designed had a con- highly motivated project teams, the Components manu-
siderable impact on the new entry section. All of these as- mill could go back into production on factured in the SMS
pects could be considered as early as in the project planning schedule as early as the end of Sep- Siemag workshops
phase. Already at this point, the equipment groups to be tember 2008, after a shutdown of four in Hilchenbach
pre-assembled were defined, later significantly reducing weeks. By the end of 2008, following are subjected to
erection time during mill shutdown. specified ramp-up and successful extensive function
completion of the availability test, the tests. This ensures
PRE-ASSEMBLY AND FUNCTION TESTS mill achieved Rasselstein’s demanded equipment quality
In the course of project implementation, SMS Siemag car- capacity and performance. (Newslet- and quick start-up.
ried out extensive pre-assembly work and function tests. ter 2/09) If so requested by a
All hydraulic adjusting cylinders were completely assem- customer, the scope
bled in our shops and subjected to various standard func- of function-testing
tion tests on our testing stand. In addition, some of the can be extended to
cylinders were tested using the original control system. include testing of the
Furthermore, all new platform components including functions of com-
valve stands, piping and cabling as well as parts of the in- plete units including
terconnecting piping in the area of the platform were com- their hydraulics and
pletely assembled in our workshops. Upon completion, all automation.
parts were disassembled suitable for final erection and
were delivered in due time for field installation.

17
COLD ROLLING MILLS 
PREPARED
FOR THE FUTURE
SMS Siemag installed a continuous exit section of the tandem mill
at Ilva Cornigliano, Italy.
As part of the modernization of the five-stand tandem cold
rolling mill No. 1 of its Genoa Cornigliano Works, Ilva placed
an order with SMS Innse for the supply, installation and
commissioning of the new continuous exit section. This
measure is one step to allow the mill to be operated as a
PL-TCM.
After a project handling time of only 16 months, erection
of the new continuous exit section started with the shut-
down of the mill in December 2008. The new carousel ten-
sion reel had been designed, manufactured and supplied in
a mere 14 months, and was pre-assembled on the new
foundation during ongoing production.
The reel is able to wind coils with a weight of 45 t and a
maximum diameter of 2.5 m. Upon completion, the coils
are transported to the downstream production facilities by
the new coil handling system.
New continuous exit section.
18
SMS group Extracts from various newsletters
Further extensive preparation work in this area was like-
wise carried out while production continued. This included
foundation work, pre-cabling, pipe routing and installation
of hydraulic valve stands.
The modernization scope included the complete new
exit equipment behind stand 5 such as rotary shear, car-
rousel tension reel, coil car, strapping and marking ma-
chines as well as a high-speed coil car for transport of the
finished coils.
The close cooperation with the customer was the key to
the success of this project. Through this modernization step
and further revamps still pending, Ilva will receive a modern
PL-TCM and will be well prepared for the future. (News-
letter 3/09)
The new carousel tension reel.
COLD ROLLING MILLS – CARBON STEEL

HIGHER DRIVE POWER

SMS Innse modernized a five-stand tandem mill at Ilva, Novi Ligure.
Ilva now is able to roll wider strip and therefore a broader product mix.

SMS Innse recently completed mod- The Sieflex motor couplings and
ernization work on the five-stand tan- spur-gear mill pinion gears were
dem mill at Ilva’s Novi Ligure opera- manufactured in the Hilchenbach
tions. The upgrade was carried out in workshops.
two steps. First, in April 2009, the sec- Ilva is highly satisfied with the suc-
ond stand of the tandem mill received cess of this measure because mill ca-
a new drive. In August 2009, modern- pacity could be increased. Plus, the
ization was completed with the instal- higher drive power now available en-
lation of new drives on stands No. 3 ables the product spectrum to be ex-
and No. 4. In addition, SMS Innse tended. In its Novi Ligure operations,
equipped the mill with a new entry Ilva can now roll wider strip as part of
group which is located upstream of the a broader product mix. (Newsletter
PL-TCM and is connected with the en- 1/10)
try looper via a bridge.
Today’s cold rolling mills operate
within a wide speed range and at high
rolling speeds. Increasing demands
are being made on the performance
and capacity of tandem mills and, con-
sequently, also on the stand drives.
This was the main reason why Ilva de-
cided to revamp the work-roll drives of
its four-high cold rolling mill.
SMS Innse’s package covered the
design, supply and installation of all
mechanical drive components for the
three central roll stands of the tandem
mill, including the pertaining central
oil lubrication system. The mechanical
drive components included:
- Sieflex motor couplings
- spur-gear mill pinion gears
- drive spindles
Combined spur-gear mill pinion gears in Ilva’s tandem mill.

19
COLD ROLLING MILLS  SMS group Extracts from various newsletters

Dismantling of old foundations in the area Modular-design double-reel exit section Strip turning for inspection of top surface
upstream of the double-reel exit section. in SMS Siemag’s Hilchenbach shops. and underside by means of “Rotary Inspect“.

ThyssenKrupp Steel, Dortmund, Germany

Modernization of five-stand PL-TCM

ThyssenKrupp Steel in Dortmund was staff involved in the project, both on the from a planned four months to six
keen to revamp its semi-continuous side of the customer and of the supplier, weeks. As early as December 31, 2003,
PL-TCM to continuous operation to and active involvement of the SMS work- the mill was back in production, rolling
boost capacity and improve product shops, the shutdown could be reduced the first strip. (Newsletter 2/09)
quality.
To enable continuous operation, the
exit section was re-designed and
equipped with a double-reel unit and a
coil handing system tailored to the
situation in the works. For quality con-
trol, SMS Siemag also integrated its
innovative “Rotary Inspect” inline in-
spection station. This ensures reliable
strip quality control.
As a result of these measures, pro-
duction capacity rose from 165,000 t to
192,000 t per month. Another benefit
was that spare-parts stockkeeping
was facilitated because all key compo-
nents of the new exit section corre-
spond to those of the TAKO “sister
mill” which SMS Siemag had built at
ThyssenKrupp Steel’s Duisburg loca-
tion in 2000.

INSTANT HELP AFTER

HEAVY FIRE IN NOVEMBER 2003
On November 26, 2003, the tandem
The modernized tandem mill with
mill was seriously damaged by a major new double-reel exit section.
fire. Thanks to the tireless efforts of all

20 20
COLD ROLLING MILLS – CARBON STEEL
Rasselstein GmbH,
Andernach, Germany
Relocation and revamp of two-stand DCR mill
At its location in Andernach, Germany,
Rasselstein GmbH, a company be-
longing to ThyssenKrupp Steel, pro-
duces tinplate material for the pack-
aging industry. Due to the shutdown of
various production units at the Dort-
mund location, the production capacity
in Andernach had to be increased.
Rasselstein GmbH took this step to
safeguard its market leadership in tin-
plate production and to cover the
packaging industry’s current and fu-
ture demand for tinplate material. So
the two-stand DCR mill was relocated
from Dortmund to Andernach, and on
this occasion was extensively upgrad-
ed by SMS Siemag.
ArcelorMittal Genk Stainless Europe, Belgium
Revamping of single-stand reversing mill
Back in 1988, SMS Siemag had built a
CVC® four-high reversing cold rolling
mill for the production of low-carbon
steel strip at Arbed in Dudelange, Lux-
embourg.
In December 2006, ArcelorMittal
Genk Stainless Europe contracted SMS
Siemag to extensively revamp the
“CRM4” cold rolling facility on the occa-
sion of its relocation to Genk, Belgium,
and to make it fit for a new job and func-
tion, i.e. the rolling of stainless steel.
The mill in Genk made it possible for
Relocated from Dortmund to Andernach:
the DCR mill No. 4.
Following dismantling of the com-
plete plant, key components such as
the mill stand, the bending system as
well as the work- and backup roll
i CUSTOMER
chocks were remachined in the SMS
BENEFITS
shops. Then, these facilities were pre-
 etaining and re-using components
R
assembled together with newly sup- of the old mill
plied parts. Finally, the equipment was Change of rolling direction
supplied for final erection in the field. Processing of wider strips
Two-stand DCR Double Cold Re- Increase of coil weights
duction mills combine reduction in the Short coil cycle times
first stand with tempering (or skin-
passing) in the second stand. This is
ideal for precisely setting the material
properties required for further pro-
cessing. (Newsletter 2/09)
the customer to cut production costs
and to increase the future production
capacity for stainless-steel strip.
The use of this reversing cold-roll-
ing stand turned out to be economi-
cally very advantageous for the cus-
tomer because the mill stand, major
parts of the mechanical equipment
and of the auxiliary and the secondary
facilities could be retained. ArcelorMit-
tal Genk Stainless Europe now has a
powerful stainless-steel mill in four- Reversing cold-rolling mill at ArcelorMittal
high design. (Newsletter 2/09) Genk Stainless Europe.
21
PROJECTS 
Shining in new splendor:
the reversing mill after restoration.
FIRE DAMAGE REMEDIED
AS FAST AS POSSIBLE
After fire damage at the reversing cold mill of Wickeder Westfalenstahl GmbH,
SMS Siemag took on the restoration of the heavily damaged plant.
“Fortunately it happens rarely – but
sometimes it does. A seemingly unim-
portant mistake during ongoing pro-
duction has disastrous consequences,
and a rolling mill catches fire. Keeping
the adverse effects for the plant user
as small as possible requires a lot of
experience. With its expert knowledge
and organizational skills SMS Siemag
was able to actively support Wickeder
Westfalenstahl GmbH, Germany, and
led a challenging repair to speedy suc-
cess,” Klaus Grimm, the responsible
22
Project Leader Cold Rolling Mill Divi-
sion, puts his experience in a nutshell.
The four-high reversing cold rolling
mill had been supplied to Wickeder
Westfalenstahl by the former SIEMAG.
It commenced operation in 1969 and
has repeatedly been modernized since
then. It is a multitalent, rolling a wide
material range from soft to highest-
strength grades and clad material in
the medium strip-size area of up to
700 mm width to a minimum final
thickness of 0.15 mm.
SMS group newsletter 02 / 2013
During ongoing production, a hy-
draulic pipe at the coiler had been
damaged. Oil had emerged from the
pipe and caught fire. The flames had
quickly spread to the mill stand and
the drive side. The fire and fire-fighting
activities had both caused heavy dam-
age to the vapor exhaust system in-
cluding stack, mechanical and electri-
cal equipment as well as to media and
measuring systems in the mill stand
area and on the drive side.
COLD ROLLING MILLS – CARBON STEEL
»OUR AMBITION WAS TO RESTORE THE ROLLING MILL
WITHIN A MINIMUM OF TIME:
SMS SIEMAG GAVE ITS BEST SUPPORT TO ACHIEVE THIS GOAL.«
Andreas Wellié, Manager Technical Services, Wickeder Westfalenstahl
After the loss had been verified,
Wickeder Westfalen­ stahl entrusted
SMS Siemag with the restoration of
the plant and the coordination of the
complete project which involved sev-
eral suppliers. SMS Siemag supplied
the mechanical equipment and was
responsible for coordination of the
overall plant assembly.
INEVITABLE EXCHANGE
The measuring devices close to the
mill stand and the hydraulic valve
stands on the drive side had been seri-
ously damaged by the flames and also
the extinguishing agents had partly to
be repaired or replaced. Mechanical
The four-high reversing cold mill stand
is ready to resume operation.
equipment such as the gear unit, drive
spindles, hydraulic adjustment system
and work roll bending system were in-
spected in the Hilchenbach workshop
i FACTS &
FIGURES
of SMS Siemag. Seals and wear parts
MILESTONES
were renewed. The complete hydraulic
Order placement  September 1, 2012
piping in the mill stand area and on the
First coil  March 18, 2013
drive side had to be exchanged.
Acceptance by Wickeder  April 17, 2013
Just slightly affected by the fire Westfalenstahl
were the coil preparation station, car-
ousel reel and recoiling line. In this As early as by the date of acceptance,
area, hydraulic valves and cylinder the mill had met the specified produc-
seals were replaced as a preventive tion data like minimum final thickness
at maximum speed for different grades.
measure. All components in the oil
Thus, the plant could be re-integrated
cellar, such as the central oil lubrica-
in the production process without delay.
tion system and oil-film-bearings lu-
brication system, were not directly
concerned, but were inspected as a cooperation with the project team of
precaution and could resume opera- Wickeder Westfalenstahl. Thanks to
tion after they had been thoroughly an intensive and well coordinated co-
cleaned. operation between all participants, the
The greatest challenge for SMS problems could be mastered in time,
Siemag was to meet the very tightly and the reversing mill could resume
calculated schedule of the project in operation according to schedule.
order to restore the operational state (Newsletter 2/13)
of the reversing mill as early as possi-
ble. Another challenge was the exist- coldrollingmills@sms-siemag.com
ing documentation. During the many
years of its existence, the plant had
been modified several times. Some
documents had to be reconstructed in
23
PROJECTS  SMS group Extracts from various newsletters

PLUS 40 PERCENT
In February 2014, International Steels Limited (ISL), Pakistan,
selected SMS Siemag to extend its Reversing
Cold Mill (RCM). The two-stand Compact Cold Mill (CCM®)
will increase the annual capacity by 40 percent.

The four-high RCM of CVC® plus de-

sign by SMS Siemag is the first cold
rolling mill of its kind in Pakistan.
Since 2011, ISL has been producing
high-quality cold strip with widths
ranging from 700 to 1,250 mm and fi-
nal thicknesses of minimum 0.25 mm
on this RCM. The annual capacity is
250,000 t. Precautions were made al-
ready in the planning phase of the
RCM to permit economical extension
of the plant to a two-stand CCM® later
on. These concerned primarily the lay- The RCM at ISL will be supplemented by a second mill stand to come
out of the foundations and media sys- as CCM®. The second mill stand will be installed on the left side.
tems. ISL recently exercized its option
and awarded SMS Siemag the order
for an extension which will increase Project Manager of SMS Siemag,
the annual capacity by 40 percent.

NO CAPACITY ADAPTATIONS
comments: “The plant extension
schedule was made to keep the down-
time as short as possible. ISL will be
i
SMS Siemag will supply the second able to start production on the CCM®
CCM®
mill stand which is of identical design in mid 2015.”
to the existing one, as four-high stand Due to the geographical proximity Compact Cold Mills
with hydraulic adjustment, CVC® plus to ISL in Pakistan, Esmech Equipment (CCM®) efficiently
and work roll bending system. The Pvt. Ltd., SMS Siemag’s Indian joint- close the capacity
supply package of the second stand venture partner, will supply further gap between single-
furthermore includes the X-Shape plant components, including equip- stand reversing mills
flatness measuring system. As the ment for roll changing, the interstand and tandem cold
capacity of the emulsion system has area, enlargement of the mill stand mills. In the range
been designed for two-stand opera- platform and stand enclosures as well up to 800,000 t per
tion right from the beginning, capacity as valve stands for the LP hydraulic year, they optimize
adaptation is not required. The only system. (Newsletter 2/14) investment and
thing to do is replace the exit-side operational costs.
equipment such as tension reel and
coil car to permit installation of the www.sms-siemag.com/
second mill stand. Torsten Seeger, cold-rolling-mills

24
PROJECTS 

EXPANSION CONCEPT
KYCR, Bangladesh, enlarges its cold rolling mill, which SMS Siemag
supplied in 2002. Annual production is increased to 170,000 t.

KYCR Coil Industries Ltd., Bangladesh, placed an order with

SMS Siemag for the expansion of their existing CVC® plus
six-high reversing cold mill to become a compact cold mill
(CCM®). Since 2002, the single-stand reversing cold mill
(RCM), which had been supplied by SMS Siemag to KYCR
Coil Industries Ltd. in Chittagong, has been producing cold
strip with widths between 600 and 1,050 mm and final thick-
nesses of minimum 0.9 mm. Accordingly, this plant with
CVC® plus technology had been specifically designed to roll
thin strip which includes operation with thin work rolls hav-
ing a minimum diameter of 200 mm for high reduction. The
existing RCM will be expanded to a two-stand CCM® with
CVC® plus in both mill stands. Thus, KYCR will increase its
annual production capacity to approx. 170,000 t. (Newsletter
2/14)

www.sms-siemag.com/cold-rolling-mills

KYCR will expand its RCM to a compact cold mill.

25
 STAINLESS STEEL
The portfolio of SMS Siemag for stainless steel rolling comprises single-stand
20-roll mills in mono block and split block design. The CVC® plus 18 HS design
can be applied in single-stand mills as well as in tandem cold mills.

26
27
COLD ROLLING MILLS 
The “SG3” 20-roll cold mill of Outokumpu Nirosta in Krefeld is being revamped.
Modernization at Outokumpu Nirosta
A sprightly 45 - ready for new challenges. SMS Siemag revamps 20-roll cold mill.
Outokumpu Nirosta in Krefeld, Ger-
many, has awarded to SMS Siemag,
Germany, an order to modernize the
20-roll cold mill “SG3” of type MB
21BB-61“. The order was placed at the
beginning of September 2014, with the
aim of technically updating the
45-year-old cold rolling stand and pre-
paring it to deal with demanding new
rolling tasks.
The 20-roll cold rolling mill of stand
type Monoblock MB 21BB-61“ had
been supplied in 1969 by SMS Siemag
(previously Demag). It was modernized
in 1991. Following the closure of the
Outokumpu works at the Düsseldorf-
Benrath location, the production previ-
ously carried out there, for example
thin mirror-finish material, is being
transferred to the Krefeld works.
REVAMP OF THE COLD ROLLING MILL
The “SG3” 20-roll cold mill, with a
strip width of 1,570 millimeters, and
strip gages of max. 10.00 millimeters
in the entry section and min. 0.50 mil-
limeters in the exit section, will con-
tinue to be used for the production of
high-grade special-steel strips made
of austenitic, ferritic and martensitic
28
SMS group Extracts from various newsletters
materials. The mill’s future rolling entry end will be replaced by an ad-
tasks will include, in particular, thin- justable, swiveling pinch roll. This will
gage ferritic strips in high-gloss qual- make it easier for the strip to be
ity (2R bright-annealed). The cold threaded into the stand. The exit end
rolling mill needs to undergo a cer- too will be provided with a bending
tain amount of conversion work in or- and pinch roll. Furthermore, new car-
der to satisfy the preconditions for ry-over tables will ensure that the
manufacturing mirror-finish materi- strip head end can be inserted direct-
al. The SMS Siemag supply scope ly into the reel slot. The above work
comprises changes to the entry and will help to achieve safe, gentle and
exit sides and on the millstand itself.
To achieve the desired strip surface
quality, the existing squeezer system
is to be converted to a dual-cassette
wiper system, including changing de-
vice, which can be operated with vari-
ous types of coated wiper rolls. One of
the aims of the conversion work is to
enable the entire thickness range to
be rolled at maximum rolling speed.
The existing strip cooling system will
be equipped with a volume control so
as to allow pre-setting of different
rolling-oil quantities, depending on
the pass schedule. The axial shifting
system of the first intermediate rolls
is to be renewed in the millstand. The
plant is also to be provided with a new
millstand door and new exhaust Still in good shape after 45 years: the mill
hoods. The pinch roll situated at the stand door. But it’ll be also renewed.
28
rapid threading and tailing-out of the
strip and thus ensure the efficient op-
eration of the rolling mill also in the
future.
Besides the equipment described
above, the SMS Siemag supply scope
also comprises the dismantling of the
components to be replaced, the per-
formance and supervision of erection
of the new equipment items, and the
commissioning of these items. A tight
time schedule has to be observed
here, since the commissioning of the
Facts + Figures
modernized mill is to take place al-
Mill stand type MB 21BB-61“
ready in July 2015, following a revamp
Material Martensites, austenites,
shutdown of 21 days.
ferrites
This is already the fourth order
Strip width 1,570 mm
within a period of a few years for the
Strip thickness Max. 10.00 mm (ingoing)
revamping of a 20-roll cold mill, Min. 0.50 mm (outgoing)
awarded to SMS Siemag by custom-
Coil weight Max. 26 t
ers in Germany, and is powerful proof
Rolling speed Max. 500 m/min.
of the confidence in the ability of SMS
Siemag to carry out modernization
work. (Newsletter 1/15)

Revamp of 20-roll cold mill

VDM Metals, Germany

In April 2014, VDM Metals GmbH, Ger-

many, commissioned SMS Siemag to
upgrade its 20-roll cold mill for high-
performance materials. The split-
block rolling mill of size SB 33-30” was
supplied by SMS Siemag and has been
in operation since 2002. On this mill,
VDM Metals rolls a broad material
spectrum of nickel-based and high-al-
loy special stainless steels from a
width range between 350 and 750 mil-
limeters down to foil thickness with a
minimum final gage of 0.02 millime-
ters. The revamp will include modifica-
tions in the entry and exit sections and
in the flatness control system area. The split-block 20-roll cold mill of VDM Metals will undergo slight modification.

29
COLD ROLLING MILLS

EXPERT SINCE 1950

SMS Siemag has more than 50 years in experience
of installing 20-high cold rolling mills.
Three modernization examples prove the know-how.

30
20-high cold rolling mills have been part of SMS Siemag’s product portfolio since the 1950s. Right from the beginning,
SMS Siemag has constantly optimized many of the technical details of these rolling mills to better measure up to the
needs and requirements of cold-strip producers. The achieved key developments contribute to higher productivity and
significantly improved product quality.
These developments are not only suited for new plants, but are also used to modernize existing facilities. The installa-
tion of individual systems, for example new rolling-oil wipers, is just one of many modernization solutions. As can be seen
from the following examples. (Newsletter 2/09)

Example 1:
Revamp of MB23-56“ mill
at Outokumpu Nyby
The 20-high cold rolling mill at Outokumpu Nyby in Tor-
shälla, Sweden, was modernized to give it more reliability in
meeting the thickness tolerances and to improve the strip
flatness. Supplied by SMS Siemag back in 1956, the rolling
mill rolls stainless-steel hot and cold strip of the AISI 300
and AISI 400 series in widths between 700 and 1,400 mm
and a final gage of minimum 0.2 mm.
Mill modernization was implemented in several steps.
First, the stand was dismantled in just three days. On this, it
was mechanically overhauled and equipped with modern
actuators for roll and crown adjustment in our workshops.
Finally, it was re-installed and put back into service. Thanks
to our tailor-made revamping schedule, production losses
could be minimized. While the stand was being modernized
in our shops, the entry and exit areas were revamped in the
customer’s works so as to enable the handling of coils with
larger diameters. In addition, a new hydraulic station was
provided. Due to the narrow space conditions, it had to be
located on top of a steel structure.
In the second revamping phase, SMS Siemag modern-
ized the axial shifting system of the inner intermediate rolls.
The new hydraulic adjusting system featuring automatic
coupling of the rolls is ideally suited for highly dynamic in-
fluencing of the strip flatness.
Example 2:
ThyssenKrupp Acciai Speciali Terni
MB22-49“
This mill, originally built in 1957, was installed in Terni in
1974. For modernization, SMS Siemag made provisions
to enable the handling of larger coils (higher coil weight,
larger coil diameter), and equipped the rolling mill with a
new rolling-oil filtering system and modern strip-thick-
ness control systems. The electrical equipment was up-
graded while retaining the main drive ratings. Today, this
rolling mill produces stainless-steel cold strip and, due
to its modular design and drive rating, is particularly
suited for the rolling of titanium strips.
Example 3:
Revamp of MB22-52“ mill (SG 2)
at ThyssenKrupp Nirosta, Krefeld
The size MB22-52“ (Mono-Block) mill built by SMS Siemag in
1963 was originally equipped with all then-modern adjusting
or control elements. Our key revamping measures included
the provision of a new hydraulic adjusting system, a crown
adjusting system, an axial shifting system in push-push de-
sign, a new media platform with hydraulic controls, new roll-
ing-oil wipers as well as thickness and flatness measuring
systems including control. The goal was to bring productivity
and especially product quality up to current standards.

31
COLD ROLLING MILLS – STAINLESS STEEL

Just 18-day downtime – Smooth

modernization at ThyssenKrupp Nirosta

SMS Siemag extensively modernized the 20-roll cold mill,
size MB21BB-64”, which had been erected in the Düssel-
dorf-Benrath works of ThyssenKrupp Nirosta in 1976.
The modernization focused on the area of the mill stand
which was equipped with a hydraulic roll adjusting system,
an axial shifting system for the inner intermediate rolls,
and a new media platform.
Advantages of the high-tech components. The hydraulic
roll adjusting system permits closest strip thickness toler-
ances to be met. The crown adjusting system serves to
adapt the roll gap to the entering strip and thus attain top
strip flatness. The axial shifting system of the inner inter-
mediate rolls helps perfect the rolling result right up to the
strip edges and facilitates roll changes. The all-in-one me-
dia platform is characterized by easy maintenance.
The new stand components were completely manufac-
tured, pre-assembled, and tested in the SMS Siemag work-
shop in Hilchenbach. Thus, final installation could be ac-
complished within a single plant downtime of just 18 days.
Commissioning progressed as scheduled and was com-
pleted 17 days ahead of the contract deadline by granting
the FAC on February 6, 2012. (Newsletter 3/12)

“FITTED WITH THE NEW HIGH-TECH COMPONENTS BY SMS SIEMAG, THE

20-ROLL COLD MILL IS PERFECTLY PREPARED TO MEET THE RISING DEMANDS
OF OUR CUSTOMERS, ESPECIALLY IN RESPECT OF THE STRIP QUALITY.”
Peter Großmann, Manager Production at ThyssenKrupp.

First strip rolled on January 7, 2012, after a conversion period of just 18 days.

32
 High-tech stand
components for
ThyssenKrupp
Nirosta, Düsseldorf

For quality and stainless-steel strip

Pre-assembled mill stand in the Hilchenbach

shops of SMS Siemag.

ThyssenKrupp Nirosta GmbH, Germa-
ny, contracted SMS Siemag in Febru-
ary 2011 for the upgrade of the 20-roll
cold rolling mill “SZ 1600” of its Düs-
seldorf-Benrath works.
Once again, TKN counts on SMS
Siemag competence in the moderni-
zation of this type of mill. The SMS
Siemag Mono-Block of size MB21BB-
64“ has been in operation since 1976.
Modernization of the stand area.
The upgrade measures will focus on
the mill stand which will receive a hy-
draulic roll adjusting system for clos-
est strip thickness tolerances, a hy-
draulic crown adjusting system and a
hydraulic axial shifting system for the
inner intermediate rolls.
Crown control. Hydraulic crown ad-
justment is implemented through ser-
vo-controlled adjusting cylinders en-
suring good flatness and optimal
adaptation of the roll gap to the mate-
rial profile.
Axial shifting of the inner interme-
diate rolls. Hydraulic axial shifting of
the inner intermediate rolls allows to
achieve a perfect rolling result right up
to the strip edges. Axial shifting of the
inner intermediate rolls is accom-
plished by means of a push-pull sys-
tem. This facilitates roll changing be-
cause the inner intermediate rolls no
longer have to be uncoupled by hand.
New media platform. The “SZ 1600”
will also receive a new media platform
in All-In-One design. Our media plat-
form is characterized by a compact
modular design and maintenance
ease. The valve units for control of the
hydraulic functions will be integrated
together with the piping.
Manufacture with pre-assembly plus
testing. All new components of the
stand will be manufactured in the Hil-
chenbach workshops, and pre-assem-
bled and tested including their piping.
Thanks to pre-assembly and testing in
our shops, the time and work needed
for final installation and commissioning
in ThyssenKrupp’s Benrath works will
be reduced to an absolute minimum. As
a result, TKN will be able to roll the first
strip already at the beginning of Janu-
ary 2012 after a mill stoppage of just
17 days. (Newsletter 3/11)
Technical data
Stand type Size MB21BB-64“
Material Austenitic, ferritic,
martensitic strip
Strip width 650 to 1,650 mm
Strip thickness
Ingoing 2.0 to 8.0 mm
Outgoing 0.5 to 6.0 mm
i ADVANTAGES
of our stand components
 etter dynamics of the actuators
B
and adjusting elements
Improved positioning accuracy,
hence better reproducibility of
product quality
Greater adjusting precision
Less wear
Closest strip thickness tolerances
and minimum off-gage lengths
Closest strip flatness tolerances
Easier roll changing

33
 Relocated and modified
RCM.

Device for automatic and

fast work roll change.

34
COLD ROLLING MILLS – STAINLESS STEEL

REVAMP OF “CRM 4”
IN GENK COMPLETED
ArcelorMittal Genk Stainless Europe issues PAC

On September 19, 2008, Arce­lor­Mittal THE REVAMPING MEASURES

Genk Stainless Europe granted SMS
Siemag the PAC for the revamping of
the “Cold Reversing Mill CRM 4” at its
location in Genk, Belgium. The project
is now in its final stage. The first coil
had already been rolled in April 2008
after a short erection time.
REVAMP WITH A MOVING HISTORY
The mill stand now revamped had
been in operation at ArcelorMittal
(previously Arbed) in Dudelange, Lux-
For the revamp, the existing CVC® plus
shifting systems were modified to
make them more compact. On the
stand entry and exit sides, we provided
holddown rolls, pinch rolls, leveling
and bending rolls as well as an oil wip-
er unit. In addition, the mill received
new reversing coilers, two coil cars
and two coil deposits.
MODIFIED ROLL CHANGING EQUIPMENT
Normally, stainless steel strips are
Technical data
Material Austenite, in the
future also ferrite
Strip width 800 to 1,600 mm
Strip thickness,
Ingoing max. 5.0 mm
Outgoing min. 0.6 mm
Coil weight max. 36 t
Technical data
Stand design Four-high CVC® 4-HS

emburg, since 1988. Supplied by SMS
Siemag, it originally was a CVC® four-
high reversing cold rolling mill for the
rolling of low-carbon steel strip. Arce-
lorMittal then decided to relocate this
mill stand to its operations in Genk. In
December 2008, ArcelorMittal Genk
Stainless Europe (formerly Ugine &
ALZ) contracted us to extensively re-
vamp the “CRM 4” reversing mill and
to make it fit for a new job and func-
tion, i.e. the rolling of stainless steels.
COSTS DOWN, CAPACITY UP
The facility in Genk makes it possible
for ArcelorMittal Genk Stainless Eu-
rope to cut production costs and in-
crease the future output of stainless
steel strip which is used, for instance,
in industrial applications, for the man-
ufacture of household goods and in the
automotive industry.
rolled in multi-roll cold mills. The use Rolling speed max. 800 m/min
of a four-high reversing mill for this Rolling force 22,000 kN
task necessitates a suitable roll- Drive rating 11,500 kW
changing system. That’s why the roll Reversing coiler No. 1 1,775 kW (2x)
changing facilities had to be modified Reversing coiler No. 2 1,775 kW (2x)
so as to enable automatic roll chang- Backup roll drive 2,200 kW (2x)
ing. The roll changing car now has two Rolling capacity 200,000 tpy
cassettes which can accommodate a
total of four roll pairs. The number of
rolls on the car was thus doubled
compared to the conventional design.
The revamping measures were
completed by the installation of an au-
tomatic oil-air coupler and a paper
winder. The hydraulic systems and the
safety equipment were adapted to the
new local conditions. All new equip-
ment was supplied and installed with-
in 12 months. (Newsletter 3/08)

35

A WORLD’S FIRST: CVC® PLUS
IN MULTI-ROLL STANDS
For quality and stainless-steel strip
NEW APPLICATIONS
Theis Kaltwalzwerke GmbH in Hagen
produces cold-rolled quality and stain-
less-steel strip in widths of up to 650
mm on a tandem cold rolling mill
which has recently been modernized.
SMS Demag – for the first time ever –
successfully installed the CVC® plus
technology in this mill’s four-high
stands which use changeable multi-
roll inserts.
Work-roll diameters of 85 to 100
mm in multi-roll operation. The con-
ventional four-high tandem mill allows
the rolling mode in mill stands 3 and 4
to be varied by adopting so-called
36
multi-roll inserts. Unlike the conven-
tional four-high mode which uses
work rolls with diameters of 275 to 310
mm, the multi-roll mode employs
work rolls with diameters of just 85 to
100 mm which are laterally supported
by means of rollers. This allows the
spectrum of rollable final gages to be
expanded, especially for higher-
strength steels.
CVC® plus technology as a flexible
control element. This necessitates a
strip-flatness control element (actua-
tor) with a flexibility as ensured in par-
ticular by the CVC® plus technology.
For each of the two operating modes a
The tandem cold mill.
CVC® plus roll contour was determined
which covers the entire roll crown
range for the respective mode. While in
four-high operation the work roll is
used as CVC® plus roll, this job or func-
tion is taken over by the driven inter-
mediate roll in the multi-roll mode.
All flatness requirements met.
wWhen using the proven CVC® plus
technology in combination with roll
bending, all flatness requirements can
now be satisfied reliably and reproduc-
ibly. This applies to soft IF grades as
well as to austenitic stainless steels
with strip widths between 320 mm and
650 mm. (Newsletter 2/07)

High-performance oil wiper unit
for ThyssenKrupp Nirosta Dillenburg
In cooperation with Voith GmbH, SMS
Siemag developed a new squeegee-
roll system for 20-high cold rolling
mills and put it through a first series of
tests in ThyssenKrupp Nirosta’s works
in Düsseldorf-Benrath, Germany.
Won over by the excellent test re-
sults, the customer decided to have
the new Nipco™ oil wiper unit installed
in one of ThyssenKrupp’s other cold
rolling mills.
In May 2011, ThyssenKrupp Nirosta
GmbH commissioned SMS Siemag to
supply our Nipco™ unit for its German
Dillenburg works to replace the exist-
ing entry- and exit-side oil wiper sys-
tems of the 20-roll stainless-steel cold
mill. The package comprises the sup-
ply of equipment, supervision of erec-
tion, commissioning, and trial opera-
tion. The revamp will increase the
mill’s productivity significantly.
Separately adjustable hydro-
static support elements.
THE NIPCO™ OIL WIPER UNIT
WITH SQUEEGEE ROLLS
Our new high-performance Nipco™ oil
wiper unit perfectly adapts to any and
i ADVANTAGES
all boundary or operating conditions. It
resulting from the Nipco™
ensures a uniform contact pressure
oil wiper unit
through individual hydrostatic support
elements which are exactly set to suit  igher rolling speed
H
the width of the strip to be rolled. This Less residual oil on the strip
prevents any deflection of the squee- Less cooling lubricant being
carried along
gee rolls which often occurs in con-
Longer service lives of the
ventional wiper systems. squeegee rolls
The Nipco™ oil wiper unit ensures Short revamping time
a uniform wiping effect across the full
width of the strip and hence a uni-
form distribution of residual oil on the
strip surface. As opposed to conven-
tional wipers, it reduces the amount
of residual oil on the strip by 30 to 60
percent. While other types of oil wip-
ers often limit the rolling speed, the
Nipco™ oil wiper unit enables a speed
increase. (Newsletter 3/11)
37
COLD ROLLING MILLS – STAINLESS STEEL

Register
Revamp matter and mill feature Reference
Actuators Outokumpu Nyby
Theis Hagen
TKS Nirosta Krefeld
TKS Nirosta Düsseldorf
AM Genk Stainless
Automation system Bilstein
OAO Severstal
Carousel reel Ilva Cornigliano
Chain-type magnetic separator OAO Severstal
Coupling of TCM with pickling line (PLTCM) Ilva Cornigliano
OAO Severstal (preparation)
Drive system Bilstein
Ilva Novi Ligure
DS System Bilstein
Entry side equipment Rasselstein
Bilstein
AM Genk Stainless
OAO Severstal
Exit side equipment Ilva Cornigliano
AM Brasil
TKS Dortmund
AM Genk Stainless
ISL Pakistan
TKS Acciai Speciali Terni
Extension Theis Hagen
ISL Pakistan
KYCR Bangladesh
Filter system TKS Acciai Speciali Teerni (rolling oil)
Fire damage Wickeder Westfalenstahl
TKS Dortmund
Flatness measuring system KS Nirosta Krefeld
Hydraulic adjusting system, Hydraulic gap control system Rasselstein
Ruukki
Bilstein
OAO Severstal
TKS Nirosta Krefeld
TKS Nirosta Düsseldorf
Media platform, cladding and exhaust system Rasselstein
OAO Severstal
TKS Nirosta Düsseldorf
Mill relocation Rasselstein
AM Genk Stainless
Mill stand replacement OAO Severstal
Nipco™ oil wiper system TKN Nirosta Dillenburg
Paper winder AM Genk Stainless
PIOS (Process-IOServer) Bilstein
Plug & Work Bilstein
Rotary Inspect TKS Dortmund
Training Bilstein (Operating personnel)
TRC© threading assistance system Bilstein

38
PUBLICATIONS

Our new brochures at a glance

W6-309E_Nipco.qxp_Neutral 14.01.14 10:48 Seite 1 W6-307E_Kaltwalzanlagen_Edelstahl.qxd_Edelstahl 18.12.13 11:46 Seite 1

Nipco®
INNOVATIVE WIPER SYSTEM
FOR COLD ROLLING MILLS
COLD ROLLING MILLS
FOR STAINLESS STEEL
Further
SMS SIEMAG SMS SIEMAG
publications
are available
METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY

Innovative wiper system Cold Rolling Mills

from our
ordering service

Modernization
concepts for a
bright future

Published in German and English Published in German and English

Order No.: W6/309D or E Order No.: W6/307D or E

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REVERSING COLD MILLS SKIN-PASS MILLS

References for a perfect finish

ONLINE
SMS SIEMAG SMS SIEMAG

FLAT ROLLING MILLS METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY

Cold mills Flat-product rolling mills

All publications of
the SMS group
can be ordered via:
www.sms-group.
com/en/print_mate-
rial.php

Published in German, English or Russian Published in German and English

Order No.: W6/304D, E or R Order No.: W6+7/304D or E
 W6-312E-NL-Sonderdruck Kaltwalzwerke · Published on February, 2015 / © SMS group / Circulation in English 500 / Printed in Germany

SMS SIEMAG AG
Flat Rolling Plants Division MEETING your EXPECTATIONS
Wiesenstrasse 30
57271 Hilchenbach, Germany
Phone: +49 2733 29-1800
Telefax: +49 2733 29-1782
E-mail: coldrollingmills@sms-siemag.com
Internet: 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 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.”