Challenges
In a constantly changing metals market, there will always be the need for ongoing investment in production processes to remain competitive. We understand this and support the downstream steel, aluminium, copper, and copper alloy sectors, with growth often associated with value-added products, such as new steel products, automotive coated products, rolled foil products, and more.
With the steadily increasing demand for higher quality and lower production costs, flat metal producers look to technological advancements to gain a competitive advantage. As they evaluate opportunities to improve existing production, producers face several operational and financial challenges:
- Ensuring a genuine return on capital investments through minimizing capital and operating expenditures on new or upgraded equipment.
- Developing new products with a wider range of intermediate and finished product sizes.
- Ensuring minimal disruption to existing production with reduced shut-down schedules.
- Utilizing accurate computer models and software tools for processes, such as rolling and coating, to promote the highest, most reliable operation and best-quality finished products.
- Seeking higher process reliability and consistency through selection and use of rugged equipment and systems to handle harsh environments and various product mill conditions.
- Relying on a changing workforce with limited experience and process knowledge.
- Expanding rolling mill product range for new ultra-high strength material without major capital spending.
- Building in enough flexibility to allow operator intervention to take place if needed, complementing the automatic processes.
- Training new workers and enhancing engineers' and technicians’ knowledge and understanding of their systems and processes.
- Having a positive impact on society and the environment.
- Finding new innovations to increase performance.
- Seeking partners to develop new products and implement production processes.
We can help.
We are experienced in brownfield and greenfield developments, including: casting, rolling; strip processing; and coating and finishing. Our services include full design and supply of equipment and Level 1 and Level 2 process automation systems; process analysis and debottlenecking; production, scheduling, and planning tools; new plant and modernization studies; plant and performance audits; training (remote or on-site); process modeling; and cross-the-board optimization.
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Benefits
- We design and supply new equipment packages, while also offering partial equipment and control system upgrades and custom modifications, commissioning, and operational support services.
- Our coating solution couples the Achieva coating control system to the precise set-up and positioning accuracy of the pot equipment to maximize performance, consistently delivering high-quality product while reducing metal coating usage. The control system can also be incorporated on coating lines with existing pot equipment to provide a step change in performance.
- Simple Coilbox™ upgrades can improve reliability and performance, while upgrades to the mandrelless transfer design improves quality, maintenance, and operations.
- The Achieva Rolling Mill Automation system offers a multifaceted solution that delivers world-class results, such as: mill set-up models for actuator references; integrated mill activities reporting; controlled strip shape and flatness; control of elongation or roll force; monitored tilt control and mill level; and more.
- Our team can help troubleshoot your existing operations, mill, or production line and provide root cause analyses of problems.
The stability of the mill likewise manifests itself in the lower cobble rate in the finishing train which is currently at 0.05% … The looper behavior is much more stable when working with the FFF mode of AGC rather than the BISRA mode.
This is my second IRTC in 15 years—a very powerful course. There is something for everyone (equipment supplier, mill manager, mill operator) with hands-on computer tutorials and discussion groups that help you to understand the various mill processes and control information presented by the very experienced lecturers. A great chance to interface with others in the metals industry.
