Energy-optimized and fully automatic production of extruded aluminum products
Zhengzhou Mingtai Transportation New Materials (ZMT) in Xingyang, Zhengzhou, China, has placed follow-up orders with SMS group for a 125-MN extrusion press and a 60-MN tube press to be installed in its new works built in Xingyang. In the summer of 2016, ZMT had already ordered an 82-MN extrusion press for the same site. The now ordered 60-MN tube press will produce 8,000 tons per year of seamless tubes in diameters of up to 400 millimeters. While the 82-MN extrusion will be designed for a maximum profile width of 700 millimeters, the 125-MN press will be able to make profiles up to 900 millimeters wide.
All three presses will make extruded products that will be used to construct underground trains and railway wagons for China’s high-speed railway network.
Besides the extrusion presses, the scope of supply will include the proven technology packages PICOS (HMI), CADEX (isothermal extrusion) and Ecodrive (energy-optimized drive concept). These modular systems designed by SMS group optimize the performance of state-of-the-art presses in terms of product quality and economy.
The press operator monitors and controls the entire production process via the PICOS.NET (Process Information and Control System) human-machine interface. This tool visualizes the production process and sets the required process parameters. It indicates actual values, includes an alarm function and provides diagnoses in the event of a malfunction in the production process. PICOS.NET coordinates the control of the various plant areas.
The CADEX (Computer Aided Direct Extrusion) software allows the extrusion process to be optimized by means of thermal simulation, providing for a productivity increase by up to ten percent. This is achieved by calculating the heat balance of each billet so as to ensure that forming takes place at the optimal billet and taper temperatures.
The use of energy-efficient drive and ancillary equipment may save up to 25 percent of energy compared to conventional presses. Thus the three presses to be installed at ZMT will qualify for the Ecoplants label.
Commissioning of the 82-MN press is scheduled to take place in spring 2018. The 60-MN and 125-MN presses are expected to come on stream in the spring of 2019.
The SMS group is a group of companies internationally active in plant construction and mechanical engineering for the steel and nonferrous metals industry. Its 14,000 employees generate sales of over EUR 3.3 bn.