Bruno Presezzi S.p.a.

Aluminium Strip Casting Lines

The Company: Bruno Presezzi S.p.a.

The company was founded in 1954.
It is now a sound manufacturing
reality that offers state-of-the-art
technical solutions for the energy, oil,
petrochemical, gas, plastics,
aluminium and steel sectors.
It designs, fabricates and markets
systems and components for the
following applications:
-Gas and steam turbines for power
plants;
-Compressors for the oil&gas;
-Systems for the production of
aluminium strip (twin roll casting).

The group: Bruno Presezzi and Presezzi Extrusion

Twin Roll Casting Lines

Reference List

Twin Roll Casting Rolls and Shells

Reference List
AK ALUMINYUM - TURKEY
ALCAST - BRAZIL
ALCOA BRAZIL, CHINA, SPAIN, USA
ALCOMET - BULGARIA
AL INVEST - CZECH REPUBLIC
ALUMINIUM CHUE CHIN HUA - THAILAND
ALUMINIUM PARS - IRAN
ALUWORKS - GHANA
ANKOR RUSSIA
ASAS - TURKEY
ASLA - SPAIN
ASSAN - TURKEY
C.G.A. ITALY
CHOIL SOUTH KOREA
COMITAL - ITALY
COMPANHIA BRASILEIRA DE ALUMINIO - BRAZIL
C.V.G. ALUCASA - VENEZUELA
EGYPTIAN COPPER WORKS - EGYPT
ELVAL - GREECE
GENERAL METALS COMPANY EGYPT
HEZAR ALUMINIUM - IRAN
HINDALCO - INDIA
HYDRO ALUMINIUM NORWAY, MALAYSIA
IEQSA - PERU
I.L.A. ITALY

IMPOL SLOVENIA
INASA - SPAIN
JW ALUMINUM U.S.A.
KALUWORKS KENYA
MANAKSIA LTD. - INDIA
MEYER ALUMINIUM - THAILAND
NORANDAL - U.S.A.
NOVELIS ITALY, LUXEMBOURG, MALAYSIA
ONURPAK TURKEY
OTEFAL SAIL - ITALY
P.T. ALUMINDO - INDONESIA
P.T. INDOALUMINIUM - INDONESIA
P.T. STARMAS INDONESIA
PMS - TURKEY
PROFILES RH FACTORY - U.A.E.
PROFILGLASS ITALY
QUALITEC NIGERIA
REYNOLD PKG GROUP U.S.A.
RUSAL ARMENIA, RUSSIA
SIMAR - ITALY
SOFIAMED - BULGARIA
TALUM - SLOVENIA
TEKNIK ALUMINYUM - TURKEY
TOWER ALUMINIUM - NIGERIA
VATCO - IRAN

Twin Roll Casting Lines

TT 1000 Caster

Total Force:

2200 ton at 260 bar

Roll Diameter: 980-880 mm

Roll Table:

1900 mm

Roll power drive: 2 x 110 kW

Max available torque in continuous
mode:
2 x 380000 Nm
Casting speed: up to 6 m/min.
AGC system included

Twin Roll Casting Lines

TT 1000 Caster - Strip productivity
(without ASG2 and MPS)
Alloy Density Thickness Speed Width Working days Availability Scrap Prod. rate Prod. rate Year production Remarks
kg/l
mm
m/min mm
%
%
ton/m/hr
ton/hr
ton

1050
1100
1200
1350
3003
3004
3005
3105
5005
5050
5052
5754
8006
8011
8079

2,705
2,710
2,710
2,705
2,730
2,720
2,730
2,720
2,700
2,690
2,680
2,670
2,740
2,710
2,720

6
6
6
6
6
6
6
6
6
6
6
6
6
6
6

1,59
1,53
1,53
1,59
1,24
1,11
1,17
1,36
1,11
1,06
1,02
1,02
1,42
1,33
1,42

1700
1700
1700
1700
1700
1700
1700
1700
1700
1700
1500
1300
1700
1700
1700

350
350
350
350
350
350
350
350
350
350
350
350
350
350
350

95
95
95
95
95
95
95
95
95
95
95
95
95
95
95

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

1,55
1,49
1,49
1,55
1,22
1,09
1,15
1,33
1,08
1,03
0,98
0,98
1,40
1,30
1,39

2,63
2,54
2,54
2,63
2,07
1,85
1,95
2,26
1,83
1,75
1,48
1,27
2,38
2,21
2,36

20795
20047
20047
20795
16367
14598
15443
17885
14490
13786
11662
10069
18812
17427
18674

Min thickness = 5mm

Min thickness = 6mm

Min thickness = 6mm

Twin Roll Casting Lines

TT 800 Caster
Total Force:

1900 ton at 280 bar

Roll Diameter: 880-790 mm

Roll Table:

1800 mm

Roll power drive: 2 x 60 kW

Max available torque in continuous mode:
2 x 270000 Nm
Casting speed: up to 3,5 m/min
AGC system included

Twin Roll Casting Lines

TT 800 Caster - Strip productivity
(without ASG2 and MPS)
Alloy Density Thickness Speed Width Working days Availability Scrap Prod. rate Prod. rate Year production Remarks
kg/l
mm
m/min mm
%
%
ton/m/hr
ton/hr
ton

1050
1100
1200
1350
3003
3004
3005
3105
5005
5050
8006
8011
8079

2,705
2,710
2,710
2,705
2,730
2,720
2,730
2,720
2,700
2,690
2,740
2,710
2,720

6
6
6
6
6
6
6
6
6
6
6
6
6

1,51
1,46
1,46
1,51
1,19
1,06
1,11
1,29
1,06
1,01
1,35
1,27
1,35

1600
1600
1600
1600
1600
1600
1600
1600
1600
1600
1600
1600
1600

350
350
350
350
350
350
350
350
350
350
350
350
350

95
95
95
95
95
95
95
95
95
95
95
95
95

1
1
1
1
1
1
1
1
1
1
1
1
1

1,47
1,42
1,42
1,47
1,17
1,04
1,09
1,26
1,03
0,98
1,33
1,24
1,32

2,35
2,28
2,28
2,35
1,87
1,66
1,75
2,02
1,65
1,56
2,13
1,98
2,12

18587
18005
18005
18587
14783
13120
13789
15967
13024
12363
16832
15662
16709

Min thickness = 5mm

Twin Roll Casting Lines

TT 600 Caster

Total Force:

1200 ton at 280 bar

Roll Diameter: 680-630 mm

Roll Table:

1800 mm

Roll power drive: 2 x 28,5 kW

Max available torque in continuous
mode:
2 x 230000 Nm
Casting speed: up to 2,5 m/min

Twin Roll Casting Lines

TT 600 Caster - Strip productivity
(without ASG2 and MPS)

Alloy Density Thickness Speed Width Working days Availability Scrap Prod. rate Prod. rate Year production Remarks
kg/l
mm
m/min mm
%
%
ton/m/hr
ton/hr
ton

1050
1100
1200
1350
3003
3005
3105
8006
8011
8079

2,705
2,710
2,710
2,705
2,730
2,730
2,720
2,740
2,710
2,720

6
6
6
6
6
6
6
6
6
6

1,35
1,32
1,32
1,35
1,12
1,05
1,12
1,18
1,12
1,18

1600
1600
1600
1600
1600
1400
1400
1500
1600
1600

350
350
350
350
350
350
350
350
350
350

95
95
95
95
95
95
95
95
95
95

1
1
1
1
1
1
1
1
1
1

1,31
1,29
1,29
1,31
1,10
1,03
1,10
1,16
1,09
1,16

2,10
2,06
2,06
2,10
1,76
1,44
1,54
1,75
1,75
1,85

16617
16278
16278
16617
13939
11359
12130
13793
13836
14605

Min thickness = 5mm

Min thickness = 5mm
Min thickness = 5mm
Min thickness = 5mm
Min thickness = 5mm
Min thickness = 5mm

Twin Roll Casting Lines

TT 1200 Caster - Design
Total Force:

3400 ton at 260 bar

Roll Diameter: 1250-1150 mm

Roll Table:

2300 mm

Roll power drive: 2 x 200 kW

Max available torque in continuous mode:
2 x 950000 Nm
Casting speed: up to 6 m/min.
AGC system included

Roll design: grooved shells and

high thermal conductivity steel

Improved strip productivity

Improved strip profile
Reduced shell slippage
Improved core maintenance
Control of strip microstructure (CLSs)

Roll design: grooved shells and

high thermal conductivity steel

Circumferential temperature uniformity:

within 2C
Transversal temperature uniformity:
within 3C (except edge area)
Eliminates shell temperature as a
variable for strip profile control
Result: improved strip profile

Level Control System

Max Distance: 500 mm

Max Range : 200 mm
Work Mode : Optical Triangulation
Resolution

High accuracy and stability allows

better control of the strip thickness
and longitudinal profile.
Allows setting alarms.

: Up to 0.1 mm

Tip Table
Structure hung to the casting stand:
- no risk of damage in case of melt spillage
- easy access
Accurate positioning through AC
servomotors (independent on two sides):
-fine adjustment of the liquid sump - better
control of strip thickness and profile
-fine adjustment of the tip to roll contact - to
allow the best surface finish

Pre-heated tip support:

safe start up
no moisture
no alloy freezing.

Metal feeding system

Narrow tundish to feed tip with
small opening reduced
maintenance small mass to be
preheated
Closed tip with internal spacers:
low thermal losses easy and
repeatable start-up
Closed tip with internal spacers:
design optimized with CFD
Closed tip with internal spacers:
the best repeatability of melt flow
distribution

Automatic Gap Control

Floating upper roll with closed

loop control of the gap
independent on two sides
Allows fine adjustment and
control of strip thickness and
cross profile, while monitoring
casting force
Pressure control is anyway
possible

Quality: Strip Profile

Thickness difference edge to
edge:
max 0.03 mm
Strip crown:
typical 0.5% of strip thickness;
typical range 0.01 mm around
target value
Thickness range within coil:
typical 0.5% of strip thickness
max 1.0% of strip thickness

Release Agent Spraying System

Precisely adjusted and metered
flow rate of release agent:
-the lowest possible amount in a
safe condition for strip sticking
-improved strip productivity
(thermal exchange)
-improved strip surface quality

Adjustable travelling speed:

-uniform distribution at any line
speed
- graphite distribution is not a
variable for strip profile

Edge Miller

-Adjustable width and

cutting speed
-Milling 0 to 25 mm
edge
-Allows more rolling
passes before further
edge trimming
-Allows casting hard
alloys with cracked
edges
-Coarse chips for
acceptable remelting
yield
-Vacuum collection on
of the chips

Control System

-Management of operating
parameters from central unit
(caster, water, optionally
furnaces)
-Data Logging
-Monitoring of parameter
trends

BP Aluminium Service
Technical support team on process development in the following areas:
- Melting cycle: furnace operation and maintenance, gas consumption,
melting yield
- Melt holding: furnace operation and maintenance, melt quality checks
- Launders: improving thermal efficiency, maintenance
- Melt degassing and filtration: survey of process efficiency, process
improvement
- Strip casting: strip productivity; strip quality (macro and micro
structure, surface, geometry); annealing; cost reduction
- Billet casting: productivity and quality; cost reduction