Partnership for progress:

THYSSENKRUPP STEEL EUROPE
MAJOR REVAMP AND NEW-BUILD
CONTRACTS FOR CORE UNITS AT
DUISBURG AND BOCHUM SITES

thyssenkrupp-steel.com
primetals.com

THYSSENKRUPP STEEL EUROPE
2 SLAB CASTERS, HOT STRIP MILL,DOUBLE REVERSING MILL
AIMING FOR HIGHER-PERFORMANCE PRODUCTS, INCREASEDFLEXIBILITY, AND GREATER CUSTOMER PROXIMITY

thyssenkrup Steel Europe, Duisburg

thyssenkrupp is forging ahead with projects
under its Strategy 20-30. The greater part of thecontracts—a revamp of the casting-rolling line,
rebuild of an existing continuous caster, both inDuisburg, and construction of a new double reversing
mill in Bochum—have been awarded to Primetals
Technologies Ltd.
The approved investment projects are implemented immediately toachieve positive portfolio effects as quickly as possible. Primetals
Technologies succeeded with a cohesive, holistic, and innovative
proposal for the revamp and new-build work.
The centerpiece of the quality offensive at thyssenkrupp Steel isthe separation of the casting-rolling line at the Bruckhausen plant.
With integrated casting and rolling sections, the existing 20-yearold unit’s quality capabilities are no longer sufficient to meet future
customer requirements.
The casting-rolling line will be replaced by a new continuous
caster, two walking-beam furnaces, and a hot strip mill. This plantlayout allows energy savings like a casting-rolling line but withhigher flexibility in production. Hot slabs can be charged directly
into the furnace and temporarily stored or forwarded for reworking
to improve quality before rolling. In addition, slabs from othersuppliers can be sent for rolling in the hot strip mill

2

Bernhard Osburg, CEO thyssenkrupp Steel:“With the biggest investment package under our Strategy 20-30,
we are going on the offensive in order to maintain and strengthen
our position as the leader in key growth and focus segments. Our
customers will require different and better products in the future:
lower tolerances, increased crash safety requirements, and steel
for more powerful electric motors. The investments in our facilities
will enable us to meet these requirements. Another important point:
as part of our transformation to climate-neutral steel, we will also
be able to offer the new high-quality grades in ‘green’ in the future.”

Dr. Arnd Köfler, COO thyssenkrupp Steel:“The interface between our upstream operations and hot strip
production is a core element of our integrated production network.
We are now making this area fit for the next generation.
By separating and rebuilding the casting and rolling sections, we
can further enhance our capabilities for high-strength steels andpremium finishes. By splitting off the rolling section into a separate
hot strip mill, we will also make our slab production more flexible.”3

2-STRAND SLABCASTERS
SGA3, SGA4CONVERSION OF THE CASTINGROLLING UNIT INTO TWOSEPARATE UNITS AND CASTERREPLACEMENT

The casting-rolling line at the Bruckhausen plant will be separated
into a new continuous caster (SGA4) and a hot strip mill with newkey components.
The plan is for the new and revamped units to be installed withminimum disruption to production. Many major components will
be manufactured in advance and then installed. At the same time,some existing plant parts can be integrated into the new units,
such as the ladle turret, which will be used to supply liquid steel
from the melt shop to the new continuous caster. The switch fromthe existing casting section of the casting-rolling line to the newcontinuous caster will begin in September 2023, with the start-up
scheduled for February 2024.
After the revamp of the casting-rolling line in 2024, the existing
continuous caster SGA1 at the Bruckhausen plant will be replacedby the new 2-strand slab caster SGA3 to provide improved surface
quality. The start-up is scheduled for January 2025.

MAIN BENEFITS• Advanced features with Connect & Cast to maximizeproduct quality and production from the beginning• Maximum system and plant availability at low
maintenance costs• Operator-friendly control concept• Fast restranding using a dummy bar top feeding system• EcoStar Spiral Rollers allow for the casting of highquality steel grades

SOLUTIONAUTOMATION FEATURESSCOPE OF SUPPLY• Butterfly ladle turret with independent liftable arms and ladle
weighing (SGA3)

Process optimization functions

Primetals Technologies will supply the entire equipment for thecasters. The scope also includes all technological packages, thebasic and process automation system, and the advisory service for
installation and start-up.

• Gantry-type tundish car and trough-type tundish (SGA3)• Straight Smart Mold cassette-type mold with DynaWidthdesigned for the use of EMS/EMBR Type G3 (SGA3)• Curved Smart Mold cassette-type mold with DynaWidth and
EMS/EMBR Mold Stirrer Type G3 (SGA4)• DynaFlex hydraulic oscillator for an improved strand-surface
quality• Strand guide with bender, Smart Segments with online andremote roll-gap adjustments for slab-thickness changes as wellas to enable dynamic soft reduction (SGA3)• Strand guide with segment 0, Smart Segments with online andremote roll-gap adjustments for slab-thickness changes as wellas to enable dynamic soft reduction (SGA4)• EcoStar Spiral rollers for ideal strand support• DynaJet air-mist nozzles with optimized spray pattern for
optimum strand cooling• Chain type dummy bar with a top-feeding system for fast
restranding• CC Optimizer (Level 2 automation)• Mold Expert for breakout pre-detection and mold monitoring,• Quality Expert (advanced edition) for quality tracking and rating
prediction• Dynacs 3D secondary-cooling model• DynaGap SoftReduction 3D fully automatic roll-gap controlsystem

PLANT DATA

SGA 3
Vertical bending
CC

SGA 4
Curved CCHeat size

365 t

365 t

Caster capacity

2.7 Mtpy

2.3 Mtpy• CC Controller (Level 1 automation)

Machine radius

9m

12 m

• LevCon - automatic mold-level-control system

Metallurgical length32.1 m35.5 m

• DynaWidth - automatic mold width adjustment

Slab thicknesses

257 mm

257 mm

• DynaFlex for flexible online adjustment of the mold-oscillation
parameters

Slab width range

900 – 1,800 mm.

900 – 1,800 mm

Strand center distance7m

7m

Slab lengths

5.7 – 12.0 m

5.7 – 10.0 m

Casting speed max.

1.3 m/min

1.4 m/min• Yield Expert for cut length optimization• Intermix Expert for calculation of mixed steel in the strand• Equipment Expert for optimized maintenance tracking
Process control functions• EMBR/EMS Mold Stirrer• Flow Master Roll strand stirrer (SGA4)• LubriCon, CoolCon, DriveCon, HydrauliCon• WamBoy, OsciBoy
Condition monitoring• Asset Life Expert (ALEX)

45

HOT STRIP MILL
WBW4MAIN BENEFITS• Improved quality, e.g., purity segregation• Improved yield, e.g., less scrap loss, fewer edge cracks

CONVERSION OF THE CASTINGROLLING UNIT INTO TWOSEPARATE UNITS• Higher flexibility: hot charging, use of different slab
dimensions and grades, caster and hot mill are notcoupled• Extending product portfolio, e.g., high strength-,e-mobility-, C-, DP-. Trip- and Multiphase Steel• Higher cooling rates due to additional cooling headerswith a higher flow rate and better efficiency• Better cooling accuracy due to new valves and coolingmodel

A single stand 4-hi reversing roughing mill will be installed rightafter the new continuous caster and the two new walking beam
reheat furnaces. In addition, the first two stands of the existing
finishing train and the strip cooling system will be modified.
The switch from the existing casting section of the casting-rolling
line to the new continuous caster will begin in September 2023.
Regular operation will continue while the new hot strip mill—themost extensive construction measure under the investment
package—is prepared and connected to the production network bylate summer 2023.
The hot strip mill will include proven, innovative, and energyefficient solutions in the new roughing train, an upgraded finishing
train with a highly innovative downstream strip cooling section, andnew automation and process models.

Dr. Arnd Köfler, COO thyssenkrupp Steel:“The reconfiguration of this area will enable us to achieve higher
quality and better utilize the capacity of our upstream melt shop
by increasing our casting and rolling capacities. This will further
improve the overall performance of our production network at a
central point with lasting positive effects, including the security ofsupply for our customers.”

SOLUTIONSCOPE OF SUPPLY• New highly efficient primary descaling unit with a new frequencycontrolled pump station

Primetals Technologies will supply the entire equipment for
the hot rolling mill from the reheat furnace exit to finishing millentry, modification of F1 & F2, and extension of the strip coolingsystem. This also includes all technological packages, the basic
and process automation system, and the advisory service for
installation and start-up.

• New full hydraulic edger• 4-hi reversing roughing mill with mechanical screw down andhydraulic gauge control cylinder, including motor and drivesystems

PLANT DATA
Annual capacity

3,100,000 t

Slab thickness

170 – 320 mm

Strip thickness

1.2 – 12.7 mm

Strip width

900 – 1,600 mm• Delay table with transfer bar side shift

The main components are:Max. mill stand force RM

47,000 kN• Encopanels® for heat conservation• Reheat furnace discharge roller tables

Max. mill stand force FM

47,000 kN• Integration of existing crank type shear• Primary descaling unit

• New crop optimization system• RM entry roller table• New secondary descaling unit to replace the existing one in frontof the finishing mill

• RM entry side guides• Increased roll force with new long stroke hydraulic gauge control
cylinders in F1 and F2• 4-hi roughing mill including motor and drive systems• New bending and shifting system in F1 and F2• Various expert systems to improve product quality and tostabilize strip steering• Vertical edger (attached to the roughing mill stand)• RM exit roller table• RM exit side guides• Encopanels®

• Model-based width optimization from roughing mill to downcoiler• Delay table• Extended strip cooling line with new model—predictive coolingmodel including control of phase-transformation and lowtemperature cooling• Scrap disposal system• Crop shear entry roller table incl. side guides• Secondary descaling unit
• HAGC cylinders for F1 & F2
• Bending and shifting system for F1 & F2
• Work and backup rolls incl. chocks for F1 & F2
• Extension of existing strip cooling with new turbo laminar coolingheaders• Hydraulic, lubrication systems for RM area
• Descaling station for RM area

67

DOUBLE
REVERSING
COLD MILLDRG
NEW 6-HIGH HYPER UC-MILL
WITH MQL

MAIN BENEFITS• The high-quality production of NGO electrical steels andadvanced high-strength steels• Minimized off-gauge and maximized yield• Increased reduction capability, small productthicknesses, and excellent shape controllability• Reduced edge-load, minimized strip break rate andoperating costs• Stable and energy-efficient production of high-grade
electrical steels• Maximum flexibility to produce a wide range of products

Primetals Technologies has also been awarded the contract
to build a double reversing mill at the Bochum site. The trend
is toward ever thinner and high-silicon materials, which placeincreased demands on cold rolling technology. The new double
reversing stand will meet these demands and significantly enhance
the site’s capabilities for non-oriented electrical steel. With its
back and forth (reversing) action, the mill can roll particularly thinmaterials. This is important for sheets used in electric motors andgenerators because it minimizes magnetic losses.

Dr. Arnd Köfler, COO thyssenkrupp Steel:“The base material for our new double reversing mill will be
supplied from our new Hot-Strip-Mill No. 4. In this way, we will
excel with high-strength multiphase or optimized electrical steel
grades by exploiting quality improvements throughout our entire
production chain.”

SOLUTIONSCOPE OF SUPPLYPLANT DATA

The reversing mill features a twin-stand 6-high HYPER UCMILL with driven work rolls and new MH-spindles for the highest
torque transmission. The mill is equipped with Minimum Quantity
Lubrication MQL® and an inductive strip heating system, dedicatedto producing non-grain oriented (NGO) electrical steel andadvanced high-strength steels (AHSS).
A compact design and advanced instrumentation and automation
systems to produce Silicon and AHSS steels permits shorteningof the off-gauge length. The mill consists of a pay-off reel, tworeversing mill stands, and two tension reels with belt wrapper
and gripper slot for optimized threading and rolling process. Twoflatness measurement devices (Contactless Shape Monitor) areintegral to the advanced flatness control system.
Primetals Technologies supplies the complete process equipment,electrics, and automation and is responsible for the installation andstart-up of the plant.

• First pass section with coil lifting car, pay-off reel, flattener, pinchroll, inductive strip heating systemand threading table

Mill type2-stand, 6-highHYPER
UC-MILL

Annual capacity

475,000 t

Main drive power2 x 3,000 kW per mill standRoll force

max. 21,600 kN

Rolling speed

max. 1,000 m/min

HYPER UC-MILL®
HYPER UC-MILL features a further development of the wellestablished UC-MILL technology with a small work roll size anda high-torque spindle. The smaller work roll diameter allows highreduction ratios and small exit gauges. A heavy work roll bending
combined with an intermediate roll bending ensures excellent
shape controllability. A unique feature of a UC-Mill is the edgeoriented intermediate roll shifting with reduced edge load and edge
drop, which is a significant advantage to produce brittle materials,
like high-grade electrical steel.

• Mill stand section with two mill stands, powerful hydraulic rollload cylinders, positive and negative work roll bending andpositive intermediate roll bending, UC-MILL intermediate roll
shifting, multizone cooling, combined MQL / emulsion sprayheader, driven work rolls with twin-drive and automatic work rollchange equipment• Exit section with thickness and contactless flatness
measurement devices and entry and exit reversing reels with
sleeve manipulation• Fluid equipment with the combined auxiliary and servo-hydraulicsystem, emulsion-, grease- and gear oil lubrication system• Advanced expert systems to improve product quality• Electrical and automation system• Engineering, erection, supervision of erection andcommissioning

PRODUCTION DATA
Material

Hot rolled and pickled

Entry strip thickness

1.6 – 4.5 mm

Exit strip thickness

0.2 – 2.3 mm

Strip width

700 – 1,570 mm

Coil weightmax. 30 t

MINIMUM QUANTITY LUBRICATION (MQL)®
MQL is a unique flexible roll-gap lubrication system, which reduces
rolling forces, energy consumption, and strip wear and improves
strip surface cleanliness of the cold rolled product. In combination
with a strip heating system, it prevents a cool-down of the strip
temperature compared to conventional emulsion systems, which isadvantageous for cold rolling of high-grade NGO products.

89AUTOMATIONANDDIGITALIZATIONALIGNED SYSTEMS ACROSS ALL
PLANT UNITS

Comprehensive Industry 4.0 solutions and high-end automation
systems will enhance the viability of the overall project. This
includes integrated process control (Level 1 automation) andoptimization (Level 2).
Further developed and improved systems are used for the newcontinuous casters. The high degree of digitalization of the plants
allows important parameters relating to the purity and homogeneityof the product to be controlled even more precisely, thus furtherenabling the ability to meet specific requirements .
A modern control platform for the hot and cold rolling mills utilizes
the newest automation technology based on SIMATIC S7-1500/TIA.
The emphasis on automation is prepared for future expansions
or changes in the product spectrum and product mix. Flexible
automation enables stable production even with changing process
conditions and speed-up mode of operation.

MAIN BENEFITS• Reliable and future-oriented equipment and automation
solutions• High-end expert systems and innovative models toimprove product quality and performance• Offline simulation for fast product development• Digital twin for simulation and replay of production
scenarios• Easy upgradeability due to modular software architecture

SOLUTION
Highlights of the project include• Digital twins, like offline layout tools, used already in the planningphase for optimal layout and engineering of the plants• Intelligent solutions for equipment monitoring and maintenance,e.g., OPAL, Strand Checker, Equipment Expert• Smart sensors and mechatronics solutions, e.g., Powder Expert,
Flow Master, ShapeMon• Highly advanced process models for continuous casting, e.g.,
Intermix Expert for exact calculation of the chemical analysis
also for the areas of mixed steel• Production of AHSS grades using patented process models forthe cooling section• High-end expert systems for rolling mills, e.g., strip steering,wedge and chamber, flatness roll and coil eccentricity• Asset Life Expert (ALEX): intelligent digital assistant in thecaster area to improve the plant availability by digitalizing knowhow based on plant operation practice, offering clear status
information, and recommending intelligent actions

1011

Primetals Technologies Austria GmbHA joint venture of Mitsubishi Heavy Industries and partners

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thyssenkrupp Steel Europe AG
Kaiser-Wilhelm-Straße 100
47166 Duisburg
Germany
thyssenkrupp-steel.com

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