First slabs rolled: thyssenkrupp Steel launches new high-tech facilities at the Duisburg location following a major investment

• New continuous casting line 4, extensively modernized hot strip mill 4 and new, fully automated slab logistics are entering the ramp-up phase

• Focus on stronger and thinner premium steels, for example for electric mobility and the energy turnaround

• High-tech facilities for greater efficiency, quality, flexibility, and security of supply

• Total investment volume of around 800 million euros

After around two years of construction and assembly work, thyssenkrupp Steel Europe has implemented major strategic investments at the Duisburg location. With the core facilities now completed, Germany's largest steelmaker has modernized and optimized its production network at key interfaces. The new continuous casting line 4, the extensively modernized hot strip mill 4 with two new walking beam furnaces, and fully automated slab logistics are at the center of the major project. This means thyssenkrupp Steel possesses one of the most modern plant networks in the European steel industry. The new units will replace the 20-year-old casting rolling line as a means of meeting increasing customer expectations and satisfying the highest material requirements in the future. At around 800 million euros, this is one of the largest investment projects in the history of thyssenkrupp Steel.

Dennis Grimm, CEO of thyssenkrupp Steel, emphasizes: "This project is a decisive milestone in strengthening our leadership in technological and quality terms, while meeting the increasing expectations of our customers. Despite a very challenging economic environment, we are able to invest around 800 million euros to further improve our competitive position. This is a strong signal for steel and the Duisburg location. The future is being created here."

State Minister for Economics, Industry, Climate Protection and Energy Mona Neubaur: "The new plant technology in Duisburg is an important step towards mod- ernizing steel production in North Rhine-Westphalia. The investment is a positive demonstration of corporate responsibility toward the location and it will contribute to increasing quality, efficiency, and flexibility. It will strengthen industrial value cre- ation in areas such as automotive construction and energy supply, ensuring that North Rhine-Westphalia remains a competitive industrial location."

High-tech facilities for stable processes and high-quality customer supply

The new units are located at the interface between upstream operations and hot strip pro- duction, making them a core feature of the integrated production network in the northern part of Duisburg. The reconfiguration that has now been completed will not only raise quality by increasing casting and rolling capacities, but will also improve capacity utilization of the up- stream basic oxygen steelmaking plant 1. This will increase the overall performance of the production network even more at a central point – with lasting positive effects on the security of supply for customers.

The new continuous casting line 4 replaces the casting section of the old casting rolling line and will ensure flexible and efficient slab production with high levels of precision. The system is also characterized by enhanced degrees of purity, improved shape accuracy, and surface quality.

The downstream hot strip mill 4, which is designed for around 3 million metric tons and un- derwent extensive modernization, has been equipped with two new walking beam furnaces that ensure more precise rolling accuracy and, above all, optimized surface quality. State-of- the-art control systems ensure the narrowest thickness tolerances, while optimized cooling processes further improve the material properties of the hot strip. The mill-edged slabs used can also be produced in significantly more flexible dimensions while allowing for an expanded product range, for example with regard to high-strength grades as well as dynamo and trans- former steels.

The completely newly created slab logistics represents the link between the two units. It en- sures fully automated, largely digital process handling. State-of-the-art control systems allow around 1.7 million metric tons per year to be synchronized in real time. This ensures maximum flexibility and efficiency in the process flow within the new system network.

All new systems are characterized by a high degree of automation and state-of-the-art control systems, for example enabling real-time monitoring of the production press through the use of digital twins. This also serves to ensure consistent and continuously optimized product quality.

The major investment will also strengthen the entire integrated site in the north of Duisburg, repositioning thyssenkrupp Steel efficiently and gearing up the business to overcome future challenges.

Chairman of the General Works Council Tekin Nasikkol: "This major project, which was agreed in a collective-bargaining agreement in spring 2020, is a clear commit- ment to Europe's largest steel location here in Duisburg. In difficult economic times, it sends a strong signal: We are creating the future with modern technology, quali- fied employees, and high-quality products. It is crucial for us now to continue invest- ing in the competitiveness of our company and our transformation, in order to se- cure good jobs for the region in the long term. Today's investments create secure jobs for tomorrow. That was just as true five years ago as it is today."

Dennis Grimm: "The new linked plant components are a rejuvenation treatment for key elements of our production network. We now possess one of the most modern production networks in the European steel industry. This will enable us to optimize our slab and hot strip qualities significantly with the aim of further developing our product portfolio in line with future requirements, particularly in the case of multi- phase steels, high-strength steels, and grades for electric mobility and the energy turnaround. With a more value-oriented portfolio, we can sustainably strengthen our earnings quality in the long term while expanding our competitive position. Addition- ally, we will provide our customers with the products that help them in their compet- itive environment."

Technical reference data of the new facilities

Hot strip mill 4
·       Length: 360 m
·       Nominal capacity p.a.: 3.1 million metric t/a
·       Strip widths: 900 mm to 1600 mm
·       Strip thicknesses: 1.2 mm to 9.0 mm

Walking beam furnaces 1 and 2
·       Temperature range: up to 1300 °C
·       Length: approx. 62 m
·       Width: approx. 11 m
·       Max. output per furnace: 380 metric t/h for cold application and 560 t/h for direct appli- cation
·       Max. slab length: 10 m
·       Max. speed: 25 m/h
·       Mixed gas firing

Continuous casting line 4
·       Metallurgic length:      35.5 m
·       Normal capacity p.a.: 2.3 million metric t/a
·       Slab width:                 900 – 1800 mm
·       Slab thickness:           257 mm

Slab storage yard
·       Fully automated with intelligent logistics control
·       Real-time synchronization of approx. 1.7 million metric tons of slabs/year
·       Significantly increased operational reliability, minimized commitment of personnel

You can watch an aerial tour of the new facilities by clicking this link: Drone flight through Europe's most modern hot strip mill.