With the successful completion of the project, Thyssenkrupp Steel has significantly expanded its product portfolio and aligned it with future market requirements, with a clear focus on high-margin premium products.

“Already during the plant's ramp-up phase, the qualitative advantages of the new facility and its potential to produce new grades became apparent. This allowed the planned concept to be validated at a very early stage,” says Thyssenkrupp Steel Head of Upstream Operations Chris Lindner.

The project separated the former combined casting and rolling line into two distinct units: a revamped caster and a modernized hot-strip mill. By reconfiguring and decoupling the casting and rolling operations, upstream melt shop capacity utilization is improved, overall process efficiency is enhanced, and flexibility in slab logistics and process control is increased.

The new facility enables substantial improvements in slab quality. In particular, the plant implemented by Primetals Technologies fully meets the high requirements for producing sophisticated grades such as multi-phase steels, high-strength steels, and advanced materials for e-mobility applications. This strengthens Thyssenkrupp Steel’s long-term competitiveness and ensures a reliable supply for customers in demanding market segments, including silicon steel grades for e-mobility, motors and generators, and high-strength steels for the automotive sector.

The project faced several challenges, including an extremely tight schedule requiring completion with minimal disruption to ongoing production. At peak times, up to 1,000 workers were on site simultaneously, following meticulously planned work sequences and strict timelines. Any deviations demanded fast and often unconventional solutions.

“The successful execution of this project is founded on the long-standing and trusted partnership between Thyssenkrupp and Primetals Technologies. Building on numerous successfully completed joint projects, both companies continue to strengthen their collaboration and drive innovation forward,” says Olaf Meininghaus, responsible for sales and business development between Primetals Technologies and thyssenkrupp.

To accelerate execution, key components were pre-assembled and fully tested prior to installation, ensuring a smooth and efficient implementation on site. At the same time, selected existing plant components were seamlessly integrated into the new system with minimal downtime. A shared, solutions-oriented approach and strong support from both Thyssenkrupp Steel and Primetals Technologies were key to achieving the project’s schedule and performance targets.

The upgraded 2-strand continuous caster No. 4 includes advanced mechanical and automation solutions. The “Dyna Width” mold-width adjustment system enables fast and flexible slab-width changes, while the “Dyna Flex” hydraulic oscillator improves strand-surface quality by adjusting mold-oscillation parameters. The Level 2 automation system, “CC Optimizer”, features modules like “Dynacs 3D”, which ensures optimal secondary cooling.

“Eco Star Spiral” rolls allow dry casting in both the bow and horizontal areas. In the horizontal section, spray cooling is completely omitted, and in the casting bow, secondary cooling can be reduced or completely switched off. The combination of these technology solutions ensures the slabs reach an ideal temperature profile for direct rolling, eliminating the need for reheating furnaces and leading to energy savings. It also keeps demanding slabs within the correct temperature window for rolling, which is crucial for high-strength steels and high-silicon steels, both of which are prone to cracking when the temperature is no longer optimal.

Additionally, the absence of secondary cooling in the horizontal strand containment section significantly reduces maintenance needs and therefore lowers operating expenses (OPEX).

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Key Facts

Continuous slab caster No.4 at Thyssenkrupp Steel

Capacity: 2.3 mio t/y

Width: 900mm to 1,800mm

Thickness: 257mm

Radius: 12m