Celebratory Commencement at Crucible of Change in DuisburgOn July 4, 2025, thyssenkrupp Steel and Primetals Technologies marked the successful start-up of slab caster No. 4 and hot-strip mill No. 4 at the Bruckhausen facility in Duisburg. This event was attended by leading political and industrial dignitaries, including Mona Neubaur, Minister of Economic Affairs and Climate Protection. The commissioning ceremony underscored a pivotal achievement in the German steel industry’s evolution toward sustainability and advanced automation.

Splendid Separation Spurs Strategic Steel SophisticationThe project separated the previously unified casting and rolling line into two distinct production streams, a newly upgraded slab caster and a fully modernized hot-strip mill. This move increased thyssenkrupp Steel’s capacity from 1.8 to 3.1 million metric tons per year. It also enabled the production of premium steel grades that align with current industrial demands, including e-mobility and energy applications.

Gritty Governance Guides Grand Industrial GoalsDennis Grimm, Chief Executive Officer of thyssenkrupp Steel, emphasized the strategic impact of the modernizations, describing them as critical in strengthening the company’s leadership in technology and quality. He noted that the investments now place thyssenkrupp among Europe’s most modern production networks, capable of delivering high-strength steels and multi-phase grades vital for the future of green transport and renewable energy.

Synergistic Synergy Surpasses Scheduling StrainsDespite an ambitious construction schedule and the presence of nearly 1,000 workers onsite at peak times, the project was delivered on time through seamless cooperation. Primetals Technologies preassembled several critical components, such as the roughing mill and descaler, adjacent to existing structures. This proactive planning allowed for a swift switchover during the brief plant shutdown, reducing delays and maintaining safety.

Slab Caster Sophistication Showcases Smart SolutionsThe new two-strand continuous slab caster, capable of producing slabs ranging from 900 to 1,800 millimetres in width and 257 millimetres in thickness, includes cutting-edge mechanical and automation technologies. Systems like DynaWidth and DynaFlex allow rapid width adjustments and improved surface quality. The Level 2 CC Optimizer includes Dynacs 3D for optimal secondary cooling, ensuring product uniformity and high efficiency.

Meticulous Maintenance Mandate Maximises Machine MettleAlongside commissioning, Primetals Technologies signed a two-year service contract to maintain and refurbish the caster’s rollers under its ECO-star program. Using the Maintenance and Asset Technology digital platform, the agreement focuses on extending roller life, ensuring consistency, and minimising downtime. This collaboration adds long-term stability to slab caster operations, reinforcing thyssenkrupp’s reliability.

Hot-Strip Heuristics Herald High-Tech HorizonsThe updated hot-strip mill boasts a single-stand 4-high reversing roughing mill, upgraded finishing stands, and a sophisticated strip cooling system. Integrated with advanced Level 1 and Level 2 automation platforms, including the Contour and Flatness Optimizer, the mill enables precise control over rolling parameters. Encopanels enhance heat retention, facilitating production of high-performance steel grades.

Modernization Milestone Marks Metallurgical MasteryThe upgrades at Bruckhausen are part of a broader roadmap initiated in 2021, involving investments in multiple facilities. The first milestone, a reversing cold mill, began operations in Bochum in September 2023. Slab caster No. 3 is scheduled for completion in 2026. thyssenkrupp Steel, which produces 11 million metric tons of crude steel annually and employs 26,000 people, plans to deliver 5 million metric tons of CO₂-neutral steel by 2030, aiming for full climate neutrality by 2045.

Key Takeaways:

• thyssenkrupp Steel and Primetals Technologies have launched new slab casting and hot-strip mill units, raising production to 3.1 million metric tons per year

• Advanced automation systems, including Dynacs 3D and Encopanels, enable production of premium steel grades for electric mobility and energy sectors

• thyssenkrupp aims to produce 5 million metric tons of CO₂-neutral steel annually by 2030 and achieve full climate neutrality by 2045