Technological Metamorphosis Elevates CoolingCapabilities
The comprehensive modernization of water management atthyssenkrupp Steel's Duisburg-Beeckerwerth site has transformed the Hot StripMill 2 (WBW 2) with state-of-the-art technology. The upgraded system deliverssignificantly improved cooling water supply, particularly for the criticalcooling section at the exit roller table in the final production stages. Thistechnological advancement represents more than just an infrastructure upgrade, itestablishes new benchmarks in environmental compliance and energy efficiencyfor steel production facilities. The modernization addresses multipleoperational challenges simultaneously, enhancing the facility's ability tomaintain precise temperature control throughout the rolling process whileoptimizing resource utilization. This strategic investment positions theBeeckerwerth site at the forefront of sustainable steel production technology,with cooling capabilities that match the most advanced facilities globally.
Water Recycling Exemplifies Circular EconomyPrinciples
Water plays an indispensable role throughout steelproduction, serving essential functions in cooling, temperature regulation, andcleaning processes such as scale removal from slab surfaces. thyssenkruppSteel's commitment to sustainability is evident in their approach to waterresource management at the Beeckerwerth plant area, where an impressive 97% ofthe 200 million cubic meters of water required annually is continuouslyrecirculated through their systems. The newly modernized water management infrastructurehas further elevated this already remarkable resource efficiency, establishinga model for circular water usage in heavy industry. This approach not onlyreduces environmental impact but also insulates operations from potential waterscarcity concerns while demonstrating responsible stewardship of naturalresources. The company's focus on water conservation aligns with broaderindustry trends toward minimizing the environmental footprint of steelproduction.
Engineering Excellence Drives Multi-YearTransformation
The complex modernization project was executed by water andwastewater technology specialist PSE Engineering GmbH, encompassing theinstallation of gravel filters, pumps, cooling towers, comprehensive plantpiping, and new electrical switchgear. The scope of work extended to include anew above-ground pipeline route, enhanced energy supply systems, and expansionof the pump infrastructure in the over-pumping plant for the cooling section.Structural engineering aspects were handled by Fenne from Gladbeck, ensuringall physical infrastructure met rigorous industrial standards. The entireconstruction period spanned three years, beginning with groundbreaking for thenew pipeline route and culminating in the recent system commissioning. Theinvestment represented a substantial financial commitment, reaching the middouble-digit million dollar range, reflecting thyssenkrupp Steel's confidencein the strategic importance of advanced water management for future operations.
Product Quality Gains Through HomogeneousCooling
The modernization delivers tangible benefits forthyssenkrupp Steel's customers through significantly improved band cooling inthe cooling section. The system now maintains a more homogeneous cooling waterinlet temperature, ensuring consistently superior product quality acrossproduction runs. This technical advancement addresses a critical aspect ofsteel strip production, where uniform cooling directly impacts materialproperties and dimensional stability. The enhanced cooling precision enablesthyssenkrupp to meet increasingly stringent customer specifications whilemaintaining high production volumes. Wolfgang Braune, Head of Hot Strip Mill 2in Beeckerwerth, emphasized this advantage: "The improved cooling waterconditions have given us greater flexibility in developing new products, makingus well-prepared for future challenges." This quality improvementstrengthens the company's competitive position in premium steel markets whereconsistency and material properties are paramount.
Automation Advances Enhance OperationalReliability
A cornerstone of the modernization is the implementation ofcentralized operational and monitoring control technology, representing asignificant leap forward in system intelligence and responsiveness. Thisautomation upgrade ensures more reliable control of water management functionswhile delivering higher process stability throughout production cycles. Thesystem incorporates energy-efficient adjustments to cooling water demandthrough variable-speed pumps and cooling tower fans, optimizing energy consumptionbased on real-time requirements. During cooling pauses, the systemautomatically reduces pumps to standby mode or shuts them down entirely duringextended rolling changes, eliminating unnecessary energy consumption. Thisintelligent automation not only improves operational efficiency but alsoreduces maintenance requirements and extends equipment lifespan through moreprecise load management and reduced mechanical stress during operation.
Future-Proofed Infrastructure Secures SiteViability
The modernized water management system at Hot Strip Mill 2now guarantees secure cooling water supply for all production facilities acrossthe Beeckerwerth site, significantly enhancing operational resilience. Thisexpanded capability was achieved partly through the strategic addition ofcooling towers with substantial capacity. The new technology enablesdramatically lower cooling water temperatures, with reductions from 43°C to24°C, creating optimal conditions for current operations while building in capacityfor future production requirements. This forward-looking approach ensures thesite remains competitive and adaptable as production demands evolve. "Thisis an important contribution to sustainable and high-performance production atthyssenkrupp Steel," noted Wolfgang Braune, highlighting the strategicsignificance of the investment beyond immediate operational improvements. Themodernization effectively removes previous cooling performance bottlenecks andeliminates overloaded cooling units that had constrained productionflexibility.
## Technical Specifications ShowcaseEngineering Magnitude
The scale of thyssenkrupp Steel's water managementmodernization becomes evident through its impressive technical specifications.The project added four powerful cooling towers, each with cooling capacity of2,000 m³/h, substantially increasing the site's total cooling capability.Eighteen additional gravel filters were installed, each with filtrationcapacity of 500 m³/h, ensuring water quality meets precise specifications fordifferent production processes. The new infrastructure includes a dedicatedpump and switch house equipped with six variable-speed pumps, complemented bythe conversion of five existing fixed-speed pumps to high-performance,variable-speed units. These technical enhancements collectively enable theremarkable reduction in cooling water temperature from 43°C to 24°C at HotStrip Mill 2, eliminating previous cooling performance bottlenecks that hadconstrained production. The comprehensive nature of these upgrades demonstratesthyssenkrupp's commitment to building infrastructure that will supportoperations for decades to come.
Key Takeaways:
• thyssenkrupp Steel has completed a three-year, middouble-digit million $ modernization of water management at itsDuisburg-Beeckerwerth Hot Strip Mill 2, featuring advanced cooling technologythat reduces water temperatures from 43°C to 24°C while maintaining 97% waterrecycling across the 200 million cubic meter annual usage.
• The modernization includes four new cooling towers (eachwith 2,000 m³/h capacity), 18 additional gravel filters (each processing 500m³/h), six variable-speed pumps in a new pump house, and conversion of fivefixed-speed pumps to high-performance variable-speed units, eliminatingprevious cooling bottlenecks.
• Head of Hot Strip Mill 2 Wolfgang Braune emphasized thatthe improved cooling water conditions provide greater flexibility fordeveloping new products while increasing energy efficiency and plantavailability, securing the future competitiveness of thyssenkrupp Steel'sproduction at the Beeckerwerth site.
