ABB technology to help optimize production for major steelmaker thyssenkrupp as part of plant revamp and new build

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  • Order placed by plant solution provider Primetals Technologies with expected commissioning in early 2024
  • Two slab casters, each with two strands, will be equipped with ABB Flow Control Mold (FC Mold) electromagnetic stirring and braking devices, enabling faster and more cost-efficient production of clean steel
  • Installation at upgraded Duisburg-Bruckhausen plant in Germany comes after more than 40 similar installations prove higher productivity and quality for slab casters at all speeds

ABB has been awarded a major contract by Primetals Technologies to help optimize production at thyssenkrupp Steel Europe’s (tkSE) Duisburg-Bruckhausen plant in Germany, using the unique and proprietary ABB Flow Control Mold electromagnetic stirring and braking technology for higher quality steel produced faster and at lower cost.

The construction of a casting rolling mill and the upgrade of an existing continuous casting plant is part of a wider project awarded to Primetals Technologies, a global leader in plant engineering for the metals industry. It is part of tkSE’s Strategy 20-30 which aims to optimize operations for the requirements of automotive customers seeking improved surfaces, thinner and high-performance steels to meet crash safety standards in the growing e-mobility market.

By using FC Mold G3 (generation 3), thyssenkrupp can prevent gas bubbles and impurities from becoming trapped in the solidifying steel as the technology will offer simultaneous stirring and braking from one fixed position on the caster. In continuous slab casting, conditions in the meniscus area of the solidifying steel are crucial to determining end-product quality and have a major impact on productivity and overall operating costs. Integrated with the caster, FC Mold uses electromagnetic fields to control meniscus flow speed and fluctuations. It enables improved process control and increased resource efficiency, requires very little maintenance and typically has a long lifespan.

With an installed base at 40 sites worldwide, performance improvements delivered by FC Mold technology are well-proven. Typically, these include 50 percent reduction in defects and up to 80 percent reduction in rejected or downgraded product. In addition, FC Mold can allow for a higher casting speed.

Thyssenkrupp is one of the world’s leading producers of carbon flat steel and drives innovation in steel and high-quality products for demanding, state-of-the-art applications. It has set itself the goal of producing three million tons of CO₂-neutral steel a year by 2030 as the industry moves towards climate-neutral steel production by 2050 in line with the UN Paris Agreement. Primetals Technologies is a pioneer and world leader in the fields of engineering, plant building, and the provision of lifecycle services for the metals industry.

Zaeim Mehraban, Global Sales Manager, Metallurgy Products at ABB

“By significantly reducing defects, rejects and downgrades the FC Mold will improve cost and resource-efficiency at tkSE, thereby supporting both sustainability and profitability goals, while contributing to the company’s Strategy 20-30 ambitions to meet customer requirements for higher performance steel grades. Backed by decades of experience working with plant builders, like Primetals, and knowledge of metallurgical processes such as slab casting from numerous installations worldwide, ABB continues to devise solutions to solve bottlenecks in steel and aluminium manufacturing processes and repeatedly prove they are effective.”

Your Challenges

  • Improve conditions in the near-meniscus area which are crucial to determining end-product quality and have a significant effect on overall productivity and operating costs
Our Solution

  • FC Mold offers simultaneous stirring and braking in the mold from one fixed position via three independent magnetic fields to control meniscus flow speed and dampen fluctuations, and minimize downward flow to allow gas bubbles to float to the surface instead of being trapped in the solidifying steel. 

    • Automatic, adaptable process control

    • Automatic quick connectors shorten mold change time

    • Very low maintenance and long lifespan 

    • Achieve up to 50% less surface surface and internal defects
    • Reduce your reject ratio by up to 80%
    • Improve productivity with a higher casting speed

    •  Lower operating costs with less rejects and downgrades

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