- Major upgrades allow thyssenkrupp Steel to focus on high-margin premium products
- Substantial improvements in slab quality enable production of multi-phase, high-strength, and e-mobility steel grades
- Direct charging of slabs increases energy efficiency while preserving high quality in sensitive steel grades such as electrical silicon steels
In April 2026, thyssenkrupp Steel issued the final acceptance certificate (FAC) for continuous slab casting machine No.4 from Primetals Technologies at its Duisburg site in Germany. 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.
Flexible and Future-Proof Production
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.
A Strong Partnership Key to Project Success
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.
State-of-the-Art Slab Caster
The upgraded 2-strand continuous caster No. 4 includes advanced mechanical and automation solutions. The DynaWidth mold-width adjustment system enables fast and flexible slab-width changes, while the DynaFlex 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.
EcoStar 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).
About thyssenkrupp Steel
The project is part of a broader modernization plan. In 2021, thyssenkrupp Steel ordered a reversing cold mill, the hot-strip mill, and two thick-slab continuous casters from Primetals Technologies.
With an annual production volume of about 11 million tons of crude steel, thyssenkrupp Steel employs around 26,000 people worldwide. The company aims to produce five million tons of CO₂-neutral steel per year by 2030 and achieve full climate neutrality in production by 2045.
Key Facts: Continuous Slab Caster No.4 at thyssenkrupp Steel
Capacity: 2.3 million tons per year
Width: 900 to 1,800 millimeters
Thickness: 257 millimeters
Radius: 12 meters
The slab caster modernization from Primetals Technologies is part of a major upgrade project that allows thyssenkrupp Steel to focus on high-margin premium products.
The upgraded 2-strand continuous caster No. 4 includes advanced mechanical and automation solutions.
Primetals Technologies, Limited, headquartered in London, United Kingdom, is a pioneer and world leader in the fields of engineering, plant building, and the provision of lifecycle services for the metals industry. The company offers a complete technology, product, and services portfolio that includes integrated electrics and automation, digitalization, and environmental solutions. This covers every step of the iron and steel production chain—from the raw materials to the finished product—and includes the latest rolling solutions for the nonferrous metals sector. Primetals Technologies is a Group Company of Mitsubishi Heavy Industries, with around 7,000 employees worldwide. To learn more about Primetals Technologies, visit the company website www.primetals.com.
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