The casting-rolling line at the Bruckhausen plant was divided into a new continuous caster SGA4 and a hot strip mill with new key components.
Challenge
The installation of the new and revamped units was successfully carried out with minimal disruption to production. Many major components were manufactured in advance and then installed. At the same time, some existing plant parts were integrated into the new units, such as the main parts of the casting platform. The switch from the existing casting section of the casting-rolling line to the new continuous caster was completed in 2025.
Solution
The solution implemented in this project features a comprehensive array of advanced technologies designed to enhance steel production efficiency and quality. The curved Smart Mold cassette-type mold with DynaWidth and EMS/EMBR Mold Stirrer Type G3 further optimizes mold stirring and steel flow, contributing to superior casting quality.
The project also incorporates the DynaFlex hydraulic oscillator, which significantly improves strand-surface quality by providing precise oscillation control. The strand guide with bender and Smart Segments allows for online and remote roll-gap adjustments, facilitating slab-thickness changes and enabling dynamic soft reduction. EcoStar Spiral rollers offer ideal strand support, while DynaJet air-mist nozzles with optimized spray patterns ensure optimum strand cooling. The chain-type dummy bar with a top-feeding system enhances the speed and efficiency of restranding operations, contributing to overall production efficiency.
Process control functions are enhanced by the CC Controller (Level 1 automation), LevCon automatic mold-level control system, and DynaWidth automatic mold-width adjustment. The DynaFlex oscillator allows flexible online adjustment of mold-oscillation parameters, while EMBR/EMS Mold Stirrer and Flow Master Roll strand stirrer ensure efficient stirring and flow control. Additional systems like LubriCon, CoolCon, DriveCon, HydrauliCon, WamBoy, and OsciBoy further streamline operations. Condition monitoring is supported by Asset Life Expert (ALEX), which provides comprehensive insights into equipment health and maintenance needs, ensuring optimal performance and minimizing downtime.
Automation features play a crucial role in optimizing the steel production process. The CC Optimizer (Level 2 automation) and Mold Expert provide advanced process optimization functions, including breakout pre-detection and mold monitoring. Quality Expert (advanced edition) enables quality tracking and rating prediction, while the Dynacs 3D secondary-cooling model and DynaGap SoftReduction 3D fully automatic roll-gap control system ensure precise cooling and gap adjustments. Yield Expert optimizes cut length, and Intermix Expert calculates mixed steel in the strand, enhancing production accuracy. Equipment Expert facilitates optimized maintenance tracking, ensuring the longevity and reliability of the equipment.
Benefits
Advanced features with Connect & Cast to maximize product quality and production from the beginning
- Maximum system and plant availability at low maintenance costs
- Operator-friendly control concept
- Fast restranding using a dummy bar top-feeding system
- EcoStar Spiral Rollers allow for the casting of high-quality steel grades.
Conclusion
thyssenkrupp Europe's Bruckhausen plant was transformed with the implementation of 2-strand slab casters SGA3 and SGA4, enhancing steel production efficiency.
- During the installation, there was minimal production disruption, integrating new and existing components seamlessly.
- Technologies like DynaFlex and Smart Segments improve strand-surface quality and slab-thickness flexibility.
- EcoStar Spiral Rollers enable high-quality steel grades.
- Advanced automation features like CC Optimizer and Mold Expert optimize quality and accuracy.
