In a significant upgrade to its production facilities, thyssenkrupp Steel has modernized the walking beam furnace, WBW 1, at its Duisburg-Bruckhausen hot strip mill, marking a major step forward in both product quality and energy efficiency. The overhaul of this key furnace, carried out in collaboration with Tenova, a global specialist in heat treatment processes, aims to meet the growing demand for high-quality electrical steel and packaging steel. The modernization, which represents a multi-million Euro investment in the low double-digit million range, positions thyssenkrupp Steel for the future markets of energy-efficient steel products.
The main benefit of the modernization is the significant improvement in the quality of steel produced, particularly electrical steel, which is essential for the energy transition. The upgraded furnace is designed to ensure a more homogeneous temperature distribution across the entire length of the steel slabs. This advanced heating process minimizes temperature variations, especially in the center of the slab, resulting in better product quality. The improved temperature uniformity also reduces defects such as surface flaws and "rails," the contact points between slabs and support systems, which are common issues in traditional heating methods.
One of the key advantages of the modernized furnace is its contribution to energy savings and efficiency. The upgraded furnace has been designed to reduce energy consumption, making it more environmentally friendly. This was achieved by optimizing several components, including the refractory lining and support pipe system, which now operate more efficiently. In addition, the new system is equipped with state-of-the-art UltraLowNOx burners, which will help significantly reduce nitrogen oxide (NOx) emissions, a crucial factor in improving air quality and meeting stringent environmental regulations.
The furnace's improved energy efficiency also includes the optimization of the pilot burner systems, which has led to a reduction in natural gas consumption. These measures are part of thyssenkrupp Steel's ongoing commitment to sustainable steel production practices, helping the company meet its environmental goals while maintaining high standards of product quality. The energy efficiency improvements also extend to the furnace's operation, where advanced control systems ensure better monitoring and management of fuel usage.
In terms of maintenance and operational efficiency, the modernized furnace is equipped with an innovative automatic descaling concept. This new system minimizes the need for manual cleaning and reduces cleaning intervals, allowing for smoother and more consistent production processes. The enhanced descaling system will not only increase the furnace’s operational uptime but also reduce maintenance costs, contributing to the overall efficiency of the production facility.
The furnace's key technical specifications include a width of 12.5 meters and a length of 55 meters, with a maximum speed of 25 meters per hour. These dimensions are designed to handle large volumes of steel, ensuring the plant can meet the needs of both current and future production demands. The modernization allows the furnace to process steel slabs with greater precision and efficiency, ensuring that thyssenkrupp Steel remains competitive in a rapidly evolving market.
The impact of the walking beam furnace upgrade is not just limited to energy efficiency and product quality. It also plays a crucial role in helping thyssenkrupp Steel meet the needs of the energy transition. Electrical steel, produced using the upgraded furnace, is essential for manufacturing components used in electric vehicles, renewable energy systems, and other green technologies. By investing in this modernization, thyssenkrupp Steel is positioning itself as a leader in the production of high-quality steel that supports global sustainability efforts.
Overall, the modernization of the walking beam furnace in Duisburg-Bruckhausen highlights thyssenkrupp Steel's commitment to improving its technological capabilities while reducing its environmental footprint. With advanced heating processes, improved energy efficiency, and reduced emissions, this upgrade sets a new standard for the steel industry, contributing to both economic growth and the global push for a greener future.
