Start-up underway: SMS group strip processing line supports thyssenkrupp Steel Europe in producing electrical steel sheet for energy-efficient electric motors

• Strip processing line with an annual capacity of 200,000 tons is now in operation
• SMS technology enables the production of electrical sheet for energy-efficient applications, for example electromobility

The commissioning of the new annealing and isolating line in Bochum is an important milestone for thyssenkrupp Steel Europe (tkSE). The electrical steel strip processing line, supplied by SMS group, enables tkSE to produce high-grade NGO steel (non-grain-oriented electrical steel strip). This product is characterized by its special magnetic properties and low core losses, which are crucial for energy-efficient motors, generators, and applications in the electromobility sector. The annealing and isolating line is designed for an annual capacity of 200,000 tons and processes electrical steel strip in widths of up to 1,350 millimeters and thicknesses of between 0.20 and 1.00 millimeters at a process speed of up to 150 meters per minute.

The strip treatment process comprises a precise heat treatment in which the cold-rolled strip is first cleaned and subsequently recrystallized. After that, a layer of insulating varnish is applied to ensure optimal electrical properties. As a result, tkSE will be able to meet the growing demand for high-performance electrical steel strip and strengthen its role as a pioneer in sustainable and energy-efficient processes and products for the future.

Technological highlights and production process
SMS group supplied the complete strip processing line from a single source: In addition to mechanical equipment, process engineering and electrical and automation systems, SMS subsidiaries supplied furnace technology from DREVER, an induction heating system for the furnace from ELOTHERM, and an automated coil transfer system from AMOVA.

The technological core of the line is the combined heat treatment and coating process. The DREVER furnace features a patented rapid heating system that attains temperatures of up to 1,100 degrees Celsius. A combination of natural gas-fired radiant tube zones, inductors from ELOTHERM, and electrically heated zones is used to precisely control the annealing process and optimize the microstructure of the electrical steel strip. For example, materials with special magnetic properties and low core losses are produced in this way. The intelligent furnace control system I-Furnace^® optimizes the production process using data-driven models that predict the material properties and allow specific adjustments to be made during production. This results in high material quality, an improved CO₂ balance, and lower production costs.

An essential element of electrical steel strip production is the advanced coating technology that is integrated in the line and used to apply a layer of insulating varnish. The technology comprises two horizontal coating systems (roll coaters), which were developed especially for electrically insulating coatings, and a flotation furnace for drying purposes. This setup ensures that the insulating varnish is applied to the strip surface in very thin, uniform layers of up to 0.5 µm without any flaws, and is dried in a contactless manner.

Technological innovations for efficient production and digital integration
The furnace rolls as well as the pay-off and tension reels in the new line are equipped with X-Pact^® Torque Drives, which transmit high torques directly and without having to use additional gear units. These compact and efficient direct drives minimize energy losses, reduce noise levels, and require minimal maintenance.

The entire plant was engineered using 3D modeling. In this way, potential risks were minimized at an early stage and a seamless integration of the new plant into the existing infrastructure was ensured. SMS’s X-Pact^® Plug and Work concept for conducting automation integration tests using the plant’s digital twin enabled final optimizations to be made before the equipment was installed. This approach allowed the facility to be put into operation within a shorter time.

The project was successfully implemented in an existing industrial environment at the tkSE site in Bochum, demonstrating SMS’s expertise in implementing complex installations within the available infrastructure during ongoing production.

With its lifecycle partnership approach, SMS offers continuous support with digital services and technical assistance to ensure maximum efficiency and availability of the plant throughout its entire lifecycle.

To increase operational efficiency, the line is equipped with an automatic coil transport system (A.C.T.^®) from AMOVA. This innovative system uses driverless transport technology to optimize coil handling and help make the production process more efficient.

“The successful commissioning of this state-of-the-art production line underlines the effective collaboration between our teams,” says Dr. Harald Espenhahn from thyssenkrupp Steel Europe. “This facility not only represents a huge step forward in our production capacities, it enables us to manufacture high-quality NGO steels that allow our customers to meet the changing demands of the market and to develop products with increased energy efficiency.”

Simone Scheidgen from SMS adds: “The collaboration with thyssenkrupp Steel Europe has once again proved to be a positive experience of collaborative partnership. The synergy between our teams has resulted in a plant that meets our shared goals of technological progress and sustainability.”

With this new production line, SMS is not only supporting thyssenkrupp Steel Europe in achieving its strategic objectives, but is also promoting the development of innovative materials that are vitally important for a sustainable future.