Press Release7 Min

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

The team from thyssenkrupp Steel Europe and SMS group is pleased to start up the pioneering plant technology for the manufacture of high-grade electrical sheet.
3D model of the new annealing and insulating line for the production of non-grain-oriented (NGO) steel at thyssenkrupp Steel Europe’s Bochum site.
The team from thyssenkrupp Steel Europe and SMS group is pleased to start up the pioneering plant technology for the manufacture of high-grade electrical sheet.
3D model of the new annealing and insulating line for the production of non-grain-oriented (NGO) steel at thyssenkrupp Steel Europe’s Bochum site.
The team from thyssenkrupp Steel Europe and SMS group is pleased to start up the pioneering plant technology for the manufacture of high-grade electrical sheet.
3D model of the new annealing and insulating line for the production of non-grain-oriented (NGO) steel at thyssenkrupp Steel Europe’s Bochum site.

Mönchengladbach, 29. Jan 2025

Summary

  • 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 insulating 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 insulating 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 the mechanical equipment, process engineering, as well as electrical and automation systems, subsidiaries provided the DREVER furnace technology, ELOTHERM induction heating within the furnace, and the automated AMOVA coil transport system.

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, ELOTHERM inductors, 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 AMOVA coil transport system (A.C.T.®). 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.

 

 

SMS group is renowned worldwide for its future-oriented technologies and outstanding service for the metals industry. The company applies its 150 years of experience and its digital know-how to provide the industry continuously with innovative products and processes – even beyond its core business – and generates worldwide sales of around 3.1 billion euros. SMS is the right partner for challenging projects, and supports its customers throughout the lifecycle of their plants, enabling profitable and resource-efficient value creation chains. Paving the way for a carbon-neutral and sustainable metals industry is the company’s stated goal. As a global player with German roots, SMS takes responsibility for its more than 14,000 employees.

 

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