At the center for steel - HKM Hüttenwerke Krupp Mannesmann GmbH

Steel:
That’s our
business.

The HKM steelworks 2
At the center for steel
Coking plant 4
A basic ingredient
Burden preparation 6
The mixture counts
Blast furnace plant 8
Some like it hot
The melting shop 10
In the fluid state
The casting shop 12
Vital strands
Mineral products and Technical Services 14
All-round know-how
Staff and quality 16
The guarantors of success
Industrial safety/Health and environmental protection 18
Responsibility in action
Purchasing/Controlling/IT 20
Getting everything right
At a glance 22
A unique range
2
At the center
for steel
Hüttenwerke Krupp
Mannesmann’s plant is
located in Duisburg, the
steelmaking heart of
Germany's Ruhr industrial
region. With its workforce
of 3480, the company produces
significantly more
than five million tonnes
of steel here each year,
The HKM steelworks
equating to approximately
12 percent of all crude steel
produced in Germany.
Since its formation in 1990
by Krupp Stahl AG and
Mannesmannröhren-Werke
AG, HKM has increasingly
specialized in the
production of slabs for

flat products and in steel
rounds for tube-making.
The range produced thus
corresponds predominantly
to the needs of the
present-day shareholders,
Thyssen Krupp Stahl AG
(50 %), Mannesmannröhren-Werke
AG (20 %)
and Vallourec & Mannesmann
Tubes SA (30 %).
HKM’s range of supplies
and services includes slabs
with widths of more than
two meters and lengths of
up to twelve meters. Steel
rounds are produced to all
widely used German and
international standards
with diameters of between
180 and 406 millimeters
and lengths of up to 14
meters. These high-quality
steel grades, with their
alloying element contents
of up to 5 percent, meet
the most stringent quality
specifications, to permit
their use, for example, in
the automotive industry.
The Huckingen location
in Duisburg, and therefore
all facilities and plant sections,
are certificated to
the international DIN ISO
9001 quality standard,
which also extends to
research and development.
Working and industrial
safety, environmental
protection and quality
are allocated equal priority
within an integrated overall
management system.
3

4
Coking plant
A basic
ingredient
Coal preparation
Bunkers 12 x 200 t
Double-cross mixer 700 t/h
Hammer mill 2 x 100 t/h + 1700 t/h
Coal storage towers 1 x 3000 t / 1 x 500 t
Coal stockyard (capacity) 50,000 t
Coal oil spraying max. 40 t/d
Coking plant
Year of construction 1984
Cross regenerative type coke ovens 70 chambers
Chamber dimensions 18.00 x 7.85 x 0.55 m
Effective chamber capacity 70 m 3
Coke mass, dry 42 t/chamber
Production capacity 1.08 million t/a
Byproducts plant
Gas treatment 60,000 m 3 /h
Annual tar/benzol production 35,000 t / 11,000 t
Sulfuric acid 8,500 t

Reducing agents are
needed to bring iron literally
to the boil. Alongside
fuel oil, HKM mainly uses
coke to supply its blast
furnaces – up to 1.5 million
tonnes each year. The coke
is needed for the production
of hot metal, where it
is used for reduction of
the iron ores to metallic
iron and supplies the heat
necessary for the blastfurnace
process. The use of
high-quality metallurgical
coke is an important precondition,
since properties
such as mechanical
strength and load carrying
capacity at high temperatures
are decisive factors
for the process.
HKM produces the major
part of the coke required
itself, in the world’s largest
single-unit coke oven battery.
Coal is distilled in this
high-capacity battery with
the exclusion of air by
means of external input
of heat. Modern environmental
safety provisions
ensure practically emissionfree
coke oven operation.
After complete carbonization,
the hot coke
pushed from the oven
chambers requires cooling.
HKM has developed for
this operation a wetquenching
process which
achieves coke moisture
contents of less than two
percent in continuous
operation.
In order to attain consistent
high quality, HKM’s
own coke is blended in
a screening plant with
bought-in coke and the
mixture is stabilized and
screened in a fallingimpact
process. The coke
breeze is used in the sinter
plant, while the lump fraction
is fed into the blast
furnace.
The process and production
control systems of
this 1984 coking plant
were long ago converted
to more modern methods.
The same applies to the
byproducts plant for
cleaning of the coke-oven
gas, which assure attainment
on the purity of lowpressure
coke oven gas.
5

Harbour
Quayage 900 m
Surface area 45,000 m 2
Cranes 4
Capacity 11 million t/a
Harbour and blast-furnace stockyard
Capacity 300,000 t
Combined stacker / reclaimer 1 x 1,200 t/h
Blending beds
Number 3
Capacity 3 x 150,000 t
Stacker 1 x 1,500 t/h
Reclaimer 2 x 1,200 t/h
Sinter plant
Capacity 6.0 million t/a
Suction area 420 m 2
Main blower 1 x 730,000 Nm 3 /h
Depression 180 mbar
Ignition furnace 3.1 m; 50 burners
Sinter cooling Two annular shaft coolers
Waste gas dedusting Electrostatic precipitator (EP)/
absorption of dioxines/furanes with lignite coke injection
Waste gas recycling system LEEP
Room dedusting EP
6
The mixture
counts
HKM’s modern and highly
efficient blast furnace
facilities make great demands
on the feed materials
used. In the case of
coke, supplies are assured
by the on-site coking plant,
while the sinter plant performs
a similar function
for the lumpening by thermal
conglomeration of
fines resulting from ore
dressing, coke breeze and
fluxes as well as remnants
of the iron and steel making
process. Sintering itself
is performed with a moistened,
homogenized, fine-
Burden preparation
particled starting mixture.
This is dumped on a conveyor
grate and then ignited
from above. The carbon
contained in the mixture
combusts with the air
drawn through the grate,
with the result that the ore
grains are thermally
agglomerated. The resultant
product is exceedingly
permeable to gas and
capable of reduction.
After screening, it is ideally
suitable for direct burdening
into the blast furnace.

The sintering plant is
equipped with a special
waste gas recycling LEEP
system (Low Emission and
Energy optimised sintering
Process) developed at HKM
to minimize energy input
and emissions.
Supply of the ores and coal
products needed for hot
metal production at HKM
constitutes a great logistical
challenge – in view,
not least of all, of the fact
that they are obtained
from all regions of the
world, and primarily from
Brazil, Canada and Australia.
Following mining, the
ores are transported in
enormous ore-carriers
with capacities as high
as 350,000 tonnes to the
harbour at Rotterdam,
where HKM partially owns
a terminal. Here the cargo
is transferred to barges,
each capable of transporting
some 2,800 tonnes of
ore. These are assembled
units of four barges each,
making it possible to
transport around 11,000
tonnes of ore to HKM’s
plant harbour on the
Rhine in a single movement.
Two ore-handling gantries
and two dock-cranes are
available for transfer of the
cargoes on the 900 meter
long quay of the harbour
basin. This facility is capable
of handling some ten
million tonnes of material
annually. Of this figure,
around nine million tonnes
is accounted for by incoming
supplies (fine ores,
lump ores, pellets, etc.).
Some one million tonnes
of cargo leaves the harbour
each year, including
both semi-finished, slag,
and tubing products, and
also other finished products
of the companies
located on the iron and
steel plant site.
7

Blast furnace AB
Year of construction 1973 1981
Last relining 1998 2000
Hearth diameter 10.3 m 11.0 m
Effective capacity 2449 m 3 2824 m 3
Charging equipment Double bell with
8
moveable armour Rotating chute
Top pressure 2.8 bar 2.8 bar
Blast temperature 1270° C 1350° C
Tuyeres 30 30
Tapping holes 2 2
Capacity 2.5 million t/a 2.7 million t/a
Hot blast stoves
Number 3 3
Dedusting
Top gas dedusting Ring slot washer Radial-flow washer
Casting-house dedusting EP EP
Slag removal
Type Granulation Slag pen
Blast furnace plant
Some like
it hot

Liquid iron temperatures
of about 1,500 degrees –
hot metal production at
HKM leaves scarcely anybody
cold.
And that’s just the way it
should be – the blast furnace
plant where such
hellish heat is generated
is one of the highlights of
an integrated iron and
steel plant.
The main reason for the
infernal scenario: Iron only
occurs naturally in the
form of chemical combinations,
predominantly with
oxygen (iron oxide).
In the blast furnaces, with
the aid of coke and hot
blast the bond between
the iron and oxygen contained
in lump ore, pellets
and sinter is broken down.
At the same time, the iron
is freed from existing
gangue (impurities) by
melting.
The reactions taking place
during the reduction of
iron oxide to iron are
complex. The engineering
know-how is therefore
even more important and
valuable. Many years of
experience, combined with
ultra-modern technology,
make it possible to operate
and control the reduction
process with the very
greatest efficiency while
at the same time keeping
the energy inputs to a
minimum.
Great importance is also
attached to the environmental
safety provisions
applied. The dust-laden
gases released at tapping
of the hot metal from the
blast furnaces are routed
through appropriate systems
for cleaning.
9

The converter plant
Hot metal desulfurization
Stands 2, immersion-lance systems (tri-injection)
Converters
Blowing stands 2
Change vessels 3
Vessel capacity 280 t
Specific volume 0.59 m 3 /t
Oxygen blowing rate 2.6 m 3 /t x min.
Capacity 6.3 million t/a
Bottom stirrers 10
Medium Argon/nitrogen
Blowing rate 0.05 m 3 /t x min.
Slag retaining device “Mannesmann slag-stopper”
Dedusting
Primary dedusting Wet electric honeycomb filter
Secondary dedusting Bag filter (2.4 million m 3 /h)
Secondary metallurgy
Facilities
Treatment stands 7
of which with vacuum tank degassing (VD) 2 x 2 (1 pump system each)
Alloying systems 3
Stirring Injection lance / bottom stirring
Wire feeder CaSi, CaFe and others
Desulfurizing agent Synthetic slag, MPE process
Ladles
Number 18
Lining Basic
10
Hot metal and scrap are
the basis of steel production.
Pure oxygen is needed
for conversion. Injection of
oxygen is the business of
the converter shop, special
treatments that of secondary
metallurgy.
The converter plant
The venue is the steelplant,
designed for production
of up to six million
tonnes of high-quality
steel annually. Liquid hot
metal and scrap are refined
via the injection of
oxygen, with lime added
as a slag-generating agent,
in refractory-lined steel
vessels known as converters.
A further effect of
this process is the diminution
of so-called “tramp”
elements in the feed
materials such as carbon,
silicon, manganese,
phosphorus and sulfur.

The melting shop
In the fluid
state
Precise adjustment of steel
composition is achieved
at HKM even with direct
tapping rates of more than
80 percent. The precondition
for this: Comprehensive
metallurgical processing
know-how, dynamic
process control and a
computer assisted system
for input of alloying elements.
In addition, HKM’s
modern change-vessel
converter system permits
the replacement of steelmaking
vessels in the
shortest possible time.
Ultra-high availability is
thus guaranteed in the
converter plant. The high
logistical challenges presented
by the supply of
hot metal and scrap, in
addition to heat and ladle
scheduling, have also long
been controlled by means
of integrated computer
systems at HKM.
Secondary metallurgy
Additional treatment of
the steel is necessary in
order to produce grades
with a particularly high
oxide cleanness and low
nitrogen, hydrogen and
sulfur contents. Both
this, and achievement
of ultra-precise alloying
specifications, are the
function of secondary
metallurgy.
Corresponding treatment
facilities have been in
place since as early as 1977,
and have been continuously
modernized.
Two ladle tank degassing
units and three argon
stirring stands nowadays
provide an optimum
secondary metal-lurgical
processing line at HKM,
further supported with
computer-assisted
methods for temperature
control and vacuum treatment.
11

Slab Caster I Caster II Caster III
Year of construction 2001 1989 2000
Type Oval-bow caster Oval-bow caster Vertical bending
12
(Twin) caster
Number of strands 4 2 2
Width 325 to 670 mm 800 to 2100 mm 850 to 2100 mm
Thickness 260 mm 260 mm 260 mm
Mould length 700 mm 700 mm 900 mm
Vertical section 3 m
Casting radii 7 bending pts.
Initial radius 5 m Initial radius 5 m Main radius 9.2 m
6 straightening pts. 6 straightening pts. 7 straightening pts.
Supported length
Length up to
27.7 m 27.7 m 36.5 m
flame cutting machine 30 m 30 m 40 m
Max. slab length 12 m 12 m 10 m
Casting speed 0.5 to 1.0 m/min. 0.8 to 1.0 m/min. 0.8 to 1.5 m/min.
Capacity 0.7 million t/a 1.8 million t/a 3.0 million t/a
Round Caster I Caster II
Year of installation 1982 1984
Type Bow caster Bow caster
Number of strands 6 5
Strand diameter 180 to 240 mm 180 to 406 mm
Casting radii
Length up to
10.5/19.5 m 10.5/13.5/18.0/30.5 m
flame cutting machine 31.1 m 36.5 m
Product length 10 to 14 m 8 to 12 m
Casting speed max. 3.5 m/min. max. 3.2 m/min.
Capacity 1.20 million t/a 0.96 million t/a
The casting shop
Vital
strands
HKM slabs and tube-making
rounds have to fulfill
ultra-high specifications.
They are used, ultimately,
for high-quality steels for
automotive panelling and
oil-field tubulars, among
many other applications.
For this reason, the liquid
steel is cast at HKM only
using the modern continuous-casting
process. This
makes it possible to guarantee
uniform solidification
and optimum structure in
the slabs and tube-making
rounds.
Slab casters
In late 2000, HKM again
set vital signals, following
its previous decisive involvement
in the development
of the process for
casting of liquid steel to
create a continuous strand
with the world’s first bowtype
continuous caster in
around 1964. One of the
world’s most modern slab
casters has now been installed,
after a construction
period of only fifteen
months. The capacity of
the new machine now enables
the BOF steelplant to
produce 400,000 tonnes
of slabs each month.

The 3 m long vertical section
and large casting radius
provide the preconditions
for outstanding
product cleanness. In addition,
the tight roll pitch
and a dynamic spray
cooling water control system
also guarantee good
internal and surface quality.
Furthermore, Soft Re-
duction of the continuouscast
slabs promotes the
formation of an optimum
center zone. This is implemented
by means of socalled
Cyberlink segments
which automatically detect
the still liquid center
of the slab and are in use
here for the first time
anywhere in the world.
Additionally, the slab
caster 1 was remodelled
obtaining a twin slab
casting machine.
The blooms produced by
this route are used as
input material for a
medium strip rolling mill.
Round casters
Two continuous casting
machines are available at
HKM for the production
of steel rounds. It is necessary,
in view of the given
tapping weights of 280
tonnes, to achieve high
casting speeds, particularly
for continuous casting of
small cross-sections.
HKM’s many years of experience
have resulted in
successful application of
this process even where
the quality requirements
for the semi-finished product
are at their highest.
The rounds thus meet all
the conditions necessary
for production of alloyed
boiler tubes, high strength
oilfield tubulars and forging
grades of all dimensions.
13

All-round
know-how
14
Mineral products and
Technical Services

The perception of potentials
is one thing, their exploitation
another thing
completely. Not at HKM,
however. Here, existing
potentials have been recognized,
utilized and consistently
expanded both
in the field of mineral
products and in the
restructuring of technical
services.
Mineral products
Around two million tonnes
of mineral products are
yielded each year at HKM,
in addition to coke, sinter,
hot metal, crude steel and
continuously cast semifinished
product. Some
80 percent is used in road
and water-system construction,
and also in the
cement industry, while the
rest is used in both internal
and external recycling
processes.
With the complete utilization
of these products,
HKM makes a significant
contribution to the conservation
of resources and
energy. This is achieved by
means of systematic control
of mineral product
quality, both within the
metallurgical processing
stages and on the route to
preparation processes in
the context of modern
quality assurance systems.
Technical Services
The efficiency of a production
company depends on
the further refinement,
replacement, availability,
dependability and safety
of existing plant and systems.
At HKM, the Plant
Engineering and Production
departments are responsible
for these tasks,
with their own maintenance
services. They receive
support, inter alia, from
the restructured Central
Workshops, which now
perform a large scope of
services previously contracted
outside the company,
thus saving expenditure
and efficiently utilizing
existing staff
potentials. The central
focus here is on consistent
orientation around products
and markets. This
is achieved by means of
segmentation into fields
of series work for continuous
casting, Large-scale
Iron and Steelplant Work,
and Urgent Iron and
Steelplant Work. Each individual
sector is responsible
in this context for the
entire range of work, including
work preparation;
within the segments, individual
work-groups are
responsible for performance
of each job. The
benefits of restructuring:
Short transport routes,
fewer interfaces, less
temporary storage – in
short, more efficient and
competitive provision of
services. In addition,
Technical Services also
maintain infrastructural
facilities such as the
energy, fluids and communications
networks, and
the around five hundred
buildings on the HKM site.
15

16
The guarantors
of success
No company succeeds on
its buildings and equipment
alone – people are
behind every product and
every service. At HKM, the
company’s 3480 staff are
its assurance of success.
And Quality is a far from
unknown word to them.
Staff
Qualification, motivation,
creativity and enthusiasm
are the foundations of our
staff’s performance. In addition,
a climate of mutual
trust creates the basis
Staff and quality
for identification with
the company, for teamoriented
work and for the
assumption of responsibility.
HKM nurtures this
commitment by promoting
systematic staff development
and continuous
further training and qualification
for each individual.
Particular importance attaches
in this context to
the training center, which
utilizes the very latest
discoveries and methods
to impart key capabilities

and qualifications. And
not only in the context of
initial occupational training,
but also of further
training. Thanks to this,
HKM is generally able to
meet demands for new
technical and managerial
staff from within the company.
The development
and furtherance of staff is
just a financial burden,
however – it also produces
tangible benefits. At HKM,
suggestions for improvements
to production procedures
and operations,
technical equipment and
industrial safety have
already produced cost-
savings measurable in
millions of Euro. And
worthwhile rewards for
the suggestion donors
in the framework of the
company’s improvement
suggestion system.
Quality with system
The commitment of HKM’s
staff to potential improvements
is a direct benefit
for the company’s customers.
Continuous improvement
of processes
and simultaneous reduction
of costs enables HKM
to provide its customers
with effective benefits
and therefore with significant
advantages vis-à-vis
the competition. And –
because quality is more
than high–value products
and services – HKM’s Quality
Management System
covers not only costs, deadline-keeping
and service
provision. Instead, it constitutes
the organizational
framework for the promo-
tion of product, process
and corporate quality, and
extends equally to all procedures,
processes and
members of staff. A particular
emphasis in this
context is always error
avoidance.
HKM is certificated as a
company to the international
DIN EN ISO 9001
quality standard.
17

Responsibility
in action
18
Industrial safety/Health and
environmental protection

There is absolutely no
reason why ecological,
social and economic interests
should contradict
each other. Responsible
thinking and action always
includes both economic,
ecological and social aspects.
All three dimensions
are taken into account and
acted upon at HKM.
Safety and health
At HKM, Safety at Work
and staff health have the
same priority as all other
corporate objectives. They
are formulated as independent
focuses in the
Corporate Guidelines.
“Zero accidents” is one of
the most important targets.
Staff are actively involved
in efforts to avoid
accidents and health
hazards on the basis of a
guiding safety code; they
also contribute to adherence
to the necessary
safety provisions and rules.
In addition, specialized
safety officers and company
doctors, assisted by
honorary safety representatives,
ensure safe equipping
and design of places
of work and working procedures
and, in addition,
promote safety awareness
and safe behavior. All this
is complemented by systematic
provisions and
courses for the promotion
of staff health. Highly
qualified rescue staff are
available within the
Industrial Medicine and
Works Fire Brigade teams
to copy with the few emergencies
which can never
be entirely excluded.
Environmental protection
Environmental safety has a
long tradition at HKM.
Significant achievements
and technical advances
have been made at
Huckingen to permit reductions
in particulates
emissions, noise, water requirements
and energy
consumption. And another
success for this strategy:
All the dust and sludge re-
sulting from air and water
cleaning processes are
100 percent recycled to
usable materials in special
recycling processes. HKM is
continuing this trend and
has invested a two-digit
million amount for the
construction of a new biological
waste-water treatment
plant for the coking
plant alone. It is now possible
to process some
80 cubic meters of wastewater
here per hour. A
further investment has
been the construction of
a plant for preparation
of commercial iron oxide.
This is used for the collection
of the 200,000 tonne
annual production of
dust from filter systems
and their preparation in
accordance with the needs
of the user departments
and companies. In order to
ensure further continuous
improvement of environmental
protection, HKM is
setting up an Environmental
Management
System (EMAS) oriented
around the international
DIN EN ISO 14001 environ-
mental standard and the
EC environmental audit
ordinance. In this context,
each individual member of
staff is also required to
include environmentally
safe behavior as a mandatory
component of his or
her work.
19

Getting
everything right
20
Purchasing/
Controlling/IT
An enormous number of individual
“cogs” are necessary
to enable an entity as
complex as HKM to run
smoothly and efficiently.
And it is not always the biggest
wheels or departments
which are the most important.Without
purchasing,
for example, or without
Cost Controlling, or without
modern information technology,
only one thing could
happen at HKM – nothing!
Purchasing
The Materials department
is responsible for the obtainment
of all goods and
services necessary for the
production process. The
department acts on fixed
principles:Whether it’s a
question of German coking
coal for HKM’s own coking
plant, foreign iron ores,
lime additives or scrap –
quality, price and assuredness
of supply are always

decisive. In addition, Materials
is also responsible
for the supply of raw materials
and for purchasing
and correct storage of the
various auxiliary and operating
utilities, and also
of spare and replacement
components. The department
is also concerned
with the obtainment
of complete plant units,
such as blast furnaces,
continuous casters and
machine tools.
Cost controlling
Trust is good – but cost
controlling makes everything
better. On the basis
of this motto, this department
provides well-founded
real-time information
for control of company
processes and for the
achievement of optimum
economic results. An integrated
cost-planning and
steering system, combined
with a permanent, in-process
cost monitoring function,
provide the guarantee
of the achievement of the
corporate targets of quality
and cost leadership.
Information technology
The digital age long ago
arrived at HKM. The complexity
of the measuring,
monitoring and automation
equipment installed
in a modern blast furnace,
for example, is of a value
equal to that of a complete
Boeing 757 aircraft. And
the “rest of the plant” is in
no way inferior. All departments
and divisions
are networked with one
another, and production is
operated and monitored
on a largely computerassisted
basis. Commercial
departments, Human
Resources and the technical
departments employ
the standard SAP software,
while the use of international
standards such as
UNIX, for example, is a
matter of course for dataprocessing
platforms.
21

A unique
range
22
At a glance
On any view at all, HKM
has got a lot to offer. Our
range of products includes
semi-finished rounds for
tube-making and long
forged product, semifinished
slab material for
hot and cold-rolled strip,
and plate as the starting
material for welded tubes.
In addition, we can also
supply coal derivatives,
construction materials
derived from iron and steel
plant slags and a range
sources of ferrous
materials.
Continuous cast rounds
Dimensions: dia. 180 to
406 millimeter.
Length depending on
format: Length multiples,
7 to 11.3 or 14.2 meter; fixed
length from 0.8 meter.
Steel grades: to all German
and foreign standards.
Continuous cast slabs
Dimensions: 260 x 800
to 2100 mm and
260 x 325 to 670 mm.
Length: max. 12 m
Individual weight:
max. 40 tonnes
Grades: to all German
and foreign standards.
Coal derivatives
Crude benzene
Raw tar
Sulfuric acid according
Metallurgical slags
Blast furnace coarse slag
Granulated slag
Steel plant slags

Crude steel capacity
Slabs 4.8 million t/a
Rounds 2.2 million t/a
Capacity for shipment 6.0 million t/a
Salient economic data (2001)
Turnover 1.2 billion €
Paid-up capital 102 million €
Assets 349 million €
Balance sheet total 598 million €
Staff (2001.12.31) 3556
The company
Legal form GmbH (= Limited Liability Company)
Start of commercial activity 01.01.1990
Shareholders
Thyssen Krupp Stahl AG 50%
Vallourec & Mannesmann Tubes SA 30%
Mannesmannröhren-Werke AG 20%
23

Hüttenwerke
Krupp Mannesmann GmbH
P.O. Box 25 11 24 · 47251 Duisburg · Germany
Ehinger Strasse 200 · 47259 Duisburg · Germany
Telephone (49) (0) 203 999 – 01
Telefax (49) (0) 203 999 – 44 11
E-mail post@hkm.de
Internet www.hkm.de
HKM 05/2002