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Simulation · Minimal Factory · Iron and steel

Bruckhausen · rolling hot strip

A hot strip mill as a model: pusher furnace, roughing and finishing stands and coiler turn glowing slabs into coils, at the steel site in northern Duisburg.

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Real are location, terrain and structures (official NRW elevation data, OpenStreetMap). The position of the rolling mills is interpreted; quantities, processes and times are model values. With your data, the model shows your site and your processes.

At the steel site of Bruckhausen in northern Duisburg, rolling mills stand as a block model on the brownfield of a former coking plant. The pusher furnace makes the slabs glowing, roughing and finishing stands roll them thin, and at the end the coiler winds the strip into a coil. Slab trains arrive from the steelworks, coil trains leave for the customers.

Five controls steer the rolling mills: investment (one to three rolling mills), workforce, supply, quality and market. The coil stockpile grows when more is rolled than sold; when it is full, the surplus goes at a 40% discount. If the slabs fail to arrive, the plants run only in part.

Real are location, terrain and structures from official NRW elevation data and OpenStreetMap. The position of the rolling mills, quantities, processes and times are an interpretation of our own and model values; one working day lasts ten seconds. The page is for museums and exhibitions, schools and universities, industrial heritage and local history.

From raw material to product

  1. 01

    supply – slab trains from the steelworks

  2. 02

    rolling mills – glowing slabs run through the stands

  3. 03

    coil yard – takes in what is not sold

  4. 04

    dispatch – coil trains to customers

A site at work

01

A site at work

Bruckhausen: At the steel site in the north of Duisburg rolling mills rise on a brownfield: glowing slabs run through the stands and come out as coils.

Rolling mill 1

02

Rolling mill 1

Rolling mill 1 – A hot strip mill: the reheating furnace makes the slabs glow, roughing and finishing stands roll them thin, at the end the coiler winds the strip into a coil.

What is shown – why – for whom

What is shown Why For whom
Pusher furnace WhyShows how the slab becomes glowing before it is rolled. For whommuseum, teaching
Roughing and finishing stands WhyShows how the glowing slab runs through the stands and is rolled thin. For whomteaching, history of technology
Coiler with finished coil WhyShows how the strip is wound into a coil at the end. For whommuseum, exhibition
Slab trains from the steelworks and coil trains to the customers WhyShows what is delivered to the rolling mill and what leaves it. For whomteaching, industrial heritage
Coil stockpile WhyShows what happens to coils the market does not take. For whomeconomics teaching, exhibition
Shaft furnace at the edge of the rolling mills and brownfield of the former coking plant WhyShows how the site fits into the real terrain. For whomlocal history, exhibition
Five controls with output, coil stockpile and daily result WhyShows connections in operations, not operating figures. For whomeconomics teaching
Rolling mill 3

03

Rolling mill 3

Rolling mill 3 – the expansion runs along as long as people, materials and market suffice.

Five levers, one works

04

Five levers, one works

Full investment – three rolling mills: capacity for the boom, but only with enough people and materials.

Films from the model

  • Above Bruckhausen

    A flight across the whole site: low approach, Rolling mill 1, then across the works to the long shot – everything moving, with the sound of the works.

  • From raw material to product

    The works’ chain in one flight – supply (slab trains from the steelworks), rolling mills, coil yard, dispatch: station by station.

  • A working day in time-lapse

    In time-lapse working days pass in seconds: shifts at the gate, traffic on the supply and dispatch routes, the stockpile (coil yard) changing along.

  • A works grows

    Investment step by step: new rolling mills appear, the workforce grows with them, then more supply and a boom in the market.

  • Bottleneck – the works respond

    First materials run short and the plant only runs in part, then the market takes too little and the stockpile fills up – in the boom the works recover.

  • Using the software

    With the full interface: open the works, set investment and market, look at stockpile and plant – every lever acts at once.

Facilities and areas in the model

  • Rolling mills

    A hot strip mill: the reheating furnace makes the slabs glow, roughing and finishing stands roll them thin, at the end the coiler winds the strip into a coil. In the game: all 3 as expansion (interpreted).

  • Coil yard

    Whatever is made but not sold ends up here; when it is full the surplus goes at a discount, when the market wants more it is drawn down.

  • Supply

    Slab trains from the steelworks. A bigger contract costs more, the store buffers short gaps.

  • Dispatch

    Coil trains to customers. The market only takes what it needs.

  • Shaft furnace

    A tall furnace building at the edge of the rolling mills, in the model from the elevation data.

When things get tight

05

When things get tight

Coil yard filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.

Medium long shot

06

Medium long shot

Medium long shot – Rolling mill 1: glowing slabs run through the stands.

Processes in the model

From raw material to product

  1. 01supply – slab trains from the steelworks
  2. 02rolling mills – glowing slabs run through the stands
  3. 03coil yard – takes in what is not sold
  4. 04dispatch – coil trains to customers

Expansion

  1. 01raise investment by one step
  2. 02another rolling mill is built on its plot
  3. 03set the workforce to match, otherwise it only runs in part
  4. 04the market decides whether it pays – success in one number at the top

Bottleneck and recovery

  1. 01supply short – the store empties
  2. 02materials missing – the plants only run in part
  3. 03market in a slump – the stockpile grows until the fire sale
  4. 04boom – the stockpile empties, the result rises

What the model can be used for

  • Museum and exhibition

    The rolling mill explains itself on the plant: the pusher furnace makes the slab glowing, the stands roll it thin, the coiler winds the strip into a coil. Each step comes with one sentence.

    For whommuseums, visitor centres, exhibitions

  • School and university

    What happens in a hot strip mill, and what is a coil? Terms like slab, pusher furnace, roughing stand and finishing stand sit where they belong.

    For whomschools, universities, vocational training

  • Industrial heritage and local history

    The steel site in northern Duisburg stands on the real terrain, on the brownfield of a former coking plant. You see how slab trains arrive and coil trains leave for the customers.

    For whomindustrial heritage, city marketing, local history societies

  • Understanding operations

    Investment, workforce, supply, quality and market act at once on output, coil stockpile and result. It becomes visible why a further rolling mill without slabs and sales costs money.

    For whomeconomics teaching, further training

Rolling mill 1 at work

07

Rolling mill 1 at work

Rolling mill 1 at work – glowing slabs run through the stands; the machines run with the works’ utilisation.

The whole software

08

The whole software

Running the works – five levers: investment, workforce, supply, quality and market; the chain shows at once what follows.

What you can change

Controls

  • Investment: Number of rolling mills (1 to 3): more money builds more, less shuts them down; without more people they only run in part.
  • Workforce: Enough people for all rolling mills – output rises, and so does success. Too many people cost wages without more output.
  • Supply: More material arrives – the plant no longer has to wait. Levels short, normal and double; supply security costs money.
  • Quality: More quality means less scrap and fewer breakdowns but costs testing and maintenance (levels low, normal, high).
  • Market: Slump, normal or boom. In a slump more is made than sold: the stockpile grows and success drops. In a boom the market takes more: the stockpile empties and success rises.

Disruptions

  • Too few people: Workers are missing, part of the plant stands still.
  • Material missing: Supply is not enough; once the store is empty the plants only run in part (message: “Parts store empty – supply is short”).
  • Too much built: More is made than the market takes: the stockpile grows; when it is full the surplus goes at a 40 % discount (message: “Stockpile full – fire sale at a discount”).
  • Market wants more: Demand is greater than the works can make; once the stockpile is empty orders are lost (message: “Stockpile empty – orders are lost”).

What the model brings

  • 01

    The real terrain as a stage

    Rolling mills, tracks and surroundings stand on terrain from official elevation data. You show the site as it lies, not as a diagram.

  • 02

    From slab to coil

    Furnace, stands, coiler: you understand the path of the steel before you steer the rolling mill yourself.

  • 03

    Bottlenecks without damage

    The slabs fail to arrive, the plants run only in part, the coil stockpile fills up. You see where it gets tight first, and set it back.

  • 04

    For big screens and the browser

    Runs in the browser and on large projections. A working day in fast motion lasts ten seconds.

  • Bruckhausen: At the steel site in the north of Duisburg rolling mills rise on a brownfield: glowing slabs run through the stands and come out as coils.
    Bruckhausen: At the steel site in the north of Duisburg rolling mills rise on a brownfield: glowing slabs run through the stands and come out as coils.
  • Bruckhausen from the other side – the same site in the afternoon sun from the south-west, with long shadows of halls and structures.
    Bruckhausen from the other side – the same site in the afternoon sun from the south-west, with long shadows of halls and structures.
  • Medium long shot – Rolling mill 1: glowing slabs run through the stands.
    Medium long shot – Rolling mill 1: glowing slabs run through the stands.
  • Far out near Duisburg – terrain, houses and trees come from official elevation data; at the edge the world fades softly into the dark.
    Far out near Duisburg – terrain, houses and trees come from official elevation data; at the edge the world fades softly into the dark.
  • From above – Bruckhausen as a model of blocks: every cell a block, buildings and terrain from elevation data and OpenStreetMap.
    From above – Bruckhausen as a model of blocks: every cell a block, buildings and terrain from elevation data and OpenStreetMap.
  • All around Duisburg: streets, tracks and water from OpenStreetMap, houses and trees from the elevation data – only the plant in the middle is built specially.
    All around Duisburg: streets, tracks and water from OpenStreetMap, houses and trees from the elevation data – only the plant in the middle is built specially.
  • At eye level – Rolling mill 1, as close as from the fence.
    At eye level – Rolling mill 1, as close as from the fence.
  • Rolling mill 1 – A hot strip mill: the reheating furnace makes the slabs glow, roughing and finishing stands roll them thin, at the end the coiler winds the strip into a coil.
    Rolling mill 1 – A hot strip mill: the reheating furnace makes the slabs glow, roughing and finishing stands roll them thin, at the end the coiler winds the strip into a coil.
  • Rolling mill 2 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
    Rolling mill 2 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
  • Rolling mill 3 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
    Rolling mill 3 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
  • Coil yard – whatever is made but not sold ends up here; when there is no room left, the surplus goes at a discount.
    Coil yard – whatever is made but not sold ends up here; when there is no room left, the surplus goes at a discount.
  • Supply – slab trains from the steelworks: a bigger contract costs more, the store buffers short gaps.
    Supply – slab trains from the steelworks: a bigger contract costs more, the store buffers short gaps.
  • Shaft furnace – a tall furnace building at the edge of the rolling mills, in the model from the elevation data.
    Shaft furnace – a tall furnace building at the edge of the rolling mills, in the model from the elevation data.
  • Rolling mill 1 close up – glowing slabs run through the stands.
    Rolling mill 1 close up – glowing slabs run through the stands.
  • Coil yard close up – coil beside coil when the trains do not collect everything.
    Coil yard close up – coil beside coil when the trains do not collect everything.
  • Supply in full swing – slab trains from the steelworks; the bigger the contract, the more is on the move.
    Supply in full swing – slab trains from the steelworks; the bigger the contract, the more is on the move.
  • Rolling mill 1 at work – glowing slabs run through the stands; the machines run with the works’ utilisation.
    Rolling mill 1 at work – glowing slabs run through the stands; the machines run with the works’ utilisation.
  • Rolling mill 3 – the expansion runs along as long as people, materials and market suffice.
    Rolling mill 3 – the expansion runs along as long as people, materials and market suffice.
  • Coil yard in day-to-day operation – coil beside coil when the trains do not collect everything.
    Coil yard in day-to-day operation – coil beside coil when the trains do not collect everything.
  • Dispatch – coil trains to customers; in a boom more is on the move, in a slump less.
    Dispatch – coil trains to customers; in a boom more is on the move, in a slump less.
  • At the gate – the shifts arrive here, paths lead to the plants, the workshop and the break area.
    At the gate – the shifts arrive here, paths lead to the plants, the workshop and the break area.
  • Full steam – all three rolling mills running, the market booming: supply and dispatch routes are at their busiest.
    Full steam – all three rolling mills running, the market booming: supply and dispatch routes are at their busiest.
  • Small investment – only Rolling mill 1 runs, the other plots lie ready as marked foundations.
    Small investment – only Rolling mill 1 runs, the other plots lie ready as marked foundations.
  • Full investment – three rolling mills: capacity for the boom, but only with enough people and materials.
    Full investment – three rolling mills: capacity for the boom, but only with enough people and materials.
  • Every facility labelled – rolling mill 1 to 3, coil yard, supplier and market; at the top the working day with the daily output, on the right success in one number.
    Every facility labelled – rolling mill 1 to 3, coil yard, supplier and market; at the top the working day with the daily output, on the right success in one number.
  • Rolling mill 1 labelled – name and number right in the picture.
    Rolling mill 1 labelled – name and number right in the picture.
  • Success in one number – 100 means it cannot get better in this market; below it the result per day, at the top the output per working day.
    Success in one number – 100 means it cannot get better in this market; below it the result per day, at the top the output per working day.
  • Where a lever acts, a ring lights up – here after a change in the market: coil yard.
    Where a lever acts, a ring lights up – here after a change in the market: coil yard.
  • Materials missing – supply is short, the store is empty: the rolling mills only run in part, the supply route is quiet.
    Materials missing – supply is short, the store is empty: the rolling mills only run in part, the supply route is quiet.
  • Coil yard filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.
    Coil yard filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.
  • Boom – the market takes more than is being made: the stockpile empties, the dispatch route is busy.
    Boom – the market takes more than is being made: the stockpile empties, the dispatch route is busy.
  • The whole software – at the top the working day with clock and output, on the right success in one number, below the tiles for works and facilities.
    The whole software – at the top the working day with clock and output, on the right success in one number, below the tiles for works and facilities.
  • Running the works – five levers: investment, workforce, supply, quality and market; the chain shows at once what follows.
    Running the works – five levers: investment, workforce, supply, quality and market; the chain shows at once what follows.
  • One lever, visible at once – market set to slump: the status line explains the bottleneck, the stockpile grows, the daily result drops.
    One lever, visible at once – market set to slump: the status line explains the bottleneck, the stockpile grows, the daily result drops.
  • Facility card – rolling mill: in operation, workforce and utilisation, plus one sentence on what happens there.
    Facility card – rolling mill: in operation, workforce and utilisation, plus one sentence on what happens there.
  • Stockpile card – coil yard: stock, space used and growth per day.
    Stockpile card – coil yard: stock, space used and growth per day.
  • Supplier card – delivery per day, store and material costs per day.
    Supplier card – delivery per day, store and material costs per day.
  • Market card – demand, sold and turnover per day.
    Market card – demand, sold and turnover per day.
  • Bottleneck in orange – supply is not enough: the line at the top and the works status say in one sentence what is missing.
    Bottleneck in orange – supply is not enough: the line at the top and the works status say in one sentence what is missing.
  • The menu – overview and plant, cutaway, restart, demo, sound and other sites, below the controls for mouse, touch and keyboard.
    The menu – overview and plant, cutaway, restart, demo, sound and other sites, below the controls for mouse, touch and keyboard.
  • Sixteen real sites – blast furnaces, collieries, car plants, harbours and a shipyard, each where it really stands.
    Sixteen real sites – blast furnaces, collieries, car plants, harbours and a shipyard, each where it really stands.

Your site as a model

Would you like to show your plant, your museum or your industrial site like this? Write to us or call. We will send you the password for starting it on request.

Start with password

Request the password if you are interested →

Ask about this

Minimal Factory: Bruckhausen · Warmband walzen

What you enter goes to this site alone and serves only to answer you.

Basis and limits

Real are the location, terrain and buildings in Duisburg (official NRW elevation data and OpenStreetMap). The plant in the middle is our own simplified interpretation: quantities, processes, times and prices are model assumptions; the economy runs in time-lapse (10 seconds are one working day). Not a simulation of real operations and no cooperation with the site.

Public sources the model is based on:

  • Wikipedia (German), article on the site: Bruckhausen, Warmbreitband
  • Geobasis NRW: digital surface and terrain models DOM1/DGM1 (Data licence Germany – Zero – 2.0)
  • OpenStreetMap contributors (ODbL 1.0): streets, tracks, water, land use

More places in the model

← Minimal Factory

Real are location, terrain and structures (official NRW elevation data, OpenStreetMap). The position of the rolling mills is interpreted; quantities, processes and times are model values. With your data, the model shows your site and your processes.