Al Ezz Dekheila Steel Company (EZDK), an Egypt-based company engaged in the manufacture and production of steel in different types and forms, has approved the completion of a full modernisation at its flagship wire rod manufacturing facility in Alexandria, Egypt completed by ABB, a leading global technology company.

The ABB project, which was completed in record two weeks, was commissioned to achieve rated speed and optimum productivity for all sizes rolled. Commissioning of the project included a complete overhaul of the legacy ABB automation and control systems including engineering, design and fabrication of a new level-1 automation technologies solution, based on the latest ABB Ability System 800xA, together with other networking systems and new DCS800 drives.

In addition, ABB commissioned DSC800-R01/R02 rebuild kits and DSC800-R00 upgrade kit for 19 DC stands drives and provided the latest ACS880 drives for the mill’s Stelmore Conveyor application, along with interfacing with existing LCI Tyrac drives.

ABB’s latest Ability System 800xA in use

EZDK, which is established as the largest independent producer of steel in the Middle East and North Africa (Mena) region, worked with the ABB team on the hot trial stage and oversaw all integration and testing, subsequently awarding the commissioning engineers certificates of appreciation for the quick turnaround time.

“We were very impressed by the technical expertise and execution skills that the ABB Metals team displayed throughout this project, and we are already experiencing efficiency improvements thanks to this investment,” said Abd El-Moneim Sewaif, Director for EZDK’s long steel division.

The project scope also included a new mobile application for level-2 collaborative production management system – ABB Ability Manufacturing Operations Management for metals – including complete tracking from furnace charging area to C hook conveyor. Commissioning of the level-2 system started in January 2020 and has now achieved stability, despite having been carried out remotely.

“Our engineers took on various challenges in completing this complex modernisation project in record time, including replacing IOs, upgrading drives, and installing a new automation platform,” said Nilabja Ash, Global Product Manager for long product rolling mills at ABB. “These efforts have resulted in a high-quality solution that has already realised productivity benefits and cost efficiencies for a highly-valued customer,” he added.

“Providing 24/7/365 access to the production management system dashboards from any mobile device, makes it even easier for customers to visualise their processes and utilise the information provided to further optimise operations,” said Ash.

Founded more than 34 years ago, EZDK is one of the largest manufacturers of metal and flat steel products in the Mena region. From its facility in Alexandria, EDZK produces an impressive 2 million tonnes of long and 1 million tonnes of flat steel products, including reinforcing bars, steel rolling mills, rolling wire and rolling steel plates. EZDK is majority-owned by Al Ezz Steel SAE, which supplies steel products to customers in the United States, Canada, Europe and China.

The company’s direct subsidiaries include Al Ezz Steel Sheet Manufacturing Company SAE, which focuses on the production of coil and rolled flat steel strips, and Steel Company for Industry, Trade and Contracting Company (Contrasteel) SAE, which is focused on the manufacture and trade in all types of metal and metal products. The company also holds shares indirectly in Egypt Company for the manufacture of pipes supplies and Casting SAE, which is engaged in manufacturing pipe supplies and construction supplies, as well as mechanical equipments.

ABB is one of the leading partners and suppliers to the metals industry, offering a complete range of products, services and end-to-end solutions that improve productivity, quality, safety and cost-efficiency in iron, steel, aluminium and other metals production processes. With over a century of experience, ABB’s offerings are tailored and highly process-specific, serving the entire industry from material yard and primary manufacturing to casting, rolling and processing lines. Across the whole metals value chain ABB demonstrates a commitment to optimising operations with high performance products and digital solutions.

ABB is a leading global technology company that energises the transformation of society and industry to achieve a more productive, sustainable future. By connecting software to its electrification, robotics, automation and motion portfolio, ABB pushes the boundaries of technology to drive performance to new levels.