ABB completes modernization for Egyptian steelmaker, with commissioning achieved in record time

New process automation and control solution at EZDK's wire rod mill in Alexandria delivers improved productivity and system diagnostics, with increased uptime

Al Ezz Dekheila Steel Company (EZDK) has approved the completion of a full ABB modernization at its flagship wire rod manufacturing facility in Alexandria, Egypt, with commissioning to achieve rated speed and optimum productivity for all sizes rolled finalized in a record two weeks.

Legacy ABB automation and control systems were completely overhauled with the project 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.

EZDK, which is established as the largest independent producer of steel in the Middle East and North Africa 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 modernization 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 realized productivity benefits and cost efficiencies for a highly-valued customer.”

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

Al Ezz Dekheila Steel Company Alexandria S.A.E. (EZDK), founded more than 34 years ago, is one of the largest manufacturers of metal and flat steel products in the Middle East and North Africa. From its facility in Alexandria, EDZK produces an impressive 2 million tons of long and 1 million tons 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.

ABB is a trusted partner and leading supplier 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 expertly 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 optimizing operations with high performance products and digital solutions.

ABB (ABBN: SIX Swiss Ex) is a leading global technology company that energizes 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. With a history of excellence stretching back more than 130 years, ABB’s success is driven by about 110,000 talented employees in over 100 countries.


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