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• ABB secures automation and control technology order from EZDK, the largest independent steel producer in the Middle East;
• ABB Ability™ System 800xA® to enhance both the control and flexibility of industrial applications at the Ezz Steel plant;
• The distributed control system will ensure efficient operations and address any water supply issues in the steel production process.
The site is a fully integrated steelmaking facility and incorporates three direct reduction plants for producing high-quality Direct Reduced Iron (DRI), with an annual production capacity of 3.1 million tons. EZDK (ezzsteel.com) is the leading steel importer and distributor in Egypt and, since it was established in 1985, has grown to become the largest independent steel producer in the Middle East and North Africa.
ABB will provide ABB Ability™ System 800xA® distributed control system (DCS) to support improvements across eight key operational areas, including three central water treatment plants and the site’s auxiliary equipment operations. The system will help streamline control and monitoring, enabling more consistent performance and easier integration of processes across the facility. By supporting both new and existing infrastructure, the system will contribute to a more unified and responsive approach to plant operations.
Unlike traditional blast furnace methods reliant on coking coal, EZDK’s DRI production uses natural gas, offering a lower-emission pathway to steelmaking. Effective water management is essential in this process for cooling and treatments that enhance productivity and product performance, such as in the thermo-mechanical treatment (TMT) of reinforcement bars crucial for modern infrastructure. The operation of the DRI plants through ABB’s System 800xA underpins EZDK’s commitment to efficient, reliable and environmentally responsible steel production.
“The efficiency and reliability of ABB’s System 800xA is integral to our operations,” said Ahmed Farrag, Utilities Electrical Maintenance Manager, at Al Ezz Dekheila Steel Co. “Integrating the application at Ezz Steel Plant ensures supplying cooling water to the production facilities with the required quality and availability to achieve the effective steel production process.”
“Through our high-quality engineering and expertise, we are able to deliver the latest in automation and electrification for EZDK’s steelmaking facility, enabling a reliable and flexible operational environment,” said Shady Rafaat, Metals and Steel Segment Account Manager at ABB North Africa. “Covering various applications, System 800xA will help to facilitate the continuation of world class operations at the Ezz Steel plant.”
ABB will manage the supply, engineering, commissioning, and startup of its System 800xA at EZDK’s water treatment facilities. The system architecture will integrate utilities into three control hubs, enabling centralized monitoring and management while maintaining the functionality of existing systems. By enhancing operator situational awareness and decision-making through high-performance visualization tools, the platform is expected to significantly improve response times during critical steelmaking processes.
Designed with flexibility and scalability in mind, the system allows for phased upgrades and future expansion, minimizing disruption while supporting long-term operational efficiency. Ultimately, the modernized system is expected to bolster the plant’s annual capacity of 3.1 million tons of high-quality steel by improving process reliability, optimizing resource usage, and contributing to more sustainable production outcomes.
The project will be led by experts from ABB’s Process Industries Metal Segment for water treatment plants, ensuring the delivery of a high-quality, turnkey solution in alignment with ABB’s global standards.
This order is the latest success story for the ABB and EZDK partnership, following the completion of a full ABB modernization at EZDK’s flagship wire rod manufacturing facility in Alexandria in 2020.
ABB (abb.com) is a global technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. By connecting its engineering and digitalization expertise, ABB helps industries run at high performance, while becoming more efficient, productive and sustainable so they outperform. At ABB, we call this ‘Engineered to Outrun’. The company has over 140 years of history and around 110,000 employees worldwide.
ABB’s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs from supplying energy, water and materials, to producing goods and transporting them to market. With its ~20,000 employees, leading technology and service expertise, ABB Process Automation helps process, hybrid and maritime industries outrun leaner and cleaner.
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