El Marakby Steel Sets New Standards with SMS Minimill Upgrade
El Marakby Steel, one of Egypt's foremost manufacturers of deformed bars and wire rod, has taken another crucial step in boosting its production capacity and staying ahead of market demands. This new phase of modernization is in collaboration with the renowned SMS Group, which has been an established partner since 2013. The planned upgrades will lead to a 10% increase in annual output, enhancing the efficiency of its minimill at the 6th of October City site.
Strategic Evaluation and Future-Proofing
In early 2023, SMS assessed El Marakby Steel’s existing melt shop to pinpoint areas for improvement. The aim was to optimize capacity and reduce costs, ensuring the plant can meet evolving industry demands. With the results of this evaluation, El Marakby Steel was able to implement significant upgrades that will enhance its overall productivity and keep it competitive in a fast-evolving market.
Key Upgrades to Enhance Performance
The 2024 modernization project focused on optimizing essential aspects of the minimill. These included upgrades to the electric arc furnace, the continuous casting plant, and the rolling mill.
• Electric Arc Furnace:
The EAF was upgraded with a 55 MVA transformer and two new-generation CONSO systems, which facilitate lime and carbon injection. The CONSO system adds chemical energy for better charge melting and superheating the liquid bath. This results in improved performance, higher metallic yield, and reduced CO₂ emissions and energy consumption.
• Continuous Casting Plant:
El Marakby Steel introduced the CONVEX® Mold Tube technology for the casting of 150 mm square billets. This technology ensures consistent product dimensions, reduces surface defects, and optimizes heat transfer, improving the overall quality of the steel produced.
• Rolling Mill Enhancements:
The upgrade includes the addition of a roughing mill stand equipped with two cantilever systems: one horizontal (1H) and one vertical (2V). These additions provide greater flexibility and efficiency, enabling the mill to process new billet sizes and achieve a coil weight of two tons in the wire rod line.
Expanding Production Capacity
As a result of the upgrades, El Marakby Steel’s annual production capacity will rise from 400,000 metric tons to 460,000 metric tons of rebar and wire rod. Additionally, the 150 mm square billet cross-section introduced in the continuous casting plant will enable further expansion of the product portfolio.
Technological Advancements for Enhanced Efficiency
The introduction of CONDOOR® automatic slag door technology guarantees enhanced efficiency by reducing power-off time and electrode consumption, leading to cost savings. Automatic cleaning cycles not only improve safety but also minimize the risk of refractory damage, a crucial factor in maintaining operational integrity.
The parabolic mold in the casting machine ensures optimal steel flow, further enhancing production quality. These technical innovations collectively contribute to El Marakby Steel's goal of being more energy-efficient, cost-effective, and sustainable in its operations.
Strengthening Industry Leadership
The partnership between El Marakby Steel and SMS Group represents a significant milestone in their long-term collaboration. Through this strategic expansion, El Marakby Steel is solidifying its position as a leader in the Egyptian steel industry and positioning itself to meet growing market demands with enhanced efficiency and capacity.
Key Takeaways:
• El Marakby Steel is upgrading its minimill in partnership with SMS Group, focused on increasing capacity and improving efficiency.
• The project will increase annual production by 10%, from 400,000 metric tons to 460,000 metric tons of rebar and wire rod.
• Key upgrades include the installation of a 55 MVA transformer, CONSO systems for lime and carbon injection, and CONDOOR® automatic slag doors for increased efficiency and reduced downtime.
• CONVEX® Mold Tube technology improves steel flow, heat transfer, and surface quality, ensuring consistent product dimensions and reducing defects.
• Rolling mill upgrades include new cantilever systems for greater flexibility and efficiency in processing new billet sizes, achieving a coil weight of two tons.
• The partnership with SMS Group marks a milestone in the company's goal to meet increasing market demands with greater capacity, sustainability, and cost-effectiveness.
