ABB, a global technology leader in electrification and automation, has won an order from Al Ezz Dekheila Steel Co. (EZDK) has awarded a contract to ABB for the enhancement of the critical operations of its three main central water treatment plants at the Ezz Steel plant in Alexandria, Egypt.

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 3.1Mt.

EZDK is a 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. It is claimed that the system will help streamline control and monitoring, enabling more consistent performance and easier integration of processes across the facility. ABB believes that by supporting both new and existing infrastructure, the system will contribute to a more unified and responsive approach to plant operations.

“The efficiency and reliability of ABB’s System 800xA is integral to our operations.”

Ahmed Farrag, utilities electrical maintenance manager, Al Ezz Dekheila Steel Co.

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 (rebar) 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 AhmedFarrag, 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.”

“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.”

Shady Rafaat, metals and steel segment account manager at ABB North Africa.

ABB will manage the supply, engineering, commissioning, and start-up 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, claims ABB.

The ABB system is claimed to allow 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 3.1Mt of high-quality steel by improving process reliability, optimizing resource usage, and contributing to more sustainable production outcomes.

The project will be led by ABB’s Process Industries Metal Segment for water treatment plants and is being promoted by the company as its latest success story in collaboration with EZDK.