El Marakby Steel initiates minimill upgrade to boost capacity and efficiency

El Marakby Steel has announced a collaboration with SMS group to upgrade its existing minimill at the company's 6th of October City site, aiming to enhance production capacity and reduce operational costs. The modernization project, set to increase annual production capacity from 400,000 to 460,000 tons, focuses on key components of the minimill, including the electric arc furnace, casting plant, and rolling mill.

Following an assessment by SMS group in early 2023, the steel manufacturer identified potential optimizations within its melt shop, resulting in a projected 10% increase in annual capacity. The modernization initiative includes introducing 150-millimeter square billets to expand El Marakby Steel’s product portfolio.

The project involves significant equipment upgrades, including the installation of a 55 MVA transformer, advanced CONSO systems for lime and carbon injection, and the CONDOOR® automatic slag door. These enhancements are expected to improve efficiency by reducing power off-time, lowering electrode consumption, and increasing metallic yield. The CONDOOR® system also aims to enhance safety through automatic cleaning cycles, minimizing refractory damage risks.

Additionally, the electric arc furnace (EAF) will benefit from the upgraded CONSO system, providing the necessary chemical energy for efficient charge melting and liquid bath superheating. The modernization also introduces the CONVEX® Mold Tube technology to the continuous casting machine, designed to improve heat transfer, surface quality, and dimensional consistency while reducing defects.

The rolling mill will receive a new roughing mill stand featuring cantilever systems in both horizontal and vertical designs. This upgrade is expected to enhance the mill’s flexibility and efficiency, allowing it to accommodate the new billet size and achieve a coil weight of two tons in the wire rod line.

The strategic partnership between El Marakby Steel and SMS group dates back to 2013. The latest upgrade is part of El Marakby Steel’s broader strategy to maintain a competitive edge in the steel industry by adapting to evolving market demands.

Enea Pasquali, Key Account Manager at SMS group, commented, “This collaboration marks a significant milestone in our partnership with El Marakby Steel. The strategic expansion ensures increased efficiency and reinforces El Marakby Steel’s position as a leader in the steel industry, well-prepared for upcoming market demands.”

El Marakby Steel specializes in manufacturing deformed bars and wire rods, serving both domestic and international markets.

Source and Photo: SMS Group