Melt shop assessment by SMS leads to an annual production increase by 10%
El Marakby, an Egyptian manufacturer of deformed bars and wire rods, already looks back on a successful partnership with SMS group. This collaboration began in 2016 with the start-up of a new Electric Arc Furnace (EAF) meltshop in Giza. By 2019, SMS group had completed El Marakby’s first minimill for rebar and wire rod at the 6th of October site, featuring a 400,000 tons per year rebar and wire rod mill. As market demands evolved, El Marakby once again sought SMS group's expertise in 2023 to explore potential upgrades for enhancing the capacity and efficiency of the minimill.
El Marakby and SMS group: a long-standing partnership
In 2023, SMS group conducted a comprehensive assessment of El Marakby's minimill melt shop, leading to a 10% increase in annual production. During this assessment, an SMS team conducted an on-site inspection, analyzing performance data, operational processes, production coordination, and raw material supply chains. SMS group devised a strategy tailored to the current plant conditions and the raw material constraints faced by El Marakby. This strategy included various operational improvements and an evaluation of the scrap supply and processing chain. Investments in scrap preparation equipment addressed the need for improved scrap density, optimizing the supply and processing chain and enhancing operational efficiency.
El Marakby and SMS take a step further to enhance efficiency with equipment upgrades
Following the assessment, El Marakby Steel now plans to leverage the insights gained to boost capacity and reduce operational costs through equipment upgrades of its minimill. Key planned enhancements include an upgrade of the electric arc furnace transformer from 45 MVA to new 55 MVA transformer and the CONDOOR® automatic slag door, which will enhance the efficiency of the EAF by reducing electrical and electrode consumption.
Thanks to Condoor®, the plant will enhance operational efficiency by reducing power off-time and electrodes consumption while increasing metallic yield. Featuring also automatic cleaning cycles Condoor® ensures significant advantages in terms of safety at the same time minimizing risks of refractory damage.
Additionally, CONSO system, SMS latest chemical package design, will ensure optimal slag and energy efficiency within the EAF . The caster will be upgraded with CONVEX® Mould Tube technology, adding 150 mm square billets to the product portfolio. The rolling mill will receive two new housing-less stands and relevant equipment to handle these billets. These upgrades will minimize operational costs, increase material yield, and expand the product portfolio, enabling El Marakby Steel to produce 2-ton coils in the wire rod line and 150 mm square billets on the caster.
By implementing these advancements, El Marakby Steel not only strengthens its market position but also sets a benchmark for future projects in the steel industry. The minimill upgrade shows a successful partnership addressing changing market requirements with enhanced efficiency and productivity.
"The assessment of the melt shop carried out by SMS group stimulated the plant operator team on site far beyond the nominal production and trained the team with regard to optimized production processes. SMS group was a reliable partner both during the preparation, coordination and conduction of the assessment”.
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