El Marakby Steel has commissioned SMS Group to upgrade its mill to boost production capacity and reduce operating costs. Following an assessment by SMS Group in 2023, annual production capacity increased by 10% from 400,000 tons to 460,000 tons.

In 2024, the modernization project focused on the electric arc furnace, casting plant, and rolling mill. Upgrades included a 55 MVA transformer, new CONSO systems for lime and carbon injection, and the CONDOOR® automatic slag door. These improvements enhanced efficiency, reduced power off-time and electrode consumption, increased metallic yield, and minimized refractory damage.

The parabolic mold in the continuous casting machine optimized steel flow, improved EAF performance, and reduced CO2 emissions. The introduction of CONVEX® Mold Tube technology for 150-millimeter square billets enhanced heat transfer and surface quality, ensuring consistent dimensions and reducing defects. A roughing mill stand with new cantilever systems increased flexibility and efficiency, allowing the mill to accommodate the new billet size.

The project expanded the product portfolio and increased production capacity to 460,000 tons of rebar and wire rod per year with a new 150-millimeter square billet cross-section in the continuous casting plant.