Emirates Steel’s 150-tonne Electric Arc Furnace (EAF) of the Phase 1 Steel Making Plant (SMP) has exceeded its designed capacity for a furnace of its size, setting a new world record, the company reported.

The feat involved 34 heats daily from the EAF that produced 5,197 tonnes of liquid steel which was converted into 4,993.8 tonnes of billets through the Continuous Casting Machine (CCM).

Emirates Steel is the largest integrated steel manufacturer in the UAE. It is a direct subsidiary of Abu Dhabi Basic Industries Corporation (Adbic) which is, in turn, wholly-owned by the Abu Dhabi government-owned General Holding Corporation.

According to Saeed Ghumran Al Romaithi, Emirates Steel’s senior vice president of operations, the SMP’s designed capacity has been exceeded in a short period of time since start-up, reaching a tap-to-tap time of 42.2 minutes and power-on time of 36 minutes.

'For such a young plant the massive effort, strong teamwork and total commitment to reach this tough target in such a short period of time cannot be underestimated; only admired, by any observer, be a layman or a steel making expert,' said Al Romaithi.

'This achievement serves as a springboard for the inevitable future successes, and more challenging targets of Emirates Steel as we continue to grow. The pride we feel in these achievements will drive us on to meet all the challenges of the future,' he added.

Two-phased expansion

Emirates Steel is implementing a two-phased expansion programme. Phase 1, already complete, transformed the company from a simple steel re-roller to the first fully-integrated steel manufacturer in the UAE and significantly increased the company’s rolling capacity to around 2 million metric tonnes per annum (TPA). Phase 2, with a production capacity of 1 million TPA, will increase the total rolling capacity to 3 million TPA.

Phase 1 comprised of a 1.6 million TPA Direct Reduction Plant, a 1.4 million TPA Steel Making Plant, a 0.48 million TPA Wire Rod and Coil Rolling Mill (RM3), a 0.62 million TPA Rebar Rolling Mill (RM2), and associated facilities. Phase 1 was completed in June 2009 at a cost of Dh3 billion ($810 million).

Phase 2, which commenced in June 2008, involves the construction and installation of a 1.6 million TPA DRI plant, a 1.4 million TPA steel billet plant, a 1 million TPA Heavy Sections Rolling Mill (RM4), and associated facilities. The budget for Phase 2 amounts to approximately Dh5.8 billion. The Phase 2 DRP and SMP are sister plants to the Phase 1 assets, thereby significantly reducing the associated technology and construction risks.

During the month of May, Phase 1 SMP achieved record production of 118,504 tonnes, compared to the January 2011 peak of 117,923 tonnes. Phase 1 DRP achieved a monthly record production of 155,243 tonnes with 94 per cent metallisation, exceeding the previous highest production of 134,950 tonnes achieved in June 2010 by 15 per cent.

Emirates Steel is strategically located in the Industrial City of Abu Dhabi (ICAD), some 35 km away from the heart of the city of Abu Dhabi. It will be among the few regional steel producers with a diversified product range, including rebar in straight and coil forms, wire rod, sections, plate, seamless pipe, longitudinally welded pipe, hot rolled coil.