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Record-low natural gas consumption achieved thanks to ENERGIRON Zero-Reformer solution
Suez Steel has achieved a new benchmark in energy efficiency at its Direct Reduction Plant (DRP) based on ENERGIRON Zero-Reformer (ZR) technology. The plant, the first large-scale industrial applications of this technology, is operating with high metallization rates while ensuring direct hot feeding to the meltshop.
The ENERGIRON ZR process, jointly developed by Tenova and Danieli , enables flexible gas reduction of iron ore pellets with high metallization and with compact plant footprint.
Through continuous operational optimization and accumulated expertise, Suez Steel has reached natural gas consumption levels slightly below 2.2 Gcal per ton (8.73 MBTU/ton) on a consistent basis for several months of continuous operations.
A key contribution to these results is the integration of the captive pellet plant recently commissioned by Suez Steel, allowing the supply of high-quality pellets with optimal reducibility characteristics for stable and efficient DRP operation.
Mr. Rafic Daou, Vice Chairman and Chief Executive Officer of Suez Steel, stated: “We are collecting the fruits of our works and our growing expertise in the field of pelletizing and iron making; these results confirm the potential of the company Suez Steel and of Egypt to reach excellency in steel industry.”
Mr. Zulfikar, Technical Manager of Suez Steel, declared: “This result has been the achievement of all the team steadily focused in seeking the best performance through relentless commitment on continuous improvement and technology development in constant partnership with our technology partners of ENERGIRON.”
Mr. Marco Lapasin, VP Danieli Centro Metallics, stated: “We are proud of these results that show the potential of the ENERGIRON process, especially when the management and the team is devoted to production and to investigate the best synergies to push the process closer to its theoretical limit. We praise this approach, and we are glad when we can contribute to the success of such an important partner like Suez Steel.”
This result establishes a world benchmark in terms of energy efficiency for gas-based direct reduction and contributes to the advancement of sustainable steelmaking, supporting reduced carbon emissions and improved environmental performance.
Steel Network Interviews Engineering Icon: Eng. Ahmed Abdo
In the world of heavy industry, where achievements are measured by the structural integrity of facilities and the precision of figures, exceptional figures emerge—those who do not merely build factories but redefine the very concepts of leadership. As part of our series featuring influential Arab figures, Arab Steel Network (Steel Network) is pleased to navigate the inspiring success story of Eng. Ahmed Abdo.
A witness to the birth of steel strongholds in Egypt and the Middle East, Eng. Abdo’s journey began in the 1990s, transforming a common "phobia" of heavy loads into a global, transcontinental success story. His name is synonymous with the region’s largest steel plants, proving that Arab excellence in civil engineering meets—and often surpasses—international standards through the innovative mastery of economic solutions for industry.
Phase I: From Sadat City to the Global Stage
Steel Network: Every journey has a beginning, and yours started during a critical period for the steel industry in the 1990s. How did you break barriers in this sector?
Ahmed Abdo: The real start was in 1994, with the emergence of the first major private factories in Sadat City and the "El Hawary Group." At that time, civil engineering related to steel and heavy-duty cranes caused apprehension due to the complexity of the loads. However, we decided from day one to respect the finest details. We learned how to strike a balance between "design over-engineering" and "actual requirement." This is where our cumulative expertise in this strategic sector began.
Steel Network: It is said that the "Ezz Sadat" project was the challenge that placed you on the map of top consultants. What happened behind the scenes?
Ahmed Abdo: The "Ezz Sadat Line 3" project with Italy’s Danieli was the ultimate test. As civil consultants, we were responsible for the precision execution required to anchor giant machinery to the ground using over 20,000 Anchor Bolts. The achievement wasn't just in the number, but in the 100% precision rate without a single error. This astonished our Italian partners and filled us with pride in our professional Arab capabilities.
Phase II: Value Engineering – The Philosophy of Economic Excellence
Steel Network: You are known for the term "Value Engineering." How did you convince investors that structural safety does not necessarily mean higher costs?
Ahmed Abdo: Our philosophy is that a successful consultant protects investments just as they protect lives. Conventional consultants might exaggerate loads to evade responsibility. However, through deep experience, we have managed to reduce project budgets by up to 60% while ensuring full, certified safety. This equation opened doors for us in Saudi Arabia in 2011, followed by projects in Ghana and Cameroon.
Steel Network: The world is talking about "Green Steel." What is your vision for this transition?
Ahmed Abdo: Green Steel is an inevitable global trend. Just as we previously transitioned to technical standards like B500, Green Steel will soon become the baseline. We are technically preparing for this shift to remain at the forefront of consulting firms providing sustainable, eco-friendly solutions.
Phase III: Trans-Border Leadership & Bold Investment
Steel Network: Your footprint has crossed Egyptian borders. Where has your compass landed?
Ahmed Abdo: Our international journey began over 20 years ago. In Qatar, we executed more than five major projects, including "National Sections" and "Qatar Engineering." In Saudi Arabia, we delivered massive projects in Jeddah, such as "Tameer Steel," spanning 120,000 square meters with a 400,000-ton capacity. Currently, in Riyadh, we have over 10 active projects with entities like "Arkan" and "Al-Mutawally." Our work also extends to integrated steel complexes in Ghana and Cameroon, with ongoing projects in Syria, Lebanon, and Central Africa.
Steel Network: As an expert who views opportunities through a strategic lens, what is your advice to Arab investors today?
Ahmed Abdo: I see an unjustified "neglect" of the African market, particularly Central Africa. There are entire countries without a single steel factory. Similarly, Syria and Iraq represent massive investment opportunities. In all honesty, our Lebanese brothers are ahead of everyone in seizing these opportunities with enviable boldness. I hope the Egyptian investor moves beyond "traditional patterns" and ventures into these promising markets more aggressively.
Phase IV: From Industry Giants to Future Leaders
Steel Network: Speaking of the figures who shaped the region's steel industry, who do you consider the true icons?
Ahmed Abdo: One cannot discuss excellence without mentioning Eng. Ahmed Ezz. He is an exceptional figure who transcended borders to become an influential variable in the global steel equation. Starting at age 35, he took unprecedented, calculated steps in restructuring this strategic industry. His institution today is not just a landmark for construction or a partner in mega national projects; it is the embodiment of pioneering Egyptian thought that has established itself as a global power.
Furthermore, we must pause at the inspiring experience of Eng. Hassan El Marakby. He is a model of a young leader who never stops evolving. Through deliberate industrial steps, he has elevated his group to global ranks—not just through capital investment, but by penetrating international markets with Egyptian products that command respect for their quality. Hassan El Marakby proved that when an Egyptian engineer possesses vision and persistence, they can turn a local product into a globally sought-after brand.
Today, I am very optimistic about the rising generation of youth who possess passion, science, and sophisticated thinking. They have a golden opportunity; current technical advancements allow them to execute complex projects faster and better than previous generations. They truly represent a promising future.
Phase V: Transferring Expertise and Creating Impact
Steel Network: You are a role model for a generation of young engineers. What is your "magic formula" for them?
Ahmed Abdo: My constant advice is "Boldness based on Science." We are raising a generation that does not fear complex mechanical foundations. In our team, we have young talents, including Eng. Mostafa Ahmed Abdo and my dedicated staff, who have confidently left their mark alongside major global firms. It brings me joy to see new blood carrying the torch and developing what we started.
Steel Network: How do you see the future of integrated engineering consultancy in our region?
Ahmed Abdo: The future belongs to those who provide "The Total Solution." We have recently moved toward the concept of Integrated Engineering, where we design the entire plant (Civil, Steel, Mechanical, Electrical) from scratch to commissioning. This was a dream for years, and now it is a reality we offer to serve the Arab industry.
"The Dream of Youth That Knows No Impossible"
BERLIN – April 15, 2026
In a new international milestone for Egypt’s national industry, the World Steel Association (worldsteel) has announced—during its Board of Members meeting held in the German capital, Berlin—the admission of "Maadi Steel" as a regular member. The company is represented by Eng. Mina Atef Hendy, the Group’s Managing Director.
International Recognition of Egyptian Excellence
This selection comes at a critical juncture for the global steel market, which is undergoing massive structural shifts. In its reports, the Association noted that the inclusion of Maadi Steel provides a powerful boost to African representation. Egypt remains one of the most vital strategic steel markets driving growth across the continent, fueled by mega national projects such as the New Administrative Capital and comprehensive infrastructure development.
Mina Atef Hendy: A Model for Ambitious Youth
This representation is more than just a seat in an international organization; Eng. Mina Atef Hendy embodies an honorable model for Egyptian and Arab youth. Through a "sincere dream" and tireless dedication, he has successfully projected his voice and his company’s brand onto the global stage, proving that the younger generation is capable of leading change when armed with expertise and knowledge.
In a powerful statement reflecting his vision, Henery emphasized that participation in this international forum aims to:
Transfer the latest global technologies to develop local production in alignment with international environmental standards.
Open new export horizons to bolster the national economy.
Focus on voluntary work and support young cadres to cultivate a new generation equipped with leadership tools in the heavy industry sector.
Steel Network Applauds the Achievement
The "Arab Steel Network" (Steel Network) expressed its immense pride in this honorable representation, asserting that a young engineer like Mina Atef Henery joining the World Steel Association is "a source of pride for every Egyptian and Arab youth" and the crowning achievement of a journey defined by sincerity and excellence.
"We at the Arab Steel Network wish Engineer Mina Atef Henery every success in his international mission. We value his role as a role model in supporting youth and sharing expertise with integrity and devotion."
Global Leadership Changes
It is noteworthy that the Berlin meeting also welcomed a new Director General for the Association, Dr. Henrik Adam, who will assume his position in the last quarter of 2026, succeeding Dr. Edwin Basson. This transition signals a new era of innovation in global steel policies—an era in which Maadi Steel will play an integral role.
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Steel Network, the leading Arab media and marketing platform for the iron and steel sector. With over 15 years of deep-rooted experience, we serve as a strategic information hub and a primary bridge for international relations within the Middle East and North Africa (MENA) region. Our operations are guided by an Advisory Board of over 16 renowned experts covering various technical and commercial specialties.
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