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The $4 trillion metals (including steel, aluminium, copper) products industry1 is a foundational supplier to numerous industries including construction, manufacturing, aerospace, automotive, and energy.
Asia-Pacific dominates with a 72.6% market share2, driven by rapid industrialization and urbanization. Europe and North America have experienced decreasing production shares but maintain important positions in the market. Europe focuses on high-value specialized metal products while the United States maintains a substantial steel industry concentrated in coastal states and Canada is a significant producer of aluminium.
Achieving a net-zero economy will also rely on metals, making the energy transition both a challenge and an opportunity for the industry - driving technological innovation, advancing electrification, and accelerating digital transformation.
The metal industry is undergoing significant transformation driven by several key trends.
The metals industry faces a mixed basket of challenges requiring proactive strategies:
ABB partners with the metals industry, offering integrated electrification, automation, metallurgical, and digital solutions across the entire metals value chain. Its technologies in the metals sector - augmented by its industrial control systems, and electrification and energy conservation through electric motor efficiency and drives. serves a variety of plants applications.
With more than 100 years of experience, ABB collaborates with producers, Original Equipment Manufacturer OEMs, and suppliers to develop customized solutions that optimize production processes from the mine to the plant, improve sustainability practices, enhance product quality, and supports the transition toward autonomous operations that utilize AI.
To help build a net-zero future by 2050, the metals industry must embrace more sustainable manufacturing practices. At ABB, we enable this transformation by driving electrification, automation, and digitalization across the steel, aluminium, and broader metals value chains. Our technologies help manufacturers reduce energy use, minimize raw material consumption, and protect workers in hazardous environments. By supporting smarter, more autonomous operations, we pave the way for circular, low-carbon production.
ABB enables decarbonization and green steel production through technologies like the ArcSave® electromagnetic stirrer and the ABB Ability™ Energy Management System. It also sources lower-carbon copper for its own electrical products and technologies, which addresses supply chain emissions and promotes a more sustainable value chain. Aluminium's infinite recyclability not only preserves the metal's properties but also offers a dramatic 95 percent reduction in energy consumption compared to virgin aluminium production.
Watch our webinar where SSAB, the Association for Iron & Steel Technology and ABB explore the challenges and opportunities in the steel industry's transition to fossil-free production.
A modular and scalable digitalization approach including AI integration allows for agile customization, predictive analysis, cost and energy optimization and increased productivity. Here are some exciting ABB digital solutions for the metal industry:
An industry-first smart factory solution for steel melt shops is a unique application, facilitating the move towards a fully connected and autonomous melt shop.
A cloud based platform can accurately predict the temperature of the steel melt within an electric arc furnace (EAF) continuously from the rise in the cooling water.
The ABB Ability Data Analytics Platform integrating advanced control systems and big data analytics help customers achieve process control, optimization, and remote diagnostics in metals manufacturing.
For round-the-clock predictive maintenance this solution enables customers to connect their operations, engineering and business management with ABB’s internet-of-things applications and expertise.
Using Model Predictive Control (MPC) to create digital twins of steel production processes, ABB’s Advanced Process Control technology processes data to predict behavior over time, which reduces the need for operators to monitor and modify processes around the clock.
ABB has won an order for four electromagnetic stirrers (AL-EMS) from world-leading aluminium furnace builder GNA alutech, an Ebner® Group member. The new melting and casting complex in U.S. is set to become a beacon for reshoring, recycling and sustainable practices and will benefit from our technology which will increase productivity, lower energy consumption and help reduce operating costs.
Real Ispat and Power Ltd. (RIPL) partnered with ABB to implement energy-efficient solutions in their steel manufacturing plant. This collaboration resulted in a more sustainable operation, characterized by reduced energy costs, lower emissions, and enhanced operational reliability.
ABB has won a Tata Steel order as part of a consortium with steel processing lines and rolling mills supplier Clecim, to provide automation, electrification and digital technology on the new advanced pickle line at Port Talbot Steelworks in the UK. The pickle line will form a major part of the green steelmaking facility supplying downstream businesses and customers with high-quality, low CO₂ steel products. ABB will be responsible for automation, leveraging the Roll@xA digital solution and ABB Ability System 800xA distributed control system with specific libraries for processing lines.
ABB now supports Çolakoğlu Metalurji A.Ş. in advancing their steelmaking operations with the ArcSave® electromagnetic stirrer (EMS), to be installed on one of the world’s largest electric arc furnaces. This collaboration marks a significant step in driving greater efficiency, sustainability, and safety in Türkiye’s steel industry.
Aurubis, Europe’s leading copper producer, implemented a major upgrade at its copper plant in Bulgaria, replacing older, motors with high-efficiency motors and drives from ABB. This upgrade resulted in significant energy savings, reduced carbon emissions, and improved process flexibility.
Leading steelmaker POSCO upgraded its hot strip mill in South Korea by replacing legacy DC roller table motors with state-of-the-art AC motor and drive packages from ABB. The solution resulted in reduced maintenance requirements- including costs and increased reliability.
ABB is taking on the challenge of design, engineering, supply and integration of an automation and electrical system for water management for a global metal customer in Egypt. Our distributed control system (DCS) ABB Ability™ System 800xA® will play a crucial role in integrating the various components and expanding the platform to control an existing station while the latest drive system ACS880 will optimize power savings.
ArcelorMittal Construction has awarded ABB a contract to deploy solutions specifically designed for metals processing at its cold rolling mill in Contrisson, France, as part of a modernization project. The solutions, which include ABB Ability™ Manufacturing Operations Management for metals (MOM4Metals), Roll-Gap (RGC) and Automatic Gauge Control (AGC), will help the world’s largest steel producer to bring productivity to a new level, improve quality and performance.
These comprehensive solutions help manufacturers optimize production processes, utilizing less raw material and energy, while maximizing output. ABB works as a collaborative partner, developing process-specific solutions that enable metals producers to scale operations effectively and proactively address challenges in unpredictable environments, ensuring their long-term success and sustainability in a rapidly evolving industry landscape.