WATCH: How CELSA and ABB drive innovation and sustainability in the steel industry

From CELSA’s initial decision to select ABB to supply the electrical system for a rolling mill expansion project, both companies have shared an ambition to integrate solutions that deliver value and ensure continuous improvement.

"ABB has been, and continues to be, our technology partner of choice. The company brings us innovation, reliability and knowledge to constantly improve our processes," says Ramon Bagés, Electrical Maintenance Manager for the rolling mill at CELSA’s steel plant in Barcelona, Spain.

Sergio Álvarez, Area Sales Manager at ABB’s Process Industries division in Spain, explains trust and open communication have been fundamental to developing the relationship:

"What began as a project-based collaboration has grown into a strategic alliance, built on transparency and a shared goal to drive technological advancement. It has allowed us to implement advanced solutions and learn from each other on every project."

Automation improving productivity

Since its early days, CELSA’s team has focused on using data from the plant to drive efficiency and competitiveness. Leveraging ABB’s control systems, the plant is fully equipped for seamless connectivity, big data integration, and digital solutions.

“CELSA’s proactive approach allows the plant to quickly adapt to new technologies and seize optimization opportunities,” says Sergio Álvarez.

One of the key milestones is the migration to the AC 800PEC control system. The solution marks a strategic shift toward a more powerful, scalable platform ready to meet future demands.

The multiplier on every ton

Well-designed automation turns variability into a manageable parameter rather than a risk. Advanced process control (APC) and closed-loop quality systems stabilize furnaces, mills and casters, lifting yield while cutting energy per metric ton. In steelmaking, where operating windows are tight and disturbances frequent, automation is the only scalable way to run closer to constraints without breaching them.

Across pelletizing, grinding and rolling, APC has delivered low-single-digit energy savings alongside throughput increases – exactly the kind of ‘boring but bankable’ improvements that compound across a site. In melt shops, orchestrating crane movements, ladle routing and thermal management with real-time recommendations has lifted casting speeds by several percentage points while reducing arcing and superheat drift. With digital tools such as ABB Ability Smart Melt Shop, these improvements become scalable and repeatable across sites. One integrated site that we worked on translated those changes into the equivalent of 24,000 extra tons per year without new steelmaking capacity. That is abatement through productivity.

According to worldsteel, many mills can still unlock 15–20% efficiency improvements in energy and CO₂ simply by standardizing to best practice and tightening control around existing assets. This is the cheapest decarbonization “project” most plants will ever fund.

“We can benefit from improved processing power and safety, as well as seamless integration with digital solutions. It places us at the forefront of rolling mill technology and helps reinforce our leading position to compete in this globalized market,” explains Ramon Bagés.

Maximizing uptime and performance with service

Through a joint service agreement, CELSA and ABB not only ensure system maintenance but steady development. The model enables CELSA to plan and roll out modernization projects every year, minimizing risks and boosting efficiency.

“Our entire installed base is fully tracked, documented, and managed by ABB. The agreement makes maintenance, replacements, and technical support much easier, enabling predictive, high-value management of our operations,” says Ramon Bagés.

Sergio Álvarez adds: “We can plan improvements in a structured way, prioritizing projects according to their impact and aligning them with CELSA's strategic objectives.”

Making a sustainable impact

The upgrades also support CELSA’s sustainability goals. Optimizing energy use, reducing waste, and extending equipment lifespan contribute directly to more responsible and efficient production.

“One of the greatest benefits of this collaboration is that every technical advancement directly reduces CELSA’s environmental impact, in line with our decarbonization strategy. Modern platforms allow for better use of resources,” says Ramon Bagés.

Pioneering cyber security solutions

CELSA’s Barcelona plant will be the first in the Group to deploy ABB’s operational technology (OT) cyber security services for distributed control systems (DCS). In today’s increasingly digital environment, protecting critical systems is essential to maintaining operational resilience.

“By taking a proactive approach to cyber security, vulnerabilities are reduced, helping prevent unplanned shutdowns. This marks a strategic shift in how digital risks are managed,” explains Sergio Álvarez.

Continuing to shape the future

Built on a solid foundation, CELSA and ABB exemplify future-ready industry practices, showing how innovation, automation, and sustainability form the essential pillars of long-term industrial transformation.