TECHNOLOGY FOCUS Managing waste
SURVIVAL & SUSTAINABILITY IN THE METALS MARKET
Frederik Esterhuizen, Global Business Line Manager, Metals & Power Conversion, ABB’s Process Industries division, says automation sits at the heart of progress in the metals industry
T
he metals industry in 2026 faces a more complex operating reality than at any point in recent decades. Demand remains structurally
strong, yet volatility in pricing, persistent energy constraints, tightening capital discipline and grid limitations are reshaping what is feasible – and when. Decarbonisation remains a priority, but its pace is uneven. Some producers are advancing pilot technologies, while others are prioritising asset performance and liquidity. Across the industry, the conversation has moved from ambition to execution. In 2026, the reality for the metals industry sustainability test. For metals producers, reliability, uptime and throughput remain non-negotiable. The economics are stark – recent research from worldsteel[1] found that improvements simply by standardising to best practice and tightening control around existing assets. In this context, automation is the foundation of operational resilience. The strongest performers are those prioritising process stability and automation and control solutions are being used to reduce variability across the parameters.
This stability directly impacts both cost and sustainability. With energy accounting for up to 20-40 percent of total production cost, even small improvements in process meaningful competitive advantage. A stable
28 April 2026 | Automation
process consumes less energy per metric ton, generates less waste and reduces environmental performance. Increasingly, producers are looking to modernise these capabilities without disrupting production. This is driving demand for automation architectures that allow new functionality to be introduced incrementally, preserving proven control systems while enabling the integration of advanced analytics, AI and digital applications over time. In practice, this means plants modernise, without exposing operations to unnecessary risk. Projects such as the new advanced pickle
line at Tata Steel’s Port Talbot site illustrate this shift. By integrating automation, is being designed for centralised, data- driven operation from the outset and laying the foundation for more connected and responsive production. Digitalisation remains a powerful
enabler, but its adoption has become more disciplined. Investments are being prioritised where they deliver clear operational outcomes such as improving yield, reducing downtime or optimising energy use. Energy management systems provide an example of measurable impact. By linking real-time energy data with production load management and cost optimisation. In practice, they have delivered savings between 5-15 percent, sometimes achieving multi-million-dollar annual reductions. At the operational level, automation and digitalisation are converging into
more autonomous, data driven manufacturing environments. By connecting process automation with centralised control, shared data architectures, advanced analytics and AI enabled decision support, producers are improving transparency, anticipation and decision quality across the production chain. In the melt shop, applications such as Smart Melt real time, improving casting speed by 4–5 percent, reducing delays and limiting personnel exposure to high risk areas. In sintering and pelletising, Advanced Process Control provides an autopilot 10–20 percent while increasing output and energy
Alongside technical challenges, the industry faces
a growing skills gap. Automation is increasingly helping to address this challenge by embedding expertise into systems. Generative AI-driven tools, such as ABB Ability Industrial Knowledge Vault, are enabling plants to capture and structure critical knowledge, making it accessible in real time. In error by up to 90 percent and improve workforce productivity by 45 percent[2].
At the same time, automation is supporting a shift toward more autonomous operations. Routine decisions, process adjustments and fault responses parameters, reducing variability and limiting exposure to hazardous environments. Importantly, this is about augmenting operator capabilities – enabling safer, more consistent execution. with discipline. Automation sits at the heart of this, coherent operational framework. Progress is being achieved through incremental improvements: stabilising processes, optimising energy use, enhancing visibility, and building workforce capability.
In this environment, survival and sustainability
are two sides of the same equation, with automation making that equation work. [1]: Energy use in the steel industry - worldsteel [2]: ABB Industrial Knowledge Vault: Unlock the power of your workforce with generative AI
ABB Process Industries division
new.abb.com/process-automation
automationmagazine.co.uk
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