Mohamed Bahgat Abd El-Baki
Meltshop Refractory Department Manager
52 Taha Yassen St., Mokattam
Summary
Dynamic Refractory Department Manager with nearly a decade of experience in the iron and steel industry, complemented by a robust background as a Senior Operations Engineer specializing in melt shop operations, including Electric Arc and Ladle Refining Furnaces, as well as ENERGIRON HYL III Direct Reduction Plant. Expertise in optimizing production processes, managing plant operations, and ensuring compliance with stringent safety and quality standards. Proven track record of implementing efficiency improvements and driving cost reductions while leading cross-functional teams to achieve operational excellence. Committed to fostering a culture of safety and continuous improvement, prioritizing the well-being of all team members and the integrity of plant operations.
Overview
3
3
Languages
10
10
years of professional experience
Work History
Refractory Department Manager
EZZ Flat Steel
07.2025 - Current
- Led the refractory team in optimizing production processes, resulting in improved operational efficiency.
- Implemented comprehensive safety protocols, enhancing workplace safety and reducing incident rates.
- Managed inventory levels of refractory materials, ensuring timely availability and reducing downtime.
- Trained and mentored staff on refractory handling techniques, resulting in improved team performance.
- Collaborated with cross-functional teams to identify and resolve production bottlenecks, driving continuous improvement.
- Analyzed refractory performance metrics to inform strategic decisions and enhance overall productivity.
- Achieving best refractory consumption rates in ladles for both Aluminum and Silicon-killed steel production alongside operations team.
Melt Shop Senior Operation Engineer
EZZ Flat Steel
11.2021 - 07.2025
Participate in the New SMP#2 construction, commissioning and startup phases with DANIELI team while holding following responsibilities: (2022 - 2023)
- Executed in-depth review of all project documentation encompassing contract scope, supply function description, and operation manuals.
- Oversee all erection activities for new steel making plant, encompassing material handling system, fume treatment plant, electric arc furnace, and ladle refining furnace.
- implementation of additional chemical package systems for EAF.
- Constructed EAF and ladle refractories in alignment with refractory supplier drawings.
- Organizing and conducting training sessions for operations team regarding standard operating procedures for new EAF and LRF featuring updates supplied by DANIELI.
Performed in senior operations engineer role duties comprised:
- Monitor all parameters influencing both EAF/LRF production process.
- Preparation of maintenance activities for meltshop scheduled maintenance.
- Evaluating and optimizing EAF melting profiles.
- Fabrication of advanced steel grades like S355J2W Weathering steel and AISI 4330.
- Revision of work standards aligned with recent changes in production process.
- Guaranteeing adherence to company policy for product quality assurance.
- Enforcing strict safety standards during all phases of production process.
- Implemented process optimization strategies to improve production efficiency and lower downtime.
- Implemented advanced melting techniques, resulting in improved steel quality and consistency.
- Coordinated with diverse teams to optimize workflows, facilitating on-time project delivery.
- Performed root cause analysis on production challenges, enabling impactful solutions and boosting reliability.
Direct Reduction Plant Operation Engineer
EZZ Steel
12.2016 - 10.2021
ENERGIRON HYL III Direct Reduction Plant with 1.9 MT/Year
- Functioned as operation engineer to enhance production efficiency.
- Implemented operational guidelines and procedures ensuring consistent production flow, achieving plant KPIs for DRI degree of metallization, specific consumption, and production rate.
- Supervise day-to-day production operations, guaranteeing optimal performance and achievement of production targets.
- Oversaw equipment maintenance, minimizing downtime and enhancing reliability.
- Supervised day-to-day production operations, ensuring optimal performance and meeting production targets.
- Focused on maintaining a secure work environment through in-depth awareness of safety regulations and protocols.
- Resolve any unanticipated equipment malfunctions inside plant facility following standard operating protocols.
Education
Research Assistant - Metallurgical and Materials Engineering Dept.
Faculty of Petroleum and Mining Engineering, Suez university.
10-2020
Bachelor of Science - Metallurgical and Materials Engineering Dept.
Faculty of Petroleum and Mining Engineering, Suez University.
07-2016
Skills
Teamwork and Team leadership
Decision Making
Communication and Presentation Skills
Time Management
Safety compliance
Technical Writing and Reporting
Software Applications
Negotiation skills
Coaching and mentoring
Accomplishments
- Collaborated with Operation team in achieving the highest Ladle Refractory lifetime 160 heats. (2026)
- Successful Startup of the New SMP#2 (1.6 MT/Year). (2023)
- Achieving the highest annual production of molten steel (t MS) since plant startup.(2022)
- Replacing internals of Process and Cooling gas areas vessels.(October 2021)
- Reactor Flow Feeders Removal Project.(January 2021)
- Project of replacing of oxide pellets coating agent to be Cement instead of Lime.(November 2020)
- Visit of HYL ZR DRI Plant Nucor Steel, Louisiana LLC, Convent, La, USA.(October 2019)
- Steam Reformer catalyst change.(March 2020)
- PGH tubes replacement by new tubes after PGH explosion incident due to gas leakage. (2018)
Extracurricular Activities
- Member at AIST ( Association for Iron & steel Technology) Foundation. (ID: 230082)
- Member at ESME (Egyptian Society of Materials Engineers), Media committee, Suez University.
- Member at Resala Charity Foundation. Member at Life Makers Foundation.
Technical Trainings and Courses
- Badische Stahl-Engineering GmbH (BSE) Meltshop Training Seminar in Kehl, Germany. Experience and Know - how in Meltshop exchange program, training for the last innovations have been introduced and utilized in Meltshop to achieve best records in productivity and plant availability. (01/12/2025 to 13/12/2025)
- Life Cycle Assessment (LCA) and Environmental Product Declaration (EPD) Training. LCA and EPD overview, Stages of LCA like PCR selection, (08/09/2024 to 11/09/2024)
- Lifting and Rigging competent person training. from Proficiency for SHE solutions Training Company. (12/11/2023 to 16/11/2023)
- Time management and critical thinking course. from LOGIC Training and HR Development Agency. (07/11/2023 to 09/11/2023)
- DANIELI Training for EAF/ LRF / RMH / FTP Operation, Q3 Intelligence Training , Automation Training for Operator Assistant/ HMI / OWS/ PWS for SMP#2 Project. (Nov 2023 - Dec 2023)
- EZZ steel internal technical courses which include the followings: 1. Refractories types, properties, selection and applications. 2. General Overview of bearing types, installation and selection. 3. Instrumentation and Automation Basics. 4. Material and Mass Balance. 5. Heat Transfer Basics. 6. Industrial Safety. 7. Lean Management.
- Project Management Course from ESLSCA Business School. Study in details the different project stages such as Initiation, Planning, Execution, Monitoring & Control and Closing phases. (Mar 2019 – Apr 2019)
- Centre for Advancement of Post Graduate Studies and Research in Engineering Sciences (CAPSCU), Faculty of Engineering, Cairo University. 1. Heat transfer and Thermodynamics. 2. Basics of Automatic control system. 3. Basics of Pneumatic system. 4. Vibration Analysis. 5. Steam Turbines. 6. Basics of Hydraulic Control System. (Sep 2017 – Oct 2017)
- EZDK Midrex Plant, Alexandria, Egypt The training in Midrex Plant No.3 included the following: 1. Midrex Plant main components: Shaft furnace, Reformer, Utilities system and Process and Cooling gas scrubbers. 2. Midrex Process and the difference between Midrex and HYL III. (Feb 2017–Apr 2017)
Personal Info.
Place of birth: Mallawy, Minia, Egypt
Martial Status: Married
Timeline
Refractory Department Manager
EZZ Flat Steel
07.2025 - Current
Melt Shop Senior Operation Engineer
EZZ Flat Steel
11.2021 - 07.2025
Direct Reduction Plant Operation Engineer
EZZ Steel
12.2016 - 10.2021
Bachelor of Science - Metallurgical and Materials Engineering Dept.
Faculty of Petroleum and Mining Engineering, Suez University.
Research Assistant - Metallurgical and Materials Engineering Dept.
Faculty of Petroleum and Mining Engineering, Suez university.