Ezz Flat Steel awards Danieli major upgrade for QSP complex in Ain Sokhna

Danieli has been awarded a contract by Ezz Flat Steel (EFS) for the complete modernization of the Quality Strip Production (QSP®) casting and rolling complex at Ain Sokhna works, Egypt. The complex was originally supplied and commissioned by Danieli in 2003.

The order follows the successful startup of Meltshop No. 2 in March 2023, also supplied by Danieli, further strengthening the long-standing partnership between the two companies. The project includes the installation of a new Vacuum Degasser-Oxygen Blowing (VDOB) plant, extending the capabilities of the existing meltshop and supporting the production of advanced steel grades.

The upgraded QSP complex will increase productivity from the original 1.175 Mtpy to 1.5 Mtpy, while enabling the production of a broader range of high added-value steels. The existing installation already represents a benchmark, being the first QSP line worldwide certified for the production of API X70 line pipe steel.

The VDOB unit will be based on a Twin Tank / Twin Cover configuration equipped with mechanical vacuum pumps and complete auxiliary systems, including dedusting, deslagging and water treatment facilities. The QSP upgrade will include extensive modernization of the thin-slab caster, with a new roll diagram and upgraded automation, along with revamping of the tunnel furnace, the hot-strip mill and include improvements to the connected water-treatment plant.

Main drive systems of the hot-strip mill will be upgraded with Danieli Q-Drive Cyclo technology, maintaining the existing power components while improving performance and reliability. The primary descaling system will be enhanced, and a new high-pressure secondary descaler operating up to 380 bar will be installed.

The automation package foresees the complete replacement of Level 1 and Level 2 systems, along with the implementation of a Level 3 Manufacturing Execution System (MES) for full production management across the Ain Sokhna facility, including advanced scheduling, quality control, and data analytics.

Further upgrades will extend the capabilities of the existing hot skin-pass mill.

Upon completion, the upgraded QSP complex will allow Ezz Flat Steel to expand its product portfolio to include IF steels, ultra-low carbon grades, bake-hardening and press-hardening steels, dual-phase steels, and advanced high-strength steels (AHSS).

The project will be implemented in two phases, with the VDOB plant scheduled to start operation in May 2027 and the full QSP upgrade to be completed by May 2028.

With this investment, Ezz Flat Steel will fully exploit the capabilities of QSP technology, achieving higher productivity, enhanced metallurgical performance, and increased flexibility for the production of high-quality hot-rolled coils.