Author: admin

Solution

qontrol customized | qurve

Short Desription

In this project, qoncept delivered a fully integrated and automated solution for tracking and optimizing the scrap handling and charging process in an electric arc furnace (EAF) steel plant. Together with our customer, we implemented a system that captures all material movements from the arrival of scrap at the plant to its final charging into the EAF.

At the core of this solution is qurve: our intelligent sensor/camera system purpose-built for steel plant environments. It integrates high-performance imaging, embedded software for real-time analysis, and robust mechanical design including cooling and protective housing to ensure reliable operation under extreme conditions. Multiple qurve units were strategically installed at key points in the process to achieve the following objectives:

  • Detection of the number and position of incoming scrap railway wagons
  • Precise localization of both scrap charging cranes using a unique camera-based positioning method

By integrating data from all qurve sensors with additional signals from the scrap charging cranes and scrap bucket transfer cars, we enabled complete tracking and real-time reporting of all scrap charging operations.

This fully automated solution allowed the customer to (1) gain full transparency into the scrap handling process, (2) optimize the performance and control of the EAF and (3) improve scrap logistics and supply chain management.

Focus Area

  • Scrap Yard Management and Charge Design
  • EAF/IF Performance Optimization

Short Description

For this project, qoncept evaluated the existing scrap classification and electric arc furnace (EAF) performance in order to increase process stability and reduce material-related production costs. Using historical production data, key indicators of EAF efficiency and melt predictability were analyzed. The study identified significant variability within existing scrap categories and assessed their impact on alloying effort and operational performance. As a result, a refined classification concept was developed, providing the basis for more consistent melt compositions and improved material logistics. The findings support both immediate and mid-term actions for optimizing resource use and furnace operation.

Focus Area

  • Production Route Design, Logistics & Tendering Support

Short Description

For this project, qoncept conducted an on-site audit to evaluate storage technologies, internal transport flows, digitalization level, and external logistics interfaces at a steel production facility. The assessment focused on identifying inefficiencies related to unstructured storage strategies, manual data handling, and space utilization. Through detailed analysis of warehouse data and transport patterns, key areas for operational improvement were identified. The results form the basis for a prioritized set of measures to reduce truck loading times, optimize storage space, and improve logistics performance.

Focus Area

  • Strategic Metallurgy & Process Development

Short Description

For this project, qoncept conducted an on-site fact-finding mission to assess the readiness of an integrated steel plant for the production of advanced alloyed materials. The evaluation covered the entire process chain, including melting, casting, forging, rolling, and remelting operations. Particular focus was placed on the alignment between equipment, process design, and product requirements. The analysis identified key challenges in achieving consistent product quality and process stability, especially when applying high-complexity alloys in a high-throughput production environment. Additional aspects included the feasibility of producing forged and remelted components, as well as the current level of process control in secondary and special metallurgy. The results form the basis for a structured roadmap aimed at stabilizing existing production routes and preparing the facility for the reliable manufacture of advanced materials.

Focus Area

  • Strategic Metallurgy & Process Development

Short Description

For this project, qoncept provided strategic and technical consulting to support the production of ferrovanadium from vanadium-rich steelmaking slag. Since the raw material must meet strict chemical requirements, the project focused on developing the metallurgical and operational know-how required to identify and qualify suitable slag sources. In addition to technical expertise, qoncept supported the client in research activities, supplier engagement, and the preparation of technically sound business plans. The work included direct discussions with potential steel producers to evaluate collaboration opportunities and ensure supply chain feasibility.

Focus Area

  • Strategic Metallurgy & Process Development

Short Description

For this project, qoncept conducted an on-site fact-finding mission to evaluate the technical readiness and equipment capabilities of an integrated steel plant aiming to enter the electrical steel market. The evaluation included equipment condition, operational practices, metallurgical flexibility, and potential upgrade needs. Based on the analysis, three families of electrical steel grades were defined according to their chemical composition and process requirements. The study confirmed that the existing set-up can produce certain grades with medium silicon content, while the newl planned shop is capable of handling more demanding grades with low carbon and high silicon content. In addition to outlining feasible production routes, qoncept recommended targeted investments to support a stable and efficient production ramp-up.

Focus Area

  • Ingot and Continuous Casting Optimization
  • Production Route Design, Logistics & Tendering Support

Short Description

For this project, qoncept evaluated the preliminary technical proposals submitted by three OEMs for the design and delivery of a new bloom casting machine. The assessment focused on key technological aspects relevant to performance, including casting cycle time, machine radius, and essential metallurgical features. Productivity calculations were aligned with the existing BOF rhythm, and solidification simulations were conducted to analyze the optimal positioning of mechanical soft reduction units. The evaluation also included a comparative analysis of critical machine components and technological options, such as electromagnetic stirring, dummy bar systems, and cooling strategies. The report concludes with initial recommendations and identifies areas where design adjustments may be necessary to achieve optimal integration into the existing meltshop environment.

Focus Area

  • Ingot and Continuous Casting Optimization

Short Description

For this project, qoncept conducted a comprehensive two-phase technical evaluation of ingot casting operations at a compact steel plant with a focus on low- and medium-alloy tool steels. Phase 1 included an on-site assessment of the casting process, equipment, and technological parameters, covering casting system preparation, powder handling, superheat control, casting execution, argon shrouding, hot topping, stripping, and subsequent forging/rolling steps. Observations were made across multiple heats and mold formats to understand influencing factors on inclusion content, yield, and surface quality. Phase 2 focused on analyzing these results and discussing strategic measures for improvement. Key areas included enhancing liquid-to-solid yield, refining hot-top strategies, and adapting process parameters for higher alloyed products. Additional discussions addressed raw material utilization, ingot casting simulation, and best practices for stainless large ingots. The aim was to identify process-driven optimization opportunities while maintaining operational reliability and product quality.

Focus Area

  • Ingot and Continuous Casting Optimization

Short Description

For this project, qoncept conducted a comprehensive technical assistance mission focused on the continuous casting operations of a steelmaking facility. The evaluation addressed multiple aspects of the casting process, including non-metallic inclusions, slag entrainment, reoxidation potential, casting powder usage, and the overall condition of the continuous casting equipment. During on-site assessments, the team analyzed material flow, process stability, and equipment performance across key components such as the ladle, tundish, mold, and strand guidance systems. Special attention was given to layout constraints affecting ladle transport and the resulting thermal and operational impacts. The study also reviewed casting powder interactions, mold wear, oscillation systems, secondary cooling efficiency, and the absence of automated cutting solutions. Based on the observed findings, qoncept proposed the replacement of the existing caster and outlined preliminary design support, bid evaluation, and metallurgical consulting options to support the implementation of an advanced continuous casting system.

Focus Area

  • Ingot and Continuous Casting Optimization

Short Description

For this project, qoncept evaluated the ingot casting process in a special steel plant with a focus on operational practices, technological parameters, and equipment conditions. The study included on-site support during multiple test heats and a detailed review of casting performance across several ingot formats. Central attention was given to the influence of casting speed interpretation and control, as well as the handling and positioning of casting powder. Additional observations covered ladle treatment conditions, hot-top application, and accretion formation at the slide gate. The findings underline the importance of consistent rising speed during casting and accurate setup of process steps to minimize segregation, inclusions, and rejection rates. Recommendations were provided to address both equipment-related and procedural aspects without interfering with the plant’s core setup.