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Focus Area

  • Ingot and Continuous Casting Optimization

Short Description

qoncept conducted a detailed fact-finding mission to assess and improve the ingot casting operations at a major European steel producer. The study included an on-site evaluation of casting equipment, materials, and technological procedures. Four heats were observed and analyzed, with focus areas including mold geometry, casting powder application, argon shrouding, casting speed, and system temperature. Key improvement areas were identified in both equipment and process control, aiming to enhance product quality, reduce surface defects, and increase overall process stability and productivity. The findings provide a robust foundation for potential follow-up actions in technology and operations consulting.

Focus Area

  • Ingot and Continuous Casting Optimization

Short Description

In this project, qoncept conducted a focused technical evaluation of ingot casting operations at a steel plant in India. The aim was to identify root causes of recurring inclusion defects and define improvement measures. On-site observations and discussions revealed reoxidation tendencies, inadequate argon shielding, and challenges in mold powder application as key factors. Based on these findings, qoncept proposed targeted recommendations related to casting parameters, stopper and nozzle design, ardon shielding strategies, and measurement integration to enhance product quality and process stability.

Focus Area

  • Production Route Design, Logistics & Tendering Support
  • Strategic Metallurgy & Process Development

Short Description

In this feasibility study, qoncept developed two layout options for a new rolling mill tailored to the needs of a Chinese steelmaker. The focus was on high-speed and die steel production. The project explores two configurations: a fully continuous mill and a reversing mill. Both configurations start with ingots and aim to achieve the final product dimensions in a single heat. The study includes process flowcharts, layout concepts, equipment lists, and indicative roll pass designs for various products (wire rods, round and square bars, and flat bars). The final report recommends a split-line configuration to enhance operational flexibility, increase yield, and better align with quality assurance practices in tool steel production.

Focus Area

  • Production Route Design, Logistics & Tendering Support

Short Description

qoncept conducted a conceptual engineering study for a new special steel meltshop covering all core process areas, including scrap yard, electric arc furnace (EAF), ladle furnace (LF), vacuum treatment (VD/VOD) and ingot casting. The scope included an on-site project alignment meeting and the preparation of a rough layout, a recommended equipment list, and high-level investment estimates. The study focused on establishing a coherent process route and evaluating the required main equipment while excluding auxiliary systems such as fume extraction, water treatment, and electrical grid support. The results provide a strategic basis for further planning, budgeting, and technical decision-making.

Focus Area

  • EAF/IF Performance Optimization
  • Secondary Metallurgy Optimization
  • Ingot and Continuous Casting Optimization 

Short Description

In this project, qoncept conducted a comprehensive fact-finding mission to evaluate key production steps at a steelmaking facility, covering the scrap yard, Electric Arc Furnace (EAF), Ladle Furnace (LF), Vacuum Degassing (VD/VOD), and ingot casting. The study involved on-site observation of multiple heats and detailed assessments of both equipment and technological practices. While the existing infrastructure was generally found to be adequate for high-grade steel production, several areas for operational improvement were identified. These included suboptimal raw material usage, insufficient production planning, manual alloy calculations, and inconsistencies in scrap yard organization and ingot casting preparation. The findings provide a detailed baseline for potential cost savings, enhanced yield, and improved product quality, forming the basis for further collaboration and targeted optimization measures.

Focus Area

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

Short Description

This project involved a comprehensive evaluation of an integrated EAF-based steel plant operating with a 100% scrap charge. The on-site fact-finding mission focused on understanding the current practices in electric arc furnace (EAF) and ladle furnace (LF) operations, alloying procedures, tapping logistics, and traceability. qoncept assessed the process design, operating parameters, and typical bottlenecks across steel grades. The final report included a critical analysis of the current process route, identified limitations in yield, temperature control, and alloying accuracy, and provided recommendations for short-term improvements and potential mid-term investments to enhance production consistency and cost-efficiency.

Focus Area

  • Ingot and Continuous Casting Optimization

Short Description

For this project, qoncept conducted a computational solidification analysis of a billet caster with a focus on stainless steel grades. The simulation was based on process-specific input data, such as casting speed, superheat, cooling rates, and geometric parameters. The analysis revealed the temperature distribution and solidification progress throughout the strand. The study provided reliable initial estimates of shell growth and solidification zones. The results were evaluated against available plant measurements and served as a basis for interpreting casting behavior and identifying areas for future process verification and optimization.

Focus Area

  • Requirements Engineering and Management 

Short Description

This project focused on defining the functional requirements for a tailored software solution to support and manage complex melting and casting operations in a foundry setting. The scope included multi-route production with induction furnaces, coordinated partial tapping, ladle tracking, and alloy-specific treatment logic. In addition to process management, the specification addressed production planning, recipe handling, material and equipment tracking, and real-time integration with MES and ERP systems. The result is a modular, scalable specification designed to improve production transparency, consistency, and metallurgical control across the entire casting workflow.

Focus Area

  • Validation, Testing and Quality Assurance

Short Description

This project focused on supporting the test planning and functional evaluation of software systems in a highly automated ingot casting environment. The aim was to validate the integration between various Level 2 systems involved in logistics, casting, and upstream meltshop coordination. qoncept proposed a structured testing strategy including the definition of test scenarios and test cases, execution of functional tests, and documentation of results. By comparing implemented features with the original specifications, the goal was to assess the system’s readiness for commissioning and ensure stable operation in one of the most complex digital casting environments in the industry.

Focus Area

  • Digitalization Strategy and Roadmapping

Short Description

In this project, qoncept developed a structured digitalization roadmap for a specialized manufacturing company as part of the Green Tech TopRunner Program. Over eight on-site workshops, the team assessed the current state of both office and shop floor processes and identified potential for digital transformation. Two strategic approaches were evaluated in detail: a modular open-source ERP system combined with track-and-trace solutions, and a fully integrated single-source software system. Based on these scenarios, concrete functional requirements were derived, including planning, dispatching, material tracking, equipment management, downtime recording, and digital work instructions. The resulting roadmap supports a step-by-step transformation aligned with the company’s agile and customer-driven operations model.