Consulting & Studies

Focus Area

Requirements Engineering and Management
Scrap Yard Management and Charge Design
Strategic Metallurgy & Process Development

Short Description

As part of this feasibility study, we analyze the existing production and quality data of the aluminium melting operation at the client with the aim of evaluating the potential for data-driven raw material optimization. The study includes in particular:

an on-site visit to assess the local production conditions;
an evaluation of the data basis with regard to completeness, consistency, and suitability for model development;
an analysis of historical production data (e.g. scrap quantities, melting parameters, chemical analyses) in order to identify relevant correlations between scrap usage and melt quality;
the development of a concept to determine whether, and in what form, a raw material optimization software solution (or a customer-specific adapted version) can be applied to this process;
an assessment of the economic potential, for example through the reduction of impurities, minimization of primary aluminium usage, and optimized scrap planning.

Special attention is given to the possibility of retrospectively evaluating scrap qualities on the basis of the available process and analysis data, in order to enable a more targeted use of critical scrap grades in the future. With the objective of reducing the existing production complexity (multiple parallel production lines, melting furnaces, holding furnaces), this study is focused on only one production line, consisting of one shredder plant and one melting furnace, in order to assess the general feasibility.

The result of the feasibility study is a final report containing an evaluation of the technical and economic feasibility of implementing an individual raw material optimization software solution for the operation at the customer.

Focus Area

Requirements Engineering and Management
Conceptual Software Engineering
Digitalization Strategy and Roadmapping

Short Description

The client plans to increase the level of digitisation in its operations, requiring full transparency and traceability across all relevant business and production processes. In order to define all requirements of a suitable software system, an assessment of the current production processes and IT infrastructure together with the key stakeholders of the client was performed. Based on the resulting requirement specification document, the client is able to make educated desicions on how to proceed in terms of relevant software solutions and implementation strategies.

Focus Area

EAF/IF Performance Optimization
Secondary Metallurgy Optimization

Short Description

For this project, qoncept provided training in the metallurgical fundamentals and operational practices of induction furnace operations, as well as the secondary metallurgy of ladle furnaces and the VD and VOD processes. The training focused on translating experience-based observations from daily steelmaking operations into a consistent framework based on liquid metallurgy, thermodynamics and kinetics. Key topics included scrap melting in the induction furnace, and the metallurgical processes of desulphurisation (DeS), degassing (DeH and DeN), and decarburisation (DeC). Through guided discussions and worked examples, the training connected metallurgical targets with practical control actions in steelmaking operations. This approach provides a shared technical language and structured understanding to support stable furnace operation, informed decision-making, and reproducible metallurgical results.

Focus Area

EAF/IF Performance Optimization
Secondary Metallurgy Optimization

Short Description

For this project, qoncept conducted a training on the metallurgical fundamentals and operational practice of electric arc furnace and AOD steelmaking in order to strengthen process understanding among furnace operators and process engineers. The training focused on translating experience-based observations from daily steelmaking operation into a consistent framework based on liquid metallurgy, thermodynamics, and kinetics. Key topics included scrap melting, energy transfer, slag–metal–gas interactions, oxygen use, and metallurgical process levers such as temperature, material additions, and stirring. Through guided discussions and worked examples, the training connected metallurgical targets with practical control actions in steelmaking operations. The outcome provides a shared technical language and structured understanding to support stable furnace operation, informed decision-making, and reproducible metallurgical results.

Focus Area

Digitalization Strategy and Roadmapping
Scrap Yard Management and Charge Design
Strategic Metallurgy & Process Development

Short Description

Investigation of a potential reduction in production cost using the qontrol maps raw material optimization software.

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.