Country: Austria

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

  • 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

In this study, qoncept conducted an on-site assessment of the ladle management practices at a steel foundry, with a specific focus on the ladle preheating process. The scope included recording and analyzing the current condition during production and jointly defining the desired state in collaboration with plant personnel. Based on these findings, the energy consumption and associated costs for ladle preheating were quantified and evaluated in relation to their impact on liquid steel temperature control. Potential areas for technological improvement were identified, and the resulting energy savings were estimated. The study concluded with an ROI-based analysis to support decision-making regarding possible upgrades or replacement of the current preheating technology.

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.

Focus Area

  • Requirements Engineering and Management
  • Wireframing and UI/UX Concepts

Short Description

In this project, qoncept supported the development of a comprehensive requirements specification for a modular software system aimed at optimizing the production of FeNiMo, FeV, and Calumet® for a European alloy producer. Based on several on-site workshops, the focus was placed on the most time- and energy-intensive stage of the smelting process: Stage 1 of the smelting operation. The scope included defining functional and non-functional requirements for process monitoring, control, and optimization in detail. This included metallurgical modeling, campaign planning, traceability, and advanced reporting. The system was designed to seamlessly integrate with existing Level 1 and ERP systems, providing a future-ready platform for scaling to subsequent process stages.

Focus Area

  • Requirements Engineering and Management
  • Wireframing and UI/UX Concepts

Short Description

In this requirement engineering project, qoncept developed a mockup-driven concept for software-based production control in copper electrolysis. Through on-site workshops with plant stakeholders, the team analyzed core process requirements and translated them into interactive interface prototypes. The solution was designed to support digital tracking of cell-level parameters, electrolyte composition, material usage, and batch-specific treatment steps. The resulting mockups illustrated how a future software system could structure production planning, resource management, and process monitoring directly at the shop floor, while enabling knowledge-based process standardization and improved operational transparency.

Focus Area

  • Requirements Engineering and Management
  • Conceptual Software Engineering

Short Description

As part of a strategic digitalization initiative at a leading Austrian steel producer, qoncept was tasked with defining a comprehensive set of functional and non-functional requirements for a new software system. The system aims to digitally map and control all processes within the finishing area, from order intake to final delivery. The project focused on building a detailed requirement specification covering all aspects of production tracking, planning, equipment monitoring, and quality assurance. In addition, qoncept structured the logic for product-level traceability, system interfaces, and real-time data capture. The result was a future-proof requirement specification that enables modular development and seamless integration into the plant’s IT architecture.

Focus Area

  • Requirements Engineering and Management
  • Conceptual Software Engineering

Short Description

As part of a strategic modernization initiative, qoncept developed a detailed requirements specification for a Level 2/3 software system to digitalize and optimize melting and casting operations in a foundry environment. The specification was the result of several on-site workshops and defined all functional and non-functional requirements related to charge tracking, process parameter recording, quality data management, energy and raw material consumption monitoring, and casting documentation. A modular architecture was proposed to ensure seamless integration with existing ERP systems and to support long-term scalability. This foundational document enabled structured vendor engagement and served as a blueprint for digital transformation.