Country: Germany

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

  • 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.

Storage Material

Hydrated Lime | Coal

Size, m3

10 | 2 x 20 | 80 | 100 | 2 x 250

Short Desription

In this project, qoncept developed a newly designed stopper rod mechanism through a complete mechanical engineering process. The work included both the detailed engineering and the construction of the system. The aim was to create a reliable and functional solution tailored to the operational requirements. By combining design, technical expertise, and practical realization, the project delivered a fully engineered and built mechanism that supports improved performance and robust operation.

Short Desription

In this project, qoncept delivered a complete spring testing unit designed for use in continuous casting operations. The system includes a robust testing stand equipped with a mobile control terminal (qonsole) and the modular software solution qontrol. The hardware enables precise evaluation of multiple springs under operational conditions, while the software provides registration, analysis, interpretation, visualization, and documentation of test results. Optional add-ons extend the system with features such as wear part tracking, maintenance planning, cloud data transfer, and predictive reporting. This integrated approach enhances efficiency, reliability, and traceability in maintenance and repair workflows.

Short Desription

In this project, qoncept performed an engineering study to evaluate the effects of increasing the ladle weight on a ladle turret. The work focused on verifying overall stability with respect to the foundation, anchoring, and slewing bearing. Structural calculations were carried out to determine whether the turret could safely accommodate the higher load conditions. The study provided a reliable basis for further decision-making regarding potential design modifications and operational safety, ensuring that the turret’s load-bearing capacity was clearly assessed under the new requirements.

Short Desription

In this project, qoncept delivered engineering services to redesign the inlet area in ingot casting. The work focused on reducing erosion and improving flow conditions to minimize inclusions in the final product. Based on provided drawings and investigations, 3D assemblies and 2D design updates were created, with attention given to optimizing selected refractory and cover components. The outcome was a refined inlet design that addressed operational challenges and provided a basis for improved casting performance.

Solution

qontrol MAPS

Short Desription

In this project, qoncept supported a German foundry in achieving two strategic goals: cost savings through raw material optimization and the digital replacement of manual stock yard management.

The solution is based on the qontrol framework and combines two dedicated applications. The qontrol MAPS charge optimization application calculates the cost-optimized scrap mix for each heat, ensuring smarter raw material use, improved energy efficiency, and substantial cost savings. In parallel, the stock yard management application replaces manual workflows with a structured digital system for managing storage locations and material movements, creating transparency and reliability across the supply chain.

Seamlessly integrated into the customer’s IT landscape, the system provides operators with clear digital charge instructions and management with detailed reporting tools. This project highlights how digitalization not only unlocks measurable cost advantages but also strengthens process reliability, transparency, and resource efficiency.

Solution

qontrol MAPS

Short Desription

In this project, qoncept delivered a trial installation of qontrol MAPS on dedicated qoncept servers to demonstrate its full capabilities and prepare the ground for a long-term software license. The project focused on evaluating how qontrol MAPS enables effective heat optimization in the steelmaking process, taking into account grade management, materials, and stock. To accomplish this, the system was provided with predefined grades and configured for material tracking and stock control. The trial included the Heat Optimization module of control maps, as well as training and support from qoncept experts.

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.