Country: Italy

Coupling Stations

Ladle (Transfer) Car - LF Station

Coupling Media

Gas

Solution

qontrol maps

Short Desription

In this project, qoncept delivered an extensible raw material management solution to reduce the cost per ton of liquid steel. The system focused on automatically characterizing incoming scrap and other raw materials, and on optimizing charge and alloying recipes based on real-time material properties. With the integration of qontrol maps and its core modules Material Characterization and Charge Optimization, producers gained continuous transparency over chemical composition, metallic yield, and energy demand of raw materials. This enabled data-driven charge mixes, reduced operational costs, and improved resource efficiency. The implementation created measurable savings while laying the foundation for further digitalization steps.

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

  • 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

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

  • 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

  • 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.

Coupling Stations

LF Station - CCM

Coupling Media

Gas - Hydraulics

Coupling Stations

EAF Tapping - LF Station - V(O)D Tank

Coupling Media

Gas