Level 2 Software System for Steel Plants
Control and optimization of steel production processes through metallurgical models, digital twins, and artificial intelligence.
qontrol L2 is a modular Level 2 software platform designed to optimize the complete steelmaking process, from raw material management and melting through secondary metallurgy and casting. By combining real-time production data, advanced metallurgical models, digital twins, and AI-driven analytics, the system transforms complex production environments into transparent, predictable, and highly efficient operations.
The result is improved yield, lower production costs, reduced energy consumption, optimized alloy usage, enhanced process stability, and complete traceability across the entire steelmaking route. Whether implemented as a single process module or a fully integrated plant-wide solution, qontrol L2 helps steel producers make better decisions, faster and with greater confidence.
our approach
Metallurgical Intelligence at the Core
Unlike conventional Level 2 systems that rely on static recipes, qontrol L2 uses advanced metallurgical models to continuously calculate process targets based on actual production conditions. Every recommendation is tailored to the current heat, enabling more accurate process control, improved steel quality, and greater operational consistency.
One Platform Across the Entire Steelmaking Route
From raw material management and melting to secondary metallurgy and casting, qontrol L2 creates a unified digital environment for all production units. A common data model, complete heat tracking, and centralized process visibility eliminate information silos and improve coordination throughout the plant.
AI-Powered Process Optimization
qontrol L2 combines metallurgical expertise with artificial intelligence to improve process understanding and decision-making. By learning from historical and real-time production data, the system continuously refines predictions, supports operators with adaptive recommendations, and helps identify optimization potential across the entire production route.
Modular, Scalable, and Easy to Integrate
Every steel plant follows its own digitalization path. qontrol L2 can be deployed as a single module, introduced step by step, or implemented as a complete plant-wide Level 2 platform. Open interfaces and standard industrial protocols ensure seamless integration with existing automation, MES, ERP, and laboratory systems.
functions & features
- Raw Material Optimization & Production Data Management
- Melt Shop Management & Metallurgical Process Control
- Casting Optimization & Quality Assurance
- Production Intelligence & Performance Analytics
Raw Material Optimization & Production Data Management
qontrol L2 creates a centralized digital foundation for steel production by combining production orders, steel grades, recipes, workflows, material definitions, stockyard information, and real-time process data within a single platform.
The system transforms raw material management into a dynamic optimization process. Scrap, alloys, DRI, fluxes, and auxiliary materials are continuously evaluated based on availability, cost, quality requirements, and operational constraints. AI-driven models characterize material performance and determine actual yield, chemical contribution, and energy demand based on production feedback.
Using this information, qontrol L2 calculates optimal charge mixes, supports bucket planning, and provides complete visibility of material movements throughout the plant. The result is lower raw material costs, improved resource utilization, reduced manual data handling, and a reliable foundation for all downstream automation and optimization functions.
Melt Shop Management & Metallurgical Process Control
qontrol L2 combines complete production visibility with advanced metallurgical intelligence across all steelmaking units.
Every heat is tracked from charging through refining and casting, creating a comprehensive digital production history. Process events, material additions, measurements, operator actions, laboratory results, and equipment movements are automatically captured and linked to the corresponding heat.
At the same time, advanced metallurgical models continuously calculate the actual state of steel and slag. Based on real-time process conditions, the system generates dynamic target values for alloy additions, temperature control, oxygen blowing, gas stirring, vacuum treatment, slag management, and refining operations.
Instead of relying on static rules and fixed recipes, operators receive adaptive process guidance tailored to the current heat. This improves process stability, reduces variability, increases yield, and helps achieve consistent steel quality across the entire melt shop.
Casting Optimization & Quality Assurance
qontrol L2 extends intelligent process control beyond secondary metallurgy and supports both continuous and ingot casting operations.
The system provides temperature prediction, superheat control, solidification modelling, mixing zone calculations, cut-length optimization, casting recipe management, and quality monitoring. Real-time process models help operators maintain stable casting conditions while identifying potential quality risks before defects occur.
By continuously monitoring casting parameters and linking them to the complete heat genealogy, qontrol L2 supports improved product quality, reduced scrap rates, lower yield losses, and more stable production performance. The result is greater confidence in product consistency and complete traceability from liquid steel to final product.
Production Intelligence & Performance Analytics
Production data only creates value when it can be transformed into actionable operational knowledge.
qontrol L2 consolidates process data, material information, laboratory results, production events, and model outputs into intuitive dashboards, heat reports, KPI cockpits, and management reports. Operators gain real-time process visibility, metallurgists receive deep analytical insights, and managers obtain a transparent overview of plant performance.
Built-in reporting and trend analysis tools help identify improvement opportunities, investigate process deviations, benchmark performance, and support continuous optimization initiatives. By turning production data into measurable business intelligence, qontrol L2 enables faster decisions, greater transparency, and long-term operational excellence across the entire steelmaking route.
across the steelmaking route
Scrap Yard (SY)
- AI-driven scrap characterization for real-time yield, composition, and energy efficiency.
- qontrol MAPS for intelligent cost optimization and raw material input management.
- Automated bucket tracking with qurve AI camera sensors.
Electric Arc Furnace (EAF)
- Scrap yard integration to ensure material tracking.
- Optimization of decarburization, dephosphorization, and slag stability.
- Automated slag chemistry management (foamability, basicity, etc.)
- Improved energy input (electrodes, burners, chemical reactions and post-combustion) to reduce operating costs.
Ladle Furnace (LF)
- Optimized heating to ensure desired hand-over temperatures.
- Dynamic calculation of alloying and deoxidation additions.
- Determination of slag former additions to control refining processes (De-S).
- Control of stirring gas flow rates to ensure homogenization and inclusion removal.
Vacuum Degassing (RH/VD)
- Optimized degassing to ensure efficient hydrogen and nitrogen removal (deep-vacuum time)
- Real-time display of steel bath temperature through well-validated metallurgical models.
- Control of gas stirring considering gas consumption, steel bath temperature and homogenization.
- Dynamic calculation of alloying and deoxidation additions.
Vacuum Oxygen Decarburization (VOD)
- Dynamic calculation of the set-points for oxygen and vacuum pressure.
- Control of oxygen blowing to optimize decarburization while limiting chromium oxidation.
- Calculation of slag reduction and alloying additions.
- Control and optimization of nitrogen additions through nitrogen purging (N alloyed steels).
- Real-time display of steel bath temperature through well-validated metallurgical models.
Argon Oxygen Decarburization (AOD)
- Dynamic calculation of the set-points for oxygen and gas flow rates.
- Control of blowing pattern (rates, O2/gas ratio) to minimize chromium oxidation during decarburization.
- Calculation of the optimum nitrogen to argon switchover point.
- Control of alloying additions to adjust steel bath temperature (prevention of overheating)
- Calculation of slag reduction strategies to recover oxidized chromium.
- Control of nitrogen gas supply to adjust the nitrogen content (N-alloyed steels)
- Real-time display of steel bath temperature through well-validated metallurgical models.
Continuous Casting (CC)
- Monitoring and adjustment of mold oscillation to reduce breakout and cracking risk.
- Dynamic EMS control based on casting speed and strand dimensions.
- Adaptive spray water control using real-time strand surface temperature models.
- Solidification modeling to calculate shell growth and internal temperature profile.
- Control of soft reduction to minimize centerline segregation while avoiding crack formation.
- Detection and separation of mixing zones to ensure chemical consistency.
- Mixing zone calculation and cut-length optimization to reduce scrap while meeting quality requirements.
- Quality monitoring through tracking of process deviations
Ingot Casting (IC)
- Setup and configuration of casting sets (plates, molds, funnels, and auxiliary equipment).
- Management of casting recipes with predefined targets for temperature, casting speed, and powder addition.
- Assignment and documentation of casting parameters per setup and heat.
- Documentation of equipment usage and material consumption per cast.
tailored to your requirements
- YOUR BENEFITS
- HOW WE SUPPORT YOU
Lower Production Costs
Reduce raw material, alloy, and energy consumption through intelligent optimization, adaptive process control, and data-driven production decisions.
Higher Yield & Product Quality
Improve metallic yield, reduce process variability, and achieve more consistent steel quality across the entire production route.
Greater Process Transparency
Gain complete visibility over materials, process events, production data, and heat genealogy through end-to-end traceability.
Future-Proof Digitalization
Implement a scalable platform that grows with your plant, supports stepwise modernization, and integrates seamlessly into existing systems.
Process Assessment & Solution Design
We analyze your production route, operational challenges, and business objectives to define the optimal Level 2 strategy.
Integration & Commissioning
Our specialists manage interface design, system integration, testing, commissioning, and ramp-up to ensure a smooth implementation.
Plant-Specific Configuration
Models, workflows, recipes, dashboards, and KPIs are tailored to your processes, steel grades, and operational requirements.
Long-Term Partnership
From operator training and metallurgical support to continuous optimization and software updates, we help maximize long-term value from your investment.
explore our products
qontrol MAPS
Automated scrap characterization, improved transparency and optimized use of raw materials from melting to the casting process.
qontrol MES
Orchestrated processes, seamless system integration and data-supported optimization for maximum efficiency in steel production.
qontrol LMS
Make every ladle count: for more safety, less downtime, and smarter decisions.