Metallurgy – Page 3

Focus Area

Scrap Yard Management and Charge Design
EAF/IF Performance Optimization
Secondary Metallurgy Optimization

Short Description

This project involved a comprehensive evaluation of an integrated EAF-based steel plant operating with a 100% scrap charge. The on-site fact-finding mission focused on understanding the current practices in electric arc furnace (EAF) and ladle furnace (LF) operations, alloying procedures, tapping logistics, and traceability. qoncept assessed the process design, operating parameters, and typical bottlenecks across steel grades. The final report included a critical analysis of the current process route, identified limitations in yield, temperature control, and alloying accuracy, and provided recommendations for short-term improvements and potential mid-term investments to enhance production consistency and cost-efficiency.

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.

Focus Area

Ingot Casting
Process and Equipment Specification

Short Description

In this project, qoncept provided consulting services for the conceptual and basic engineering of a complete ingot casting area. The scope included the development of a layout sketch from both technological and mechanical perspectives, a detailed process description, and a technical specification for the required equipment. In addition, a functional outline for the digitalization of the ingot casting process was prepared to support future automation and system integration activities. The deliverables served as a foundation for subsequent engineering and investment planning.

Focus Area

Ingot and Continuous Casting Optimization
Process Modelling

Short Description

For this project, qoncept developed a structured logic to calculate the temperature-dependent thermophysical properties of steel grades. The tool, which was based on regression models, covered key parameters such as heat capacity, thermal conductivity, density, and latent heat. Two steel categories were included: low-alloyed and stainless. The tool was then extended to cover broader alloy ranges. The implementation included a microsegregation-based method to estimate solidus and liquidus temperatures. This solution allows users to evaluate steel grades more effectively and improve the solidification calculations of continuous and ingot casting processes.

Focus Area

EAF/IF Performance Optimization
Secondary Metallurgy Optimization
Ingot and Continuous Casting Optimization

Short Description

In this project, qoncept conducted a fact-finding study at a special steel plant with downstream forging and rolling operations. The assessment covered the full meltshop process, including scrap yard, electric arc furnace (EAF), ladle furnace (LF), and the planned investment in a vacuum treatment unit (VD/VOD). The study focused on evaluating process setup, material and energy flows, metallurgical practices, and coordination across production steps. Several optimization opportunities were identified, addressing both operational routines and mid-term strategic planning. The results were summarized in a structured report to support future investment decisions and targeted process improvements in steelmaking operations.