Solution

qontrol steelmaking

Short Desription

In this project, qoncept realized a fully integrated software system covering both process automation and operating management functionalities to optimize the entire value chain from scrap to the finished cast ingot. Based on the qontrol framework, the solution seamlessly integrates all major steelmaking steps (Scrap Yard, EAF, LF, V(O)D, and Ingot Casting) into one extensible digital platform.

At Level 2, the system ensures real-time process monitoring and control. Dedicated operator workstations and software provide direct interaction with the equipment, while dynamic setpoint control and delay tracking secure stable and efficient operations. All relevant process data are captured at Level 1, transferred to Level 2, and managed in real time to ensure precise production execution.

On the MES level, the solution manages production workflows, optimizes metallurgical processes, and integrates higher-level planning. Key modules include raw material optimization, order and line-up management, master data management for steel grades and treatments, as well as recipe handling for melting, refining, and degassing. Additional features such as stockyard management, reporting, and advanced delay tracking provide full traceability and actionable insights.

The result is a comprehensive, future-proof software system that delivers end-to-end transparency, optimized resource utilization (qontrol maps included), and significantly improved efficiency across the entire EAF steelmaking process chain.

Solution

qontrol steelmaking

Short Desription

In this project, qoncept started the implementation of its qontrol maps software in a foundry. The introduction began as an off-line solution for charge optimization and was gradually expanded with coupling to SAP and the full integration of the scrap yard. The cost-optimized charge calculation generated measurable savings, which supported the further rollout of the software integration.

Building on this foundation, the system was extended to cover the EAF, two induction furnaces (IF), an AOD, and the casting shop. With seamless integration into the IT landscape, the solution combines office applications for product definitions, order planning, charge preparation, production overview, and reporting with shop floor applications for real-time process monitoring and operator interaction.

At the process control level, the software ensures process data acquisition, heat and material tracking, real-time monitoring of metallurgical operations, and dynamic setpoint control. By linking advanced metallurgical models with practical operator guidance, the system standardizes process know-how, ensures secure material supply, and improves resource efficiency across the foundry’s value chain.