Tools built on a working process model
These are the products behind our digitalization work. Each one exists because a project needed it, which is why none of them requires you to replace what you already run.
What we offer
Meltshop simulator
A high-fidelity control room simulator for operator training. New operators learn the sequence, the alarms and the recovery procedures without a real heat at stake, and existing crews can rehearse abnormal conditions that nobody wants to practise on live plant.
Built on the same Level 2 models that run the plant, so the behaviour a trainee sees matches what they will meet on shift.
Smart plant suite
The analytics layer: specific energy per tonne, CO2 tracking, intensity KPIs, alloy recovery prediction and heat loss calculation, all fed from the plant historian rather than from spreadsheets.
Includes a yield optimisation model covering tapping weight and alloy recovery, plus long-term trend analysis and benchmarking against comparable plants.
Digital twin
A plant-level simulation that reproduces melt shop thermal and metallurgical behaviour, used to validate a design before execution and to answer operating questions afterwards.
Real-time process state estimation combines sensor fusion with physics-based models, so the twin stays aligned with the plant instead of drifting after commissioning.
CFD & FEA centre
Numerical validation as a service: furnace gas flow, fume extraction, combustion and arc behaviour by CFD; structural and thermal finite-element analysis for critical components.
Used on our own designs and available on yours. The canopy and ventilation studies delivered for long-products plants in Spain and Portugal are one example.
3D scan & industrialize
Laser scanning of what is actually installed, turned into a model you can engineer against. The same route takes a worn part with no drawings through to a manufacturable replacement.
This is the practical basis for both brownfield design and reverse engineering: measure first, then design to the geometry that exists rather than the one on file.
Remote operations centre
A process data connection to our engineers for real-time monitoring, alarm trend analysis and remote troubleshooting on furnace, ladle furnace, caster and injection systems.
Includes scheduled monthly energy and production reviews, camera-assisted remote commissioning support, and 24/7 cover for critical breakdowns.
Want one of these on your plant?
Tell us the duty, the layout and the cycle. We will tell you what needs to change to make it fit.