Stabilise metallurgical processes without slowing down production

Steel production relies on a sequence of demanding thermo-metallurgical stages — melting, refining, continuous casting and downstream processing where temperature, chemical composition, energy and throughput directly impact material quality, yield and equipment availability.

Even minor deviations can lead to metallurgical defects, excessive energy consumption, casting instabilities or costly downtime on critical units.

Indao transforms data from furnaces, converters, secondary metallurgy, casting lines and utilities into reliable operational indicators and concrete recommendations.

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Why steelmaking processes are different

Continuous thermal processes where metallurgical precision and energy stability must remain perfectly aligned.

Highly coupled thermo-chemical processes

Any variation in composition or temperature immediately affects steel quality and downstream operations

Narrow operating windows

Bath temperature, alloy content and solidification conditions determine final mechanical properties

High energy intensity

Melting, refining and thermal holding represent a major share of operating costs

The challenges you face

  • Metallurgical control: stabilise chemical composition and bath temperature to ensure product quality
  • Continuous casting stability: reduce surface defects, inclusions and breakouts caused by process instabilities
  • Energy performance: optimise electricity or fuel consumption across furnaces and thermal treatments
  • Equipment availability: anticipate drifts affecting ladles, converters, moulds or cooling systems
  • Material quality & compliance: reduce scrap and rework caused by metallurgical deviations

The limits of your current tools

  • Data often fragmented across melting, refining and casting stages
  • Operations driven by isolated parameters rather than full melt dynamics
  • Laboratory analyses available with delay relative to operational decisions
  • Fixed-threshold alarms not suited to fast process variations
  • Difficulty linking energy performance with steel quality outcomes

What Indao delivers in practice

We design advanced analytics solutions that genuinely improve steelmaking performance, with AI as a support : explainable, controlled and field-oriented.

Real-time tracking of temperatures, compositions and operating regimes, considering material characteristics and quality targets
Continuous estimation of indicators related to solidification, bath stability and casting performance based on process data
Analysis of interactions between melting, secondary metallurgy and continuous casting to identify root causes of deviations
Identification of thermal and electrical inefficiencies to reduce specific energy consumption
Structured historisation of operating conditions to support quality analysis and continuous improvement
Seamless connection to existing systems (DCS, Level 2, laboratory, energy supervision) without disrupting operations

What you gain

Operational results, not just more dashboards

More consistent steel quality

Reduced compositional deviations and metallurgical defects

More stable casting operations

Anticipation of instabilities
→ fewer production incidents

Improved energy performance

Optimised furnaces and thermal treatments
→ lower consumption

Increased equipment availability

Early detection of drifts affecting critical assets

More robust operational decisions

Clear understanding of interactions between material, thermal behaviour and energy

Controlled integration

Progressive, secure deployment aligned with existing practices

See clearly. Act decisively. Optimise sustainably.

Decisions that have already proven their impact

  • Process Performance Optimization

2Valorise

Optimising the steam network to maximise cogeneration plant performance
  • Energy

CoCEPTIO

Structuring and leveraging HVAC data to improve energy efficiency
  • Process Performance Optimization

CRM Group

Identifying key parameters in hot rolling to better control process performance
  • Data-driven Decision-Making

EKO-MYŚL

Centralising waste and energy data to improve operational control

Want to make decisions differently?

Let’s explore how your data can become a concrete operational lever.

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Whatever your activity in the metals & minerals sector

Concrete levers at the core of processes

Cement

Optimise thermal process control (kiln, preheating, grinding) by stabilising operating conditions and reducing specific energy intensity per tonne

Mining

Control processing and beneficiation plants more precisely to maximise operational availability and overall energy performance

Non-ferrous metals

Correlate process parameters, energy consumption and material quality to reduce metallurgical variability and yield losses

Glass

Stabilise furnace thermal conditions to improve product homogeneity, energy efficiency and equipment lifetime

Construction & materials

Optimise energy-intensive processes by strengthening operational robustness and control of production conditions