Continuous-Charge EAFs Need Continuous Intelligence
Why Consteel® steelmaking is ready for hybrid Level-2 control combining first-principles metallurgy, dynamic state estimation and machine learning.
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ExtractMet knowledge centre
Insights for smarter metallurgy
Sixteen full-length articles on Level-2 process control, digital twins, AI and machine learning, MIDREX direct reduction, ironmaking, sintering, steelmaking, copper smelting, ferroalloys, green steel and Hall–Héroult aluminium smelting—published here in complete HTML form.
Articles & technical perspectives
From plant data to better operating decisions
Deep technical articles spanning process control, Level-2 modelling, digital twins, ironmaking, steelmaking, ferroalloys, AI/ML and decarbonization.
New process-control deep dives
Hybrid Level-2 and operator-guidance solutions
Focused articles on Consteel EAF, conventional EAF, BOF/LD, MIDREX and rotary-kiln DRI, blast-furnace ironmaking, sintering, induction-furnace steelmaking, copper smelting and Hall–Héroult aluminium-smelting control.
Beyond Endpoint Guesswork: Hybrid Level-2 Intelligence for BOF / LD Steelmaking
A detailed Level-2 process-control perspective for oxygen steelmaking, integrating static calculation, dynamic prediction, metallurgical constraints and plant-data intelligence.
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The Electric Arc Furnace Needs More Than Automation: It Needs a Smarter Level 2
A hybrid physics-and-data Level-2 architecture for charge planning, melting-state prediction, energy control, endpoint guidance and plant-specific EAF optimization.
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Rotary-Kiln DRI Needs a Smarter Operating Layer
Hybrid first-principles and machine-learning control for kiln thermal state, reduction progress, gas behaviour, product metallization and operator guidance.
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Your MIDREX Plant Has More Data Than Ever. Is It Helping You Make Better DRI?
Hybrid first-principles and machine-learning models for static operating targets, dynamic process-state prediction, gas utilization, metallization, energy and operator guidance.
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From Operator Experience to Intelligent Steelmaking
Hybrid process control for induction-furnace mini-mills, with optimized charge planning, dynamic state prediction and practical decision support for MSME steel plants.
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The Hall–Héroult Pot Is Already Data-Rich. What It Needs Next Is Process Intelligence.
A hybrid Level-2 framework combining first-principles metallurgy, dynamic state estimation, soft sensors and machine learning for smarter aluminium reduction cells.
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The Blast Furnace Needs More Than Automation: It Needs a Smarter Level 2
Hybrid first-principles and machine-learning process control for hidden-state estimation, burden and thermal-state guidance, fuel-rate reduction, productivity and explainable operator decisions.
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Beyond Burn-Through Point: Hybrid Level-2 Intelligence for Iron Ore Sintering
Static and dynamic process models, BTP prediction, permeability and thermal-state estimation, machine learning and operator guidance for stable sinter quality, fuel rate and productivity.
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Copper Smelting Has a Data Problem: Why Furnaces and Converters Need a Smarter Level-2
Hybrid process intelligence for flash smelting, ISASMELT™, Mitsubishi continuous smelting and Peirce-Smith/flash converting, connecting thermochemistry, dynamic state estimation and plant data.
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Process intelligence across the metals value chain
Foundational perspectives covering plant-wide intelligence, AI/ML, ironmaking, steelmaking, ferroalloys and green steel.
Why Metallurgical Process Intelligence Is the Next Big Advantage in Metals and Mining
Physics-based modelling, plant data, digital twins and circular metallurgy as a practical route to measurable industrial value.
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From Process Data to Process Intelligence
A practical guide to combining AI, machine learning, digital twins and operator knowledge for quality, energy, yield and productivity gains.
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Ironmaking Needs a Smarter Operating Layer
Digital-twin-enabled process control for blast furnaces, gas-based shaft furnaces, COREX/FINEX and rotary-kiln DRI operations.
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Steelmaking Process Control Is Entering Its Digital Twin Era
Plant-specific control models for EAF, BOF, secondary metallurgy and continuous casting, from pilot to shop-floor deployment.
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From Megawatts to Metallurgical Intelligence
How digital twins can stabilize ferroalloy smelters, improve metal recovery, reduce specific energy and strengthen furnace control.
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Green Ironmaking and Green Steelmaking Need More Than New Equipment
A process-intelligence layer for hydrogen-ready DRI, low-carbon EAF steelmaking, transition pathways and plant-wide carbon decisions.
Read the full article →Turn an article theme into a plant-specific project
Begin with one measurable operating problem and build an auditable model, pilot or digital-twin roadmap around it.