The fastest way to simulate your production and logistics without compromising.
Industry-leading simulation models, honed through 100+ plant configurations.
Unifying metallurgical and logistical competence for a seamless collaboration.
Achieving the shortest project timelines to accommodate any schedule.
We offer simulation models for every part of the value chain of steel making. Explore key areas with essential model features and the typical challenges our simulations address.
An exceptional scrap yard model captures every detail. From accurate kinematics of scrap handling equipment to realistic working schedules, the model includes steel grade-based scrap bucket recipes down to the scrap layers. A realistic scrap pile model is essential for managing tasks and asset utilization efficiently, featuring offload, bulk, and up-piling areas with dynamic heights.
Typical applications:
Cranes are at the heart of melt shop logistics. Precise trajectory planning to avoid any obstacles using parallel or sequentially movements in all axes, is the mandatory. Multiple cranes in the same bay must coordinate their work, clearly stating which should go first while others yield. For a full workload not only ladles must be considered but also other transports like tundishes, slag pots, big bags, or pallets. Our model incorporates these and many additional features to clearly identify the bottleneck in the production.
Typical applications:
From the run-out of the caster to storage and finally to the reheating furnace, this area is pure logistics. For realistic production the simulation model must operate at the billet, bloom, or slab level. Only with mechanically accurate implementation of pusher tables, cooling beds and roller tables can bottlenecks be identified. The location of each billet must be specified down to the stack and level to determine production limits for various formats, lengths, and steel grades combinations.
Typical applications:
You have urgent questions and tight deadlines?
This is perfect for you!
To ensure your decisions are watertight, you need the right experts. Define your objectives, and we'll get to work, delivering best-in-class simulation models in the shortest possible time.
We handle everything from data analysis and model development to simulation, evaluation, and reporting.
Our goal is to prepare you for informed decision-making with absolute confidence.
Our workflow is as follows:
You will receive:
Want to run simulation yourself?
No problem!
Our software is tailored to the needs of steelmakers, eliminating the need for specialized training in logistics modeling. No coding or scripting required.
Our promise: We are always here to help. Our team works with these models daily, ensuring we know exactly what to do. Get results faster!
Best practice:
If you need a specific feature, we are happy to implement it for you. You'll have the requested feature available quickly, without having to dive deep into the source code yourself.
"I highly recommend FESIOS as a reliable partner!"
"Extremely time and money saving work"
A simulation project typically takes 6-12 weeks from start to the delivery of the final report.
The main phases are:
2-3 weeks: Creating and validating the base model of your plant and conducting the on-site workshop. The timeframe depends on the complexity of your plant (e.g., the number of casters) and whether all data is available in a timely and comprehensible manner.
3-4 weeks: Building the new plant configuration, running the simulation, and discussing the initial results and iterations for improvement. For smaller projects, this could be the final phase.
3-5 weeks: Depending on the project scope and whether multiple plant configurations or phases need to be simulated and compared, this phase includes running the simulations, discussing the results, and making improvements.
1 week: Finalizing the project, and creating the final documentation.
We collect two types of data:
General Information: This includes site and equipment details such as plant layouts, relevant cross-sections, height information, and equipment specifications (main dimensions, speeds, times). This data is essential for building up the model.
Production Data: These are records of your operational activities, automatically collected from your IT system. For the melt shop, this includes historical production data with timestamps indicating when each process started and stopped. We prefer to analyze a full year's production data to assess process times, production routes, sequence lengths, and other relevant information for each steel grade. This data is used to create realistic production schedules and serves as a validation baseline.
If the plant is not yet operational or production data is missing, we can leverage our extensive experience with other production data to fill the gaps and make informed assumptions.
Two key components are involved: the technical validation of the model based on data, and the residual uncertainty, which must be managed through the modeller's expertise and the robustness of the simulation model.
We achieve technical accuracy in our models through a thorough validation phase in every project. We start with what you know best: your current plant. We create a base model of your plant and use historical production data to validate the simulation. For melt shops this involves comparing process start timestamps and KPIs like time steel spends in ladles, sequence lengths, number of ladles in the hot cycle, and waiting times. Thorough validation ensures the model closely mirrors reality. New plant configurations, equipment and production processes can now be incorporated and compared against the validated base model, knowing that the underlying dynamics are capture correctly.
However, a model is always a simplification of the real world, so there can never be a guarantee that it is 100% correct. To address any remaining uncertainty, we depend on the setup and the execution of the work. The higher the experience of the simulation expert and the more iterations and variations the simulation model undergoes, the more likely the results are to be trustworthy. This is what sets FESIOS apart from other simulation providers.
Yes, you can run your own simulations with a user license.
Our software is specifically designed for the production areas and challenges of steelmaking. It is user-friendly and requires no prior experience in modeling, scripting, or coding. Best of all, if you encounter any issues, you can easily reach out to us for swift assistance.
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Learn MoreAs metallurgists, logistics experts, and software engineers, we channel our collective energy into one mission:
"To advance the steel industry by providing the world's best simulation solutions that drive efficiency, sustainability, and excellence"
Since 2020, our team of 5 has completed 30+ projects and modeled over 100 plant configurations.
Discover the difference. Contact us today!!
