The Simulations Trusted BY Steelmakers

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.

Trusted By Top Professionals

Models and Areas

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.

Scrap Yard

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:

  • Integrating scrap processing plants
  • Reducing bucket loading time
  • Optimize scrap manipulator fleet
  • Reduce production losses of EAFs
Scrap yard simulation overview
Melt shop simulation

Melt Shop

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:

  • Production increase, new steel grades and routes
  • Any major CAPEX investment
  • Crane workload and production limits
  • Decarbonization and Green Steelmaking

Semi-Finished Products

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:

  • Production increase and storage optimization
  • New formats, grades and length combinations
  • Optimizing billet stacking and retrieval logic
  • Evaluating hot charging limits
Semi-finished products simulation

Product and Services

Logistics Study and Consulting

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:

  1. Data Analysis and Model Development
  2. On-Site Workshop and Model Validation
  3. Simulation of Future Production Scenarios
  4. Result Analysis and Iterative Improvements
  5. Final Report

You will receive:

  • Presentations for each progress meeting
  • Final report and executive summary
  • Access to simulation software to review output and results

Simulation Software

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:

  1. We create the initial plant model for you, either as part of a consulting project or dedicatedly.
  2. We train you on the model, conducting results analysis and iterations together.
  3. You take over, and we remain at your service.
  4. You become an expert yourself, only contacting us for critical issues.

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.

Interested? Schedule a Meeting
5 stars
"I highly recommend FESIOS as a reliable partner!"
Robert Richter
Robert Richter
Head of Business Integration Green Steel
ArcelorMittal Europe - Flat Products - Eisenhüttenstadt
5 stars
"Extremely time and money saving work"
Nazmi Sarikaya
Nazmi Sarikaya
Supply Chain Director
Kardemir Çelik Sanayi

FAQs

How long does a simulation project typically take?

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.

What data do I have to provide?

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.

How do I know if the simulation is correct?

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.

Will I be able to use the simulation myself later?

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.

Explore the latest articles

Case Study

Is your scrap yard ready for a production increase?

A production increase to 1.3 million tonnes per year didn't just challenge the melt shop — it tested the scrap yard too. How FESIOS identified and resolved the bottleneck.

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Insights

Four ways to exchange EAF electrodes, compared by EAF idle time and the working time of the cranes.

Each electrode exchange causes idle time for the EAF, and the crane is occupied for an even longer duration. Compare four exchange methods by EAF idle time and crane working time.

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How to determine crane bottlenecks in the EAF charging bay

A step-by-step method for anyone planning to add an EAF to an existing BOF melt shop. Verify that your cranes won't become the bottleneck.

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About Us

As 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!!

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