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Zester
A welder in a mask working on a steel part
All applications

Foundry A grey and SG iron foundry melt shop

Correcting the melt the way the metallurgist does

Spectrometer and furnace data meet a log of the metallurgist's additions, and an agent recommends the charge correction he would make.

Stage
Reference design
Sector
Foundry
Capabilities
Agentic AIIndustrial IoT
Deployment
On-premise PC beside the spectrometer; furnace data via gateway.
Integrations
Spectrometer export, induction furnace panel (Modbus), heat log, WhatsApp
MELT+ FeSiSPECTROAGENT: CHARGE CORRECTIONEDIT
Signal path. Illustration, not a site photograph.

The knowledge at risk

It lives in the head of the metallurgist.

He reads a spectro print, glances at the scrap mix and says how much ferro-silicon to add. He adjusts for the scrap supplier he knows is inconsistent.

Shop-floor constraints

  • Minutes matter: the furnace is holding at temperature.
  • Scrap quality varies by supplier and by day.
  • The recommendation must show its arithmetic, or it will not be trusted.

What we build

  1. 01

    Read the sample

    Spectrometer results are imported the moment the sample is burned.

  2. 02

    Read the furnace

    Weight, temperature and power come from the furnace panel.

  3. 03

    Recommend the correction

    An agent computes additions to hit target chemistry, weighted by how this scrap has behaved before.

  4. 04

    Log what he actually did

    The metallurgist accepts or edits. His final additions and the next sample close the loop.

Today: what it improves

  • Faster corrections with the arithmetic shown.
  • Fewer heats out of specification.
  • A heat log that writes itself.

Over time: how it learns

Every heat as a chain: charge, sample, correction, result, with the expert's edits.

  • D1Charge mix by supplier and weight
  • D2Spectrometer results before and after each correction
  • D3The agent's proposal and the metallurgist's final additions
  • D4Furnace temperature and power curve per heat

Recorded on site and owned by the plant. The system uses it to keep learning your floor.

Architecture

  1. 01

    Capture

    Spectrometer export, furnace panel, charge weighing

  2. 02

    Edge

    Gateway: data acquisition and heat-level join

  3. 03

    Knowledge

    Target specs, ferro-alloy recoveries, supplier history

  4. 04

    Agent

    Charge-correction calculator with explained reasoning

  5. 05

    Surface

    Melt-shop screen, heat log, WhatsApp to the metallurgist

What we will measure

  • Fewer heats need a second correction.

    PILOT MEASUREMENT REQUIRED: corrections per heat before and after.

  • Chemistry lands on target more often.

    PILOT MEASUREMENT REQUIRED: share of heats within spec on first pour.

  • Recommendations match the metallurgist.

    PILOT MEASUREMENT REQUIRED: difference between proposed and final additions.

Run a plant with an expert like this?

Tell us whose judgement your floor cannot run without. That is where a pilot starts.

Solve a Real Problem[email protected]