Solutions Metallurgical

Cybernetica uses model-based techniques and intelligent data processing to deliver operator support and advanced process control solutions (APC) to our customers in the metallurgical industry.

Typical challenges

  • Few and often indirect measurements
  • Extreme temperatures and aggressive environments
  • Inhomogeneous raw materials

Our services for the metallurgical industry

  • Model predictive control based on first principles models
  • Online models and applications for soft sensing
  • Training simulators
  • Thermal imaging – advanced image processing


We have long experience in working with a variety of metallurgical challenges, including:

  • Aluminium electrolysis
  • Electric Arc Furnace
  • Submerged Arc Furnaces
  • Oxygen refining converters
  • Ladle refining
  • Metal extrusion


Our main work with process metallurgy and related industries is in the areas:

  • Aluminium
  • Ferroalloys
  • Solar grade silicon
  • Stainless and carbon steel
  • Calcining

NMPC and digital solutions for metallurgical processes

Cybernetica’s flexible digital technology can be used to develop a wide variety of applications based on the specific plant needs. We have extensive experience working with custom process models and our offline tools provide the testing capabilities needed to tune models for special circumstances.

Model-based optimisation solutions

Typical objectives of our model-based optimisation applications for metallurgy include:

  • Monitoring/early warning of disturbances and drift in process operation
    • Process quality
    • Efficiency
    • Emissions
    • Other
  • Optimisation of process inputs
    • Power
    • Raw material additions
    • Process set points (e.g. fans, heat exchangers)
  • Compliance with product quality and operation constraints

Thermal imaging

Cybernetica InSight is a flexible framework for thermal imaging that supports custom image processing algorithms. By combining thermal imaging with advanced image processing algorithms, we provide new measurements of both temperature and geometry.

Read more about the possibilities with Cybernetica InSight.

Case Aluminium electrolysis

Production of aluminium is a power consuming process where large amounts of electric power is needed. Alumina, processed from bauxite, reacts with anode carbon in Hall-Héroult electrolysis cells to produce the aluminium metal.

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Case Electric arc smelting furnaces

A key challenge in large industrial submerged arc electric furnaces is the lack of direct measurements of the furance hearth. The operating conditions in the furnace hearth, typically consisting of a coke-bed or a crater are so harsh with extreme temperatures and aggressive chemical conditions that measurement equipment will not survive long enough to make proper measurements.

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Case Metal refining processes

In metal refining the aim is to obtain the specification of one or several chemical components within product specifications, while at the same time obtain a product temperature within a preferred narrow window within a defined margin above the melting temperature. At the same time, production amounts should be optimized, at a lowest possible cost.

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