Case Studies

    Measurable Results From Complex Challenges

    Each project demonstrates our approach: understand the physics, model the system, implement the solution, measure the outcome.

    Boiler Control System

    Power & Steam

    The Challenge

    A steel facility experienced chronic instability in steam temperature and pressure, leading to production losses, excessive fuel consumption, and frequent manual interventions.

    Our Approach

    Advanced PID control with feedforward compensation, incorporating a first-principles thermal model adapting in real-time to load changes and fuel quality variations.

    Results

    • 30% improvement in thermal efficiency
    • 50% reduction in manual operator interventions
    • Payback period under 6 months

    Hearth Wear Study

    Metals Processing

    The Challenge

    Unpredictable refractory degradation in a blast furnace hearth was leading to unplanned shutdowns costing millions in lost production.

    Our Approach

    3D thermal model of the hearth wall incorporating thermocouple data, cooling water temperatures, and process history — predicting wear patterns and remaining life.

    Results

    • 40% extension of hearth campaign life
    • Eliminated surprise shutdown events
    • 20% reduction in refractory material costs

    Rolling Setup Models

    Hot & Cold Rolling

    The Challenge

    Complex inter-variable relationships between roll force, strip thickness, tension, and speed caused long setup times and excessive off-gauge material.

    Our Approach

    First-principles physics models for force prediction and temperature evolution, feeding a real-time adaptation system based on incoming coil properties.

    Results

    • 25% reduction in setup time
    • 18% less off-gauge material
    • Consistent quality across all product grades

    Hydraulic Simulator

    Automation & Control

    The Challenge

    A major equipment upgrade required extensive control logic changes with no safe way to test the new code before commissioning on live equipment.

    Our Approach

    Real-time digital twin of the hydraulic system connecting directly to the PLC for hardware-in-the-loop testing before deployment.

    Results

    • Zero commissioning errors on deployment
    • 3 weeks saved on commissioning timeline
    • Now used as an ongoing operator training tool

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