Materials · Steel

Material quality and energy
efficiency, secured together

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Challenges on materials sites

Recurring problems in heat treatment, forming and coating.

Small process shifts decide quality

Furnaces, compressed air, cooling water and forming equipment run continuously, and a slight difference in conditions stays in the product.

Heat treatment needs stability and energy control together

Temperature, hold time and cooling conditions set the material properties, so getting only one of them right will not repeat the result.

Complex energy flow, frequent peaks

Energy is scattered across processes while high-temperature, high-power equipment runs together, making both over-consuming segments and peak demand hard to pin down.

Representative use cases

What Refinery
actually does
on a materials site.

Peak demand monitoring and target-based load control

Problem
Peaks driven up by high-power equipment running together
Approach
A target demand is set and peak usage is held inside it, with an alert raised before the target is exceeded.
Outcome
Lower electricity charges and reduced peak risk

Demand-based compressed air control and monitoring

Problem
Compressed air equipment overrunning against real demand
Approach
Power draw, pipeline flow, temperature and humidity are measured together so supply is controlled to match demand.
Outcome
Lower energy use and longer equipment life

Heat-treatment temperature and time analysis

Problem
Process deviations confirmed only once the piece is out
Approach
Furnace temperature, hold time and cooling curves are stacked batch by batch and compared with the normal pattern.
Outcome
Steadier material quality

Energy flow visualized by process

Problem
No visibility into which process consumes the energy
Approach
Processes and assets are connected through an ontology so energy flow gathers into one structure and lines up on equal terms.
Outcome
Over-consuming segments identified and process efficiency improved

Remote cooling water control and monitoring

Problem
Cooling water equipment that has to be checked on foot
Approach
Cooling water temperature, flow and pump state are monitored remotely, and any departure from the band is raised at once.
Outcome
Steadier equipment operation

Vibration-based equipment monitoring

Problem
Rotating-equipment faults that surface only after a stop
Approach
An AI agent reads anomalies in vibration trends to catch early signs, and proposes both the likely cause and the next action with the history behind it.
Outcome
Failures prevented and maintenance made more efficient

How it fits together

How site data gains meaning and turns into a decision.

Site
  • Heat-treatment furnaces
  • compressed air
  • cooling water
  • forming equipment sensors
Connect
  • SCADA
  • PLC
  • FEMS
  • Modbus TCP
  • CAN
  • LTE-M
Refinery
  • Ontology
  • AI agent
  • rules and automation
Use
  • Process dashboard
  • peak alerts
  • quality history

Where PLC or FEMS already exists, Refinery sits on top of it and integrates both ways rather than replacing it. Where none exists, collection is built from the ground up.

Systems we connect to

The systems and protocols commonly used on materials sites.

SCADAPLCFEMSMESModbus TCP⁠/⁠IPCANOPC-⁠UALTE-M

Systems not listed here can still be connected over standard protocols and APIs. Get in touch and we will walk through it.

What you gain

Benefits across operations, engineering and management.

Steadier heat-treatment quality

Temperature patterns are kept batch by batch so the same result repeats.

Compressed air matched to demand

Only what is needed is supplied, cutting waste and leaks.

Peak demand caught early

Load is lowered before peak demand is reached.

Energy variance by process

Energy is split process by process to pin over-consuming segments.

Failures prevented

Vibration catches faults early, making maintenance more efficient.

Let’s find the answer that fits
your materials operation, together.

Request a demo