Ferroalloy additions, Fe-Si, Fe-Mn, Fe-Cr and the rest, are one of the largest single cost lines in steelmaking after raw iron and energy, and the most common way plants overspend on them has nothing to do with market price. It is overcorrection: adding more alloy than the chemistry target actually needs because the lab result lags the addition by several minutes, so operators add a safety margin rather than wait. Real-time chemistry tracking removes the guesswork that margin is covering for. See alloy addition accuracy tracked against real-time chemistry on your own heats.
Add the Alloy the Chemistry Needs, Not a Margin for Uncertainty
iFactory AI tracks Fe-Si, Fe-Mn, and Fe-Cr additions against real-time chemistry so operators can trust the target instead of adding a safety buffer.
Why Overcorrection Is the Default
A lab chemistry result takes minutes to come back, and in that gap the heat keeps moving toward tap.
Operators who have been burned by an off-spec heat learn to add a little extra Fe-Mn or Fe-Si rather than risk missing the grade target, and that habit, repeated across thousands of heats a year, adds up to a real cost.
Where the Overspend Concentrates
Not every alloy addition carries the same overcorrection risk. The table below shows typical patterns by alloy type.
| Alloy | Typical Margin Added | Cost Sensitivity | Correction Approach |
|---|---|---|---|
| Fe-Si | 3-6% over target | High, price-volatile | Real-time silicon tracking |
| Fe-Mn | 4-8% over target | Moderate | Tighter addition timing |
| Fe-Cr | 2-5% over target | High, grade-critical | Continuous chromium tracking |
See Your Own Alloy Addition Accuracy
Book a 30-minute session and iFactory AI will show where alloy margin is being added on your own recent heats.
What Real-Time Tracking Actually Does
The system does not replace the lab. It closes the gap between additions and lab confirmation.
Continuous Chemistry Estimate
Combines charge composition and known yield factors to estimate chemistry between lab samples.
Addition Recommendation
Suggests the alloy quantity needed to hit target, based on the live estimate.
Lab Confirmation Tie-In
Reconciles the estimate against each lab result to improve accuracy over time.
Campaign Cost Tracking
Rolls up alloy spend against target to show savings by grade and campaign.
Accuracy Builds Trust Over a Campaign
The bars below show an illustrative trend in addition accuracy over the first weeks of rollout.
A Composite Campaign Comparison
Twelve grades tracked for alloy cost against target before and after real-time tracking went live.
Rolling It Out on the Melt Shop Floor
iFactory AI arrives turnkey, built to connect to existing charge, lab, and alloy addition systems.
Frequently Asked Questions
Does this replace our chemistry lab?
No, the lab remains the authoritative chemistry check. The live estimate fills the gap between lab samples and reconciles against each lab result to stay accurate, rather than replacing the lab process. Support can walk through how the two work together on your melt shop floor.
How fast do operators start trusting the live estimate?
Accuracy typically builds over the first few weeks as the model calibrates against your specific grades and charge patterns, and most plants see margin reduction accelerate once operators see consistent agreement with lab results. See a sample accuracy ramp-up in a walkthrough.
Does this work across all our grades, including specialty alloys?
Yes, the model is calibrated per grade using your own production history, so high-chromium and other specialty alloy grades get their own tracking rather than a generic estimate.
What data do we need to get started?
Charge composition records, lab chemistry results, and alloy addition logs by heat are the core inputs. Most plants already hold these across melt shop and lab systems.
How does this connect to cost per tonne reporting?
Alloy spend against target rolls up by grade and campaign, so savings show up directly in cost per tonne tracking alongside other driver analytics. Ask support how alloy savings are reported in your cost system.
Stop Paying for a Chemistry Margin You Don't Need
iFactory AI tracks alloy additions against real-time chemistry so operators can trust the target. Book a walkthrough to see it on your own melt shop.
