Transforming EAF Melt Data Management with an In-House Workflow Tool

PLANT TALK

Plant Talk is an in-house microservice platform developed to connect engineers, researchers, and operators before, during, and after every electric-arc furnace (EAF) melt.

Plant Talk addresses the pervasive challenge of “dark data” - the unstructured, undocumented insights that often reside in emails, chats, and word-of-mouth exchanges.It captures real-time process inputs, contextual observations, and safety notes in a centralised hub.

Since its deployment, Plant Talk has enhanced data trust and reproducibility, streamlined collaboration across the Normanton Plant, laboratories, and plant teams, and provided clean, rich inputs for MPI’s SteelGenie AI predictive-analytics tool, driving higher-quality, more consistent steel compositions.

WHY PLANT TALK HAS BEEN DEVELOPED

The steel and metals sector is undergoing rapid digital transformation, yet many production workflows remain reliant on fragmented, manual record-keeping. Informal communications - vital decisions exchanged via Teams chats or spoken “tribal knowledge” escape formal archiving, resulting in inefficiencies and duplicated efforts. Recognising this gap, MPI leveraged its expertise in mid-TRL R&D to build Plant Talk, a tailor-made platform that integrates seamlessly with EAF/LAF operations, lab analysis (OES, XRF, XRD), and AI pipelines like SteelGenie AI.

Plant Talk’s modular micro-service architecture is process-agnostic, enabling rapid configuration across any workflow, from ladle metallurgy to rolling or finishing. Plant Talk augments rather than replaces existing data systems, so its value reaches far beyond EAF melts to any industrial setting.

THE OPPORTUNITY

• Dark Data Unlock: Unused insights in emails, messaging, and oral exchanges represented untapped potential for operational and quality gains.
• Collaboration Gaps: Disconnected silos between plant operators, lab analysts, and researchers hindered rapid troubleshooting and process optimisation.

MPI saw a proactive opportunity to revolutionise data workflows by creating a tool “by Steel Makers, for Steel Makers,” ensuring every observation - from safety notes to melt-purpose definitions - was captured, contextualised, and available for analysis.

THE PROJECT

1. Platform Design & Development
• Built Plant Talk as a microservice with modular architecture, enabling future extension to other processes.
• Developed role-specific interfaces for EAF/LAF operators, lab analysts, researchers, and managers.
2. Digital Data Capture
• Real-time recording of melt inputs (e.g., DRI, ferrochrome, tantalum additions) and contextual notes on purpose, methods, and safety.
• QR-code tracking for samples and melts, automatically linking lab results to process records.
3. Centralised Information Hub
• Unified repository for all experimental data, ensuring reproducibility, accountability, and streamlined retrieval.
4. AI & Analytics Integration
• Embedded live-data ingestion via MQTT into SteelGenie AI, providing dynamic recipe predictions based on the most recent analysis.

THE RESULTS

• Enhanced Data Trust: Comprehensive, time-stamped records ensure quality control and full traceability.
• Improved Collaboration: Cross-department visibility has reduced troubleshooting time by enabling immediate access to observations and results.
• Process Optimisation: Reliable data feeds into SteelGenie AI have improved first-pass yield of target steel compositions by reducing variability.
• Reproducibility & Accountability: Detailed experimental logs support patent filings and strengthening MPI’s scientific integrity.
• User Adoption: Positive feedback from EAF operators and lab analysts highlights the platform’s ease of use and role-specific functionality.

WHY CHOOSE MATERIALS PROCESSING INSTITUTE

• Domain Expertise: Decades of steelmaking R&D is applied to help deliver new AI driven processes.
• Specialist Facilities: Access to lab-scale and pilot-scale furnaces, advanced materials characterisation, and integration with existing 7 tonne EAF.
• In-House Development: Rapid, iterative tool creation aligned with operational realities, ensuring high adoption and immediate impact.
• AI Integration: Native compatibility with SteelGenie AI for predictive composition modelling, leveraging both live and historical data.

Interested in leveraging digital workflows and AI-driven insights for your operations? Visit https://www.mpiuk.com/contact-us.htm or email enquiries@mpiuk.com to learn how Plant Talk and SteelGenie AI can transform your processes.