🇧🇷Brazil

Falhas de Qualidade por Mistura Inadequada de Cargas em Fornos de Arco Elétrico

Updated: Feb 20263 verified sources

Definition

Scrap quality inconsistency directly drives rework. Poor scrap classification results in higher residual alloys, contaminants, and impurities entering the melt. Data analytics applications have demonstrated 4.4% lower scrap rates through optimized operating parameters. Without optimization, contaminant levels worsen over successive scrap-reuse cycles, degrading available steel grades.

Key Findings

Financial Impact: PROVEN: 4.4% scrap rate reduction achievable via analytics optimization. For a 100-ton/day EAF facility: 4.4 tons/day = ~1,600 tons/year × R$ 2,500–R$ 3,500/ton scrap loss = R$ 4,000,000–R$ 5,600,000 annual impact. Conservative rework rate in quality-driven facilities: 2–5% of output.
Frequency: Per melt cycle; EAF typically operates 4–6 melt cycles per day.
Root Cause: Unverified scrap composition from multiple suppliers; lack of incoming scrap laboratory analysis; charge mix decisions based on cost minimization rather than metallurgical optimization; absence of digital twin simulations to predict melt quality.

Why This Matters

The Pitch: Brazilian EAF operators lose 4.4%+ of output to quality defects due to unoptimized scrap composition. Automated charge mix modeling and real-time scrap quality assessment eliminate rework loops and customer compensation claims.

Affected Stakeholders

Metallurgists (charge mix recipe development), EAF operators (melt control), Quality assurance (chemical analysis), Supply chain (scrap sourcing and classification), Customer service (handling customer compensation for spec failures)

Deep Analysis (Premium)

Financial Impact

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Current Workarounds

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Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

Ociosidade e Atrasos por Classificação Manual de Sucata

LOGIC-based estimate: Manual scrap classification = 40–60 hours/month per facility. At Brazilian industrial labor cost (R$ 80–120/hour all-in): R$ 3,200–R$ 7,200/month = R$ 38,400–R$ 86,400/year per facility. Capacity loss from melt queue delays: conservatively 2–4 unscheduled production delays/month × 4 hours = 8–16 hours/month × R$ 5,000–R$ 8,000 lost production value = R$ 40,000–R$ 128,000/year per facility. **Total per facility: R$ 78,400–R$ 214,400/year.**

Decisões Subótimas de Compra de Sucata por Falta de Visibilidade de Qualidade

LOGIC-based estimate: Assume average EAF facility processes 100 tons/day of scrap input. If poor quality forces 10–15% additional dilutant cost (pig iron/DRI at premium): 10–15 tons/day × (R$ 500–R$ 1,000 premium over scrap cost) = R$ 5,000–R$ 15,000/day = R$ 1,500,000–R$ 4,500,000/year per facility. Conservative estimate: 5% overpay on scrap sourcing = R$ 800,000–R$ 1,200,000/year per 100-ton facility.

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