Skip to content

 More Yield, Less Cost – The Value of Fast Slag Analysis in Verona 

Redefining Slag Analysis

Short Summary:
At Acciaierie di Verona, part of the Pittini Group, fast slag analysis has been in use since May 2025. With reliable results available in around 20 seconds, the system enables real-time process control. This provides a clear and continuous view of the process status, supporting more stable operations, improved steel quality, and measurable economic benefits in both Opex and Capex.

Initial Situation / Plant Context:
Acciaierie di Verona operates a classical EAF–LF minimill with a broad product portfolio, serving applications from construction to cold drawing and the mechanical industry. Production is based on scrap, with all the typical variability this brings.
The plant stands out due to its location in Verona, a city known worldwide for culture and tourism, including its association with Romeo and Juliet. Running a steel plant in such an environment requires controlled and efficient processes with minimal disruption.
In this setup, slag is a key control parameter. Its composition directly influences desulfurization efficiency, steel cleanliness, refractory wear, and metallic yield.

Challenge (Pain Points):
In general, slag control in EAF and LF operations is limited by the speed and practicality of available analysis methods. Conventional XRF-based workflows require time-consuming sample preparation and centralized lab infrastructure. This creates a structural delay between sampling and decision-making. In practice, this means that process adjustments are often based on outdated data or operator experience. Especially with increasing scrap variability, this leads to fluctuations in FeO content, basicity, and overall slag performance. The result is reduced process stability, lower yield, higher refractory wear, and avoidable energy consumption.

Pittini 2
QLX9 in Operation at Pittini Verona
QLX9 Pittini in the control room
QLX9 Pittini in the control room

Solution (Implementation of QuantoLux Technology):
Since May 2025, QuantoLux QLX9 has been used at Acciaierie di Verona for rapid slag analysis directly close to the process. The workflow is simple and designed for industrial use:

  • minimal sample preparation
  • direct Laser OES (LIBS-based) measurement
  • multi-element results within ~20 seconds scanning time

The total turnaround time is around 2–3 minutes. Compared to traditional XRF methods, this significantly reduces the delay between sampling and action. At the same time, Laser OES complements XRF, especially in situations where fast feedback and flexible handling are required. Today, the installation in Verona is part of a growing installed base. In Italy and Slovenia combined, four QLX9 slag analyzers are already in operation, reflecting increasing acceptance of fast, on-site slag analysis in EAF-based steelmaking.

Results (Measured Impact):
From a business perspective, the value of fast slag analysis becomes visible in several areas. In general, the main driver is the reduction of uncertainty in process control. At Acciaierie di Verona, this translates into improved desulfurization performance, lower oxidation levels in the EAF slag, and extended ladle lifetime. These effects are well known in the industry: better slag control leads to improved metal recovery, lower flux consumption, and reduced refractory wear. Faster data availability also increases the number of effective process corrections per heat. Instead of reacting once, operators can adjust multiple times if needed. This improves consistency across heats and reduces variability. Overall, the economic impact is a combination of yield improvement, cost reduction, and increased process stability.

Operational Impact (Daily Work):
In daily operation, the main change is the availability of immediate feedback. Operators no longer need to wait for lab results but can work with near real-time data. In general, this leads to faster and more confident decisions. Process steps such as slag conditioning at the LF become more controlled and repeatable. Manual effort for sample preparation is reduced, and the dependency on centralized lab workflows decreases. The system is easy to use, which supports acceptance in the melt shop environment. Over time, this also improves the overall data quality and transparency of the process.

Strategic Context:
The Italian steel industry has a very specific structure. In contrast to regions with large integrated BF–BOF plants, Italy is dominated by electric steelmaking. The majority of production is based on EAF minimills, often highly specialized and focused on specific product niches with demanding quality requirements. This setup leads to a strong dependence on scrap quality and flexibility in raw material sourcing. At the same time, it requires precise and fast process control to manage variability and maintain consistent product quality. In general, this environment increases the importance of real-time data. Fast slag analysis fits directly into this need. It enables operators to react quickly to changing conditions and supports stable, repeatable processes even with variable input materials.

Laser OES-based slag analysis complements established technologies such as XRF, especially where speed, flexibility, and minimal sample preparation are critical. It supports higher sampling frequency and enables data-driven decision-making directly at the process. For plants operating in constrained environments—such as urban locations like Verona—efficient and stable processes are even more important. Fast slag analysis contributes directly to this objective.

Customer Voice:
“Acciaierie di Verona runs a minimill producing a wide variety of steel grades, servicing applications in the building sector to cold drawing and mechanical industry. QuantoLux Slag Analyzer proved to be an excellent tool of the control of the metallurgical process. Its fully reliable, fast response results - 20 seconds of scanning following 2 minutes of sample preparation - helped us to improve steel cleanliness, fostering desulphurization, extending ladles' life, reducing primary furnace slag oxidation and, last but not least, improved confidence of operators in the implementation of the practices. All in all, QuantoLux was a highly valuable investment with relevant benefits in Capex and Opex.” — Antonio Della Gaspera

Conclusion: 
Fast slag analysis reduces the gap between measurement and action. In general, this directly improves process control, reduces costs, and increases operational stability. At Acciaierie di Verona, this translates into a clear and measurable business case.