The cheapest charge that still makes the grade.
Every scrap in your yard carries a dozen elements at once, and not all of them survive the melt. This works out — for each grade you make — exactly what to charge, what it will cost, and which of your chemistry limits is the expensive one.
By invitation. Two logins per plant.
Cost / t finished
₹29,021.76
Batch cost
₹5,80,435.11
Charge needed
20.619 t
Materials
3
| Material | Tonnes | % of charge |
|---|---|---|
| Machine Turnings | 9.114 | 44.2% |
| Shredded Auto Scrap | 8.310 | 40.3% |
| Sponge Iron (DRI) | 3.195 | 15.5% |
What makes this hard
A good melter approximates. A spreadsheet cannot keep up.
Every scrap carries a dozen elements at once
Buy a lorry of turnings for its carbon and you have also bought its copper, its sulphur and its phosphorus. There is no such thing as adding one element on its own.
Not all of it survives the melt
Silicon and manganese burn off, at different rates in swarf than in bar ends. What you charge and what you get are two different chemistries, and only one of them is on the certificate.
Phosphorus you cannot melt out
An induction furnace has no slag chemistry to speak of. Whatever phosphorus goes in, comes out. It is the limit that binds most often, and the one nobody has costed.
Thirty-odd materials, a dozen elements, a stock limit on every one and a window at both ends of every element — that is more combinations than anyone can hold in their head, and more than a spreadsheet will search. So the yard gets charged the way it was charged last time, and the cost of that is invisible.
The number nobody has
The last 0.01% of phosphorus tolerance is costing ₹4,071 a tonne.
On a plain low-carbon grade, holding phosphorus one hundredth of a percentage point tighter would add ₹4,071 to every tonne of steel — 14% of the entire cost of the metal.
On a case-hardening grade from the same yard it cannot be done at all, at any price. No combination of that scrap goes lower, because an induction furnace cannot remove phosphorus.
Nobody knew that before, because nobody could compute it.
Worked from a demonstration yard of thirteen materials and three grades. Every figure on this page is produced by the same calculation the product runs, from inputs we publish — not an illustration.
| El | Min | Max | Expected | Window | Holding it |
|---|---|---|---|---|---|
| C | 0.0000 | 0.1200 | 0.1200 | At maximum | |
| Mn | 0.2500 | 0.5000 | 0.3454 | ||
| S | 0.0000 | 0.0350 | 0.0295 | ||
| P | 0.0000 | 0.0300 | 0.0300 | At maximum | |
| Cu | 0.0000 | 0.2500 | 0.1713 |
What it gives you
Three answers, for every grade you make.
What to charge
The exact tonnage of each material, to the kilogram, priced at what you actually paid for it — and never more than you have in the yard.
What you will get
The chemistry that mix will produce after melting losses, element by element, against your window for the grade — and which limits it is sitting on.
What your limits cost
For each limit the mix is holding, what one hundredth of a percentage point tighter would add per tonne. In money, not in theory.
And when a grade cannot be made at all
It says which limit is out of reach, by how much, and which material in your yard is putting it there — then names what would fix it, including the things you have run out of. That is the case for the purchase, written for you.
Your yard goes in from a spreadsheet
Materials, chemistry, recovery rates and grade windows import from Excel in one go, with a preview before anything is saved. Results come back out as a workbook or a printable charge sheet for the furnace floor.
It does not replace your metallurgist.
It does the arithmetic they do not have time to do, exactly. The judgement — heel practice, slag, trim additions, what the customer will actually accept — stays with the people who have it. Every result carries that warning, on screen and on paper.
Access
By invitation, two logins per plant.
One for whoever maintains the yard and the grade windows, one for whoever reads the charge sheet. Tell us about your shop and we will set it up.