Artificial Intelligence in Steelmaking: European iSteel-Expert Project Successfully Concluded

Artificial Intelligence in Steelmaking: European iSteel-Expert Project Successfully Concluded

Extremely high temperatures and power levels, complex processes, and decisions that demand both expertise and rapid response. Today, at an Italian steel plant belonging to the Pittini Group, a system developed through the collaboration between the Sant'Anna School of Advanced Studies and Tenova is supporting operators in monitoring the electric arc furnace using advanced artificial intelligence techniques.

This is the outcome of iSteel-Expert, a European project funded by the Research Fund for Coal and Steel (RFCS), the European Union programme dedicated to research and innovation in the steel and coal sectors. After three years of activity, the project has successfully reached its conclusion. Throughout the project, the Sant'Anna School of Advanced Studies and Tenova S.p.A. worked side by side to transform research into a practical industrial solution-not a laboratory prototype, but a system that has been installed, validated, and is currently operating under real industrial conditions.

Coordinated by Tenova, a global leader in technologies for the metals industry, the project developed a virtual expert assistance system capable of monitoring the steelmaking process around the clock, collecting and analysing plant data, and supporting operators in process control, maintenance, and anomaly management.

By integrating advanced sensors, digital platforms, machine learning algorithms, and data visualisation tools, iSteel-Expert helps improve the reliability, safety, and efficiency of steel production operations. One of the project's most significant achievements is its demonstrative nature: the platform has been implemented and validated under real operating conditions at the Pittini Group's SiderPotenza steel plant, where it remains fully operational.

The Contribution of the Sant'Anna School of Advanced Studies

Within the project, the Sant'Anna School of Advanced Studies played a key role in developing artificial intelligence tools for image analysis, anomaly detection, and classification, contributing multidisciplinary expertise in metallurgy, data analytics, and computer science.

In particular, the research team from the TeCIP Institute (Institute of Telecommunications, Computer Engineering and Photonics), led by Professor Valentina Colla, developed machine learning-based image processing techniques to detect critical events, such as the presence of personnel near the furnace during operations where access is not permitted, or excessive smoke emissions. The team also developed advanced process data analysis methods for the early identification of abnormal operating conditions. Through these technologies, artificial intelligence contributes to the development of tools that enhance operators' situational awareness and improve the management of information generated by the plant.

"The iSteel-Expert system demonstrates how Artificial Intelligence can be used to enhance operators' capabilities in a challenging and complex industrial environment. Rather than replacing people, it supports the daily work of plant technicians, helps preserve and expand company know-how, and facilitates its transfer to future generations. The project also stands as an excellent example of collaboration between academia and industry, built on a continuous and productive exchange in which the university drives the exploration of cutting-edge technologies, while the company contributes its extensive expertise in transforming scientifically validated solutions into practical industrial tools through its flexible and highly customisable development platforms."

Artificial Intelligence Serving Safety and Efficiency

Among the project's most innovative outcomes is the application of advanced artificial intelligence and computer vision techniques to monitor steel production operations. The algorithms developed can detect critical events, identify potential anomalies, and assist personnel in managing the production process, delivering tangible benefits in terms of safety, operational efficiency, and process repeatability.

To explain the technologies developed in an accessible way, the project team also produced an outreach video illustrating how artificial intelligence is integrated into the iSteel-Expert system.

The iSteel-Expert consortium also included two academic partners-Université Catholique de Lille and Universidad de La Rioja-as well as the Italian SME Sim4Future. These partners developed an integrated training environment based on simulation, virtual reality, and advanced human-machine interaction technologies, further enhancing the system's potential to support the digital transformation of steel plants.