- 4 July 2023
- July 2023
Seven Gerdau plants are operating Q-Reg electrode-control systems, ordered all at once
Supplied by Danieli Automation, Q-Reg allows excellent performance improvements in all the Brazilian installations

Seven electric arc furnaces of Gerdau in Brazil have been recently upgraded with the innovative Danieli Q-Reg advanced electrode-control system.
Patented Q-Reg provides control for the electrodes based on a high-performance HiPAC process controller, with fast data acquisition and real-time process parameters elaboration.
Also, it delivers ideal arc coverage for each electrode, improves arc stability, and analyzes radiation index.
These process feedbacks make possible the dynamic adjustment of the setpoints, to maximize furnace efficiency and protect against panels damages, thus ensuring a reliable and safe operation.
Furthermore, Q-Reg advanced diagnostic tools enable deeper insight on every heat, including visualization of circular diagrams and variable trends, Gauss, 3D visualization and Fast Fourier Transform (FFT) of electrical parameters.
Gerdau Brasil benefits from the local assistance and maintenance services of Danieli do Brasil.
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Following here are the feedbacks from seven Gerdau process specialists:
Francisco Willian da Silva Gomes, Process Specialist
“The installation of Danieli Q-Reg regulator on the EAF at Cearense provided significant impacts on the process and operational stability.
“After installing the equipment, a reduction of electric power consumption in the EAF, a PowerOn reduction (about 7%) and a considerable decrease in the occurrence of breakdowns (about 50%, with a strong impact on operational exposure to process) were noticed.
“These reductions were confirmed by the decrease in the consumption of electrodes (approx. 13%). During the period, there were variations in the use of scrap and pig iron (0 to 18% of cold load) and operational improvements (optimization of chemical recipe, cold load stabilization, etc.); in these challenging scenarios, the regulator allowed us to capture the excellent performance of our furnace and ensure operational safety.”
Guilherme Pimentel Silva, Process Specialist
“At Gerdau São Paulo, the Q-REG took process performance and control to the next level. We had a significant improvement in electric power indicators of almost 8%, electrode consumption with gains of almost 10%, and elimination of electrode breakdown for more than four months, as well as a refined power control in the furnace that greatly contributed to a significant PowerOn reduction.
“From a safety point of view, there is a monitor for panel temperature, associated with the regulator and able to work in case of emergency without the operator’s intervention. In addition to this, we are fully supported by Danieli for modifications and assistance in case of failure.”
Luiz Maurício B. de Azevedo, Process Specialist
“Danieli Q-Reg regulator helped us with the electric power consumption. Another advantage is that the regulator has a very user-friendly and intuitive interface, which facilitates analyses and corrections.”
Felipe das Dores Machado, Process Specialist
“As a consequence of transparency, speed and interest in carrying out a good job, we were able to perform the start-up in a short time and with minimal impact on our process. Based on the qualitative analysis, immediately after using the Q-Reg regulator, we observed a visible improvement in electrode stabilization during the melting phase, an increase of electric power that ensures a PowerOn reduction of 2.7 min/run.”
Bruno Veiga Fontana, Process Specialist
“With the new regulator, we had a significant reduction of panel heating, as well better operational safety conditions. All this is combined with a modern and user-friendly work layout.”
Anderson Araújo, Process Specialist
“We were able to reduce the trips’ PowerOff by approximately 20%. The possibilities for adjustment and data analysis, and adjustment reliability give a huge expectation of performance increase.”
Manuela Arend Prediger, Process Specialist
“The solution that was implemented speeds up decision-making for process improvements and helped in dealing with failures. Moreover, the technical support of Danieli specialists has been fundamental to adjusting the regulator in order to find the potential gains that the equipment can provide to the process.”
- Enrico Plazzogna
- e.plazzogna@dca.it
- +39 0432 518 618