Intelomelt Alu

🧮 Charge Calculator

MF Charge Planning — Predict Bath Chemistry

● Heat Information

Heat No. / Batch No.

Grade / Alloy

Melt Date

Shift

Melt Furnace (MF)

Hold Furnace (HF)

Operator

Target Tap Weight (kg)

Shift Supervisor

● Charge Materials (MF)

Material	Weight (kg)	Recovery %	Liquid (kg)	/kg	Cost

Total Charge / Liquid Yield 0 kg → 0 kg Material Cost 0.00

● Process Times Enter start & end times — cycle times calculated automatically

Process Step	Start	Cycle Time
── MF SIDE ──
MF Charging		—
Mix & Melting		—
Drossing 1		—
Fe Removal 1		—
Half Sample Time		—
── HF SIDE ──
Liquid Transfer		—
HF Process Start		—
Correction (HF)		—
Drossing 2		—
Fe Removal 2		—
Final Sample Time		—
Casting		—
Overall Cycle Time	Charge Start → Casting End

Dross Weight (kg)

Fe Removed (kg)

Ingots Produced (kg)

Rejections (kg)

SLO (kg)

Spillage (kg)

♻ By-product Rates (AED/kg) — sale/recovery price per kg for this heat

Dross Rate

Fe Rate

SLO Rate

Rejects Rate

Spillage Rate

Bath °C

Launder °C

Dis.Wheel °C

Mold °C

Atmo. °C

🛢 Oil Consumption — start/end in inches → auto-converted to litres

MF Start (in)

MF End (in)

MF Used (L)

HF Start (in)

HF End (in)

HF Used (L)

Total Oil (L)

L per inch (MF)

L per inch (HF)

Material	Charge kg	Recovery%	Liquid kg	/kg	Cost	%Total
TOTAL	—	—	—	—	—	100%

📦 Stock / Inventory

Raw material stock levels — update after receipts or physical count

Show low stock only

Raw Materials / Scrap

Total Materials

—

Low Stock (<500 kg)

—

Zero Stock

—

Total Stock (t)

—

Code	Material	Type	Stock (kg)	Cost/kg	Stock Value	Status	Adjust

Correction Materials / Additives (HF)

Total Additives

—

Low Stock (<100 kg)

—

Zero Stock

—

Total Stock (kg)

—

Code	Material	Type	Stock (kg)	Cost/kg	Stock Value	Status	Adjust

📥 Import Stock from Excel (Stock Report.xlsx)

Stock Report File

Dry run (preview only)

⚡ Charge Optimiser

Least-cost scrap mix — Linear Programming

● Optimiser Settings

Grade / Alloy

Target Liquid (kg)

Additives Max % (of total charge)

Respect stock limits

⚗️ HF Trim Calculator

HF Stage — Enter spectro, get addition quantities

● Spectro Input

Heat No.

Grade

Bath Weight (kg)

Sample Type

Charge Start

Charge End

Spectro Values (%)

📋 Heat Log

⬇ Export Excel

Heat No.	Date	Grade	Furnace	Operator	Tap Wt (kg)	← Half Sample					← Final Sample					📦 Bundles	Actions
						Si	Fe	Cu	Mn	Mg	Si	Fe	Cu	Mn	Mg

📦 Ingot Bundles

Log bundle weights per heat — 86 ingots per bundle

#	Bundle No.	Weight (kg)	Ingots	Notes	Del
Select a heat to load bundles, or click + 25 Rows to start entering data.
TOTAL		—	—

📦 Charge Details

Material-level breakdown per heat — kg, recovery, cost

Heat No	Date	Grade	Material	Charge (kg)	Recovery %	Liquid (kg)	Cost/kg	Line Cost (AED)

● Per-Heat Cost Summary

Heat No	Date	Grade	Materials	Total Charge (kg)	Total Liquid (kg)	Total Cost (AED)	Cost/kg Metal

📈 Recovery Learning

Back-calculate actual liquid recovery and improve material factors

● Analyse Heat Recovery

After casting is complete, enter the actual ingots produced. The system compares predicted vs actual liquid yield and suggests updated melt loss factors per material.

Heat No.

Ingots Produced (kg)

● Recovery History

Heat	Material	Prev Rec%	Actual Rec%	New ML%	Status	Date

🏷 Grade Manager

Aluminium alloy grades and chemistry specifications

● Grade List

Code	Name	Si Aim	Fe Max	Cu Aim	Actions

● New Grade

Grade Code

Grade Name

Aim Chemistry (%)

Min / Max Limits (%)

Element	Min %	Max %

📦 Raw Materials

Scrap, ingots and alloys for MF charging

● Material List

Code	Name	Type	Stock	Rec %	Si	Fe	Cu	Actions

● New Raw Material

Code

Name

Type

Stock (kg)

Cost ($/kg)

Loss Factors Recovery = 100 − Fe Solids − Dross − Melt Loss

Fe Solids %

Dross %

Melt Loss %

Liquid Recovery —

Chemistry (%)

🧪 Additives Manager

HF stage additives — ingots, silicon, dilution materials

● Additives List

Code	Name	Type	Supplier	Rec %	Si	Fe	Actions

● New Additive

Code

Name

Type

Supplier

Cost ($/kg)

Loss Factors

Fe Solids %

Dross %

Melt Loss %

Chemistry (%)

📥 Import Library

Bulk-import grades, raw materials, or correction materials from CSV or Excel

Import Grades

CSV / Excel columns required:


          code, name,

          Si_min, Si_max, Fe_min, Fe_max, Cu_min, Cu_max,

          Mn_min, Mn_max, Mg_min, Mg_max, Cr_min, Cr_max,

          Ni_min, Ni_max, Ti_min, Ti_max, Zn_min, Zn_max,

          Pb_min, Pb_max, notes

CSV / Excel columns required:


          code, name, type, cost_per_kg, melt_loss_pct, stock_kg,

          Si, Fe, Cu, Mn, Mg, Cr, Ni, Ti, Zn, Pb

CSV / Excel columns required:


          code, name, type, supplier, cost_per_kg, melt_loss_pct,

          Si, Fe, Cu, Mn, Mg, Cr, Ni, Ti, Zn, Pb

⬇ Download Template CSV — fill in and upload below

📂

Click to choose file or drag & drop

CSV or XLSX accepted

Preview & Result

Upload a file to preview rows before importing.

⚙ Settings

Company branding for printed reports

● Company / Report Branding

These details appear on every printed batch report (GOM-PLB-012 format). Configure once per customer installation.

Company Name

Address

Phone

Email

Report Reference No.

Currency Symbol

USD Exchange Rate (1 USD = x AED) — used for USD cost reporting

Default By-product Rates (AED/kg)

Dross Rate (AED/kg)

Fe Removed Rate (AED/kg)

SLO Rate (AED/kg)

Rejects Rate (AED/kg)

● Report Preview

—

— | —

Ref: —

● About

⬡ Intelomelt Alu — Aluminium Melt Intelligence System

Version 1.0 · 2026 · Powered by Intelomelt Platform

🤖 AI Metallurgy Assistant

Aluminium alloy chemistry · process troubleshooting · defect analysis

Active provider: checking…

👋 Hi! I'm your aluminium foundry assistant.

I can help with:
• Chemistry interpretation (ADC12, LM6, A380…)
• Charge & trim correction advice
• Recovery factor troubleshooting
• Casting defect root cause analysis

What do you need?

Quick:

📊 Dashboard

Production & Quality KPIs

Period:

⏳ Loading dashboard…

—

Heats (Period)

—

Heats / Day

—

Avg Cycle (min)

—

Avg Liquid kg/Heat

—

Total Tonnes

—

Avg Dross %

📅 Heats per Day

🥧 Heats by Grade

💰 Heat-wise Cost Analysis (AED) Input Cost By-product Revenue Net Cost

—

Total Input (AED)

—

By-product Rev (AED)

—

Net Cost (AED)

—

Net Cost (USD)

♻ Dross kg per Heat

♻ SLO kg per Heat

♻ Fe Removed kg per Heat

🔬 Grade Chemistry Trend MF (solid line) · HF (dashed) · Spec band (shaded)

Grade:

📉 RPT Density Index Trend

⚠ Defect Distribution

⏱ Process Time per Heat (minutes) ■ Charging ■ Drossing ■ Fe Removing ■ Correction

⏱ Charging Time (min)

⏱ Drossing Time (min)

⏱ Fe Removing Time (min)

⏱ Correction Time (min)

🛢 Oil Consumption per Heat (L)

🛢 Recent Oil Consumption

Heat	Date	MF (L)	HF (L)	Total (L)

⏰ Process Times per Heat (minutes)

Heat	Date	Charging	Drossing	Fe Removing	Correction	Cycle Total

🧪 RPT Results

Heat	Grade	Date	Density Index %	Result

🧪 RPT / Degassing Log

Reduced Pressure Test & Degassing Records

● Log New RPT Entry

Heat No.

Grade

Date

Operator

Density ATM (g/cm³)

Density VAC (g/cm³)

Density Index %

H₂ (cc/100g)

Degas Method

Gas Type

Degas Time (min)

Gas Flow (L/min)

Melt Temp (°C)

Flux (kg)

Result / Assessment

Notes

● RPT History

Heat	Grade	Date	DI %	H₂	Method	Result

🫧 Grain Refiner & Modifier Calculator

Calculate AlTiB, AlSr additions and fade timer

● Grain Refiner Calc

Additive

Melt Weight (kg)

Current Ti (ppm)

Target Ti (ppm)

● Modifier Calc & Fade Timer

Modifier

Melt Weight (kg)

Current Sr (ppm)

Target Sr (ppm)

● Fade Timer

Initial ppm (after addition)

Elapsed (min)

● Degassing Time Calculator

Melt Weight (kg)

Initial H₂ (cc/100g)

Target H₂ (cc/100g)

Gas Flow (L/min)

Method

Gas Type

Rotor RPM

Melt Temp (°C)

⚠ Casting Defect Log

Log and track casting defects by type, heat, and severity

● Log New Defect

Heat No.

Grade

Date

Operator

Defect Type

Severity

Defect Wt (kg)

Rejection % (qty)

Melt Temp (°C)

Density Index (%)

Root Cause

Corrective Action

● Defect History

Heat No.	Grade	Defect Type	Severity	Wt (kg)	Date

🔬 Spectrometer Import

OES / Metal Power format — Sample Name must end _HALF or _FINAL

▲ Upload OES CSV

📂

Drop CSV here or click to browse

Metal Power / Bruker OES — .csv or .txt

🔬

Upload a CSV to see parsed results here

● Import History

Date	Sample	Heat	Stage	Si	Fe	Cu	Mn	Mg	Ni	Op.
No imports yet

▼ Generic CSV Import (Metal Power / Bruker column-header format)

Source format

Link to Heat No.

Grade

Operator

Paste CSV or upload file

📁 File

📷 AutoWatch

Scans a folder every 10 minutes — auto-imports OES files when heat & stage are detected

Loading...

⚙ Watch Folder Settings

Folder path (where Metal Power / Bruker exports OES files)

AutoWatch

How it works:
Every 10 minutes the app scans the folder for .csv and .txt files.
• Files with Sample Name = HEATNO_HALF or HEATNO_FINAL are auto-imported.
• Files with a Heat No header field but no stage suffix are skipped (stage unknown).
• Each file is only imported once — tracked by filename + modification time.
• The heat record must already exist in the Melt Log for the import to succeed.

☰ Import Log

Time	File	Heat	Stage	Status	Message
No log entries yet

🧮 Charge Calculator

📦 Stock / Inventory

⚡ Charge Optimiser

⚗️ HF Trim Calculator

📋 Heat Log

📦 Ingot Bundles

📦 Charge Details

📈 Recovery Learning

🏷 Grade Manager

📦 Raw Materials

🧪 Additives Manager

📥 Import Library

⚙ Settings

🤖 AI Metallurgy Assistant

⚙ AI Provider Settings

✏ Edit Heat —

📊 Dashboard

🧪 RPT / Degassing Log

🫧 Grain Refiner & Modifier Calculator

⚠ Casting Defect Log

🔬 Spectrometer Import

📷 AutoWatch