AI Revolution in Roll Design: Sayyed Fazal Mehdi Honored at IRD North America Fall 2025 Conference
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By Sayyed Fazal Mehdi, Edited by Adam Rizvi, The India Observer, TIO: Richmond, Virginia – October 2025:
The Institute of Roll Design (IRD) North America Fall 2025 Conference in Richmond, Virginia, drew more than 100 professionals from around the world to explore the latest innovations redefining the steel industry. Among the highlights was the recognition of “AI in Roll Pass Design,” authored and presented by Sayyed Fazal Mehdi, Roll Pass Designer at Nucor Steel Utah, which earned the prestigious Best Operator Paper Award.
Widely regarded as one of the leading global platforms for roll mill operators, pass designers, and technology experts, the IRD Conference fosters collaboration and knowledge exchange to advance the future of steelmaking. This year, delegates from Italy, India, Canada, and the UK focused on the transformative power of artificial intelligence in traditional steel production.
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Transforming a Core Steelmaking Process
Roll pass design — the engineering discipline that determines roll shapes and sequences used to transform billets into finished steel products — lies at the heart of every efficient, high-quality mill.
In his paper, Mehdi distinguished between automation and true AI, offering a live demonstration of how machine learning can optimize roll pass design. His model showcased how AI-driven prompts enhance decision-making, predict rolling flaws before production, and develop intelligent checklists to guide process control.
“AI doesn’t replace the designer — it empowers them,” Mehdi explained. “It learns from years of experience and helps us make faster, smarter, and more consistent design decisions.”
An ‘Eye-Opener’ for Industry Professionals
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Attendees described Mehdi’s presentation as both practical and visionary.
“It was an eye-opener,” said one participant from Canada. “His approach showed exactly how AI can take roll pass design from experience-based to evidence-based engineering.”
Held in the historic city of Richmond, Virginia, the conference buzzed with technical discussions and a shared drive toward innovation. Mehdi’s work stood out for its real-world applicability, sparking conversations among engineers eager to integrate AI into their mills.
Forging the Future: Smarter, Sustainable Steelmaking
Industry experts view AI as a catalyst for efficiency, cost reduction, and sustainability. By minimizing energy losses and optimizing operations, AI-driven tools can help steelmakers enhance product quality while reducing carbon footprints.
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As the conference concluded, enthusiasm for AI’s potential was unmistakable.
“Winning this award is an honor,” Mehdi said. “But the true reward will come when more designers and operators start exploring AI and bring even more innovative ideas to future conferences — making our North American steel mills more efficient, safe, and sustainable.”
The steel industry is clearly entering a new era — one where intelligence and metallurgy unite to forge not just stronger steel, but a smarter and more sustainable future.
Curated by Humra Kidwai
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