Our Services

We work directly with plant metallurgists and process engineers to solve high-temperature processing problems, from optimising an existing furnace route to evaluating an entirely new flowsheet.

Our consulting draws on decades of original research in slag chemistry, thermodynamics, and process modelling, applied to practical outcomes in ferrous and base metals operations.

Service offerings

Process Modelling

We help optimise metallurgical performance through process modelling, covering management of impurities, metal recovery, refractory life and fuel consumption.

  • Our models draw on decades of experimental data and fundamental understanding of slag chemistry, thermodynamics and kinetics.
  • We work directly with plant metallurgists to translate model outputs into practical process improvements.

Feasibility Studies

We help companies develop and evaluate energy efficient process flowsheets for lower-grade ores and complex feed materials.

  • We apply fundamental knowledge of melt chemistry and reaction kinetics to assess whether a process route is viable before significant capital is committed.
  • We cover smelt, leach, and concentrate options, drawing on extensive experimental data and thermodynamic modelling capability.

Towards Zero Waste

We advise on efficient use of resources and renewable carbonaceous fuels in metallurgical processes.

  • This includes assessment of biomass and charcoal as reductants and fuels in iron and steelmaking, and dry granulation of slags for waste heat recovery and value-added by-product production.
  • We help clients identify practical pathways to reduce both waste streams and GHG emissions without compromising metallurgical performance.

Sustainability Assessments

We facilitate assessment of industrial ecology and sustainability using life cycle assessment methodology.

  • We evaluate the environmental footprint of metallurgical processes from raw material extraction through to product delivery.
  • We help clients identify where the greatest opportunities for GHG reduction and resource efficiency lie.

Technical Training

On-site courses for graduate metallurgists and plant engineers, focused on thermodynamics and kinetics for ferrous and base metals processing.
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Frequently asked questions

What does a pyrometallurgy consultant do?

A pyrometallurgy consultant applies fundamental knowledge of high-temperature chemistry and process engineering to solve practical problems in metals production. This includes optimising existing smelting and refining operations, evaluating new process routes, managing impurities, and reducing energy consumption and emissions.

How is process modelling used in metallurgy?

Process modelling in metallurgy uses mathematical models of slag chemistry, thermodynamics, and reaction kinetics to simulate and optimise furnace and reactor performance. Models are validated against experimental data and used to predict the effects of changes to raw materials, operating conditions, or process design before implementation.

What is life cycle assessment in mining and metallurgy?

Life cycle assessment (LCA) in mining and metallurgy evaluates the environmental footprint of a process from raw material extraction through to product delivery. It quantifies greenhouse gas emissions, energy consumption, water use, and waste generation, helping operators identify where the greatest opportunities for environmental improvement lie.

What is the role of slag in steelmaking?

Slag is a molten oxide mixture that forms during steelmaking and plays a critical role in process performance. It absorbs impurities removed from liquid steel, protects the metal from atmospheric oxidation, and influences heat transfer and refractory wear. Controlling slag chemistry — its basicity, viscosity, and oxidation state — is one of the primary levers for improving metal quality, reducing impurity levels, and extending furnace lining life.

How do you reduce refractory wear in a furnace?

Refractory wear in pyrometallurgical furnaces is primarily controlled by the chemistry and physical properties of the slag in contact with the refractory lining. Key strategies include adjusting slag composition to reduce its corrosivity toward the refractory material, operating at slag saturation with respect to the refractory oxide, and controlling temperature and fluid flow to minimise erosion. Process modelling can be used to identify the optimal slag practice for a given refractory system.

What causes metal losses in pyrometallurgical processes?

Metal losses in smelting and converting occur through several mechanisms: metal or matte droplets entrained in the slag phase, dissolution of metal values in the slag at thermodynamic equilibrium, and volatilisation of elements such as lead and zinc at high temperatures. Minimising metal losses requires understanding the thermodynamic distribution of each element between metal, matte, slag, and gas phases — which depends on temperature, oxygen potential, and slag composition.

What is the difference between a feasibility study and a scoping study in metallurgy?

A scoping study is a high-level, low-cost assessment of whether a process concept is worth pursuing further — it identifies the most promising options and eliminates clearly unviable ones. A feasibility study goes deeper, developing a preferred process route in sufficient detail to support a capital investment decision. Both rely on process modelling, thermodynamic analysis, and assessment of feed material characteristics to evaluate technical and economic viability.