METVORA
MANAGEMENT CONSULTANCY
Operational, project & commercial solutions for the steel and aluminium industries
Metvora helps steel and aluminium businesses improve plant services, recover value from by-products and deliver industrial projects. We define requirements and support implementation against agreed cost, safety and performance objectives.
We work with producers, processors and investors to turn operating problems into practical, commercially sound solutions. We establish what the plant needs, define the operating method and prepare clear scopes for equipment suppliers and contractors. Our support continues through procurement, mobilisation and verification of the agreed performance.
Select the service area relevant to an existing operation, a new facility or an expansion project.
Meltshop ancillary services, scrap management, material handling & resource recovery
Metvora advises on the non-core activities surrounding steelmaking while the producer retains control of metallurgy and furnace operations. We define service and equipment requirements, coordinate specialist inputs, close interface gaps and support procurement, mobilisation and delivery across EAF and LF slag handling and processing, pot-carrier operations, tundish and skull handling and cutting, metal recovery and other steelmaking by-products.
Steel consulting services
Appoint Metvora for a focused assignment or independent client-side support—from feasibility and tender preparation through specialist coordination, contractor selection, mobilisation, commissioning and performance improvement.
Feasibility studies and business cases; production data books; RFIs and RFQs; equipment and service specifications; bid evaluation; whole-life cost and risk review; contractor recommendation, negotiation and mobilisation planning.
Operating philosophy, material-flow and cycle model, make-or-buy analysis, scope boundaries, equipment and manpower requirements, RACI, service levels and KPIs—developed around the production plan and site constraints.
Define methods, equipment and safety controls for under-furnace digging, tapping-pit cleaning, furnace-area housekeeping and industrial cleaning. Review exclusion zones, SOPs, manpower requirements, training, competency and contractor performance.
Define slag-pot availability, pot-carrier fleet and cycle requirements, controlled transport, tipping and cooling, slag-pit capacity and safe methods for tundish and skull handling, cutting and movement.
Define the design basis and coordinate specialist plant layouts for facilities with annual processing capacities from 150 ktpy to over 1.0 Mtpy. Scope covers slag receipt, cooling and weathering, crushing, screening, magnetic metal recovery, LF slag powder recovery, material flows, equipment duties, stockpiles, product storage, utilities and performance criteria.
Slag characterisation, leachability and expansion testing, environmental approval, authority engagement, product specifications, industrial trials and customer qualification. Market and feasibility studies establish viable sales and offtake routes for road, asphalt, concrete and civil applications.
Develop the project and process design basis for DRI fines, mill scale, sludge, EAF dust and other metal-bearing residues. Coordinate feedstock characterisation, testwork, binder selection and specialist plant design; define capacity, equipment requirements, CAPEX/OPEX, tender criteria, supplier evaluation and performance guarantees.
Define sourcing, receipt, inspection, segregation, impurity removal, preparation, inventory control and furnace-delivery requirements for HMS 1 & 2, shredded and internally generated scrap. Review scrap-cleaning plants, shredders, excavators and manual sorting; support supplier qualification, logistics and commercial terms.
Holding furnaces, rotary furnaces, dross recovery & saltcake processing
Metvora advises aluminium producers, recyclers and investors on holding-furnace and rotary-furnace operations, dross metal recovery, saltcake treatment and recovered-product markets. Assignments can improve an existing operation or define the business case, specialist scope and procurement route for a new facility.
Verify dross or scrap availability, develop the mass balance and business case, compare technology routes, define capacity and utilities, assess logistics and permitting, and coordinate the specialist studies required to select and approve the site.
Prepare RFI/RFQ packages and technical specifications; define process guarantees and acceptance criteria; clarify and evaluate bids; recommend contractors; and coordinate design review, commissioning and performance testing.
Review feed mix, holding and rotary furnace practice, metal yield, salt consumption, cycle time, residue generation, equipment availability and operating cost; identify practical changes to recover more aluminium and reduce saltcake generation.
Assess scrap grades, availability and sourcing; define furnace concept, charging and material flows; align alloy and product strategy with market demand and identify target customers.
Characterise legacy and ongoing saltcake; define crushing, washing or other treatment routes; assess recovery of metallic aluminium, salts and alumina-rich material; plan stockpile drawdown and establish environmental, operating and commercial requirements.
Develop suitable oxide-rich materials for cement applications and metallurgical additives for steelmaking. Define product specifications, coordinate trials and customer qualification, and support pricing, logistics and offtake negotiations.
Project definition, specialist coordination, procurement & delivery assurance
Metvora supports the customer from concept and site approvals through engineering, procurement, construction and commissioning. We define capacity and material flow, assess CAPEX and OPEX, coordinate specialist inputs and help manage the interfaces between equipment suppliers and construction contractors.
Options, material balance, capacity, technology, CAPEX/OPEX, schedule, risks and recommended business case.
Coordinate specialist masterplanning and plant layouts; develop utility and employment inputs; support land leasing, authority applications, environmental studies and EIA approvals.
Production data books, technical specifications, RFI/RFQ packages, design responsibilities, guarantees, interfaces and commercial structure.
Clarifications, compliance matrix, bid levelling, whole-life cost, risk allocation, recommendation and negotiation.
Design and constructability review, OEM/EPC and supplier coordination, milestones, critical path, change and recovery actions.
Mobilisation, staffing, SOPs, training, spares, trials, acceptance testing, handover and early performance review.
Review the site, data, risks, materials, constraints and interfaces. Separate symptoms from the actual operating problem.
Set the operating philosophy, equipment, people, outputs, responsibilities and measurable performance requirements.
Prepare the technical package, test the market, level proposals and negotiate a balanced, enforceable contract.
Support mobilisation, training and readiness; then track performance and remove the causes of operational leakage.
Our approach connects the operating method with equipment requirements, contractor responsibilities and the commercial value of the result.
Practical experience includes slag handling, metal recovery and briquetting at SULB, and mill services covering scrap handling, cleaning, pre-shredding and tundish cutting at Ezz Steel. This knowledge helps define equipment duties, working methods and contractor scopes.
Rotary-furnace dross treatment and saltcake processing at Askar combined aluminium and salt recovery with oxide product development. Material trials and customer qualification established routes into cement applications and metallurgical additives for steelmaking.
TALEX casthouse and extrusion development covered a 30-tonne furnace, land-lease negotiations, approvals, equipment procurement and construction coordination. It provides practical insight into the decisions and interfaces an industrial customer must manage.
International aluminium and steel project execution at Siemens-VAI covered engineering, procurement, construction and commissioning. This experience helps connect supplier commitments with construction interfaces, start-up requirements and acceptance criteria.
These examples and results draw on work in previous leadership roles. They are not Metvora engagements.
Managing Director
Ali leads Metvora with 30+ years of international experience, combining practical plant knowledge with commercial judgement.
He works directly with customers to understand the operating problem, establish a commercially sound solution and guide its delivery. His approach puts clear responsibilities and follow-through at the centre of each assignment, from initial assessment to performance verification.
Metvora coordinates specialist inputs and keeps equipment suppliers and contractors aligned with the customer’s requirements. The aim is a solution that works in the plant and delivers the agreed value.
Discuss your requirementsDiscuss one material stream, operating issue or project. We can agree the decision to resolve, the information needed and a focused scope for assessment and implementation support.
OfficeFloor 2, Building 1913, Road 2124
Block 321, Qudaibiya, Bahrain