Steel plant with molten metal and industrial operations
Extractive metallurgy · Process intelligence · Sustainability

Driving sustainable metallurgy through innovation, efficiency and decarbonization

ExtractMet helps metals and mining organizations solve complex shop-floor problems through first-principles engineering, plant-data analysis, modelling, simulation and experimental studies.

Explore our capabilities Start your journey
01

Process optimization

02

Waste reduction

03

Advanced process control

04

Decarbonization

About ExtractMet

A metallurgical consultancy company built around science, plant reality and measurable outcomes

ExtractMet Pvt. Ltd. is a dedicated metallurgical firm focused on enhancing the metallurgical sector across the country.

Specializing in extractive metallurgy, we offer metallurgical engineering solutions that deliver measurable return through process optimization, waste reduction and sustainable technology implementation. Our work addresses fundamental challenges across ferrous and non-ferrous industries, including critical minerals and rare earths.

With expertise in advanced process control through modelling, simulation and experimental studies, we are committed to delivering impactful improvements to metal-extraction processes and industrial practices.

Long-term vision

Development of an industrial setup with pilot-scale facilities for key metals and mining operations, including iron and steel production and critical-mineral exploration. A 12,000-tonne-per-year mini steel plant is also planned at an advanced stage of development.

Our services

Integrated support across the metallurgy value chain

Process optimization, advanced process control and digital twins, followed by pyrometallurgical operational support, R&D lab setup, metallurgical testing, mineral characterization, beneficiation, extraction and sustainability solutions.

Metallurgical modelling and simulation software tools
01

Process Optimization, Control & Digital Twins

Simulation of large-scale industrial processes, validated with plant data and integrated with techno-economic analysis, AI and machine learning.

  • Pilot-to-commercial-scale techno-economic optimization
  • Data-driven solutions for industrial processes and smelters
  • First-principles simulation for process optimization and scale-up
  • AI-enabled control and shop-floor-implementable digital twins
Explore SmartMelt Digital-twin portfolio Model catalogue Open Online Model Demo Hub Article: AI, ML & digital twins →Article: steelmaking process control →Level-2 & process-control articles →Article: Hall–Héroult Level-2 aluminium control →Article: blast-furnace hybrid Level-2 →Article: sintering hybrid Level-2 →Article: copper smelting Level-2 →
Industrial and mining waste prepared for recycling
02

Waste Recycling & Utilization

Knowledge-based solutions and training for efficient recycling and utilization of mining and plant wastes.

  • Transforming mining waste into a resource through circular-economy innovation
  • Magnetizing reduction roasting to maximize yield from lean ores
  • Custom process design for plant-waste recycling
Article: metallurgical process intelligence →
Submerged arc furnace used for ferroalloy production
03

Process Control in Ferroalloy Production

Knowledge-based solutions and training for ferroalloy production and submerged-arc-furnace operations.

  • Optimization and control of submerged-arc melting for ferrochrome production using fundamental analysis and rigorous plant-data studies
  • Optimization of temperature, charge mix, Cr/Fe ratio, slag condition and key operating parameters for maximum chromium recovery
  • Techno-economic, economic-viability and environmental-sustainability evaluation
Article: ferroalloy digital twins →
Large-scale mineral processing and metallurgical operation
04

Pyrometallurgical Operational Support

Operational support, data acquisition, validation, analysis, laboratory experiments and simulation for optimized process control.

  • Induction-furnace steelmaking refining and quality control
  • BOF, blast-furnace and EAF optimization and control
  • Secondary-steelmaking quality control for RH, LF, VAD and related processes
  • COREX and MIDREX alternative-ironmaking optimization
  • Copper-smelter and refinery optimization and control
Article: smarter ironmaking operations →Article: rotary-kiln DRI control →Article: blast-furnace Level-2 control →Article: copper-smelting Level-2 control →
Critical-metal extraction through hydro, pyro and bio-metallurgy
05

Critical Metals & Rare Earths

Extractive-metallurgy solutions for critical metals and rare earths used in batteries, electric vehicles and energy-storage applications.

  • Optimization of lithium, cobalt and nickel recovery for battery supply chains
  • Sustainable rare-earth-magnet extraction and processing for EV applications
  • Process-flowsheet development for emerging energy materials
Molten steel production in an industrial plant
06

Decarbonization & Green Steel

Knowledge-based solutions and training to decarbonize large-scale iron and steel operations through an intelligent engineering approach.

  • Green iron and steel technologies using modelling, simulation and real-data validation
  • Green-hydrogen integration feasibility studies
  • EAF optimization for scrap-based production
  • Comprehensive roadmaps to reduce carbon emissions and advance toward net zero
Article: green ironmaking & steelmaking →
Modern metallurgical research and development laboratory
07

R&D Laboratory Setup

Comprehensive R&D laboratory design, equipment planning and sourcing of high-precision equipment in line with relevant ISO standards.

Microscopy images used for mineral characterization
08

Metallurgical Testing & Mineral Characterization

Customized mineral-chemistry and characterization reports covering liberation, particle-size distribution, interlocking phases and beneficiation of low-grade ores.

  • Ferrous and non-ferrous raw materials and products
  • XRD, SEM-EDS, XRF and ICP-OES
  • TGA-DTA, DSC and FTIR analysis
High-temperature industrial furnace with heated metal
09

High-Temperature Furnace Design

Support for the design of high-temperature furnaces tailored to laboratory-scale applications and experimental requirements.

Steelmaking operations used for industry training
10

Workshops, Training & Short Courses

Customized capacity-building programs for shop-floor operators, engineers, scientists, researchers and management teams.

View training areas
  1. Blast furnace, DRI and steelmaking training for shop-floor operators and R&D personnel
  2. Inclusion engineering and secondary-steelmaking quality control
  3. Copper extraction through pyrometallurgical routes
  4. Process-engineering principles and software for pyrometallurgical extraction
  5. Slag chemistry, resource balance, transport phenomena and process-metallurgy fundamentals
  6. Decarbonization and technology-roadmap development for iron and steel
  7. Sustainable extraction of critical minerals and rare earths, including flowsheet development
  8. Sustainable processing of iron-ore minerals
  9. Decarbonization implementation for plant management and shop-floor teams
Commodity-market and financial analysis illustration
11

Metals & Mining Market Intelligence

Metallurgical process knowledge combined with specialized market research and financial forecasting.

  • Short- and long-term commodity-price projections for iron ore, steel products, base metals and battery metals
  • Global and regional supply-demand analysis, asset-level capacity and utilization models, and green-steel uptake forecasts
  • Company and project cash-flow models with price, cost and capital-expenditure scenarios
How we work

From plant challenge to implementable solution

Our work combines fundamental metallurgy with data, experimentation and operational context rather than relying on generic recommendations.

01

Diagnose

Define the operational, quality, cost or sustainability problem and identify the decisions that matter.

02

Measure

Acquire, clean and validate plant, laboratory and process data to build an auditable technical baseline.

03

Model

Apply mass and heat balances, thermochemistry, kinetics, simulation, AI and machine learning as appropriate.

04

Validate

Test recommendations through experimental studies, historical data and plant-specific operating constraints.

05

Implement

Translate findings into practical operating strategies, training, dashboards or digital-twin tools.

Company directors

Academic depth with multidisciplinary industrial ambition

Founder & Director

Dr. Ajay Kumar Shukla

PhD, Process Metallurgy, IIT Kanpur, India

Professor, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras, Chennai. Founder and Director, ExtractMet Private Limited, under the Incubation Cell, IIT Madras.

ajayshukla@extractmet.com Academic profile
Director

Dr. Shubhra Shukla

Director, ExtractMet Private Limited, under the Incubation Cell, IIT Madras, contributing multidisciplinary scientific capability to the company.

shubhra.awasthi@extractmet.com
Extended expertise

Panel of external experts

ExtractMet is assisted by external experts in key areas of mining, metallurgy, data science and computing.

View expert panel
Contact us

Bring us your metallurgical challenge

Contact us about your company, plant, process-development or training requirements. We will do our best to respond as soon as possible.

Phone+91 90258 76545 General enquiriesinfo@extractmet.com Technical enquiriesajayshukla@extractmet.com

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