What we do

Feasibility studies, debottlenecking and process optimization for Direct Reduced Iron plants, delivered by engineers with 120+ years combined DRI expertise.

Engineering first. AI where it creates measurable value.

Mission & vision

Mission

To empower iron and steel industries by delivering innovative engineering solutions that maximize plant efficiency, reliability and productivity.

Vision

To be the leading engineering partner for DRI plants worldwide, setting benchmarks in excellence and innovation.

Is this your plant?

Furnace throughput sitting below nameplate capacity.

Recurring unplanned shutdowns cutting into availability.

Planning an expansion, upgrade, or new plant that needs feasibility studies through detail engineering.

Services

Existing plants

Improve the plant you already have

Debottlenecking & process optimization — locating and clearing the actual constraint, not just the symptom.

Water, solids & gas system troubleshooting

Byproduct utilization

Total production management systems — production and maintenance.

Capacity upgradation & expansion — brownfield upgrades to existing DR modules.

Technical due diligence & safety studies

New plants

Design the plant you're planning

Feasibility studies — including H2-based DRI feasibility for industrial and pilot plants.

Conceptual engineering & FEED studies

Process simulation, P&IDs & control philosophy

Basic & detail engineering — an alternative to routing basic engineering through the OEM.

Commissioning / implementation

Make the design work in reality

Commissioning support — on-site engineering through startup and handover.

Pre-commissioning support

Technical training & operator support

How we work

1. Diagnose

Process simulation to locate the actual constraint, not just the symptom.

2. Engineer

Detail design, P&IDs, equipment specs, and construction drawings.

3. Validate

Stress analysis and CFD studies before anything is built.

4. Commission

On-site engineering support through startup and handover.

DRI quality estimator

See what DRI quality your pellets can deliver

Enter basic pellet quality parameters and a target metallization degree, and get an indicative DRI product analysis via mass balance — plus the downstream EAF energy impact of your gangue level. This is a screening-level estimate, not a substitute for a proper engineering study.

Pellet total Fe (%)

Pellet gangue, SiO2+Al2O3 (%)

Target metallization (%)

Target carbon (%)

Methodology: this is a direct mass balance, not a regression. Metallization = metallic Fe ÷ total Fe in the DRI (the fraction of iron that has been reduced to its metallic state). Reducing Fe2O3 to metallic Fe removes oxygen at a fixed stoichiometric ratio (48 g O per 111.7 g Fe2O3-bound Fe, i.e. 0.4297 kg O per kg Fe reduced); the pellet's Fe and gangue are conserved in mass but concentrated as that oxygen leaves, and carbon addition dilutes the result back down to the target carbon level. Reference ranges used for comparison — DR-grade pellet Fe ≥67%, pellet gangue not exceeding 3–4%, metallization 92–96%, DRI total Fe 91–93%, DRI gangue 3–5%, CDRI carbon 0.5–3% (up to 4.5% with adjustable-carbon technology) — are drawn from Midrex technical publications and industry references. The EAF energy impact uses a published rule of thumb of roughly +20 kWh/tonne of DRI charged per 1% increase in acid gangue (SiO2+Al2O3), benchmarked against a 3% gangue baseline; actual impact depends on furnace design, scrap/DRI ratio, and operating practice. Screening-level only — not a substitute for a full process simulation, which is exactly what our diagnose step (above) is for.

Track record

120+

Years combined team expertise

DRI plants our team has collectively worked on

Countries our team has collectively worked in

These figures reflect the combined individual expertise of our engineers across their careers, including work at prior employers, not project counts delivered under the AI Engineering Solutions name alone.

Where we've worked

25 DRI plants, 13 countries, 5 regions

Drawn from our engineers' combined project history — greenfield, brownfield, capacity upgrades and debottlenecking, across every major DRI-producing region.

Middle East

Qatar · Saudi Arabia · Oman · Bahrain · Iran

South Asia

India · Pakistan

Americas

Mexico · Venezuela · Trinidad & Tobago

Africa

South Africa · Libya

Southeast Asia

Malaysia

Plant and country counts reflect the combined individual expertise of our engineers across their careers — the same basis as the track record figures above — not projects delivered under the AI Engineering Solutions name. Client and project details available on request.

Have a specific bottleneck in mind?

Hisar, Haryana, India · info@aienggsol.com · +91 98792 02694

Talk to an engineer