HELPING METALS PRODUCERS SOLVE HARD OPERATING PROBLEMS

Experience That Comes From the Mill Floor

Morey Industrial Consulting helps steel, ironmaking, and heavy industrial teams solve complex operating, technical, and strategic problems. With more than 20 years of experience in the metals industry, including work at one of North America’s largest steel producers, I bring practical plant experience, process understanding, and business judgment to each engagement.

My work focuses on blast furnace operations, steelmaking, decarbonization, process modeling, value recovery, technical due diligence, and operational improvement — always with the goal of turning complex technical issues into clear, actionable decisions.

Practical Support for Industrial Decision-Making

Blast furnace, sintering, and ironmaking support Troubleshooting, performance improvement, operating strategy, burden/fuel review, and technical support for ironmaking operations.

Techno-economic assessment and project comparison Practical evaluation of process options, decarbonization pathways, capital tradeoffs, operating cost impacts, and commercial feasibility.

Decarbonization and low-carbon metals strategy Support for hydrogen, natural gas, syngas, top-gas recycle, carbon capture, waste heat, alternative fuels, and emissions-reduction planning.

Waste, byproduct, and value-capture workshops Identification of opportunities to recover value from slags, dusts, residues, off-gases, and other industrial byproducts.

Lean Six Sigma, Kaizen, and operational improvement Structured problem-solving, process improvement, team workshops, and plant-level execution support.

Expert witness and technical review
Independent technical assessment, litigation support, process review, and clear explanation of complex industrial issues.

Find out more

Joe Morey gives a lecture at Carnegie Mellon.

A Practical, Plant-Focused Approach

At Morey Industrial Consulting, the approach is straightforward: understand the real operating problem, separate symptoms from root causes, quantify the options, and help the team make a practical decision.

I work closely with clients to combine plant experience, technical analysis, economics, and structured problem-solving. The goal is not just to produce a report — it is to create a clear path toward improved performance, reduced waste, lower cost, or better strategic direction.

Transparent communication
Practical, plant-informed recommendations
Technical and economic analysis with an emphasis in circularity
Lean Six Sigma and Kaizen-based problem solving
Clear deliverables that support action

Client Testimonials

Ozinga Cement

We have been extremely pleased with the expertise and support provided by Joe in supporting our granulation operations, developing operator training, and evaluating capital projects in the integrated iron and steelmaking space. His deep technical knowledge, common sense methods, and hands-on approach have been invaluable to our team. His guidance has not only improved our process efficiency but has also strengthened our operators’ capabilities, ensuring long-term operational excellence. We highly appreciate his professionalism, responsiveness, and dedication to our success and look forward to continuing our collaboration.

Joseph Brunner - Vice President Manufacturing

Helios - Sodium Ironmaking

Joe has extensive experience in the steelmaking industry, which has been a significant asset to our company. His insightful business perspective, professionalism, and collaborative nature made working with him a seamless experience. Always available and efficient in communication, Joe managed to complete a highly complex project in a notably short timeframe, showcasing his dedication and commitment to excellence. We strongly endorse him for any consultancy role in the steelmaking industry or related fields.

Chen Shnitman Balili - Product Lead Helios

Services

Blast furnace operational assistance AND TECHNICAL CONSULTING

Iron and slag being separated during a cast from a blast furnace.

Blast Furnace and Recovery Assistance

Blast furnace start-ups from unplanned and even some planned situations can be tricky. We all know that missteps are very costly resulting in lost production and increased costs for the site. Why not have someone with international experience starting up blast furnaces at multiple different plants there for assistance?

If desired, this process can also come with an improvement analysis for the client regarding the recovery process, avoiding the root causes or both.

Blast Furnace Operational Evaluation

The blast furnace operational costs and productivity play a significant role in the overall performance of the plant. Some important aspects are:

Fueling, material costs and yields
Blast furnace efficiency
Reliability
Stove performance
Gas plant performance
Flaring
Raw material handling
Casting operations
Many, many others

There is often much to learn from an independent external 3rd party look into the process. Give me a call and let's do a deep dive into potential improvements today!

Hot metal casting from a blast furnace tap hole.

Blast Furnace Operational Assistance

There are few things in the steel plant that are as troublesome as blast furnace problems that are sometimes difficult to pinpoint.

A 3rd party look can often help lead to ideas that may often be what is needed to resolve the situation. Capability building through training, procedural review, and other necessary items will be included as needed.

LEAN Six Sigma based Consulting

Sticky notes on a process flow diagram during a brainstorming exercise.

Value Stream Mapping and Analysis

Jump start your portfolio of improvement projects through the identification of the critical few opportunities to take your organization to the next level.

Together we will identify actionable bottlenecks, areas of waste, and quality opportunities that make that difference that your customer desires.

Data-informed Brainstorming

Data-based brainstorming is a great exercise to bring people who perform a process together and create often magical results.

This is a capability exercise where I will coach your team to lead these interactions in order to drive a culture of continuous improvement.

Expert Witness

Drawing upon 28+ years of operating experience in multiple levels of operational management to provide expert testimony regarding operational and technical aspects of the steelmaking process.