About Us - FESIOS
Steel plants face capital decisions worth tens of millions — a new EAF, a scrap yard redesign, a capacity ramp that strains everything downstream. These decisions are made once. The wrong one can’t be undone cheaply: you don’t relocate a caster twice, and you don’t get back the years spent fixing a layout that should never have been built.
We exist to make sure that doesn’t happen.
Who We Are
FESIOS is based in Gmunden, Austria. In the last five years we’ve completed 75 projects across more than 25 steel plants. Our clients include voestalpine, ArcelorMittal, Dillinger, and Saarstahl.
Metallurgists, process engineers, and logistics specialists — people who’ve worked the plant floor before they ever touched a simulation model. We don’t fit neatly into one category. We’re part consultants, part analysts, part toolmakers — and that combination is the point.
What We Do
Before a steel plant invests in new equipment, expands capacity, or changes how it operates, there’s a window where the decision can still be shaped. That’s where we come in.
We model the plant. We run the scenarios. We find the bottlenecks before the concrete is poured. And we give decision-makers the evidence they need to commit with confidence — or to change course before it’s too late.
Three Ways We Work
Consultants who understand steelmaking. We don’t just build models — we understand what happens inside a melt shop, on a scrap yard, in a rolling mill. Our team includes metallurgists, process engineers, and logistics specialists. The insights come from that domain knowledge, not just from the simulation.
Analysts armed with purpose-built tools. We’ve built our own discrete-event simulation platform, purpose-built for steel. That means studies that take other firms months take us weeks. No generic software. No adapting tools that weren’t designed for the job.
Software providers who leave the tools behind. If a customer wants to keep the model running after the project, they can. Our tools stay with the plant. No license dependency, no lock-in, no black box.
Track Record
75 projects. 25+ steel plants. Five years.
At Dillinger Hütte, our simulation showed that the planned EAF position would create a bottleneck within three years of a capacity ramp-up — and proved that an alternative location achieves the same output. Double-digit million Euros in capex were redirected before a single foundation was laid.
At ArcelorMittal Belval, we modeled the impact of a new EAF on the entire downstream flow — caster, ladle logistics, crane utilization — and identified the sequence changes needed to hit the target output.
At voestalpine Donawitz, a plant modernization involving a new caster and crane upgrades was validated against the existing flow before go-live.
Zero surprises after go-live.
The Team
Every project is led by a senior engineer who has seen the inside of steel plants, not delegated to a junior. Our size means direct access and fast turnaround — studies that typically take three to six months are delivered in four to eight weeks.
If you have a decision to make and you want the evidence before you make it — that’s what we’re here for.