A new ironmaking process with a projected capacity of three tons of hot metal per hour based on the Hydrogen-based Fine-Ore Reduction (HYFOR) and Smelter technology is being progressed by a consortium of companies.
Primetals Technologies, with its strategic partner Mitsubishi Corporation (TYO:8058), mining giant Rio Tinto (ASX:RIO), and steel and technology group voestalpine, have signed a cooperation agreement to fast-track the development of fluidised bed and smelter technologies.
The participants will implement and operate an industrial-scale prototype plant featuring a new process for potential net zero CO2 emissions ironmaking at the voestalpine site in Linz, Austria. Startup of the plant is scheduled for mid-2027.
Funding for the investment and operation of this prototype plant has been provided by the Austrian federal government through its ‘Transformation of Industry’ program managed by Kommunalkredit Public Consulting and the ‘Twin Transition’ initiative managed by Austria Wirtschaftsservice.
Additionally, the European Union supports the venture through the European Union Research Fund for Coal and Steel within the Clean Steel Partnership (CSP) and the European Union Clean Hydrogen Partnership within the Hydrogen Valleys – areas where hydrogen serves more than one end sector or application in the mobility, industry, and energy sectors.
Kenichiro Tauchi, COO, Ferrous Raw Materials Division of Mitsubishi Corporation, says HYFOR and Smelter are new promising technologies to accelerate the decarbonisation of the steel industry.
HYFOR is touted as the world’s first direct reduction technology for iron ore fines that does not require any agglomeration steps. Since 2021, Primetals Technologies has operated a pilot plant on voestalpine’s premises in Donawitz, Austria, and has run numerous successful test campaigns.
The smelter is a furnace powered by renewable energy used for melting and final reduction of direct reduced iron (DRI). It produces potential net zero CO2 emissions hot metal for the steelmaking plant.
Primetals Technologies CTO Alexander Fleischanderl says the project represents a significant advancement in future-proof ironmaking.
“For the first time, we will implement a continuous production process with hydrogen-based direct reduction. The combination of HYFOR and Smelter is a highly innovative development with the potential to transform the industry, similar to the impact the LD converter (BOF) had on steel production,” says Fleischanderl.
“Mining and trading of ferrous raw materials has been one of our core businesses for many decades and we envision to develop a new supply of low emission metallics to support steel decarbonisation.
Herbert Eibensteiner, CEO of voestalpine, says with greentec steel, voestalpine has a clear phased plan for steel production with net zero CO2 emissions.
In a first step, one green-powered electric arc furnace will be put into operation at each of the company’s sites in Linz and Donawitz starting in 2027.
By 2029, Eibensteiner says voestalpine will have reduced its CO2 emissions by up to 30% compared to 2019. That is equivalent to almost 5% of Austria’s entire annual CO2 emissions, “making greentec steel the largest climate protection program in Austria”.
“Our long-term strategy is to use green hydrogen to achieve carbon-neutral steel production. Together with Primetals Technologies and Rio Tinto, we are taking an entirely new and promising approach to research into hydrogen-based pig iron production,” says Eibensteiner.
As one of the world’s largest iron ore producers, Rio Tinto will draw on its expertise in iron ore quality and preparation to provide technical input to the project. Additionally, Rio Tinto will supply 70% of the iron ore for the new plant from across its global operations. It will also support Primetals Technologies to accelerate the commercialisation of the technology.
By contributing Rio Tinto’s ironmaking expertise and iron ores from its Pilbara, Iron Ore Company of Canada, and future Simandou operations, the mining giant aims to advance the development and adoption of fluidised bed technology.
Write to Adam Orlando at Mining.com.au
Images: Primetals
