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【Ferro-alloys.com】: Primetals Technologies, together with partner Mitsubishi, steel producer voestalpine and mining major Rio Tinto, has signed a cooperation agreement to implement an industrial-scale hydrogen-based ironmaking prototype plant in Linz, Austria.

The partners aim to fast-track the development of fluidised bed and smelter technologies that could lead to net-zero CO2 emissions in ironmaking. The plant, scheduled for startup in mid-2027, will mark the first time a hydrogen-based direct reduction (DR) plant for iron-ore fines is integrated with a smelter, producing hot briquetted iron, hot metal, and pig iron.

The prototype facility will combine two core technologies from Primetals Technologies — hydrogen-based fine-ore reduction (HYFOR) and the Smelter. HYFOR is the first DR technology to process iron-ore fines without agglomeration, and has been in pilot operation since 2021 at voestalpine’s Donawitz site. The Smelter uses renewable energy to melt and further reduce the direct reduced iron (DRI), producing hot metal with potential net-zero CO2 emissions.

“This 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,” said chief technology officer and head of green steel at Primetals, Alexander Fleischanderl.

“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. We are extremely proud to have the support of strong partners in voestalpine, Rio Tinto and Mitsubishi, and together, we are poised to make a big difference to the future of net-zero CO2 emissions ironmaking.”

The new plant will have a designed capacity of three tons of hot metal per hour.

Mitsubishi, a strategic partner in the development, will support the scale-up of the technology through its ferrous raw materials business. “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,” said Kenichiro Tauchi, COO of the group's ferrous raw materials division.

“HYFOR and Smelter are new promising technologies to accelerate the decarbonisation of the steel industry and Mitsubishi Corporation, as a strategic partner of Primetals Technologies, is excited to participate in the development of these groundbreaking technologies together with leading partners in the steel supply chain.”

voestalpine views the project as aligned with its greentec steel strategy. “With greentec steel, voestalpine has a clear phased plan for steel production with net zero CO2 emissions,” said voestalpine CEO Herbert Eibensteiner.

“In a first step, one green-powered electric arc furnace will be put into operation at each of our sites in Linz and Donawitz starting in 2027. By 2029, we will have reduced our 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 programme 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.”

Rio Tinto, one of the world’s largest producers of iron-ore, will provide 70% of the iron-ore feedstock for the plant, sourced from its operations in the Pilbara, the Iron Ore Company of Canada, and future Simandou operations.

“We are delighted to join a consortium that encompasses the entire iron and steelmaking value chain,” said Rio Tinto general manager for steel decarbonisation, Thomas Apffel. “By contributing our ironmaking expertise and iron ores from our Pilbara, Iron Ore Company of Canada, and future Simandou operations, we aim to advance the development and adoption of fluidised bed technology. This fines-based ironmaking solution presents a compelling alternative to shaft furnace technology by eliminating the need for pelletisation, potentially offering substantial benefits to both steelmakers and miners. Rio Tinto welcomes additional participants to the consortium and looks forward to supporting the widespread implementation of this innovative technology.”

The project has secured funding from several EU and Austrian government initiatives. These include the Austrian federal government’s “Transformation of Industry” programme managed by Kommunalkredit Public Consulting (KPC), the “Twin Transition” initiative managed by Austria Wirtschaftsservice (aws), the EU Research Fund for Coal and Steel under the Clean Steel Partnership, and the EU’s Clean Hydrogen Partnership within the Hydrogen Valleys framework.

• [Editor:Alakay]