ANU – De-risking large-scale Australian fine-ore hydrogen ironmaking

R&D Focus Areas:
Industrial heat processes, Techno-economic evaluation

Lead Organisation:
Australian National University

Partners:
Swinburne University of Technology
The University of Newcastle
HILT CRC Limited
FMG Procurement Services Pty Ltd
Grange Resources (Tasmania) Pty Ltd
Roy Hill Holdings Pty Ltd
Primetals Technologies Austria GmbH

Status:
Active

Start date:
March 2024

Completion date:
April 2028

Key contacts:
John Pye – john.pye@anu.edu.au

Funding:
AUD$4.82 million – Australian Renewable Energy Agency (ARENA)

Project total cost:
AUD$13.69 million

Project summary description (as published by ARENA):
In this project, hydrogen direct reduction ironmaking (H2DRI) is examined in the context of Pilbara iron ores. Preliminary work conducted in the Heavy Industry Low-carbon Transition (HILT) CRC has indicated that H2DRI, if combined with two-step smelter-BOF steelmaking, could be highly competitive even when applied to the frequently lower-grade ores from the Pilbara.

Although the process is understood, it has yet to be realised in commercial processing, and there are multiple aspects where significant technological risks remain. This project seeks to de-risk a number of the risks associated with this pathway, by improving understanding of the fluidised bed reduction process, both reactor design and chemical kinetics, by examining technoeconomics of end-to-end processes including with alternative/unconventional Pilbara ores, and by addressing issues to do with safely shipping hot-briquetted iron made with lower-grade ore, and examining novel approaches for smelting using these same ores.  

The project will include techno-economic analysis, professional pre-feasibility studies, and a plan for upscaling and commercialising the most promising concepts to support Australia’s green steel platform.

The objectives for the project will be achieved through the following Outcomes:

1. Reduction in or removal or barriers associated with using lower-grade Australian iron ores in low emissions iron and steel production;
2. Development of innovative and / or step change emissions abatement pathways for iron and steel production using Australian iron ores;
3. Increased research capacity in the Australian iron and steel sector, and the facilitation of collaboration between research groups and industry;
4. Improvement in the technology readiness and commercial readiness of iron and steel production technologies;
5. Development of technologies to reduce the risks of DRI including coatings and lower-temperature reactor cascades;
6. A targeted cost reduction of 10% from a combination of the technologies developed.

Related publications and key links:
https://arena.gov.au/projects/anu-de-risking-large-scale-australian-fine-ore-hydrogen-ironmaking/

Higher degree studies supported:
None at this stage.

 

April 2024