Mid-West Green Iron Project (New Project added September 2025)

September 29th, 2025

Mid-West Green Iron Project

Progressive Green Solutions is developing a large-scale, renewables-based project in the mid-west region of Western Australia targeting the further processing of mid-west region magnetite ore into pellets and hot briquetted iron (the latter through the use of hydrogen for process heat) to supply global markets.

Main proponents:

Progressive Green Solutions

 Main end-use classification:

Industrial production – focus on iron ore pellets/HBI production

 Status:

Under development – FEED has commenced

 Estimated cost:

Phase 1 total project capital cost is estimated at AUD$5.5 billion
Other involvement:

 

 Production details:

Phase 1: 1.4 GW electrolysis plant, ~180,000 tonnes of renewables-based hydrogen production per annum

 Location:

Western Australia, Australia

 Announced funding:

 

Project description

The Mid-West Green Iron Project, located in the city of Greater Geraldton, Western Australia, is a large-scale, renewables-based project in the mid-west region of Western Australia targeting the further processing of mid-west region magnetite ore into pellets and hot briquetted iron (the latter through the use of hydrogen for process heat) to supply global markets.

Phase 1 of the project includes the following main elements:

  • A seven million tonnes per annum (Mtpa) renewables-based iron ore pellet plant, of which 3.5 Mtpa would be exported and the remainder processed to 2.5 Mtpa Direct Reduced Iron (DRI) / Hot Briquetted Iron (HBI).
  • Renewable energy capacity of 2.6 GW (combined new wind and solar capacity).
  • Battery Energy Storage System of 500 MW / 4GWh.
  • Electrolysis plant of 1.4 GW capable of producing around 180,000 tonnes of renewables-based hydrogen per annum.

In September 2025, it was announced that thyssenkrupp nucera was selected as its preferred supplier of (Alkaline) electrolysers for the project.

The project proponent has advised that the project metals plant technology will be supplied by the German-based SMS Group (with Midrex Direct Reduction technology for the production of DRI/HBI) and that the project finance is led by German sovereign-owned KfW IPEX Bank, and will utilise German Government Export Credit Agency, Euler Hermes’ export credit guarantees (Hermes Cover).

Supply of magnetite iron ore for the Phase 1 pellet plant would come primarily from the Karara iron ore mine, currently producing 8 Mtpa of magnetite concentrate.

The project proponent has advised of the current (September 2025) status of the Phase 1 project as:

  • 480 hectares of private land has been secured.
  • Application for the Strategic Industrial use and development approval has commenced.
  • Ongoing Bankable Wind Monitoring and secured 365 days of Hourly Wind & Solar Generation profile data.
  • Class 3 Engineering Design and Feasibility Study has been completed.
  • Front-end Engineering Design has commenced.

First production is expected in 2029, with export from the project anticipated in the first quarter of 2030.

Phase 2 project ambitions include up to a 30 Mtpa renewables-based pellet plant, including up to 7.5 Mtpa additional HBI export by 2032.

 

Reviewed (reviewed by the project proponent): September 2025