Primetals Technologies, together with its strategic partner Mitsubishi Corporation (earlier post)), Rio Tinto, and globally leading steel and technology group voestalpine, 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.

Hydrogen-based direct reduction and smelting. The new ironmaking process with a projected capacity of three tons of hot metal per hour is based on the HYFOR and Smelter solutions from Primetals Technologies. HYFOR is 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.

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. 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 Corporation, and together, we are poised to make a big difference to the future of net-zero cO₂ emissions ironmaking.

—Alexander Fleischanderl, Chief Technology Officer and Head of Green Steel at Primetals Technologies

Rio Tinto, one of the world’s largest iron ore producers, will draw on its extensive 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 commercialization of the technology.

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 fluidized bed technology. This fines-based ironmaking solution presents a compelling alternative to shaft furnace technology by eliminating the need for pelletization, 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.

—Rio Tinto General Manager, Steel Decarbonisation Thomas Apffel

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 (KPC) and the “Twin Transition” initiative managed by Austria Wirtschaftsservice (aws). In addition, 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, i.e. areas where hydrogen serves more than one end sector or application in the mobility, industry, and energy sectors.