The project investigates key technical barriers to H₂DRI processing with a focus on flash reduction. Work will include studying the formation of fayalite, a by-product that reduces product quality, and exploring ways to minimise its occurrence.

Detailed laboratory experiments will be conducted using Swinburne University of Technology’s hydrogen reduction rig to examine the reduction kinetics of hematite and goethite ores, focusing on variables such as temperature, gas composition and particle size.

The project will also optimise flash reduction for magnetite ores by testing pre-oxidation techniques and other pre-treatment steps. The University of Adelaide will assess particle residence times in laboratory-scale reactors to refine reactor design and improve processing efficiency.

The key project aims include:

• Investigating the formation of fayalite during H₂DRI processes, including its impact on metallisation and strategies to mitigate its effects.
• Studying ore reduction kinetics to determine how factors such as ore type, temperature, particle size and gas composition influence the reduction of hematite and goethite ores in the ZESTY reactor.
• Optimising the flash reduction process for magnetite ores, including the effects of pre-oxidation and other pre-treatment methods.
• Residence time analysis: Measure and model particle residence times in lab-scale reactors to improve reactor design and efficiency for Australian iron ores.

By addressing these challenges, the project aims to enhance the viability of H₂DRI technologies, helping to secure a competitive position for Australian iron ores in the green steel market.

• 1.1 Producing green iron products from magnetite
• 1.2 Producing green iron products from hematite/goethite ores

• Low-carbon iron exports from direct shipping ores
• Alternative low-carbon ironmaking
• Assessment of hydrogen direct reduction routes for Australian ores
• Decarbonising production of green iron products from magnetite ores

• De-risked the flash reduction technology.
• Improved understanding, quantification and mitigation of the risk of fayalite formation from silica-rich Australian iron ores.
• Support for scaling up ZESTY technology through detailed kinetic study of goethite/hematite ores.
• Improved understanding of the performance of magnetite ores in flash reduction process.

RP1.015 De-risking flash reduction of Australian iron ores