Overview
There is a strong international push towards the development of Hydrogen Direct Reduced Iron (DRI) processes. This is likely to have a significant impact on Australian iron ores in future iron ore markets as there are questions about their ability to be used in cost-effective hydrogen ironmaking processes. This project will build an understanding of the end-to-end techno-economics of hydrogen direct reduced ironmaking in the Australian context, with an emphasis on understanding the impacts of Australian ore grades on the overall process design.
Project Details
This project commences with an options study followed by techno-economic analysis of a selected process pathway. The options study will provide a broad overview of green steel pathways, together with collection of published data on the cost and performance of process steps relevant to hydrogen-based ironmaking including upstream beneficiation, the reduction process itself including feed preheating and fuel supply, and downstream process options for slag removal and/or co-products. Techno-economic analysis will involve integrated process pathways coupling physical models of the different process components and calculation of performance and cost of the overall process.
Identified Pathways
Low-carbon iron exports from Pilbara ores
Outcomes
Outcomes include a detailed iron-ore-to-molten-steel integrated process model including process and cost performance, and a clear proposition describing the conditions required for the success of fluidised bed H₂DRI for Australian ores, and some identified future challenges. It is noted that the important alternative shaft furnace DRI pathway with optional melter will be performed within a separate project.
In addition, the techno-economic analysis provided by this project will provide an improved understanding of the challenges and opportunities for large-scale green steel production using Australian, and especially Pilbara, iron ores, whether in Australia or overseas. Future work may include lab-based testing, more detailed component modelling and costing, or evaluation of newly uncovered process configurations.