Overview
There is a strong international push towards the development of Hydrogen DRI processes that are likely to have significant impact on the desirability of Australian Iron ores in future iron ore markets. There are several options available for Hydrogen DRI processing of Australian Ores, they include Shaft processes (e.g. Midrex), fluidised bed and Flash Smelting. Flash Smelting involves rapidly reacting fine iron ore in a hot gaseous environment and is distinct from a fluidised bed by (a) the particles fall through a shaft and are collected after reaction at the bottom of a shaft and (b) no bed structure is established in the furnace. A Flash Ironmaking process using Hydrogen has been developed by the Sohn team in the USA over the last decade. There is significant published data on the Sohn laboratory work but limited data on how the process works for different ores or the techno-economics of the process. Calix, an Australian based company with a background in calcining technology has been developing a new flash ironmaking technology over the last twelve months called ZESTY (Zero Emissions Steel Technology) based on its commercialised electrically heated flash calcination technology.
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