• First industrial scale pilot converts 80 tonnes of low grade ore into DRI using green hydrogen.
  • Breakthrough enables use of 56% iron content ore, reducing reliance on premium feedstock.
  • Technology could cut costs and expand global supply for green steel production.

An international consortium led by Germany’s Federal Institute for Materials Research and Testing has successfully completed the first industrial scale pilot test to extract iron from low grade ore using green hydrogen, marking a significant milestone in the global transition to low carbon steel.

The trial was conducted at the Oshivela site in Namibia and operated by HyIron Green Technologies. During the pilot, approximately 80 tonnes of untreated iron ore sourced from Australia were processed into Direct Reduced Iron. The project demonstrated the ability to work with ore containing just 56% iron, well below the roughly 70% typically required by conventional hydrogen based DRI shaft technologies.

At the core of the process is an electrically powered hydrogen rotary kiln developed by TS Elino GmbH. The system is designed to achieve throughput of around five tonnes per hour, providing a scalable pathway for industrial deployment.

The breakthrough addresses a key constraint in the emerging green steel sector, namely the limited availability and high cost of premium grade iron ore. By enabling the use of lower grade material, the process removes the need for costly pelletisation and reduces dependence on high grade ores, which can be priced at nearly twice the level of standard grades.

The development also broadens the potential supply base for climate neutral steel making. Resource rich countries such as Australia could benefit from exporting lower grade ores that were previously less attractive for green steel applications.

Further validation is underway as the refined iron produced in Namibia is being shipped to Germany for detailed analysis by Salzgitter Mannesmann Forschung GmbH. The assessment will determine its suitability for use in commercial applications including automotive manufacturing and infrastructure projects.

Author: Bryan Groenendaal