Project partners, Primetals Technologies, Rio Tinto and Voestalpine have started construction on an industrial-scale, hydrogen-based demonstration ironmaking plant.

The plant, located in Linz, Austria, will implement a new process for potential net-zero CO₂ emissions ironmaking.

The partners aim to accelerate the development of hydrogen-based direct reduction and smelter technologies, providing a potential alternative to blast furnaces for hot metal and commercial hot-briquetted iron (HBI) production.

Herbert Eibensteiner, CEO of Voestalpine, said: “To achieve our long-term goal of net-zero CO₂ emissions in steel production by 2050, we are researching new processes in collaboration with partners from industry and science, as well as investing in groundbreaking steel production projects.

“Seeing construction underway of the globally unique Hy4Smelt demonstration plant once again confirms our technological and innovation leadership in green steel production."

The plant will produce, hot metal, HBI, and pig iron using Hydrogen-based Fine-Ored Reduction (HYFOR) and Smelter solutions from Primetals.

HYFOR eliminates the need for agglomeration of the iron ore fines, as well as featuring a reduction in gas temperatures, in-situ recycling of captured dust particles and high metallisation of the direct-reduced iron (DRI) and HBI.

Dr. Alexander Fieishanderi, head of green steel at Primetals, added: “The steel industry urgently needs to transition. Coal-fired blast furnaces, which have been the backbone of ironmaking for centuries, come at a significant and growing environmental cost.

“This is exactly where HYFOR and Smelter come in: with these solutions, we are paving the way for a new era in ironmaking.”

Rio Tinto will supply 70% of the iron ore for the demonstration plant.

Rafael Azevedo, general manager of iron ore sales and marketing Atlantic for Rio Tinto, remarked: “By contributing our iron ores and technical expertise, we’re helping to explore new pathways for low-emissions ironmaking.

“There’s still a lot to learn, but we’re optimistic about the potential of fluidized bed and electric smelting technologies to support the steel industry’s transition."

For the project, Primetals has also entered a strategic partnership with Mitsubishi Corporation, where they will provide insight into supply solutions, product trading and market needs.

The project has been funded by the Austrian federal government with the European Union also supporting the venture.

Startup is due to take place by the end of 2027.