DE
ENProject Hy4Smelt
Hydrogen-based fluidised bed direct reduction of ultra-fine iron ores and smelting to green hot metal
Overall approach
The project Hy4Smelt demonstrates a breakthrough process of hydrogen-based, CO2-neutral reduction and melting of non-agglomerated low/medium-grade iron ore, meeting objectives set by the EU on clean steel technologies, sustainability, and competitiveness. The Hy4Smelt industrial-scale demonstrator is first-of-its-kind worldwide in processing ultra-fine iron ores in an innovative fluidised bed direct reduction with 100 % green H2 (HYFOR) and melting the direct reduced iron in a renewable powered electric furnace (Smelter). The green hot metal is further processed to crude steel in an existing Basic Oxygen Furnace. The Hy4Smelt process offers highest flexibility in the use of iron ore grades that are not used for direct reduction today. It is also in line with EU’s zero-waste goal, as the Smelter slag will be qualified as a secondary, alternative raw material to Blast Furnace (BF) slag for the cement sector. Hy4Smelt initiates a massive transformation to a H2-based and circular steel sector. It establishes the EU as a leader for carbon neutral steelmaking.
Hy4Smelt will enable the transformation towards a H2-based, sustainable and circular steel production, substantially reducing CO2 emissions. Hy4Smelt will raise awareness of the necessity that handling low grade ores for green hot metal production must be scaled up to push forward the EU towards a resource-efficient and competitive economy.
Objectives
- Demonstrate the production of green hot metal in continuous operation
- Replacing the BF with breakthrough HYFOR and Smelter technologies to foster GHG neutrality with 100 % green power, H2 and secondary carbon carrier supply.
- Enable the direct use of ultra-fine iron ore (particle size < 500 µm) to avoid agglomeration and further reduce emissions by up to 200 kg CO2 per tonne of hot metal
- HYFOR can process haematitic, magnetitic, sideritic and limonitic ultra-fine ores and, with grinding, larger sinter-fines
- The novel Smelter is operated continuously under reducing atmosphere enabling processing of high gangue iron ore to green hot metal, thus demonstrating an uppermost flexibility in feed materials
- Fully integrate Hy4Smelt in an existing steel plant
- Qualify the Smelter slag as secondary raw material for the cement industry to support circular economy and secure slag availability after BF phase out
PROJECT TIMELINE:
1 April 2025 – 30 September 2029
FUNDING SCHEME:
This project has received funding from the Research Fund for Coal and Steel RFCS-2024-CSP-Big Tickets for Steel of the European Union under Grant Agreement no. 101193416
PROJECT CONSORTIUM:
Starting with the project coordinator, the consortium is composed as follows: