Industrial-Scale Hydrogen-Based Steel Production Achieves Breakthrough in Namibia

The transition to climate-neutral steel manufacturing has reached a new milestone with the successful implementation of hydrogen-based direct reduction of iron ore at an industrial scale in Namibia. This development marks a significant step toward reducing the carbon footprint of an industry responsible for approximately seven percent of global CO₂ emissions.

Led by an international consortium under the project SuSteelAG (Sustainable Steel from Australia and Germany), the innovative process enables the conversion of iron ore--including grades with lower iron content--into high-quality direct reduced iron using hydrogen as a reducing agent. The initiative is coordinated by the German Federal Institute for Materials Research and Testing (BAM) and involves partners from Australia, Germany, and Namibia.

Utilizing Lower-Quality Iron Ore for Green Steel

Traditionally, climate-neutral steel production has relied on premium iron ores with an iron content of around 70 percent, which are both scarce and costly. Furthermore, these processes typically require the use of shaft furnaces and extensive pre-treatment of ores into pellets, adding to energy consumption and costs. The new hydrogen-based method developed in Namibia is capable of utilizing iron ores with a lower iron content, thereby expanding the range of raw materials suitable for environmentally friendly steel manufacturing.

Successful Industrial Testing in Oshivela

At the Oshivela site in Namibia, the consortium achieved a notable accomplishment by processing 80 tonnes of Australian iron ore with an iron content of approximately 56 percent in an electrically powered rotary kiln reactor. This process was completed at a throughput of roughly five tonnes per hour, demonstrating the method's industrial viability. The successful conversion of untreated, lower-grade iron ore into direct reduced iron evidences the economic and technical feasibility of this approach for large-scale green steel production.

This breakthrough addresses a key challenge in the industry: the limited availability of high-grade ores. By making use of more abundant, lower-quality ores, the hydrogen-based direct reduction process mitigates potential supply bottlenecks and accelerates the global transition to sustainable steel production.

Next Steps and Research Collaboration

The direct reduced iron produced in Namibia will be transported to Germany for further analysis and potential utilization in green steel manufacturing, particularly for automotive and other industrial applications. Research institutions such as RWTH Aachen University will study how to further optimize the hydrogen-based reduction process for various iron ore qualities, ensuring continued innovation and efficiency improvements.

Project Partners and Support

The rotary kiln reactor in Namibia is operated by HyIron Green Technologies, with significant input from the German industrial kiln manufacturer TS Elino GmbH. The iron ore was supplied by Fortescue, an Australian mining and technology corporation. In addition to HyIron and BAM, consortium members include the Fraunhofer Institutes for Surface Engineering and Thin Films (IST), Ceramic Technologies and Systems (IKTS), Heidelberg Manufacturing Deutschland GmbH, and HANSAPORT. The project receives funding of approximately 4.5 million euros from Germany's Federal Ministry for Research, Technology and Space as part of the 7th Energy Research Programme. The establishment of the rotary kiln in Namibia was also supported by the Federal Ministry for Economic Affairs and Energy.

The success of this initiative demonstrates the potential for sustainable hydrogen-based steel production on a global scale, offering a solution to one of the most carbon-intensive industrial sectors and paving the way for broader adoption of green technologies in heavy industry.