HYFOR®- test plant in Leoben, Austria

Ironmaking

HYFOR®: Hydrogen-Based Fine-Ore Reduction

Transforming Iron Production with Zero-Carbon Emission

Solutions

Ironmaking

Direct Reduction

Revolutionizing Iron Making with HYFOR®

HYFOR® (Hydrogen-Based Fine-Ore Reduction) is an innovative direct reduction process that significantly reduces carbon emissions. This method utilizes hydrogen as a reducing agent to convert iron ore concentrate (pellet feed size) into direct-reduced iron (DRI), bypassing traditional carbon-intensive processes like coke-based blast furnaces. By employing hydrogen, which produces water as a by-product instead of carbon dioxide, this technology aligns with global sustainability goals and the transition to low-carbon steel production. The adoption of hydrogen-based direct reduction enhances environmental performance and positions the steel industry at the forefront of technological advancement and ecological responsibility.

HYFOR® (Hydrogen-based fine-ore reduction) is a groundbreaking hydrogen-based direct reduction process developed by Primetals Technologies. It utilizes hydrogen to process iron ore fines, eliminating the need for agglomeration processes like sintering or pelletizing. This innovative approach significantly reduces carbon emissions to zero and produces water as a by-product. HYFOR® directly addresses one of the most pressing challenges in the steel industry—decarbonization. HYFOR® bypasses traditional, carbon-intensive methods, minimizing emissions and enhancing operational efficiency.

Benefits of HYFOR®

  • Zero Carbon Emissions: The hydrogen-based direct reduction plant drastically cuts carbon emissions, aligning with global sustainability goals.
  • Efficient Resource Utilization: Eliminates the need for sintering or pelletizing, reducing energy consumption and operational costs.
  • Innovative Collaboration: Developed in partnership with industry leaders, ensuring cutting-edge technology and expertise.
  • Enhanced Steel Quality: Produces high-quality DRI suitable for various steelmaking processes.
  • Future-Ready Technology: Paves the way for a hydrogen-based economy, supporting long-term environmental and economic benefits.
HYFOR®-pilot plant in Austria

HYFOR®-pilot plant in Austria

Plant operators in the control-room of the HYFOR®-pilot plant

Plant operators in the control-room of the HYFOR®-pilot plant

Material distribution of the HYFOR®-pilot plant

Material distribution of the HYFOR®-pilot plant

Upper material bin of the HYFOR®-pilot plant

Upper material bin of the HYFOR®-pilot plant

Fluidized bed reactor of the HYFOR®-pilot plant

Fluidized bed reactor of the HYFOR®-pilot plant

Digitalization

Automation & Digital Solutions

Digitalization

Through-Process Quality Control

Ensure top-quality steel production with TPQC. Leverage real-time data, predictive analytics, and defect prevention for enhanced efficiency and precision.

Production Management Ironmaking

Optimize ironmaking efficiency with integrated production management solutions. Improve planning, reduce costs, and enhance coordination of ironmaking processes.

Central Operation Cockpit

Streamline steel plant operations with real-time monitoring, automated alerts, and advanced tools for safety, efficiency, and consistent quality.

ALEX: Asset Life Expert

Monitor condition, detect failures early, and optimize maintenance with Asset Life Expert (ALEX) for steel plants.

MAT: Maintenance Asset Technology

Leverage advanced Maintenance Asset Technology (MAT) to optimize equipment performance, reduce downtime, and improve operational efficiency.

Energy Management System

The energy management system enhances operational efficiency through predictive algorithms to optimize energy use at ironmaking plants, steel plants and rolling mills.

The Virtual Plant

Train operators and test automation systems with a digital twin. Enhance skills, ensure system reliability, and enable fast start-ups in steel production.

Metals Business Intelligence

Empower steel production with Metals Business Intelligence, offering data-driven insights, customizable dashboards, and streamlined decision-making tools.

Electrification

Medium-Voltage Power Supply

Medium-Voltage Power Supply, Substations, and Transformers

Medium-Voltage Drives and Motors

The customizable dimensions of medium-voltage drives and motors enhance flexibility and adaptability. Additionally, their design minimizes distortion of the supply grid. Combined with a robust and durable construction, these features make them ideal for the various demands of steel plants.

Digital Power Substation

Optimize energy use and reliability with the Digital Power Substation. Leverage real-time analytics, predictive maintenance, and scalable architecture for steel and aluminum plants.

Low-Voltage Drives and Motors

With various applications throughout the steel industry, low-voltage drives and motors enhance product quality and ensure optimal plant productivity.

Static Synchronous Compensator (STATCOM)

The static synchronous compensator (STATCOM) is a power quality and harmonics management system that enhances steel plant energy performance, reduces operational expenses, and ensures compliance with IEC and utility standards.

Environmental Solutions

Environmental Solutions for HYFOR®

Secondary dedusting plant

Solutions

Off-Gas Cleaning

Secondary Dedusting

Ensure clean air and compliance with secondary dedusting systems for steelmaking. Capture emissions efficiently, enhance safety, and reduce energy costs across steel plants.

MEROS plant at Acciaierie d'Italia in Taranto in Italy

Solutions

Off-Gas Cleaning

MEROS®: Maximized Emission Reduction of Sinter Plants

Achieve superior off-gas cleaning with MEROS. Reduce pollutants like SOx, NOx, and heavy metals. Modular design ensures compliance and efficiency in agglomeration plants.

Gas Fermentation: Microbial fermentation of process gases

Solutions

Ironmaking

Carbon Capture, Utilization & Storage

Transform steel industry emissions with Carbon Capture, Utilization, and Storage technology. Aim for net-zero carbon and enhance competitiveness.

Services

Explore Next Level Services. Now

Services

Consulting

Consulting Services

Consulting services support every stage of a plant's lifecycle, leveraging decades of expertise to benefit producers worldwide.

A maintenance engineer can fix a task in the field using his tablet and the software m.doc operations

Services

Digitalization

m.doc Operations

Streamline maintenance and operations with m.doc Operations, offering fast mobile access, real-time data in documents, and enhanced plant safety.

Screenshot of software m.connect

Solutions

Digitalization

m.connect: Cloud-based Data Analysis and Archival Tool

Optimize steel production with m.connect, a cloud-based tool offering real-time KPI tracking, centralized data storage, and actionable insights.

Solutions

Ironmaking

Direct Reduction

Green Steel

Energy Efficiency

Raw Material Flexibility

Reduce environmental impacts

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