HYFOR®: Hydrogen-Based Fine-Ore Reduction

HYFOR® (Hydrogen-Based Fine-Ore Reduction) is an innovative direct reduction process that significantly reduces carbon emissions. This method uses hydrogen as a reducing agent to convert iron ore concentrate (pellet feed size) into direct-reduced iron (DRI), bypassing traditional carbon-intensive processes such as 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.

Primetals Technologies has developed a new direct reduction process, the HYFOR® (hydrogen-based fine-ore reduction) process, directly reducing iron ore fines using 100% hydrogen.

In the HYFOR® process, ultra-fine iron ore is directly reduced to DRI (direct reduced iron) in a fluidized-bed reactor cascade. It is the first method worldwide that can process iron-ore concentrates of different qualities, where 100% of the particles are less than 0.15 mm in size.

The process is made up of three parts: the preheating-oxidation unit, a gas purification system, and the actual reduction unit. Inside the preheating-oxidation unit, the fine-ore concentrate is heated to over 800 °C and fed into the reduction unit, where hydrogen is used as the reduction gas. The hot DRI leaves the reduction reactor at around 600 °C and is subsequently cooled. The technology is based on a modular structure, allowing it to be scaled up or down for each customer to suit steelworks of all sizes.

As no agglomeration steps, such as pelletizing or sintering, are required, this enables investment and operating costs to be reduced. The process uses green hydrogen instead of coal and is therefore significantly lowering CO₂ emissions. The aim is to use this new technology to cut primary energy consumption by 20% and CO₂ emissions by up to 100%, shrinking the carbon footprint of crude steel production by 80%.

Primetals Technologies, voestalpine, Rio Tinto, and other project partners are currently validating the potential of HYFOR in the HY4SMELT demonstration plant. It is the first of its kind worldwide, processing ultra-fine iron ores in an innovative fluidized bed direct reduction with 100 % green hydrogen using the HYFOR Technology and melting the direct reduced iron in the Smelter, an electric smelting furnace. Read more about the project.

Benefits of HYFOR®

• Zero carbon emissions: the hydrogen-based direct reduction plant drastically cuts carbon emissions, aligning with global sustainability goals.
• Pellet feed utilization: the HYFOR® process is a first-of-its-kind worldwide in processing ultra-fine iron ores in an innovative fluidized bed direct reduction.
• 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.
• Future-ready technology: paves the way for a hydrogen-based economy, supporting long-term environmental and economic benefits.