Breakthrough Pilot Testing Results for the Hydrogen Direct Flash Reduced Iron Process

Calix’s Zero Emissions Steel TechnologY (ZESTY) is a flash reduction process based on the indirectly heated Calix Flash Calcination technology. In 2024, Calix completed a second testing campaign (over 100 runs) with six Australian-sourced hematite/goethite iron ores. The campaign demonstrated it is possible to achieve commercially viable metallization degrees for a range of ores approaching near-theoretical minimum hydrogen consumption. This paper covers the ore testing campaign, the preliminary results on downstream testing of the hydrogen direct reduced iron (H-DRI) produced, and the status of technology readiness level development and commercial scale-up, including the design-ready 30,000-metric-tons-per-annum H-DRI demonstration plant.

Authors:

Mr. Chris Ormston | Calix Ltd.
 

Dr. Yun Xia | Calix Ltd.
 

Mr. Thomas Dufty | Calix Ltd.
 

Dr. Shabnam Sabah | Swinburne University of Technology
 

Dr Salwan Al-Assafi | Calix Ltd.
 

Mr Andrew Okely | Calix Ltd.
 

Dr Jiayi (Jerry) Fu | Calix Ltd.
 

Sebastiaan Van Dorp | Calix Limited
 

Dr. Akbar Rhamdhani | Swinburne University of Technology
 

Dr. Geoffrey Brooks | Swinburne University of Technology
 

Dr Mark Sceats | Calix Ltd.
 

Dr. Matt Boot-Handford | Calix Ltd.
 

Session Chairs:

Euan Evenson | Linde Inc.