End-to-End Techno-Economics of Fluidized Bed Hydrogen Direct Reduced Ironmaking With Pilbara Ores

Fluidized bed hydrogen direct reduced ironmaking (FBH₂DRI) of Pilbara and other Australian iron ore is evaluated via end-to-end techno-economic process modeling. Costs and performance of beneficiation for upstream gangue removal are contrasted with electric arc (EAF) or electric smelter/basic oxygen furnace (BOF) for downstream gangue removal. The trade-off is large tailings waste versus heavy energy and flux costs for smelting lower-grade DRI. Results show that FBH₂DRI-smelter-BOF steel made with low-grade ores is a significantly competitive pathway versus FBH₂DRI-EAF, requiring less beneficiation in optimized routes. Repercussions for the market viability of alternatives ores are examined.

Alireza Rahbari | Australian National University
 

Ms. Shabnam Sabah | Swinburne University of Technology
 

Mohammad Shahabuddin | Swinburne University of Technology
 

Joe Coventry | Australian National University
 

Dr. Geoffrey Brooks | Swinburne University of Technology
 

Dr. M. Akbar Rhamdhani | Swinburne University of Technology
 

John Pye | Australian National University