HILT CRC – upgrading iron ore for DRI production using seawater
- $1.43m Funded by ARENA
- $5.72m Total project cost
Summary
HILT CRC will lead the development of a scalable hydrometallurgical caustic leaching process to upgrade iron ore using the reagents derived from seawater reverse osmosis (RO) brines.
Need
This project was selected as part of the competitive Iron and Steel R&D Funding Round under the Transformative Research Accelerating Commercialisation (TRAC) Program to create solutions for Australian iron ore, predominantly comprised of lower grade ore from the Pilbara, and to decarbonise domestic steel production. Near-term investment in innovative R&D is a critical enabler to rapidly develop the technologies required to transition to a net zero future state. Projects supported by the Iron and Steel R&D Funding Round seek to accelerate novel and innovative low emissions iron and steel technologies using Australian iron ore.
When producing iron ore for direct reduced iron (DRI), achieving high-grade material is essential. Alkaline leaching of impurities, under appropriate operating conditions, presents a unique solution to upgrading iron ore sourced from the Pilbara region.
The project aims to improve commercial viability of low-grade iron ore beneficiation through generation of valuable by-products and using seawater RO brines.
Action
The project will be delivered in two stages, a Core Research Stage followed by a Research Commercialisation Stage. Research activity will be undertaken by Curtin University, in collaboration with HILT CRC and project partners.
The Core Research Stage involves further development of the hydrometallurgical caustic leaching process to upgrade iron ore from 47-56% iron to 63-67% iron, using reagents derived from seawater RO brines by nanofiltration and bi-polar membrane electrodialysis while simultaneously providing valuable by-products, such as lithium salts, zeolites, silica and calcium and magnesium phosphates.
The Research Commercialisation Stage involves completing an engineering study and costing of a pilot beneficiation plant, including an integrated process simulation to support decisions towards commercialisation and scaling of the technology.
Outcome
The project will achieve the following outcomes:
- Reduction in cost associated with using lower-grade Australian iron ores in low emissions DRI production through development of a hydrometallurgical caustic leaching process to upgrade iron ore using the reagents derived from seawater RO brines.
- Increased research capacity in the Australian iron and steel sector, and the facilitation of collaboration between research groups and industry.
- Improved commercial viability of low-grade iron ore beneficiation through generation of valuable by products and using seawater RO brines derived from hydrogen production.
Additional Impact
Within this project, four higher education students (2 MPhil and 2 PhD studies) will be trained in relevant technologies to contribute to a skilled workforce for future low emissions iron and steel technologies using Australian iron ore.
