Rio Tinto’s BioIron™ proves successful for low-carbon iron-making

Rhea-AI Summary

Rio Tinto has successfully proven its low-carbon iron-making process, BioIron™, using Australian ores in a pilot plant in Germany. This innovative method employs raw biomass as a reductant and microwave energy, potentially leading to near-zero CO₂ emissions in steelmaking. Following extensive testing, the company plans to develop a larger pilot plant to further evaluate this process, which could significantly impact global decarbonization efforts in the steel industry. The promising results have also garnered independent support from the engineering firm Hatch.

Positive

• Successful testing of BioIron™ process in Germany indicates potential for near-zero CO₂ emissions in steelmaking.
• Rio Tinto plans to scale up BioIron™ with a larger pilot plant to evaluate commercial viability.
• Independent technical review by Hatch confirms BioIron™'s capability to reduce greenhouse gas emissions.
• BioIron™ is well-suited for Pilbara iron ore fines, enhancing efficiency in iron production.

Negative

• None.

MELBOURNE, Australia--(BUSINESS WIRE)-- Rio Tinto has proven the effectiveness of its low-carbon iron-making process using ores from its mines in Australia in a small-scale pilot plant in Germany, and is now planning the development of a larger-scale pilot plant to further assess its potential to help decarbonise the steel value chain.

The process, known as BioIron™, uses raw biomass instead of metallurgical coal as a reductant and microwave energy to convert Pilbara iron ore to metallic iron in the steelmaking process. BioIron™ has the potential to support near-zero CO₂ steel-making, and can result in net negative emissions if linked with carbon capture and storage.

Over the past 18 months, the process has been tested extensively in Germany by a project team from Rio Tinto, sustainable technology company Metso Outotec, and the University of Nottingham’s Microwave Process Engineering Group. Development work was conducted in a small-scale pilot plant using batches of 1,000 golf ball-sized iron ore and biomass briquettes.

Rio Tinto Chief Commercial Officer, Alf Barrios, said “Finding low-carbon solutions for iron and steelmaking is critical for the world as we tackle the challenges of climate change. Proving BioIron works at this scale is an exciting development given the implications it could have for global decarbonisation.

“The results from this initial testing phase show great promise and demonstrate that the BioIron process is well suited to Pilbara iron ore fines. BioIron is just one of the pathways we are developing in our decarbonisation work with our customers, universities and industry to reduce carbon emissions right across the steel value chain.”

BioIron™’s potential was confirmed in a comprehensive and independent technical review by Hatch, the global engineering, project management and professional services firm. Hatch noted the thorough work completed by the team and BioIron™’s capacity to reduce greenhouse gas emissions while converting Pilbara iron ore into iron and steel.

The BioIron™ process will now be tested on a larger scale, at a specially designed continuous pilot plant with a capacity of one tonne per hour. The design of the pilot plant is underway and Rio Tinto is considering suitable locations for its construction.

The BioIron™ process works using lignocellulosic biomass including agricultural by-products (e.g. wheat straw, canola stalks, barley straw, sugar cane bagasse) or purpose-grown crops. The biomass is blended with iron ore and heated by a combination of combusting gases released by the biomass and high-efficiency microwaves that can be powered by renewable energy.

Rio Tinto is aware of the complexities around the use of biomass supply and is working to ensure only sustainable sources of biomass are used. Accordingly, the company is undertaking a benchmarking study of biomass certification processes. Through discussions with environmental groups, as a first step Rio Tinto have ruled out sources that support the logging of old growth and High Conservation Value forests.

Notes to editors

Steelmaking accounts for 8 percent of the world’s carbon emissions, and 66 percent of Rio Tinto’s Scope 3 emissions.

The BioIron™ process is well suited to Pilbara iron ore fines and is a highly efficient use of biomass as it is primarily used as a reductant, with microwave energy driving the iron ore reduction reactions to remove the oxygen from the iron ore.

View source version on businesswire.com: https://www.businesswire.com/news/home/20221122005408/en/

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FAQ

What is the BioIron™ process developed by Rio Tinto?

The BioIron™ process is an innovative low-carbon iron-making method that uses raw biomass as a reductant and microwave energy to convert Pilbara iron ore into metallic iron, with the potential for near-zero CO₂ emissions.

When will Rio Tinto scale up the BioIron™ process?

Rio Tinto is planning the development of a larger pilot plant for the BioIron™ process, designed to have a capacity of one tonne per hour.

What are the environmental benefits of Rio Tinto's BioIron™ process?

The BioIron™ process can lead to near-zero CO₂ emissions during steel production and has the potential for net negative emissions when integrated with carbon capture and storage technologies.

Who collaborated with Rio Tinto on the BioIron™ project?

Rio Tinto collaborated with sustainable technology company Metso Outotec and the University of Nottingham’s Microwave Process Engineering Group on the BioIron™ project.

How does the BioIron™ process affect Rio Tinto's carbon emissions?

Steelmaking accounts for 66 percent of Rio Tinto's Scope 3 emissions, making BioIron™ a crucial step in reducing its overall carbon footprint in the steel production industry.