Unlocking Asia-Pacific as a First Mover 2025
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Preferred technology pathways to prioritize for green iron-making in Australia
(% workshop participants)FIGURE 1
Notes: Survey of Adelaide workshop participants, August 2025. Indicative data only . Number of participants (“n”) = 44. DRI = dir ect r educed ir on,
CCS = carbon captur e & storage.Green hydr ogen-
based DRINatural gas-based
DRI with pr ogressive
hydrogen blending
over the subsequent
10-15 yearsGas-based DRI with
CCS and the
possibility of blending
hydrogen later onElectr olysis: high
temperatur eElectr olysis: low
temperatur eGreen hydrogen-based DRI is by far the most preferred pathway
2%0%59%
16%23%
To produce direct reduced green iron, Australia
either needs to invest in beneficiation and electric
smelting of Pilbara’s ubiquitous hematite; or it must
ramp up mining of its DRI-preferred magnetite ore.
Both pathways are valid.
With countries such as Brazil, Canada and Sweden
already well-advanced down the DRI pathway,
the Institute for Energy Economics and Financial
Analysis (IEEFA) argues that “if it wants to remain
competitive, Australia must focus on developing its magnetite iron ore sector,” even though building the
infrastructure to concentrate raw magnetite ore into
high-grade pellets is likely to take “up to a decade”.30
Clarity on the direction of the technology – and
which options are commercially viable – is critical
for investors on the supply side. However, on the
demand side, buyers (including those associated
with FMC and RMI) are technology-agnostic. The
main criterion is that the product is authentically
certified as near-zero emissions.
Existing magnetite iron ore facilities
Australia’s magnetite iron ore sector has developed
over the past two decades and currently features
a handful of major facilities capable of delivering
large-scale ore concentrate and pellets ready for
DRI production (see Figure 2 and Table 1):31
Iron Bridge (Pilbara, WA): Fortescue’s first
magnetite mining operation, which (unlike its
hematite operations) produces a wet magnetite
concentrate that is transported via a 135 km
specialist slurry pipeline to Port Hedland. In June
2025, the company applied for permission to build
a 2.1 GW wind farm and a 220 kV transmission line
to support the decarbonization of this operation.32,33
Sino Iron-Cape Preston (Pilbara, WA):
Commissioned in 2013, this CITIC Pacific Mining
facility has a designed capacity of 24 Mtpa magnetite concentrate. The project cost a reported
$12 billion – far over budget – and was thought to
have delivered around 14 Mt in 2024.
Karara (Mid West): This plant shipped its first
magnetite concentrate in 2013 and has a current
capacity of 8 Mtpa. Plans to expand to 37 Mtpa
have not yet materialized.
SIMEC Mining (SA): This facility in South Australia’s
Middleback Ranges has been mining 2.2 Mt
of magnetite to produce 1.3 Mtpa of pellets for
use at Whyalla Steelworks. The company’s plan
to expand production to 15 Mtpa of DR-grade
concentrate rests on the future of Whyalla, currently
in administration.
Savage River (Tas): This is Australia’s oldest
operating iron ore concentrate facility, located in
Tasmania. Annual magnetite pellet capacity is 2.6 Mt.Green iron pilot projects and capacity
Unlocking Asia-Pacific as a First Mover: Australia’s Green Iron Opportunity
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