Fortescue produces first hot metal using electric smelting

Fortescue has reached a milestone in its Green Metal Project by producing its first hot metal using an electric smelting process at the Christmas Creek hub in Western Australia. The project utilizes an electric smelting furnace to feed direct reduced iron into the process, aiming to create a low-emission or zero-carbon metal feed for steel mills.

During the initial commissioning phase, the facility used a blended feedstock. The project is designed to test new technology and develop a pathway for producing commercial-scale green metal using Pilbara ore. Fortescue aims to leverage Australia’s renewable energy resources to build a new industrial economy around green metal production.

The Christmas Creek facility includes a green hydrogen plant commissioned in 2024, which can produce approximately 530 kilograms of renewable fuel daily. While Fortescue previously held larger ambitions for green hydrogen production, it has scaled back some plans due to global market conditions. However, the company maintains its goal of reaching ‘real zero’ emissions at its Pilbara operations by 2030 through significant investments in solar and wind capacity.