Industrialisation of hydrogen-based technology for recycling of steelmaking residuals

GreenIron has developed a patented, hydrogen-based technology for fossil-free and CO₂-neutral extraction of metals from waste, residuals, and secondary flows generated by the steel industry. Using this technology, GreenIron has successfully produced iron, nickel, copper, and molybdenum without fossil fuels or direct emissions.

The presentation covers the journey from pilot development to industrialisation, with a focus on the commissioning of GreenIron’s first full-scale production site in Sweden during 2025. It presents case studies on hydrogen reduction of steel industry by-products such as mill scale and filter dust, supported by pilot plant and commissioning data demonstrating technical and economic feasibility.

GreenIron’s modular process enables highly energy-efficient reduction of metal oxides to pure metal at small-scale units of approximately 35,000–40,000 tonnes input per furnace per year. The compact footprint allows local installation at steel plants, foundries, and recycling facilities, enabling on-site recycling of residues and reintegration of recovered metals into steelmaking processes.

By targeting major underutilised waste streams - such as mill scale and filter dust, which together account for over 5 million tonnes annually in Europe and North America - GreenIron provides a scalable, circular, and sustainable alternative to fossil-based recycling routes, improving resource efficiency and reducing CO₂ emissions across the steel value chain.