Fortescue has begun installing core Metso equipment for its Christmas Creek Green Metal Project in the Pilbara, marking a key step toward demonstrating hydrogen-based, low-emission steelmaking. Installation work started in September 2025, following Metso’s contribution of the project’s core process design and technology.
The project will showcase the production of high-purity green metal using renewable energy, incorporating Metso’s Circored fluidized-bed direct reduction process and its electric DRI Smelting Furnace. Together, these technologies enable hydrogen-based reduction and fossil-free smelting for downstream steel processing. Initial output is expected to exceed 1,500 tons per year, with ongoing studies exploring a future commercial-scale facility.
The Circored process relies solely on green hydrogen and can use fine iron ore without pelletization, producing highly metallized DRI suitable for electric smelting. The electric smelting furnace route, designed to replace traditional blast furnaces, is particularly suited to Australia’s low-to-medium-grade Pilbara ores, materials that historically have not been viable for DRI production due to higher gangue content.
Fortescue aims to leverage this technology pathway to unlock the Pilbara’s vast ore resources for green ironmaking and accelerate the shift toward low-carbon steel production.
