Starting in late 2027, we will use Hy4Smelt to research steel production with net-zero CO2emissions. Construction of the world’s first demonstration plant—which combines hydrogen-based direct reduction for ultrafine iron ores with an electric smelting process—is in full swing.
Since the groundbreaking in September 2025, construction has included a smelter hall, a grinding and drying plant, the foundation for the HYFOR tower, and a hydrogen pipeline approximately one kilometer long leading to the neighboring H2-Future plant. That is where the hydrogen required for direct reduction is produced.
Since the summer, the steel structure—weighing approximately 2,800 metric tons—has also been taking shape. Starting in the fall of 2026, the core equipment will arrive, including the smelter furnace and the HYFOR reactors, in which the iron ore is reduced to sponge iron using innovative fluidized-bed technology and hydrogen. Work on the outdoor facilities will then begin as well.
The construction of the facility is a key project within our greentec steel transformation program, through which we are demonstrating innovative approaches to steel production. At the same time, the research facility marks a milestone on our path to decarbonization, with the goal of producing steel with net-zeroCO2emissions by 2050.
The massive demonstration plant is scheduled to be completed in 2027, and research operations are set to begin in November 2027 and continue for the next three years.
Michael S. and Bernhard E. are leading this project. About 50 employees will work in shifts at Hy4Smelt. To prepare them for working with hydrogen as a new medium, relevant training programs are already underway. The leading metallurgical competence center K1-MET is supporting us as a scientific partner.
The research project, which we are carrying out together with the international plant manufacturer Primetals Technologies and the mining group Rio Tinto, not only places high demands on time management but also presents organizational challenges: “Since this is a consortium project, it was necessary to establish common processes across corporate boundaries and clearly define roles and responsibilities. That was quite complex,” explains Michael S.
While Primetals Technologies is responsible for the development and implementation of the innovative plant technologies, Rio Tinto provides not only technical expertise but also approximately 70 percent of the iron ore for the Hy4Smelt plant.
Strong support from top management, streamlined structures, and a fair distribution of tasks and costs ensure that the project is progressing according to schedule.
Hy4Smelt combines two technologies for producing high-quality iron: hydrogen-based direct reduction for ultrafine iron ores (HYFOR®—short for Hydrogen-Based Fine-Ore Reduction) and the electric smelting process (smelter).
By the end of 2027, the Hy4Smelt facility—the world’s first demonstration plant to combine hydrogen-based direct reduction for ultrafine iron ores with an electric smelting process—will be completed at the Linz site.
Within the framework of our focus greentec steel, we provide an overview of our concrete steps on the way towards long-term green steel production and the innovative processes we are using on this way. We provide information about the challenges we face and the breakthrough technologies we are already researching today in order to achieve our goal of steel production with net zero CO2 emissions by 2050. funded by the BMK’s environmental support program.
Die voestalpine ist ein weltweit führender Stahl- und Technologiekonzern mit kombinierter Werkstoff- und Verarbeitungskompetenz. Die global tätige Unternehmensgruppe verfügt über rund 500 Konzerngesellschaften und -standorte in mehr als 50 Ländern auf allen fünf Kontinenten. Sie notiert seit 1995 an der Wiener Börse. Mit ihren Premium-Produkt- und Systemlösungen zählt sie zu den führenden Partnern der Automobil- und Hausgeräteindustrie sowie der Luftfahrt- und Öl- & Gasindustrie und ist darüber hinaus Weltmarktführer bei Bahninfrastruktursystemen, bei Werkzeugstahl und Spezialprofilen. Die voestalpine bekennt sich zu den globalen Klimazielen und verfolgt mit greentec steel einen klaren Plan zur Dekarbonisierung der Stahlproduktion.