Metso has delivered the core process design and supplied key technologies for Fortescue Ltd’s Christmas Creek Green Metal Project in the Pilbara, Western Australia, where installation of Metso equipment began in September 2025. The project aims to showcase the production of high-purity green metal using renewable energy to power hydrogen-based reduction and electric smelting technologies for future downstream steel production.
At the heart of the demonstration plant are Metso’s Circored™ fluidised bed direct reduction process and its electric DRI Smelting Furnace—technologies designed to support low-emission steelmaking pathways.
“Green metal presents a huge opportunity for Australia’s iron ore industry, and Fortescue is determined to lead the way,” said Dino Otranto, Fortescue’s Chief Executive Officer of Metals and Operations. “Through the Christmas Creek Green Metal Project, we’re combining cutting-edge technologies, including Metso’s Circored™ process and DRI Smelting Furnace, with Fortescue’s track record in project delivery to pioneer low-emission pathways for steelmaking.”
The initial demonstration plant will produce more than 1,500 metric tonnes per year, with ongoing studies evaluating the development of a future commercial-scale facility.
Breakthrough Technologies Advancing Green Steel
“This project, which implements the Circored™ and DRI smelting solutions, underscores our commitment to advancing sustainable and efficient industrial processes,” said Attaul Ahmad, vice president, Ferrous and Heat Transfer at Metso. “The Circored™ process uses solely green hydrogen instead of fossil reductants. This flexible fine-ore fluid bed process—eliminating the need for pelletisation—produces highly metalised direct reduced iron that can be fed directly into electric smelting furnaces for carbon-free steelmaking.”
Jyrki Makkonen, vice president, Smelting at Metso, added: “The low-emission electric smelting route, which replaces traditional blast furnaces in producing hot metal, is ideally suited to Australia’s abundant low- to medium-grade Pilbara iron ores. The goal of the Metso DRI Smelting Furnace technology is to unlock the use of these vast ore reserves for green ironmaking, even though they have historically been unsuitable for the DRI route due to higher gangue content. We are excited to see the furnace taking shape at Christmas Creek, where foundations are now in place and the first equipment was installed in September.”
For more information visit www.metso.com
