FerraVolt Technology
Next-Generation Green Ironmaking
We are developing a next-generation green ironmaking solution to accelerate the decarbonisation of the iron and steel sector
The hydrogen rotary kiln is a modular, zero-emission solution for ironmaking that re-engineers the conventional rotary kiln technology to replace fossil fuels with green hydrogen and renewable electricity
Only water vapour, no CO2 emissions
The use of solid carbon for iron ore reduction in existing kilns is replaced by gaseous hydrogen producing only water vapour.
Flexibility by electrical heating
Hydrogen gas is an efficient iron ore reductant at lower temperatures which enables the use of a flexible, electrical heating source.
Independent of ore shape and type
The rotary kiln process is tolerant towards a variety of iron ore types, regardless of shape or chemical composition.
FerraVolt ironmaking - How does it work?
The process is based on a refractory-lined rotary kiln in which iron ore fines or pellets are continuously reduced to Direct Reduced Iron (DRI) using hydrogen as the reductant.
The kiln is slightly inclined and rotates to ensure controlled solids transport and mixing. Iron ore is fed at the elevated end, while hydrogen is introduced at the discharge end, creating a counter-current gas–solid flow.
At elevated operating temperatures, iron oxides are stepwise reduced to metallic iron. Water vapor generated during the reaction exits with the off-gas for downstream separation, and the metallized DRI is continuously discharged from the lower end of the kiln.
Technology Designed for Industrial Transition
FerraVolt is an ironmaking technology purpose-built for the transition to fossil-free industry. Its system architecture, process design, and energy integration are engineered from the outset to operate within electrified, hydrogen-based, and renewable-driven power systems:
Electrically heated high-temperature process platform
Heat is supplied through integrated electrical resistance systems rather than combustion, enabling stable temperature control, rapid power modulation, and full decoupling from fossil fuels.
Hydrogen-based direct reduction in a controlled rotary kiln environment
Iron ore fines or pellets are reduced to metallic iron in a continuously operated, counter-current rotary kiln, designed for precise control of temperature, residence time, and gas atmosphere.
Integrated with variable renewable electricity
The process is engineered to respond to fluctuations in power availability, allowing controlled ramping, load adjustment, and adaptation to variations in feedstock and hydrogen supply.
Modular and scalable architecture
The system is designed for stepwise deployment, distributed plant concepts, and capacity scaling without reliance on giga-scale, continuously operated units.
Competitive investment and operating cost structure
The moderate unit scale, simplified plant layout, and reduced infrastructure requirements enable lower upfront investment and efficient operation, particularly in power-constrained or emerging industrial regions.
FerraVolt ironmaking - When does it makes sense?
FerraVolt is designed for flexible deployment across different industrial configurations and market contexts.
The technology supports both stand-alone iron production and integrated steel value chains, enabling fossil-free iron units to be positioned where energy, raw materials, and demand create the strongest business case.
Its modular scale and electrically driven architecture make it suitable for phased investments, regional industrial clusters, and new greenfield developments.
Merchant Green HBI
Distributed Iron Production
Green Steelmaking Feedstock
Copyright 2026©
All Rights Reserved
