Formidable Feasibility Fuels Future FurnaceIn a landmark move for Australia’s resource sector, the NeoSmelt consortium announced its selection of Hatch as the engineering & technology partner to develop what could become the nation’s largest electric smelting furnace. Located in the iron-rich Pilbara region, this ambitious project seeks to transform how molten iron is produced by shifting away from high-emission blast furnace methods towards the direct reduced iron electric smelting furnace route. With feasibility studies that began in the second quarter of 2025, the consortium aims to finalise investment decisions by 2026 and commence operations by 2028.

Collaborative Capabilities Catalyse Consortial ConfidenceHatch brings over seven decades of experience in furnace engineering and large-scale industrial projects. The company’s CRISP+ technology, at the heart of the NeoSmelt pilot plant, promises higher efficiency and significantly reduced CO₂ emissions. “We’re thrilled to bring our smelting technology expertise to a project that has the potential to redefine ironmaking,” said John Bianchini, chair & CEO of Hatch. He added, “Our goal is to enable the industry to produce iron with a fraction of the carbon footprint it carries today.” The scope of Hatch’s role includes project management, engineering design and integrating the smelter with the broader balance of plant infrastructure.

Pilbara Potential Promises Progressive ProductionThe NeoSmelt project is uniquely positioned to leverage the Pilbara region’s abundant, high-quality iron ore. Instead of exporting raw ore as in traditional models, this project seeks to add value locally by producing low-carbon molten iron. This move could transform the Pilbara from being primarily a mining hub into a global leader in decarbonised metallurgy. “Using our local resources to create greener iron means more jobs and technological development here at home,” commented a spokesperson from Mitsui Iron Ore Development, highlighting the regional benefits.

Investment Intentions Inspire Industry InnovationThe project’s timeline reflects both its ambition and its scale: feasibility studies in 2025, investment decision by 2026, and operational launch by 2028. These milestones are backed by the consortium’s shared commitment to accelerate the transition towards low-carbon materials. Industry analysts note that if successful, NeoSmelt could become a model for other global iron & steel producers seeking to meet climate targets while remaining cost-competitive.

Visionary Voices Validate Vital VentureJohn Bianchini of Hatch praised the consortium’s forward-thinking vision: “The NeoSmelt team, comprising some of the world’s most respected mining and energy companies, is demonstrating what can happen when industry leaders work together to tackle climate challenges.” His optimism echoes across the sector, as projects like NeoSmelt are seen as essential to meet the growing demand for green steel from sectors like construction and automotive manufacturing.

Consortium’s Cohesion Cultivates Courageous CommitmentThe NeoSmelt consortium unites BHP, BlueScope, Mitsui Iron Ore Development, Rio Tinto & Woodside Energy, companies whose combined scale, expertise and resources enhance the project’s credibility. Each partner contributes unique strengths: from BHP’s mining expertise to Woodside’s experience in energy infrastructure and BlueScope’s knowledge of steel markets. Their shared commitment is rooted in the belief that sustainable iron production is not only environmentally necessary but economically viable.

Technological Triumph Transforms Traditional TacticsCRISP+ technology is central to NeoSmelt’s innovation. Unlike traditional blast furnaces, this electric smelting furnace can integrate renewable energy, significantly lowering the carbon intensity of molten iron production. The process also provides flexibility, allowing the use of hydrogen or other low-carbon reductants, which aligns with long-term decarbonisation pathways. “It’s about rethinking every part of the ironmaking process to cut emissions without compromising output,” explained a Hatch project engineer.

Economic Edge Elevates Environmental EndeavourBeyond environmental goals, the project is poised to deliver tangible economic benefits: job creation, local supply chain development and positioning Western Australia as a global centre for advanced, sustainable metallurgy. Analysts estimate that if scaled up, NeoSmelt could reduce annual CO₂ emissions by millions of metric tons while capturing a share of the growing global green steel market. A Rio Tinto spokesperson summed it up: “This is more than just a plant, it’s a statement about Australia’s role in the sustainable future of steel.”

Key Takeaways:

• NeoSmelt consortium selects Hatch to design Australia’s largest electric smelting furnace in the Pilbara.

• Project aims to produce low-carbon molten iron by 2028 using advanced CRISP+ technology.

• Partnership reflects industry-wide effort to decarbonise iron & steel production and boost local economic growth.