Servomex has played a vital role in a groundbreaking project for sustainable industrial development: the supply of gas analysis technologies to a global steel technology company with a presence in over 20 countries, for use in a revolutionary process that removes carbon emissions from iron and steel production. A significant leap forward in the global transition to fossil-free steel production, Servomex’s cutting-edge analysers, expert domain knowledge, and commitment to partnership have enabled the company to deliver a zero-carbon variant of its direct reduction steelmaking process to create a revolutionary green steel facility.

A revolution in green steel production

This large-scale project utilises a giga-scale green hydrogen plant powered entirely by renewable energy sources – including wind and hydropower. The hydrogen produced will replace traditional carbon-based fuels in the reduction of iron ore, eliminating carbon dioxide (CO₂) emissions from the process. The facility is under construction with production due to commence in 2026 and full capacity to be reached by 2030. This revolutionary approach is projected to reduce 300 million tonnes of CO₂ emissions by 2040, setting a benchmark for decarbonisation in heavy industry. The steel produced will meet the growing demand for sustainable materials and be used by industry leaders including leading European car manufacturers

Enabling the process transition from fossil fuels to hydrogen

At the heart of the project was the modification of its direct iron reduction (DIR) process. Traditional DIR processes rely on coke to reduce iron ore to iron, generating significant CO₂ emissions as a byproduct; the new plant has adapted the process to utilise the green hydrogen produced at the site, fundamentally transforming the reduction reaction:

– Traditional Process: Coke + Iron Ore = Iron + CO₂

– New Green Process: H₂ + Iron Ore = Iron + H₂O (water)

This innovation eliminates CO₂ emissions, making it a cornerstone of sustainable steel production.

A partnership for safety, efficiency and reliability

High-performance gas analysis technologies were required to ensure the safety, efficiency, and reliability of the hydrogen systems used in the DIR process. With more than forty years of successful partnership with the steel and iron company, Servomex was highly familiar with the application and recommended the installation of three SERVOTOUGH 2500 photometric and three SERVOTOUGH Oxy oxygen analysers to monitor the process. Designed for analysing corrosive, toxic and flammable gas streams, the SERVOTOUGH 2500 analysers measure hydrogen concentrations to ensure optimised performance of the reduction process. SERVOTOUGH Oxy 1900 analysers utilise Servomex’s renowned Paramagnetic sensing technology to provide the stable, reliable percentage oxygen measurements required to maintain process safety and efficiency. Integrated with complementary sampling systems into a single analyser house by Servomex’s in-house systems team, Servomex’s solution seamlessly combined with the company’s proprietary and third[1]party technologies to achieve the comprehensive gas monitoring and analysis capability required.

The benefits of partnership

The deployment of Servomex’s gas analysis technologies delivered multiple benefits to the project:

– Enhanced Process Efficiency: Accurate monitoring of gas compositions ensures that the hydrogen reduction process operates at peak efficiency, minimising resource use and maximising output.

 – Safety Assurance: As hydrogen is highly flammable, Servomex’s precise oxygen measurements are critical for maintaining safe operating conditions.

– Sustainability Gains: By facilitating the use of green hydrogen in place of coke, Servomex’s solutions contribute directly to the elimination of CO₂ emissions.

– A Reliable Solution: Servomex’s decades[1]long partnership ensured a seamless integration of Servomex technologies into the facility.

Pioneering the future of green steel