Rio Tinto has shelved its $215 million BioIron research centre in Rockingham, Western Australia, after more than a decade of development. The site will be handed to technology company Calix for a green iron demonstration plant, with Rio Tinto investing $35 million in the project.
The BioIron process aimed to use biomass and microwave energy to convert Pilbara iron ore into raw iron, reducing carbon emissions by 95%. However, Rio Tinto acknowledged that its furnace designs required additional development to minimise risks and optimise performance.
Calix's Zesty technology uses electric heating and hydrogen reduction to produce iron with zero carbon emissions. The demonstration plant is expected to produce 30,000 tonnes of iron per year, with Rio Tinto supplying up to 10,000 tonnes of iron ore subject to conditions.
Calix chief executive Phil Hodgson said the partnership validates their technique and holds enormous potential to decarbonise Western Australia's iron industry. The project has received nearly $45 million in grant funding from the Australian Renewable Energy Agency.
Curtin University associate professor Tejas Bhatelia noted that the shift reflects the technologies' readiness levels, with hydrogen-based methods offering advantages in scalability and logistics compared to biomass. The project now enters a detailed engineering phase ahead of a final investment decision in 2026.
