GreenIron has selected ABB’s distributed control system to automate and optimise its hydrogen-based metal production process at its first commercial facility in Sandviken, Sweden.
This marks a step in industrialising fossil-free sponge iron production to reduce carbon emissions in the metals and mining industries using the ABB Ability System 800xA.
Producing fossil-free sponge iron, GreenIron’s patented process uses hydrogen instead of coal. Unlike conventional methods that rely on carbon-intensive processes, GreenIron’s approach generates only water as a by-product. A single furnace is projected to cut carbon emissions by approximately 56 000 tonnes per year compared to traditional coal-based methods. If scaled to 300 furnaces, the emissions reduction could account for around 35% of Sweden’s annual carbon output.
The integration of ABB’s System 800xA will manage GreenIron’s industrial processes by integrating control, safety and power management into a centralised platform. The system will provide full plant visibility, enabling operational stability, real-time insights and improved decision-making – an important step in scaling GreenIron’s operations. “The collaboration with ABB is a crucial part of our scaling up and future growth as we commence commercial production,” said Ulrika Molander, Chief Operating Officer of GreenIron. “ABB’s system will enable us to make informed decisions, stabilise operations at every stage and analyse data for our continued journey. It’s an exciting time for us.”
Beyond reducing emissions, GreenIron’s process contributes to circularity by recovering raw materials from landfills, industrial residues and virgin ore. The resulting sponge iron can be used in electric arc furnaces, smelting plants and foundries to support the transition to cleaner steel and metal production.
Ensuring a carbon-free metal production value chain, ABB and GreenIron’s technologies are designed to work with renewable energy sources such as wind and solar. Allowing for improved productivity, cost modelling and resource allocation, the system also supports GreenIron’s commercialisation efforts by providing centralised control and scalability for future expansion.
Metals and mining industries account for around 8% of global carbon emissions, according to the International Energy Agency.
“Together with GreenIron, we’re working on fulfilling sustainability objectives demanded by the metals industry and wider society,” said Martin Björnmalm, Local Business Line Manager for Metals at ABB Process Industries Sweden.
