This project, primarily a desktop-study will embrace literature review, industry consultation, brainstorming, process flow-sheeting and process modelling and simulation. The project will begin with identifying a suite of mineral resources that are mined, processed in WA (and Australia in general), and associated refined metals. Process flowsheets will be devised to follow the material and energy flows in alternative process scenarios for each mineral/metal type so as to identify where and how the renewable H2 and NH3 as well as the renewable electricity and O2 by-product, can be used to decarbonise the process. The processes, operation units, and technology components will be evaluated in terms of technology readiness level, complexity, scalability and cost as well as the amount of carbon emissions that can be offset. This will provide crucial information to assist in appreciation for potential end-users and volumes of demand for renewable H2.
The challenge
The mining, mineral processing, and metal refining industries are highly energy-intensive and generate considerable greenhouse gas (GHG) emissions from both fossil energy use and process-related sources. Decarbonising this sector is essential for achieving Western Australia’s (WA) net-zero emissions target and can also support global sustainable development by enabling the export of low-emission products. Renewable hydrogen, produced via renewable energy-powered water electrolysis, offers a potential decarbonisation pathway by serving both as a fuel and reductant in mineral processing and metal refining processes. Leveraging WA’s abundant renewable resources and rich mineral reserves presents a significant opportunity to establish a low-carbon, high-value mineral processing and metal refining industry.
This project aims to identify opportunities and evaluate pathways for the large-scale integration of renewable energy, renewable hydrogen, ammonia, and oxygen by-product into mineral processing and metal refining in WA. Renewable ammonia synthesised from renewable hydrogen is considered alongside hydrogen as it provides a practical means for hydrogen storage and transport, while also serving as a low-carbon feedstock as well as a fuel for heat utility in mineral processing and refining.
The approach
The assessment began with the development of mineral selection criteria to screen the most significant mineral resources. The potential for renewables integration within each main step of production for the selected minerals was then assessed. A Multi-Criteria Decision Analysis Model was developed and deployed to quantify potential GHG emissions reduction and renewables uptake across the value chain, thereby supporting the evaluation of WA’s most suitable pathways to decarbonisation.
WA locally produced minerals, such as alumina (with potential for future aluminium, currently produced in other Australian states where electric power prices are relatively low), nickel, copper, and cobalt, lithium, lead, vanadium, tungsten, gold, and mineral sands (ilmenite, rutile, and zircon) are evaluated based on their global competitiveness, resource longevity, energy demand, carbon footprint, market value, and technical feasibility of transition to renewables. Alumina, lithium, gold, copper, nickel, and cobalt were short-listed for detailed analysis. Conceptual process flowsheets for each selected mineral present a step-by-step visualisation of integration opportunities across the production chain, along with the in-depth analysis of the new equipment/technology required for the transition. Renewable energy utilisation, requiring new equipment and technologies, mainly includes (a) electrification of mining equipment and (b) fuel substitution for heating processes, such as utility boilers and other thermal operations. Mineral-specific integration opportunities vary according to process characteristics. The key pathways for each mineral are: (a) Aluminium: renewable hydrogen as a fuel for steam generation, and renewable energy for the electrolytic reduction process. (b) Nickel: renewable hydrogen as a fuel for steam generation, ammonia, and oxygen as chemical reagents. The application of renewable energy is influenced by ore type, covering all production stages in the case of sulphide ores and concentrated primarily in the mineral processing and refining stages for laterite ores. (c) Lithium: renewable hydrogen for steam generation and renewable energy for refining. (d) Gold: renewable hydrogen as fuel for fuel cell-powered trucks and other mining equipment, oxygen as a reagent, and renewable energy for driving equipment in the crushing step. (e) Copper: renewable hydrogen as fuel for fuel cell-powered trucks and other mining equipment, and renewable energy for equipment operation in the refining stage.
The outcome
With a brave and ambitious assumption that all the aforementioned opportunities for renewables integration can be realised to decarbonise the mineral sector in WA, alumina production currently presents the highest potential for renewable uptake, 1418 tonnes of renewable hydrogen and 1537 GWh of renewable electricity per annum. Looking ahead, if aluminium smelting were to be carried out locally, a futuristic scenario, it would offer a substantial opportunity for renewable electricity integration, with an estimated annual demand reaching 111,526 GWh. Nickel and lithium hydroxide production also show significant potential. For nickel, combining sulphide and laterite ore processing routes yields an estimated annual requirement of 2008 GWh of renewable electricity, 108 tonnes of hydrogen, 162 tonnes of oxygen, and 108 tonnes of ammonia. A similar situation exists for lithium: current lithium concentrates and lithium hydroxide production are estimated to require 1467 GWh of renewable electricity and 115 tonnes of hydrogen per year. In a forward-looking scenario where all lithium concentrate produced in WA is further processed into lithium hydroxide, the annual renewable demand would increase to approximately 3464 GWh of renewable electricity and 412 tonnes of hydrogen. However, the realisation of these scenarios will ultimately depend on market demand for lower-carbon metals and government policy support.
The impact
These findings, as an initial step in identifying practical opportunities for renewable energy integration in WA’s mineral and metal industries, could assist BP in shaping its business strategy for the renewable project development. However, further R&D via systematic study is necessary to give BP and its potential end-users the confidence in these proposed decarbonisation applications of BP’s renewables. Critical technical questions such as 1) What’s the efficiency and associated costs if hydrogen is used as a fuel for steam generation or providing high temperatures for calcination? 2) Does the hydrogen calciner affect the alumina product quality? 3) In what form (e.g., green ammonia, sustainable liquid fuels, methanol), does BP’s renewable hydrogen need to be at lower costs for transportation? 4) Does compressed air energy storage (CAES) have a role in providing a stable 24/7 renewable electricity supply to power the hydrogen generation or mineral processing sector in WA? needs to be answered via a more in-depth desktop study, targeted laboratory experimental campaign, as well as process modelling and detailed techno-enviro-economic assessment.
It is also worth noting that the WA state government is spearheading the WA Advanced Biofuel Strategy under the 2025 Made in WA Plan, aiming at an ambitious 80% emissions reduction target by 2030. Biofuels / sustainable liquid fuels, produced via hydrotreating of pyrolysis liquid products generated from various biomass and wastes, catalytic synthesis of pyrolysis syngas, anaerobic digestion biogas, and transesterification of fatty acids (from animal tallow, used cooking oil, waste oil, and oil produced from oilseeds), depend heavily on renewable hydrogen to enhance process efficiency, product yield, and quality. Therefore, BP’s renewable hydrogen could play a transformative role in these emerging biofuel pathways, which align with strategic government priorities. By leveraging the shared hydrogen infrastructure for both minerals processing and biofuel production, WA can significantly increase utilisation, reduce costs, and amplify environmental benefits of both renewable hydrogen and biofuels initiatives. This cross-sector synergy lays the foundation for a thriving hydrogen economy, connecting clean mineral production with next-generation fuels, and creating compelling opportunities for BP and partners through initiatives like the FEnEx CRC. Realising this integrated vision could accelerate WA’s leadership in low-carbon industries, delivering strong economic value and attracting global investment. The UWA CFE is a world leader in biofuels and bioenergy R&D and is standing ready to assist bp and the WA bioresources industry in the pursuit of a low-carbon economy.
Next steps
With the World’s most advanced knowledge, systematic analytical tools for process assessment, and unique knowhow, the FEnEx CRC’s relevant research team stand ready to assist the WA mining and minerals industry in their effort to decarbonise the economy, in particular, in answering the critical technical questions identified in the present research.
Project researchers
- Prof. Dongke Zhang
- Mr Zhezi Zhang
- Mr Jianting Lin
- Ms Mengqing Zhao
- Dr Chiemeka Okoye
- Dr Huanran Wang
- Dr June Wu
Project Status
Complete
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