Green iron is on the global mining agenda, with companies like Bedeschi creating the path forward through technical excellence and design versatility.
September this year saw the Australian Government announce an initiative aimed at attracting investment in the burgeoning green iron sector and complement the nation’s emerging and established mining projects, as well as its wind and solar energy infrastructure.
With an initial $500 million in funding available, the National Development Stream of the Green Iron Investment Fund is positioned to incentivise private investment and put Australia in pole position to lead the global shift to green energy and steel.
“Green iron is a major opportunity to grow Australia’s iron ore industry and build a new industrial sector,” Federal Minister for Industry and Innovation Tim Ayres said.
There’s little doubt Australia is among the pacesetters in the race to adopt more sustainable and environmentally friendly methods for iron ore processing and steelmaking. Yet achieving those ambitions will take more than funding.
Delivering the full benefits of a green steel transition depends on engineering excellence, innovation and problem-solving across every step of the production chain, from ore handling to direct reduction and final steelmaking.
That’s where companies like Bedeschi come in.
Technical excellence, forward-thinking
Bedeschi stands at the forefront of bulk material handling and transport, pioneering advanced solutions with Italian engineering excellence since 1908. Headquartered in Limena (Padua), Italy, the company merges tradition with innovation to serve a global clientele across the mining, cement, port and grain industries.
The family-owned outfit operates internationally with subsidiaries in Australia, the US, Germany and Hong Kong, specialising in delivering turnkey solutions and cutting-edge equipment designed for performance, reliability and sustainability.
As part of its global strategy, the company has expanded its presence through local subsidiary Bedeschi Australia, with a focus on the growing iron ore and green steel markets.
“Bedeschi has made significant contributions to the global green steel and energy transition in recent years,” Bedeschi Australia chief executive officer (CEO) Uwe Zulehner said.
“We’ve developed and delivered specialised machinery for the efficient handling of sensitive materials such as hot briquetted iron [HBI] and iron ore pellets. These aren’t standard solutions; they require a high degree of customisation to meet strict quality standards and reduce environmental impact, especially when handling fines.”
With more than a century of experience, Bedeschi is recognised worldwide for its versatility and expertise in handling a comprehensive range of bulk materials. Its solutions are designed to enable the efficient movement and processing of a wide range of materials, including iron ore, cement, base metals and fertilisers.
This multi-faceted expertise is complemented by in-house capabilities. The company proudly operates its own manufacturing workshop in Italy, where it designs and produces key mechanical components to the highest standards of quality and precision.
This combination of technical mastery and direct production control allows Bedeschi to offer tailor-made solutions that consistently meet the evolving needs of its clients worldwide.
Tailored HBI and DRI handling solutions
HBI is a densified briquette form of direct reduced iron (DRI), produced at temperatures exceeding 650°C. Known for its high density and purity, HBI is widely used in steelmaking either alongside scrap metal or as a standalone feedstock.
However, the handling of HBI poses specific challenges due to its physical properties and sensitivity to environmental conditions. Bedeschi addresses these issues with customised engineering solutions designed to ensure the safe, efficient and reliable movement of HBI throughout every stage of the handling process.
One of the most critical issues in HBI handling is minimising mechanical damage during transport. Since briquettes can fracture when subjected to excessive impact or uncontrolled free-fall, Bedeschi has designed systems that significantly reduce drop heights. This approach helps preserve the mechanical integrity of the briquettes and maintain the overall quality of the material.
Storage is another key aspect that requires careful consideration. If not properly managed, HBI can experience self-heating and oxidation, leading to safety risks and material degradation. To mitigate this issue, Bedeschi provides optimised storage solutions engineered for controlled aeration, temperature regulation and material flow continuity.
In terms of conveying, advanced systems are deployed that include variable-speed belt conveyors, precisely engineered transfer points, and chutes optimised using discrete element method simulations. These features work together to help ensure smooth, controlled material movement, reducing wear on equipment and preventing product degradation and dust emissions.
In addition, Bedeschi implements first-in, first-out stockpile management strategies to help ensure consistent material turnover, minimise residence time in storage, and deliver a uniform charge to the furnace.
One of Bedeschi’s most significant recent achievements was the full engineering, procurement and construction (EPC) contract awarded by Voestalpine, a leading international steelmaker, for the upgrade of its direct reduced iron plant in Portland, Texas.
The scope of supply included complete mechanical, electrical and civil works; fabrication, erection and commissioning of an iron ore pellet handling and screening system; 1.5km of conveyor systems with a capacity of up to 1550 tonnes per hour (t/h); two screening towers with the same capacity, including fines separation; and a rail-mounted ship loader with a boom length of 50m and a loading rate of 2400t/h.
This system handles the full logistics of iron ore pellets and HBI, ensuring efficient material flow while prioritising product integrity. The shiploader features a purpose-designed loading chute that minimises impact, preserving the structural integrity of the HBI briquettes during vessel loading while minimising the risk of dust emissions.
Bedeschi again demonstrated its expertise in 2024, when it secured a new order for the supply of a complete material handling system for a DRI production plant in Europe.
This system includes train unloading and loading, a stockyard system with reclaiming operations, and all necessary conveyor belts. It will play a crucial role in a highly advanced plant dedicated to producing DRI for modern electric arc furnace (EAF) steelmaking, eliminating the need for traditional blast furnaces.
The company’s train-loading systems are designed to handle materials gently, minimising transfer points and vertical drops. This careful handling not only preserves the quality of the DRI but reduces dust generation and material degradation, further enhancing the environmental sustainability of the entire process.
This innovative process is more energy-efficient and environmentally friendly, as it replaces coal with greener energy sources, allowing the production of low-emission steel. Bedeschi is proud to support this recent and forward-thinking development through its engineering expertise.
Positioning for Australia’s green iron future
With several green iron and HBI-related projects under development in Australia, Bedeschi is positioning itself as a key partner in delivering turnkey solutions tailored to local requirements.
Its record of engineering excellence coupled with its multi-faceted expertise places the company in good stead to provide Australian mining operations with a trusted partner in advancing towards a green steel future.
“Australia is becoming a major hub for green iron initiatives,” Zulehner said.
“The experience we’ve gained from global EPC project deliveries enables us to support Australian customers by shortening the learning curve when it comes to handling sensitive fine materials. We’re focused on ensuring efficient project execution and delivering positive operational outcomes – fast.”
By combining more than a century of design heritage with cutting-edge innovation, Bedeschi is helping bridge the gap between aspiration and execution, turning the vision of green iron into a working industrial reality.
This feature appeared in the November issue of Australian Mining magazine. Get 50 per cent off your Australian Mining annual magazine subscription during our Black Friday sale. Visit our subscription page and use the code: AMBF25. Ends on 27 November 2025.
