GFG Liberty Steel Australia Whyalla steel plant
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GFG Liberty Steel Australia Whyalla steel plant, also known as Liberty House, Liberty OneSteel Whyalla, is a steel plant in Whyalla, South Australia, Australia that operates electric arc furnace (EAF), basic oxygen furnace (BOF), blast furnace (BF), and direct reduced iron (DRI) technology.
Location
The map below shows the exact location of the plant in Whyalla, South Australia, Australia:
- Location: 172 Lacey Street, Whyalla, South Australia 5600, Australia
- Coordinates (WGS 84): -33.009381, 137.587836 (exact)
Background
Plant History
The Whyalla Steelworks is an integrated and electric steelworks with current capacity of approximately 2.6 million tonnes per annum of cast steel and hot rolled product.[1] GFG Alliance states that the plant is Australia’s "only manufacturer of special grade billet and steel long products" and that it produces "semi-finished steel billets to Liberty Steel and produces custom made hot rolled structural, rail and sleeper products for internal and external customers."[2]
Blast Furnace Closure
On September 13, 2026 it was announced that the blast furnace will be permanently shutdown.[3] As a result, at least 500 employees at the plant have lost their jobs.[3] State and federal governments created a $10.2 million package to support those affected. [3]
The sale of the plant is still moving forward with Jindal Steel and M Resources as the final two bidders.[4] Though, BlueScope Steel still has the last offer.[3] The sale of the plant will happen by the end of 2026.[3] The DRI-EAF units will still be built by the new owners but unclear when.[4]
Corporate ownership changes
In April 2016 Arrium appointed KordaMetha to restructure the debt-laden business which included the Whyalla Steelworks. KordaMentha aimed to sell the Whyalla Steelworks and related businesses as an integrated package.[5]
In late September 2017 Liberty House GFG announced that it had bought the Whyalla Steelworks.[6]
In early 2020, Whyalla Steelworks, previously known as Liberty OneSteel or Liberty Steel Whyalla announced a name change to "InfraBuild Steel Centre Whyalla. InfraBuild remains a company of the Liberty Group.[7]
In February 2025 it was reported that GFG owes over $300 million of unpaid bills to SA Water. Since they have not been able to pay this money back, the SA government put the plant under administration. In addition to unpaid bills, GFG has not paid their workers either. If this plant closes, Australia will suffer. They are the largest exporter of iron ore in the world and this plant specifically provides steel for railroads and construction.[8][9]
Coal Supply
In January 2018 the GFG Alliance announced that its mining division, SIMEC Mining, had entered into an agreement to buy Glencore’s Tahmoor coal mine in New South Wales. At the time the mine had annual production of about 2 million tonnes of coal a year with most of its product being high-quality coking coal used for primary steel making in blast furnaces.[10]
The company described the purchase of the mine, which ws scheduled to be completed in the first quarter of 2018, as "a key element in the GFG Alliance’s transformation plan for its flagship Whyalla Steelworks in South Australia that is designed to optimise and expand production, thereby securing its long term sustainability."
In the media release Gupta stated "the acquisition of the Tahmoor mine is an exciting step forward in our stated strategy to create fully-integrated, end-to-end businesses in Australia, from raw materials and energy right through to high-value finished products ready for market ... Through this purchase we secure and de-risk an important feed for the Whyalla Steelworks."[10]
The purchase of the Tahmoor mine was completed on April 20, 2018.[11]
Power supply
Existing power supply
The South Australian grid, run by the then Electricity Trust of South Australia (ETSA), was extended to Whyalla by the late 1950s. While the town's supply was progressively transferred to ETSA during the 1960s, BHP continued to supply much of its own needs and those of some other customers that were not economic to transfer to the ETSA network. As BHP's power needs grew it began to use grid power for a greater portion of its own needs.[12] However, as of 2016 the steelworks continues to generate its own electricity to lower its energy costs and increase security of supply.
As of 2005, the Whyalla Steelworks has 66.5 MW of dedicated electricity generating capacity on-site. 57.5 MW of this capacity consists of three turbo alternators driven by steam raised in various boilers, fired primarily by waste blast furnace and coke oven gases. The boilers can also be fired with supplementary fuel oil and natural gas. The boilers also provide steam for process use around the plant. Two 4.2 MW gas turbines operate exclusively on purchased natural gas.[12][13]
Despite this on-site capacity, the plant relies on purchased electricity for a substantial portion of its needs, and only exports power to the grid occasionally.
Renewable energy plans
As part of its plan to overhaul the business, GFG Alliance announced in August 2017 that it proposed to invest up US$1 billion in the Whyalla steelworks and associated mining businesses including to "improve energy generation capabilities, including a new co-generation power plant to capture and reuse waste gases, generating on-site captive power." The announcement also proposed investment in "new large-scale pumped hydro and solar power plants to assist in addressing Australia’s energy imbalance and high energy costs. [6]
Several weeks later GFG Alliance announced that, via its SIMEC Energy subsidiary, had bought a majority shareholding in the energy company ZEN Energy "to deliver cheaper, more reliable and environmentally sustainable energy for SIMEC’s mining operations in South Australia and Liberty OneSteel’s operations in South Australia, Victoria, New South Wales, Queensland, and Western Australia."[14]
The company explicitly stated that its "main focus" in the development of new energy projects would be on renewable energy.[14]
In late October 2017 the Board of ZEN Energy announced that its board had adopted a strategic plan of proving 1000 megawatts of "additional dispatchable renewable generation assets to support long-term electricity supply contracts with South Australia’s large industrial users, including the Liberty OneSteel Whyalla Steelworks." [15]
Included in its proposals "for early development" were "200MW of solar photovoltaics, comprising 80MW in the Whyalla Council industrial area, expanded by 120MW on adjacent land owned by Liberty OneSteel; 100MW/100MWh battery at Port Augusta; a 100MW of demand response at the Whyalla Steelworks and other SA sites; and 120MW/600MWh pumped hydro storage facility at a disused iron ore mine pit in the Middleback Ranges." [15]
Transition
In June 2020, the company announced its plans to transition the plant away from BF-BOF technology by 2024, making it a "GreenSteel" facility. The BF-BOF equipment will be phased out in favor of a 1.5mtpa EAF and 1.8mtpa DRI plant, which will be fed by natural gas until they are able to produce green hydrogen to feed it instead. The project aims to leverage renewable energy sources, such as solar and hydroelectric power, to achieve carbon-neutral steel production, reduce emissions, and create sustainable jobs in the region. The transformation is expected to position Whyalla Steel as a global leader in environmentally friendly steel manufacturing.[16]
Workplace accidents
During the attempted revival of the blast furnace, three steelworkers were injured. One employee who suffered a leg injury was flown to a hospital in Adelaide while the other two were treated on the scene for minor burns.[17]
Ownership Tree
This ownership tree is part of the Global Energy Ownership Tracker, a project of Global Energy Monitor.
Low-emissions/green steelmaking
This steel plant is associated with a green steel project tracked in the Green Steel Tracker. Details about the project are included below.
Table 1: Green Steel Project Details
| Project 1 | |
|---|---|
| Project name | Liberty Steel Whyalla Transformation Program |
| Company | Liberty Steel Group |
| Company has climate goals? | Yes |
| Location | Whyalla, Australia |
| Project website | Site |
| Project scale | Full scale |
| Project status | Paused or postponed |
| Technology to be used | NG-DRI to H-DRI |
| Technology details | DRI+EAF Fed by Natural Gas in transitioning to green H2 |
| Iron production capacity (million tonnes per year) | Not applicable |
| Steel production capacity (million tonnes per year) | 1 |
| CO2 capture (million tonnes CO2 per year) | Not stated |
| Hydrogen generation capacity (MW) | 2 |
| Investment size (m USD) | 760 |
| Partners | Not stated |
| Date of announcement | 6/10/2020 |
Plant Details
Table 2: General Plant Details
| Start date | Workforce size | Power source | Iron ore source | Coal source |
|---|---|---|---|---|
| 1941[18] | 1500[19] | 66.5 MW Captive Power Plant; South Australian Grid, Santos (gas supplier)[20][21][22] | Simec Mining (part of GFG Alliance)[22][23] | Tahmoor mine (M0103)[24][25][26] |
Table 3: Ownership and Parent Company Information
| Parent company | Parent company PermID | Parent GEM entity ID | Owner | Owner company PermID | Owner GEM entity ID |
|---|---|---|---|---|---|
| GFG Alliance Ltd [100.0%] | 5057811578 [100.0%] | E100001000556 [100.0%] | GFG Alliance Ltd [100%][27] | 5057811578 | E100001000556 [100%] |
Table 4: Process and Products
| Steel product category | Steel products | Steel sector end users | ISO 14001 | ISO 50001 | Responsible steel | Main production equipment |
|---|---|---|---|---|---|---|
| semi-finished, finished rolled[28] | rod, tube, wire, bar[28] | building and infrastructure, energy, steel packaging, tools and machinery[28] | unknown | unknown | unknown | BF; DRI; EAF; BOF |
Table 5: Plant-level Crude Steel Production Capacities (thousand tonnes per annum)
| Capacity operating status1 | Basic oxygen furnace steelmaking capacity | Electric arc furnace steelmaking capacity | Nominal crude steel capacity (total) |
|---|---|---|---|
| announced | – | 1500[29][30] | 1500[29][30] |
| mothballed pre-retirement | 1200[18][31] | – | 1200[18][31] |
Table 6: Plant-level Crude Iron Production Capacities (thousand tonnes per annum)
| Capacity operating status1 | Blast furnace capacity | Sponge iron/DRI capacity | Nominal iron capacity (total) |
|---|---|---|---|
| announced | – | 1800[29] | 1800[29] |
| mothballed pre-retirement | 1200[32][33] | – | 1200[32][33] |
Table 7: Upstream Products Production Capacities (thousand tonnes per annum)
| Ferronickel | Sinter | Coke | Pellets |
|---|---|---|---|
| NF | NF | NF[34] | NF |
Table 8: Actual Plant-level Crude Steel Production by Year (thousand tonnes per annum)
| Year | BOF production | Other/unknown steel production | Total (all routes) |
|---|---|---|---|
| 2019 | unknown | unknown | – |
| 2020 | unknown | unknown | – |
| 2021 | unknown[35] | –[35] | –[35] |
| 2022 | 1022[36] | –[36] | 1022[36] |
| 2023 | 886[36] | –[36] | 886[36] |
| 2024 | unknown | unknown | – |
| 2025 | unknown | unknown | – |
Table 9: Actual Plant-level Crude Iron Production by Year (thousand tonnes per annum)
| Year | BF production | Other/unknown iron production |
|---|---|---|
| 2019 | unknown | unknown |
| 2020 | unknown | unknown |
| 2021 | unknown | unknown |
| 2022 | unknown | unknown |
| 2023 | unknown | unknown |
| 2024 | unknown | unknown |
| 2025 | unknown | unknown |
Unit Details
Table 10: Blast Furnace Details
| Unit name | Status | Construction date | Start date | Furnace manufacturer and model | Current size | Current capacity (ttpa) | Decarbonization technology | Most recent relining |
|---|---|---|---|---|---|---|---|---|
| BF 2 | mothballed pre-retirement[37][33] | 1965[22] | 1965[38][22][39] | Hoogoven[38] | 1884.0[38] | 1200[32][33] | unknown | 2011-06[40] |
Table 11: Direct Reduced Iron Furnace Details
| Unit name | Status | Start date | Furnace type | Current capacity (ttpa) |
|---|---|---|---|---|
| unknown DRI (1) | announced[41] | 2027[42] | not found | 1800[29] |
Table 12: Electric Arc Furnace Details
| Unit name | Status | Announced date | Start date | Furnace manufacturer and model | Current capacity (ttpa) | Current size (tonnes) |
|---|---|---|---|---|---|---|
| unknown EAF (1) | announced[41] | 2020[43] | 2027[44][42] | Danieli Q-One technology[36][42] | 1500[30][29] | 160.0[45][46][47][48][29] |
Table 13: Electric Arc Furnace Feedstock Details
| Unit name | Scrap-based | % scrap | % DRI | % HBI | % sponge iron (unknown if DRI or HBI) | % basic/merchant pig iron | % granulated pig iron | % pig iron (unknown if basic/merchant or granulated) | % other iron |
|---|---|---|---|---|---|---|---|---|---|
| unknown EAF (1) | yes[30] | >0[30] | unknown | unknown | unknown | unknown | unknown | unknown | unknown |
Table 14: Basic Oxygen Furnace Details
| Unit name | Status | Start date | Current capacity (ttpa) | Current size |
|---|---|---|---|---|
| unknown BOF (1) | mothballed pre-retirement[49][37] | 1964 | 1200[31][18] | 100.0 m3[50][28] |
Articles and Resources
Additional data
To access additional data, including an interactive map of steel plants, a downloadable dataset, and summary data, please visit the Global Iron and Steel Tracker on the Global Energy Monitor website.
References
- ↑ Liberty Steel Australia, Liberty Steel, Retrieved on: May 21, 2020
- ↑ LibertyGRG Group, "Liberty in Australia", September 2018, page 11.(Pdf)
- ↑ 3.0 3.1 3.2 3.3 3.4 "'Hard roads ahead' as Whyalla steelworks cuts hundreds of jobs". Retrieved 2026-10-07.
- ↑ 4.0 4.1 "Two remaining Whyalla steelworks bidders announced, BlueScope retains last offer right". Retrieved 2026-10-07.
- ↑ "Arrium Australia: Saving a global business with local impact", KordaMetha website, accessed January 1, 2019.
- ↑ 6.0 6.1 "GFG Alliance completes landmark acquisition of Arrium", GFG Alliance, August 31, 2017.
- ↑ Liberty GFG Alliance, Liberty Steel, Retrieved on: May 21, 2020
- ↑ "SA government forces Whyalla steelworks into administration". Retrieved 2025-12-02.
- ↑ "Whyalla steelworks' owner GFG owes $15 million to SA Water". Retrieved 2025-12-02.
- ↑ 10.0 10.1 "GFG Alliance agrees purchase of Glencore’s Australian metallurgical coal mine", Media Release, January 2, 2018.
- ↑ "Tahmoor Coking Coal Employees Welcomed to the GFG Family", Media Release, April 20, 2018.
- ↑ 12.0 12.1 Mark Parry, "Network service provider registration exemption", Australian Energy Regulator, December 9, 2005.
- ↑ "Waste Heat to Power Systems," EPA, Last Updated: May 30, 2012
- ↑ 14.0 14.1 ZEN Energy, "GFG Alliance invests in ZEN Energy to create a new Australian National Energy Champion", Media Release, September 20, 2017.
- ↑ 15.0 15.1 ZEN Energy, "New ZEN Energy Launches Gigawatt Program to Support SA Industry", Media Release, October 30, 2017.
- ↑ "GFG Announces Updated Plan To Transform Whyalla Steel Into A World Leading "GREENSTEEL" Facility". GFG Alliance. June 10, 2020.
{{cite web}}: CS1 maint: url-status (link) - ↑ "Whyalla workers injured at steelworks' blast furnace". Retrieved 2026-10-07.
- ↑ 18.0 18.1 18.2 18.3 https://web.archive.org/web/20220113195449/https://www.gfgalliance.com/whyalla-transformation/about-the-steelworks/. Archived from the original on 2022-01-13.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20220120125511/https://www.afr.com/companies/manufacturing/gupta-s-whyalla-steelworks-reverses-losses-20210303-p577ab. Archived from the original on 2022-01-20.
{{cite web}}: Missing or empty|title=(help) - ↑ (PDF) https://www.aer.gov.au/system/files/OneSteel's%20application%20to%20be%20exempt%20from%20registering%20as%20an%20NSP%20(9%20December%202005).pdf.
{{cite web}}: Missing or empty|title=(help) - ↑ (PDF) https://web.archive.org/web/20240130192840/https://www.epa.gov/sites/default/files/2015-07/documents/waste_heat_to_power_systems.pdf. Archived from the original (PDF) on 2024-01-30.
{{cite web}}: Missing or empty|title=(help) - ↑ 22.0 22.1 22.2 22.3 https://web.archive.org/web/20230412043507/https://en.wikipedia.org/wiki/Whyalla_steelworks. Archived from the original on 2023-04-12.
{{cite web}}: Missing or empty|title=(help) - ↑ (PDF) https://web.archive.org/web/20241218005057/https://www.gfgalliance.com/wp-content/uploads/2023/11/LPMA_Sustainability_Report_2022_FA.pdf. Archived from the original (PDF) on 2024-12-18.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20210817230946/http://www.simec.com/news/gfg-alliance-agrees-purchase-of-glencore-s-metallurgical-coal-mine/. Archived from the original on 2021-08-17.
{{cite web}}: Missing or empty|title=(help) - ↑ https://www.gem.wiki/Tahmoor_Coal_Mine.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20220127021337/https://www.gfgalliance.com/media/tahmoor-coking-coal-employees-welcomed-gfg-family/. Archived from the original on 2022-01-27.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20240125062507/https://www.gfgalliance.com/about-us/. Archived from the original on 2024-01-25.
{{cite web}}: Missing or empty|title=(help) - ↑ 28.0 28.1 28.2 28.3 https://web.archive.org/web/20220823203329/http://www.libertyhousegroup.com/our-businesses/liberty-steel/liberty-steel-australia/. Archived from the original on 2022-08-23.
{{cite web}}: Missing or empty|title=(help) - ↑ 29.0 29.1 29.2 29.3 29.4 29.5 29.6 https://web.archive.org/web/20230404055858/https://www.gfgalliance.com/media-release/liberty-steel-in-whyalla-announces-the-phase-out-of-coal-based-steelmaking-with-purchase-of-a-low-carbon-emissions-electric-arc-furnace/. Archived from the original on 2023-04-04.
{{cite web}}: Missing or empty|title=(help) - ↑ 30.0 30.1 30.2 30.3 30.4 https://libertysteelgroup.com/liberty-steel-in-whyalla-announces-the-phase-out-of-coal-based-steelmaking-with-purchase-of-a-low-carbon-emissions-electric-arc-furnace/.
{{cite web}}: Missing or empty|title=(help) - ↑ 31.0 31.1 31.2 www.recyclingtoday.com https://web.archive.org/web/20250905020525/https://www.recyclingtoday.com/news/gfg-liberty-steel-blast-electric-arc-furnace-switch-australia-recycling-whyalla/. Archived from the original on 2025-09-05. Retrieved 2024-12-17.
{{cite web}}: Missing or empty|title=(help) - ↑ 32.0 32.1 32.2 https://web.archive.org/web/20210516095300/https://www.argusmedia.com/en/news/2113013-gfg-to-overhaul-australias-whyalla-steelworks. Archived from the original on 2021-05-16.
{{cite web}}: Missing or empty|title=(help) - ↑ 33.0 33.1 33.2 33.3 https://web.archive.org/web/20240125054730/https://libertysteelgroup.com/our-operations/liberty-steel-australia/. Archived from the original on 2024-01-25.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20240119051953/https://www.seaisi.org/details/23580?type=news-rooms. Archived from the original on 2024-01-19.
{{cite web}}: Missing or empty|title=(help) - ↑ 35.0 35.1 35.2 (PDF) https://web.archive.org/web/20230116180549/https://libertysteelgroup.com/wp-content/uploads/2022/12/Liberty-Steel-Sustainability-Report-2022.pdf. Archived from the original (PDF) on 2023-01-16.
{{cite web}}: Missing or empty|title=(help) - ↑ 36.0 36.1 36.2 36.3 36.4 36.5 36.6 (PDF) https://web.archive.org/web/20240209185700/https://libertysteelgroup.com/wp-content/uploads/2023/11/Liberty-Steel-Sustainability-Report-2023.pdf. Archived from the original (PDF) on 2024-02-09.
{{cite web}}: Missing or empty|title=(help) - ↑ 37.0 37.1 https://www.abc.net.au/news/2026-05-08/sa-premier-maliauskas-whyalla-steelworks-blast-furnace-shut-down/106658540.
{{cite web}}: Missing or empty|title=(help) - ↑ 38.0 38.1 38.2 https://www.researchgate.net/publication/298108016_OneSteel_Whyalla_Blast_Furnace_campaign_extension.
{{cite web}}: Missing or empty|title=(help) - ↑ "Sanjeev Gupta's Whyalla steelworks crippled by blast furnace strife". Australian Financial Review. 2024-04-11. Archived from the original on 2025-04-30. Retrieved 2025-01-22.
- ↑ https://web.archive.org/web/20240110005146/https://www.afr.com/companies/mining/reline-of-whyalla-furnace-is-timely-20110223-ilokt. Archived from the original on 2024-01-10.
{{cite web}}: Missing or empty|title=(help) - ↑ 41.0 41.1 https://web.archive.org/web/20220121110404/https://www.gfgalliance.com/whyalla-transformation/. Archived from the original on 2022-01-21.
{{cite web}}: Missing or empty|title=(help) - ↑ 42.0 42.1 42.2 "LIBERTY Successfully Completes Magnetite Testing for Hydrogen DRI-EAF Production in Whyalla". LIBERTY Steel Group. 2024-05-15. Archived from the original on 2024-12-18. Retrieved 2024-12-14.
- ↑ "GFG Alliance Update". The Australian Workers' Union. Archived from the original on 2025-09-05. Retrieved 2024-12-17.
- ↑ https://web.archive.org/web/20240214053822/https://gmk.center/en/news/liberty-steel-received-41-5-million-for-decarbonization-of-its-south-australian-plant/. Archived from the original on 2024-02-14.
{{cite web}}: Missing or empty|title=(help) - ↑ (PDF) https://web.archive.org/web/20220126122208/https://www.gfgalliance.com/wp-content/uploads/2021/09/051721-GFG_Sustainability-Report_2020_FINAL.pdf. Archived from the original (PDF) on 2022-01-26.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20220318121807/https://eurometal.net/greensill-crisis-may-affect-whyalla-dri-eaf-conversion-reports/. Archived from the original on 2022-03-18.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20220114135133/https://www.gfgalliance.com/media-release/gfg-announces-updated-plan-to-transform-whyalla-steel-into-a-world-leading-greensteel-facility/. Archived from the original on 2022-01-14.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20221216153650/https://www.pv-magazine-australia.com/2022/08/24/sas-whyalla-steelworks-hits-green-steel-milestone-with-first-batch-of-premium-magnetite/. Archived from the original on 2022-12-16.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20220710185220/https://www.libertygfg.com/liberty-primary-steel/. Archived from the original on 2022-07-10.
{{cite web}}: Missing or empty|title=(help) - ↑ AIST
