This post is dedicated to a conversation with one of the key figures behind the project: Chris Barrington. With over five decades of experience in the international iron and steel industry, Chris has not only witnessed major developments across the natural resources and iron ore sectors, but he has also actively helped shape them.

As one of the initiators of HBI C-Flex, his deep understanding of direct reduced iron (DRI) and maritime safety has played an important role in guiding the project’s direction.

In this interview, Chris reflects on the origins of the project, the technical and regulatory challenges it addresses, and the broader shifts transforming the industry, from hydrogen-based steelmaking to evolving global supply chains. He also shares advice for the next generation of engineers and offers personal reflections on a long and impactful career.

We’re pleased to present the full interview below, you can also download this special issue of the HBI C-Flex newsletter here.

Interview with Chris Barrington

Where did the idea for this project come from?

The genesis of the project dates back several years when Cleveland Cliffs’ Toledo HBI plant was planned to produce HBI with variable carbon content. As higher carbon content equates to lower iron content, the question arose as to whether or not HBI with high carbon content would satisfy the description in the International Maritime Solid Bulk Cargoes (IMSBC) Code schedule for direct reduced iron (DRI) (A) of apparent density of 5,000 kg/m3 and thus be safe to ship. The scope of the project expanded to cover HBI produced from lower quality iron ore for the same reason.

You’ve worked in many parts of the iron and steel value chain — what’s the most significant change you’ve seen in the industry over the past few decades?

Three changes are worthy of mention:

• The growth in direct reduction of iron ore, from about 17 million tonnes in 1970 to 136 million tonnes in 2023.
• The change in the iron ore pricing mechanism, which started around 2010 as the traditional annual price negotiations between producers and consumers were replaced by index-based pricing on a quarterly, monthly or spot basis.
• Probably the most significant development affecting the iron ore to steel value chain has been the longer term focus on “green” steel and the need to reduce GHG emissions along the value chain, especially in iron production.

Once this project is completed, what do you hope the legacy will be?

First of all, a bit of history: when I first became involved with maritime regulation and the International Maritime Organisation, DRI had a bad reputation among the maritime community, due to a number of serious incidents at sea involving loss of life, vessel and cargo. It has been a long road to convince maritime stakeholders, the shipping industry, its representative organisations and regulatory authorities that, at the top level, safety is of paramount importance to our industry and at the operational level the various forms of DRI can be shipped safely provided that the requisite precautions and procedures are properly followed.

Thus, the legacy of HBI C-Flex must be that developments in the production and quality of HBI are matched by appropriate developments in maritime regulations and that the confidence that has been built between the DRI industry and its maritime stakeholders is maintained.

Do you think the industry is ready to fully embrace hydrogen-based steelmaking, or are there still major roadblocks?

As far as the DRI industry is concerned, it is absolutely ready to embrace hydrogen-based steelmaking – the principal technology providers have developed appropriate process flowsheets and there have been positive steps, for example the HYBRIT joint venture and the Stegra project in Sweden and Primetals’ HYFOR process development.

At the same time, it has to be recognised that there are various hurdles along the pathway to hydrogen-based steelmaking, not the least of which is the availability of an economically viable supply of green hydrogen. One likely development in some cases is the decoupling of iron and steel production, with iron production shifting to where energy/hydrogen (and iron ore) is most economically available.

What recommendation would you give to the next generation of metallurgists, materials scientists or process engineers entering the industry now?

Think “green”, but recognise that there are many practical challenges ahead, in terms of both the roadmap and timescale – there is no “one size fits all” solution. Collaboration across the value chain is a critical success factor.

Looking back, is there a moment in your career that you appreciate the most?

I’ve been privileged to have had a fascinating and enjoyable career path, stimulated by a variety of interesting challenges over the past 55 years. High on the list has been the challenges of DRI and maritime regulation, for example the success in inclusion of the DRI (D) schedule in the IMSBC Code, success it has to be said that could not have been achieved without the excellent teamwork and collaboration among those involved.

Meet Chris Barrington

Chris Barrington has over 50 years of experience in international natural resources, including 17 years in the global iron ore industry. He has worked in ore purchasing and ore marketing for British Steel, Samarco and LKAB, and served as Managing Director of Fergusson Wild & Co., which is  a processor and distributor of industrial minerals then belonging to the Stinnes/Veba group. In 2000 Chris founded a business for minerals distribution, sold to Prince Minerals in 2007.

From  2005 to 2011 he led the International Pig Iron Association, now the International Iron Metallics Association where he was Chief Adviser until the end of 2024  (he was also Acting Secretary General from 2015 to 2019). Chris also managed the REACH Iron Platform and REACH Boron Consortium for EU chemical regulation compliance and founded the Zircon Industry Association, serving as Executive Director until 2015. He is now retired but undertakes occasional consultancy assignments.