Scalable Dry Precision Separation
On belt magnetic separation
Unlocking water stranded mineral assets
Scalable Dry Precision Separation
On belt magnetic separation
Unlocking water stranded mineral assets
About DryFlow
Waterless Mineral Processing
DryFlow Magnetics is an Australian industrial technology company pioneering patented dry magnetic separation for mineral processing — delivering high-grade results without a single drop of water. Backed by grant funding from CSIRO and the South Australian Government, DryFlow is reshaping sustainable mining in water-stressed regions.
Originally developed to concentrate low-grade magnetite in South Australia, DryFlow’s technology is now demonstrating effectiveness across a broad range of ore streams — including hematite, copper, nickel, cobalt, rare earths, and other critical minerals.
Unlike conventional methods, DryFlow operates entirely water-free, unlocking mineral resources previously stranded in arid and remote regions. Independent validation confirms the technology can upgrade low-grade magnetite to benchmark and premium-grade iron concentrates, ideally suited to the green steel supply chain.
DryFlow also supports environmental remediation by recovering value from tailings and removing Potentially Acid Forming (PAF) materials such as pyrite and pyrrhotite.
With an addressable market in Australia alone exceeding $1 trillion, and over half the world’s mineral assets located in water-constrained regions (McKinsey), DryFlow offers a breakthrough solution for more sustainable, scalable, and cost-effective mineral production.
About DryFlow Magnetics
Our History
Industry & Research Collaboration
Kuchel Separation Process
South Australia is the driest State on the driest continent and hosts billions of tonnes of water stranded magnetite iron ore. DryFlow's robust technology was developed to deliver efficient separation of magnetite iron ore in harsh remote operating environments. It has been extensively tested and proven across numerous ores, repeatedly ta
South Australia is the driest State on the driest continent and hosts billions of tonnes of water stranded magnetite iron ore. DryFlow's robust technology was developed to deliver efficient separation of magnetite iron ore in harsh remote operating environments. It has been extensively tested and proven across numerous ores, repeatedly taking low grade magnetite with <30% Fe up to DRI grade (67%+) concentrate, suitable for new generation low carbon steel fabrication plants.
Kuchel Separation Process
Industry & Research Collaboration
Kuchel Separation Process
Invented by Ian Kuchel and protected by a global patent portfolio, DryFlow's dynamic stacked magnetics technology achieves high efficiency separation through self fluidisation of the ore. Unlike other dry separation technologies it does not require energy intensive drying and air-forced fuidisation, in fact DryFlow is effective even with
Invented by Ian Kuchel and protected by a global patent portfolio, DryFlow's dynamic stacked magnetics technology achieves high efficiency separation through self fluidisation of the ore. Unlike other dry separation technologies it does not require energy intensive drying and air-forced fuidisation, in fact DryFlow is effective even with moisture levels >10%. DryFlow creates a dynamic magnetic induction field along the entire length of the ore carrying belt, ensuring magnetic particles have sufficient residence time to disentangle from the waste rock and form a clean concentrate.
Industry & Research Collaboration
Industry & Research Collaboration
Industry & Research Collaboration
We actively partner with leading research institutions such as CSIRO, University of South Australia, University of Technology Sydney, industry partners including Loesche, Siemens, Joest, Century Engineering and Ammjohn Solutions with a continuous innovation drive to efficiently decarbonised metals supply chains. We have a dedicated resea
We actively partner with leading research institutions such as CSIRO, University of South Australia, University of Technology Sydney, industry partners including Loesche, Siemens, Joest, Century Engineering and Ammjohn Solutions with a continuous innovation drive to efficiently decarbonised metals supply chains. We have a dedicated research facility in partnership with Bureau Veritas, a leading global testing and certification company and work hand in hand with mining companies to enhance production, unlock stranded assets and use waterless magnetic technology to recover valuable minerals from waste streams.
Our Partners
Our Team
Stephen Harrison - Non-executive Chairman
Stephen is an experienced leader in Australia's energy and resources industry. He has taken a number of companies from startup through to IPO and sale. He has led numerous venture and growth investments and has supported multiple successful Australian technologies through commercialisation in areas ranging from non-conventional energy to radioactive waste storage and environmental solutions. He is founder and Chairman of ASX listed Noble Oak and is an experienced director of both private equity backed and listed companies.
Brett Boynton, CFA - Founder and Corporate Lead
Brett is a co-founder of DryFlow and responsible for corporate development and building the ecosystem that delivers DryFlow's capability into industry, accelerating the transition to low carbon green steel. Brett is an experienced entrepreneur with multiple successful startups in mining tech, fintech and agriculture.
Jon Robbeson - Founder and Technical Lead
Jon is a co-founder and brings decades of on the ground technical and commercial experience throughout the mining value chain and METS sector. He has experience building & leading high performing teams, is a strong supporter of new technology adoption and an active mentor, bringing innovation and the next generation into the industry. He is a Fellow Chartered Professional & Chair elect of the Sydney Branch of the AusIMM, Australia's peak body for mining professional
Ivan Mellado -Non-executive Director
Ivan is a deep tech specialist working closely with research institutions developing groundbreaking fundamental science. He has guided numerous startups through commercialisation and brings decades of experience in building IP strategies. Ivan is a professional venture investor and has a passion for driving the value of tech investment.
Elena Stocker - Chief Innovation Officer
Elena brings extensive experience in industrial technology, underpinned by a Mechanical Engineering degree from Ural State Technical University and an MBA from Macquarie University. A seasoned technologist, she possesses deep expertise in industrial hardware processes across multiple commodities, successfully managing solutions from equipment design through to manufacture and customer implementation.
Her core strengths lie in process innovation, lean operations, and integrating ESG principles into industrial practices. Elena is also a passionate advocate for diversity and inclusion, contributing actively to initiatives such as AusIMM, Women in Mining, and UTS Women in STEM Research, where she serves on committees and mentors the next generation of talent.
Nadia Huang - Chief Strategy Officer
Nadia is an experienced international commodities trader with a wealth of knowledge in the steel supply chain. She brings a deep understanding of cross border markets and a unique view to business opportunities. Nadia also has experience in international cooperation, project implementation, finance and social entrepreneurship. She completed Masters in Commerce at University of Sydney in International Business and Corporate Strategy.
FAQ: DryFlow Magnetics and Dry Magnetic Separation
What is DryFlow Magnetics?
DryFlow Magnetics Pty Ltd is an Australian industrial technology company that has developed and patented a scalable dry magnetic separation technology for mineral processing. Unlike traditional methods that rely heavily on water, DryFlow's technology operates entirely without water. They initially focused on iron ore (magnetite) but are expanding to include hematite, copper, nickel, cobalt, rare earths, and other critical minerals.
How does DryFlow's technology work?
DryFlow's technology utilizes solid-state magnetics and mechanical separation on the ore carrying belt. Our patented stacked magnetic system creates a dynamic induction zone along the belt to generate efficient self-cleaning and separation of concentrates from host rock. This process allows DryFlow to upgrade low-grade iron ores, producing high-grade concentrates (including DRI grade, 67%+ Fe) and dry tailings that are easier to manage.
What problem does DryFlow's technology address?
Traditional wet magnetic separation requires significant amounts of water, which is a major limitation for global mining operations located in water-stressed regions. This water scarcity has left billions of tonnes of mineral assets, particularly magnetite iron ore in remote arid regions, stranded and uneconomic to process. Additionally, the industry faces pressure to decarbonise, and wet processing has a larger environmental footprint. DryFlow's waterless approach directly addresses these challenges, unlocking these stranded assets and offering a more environmentally friendly alternative.
How does DryFlow's technology support the "green steel" movement?
The transition to "green steel" production, which uses technologies like Electric Arc Furnaces and Hydrogen Direct Reduction, requires higher-grade iron feedstock (67%+ Fe) compared to traditional blast furnaces. Magnetite is the preferred feedstock for these new processes due to its lower energy requirement to reduce to base iron and higher iron content than hematite. DryFlow's technology is proven to upgrade low-grade iron ore (under 30% Fe) to this high-grade DRI standard, making it suitable for green steel production and enabling miners to participate in this growing premium market. Using higher-grade ore also reduces emissions in existing iron-making processes, making it a transition solution as well.
What is DryFlow's business model?
DryFlow operates on a "Separation-as-a-Service" (SaaS) business model for the mining industry. This involves forming turnkey partnerships, initially with companies like Siemens and Loesche, to provide a full technology stack for comminution (crush/grind) and separation. We seek long-term contracts (5+5 years) and generate revenue through an annual base fee plus a processing fee per tonne, targeting sustainable gross margins. This partnership and SaaS approach allows for scalable deployment and long-term recurring revenue streams.
How does DryFlow's technology compare to other dry separation methods, such as Vale's New Steel FDMS?
While Vale acquired New Steel for $500 million in 2018 for its dry magnetic separation technology (FDMS), DryFlow highlights several advantages. Vale's FDMS required significant CAPEX and OPEX due to the need for drying ore to below 1% moisture and high energy consumption for air fluidisation. DryFlow's technology has been tested and proven to be efficient with moisture content up to 12% on the belt, eliminating the need for drying CAPEX. It also has lower power draw due to its on-belt solid-state magnetics. Additionally, DryFlow can separate efficiently at larger particle sizes initially, reducing grinding requirements, and its throughput is determined by the size of the belts, offering less scale-up risk compared to Vale's technology which relied on banking multiple smaller units.
What is the current status of DryFlow Magnetics?
DryFlow is currently raising A$8 million (US$5 million) in a seed round to fund the fabrication and testing of a 20+ tonne per hour (tph) commercial pilot plant. They have completed extensive independent validation with various institutions and industry partners, demonstrating the effectiveness of their technology across different ore types. They have also secured grants and established multiple mine partnerships for testing and potential commercial agreements. A 20 tph plant design is completed, and a 200 tph plant design is underway, with fabrication for the commercial pilot expected in 2025.
What are the potential applications and market size for DryFlow's technology?
Beyond iron ore, DryFlow's technology is applicable to a wide range of magnetic and paramagnetic minerals and materials, including copper (especially in IOCG deposits), nickel, cobalt, rare earths, and the reprocessing of tailings and stockpiles. This expands their total addressable market significantly. The global steel industry alone is a US$1.5 trillion per year market, and Australia exports 750 million tonnes of iron ore annually. The immediate cleaner feedstock market opportunity is substantial as the industry transitions to green steel, with a strong demand for higher-grade iron ore that DryFlow can provide. Their technology's ability to unlock water-stranded deposits in regions like South Australia further highlights its market potential.
