As the backbone of the modern world, steel has deeply transformed our cities, infrastructure, institutions, and lives. Steel is now critical to advancing energy transition technologies, like wind turbines and EVs needed to displace fossil fuels. Steel is also one of the largest emitters of CO2 – if the steel industry were a country, its carbon emissions would rank third in the world, after China and the US. With two tonnes of CO2 produced for every one tonne of steel and two billion tonnes of steel produced every year, successfully transitioning to a global low-carbon economy depends on decarbonizing steelmaking.
The majority of steel today – 70% globally – is made the same way it’s been made for hundreds of years – iron ore is melted in furnaces at almost 1600 °C (3000 °F) using coal from coke, and then the molten iron is converted into steel through a series of subsequent steps, emitting two tonnes of CO2 for every one tonne of steel produced. Steel is 98% iron, and the ironmaking process, converting iron ore into molten iron, accounts for 90% of steel emissions.
One of the major limitations to decarbonizing steelmaking, which we refer to as the “Iron Ore Challenge,” is the dwindling availability of naturally occurring high grade iron ores. Traditional steelmaking and alternative decarbonization approaches require high grade commercial ores – 62% or more iron by weight. The trend to a higher reliance on lower carbon emissions EAF [Electra Arc Furnace] steelmaking will require iron ores typically between 65% and 68% Fe. Such naturally occurring direct mining ores are becoming rare and is forecast to be in short supply by the early 2030s.
Our electrochemical-hydrometallurgical solution operates predominantly at about 60 °C (140 °F), utilizes ores with an iron content below 55%, can be powered by intermittent renewable electricity, and releases only oxygen into the atmosphere.
Our process produces high-purity, clean iron metal plates that can be fed directly into electric arc furnaces, aka EAFs. EAFs account for 70% of steel production in the United States, and about 30% of global steel production, and are fed primarily by recycling scrap steel and iron supplemented with ore-based iron such as HBI (hot briquetted iron) and DRI (direct reduced iron). When paired with renewable energy, both Electra’s clean ironmaking process and EAF steelmaking can be emissions free.
Scrap steel often contains difficult-to-remove impurities – like copper in cars – which reduces the quality of the final steel product surface. EAFs add ore-based iron metal free of those impurities to dilute the copper (and other impurities) and improve the quality of steel produced. Other impurities in the iron metal, referred to as “gangue” (mainly silica and alumina) require additional removal steps, increasing operating costs and waste for EAF operators. With zero gangue, potentially zero embedded carbon emissions, and cost-competitive with prime-grade scrap and ore-based metallic iron produced by fossil fuels, Electra’s clean iron is an ideal feedstock for EAF steelmaking, paving the way for a cleaner, more sustainable steel industry.
Circularity is a fundamental driver for Electra in addition to decarbonization and sustainability. Infinitely recyclable, steel is the only material group today that can meet tomorrow’s needs for a fully sustainable, circular economy. By generating a clean iron feedstock out of low-grade ores, Electra’s technology furthers green steelmaking, improves its competitiveness, and lowers carbon emissions for the steel industry, while continuing to meet the global demand for steel. With Electra, eliminating ironmaking emissions is within reach, without sacrificing reliability or resilience.