Electrolysis could be key to net-zero steel future: SSNA

Electrolysis processes developed by Boston Metal and Electra that eliminate the need for coal in steel production could be key to a net-zero emissions future for the metallics industry, attendees learned at Fastmarkets’ conference on January 17-19 in Dallas

Woburn, Massachusetts-based Boston Metal plans to begin licensing its molten-oxide electrolysis (MOE) technology to the steel industry in 2025, with wide-scale use expected in the second half of this decade, Adam Rauwerdink, senior vice president of business development, told Fastmarkets in an interview on the sidelines of Fastmarkets’ Scrap & Steel North America 2023 event.

In the long-term, the technology is ideal for greenfield projects, but there are opportunities to co-locate the modular MOE cells next to existing steel mills in the near-term too, Rauwerdink said.

Boston Metal is testing this same technology to process mining waste and other minerals in Brazil.

Boulder, Colorado-based Electra uses a low-temperature, oxygen-decoupled electrolysis process to refine iron ores with as low as 30-35% iron content at 60ºC (140ºF), according to Sandeep Nijhawan, the company’s cofounder and chief executive officer.

“Because we use a low-temperature process, we can start and stop production at our plant on demand, based on the availability of intermittent renewables like wind and solar,” Nijhawan told Fastmarkets. “This aspect is critical because metallic ironmaking is a highly energy-intensive process and cost is a critical factor.”

Electra is building its pilot plant this year and plans to present demonstrations for commercial deployment by the end of the decade, he said. Last month, Electra announced a partnership with Nucor to scale this technology and lower the steelmaker’s carbon emissions.

Such breakthroughs in technology could lead to significant reductions — or even the elimination — of the “green premium,” according to market participants.

What to read next
The Mexico Metals Outlook 2025 conference explored challenges and opportunities in the steel, aluminum and scrap markets, focusing on tariffs, nearshoring, capacity growth and global trends.
The recent US-China agreement to temporarily reduce tariffs is a major step for global trade, with tariffs on US goods entering China dropping from 125% to 10% and on Chinese goods entering the US decreasing from 145% to 30% starting May 14. While this has boosted markets and created optimism, key industries like autos and steel remain affected, leaving businesses waiting for clearer long-term trade policies.
Fastmarkets announce the release of a new suite of insights and pricing products, across the carbon credits, carbon removals, and compliance carbon markets.
The US-UK trade deal removes Section 232 tariffs on British steel and aluminium, reduces automotive tariffs and sets a framework for addressing global trade issues.
Ford Motor Company will offset $1 billion of an expected $2.5 billion exposure from tariffs and remains "on track and within our original full-year guidance range of $7 billion-8.5 billion" in operating earnings for 2025, Jim Farley, president and chief executive officer, said during the automaker's first-quarter earnings call on Monday March 5.
The price assessments concerned were: MB-STE-0185 steel cold-rolled coil, fob mill US, $ per cwt MB-STE-0186 steel hot-dipped galvanized coil (cold-rolled base), fob mill US, $ per cwt MB-STE-0172 steel cut-to-length plate carbon grade, fob mill US, $ per cwt This consultation was done as part of our published annual methodology review process. No feedback […]