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Electrowinning is a time-tested method for removing impurities from metals, and it’s able to run on clean electricity and at the same temperature as a fresh cup of coffee. Could it help clean up heavy industry by replacing the gigantic coal-fired blast furnaces used to purify iron, a key ingredient in steelmaking?
Sandeep Nijhawan, CEO and cofounder of electrolytic clean-iron technology startup Electra, thinks so. On Thursday, the Boulder, Colorado-based firm announced that it has raised $186 million from investors, including some major players in the trillion-dollar global iron and steel industry, to further test its proposition.
Thursday’s round was led by Capricorn Investment Group and Temasek Holdings, and included previous investors Breakthrough Energy Ventures, Lowercarbon Capital, and S2G Investments. It also included Rio Tinto, Roy Hill, and BHP’s venture capital arm, representing some of the world’s largest iron ore suppliers; leading steelmakers Nucor and Yamato Kogyo; and major iron and steel buyers organizations Interfer Edelstahl Group and Toyota Tsusho Corp., the trading arm of Toyota Group and supplier to Toyota Motor Corp.
“This broad, very sophisticated, strategic investor base gives us a vote of confidence that our solution can potentially be an integral part of the value chain,” Nijhawan said.
The new funding will finance Electra’s first demonstration-scale project, which aims to produce about 500 tonnes of high-purity iron annually when it opens next year — a droplet in the nearly 1.9 billion tonnes of steel produced globally in 2023. The company hopes to have a commercial-scale production site, of undisclosed size and capacity, operational in 2029, Nijhawan said.
Steelmaking accounts for 7% to 9% of global greenhouse gas emissions, and most of those emissions are tied to the process of purifying iron in blast furnaces that burn metallurgical coal at temperatures of around 1,600 degrees Celsius.
Cutting that carbon footprint requires shifting to electric arc furnaces that use electricity to melt a mix of steel scrap and purified iron into new steel. But to clean up the industry, the purified iron going into those furnaces must first be produced in ways that don’t choke the atmosphere.
“We are replacing how iron has been made for centuries,” Nijhawan said. “When you think about that transition, you think about a long-term view of how you create a stable business in that environment.”
Electra’s process is competing against a number of alternative methods for making lower-carbon iron. The most prevalent approach to date — and the one that’s gotten billions of dollars of investment — is direct reduction of iron via hydrogen.
Direct reduced iron is being deployed by the biggest green-steel projects in the world, such as the H2 Green Steel and Hybrit plants in Sweden. But early-stage efforts to build up capacity for hydrogen direct reduced iron in the U.S. have faltered in the face of high costs, lack of commitments from buyers, and more recently, the Trump administration’s U-turn on Biden-era policies supporting industrial decarbonization. The process also requires cost-effective production of carbon-free hydrogen, a challenging prospect in and of itself.
Boston Metal, a spinout of the Massachusetts Institute of Technology, aims to decarbonize steelmaking with a very different method known as molten oxide electrolysis, which uses electricity to heat iron ore to blast-furnace temperatures. The startup plans to open its first demonstration plant in 2026. That process avoids carbon emissions but still requires super-high temperatures and hefty electricity inputs.
Electra’s approach, electrowinning, is already used to purify metals such as copper, nickel, and zinc. It works by dissolving iron ores into an aqueous acidic solution to separate iron ions from impurities in the ores, and then electrifying the solution to deposit pure iron onto metal plates.
Electra’s quest to purify iron via electrowinning has faced some key challenges. For example, the company had to figure out how to accelerate the dissolution of iron ore in the solution and how to maintain the purity of the ions collected through the electrowinning process, Quoc Pham, the company’s cofounder and chief technology officer, told Canary Media in 2023. A handful of research consortiums and corporations are pursuing electrowinning iron but using an alkaline rather than an acidic solution.
Electra has produced plates of pure iron in pilot tests. That’s just the first of many steps in proving it can cost-effectively scale up the technology to operate in high-throughput industrial settings using iron ores with a wide mix of chemical compositions, Nijhawan said.
But success on those fronts could unlock a lot of opportunities for Electra investors along the iron and steel value chain, he said — starting with the company’s longest-running strategic investor and top U.S. steelmaker Nucor.
Nucor exclusively uses electric arc furnaces, which require careful calibration of the mix of scrap steel and purified iron going into them to produce different grades of steel for diverse industrial sectors.
Those include the automotive manufacturing market, where advances in electric arc furnaces are overcoming longstanding beliefs that only blast-furnace steel can meet automakers’ quality standards, and where automakers like Hyundai are making multi-billion-dollar investments in the electric equipment.
“We’re seeing a shift in the automotive sector,” Noah Hanners, Nucor’s executive vice president for sheet products, said in a Thursday statement. “As we produce more [electric arc furnace] steel for the automotive market, our demand for sustainable feedstocks like Electra’s product will only continue to grow.”
Electra’s technology can also purify a wide range of iron ores, which could open up new markets for iron-mining giants like those investing in the startup’s latest round, Nijhawan noted. That’s particularly valuable for low-carbon steelmaking since hydrogen direct reduced iron can handle only a narrow range of impurities, which could limit its use to the available supplies of higher-quality ores.
Nijhawan highlighted another distinguishing feature of Electra’s approach — its modularity. A typical steel plant that uses a blast furnace or the direct reduced iron process costs billions of dollars, takes years to build, and involves coordinating the delivery of massive amounts of iron and fuel.
Electra’s electrolytic modules, by contrast, can be deployed at a variety of scales to match supply and demand dynamics in different markets. “One electrical array can go up to 50,000 tons, for example, and you can do that again and again,” he said. “It’s not like you have to go build a 2-million-ton plant to become economically viable.”
That optionality could ease concerns from investors wary of sinking billions of dollars into a single facility using a novel technology, he said. It also allows Electra to test its modules and improve performance and cost in succeeding generations.
Similar dynamics have helped propel solar panels and lithium-ion batteries to the cheapest and most easily deployable energy technology today, he noted. “It helps you to have the same repeat unit that you’re perfecting for quality, for defects — and to learn fast as a result.”
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