The first green steel plant backed by big names such as Bill Gates and Amazon has opened in Colorado, USA. Electra, an innovative startup, has established this revolutionary project that uses renewable energies to produce clean metallic iron from ores with high impurities.
This pioneering approach aims to significantly reduce the environmental impact associated with steel production, which is currently responsible for 90% of CO₂ emissions in this industry. Electra seeks not only to reduce these emissions, but also to achieve emission-free iron production through the integration of renewable energy sources. Iron production is responsible for 90% of CO₂ emissions in steel production, which in turn contributes 7% to global emissions.
Processes inside the green steel plant
Electra has developed an innovative technique that employs large-scale electrochemical and hydrometallurgical processes to purify low-grade iron ores into highly refined iron at only 60 degrees Celsius, a temperature comparable to that of a cup of coffee. This method contrasts with conventional processes that require coal-fired furnaces and operate at considerably higher temperatures.
With a founding team experienced in complex electrochemical systems, Electra has created a unique process that purifies iron ore by electrochemistry at 60 degrees Celsius, using renewable electricity. This refined iron is then converted into steel using existing infrastructure, such as electric arc furnaces. This technique contrasts with the conventional process, where approximately 69% of the steel is produced at temperatures close to 1,600 degrees Celsius, using coal and generating about two tons of carbon dioxide. carbon dioxide for every ton of steel produced.
The oxygen decoupled electrolysis (ODE) process developed by Electra addresses two crucial challenges in the steel industry:
First, there is the need to reduce carbon dioxide emissions in steelmaking, an industry that is currently responsible for 1.9 million metric tons of crude steel and emits about 3.7 gigatons of carbon dioxide per year, representing approximately 10% of total global emissions. Electra proposes a solution by converting iron ore to iron using its innovative process, which could eliminate up to 90% of the emissions associated with steelmaking.
Secondly, there is the “iron ore challenge”, as commercial ores with an iron content of 62% or higher are expected to become scarce in the coming years. Steelmaking with hydrogen or natural gas-based technologies requires ores with an iron content of 67% or more, which further aggravates the situation in terms of cost and ore supply. However, the Electra process can utilize lower grade ores, with iron content as low as 35%, without the need for costly milling, beneficiation and pelletizing operations. This allows for a more diversified supply chain and reduces pressure on higher grade minerals.
It is important to mention that the pilot project aims to manufacture 1 m² pure iron plates, with plans to gradually increase its production capacity to validate its modular design.
New business opportunities
According to reports, Electra intends to link the iron sheets created in this initial trial to expand production to commercial levels. BHP, a leading supplier of seaborne iron ore to the steel industry and an investor in Electra, supplied the iron ore for the pilot project.
In 2022, the company was able to secure $85 million in funding from investors, including Breakthrough Energy Ventures, the energy innovation fund established by Bill Gates. Carmichael Roberts, co-leader of the fund’s investment committee, commented, “The cost-effective, carbon-free electrification of ironmaking represents a paradigm shift in the way steel has been produced for centuries.”
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Source: ecoinventos.com
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