Electra

Electra is developing a process for producing iron at the temperature of a cup of coffee using unconventional feedstocks. The process involves two electrochemical cell stacks: First, an ultra-low-cost acid-base generator that uses electricity to produce sulfuric acid and sodium hydroxide, and then uses these chemicals for the processing and separation of the feedstock into its constituent materials, including ferrous hydroxide. The second electrochemical cell stack is an electrowinning cell that converts ferrous hydroxide into iron metal at an unprecedented high efficiency. If successful, the project will produce iron for use in green steel with 80% less greenhouse gas emissions at half the cost of existing fossil fuel-based processes.

Automotive companies, which are leaders in the adoption of green steel, are apt future supporters of Electra’s proposed technology. While the ARPA-E project will focus on producing a prototype, subsequent phases would build a demonstration plant and commercial plant at or near an existing steel mill. Co-products from this process can also be recycled at a steel plant for use as flux materials, potentially enabling circularity and sustainability in steelmaking.