US Steel and Molten Industries to develop a pilot-scale iron reduction system

The $5.4 million grant, awarded and funded through the DOE’s Industrial Efficiency and Decarbonization Office and Hydrogen and Fuel Cell Technologies Office, will catalyze the project focused on carbon-neutral steel production, with the main objective being to demonstrate the integration of methane-pyrolysis-driven hydrogen production with a pilot direct reduced iron (DRI) shaft furnace at Molten's facility. Anticipated outcomes include significant energy, carbon intensity, and cost reductions.

Molten’s technology uses renewable electricity to break down methane from natural gas or waste sources into hydrogen gas and solid graphite, offering a 75% reduction in energy intensity compared to water electrolysis, an alternative for zero-carbon hydrogen. This grant was awarded shortly after Molten announced its $25M Series A fundraise.

US Steel will contribute its Minnesota iron ore for the project. According to the steelmaker, Molten’s technology has the potential to eliminate up to 60Mt of CO₂ from the 84Mt of greenhouse gas emissions in US crude steel production.

Molten Industries CEO, Kevin Bush stated, "This collaboration with US Steel and CPFD Software is an exciting first step in Molten’s mission to decarbonize the world’s heavy industries. Our process delivers hydrogen at high temperatures required for ironmaking and steelmaking, saving energy and cost for steel manufacturers. We are confident that our joint efforts will pave the way for a future where carbon-neutral steel production is not just a possibility but a reality."

“Achieving US Steel’s 2050 net zero emissions goal requires the development and commercialization of various technologies, some of which have yet to be available on a broad scale,” said Christian Gianni, US Steel senior vice president and chief technology officer. “This collaboration, thanks to the DOE grant, is an investment in the future of sustainable American steel.”

“This project is indicative of a broad energy transition underway spanning multiple industrial sectors, and we are pleased to see our technology and expertise contribute toward the decarbonization of American steel production,” said Peter Blaser, CPFD’s vice president of operations.