Hertha Metals has demonstrated a proprietary single-step pyrometallurgical course of that converts low-grade iron ore straight into molten metal or 99.97% purity iron, with out a number of phases or coal enter. The continual pilot plant in Conroe, Texas, has been working at 1 tonne per day since late 2024. The method helps feedstocks corresponding to sub-60% purity ores, fines and millscale—unlocking lower-cost uncooked supplies and beforehand untapped US reserves.
In comparison with conventional blast furnace or DRI-based strategies, Hertha says its furnace is 30% extra energy-efficient and may cut back emissions by over 50% utilizing pure gasoline. When fueled with hydrogen, it permits as much as 98% emissions discount with out {hardware} modifications. The furnace is modular and integrates into present metal mills, with minimal viable scales as little as 500,000 tonnes per 12 months.
Backed by $17 million in new funding, Hertha plans to scale to 9,000 tonnes per 12 months by 2026, concentrating on high-purity iron provide for NdFeB uncommon earth magnet manufacturing—a essential part of EV motors that’s presently 90% import-dependent. Future plans embody 500,000 tonnes/12 months metal manufacturing, reaching micro mill scale. The system helps tunable output—both crude metal or high-purity iron—relying on downstream necessities.
SEE ALSO: A more in-depth take a look at uncommon earth everlasting magnets
Supply: Hertha Metals
