Boston Metal

Last updated
Boston Metal
Industry steel industry technology
Founded2013
Headquarters Woburn, Massachusetts
Key people
Tadeu Carneiro, Chairman & CEO
Website www.bostonmetal.com
Footnotes /references
[1]

Boston Metal is a company developing a technology known as molten oxide electrolysis (MOE) to decarbonize steelmaking and recover high-value metals from mining waste. The company is based in Woburn, Massachusetts, with its Brazilian subsidiary, Boston Metal do Brasil, based in Coronel Xavier Chaves, Minas Gerais. [2]

Contents

History

Boston Metal's core technology was developed by researchers at Massachusetts Institute of Technology after professor Donald Sadoway demonstrated the use of electrical currents to break down metal oxides in an electrolytic cell to produce molten metal and oxygen gas. [3] Laboratory tests revealed that Sadoway's anode material could produce steel. The team published a paper in Nature in 2013. [4] Boston Metal was founded that year. [5]

Tadeu Carneiro joined the company as CEO in 2017 adding more than 40 years of experience and leadership in the metals industry. [6] He was named a Boston Globe Tech Power Player in 2023. [7]

In 2022, Boston Metal completed the first test of its semi-industrial 25,000-amp (MOE) cell, a key step in commercializing the technology. [8]

The company launched its Brazilian subsidiary focused on high-value metals production in 2022 and began construction in Brazil in Coronel Xavier Chaves. [9]

Boston Metal currently has more than 200 employees. [8] In 2024, the company was selected for the TIME100 Most Influential Companies list, [10] and its green steel solution, MOE, was recognized as one of Fast Company’s World Changing Ideas. [11] Boston Metal was named North American Company of the Year by the Cleantech Group in 2023, [12] a 2023 Norrsken Impact/100 nominee, [13] received the S&P Platts Global Metal Award in 2021, [14] a Bloomberg New Energy Finance Technology Pioneer in 2020, [15] and is currently on the Global Cleantech 100 list by the Cleantech Group. [16] The United States Department of Energy (DOE) announced in November 2023 that it would provide the company with funding to support the building of a new facility in Weirton, West Virginia. [17] The plant will manufacture critical materials needed for clean power, fuel cells, and green steel supply chains. [18]

Boston Metal has raised over $370,000,000 as of January 2024. [19]

Technology

Boston Metal's MOE technology offers an approach to steelmaking that does not involve direct carbon emissions. [5] For a century electrolysis has been the primary method of producing aluminum. Boston Metal is applying a variant of the technique to iron. [20]  In the MOE cell, an inert anode is immersed in an electrolyte containing iron ore. An electric current is applied to the electrolyte. When the cell reaches 1600C, the iron is reduced, yielding liquid iron. The MOE platform differs from traditional steelmaking in that it can be powered by renewable electricity and eliminates many steps in the production process, including the use of coal/coke. [21]

The technology can also be applied to extract valuable metals from low-concentration materials conventionally considered waste, reducing financial and environmental impacts. [22]

Related Research Articles

<span class="mw-page-title-main">Anode</span> Electrode through which conventional current flows into a polarized electrical device

An anode is an electrode of a polarized electrical device through which conventional current enters the device. This contrasts with a cathode, an electrode of the device through which conventional current leaves the device. A common mnemonic is ACID, for "anode current into device". The direction of conventional current in a circuit is opposite to the direction of electron flow, so electrons flow from the anode of a galvanic cell, into an outside or external circuit connected to the cell. For example, the end of a household battery marked with a "+" is the cathode.

<span class="mw-page-title-main">Electrochemistry</span> Branch of chemistry

Electrochemistry is the branch of physical chemistry concerned with the relationship between electrical potential difference and identifiable chemical change. These reactions involve electrons moving via an electronically-conducting phase between electrodes separated by an ionically conducting and electronically insulating electrolyte.

<span class="mw-page-title-main">Electrochemical cell</span> Electro-chemical device

An electrochemical cell is a device that generates electrical energy from chemical reactions. Electrical energy can also be applied to these cells to cause chemical reactions to occur. Electrochemical cells that generate an electric current are called voltaic or galvanic cells and those that generate chemical reactions, via electrolysis for example, are called electrolytic cells.

<span class="mw-page-title-main">Fuel cell</span> Device that converts the chemical energy from a fuel into electricity

A fuel cell is an electrochemical cell that converts the chemical energy of a fuel and an oxidizing agent into electricity through a pair of redox reactions. Fuel cells are different from most batteries in requiring a continuous source of fuel and oxygen to sustain the chemical reaction, whereas in a battery the chemical energy usually comes from substances that are already present in the battery. Fuel cells can produce electricity continuously for as long as fuel and oxygen are supplied.

<span class="mw-page-title-main">Electrolysis</span> Technique in chemistry and manufacturing

In chemistry and manufacturing, electrolysis is a technique that uses direct electric current (DC) to drive an otherwise non-spontaneous chemical reaction. Electrolysis is commercially important as a stage in the separation of elements from naturally occurring sources such as ores using an electrolytic cell. The voltage that is needed for electrolysis to occur is called the decomposition potential. The word "lysis" means to separate or break, so in terms, electrolysis would mean "breakdown via electricity."

The Hall–Héroult process is the major industrial process for smelting aluminium. It involves dissolving aluminium oxide (alumina) in molten cryolite and electrolyzing the molten salt bath, typically in a purpose-built cell. The Hall–Héroult process applied at industrial scale happens at 940–980 °C and produces 99.5–99.8% pure aluminium. Recycling aluminum requires no electrolysis, thus it is not treated in this way.

<span class="mw-page-title-main">Steelmaking</span> Process for producing steel from iron ore and scrap

Steelmaking is the process of producing steel from iron ore and/or scrap. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur, and excess carbon are removed from the sourced iron, and alloying elements such as manganese, nickel, chromium, carbon, and vanadium are added to produce different grades of steel.

<span class="mw-page-title-main">Electrolytic cell</span> Cell that uses electrical energy to drive a non-spontaneous redox reaction

An electrolytic cell is an electrochemical cell that utilizes an external source of electrical energy to force a chemical reaction that would otherwise not occur. The external energy source is a voltage applied between the cell's two electrodes; an anode and a cathode, which are immersed in an electrolyte solution. This is in contrast to a galvanic cell, which itself is a source of electrical energy and the foundation of a battery. The net reaction taking place in a galvanic cell is a spontaneous reaction, i.e., the Gibbs free energy remains -ve, while the net reaction taking place in an electrolytic cell is the reverse of this spontaneous reaction, i.e., the Gibbs free energy is +ve.

<span class="mw-page-title-main">Industrial processes</span> Process of producing goods

Industrial processes are procedures involving chemical, physical, electrical, or mechanical steps to aid in the manufacturing of an item or items, usually carried out on a very large scale. Industrial processes are the key components of heavy industry.

<span class="mw-page-title-main">Basic oxygen steelmaking</span> Steelmaking method

Basic oxygen steelmaking, also known as Linz-Donawitz steelmaking or the oxygen converter process, is a method of primary steelmaking in which carbon-rich molten pig iron is made into steel. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and changes it into low-carbon steel. The process is known as basic because fluxes of calcium oxide or dolomite, which are chemical bases, are added to promote the removal of impurities and protect the lining of the converter.

The chloralkali process is an industrial process for the electrolysis of sodium chloride (NaCl) solutions. It is the technology used to produce chlorine and sodium hydroxide, which are commodity chemicals required by industry. Thirty five million tons of chlorine were prepared by this process in 1987. The chlorine and sodium hydroxide produced in this process are widely used in the chemical industry.

<span class="mw-page-title-main">Molten carbonate fuel cell</span>

Molten-carbonate fuel cells (MCFCs) are high-temperature fuel cells that operate at temperatures of 600 °C and above.

<span class="mw-page-title-main">High-temperature electrolysis</span> Technique for producing hydrogen from water

High-temperature electrolysis is a technology for producing hydrogen from water at high temperatures or other products, such as iron or carbon nanomaterials, as higher energy lowers needed electricity to split molecules and opens up new, potentially better electrolytes like molten salts or hydroxides. Unlike electrolysis at room temperature, HTE operates at elevated temperature ranges depending on the thermal capacity of the material. Because of the detrimental effects of burning fossil fuels on humans and the environment, HTE has become a necessary alternative and efficient method by which hydrogen can be prepared on a large scale and used as fuel. The vision of HTE is to move towards decarbonization in all economic sectors. The material requirements for this process are: the heat source, the electrodes, the electrolyte, the electrolyzer membrane, and the source of electricity.

<span class="mw-page-title-main">Castner process</span> Process for manufacturing sodium metal

The Castner process is a process for manufacturing sodium metal by electrolysis of molten sodium hydroxide at approximately 330 °C. Below that temperature, the melt would solidify; above that temperature, the molten sodium would start to dissolve in the melt.

<span class="mw-page-title-main">Electrolysis of water</span> Electricity-induced chemical reaction

Electrolysis of water is using electricity to split water into oxygen and hydrogen gas by electrolysis. Hydrogen gas released in this way can be used as hydrogen fuel, but must be kept apart from the oxygen as the mixture would be extremely explosive. Separately pressurised into convenient 'tanks' or 'gas bottles', hydrogen can be used for oxyhydrogen welding and other applications, as the hydrogen / oxygen flame can reach approximately 2,800°C.

<span class="mw-page-title-main">Electrometallurgy</span>

Electrometallurgy is a method in metallurgy that uses electrical energy to produce metals by electrolysis. It is usually the last stage in metal production and is therefore preceded by pyrometallurgical or hydrometallurgical operations. The electrolysis can be done on a molten metal oxide which is used for example to produce aluminium from aluminium oxide via the Hall-Hérault process. Electrolysis can be used as a final refining stage in pyrometallurgical metal production (electrorefining) and it is also used for reduction of a metal from an aqueous metal salt solution produced by hydrometallurgy (electrowinning).

<span class="mw-page-title-main">Molten-salt battery</span> Type of battery that uses molten salts

Molten-salt batteries are a class of battery that uses molten salts as an electrolyte and offers both a high energy density and a high power density. Traditional non-rechargeable thermal batteries can be stored in their solid state at room temperature for long periods of time before being activated by heating. Rechargeable liquid-metal batteries are used for industrial power backup, special electric vehiclesand for grid energy storage, to balance out intermittent renewable power sources such as solar panels and wind turbines.

<span class="mw-page-title-main">Donald Sadoway</span> Professor of materials chemistry at the Massachusetts Institute of Technology

Donald Robert Sadoway is professor emeritus of materials chemistry at the Massachusetts Institute of Technology. He is a noted expert on batteries and has done significant research on how to improve the performance and longevity of portable power sources. In parallel, he is an expert on the extraction of metals from their ores and the inventor of molten oxide electrolysis, which has the potential to produce crude steel without the use of carbon reductant thereby totally eliminating greenhouse gas emissions.

<span class="mw-page-title-main">Aluminium smelting</span> Process of extracting aluminium from its oxide alumina

Aluminium smelting is the process of extracting aluminium from its oxide, alumina, generally by the Hall-Héroult process. Alumina is extracted from the ore bauxite by means of the Bayer process at an alumina refinery.

<span class="mw-page-title-main">Solid oxide electrolyzer cell</span> Type of fuel cell

A solid oxide electrolyzer cell (SOEC) is a solid oxide fuel cell that runs in regenerative mode to achieve the electrolysis of water by using a solid oxide, or ceramic, electrolyte to produce hydrogen gas and oxygen. The production of pure hydrogen is compelling because it is a clean fuel that can be stored, making it a potential alternative to batteries, methane, and other energy sources. Electrolysis is currently the most promising method of hydrogen production from water due to high efficiency of conversion and relatively low required energy input when compared to thermochemical and photocatalytic methods.

References

  1. ↑ "Boston Metal".
  2. ↑ "Disclosure". disclosures.ifc.org. Retrieved 2023-09-28.
  3. ↑ "A new way to make steel could cut 5% of CO2 emissions at a stroke". MIT Technology Review.
  4. ↑ Allanore, Antoine; Yin, Lan; Sadoway, Donald R. (May 2, 2013). "A new anode material for oxygen evolution in molten oxide electrolysis". Nature. 497 (7449): 353–356. Bibcode:2013Natur.497..353A. doi:10.1038/nature12134. hdl: 1721.1/82073 . PMID   23657254. S2CID   4379353 – via www.nature.com.
  5. 1 2 "How green steel made with electricity could clean up a dirty industry". MIT Technology Review.
  6. ↑ Joffe, Benjamin (October 11, 2021). "Boston Metal's Tadeu Carneiro: Decarbonizing Steel Production". SOSV Climate Tech Summit.
  7. ↑ "Tech Power Players 50 | Boston Globe Technology". BostonGlobe.com. Retrieved 2023-09-28.
  8. 1 2 "Who We Are". Boston Metal. 2023.
  9. ↑ "High Value Metals". Boston Metal.
  10. ↑ https://time.com/6979959/boston-metal/
  11. ↑ https://www.fastcompany.com/91073088/boston-metal-world-changing-ideas-2024
  12. ↑ "Cleantech Group Names the 2023 Global Cleantech Awards for Company of the Year, Rising Star of the Year, Geographic Companies of the Year, and More | Cleantech Group". www.cleantech.com.
  13. ↑ "Boston Metal Recognized as One of "100 Ways to Fix The Future" on the Prestigious Norrsken Impact/100 List". disclosures.ifc.org.
  14. ↑ "Winners | S&P Global Commodity Insights Global Metals Awards". www.spglobal.com.
  15. ↑ "Ten Innovative Companies Named as 2020 BNEF Pioneers". BloombergNEF. 2020-07-14. Retrieved 2024-01-31.
  16. ↑ "The Global Cleantech 100". Cleantech Group. Retrieved 2024-01-31.
  17. ↑ "Biden-Harris Administration Announces Actions to Strengthen Clean Energy Supply Chains and Accelerate Manufacturing in Energy and Industrial Communities". Energy.gov. Retrieved 2023-11-30.
  18. ↑ "Former Coal Towns Get Money for Clean-Energy Factories". The New York Times. November 27, 2023.
  19. ↑ "FAQ". Boston Metal.
  20. ↑ "Green steel without green hydrogen — can it work?". Canary Media. February 15, 2022.
  21. ↑ "Steeled For Impact: the Near Zero opportunity for industry". February 15, 2023.
  22. ↑ "Boston Metal to test molten oxide electrolysis tech on mining waste in Brazil". International Mining. 2023.
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