Hertha Metals, a company founded in 2022 by CEO Laureen Meroueh, is advancing a new steel manufacturing method that aims to reduce reliance on foreign imports. The United States, currently the world’s largest steel importer, has traditionally produced steel using coal-based processes similar to those developed centuries ago. Hertha Metals introduces an innovative approach that uses natural gas and electricity, or hydrogen, to transform iron ore of any grade into molten steel in a single step. This method is more energy-efficient, using 30% less energy and being 25% more cost-effective compared to existing U.S. steel mills.
The company has been operating a pilot facility near Houston, Texas, since late 2024, producing one ton of steel per day. This facility showcases what the company claims is the largest demonstration of a single-step steelmaking process. Hertha Metals plans to scale up production, with construction underway for a plant capable of producing 10,000 tons of steel annually by 2027. This plant will also create high-purity iron, critical for magnet production in sectors like consumer electronics and aerospace, aiming to reduce U.S. dependency on imported materials.
By integrating its technology into existing infrastructure, Hertha Metals seeks to modernize and increase the domestic production of steel and high-purity iron. The company’s process is notable for performing gaseous reduction while the iron oxide is in a molten state, unlike traditional methods that require multiple steps and additional resources. Looking forward, Hertha plans to partner with U.S. steel producers to establish a commercial-scale plant by 2030, which is expected to produce half a million tons of steel annually, working towards enhancing U.S. capability in essential materials.
Source: MIT News
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https://news.mit.edu/2026/new-way-make-steel-could-reduce-americas-reliance-imports-0213