Boston Metal, an MIT spin-off established in 2013, is pioneering an approach to steel production that significantly reduces carbon emissions. Traditional steelmaking methods rely on coal-based blast furnaces, emitting approximately 3 billion tons of CO₂ annually—a substantial contributor to global greenhouse gas emissions. Boston Metal's innovative process, known as molten oxide electrolysis (MOE), uses electricity to convert iron ore into molten iron, producing oxygen as the sole byproduct. When powered by renewable energy sources, MOE has the potential to render steel production entirely carbon-neutral.

Currently, Boston Metal's industrial-scale facility can produce one ton of steel per month. The company plans to launch a demonstration plant capable of producing one ton per day by late 2026, with operations commencing in 2027. This facility will serve as a proof of concept, showcasing the scalability and economic viability of MOE technology. Upon successful demonstration, Boston Metal intends to license this technology to steel manufacturers worldwide, facilitating a transition toward more sustainable production practices.

The MOE process involves reactors with large anodes that pass electrical currents through chambers filled with iron ore. These currents elevate temperatures to approximately 2,900°F, melting the iron. While the energy demands are significant, integrating renewable energy sources such as solar, wind, or nuclear power could achieve a fully decarbonized steel production process. Given the scale of global steel production, adopting MOE technology could substantially reduce industrial carbon emissions, marking a pivotal advancement in combating climate change.