Zero-Emission Iron Production Technology

A new way to produce green metals

Element Zero is developing a patented electrochemical process that uses renewable energy to convert metal ores into metal without CO₂ emissions. Our initial focus is green iron, with potential applications across other metals including nickel and silicon.

For iron production, our process is designed to use 30–40% less energy per tonne than conventional coal- or gas-based processes.

Starting with iron ore

Iron and steel production accounts for around 7% of global energy-system CO₂ emissions, making it one of the largest sources of industrial emissions. Element Zero’s technology targets the emissions-intensive ironmaking stage by converting iron ore directly into iron using renewable-powered electrochemistry.

Our patented technology covers:

The electrochemical reduction process
The integrated mineral processing circuit
A custom-designed electrolyte

One Platform – Multiple Metals

How it works: Electroreduction

Electroreduction is at the core of Element Zero’s technology. Using renewable electricity and a custom electrolyte, the process dissolves metal ores and electrochemically converts them into metal at substantially lower temperatures than conventional ironmaking.

Fast ore dissolution: Iron ore dissolves within 15–30 minutes, with complete dissolution achieved within approximately 60 minutes.
Iron output: Produces iron at approximately 98% purity.
Lower energy requirement: Uses 30–40% less energy per tonne of iron than conventional coal or gas based methods.
Renewable-energy compatible: Designed to operate with intermittent renewable energy sources including solar and wind.
Flexible feedstock: Capable of processing iron ores ranging from approximately 30% to 72% Fe.
Low temperature operation: Operates at at approximately 250–300°C, enabling rapid ramp-up and ramp-down.
Membrane free design: Does not require membranes, helping simplify the process design and reduce equipment.

Designed for green metals

Iron is Element Zero’s immediate commercial focus. The underlying electrochemical platform also has potential applications across other metals and minerals, with testing undertaken across materials including nickel, titanium, tin and silica.

Circular, clean, and energy-efficient

The process is designed as a closed-loop system, with the electrolyte recovered and reused rather than consumed during metal production. Valuable mineral components separated from the ore may also be recovered as useful by-products.

It uses renewable energy to convert iron ore into high-purity iron through electroreduction.

Because it operates at low temperatures and avoids fossil fuels, it uses 30-40% less energy than traditional coal or gas-based methods; with zero CO₂ emissions.