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The green steel firms looking to revive US steel making

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The green steel firms looking to revive US steel making


Chris BaraniukTechnology Reporter

Boston Metal Glowing, molten steel is funneled into a bowl at Boston Metal's plant.Boston Metal

Making steel using electricity is less carbon intensive than traditional methods

An activity centre for babies and toddlers, an Indian restaurant, an indoor golf centre – and a mini experimental steel plant. These businesses are among those that make up a small retail and industrial estate in the city of Woburn, Massachusetts.

“People are dropping off their kids. That kind of shows you an extreme example of what the future of steel looks like,” says Adam Rauwerdink, vice president of business development at US-based green steel start-up, Boston Metal. “You can be making steel and sharing a parking lot with a daycare.”

Boston Metal has come up with a way of using electricity to remove oxides and other contaminants from iron ore, which is the substance you have to mine from the Earth before you can make new steel.

The process involves distributing the ore within an electrolyte and then using electricity to heat this mixture to 1,600C. Molten iron then separates from impurities and can be tapped off.

Traditionally, extracting that all-important iron from ores requires blast furnaces that run on fossil fuels. But the iron and steel industry are responsible for 11% of global emissions – a huge amount, equivalent to all the world’s private cars and vans – and so now a race is on to find greener ways of producing these important metals.

US companies are, arguably, at the forefront. Steelmaking in the US is already greener than in many countries, thanks to the popularity of electric arc furnaces there. These furnaces use electricity, not heat from burning fossil fuels, to melt scrap steel – for example – and recycle it.

Plus, a handful of emerging start-ups such as Boston Metal say they can go one better and use electricity for the iron-making process, a crucial step in making brand new, or virgin, steel.

However, the Trump administration has taken a less than enthusiastic stance towards renewable energy and decarbonisation projects. It remains to be seen whether these new start-ups will make a big, molten splash in the steel industry any time soon.

Switching from traditional blast furnaces to electric arc furnaces can lower carbon emissions per tonne of steel produced from 2.32 tonnes of CO2 to 0.67 tonnes of CO2.

For iron-making, some plants could use green hydrogen – made using electricity from 100% renewable sources – says Simon Nicholas, lead steel analyst at the Institute for Energy Economics and Financial Analysis.

But switching iron and steel-making plants over to green hydrogen hasn’t gone as smoothly as some had expected.

In June, Cleveland-Cliffs, a major US steel producer, appeared to back away from its plans to build a $500m (£375m) hydrogen-powered steel plant in Ohio. The BBC has contacted Cleveland-Cliffs for comment.

“We’re seeing projects cancelled, proponents pulling out of projects all over the place,” says Mr Nicholas, of green hydrogen initiatives, specifically.

Bloomberg via Getty Images A roll of molten steel glows yellow and orange at a steel plant in Indiana.Bloomberg via Getty Images

Electric arc furnaces melt scrap to make new rolls of steel

Plus, there is a limit to how much steel-making can rely on electric arc furnaces since they currently largely rely on a supply of scrap steel.

A relatively low supply of scrap steel in China, versus demand, has slowed the rollout of electric arc furnaces there, according to some analyses.

These headaches would suggest that there is a niche for companies developing alternative ways of making iron and steel. Boston Metal is one.

“It looks a lot like how we make iron and steel today – it’s a lot easier to conceive how that would get to scale [as a result],” says Paul Kempler, an expert in electrochemistry and electrochemical engineering at the University of Oregon.

However, he notes that there are still challenges in ensuring that electrolysis systems like this don’t corrode too quickly over time. Boston Metal says it hopes to have its first demonstration-scale steel plant operational by 2028.

Electra Workers in blue overalls stand each side of a frame holding a sheet of Electra's steel.Electra

Steel collected on a plate at Electra’s plant in Colorado

Separately, the US firm Electra is taking a different approach to producing highly purified iron from ores. Unlike Boston Metal, Electra’s process runs at a relatively low temperature, around 60-100C. First, iron ore is dissolved into an acidic solution and then an electrical charge causes the iron to collect onto metal plates. This is similar to the process currently used for making sheets of copper and zinc today.

“These plates are extracted automatically out of the solution and the iron is harvested,” says Sandeep Nijhawan, co-founder and chief executive. A demonstration plant in Colorado, which could produce 500 tonnes of iron annually, is currently set to open next year.

Initially, iron produced in this manner would cost more than iron made using traditional techniques. But that “green premium” could fall away should the company be able to scale sufficiently, says Mr Nijhawan.

Bloomberg via Getty Images A steelworker runs a long metal tool along a steel plate causing countless sparks to fly in all directions. Bloomberg via Getty Images

A plentiful supply of renewable energy is crucial for greening steel production

Mr Nicholas says that emerging technologies such as this are hopeful, but one challenge they face is in breaking into the market in a big way within just a few years, since the need to slash emissions and curb climate change is become more and more urgent: “We’re running short of time for addressing carbon emissions.”

Companies such as Electra and Boston Metal offer a completely different vision of the steel-making industry but they won’t get far without further investment – and a market that appreciates what they are doing.

President Donald Trump’s tariffs on steel imports to the US are supposedly designed to protect the domestic steel industry – and yet they risk raising the cost of steel substantially for US customers.

I ask whether Dr Rauwerdink, for one, is happy to see this move, or not. “We’re quite happy to see the strong focus on critical metals,” he says, arguing the tariffs are “beneficial” for Boston Metal.

Though he acknowledges that US government’s attitude towards renewable electricity, which Boston Metal says it want to prioritise as an energy source, has changed lately. And, globally, keeping the cost of renewable energy low is important for any firm hoping to electrify industries previously dominated by fossil fuels.

“The industry has growing pains there, for sure,” he says.

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Ticketmaster parent Live Nation reaches settlement with Department of Justice over antitrust concerns

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Ticketmaster parent Live Nation reaches settlement with Department of Justice over antitrust concerns


Signs are seen at the Live Nation NYC headquarters on May 23, 2024 in New York City. 

Michael M. Santiago | Getty Images

Live Nation Entertainment has reached a settlement with the Department of Justice over antitrust concerns surrounding its Ticketmaster platform, a senior DOJ official said Monday.

The settlement would see Ticketmaster unwind some of its exclusivity agreements with musical artists and open up the ticketing industry to greater competition. It still needs approval by more than 20 states that had filed suit and by the court.

As part of the settlement, Ticketmaster will offer a standalone third-party ticketing system for other companies like SeatGeek to use its technology. Live Nation has also agreed to divest at least 13 of its amphitheaters and will no longer be able to require artists to use other Live Nation products tied to its venues. It has also agreed to pay roughly $280 million in civil penalties.

Shares of Live Nation rose 5% in morning trading. Live Nation and Ticketmaster did not immediately respond to requests for comment.

Ticketmaster has long faced criticism that its dominance in the live events and ticketing space pushes up prices for consumers. The company has come under heightened scrutiny in recent years from fans who argue that it’s become harder and pricier to snag coveted event tickets.

In 2022, the backlash boiled over when the rollout of tickets for Taylor Swift’s Eras Tour was mishandled, leading to a probe of the company. And in 2024, the DOJ — along with more than two dozen states — sued to break up Live Nation and Ticketmaster, which merged in 2010.

In September, Live Nation was separately sued by the Federal Trade Commission over what the agency called “illegal” ticket resale tactics. The FTC said Ticketmaster controls roughly 80% of major concert venues’ ticketing.

In a Monday statement, New York Attorney General Letitia James said her office would continue to fight against Live Nation’s alleged monopoly even after its agreement with the DOJ.

“The settlement recently announced with the U.S. Department of Justice fails to address the monopoly at the center of this case, and would benefit Live Nation at the expense of consumers. We cannot agree to it,” said James, who is joined by the attorneys general of more than 20 other states.

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How the Iran war may affect your bills and finances

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How the Iran war may affect your bills and finances



The conflict in the Middle East could raise the cost of petrol, household energy bills and even food.



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Oil crosses $100 mark amid Iran war as violence erupts at petrol pumps in South Asia

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Oil crosses 0 mark amid Iran war as violence erupts at petrol pumps in South Asia


Oil prices surged past $115 (£86.47) a barrel on Monday as fuel shortages sparked rationing and violence in South Asia, as the Iran war continues to choke the world’s most critical energy route.

Brent crude rose to $115.31 (£86.47) a barrel, up 24 per cent from Friday’s close and the highest since 2022, as the USIsraeli war with Iran entered its second week. The Strait of Hormuz remained effectively closed to most operators.

West Texas Intermediate crude hit $116.33 (£87.41), up 28 per cent. Brent has not traded at current levels since Russia invaded Ukraine in 2022.

The surge in energy prices is causing rationing and closure of petrol stations in import-dependent South Asia.

In Sialkot, Pakistan, a man opened fire at a petrol station on Saturday after workers refused to fill jerry cans, killing one worker and critically injuring two others. Separately, a man was killed in Karachi in another fuel queue altercation.

Pakistan raised petrol prices by PKR55 (£0.15) per litre on Friday, the largest ever single increase, to PKR321 per litre, after weeks of warnings that its exposure to Hormuz-linked supply was among the highest of any emerging market.

In Bangladesh, authorities on Monday brought forward university Eid holidays as an emergency measure to cut electricity use and ease fuel pressure after Qatar suspended Liquefied natural gas (LNG) deliveries.

Fire erupting at an oil depot in Tehran after being struck by missiles (UGC)

Officials said university campuses consume large amounts of electricity for residential halls, classrooms, laboratories and air conditioning, and the early closure would help ease pressure on the country’s strained power system.

Five of the country’s six fertiliser factories have also closed.

Bangladesh already imposed daily fuel limits last week – motorcyclists are capped at two litres, private cars at 10 – after panic buying emptied stations across the country.

“About 95 per cent of our fuel must be imported,” Bangladesh Petroleum Corporation said, urging consumers not to hoard.

Meanwhile, bigger economies are also affected. Japan said on Sunday it had instructed a national oil reserve storage site to prepare for a possible release of crude, the first such directive since 2022.

Japan holds 254 days of emergency reserves, one of the highest, but sources 95 per cent of its crude from the Middle East, with roughly 70 per cent shipped through the Strait.

Queues at a gas station in Karachi, Pakistan, on Saturday

Queues at a gas station in Karachi, Pakistan, on Saturday (AFP/Getty)

India, which imports more than 88 per cent of its oil, sought to calm concerns. Oil minister Hardeep Puri said the country held “sufficient stocks” and directed all LPG (liquefied petroleum gas) refineries, public and private, to increase production.

Analysts are now warning that oil prices could exceed $150 a barrel – a level that could be catastrophic for the global economy.

Oil prices have now gathered all the ingredients for a perfect storm,” Muyu Xu, senior oil analyst at Kpler, told Reuters. “If the disruption in the Strait of Hormuz persists for another one to two weeks, we could see prices move toward $130–150 a barrel.”

BMI, a unit of Fitch Solutions, said Pakistan and India are the most vulnerable major emerging markets, citing their energy import dependence and high exposure to Hormuz. Egypt and Turkey, it said, face the greatest risk outside the Gulf because of fragile external positions and large energy subsidies.

The shortages come as Iraq, Kuwait and the UAE cut oil production as storage tanks fill due to the reduced ability to export through the Strait.

The Strait of Hormuz remained effectively closed, causing global financial chaos

The Strait of Hormuz remained effectively closed, causing global financial chaos (AFP/Getty)

Iran‘s parliament speaker, Mohammad Bagher Ghalibaf, warned that the war’s impact on the oil industry “would spiral” after Israeli strikes on oil depots in Tehran and a petroleum transfer terminal killed four people overnight.

Roughly 15 million barrels of crude oil, about 20 per cent of global supply, typically pass through the Strait each day, according to Rystad Energy.

The energy minister of Qatar, one of the world’s largest LNG producers, warned that it expects all Gulf energy producers to shut down exports within weeks if the Iran conflict continues.

“Everybody that has not called for force majeure we expect will do so in the next few days if this continues,” Saad al-Kaabi told FT on Friday. “All exporters in the Gulf region will have to call force majeure.”

US energy secretary Chris Wright told CNN on Sunday that gas prices would be back under $3 a gallon “before too long”, describing the spike as “a weeks, not a months thing”.



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