The steelmaker is working with Molten Industries and CPFD Software to design, build and test a pilot-scale system that integrates hydrogen produced through methane pyrolysis with a direct reduction shaft furnace. The project is being catalyzed by a US$5.4 million grant from the U.S. Department of Energy (DOE)’s Industrial Efficiency and Decarbonization Office and Hydrogen and Fuel Cell Technologies Office. 

Molten’s technology uses renewable electricity to break down methane from natural gas or waste sources into hydrogen gas and solid graphite, offering a 75% reduction in energy intensity compared to water electrolysis, an alternative for zero-carbon hydrogen.

The project leverages U. S. Steel’s expertise as a vertically integrated steel producer. U. S. Steel will contribute its Minnesota iron ore for the project and potentially showcase clean steel production in an electric arc furnace using the direct reduced iron made with clean hydrogen.

"Achieving U. S. Steel’s 2050 net zero emissions goal requires the development and commercialization of various technologies, some of which have yet to be available on a broad scale," said U. S. Steel senior vice president and chief technology officer Christian Gianni. 

"This collaboration, thanks to the DOE grant, is an investment in the future of sustainable American steel."