Boston Metal
| Company type | Private |
|---|---|
| Industry | Steelmaking technology, Clean energy technology |
| Founded | 2013 |
| Founder | Donald Sadoway (technology founder) |
| Headquarters | Woburn , United States |
Area served | United States, Brazil |
Key people | Tadeu Carneiro (CEO) |
Number of employees | 200+ (2024) |
Boston Metal is an enterprise pioneering molten oxide electrolysis (MOE) technology aimed at decarbonizing steelmaking and extracting valuable metals from mining residues. The company is based in Woburn, Massachusetts and operates a Brazilian branch, Boston Metal do Brasil, located in Coronel Xavier Chaves, Minas Gerais.
History
The foundational technology behind Boston Metal stems from research at MIT led by professor Donald Sadoway, who demonstrated the use of electrical currents to decompose metal oxides into molten metal and oxygen gas. Experimental work validated the feasibility of steel production through this method, with significant results published in Nature in 2013—the year Boston Metal was established.
In 2017, Tadeu Carneiro was appointed CEO, bringing more than four decades of experience in the metals sector. Carneiro was acknowledged as a Boston Globe Tech Power Player in 2023 for his effective leadership.
By 2022, Boston Metal had finalized testing on its semi-industrial MOE cell capable of 25,000 amps, marking a key step toward commercialization. That same year, the company inaugurated its Brazilian subsidiary dedicated to producing high-value metals, with construction progressing in Coronel Xavier Chaves.
As of 2024, Boston Metal employs upwards of 200 professionals and has been recognized on the TIME100 Most Influential Companies list. It also received Fast Company’s World Changing Ideas award for its sustainable steelmaking innovation. In 2023, it was honored as North American Company of the Year by Cleantech Group and included in the Global Cleantech 100 list. Other accolades comprise the S&P Platts Global Metal Award (2021) and Bloomberg New Energy Finance Technology Pioneer (2020).
In November 2023, the U.S. Department of Energy announced funding support for Boston Metal’s new manufacturing plant in Weirton, West Virginia, intended to produce critical materials for clean energy technologies, fuel cells, and green steel supply chains.
By January 2024, Boston Metal had secured over $370 million in investment funding.
Technology
Boston Metal’s MOE process transforms steel production by removing direct carbon emissions. This approach adapts a century-old electrolysis technique previously used for aluminum to iron manufacturing. Within the MOE cell, an inert anode is submerged in an iron ore electrolyte; when heated to approximately 1600°C and powered by electricity—preferably sourced from renewables—molten iron is generated without relying on coal or coke, simplifying the process and cutting emissions.
Additionally, this technology facilitates the recovery of precious metals from low-grade ores that are normally discarded as waste, improving economic value and environmental impact. By addressing industry demands for cleaner steel production and aligning with global decarbonization efforts, Boston Metal establishes a competitive position within the steel market.