Ferrosilva produces low‑carbon direct reduced iron (DRI) by gasifying forestry residues into synthesis gas that reduces iron‑ore pellets, while capturing the resulting biogenic CO₂ as a liquid product. The process cuts electricity use by about 90% compared with hydrogen‑based routes and delivers a net carbon reduction of roughly 845 kg CO₂ per tonne of steel, also generating renewable BTX chemicals.
Funding
Funding not disclosed
Founders
Product
Problem
Conventional steelmaking relies on fossil‑based coke and large amounts of electricity for hydrogen‑based direct reduction, resulting in high CO₂ emissions and substantial energy consumption. This makes it difficult for the steel industry to meet climate targets while maintaining cost‑effective production.
Solution
Ferrosilva offers a low‑carbon steel production pathway that combines established biomass gasification, direct reduction of iron‑ore pellets in a shaft furnace, and carbon‑capture technology. Forestry residues such as logging tops, branches, and sawmill waste are converted into synthesis gas (CO and H₂) that reduces iron ore to fully carbonized DRI, while the resulting biogenic CO₂ is captured as a liquid product for use in other industries. The process eliminates the need for electricity‑intensive electro‑lysis hydrogen, cutting electricity demand by about 90% compared with hydrogen‑based routes and achieving a net carbon reduction of roughly 845 kg CO₂ per tonne of crude steel. By valorising otherwise waste biomass, Ferrosilva creates a resilient supply chain that benefits the forestry, energy, and steel sectors and supports a fossil‑free future.
Target Audience
Primary customers are steel producers seeking low‑carbon DRI supply, as well as forestry and bioenergy companies looking to monetize residues and chemical manufacturers interested in renewable BTX feedstocks.
Features
- Biomass gasification of forestry residues to produce synthesis gas for iron‑ore reduction
- Direct reduction reactor using high‑value iron‑ore pellets in a shaft furnace to produce fossil‑free DRI
- Integrated carbon‑capture system delivering liquid biogenic CO₂ for downstream industrial use
- Generation of biogenic BTX (benzene, toluene, xylene) as additional renewable chemical feedstock
- Energy‑efficient operation requiring ~90% less electricity than electro‑lysis hydrogen routes
- Life‑cycle analysis showing a carbon sink of 845 kg CO₂ per tonne of steel, with potential zero‑emission output when captured CO₂ is sold