energy transition materials

DOE grants Houston-area energy tech co. over $5M for rare earth elements study

A company headquartered in The Woodlands has secured funding to study the recovery of rare earth elements as they pertain to the energy transition. Photo via tetratec.com

The Woodlands-based Tetra Technologies, an energy technology and services company, has picked up nearly $5.4 million in U.S. Department of Energy funding to study the recovery of rare earth elements and other critical minerals from coal byproducts in Pennsylvania.

The funding also will enable Tetra to explore converting coal byproducts, known as underclay, into clays that could be sold. In addition to the DOE funding, the company also secured about $1.3 million for a total of $6.7 million.

Publicly traded Tetra got the funding as part of a more than $17 million package aimed at designing and building facilities to produce rare earth elements, along with other critical minerals and materials, from coal resources. The Department of Energy (DOE) says these minerals and materials will go toward generating clean energy.

Rare earth elements can be derived from the country’s more than 250 billion tons of coal reserves, over 4 billion tons of waste coal, and about 2 billion tons of coal ash, according to DOE.

Clean energy fixtures like solar plants, wind farms, and electric vehicles generally require more minerals to build than their fossil-fuel-based counterparts, according to the International Energy Agency. For example, a typical electric car requires six times the mineral resources of a conventional car and an onshore wind plant requires nine times more mineral resources than a gas-fired plant.

The American Geosciences Institute says rare earth elements, a set of 17 metallic elements, also are an essential component of many tech-dependent products. These include cell phones, flat-screen TVs, and radar and sonar systems.

China is the top country for production of rare earth elements, with the U.S. far behind at No. 2.

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A View From HETI

Hertha Metals has broken ground on its new iron and steel “innovation complex." Photos courtesy Hertha Metals

Shortly after announcing a $133.65 Series A funding round, Conroe-based Hertha Metals broke ground Oct. 8 on a $100 million factory that will produce steel-grade and magnet-grade high-purity iron.

Hertha’s Chalyx plant, located in Conroe, will manufacture a total of about 10,000 metric tons per year of magnet-grade and steel-grade high-purity iron. The factory will use Hertha’s single-step process to generate high-purity iron for rare-earth-magnet and steel manufacturers in the U.S.

Hertha says Chalyx will be the first U.S. commercial plant for production of magnet-grade high-purity iron.

Chalyx is being built next to Hertha’s headquarters and its Pi100 pilot plant, which will remain in operation. Chalyx and Pi100 will form the first modern-day iron and steel “innovation complex” in the U.S., the company says.

“I founded Hertha Metals because I believed we could significantly improve how the world makes iron and steel from ore, and that an industry so fundamental to our future still had enormous room for invention,” Laureen Meroueh, founder and CEO of Hertha, said in a press release.

The 4-year-old startup says the Chalyx complex will lay the foundation for its first 500,000-ton-per-year steel mill.

Chalyx’s first priority is making high-purity iron for U.S. manufacturers of rare-earth magnets, Hertha says. These magnets are critical components for electric vehicles, data centers, wind turbines and defense systems.

China produces an estimated 94 percent of high-purity iron for rare-earth magnets, according to Hertha.

Aside from iron for rare-earth magnets, Chalyx will make iron and steel for pilot projects in the steel industry.

The plant is expected to come online in late 2027, with production of magnet-grade high-purity iron starting in early 2028.

Today, Hertha employs 32 people, the company says. Once it’s fully operating, the Chalyx plant will employ about 50 people.

Just ahead of the groundbreaking, Hertha announced the $133.65 million Series A round, co-led by Khosla Ventures and Doerr Capital. The round included a $65 million equity investment from the Pentagon.

“Iron and steel have shaped human progress for thousands of years. And I believe there is still an enormous amount left to invent,” Meroueh said at the groundbreaking ceremony.

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