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Remell Bryant fed steel coils into the “cold strip” as a way to support her daughter as a single mother.
Valerie Denney worked on the “pickle line,” removing impurities from hot steel, before shifting to a career in public relations.
Jack Weinberg tested metallurgical content until he was laid off, then went on to negotiate international environmental treaties.
Terry Steagall played on the banks of a polluted river near the steel mill as a child, then spent 41 years inside the mill as a machinist, repairing gearboxes, cranes, and line shafts, before retiring in 2023.
Now, the four are collaborating to demand a shift away from coal-based steelmaking and toward cleaner methods for the Northwest Indiana industry in which they once worked. They’re all members of Gary Advocates for Responsible Development (GARD), a grassroots group founded in 2021 by former steelworker Dorreen Carey.
Such a transition could save thousands of jobs, create new economic opportunities, and avoid about $75 million in healthcare costs in the region, according to a report released Thursday by the Indiana University Environmental Resilience Institute and the consultancy 5 Lakes Energy, and commissioned by Indiana Conservation Voters.
Only six integrated mills — facilities that produce both steel and the iron needed to make it — are operating in the United States, and three of them are in Northwest Indiana. With their hulking, polluting blast furnaces, these mills may soon become a thing of the past in the U.S., as steel is increasingly being produced in smaller and cleaner operations, frequently in the Southern states.
The GARD organizers echo the report’s authors and other industry experts in warning that if Indiana’s mills don’t modernize and clean up, they could go the way of the other steel mills that once proliferated in the region, but were shuttered during the steel industry crisis of the late 1970s and ’80s. The region still hasn’t recovered from that era, and further closures could mean thousands of job losses and gutted public coffers. The report notes that Northwest Indiana’s steel mills once had more than 65,000 workers but employ only about 9,000 today. Without modernization, the study estimates, Northwest Indiana steel mill jobs could fall below 5,000 by 2034.
Converting a traditional integrated mill to much-cleaner direct reduced iron (DRI) technology costs billions of dollars, and the Biden-era incentives that could have encouraged companies to make the switch were eliminated by the Trump administration. It’s a hard sell, but GARD considers global steelmaker Nippon Steel’s 2025 acquisition of U.S. Steel’s Gary Works mill, in Gary, Indiana, an opportunity.
Steagall said he “didn’t see a pathway” to green steel until the Japanese company entered the picture.
Nippon plans to allocate $3.1 billion for upgrades to Gary Works. About $300 million of that will go toward relining its largest blast furnace — which will extend its life for about another 20 years. The company could use some of the remaining money to replace the mill’s three other blast furnaces with a DRI plant, GARD proposes in a recent report.
It would cost about $3.6 billion to transition Gary Works to cleaner steelmaking, according to the Indiana University report. Modernizing the area’s other two mills, both owned by Cleveland-Cliffs, would cost $2.8 billion to $3 billion each. That’s in line with what the companies have indicated they will spend to maintain those operations.
In a February earnings call, Cleveland-Cliffs announced that it is planning to reline an Indiana blast furnace next year. The company had in fact proposed a DRI conversion at one of its Ohio mills, but backed off the plan after Trump took office in 2025.
Advocates note that the crucial technologies needed for green steel — DRI and electric furnaces — already exist at commercial scale, and efforts are gaining steam globally to combine the two. Many existing DRI plants use natural gas, which results in much lower emissions than the coal that fuels blast furnaces. But using green hydrogen — produced by splitting water atoms using renewable electricity — would slash emissions even further.
The national climate research groups RMI and Industrious Labs are also touting the feasibility of greening the nation’s integrated steel mills. An RMI analysis shows that such overhauls cost roughly the same as relining and upgrading existing infrastructure.
The biggest challenge may be convincing company leaders to make a major change in an industry that “has never been known to move quickly,” as Steagall put it.
In an integrated steel mill like Gary Works, iron is added to a blast furnace, where it undergoes chemical reactions involving limestone and coke — a baked-down, concentrated form of coal. Molten iron is then converted to “primary steel” in a separate stage. This process results in the type of high-quality, flat-rolled steel suitable for automobiles and buildings.
But it is highly polluting, with about 2 million metric tons of carbon dioxide released for each ton of steel produced globally, along with high levels of particulate matter, sulfur dioxide, nitrogen oxides, and other pollutants.
The fortunes of Gary Works and other integrated steel mills declined starting in the late 1970s because of slowing demand and competition from abroad, including from “mini-mills,” which use electric arc furnaces to make steel — mostly from scrap metal — without producing any iron on-site. Integrated mills in Indiana, Illinois, Ohio, and Pennsylvania downsized their operations and then closed over several decades, transforming thriving cities into Rust Belt relics. Nationwide, steel sector employment fell from about 512,000 in 1974, according to a study by the National Bureau of Economic Research, to about 85,000 today, according to Federal Reserve Economic Data.
“Republic Steel, Bethlehem Steel, J&L Steel, they all shut down or were liquidated,” said Weinberg, who worked for eight years in Gary Works’ sheet and tin division.
Though the Gary Works mill survived, its workforce was greatly reduced – from more than 30,000 people at its peak in the 1970s to about 4,300 people today. By the 2010s, the city was notorious for its abandoned buildings and urban decay.
As GARD organizers see it, without investments in clean steel, Gary’s fortunes could fall further. The plant’s market niche — high-quality primary steel — is vulnerable to competition from the electric arc furnaces that make at least 60% of the country’s steel today.
Facilities using electric arc furnaces have typically not produced the highest-quality steel, mainly owing to their reliance on recycled steel scrap. But they do still require at least some virgin iron to produce steel, which can come from integrated mills or from on-site DRI facilities. Automakers typically demand steel made in integrated mills, but electric arc furnaces could increasingly compete for that market as their steel quality improves.
Big River Steel, along the Mississippi River in Osceola, Arkansas, is a prime example. Its electric arc furnace uses iron from Gary Works to make high-quality steel. U.S. Steel acquired the mill in 2021, and now it’s part of Nippon’s portfolio. Nippon announced in November that it will build a DRI plant at Big River, which would potentially displace the metal it currently sources from Indiana.
So, such electric arc furnace operations could become competitors, rather than customers, of integrated mills like Gary Works. And they could gain a market advantage if automakers and other industries demand a cleaner supply chain, as GARD and other decarbonization advocates predict.
Nippon lags behind most of its peers globally in its readiness for greening operations, according to a scorecard released March 30 by the international climate advocacy organization SteelWatch. The organization analyzed the decarbonization progress and potential of 18 major steel companies in 29 countries and found that Nippon ranked 17th; U.S. Steel, which was ranked before the acquisition, came in eighth; and Cleveland-Cliffs was sixth. While U.S. Steel could help facilitate Nippon’s decarbonization, SteelWatch said, the plan to reline rather than convert the Gary Works blast furnace represents a “backward trajectory.”
There’s a strong public health argument for greening the mills.
Emissions from blast furnaces are linked to an increase in various cancers, asthma, pulmonary disease, and other ailments. Industrious Labs found that in 2022, Gary Works emitted 182 tons of 24 different toxic chemicals. The health impacts are also a clear environmental injustice: 97% of those living within a three-mile radius of Gary Works are people of color, and almost two-thirds are low-income, according to Industrious Labs’ analysis.
Indiana University’s report found that Gary Works annually emits eight times more carbon monoxide and 50% more particulate matter than the state’s largest coal plant; and the region’s three primary steel mills account for not only the $75 million in healthcare costs but also 27,8000 work days and 26,700 school days lost to illness each year.
GARD member Natalie Ammons did not work in the mills, but her husband did. And she blames the Gary Works blast furnace for his early death from cancer.
Her family’s health problems have continued. Two of Ammons’ granddaughters, both of whom live near the mill, rely on breathing machines that look like scuba apparatus, she said. Modeling done by Industrious Labs using federal algorithms shows up to 114 premature deaths and over 31,000 asthma attacks linked to pollution from Gary Works each year.
Bryant retired from Cleveland-Cliffs Indiana Harbor refinery about four years ago, because she had developed a nodule on her thyroid that impeded her breathing. She attributes it to her exposure to pollution there.
“I was always super healthy. It is odd that happened shortly after I worked a lot of overtime in the lime plant,” she said.
Steagall cites examples like these in calling for Nippon to be “a good corporate citizen” for its American neighbors.
“They’ve got to make their mind up,” he said. “Do they want to be the king of steel or the king of death?”
Nippon has not responded to GARD’s proposals and requests for dialogue nor to a request for comment for this story.
The United Steelworkers union, which the GARD members once belonged to, has similarly not engaged with them. While GARD notes that unions are often reluctant to consider any changes that could disrupt the job market, it warns that the shift to mills in the South with electric arc furnaces could be disastrous for the union — as those plants are typically not unionized. (United Steelworkers did not respond to a request for comment.)
At a recent symposium at Purdue University Northwest, students and faculty clamored to hear more about GARD’s vision for the industry’s future. After the event, the GARD members gathered around a table and reminisced about the jobs they used to do. Their eyes lit up describing the complexities of the steelmaking process.
The metal “runs through a big acid bath, then we cut it to specification,” Denney said of the pickle line where she had worked. “At the end, they oil it, and you have this beautiful, very shiny, gorgeous steel.”
Gary itself could be similarly transformed, through clean steel, she imagines.
“People are used to Gary being kind of a throwaway city,” she said. “It’s all bad. There’s an opportunity for it to be all good now for the first time in a while. Nippon could be part of this change. It could be part of changing Gary forever.”
Maria Gallucci contributed reporting for this article.
A clarification was made on April 2, 2026: This story has been updated to clarify that direct reduced iron plants and electric furnaces exist separately at commercial scale.
Small, sun-driven power plants could soon be coming to backyards and balconies across New England. Lawmakers in all six of the region’s states are considering bills that would allow residents to take advantage of solar panel kits that plug in to standard home outlets, and supporters are optimistic that most — perhaps all — of these measures will succeed.
“As a concept, plug-in solar has a lot of momentum going on right now,” said Connor Yakaitis, deputy director of the Connecticut League of Conservation Voters. “It’s got bipartisan momentum. It’s got interest and intrigue from the utilities.”
Maine’s legislation is close to final passage, and could land on the governor’s desk as soon as next week. Stand-alone measures in New Hampshire and Vermont have each been green-lit by one legislative chamber. Plug-in solar provisions are part of a sprawling energy bill approved by the Massachusetts House of Representatives and working its way through the Senate. In Connecticut, permission for plug-in systems is part of a larger solar bill that has advanced out of a joint committee. Rhode Island’s bill has been held for study by a House committee.
“I am optimistic the bill will get passed,” said Sam Evans-Brown, executive director of Clean Energy New Hampshire, one of the organizations pushing the legislation in the Granite State. “We’re going to be able to come up with language that works for everybody.”
New England is not alone in its enthusiasm for plug-in panels, also commonly called “balcony solar” or “portable solar.” Interest in DIY solar is surging across the country, as escalating energy prices have people — and their elected representatives — searching for ways to lower their bills. Spiking oil prices caused by the Trump administration and Israel’s war with Iran are further heightening cost concerns.
Plug-in solar’s money-saving potential is attracting support from both sides of the aisle. In March 2025, deep-red Utah became the first to authorize the technology. A year later, similar legislation has passed in Virginia and awaits the governor’s signature, and bills are active in more than 20 other states, including some decidedly right-leaning places like Idaho and Oklahoma.
“We think this has taken off because people are thrilled about saving money and having some power to insulate themselves from rising energy bills,” said Cora Stryker, co-founder of Bright Saver, a nonprofit that promotes plug-in solar. “Crucially,” she noted, the legislation “has no fiscal implications. The price tag is zero.”
The matter is perhaps even more pressing in New England, where electricity prices are higher than almost anywhere else in the mainland United States. Homes in the region depend heavily on oil and natural gas for heating, exposing residents to high and volatile fuel prices.
“We are looking for any possible way to bring energy bills down for my constituents,” said Rhode Island state Rep. June Speakman (D), the House sponsor of her state’s balcony solar bill.
Balcony solar has taken off in Europe — most notably in Germany — over the past few years. The systems can be purchased online or from major retailers, like Ikea, and assembled at home. They plug in to a standard exterior outlet and send energy into the wires, rather than drawing electricity out, generally producing about enough power to run a refrigerator.
Plug-in solar systems are modestly sized, which means they can fit into most any sunny spot — from a well-lit backyard to an apartment-building balcony. The kits are relatively low-priced; today, they average about $3 per watt, according to Bright Saver, and the cost is likely to fall by about half once at least five states authorize their use. These prices make them accessible to consumers who can’t afford the upfront cost of rooftop solar panels. Also unlike rooftop solar, these systems can be installed without help from an electrician or approval from a utility company, which means they are an option for renters as well as homeowners.
“It’s not only empowering, but it’s also easy, and it’s so much cheaper,” Stryker said.
In the U.S., balcony solar has inhabited a sort of regulatory gray area, neither prohibited nor expressly authorized by law. The crop of bills working through state legislatures attempts to fix that problem. Provisions vary from state to state, but all the New England measures would allow residents to install systems up to 1,200 watts without utility approval or interconnection agreements. The new rules would also require the solar equipment to be certified by a national safety testing organization, like UL Solutions, which launched a testing program for these systems earlier this year.
In addition to laying out practical rules, these bills could have a more intangible impact, supporters say. They let residents know that plug-in solar is a viable option, not just a questionable technology the internet is trying to sell you.
“Legislation sends a signal that not only is this a thing that’s available on Temu — it’s also a thing you can and should consider buying,” Evans-Brown said.
Illinois could soon follow in the footsteps of Utah and Virginia with a law allowing plug-in solar arrays, often called “balcony solar.”
A bill that would make it simpler to install plug-in solar passed out of the state legislature’s Senate Energy and Public Utilities Committee on March 12. It’s now scheduled for a hearing in the full Senate, and a House committee on utilities is also considering the bill. Advocates are hopeful that the measure will pass both Democratic-controlled chambers this legislative session, which runs through the end of May, and then be signed by the state’s Democratic governor, JB Pritzker.
People are already plugging in these kinds of off-the-shelf small solar arrays to help power their homes, experts say. But legislation would ensure that more people can access the cost-saving clean power. Illinois’ bill would mandate that utilities allow people to plug in solar systems of up to 1,200 watts, without interconnection agreements, fees, or other barriers. That’s about enough energy to run a refrigerator and a few other appliances.
In Illinois, such units could save households up to $400 a year, according to an analysis by the advocacy group Solar United Neighbors, which notes that plug-in solar currently costs about $3 per watt, or about $2,000 for a typical model. Advocates predict that the cost will come down quickly if more states pass plug-in solar laws and the market expands.
More than two dozen other states are considering such bills. The concept has enjoyed bipartisan support across the country, with Utah’s Republican-dominated legislature passing the first law in March 2025. The Virginia legislature passed its law by a unanimous vote on March 11. Illinois’ red-state neighbors — Indiana, Iowa, and Missouri — have also introduced bills.
The momentum comes as affordability concerns mount nationwide. Electricity prices have spiked in many parts of the country, driven by factors including extreme weather and wildfires, natural gas price fluctuations, and the cost of infrastructure to get power where it’s needed. In Illinois, customers are seeing their bills rise sharply because of increasing electricity demand that is driven in part by data centers.
Illinois’ plug-in solar measure would go a step further than most by stipulating that homeowners’ associations and landlords could not enact rules, fees, or insurance requirements around arrays of 391 watts or less, proponents say. This would ensure that renters and condominium owners could take advantage of the option.
Despite the fast-growing enthusiasm for plug-in solar, some bills, like one in Wyoming, have failed. Utilities have raised safety concerns, such as danger to lineworkers if the arrays don’t shut off during power outages and continue sending electricity onto the grid, or a home’s electric system becoming overloaded.
Plug-in solar proponents note that safety concerns can be managed, especially through legislation that requires specific certification, as the Illinois bill does.
“This is a disruptive technology to the American market, and all disruptive technologies are good for the consumer and bad for the power structures,” said Cora Stryker, who co-founded the nonprofit organization Bright Saver last year to sell affordable plug-in solar kits. “We believe these are strategic efforts to confuse legislators and the public, but the real motivation is the threat to the business models of very powerful entities.”
The Illinois bill would mandate that plug-in solar systems not send any electricity into the home when the larger grid has an outage. That means the panels wouldn’t help during a blackout unless paired with a battery, but they would avoid harming lineworkers. Arrays that are commercially available already typically include such safeguards as part of the built-in microinverter.
The Illinois bill would also require that plug-in units be certified by UL Solutions (formerly Underwriters Laboratories) or an equivalent entity.
Hannah Birnbaum, co-founder and chief of advocacy at the nonprofit Permit Power, which focuses on reducing the bureaucracy involved in getting rooftop solar, said that it’s crucial to pass laws that include these sorts of safety provisions. Otherwise, people will continue to install unregulated systems, she said.
In California, for example, customers are already “quietly” using portable solar panels — even though the state has yet to pass the plug-in solar bill it’s considering.
“The real risk is inaction,” Stryker said. “Now there’s so much enthusiasm for plug-in solar, people are buying whatever systems they can get. It’s a regulatory gray area.”
In Illinois, utilities have thus far not raised opposition. ComEd spokesperson David O’Dowd said the utility does not have a position on the bill. Ameren did not respond to a request for comment.
Should the bill pass in Illinois, it would add to the state’s already robust incentive program encouraging residents, businesses, churches, schools, and other nonprofits to get rooftop solar. Clean energy advocates say plug-in solar provides a more affordable and convenient option, and one that’s accessible to both renters and those whose homes aren’t conducive to rooftop solar.
“It’s an untapped resource” in meeting larger clean-energy goals, according to Nick Johnson, an associate professor of sustainability and economics at Principia College in southwestern Illinois. Johnson was among over 100 residents who filed witness slips with the legislature in support of the bill.
“It’s a drop in the bucket for what we need, but every little bit helps,” he added.
In Germany, more than a million households have plug-in solar — a fact often underscored by advocates trying to popularize the technology in the U.S., where it’s still in the early stages. Even in Utah, only a few thousand households have plugged in the devices since they became legal.
Advocates expect the systems will take off once more states make it simpler for people to adopt them.
For her part, Kavi Chintam, Illinois campaign manager for the advocacy group Vote Solar, said she plans to put a plug-in solar array in her yard after the law passes. Her mother wants a solar array on her balcony, to power her TV.
“At a time when electricity prices are rising and rising, it gives an option for people to shave off some of that cost,” Chintam said. “There is something really empowering about seeing a panel you installed on your home. As the market expands, there will be more opportunities for people just to see these things out and about.”
See more from Canary Media’s “Chart of the Week” column.
Clean energy is on a tear. In China and India, it’s growing so fast it’s starting to unseat king coal. In the European Union, solar and wind now produce more electricity than do all fossil fuels combined. Even in the U.S., amid the Trump administration’s attacks on clean energy, nearly all new power capacity comes from renewables and batteries.
But who, exactly, is making all of the solar panels, wind turbines, battery packs, and electric vehicles enabling this transition?
In a word: China. Let’s look at the latest numbers from the Clean Investment Monitor by Rhodium Group and the Massachusetts Institute of Technology. Right now, over 90% of the world’s solar manufacturing capacity is in China. So is 83% of the planet’s battery production capacity, and nearly three-quarters of wind technology manufacturing capacity. China’s grip on the EV sector almost looks measly in comparison, at just two-thirds.
China’s lead is explained by several factors. For one, the country itself uses way more clean energy tech than does any other, due not only to its massive population but also Beijing’s concerted effort to make the nation more self-sufficient on energy. Last year, more than half of the solar and wind installed worldwide plugged into China’s grid. The country dominates global EV adoption, too.
But China also exports enormous amounts of these technologies. The country’s expansion of manufacturing to meet its own domestic energy goals has allowed it to produce super-cheap solar panels, batteries, wind turbines, and EVs. That’s made clean energy more attractive to buyers in other countries.
But China’s investment in these factories is contracting, hard. Last year, it invested $60 billion in cleantech manufacturing overall — less than half of what it put in the year before. In 2023, it spent $50 billion on clean energy manufacturing in a single quarter. Investment in clean energy manufacturing has been sluggish in the U.S. and Europe, too, for what it’s worth, but it’s not crashing at anywhere near the same rate.
China is pulling back for a pretty intuitive reason. It’s already built more clean energy manufacturing capacity than the world wants to use at the moment. The Clean Investment Monitor team expects this mismatch to get even worse by 2030, so as it stands, it makes little sense for China to continue speeding ahead on new factory construction.
Overall, the clean-energy manufacturing picture could look a bit different by the end of this decade — but only by a little. Even with the U.S., Europe, India, and others expected to make some headway in the battery and EV markets, China’s lead ultimately isn’t expected to go anywhere.
Breaker boxes can be a hidden stumbling block for households looking to go electric. Many of these devices are too small to support the electrical needs of a home plus the addition of an EV charger, a heat pump, and other power-hungry appliances. But upgrading them can take lots of time and money.
Smart electrical panels — smartphone-controllable versions of the electromechanical devices found in most homes — could help solve this problem. While more expensive up front than the old-school gear they’re replacing, smart panels don’t require complicated utility upgrades — and they may be able to save homes and businesses money in the long run.
Leading smart-panel startup Span and major electrical-equipment manufacturer Eaton just announced a strategic partnership to try to boost adoption of the devices. Eaton will also make a $75 million investment in the San Francisco–based startup, which has now raised a total of nearly half a billion, including a $176 million Series C last month.
Eaton, which reported $27.4 billion in revenue last year, will tap its extensive distributor and installer networks to promote Span’s devices. These range from sleek, iPhone-shaped electrical panels aimed at high-end homes with complex electrical-management needs to devices designed for smaller homes, multifamily buildings, and small commercial properties.
Eaton also makes its own version of smart controls in the form of digital circuit breakers, which are the individual devices that plug into slots in standard electrical panels to prevent household circuits from overloading. Those AbleEdge devices are used in control systems from home battery vendors including Tesla and Lunar Energy, and are a core building block of Eaton’s “home as a grid” business strategy, Paul Ryan, vice president and general manager of the company’s energy transition business, told Canary Media.
“Homes are becoming more electrified. EV adoption continues to increase. That all puts a stress on the home and on the grid,” he said. “We have to manage our power more effectively.”
Homeowners who want to electrify may need to upgrade their electrical panels or pay for even more expensive utility-grid upgrades. Instead, smart panels and circuit breakers can actively shift and throttle appliances — like EV chargers and clothes dryers — to keep loads within safe limits, saving tens of thousands of dollars per home, Ryan said.
The smart panels can also generate savings if they’re used to manage the flow of power from rooftop solar panels, batteries, and backup generators on household circuits, he said. Currently, that job is performed using complicated combinations of traditional electrical gear.
These potential benefits have driven a wave of companies to invest in the sector. Along with Eaton and fellow electrical-equipment manufacturers Schneider Electric and Leviton, these include startups like Lumin and vendors of solar energy systems, batteries, and backup generators like FranklinWH, Generac, and Savant.
Span’s smart electrical panel was one of the first to hit the market in 2019, and the first to earn certification under the UL 3141 power control systems standard offered by Underwriters Laboratories, the premier standards-setting body for electrical equipment. Before Eaton, the company had also picked up partners including leading U.S. residential solar and battery installer Sunrun, utility smart meter and communications giant Landis+Gyr, and major U.S. homebuilder PulteGroup.
Span CEO Arch Rao told Canary Media that the startup will continue to operate independently while co-branding its smart panels under the Eaton label.
“They’ve come onboard not just as an investor but as a key partner for scaling our products in the market, particularly in the residential ecosystem,” Rao said. “We’re able to support electrification of all types of existing homes with main-panel replacement, subpanels, load controls, EV charging, and heat pump integration.”
Just as important, Ryan said, Eaton has “expansive manufacturing capabilities and a very strong supply chain. We’ll be collaborating together to help drive down the cost of these solutions and make it more affordable.”
That last point addresses the big question mark for smart panels and circuit breakers: cost. Span’s marquee smart panel retails for about $3,500, well above the $1,000 to $2,500 all-in cost of installing a traditional electrical panel.
In general, digitally enabled panels and circuit breakers cost roughly twice as much as old-fashioned electromechanical equipment does. The price differential has been a barrier to more widespread adoption of these kinds of products, which have already seen one major contender exit the market. Schneider Electric, the French electrical-equipment giant that competes with Eaton in global markets, recently discontinued its Schneider Pulse smart panel.
Other technologies could well offer a cheaper route to doing what smart electrical panels do, according to Ben Hertz-Shargel, global head of grid edge at research firm Wood Mackenzie. In a 2024 opinion piece, he highlighted options ranging from next-generation utility smart meters to controls embedded in EV chargers, batteries, and electric appliances themselves.
“Low-cost smart meters with plenty of compute [capacity] are being deployed at scale today,” Hertz-Shargel told Canary Media in an interview this month. “The question is, do we need more dedicated energy hardware in the home? The lowest-cost solution will always rely on software. It seems a smart meter and an EV charger, or a battery, are the only devices you need.”
Rao pushed back on that proposition. While individual devices can throttle their power use, smart panels offer a more holistic way to oversee and control a home’s overall power demands, he said.
And utility smart meters are “not purpose-built for avoiding a service upgrade, or for adding new electrical loads to your home, most of which require not just sensing, but real-time controls,” Rao added.
Span has been working with a number of utilities, including Pacific Gas & Electric in California, that are interested in using its technology in concert with smart meters and grid control platforms for the additional home device-management flexibility it offers, he noted.
Span and Eaton also plan to launch “joint solutions” that combine both companies’ technologies in the second half of this year. “There are obviously a lot of interesting opportunities for technology partnerships,” Rao said, though he declined to provide details.
Lots of Americans are electrifying their cars and homes, enticed by the prospect of lower bills, cleaner air, and less planet-warming pollution. But all that new electric equipment creates a serious challenge: It requires bigger, better infrastructure to manage the increased flow of electrons, from the electrical panels in individual buildings to the transformers and power lines that make up the grid at large.
Pacific Gas & Electric, California’s largest utility, is testing a one-two punch of technologies that could let it and customers sidestep those expensive upgrades. The first are devices from smart-electrical-panel startup Span, which plug into utility meters and control when and how a home uses power, avoiding the need for higher-capacity panels. The second are the latest digital controls from smart-meter vendor Itron, which can ensure that the collective power demands of multiple customers don’t push local grid transformers beyond their limits.
Working in concert, these technologies could help individual customers avoid thousands of dollars of upgrade costs to electrify their homes, said Quinn Nakayama, PG&E’s senior director of grid research innovation and development. And if deployed at scale, they could allow the utility to delay billions of dollars in grid upgrades, which should help reduce rates for all its customers, he said.
To be clear, PG&E isn’t promising those results right away. The pilot with Span will start by installing the company’s meter-connected devices at PG&E employees’ homes in the coming months, with a larger rollout to volunteer customers envisioned for 2027, Nakayama said. And PG&E will upgrade existing smart meters with Itron’s technology at about 1,000 homes this year; if they’re cost-effective, the utility may seek to incorporate the capability in hundreds of thousands of customers’ meters through 2030.
“Our service planners, when they interconnect new loads, always have to imagine the worst-case scenario,” Nakayama said. “This enables us to give them the tools and the assurances that those worst-case scenarios will never occur.”
PG&E isn’t the only utility looking for ways to meet growing electricity demand without blowing out its grid budget. Utility rates are on the rise across the U.S., in large part because of the increasing cost of maintaining and upgrading the poles, wires, and substations that deliver power to customers. But PG&E is under particular scrutiny from lawmakers, given its steep electricity rate hikes over the past decade.
Utilities also want to sell more power across their wires. The more they can expand capacity for EVs, heat pumps, and other power-using devices, the more money they can bring in to cover the cost of new infrastructure. This, in turn, eases upward rate pressure for customers at large.
One way utilities could sell more power over existing wires is by tapping the capacity of virtual power plants — collections of rooftop solar and battery systems, EV chargers, appliances, and thermostats that can be controlled collaboratively to reduce grid strain. In recent years, PG&E has run multiple VPP pilots with EV chargers, and it launched a project with Span, Sunrun, and other vendors in 2025 to test how smart electrical panels and solar-charged batteries that customers have already installed could relieve local grid constraints.
However, utilities are loath to rely on novel technologies to replace tried-and-true grid upgrades. If a VPP doesn’t work, for example, local transformers or neighborhood substations can overheat and break down under increased stress. That’s why PG&E’s latest experiment is covering its bases with devices that can control excess power use both at the home and on the grid.
To moderate home energy use, PG&E is using Span’s latest smart-electrical-panel device, which is designed to plug directly into utility meters. The Span device can actively monitor and control household circuits powering air conditioners, refrigerators, and clothes dryers, as well as EV chargers, heat pumps, and other more advanced energy systems.
Adding a major new power draw to a home, like an EV charger, often requires an electrical panel upgrade, which can cost thousands of dollars and add weeks to months to an installation. It can also trigger an upgrade to the local grid, which can take months to complete and cost anywhere from several thousand dollars for replacing a transformer on an overhead power line to around $50,000 for digging up and replacing underground service transformers and power lines.
“Nobody wants to pay that,” Nakayama said.
But those upgrades are predicated on the assumption that the new EV chargers will be drawing maximum power at the same time that all the other homes in the neighborhood are maxing out their electricity use, stressing their shared grid infrastructure. That’s usually during hot summer afternoons and evenings when air conditioners are running full tilt.
Span’s tech allows PG&E to offer those customers an alternative, Nakayama said: Let the smart device curb grid stress by reducing charging speeds during those peak hours. Most EVs require only several hours to recharge their batteries, giving them time to ease off on charging for a while yet still fill up overnight.
“I think most people are OK if their car charges a little bit slower, as long as it charges by 6 in the morning,” he said. That’s called managed charging, a concept that utilities across the country are exploring as they prepare to handle millions of new EVs coming online over the ensuing decades.
Span’s software also lets customers set other parameters to keep their total household electricity use below those limits, like delaying clothes dryers until later at night or easing off on air conditioning, Nakayama said. These kinds of technological solutions are going to be important for the more than 600,000 of PG&E’s roughly 5.5 million customers that the utility expects to need some kind of electrical service upgrade in the next 10 years to meet state electrification goals.
Span CEO Arch Rao said the company is working with other utilities interested in using its equipment for similar purposes. “A lot of the technical validation work has already been completed,” he said. “It’s now about customer recruitment and enrollment.”
So that takes care of individual homes. But how can PG&E ensure those controls are actually relieving local grid stress? That’s where Itron’s smart meter technology comes in, Nakayama said — or more specifically, Itron’s latest chipsets, which can be plugged into the smart meters that PG&E has already installed.
Like traditional utility meters, smart meters track a home’s electricity usage. But they use onboard computers and wireless networks to upload those readings to utilities, rather than requiring employees to come by to check the readings once a month. U.S. utilities have deployed nearly 120 million of these smart meters over the past two decades.
In utility parlance, smart meters are known as “advanced metering infrastructure,” or AMI. Older “AMI 1.0” technology can do some advanced tasks, like detect power outages and communicate via wireless networks with other meters and the utility. But it lacks the computing power and real-time capabilities to do more complex things, like actively communicate with and control devices in homes and businesses.
Enter Itron’s latest “AMI 2.0” technology. If AMI 1.0 is like a flip phone, AMI 2.0 is more like a modern smartphone, capable of uploading applications that can undertake the novel tasks that PG&E is now exploring.
In other words, “the meter is no longer just a meter — it’s a controller,” said Nick Tumilowicz, head of Itron’s distributed energy management solutions business. The company’s AMI 2.0 technology has already been controlling Level 2 EV chargers at hundreds of PG&E customers’ homes through a pilot project launched in late 2024, he said. Itron has used the same technology to manage school bus charging in New York City and Tesla Powerwall batteries for Colorado utility Xcel Energy.
Smart meters can also do something that in-home devices can’t, Nakayama said: communicate with all the other meters in the neighborhood to check how their shared electrical loads are impacting the transformers they’re connected to.
All those meters are linked in a wireless network and “speak the same language,” he said. Once an AMI 2.0 meter is connected, “it has the ability to say to its surrounding AMI 1.0 meters, ‘We’re all on the same service transformer,’” he said. “And it can do simple math, and figure out what that service transformer limit is,” as well as determine much demand the transformer faces from homes.
The tech then feeds that data back to the EV chargers and electrical panels that are linked to the AMI 2.0 meter, he said. For instance, if other nearby homes are using more power than usual and stressing the local transformer, PG&E could direct those smart panels and EV chargers to throttle power.
Finding ways for neighborhoods to electrify without crushing the grid will require a lot more solutions like these, said Ben Hertz-Shargel, global head of grid edge at research firm Wood Mackenzie.
“There is so much risk — and so much opportunity — on the distribution system. If electrification happens in an unmanaged way, it will be extremely expensive,” he said.
On the other hand, utilities have to make sure the technologies they’re deploying don’t add more costs than the benefits they deliver, Hertz-Shargel said. For example, PG&E’s new pilots are funded through state grants, and the utility will need to prove their cost-effectiveness before asking regulators to let it charge customers at large to deploy them more broadly as part of a rate case.
That evidence is particularly challenging to come up with when trying to avoid upgrades to the low-voltage network that brings power directly to houses, since most utilities don’t have solid details on that part of the grid.
“The problem is that utilities don’t have good data on these assets below the substation,” Hertz-Shargel said. “These devices need to not only solve the thermal overload problem but provide the ground-truth data to prove that they’re solving the problem — such as that the transformer stayed well below its power rating.” If that evidence is lacking, these technologies will be a harder sell to planning teams, he said.
“It’s smart for PG&E to try these different solutions,” Hertz-Shargel said. “I think the ones that survive will be the ones that are most cost-effective.”
Base Power, the Texas-based home-battery juggernaut, just revealed how it’s spending some of the $1 billion it raised in October. The startup’s plan is to build one of the nation’s largest fleets of home batteries, for a cooperative utility outside Dallas–Fort Worth.
Cleantech startups and advocates alike keep promising that small-scale energy devices such as residential batteries and thermostats can be coordinated and operated like traditional power plants. But in practice, it’s been harder for companies to build enough aggregated capacity, with high enough reliability, to truly match the performance that utilities are used to at their large-scale gas power plants. The new Base Power project tackles this challenge head-on.
Base Power will work to install 100 megawatts of home battery capacity in the territory of member-owned utility Denton County Electric Cooperative, known as CoServ, over the next two years. Crucially, that scale equates to the output of a natural-gas-fired peaker plant, a class of smaller conventional power plants that fire up when demand is highest. While building a new gas peaker could take around five years of permitting and construction, Base Power can deliver the capacity in two years by striking deals with homeowners and installing each system in a day, said Tim Pianta, the company’s head of utility partnerships.
“The whole business is oriented around, How do we get dispatchable megawatts on the grid really quickly to drive down grid and power supply costs? And I think this is a really good application of that,” he said.
In partnership with CoServ, Base Power will pitch the utility’s customer-owners on whole-home backup power for an installation fee starting at $695 and a monthly $19 subscription. That’s a slim fraction of the cost to buy a big enough battery on the open market, which could easily run to $15,000 or $20,000. Base Power can afford to offer that bargain because it retains ownership of the batteries and will call on them to fulfill a grid capacity contract for the utility.
On the utility side, this contract should offer the fastest path to adding capacity affordably, Pianta said. While CoServ could purchase power from the wholesale market managed by the Electric Reliability Council of Texas or build its own peaker plants, the battery fleet gives the utility the option to buy power when it is cheap and deliver it when prices are high. Lowering the amount of power CoServ has to ship in during peak times also reduces the utility’s transmission costs, he added.
In short, this deal is an affordability play for CoServ — the third-largest electric coop in the U.S., serving 330,000 electric meters — at a time when average U.S. electricity costs are rising faster than inflation (and gasoline and natural gas prices have also spiked, at least temporarily, following the U.S. attacks on Iran).
“That’s a core value proposition for them: driving down costs of their power supply. And then, in tandem with that,” Pianta said, is “the ability to offer members dramatically more affordable resiliency than they would otherwise be able to get.”
Base Power launched in 2023 with a similar offering in parts of Texas where customers can choose their retail electricity provider; the startup sells cheap backup power and a cheap electricity subscription, then dispatches the batteries in ERCOT to recoup the cost of installation. The company then launched a parallel business packaging this concept for utilities in parts of Texas where customers have just one local retailer to pick from. The CoServ collaboration marks the fifth of these deals, and the largest — all five total 180 megawatts.
First, though, Base Power must deliver on this ambitious promise. For the CoServ deal, Base Power sales associates will have to convince some 5,000 homeowners to pay for backup power. Even with a low price, that entails a significant ground game, and will depend on the level of customer interest in battery backup.
Pianta noted that CoServ “already has a very reliable system, so they have very few outages.” That compliment may be constructive for maintaining a strong partnership with the utility, but it runs against the usual marketing playbook for home backup — evoking the risk of being left in the dark by utility failures. This tension is playing out around the country in places where battery vendors have opted to sell their wares in partnership with utilities, instead of running insurgent marketing against them.
This being Texas, memories of the deadly Winter Storm Uri in 2021, which precipitated a systemwide collapse of natural gas and electricity supply, could motivate residents to sign up. The small investment and monthly fee could be an enticing insurance policy for Texans who harbor a healthy skepticism of politicians’ efforts to fortify the state energy system in the wake of that disaster (and the often-politicized response has left plenty of room for skepticism).
Pianta said Base Power will hit the 100-megawatt deployment target by leaning on its vertically integrated business model, in which the company designs, builds, sells, installs, and maintains its batteries, rather than outsourcing those functions.
“Base has been building up for a long time now, both the supply capacity to deliver that type of resource and the deployments engine to develop that local capacity really quickly,” Pianta said. The company is ramping up manufacturing in the former Austin American-Statesman building, and it has reached an installation pace of more than 60 customers per day, for a total of 300 megawatt-hours in operation.
The contract also protects CoServ customers, stipulating that the utility pays only for the capacity that Base Power actually delivers, Pianta said. This aligns incentives between the utility and the startup, giving the latter good reason to move swiftly on installing its batteries.
Longer term, the project will serve as a large-scale test case for decentralized batteries as an effective competitor to traditional fossil-fueled power plants. CoServ leadership thought this would be a good deal for serving its customers’ electricity demand, but the price point for that 100 megawatts matters only if the batteries work en masse. That’s why Base Power retains control and ownership of the batteries: It doesn’t have to worry about homeowners using the batteries in ways that undermine their availability when the utility wants them to discharge.
Beyond the efficacy of the battery network, Base Power must prove its overarching business case: Does paying all the money to build an in-house battery empire pay off in the end? Can the home battery market support a corporate newcomer with a $4 billion valuation and major investment from Silicon Valley royalty like Andreessen Horowitz? The only way to settle those questions is to install a lot more batteries.
One of the most promising low-carbon cement startups, Sublime Systems, has hit a major roadblock in its efforts to scale up production.
The startup said this week that it had laid off about two-thirds of its workforce, having already paused construction in December on its forthcoming commercial-scale facility in Holyoke, Massachusetts. The actions were in response to the Trump administration clawing back an $87 million award last year from the Department of Energy’s now mostly gutted Office of Clean Energy Demonstrations.
The grant, which was meant to help Sublime build the Holyoke manufacturing plant, was swept up in the administration’s broader rollback of billions of dollars in previously awarded funding for projects that curb carbon emissions from industrial facilities.
Ever since then, “the company has faced compounding challenges in assembling the capital stack required to scale our operations,” a Sublime spokesperson said on Thursday in an email to Canary Media. Sublime said its project had been expected to create hundreds of direct and indirect jobs in the region.
Sublime, an MIT spinout, has raised over $200 million in total funding, including the federal grant. The six-year-old company is part of a bigger global push to develop novel ways of making cement, without producing planet-warming pollution in the process.
Traditional cement — which is mixed with sand, gravel, and water to form concrete — is responsible for roughly 8% of global carbon dioxide emissions. Nearly all cement is made today by heating carbon-rich limestone in fossil-fuel-burning kilns as hot as molten lava.
Sublime’s approach is very different. It involves electrically charging a bath of chemicals and calcium silicate rocks. In March 2024, the Biden administration awarded Sublime and other producers a collective $1.5 billion to slash the carbon impact of cement, as part of a larger $6 billion investment in industrial decarbonization projects.
Before this week’s layoffs, Sublime employed as many as 90 people, and it was making progress around proving its technology and securing key customers, including Microsoft.
Last summer, Sublime completed a “pilot pour” of its low-carbon cement at a data center campus in northern Virginia owned by Stack Infrastructure. And in May, Microsoft signed a binding deal to purchase up to 622,500 metric tons of Sublime’s cement products — enough to build roughly 30 professional football stadiums — from the startup’s forthcoming manufacturing facilities.
This week’s setback casts doubt on Sublime’s ability to supply Microsoft with that cement, as Bloomberg first reported. The tech giant declined to comment directly on how Sublime’s layoffs might affect Microsoft’s own goals to reduce carbon emissions from infrastructure projects.
However, Microsoft “remains committed to advancing low‑carbon building materials and continues to work with Sublime and a range of partners to support our long‑term sustainability goals,” a spokesperson said by email.
Microsoft has also invested in the clean-cement startup Fortera to support construction of that firm’s 400,000-ton-per-year facility. And it’s partnering with RMI and the Center for Green Market Activation to develop a system enabling companies to purchase “environmental attribute certificates” that represent the emissions reductions provided by cleaner cement and concrete — without actually buying the physical product.
Sublime said it continues to see “strong customer demand and industry backing” and is sticking to its goal of building the first electrochemical cement plants in the United States and Europe by 2030. The startup added that it remains in talks with the Department of Energy to try to restore its award and resume construction on its Holyoke facility.
“Sublime remains strong and well-positioned to continue to attract capital, commercialize its technology and meet market demand,” the company said.
China is accelerating its efforts to clean up heavy industry, allocating money for the first time last year to help hard-to-decarbonize sectors increase the use of fuels such as green hydrogen. The push comes as the country continues building more solar panels, wind turbines, and nuclear reactors and expanding its grid faster than anywhere else in the world.
Those two trends are converging to spur the greening of aluminum in particular — a commodity that requires so much power to manufacture that it’s nicknamed “congealed electricity.”
Aluminum production hit a record high last year in China as demand for the alloy, which is used in virtually every kind of electrical application, soared in tandem with the country’s data center boom, according to numbers the National Bureau of Statistics released in January. Prices of the globally traded commodity have spiked by nearly 35% in the past year, meaning that aluminum produced with clean electricity, which comes with a green premium, is more competitive.
At the same time, Beijing’s latest policies to steer its world-leading aluminum smelters away from coal are just taking effect. While the most recent national statistics showed steel production at a seven-year low — a result of the shift away from housing construction — analysts say the surging demand for aluminum could speed up the pace of that industry’s transformation.
“I do expect green aluminum production to pick up, even as other commodities retrench,” said Xinyi Shen, the head of the China team at the Centre for Research on Energy and Clean Air, a Finnish nonprofit that tracks Chinese heavy industry. “In China, aluminum decarbonization is progressing … showing stronger policy momentum than steel at the moment.”
There are limits to how quickly the shift can take place. China has for the past decade maintained a cap on aluminum production to prevent smelters from oversupplying and destabilizing the power grid. New production to meet surging demand is quickly approaching that limit, according to a December analysis from the bank ING. But already, the industry is starting to reorient production toward decarbonization.
One way China’s aluminum industry is going green is through recycling. Producing secondary aluminum requires only about 5% of the energy needed to produce primary aluminum, meaning that carbon emissions are typically up to at least 80% lower. Between 2015 and 2024, China’s recycled aluminum output grew by about 6.25% per year, reaching nearly 11 million metric tons in 2024. In March 2025, Beijing set a target of more than 15 million tons of recycled aluminum by 2027.
“This pathway is already cost-competitive and relatively insulated from power-price volatility, so it’s likely to keep expanding even in a softer macro environment,” Shen said.
The other way is by transitioning existing smelters to using clean power. Since nearly 70% of primary aluminum production relies on coal-fired or natural-gas-fired power plants, the sector produces about 2% of global greenhouse gas emissions. The rest is largely powered from hydroelectric dams, next to which older smelters were traditionally sited.
The power-intensive smelting process involves blasting a molten bath of cryolite with an electrical current that separates out dissolved aluminum and yields a molten metal that can be cast into ingots, billets, or bars. In China, where most of the world’s aluminum is produced, the vast majority of that electricity has historically come from coal. Under its new regulations, Beijing wants most of the power that smelters consume to come from renewables.
Last year, aluminum became the first energy-intensive industrial sector subject to a new renewable power mandate requiring green electricity to supply 70% of smelters’ electrons, up from just over 25%.
“Compliance is expected to be met increasingly through green power contracts and renewable-energy certificates, partly in response to both China’s domestic climate goals and emerging international green trade standards,” Shen said.
China has begun shifting its smelting capacity to provinces with excess hydropower or room for wind and solar arrays to offset coal- and gas-fired production.
Even before Beijing mandated that aluminum producers use more renewable power, smelters were already “looking at moving to hydro-rich regions” such as Yunnan province, David Fishman, a Shanghai-based analyst who tracks the Chinese electrical industry at the Lantau Group consultancy, wrote in a thread on X last month.
Wind and solar trailed behind hydropower, nuclear, and coal in the list of the lowest retail power prices in China, Fishman wrote. But he said that buying renewable energy credits was just as valid a solution if those certificates come from vetted, reputable sources in places with expanding production, such as Inner Mongolia or Xinjiang. Still, he noted, relocating to renewables-rich regions “isn’t just about cheap power.”
“It’s also about reducing uncertainty around long-term compliance with rising clean power quotas, which is becoming a C-suite level strategic variable,” Fishman wrote. “This is as true [if] you’re moving the smelter to Yunnan (for all its hydropower) or Xinjiang (where you’re going to have to pursue a wind/solar solution).”
A big open question is whether Chinese companies will start operating new smelters in other countries, and whether those facilities will be powered with renewable electricity, said Seaver Wang, the director of the climate and energy team at the Breakthrough Institute, a research nonprofit in California.
“The next big story in global aluminum is whether Chinese firms start developing overseas, particularly in Indonesia and Vietnam,” Wang said, noting that Indonesian advocates he’d spoken to feared that the facilities would use coal. “With aluminum capacity in China capped, where is the industry spilling over into?”
Rising demand globally for lower-carbon products is spurring on Chinese industry. That’s particularly true now that the European Union’s carbon tariff — the first in the world — took effect in January. Brussels is considering establishing a way to selectively exempt industries from the levies. But the bloc has so far vowed to keep requiring importers to buy carbon certificates to offset the emissions produced during manufacturing.
The China Nonferrous Metals Industry Association rolled out updated rules last year for the certification and trading of “green electricity aluminum,” in a move Shen said was “intended to ensure that low-carbon aluminum carries recognized commercial value in the market, rather than being merely a reporting label.”
Last summer, a Chinese steelmaker scheduled its debut shipment of green steel to a buyer in Italy, carving out the start of a supply chain that would comply with the EU’s carbon tariff. In November, top steel trade associations in Europe and China agreed to work together to create uniform standards for what qualifies as green.
If China’s experience with solar panels and batteries — in which its efforts to meet domestic demand led to a flood of cheap exports — is any indicator, the global market could soon have an influx of green aluminum.
When rockets blast off Earth, they rely on tiny metal powders to help propel them into space. Now, an emerging group of startups and scientists is hoping to harness these particles for something more terrestrial: producing carbon-free energy for factories.
Powdered iron can be combusted in industrial boilers to supply the hot water and steam needed to produce everything from beer and baby formula to paper and plastic resins — without directly emitting carbon dioxide. The concept is about a decade old, but companies are just starting to make serious inroads to put the technology into practice.
Last week, the Dutch startup Renewable Iron Fuel Technology, or Rift, said it raised almost 114 million euros ($131 million) in private financing and public grants to develop its first commercial project, making it a front-runner in the space. Rift already operates two pilot units in the Netherlands. With the new investment, the firm plans to build a fuel-production plant and deploy its boilers in about 10 industrial facilities in Europe, the first of which is set to fire up in 2029.
“This represents a concrete step toward decarbonizing industrial heat at scale,” said Mark Verhagen, CEO of the Eindhoven-based Rift.
Around the world, most factories burn fossil fuels to get the heat they need for industrial processes, which is why the sector accounts for more than one-third of energy-related CO2 pollution globally. Rift estimates that its current system can reduce emissions by almost 80%, on a life-cycle basis, when compared with those of a fossil-gas-fired boiler.
The startup is seeking to scale at a pressing time in the European Union, where manufacturers are facing tighter restrictions on emissions and new policies aimed at shifting factories toward cleaner heat sources. The region is also grappling with ballooning gas prices caused by Russia’s 2022 invasion of Ukraine — and now the U.S. and Israel’s war on Iran.
Rift’s approach replaces gas with iron, a highly energy-dense and abundant element that is ground down to resemble sand.
The startup begins by putting iron powder in a specialized boiler, then injecting air and making a little spark that yields a big flame. As the iron burns, it produces heat that can be used directly for manufacturing or district-heating networks. To start, Rift is focused on supplying medium-temperature heat, of around 250 degrees Celsius (482 degrees Fahrenheit).
“The only product that remains are the ashes,” Verhagen said.
Rift will initially use a small amount of virgin iron powder, sourced from industrial suppliers. But the goal is to continually recycle the ashes — which are pure iron oxide — to make new fuel. When combined with low-carbon hydrogen, iron oxide splits into water and iron powder, the latter of which will be returned to the boiler.
As a technology, iron fuel has plenty of hurdles to overcome before it can replace gas in factories. Researchers are still improving the iron-combustion process and the techniques for collecting iron oxide. Companies need to build up supply chains for sourcing and recycling iron powder. And using green hydrogen — the kind made with renewable energy — for fuel production remains challenging, given that supplies are limited and costly.
Developers also need to bring down their production costs in order to compete with the incumbent fossil fuels. Rift, for its part, is working to improve its economic performance with the buildout of its first commercial project, Verhagen noted. The company says it can currently deliver iron fuel for a price of 140 euros per metric ton.
The investment round announced on March 3 includes more than 83 million euros in Series B funding, led by the Dutch pension fund PGGM, as well as a grant of nearly 31 million euros from the EU’s Innovation Fund. Rift had previously raised 11 million euros from investors in 2024, which enabled it to conduct durability tests at its two pilot projects.
“We have closely followed Rift’s development and see strong potential for tangible industrial impact,” Tim van den Brule, investment director at PGGM Infrastructure, said in a press release. “Many industrial innovations stall in the transition from demonstration to realization,” he added, which is why the firm is providing Rift with capital “through to execution.”
Rift is not alone in this fledgling field. Other players include the Dutch startup Iron+ and the Canadian firms Altiro Energy, FeX Energy, and GH Power, along with Ferron Energy in Australia and Fenix Energy in France.
The companies can all trace their roots to early research efforts led by Philip de Goey from Eindhoven University of Technology and Jeff Bergthorson from Montreal’s McGill University. The professors were inspired to pursue metal fuels for energy purposes after observing how powders burned at the European Space Research and Technology Centre in the Netherlands. In particular, they saw iron powder as an appealing alternative to gaseous hydrogen fuel — which has been held up as a more direct replacement for fossil gas but is difficult to store and transport.
In 2020, Eindhoven researchers and students, including Verhagen, built their first 100-kilowatt iron fuel boiler at a nearby brewery. That year, Rift spun out of the student team, with support from the Bill Gates–led Breakthrough Energy Fellows program. The startup later launched a 1-megawatt system that provides heating to some 500 homes in the Dutch city of Helmond; it operates another pilot unit at a cleantech park in Arnhem.
In 2025, Rift signed its first customer contract with the Dutch firm Kingspan Unidek, which makes building insulation and plans to install an iron-fueled boiler at one of its plants.
Verhagen said that, as well as with slotting into existing operations like Kingspan’s, the technology could also work alongside other types of clean-heat solutions that are gaining momentum globally, such as thermal batteries, which store electricity to provide on-demand heat, and highly efficient industrial heat pumps.
Iron fuel could serve as the “baseload” source that supplements electrified technologies, or that kicks in when electricity prices are high or otherwise constrained. “We see that there’s a unique fit” for Rift’s system, he said.
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