Helix Carbon’s ironmaking proposal uses electrolysis to convert carbon dioxide in furnace exhaust into carbon monoxide, then reuses that gas in the furnace to reduce coal use.
The startup says its design can process raw exhaust without prior cleaning and could replace 33% of the coal used.
It estimates savings of $14 per ton of iron; these figures are company claims.
Helix Carbon, a new company introduced at TechCrunch Disrupt in San Francisco in October 2026, proposes a way to keep this gas from ending up in the environment, but instead reuse it.
How the technology works
The company has created a device that uses electricity to convert carbon dioxide into carbon monoxide. The carbon monoxide can then be returned to the furnace and replace some of the coal that is burned.
According to the company, the device has the ability to process flue gases directly from the furnace without the need for prior cleaning. Helix Carbon estimates that its method could replace 33% of the coal currently used.
Profit for the industry
Beyond the environmental benefit, the company claims its method can reduce production costs by about $14 per ton of iron, a significant saving for an industry where profit margins are typically very thin.
Helix Carbon is also looking at using its technology in the chemical industry, converting waste gases into raw materials for the production of chemical products.
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