Hertha Metals’ $100M Texas iron plant: supply and process notes for mine planners
Reviewed by Joe Ashwell

First reported on MINING.com
30 Second Briefing
Hertha Metals has broken ground on its $100 million Hertha Chalyx plant in Conroe, Texas, designed to produce about 10,000 tonnes per year of combined steel-grade and magnet-grade high-purity iron using domestic ore from Minnesota’s Iron Range and Texas natural gas. The facility, adjacent to the Pi100 pilot plant where 99.95% purity was achieved in August, will scale Hertha’s FLEXHERS process, which couples electric arc furnace technology with natural gas or hydrogen. First magnet-grade output is targeted for early 2028, feeding US NdFeB magnet makers that currently rely on China for an estimated 94% of high-purity iron.
Technical Brief
- FLEXHERS process integrates electric arc furnace smelting with either natural gas or hydrogen as reductant.
- Pi100 pilot achieved 99.95% iron purity in August, matching top-tier NdFeB magnet specifications.
- Chalyx and Pi100 together form a dedicated iron and steel innovation complex in Conroe, Texas.
- Plant capex (~$100 million) is covered within a $133.65 million Series A financing round.
- US government contributed $65 million as equity, structured to “crowd in” additional private capital.
- NdFeB magnets comprise roughly 70% high-purity iron by weight, driving tight impurity tolerances.
- Hertha is undergoing supplier qualification with major US rare earth magnet manufacturers for Pi100 output.
- Successful Chalyx operations are intended to de-risk a subsequent 500,000 t/y commercial steel mill deployment.
Our Take
Hertha Metals appears in only a small subset of the 1257 Mining stories and 288 iron/iron ore keyword pieces in our database, signalling that a dedicated magnet-grade iron producer in the USA is still relatively unusual compared with traditional iron ore or steel coverage.
The August 2026 FLEXHERS item on 99.95% purity iron in Conroe, Texas, shows that the Pi100 and FLEXHERS work referenced here are not just lab-scale but have already run at demonstration scale on fully domestic iron ore feed, which materially de-risks the planned Chalyx plant ramp-up.
Prepared by collating external sources, AI-assisted tools, and Geomechanics.io’s proprietary mining database, then reviewed for technical accuracy & edited by our geotechnical team.
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