Hertha Metals’ $133m Texas iron plant: process and cost lens for engineers
Reviewed by Joe Ashwell

First reported on MINING.com
30 Second Briefing
Texas startup Hertha Metals has raised $133.65 million in Series A funding, including $65 million from the US government’s IBAS programme, to build its Hertha Chalyx plant targeting 10,000 tonnes per year of steel-grade and magnet-grade high-purity iron. The facility will deploy the FLEXHERS process—a single continuous hydrogen/natural-gas reduction reactor coupled with electric arc furnace technology—claiming 25% lower production costs than blast furnaces and emissions cuts of 50% (natural gas) to up to 98% (hydrogen). Chalyx, alongside the existing 360 t/y Pi100 pilot in Conroe, aims to create a fully domestic feedstock source for NdFeB magnet and defence manufacturers.
Technical Brief
- FLEXHERS uses a single continuous reduction reactor, replacing the traditional multi-step, coal-based blast furnace route.
- The reactor is designed to accept any grade of iron ore as feed, increasing ore sourcing flexibility.
- Electric arc furnace integration enables direct production of both steel and high-purity iron on the same site.
- Pi100 is already in active supplier qualification with major US rare-earth magnet manufacturers.
- NdFeB permanent magnets comprise roughly 70% high-purity iron by weight, driving tight impurity control requirements.
- IBAS’s $65M equity stake links the project explicitly to US defence industrial base resilience objectives.
Our Take
The related June 2026 piece on Hertha Metals’ 10,000 t/y Conroe plant indicates this Series A raise is backing a scale-up path from the current 360 t/y demonstration facility toward commercial volumes specifically targeted at NdFeB magnet supply chains in the US.
With FLEXHERS claiming up to 98% emissions reduction when using hydrogen, Hertha’s magnet-grade iron positions Texas within the small subset of our Materials coverage where decarbonised iron and steel processes are being tied directly to rare earth and EV supply security rather than generic green steel markets.
The involvement of US Government-linked entities such as IBAS and DFARS-related defence framing, alongside investors like Toyota Ventures and Siemens Financial Services, signals that Hertha’s magnet-grade iron is being treated as dual-use infrastructure for both defence and automotive OEMs seeking non-Chinese NdFeB magnet inputs.
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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