Helix Carbon is addressing the significant pollution problem caused by the iron and steel industries by innovating around blast furnace emissions rather than replacing existing infrastructure. Their technology captures carbon dioxide waste from the blast furnace exhaust and converts it back into carbon monoxide using a specialized electrolyzer they developed. This carbon monoxide is then recycled into the blast furnace, reducing the need for coke, a coal-derived material traditionally used to convert iron ore into metallic iron.

The company’s electrolyzer stands out because it can process the raw exhaust gases directly without requiring purification, unlike most electrolyzers that need clean, concentrated CO2. By reinjecting carbon monoxide into the furnace, Helix Carbon aims to reduce coke usage by about one-third, which translates to roughly $14 in savings per ton of iron. This reduction not only lowers carbon emissions significantly but also improves profit margins for iron producers, a crucial factor given the industry's typically thin margins.

The iron and steel market, valued at around $2 trillion, presents a huge opportunity for Helix Carbon, though the sector is traditionally slow to adopt new technologies due to the longevity of existing blast furnace equipment—some units have been operational for over a century. To generate revenue sooner, Helix Carbon is also targeting the specialty chemicals sector, using their process to produce chemicals onsite by utilizing carbon emissions as raw materials.

Helix Carbon showcased their innovation during the Startup Battlefield competition at TechCrunch Disrupt 2026 in San Francisco. Co-founder and CEO David Brown emphasized that decarbonizing steel production cannot be achieved without addressing the blast furnace emissions. Their solution, focused on upgrading existing blast furnaces to reduce coke consumption and emissions simultaneously, represents a promising step forward in making the iron industry both cleaner and more cost-effective.