A key feedback loop: building electricity infrastructure and electrifying metals production.

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Energy infrastructure requires metals, and metals production requires energy. A transparent, physical model of the metals-energy system is presented to explore under what conditions this dependence constrains or accelerates the transition to a net-zero economy. While the mineral (as high as 340 Mt yr-1 iron ore, 210 Mt yr-1 limestone, 250 Mt yr-1 bauxite and 5.5 Gt yr-1 copper ore in the 2040-2050 decade, assuming no improvements) and total energy (up to 22 EJ yr-1) requirements for building low-carbon energy infrastructure are significant, it compares favourably with the current extraction and energy use supporting the fossil fuel system (15 Gt yr-1 fossil minerals and ~38 EJ yr-1). There are levers to significantly reduce material use and associated impacts over time. The metals industry can play a key reinforcing role in the transition by adapting to the increasing supply of renewable electricity. Specifically, direct electrolysis can extract metal from ore close to the thermodynamic limit, to make efficient use of low-C electricity. The unique features of emerging technologies for iron extraction, molten oxide electrolysis and molten sulphide electrolysis are considered in this evolving system. Electrification enables elegant separations and provides a pathway to build out infrastructure while reducing environmental impacts, though material efficiency measures will still be crucial to meet 2050 carbon budgets.This article is part of the discussion meeting issue 'Sustainable metals: science and systems'.