High-efficiency Continuous Electrolysis of Iron Ore for Carbon-Emission-Free Iron Production

Iron (Fe) & steel production accounts for 7% of total industry CO2 emission. Currently, blast furnace-basic oxygen furnace (BF-BOF) route produces 71% of global crude steel production. However, this process uses carbon (usually coke) as the reductant, which binds with oxygen in Fe ore and generates CO2. Direction reduction of ore (DRI) routes reduces Fe ore to sponge Fe via a solid-state process using reducing gas (commonly a mixture of H2 and CO). However, the reducing gas comes from reformed natural gas, syngas, or coal, which has a heavy carbon footprint. In this proposal, we aim to develop a novel electrolysis process to continuously convert Fe ore (Fe oxide) to Fe metal and oxygen at low temperatures (25-90 ?C). The project is expected to bring several anticipated public benefits. The first and most significant benefit of this project is its potential to reduce carbon emissions. Currently, iron production is a carbon-intensive process that accounts for a significant portion of global greenhouse gas emissions. By developing a carbon-emission-free iron production process, this project has the potential to significantly reduce carbon emissions and contribute to mitigating climate change. This, in turn, could lead to a healthier environment and a more sustainable future for generations to come.