Mechanism Study of Iron Electrodeposition from Iron Oxide/Ore Suspension in an Alkaline Electrolyte

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🔬研究者:Provides mechanistic insights for electrochemical iron reduction, aiding in the rational design of electrolytic iron production systems.

🏢実務担当者:Offers process parameters and mechanistic understanding for companies developing electrolytic iron technology.

🏛政策担当者:Supports the case for funding fundamental research into breakthrough steel decarbonization technologies.

Global steel production exceeded 1.9 billion tons in 2021, with the iron and steel sector contributing nearly 7% of worldwide CO₂ emissions [1] . Conventional blast furnaces consume ~20–30 GJ per ton of steel, while even hydrogen-based reduction requires costly infrastructure and faces storage and transport challenges [2] . Alternatively, electrolytic iron production offers a carbon-free, electricity-driven pathway to meet the industrial decarbonization targets. Over the last decade, there has been dedicated research on iron electrodeposition/electrowinning from iron-oxide-suspension in an alkaline electrolytic environment [3] . However, it remains an open question on the exact mechanism of this electro-conversion process. This work aims to leverage our fundamental understanding of underlying physics in the iron electrodeposition process, shedding light to the open question on mechanisms. To this end, we have conducted a systematic experimental study with well-defined systems involve suspension-based (slurry) electrolyte and homogeneous electrolyte with dissolved iron ions. The experimental investigation spans over wide ranges of system parameters/conditions, include feedstock composition, current density, temperature, electrode material, solid concentration, pre-treatment, etc. Quantitative characterization of the process involves measurement using, Scanning Electron Microscope (SEM), X-ray diffraction (XRD) and UV-Visible spectroscopy. These comprehensive experiments and characterization have revealed a combined conversion mechanism of both solid-state electroreduction with Fe₃O₄ as an intermediate and dissolution-redeposition pathway, leading to a complex reaction map. The dominating role of individual conversion pathway depending on several system conditions can lead to different deposit morphology and efficiency. This work enhances the fundamental understanding of electrochemical iron reduction in powder-based suspensions, which informs the design and scaling of the electrolytic iron production process, contributing to sustainable iron and steel production. Reference [1] Fan, Z. and Friedmann, S.J., 2021. Low-carbon production of iron and steel: Technology options, economic assessment, and policy. Joule, 5(4), pp.829–862. [2] Shahabuddin, M., Brooks, G. and Rhamdhani, M.A., 2023. Decarbonisation and hydrogen integration of steel industries: Recent development, challenges and technoeconomic analysis. Journal of Cleaner Production, 395, 136391. [3] Majid, A.I., Finotello, G., van der Schaaf, J., Deen, N.G. and Tang, Y., 2024. On the formation of dendritic iron from alkaline electrochemical reduction of iron oxide prepared for metal fuel applications. Chemical Engineering Science, 291, 119931. Figure 1

• semanticscholar https://doi.org/10.1149/ma2026-01572760mtgabsfirst seen 2026-07-20 05:13:51