アルカリ電解液中での酸化鉄/鉄鉱石懸濁液からの鉄電析のメカニズム研究

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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.

2021年の世界の鉄鋼生産量は19億トンを超え、鉄鋼部門は世界のCO₂排出量の約7%を占めている[1]。従来の高炉は鉄1トンあたり約20〜30GJを消費し、水素ベースの還元法でさえも高コストなインフラを必要とし、貯蔵・輸送の課題に直面している[2]。代替として、電解による鉄製造は、炭素フリーで電力駆動の経路を提供し、産業の脱炭素化目標を達成する可能性がある。 過去10年にわたり、アルカリ性電解環境における酸化鉄懸濁液からの鉄の電解析出/電解採取に関する研究が dedicated に行われてきた[3]。しかし、この電気変換プロセスの正確なメカニズムについては未だに未解決の疑問が残っている。本研究は、鉄電解析出プロセスの基礎となる物理に関する我々の理解を活用し、メカニズムに関する未解決の疑問に光を当てることを目的とする。この目的のため、懸濁液ベース（スラリー）電解質と溶解した鉄イオンを含む均一電解質を含む明確に定義された系を用いて、系統的な実験研究を実施した。実験的調査は、原料組成、電流密度、温度、電極材料、固体濃度、前処理など、広範囲のシステムパラメータ/条件にわたる。プロセスの定量的特性評価には、走査型電子顕微鏡（SEM）、X線回折（XRD）、UV-Visible分光法を用いた測定が含まれる。これらの包括的な実験と特性評価により、Fe₃O₄を中間体とする固体状態の電気還元と溶解-再析出経路の両方の複合変換メカニズムが明らかになり、複雑な反応マップが得られた。個々の変換経路の支配的役割はいくつかのシステム条件に依存し、異なる析出形態と効率をもたらす可能性がある。 本研究は、粉末ベースの懸濁液における電気化学的鉄還元の基礎的理解を向上させ、電解鉄製造プロセスの設計とスケールアップに情報を提供し、持続可能な鉄鋼生産に貢献する。 参考文献 [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. 図1

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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

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