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Low-temperature electrolysis of iron ores is a novel technology aimed at reducing the environmental impact of current iron-making that is responsible for heavy CO2 emissions. This technology under development by ArcelorMittal involves the electrolysis of an iron oxide ore suspension in a hot (110 °C) caustic (50 wt.% NaOH) solution at a high current density (1000 A/m2). Research conducted at McGill under the sponsorship of ArcelorMittal is seeking to understand the effect of various iron ore properties (mineralogy, impurities) and electrolytic process parameters (temperature, caustic concentration, suspension conditions, electrode configuration, voltage range, and mode, etc.). Tests are carried out in batch and continuous benchtop electrolysis setup and reacting iron oxide particles as well as the metallic iron deposit are characterized to determine transformation and deposition mechanisms. In this chapter, we aim to present some recent results obtained at less severe conditions, namely reduced T (50 °C down from 110 °C), and NaOH concentration (30% down from 50%) using synthetic hematite. In this project, the electrolysis time, initially set at 6 hours, has been extended to 24, 48, and 72 hours. These extended electrolysis periods provide new insight about the dynamics of the process both in terms of current efficiency (time-dependent electrode polarization), oxide reduction evolution, and metal deposit growth.

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Direct Electrolytic Conversion of Hematite to Metallic Iron in a Caustic Solution at 50 °C

  • 会议论文

  • 发表日期：

    2025年

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  • Philip Gamboa,
  • Arian Norouzi,
  • Kristian Waters,
  • George P. Demopoulos

摘要

Low-temperature electrolysis of iron ores is a novel technology aimed at reducing the environmental impact of current iron-making that is responsible for heavy CO2 emissions. This technology under development by ArcelorMittal involves the electrolysis of an iron oxide ore suspension in a hot (110 °C) caustic (50 wt.% NaOH) solution at a high current density (1000 A/m2). Research conducted at McGill under the sponsorship of ArcelorMittal is seeking to understand the effect of various iron ore properties (mineralogy, impurities) and electrolytic process parameters (temperature, caustic concentration, suspension conditions, electrode configuration, voltage range, and mode, etc.). Tests are carried out in batch and continuous benchtop electrolysis setup and reacting iron oxide particles as well as the metallic iron deposit are characterized to determine transformation and deposition mechanisms. In this chapter, we aim to present some recent results obtained at less severe conditions, namely reduced T (50 °C down from 110 °C), and NaOH concentration (30% down from 50%) using synthetic hematite. In this project, the electrolysis time, initially set at 6 hours, has been extended to 24, 48, and 72 hours. These extended electrolysis periods provide new insight about the dynamics of the process both in terms of current efficiency (time-dependent electrode polarization), oxide reduction evolution, and metal deposit growth.