Iron metal production by bulk electrolysis of iron ore particles in aqueous media

The production of iron metal with low greenhouse gas emissions can be performed by electrolysis. However, the electrolytic reduction of iron ore is not a technique that has reached a high degree of knowledge and development. With the aim of getting insight into the electrochemical reaction mechanism, this work shows that the reduction of iron ore to metal at low temperature in alkaline electrolyte is possible and occurs in a solid-state macroscopic mode. Electrochemical reactions take place in the volume of the solid, progressing from its outer surface toward the core, leading to full conversion to metal. A magnetite intermediate phase has been identified and high current efficiency is measured. Such a reaction occurs at high reaction rates, which further stimulates the interest of producing iron metal by the sole use of electricity. (C) 2008 The Electrochemical Society.