Researchers at the University of Oregon have developed a groundbreaking method for producing iron for steel without relying on fossil fuels, utilizing electrochemical processes.

This cleaner approach to iron production is essential for reducing carbon emissions in the steelmaking industry, which has traditionally been a significant contributor to greenhouse gases.

The innovative process replaces conventional carbon-heavy blast furnaces with a method that employs saltwater and iron oxide to generate pure iron through electrochemical reactions.

By using inexpensive reactants like saltwater and iron oxide, the new method is positioned to be economically viable, making it an attractive alternative to traditional methods.

Recent lab tests have shown that porous iron oxide nanoparticles can produce iron more quickly than denser particles, highlighting a crucial factor for scaling the process economically.

The study emphasizes the need for electrodes with larger surface areas to enhance reaction rates and potentially lower production costs, making the new method competitive with existing steelmaking techniques.

This research demonstrates that industrial needs can be met sustainably, presenting a new perspective on industry practices without causing environmental harm.

Led by chemist Paul Kempler, the research team advocates for the use of naturally sourced, variable iron-rich materials rather than relying solely on purified chemical supplies.

To transition their method from the lab to real-world applications, the researchers are collaborating with civil engineers and an electrode manufacturing company to address scalability challenges.

They have established guiding design rules to identify low-cost iron oxides that can enhance the efficiency of the electrochemical reactors.

With nearly 2 billion metric tons of steel produced globally in 2024 using fossil fuel-intensive methods, the potential for decarbonizing iron production could lead to significant reductions in greenhouse gas emissions.

This decarbonization effort is comparable to the impact of converting all gas vehicles to electric, highlighting its importance in the fight against climate change.