Electrometallurgy Today, 2025, №04

2025 №04 (04)

DOI of Article 10.37434/sem2025.04.05

2025 №04 (06)

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"Suchasna Elektrometallurgiya" (Electrometallurgy Today), 2025, #4, 31-36 pages

Overview of the processes of producing iron by electrolysis

V.O. Shapovalov, D.M. Zhyrov, F.K. Biktagirov, O.V. Hnatushenko, V.V. Barabash, A.P. Ignatov

E.O. Paton Electric Welding Institute of the NAS of Ukraine 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: biktagirfk@ukr.net

Abstract
Due to the urgent need for decarbonization of metallurgical production, the development of carbon-free technologies for iron reduction has gained particular importance. It was noted that hydrogen as a reducing agent is currently practically not applied for extracting iron from ore materials for various reasons, including cost and safety concerns. Research in this area is still at the investigative stage. Electrolytic methods for extracting iron from its oxides appear more promising in this regard, with several approaches currently at different stages of scientific investigation and technological implementation. The paper discusses the specific features of the main processes of electrolytic reduction of iron from ore materials, particularly high-temperature technologies such as Molten Oxide Electrolysis and ULCOLYSIS, as well as low-temperature processes like ULCOWIN and SIDERWIN. In the high-temperature methods, the electrolyte is an oxide melt composed of silicon, aluminum, and magnesium oxides at 1550–1600 °C. Iron oxide is added into this melt, and when electric current is applied, iron is deposited on the cathode, while oxygen is released at the anode. Research has established the key technological parameters for this process: composition of the molten oxide, electric current intensity and voltage, and optimal iron oxide content. Despite challenges in selecting materials that are stable at high temperatures for reactor and electrodes, this technology has progressed from laboratory research to the pilot production stage. Low-temperature electrolysis of iron oxide is carried out at 100–110 °C in an alkaline medium. Although this process has lower productivity compared to the high-temperature methods, its advantages include lower electricity consumption as well as reduced capital and operational costs. Intensive efforts are currently underway to improve the process, with plans to construct a plant for iron production through low-temperature electrolysis. 18 Ref., 1 Tabl., 4 Fig.
Keywords: CO2 emissions, hydrogen, green technologies, iron electrolysis, Molten Oxide Electrolysis, ULCOWIN, ULCOLYSIS, SIDERWIN

Received: 16.07.2025
Received in revised form: 30.07.2025
Accepted: 08.10.2025

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