The Paton Welding Journal, 2026, №01

2026 №01 (04)

DOI of Article 10.37434/tpwj2026.01.05

2026 №01 (06)

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The Paton Welding Journal, 2026, #1, 33-38 pages

Review 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 NASU. 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. Works in this area are still at the research stage. Electrolytic methods for extracting iron from its oxides appear more promising in this regard, with several approaches currently at different stages of research 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 ULCOLYS IS, as well as low-temperature processes like ULCOWIN and SIDERW IN. 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 passes, iron is deposited on the cathode, while oxygen is released on 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 efficiency 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 build a plant for iron production by low-temperature electrolysis.
Keywords: CO2 emissions, hydrogen, green technologies, iron electrolysis, Molten Oxide Electrolysis, ULCOWIN, ULCOLYS IS, SIDERW IN

Received: 16.07.2025
Received in revised form: 30.07.2025
Accepted: 28.10.2025

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Suggested Citation

V.O. Shapovalov, D.M. Zhyrov, F.K. Biktagirov, O.V. Hnatushenko, V.V. Barabash, A.P. Ignatov (2026) Review of the processes of producing iron by electrolysis. The Paton Welding J., 01, 33-38.

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