Electrons to Iron: green iron powder production via low-temperature electrolysis

We are on the eve of a worldwide ironmaking transition. Low-temperature electrolysis (/electrodeposition) for ironmaking has recently received increasing attention as it makes direct usage of (renewable) electricity. One problem, fundamental understanding of metal electrodeposition is largely lacking. Nobody truly understands the process. With EcoIron I want to devote my knowledge in experimental and numerical chemical engineering process to the challenge of leveraging the state-of-the-art metal electrodeposition science. Such knowledge has a huge application potential in green steel production and iron-based energy storage. Four work packages (WP) are outlined: 1.to determine the governing mechanism and kinetics of oxide-to-iron electrochemical transformation from systematic experiments and characterization. The outcome will close a long-lasting scientific debate on dissolution-redeposition vs. solid-state reduction mechanism. 2.to unveil the mechanism and conditions for formation and microstructure evolution of iron dendrites using advanced X-ray visualization techniques. The impact of this groundbreaking knowledge stretches beyond the metal production community to the rechargeable battery community. 3.to clarify the roles of particle-bubble transport and species-current transfer via advanced CFD-electrochemical coupled modelling, offering strategies to enable faster conversion. This will lead to a breakthrough in metal electrowinning technologies and an advanced numerical tool for the scientific community.4.to demonstrate a novel process for continuous production of electrolytic iron powder. This unites, translates, and validates the scientific knowledge from WPs1-3.The combined outcomes in this project constitute a breakthrough in the metal electrodeposition science. EcoIron is a beginning, which lays a robust foundation for more inclusive scientific and technological advance in the field on electrolysis for metal production to drive the sustainability