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Iron ore electrolysis

Another developing possible technology is iron ore electrolysis, where the reducing agent is simply electrons as opposed to H, CO, or carbon. One method for this is molten oxide electrolysis. Here, the cell consists of an inert anode, a liquid oxide electrolyte (CaO, MgO, etc.), and the molten steel. When heated, the iron ore is reduced to iron and oxygen. Boston Metal is at the semi-industrial stage for this process, with plans to reach commercialization by 2026. Expanding a pilot plant in Woburn, Massachusetts, and building a production facility in Brazil, it was founded by MIT professors Donald Sadoway and Antoine Allanore.

A research project which involved the steel company ArcelorMittal tested a different type of iron ore electrolysis process in a pilot project called Siderwin. It operates on relatively low temperatures (around 110 °C), while the Boston Metal process operates on high temperatures (~1.600 °C). As of March 2023 ArcelorMittal is investigating whether the company wants scale up the technology and build a larger plant, and expects an investment decision by 2025.