The steel industry is a major contributor to greenhouse gas emissions, making up about 7–9% of all emissions worldwide. Conventional iron extraction, which burns coal to operate blast furnaces, is largely responsible for this impact. With increasing demand for decarbonization, industries are seeking new ways to reduce their environmental impact while maintaining high production levels. 

A recent publication in ACS Energy Letters shares a cleaner idea: using an electrochemical method to obtain iron from artificial ores at low-temperature settings. The technique not only reduces emissions but may also be cost-competitive with current industrial processes. 

Electrochemistry and Iron Reduction 

Researchers found that both α-Fe₂O₃ and γ-Fe₂O₃ iron(III) oxide particles could be reduced to elemental iron by being immersed in an aqueous sodium hydroxide (NaOH) solution. This electrochemical reaction occurs at relatively low temperatures (80–90°C), in stark contrast to traditional high-temperature furnace operations. 

They noted that operating under alkaline conditions significantly enhances the current efficiencies and faradaic efficiency of the process, while minimizing unwanted side reactions such as the hydrogen evolution reaction. 

The significance lies in the method’s ability to produce metallic iron without direct carbon emissions, offering a cleaner pathway that aligns with net-zero emission goals. As a controlled and efficient approach, this technique represents a substantial advancement in the reduction of iron oxides for sustainable metallurgical applications. 

How the Study Was Conducted 

Researchers found that both α-Fe₂O₃ and γ-Fe₂O₃ iron(III) oxide particles could be reduced to elemental iron by being immersed in an aqueous sodium hydroxide (NaOH) solution. This electrochemical reaction occurs at relatively low temperatures (80–90°C), in stark contrast to traditional high-temperature furnace operations. 

They noted that operating under alkaline conditions significantly enhances the current efficiencies and faradaic efficiency of the process, while minimizing unwanted side reactions such as the hydrogen evolution reaction. 

The significance lies in the method’s ability to produce metallic iron without direct carbon emissions, offering a cleaner pathway that aligns with net-zero emission goals. As a controlled and efficient approach, this technique represents a substantial advancement in the reduction of iron oxides for sustainable metallurgical applications. 

Secondary electron SEM images of iron films grown at (a) −250 mA cm–2 from pc-Fe2O3, (b) −800 mA cm–2 from pc-Fe2O3, (c) −250 mA/cm2 from an-Fe2O3, and (d) −450 mA cm–2 from an-Fe2O3. Unreacted and partially reacted pc-Fe2O3 particles are visible as lighter contrast regions on crystalline Fe as confirmed via EDX, while unreacted and partially reacted an-Fe2O3 particles are visible as rounded regions in the top left of (c) and are not present in (d) (Supporting Information). (Konovalova et al., 2025) 

Understanding Electrochemical Ironmaking 

Unlike the traditional iron extraction industrial process which uses coke and very high temperatures over 1,500°C, electrochemical extraction happens at much lower temperatures and is less harmful to the environment. In alkaline conditions, an electric potential can be applied to bring about the change Fe³⁺ to Fe⁰. 

The researchers highlight that the cathodic compartment and electrolysis conditions—particularly alkaline versus acidic conditions—play a crucial role in maximizing efficiency and minimizing hydrogen overpotential.