Electrochemical cogeneration of iron and commodity chemicals
EP4758285A1Pending Publication Date: 2026-06-17FORM ENERGY INC
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- FORM ENERGY INC
- Filing Date
- 2024-08-06
- Publication Date
- 2026-06-17
AI Technical Summary
Technical Problem
Conventional ironmaking processes are inefficient and environmentally detrimental, emitting significant CO2 and relying on high-grade ores, while existing electrochemical methods face challenges in cost competitiveness and scalability.
Method used
The chlor-iron process employs an electrochemical reactor with a magnetic field to continuously produce iron metal from low-grade ores, simultaneously generating valuable co-products like NaOH and chlorine, which help offset production costs and sequester CO2.
Benefits of technology
This approach achieves a cost-competitive ironmaking process with reduced CO2 emissions, capable of producing steel at a levelized cost of $520/tonne-HRC while eliminating over 80 megatons of CO2 per year.
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Smart Images
Figure US2024041108_13022025_PF_FP_ABST
Abstract
An electrochemical reactor comprising a source of a magnetic field positioned in proximity to a cathode and configured to generate a magnetic field; and an electrochemical cell comprising an anode and the cathode, and further comprising a catholyte channel configured to direct a catholyte stream comprising an iron-containing feedstock to the cathode; an anolyte channel configured to direct an anolyte stream comprising a metal chloride to the anode, wherein the catholyte channel and the anolyte channel are disposed between the cathode and the anode; and a separator disposed between the catholyte channel and the anolyte channel, wherein the electrochemical reactor is configured to electrochemically oxidize chloride anions to chlorine gas at a surface of the anode, and wherein the electrochemical reactor is further configured to electrochemically reduce the iron-containing feedstock to an iron particle comprising iron metal at the surface of the cathode and in the magnetic field.
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