Carbon-Free Iron for a Sustainable Future

Iron and steel manufacturing from both primary and secondary sources continues to be an essential enabler for a strong domestic economy. Primary iron production is dominated by integrated steel mills, which use a blast furnace to convert coke and iron ore into pig iron; the pig iron is then purified in a basic oxygen Simplified cross-section schematic for the proposed molten oxide electrolysis cell. furnace (BOF) to make steel. In recent The liquid metal is produced at the cathode while oxygen gas is evolved on the years, integrated producers have anode. Graphic image courtesy of Boston Metal. typically accounted for 35-40% of total domestic steel production. However, laboratory-scale furnace system, which • Reduction in net carbon dioxide this integrated production process will then test the inert anodes at different emissions by about 20% when using consumes a disproportionate share operating conditions (e.g., various grid electricity produced from natural of energy – accounting for nearly temperatures, electrical currents, and gas, which increases to more than a two-thirds of total energy consumed in geometry). The inert anodes will then be 90% reduction using grid electricity scaled up and incorporated into a pilot- produced from carbon-free sources U.S. steel production and over 90% of scale MOE cell. The pilot-scale MOE including solar, nuclear, and wind total direct carbon dioxide emissions cell will be optimized to accommodate at these production facilities. Due to the new inert anode designs. The pilot- • Modular MOE design means that a potential all-electric steelmaking increasing strict emissions standards scale inert anodes will then be tested for final MOE cell optimization, including changeover could be gradual as and cleanliness levels in high perfor- week-long inert anode performance and incremental capacity is converted or mance steel applications, alternative endurance experiments. added ironmaking processes have recently seen increased interest and produc- Benefits for Our Industry and Applications in Our Nation’s tion opportunities. These alternative Our Nation Industry ironmaking processes have the poten- The MOE cell is expected to produce The MOE technology will have a tial to significantly reduce energy, carbon free iron while potentially variety of benefits to iron and steel manufacturers. MOE can be applied to cost, and environmental impact. reducing energy usage, cost, and environmental impact. Using state-of- producing primary iron. MOE-produced This project is expected to advance the-art MOE technology is anticipated iron can also be used as a scrap molten oxide electrolysis (MOE), to have a variety of benefits for iron and substitute to improve the quality of steel an emerging technology for primary steel production compared to current U.S. produced by electric arc furnaces (EAF). iron and steel production. The MOE iron production facilities, including: Other applications for MOE include technology consists of an inert anode, ferrochromium production and specialty a cathode, and an oxide electrolyte. • Energy savings of at least 20% at the steels and alloys, such as low-carbon The project will begin by acquiring iron production facility; though net advanced high strength steels and operational knowledge and requirements impacts would depend on the source of electrical steels. for developing and operating an inert electricity anode. This development will occur in a

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Project Description anodes. These anodes will be designed Project Partners The project objective is to mature to be capable of operating in MOE Boston Metal the molten oxide electrolysis (MOE) self-heated cells (1000’s of amps). These Woburn, MA technology for iron production. While anodes will also be tested in the MOE Principal Investigator: Dr. Richard lessons were learned from previous cells when the new designs are procured. Bradshaw efforts, significant development is needed Email: [email protected] The third pathway will determine the to successfully run an inert anode in a final optimization for the inert anodes MOE self-heated cell at a production with respect to endurance in the MOE For additional information, scale to produce carbon-free iron. The cells. This will be accomplished via project outcomes address MOE cell please contact longer duration MOE cell experiments design steps: (a) development and design Steve Sikirica (~1 week each). The purpose for these of inert anodes with respect to operational Technology Manager experiments will be to study the inert requirements; (b) modification and U.S. Department of Energy anode life expectancy, as well as the iron optimization of the MOE cell design to Advanced Manufacturing Office production efficiency. accommodate anode operation; and (c) Phone: (202) 586-5041 pilot-scale demonstration of carbon-free Email: [email protected]  iron ingots. The pilot-scale MOE cells Milestones should benchmark the inert anodes’ This three-year project began in 2018. performance and functional behavior, and validate stable iron and oxygen • Develop detailed operational production with an anode mass reduction knowledge and requirements needed of less than 5% over the course of the to pre-condition, start and run an inert week-long experiment. anode (Completed) • Derive, procure, and test new pilot- Barriers scale inert anode designs that meet • Successive refinement of the inert the necessary MOE self-heated cell anodes’ composition, geometry, and operational requirements (2020) supporting systems is required, which indicates that the pilot-scale tests may • Successfully operate and document require significant revisions to the stable oxygen and iron production with MOE cells a pilot scale MOE cell (2021)

• Full-scale MOE prototypes will need Technology Transition to successfully demonstrate improved anode performance, as well as reduced Following successful project completion, energy consumption and carbon Boston Metal intends to advance the emissions technology towards commercialization rapidly. A commitment from a partner or consortium will be required to build Pathways a small-scale commercial demonstration The project is structured to address key plant, which is anticipated within barriers and minimize risk. The ultimate one year after project completion. goal is to produce MOE self-heated cells Construction of the first production plant for primary iron and steel production that using the MOE technology could be could be subsequently commercialized. completed within three years after this project ends. It is likely Boston Metal The first project pathway will validate would bundle high-value components, the operational conditions for sub-scale licensed IP, and technical support to inert anodes. This validation will involve customers who plan to build plants that rapid testing for these anodes in a small produce iron. These customers include “lab cell” furnace system to determine current users of low-carbon steels, iron the current, geometry, temperature, and and steel producers, and potentially alloy composition impacts on anode mining firms looking to move up the performance and longevity. value chain. Technical support provided will enable the MOE design to be scaled The second pathway will seek to apply up or down as needed to meet customer the obtained knowledge from laboratory- For more information, visit: requirements. scale anode tests to develop pilot-scale energy.gov/eere/amo DOE/EE-1839 • August 2019