A Rotating Disc Electrochemical Reactor to Produce Iron Powder for the Co2-Free Iron Fuel Cycle

Iron (Fe) is a promising candidate for energy carriers due to its high energy density, abundance, and transportability. Energy is released during the combustion of iron powder. Iron oxide particles are the product of combustion, which can be easily collected and reduced back to metallic iron, thus enforcing an iron fuel cycle. Electrochemical reduction of iron oxide in alkaline media is a promising approach for the reduction process as it is CO2-free and requires low temperature/energy. In the context of the iron fuel cycle, we promote electroreduction with dendrite-rich structures rather than compact deposit layers for easy harvesting and conversion of deposits to iron powder. This study presents the design and performance of an electrochemical reactor with a rotating disc system, designed for the continuous production of electrolytic iron powder. The reactor facilitates an integrated and automated process of electroreduction of iron oxide (from electroreduction to cleaning, drying, and dendrite/powder harvesting). Our proof of concept experiments show that iron deposits with dendritic structures can be produced in various conditions (anode configurations and rotating speeds), and are mainly located on the disc edge. The growth of dendrites at the edge of the disc favour harvesting and conversion to iron powder. Current efficiencies of more than 85-90 % are achieved in this study. Insights from the present study open new perspectives for the circularity of the iron fuel cycle. Furthermore, this technique provides a novel contribution to powder production in sustainable iron/steel-making technologies.