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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Space foundry

Certain embodiments of the inventive technology may be described as apparatus for melting and reshaping metal from a first shape into a second shape in a microgravity or zero gravity environment, such as a space foundry, where such apparatus includes feedstock input componentry (5) configured to accept conductive metal feedstock (7) having the first shape, a furnace and a furnace pre-stage (22) established upflow of the furnace, a plurality of electromagnetic field generators (10), each of which is configured to generate an electromagnetic field, to, e.g., steer, melt and/or move the metal, whether melt or otherwise, and casting componentry (15) configured to reshape molten metal to the second shape. Certain embodiments may achieve a high degree of control over electromagnetic fields by offering individual adjustment of one or more electrical parameters of the electromagnetic field generators (10).

Pawelski, Joseph W.↗
DOE OSTI2023

CHALLENGES IN THE DEVELOPMENT OF THE ELECTROREFINING PROCESS AT Y-12

In order to ensure future capabilities of the Y-12 site as older buildings retire, a new process was developed, the Metal Purification Process. The purpose of this new process is to provide a simpler and more efficient uranium metal purification that the previous multi-staged, complex chemical processes. The basis for this technology currently exists in the US DOE complex, but it has not been utilized on a large scale for uranium at higher enrichments. The system requires larger-geometry vessels and furnaces in order to meet the through-put requirements. The crux of the process is the electrorefining cell, consisting of several concentric liners and an unfavorable geometry cylindrical crucible. Within the crucible, a molten Li-CL-KCL-UCL3 salt electrolyte is present. ‘Dirty’ metal is placed into a loading basket and loaded into an electrorefining cell. Here, the metal reacts into the molten salt within the cell to form UCL3, while ‘clean’ metal simultaneously plates out from the salt electrolyte in the form of metal dendrites. These dendrites are then collected and removed from the cell. After removal from the cell, the dendrites are taken to a furnace to remove adhered salts. Then, the salt-free dendrites are moved to a separate furnace for consolidation into the final product form. The development of the Criticality Safety Evaluation for this complex system brought with it many NCS Challenges and lessons learned. These challenges include: design decisions for ensuring subcriticalty in the electrorefining cell during abnormal conditions, the interface of the main glovebox system with auxiliary systems such as the purification system and designated storage, implementation of mass tracking, and concerns from production and operation regarding the movement of material within the system.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modifying the pore size distribution in Fe-rich inorganic polymer mortars: An effective shrinkage mitigation strategy

Highlights: • Inorganic polymer mortar has mainly macropores and a drying shrinkage of 5.1 mm/m. • 2-methyl-2,4-pentanediol acts as air entrainer in inorganic polymer mortars. • Optimal dosage 2 wt% 2-methyl-2,4-pentanediol reduced drying shrinkage to 1.8 mm/m. • Heat curing inorganic polymer mortars reduced drying shrinkage more than 50%. • Blast Furnace slag addition increased drying shrinkage and reduced strength. Inorganic polymer (IP) binder is formed upon alkali-activation of Fe-rich (41 wt%) metallurgical slag leading to materials with mechanical properties comparable to ordinary Portland cement binders. Crack formation is reported in IPs, which can be related to volumetric stability, which is to date not thoroughly understood in IPs. This study determined the autogenous and drying shrinkage of IP mortars. Shrinkage mitigation strategies, such as the addition of 2-methyl-2,4-pentanediol (2MPL), blast furnace slag (GGBFS), and applying heat curing, were used separately or in combination. IP mortars exhibited autogenous expansion and high drying shrinkage. The addition of 2MPL led to a porosity increase, as air was entrained, decreasing the drying shrinkage with 64%. Additional heat curing had no effect on samples with 2MPL. Introducing GGBFS resulted in smaller pores, increasing drying shrinkage. Shrinkage in IP mortars is driven by its pore size distribution and higher shrinkage resulted in lower flexural strength.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Carbon and energy cost impacts of electrification of space heating with heat pumps in the US

In order to meet climate goals, it will be necessary to significantly reduce the greenhouse gases emitted by homes. A key factor in the US is to reduce the on-site combustion of fossil fuels for heating end-uses and to replace this with use of electric heat pump technologies connected to a low-carbon grid. The replacement of natural gas furnaces with electric heat pumps is a key home decarbonization strategy. However, the potential for space heating electrification to reduce greenhouse gas emissions depends on the carbon dioxide equivalent (CO 2 e) content of the electricity used by the heat pump. This varies considerably depending on the source of electricity, with large state to state variability. Furthermore, household energy costs are likely to be impacted by the electrification of space heating, because retail energy prices for both natural gas and electricity in each state vary by factors of seven and four, respectively. Contractors, energy programs, government and building code officials, as well as consumers need clear indications of the likely CO 2 e and energy cost impacts of proposed electrification projects, because these will affect decarbonization choices and rationales around scaled heating electrification. Government and utility programs also need to be aware of the likely outcomes of any supported/incentivized measures. Here, in this paper, we investigate these effects by looking at new metrics to analyze the change in CO 2 e emitted and the cost to meet home heating loads when switching from a natural gas furnace to a heat pump for the contiguous 48 states of the mainland US.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Ultraviolet Laser Activation of Phosphorus-Doped Polysilicon Layers for Crystalline Silicon Solar Cells

In crystalline silicon photovoltaics (c-Si PV), a pulsed laser can be used as a substitute for a high-temperature furnace dopant diffusion/activation step. In contrast to furnace-based activation, lasers can be used to achieve highly localized doping with controlled dopant concentrations, useful in advanced architectures such as the interdigitated back contact (IBC) solar cell. In this study, a pulsed ultraviolet (UV) laser is utilized for phosphorus dopant activation within a low-pressure chemical vapor deposited (LPCVD) polycrystalline silicon (poly-Si) passivated contact layer. The highest implied open-circuit voltage iV oc values achieved using this approach reach 726 mV. However, this comes at the expense of high specific contact resistivities ρ c , which is attributed to a lower dopant concentration across the poly-Si(n + )/SiO x /c-Si interface. Regardless, the optimum iV oc , ρ c combination is measured at a laser fluence of 0.78 J cm -2 producing values of 712 mV and 89 mΩ-cm 2 , respectively. These values are still compatible with high-efficiency solar cell designs, underscoring the feasibility and effectiveness of this approach.

14 SOLAR ENERGY↗
DOE OSTI2022

Thermal conductivity of salvaged fused cast alumina used in the glass industry

Fused cast alumina (FCA) has been and continues to be used as a refractory material in energy intensive industries such as glass melting and chemical processing. In-service degradation due to high temperature exposure in harsh environment affects the designed furnace thermal profiles and energy consumption. Phase transformation may occur at the refractory hot face during glass melting altering the properties. Three FCA blocks recovered from industrial furnaces were investigated in this study. The as-received FCA consists primarily of a mixture of alpha (α) and beta (β) alumina that has a thermal conductivity value of 5–6 W/mK. The Hot Disk method was used to obtain thermal conductivity directly on the refractory blocks. At the hot face, a transformation from β to α alumina occurred and was confirmed by an X-ray diffraction study. Thermal conductivity measurements as a function of position also showed a clear transition from β to α alumina at both ends of a complete block with no voids. Thermal conductivity of the α alumina tripled compared to β alumina. This study provides important information of heat transfer and thermal conductivity evolution to refractory manufacturers and users.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cost and Life Cycle Analysis for Deep CO 2 Emissions Reduction for Steel Making: Direct Reduced Iron Technologies

Among heavy industrial sectors worldwide, the steel industry ranks first in carbon dioxide (CO 2 ) emissions. Technologies that produce direct reduced iron (DRI) enable the industry to reduce emissions or even approach net‐zero CO 2 emissions for steel production. Herein, comprehensive cradle‐to‐gate (CTG) life cycle analysis (LCA) and techno‐economic analysis (TEA) are used to evaluate the CO 2 emissions of three DRI technologies. Compared to the baseline of blast furnace and basic oxygen furnace (BF–BOF) technology for steel making, using natural gas (NG) to produce DRI has the potential to reduce CTG CO 2 emissions by 33%. When 83% or 100% renewable H 2 is used for DRI production, DRI technologies can potentially reduce CO 2 emissions by 57% and 67%, respectively, compared to baseline BF–BOF technology. However, the renewable H 2 application for DRI increases the levelized cost of steel (LCOS). When renewable natural gas (RNG) and clean electricity are used for steel production, the CTG CO 2 emissions of all the DRI technologies can potentially be reduced by more than 90% compared to the baseline BF–BOF technology, although the LCOS depends largely on the cost of RNG and clean electricity.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Sensitization and Mechanical Response of Cu‐Containing Steel Rods

The iron and steel manufacturing sector significantly adds to global greenhouse gas emissions, caused primarily by the carbothermic reduction of iron ore. Recycling scrap steel offers an effective decarbonization strategy but introduces impurities like copper (Cu) that can negatively impact mechanical properties. This study investigates the effects of Cu content and heat treatment on the mechanical performance and sensitization of steel wire rods for tire manufacturing. Steel rods with 0.04 and 0.21 wt% Cu are heated to 1050 or 1200 °C, then air quenched, or furnace cooled. Tensile testing coupled with microscopic analysis is used to evaluate mechanical properties and assess the sensitization effects. Higher Cu content leads to larger sensitized zones with increased Cu precipitation along grain boundaries. Ductility and toughness, crucial for wire drawability, are found to be reduced, despite higher ultimate strength. Slower furnace cooling is seen to result in smaller sensitized zones compared to air quenching, suggesting a pivotal role of cooling rate in sensitization control. The findings provide insights into optimize heat treatment parameters and Cu content limits, balancing mechanical performance and maintaining drawability for enhanced scrap steel recycling in tire production.

copper↗
DOE OSTI2024

Environmental barrier coatings on SiC without a silicon bond coating: oxidation resistance, failure modes, and future improvements

Environmental barrier coatings (EBCs) are used to mitigate chemical reactions between SiC ceramic matrix composite (CMC) components and the H 2 O in combustion gas in turbine hot sections. CMCs are currently temperature-limited by the Si-bond coating, which melts at ~ 1414 °C. This work explores EBCs where the bond coating was removed to achieve higher operating temperatures. Various versions of enhanced roughness SiC were utilized to improve EBC adhesion to the substrates prior to 1 h furnace cycle testing in steam at 1250–1425 °C. The enhanced SiC roughness resulted in short coating lifetimes as the roughness was oxidized away with SiO 2 formation. Further, isothermal furnace exposures at 1400–1600 °C showed Yb 2 Si 2 O 7 /Yb 2 SiO 5 EBC microstructural changes, resulting in premature debonding from the substrates. Finally, this work provides baseline requirements for the development of both next-generation EBCs and bond coating strategies to overcome the current limitation of the Si-bond coating melting temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Experimental study and demonstration of pilot-scale, dry feed, oxy-coal combustion under pressure

In this paper, we discuss how pressurized oxy-combustion is a promising technology for low-carbon, fossil fuel utilization. It has the potential of improved efficiency and economics compared with conventional atmospheric pressure oxy-combustion. Washington University in St. Louis has proposed a new pressurized oxy-combustion process, namely Staged Pressurized Oxy-Combustion, which has the potential to improve further the plant efficiency, operational flexibility, and economics. This process burns pulverized coal in a pressurized, oxy-combustion environment, which has not been demonstrated in a pilot-scale system before. To address this gap, a 100 kWth pressurized oxy-combustion facility was designed and constructed. This facility has a unique burner and furnace design featuring a co-axial, low-mixing flow field, which is drastically different from conventional coal-fired boiler designs where strong mixing is sought by introducing swirl or recirculating flows. This work aims to present the first pilot-scale experimental results of a dry-feed, pressurized oxy-combustion system. The tests focused on exploring flame stability and shape, char burnout, and fine particulate matter formation. Testing results suggest that the burner has excellent flame stability. The flame shape is consistent with the design philosophy and agrees with large eddy simulations. Importantly, complete char combustion can be achieved with an oxygen mole fraction in the flue gas of only 0.8%, as opposed to a required value of ~3% for conventional atmospheric pressure air-fired or oxyfuel combustion, which reduces the costs of both oxygen generation upstream and oxygen removal downstream. The testing results show promise for dry-feed, pressurized oxy-combustion, and the new burner and furnace design.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Toward a tunable fabrication of multifunctional iron-aluminum spinels via solution combustion synthesis: The effects of fuel, heating mode, and Fe:Al precursor ratio

The solid solutions of iron and aluminum spinels (hercynite, maghemite, magnetite, and γ-alumina) are promising materials for emerging technologies such as solar thermochemical fuel production and clean dehydrogenation of fossil fuels. Solution combustion synthesis (SCS) is an attractive technique for the fabrication of these materials as it has been used for synthesis of many nanoscale oxides. However, the design space of SCS is large with many synthesis parameters affecting the properties of the combustion products. To optimize the SCS of these materials, it is important to determine which parameters yield the best properties. In the present work, FeAlO x nanocomposites were obtained by SCS using iron nitrate and aluminum nitrate as precursors and oxidizers. Two fuels (citric acid and glycine), three Fe:Al molar ratios (1:2, 1:1, and 2:1) in the precursors, and three heating modes (hotplate, muffle furnace, and microwave oven) were compared. The products were characterized by X-ray diffraction analysis, scanning electron microscopy, Brunauer-Emmett-Teller surface area analysis, and laser diffraction particle size analysis. The fuel used had the largest impact on the combustion behavior and hence the material properties. The high combustion temperature of glycine allowed for the formation of an FeAl 2 O 4 /Fe 3 O 4 solid solution, while the lower-temperature combustion of citric acid yielded Al-substituted γ-Fe 2 O 3 with high amorphous content. With citric acid, the specific surface area as high as 200 m 2 /g was achieved. The effect of Fe:Al precursor ratio was clearly seen in variations of the lattice parameter, which demonstrated the ability to tune the phase composition. The heating mode had minor effects on material properties, but some differences were observed. As a result, all products obtained by SCS in a microwave oven had low specific surface areas compared to those obtained with a hotplate and a muffle furnace.

Alumina↗
DOE OSTI2024

Dielectric and magnetic properties of microwave-absorbing FeAl x O y catalysts fabricated via solution combustion synthesis

Iron-based alumina (FeAl x O y ) nanocomposites are microwave-absorbers and catalysts, which makes them promising for emerging microwave-assisted thermocatalytic technologies. Solution combustion synthesis (SCS) has been used to synthesize FeAl x O y powders, and prior work has demonstrated that adjusting SCS parameters significantly changes phase composition and specific surface area of the products. However, it is unclear how synthesis parameters affect their microwave-absorbing properties, which are essential for optimizing microwave-assisted technologies. To address this challenge, in the present work, twelve different FeAl x O y products were synthesized at different combinations of the SCS parameters such as two fuels (citric acid and glycine), two heating modes (hotplate and muffle furnace), and three Fe:Al molar ratios (2:1, 1:1, 1:2). Dielectric and magnetic properties of the products were characterized using a network analyzer and a vibrating sample magnetometer. Based on the measured permittivity and permeability, penetration depth and reflection loss were calculated as a function of frequency and bed thickness. The products were heated by microwaves at 2.45 GHz and then examined with X-ray diffraction (XRD) analysis. For all products, the magnetic saturation was lower than for bulk iron oxides because of the small crystallite size and aluminum substitution. The use of glycine induced high dielectric losses and enabled fast microwave-heating rates compared to citric acid. Higher Fe:Al ratio also led to higher dielectric and magnetic losses. With glycine fuel, SCS in a furnace induced larger penetration depth and lower microwave absorption than SCS on a hotplate. The minimization of reflected power was more sensitive to the thickness of the product bed than to the frequency of the electromagnetic field. Post-heating XRD analysis revealed different phase transformations in the FeAl x O y powders depending on the SCS parameters. As a result, an FeAl x O y material, synthesized via incipient wetness impregnation, lacked magnetic losses and did not heat well as compared to the SCS products.

Combustion synthesis↗
DOE OSTI2026

Elucidating key reducing species beyond ions in hydrogen plasma smelting reduction of iron ore

Hydrogen plasma smelting reduction (HPSR) of iron ore has attracted significant attention over the past decade due to its high-temperature operation, rapid plasma mediated reduction kinetics, and simpler density-based separation of molten iron product, compared to H2-based solid-state reduction. All of these attributes enable processing of low-grade ores for downstream use in electric-arc furnaces, as virgin iron with low gangue content is required for high quality steel and improved furnace operation. While positive ions exist within the plasma arc, this work demonstrates that near the anodic ore surface, hydrogen radicals and vibrationally excited hydrogen species dominate and their densities correlate well with observed reduction rates. Species concentrations in the transferred plasma arc and at the plasma-ore interface are evaluated using coupled thermal plasma and near-wall non-equilibrium plasma models. The thermal plasma model is validated against experimental voltage data and spectroscopic measurements of plasma temperature and density for varying current inputs. Modeling of the near surface thermochemical non-equilibrium and micrometer scale anode sheath layer reveals, in addition to the expected H + , significant concentrations of ArH + and H$^+_3$ ions, typically not observed in thermal plasmas under thermodynamic equilibrium. Our results show that the inverted sheath structure at the anodic ore surface strongly suppresses reactive positive ion fluxes, while non-equilibrium electron-impact processes generate abundant hydrogen radicals and vibrationally excited species. These findings highlight the critical role of non-equilibrium effects in hydrogen arc-driven iron ore reduction and advance understanding beyond prevailing hypotheses centered on hydrogen ion-driven mechanisms.

08 HYDROGEN↗
DOE OSTI2020

The impact of behavioral and geographic heterogeneity on residential-sector carbon abatement costs

Analyses of monetary and emissions savings from residential efficiency upgrades usually neglect behavioral differences between consumers. Variations in behavior are frequently large: 13% of the U.S. population sets thermostats for cooling at 20 °C (68 °F) or lower and 15% at 25.5 °C (78 °F) or higher. Efficiency analyses should account for behavioral heterogeneity as well as variations in climate and housing characteristics. We model energy and economic savings of efficiency upgrades for U.S. single-family detached houses, accounting for differences in thermostat settings, climate zone, fuel prices, and home characteristics. We consider five efficiency interventions: wall insulation, attic insulation, air sealing, high-efficiency furnaces, and high-efficiency air conditioners. Energy and economic savings vary widely by consumer; the average net present value for wall insulation is $3,020 United States Dollar (USD), but considering heterogeneity, it has a 10th percentile value of -$231 and 90th percentile value of $5,000. Neglecting heterogeneity, technology upgrades can be prioritized from lower to higher carbon abatement costs: air conditioners, wall insulation, furnace, air sealing, and attic insulation. Accounting for heterogeneity reorders this prioritization, and consumer-specific conditions affect mitigation costs such that technologies are mixed in with one another and are no longer arranged one after another. These results indicate that interventions to improve efficiency should consider differences between consumers.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

CO 2 conversion to syngas via electrification of endothermal reactors: Process design and environmental impact analysis

CO 2 utilization via reverse water gas shift (rWGS) reaction has been proposed as a path to the sustainable utilization. Here this work presents a detailed process modelling study where steam methane reforming (SMR) generated hydrogen was combined with rWGS to produce syngas (CO + H 2 ) with various hydrogen-to-carbon oxide ratios. To further decrease CO 2 emissions that may offset the benefits of CO 2 converted in rWGS, electrification of endothermal reactors, both SMR and rWGS was considered where CO 2 emitting fuel burning in the furnace was replaced by the emerging ohmic (resistive) heating. Material and energy inventory obtained from process design calculations was used to perform Life Cycle Analysis (LCA) to calculate environmental impacts of CO 2 consumption and reactor electrification. The results showed that greenhouse gas emissions, in CO 2 kg equivalent, were the lowest when both SMR and rWGS were heated using wind-generated electricity, decreasing from 25 to 10 kg CO 2 equivalent for H 2 :CO = 2:1 while the conventional electricity mix used for furnace electrical heating across the board of scenarios generated highest environmental impacts, much higher than those that used natural gas as fuel. Process economics calculations suggested that, when both SMR and rWGS were electrically heated, the process only showed product syngas cost parity with the conventional fuel heated design when electricity cost was ~$0.008/kWh. This suggests that CO 2 utilization scenarios involving process electrification need to be carefully considered from the total design perspective so they do not produce more greenhouse gases than in conventional non-electrified scenarios.

42 ENGINEERING↗
DOE OSTI2023

Reviewing flexibility in industrial electrification: Focusing on green ammonia and steel in the United States

The renewable energy transition in the power sector involves a paradigm shift for flexibility. Flexible demand is more attainable than before, while supply flexibility faces new constraints due to the increased share of variable renewable resources. Increased demand flexibility can allow less use of peaking power plants and avoid need for additional capacity. Industrial flexibility could be especially interesting in this regard, as industrial customers are larger on average than other customers and have typically provided the largest share of demand response in the United States. We consider industrial demand, studying characteristics of flexible industrial loads. We then examine the dynamics of change occurring around industrial load flexibility by focusing on two case studies: green ammonia and steel production via electric arc furnaces. Electric arc furnace steel production is an important component of current demand response programs, whereas green ammonia and green fuels offer new paradigms for flexibility. We analyze the structure and functions of the technological innovation systems of load flexibility in those two industries via interviews with twenty-two stakeholders. Here, we conclude that in the United States these technological innovation systems are not well-functioning for industry in general or for steel, but do seem to be present for green ammonia. Additionally, explicit connections between scope two greenhouse gas emissions (those from purchased energy) and flexibility are lacking, and likewise industry stakeholders do not appear to make a connection between decarbonization and load flexibility, thus flexible demand is not viewed as a tool in industrial decarbonization.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Additive manufacturing of AISI M2 tool steel by binder jetting (BJ): Investigation of microstructural and mechanical properties

The presented research demonstrates for the first time the successful processing of AISI M2 tool steel by binder jetting, a promising additive manufacturing technique capable of producing complex shapes with minimal residual stresses and isotropic properties. The optimal printing parameters were explored by varying processing parameters such as the binder saturation (45 %–105 %), binder set time (0 to 10 s), targeted bed temperature (50–60 °C), oscillator (2600–2750 rpm), recoater (20–28 mm/s), and roller speeds (200–300 rpm). Microstructural characterization and evaluation of mechanical properties of binder jetted parts were performed using x-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) to study their chemical composition, powder morphology, microstructure, carbide morphologies, relative density, hardness, compressive strength, and ductility. Two powder sizes (5 and 10 μm) were used, and sintering was performed at varying temperatures (1270, 1280, and 1300 °C) and durations (60 and 120 min), followed by a furnace, air, and water cooling. An optimum hardness of ~970 HV was obtained when parts were sintered at 1270 °C for 60 min, followed by water quenching. Impressive compressive strength of ~ 3580 MPa was observed in the sample sintered at 1280 °C for 60 min duration, followed by air cooling. Furnace-cooled parts showed the highest density of ~95 %, whereas the relative density of air- and water-cooled parts varied between ~91 to 93.50 %, respectively. The microstructure of sintered samples revealed the formation of M 6 C stable carbide, M 2 C metastable carbide, MC as a secondary carbide, and a-Fe matrix, which contributed to the observed increase in mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Electrochemical chlor-iron process for iron production from iron oxide and salt water

The iron and steel industry accounts for ~8% of global greenhouse gas emissions. Electrochemical reduction of iron ore to metal for electric arc furnaces can enable sustainable steel production, but existing electrochemical processes require expensive capital or electrolytes. Here we report a low-temperature, electrochemical cell that consumes low-cost and abundant iron oxide and aqueous sodium chloride, while co-producing sodium hydroxide and chlorine. Industrially relevant current densities and Faradaic efficiencies for iron production were demonstrated, with 94% selectivity to iron metal at an applied current density of 200 mA cm –2 . Freestanding films of phase-pure iron were formed after 4h of continuous, stable electrolysis. The process can lead to levelized costs of iron that are competitive with iron produced in fossil-fuel-powered blast furnaces, and the co-produced sodium hydroxide can be used for CO 2 capture from the air or ocean, creating a net-negative-emission process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗