Critical STEP advances for sustainable i

The production of iron through carbothermal reduction has been a cornerstone of industrial technology but contributes significantly to greenhouse gas emissions. This study addresses the pressing need for a sustainable, CO2-free process in iron production through the STEP (Sustainable Electrochemical Technology for iron Production) method, which utilizes the electrochemical reduction of iron oxides in a lithium carbonate medium. We systematically analyze the electrochemical parameters critical for achieving high coulombic efficiency and low electrolysis potentials, which are essential for sustainable iron generation. Our methodology includes a new analytical approach to ensure the purity of produced iron and identifies optimal configurations for cathodes, anodes, and electrolytes. The findings demonstrate that the electrochemical reduction of iron (III) oxide yields iron with efficiencies approaching 100%, thus providing a feasible and eco-friendly alternative to traditional methods. This advancement not only enhances the economic viability of iron production but also mitigates detrimental environmental impacts associated with carbon dioxide emissions. The results of this research position the STEP Iron process as a significant advancement toward sustainable metal production. This document serves as supplementary information that details the experimental setup, methodologies employed, and key electrochemical findings supporting the STEP Iron process.