Iron oxide was electrochemically split into iron and oxygen gas in molten Na(2)CO(3)-K(2)CO(3) at 750 degrees C using a solid iron oxide cathode and a Ni10Cu11Fe alloy inert anode. Fe(2)O(3) was electrochemically reduced to Fe on the cathode, releasing oxygen anions into the electrolyte and which were oxidized on the anode to generate O(2). The cathodic current efficiency was as high as 95% and the energy consumption for producing 1 kg iron was 2.87 kWh, only half of the current industrial energy consumption of blast-furnace steel production. Due to the cost-affordable inert anode and the high energy efficiency, the method demonstrated in this work shows promise as a practical "green" iron production process. (C) 2011 Elsevier B.V. All rights reserved.
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