Greener Steel Production Requires More Electrochemical Engineers

In the 1800s, aluminum was considered more valuable than gold or silver because it was so expensive to produce the metal in any quantity. Thanks to the Hall-Héroult smelting process, which pioneered the electrochemical reduction of aluminum oxide in 1886, electrochemistry advancements made aluminum more available and affordable, rapidly transforming it into a core material used in the manufacturing of aircraft, power lines, food-storage containers and more.

As society mobilizes against the pressing climate crisis we face today, we find ourselves seeking transformative solutions to tackle environmental challenges. Much as electrochemistry modernized aluminum production, science holds the key to revolutionizing steel and iron manufacturing.

Electrochemistry can help save the planet

As the world embraces clean energy solutions such as wind turbines, electric vehicles, and solar panels to address the climate crisis, changing how we approach manufacturing becomes critical. Traditional steel production—which requires a significant amount of energy to burn fossil fuels at temperatures exceeding 1,600 °C to convert ore into iron—currently accounts for about 10 percent of the planet’s annual CO₂ emissions. Continuing with conventional methods risks undermining progress toward environmental goals.

Scientists already are applying electrochemistry—which provides direct electrical control of oxidation-reduction reactions—to convert ore into iron. The conversion is an essential step in steel production and the most emissions-spewing part. Electrochemical engineers can drive the shift toward a cleaner steel and iron industry by rethinking and reprioritizing optimizations.

When I first studied engineering thermodynamics in 1998, electricity—which was five times the price per joule of heat—was considered a premium form of energy to be used only when absolutely required.

Since then the price of electricity has steadily decreased. But emissions are now known to be much more harmful and costly.

Engineers today need to adjust currently accepted practices to develop new solutions that prioritize mass efficiency over energy efficiency.

In addition to electrochemical engineers working toward a cleaner steel and iron industry, advancements in technology and cheaper renewables have put us in an “electrochemical moment” that promises change across multiple sectors.

The plummeting cost of photovoltaic panels and wind turbines, for example, has led to more affordable renewable electricity. Advances in electrical distribution systems that were designed for electric vehicles can be repurposed for modular electrochemical reactors.

Electrochemistry holds the potential to support the development of clean, green infrastructure beyond batteries, electrolyzers, and fuel cells. Electrochemical processes and methods can be scaled to produce metals, ceramics, composites, and even polymers at scales previously reserved for thermochemical processes. With enough effort and thought, electrochemical production can lead to billions of tons of metal, concrete, and plastic. And because electrochemistry directly accesses the electron transfer fundamental to chemistry, the same materials can be recycled using renewable energy.

As renewables are expected to account for more than 90 percent of global electricity expansion during the next five years, scientists and engineers focused on electrochemistry must figure out how best to utilize low-cost wind and solar energy.

The core components of electrochemical systems, including complex oxides, corrosion-resistant metals, and high-power precision power converters, are now an exciting set of tools for the next evolution of electrochemical engineering.

The scientists who came before have created a stable set of building blocks; the next generation of electrochemical engineers needs to use them to create elegant, reliable reactors and other systems to produce the processes of the future.

Three decades ago, electrochemical engineering courses were, for the most part, electives and graduate-level. Now almost every institutional top-ranked R&D center has full tracks of electrochemical engineering. Students interested in the field should take both electroanalytical chemistry and electrochemical methods classes and electrochemical energy storage and materials processing coursework.

Although scaled electrochemical production is possible, it is not inevitable. It will require the combined efforts of the next generation of engineers to reach its potential scale.

Just as scientists found a way to unlock the potential of the abundant, once-unattainable aluminum, engineers now have the opportunity to shape a cleaner, more sustainable future. Electrochemistry has the power to flip the switch to clean energy, paving the way for a world in which environmental harmony and industrial progress go hand in hand.

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