Currently, blast furnace-produced pig iron remains the mainstream, with a mature process and large-scale production lines, emitting 1.8–2.2 tons of CO₂ per ton of iron. The sulfur content is 0.02–0.05%, and must be removed through converter refining. In recent years, the technology for producing hydrogen iron through hydrogen reduction has developed rapidly.  By using hydrogen for direct reduction at 800–1200°C, carbon emissions are significantly reduced, and the product is sponge iron (with a metallization rate of 92–96%, S ≤ 0.008%, P ≤ 0.03%). Therefore, there is an urgent need to study the high-purity characteristics of hydrogen iron, to lay the material technology foundation for developing unique products.

High-purity electric iron is obtained using the green electricity one-step method, without the consumption of coke and hydrogen during production.The current preparation methods include three routes: molten oxides, molten salts, and aqueous solutions.Boston Metal in the U.S. and SIDERWIN in the EU have established pilot scale production lines.China is also making synchronous breakthroughs in this field.The challenges in the preparation of electric iron include the service life of the electrode, circulation of the electrolyte solution, and continuous production.The electric iron products is high-purity iron.Based on the technology of electric iron preparation, the technology of specialty cutting-edge steel materials is researched.

High-purity electric iron is obtained using the green electricity one-step method, without the consumption of coke and hydrogen during production.The current preparation methods include three routes: molten oxides, molten salts, and aqueous solutions.Boston Metal in the U.S. and SIDERWIN in the EU have established pilot scale production lines.China is also making synchronous breakthroughs in this field.The challenges in the preparation of electric iron include the service life of the electrode, circulation of the electrolyte solution, and continuous production.The electric iron products is high-purity iron.Based on the technology of electric iron preparation, the technology of specialty cutting-edge steel materials is researched.

The massive accumulation of high-iron red mud generated by the alumina industry represents a significant iron resource that urgently requires efficient extraction. This matter bears critical implications for environmental protection, resource circularity, and the sustainable development of the aluminum industry.

It is imperative to establish integrated iron extraction-material production technology specifically tailored for red mud. This will transform solid waste iron sources into distinctive novel steel materials, thereby achieving triple benefits in environmental protection, resource utilization, and industrial advancement.

The purification of iron remains a persistent theme. With the leadership of Japan and the United States in this field, China has achieved the mass production of 4N high purity iron via both pyrometallurgical and hydrometallurgical processes, and successfully prepared 5N ultrahigh purity iron. The future work focuses on reducing costs, improving efficiency, and achieving the 6N iron and high-purity iron with specific elements of extremely low level (0.01 ppm). Ultra-high-purity iron, adopted as raw materials, functional materials and high-purity substances as well, has been deeply involved into the manufacturing of alloys, electromagnetic components, standard materials and so on. With each advance in purity, the iron recover its nature chemical and physical properties, and its performance in mechanics, electromagnetism, and corrosion resistance undergoes a huge leap, and it opens up a new road map for pure iron.

The purification of iron remains a persistent theme. With the leadership of Japan and the United States in this field, China has achieved the mass production of 4N high purity iron via both pyrometallurgical and hydrometallurgical processes, and successfully prepared 5N ultrahigh purity iron. The future work focuses on reducing costs, improving efficiency, and achieving the 6N iron and high-purity iron with specific elements of extremely low level (0.01 ppm). Ultra-high-purity iron, adopted as raw materials, functional materials and high-purity substances as well, has been deeply involved into the manufacturing of alloys, electromagnetic components, standard materials and so on. With each advance in purity, the iron recover its nature chemical and physical properties, and its performance in mechanics, electromagnetism, and corrosion resistance undergoes a huge leap, and it opens up a new road map for pure iron.

Drawing on the experience of high pure iron purification, the path to high-purity steel is now clear.By establishing a technological system for high-purity steel materials, strength and toughness are simultaneously improved.This leads to breakthroughs in key service characteristic, such as corrosion resistance, wear-resisting property, and fatigue resistance, leading the comprehensive iteration and upgrade of steel materials.

New applications for iron are continuously being explored. Breakthroughs in iron-air battery technology offer inherently safe and cost-effective solutions for power grids and long-duration energy storage, while also consuming vast quantities of iron. Iron is also a key trace element for maintaining human iron stability and ecological balance: iron biofortified corn can synergistically alleviate iron-deficiency anemia and increase crop yields. Furthermore, the interfacial reactivity of zero-valent iron (ZVI) in environmental remediation urgently requires continued technological innovation.