Penn State DuBois and DuBois-based Metaltech, a powdered metal manufacturer, recently announced their partnership for a research initiative focused on next-generation energy storage.
The initiative will develop sponge iron electrodes for use in iron-air batteries by repurposing a byproduct of steelmaking called mill scale. Mill scale usually typically contains approximately 70 percent iron along with iron oxides and contaminants like oils and lubricants.
“Recycling mill scale into sponge iron for battery electrodes not only addresses an environmental challenge but also adds value to a waste product,” Ramakrishnan Rajagopalan, Penn State DuBois professor of engineering, said. “This project gives our students hands-on experience with advanced manufacturing and energy storage solutions.”
Iron-air batteries use iron as the negative electrode paired with an air-based positive electrode in an alkaline electrolyte. They are a cost-effective and environmentally friendly option for large-scale energy storage. Metaltech uses a hydrogen-based reduction process to produce sponge iron.
Engineering staff from Metaltech and Penn State DuBois faculty and students will work together. The researchers will create sponge iron electrodes from mill scale. Using a direct reduction process that removes oxygen from iron oxides at high temperatures, mill scale can be converted into high-purity sponge iron.
The 2025 Manufacturing PA Innovation Program awarded the project a $70,000 grant.