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New Process Takes Energy From Coal Without Burning It

rtoz writes "Ohio State students have come up with a scaled-down version of a power plant combustion system with a unique experimental design--one that chemically converts coal to heat while capturing 99 percent of the carbon dioxide produced in the reaction. Typical coal-fired power plants burn coal to heat water to make steam, which turns the turbines that produce electricity. In chemical looping, the coal isn't burned with fire, but instead chemically combusted in a sealed chamber so that it doesn't pollute the air. This new technology, called coal-direct chemical looping, was pioneered by Liang-Shih Fan, professor of chemical and biomolecular engineering and director of Ohio State's Clean Coal Research Laboratory."

46 of 365 comments (clear)

  1. Scaling is the Key! by Irate+Engineer · · Score: 4, Insightful

    Sounds nice, except for the 'combusted in a sealed chamber' bit. How is this going to scale up so they can feed 100 tons/hr through the plant cycle? That is the question.

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    1. Re:Scaling is the Key! by Spy+Handler · · Score: 5, Interesting

      just build it bigger!

      Or if that can't be done economically, just build millions of little ones!

      Oh that's not economically feasible either because each one requires a lot of labor to build? Hmm.... *thinks*

      Ok let's just forget about the whole thing and go nuclear.

    2. Re:Scaling is the Key! by vidnet · · Score: 4, Interesting

      The part that worried me was more the fact that CO2 was still produced, it was just contained within the chamber (the benefit of their technique seemed to just be less/no air space required in the chamber).

      Sequestering CO2 is not simple, and is currently done mostly by pumping it into used oil fields. It's not certain whether these costs were factored in.

    3. Re:Scaling is the Key! by MBCook · · Score: 4, Interesting

      Coal is 84% carbon, 10% oxygen, 4% hydrogen, and 2% nitrogen (or so). Short of nuclear fission or fusion, you're going to get carbon and oxygen out of it no matter what you do.

      The question is how much energy you get out. If this process were twice as efficient (in terms of CO2 per MW) then it would still be a worthwhile improvement wouldn't it?

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    4. Re:Scaling is the Key! by icebike · · Score: 3, Informative

      Sounds nice, except for the 'combusted in a sealed chamber' bit. How is this going to scale up so they can feed 100 tons/hr through the plant cycle? That is the question.

      The key to the technology is the use of tiny metal beads to carry oxygen to the fuel to spur the chemical reaction. For CDCL, the fuel is coal that’s been ground into a powder, and the metal beads are made of iron oxide composites. The coal particles are about 100 micrometers across—about the diameter of a human hair—and the iron beads are larger, about 1.5-2 millimeters across. Chung likened the two different sizes to talcum powder and ice cream sprinkles, though the mix is not nearly so colorful.

      The coal and iron oxide are heated to high temperatures, where the materials react with each other. Carbon from the coal binds with the oxygen from the iron oxide and creates carbon dioxide, which rises into a chamber where it is captured.

      They ran this for 9 days straight. They only stopped because they were tired. Scaling it up probably is not that much of a problem.
      The bigger problem might be obtaining both the fuel and the oxidizers in quantity economically.

      Coal powered that finely would be rather dangerous, because it has so much surface area. Exposure to air, any spark could set it
      off. Handling it would require special care never to let it flow around or accumulate around the crushers. They might have to
      make it in a slurry just for safety, then waste more heat drying it before use.

      TFA shows them handling bottles of it, and even then they are wearing masks.

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    5. Re:Scaling is the Key! by toejam13 · · Score: 3, Informative

      It isn't expensive when all of the senators and representatives from coal burning states insert major tax credits (read: corporate welfare) into bills to pay for such boondoggles. Eventually, such things get passed and we all pay for it.

      You should read up on how the federal government subsidies coal liquefaction. It is a complete and total scam.

    6. Re:Scaling is the Key! by Anonymous Coward · · Score: 5, Funny

      Maybe we should start burning C-level executives instead of coal.

    7. Re:Scaling is the Key! by trout007 · · Score: 4, Informative

      You are forgetting the other part of the reaction. Air is 78% Nitrogen and 21% Oxygen. In this reaction the Iron removes the Oxygen from the air before it gets into the reactor. So no Nitrogen in the reactor means NOx and no Nitrogen gas to remove from the waste stream.

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    8. Re:Scaling is the Key! by icebike · · Score: 5, Interesting

      Sequestering CO2 is not simple, and is currently done mostly by pumping it into used oil fields. It's not certain whether these costs were factored in.

      Sequestering it is a lot simpler if you can simply draw if off the top of the CLOSED chamber rather than trying to scrub it out of the stack.
      You've got half the battle won already.

      What to do with it long term is another problem. But its a problem you would have anyway, so having the CO2 handed to you all
      contained is better than where we are today.

      Besides coal ash, it appears CO2 is the only by-produce that is not recycled back into the feed-stock.

      But, hey, Clean Coal stories have to be knocked down immediately. We can't have it prove even partially successful under any
      circumstance. /rollseyes.

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    9. Re:Scaling is the Key! by Irate+Engineer · · Score: 4, Interesting

      This is the kind of science that will save us from Global warming. I know how grand Solar and wind seem grand, but they aren't powering shit yet.

      Wind is powering all sorts of "shit" in Europe. Denmark is pushing about 28% penetration of wind into their power market and many of the surrounding countries have penetrations of 10-20%. And they are building a hell of a lot of offshore wind farms.

      Just because the U.S. is slow to get off its ass doesn't mean the rest of the world is.

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    10. Re:Scaling is the Key! by Charliemopps · · Score: 3, Informative

      Sequestering CO2 is easy. You just don't have a clue how it works. The CO2 is pumped into abandon oil fields at VERY high pressures. This actually results in a return of the field to oil production, as the CO2 forces out more oil. The hydrostatic pressure at that depth is so great that it forces the CO2 into its liquid form. It's not going to suddenly escape to the surfaces, it's miles down and under unfathomable pressure. If we had an earthquake strong enough to crack that, we'd have far more to worry about. Like the really nasty gasses getting released from natural fissures or the earth splitting asunder.

    11. Re:Scaling is the Key! by hairyfeet · · Score: 4, Insightful

      No matter how you slice it you're still left with an assload of carbon that has to go SOMEWHERE so what are you gonna do with it? Frankly that's always been the problem, what to do with all the waste that is left over. TFA I notice is awful light on the details about what EXACTLY if left after this chemical burning, is it a paste, a gel, powder, maybe i missed it but I couldn't find any clear answer on that.

      But at the end of the day that is still hundreds of tons of waste you are gonna have to put somewhere, the big question is where because as we saw with Yucca flats pretty much any place you pick is gonna have NIMBYs coming out the woodwork so what are you gonna do with it? This is why I've always supported the new nuclear reactors with reprocessing, it lets you re-use as much as possible until the waste is much smaller and has a much lower half life but no matter how you slice it the stuff left over is gonna have to be put somewhere.

      But like coal or hate it we are gonna end up having to use at least some of it because our power needs have gone nowhere but up and this at least sounds like the waste is in solid form instead of gas which will make handling and disposal easier, if not politically then at least physically.

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    12. Re:Scaling is the Key! by tsotha · · Score: 4, Funny

      TFA I notice is awful light on the details about what EXACTLY if left after this chemical burning, is it a paste, a gel, powder, maybe i missed it but I couldn't find any clear answer on that.

      Maybe it's diamonds. Boy, are those Belgian airport thieves going to be pissed.

    13. Re:Scaling is the Key! by ATMAvatar · · Score: 5, Funny

      It wouldn't work, anyways. Bullshit has a lower energy density than coal.

      --
      "They that can give up essential liberty to obtain a little temporary safety deserve neither liberty nor safety."
    14. Re:Scaling is the Key! by multimediavt · · Score: 5, Informative

      Coal powered that finely would be rather dangerous, because it has so much surface area. Exposure to air, any spark could set it off.

      Uh, yoohoo, over here! They already use coal dust in existing coal burning power plants. I think they have the processing handling issues down for that bit. And, there hasn't been a major coal dust accident since 1962.

      BTW, for those that trashed my 'we need to stop burning stuff' comments regarding how we generate energy. THIS is exactly what I meant. Applause for the researchers. If this does scale and proves out, they should get a Nobel for it!

      'Nuf said.

    15. Re:Scaling is the Key! by jd2112 · · Score: 4, Funny

      It wouldn't work, anyways. Bullshit has a lower energy density than coal.

      But coal is a finite resource. Washington DC alone proves there is an unlimited supply of bullshit.

      --
      Any insufficiently advanced magic is indistinguishable from technology.
    16. Re:Scaling is the Key! by hairyfeet · · Score: 3, Insightful

      You joke but there is a reason why China is gonna have 25 new nuclear reactors up and running before we get a single one out of committee and that is because no matter what you propose the NIMBYs will try to cock block. Wind? "It'll spoil our view and kill the birds!" Hydro? "It'll run the flow and hurt the fishies!" No matter what tech you use the NIMBYs will come out and try to cock block you here.

      So I doubt even being made in Ohio with Ohio coal will help, the NIMBYs will come try and cock block anything being built there. I swear listening to the NIMBYs you'd think the power fairy was gonna provide our needs, because they sure as fuck don't want a single thing built.

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    17. Re:Scaling is the Key! by pixelpusher220 · · Score: 4, Insightful

      there is a reason why China is gonna have 25 new nuclear reactors up and running before we get a single one out of committee

      And that reason is quite simply, China does not care about it's people.

      --
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    18. Re:Scaling is the Key! by Tuqui · · Score: 4, Informative

      It's not going to suddenly escape to the surfaces, it's miles down and under unfathomable pressure. If we had an earthquake strong enough to crack that, we'd have far more to worry about.

      If you think that nothing could happen, read about Lake Nyos disaster.

    19. Re:Scaling is the Key! by fluffy99 · · Score: 3, Informative

      As this is chemical, and not combustion, (yes yes, sealed chamber...) it should not take up as nearly as much land as required by current plants. Also, just think of all the job creation all those small power plants will require!!!

      Any chemist will tell you that combustion is a chemical reaction. What's interesting about this process is that oxidized iron is used to provide oxygen to "burn" the coal instead of injecting air into the combustion chamber. Not using air lowers the overall gaseous output you need to deal with and the output is a bit cleaner as you don't have to scrub some of the crap like NOX out. You still get sulfur compounds and the heavy metals you'd see with traditional burning.

    20. Re:Scaling is the Key! by AJWM · · Score: 3, Insightful

      Coal is 84% carbon, 10% oxygen, 4% hydrogen, and 2% nitrogen (or so). Short of nuclear fission or fusion, you're going to get carbon and oxygen out of it no matter what you do.

      Now there's an idea. You'd actually get more energy running the 0.0...whatever percent thorium that's in coal through a fission reactor than you do by oxidizing the carbon.

      --
      -- Alastair
    21. Re:Scaling is the Key! by AmiMoJo · · Score: 3, Insightful

      In principal I have no problem with the government subsidizing energy, just as long as it subsidizes the right stuff. Efficiency improvements and clean energy are fine, gas and nuclear not so much.

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    22. Re:Scaling is the Key! by serviscope_minor · · Score: 4, Insightful

      "Needs of the many outweigh the needs of the few" (ST reference) is the basic theme of China.

      You are forgetting that most of the western world, having industrialised earlier has been through the "let's trash the environment" stage, and after decades of rivers which burn or stink so badly they make a capital city nearly uninhabitable or spills of toxic waste which cause all sorts of nasty deaths, the western countries have solwly and painfully come to the realisation that it's actually not a very good idea to do all that.

      I think this has little to do with cultural values and much to do with industrialisation being difficult and because it is easier to mess things up than not, and therefore comes earlier on in the process.

      Also, it's a product of industrialising countries nort really quite realising how much they can mess stuff up until they experience it.

      --
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    23. Re:Scaling is the Key! by ByteSlicer · · Score: 3, Funny

      Yeah, but it contains a lot of hot air, so you can use that to drive a turbine. Unless they sell it first.

    24. Re:Scaling is the Key! by interkin3tic · · Score: 3, Insightful

      Because it's not that simple. The free market chooses the cheapest route, but that ignores externalized costs. Externalized costs which are still costs to the rest of us. Right now, that cheapest route is coal, and those externalized costs are very high.

      If they raise taxes to implement whatever clean energy you prefer, but prevent climate change, a lot more people will come out ahead on that transaction than lose out. The only reason we're not already doing it is that the few would-be-losers are being astonishingly selfish and short-sighted.

  2. You keep using that word... by Kenja · · Score: 3, Informative

    combust:
    Verb
    1. Consume by fire.
    2. Be consumed by fire.

    --

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    1. Re:You keep using that word... by icebike · · Score: 4, Informative

      A better word might have been "oxidized" but the good professor probably was trying not to confuse the journalism major
      who wrote the story with words too big for their tiny world view.

      Lots of CO2 is produced, but it is retained in the chamber and captured, and oxygen and coal are fed in continuously.
      They operated it for 9 days straight.

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  3. Re: Bullshit by Anonymous Coward · · Score: 5, Funny

    I love reasons! Care to share?

  4. Other factors to consider by SketchOfNight · · Score: 5, Interesting

    How does the lack of pollution from the process compare against that generated from the acquisition of the coal?
      Is it possible/practical to convert an existing coal power plant?
      Is there an appreciable energy/pollution cost to produce the fine powder coal used in the process?
      How much energy is consumed or how much pollution is produced in transporting the coal to the reactor?
      Is the process itself efficient in regards to the energy output when compared against the total energy costs?

    I'm sure there's a lot of other things that don't spring to mind instantly, but I'm certainly not an expert on any of this. Doubts notwithstanding, this is pretty cool.

  5. No emission-less by OzPeter · · Score: 5, Informative

    Its not emission-less. If you read his presentation from 2008 you'll see that the C02 is the byproduct of the reaction that is is used to transfer heat to the steam boiler. The C02 still gets generated as before, just now it can be more readily sequestered - assuming that you want to spend the money on that part of the equation.

    Coal Direct Chemical Looping Retrofit for Pulverized Coal-fired Power Plants with In-Situ CO2 Capture (PDF - but why the hell in this day and age do I need t tell you that? Can't you just look at the link?)

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    1. Re:No emission-less by Raptoer · · Score: 4, Insightful

      Even if you don't sequester the carbon and just put it out a smoke stack you're still at an advantage over normal coal burning. One of the major problems with coal burning is not the CO2, but the fly ash that contains heavy metals and causes respiratory problems. This process allows for those heavy metals to be contained in the coal ash which is kept within the plant. Depending on the concentration of metals in the ash it may be economical to mine the ash.

      Additionally since the CO2 is pure it can be used industrially without having to distill out the nitrogen that you would if you got it from regular burning.

  6. Re:Um, WHY? by foniksonik · · Score: 4, Informative

    There is no burning. Apparently that is the key innovation. The chemical reaction between the coal dust and the rust pellets releases the CO2 in a very controlled manner with the CO2 being separated cleanly rather than mixed up with smoke aka carbon molecules. That must make the CO2 capture much much easier.

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  7. Re: Oh Rly? by pollarda · · Score: 3, Funny

    What Virginia mountains? I don't know what you are talking about, I don't see any....

  8. Re:Like healthy citarettes by Bill,+Shooter+of+Bul · · Score: 4, Insightful

    We already burn a crap load of coal for our electricity. Wouldn't it be great if we worked to make it clean-er ( at least in terms of soot and mercury released into the air)? There isn't much on the horizon that could replace coal over night. We should try to find something will all due haste, but it wouldn't hurt to get the low hanging fruit. Its pretty much what Obama is doing now and its a sensible approach.

    --
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  9. RTFA-ing is the Key! by TubeSteak · · Score: 4, Informative

    The researchers are about to take their technology to the next level: a larger-scale pilot plant is under construction at the U.S. Department of Energy's National Carbon Capture Center in Wilsonville, AL. Set to begin operations in late 2013, that plant will produce 250 thermal kilowatts using syngas.

    From 25 kw to 250kw
    Sounds like they're scaling it up.

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    1. Re:RTFA-ing is the Key! by Nethemas+the+Great · · Score: 5, Informative

      RTFA, the process is designed to work with two of the already commonly available forms of fuel to power companies, crushed coal and coal derived syngas.

      --
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  10. Re:Um, WHY? by Anonymous Coward · · Score: 5, Informative

    Why not just burn coal and air in an oven and capture the CO2

    Because only part of the air gets converted to CO2. Most of the air is nitrogen, and only ~21% is oxygen. Even if you have complete conversion of the oxygen to CO2 (not going to happen), you'd end up with exhaust gas that's mostly nitrogen with some carbon dioxide mixed in. This nitrogen/carbon dioxide mix is difficult to deal with. To do anything with the CO2 you'd have to separate it from the nitrogen and residual oxygen, which gets complicated and expensive.

    The hard part is surely the CO2 capture, not the burning.

    Exactly. This new method attempts solve that by separating the CO2 generation stage from the air-using stage. If you could effectively separate them, you'll get a pure CO2 stream in one half of the reactor (which if you can keep closed you can pump off into storage tanks) and you'll keep the nitrogen/depleted-oxygen mix in the other half of the reactor, away from your pure CO2.

    The way it works is to use iron oxide as an oxygen shuttle. The iron oxide pellets grab oxygen from the air half of the reactor, and are then transferred as a relatively gas-free solid to the coal half of the reactor, where they give up their oxygen to produce a relatively pure stream of CO2. The pellets are then separated from the coal ash and transferred as a relatively gas-free solid back to the air half of the reactor, where they are recharged with oxygen. If you engineer it right, you could conceivably make it a continuous feed operation, where you shuttle the iron oxide beads back and forth through airlocks, keeping most of the CO2 in the sealed reactor where it can be pumped off as a comparatively pure gas.

  11. Re:Efficiency is the key flaw by viperidaenz · · Score: 5, Informative

    It's 2.5% less efficient than a normal coat power station.
    Normal plant: 36.43%
    This thing: 33.93%

    It actually produces 10% more power from the turbine, but the supporting pumps, fans and compressors need to be powered.

  12. Re:Bullshit by hedwards · · Score: 4, Insightful

    Coal isn't clean though. This would clean up the side of the equation where you're burning it. But, it would do absolutely nothing for the mining aspect of it. Which is a huge mess as it stands. If you want to burn things for energy, you're better off starting with something like trees which are mostly carbon neutral as it is.

    Sure, it's technically clean if you ignore the incredible damage that it reeks on the landscape, but it's definitely not clean in a practical sense.

  13. Re:Um, WHY? by multimediavt · · Score: 4, Informative

    There is no burning. Apparently that is the key innovation.

    Coal is oxidized to produce CO2 and heat. That's "burning", regardless of whether you use air or iron oxides as the oxidizer.

    Ummm, sorry, I'm gonna have to go with the Ph.D. in Chemistry on this one buddy, and he says it's NOT burning. I would not call your comment, Informative. Uninformed, but not informative. Ooo, that's a t-shirt right there...

  14. Know how I know you didn't read the article? by Weaselmancer · · Score: 4, Interesting

    From TFA:

    No other lab has continuously operated a coal-direct chemical looping unit as long as the Ohio State lab did last September. But as doctoral student Elena Chung explained, the experiment could have continued.

    “We voluntarily chose to stop the unit. We actually could have run longer, but honestly, it was a mutual decision by Dr. Fan and the students. It was a long and tiring week where we all shared shifts,” she said.

    Fan agreed that the nine-day experiment was a success. “In the two years we’ve been running the sub-pilot plants, our CDCL and SCL units have achieved a combined 830 operating hours, which clearly demonstrates the reliability and operability of our design,” he said.

    His entire staff of grad students manned the thing and kept feeding it coal for a week and it ran nonstop the whole time, and could have kept going. So this appears to be a solved problem.

    --
    Weaselmancer
    rediculous.
  15. Re:Pure oxygen.. by trout007 · · Score: 4, Informative

    I emailed the authors after I wrote that and they emailed me back quickly. They said the only NOx comes from the Nitrogen in the Coal. None is produced in the combustion of Iron.

    This would significantly lower the scrubbing requirements and cost.

    --
    I love Jesus, except for his foreign policy.
  16. Actually capturing is the key by gargleblast · · Score: 4, Informative

    Actually capturing is the key. A carbon capturing plant is always going to be less efficient than a non-capturing plant. Try looking at it this way:

    36.43% Non-capturing plant
    29.14% Post-combustion capturing plant (36.43/1.25)
    33.93% This thing

  17. Coal is an amazing source of power by Grayhand · · Score: 4, Interesting

    For a fuel that requires little or no processing it's extremely energy dense. Ultimately the problem wouldn't be with the process but the budget minded power companies. There's a reason "clean coal" is like bigfoot, largely a myth. Clean coal would cost more money reducing profits. It's the reason the industry doesn't remove mercury and coal dust from the exhaust, reduced profits. They even had a government mandate and the still waited until the deadline and are now saying it's too hard. The process can trap 99% of the CO2, the trick is keeping the power companies from not releasing it into the atmosphere to save money. White Diesel is a great source of fuel and second only to natural gas for being a clean fossil fuel but it involves stripping of the CO2 and you are faced with the same problem. Sequestration isn't as simple as it sounds. Compressing huge amounts of CO2 gas takes energy and the underground storage areas don't tend to be near power plants. When you start burning more coal just to store the CO2 from the last batch the efficiency goes way down. If the existing plants had been positioned and built with all this in mind we wouldn't have all these problems. Now there are no cheap and easy solutions. Personally I prefer using algae or greenhouses to store the CO2. Try this approach, pump the CO2 into large cheap greenhouses that grow Kenaf, it's related to hemp but totally legal and interchangeable with industrial hemp. Use as much as industry needs for fiber and seed oil then turn the rest into biochar, a good one to read up on if you aren't familiar. The char can be mixed with farmland improving the soil and it'll absorb the excess fertilizer reducing run off and reducing the amount needed to grow food. The carbon is stored for thousands of years, if not millions. The power companies get to make extra money off the Kenaf and they greatly reduce the CO2 and mercury released. The Mercury will get trapped in the char and the CO2 will be stored as solid carbon. These days they try to solve everything with technology when mother nature has been doing it for billions of years.

  18. Re:Bullshit by Anonymous Coward · · Score: 3, Interesting

    I've always been confused by "Carbon Neutral" propaganda. For example, we have always had the same amount of carbon in the environment. Just over the years it's been sequestered into oil/coal/etc. However, now if it's been out of commission for thousands of years and it's somehow out of the equation. So burning oil/coal/etc is just normalizing the balance.

    No, no, no! You missed the biggest sink for carbon. The one that is orders of magnitude greater than all the others put together: limestone (60 million gigatons vs the 720 gigatons in the atmosphere and the 38,000 gigatons in the oceans). If you think that normalizing the balance with all of the carbon that has been taken out of the environment is a good thing, then you must be from Venus.

  19. They still burn the coal by Neil+Boekend · · Score: 3, Interesting

    They just burn it with pure oxygen instead of with air. The innovation, and it is an innovation IMHO, is that they used iron to capture and transfer the oxygen. This prevents the forming of NOx, which is a good thing.
    This means they can burn the coal hotter without emitting dangerous amounts of NOx.
    1. They let iron pellets rust. Or they buy rust in the first place.
    2. They put the rust pellets into the chamber with coal dust.
    3. They ignite the mixture (this requires a bit more heat than usual burning. At least 1566 ÂC or 2850.8 F)
    4. The coal dust pulls the oxygen out of the rust and binds it with the carbon into quite pure CO2.
    5. Heat (a lot of it)
    6. Use the heat in a default thermoelectric power plant.
    7. The pellets can rust again, to capture oxygen.
    8. ...
    9. Profit.

    If they would combine it with an iron smelting plant then the energy required in step 4 to pull the oxygen out of the rust would not be wasted. Then the iron pellets are one of the end results. Of course, then you'd have to emit step 7.

    To me this seems familiar. If I am correct this is the way Thermite works, just with aluminium powder instead of coal dust.

    --
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