Abstract

A method of making a material for capturing carbon dioxide from the earth's atmosphere, comprises producing an acid and a base with an electrochemical acid-base generator; dissolving a mineral in the acid to produce a mineral rich solution, separating silica from the mineral rich solution to form a silica depleted solution; adding a first portion of the base to the silica depleted solution to remove impurities by precipitation, adding a second portion of the base until ferrous hydroxide (Fe(OH)2) precipitates, then pausing base addition and removing the ferrous hydroxide precipitate from the solution. Then adding a third portion of the base to the iron-depleted solution to precipitate magnesium hydroxide (Mg(OH)2) and/or calcium hydroxide (Ca(OH)2). Then recovering a salt solution and directing the recovered salt solution to the electrochemical acid-base generator to produce a new acid and a new base. The magnesium hydroxide and/or calcium hydroxide may be used to capture and sequester carbon dioxide from a CO2-containing gas (e.g., air) by forming a carbonate or from the ocean by forming bicarbonate.

IPC Classes  ?

• C25B 1/20 - Hydroxides
• C02F 1/461 - Treatment of water, waste water, or sewage by electrochemical methods by electrolysis
• C02F 101/10 - Inorganic compounds
• C02F 103/08 - Seawater, e.g. for desalination
• C25B 1/22 - Inorganic acids
• C25B 9/19 - Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof with diaphragms
• C25B 9/70 - Assemblies comprising two or more cells
• C25B 15/08 - Supplying or removing reactants or electrolytes; Regeneration of electrolytes

Abstract

Methods and systems for producing are disclosed. A method for producing iron, for example, comprises: providing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell; wherein the first anolyte has a different composition than the first catholyte; dissolving at least a portion of the iron-containing ore using an acid to form an acidic iron-salt solution having dissolved first Fe3+ ions; providing at least a portion of the acidic iron-salt solution to the first cathodic chamber; first electrochemically reducing said first Fe3+ ions in the first catholyte to form Fe2+ ions; transferring the formed Fe2+ ions from the dissolution subsystem to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing a first portion of the transferred formed Fe2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal.

IPC Classes  ?

• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
• C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
• C22B 5/00 - General processes of reducing to metals
• C25C 7/02 - Electrodes; Connections thereof
• C25C 7/04 - Diaphragms; Spacing elements

Abstract

Methods and systems for dissolving an iron-containing ore are disclosed. For example, a method of processing and dissolving an iron-containing ore comprises: thermally reducing one or more non-magnetite iron oxide materials in the iron-containing ore to form magnetite in the presence of a reductant, thereby forming thermally-reduced ore; and dissolving at least a portion of the thermally-reduced ore using an acid to form an acidic iron-salt solution; wherein the acidic iron-salt solution comprises protons electrochemically generated in an electrochemical cell.

IPC Classes  ?

• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
• C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
• C22B 5/00 - General processes of reducing to metals
• C25C 7/02 - Electrodes; Connections thereof
• C25C 7/04 - Diaphragms; Spacing elements

Abstract

Methods and systems for producing iron from an iron-containing ore are disclosed. For example, a method for producing iron comprises: providing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell and a dissolution tank; dissolving the iron-containing ore to form an acidic iron-salt solution; reducing Fe3+ ions to form Fe2+ ions and electrochemically generating protons in the first electrochemical cell; circulating solution between the dissolution tank and the first electrochemical cell; transferring formed Fe2+ ions from the dissolution subsystem to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing a first portion of the transferred formed Fe2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal. The methods and systems optionally include removing one or more impurities found in the feedstock.

IPC Classes  ?

• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
• C21B 13/00 - Making spongy iron or liquid steel, by direct processes
• C21C 5/52 - Manufacture of steel in electric furnaces
• C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
• C22B 5/00 - General processes of reducing to metals
• C25B 1/04 - Hydrogen or oxygen by electrolysis of water
• C25B 15/08 - Supplying or removing reactants or electrolytes; Regeneration of electrolytes
• C25C 7/04 - Diaphragms; Spacing elements
• C25C 7/08 - Separating of deposited metals from the cathode
• C25D 3/20 - Electroplating; Baths therefor from solutions of iron

Abstract

Methods and systems for producing iron from an iron-containing ore and removing impurities found in the iron-containing ore are disclosed. For example, a method for producing iron comprises providing a feedstock having an iron-containing ore and one or more impurities to a dissolution subsystem comprising a first electrochemical cell; producing an iron-rich solution, in the dissolution subsystem; treating the iron-rich solution to remove at least a portion of one or more impurities by raising a pH of the iron-rich solution from an initial pH to an adjusted pH thereby precipitating at least a portion of the one or more impurities in the treated iron-rich solution; delivering the treated iron-rich solution to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing at least a first portion of the transferred formed Fe2+ ions to Fe metal; and removing the Fe metal from the second electrochemical cell thereby producing iron.

IPC Classes  ?

• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
• C25C 7/04 - Diaphragms; Spacing elements

Abstract

A method of making a material for capturing carbon dioxide from the earth's atmosphere, comprises producing an acid and a base with an electrochemical acid-base generator; dissolving a mineral in the acid to produce a mineral rich solution, separating silica from the mineral rich solution to form a silica depleted solution; adding a first portion of the base to the silica depleted solution to remove impurities by precipitation, adding a second portion of the base until ferrous hydroxide (Fe(OH)2) precipitates, then pausing base addition and removing the ferrous hydroxide precipitate from the solution. Then adding a third portion of the base to the iron-depleted solution to precipitate magnesium hydroxide (Mg(OH)2) and/or calcium hydroxide (Ca(OH)2). Then recovering a salt solution and directing the recovered salt solution to the electrochemical acid-base generator to

IPC Classes  ?

• C25B 1/20 - Hydroxides
• C02F 1/461 - Treatment of water, waste water, or sewage by electrochemical methods by electrolysis
• C25B 1/22 - Inorganic acids
• C25B 9/19 - Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof with diaphragms
• C25B 9/70 - Assemblies comprising two or more cells
• C25B 15/08 - Supplying or removing reactants or electrolytes; Regeneration of electrolytes
• C02F 101/10 - Inorganic compounds
• C02F 103/08 - Seawater, e.g. for desalination

Abstract

Aspects disclosed herein include a method for stabilizing a lead anode, the method comprising: operating an electrochemical cell comprising performing electrochemical reduction at a first cathode and electrochemical oxidation at a first anode; wherein: the electrochemical cell comprises a first anodic chamber having a first anolyte in contact with the first anode, a first cathodic chamber having a first catholyte in contact with the first cathode, and a first separator separating the first anolyte from the first catholyte; the first anode is a lead electrode; each of the first anolyte and the first catholyte independently comprises aqueous iron cations and aqueous anions; and the first anolyte comprises the aqueous iron cations at a concentration selected from the range of 0.01 M to 0.5 M.

IPC Classes  ?

• C25B 11/042 - Electrodes formed of a single material
• C25B 9/00 - Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
• C25B 9/19 - Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof with diaphragms
• C25B 1/04 - Hydrogen or oxygen by electrolysis of water
• C25B 15/08 - Supplying or removing reactants or electrolytes; Regeneration of electrolytes

Abstract

Included herein are methods of dissolving and purifying an ore containing hematite and/or magnetite iron oxide, the method comprising: thermally reducing a first portion of the ore at sufficient temperature and for a sufficient time to convert a portion of the iron oxide to magnetite to produce high-magnetite ore; thermally reducing a second portion of the ore at sufficient temperature and for a sufficient time to convert a portion of the iron oxide to metallic iron to produce high-metallic ore; first contacting an acid solution with the high-magnetite ore; and then second contacting

IPC Classes  ?

• C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
• C01G 49/06 - Ferric oxide (Fe2O3)
• C25B 9/17 - Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof
• C01G 49/02 - Oxides; Hydroxides
• B03B 7/00 - Combinations of wet processes or apparatus with other processes or apparatus, e.g. for dressing ores or garbage

Abstract

Described herein are various aspects of systems and methods for extracting and isolating re-usable materials from a metallurgical slags such as iron slag, steel slag, blast furnace slag, BOF slag, and/or EAF slag using aqueous acid and base solutions. In some aspects, the acid and base solutions or materials may be produced electrochemically in a salt-splitting acid-base generation (ABG) cell or cell-stack.

IPC Classes  ?

• C21B 3/04 - Recovery of by-products, e.g. slag
• C22B 7/04 - Working-up slag
• C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
• C22B 3/44 - Treatment or purification of solutions, e.g. obtained by leaching by chemical processes
• C22B 21/00 - Obtaining aluminium
• C22B 26/22 - Obtaining magnesium
• C22B 47/00 - Obtaining manganese
• C25B 15/08 - Supplying or removing reactants or electrolytes; Regeneration of electrolytes
• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese

Abstract

Methods and systems for dissolving an iron-containing ore are disclosed. For example, a method of processing and dissolving an iron-containing ore comprises: thermally reducing one or more non-magnetite iron oxide materials in the iron-containing ore to form magnetite in the presence of a reductant, thereby forming thermally-reduced ore; and dissolving at least a portion of the thermally-reduced ore using an acid to form an acidic iron-salt solution; wherein the acidic iron-salt solution comprises protons electrochemically generated in an electrochemical cell.

IPC Classes  ?

• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
• C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
• C22B 5/00 - General processes of reducing to metals
• C25C 7/02 - Electrodes; Connections thereof
• C25C 7/04 - Diaphragms; Spacing elements

Abstract

2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal.

IPC Classes  ?

• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
• C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
• C22B 5/00 - General processes of reducing to metals
• C25C 7/02 - Electrodes; Connections thereof
• C25C 7/04 - Diaphragms; Spacing elements

Goods & Services

Metal hydroxides; carbon neutral materials, namely, calcium oxide, magnesium oxide, and metallurgical fluxes; chemical reagents for metallurgical fluxes; chemical reagents for smelting, melting, foundry, and casting of metal; chemical reagents for carbon sequestration; recycled metal hydroxides; recycled metal oxides; metallurgical fluxes for smelting, melting, foundry, and casting of metal. Metals, alloys, iron and steel; ore-based electrolytic iron; materials of metal for use in carbon capture and/or sequestration; recycled metal compounds, recycled metal solids, and recycled metal powders. Ore treating machines; electrochemical acid generators; ore dissolution reactors; iron plating reactors; ore processing machines; carbon capture and/or sequestration systems and instrumentation, namely, chemical reactors; metallurgical slag recycling reactors. Electrochemical machines for the processing of ores and metallurgical slags; electrochemical machines for the production of ore-based metals from ores and for the processing of metallurgical slags into metallurgical fluxes and recycled metals or metal oxides. Business services, namely, providing business information for the mining and resource industry, mine planning, maintenance scheduling, producing scheduling, equipment scheduling, materials management, quality management. Construction of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags; installation and repair services of equipment used for mine extraction, processing of ores, and recycling of metallurgical slags. Electrochemical processing for iron and steel fabrication to the order and specification of others; custom manufacturing services in the processing of metals, alloys and metallurgical fluxes; custom processing of metal ores to the specification of others; electrochemical processing for carbon capture and/or sequestration; custom manufacturing services using electrochemistry; electrochemical processing for manufacturing carbon capture and sequestration materials; custom manufacturing services in the electrochemical processing of ores and metallurgical slags; custom processing of metallurgical fluxes to the specification of others; custom manufacturing services in the electrochemical recycling of metallurgical slags. Design of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags.

Goods & Services

Metal hydroxides; carbon neutral materials; chemical reagents for metallurgical fluxes; chemical reagents for smelting, melting, foundry, and casting of metal; chemical reagents for carbon sequestration. Metals, alloys, iron and steel; ore-based electrolytic iron; carbon capture and/or sequestration materials; recycled metal compounds, recycled metal solids, recycled metal hydroxides, recycled metal powders and recycled metal oxides; metallurgical fluxes for smelting, melting, foundry, and casting of metal. Ore treating machines; electrochemical acid generators; ore dissolution reactors; iron plating reactors; ore processing systems and instrumentation being ore treating machines; carbon capture and sequestration systems and instrumentation, namely, chemical reactors; metallurgical slag recycling reactors. Electrochemical systems, reactors and instrumentation for the processing of ores and metallurgical slags; electrochemical systems, reactors and instrumentation for the production of ore-based metals from ores and for the processing of metallurgical slags into metallurgical fluxes and recycled metals or metal oxides. Business services, namely, providing information for the mining and resource industry, mine planning, maintenance scheduling, producing scheduling, equipment scheduling, materials management, quality management. Installation and repair services of equipment used for mine extraction, processing of ores, and recycling of metallurgical slags. Electrochemical processes for iron and steel fabrication to the order and specification of others; manufacturing services in the processing of metals, alloys and metallurgical fluxes; custom processing of metal ores to the specification of others; electrochemical processes for carbon capture and/or sequestration; manufacturing services using electrochemistry; electrochemical processes for manufacturing carbon capture and sequestration materials; manufacturing services in the electrochemical processing of ores and metallurgical slags; custom processing of metallurgical fluxes to the specification of others; manufacturing services in the electrochemical recycling of metallurgical slags. Design and construction of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags.

Goods & Services

(1) Metal hydroxides; carbon neutral materials; chemical reagents for metallurgical fluxes; chemical reagents for smelting, melting, foundry, and casting of metal; chemical reagents for carbon sequestration. (2) Metals, alloys, iron and steel; ore-based electrolytic iron; carbon capture and/or sequestration materials; recycled metal compounds, recycled metal solids, recycled metal hydroxides, recycled metal powders and recycled metal oxides; metallurgical fluxes for smelting, melting, foundry, and casting of metal. (3) Ore treating machines; electrochemical acid generators; ore dissolution reactors; iron plating reactors; ore processing systems and instrumentation being ore treating machines; carbon capture and sequestration systems and instrumentation, namely, chemical reactors; metallurgical slag recycling reactors. (4) Electrochemical systems, reactors and instrumentation for the processing of ores and metallurgical slags; electrochemical systems, reactors and instrumentation for the production of ore-based metals from ores and for the processing of metallurgical slags into metallurgical fluxes and recycled metals or metal oxides. (1) Business services, namely, providing information for the mining and resource industry, mine planning, maintenance scheduling, producing scheduling, equipment scheduling, materials management, quality management. (2) Installation and repair services of equipment used for mine extraction, processing of ores, and recycling of metallurgical slags. (3) Electrochemical processes for iron and steel fabrication to the order and specification of others; manufacturing services in the processing of metals, alloys and metallurgical fluxes; custom processing of metal ores to the specification of others; electrochemical processes for carbon capture and/or sequestration; manufacturing services using electrochemistry; electrochemical processes for manufacturing carbon capture and sequestration materials; manufacturing services in the electrochemical processing of ores and metallurgical slags; custom processing of metallurgical fluxes to the specification of others; manufacturing services in the electrochemical recycling of metallurgical slags. (4) Design and construction of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags.

Goods & Services

(1) Metal hydroxides; carbon neutral materials, namely, calcium oxide, magnesium oxide, and metallurgical fluxes; chemical reagents for metallurgical fluxes; chemical reagents for smelting, melting, foundry, and casting of metal; chemical reagents for carbon sequestration; recycled metal hydroxides; recycled metal oxides; metallurgical fluxes for smelting, melting, foundry, and casting of metal. (2) Metals, alloys, iron and steel; ore-based electrolytic iron; materials of metal for use in carbon capture and/or sequestration; recycled metal compounds, recycled metal solids, and recycled metal powders. (3) Ore treating machines; electrochemical acid generators; ore dissolution reactors; iron plating reactors; ore processing machines; carbon capture and/or sequestration systems and instrumentation, namely, chemical reactors; metallurgical slag recycling reactors. (4) Electrochemical machines for the processing of ores and metallurgical slags; electrochemical machines for the production of ore-based metals from ores and for the processing of metallurgical slags into metallurgical fluxes and recycled metals or metal oxides. (1) Business services, namely, providing business information for the mining and resource industry, mine planning, maintenance scheduling, producing scheduling, equipment scheduling, materials management, quality management. (2) Construction of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags; installation and repair services of equipment used for mine extraction, processing of ores, and recycling of metallurgical slags. (3) Electrochemical processing for iron and steel fabrication to the order and specification of others; custom manufacturing services in the processing of metals, alloys and metallurgical fluxes; custom processing of metal ores to the specification of others; electrochemical processing for carbon capture and/or sequestration; custom manufacturing services using electrochemistry; electrochemical processing for manufacturing carbon capture and sequestration materials; custom manufacturing services in the electrochemical processing of ores and metallurgical slags; custom processing of metallurgical fluxes to the specification of others; custom manufacturing services in the electrochemical recycling of metallurgical slags. (4) Design of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags.

Abstract

2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal.

IPC Classes  ?

• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
• C22B 5/00 - General processes of reducing to metals
• C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
• C25C 7/04 - Diaphragms; Spacing elements
• C25C 7/02 - Electrodes; Connections thereof

Abstract

Methods and systems for dissolving an iron-containing ore are disclosed. For example, a method of processing and dissolving an iron-containing ore comprises: thermally reducing one or more non-magnetite iron oxide materials in the iron-containing ore to form magnetite in the presence of a reductant, thereby forming thermally-reduced ore; and dissolving at least a portion of the thermally-reduced ore using an acid to form an acidic iron-salt solution; wherein the acidic iron-salt solution comprises protons electrochemically generated in an electrochemical cell.

IPC Classes  ?

• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
• C25C 7/04 - Diaphragms; Spacing elements
• C22B 5/00 - General processes of reducing to metals
• C25C 7/02 - Electrodes; Connections thereof
• C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions

Goods & Services

Metal hydroxides; carbon neutral materials; chemical reagents for metallurgical fluxes; chemical reagents for smelting, melting, foundry, and casting of metal; chemical reagents for carbon sequestration, none of the goods for use in the fields of printed circuit boards and semiconductor resist manufacturing industries. Metals, alloys, iron and steel; ore-based electrolytic iron; carbon capture and/or sequestration materials; recycled metal compounds, recycled metal solids, recycled metal hydroxides, recycled metal powders and recycled metal oxides; metallurgical fluxes for smelting, melting, foundry, and casting of metal. Ore treating machines; electrochemical acid generators; ore dissolution reactors; iron plating reactors; ore processing systems and instrumentation; carbon capture and/or sequestration systems and instrumentation; metallurgical slag recycling reactors. Electrochemical systems and instrumentation for carbon capture and/or sequestration; electrochemical systems, reactors and instrumentation for the processing of ores and metallurgical slags; electrochemical systems, reactors and instrumentation for the production of ore-based metals from ores and for the processing of metallurgical slags into metallurgical fluxes and recycled metals or metal oxides. Business services, namely, providing information for the mining and resource industry, mine planning, maintenance scheduling, producing scheduling, equipment scheduling, materials management, quality management. Construction of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags. Electrochemical processes for iron and steel fabrication to the order and specification of others; manufacturing services in the processing of metals, alloys and metallurgical fluxes; custom processing of metal ores to the specification of others; electrochemical processes for carbon capture and/or sequestration; manufacturing services using electrochemistry; electrochemical processes for manufacturing carbon capture and carbon sequestration materials; manufacturing services in the electrochemical processing of ores and metallurgical slags; custom processing of metallurgical fluxes to the specification of others; manufacturing services in the electrochemical recycling of metallurgical slags. Design of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags.

Goods & Services

Electrochemical processing of iron and steel for fabrication to the order and specification of others; custom manufacturing of general product lines in the field of steelmaking and recycled metals and oxides using processing of metals, alloys and metallurgical fluxes; custom processing of metal ores to the specification of others; electrochemical processes for processing metal carbonates carbon capture and sequestration; custom manufacturing services using electrochemistry for the processing of metals, alloys, metallurgical fluxes, metallurgical slags, ores and oxides; custom manufacturing carbon capture and sequestration materials using electrochemical processes; custom manufacturing services of general product lines using electrochemical processing of ores and metallurgical slags; custom processing of metallurgical fluxes to the specification of others; custom manufacturing services for the manufacture of recycled metals and oxides in the electrochemical recycling of metallurgical slags; custom manufacturing of equipment being electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags Metal hydroxides, namely, calcium hydroxide and magnesium hydroxide; carbon neutral materials, namely, calcium oxide, magnesium oxide, and metallurgical fluxes; chemical reagents for metallurgical fluxes; chemical reagents for smelting, melting, foundry, and casting of metal; chemical reagents for carbon sequestration; metallurgical fluxes for smelting, melting, foundry, and casting of metal; carbon capture and sequestration materials, namely, calcium carbonate and magnesium carbonate; recycled metal compounds and recycled metal solids, namely, aluminum oxide, chromium oxide, iron oxide and magnesium oxide for use in further manufacturing; none of the goods for use in the fields of printed circuit boards and semiconductor resist manufacturing industries Common metals and their alloys; steel; ore-based electrolytic iron; recycled metal compounds and recycled metal solids, namely, aluminum ingots, chromium, magnesium ingots, recycled iron, and electrolytic iron for use in further manufacture; recycled metal powders for use in further manufacture Ore treating machines; electrochemical generators being a machine for generating acids; ore dissolution reactors being an industrial chemical reactor; iron plating reactors being an industrial chemical reactor; ore processing systems and instrumentation being machines; carbon capture and sequestration systems and instrumentation, namely, industrial chemical reactors; metallurgical slag recycling reactors being industrial chemical reactors; electrochemical systems, reactors and instrumentation for the processing of ores and metallurgical slags, namely, industrial chemical reactors Business services, namely, online information in relation to resource planning for the mining and resource industry, mine planning, maintenance scheduling, producing scheduling, equipment scheduling, materials management, quality management Construction of buildings for use in mine extraction, processing of ores and recycling of metallurgical slags; installation and repair services of equipment used for mine extraction, processing of ores, and recycling of metallurgical slags Design of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags

Goods & Services

Custom manufacturing of recycled metals and oxides and electrochemical processing of ore-based metals and metallurgical slags to be used later in further manufacture of recycled metals and oxides; custom manufacture of electrochemical stacks for use in processing and recycling of metallurgical slags Chemical reagents for metallurgical fluxes; chemical reagents for smelting, melting, foundry, and casting of metal; chemical reagents for carbon sequestration; metallurgical fluxes for smelting, melting, foundry, and casting of metal; recycled metal compounds and recycled metal solids, namely, aluminum oxide, chromium oxide, iron oxide, calcium and magnesium oxide for use in further manufacture; none of the goods for use in the fields of printed circuit boards and semiconductor resist manufacturing industries Recycled metal compounds and recycled metal solids, namely, aluminum ingots, chromium, magnesium ingots, recycled iron, and electrolytic iron for use in further manufacture; recycled metal powders for use in further manufacture; ore-based electrolytic iron Machines and industrial electrochemical reactors for recycling metallurgical slags; electrochemical systems, reactors and instrumentation for the production of ore-based metals from ores and for the processing of metallurgical slags into metallurgical fluxes and recycled metals or metal oxides, namely, industrial chemical reactors Construction of buildings for use in processing and recycling of metallurgical slags; installation and repair services of equipment used for processing and recycling of metallurgical slags Design of buildings and equipment, namely, electrochemical stacks, for use in processing and recycling of metallurgical slags

Goods & Services

Electrochemical processing of iron and steel for fabrication to the order and specification of others; custom manufacturing of general product lines in the field of steelmaking and recycled metals and oxides using processing of metals, alloys and metallurgical fluxes; custom processing of metal ores to the specification of others; electrochemical processes for processing metal carbonates carbon capture and sequestration; custom manufacturing services using electrochemistry for the processing of metals, alloys, metallurgical fluxes, metallurgical slags, ores and oxides; custom manufacturing carbon capture and sequestration materials using electrochemical processes; custom manufacturing services of general product lines using electrochemical processing of ores and metallurgical slags; custom processing of metallurgical fluxes to the specification of others; custom manufacturing services for the manufacture of recycled metals and oxides in the electrochemical recycling of metallurgical slags; custom manufacturing of equipment being electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags Metal hydroxides, namely, calcium hydroxide and magnesium hydroxide; carbon neutral materials, namely, calcium oxide, magnesium oxide, and metallurgical fluxes; chemical reagents for metallurgical fluxes; chemical reagents for smelting, melting, foundry, and casting of metal; chemical reagents for carbon sequestration; metallurgical fluxes for smelting, melting, foundry, and casting of metal; carbon capture and sequestration materials, namely, calcium carbonate and magnesium carbonate; recycled metal compounds and recycled metal solids, namely, aluminum oxide, chromium oxide, iron oxide and magnesium oxide for use in further manufacturing; none of the goods for use in the fields of printed circuit boards and semiconductor resist manufacturing industries Common metals and their alloys; steel; ore-based electrolytic iron; recycled metal compounds and recycled metal solids, namely, aluminum ingots, chromium, magnesium ingots, recycled iron, and electrolytic iron for use in further manufacture; recycled metal powders for use in further manufacture Ore treating machines; electrochemical generators being a machine for generating acids; ore dissolution reactors being an industrial chemical reactor; iron plating reactors being an industrial chemical reactor; ore processing systems and instrumentation being machines; carbon capture and sequestration systems and instrumentation, namely, industrial chemical reactors; metallurgical slag recycling reactors being industrial chemical reactors; electrochemical systems, reactors and instrumentation for the processing of ores and metallurgical slags, namely, industrial chemical reactors Business services, namely, online information in relation to resource planning for the mining and resource industry, mine planning, maintenance scheduling, producing scheduling, equipment scheduling, materials management, quality management Construction of buildings for use in mine extraction, processing of ores and recycling of metallurgical slags; installation and repair services of equipment used for mine extraction, processing of ores, and recycling of metallurgical slags Design of buildings and equipment, namely, electrochemical stacks, for use in mine extraction, processing of ores and recycling of metallurgical slags

Abstract

Methods and systems for producing are disclosed. A method for producing iron, for example, comprises: providing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell; wherein the first anolyte has a different composition than the first catholyte; dissolving at least a portion of the iron-containing ore using an acid to form an acidic iron-salt solution having dissolved first Fe3+ ions; providing at least a portion of the acidic iron-salt solution to the first cathodic chamber; first electrochemically reducing said first Fe3+ ions in the first catholyte to form Fe2+ ions; transferring the formed Fe2+ ions from the dissolution subsystem to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing a first portion of the transferred formed Fe2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal.

IPC Classes  ?

• C21B 15/00 - Other processes for the manufacture of iron from iron compounds
• H01M 8/04014 - Heat exchange using gaseous fluids; Heat exchange by combustion of reactants
• H01M 8/04746 - Pressure; Flow

Abstract

Methods and systems for producing iron from an iron-containing ore are disclosed. For example, a method for producing iron comprises: providing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell and a dissolution tank; dissolving the iron-containing ore to form an acidic iron-salt solution; reducing Fe3+ ions to form Fe2+ ions and electrochemically generating protons in the first electrochemical cell; circulating solution between the dissolution tank and the first electrochemical cell; transferring formed Fe2+ ions from the dissolution subsystem to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing a first portion of the transferred formed Fe2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal. The methods and systems optionally include removing one or more impurities found in the feedstock.

IPC Classes  ?

• C21B 11/00 - Making pig-iron other than in blast furnaces
• C21B 13/00 - Making spongy iron or liquid steel, by direct processes
• C21B 13/14 - Multi-stage processes

Abstract

Methods and systems for producing iron from an iron-containing ore and removing impurities found in the iron-containing ore are disclosed. For example, a method for producing iron comprises providing a feedstock having an iron-containing ore and one or more impurities to a dissolution subsystem comprising a first electrochemical cell; producing an iron-rich solution, in the dissolution subsystem; treating the iron-rich solution to remove at least a portion of one or more impurities by raising a pH of the iron-rich solution from an initial pH to an adjusted pH thereby precipitating at least a portion of the one or more impurities in the treated iron-rich solution; delivering the treated iron-rich solution to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing at least a first portion of the transferred formed Fe2+ ions to Fe metal; and removing the Fe metal from the second electrochemical cell thereby producing iron.

IPC Classes  ?

• C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
• C22B 3/04 - Extraction of metal compounds from ores or concentrates by wet processes by leaching
• C22B 3/22 - Treatment or purification of solutions, e.g. obtained by leaching by physical processes, e.g. by filtration, by magnetic means
• C22B 3/44 - Treatment or purification of solutions, e.g. obtained by leaching by chemical processes
• C01G 49/00 - Compounds of iron

Abstract

Methods and systems for dissolving an iron-containing ore are disclosed. For example, a method of processing and dissolving an iron-containing ore comprises: thermally reducing one or more non-magnetite iron oxide materials in the iron-containing ore to form magnetite in the presence of a reductant, thereby forming thermally-reduced ore; and dissolving at least a portion of the thermally-reduced ore using an acid to form an acidic iron-salt solution; wherein the acidic iron-salt solution comprises protons electrochemically generated in an electrochemical cell.

IPC Classes  ?

• C01G 49/06 - Ferric oxide (Fe2O3)
• H01F 1/055 - Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5

Abstract

Methods and systems for producing iron from an iron-containing ore and removing impurities found in the iron-containing ore are disclosed. For example, a method for producing iron comprises providing a feedstock having an iron-containing ore and one or more impurities to a dissolution subsystem comprising a first electrochemical cell; producing an iron-rich solution, in the dissolution subsystem; treating the iron-rich solution to remove at least a portion of one or more impurities by raising a pH of the iron-rich solution from an initial pH to an adjusted pH thereby precipitating at least a portion of the one or more impurities in the treated iron-rich solution; delivering the treated iron-rich solution to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing at least a first portion of the transferred formed Fe2+ ions to Fe metal; and removing the Fe metal from the second electrochemical cell thereby producing iron.

IPC Classes  ?

• B82Y 25/00 - Nanomagnetism, e.g. magnetoimpedance, anisotropic magnetoresistance, giant magnetoresistance or tunneling magnetoresistance
• B82Y 40/00 - Manufacture or treatment of nanostructures
• C01G 49/06 - Ferric oxide (Fe2O3)

Abstract

Methods and systems for producing iron from an iron-containing ore are disclosed. For example, a method for producing iron comprises: providing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell and a dissolution tank; dissolving the iron-containing ore to form an acidic iron-salt solution; reducing Fe3+ions to form Fe2+ions and electrochemically generating protons in the first electrochemical cell; circulating solution between the dissolution tank and the first electrochemical cell; transferring formed Fe2+ions from the dissolution subsystem to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing a first portion of the transferred formed Fe2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal. The methods and systems optionally include removing one or more impurities found in the feedstock.

IPC Classes  ?

• C21B 11/00 - Making pig-iron other than in blast furnaces
• C21B 13/00 - Making spongy iron or liquid steel, by direct processes
• C21B 13/14 - Multi-stage processes

Abstract

Methods and systems for dissolving an iron-containing ore are disclosed. For example, a method of processing and dissolving an iron-containing ore comprises: thermally reducing one or more non-magnetite iron oxide materials in the iron-containing ore to form magnetite in the presence of a reductant, thereby forming thermally-reduced ore; and dissolving at least a portion of the thermally-reduced ore using an acid to form an acidic iron-salt solution; wherein the acidic iron-salt solution comprises protons electrochemically generated in an electrochemical cell.

IPC Classes  ?

• C01G 49/06 - Ferric oxide (Fe2O3)
• H01F 1/055 - Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
• C04B 35/26 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on ferrites

Abstract

Methods and systems for producing are disclosed. A method for producing iron, for example, comprises: providing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell; wherein the first anolyte has a different composition than the first catholyte; dissolving at least a portion of the iron-containing ore using an acid to form an acidic iron-salt solution having dissolved first Fe3+ions; providing at least a portion of the acidic iron-salt solution to the first cathodic chamber; first electrochemically reducing said first Fe3+ions in the first catholyte to form Fe2+ions; transferring the formed Fe2+ions from the dissolution subsystem to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing a first portion of the transferred formed Fe2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal.

IPC Classes  ?

• C21B 15/00 - Other processes for the manufacture of iron from iron compounds
• H01M 8/04014 - Heat exchange using gaseous fluids; Heat exchange by combustion of reactants
• H01M 8/04746 - Pressure; Flow

Abstract

22222-containing gas (e.g., air) by forming a carbonate or from the ocean by forming bicarbonate.

IPC Classes  ?

• B01J 41/14 - Macromolecular compounds obtained by reactions only involving unsaturated carbon-to-carbon bonds
• B01J 47/12 - Ion-exchange processes in general; Apparatus therefor characterised by the use of ion-exchange material in the form of ribbons, filaments, fibres or sheets, e.g. membranes
• C25B 1/02 - Hydrogen or oxygen

Abstract

A method of making a material for capturing carbon dioxide from the earth's atmosphere, comprises producing an acid and a base with an electrochemical acid-base generator; dissolving a mineral in the acid to produce a mineral rich solution, separating silica from the mineral rich solution to form a silica depleted solution; adding a first portion of the base to the silica depleted solution to remove impurities by precipitation, adding a second portion of the base until ferrous hydroxide (Fe(OH)2) precipitates, then pausing base addition and removing the ferrous hydroxide precipitate from the solution. Then adding a third portion of the base to the iron-depleted solution to precipitate magnesium hydroxide (Mg(OH)2) and/or calcium hydroxide (Ca(OH)2). Then recovering a salt solution and directing the recovered salt solution to the electrochemical acid-base generator to produce a new acid and a new base. The magnesium hydroxide and/or calcium hydroxide may be used to capture and sequester carbon dioxide from a CO2-containing gas (e.g., air) by forming a carbonate or from the ocean by forming bicarbonate.

IPC Classes  ?

• B01J 41/14 - Macromolecular compounds obtained by reactions only involving unsaturated carbon-to-carbon bonds
• B01J 47/12 - Ion-exchange processes in general; Apparatus therefor characterised by the use of ion-exchange material in the form of ribbons, filaments, fibres or sheets, e.g. membranes
• C25B 1/02 - Hydrogen or oxygen

Goods & Services

Electrochemical processes for processing metal carbonates for carbon capture and sequestration; custom manufacturing services using electrochemistry for the processing of metals, alloys, metallurgical fluxes, metallurgical slags, ores and oxides; custom manufacturing carbon capture and sequestration materials using electrochemical processes; custom manufacture of electrochemical stacks for use in processing and recycling of metallurgical slags Metal hydroxides, namely, calcium hydroxide and magnesium hydroxide; carbon neutral materials, namely, calcium oxide, magnesium oxide, and metallurgical fluxes; carbon capture and sequestration materials, namely, calcium carbonate and magnesium carbonate; none of the goods for use in the fields of printed circuit boards and semiconductor resist manufacturing industries Ore treating machines; electrochemical generators being a machine for generating acids; ore dissolution reactors being an industrial chemical reactor; iron plating reactors being an industrial chemical reactor; ore processing systems and instrumentation being machines; carbon capture and sequestration systems and instrumentation, namely, industrial chemical reactors Business services, namely, online information in relation to resource planning for the mining and resource industry, mine planning, maintenance scheduling, producing scheduling, equipment scheduling, materials management, quality management Construction of buildings for use in mine extraction and processing of ores; installation and repair services of equipment used for mine extraction and processing of ores Design of buildings and equipment, namely, electrochemical stacks, for use in mine extraction and processing of ores

Goods & Services

Treatment of materials in the nature of electrochemical processes for iron and steel fabrication to the order and specification of others; manufacturing services in the nature of processing of metals and alloys; custom processing of metal ores to the specification of others Common metals and their alloys; iron oxide; steel; electrolytic iron; recycled iron

Goods & Services

Custom manufacturing of general product lines in the field of steelmaking using electrochemical processing of ores Electrochemical systems, reactors and instrumentation, namely, industrial chemical reactors for the processing of ores into purified metals, namely, metallic iron