Methods and systems for iron production

Description

METHODS AND SYSTEMS FOR IRON PRODUCTION Separated from BR112023019059-2, filed on March 24, 2022. CROSS-REFERENCE TO RELATED REQUESTS

[0001] This application claims the benefit and priority of U.S. Provisional Patent Application Serial No. 63 / 165,502, filed March 24, 2021, which is incorporated herein by reference in its entirety for all purposes to the extent that it is not inconsistent with this document. GOVERNMENT FUNDING

[0002] The inventions in this application were made with government support under Award Number 2039232 granted by the US National Science Foundation. The government has certain rights to inventions contained herein. FIELD OF THE INVENTION

[0003] The present invention relates generally to the fields of electrochemistry and hydrometallurgy and, more particularly, to systems and methods for extracting iron from iron-containing feedstocks using electrochemical and / or hydrometallurgical processes. BACKGROUND OF THE INVENTION

[0004] Iron oxide ores can be converted into relatively pure metallic iron by removing the oxygen (i.e., reducing the oxides) and recovering the metallic iron in a form that can be processed into useful goods in subsequent processes. The iron can then be transformed into steel by adding a small amount of carbon and other elements, depending on the type of steel to be manufactured. For thousands of years, both tasks (reduction and addition of carbon) were achieved predominantly by heating the iron ore to very high temperatures (e.g. Petition 870260045431, dated 05 / 13 / 2026, page 10 / 460 2 / 200 plo, approximately 1,700 °C) in the presence of carbon, typically produced by burning coal (or coke). The carbon monoxide produced by burning coal or coke combines with oxygen in iron oxides, thereby reducing the oxides to metallic iron and releasing carbon dioxide. In fact, modern steel production is responsible for about 10% of global CO2 emissions. SUMMARY OF THE INVENTION

[0005] Methods and associated systems are provided in this document for producing substantially pure metallic iron from iron-containing ores and / or other iron-containing feedstocks. Several embodiments of methods and systems are described in this document for converting iron ore from an impure ore or other state into metallic iron using chemical and / or electrochemical conversion techniques without the need to burn fossil fuels. In particular, several embodiments described in this document allow for the dissolution of the iron ore material in an acidic solution, chemical and / or electrochemical adjustment of the properties of the acidic solution, and electroplating of iron (and optionally other metals) from the acidic solution in an electrochemical cell.

[0006] Various embodiments of the systems and methods include at least one independent first electrochemical process to adjust the parameters of the acid solution in order to increase or accelerate the dissolution of the ore and a second independent electrochemical process to galvanize the iron from an acid solution.

[0007] Optionally, embodiments of the methods described in this document may provide a process for galvanizing iron from an iron-containing ore, such that the steady-state operation is characterized by the overall input consisting substantially of iron-containing ore and the overall output consisting substantially of high-purity iron, wherein the water Petition 870260045431, dated 05 / 13 / 2026, p. 11 / 460 3 / 200 and the acid are regenerated as part of the process. Optionally, embodiments of the method described herein may provide a process for galvanizing iron from an iron-containing ore that is substantially free of CO2 generation during steady-state operation. Optionally, embodiments of the methods described herein may provide a process for galvanizing iron from an iron-containing ore that is substantially free of Cb(g) generation during steady-state operation. Optionally, embodiments of the methods described herein may also include processes for manufacturing steel using the high-purity iron produced according to embodiments herein.

[0008] A method for processing and dissolving an iron-containing ore is described, the method comprising: Thermally reduce one or more iron oxide materials other than magnetite in iron-containing ore to form magnetite in the presence of a reducing agent, thereby forming a thermally reduced ore; and dissolve at least part of the thermally reduced ore using an acid to form an acidic solution of iron salt; in which the acidic iron salt solution comprises electrochemically generated protons in an electrochemical cell.

[0009] Also described is a method for processing and dissolving an ore containing iron, the method comprising: In a dissolving tank, place the iron-containing ore in contact with an acid to dissolve at least part of the iron-containing ore, thus forming an acidic solution of iron salt that has dissolved Fe3+ ions; recirculate at least part of the acidic iron salt solution between the dissolution tank and a cathodic chamber of a cell. Petition 870260045431, dated 05 / 13 / 2026, page 12 / 460 4 / 200 electrochemistry, the electrochemical cell comprising a cathode in the presence of at least part of an acidic iron salt solution that serves as a catholyte in the cathodic chamber, an anode in the presence of an anolyte and a separator that separates the catholyte from the anolyte; electrochemically reduce at least a portion of the dissolved Fe3+ ions from the catholyte at the cathode to form Fe2+ ions in the catholyte; and electrochemically generate protons in the electrochemical cell and feed the electrochemically generated protons to the catholyte; wherein the acidic iron salt solution in the dissolving tank, in the presence of the iron-containing ore, is characterized by a steady-state concentration of free protons that is at least 0.2 M.

[0010] A method for processing and dissolving an iron-containing ore is also described, the method comprising: Thermally reducing one or more iron oxide materials other than magnetite in iron-containing ore to form magnetite in the presence of a reducing agent, thereby forming thermally reduced ore; wherein the reducing agent comprises gaseous H2; and wherein at least part of the gaseous H2 is generated chemically through a reaction of metallic iron with an acid and / or at least part of the gaseous H2 is generated electrochemically through a parasitic hydrogen evolution reaction of an iron galvanizing process; and dissolving at least the thermally reduced ore using an acidic solution to form an iron salt solution; whereby the dissolution step involves dissolving the magnetite formed in said acidic solution.

[0011] Additionally, a system for processing and dissolving an iron-containing ore is described, the system comprising: Petition 870260045431, dated 05 / 13 / 2026, page 13 / 460 5 / 200 a first dissolving tank to dissolve a first ore containing iron using a first acid; wherein: The dissolution of the first ore in the first acid forms a first acidic solution of iron salt comprising Fe3+ ions dissolved in the first dissolution tank; an electrochemical cell fluidically connected to the first dissolution tank; wherein: The electrochemical cell comprises a cathodic chamber having a catholyte in the presence of a cathode, an anodic chamber having an anolyte in the presence of an anode, and a separator separating the catholyte and the anolyte; and a first circulation subsystem that circulates at least part of the first acidic iron salt solution from the first dissolution tank to the cathodic chamber and at least part of the electrochemical cell catholyte to the first dissolution tank; whereby at least some of the Fe3+ ions from the first acidic iron salt solution are electrochemically reduced at the cathode to Fe2+ ions at the catholyte, thereby consuming the Fe3+ ions from the first acidic iron salt solution.

[0012] A method for producing iron is described, the method comprising: feeding a raw material containing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; and Petition 870260045431, dated 05 / 13 / 2026, page 14 / 460 6 / 200 where the first anolyte has a different composition from that of the first catholyte; Dissolve at least part of the iron-containing ore using an acid to form an acidic solution of iron salt that has dissolved Fe3+ ions first; feed at least part of the acidic iron salt solution containing at least some of the first Fe3+ ions to the first cathodic chamber; first, electrochemically reduce the aforementioned first Fe3+ ions in the first catholyte to form Fe2+ ions; Transfer the Fe2+ ions formed from the dissolution subsystem to an iron galvanizing subsystem that has a second electrochemical cell; Second, electrochemically reduce a first portion of the Fe2+ ions formed, which are transferred to metallic Fe at a second cathode of the second electrochemical cell; and remove the metallic Fe from the second electrochemical cell, thereby producing iron.

[0013] A method for producing iron is also described, the method comprising: feeding a raw material containing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell; wherein the first electrochemical cell comprises a first anodic chamber having gaseous H2 in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anodic chamber from the first catholyte; and dissolving at least part of the iron-containing ore using an acid to form an acidic solution of iron salt which has Petition 870260045431, dated 05 / 13 / 2026, p. 15 / 460 7 / 200 first dissolved Fe3+ ions; feed at least part of the acidic iron salt solution containing at least some of the first Fe2+ ions to the first cathodic chamber; first, electrochemically reduce the aforementioned first Fe3+ ions in the first catholyte to form Fe2+ ions; Transfer the Fe2+ ions formed from the dissolution subsystem to an iron galvanizing subsystem that has a second electrochemical cell; Second, electrochemically reduce a first portion of the Fe2+ ions formed, which are transferred to metallic Fe at a second cathode of the second electrochemical cell; and remove the metallic Fe from the second electrochemical cell, thereby producing iron.

[0014] A system for producing iron is also described, the system comprising: a dissolution subsystem that has a dissolution tank and a first electrochemical cell fluidically connected to the dissolution tank; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; and wherein the first anolyte has a composition different from that of the first catholyte; and an iron galvanizing subsystem fluidically connected to the dissolution subsystem and having a second electrochemical cell; and Petition 870260045431, dated 05 / 13 / 2026, page 16 / 460 8 / 200 a first intersubsystem fluidic connection between the dissolution subsystem and the galvanizing subsystem; in which: The dissolving tank receives a raw material containing iron ore; The dissolving tank comprises an acidic solution of iron salt to dissolve at least part of the iron-containing ore to generate first dissolved Fe3+ ions; The first Fe3+ ions are electrochemically reduced at the first cathode to form Fe2+ ions at the first catholyte; The Fe2+ ions formed are transferred from the dissolution subsystem to the iron galvanizing subsystem through the first intersubsystem fluid connection; The second electrochemical cell comprises a second cathode to reduce at least a first part of the Fe2+ ions formed transferred into metallic Fe; and the metallic Fe is removed from the second electrochemical cell.

[0015] Additionally, a system for producing iron is described, the system comprising: a dissolution subsystem that has a dissolution tank and a first electrochemical cell fluidically connected to the dissolution tank; wherein the first electrochemical cell comprises a first anodic chamber containing gaseous H2 in the presence of a first anode, a first cathodic chamber containing a first catholyte in the presence of a first cathode, and a first separator separating the first anodic chamber from the first catholyte; and an iron galvanizing subsystem fluidically connected to the dissolution subsystem and containing a second electrochemical cell; and Petition 870260045431, dated 05 / 13 / 2026, page 17 / 460 9 / 200 a first intersubsystem fluidic connection between the dissolution subsystem and the galvanizing subsystem; in which: The dissolving tank receives a raw material that contains iron ore; The dissolving tank comprises an acidic solution of iron salt to dissolve at least part of the iron-containing ore to generate first dissolved Fe3+ ions; The first Fe3+ ions are electrochemically reduced at the first cathode to form Fe2+ ions at the first catholyte; The Fe2+ ions formed are transferred from the dissolution subsystem to the iron galvanizing subsystem through the first intersubsystem fluid connection; The second electrochemical cell comprises a second cathode to reduce at least a first part of the Fe2+ ions formed transferred into metallic Fe; and the metallic Fe is removed from the second electrochemical cell.

[0016] A method for producing iron is described, the method comprising: to feed a raw material that has an ore containing iron and one or more impurities to a dissolution subsystem that comprises a first electrochemical cell; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; Dissolve at least part of the iron-containing ore using an acid to form an acidic solution of iron salt having first dissolved Fe3+ ions; Petition 870260045431, dated 05 / 13 / 2026, p. 18 / 460 10 / 200 feed at least part of the acidic iron salt solution containing at least some of the first Fe3+ ions to the first cathodic chamber; first, electrochemically reduce the aforementioned first Fe3+ ions in the first catholyte to form Fe2+ ions; to produce an iron-rich solution in the dissolution subsystem, the iron-rich solution having at least a portion of the formed Fe2+ ions and at least a portion of one or more impurities; Treat at least a portion of the iron-rich solution to remove at least some of one or more impurities from the iron-rich solution, thereby forming a treated iron-rich solution that has at least some of the Fe2+ ions formed; wherein the treatment step comprises increasing the pH of the iron-rich solution from an initial pH to an adjusted pH, thereby precipitating at least some of one or more impurities in the treated iron-rich solution; feed at least a first portion of the treated iron-rich solution to an iron galvanizing subsystem that has a second electrochemical cell; Second, electrochemically reduce at least a first portion of the Fe2+ ions formed and transferred to metallic Fe at a second cathode of the second electrochemical cell; and remove the metallic Fe from the second electrochemical cell, thereby producing iron.

[0017] A system for producing iron is also described, the system comprising: a dissolution subsystem that has a first dissolution tank and a first electrochemical cell fluidically connected to the first dissolution tank; Petition 870260045431, dated 05 / 13 / 2026, page 19 / 460 11 / 200 wherein the first electrochemical cell comprises a first cathodic chamber having a first anolyte in the presence of a first anode, a second anodic chamber having a first catholyte in the presence of a first cathode and a first separator separating the first anolyte from the first catholyte; and an iron galvanizing subsystem fluidically connected to the dissolution subsystem and having a second electrochemical cell; and a first impurity removal subsystem; in which: The first dissolution tank receives a raw material containing one or more iron-bearing ores and one or more impurities; The first dissolution tank comprises an acidic solution of iron salt to dissolve at least part of one or more iron-containing ores to generate first Fe3+ ions dissolved in the acidic iron salt solution; at least a portion of the acidic iron salt solution containing at least some of the first Fe3+ ions is supplied to the first cathodic chamber; The first Fe3+ ions are electrochemically reduced at the first cathode to form Fe2+ ions at the first catholyte; An iron-rich solution is formed in the dissolution subsystem, the iron-rich solution having at least a portion of the formed Fe2+ ions and at least a portion of one or more impurities; At least a portion of the iron-rich solution is supplied to the first descaling subsystem to remove at least a portion of one or more impurities from the iron-rich solution, thereby forming a treated iron-rich solution that has at least a portion of the Fe2+ ions formed; Petition 870260045431, dated 05 / 13 / 2026, page 20 / 460 12 / 200 where the pH of the iron-rich solution is increased, in the first impurity removal subsystem, from an initial pH to a pH adjusted to precipitate the removed portion with one or more impurities; At least a portion of the treated iron-rich solution is fed from the first impurity removal subsystem to the iron galvanizing subsystem; The second electrochemical cell comprises a second cathode to reduce at least a portion of the transferred Fe2+ ions to metallic Fe; and the metallic Fe is removed from the second electrochemical cell.

[0018] A method for producing iron is further described, the method comprising: In a first dissolution tank, bring an initial ore containing iron into contact with an acid to dissolve at least part of the iron-containing ore, thus forming an acidic solution of iron salt that has the first Fe3+ ions dissolved; circulate at least part of the acidic iron salt solution between the first dissolution tank and a first cathodic chamber of a first electrochemical cell, thus feeding at least part of the first Fe3+ ions to a first catholyte of the first cathodic chamber; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; first, electrochemically reduce at least a portion Petition 870260045431, dated 05 / 13 / 2026, page 21 / 460 13 / 200 of the first Fe3+ ions at the first cathode to form Fe2+ ions at the first catholyte; to generate protons electrochemically in the first electrochemical cell; wherein the circulation step comprises feeding at least a portion of the electrochemically generated protons and at least a portion of the Fe2+ ions formed from the first catholyte to the acidic iron salt solution; to produce a first iron-rich solution that has Fe2+ ions formed in a dissolution subsystem, the dissolution subsystem comprising the first dissolution tank and the first electrochemical cell; transfer at least part of the first iron-rich solution to an iron galvanizing subsystem, the iron galvanizing subsystem comprising a second electrochemical cell; Second, to electrochemically reduce a first portion of the Fe2+ ions formed into metallic Fe at a second cathode of the second electrochemical cell; wherein the second electrochemical cell comprises a second cathodic chamber having a second catholyte in the presence of the second cathode, a second anodic chamber having a second anolyte in the presence of a second anode, and a second separator separating the first anolyte from the first catholyte; and removing metallic Fe from the second electrochemical cell thereby producing iron.

[0019] Additionally, a system for producing iron is described, the system comprising: a dissolution subsystem to produce an iron-rich solution, wherein the dissolution subsystem comprises a first Petition 870260045431, dated 05 / 13 / 2026, page 22 / 460 14 / 200 dissolution tank, a first electrochemical cell and a first circulation subsystem, in which: In the first dissolution tank, an ore containing iron is brought into contact with an acid to dissolve at least part of the iron-containing ore, thereby forming an acidic solution of iron salt containing dissolved Fe3+ ions; The first circulation subsystem circulates at least part of the acidic iron salt solution between the first dissolution tank and a first cathodic chamber of the first electrochemical cell, thus feeding at least part of the first Fe3+ ions to a first catholyte of the first cathodic chamber; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having the first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; The first electrochemical cell electrochemically reduces at least a portion of the first Fe3+ ions at the first cathode to form Fe2+ ions at the first catholyte; the first electrochemical cell generates protons electrochemically and feeds the electrochemically generated protons to the catholyte; wherein the first circulation system feeds the electrochemically generated protons from the first catholyte to the acidic iron salt solution; and the iron-rich solution produced in the first subsystem comprises the Fe2+ ions formed; a transition subsystem comprising an initial intersubsystem fluid connection to transfer at least a portion of the iron-rich solution to an iron galvanizing subsystem; the iron galvanizing subsystem comprising a Petition 870260045431, dated 05 / 13 / 2026, page 23 / 460 15 / 200 second electrochemical cell; wherein the second electrochemical cell comprises a second cathodic chamber having a second catholyte in the presence of the second cathode, a second anodic chamber having a second anolyte in the presence of a second anode, and a second separator separating the first anolyte from the first catholyte having a second catholyte in the presence of a second cathode; where at least a first portion of the Fe2+ ions formed and transferred are electrochemically reduced to metallic Fe at the second cathode; and an iron removal subsystem to remove metallic Fe from the second electrochemical cell, thereby producing iron. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1A. Schematic diagram of a possible approach to producing iron by combining galvanizing with oxygen generation.

[0021] Figure 1B. Schematic diagram of a possible approach to producing iron by dissolving an iron feedstock in sulfuric acid and combining galvanizing with oxygen generation with an example of acid chemistry with approximate pH ranges.

[0022] Figure 2. Schematic diagram illustrating a raw material dissolution and acid regeneration subsystem.

[0023] Figure 3. Schematic diagram illustrating an iron galvanizing subsystem.

[0024] Figure 4. Schematic diagram illustrating a two-stage iron conversion system with several subsystems.

[0025] Figure 5A and Figure 5B. Schematic process flow diagrams illustrating alternative processes for allocating an iron-rich acid solution from a dissolution subsystem to anolyte and catholyte tanks of a galvanizing subsystem. Petition 870260045431, dated 05 / 13 / 2026, page 24 / 460 16 / 200

[0026] Figure 6. Schematic diagram illustrating a two-stage iron conversion system with several subsystems, including an acid regeneration subsystem comprising oxygen evolution and also demonstrating possible fluid flows between the subsystems.

[0027] Figure 7A. Graph illustrating experimental data showing the conversion of ferric ions to ferrous ions and the production of acid in an acid regeneration cell during dissolution coupled to acid regeneration and ferric reduction: using an initial 1.8 M ferric sulfate solution representing the end of a galvanizing process, ferrous oxide was generated via electrochemical reduction in electrochemical cell 1, as evidenced by the increase in [Fe2+] concentration. The acid generated allowed for greater dissolution of the iron oxide, since the final total iron concentration was 2.5 M.

[0028] Figure 7B. Graph illustrating experimental data showing the dissolution rates of hematite and magnetite ores at various concentrations of sulfuric acid.

[0029] Figure 7C. Graph illustrating experimental data showing the rate of dissolution of ores in sulfuric acid.

[0030] Figure 8A. Solubility diagram illustrating the solubility of various metal hydroxides at various pH values ​​of the solution.

[0031] Figure 8B and Figure 8C. Solubility diagrams illustrating the solubility of various iron phosphates and iron oxides.

[0032] Figure 8D. Solubility diagram illustrating the solubility of iron phosphate and ferric iron hydroxide.

[0033] Figure 8E. Solubility diagram illustrating the solubility of aluminum phosphate and aluminum hydroxide.

[0034] Figure 9. Process flowchart showing certain exemplary embodiments, including the use of H2 generated during the galvanizing of iron in a process for the conversion of oxides of Petition 870260045431, dated 05 / 13 / 2026, page 25 / 460 17 / 200 iron, such as hematite, into magnetite, followed by dissolution of the magnetite coupled to an acid regeneration cell.

[0035] Figure 10. A schematic system diagram illustrating an example of a system and process for dissolving ores treated in various ways coupled with an acid regeneration system.

[0036] Figure 11. A process flowchart that schematically illustrates a process for converting solid iron raw material into pure galvanized iron, including optional intermediate treatment steps.

[0037] Figure 12. Graph of alpha (a) versus time for the reduction of hematite to magnetite with 5% H2 - 95% Ar gas.

[0038] Figure 13A. Diagram of an exemplary flow cell according to certain modalities.

[0039] Figure 13B. Efficiency versus pH graph for electrolytic extraction using chloride and sulfate chemistries. The efficiency of Fe electroplating is greater than 80% for pH > 2 in the sulfate chemistry.

[0040] Figure 14. Diagram of an exemplary acid regeneration cell. For example, this cell can operate at 400 mA / cm2 for a Faradaic efficiency greater than 97%.

[0041] Figure 15. CV scan plot showing that, in hydrochloric acid chemistry, hydrogen evolution occurs at a markedly higher rate at a pH below 2, with the pH controlled by the HCl concentration.

[0042] Figures 16A-16B. Current density versus voltage graphs at 20 °C (Figure 16A) and 60 °C (Figure 16B) in the presence of 1M NH4Cl (Figure 16A) or 1M (NH4)SO4 (Figure 16B), with the parameters summarized in the insets. Chlorides have lower hydrogen generation than sulfates at room temperature and have a similar rate at 60 °C.

[0043] Figures 17A-17B. Current density versus current density graphs Petition 870260045431, dated 05 / 13 / 2026, page 26 / 460 18 / 200 voltage for the Fe(II) / Fe(s) (Figure 17A) and Fe(III) / Fe(II) chemistries, with certain parameters summarized in the inserts. Increasing the chloride concentration improves the reversibility for both the Fe(II) / Fe(s) and Fe(III) / Fe(II) pairs.

[0044] Figure 18. Schematic diagram illustrating a chemical plant configured to carry out the iron conversion processes described in this document.

[0045] Figure 19. Example of a current-voltage curve for an acid regeneration cell.

[0046] Figure 20. Example of a current-voltage curve for a galvanizing cell.

[0047] Figures 21A - 21C. XRD spectrographs illustrating a commercial source of iron ore containing substantial amounts of geotite and hematite (Figure 21A). After heat treatment at 450 °C, the geotite is completely converted to hematite with a larger surface area (Figure 21B). After heat treatment in a 4% hydrogen atmosphere at 450 °C, an almost complete reduction to magnetite is achieved (Figure 21C).

[0048] Figure 22. Process flowchart illustrating a process for manufacturing green steel and green steel products from iron produced by one or more of the processes described in this document.

[0049] Figure 23. Schematic diagram illustrating the use of a redox mediator pair to dissociate the oxygen evolution from the reduction of ferric iron to metallic iron. Statements concerning chemical compounds and nomenclature

[0050] In general, the terms and phrases used in this document have their meaning recognized in the art, which can be found Petition 870260045431, dated 05 / 13 / 2026, page 27 / 460 19 / 200 by reference to standard texts, periodical references, and contexts known to those skilled in the art. The following definitions are provided to clarify their specific use in the context of the present invention.

[0051] In various embodiments, the present invention provides processes, systems and methods for enabling efficient, low-temperature aqueous hydrometallurgical processes for the production of pure iron from various iron source materials, including relatively low-purity iron feedstock materials. In general terms, an iron feedstock is dissolved in an acidic aqueous solution and the metallic iron is electrolytically galvanized and removed as a solid. In various embodiments, the iron or aqueous iron feedstock materials can be converted from one form to another during one or more process steps.

[0052] As used in this document, the terms pure iron and high-purity iron are used in a relative sense to refer to a metallic iron material that is purer than a source iron material and contains an acceptably low amount of one or more impurities.

[0053] As used in this document, the terms iron source material and iron feedstock are used synonymously to refer to materials containing iron that can be used as inputs in the various systems and methods described in this document. Iron source materials and iron feedstock may include iron in any form, such as oxides, hydroxides, oxyhydroxides, carbonates or other iron-containing compounds, ores, rocks or minerals, including any mixtures thereof, in natural states or beneficiated or purified states. The term iron-containing ore or simply iron ore may include materials recognized, known or referred to in the art as iron ore(s). Petition 870260045431, dated 05 / 13 / 2026, page 28 / 460 20 / 200 iron, rock(s), natural rock(s), sediment(s), natural sediments, minerals and / or natural minerals, whether in natural states or in beneficiated states or otherwise purified or modified. Some embodiments of the processes and systems described in this document may be particularly useful for iron ores, including hematite, goethite, magnetite, limonite, siderite, ankerite, turgite, bauxite or any combination thereof.

[0054] Optionally, an iron source material or iron feedstock may comprise an iron metallic material such as, but not limited to, iron powder (e.g., fine particles produced as a byproduct of iron or steelmaking processes in blast furnaces, oxygen furnaces, electric arc furnaces, etc.), iron powder, steel scrap and / or cast iron scrap. Iron source materials and iron feedstocks may also contain various other non-ferrous materials, generally referred to as impurities.

[0055] As used in this document, the term impurity refers to an element or compound other than a desired end-product material (e.g., iron). In various embodiments, depending on the intended end use of a product material, a given element or compound may or may not be considered an impurity. In some cases, one or more elements or compounds that may be impurities to a process or subprocess may be isolated or purified, collected, and sold as by-product material.

[0056] In various embodiments of this document, various compositions, compounds or solutions may be substantially isolated or purified to a degree sufficient for the purposes described herein. In various embodiments, a substantially purified composition, compound or formulation (e.g., solution) Petition 870260045431, dated 05 / 13 / 2026, page 29 / 460 21 / 200 solutions of ferrous iron, ferric iron solutions or galvanized metallic iron) may have a chemical purity of 90% (e.g., molarity of ionic or weight concentrations), optionally for some applications 95%, optionally for some applications 99%, optionally for some applications 99.9%, optionally for some applications 99.99% and optionally for some applications 99.999% pure.

[0057] Reference in this document to a tank is intended to include any suitable container for holding liquids, such as highly acidic or caustic aqueous solutions, if necessary. In some embodiments, such a container may include additional features or components to assist or improve the mixing of the solid and / or liquid contents of the container. For example, a dissolving tank may include passively or actively operated structures or features to agitate a solid / liquid solution or mixture. A dissolving tank or other tank useful in the systems and methods of this document may also include features to allow the spraying of a gas into or through the solid and / or liquid contents of the tank to increase the contact of the gas with solid and / or liquid materials within the tank. Various tanks may also include baskets, sieves, pans, filters, or other structures to collect and separate solids from liquids.In some embodiments, a tank can be configured to direct the flow of liquid or gas through the tank in order to agitate the mixture within it (e.g., flow-directing structures, pumps, impellers, deflectors, impellers, agitator bars, agitator blades, vibrators, cyclonic flow channels, etc.).

[0058] In some embodiments described in this document, a system for converting iron ore into metallic iron (i.e., an iron conversion system) may comprise two or more sub Petition 870260045431, dated 05 / 13 / 2026, page 30 / 460 22 / 200 systems. Some embodiments include a dissolution subsystem in which the components of an iron-containing feedstock are dissolved in an aqueous solution. Some embodiments further include a galvanizing subsystem in which the dissolved iron is electrochemically reduced to metallic iron in an electrogalvanizing process (or simply galvanizing). The metallic iron can subsequently be removed from the iron galvanizing subsystem.

[0059] In some embodiments, an aqueous solution containing iron may be transferred and treated in a transition subsystem after exiting the dissolution subsystem and before being fed to the galvanizing subsystem. Treatments within the transition subsystem may include pH adjustment, impurity removal, filtration, or other processes. In some embodiments, any of the above subsystems may be fluidically coupled to each other via an intersubsystem fluidic connection that may comprise any combination of fluid transport conduits (pipes, channels, troughs, etc.) and any number of flow control devices, including valves, pumps, expansion chambers, gas-liquid separators, solid-liquid separators, filters, or other similar devices.

[0060] The term iron electrogalvanizing (or iron galvanizing, as used herein as a synonym) refers to a process by which dissolved iron is electrochemically reduced to metallic iron on a cathodic surface. Equivalent terms electrodeposition, electroforming, and electroexposure are also used herein as synonyms for iron galvanizing. The shape or form factor of galvanized iron need not be a plate by any definition of this term. For example, iron Petition 870260045431, dated 05 / 13 / 2026, page 31 / 460 23 / 200 galvanized material can take any shape and can be deposited on any suitable cathodic surface, as described in various embodiments of this document.

[0061] The term dissolution step includes processes that occur in the dissolution subsystem, including, but not limited to, dissolution of iron oxide materials and electrochemical process(es) that occur in or through an acid regeneration cell, including, but not limited to, the claimed step of electrochemically reducing Fe3+ ions to Fe2+ ions in the acid regeneration cell. The dissolution step processes may also include the oxidation of water or hydrogen gas in the first electrochemical cell, for example, to generate protons, which may allow the regeneration of the acid (in the form of protons) that is used to facilitate the dissolution of an iron-containing feedstock.

[0062] The term galvanizing step includes process(es) occurring in the galvanizing subsystem including, but not limited to, the electrochemical process(es) occurring in or through the claimed galvanizing cell including, but not limited to, the step of electrochemically reducing Fe2+ ions to metallic Fe in the galvanizing cell, also referred to herein as the galvanizing cell. The iron galvanizing process may also include the oxidation of a second portion of Fe2+ ions to form Fe3+ ions. In some embodiments, such Fe2+ ions may be supplied from the first electrochemical cell or from another part of the system.

[0063] As used in this document, unless otherwise specified, the terms ferrous iron solution or ferrous solution may refer to an aqueous solution containing dissolved iron that is at least predominantly (i.e., between 50% and 100%) in the Fe2+ (i.e., ferrous) ionic state with the remainder being iron Petition 870260045431, dated 05 / 13 / 2026, p. 32 / 460 24 / 200 dissolved, being in the ferric state Fe3+. Similarly, the term ferrous ion refers to one or more ions in the ferrous state (Fe2+).

[0064] As used in this document, unless otherwise specified, the terms ferric iron solution or ferric solution may refer to an aqueous solution containing dissolved iron that is at least predominantly (i.e., between 50% and 100%) in the Fe3+ (i.e., ferric) ionic state, with the remainder of the dissolved iron being in the ferrous Fe2+ state. Similarly, the term ferric ion refers to one or more ions in the ferric state (Fe3+). Both ferric and ferrous solutions may also contain other dissolved ions or colloidal or particulate materials, including impurities.

[0065] As used in this document, any reference to a PEM or proton exchange membrane may be interpreted as also including a CEM or cation exchange membrane, both terms possibly including any available membrane material that selectively allows the passage of positively charged cations and / or protons. The abbreviation AEM is used to refer to anion exchange membranes selective for negatively charged aqueous ions and includes any available anion-selective membrane.

[0066] As used in this document, aqueous protons and electrochemically generated protons are intended to include aqueous protons and aqueous hydronium ions.

[0067] As used in this document, the term unprocessed ore refers to an iron-containing ore that has not been thermally reduced or air-roasted in accordance with embodiments described in this document. Unprocessed ore is optionally a raw iron-containing ore. Petition 870260045431, dated 05 / 13 / 2026, p. 33 / 460 25 / 200

[0068] As used in this document, electrochemically generated ions, such as electrochemically generated protons and electrochemically generated iron ions (e.g., Fe2+, Fe3+), refer to ions that are generated or produced in an electrochemical reaction. For example, the electrochemical oxidation of water at an anode can generate electrochemically generated protons and electrochemically generated oxygen.

[0069] As used in this document, the term thermal reduction refers to a heat treatment at an elevated temperature in the presence of a reducing agent. Thermal reduction is also referred to in the art as reduction roasting. Optionally, thermal reduction is carried out at a selected temperature in the range of 200 °C and 600 °C. Optionally, the reducing agent is a gas comprising gaseous hydrogen (H2).Further description and potentially useful thermal reduction methods can be found in the following reference, which is incorporated herein in its entirety: Hydrogen Reduction of Hematite Ore Fines to Magnetite Ore Fines at Low Temperatures, Hindawi, Journal of Chemistry, Volume 2017, Article ID 1919720.

[0070] As used in this document, the term parasitic hydrogen or hydrogen (H2) from a parasitic hydrogen evolution reaction of an iron plating process refers to hydrogen gas (H2) generated electrochemically by a side reaction simultaneously with an iron plating reaction (e.g., Fe2+ to Fe or Fe3+ to Fe2+ to Fe) in the same electrochemical cell. Further description and potentially useful embodiments regarding parasitic hydrogen evolution can be found in the following reference, which is incorporated herein in its entirety: An Investigation into Factors Affecting the Iron Plating Reaction for an All-Iron Flow Battery, Journal of the Electrochemical Society 162 (2015) A108. Petition 870260045431, dated 05 / 13 / 2026, page 34 / 460 26 / 200

[0071] As used in this document, the term air roasting refers to a heat treatment carried out at an elevated temperature in the presence of air. Air roasting of ore, such as iron-containing ore, can break down or reduce the average particle size of an ore. Optionally, open-air roasting is carried out at a selected temperature in the range of 300 °C and 500 °C. Further description and potentially useful embodiments of air roasting can be found in the following reference, which is incorporated into this document in its entirety: Study of the Calcination Process of Two Limonitic Iron Ores Between 250 °C and 950 °C, Revista de la Facultad de Ingeneria, p. 33 (2017).

[0072] As used in this document, the term redox pair refers to two chemical species, such as ions and / or molecules, that correspond to a reduced species and an oxidized species in an electrochemical reaction or a half-cell reaction. For example, in the electrochemical reduction of Fe3+ ions to Fe2+ ions, the corresponding redox pair is Fe3+ / Fe2+, where Fe3+ is the oxidized species and Fe2+ is the reduced species. As used in this document, the order in which a redox pair is described (e.g., Fe3+ / Fe2+ vs. Fe2+ / Fe3+) is not intended to denote which species is the reduced species and which is the oxidized species. Further description and potentially useful embodiments of redox pairs can be found in the following reference, which is incorporated herein in full: Redox - Principles and Advanced Applications, book by Mohammed Khalid, Chapter 5: Redox Flow Battery Fundamentals and Applications.

[0073] As used in this document, the terms steady state and steady-state generally refer to a condition or set of conditions that characterize a process, a method step, a reaction or reactions, a solution, a (sub)system, etc., that are true for longer than they are not. Petition 870260045431, dated 05 / 13 / 2026, p. 35 / 460 27 / 200 true during the operation or performance of the process, method step, reaction or reactions, solution, (sub)system, etc. For example, the dissolution of an ore or feedstock can be characterized by a steady-state condition, where the steady-state condition is true during at least 50%, optionally at least 60%, optionally at least 70%, optionally at least 80%, optionally at least 90%, optionally at least 95% of a time during which dissolution is occurring. For example, a steady-state condition can exclude the conditions that characterize the transient initiation and termination phases of a process, such as the dissolution of a feedstock.

[0074] The term cathodic chamber refers to a region, compartment, container, etc. comprising a cathode, or at least a part or surface thereof, and a catholyte. The term anodic chamber refers to a region, compartment, container, etc. comprising an anode, or at least a part or surface thereof, and an anolyte.

[0075] As used in this document, the term iron-rich solution may also be referred to as an iron-rich solution or a ferrous product solution, which corresponds to the iron ion-rich solution formed in the ore dissolution subsystem.

[0076] As used in this document, the term ore dissolution subsystem may also be referred to as dissolution subsystem, first subsystem, and STEP 1. The dissolution subsystem comprises the acid regenerator described in this document.

[0077] As used in this document, the term galvanizing subsystem can also be referred to as the second subsystem and STEP 2.

[0078] As used in this document, the term pH of Petition 870260045431, dated 05 / 13 / 2026, page 36 / 460 28 / 200 precipitation refers to a pH at which one or more of the cited ions or salts are thermodynamically favored or expected to precipitate from the host aqueous solution. In general, the solubility of ions and salts dissolved in an aqueous solution can depend on the pH of the aqueous solution. As the pH increases in the acidic region, many metal ions form metal hydroxides that tend to precipitate from the host solution due to decreased solubility. The precipitation pH is defined in this document as the pH that corresponds to a point where the solubility of a given ion or salt is below a concentration limit. The precipitation pH may be a maximum limit beyond which the solubility of a given ion or salt is less than 1 mM, optionally less than 0.1 mM.

[0079] As used in this document, the term metallic iron refers to a material comprising metallic iron such as, but not limited to, scrap iron, galvanized iron, iron powder, etc.

[0080] As used in this document, the term supporting salt and supporting ion refers to a salt and an ion, respectively, that correspond to or serve as a supporting electrolyte or that at least partially form a supporting electrolyte when dissolved in order to increase the conductivity of a host solution. In some embodiments, for example, the electrolytes and solutions in the dissolution subsystem and the galvanizing subsystem may contain dissolved iron species, acid, and additionally, inert salts that serve as a supporting electrolyte to increase the conductivity of the electrolyte, which may be particularly beneficial at low ferrous concentrations, where the inert salts that serve as a supporting electrolyte to increase conductivity may be referred to as supporting salts. Supporting salts may include any salt Petition 870260045431, dated 05 / 13 / 2026, p. 37 / 460 29 / 200 electrochemically inert, such as sodium chloride, potassium chloride, ammonium chloride, sodium sulfate, potassium sulfate, ammonium sulfate, sodium chloride, potassium chloride, ammonium chloride or others, or combinations of salts. The concentration of the supporting salts in the solution, if used, may vary from about 0.1 to about 1 M, for example.

[0081] As used in this document, the term % by weight or % by weight refers to a percentage by weight or a mass fraction represented as a percentage by mass. The term % at or % at refers to an atomic percentage or an atomic ratio represented as a percentage of one type of atom relative to the total number of atoms in a given substance, such as a molecule, compound, material, nanoparticle, polymer, dispersion, etc. The term % molar refers to the molar percentage or percentage by moles. The term % by volume refers to the percentage by volume.

[0082] As used in this document, the term and / or is used in this document, in the description and in the claims, to refer to a single element individually or to any combination of elements in the list in which the term and / or appears. In other words, a listing of two or more elements that has the term and / or is intended to cover embodiments that have any of the individual elements alone or that have any combination of the listed elements. For example, the phrase element A and / or element B is intended to cover embodiments that have only element A, that have only element B, or that have both elements A and B considered together. For example, the phrase element A, element B and / or element C is intended to cover embodiments that have element A only, that have element B only, that have element C only, that have elements A and B taken together, that have elements A and C. Petition 870260045431, dated 05 / 13 / 2026, p. 38 / 460 30 / 200 taken together, which have elements B and C taken together, or which have elements A, B, and C taken together.

[0083] As used in this document, the term ± refers to an inclusive range of values, such that X ± Y, where each of X and Y is independently a number, refers to an inclusive range of values ​​selected from the range XY to X+Y. In cases of X ± Y where Y is a percentage (e.g., 1.0 ± 20%), the inclusive range of values ​​is selected from the range XZ to X+Z, where Z equals X*(Y / 100). For example, 1.0 ± 20% refers to the inclusive range of values ​​selected from the range 0.8 to 1.2. DETAILED DESCRIPTION OF THE INVENTION

[0084] In the following description, numerous specific details of devices, device components, and methods are presented to provide a complete explanation of the precise nature of the various inventions described herein. However, it will be evident to those skilled in the art that the various inventions can be practiced without these specific details. Without wishing to be bound by any particular theory, there may be in this document discussion of beliefs or understandings of underlying principles relating to the devices and methods described herein. It is recognized that, regardless of the ultimate correctness of any mechanistic explanation or hypothesis, an embodiment of devices and methods may nevertheless be operational and useful.

[0085] Steel, a commodity valued at billions of dollars, is the cornerstone of the industrial world, responsible for three gigatons or about 10% of global carbon dioxide emissions per year. The conventional steel production process generates large CO2 emissions because coke (purified coal) is used as a reducing agent for iron ore (that is, to reduce iron oxide to metallic iron) and the Petition 870260045431, dated 05 / 13 / 2026, p. 39 / 460 31 / 200 Coal is used as fuel to heat and melt iron. Coal-based iron and steel production has been the most common and cheapest process for centuries. Unfortunately, the true social cost has only been postponed to the present, when rising atmospheric CO2 increasingly threatens to cause catastrophic climate change.

[0086] As the cost of renewable, carbon-free energy decreases, the shift from fossil fuels to clean electricity for steel production is an increasingly attractive alternative. However, the intermittent nature of renewable energy generation sources and the complexities of dissolving and reducing iron ores and removing impurities make electrically driven iron production very challenging.

[0087] The need for compatibility with the intermittency of renewable energies is particularly at odds with high-temperature processes that are difficult to refuse or interrupt unless a large reserve energy storage is available to maintain the high temperature. Therefore, there is a need for a low-temperature electrical process to produce sufficiently pure iron from iron ore, which also exhibits good compatibility with the intermittency of renewable energy.

[0088] Conventional wisdom among experts in the fields of hydrometallurgy and iron processing suggests that hydrometallurgical iron processing is economically impractical due to perceived thermodynamic and economic limitations in the dissolution rate of iron feedstocks, particularly iron oxide ores. These experts are even more skeptical about the ability to efficiently extract iron through galvanization due to the possibility of an electrochemical back-and-forth between the Fe2+, Fe3+, and Fe0 states in contact with an acidic solution. The systems and Petition 870260045431, dated 05 / 13 / 2026, page 40 / 460 32 / 200 methods described in this document provide various mechanisms for overcoming these perceived obstacles.

[0089] In various embodiments, the present invention provides processes, systems, and methods to enable efficient, low-temperature aqueous metallurgical processes for producing relatively pure metallic iron from various iron source materials, including relatively low-purity iron feedstock materials that may be incompatible with other available iron production and steelmaking processes. Solution-based iron extraction processes, such as those described herein, can generally allow for the highly economical separation and removal of impurities from iron feedstock materials of varying purity, while emitting zero greenhouse gases using clean electrical energy sources. In some cases, the waste materials produced during one process step can be advantageously used to improve other process steps.Several examples of these and other advantages will become evident from the description presented in this document.

[0090] In several embodiments described in this document, metallic iron can be extracted from iron feedstocks (including those with large amounts of iron oxide, such as most iron-containing ores) by dissolving the iron feedstock in an acidic solution, optionally treating the solution to remove some impurities, and then electrolytically depositing the metallic iron from the solution in a solid form that can be removed and used in subsequent processes to manufacture steel or other iron-containing products.

[0091] Most iron oxide ores contain iron in the iron(III) state. For example, the very common mineral hematite (Fe2O3) is entirely in the iron(III) state, and magnetite (Fe3O4) contains Petition 870260045431, dated 05 / 13 / 2026, p. 41 / 460 33 / 200Fe(III) in addition to Fe(II). When dissolved, hematite will dissociate into Fe3+ ions and magnetite will dissociate into Fe3+ and Fe2+ ions. To deposit iron electrolytically, any Fe3+ will first need to be reduced to Fe2+. In some embodiments of systems and methods described herein, the reduction of Fe3+ to Fe2+ and electroplating can be done in a single electrolytic cell, usually at the cost of substantial parasitic hydrogen evolution due to the incidental electrochemical reduction of protons to form hydrogen gas. In some embodiments, such hydrogen evolution is termed parasitic because it consumes charge and reagents from the cell and may be thermodynamically favored under certain conditions over more desirable reactions, such as the reduction of Fe2+ to Fe. In other embodiments of this document, the reduction of Fe3+ to Fe2+ and the electrolytic deposition step are performed in two separate electrolytic cells.This allows for the decoupling of processes and further facilitates the removal of impurities and other beneficial processes in the system.

[0092] Optional features, benefits and / or embodiments of the systems and methods described herein may include any of the following: (i) any acid may be used for dissolving iron feedstock materials including, but not limited to, hydrochloric acid, sulfuric acid, phosphoric acid, nitric acid, acetic acid, oxalic acid, citric acid, boric acid, perboric acid, carbonic acid, methanesulfonic acid or any mixture or combination thereof or other acids; (ii) the iron feedstock may include any iron-containing material that can be dissolved in an acid in a system such as those described herein, including steel scrap, cast iron scrap, iron powder, iron dust, iron ores or other iron-containing minerals; (iii) may include any iron oxide such as, but Petition 870260045431, dated 05 / 13 / 2026, page 42 / 460 34 / 200 without limitations, hematite (Fe2Oa), magemite, ferrihydrite, magnetite (FeaO4) or hydroxides, such as geotite (FeOOH), acaganite, lepidocrocite, ferrihydrite, limonite or any combination thereof; (iv) the various electrochemical cells and systems described herein may be operated over a wide pH range in the acidic range from less than zero to seven; and / or (v) hydrogen oxidation or other reactions may be used to replace water oxidation at the anode of the electrochemical cells.

[0093] To produce pure iron for steel production in large volumes, it is desirable that the iron-containing feedstock be a relatively low-cost source of iron. Iron ores exist in a wide range of purity, with common impurities including silicates, kaolinite (a clayey silicate mineral), phosphorus compounds, aluminum, sulfur, magnesium, calcium, and other elements or minerals. Since existing steel production processes require relatively high-purity iron ores, lower-purity ores and scrap materials with large amounts of impurities may be available at lower costs.The various aqueous iron production systems and methods described in this document can be used with iron feedstocks of any purity grade, including high-purity iron ores, low-purity iron ores, iron or steel scrap, iron powder, or other iron-containing materials, including many which would otherwise be considered waste due to their incompatibility with existing high-volume steel production processes. For example, fines or tailings from mining and ore beneficiation processes can also be used as iron feedstock materials in various embodiments of the systems and methods described in this document. Petition 870260045431, dated 05 / 13 / 2026, page 43 / 460 35 / 200

[0094] In some embodiments, iron ore (and other iron feedstocks) can be converted into an aqueous solution by dissolving the feedstock material in acid; however, the process is not necessarily easy or quick at low temperatures. Some exemplary embodiments are provided in this document for the pretreatment of some iron feedstock materials to improve the dissolution processes and / or subsequent removal of impurities. These may advantageously include the reuse of waste materials produced by other stages of the process.

[0095] Iron can be produced at low temperatures (broadly defined as below 120 °C and, in some specific forms, below 80 °C or below 70 °C) by galvanizing a solution containing dissolved iron salts. Since there is no need to continuously maintain a high temperature, such low-temperature processes are much more compatible with the intermittency of renewable energy sources.

[0096] In several embodiments of this document, iron dissolved in an aqueous solution can be electrochemically converted to metallic iron in a single step or in multiple steps. Iron can exist in solution in the form of ferric Fe3+ ions or ferrous Fe2+ ions. To convert any dissolved Fe3+ ions to metallic iron (Fe°), they must first be reduced to Fe2+ ions. In some embodiments, the reduction of Fe3+ to Fe2+ and the reduction of Fe2+ to Fe° can be done in a single cell. In other embodiments (for example, as described in this document with reference to Figure 2 - Figure 6), the reduction of ferric Fe3+ to ferrous Fe2+ can be dissociated from the reduction of Fe2+ to metallic iron Fe°. ONE-STEP IRON CONVERSION

[0097] In some embodiments, metallic iron can be produced from an aqueous solution of iron in a process in a Petition 870260045431, dated 05 / 13 / 2026, page 44 / 460 36 / 200 single step by reducing ferric and / or ferrous ions (from dissolving an iron feedstock in acid) into metallic iron through galvanization in a cathodic chamber of an electrochemical cell while oxidizing water to generate oxygen in the anode half-cell chamber.

[0098] An iron feedstock can be converted into an aqueous solution by dissolving the feedstock in acid (for example, as described in various embodiments elsewhere in this document). Once in solution, ferric iron can be directly converted to metallic iron using an electrolytic cell in which the reduction of ferric iron to metallic iron occurs at the cathode and the oxidation of water to oxygen occurs at the anode, according to the equations: Half-reaction at the anode: H2O ^ 2H++ 1 / 2O2 + 2e (EQ 1) Half-reaction at the cathode: Fe3++ 3e ^ Fe (EQ 2) General reaction: 2Fe3++ 3H2O ^ 6H++ 3 / 2O2 + 2Fe (EQ 3)

[0099] Figure 1A shows a schematic of the conversion according to this process. However, the dissolution of iron ore oxides in acids is generally not rapid and generates ferric salt (Fe3+) in most cases. The presence of predominantly ferric salt in the dissolved ore solution can cause inefficient galvanization of metallic iron due to interactions between the ferric iron in solution and the galvanized metallic iron. More seriously, if a proton exchange membrane (PEM) is used as a separating membrane in the electrochemical cell, the acid is generated on the cathode side, which is also the galvanization side. As a result, the acid produced tends to attack the galvanized iron, causing a very low Coulombic (or faradaic) efficiency in the cell.

[0100] In addition, the low pH of the acidic solution is likely Petition 870260045431, dated 05 / 13 / 2026, pp. 45 / 460 37 / 200 causes a parasitic hydrogen evolution reaction during iron galvanization. This hydrogen evolution further decreases the Coulombic (or faradaic) efficiency of the one-step iron conversion process. However, any hydrogen generated can be captured and reused for another purpose, as described elsewhere in this document.

[0101] Alternatively, as shown in Figure 1B, an anion exchange membrane (AEM) can be used. In this case, the acid is generated on the anode side, avoiding direct attack on the galvanized iron by the acid, but the acid is mixed on the water side, causing significant dilution and the acid cannot be easily recovered for later use in dissolving the iron ore. This would imply a production of non-recoverable acid and a large generation of acid waste.

[0102] In an alternative embodiment, instead of oxidizing water at the anode of the electrolytic cell, a stream of gaseous hydrogen can be directed to the anodic chamber to be oxidized at the anode. In some embodiments, such a hydrogen-depolarized anode can be made from lower-cost materials than may be required in some embodiments of an oxygen-developing anode. In several embodiments, the hydrogen for such an embodiment can be supplied from a hydrogen storage system or a hydrogen production system, such as a water electrolyzer (e.g., a PEM water electrolyzer, an AEM water electrolyzer, or an alkaline water electrolyzer).

[0103] An alternative two-stage iron conversion process overcomes the above shortcomings, while introducing new synergistic advantages. TWO-STAGE IRON CONVERSION

[0104] With reference to Figure 2, Figure 3, Figure 4 and Figure 6, in Petition 870260045431, dated 05 / 13 / 2026, pp. 46 / 460 38 / 200 In some embodiments, an iron conversion system 100 can be separated into two main subsystems: a dissolution subsystem 102 and a galvanizing subsystem 130. The dissolution subsystem 102 can generally be configured to dissolve iron feed materials 152 efficiently and relatively quickly at low temperatures to form a dissolved iron solution 122. The dissolution subsystem 102 can further be configured to convert ferric ions (Fe3+) in the dissolved iron solution 122 into ferrous ions (Fe2+) in an acid regeneration cell 104 before the dissolved iron solution 122 is transferred to a galvanizing cell 132 in the galvanizing subsystem 130.The galvanizing subsystem 130 can generally be configured to electrolytically galvanize dissolved ferrous iron into a solid form that can be removed in 148 and sold as relatively pure iron, and to prepare the galvanizing subsystem 130 for further galvanizing. Once the dissolved iron solution 122 is sufficiently depleted of ferrous iron by the galvanizing cell 132, it can be returned to the dissolution subsystem 102 for use in subsequent dissolutions coupled to the acid regeneration cell 104.

[0105] As will be described further below, in some embodiments the dissolved iron solution 122 can be divided into a galvanizing anolyte and a galvanizing catholyte. The galvanizing anolyte can be recirculated between a galvanizing anolyte tank 144 and the anodic chamber 138 of the galvanizing cell 132, within which the species in the galvanizing anolyte will be oxidized at the anodic electrode 140. The galvanizing catholyte can be recirculated between a galvanizing catholyte tank 142 and the cathodic chamber 134 of the galvanizing cell 132 where the iron will be galvanized at the cathode electrode 108. The iron can be removed at 148 from the galvanizing cell 132 by various methods, examples of which are described Petition 870260045431, dated 05 / 13 / 2026, pp. 47 / 460 39 / 200 below. In some cases, gaseous hydrogen may be released 146 from the cathodic chamber of the galvanizing cell 134. This gaseous hydrogen may be captured and stored for use in other subprocesses described in this document.

[0106] Separating the reduction of ferric iron to ferrous iron from the reduction of metallic iron to iron allows substantial improvements and cost savings in the overall system 100 compared with carrying out both reduction steps in a single galvanizing cell (for example, as described with reference to Figure 1A and Figure 1B).

[0107] As shown, the acid regeneration cell 104 can be configured to reduce ferric ions (produced during the dissolution of the raw materials 120) to ferrous ions in a cathodic chamber 106 while oxidizing a consumable reagent, supplied from a reagent source 116, at the anode 112. In some embodiments, the anodic reagent may be water and the anode 112 may release oxygen 111 from an anodic chamber 110. In alternative embodiments, the anode of the acid regeneration cell 110 may be configured to oxidize a gaseous hydrogen reagent supplied by the reagent source 116 (which may be a storage system or a hydrogen production system, such as a water electrolyzer).

[0108] In various embodiments, one or more treatment steps 124, 126, 128, 125, 127 may be performed to adjust the dissolved iron solution 122 to remove materials or to increase or decrease the concentrations of one or more components of the solution. For example, a treatment step 124 (Figure 2, Figure 6) may comprise directing the dissolved iron solution 122 exiting a dissolution tank 118 through a treatment vessel configured to remove solid particles and / or colloidal dispersions of materials released during dissolution. In some cases, silica from Petition 870260045431, dated 05 / 13 / 2026, pp. 48 / 460 40 / 200 iron raw materials may enter the dissolved iron solution 122 as a gel-like mass in a colloidal dispersion, which may interfere with operations within an acid regeneration cell 104. A treatment step 124 may comprise contacting the solution with a flocculant, such as polyethylene glycol, polyethylene oxide, or other flocculant known to be effective in removing colloidal silica from a solution. The treatment step 124 may further comprise any other solid-liquid separation techniques, devices, or additives as necessary to remove materials that may be detrimental to operations in the acid regeneration cell 104.

[0109] The galvanizing subsystem 130 may comprise a galvanizing cell 132 having a cathode electrode 136 in a cathodic chamber 134 that is fluidically coupled to a catholyte tank 142 and an anode electrode 140 in an anodic chamber 138 that is fluidically coupled to an anolyte tank 144. Iron ions may be reduced to galvanized metallic iron in the cathodic chamber 134 of the galvanizing cell 132, while ferrous ions are oxidized to ferric ions in the anodic chamber 138 of the galvanizing cell 132. Dissolution of iron raw material assisted by acid regeneration:

[0110] It has been discovered that the dissolution of iron ores (and other iron feedstocks) can be greatly accelerated by the use of an acid regeneration cell coupled to a dissolution tank 118. As shown in Figure 2, an acid regeneration cell 104 can be configured to recirculate an acid dissolution solution 122 between a cathodic chamber 106 of the acid regeneration cell 104 and one or more dissolution tanks 118. A source 116 of a consumable reagent 117 oxidizable to protons (e.g., Petition 870260045431, dated 05 / 13 / 2026, pp. 49 / 460 41 / 200 water, hydrogen gas or other oxidizable gaseous or aqueous substance to form protons) can be fluidically coupled to the anodic chamber of the acid regeneration cell 104.

[0111] The dissolution of an iron feedstock 120 coupled to an acid regeneration cell 104 involves dissolving the iron feedstock material in an aqueous acid solution in which the acid is electrochemically regenerated by an electrolytic acid regeneration cell 104. An example is provided below with reference to a hydrochloric acid (HCl) solution and in reference to Figure 2; however, the process is not limited to hydrochloric acid and can be conducted substantially in the same manner with any acid, including sulfuric acid, nitric acid, citric acid, acetic acid, boric acid, methanesulfonic acid, oxalic acid, or other acids. Similarly, hematite (Fe2O3) is given as an example of an iron ore feedstock, however, the process applies to all other iron feedstock materials, including goethite, magnetite (Fe3O4), siderite (FeCO3) and other ores and any other iron feedstocks.

[0112] In some embodiments, the iron feedstock 120 may be crushed or ground to form particles within a desired range before introduction into the dissolution tank 122. In other embodiments, the feedstock 122 may be pretreated by air roasting and / or thermal reduction (as described herein with reference to Figure 9 and Figure 10) before introduction into the dissolution tank 118.

[0113] When hematite is dissolved in a hydrochloric acid solution, the following reaction occurs: Fe2O3 + 6HCl ^ 2Fe3++ 6Cl-+ 3H2O (EQ 4)

[0114] Hematite transforms into ferric chloride when dissolved in hydrochloric acid solution. The dissolution of iron oxide in Petition 870260045431, dated 05 / 13 / 2026, page 50 / 460 42 / 200 is generally not a rapid reaction, and experiments have shown that increasing concentrations of ferric chloride (FeCh) as a product of hematite dissolution tend to slow the dissolution rate. On the other hand, increasing acid concentrations tend to support faster dissolution. Experiments have also shown that the addition of ferrous salts (Fe2+), such as ferrous chloride (the reduced form of ferric chloride), also tends to increase the dissolution rate. In fact, the combination of these effects can result in the substantially complete dissolution of hematite or goethite ores within acceptable timeframes of less than about 24 to 30 hours.

[0115] In one embodiment, the raw material dissolution process can be coupled to an electrochemical process, as shown in Figure 2. The dissolution tank 118 can be partially filled with solid iron raw material 120 (e.g., hematite and / or goethite in this example) and an acidic solution 122 (hydrochloric acid in this example). The hematite and / or goethite raw material can be partially dissolved by the acid to form a ferric chloride solution (i.e., FeCh which dissociates into Fe3+ and Cl- ions in solution), consuming acid while generating water in the process. If other types of iron ore are used, such as magnetite (Fe3O4) or siderite (FeCO3), the formation of ferrous chloride in addition to ferric chloride is possible.

[0116] The ferrous and ferric chloride solution 123 (denoted Fe2++ Fe3+ in Figure 2) can be fed from the dissolution tank 118 to the cathodic chamber 106 of the acid regeneration cell 104 (which may be a multi-cell stack). The acid regeneration cell 104 includes a cathode 108, an anode 112, and a separating membrane 114. The separating membrane 114 can be of any available type, including proton exchange membranes (PEMs) (or cation exchange membranes), anion exchange membranes (AEMs), microporous separators Petition 870260045431, dated 05 / 13 / 2026, page 51 / 460 43 / 200 polymeric or ceramic rosos or other porous separators, ionomers or combinations thereof.

[0117] In some embodiments, it is advantageous that the acid regeneration cell separator 114 be a PEM membrane or a microporous separator or a combination thereof to provide acid regeneration (protons) in the catholyte, allowing the protons produced in the anode 112 to pass through the cathodic chamber 106. Water from a reservoir 116 can be fed to the anodic chamber 110 of the acid regeneration cell 104. When an electric current is applied to the cell 104, the water is oxidized to generate gaseous oxygen and protons, according to half reaction (5). Half-reaction at the anode: H2O ^ 2H++ 1 / 2O2 + 2e (EQ 5)

[0118] If a proton exchange membrane (PEM) or a microporous separator is used as a separating membrane between the anode and cathode, the proton generated by the electrolysis of water (according to equation (5)) migrates from anodic chamber 110 to cathodic chamber 106.

[0119] At cathode 108, the reduction of ferric to ferrous occurs according to: Fe3++ e ^ Fe2+(EQ 6)

[0120] Note that the reaction can be controlled to stop at ferrous generation without going all the way to metallic iron deposition in the acid regeneration cell 104 or even just to hydrogen generation. Iron deposition can be caused by an insufficient supply of Fe3+ ions to the acid regeneration cell 104 at the current density at which it is being run. That is, if Fe3+ ions are being electrochemically reduced to Fe2+ at a faster rate than Fe3+ ions are being replaced by Fe3+ ions from the newly dissolved feedstock (e.g., at a very low or very high flow rate for a given current), then the next most likely reactions will be the reduction of Petition 870260045431, dated 05 / 13 / 2026, page 52 / 460 44 / 200 water to form hydrogen gas and then iron deposition. If this occurs, it will be detectable as a dramatic increase in cell voltage of at least 0.77 V above the steady-state ferric reduction. Therefore, if a significantly higher cell voltage (e.g., 0.77 V or more) than the ferric-to-ferrous conversion potential is detected, then hydrogen generation and / or iron deposition can be stopped and further prevented by increasing the flow rate of the ferric solution and / or decreasing the current density applied to the acid regeneration cell 104. In some embodiments, the current density of the acid regeneration cell can be increased or decreased in response to a detected or reported increase or decrease in the power available from an intermittent or renewable energy source.

[0121] On the other hand, some amount of iron deposition in the acid regeneration cell 104 is not necessarily a problem, since any iron deposited will be dissolved by new ferric (Fe3+) when the ferric concentration increases again. Therefore, in some embodiments, in response to the detection of iron deposition in the acid regeneration cell 104, the catholyte flow rate can be increased and / or the electric current applied to the acid regeneration cell 104 can be increased until the voltage returns to a normal range due to an increase in the concentration of ferric ions.

[0122] As the ferric solution is converted into a ferrous solution, the same result can occur (i.e., the amount of Fe3+ available may be too low for the applied current). Therefore, in some embodiments, it may be beneficial to operate the acid regeneration cell according to a so-called DC-CV protocol, in which the cell is operated at a constant current (DC), allowing the voltage to vary, until a threshold voltage is reached, where the threshold voltage indicates the start of iron deposition (or an average voltage). Petition 870260045431, dated 05 / 13 / 2026, p. 53 / 460 45 / 200 (mixed potential between ferric to ferrous conversion and iron galvanization). Upon reaching the cell's limit voltage (or half-cell), the acid regeneration cell 104 can be operated at a constant voltage equal to or below the limit voltage, allowing the current to decrease and asymptotically approach zero. The constant voltage can be applied until a target current or current density is reached (e.g., about 0.1 mA / cm2 to about 10 mA / cm2, optionally about 0.1 mA / cm2 to about 0.5 mA / cm2) or for a sufficient time for sufficient Fe3+ to be converted to Fe2+. The target current and / or the time required to reach sufficient current can be determined empirically and based on economic factors.

[0123] The proton from anode 112 of the acid regeneration cell 104 forms an acid with anions made available by the reduction of the ferric iron salt (e.g., hydrochloric acid can be formed with the chloride made available by the reduction of ferric chloride). The solution 125 exiting the cathodic chamber 106 of the acid regeneration cell 104 is thus enriched in ferrous salt and acid (e.g., ferrous chloride and hydrochloric acid). Since the formation of metallic iron is generally avoided at this stage, there is no loss of efficiency due to the acid attack on the metal. The solution 125 is then returned to the dissolving tank where the newly generated acid is used to dissolve more iron feedstock 120, converting it into ferric salt (e.g., ferric chloride) and the process continues. The acid is thus regenerated for further dissolution of the iron ore.

[0124] On the anode side 112 of the acid regeneration cell 104, the solution 117r exiting the anodic chamber 110 can be fed through a gas-liquid separation device (not shown in Figure 2) where oxygen can be removed from the solution before returning the remaining water to the water reservoir and subsequently back to the anodic chamber of the acid regeneration cell. Petition 870260045431, dated 05 / 13 / 2026, page 54 / 460 46 / 200 104. Alternatively or additionally, gas separation can be done directly within the water reservoir 116.

[0125] One function of the acid electrochemical regeneration cell 104 is to reduce ferric iron to ferrous iron, thereby converting the dissolution product into a different product with a reduced oxidation state. This removal of ferric ions prevents the accumulation of the dissolution product and has been found to substantially improve the dissolution rate of iron ore to a greater degree than expected. Furthermore, the process converts ferric iron, the accumulation of which could impede further dissolution, into ferrous iron, a compound that has been found to have a beneficial effect on the dissolution of iron oxide. During the dissolution process with continuous liquid recirculation, the acid regeneration cell 104 causes the ferric concentration to remain relatively low while increasing the ferrous concentration, thus generating double benefits for the dissolution of iron feedstocks containing substantial amounts of iron oxide.

[0126] A second function of the acid regeneration cell 104 is to regenerate the acid that is consumed by the dissolution of the iron feedstock. Without the acid regeneration cell 104, the acid concentration would progressively decrease as the dissolution progresses and the acid is consumed in the dissolution reaction. When a PEM is used as a separating membrane in the acid regeneration cell 104, the acid is regenerated and mixed with the iron-rich solution in the cathodic chamber 106 and returned to the dissolution tank 118, where both have a positive benefit on the dissolution of the iron feedstock 120.

[0127] In some embodiments, the dissolution tank 118 may be maintained at a temperature above ambient, since the higher temperature aids dissolution. Temperature ranges Petition 870260045431, dated 05 / 13 / 2026, page 55 / 460 Typical 47 / 200 temperatures can range from 20 to 120 °C, preferably between 40 and 100 °C in some embodiments and, particularly, between about 50 °C and about 90 °C. In several embodiments, the acid regeneration cell 104 can be operated at a temperature of about 40 °C to 80 °C, preferably around 60 °C + / - 10 °C. The current density applied to an acid regeneration cell 104 can range from about 0.1 A / cm2 to about 2 A / cm2.

[0128] In some embodiments, the final targets for dissolved iron concentration may typically be between 0.1 M and 4 M, preferably between 0.5 and 2 M in some embodiments. In general, the iron concentration should be kept below its solubility limit in the solution used, in order to avoid unwanted precipitation.

[0129] The flow rate of the catholyte through the cathodic chamber of the acid regeneration cell 106 can be controlled to provide at least the stoichiometric ratio of ferric ions to electrons for a given current applied through the acid regeneration cell 104 (as described above). Similarly, the flow rate of water (or other reagent) in the anodic chamber 110 is preferably maintained above the stoichiometric requirement for water splitting (or other reagent-consuming reaction) in the current applied to the acid regeneration cell 104. In various embodiments, the current applied to the acid regeneration cell 104 may be in the range of about 0.1 mA / cm2 to about 2,000 mA / cm2 or, in some more particular embodiments, in the range of about 0.5 mA / cm2 to about 1,000 mA / cm2 or may be variable within this range, depending on the available ferric concentration and / or the availability of electricity.As will become evident from the present invention and the accompanying drawings, the acid regeneration cell 104 can be operated at a different current density than the galvanizing cell 132. Petition 870260045431, dated 05 / 13 / 2026, page 56 / 460 48 / 200

[0130] In some embodiments, the cathode 108 for the acid regeneration cell 104 may be any carbon- or graphite-based electrode, such as carbon or graphite felt, paper or fabric, or any electrode material stable in the ferric / ferrous salt environment. The anode 112 of the acid regeneration cell 104 may be any typical electrode available in the water electrolysis technique including, but not limited to: precious metal electrodes (e.g., mixed metal oxides comprising metal and oxides or other compounds of Ir, Ru, Pt, Rh, Pd, etc.), dimensionally stable anode (DSA), lead and lead dioxide electrodes, other oxide-based electrodes, etc. The metal or mixed metal oxides may or may not be supported on a catalyst support, including titanium particles, etc.In some embodiments as described herein, the anode 112 of the acid regeneration cell 104 may be a hydrogen-depolarized anode configured to oxidize gaseous hydrogen and may therefore comprise any suitable hydrogen oxidation catalyst similar to those conventionally used in PEM-based hydrogen fuel cells, including platinum on carbon or any other hydrogen oxidation catalyst. The acid regeneration cell 104 may operate over a wide temperature range, from 20 to 100 °C, preferably from 40 to 80 °C in some embodiments.

[0131] The aqueous solution to be fed to the anodic chamber 110 of the acid regeneration cell 104 may be pure water or may include salts to increase the osmotic pressure relative to the catholyte, as described further below. In the case of sulfate chemistry, for example, the salt may include any soluble sulfate salt, such as ferric sulfate, sodium sulfate, potassium sulfate, ammonium sulfate, etc. Such supporting salts may be particularly beneficial in the electroplating cell. Petition 870260045431, dated 05 / 13 / 2026, page 57 / 460 49 / 200 in order to maintain the conductivity of the electrolyte, since ferrous iron is removed from the solution by the galvanizing reaction. This water may come from an external source or may be recovered from the system, since the dissolution of iron ore generates water, or it may be a combination of externally and internally recovered water.

[0132] As described in this document, water is produced by the dissolution of ores (which may also contain water in some cases). As a result, the water content continuously increases in the catholyte of the acid regeneration cell (i.e., the iron-rich acid solution that will eventually be transferred to the galvanizing cell), with greater dissolution of the ore causing greater dilution of the solution. At the same time, water is being split (and therefore consumed) in the anolyte of the acid regeneration cell 104. Therefore, it may be desirable to extract water from the catholyte of the acid regeneration cell 104 and add the extracted water to the water source feeding the anolyte. In some embodiments, this can be achieved by osmosis.Thus, in some embodiments, the anolyte 117 of the acid regeneration cell 104 can be supplied with a salt concentration that exceeds a maximum salt concentration in the acid regeneration catholyte 123 so as to create osmotic pressure for water to pass from the catholyte to the anolyte. In alternative embodiments, water can be extracted from the acid regeneration cell catholyte by means of more active methods such as rapid distillation, membrane distillation, reverse osmosis or other methods. The separated water can be filtered or otherwise purified, if necessary, before adding it to the acid regeneration cell anolyte at any convenient point.

[0133] In some embodiments, the acid solution can circulate continuously between the cathodic chamber of the acid regeneration cell 104 and a dissolution tank 118. In each cycle through the tank of Petition 870260045431, dated 05 / 13 / 2026, p. 58 / 460 50 / 200 dissolution 118, a portion of the acid will be consumed by the dissolution reaction (e.g., equation 4 above) and, in each cycle through the acid regeneration cell 104, a portion of the acid will be regenerated simultaneously with the reduction of a portion of the ferric acid. Therefore, by continuously recirculating the acid catholyte between the acid regeneration cell 104 and the dissolution tank 118, a steady-state acid concentration (e.g., measured by proton concentration or pH) can be maintained in the catholyte during most of the dissolution process. For example, in some embodiments, during steady-state dissolution operation coupled with acid regeneration, a proton concentration in the catholyte of at least 0.2 M can be maintained.In some embodiments, during normal operation, the initial state, defined as the start of a new cycle, corresponds to a predominantly ferric solution returning from the galvanizing subsystem, which has a low acid content. In some embodiments, the initial acid concentration (after the return of the electrolyte from the acid regeneration subsystem and before restarting the acid regenerator) will typically be at its lowest point in the cycle, generally less than 0.2 M (moles per liter). The reduction of the returned ferric iron in the acid regeneration cell can create the acid.

[0134] As shown in Figure 6, the dissolution tank 118 may comprise many separate tanks 118 that may be used sequentially or otherwise to further decouple the dissolution subsystem process and device 102 from the galvanizing process and device 130, conferring additional advantages with respect to managing the different reaction rates of the two stages. For example, in some embodiments, an acid solution may be recirculated between the acid regeneration cell 104 and a first dissolution tank 118 until a dissolution interruption point is reached. Petition 870260045431, dated 05 / 13 / 2026, page 59 / 460 51 / 200 desired cation is achieved, at which point the valves or other flow control devices can be operated to interrupt the flow between the acid regeneration cell 104 and the first dissolution tank 118 and to couple the acid regeneration cell 104 to a second dissolution tank 118. Alternatively or additionally, in some embodiments, an acid solution (acid regeneration catholyte) can be left resident in a dissolution tank 118 for a period of time before resuming flow with the acid regeneration cell 104. In these and other embodiments, a single acid regeneration cell 104 can be coupled to multiple different dissolution tanks 118 at different times.

[0135] In some embodiments, the conversion of Fe3+ to Fe2+ (ferric to ferrous) can typically be conducted as asymptotically as possible to a solution that is 0% ferric and 100% ferrous. In practical terms, some ferric ions will likely remain in solution when the dissolution process is considered complete, and the acidic pH may remain lower than the natural pH of a pure ferrous iron solution. If the pH of the solution remains too low (i.e., lower than the natural pH of a pure ferrous solution) during the iron galvanizing process, then a parasitic hydrogen evolution reaction may occur until excess protons are developed.In some embodiments, any remaining acid near the end of a dissolution process may be consumed by contact of the acid solution with a quantity of a highly soluble ore material (e.g., magnetite), as described herein with reference to Figure 10. Alternatively, any remaining ferric acid or ferric acid present at the end of the dissolution may be consumed in a treatment with accessory iron (which may also result in the evolution of hi). Petition 870260045431, dated 05 / 13 / 2026, page 60 / 460 52 / 200 hydrogen), as described below. Any hydrogen that is developed by such reactions can be captured and reused for another purpose, as described elsewhere in this document.

[0136] In various embodiments, the acidic solution in the catholyte 122 of the acid regeneration cell 104 may have a variable acid concentration ranging from 0.01 M to 6 M. As dissolution proceeds, the acid will be consumed. The acid regeneration cell 104 advantageously recovers one mole of protons for each mole of ferric iron that is reduced. However, each mole of ferric matter dissolved from the feedstock consumes three moles of protons, so further dissolution of the feedstock will further decrease the total proton concentration in the catholyte.

[0137] Therefore, in some embodiments, a dissolution process can be terminated when the acid concentration (e.g., measured by pH or another proton concentration measure) reaches a predetermined low point. For example, in some embodiments, a dissolution process can be terminated when the proton concentration in the acid regeneration catholyte falls to a low point of 0.4 M, 0.3 M, 0.2 M, 0.1 M (corresponding to a pH of 0.4, 0.52, 0.7, 1, respectively) or a lower point.

[0138] Alternatively or additionally, a dissolution process can be terminated when a total iron concentration (i.e., the sum of the Fe2+ and Fe3+ concentrations) reaches a desired maximum. In various embodiments, a desired maximum iron concentration can be from about 1 M to about 4 M. The total iron concentration can be measured using coulometric titration techniques, optical methods such as UV-visible spectroscopic analysis, red / green / blue (RGB) analysis, or other optical or spectroscopic techniques. In some specific embodiments, a dissolution process can be stopped when the desired iron concentration is reached. Petition 870260045431, dated 05 / 13 / 2026, p. 61 / 460 53 / 200 reaches a maximum of 1 M, 1.5 M, 2 M, 2.5 M, 3 M, 3.5 M, 4 M or higher, for example, depending on the acid chemistry.

[0139] In some embodiments, once a dissolution end condition has been identified, the ferrous iron-rich acid solution can be transferred from the acid regeneration cell 104 to a subsequent process step. In some embodiments, the next step may be an accessory iron treatment, as described below. In other embodiments, the ferrous iron-rich solution can be transferred directly to the galvanizing subsystem.

[0140] In other embodiments, when a dissolution end condition is identified, the electric current to the acid regeneration cell can be interrupted so as to cease acid regeneration, and the iron-rich acid catholyte can be brought into contact with a thermally reduced ore, such as magnetite, to consume a portion of the remaining acid. In some embodiments, the magnetite can be added to the dissolution tank after (or immediately before or approximately at the same time as) interrupting the current to the acid regeneration cell. In other embodiments, the catholyte solution can be redirected to a separate container containing substantially only magnetite ore.Since magnetite dissolves very rapidly compared to other types of ore (as described in this document), the contact of the catholyte solution with the magnetite at the end of the dissolution will tend to consume a portion of the remaining acid (protons), thus decreasing the amount of acid to be removed or consumed in subsequent steps (for example, in a galvanizing cell, in a polishing cell, or in an accessory iron treatment, as described in this document). In various embodiments, other processes involving the sequential dissolution of differently processed ores are possible, some embodiments of which are described. Petition 870260045431, dated 05 / 13 / 2026, page 62 / 460 54 / 200 below with reference to Figure 5A and Figure 5B.

[0141] In other embodiments, when a dissolution end condition is identified, the electric current to the acid regeneration cell 104 can be interrupted so as to cease acid regeneration and the iron-rich acid catholyte can be contacted with a reduced ore, such as magnetite, to consume a portion of the remaining acid. In some embodiments, magnetite can be added to the dissolution tank 118 after (or immediately before or approximately at the same time as) stopping the current to the acid regeneration cell 104. In other embodiments, the catholyte solution can be redirected to a separate container containing substantially only magnetite ore (as further described with reference to Figure 10 below).Since magnetite dissolves very rapidly compared with other types of ore (as described in this document), the contact of the catholyte solution with the magnetite at the end of the dissolution will tend to consume a portion of the remaining acid (protons), thus decreasing the amount of acid to be removed or consumed in subsequent steps (for example, in a galvanizing cell, in a polishing cell or in an accessory iron treatment, as described in this document). In several embodiments, other processes involving the sequential dissolution of differently processed ores are possible, some embodiments of which are described below with reference to Figure 10.

[0142] In some embodiments, as described elsewhere in this document, an optional solid-liquid separation step 124 can be performed after each cycle through a dissolution tank.In some cases, the dissolution of the iron raw material may cause a quantity of silica (or other undissolved material) to enter the liquid as particles or a colloidal dispersion. Therefore, in some embodiments, it may be desirable to separate the silica. Petition 870260045431, dated 05 / 13 / 2026, p. 63 / 460 55 / 200 solid material(s) from the solution before returning the solution to the acid regeneration cell 104. In some embodiments, the solids can be removed at this stage by any suitable solid-liquid separation device or technique, including filtration, gravity sedimentation, hydrocyclones, flocculation, high-shear or low-shear cross-flow separation, or any combination thereof or similar. In some embodiments, colloidal material, such as silica, can be removed by flocculation with a flocculant, such as polyethylene glycol, polyethylene oxide, or similar materials. In some embodiments, an additional treatment step 126 (Figure 4), such as an accessory treatment with iron, a solid-liquid separation, or another treatment process, can be carried out on all the liquid exiting the dissolution subsystem 102.In some embodiments, for example, insoluble materials, such as quartz, can be separated by filtration or other solid-liquid separation. In some embodiments, for example, the insoluble but fine suspension, such as colloidal silica, can be removed in a separate step, such as flocculation, optionally followed by filtration, sedimentation and / or other means of physical separation.

[0143] In several embodiments, an acid regeneration cell 104 can be configured as a single cell or as a stack of cells in which multiple electrochemical acid regeneration cells are combined into a common unit 104, either in a series-connected electrically bipolar configuration, or in a parallel-connected electrically monopolar configuration, or in a combination thereof.Acid regeneration cell stacks can be configured in any common manner for electrochemical cell stacks, including filter-press configurations (e.g., compressed by hydraulic pistons or by tie rods or others). Petition 870260045431, dated 05 / 13 / 2026, page 64 / 460 56 / 200 compression devices) or other configurations. In various embodiments, typical additional components of an electrochemical cell may include current collectors, bipolar plates, flow channels, terminal plates, etc.

[0144] In several embodiments, additional components or equipment may be included, such as filtration systems, pumps and heat exchangers, etc., to provide other operations, including fluid transfer from the dissolution tank to the acid regeneration cell 104 and to / from other subsystems and to allow temperature regulation. In some embodiments, raw ore, roasted ore and / or reduced ore may be supplied, such as in a selected sequence, in the same dissolution tank, for example, to selectively vary the feedstock conditions. In some embodiments, instead of using multiple tanks, raw ore, roasted ore and / or reduced ore may be supplied, such as in a selected sequence, in the same dissolution tank, for example, to selectively vary the feedstock conditions. IRON TREATMENT (ACCESSORY)

[0145] In some embodiments, all or part of an iron-rich acid solution at the end of a dissolution process can be directed to a reaction vessel in which an accessory iron treatment process can be carried out. Depending on the condition of the iron-rich acid solution at the end of dissolution and the desired condition of a solution to be fed to a galvanizing subsystem, one or more of three possible reactions can occur: acid consumption, ferric reduction and / or impurity precipitation.

[0146] Metallic iron used for the purpose of reacting or otherwise modifying the composition of an acidic, iron-rich solution is referred to herein as accessory iron and may include Petition 870260045431, dated 05 / 13 / 2026, page 65 / 460 57 / 200 any material comprising metallic iron in particles of a size sufficiently small to promote the desired reactions with the solution. Iron accessory materials may include, but are not limited to, steel scrap, iron scrap, iron powder (e.g., fine powder containing particulate iron from other industrial processes), pig iron, electrolytic iron, or recycled iron from any iron conversion process described herein (or other processes), or combinations thereof or of other materials containing metallic iron. Iron accessory materials may have any particle size, but smaller particles may generally be capable of faster reaction rates. However, even relatively large particles (e.g., larger than 2 cm) may be used as iron accessory in some embodiments.

[0147] When an acidic solution rich in iron comes into contact with metallic iron, any remaining acid will tend to react with the metallic iron to convert the metallic iron into ferrous ions (Fe2+) while releasing hydrogen gas according to: Fe + 2H' > Fe2++ H2 (EQ 7)

[0148] Therefore, in some embodiments, the accessory iron reaction vessel (e.g., a tank or other vessel in which the solution can come into contact with the accessory iron) can be configured as a closed vessel from which the developed hydrogen gas can be collected and directed to another vessel, process, or subsystem as described elsewhere in this document.

[0149] In some embodiments, any remaining Fe3+ ions present in the iron-rich acid solution at the end of a dissolution process can be reduced to Fe2+ by exposing the Fe3+ ions to metallic iron, which will be dissolved and react with the ferric ions to convert them into ferrous ions. For example, Fe3+ can be Petition 870260045431, dated 05 / 13 / 2026, p. 66 / 460 58 / 200 is reduced in Fe2+ when a predominantly ferrous solution flows over or through a quantity of metallic iron particles (accessory iron). This will have the effect of converting some of the metallic iron and Fe3+ into Fe2+ in solution according to the equation: Fe3++ Fe ^ 2Fe2+(EQ 8)

[0150] Advantageously, these two reactions (acid consumption and ferric reduction) will increase the efficiency of iron galvanizing in the galvanizing subsystem, both by decreasing (or potentially eliminating) Fe3+ and by decreasing the occurrence of the parasitic hydrogen evolution reaction during the iron galvanizing process.

[0151] In some embodiments, the excess acid and ferric ions can be consumed in a separate electrochemical cell (polishing cell) configured to electrolytically convert the remaining Fe3+ to Fe2+ and increase the pH of the catholyte by consuming acid. Such a cell can allow the dissociation of impurity removal from the excess acid and ferric consumption process. In some embodiments, a polishing cell can be configured substantially similarly to a galvanizing cell, but without the need to provide metallic iron removal.In some embodiments, a polishing cell can be configured to cause the evolution of H2 without any electroplating and using precious metal electrodes, such as Pt, at the cell's cathode. IMPURITIES REMOVAL

[0152] Some impurities, including kaolinite and other silicate minerals, are generally insoluble in the acidic solution produced in the acid regeneration cell. Therefore, when ores or other raw materials containing such insoluble impurities are crushed into small particles and placed in a dissolving tank connected to an acid regeneration cell 104, the insoluble impurities Petition 870260045431, dated 05 / 13 / 2026, page 67 / 460 59 / 200 can be filtered from the solution, collected at the bottom of the tank and removed from the tank as solids or removed by means of any other suitable solid-liquid separation technique or device. In various embodiments, the collected solid impurities can be treated and disposed of or used in other processes for which the impurities can be feedstocks.

[0153] Some solid impurities, including some forms of amorphous silica, may tend to form a colloidal dispersion in the acidic solution. Such materials can be separated from the solution by flocculation with a flocculant, such as polyethylene glycol or polyethylene oxide. However, some silica may remain dissolved.

[0154] Some impurities can form compounds of relatively low solubility with iron or other materials in solution. The term solubility refers to the thermodynamic solubility limit of the compound in a given solution, which is the concentration limit above which the compound will begin to precipitate from the solution as a solid.

[0155] Significant soluble impurities include compounds of aluminum, silicon, titanium, and phosphorus, among others. Aluminum compounds dissolve to form Al3+ cations, and phosphorus can typically dissolve to form phosphate PO43-. These impurities can pose several problems for subsequent processes such as pumping, filtration, acid regeneration, iron galvanizing, etc. Aluminum impurities can exist in iron ores in amounts up to about 10 percent by weight of the unprocessed ore. Although phosphorus tends to exist in much smaller amounts (e.g., typically less than 1%, but can be more), even small amounts of phosphorus must be removed before steelmaking processes and is therefore undesirable in galvanized iron produced by the galvanizing cell. In particular, impurities have been found Petition 870260045431, dated 05 / 13 / 2026, page 68 / 460 60 / 200 aluminum and phosphorus interfere with iron galvanizing processes.

[0156] As shown in Figure 8A, the solubility of aluminum hydroxide decreases significantly as the pH increases above 3 (e.g., a solubility drop of 6 orders of magnitude between a pH of 3 and 5). Although not shown, iron(II) hydroxide (Fe(OH)2 or ferrous hydroxide) has a higher solubility in this pH range. This suggests that aluminum hydroxide (Al(OH)3) can be precipitated without substantial precipitation of iron ions by increasing the pH above 3 to about 5 (e.g., from a pH of about 1 or 2 at the end of dissolution). Similarly, iron or aluminum phosphates can also be precipitated without necessarily precipitating substantial amounts of iron for similar reasons. In some cases, colloidal silica can also be removed by increasing the pH of the solution (e.g., by flocculation along with precipitation of other species).Titanium hydroxide, if present, will also precipitate in a similar pH range and can also be separated and removed from the solution.

[0157] In general, it is desirable to increase the pH of the dissolved ore solution without adding new elements to the solution (since any new elements may affect and / or further complicate other processes). Therefore, in some embodiments, metallic accessory iron can be used to increase the pH of the solution sufficiently to precipitate these impurities.

[0158] As the pH increases with the additional consumption of accessory iron (i.e., by reacting with acid to form hydrogen gas), phosphorus will tend to precipitate predominantly as an aluminum phosphate salt, so that iron is not necessarily consumed during phosphorus removal. Al3+(aq) + PO43-(aq) (at pH = 1) ^ AlPÜ4(s) (at pH = 3) (EQ 9) Petition 870260045431, dated 05 / 13 / 2026, pp. 69 / 460 61 / 200

[0159] For metallic cations such as aluminum, iron displaces the cation in solution to precipitate the metal as hydroxide. In a system designed to produce substantially pure iron, the amount of an impurity can be expressed in terms of the molar ratio of the impurity to iron. For example, for each mole of aluminum to be removed, 1.5 moles of accessory iron must be used according to equation 10 (using sulfuric acid as a non-limiting example): Al2(SO4)3 (aq ) + 3Fe + 6H2O ^ 2Al (OH)3 (s) + 3FeSO4 (aq ) + 3H2 (EQ 10)

[0160] Water is consumed and hydrogen gas is generated by this reaction. The protons removed were acidic due to the hydrolysis of the cation (equation 11 below). In some cases, at least a portion of the hydrogen gas developed can be collected and used in another process within the system, as described in this document. Al3++ H2O ^ AlOH2++ H+(EQ 11)

[0161] In some cases, it may be beneficial to remove impurities by adding iron only to the portion of the iron-rich acid solution to be used for iron galvanizing (i.e., the portion of the solution to be used as the galvanizing catholyte). Therefore, in the case where an acid regenerator is used and the electrolyte is split into two parts for the galvanizing step, only the portion designated as the galvanizing cell catholyte (e.g., about 1 / 3 of the electrolyte exiting the acid regenerator) can be treated by adding accessory metallic iron.

[0162] As metallic iron is dissolved in the solution, it will also convert any dissolved ferric iron (Fe3+) into ferrous iron (Fe2+). For example, 0.5 mol of metallic iron will be consumed for each mole of ferric sulfate converted into ferrous sulfate according to Equation EQ 12 (as, for example, in the case of sulfuric acid): Petition 870260045431, dated 05 / 13 / 2026, page 70 / 460 62 / 200 Fe2(SO4)3 + Fe^3FeSO4 (EQ 12)

[0163] Dissolved metallic iron can also consume the remaining acid in the treated electrolyte in a molar ratio of 1 to 1 according to Equation EQ 13: H2SO4 + Fe ^ FeSO4 + H2 (EQ 13)

[0164] Therefore, the amount of accessory iron to be added to a quantity of electrolyte can be determined based on measured, estimated, or presumed amounts of impurities (e.g., aluminum and / or phosphorus in particular), remaining ferric ions, and remaining acid. It may be beneficial to expose the electrolyte to excess accessory iron (i.e., more metallic iron than is required to achieve the reactions of Equations EQ 10, EQ 11, EQ 12, EQ 13, so that some metallic iron remains after such reactions have occurred as much as is desired). If necessary, the accessory iron can be separated from the precipitated impurities by various separation methods, including flotation, filtration, and magnetic separation. Similarly, the precipitated impurities can be removed from the solution by means of any suitable solid-liquid separation devices or techniques.In some embodiments, the treated solution can be pumped out of the vessel where the impurity removal treatment (and / or accessory iron) is carried out, leaving the metallic iron and precipitated impurities in the tank for the next treatment cycle.

[0165] Even if aluminum is not present, phosphorus can be effectively removed by precipitation of iron phosphates, as suggested by the solubility diagram in Figure 8B and Figure 8C, which shows the solubility of various phosphate and iron oxide compounds. At the beginning of the treatment phase, there is always a residual ferric concentration. As seen in Figure 8C, ferric phosphate has a very low solubility and therefore, as soon as the pH increases due to the reaction in EQ. 7, the iron phosphate will precipitate from the solution. Petition 870260045431, dated 05 / 13 / 2026, page 71 / 460 63 / 200

[0166] Several other methods of managing or removing impurities can be used depending on the type of impurity. For example, insoluble impurities can simply be removed as solids by filtration, gravity, centrifugal separation, or other mechanical separation. Soluble impurities that could interfere with the galvanizing of iron can be removed by forming compounds with other materials, such as iron (including during treatment with accessory iron), aluminum, or can simply be deposited along with the iron if the concentration of such impurities in the final galvanized material is acceptable (which may depend on the specific product or end use of a produced iron material).

[0167] Soluble impurities that are harmless to galvanizing can simply be left in solution. Eventually, the concentrations of such impurities may increase to such an extent that they can be removed by water extraction. Alternatively, the concentration of infrequent impurities may eventually increase (for example, over sufficient cycles of dissolution and galvanizing) enough to be removed by precipitation due to a change in pH or by other methods. In still other embodiments, an electrolytic solution can simply be replaced when such impurities reach sufficient levels. IRON GALVANIZING SUBSYSTEM

[0168] In some embodiments, the one-step iron conversion process described above with reference to Figure 1A and Figure 1B can be adapted for use in converting ferrous iron produced in the acid regeneration cell 104 into metallic iron in a second electrochemical cell configured differently from the galvanizing cell 132 described above. In such embodiments, the ferrous iron solution from the acid regeneration cell 104 can be used for galva Petition 870260045431, dated 05 / 13 / 2026, page 72 / 460 64 / 200 oxidize metallic Fe at the cathode of an electrochemical galvanizing cell (not shown), while simultaneously oxidizing water at the anode of the same galvanizing cell. An anion exchange membrane can be used in this document so that the acid is generated on the anode side (i.e., the water oxidation side, thus minimizing acid reactions with the galvanized iron). However, such embodiments have the disadvantage that the water separation electrode can be relatively expensive and is therefore more economically operated at a high current density, while the iron galvanizing reaction proceeds relatively slowly and cannot be effectively conducted at high current densities.

[0169] In some embodiments, a lead oxide electrode can be used as a relatively low-cost oxygen evolution anode in a galvanizing cell, which can make lower current density operation more economically practical. In an alternative embodiment, the galvanizing cell anode can be a hydrogen oxidation anode configured to oxidize gaseous hydrogen supplied from a source, such as a hydrogen storage device or directly from a water electrolyzer (e.g., a PEM, AEM, or alkaline water electrolyzer). Another approach to lowering galvanizing cell costs is to associate the iron deposition reaction (ferrous reduction) with a different oxidation reaction, such as the oxidation of a portion of the ferrous solution from the dissolution subsystem.

[0170] With reference to Figure 6 (but also to other figures), some embodiments of an iron conversion system 100 may include a galvanizing subsystem 130 configured to produce metallic iron from the aqueous iron solution produced in the dissolution subsystem. As described above, the dissolution process Petition 870260045431, dated 05 / 13 / 2026, page 73 / 460 65 / 200 in the dissolution subsystem 102 can be operated until the iron concentration in the solution reaches a desired value. At this point (or after subsequent treatment, such as treatment with accessory iron), the solution is preferably a predominantly ferrous solution. In some embodiments, the solution can then be divided into two separate streams representing a catholyte and an anolyte to be used in a galvanizing cell 132.

[0171] The solution exiting the dissolution subsystem 102 can be transferred to a galvanizing subsystem 130 via a transfer system 164. The transfer system 164 is illustrated as a simple conduit, but may include any number of flow control or process control devices as needed. Similarly, at the end of a galvanizing process, some consumed electrolytic solutions may be transferred from the galvanizing subsystem 130 to the dissolution subsystem 102 via transfer 166, which may also include any number of flow control or process control devices as needed.

[0172] In some embodiments, a solution entering a galvanizing subsystem 130 may be divided into catholyte and anolyte streams in proportions of approximately one-third and two-thirds of the original liquid volume entering the galvanizing subsystem 130. The one-third volume may be directed to and stored in one or more catholyte storage tanks 142, and the two-thirds volume may be directed to and stored in one or more separate anolyte storage tanks 144. For simplicity of description, it is assumed in this document that there is one catholyte storage tank and one anolyte storage tank. In various embodiments, the two tanks 142, 144 may have different volumes or may have the same volume and the volumes Petition 870260045431, dated 05 / 13 / 2026, page 74 / 460 66 / 200 can be used at different volumetric rates. The catholyte tanks 142 and anolyte 144 can be fluidically connected to the cathodic chamber 134 and anodic chamber 138, respectively, of an electrochemical galvanizing cell 132.

[0173] The electroplating cell 132 may include a cathodic chamber 134 having a cathodic electrode 136, a membrane 150 and an anodic chamber 138 having an anodic electrode 140. The two electrodes 136, 140 are separated by a membrane 150, which may be a PEM, AEM or microporous separator. Typical additional components of an electrochemical cell or stack may include current collectors, bipolar plates, flow channels, terminal plates, etc., depending on the chosen electroplating cell configuration. Examples of electroplating cell configurations are described elsewhere in this document, but any electroplating cell configuration may be used.

[0174] As shown in Figure 4, a galvanizing cell 132 can be configured to galvanize metallic iron on a cathode electrode 136 while oxidizing a portion of the Fe2+ ions into Fe3+ ions. In this configuration, the cost of an oxygen-evolving anode is avoided by using a very low-cost carbon or graphite anode material.

[0175] When an electric current is applied through the galvanizing cell, metallic iron is galvanized at the cathode, reducing ferrous ions according to: Fe2++ 2e A Fe (QA 14)

[0176] Simultaneously, the ferrous solution anolyte stream can be oxidized to ferric at the anode of the galvanizing cell, according to: 2Fe2+Al2Fe3++ 2e (EQ 15)

[0177] The combination (EQ 14) and (EQ 15) gives the general reaction of Petition 870260045431, dated 05 / 13 / 2026, page 75 / 460 67 / 200 galvanizing cell: 3Fe2+A2Fe3' + Fe (EQ 16)

[0178] The electrogalvanizing reaction of iron requires two electrons per ferrous ion (Fe2+), while the oxidation of ferrous to ferric (Fe3+) requires only one electron per ion. To achieve charge balance, there is a need for twice as many ferrous ions on the anode side 138 of the galvanizing cell 132 as on the cathode side 134. This is the ratio for dividing the ferrous solution entering the galvanizing subsystem into 1 / 3 (catholyte) and 2 / 3 (anolyte) of the initial ferrous solution of the acid regeneration cell 104. This implies that the anolyte flow rate through the anode side 138 of the galvanizing cell 132 can be twice that of the catholyte through the cathode side 134. In some embodiments, the anolyte flow rate can be more than twice the catholyte flow rate. In some applications, the anolyte flow rate may be less than twice the catholyte flow rate.

[0179] In some embodiments, the ferrous solution entering the galvanizing subsystem 130 can be divided into anolyte and catholyte portions in different proportions, depending on the efficiency of one or both electrodes, the total iron concentration, or other factors. Therefore, in several embodiments, the ferrous solution entering the galvanizing subsystem can be divided into catholyte and anolyte portions in catholyte / anolyte ratios of about 90% / 10% to about 20% / 80%, optionally 70% / 30% to about 30%. % / 70% and, in some particular embodiments, the catholyte / anolyte ratios may include 80% / 20%, 70% / 30%, 75% / 25%, 70% / 30%, 65% / 45%, 60% / 40%, 65% / 35%, 50% / 50%, 45% / 65%, 40% / 60%, 35% / 65%, 33% / 67%, 30% / 70%, 25% / 75%, 20% / 80% (all values ​​may vary by + / - 3%).

[0180] The galvanizing anolyte and catholyte can be recirculated between their respective tanks 144, 142 and their respective chambers. Petition 870260045431, dated 05 / 13 / 2026, page 76 / 460 68 / 200 half cell 138, 134 in the galvanizing cell 132 for any number of galvanizing cycles (where a galvanizing cycle comprises the complete replacement of a volume of anolyte and catholyte in the galvanizing cell). In some embodiments, the fluid circulation of the galvanizing anolyte and galvanizing catholyte may be continuous when electric current is applied.

[0181] In some embodiments, the galvanized iron can be removed in 148 from the cathodic chamber 134 and / or the cathodic substrate and the galvanized electrolytes can be recycled to the dissolution subsystem 102 for reuse in further dissolution and acid regeneration operations. In some embodiments, the galvanizing process can be completed once a desired quantity of iron has been discontinuously galvanized. In other embodiments, the galvanized iron can be continuously removed from the galvanizing cathodic chamber 134 and the electrolytes can be replaced once the reagents (e.g., Fe2+) have been consumed beyond a desired point.

[0182] In various embodiments, the 134 cathodic galvanizing half-cell can be configured to galvanize iron in any manner that allows for the removal of the galvanized iron material. Various methods of galvanizing and metal removal are used in other hydrometallurgical galvanizing operations, any of which can be adapted for use in the present iron galvanizing system.

[0183] Depending on the method chosen for galvanizing and removing iron from the cathodic half-cell, the galvanizing cell can be operated in a discontinuous mode, in which galvanizing is interrupted as soon as a desired amount of iron has been galvanized so that the iron can be removed. Alternatively, the galvanizing cell can be configured so that galvanizing Petition 870260045431, dated 05 / 13 / 2026, page 77 / 460 69 / 200 occur in a continuous mode with the iron being continuously removed from the cathodic chamber. In some embodiments, the continuous removal of galvanized iron may be similar to the configurations used in some conventional electrolytic zinc and copper extraction systems.

[0184] For example, iron may be galvanized as a plate or sheet on a solid metal or graphite substrate (e.g., steel, copper, lead, zinc, nickel, or other material galvanized or electrogalvanized with one or more of the same or other metals or their alloys). In several embodiments, the cathodic electrode and / or galvanizing substrate 136 may be removable from the cathodic chamber 134 or may be configured so that iron can be removed from the cathodic chamber 134 without removing the cathodic electrode or substrate 136. In some embodiments, a substrate may be removable from a cathodic electrode.In some embodiments, such a substrate may be substantially flat, and the galvanized iron may be removed discontinuously by chipping, forging, scraping, bending, or otherwise separating a flat iron plate from the substrate. In other embodiments, a substrate may be cylindrical, and the galvanized iron may be removed continuously by rotating the cylinder against one or more knives that separate the galvanized iron as a sheet, wire, strip, or other continuous material. In still other embodiments, the iron may be galvanized on a continuous belt that moves through a cathode of the galvanizing cell, and the iron may be separated from the belt at a location outside the cathodic chamber. In other embodiments, the iron may be separated into seed particles that may increase in size according to particle growth, and the particles may be removed from the cathodic chamber by any suitable separation mechanism.Several other galvanizing and iron removal processes can also be used. Petition 870260045431, dated 05 / 13 / 2026, p. 78 / 460 70 / 200

[0185] In several embodiments, the end of galvanizing can be determined based on the mass of galvanized iron, the measured remaining concentration of ferrous ions in the galvanizing catholyte, the cell voltage, or other metrics. For example, in some embodiments, a galvanizing cycle can be completed when a target thickness between about 1 mm and about 10 mm is reached.

[0186] Once the anolyte and electroplating catholyte are substantially depleted of reagents, i.e., ferrous materials, the electrolytes can be redirected to another process. In some embodiments, the catholyte may have a lower ferrous content than initially, and the anolyte may have predominantly ferric species instead of ferrous ones. In some embodiments, the consumed anolyte and catholyte can be combined and redirected back to the dissolution tank or the acid regeneration cell 104 of the dissolution subsystem to be reused in a new dissolution cycle.

[0187] In some embodiments, it may be desirable to maintain at least a minimum concentration of Fe2+ ions in the galvanizing catholyte during galvanizing. Experiments have shown that when the ferrous concentration of the galvanizing catholyte falls below about 0.25 M, the efficiency of the galvanizing cell and the quality of the galvanizing tend to degrade. Therefore, in some embodiments, it may be desirable to maintain a ferrous concentration of at least 0.25 M or more throughout the galvanizing process.

[0188] In order to effectively maintain a minimum ferrous concentration and use the electrolyte optimally, an alternative approach can be used to establish anolyte and catholyte volumes for the galvanizing subsystem. For example, to maintain a minimum ferrous concentration in the galvanizing catholyte, it may be beneficial to stop galvanizing when the ferrous concentration of the catholyte drops to a Petition 870260045431, dated 05 / 13 / 2026, page 79 / 460 71 / 200 low point (e.g., as measured by optical, spectroscopic or other methods) or when the electroplating voltage of the cell rises above a set point (e.g., above about 2.4 V, 2.5 V, 2.6 V, 2.7 V, 2.8 V, 2.9 V or 3 V in various embodiments) and then use the consumed catholyte as anolyte in a new electroplating process.

[0189] Figure 13A illustrates an experimental galvanizing cell 1300 comprising compression terminal plates 1302 and 1314, current collector plates 1304, 1312, electrode transport plates 1306 and 1310 supporting an anode electrode 1318 and a cathode electrode 1320 with a space 1316 in which the galvanized iron can expand. A separator 1308 divides the chamber containing the anode from the chamber containing the cathode.

[0190] Figure 5A and Figure 5B illustrate embodiments for storing and using galvanizing anolyte and galvanizing catholyte solutions that can advantageously facilitate maintaining at least a minimum iron concentration in the galvanizing catholyte while producing a ferric-rich solution to be returned to the dissolution subsystem upon completion of galvanizing. Figure 5A illustrates a process 500 in which, after the end of a dissolution process 502 (and optionally after performing an accessory iron treatment step), 100% of the iron-rich solution can be directed to the galvanizing catholyte tank while the galvanizing anolyte tank comprises catholyte consumed from a previous galvanizing cycle in block 510. A galvanizing process can then be carried out, which galvanizes the iron from the catholyte and oxidizes the iron to ferric in the anolyte.At the end of the galvanizing process 506, the consumed anolyte can be returned in 508 to the dissolution subsystem and the consumed catholyte can be directed in 510 to the galvanizing anolyte tank for the next galvanizing cycle. Petition 870260045431, dated 05 / 13 / 2026, p. 80 / 460 72 / 200 In various embodiments, directing the consumed catholyte to the anolyte tank may actually involve moving the consumed catholyte to a separate tank or simply altering the controls (e.g., valves, pumps, etc.) to designate the tank containing the consumed catholyte as a new anolyte tank.

[0191] Figure 5B illustrates an alternative process 550 in which, after the end of a dissolution cycle 552 (and optionally after carrying out an accessory iron treatment step), the iron-rich solution of the dissolution subsystem can be split 554 into approximately 1 / 3 catholyte and 2 / 3 anolyte quantities and galvanizing can proceed as described above. At the end of galvanizing 556, the consumed galvanizing anolyte (which contains predominantly ferric) can be directed in 558 back to the acid regenerator of the dissolution subsystem, and the consumed galvanizing catholyte can be directed to a hematite dissolution step near the end of the dissolution process in the dissolution subsystem in block 560. In one embodiment, for example, the anolyte and catholyte are combined together, and at least a portion of the combined solution is sent to the dissolution subsystem / acid regeneration cell.

[0192] In some embodiments, the electrolytes and solutions in the dissolution subsystem and the galvanizing subsystem may contain dissolved iron species, acid, and additionally inert salts that serve as supporting electrolytes to increase the conductivity of the electrolyte, which may be particularly beneficial at low ferrous concentrations. The supporting salts may include any electrochemically inert salt, such as sodium chloride, potassium chloride, ammonium chloride, sodium sulfate, potassium sulfate, ammonium sulfate, or other salts or combinations thereof. The concentration of the supporting salts in the solution, if used, may vary from about 0.1 to about 1 M. Petition 870260045431, dated 05 / 13 / 2026, page 81 / 460 73 / 200

[0193] In various embodiments, a ferrous oxidizing anode of the galvanizing cell may be any carbon- or graphite-based electrode, such as carbon / graphite felt, paper or fabric, or any electrode material stable in the ferric / ferrous salt environment. The cathode of the galvanizing cell, which is the galvanizing electrode, may be any suitable conductive substrate for galvanizing including, but not limited to, foil, plate, mesh, etc., and may be made of any material, including carbon, graphite, steel, stainless steel, copper, zinc, titanium, or alloys, or other combinations thereof or of other materials. Furthermore, the substrate may comprise a multi-layered structure with a core made of one type of material (e.g., a metal) for structural purposes and a surface made of another type of material for compatibility with the galvanizing process and / or the acid solution.Examples of such multi-layered structures include copper-plated or aluminum-plated galvanized steel or stainless steel, copper-plated or stainless steel, or other multi-layered materials.

[0194] Figure 19 illustrates an experimentally determined relationship between current density (measured in mA / cm2) and cell voltage for an acid regeneration cell 104. Figure 20 illustrates an experimentally determined relationship between current density (measured in mA / cm2) and cell voltage for an iron galvanizing cell. As can be seen, the acid regeneration cell can be operated at much higher current densities before reaching the cell voltage achieved by the galvanizing cell with a much lower current density. The water splitting reaction in the acid regeneration cell can also typically use more expensive catalysts, leading to higher capital expenditure for such a cell. These factors suggest that it may be more economical to operate the acid regeneration cell at current densities Petition 870260045431, dated 05 / 13 / 2026, page 82 / 460 74 / 200 higher to obtain the value of the most expensive cell. On the other hand, the iron galvanizing reaction can be better performed at relatively low current densities to obtain galvanized iron with the desired properties. Since the iron galvanizing cell also typically uses cheaper electrodes, operating the galvanizing cell with a lower current density is more economically viable. In various embodiments, the current density applied to a galvanizing cell can be in the range of about 20 to 300 mA / cm2.

[0195] In several embodiments, the catholyte and anolyte galvanizing tanks can be maintained at temperatures between 40 and 80 °C and the galvanizing cell can be operated in a similar temperature range.

[0196] As will be understood with reference to the drawings, the dissociation of the raw material dissolution and acid regeneration stage from the iron galvanizing (deposition) stage confers substantial advantages with little or no theoretical cost, since the two processes together consume fundamentally the same total theoretical energy as the one-step iron conversion process described above. Similarly, the dissociation of the dissolution tanks from the galvanizing anolyte and galvanizing catholyte tanks can confer additional advantages for managing the different reaction rates of the two processes.

[0197] In several embodiments, the iron galvanizing cell(s) can advantageously be operated at a current density between about 20 mA / cm2 and about 500 mA / cm2, optionally 20 mA / cm2 and about 200 mA / cm2 and optionally 20 mA / cm2 and about 100 mA / cm2 and, in some embodiments, between about 50 mA / cm2 and about 300 mA / cm2, optionally 50 mA / cm2 and about 200 mA / cm2 and optionally 50 mA / cm2 and about 100 mA / cm2 and, in Petition 870260045431, dated 05 / 13 / 2026, p. 83 / 460 75 / 200 in some embodiments, between approximately 75 mA / cm2 and approximately 250 mA / cm2, optionally 75 mA / cm2 and approximately 200 mA / cm2 and optionally 75 mA / cm2 and approximately 100 mA / cm2. In one embodiment, the iron galvanizing cell(s) may be operated at a current density equal to or less than 500 mA / cm2, optionally equal to or less than 400 mA / cm2, optionally equal to or less than 300 mA / cm2, optionally equal to or less than 200 mA / cm2, optionally equal to or less than 100 mA / cm2. In some embodiments, the galvanizing current densities may be variable during the galvanizing operation depending on process conditions and / or electricity availability. Pre-treatment of iron raw material to aid in dissolution.

[0198] Figure 9 provides a high-level schematic illustration of an iron conversion system 100 according to some embodiments. The diagram in Figure 9 shows a pretreatment section 920, a dissolution subsystem 102 comprising a dissolution section 908, an acid regeneration section 910 (each of which is described above), and a galvanizing section 130 from which iron can be removed 922. Oxygen can be released from the acid regeneration section 910 and hydrogen can be developed from the galvanizing section 130 and / or the impurity treatment section 918 between the acid regeneration 910 and galvanizing 130 sections. The developed hydrogen can be returned to a pretreatment section 920 for use in some pretreatments.Additional impurity removal steps (e.g., removal of solid impurities, organic impurities, undissolved solids, or other impurities) 914 and 916 can be performed between the pretreatment section 920 and the dissolution subsystem 102. As illustrated in Figure 9, for example, goethite and hematite can be thermally reduced to magnetite. Petition 870260045431, dated 05 / 13 / 2026, page 84 / 460 76 / 200 optionally where the reducing agent is gaseous H2 developed during galvanizing. As illustrated in Figure 9, for example, impurities can be removed at various stages of the process, such as in the dissolution subsystem (e.g., between dissolution and the acid regenerator (first electrochemical cell) and / or between the dissolution subsystem and the iron galvanizing subsystem.

[0199] As illustrated, prior to a dissolution subsystem 102, the iron feedstocks and particularly some iron ores may be treated or modified to facilitate dissolution. In some embodiments, goethite ores 902 may be converted into hematite ores 904, which may be converted into magnetite ores 906. In other embodiments, some parts of the ore may be retained in the form of goethite or hematite.

[0200] Raw materials containing iron may contain iron or iron oxides in one or more of many possible forms, including steel, steel scrap (or iron scrap) mixed with other metals and non-metals, metallic iron of various purities, or iron oxides (including hydroxides and oxyhydroxides). However, some iron oxides commonly found in iron-containing ores dissolve relatively slowly. The following paragraphs refer to improvements in the dissolution of iron-containing ores.

[0201] Different iron oxides have different dissolution kinetics. For example, magnetite (Fe3O4, which contains Fe3+ and Fe2+) dissolves much more readily than oxides containing only Fe3+, such as hematite (Fe2O3) and goethite (FeO(OH)). The difference in dissolution kinetics can reach 40 times between hematite and magnetite, for example. Many commercially available and economically viable iron ores contain large amounts of hematite and / or goethite. Optional embodiments in this document include the conversion of at least a portion of the iron oxides, such as hematite. Petition 870260045431, dated 05 / 13 / 2026, page 85 / 460 77 / 200 and / or goethite, in an ore containing iron, can be converted to magnetite for the benefit of faster dissolution. Conversion to magnetite can also offer the advantage of allowing magnetic separation of magnetite-containing materials from iron forms other than magnetite prior to acid dissolution. Processing raw material ore to convert certain iron oxides to magnetite is an optional aspect that may be advantageous for some applications, but is not necessary for the operation of the methods described in this document.

[0202] In other cases, it has been found that simply heating some hematite or goethite ores to sufficient temperatures, even under an air atmosphere (i.e., air roasting), can cause a sufficient morphological alteration in the ore structures to allow acid dissolution of those roasted ores within an acceptable time period (e.g., on the order of about 24 hours + / - 6 hours), particularly when the dissolution is associated with an acid regeneration cell 104, as described in this document. In some cases, even entirely untreated raw ores can be dissolved within acceptable timeframes by associating the dissolution with an acid regeneration cell 104.

[0203] As illustrated in the X-ray diffraction patterns shown in Figure 21A, Figure 21B and Figure 21C, goethite can be converted to hematite by air roasting at a temperature between about 200 °C and 600 °C and hematite can be thermally reduced to magnetite in hydrogen at a temperature between 300 °C and 600 °C.

[0204] In several embodiments, air roasting can be carried out by heating the ore in an air atmosphere at a temperature between about 200 °C and 600 °C for a period of about 1 minute to about one hour. In some specific embodiments, the Petition 870260045431, dated 05 / 13 / 2026, p. 86 / 460 78 / 200 Air roasting may involve heating the ore to a temperature of about 200 °C to about 400 °C. In several embodiments, air roasting of the ore may include a build-up time to reach the target temperature from an initial temperature (e.g., ambient temperature). In some embodiments, an air roasting period may begin when the ore material reaches an initial target temperature.

[0205] In several embodiments, thermal reduction can be carried out by heating the ore in a reducing atmosphere at a temperature between about 300 °C and 600 °C for a period of time from about 1 minute to about 5 hours, depending on the extent of reduction required and the morphology of the materials to be reduced. In some embodiments, the reducing atmosphere may comprise a gas mixture of about 1% to about 10% gaseous hydrogen (or other reducing gas) with an equilibrium of an inert gas, such as nitrogen, argon, or another inert gas. In some embodiments, gas mixtures with much higher hydrogen content, even close to 100% H2, may be used. In some embodiments, a thermal reduction atmosphere may also be humidified to contain about 5% to about 10% water vapor.

[0206] In some specific embodiments, thermal reduction may involve maintaining the ore at a temperature of about 300 °C to about 500 °C, in some specific embodiments at a temperature of about 375 °C, 400 °C, 425 °C, 450 °C, 500 °C, 525 °C, 550 °C or more. In several embodiments, when thermally reducing the ore, the ore may be exposed to an air (or other non-reducing) atmosphere for a build-up time until a target temperature is reached, so as to conserve gaseous hydrogen which may be ineffective before reaching the target temperature. In some embodiments, a period of thermal reduction time may begin Petition 870260045431, dated 05 / 13 / 2026, p. 87 / 460 79 / 200 when the ore material reaches a first target temperature.

[0207] In some embodiments, it may be desirable to interrupt the thermal reduction of iron ore before complete reduction to metallic iron, such as by removing the ore, lowering the temperature, or maintaining a sufficient moisture level to prevent reduction to metallic iron. In other embodiments, a portion of the ore may be reduced to metallic iron before proceeding to a dissolution step.

[0208] Hematite can be reduced to magnetite using a reducing agent such as hydrogen, carbon monoxide, synthesis gas, etc. This can be done for many different purposes, particularly for iron beneficiation using magnetic separation.This document considers that iron production processes, such as galvanizing, may involve the generation of a reducing agent, such as hydrogen, optionally as a secondary reaction (e.g., through a parasitic reaction or during galvanizing) or as a direct result of an intermediate process step (e.g., an accessory iron treatment step, as described in this document).

[0209] Reducing agents, such as hydrogen produced by parasitic or incidental reactions, instead of being wasted, can be captured and used to reduce iron oxides, such as hematite and goethite, in the ore, to magnetite. As a result, some of the energy wasted by generating a reducing agent as a byproduct in a different process (e.g., hydrogen from galvanizing or another process) can be recovered, and at the same time, the reduced ore becomes much easier to dissolve.

[0210] In general, according to certain embodiments, at least part of the reducing agent, such as H2, may be a product of any portion, step or reaction of a process to produce iron.

[0211] According to certain modalities, the reducer, such Petition 870260045431, dated 05 / 13 / 2026, page 88 / 460 80 / 200 as H2, can be generated before and / or externally to an iron galvanizing process or electrochemical cells thereof. H2 generation can occur during a galvanizing process when, for example, the pH is low (e.g., too much residual acid in an inlet stream fed to a galvanizing cell), resulting in a reduction in the Faradaic efficiency of galvanizing, which allows a side reaction (or parasitic reaction) that generates H2 simultaneously with the iron galvanizing. Thus, when galvanizing begins, there may be significant H2 generation until the pH increases to about 2 (or another value, depending on the acid chemistry used). In some embodiments, a similarly configured galvanizing cell or polishing cell can be set up to allow the collection and storage of the hydrogen gas generated during such operations.

[0212] According to certain embodiments, the systems and methods described herein may include a combination of the above approaches as a solution to improve the dissolution of iron in acids. According to certain embodiments, the methods described herein may include the use of a byproduct of a reaction (such as hydrogen) or byproduct in the iron manufacturing process for the conversion of iron ore other than magnetite or iron oxide compounds other than magnetite into an ore containing iron in magnetite to improve the dissolution kinetics. According to certain embodiments, the methods described herein may include the combination of (i) reduction of iron oxide (e.g., an oxide ore) to magnetite with (ii) dissolution of the resulting material (magnetite) using acid.

[0213] In certain embodiments, the methods described in this document may include raw material that is a Petition 870260045431, dated 05 / 13 / 2026, p. 89 / 460 81 / 200 iron-containing ore (e.g., ore, iron ore, rock, sediment, minerals). According to certain embodiments, the methods described herein may include a reducing agent (to convert iron oxides other than magnetite into magnetite) that is a byproduct of another reaction step in the overall iron manufacturing process. According to certain embodiments, the methods described herein may include the generation of a reducing agent (to convert iron oxides other than magnetite into magnetite) from a combination of an internal source (e.g., byproduct of the overall iron manufacturing process) and an external source, including a hydrogen storage facility, a natural gas reforming system supplying gaseous hydrogen, or a water electrolyzer.According to certain embodiments, the methods described herein may include a reducing agent (to convert iron oxides other than magnetite into magnetite) that is hydrogen, carbon monoxide, natural gas, synthesis gas, or a combination thereof. According to certain embodiments, the methods described herein may include the use of a byproduct of an electrochemical galvanizing reaction to conduct a different reaction, such as the use of hydrogen byproduct to reduce iron oxides. The byproduct may be generated directly in the galvanizing cell or before the galvanizing cell in a separate reactor with a similar net production of gaseous hydrogen.

[0214] According to certain embodiments, a method for dissolving iron ore containing iron that has one or more iron oxide materials other than magnetite is included in this document, the method comprising: exposing the iron ore to a reducing agent at a temperature between 200 °C and 600 °C and converting at least a portion of the iron oxides in the ore into magnetite, thereafter Petition 870260045431, dated 05 / 13 / 2026, page 90 / 460 82 / 200 mode, forming a processed ore and dissolving the processed ore using an acid to form an iron salt solution. Optionally, the reducing agent is the byproduct of another reaction in an iron production process.

[0215] In various embodiments, the systems and methods described in this document can be configured to dissolve quantities of iron-containing ore materials treated differently in order to achieve a desired concentration of dissolved iron within an acceptable time period (e.g., within about 24 or 30 hours). In general, as described in this document, the dissolution of iron oxide has been found to be substantially enhanced in the presence of ferrous ions and in the presence of sufficient acid, as created by the acid regenerator. However, the reduction of hematite ores to magnetite showed a substantial improvement in dissolution rates and completeness in any environment.

[0216] As illustrated in Figure 10, a dissolution subsystem 1000 may comprise an acid regenerator 104 coupled to a plurality of dissolution tanks containing ore 1010, 1012, 1014 (or more or less in other embodiments). As shown, each tank may contain a differently processed mineral material. For example, a first tank 1010 may contain raw ore that has not been thermally pretreated. This raw ore may contain goethite and / or other types of ore. A second tank 1012 may contain ore that has been roasted as described above, for example, air roasting, and may contain hematite and / or other types of ore. A third tank 1014 may contain thermally reduced ore as described above and may contain substantial quantities of magnetite and other types of ore.

[0217] As described above and illustrated in Figure 7C (which Petition 870260045431, dated 05 / 13 / 2026, page 91 / 460 Figure 83 / 200 shows the dissolution time for ores treated differently in an excessive amount of sulfuric acid. Reduced ore dissolves very quickly, reaching complete dissolution in a matter of hours, while roasted ore dissolves much more slowly, although the dissolution rate can be increased somewhat by increasing the temperature and / or the amount of ferrous ions in solution. Although not illustrated, it has been shown that raw ore dissolves more slowly than roasted ore.

[0218] In relation to Figure 7B, trace 708 illustrates the dissolution of magnetite in 0.1 M sulfuric acid compared with the dissolution of hematite in 0.1 M sulfuric acid 706, hematite in 0.3 M sulfuric acid 704 and hematite in 0.5 M sulfuric acid 702.

[0219] The system in Figure 10 illustrates several possible processes that can be applied to selectively direct a dissolving solution with a higher acid content from an acid regenerator 104 to one or more of the dissolving tanks 1010, 1012, 1014. For explanatory purposes, a process will be described during which the acid solution will be recirculated for ten (10) cycles between the acid regenerator 104 and one or more of the tanks 1010, 1012, 1014, where each cycle begins at the outlet of the acid regenerator 104. Although 10 cycles are described in this example, any number of cycles can be used, depending on various details of a specific implementation. In other cases, the cycles may simply represent relative time periods during which the solution comes into contact with each of the ore types, and different configurations of tanks, fluid conduits, valves, etc. may be used.For example, instead of changing where the fluid is directed, the solid content of a single dissolving tank can be changed over several periods of time, roughly corresponding to the number of cycles described in the example below.

[0220] During the first group of 10 cycles, the acidic solution Petition 870260045431, dated 05 / 13 / 2026, p. 92 / 460 84 / 200 can be directed to the raw ore tank 1010 by opening valve 1030. The acid solution exiting the raw ore tank 1010 can be returned to the acid regeneration cell 104 by opening valve 1022. During a second group of 10 cycles, the acid solution can be directed to the roasted ore tank 1012 by opening valve 1032. The acid solution exiting the roasted ore tank 1012 can be returned to the acid regeneration cell 104 by opening valve 1024. In some embodiments, during a third group of 10 cycles, the acid solution can be directed to the reduced ore tank 1014 by opening valve 1034. The acid solution exiting the roasted ore tank 1014 can be returned to the acid regeneration cell 104 by opening Valve 1026 may instead (or additionally) be directed to downstream processes 1016 (e.g., decontamination, iron accessory treatment, galvanizing, etc.).) when opening valve 1028.

[0221] Therefore, by altering the number of cycles in each dissolution tank, the acid solution can come into contact with differently treated ores for different periods of time. In several examples, the acid solution can be brought into contact with raw ore 1010 for 0 to 9 of the cycles, with roasted ore 1012 for 0 to 9 of the cycles, and with reduced ore 1014 for 1 to 10 of the cycles. In general, it is desirable to contact the acid solution with reduced ore 1014 at least during the final cycle before directing the solution to downstream process steps 1016. Since the dissolution of reduced ore proceeds relatively quickly, ending the dissolution process with reduced ore serves to consume a portion of the remaining acid, further simplifying downstream steps, as described elsewhere in this document.

[0222] Any of the cycle combinations (or proportional residence time) in Table 1 below may be used: Petition 870260045431, dated 05 / 13 / 2026, page 93 / 460 85 / 200 Table 1: Options for Dissolving Iron Ores Differently Treaties Number of acid cycles in each type of ore treatment. Gross 0 0 0 0 0 0 0 0 0 0 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 Roasted 9 8 7 6 5 4 3 2 1 0 9 8 7 6 5 4 3 2 1 0 0 0 0 0 0 0 0 0 Reduced 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 2 1

[0223] In some respects, a method may comprise dissolving an iron feedstock in an acid; producing metallic iron by evolving oxygen gas from water at an anode of an electrochemical cell while galvanizing metallic iron from a ferric iron solution at a cathode of an electrochemical cell or during a treatment step and developing hydrogen in a side reaction at the cathode of the electrochemical cell, collecting the hydrogen, transferring the hydrogen to a reaction chamber and thermally reducing the iron feedstock in the reaction chamber with the hydrogen.

[0224] In some aspects, a method may comprise dissolving an iron feedstock in an aqueous acidic solution in a dissolving tank; circulating the solution from the dissolving tank to an acid regeneration cell; converting ferric ions in the solution to ferrous ions at a cathode of the acid regeneration cell while developing oxygen from the water at the anode of the acid regeneration cell; transferring a first portion (anolyte) of the solution to an anolyte tank of an iron galvanizing system; transferring a second portion (catholyte) of the solution to a catholyte tank of the iron galvanizing system, optionally including a treatment step to remove impurities and produce H2; circulating the anolyte and catholyte between their respective tanks and an iron galvanizing cell; oxidizing the ferrous iron to ferric iron in the anolyte at the anode of the galvanizing cell while galvanizing the metallic iron from the ferrous iron in the. Petition 870260045431, dated 05 / 13 / 2026, page 94 / 460 86 / 200 catholyte in the cathode of the galvanizing cell and while developing parasitic hydrogen in the cathode during galvanizing and / or optionally use the H2 generated in the treatment step to remove impurities and produce H2; collect the hydrogen and transfer the hydrogen to a reaction chamber and thermally reduce the iron feedstock in the reaction chamber with the hydrogen.

[0225] In some respects, a method may comprise producing hydrogen by mixing an aqueous acidic solution with metallic iron, collecting the hydrogen, transferring the hydrogen to a reaction chamber, and thermally reducing the iron feedstock in the reaction chamber with the hydrogen.

[0226] In some respects, a method may comprise mixing an acidic aqueous solution of ferrous iron with metallic iron, converting the residual ferric ions in the acidic aqueous solution of ferrous iron into ferrous ions while producing hydrogen from the reaction of the residual acid with the metallic iron, collecting the hydrogen, transferring the hydrogen to a reaction chamber, and thermally reducing the iron feedstock in the reaction chamber with the hydrogen.

[0227] In some aspects, the embodiments described in this document include: a method for dissolving iron oxide materials in acidic solution, the method comprising: feeding a feedstock comprising iron oxide materials; feeding a dissolution tank; feeding an electrochemical cell having a cathode, a membrane and an anode; dissolving the feedstock in the dissolution tank in an acidic solution, wherein the dissolution releases Fe3+ into the acidic solution; and circulating the acidic solution between the dissolution tank and the cathode of the electrochemical cell to electrochemically reduce Fe3+ to Fe2+ and simultaneously generate protons, wherein the circulation step comprises returning the reduced and acidified solution comprising the acid and Fe2+ ions to the dissolution tank for Petition 870260045431, dated 05 / 13 / 2026, page 95 / 460 87 / 200 dissolve more iron oxide materials. EXAMPLE: PRETREATMENT AND DISSOLUTION OF ORE

[0228] This example provides certain exemplary and optional embodiments of an ore processing method for increasing the magnetite content in an iron-containing ore. The processing of feedstock ore to convert certain iron oxides into magnetite is an optional aspect that may be advantageous for some applications, but is not necessary for the operation of the methods described herein for the production of high-purity iron.

[0229] In one aspect, a method for processing an iron-containing ore that has one or more iron oxide materials other than magnetite comprises: processing the iron-containing ore to form a processed ore, the processing step comprising: exposing one or more iron oxide materials other than magnetite from the iron-containing ore to a reducing agent at a selected temperature in the range of 200 °C to 600 °C to convert at least part of one or more iron oxide materials other than magnetite into magnetite, thereby forming the processed ore; and dissolving at least part of the magnetite using an acidic solution to form an iron salt solution; wherein the reducing agent is at least partly a product of: an electrochemical process, a process for producing iron, a chemical reaction involving iron as a reactant and / or a chemical reaction between a metal and an acid.

[0230] Optionally, in the method for processing an ore containing iron, at least part of the reducing agent is a product of an electrochemical and / or chemical reaction of the iron production process. Optionally, in the method for processing an ore containing iron, at least part of the reducing agent is a product of an iron galvanizing process. Optionally, in the method for processing an ore containing iron, at least part of the reducing agent is electrochemically H2. Petition 870260045431, dated 05 / 13 / 2026, page 96 / 460 88 / 200 generated. Optionally, in the method for processing an ore containing iron, at least part of the reducing agent is chemically generated H2. Optionally, in the method for processing an ore containing iron, at least part of the reducing agent is H2 generated through water electrolysis. Optionally, in the method for processing an ore containing iron, at least part of the reducing agent is H2 generated from a reaction between a metal, such as iron, and an acid. Optionally, in the method for processing an ore containing iron, at least part of the reducing agent is H2, a combination of electrochemically generated H2 and a product of a chemical reaction between a metal and an acid.

[0231] The reducing agent may originate from a process that is part of the method for processing an iron-containing ore and / or from a separate method. Optionally, in the method for processing an iron-containing ore, the method comprises the process for producing iron. Optionally, in the method for processing an iron-containing ore, the method comprises galvanizing metallic iron, collecting the reducing agent produced during the galvanizing step, and feeding the reducing agent to the processing step. Optionally, in the method for processing an iron-containing ore, the method comprises the electrochemical process, the process for producing iron, the chemical reaction involving iron as a reactant, and / or the chemical reaction between a metal and an acid. Optionally, in the method for processing an iron-containing ore, the method comprises the process for producing electrochemically generated H2.Optionally, in the method for processing an ore containing iron, the method comprises the process for producing H2 through a reaction between a metal, such as iron, and an acid.

[0232] Optionally, in the method for processing an ore containing iron, the reducing agent comprises H2, CO, natural gas, synthesis gas or any combination thereof.

[0233] Optionally, in the method for processing an ore that Petition 870260045431, dated 05 / 13 / 2026, page 97 / 460 89 / 200 contains iron; the method involves extracting at least some of the magnetite from the processed ore between the processing and dissolution stages.

[0234] In some embodiments, the conversion of non-magnetite iron oxides into magnetite may be incomplete after the first exposure step, resulting in some amount of unconverted non-magnetite iron oxide which may then be further processed. Optionally, in the method for processing an ore containing iron, the processed ore comprises unconverted non-magnetite iron oxide material; and wherein the method further comprises: separating at least a portion of the unconverted non-magnetite iron oxide materials into magnetite from the processed ore; and recycling the separated unconverted non-magnetite iron oxide material back to the processing step to convert the unconverted non-magnetite iron oxide material into magnetite.Optionally, in the method for processing an ore containing iron, the dissolution step comprises exposing the processed ore to an acidic solution; wherein at least a portion of the exposed processed ore is not dissolved in the acidic solution; wherein the undissolved portion of the processed ore comprises an unconverted iron oxide material other than magnetite; and wherein the method further comprises: recycling the unconverted iron oxide material other than magnetite back to the processing step to convert the unconverted iron oxide material other than magnetite into magnetite.

[0235] Optionally, in the method for processing an ore containing iron, one or more iron oxide materials other than magnetite comprise hematite and / or goethite.

[0236] Optionally, in the method for processing an ore containing iron, the acidic solution (to dissolve at least part of the Petition 870260045431, dated 05 / 13 / 2026, page 98 / 460 90 / 200 magnetite) comprises hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, citric acid, oxalic acid, boric acid, or any combination thereof.

[0237] Optionally, in the method for processing an ore containing iron, the iron salt solution comprises aqueous Fe2+ and / or Fe3+ ions.

[0238] In another aspect, a method for processing an iron-containing ore that has one or more iron oxide materials other than magnetite comprises: processing the iron-containing ore to form a processed ore, the processing step comprising: exposing one or more ores other than magnetite from the iron-containing ore to a reducing agent at a selected temperature in the range of 200 °C to 600 °C to convert at least a portion of one or more iron oxide materials other than magnetite into magnetite, thereby forming the processed ore; and dissolving at least a portion of the magnetite using an acidic solution to form an iron salt solution. ADDITIVE MATERIALS TO IMPROVE DISSOLUTION

[0239] A mixed solution of sulfate and chloride may be used, such as by using a mixture of sulfuric acid and hydrochloric acid. In some embodiments, such a mixture may be produced by mixing a chloride salt in a sulfuric acid solution or mixing a sulfate salt in a hydrochloric acid solution. In other embodiments, other acid mixtures may be used to dissolve the iron ore materials. ACID CHEMISTRY SELECTION

[0240] In various embodiments, the systems and methods described in this document can be used with any acid for dissolving iron raw materials and / or as a base for the ferrous solution used for iron galvanizing. Suitable acids may include, but are not limited to, hydrochloric acid, sulfuric acid, phosphoric acid, nitric acid. Petition 870260045431, dated 05 / 13 / 2026, page 99 / 460 91 / 200 tric acid, acetic acid, oxalic acid, citric acid, boric acid, methanesulfonic acid, or any combination thereof. As will be understood by reference to the present description and the attached figures, the selection of acid chemistry can confer various advantages and trade-offs. The selection of a specific acid chemistry may be based on these or other technical and / or economic factors, among others. Several selection considerations are presented in Table 2. Table 2: Basis for Acid Chemistry Selection Metric Preferred Choice Reasons Safety Sulfuric acid Sulfuric acid is less corrosive. Frequently used in classical electroextraction. Dissolution Hydrochloric acid Dissolution rate in hydrochloric acid >> sulfuric acid. Some ores have minimal dissolution in sulfuric acid at 6M and 60°C, while the ore dissolves easily in hydrochloric acid up to 1M and 60°C. Anode stability Sulfuric acid Acid leaks through the PEM into the acid regenerator resulting in a pH ~2 at the anode. Under these conditions, anode life and stability and oxygen evolution are significantly better in sulfuric acid than in hydrochloric acid. Also, note that classical electroextraction is done in sulfuric acid at a pH < 0 using lead anodes with a lifespan > 5 years. Sulfuric Acid Impurity Management: Similar to ore dissolution, impurities also have much lower solubility in sulfuric acid than in hydrochloric acid.Capex Sulfuric acid Vapor pressure of hydrochloric acid >> sulfuric acid. This requires a fully sealed stack when using hydrochloric acid.

[0241] In some embodiments, an electrolyte or acid solution used in an acid regeneration cell (anolyte and / or catholyte) or a galvanizing cell (anolyte and / or catholyte) may include salts of Petition 870260045431, dated 05 / 13 / 2026, pp. 100 / 460 92 / 200 support or other additives besides the acid and dissolved species described in this document. For example, the supporting salts in any of the above electrolytic solutions may include sodium sulfate, potassium sulfate, ammonium sulfate, sodium chloride, potassium chloride, ammonium chloride or others or any combination thereof.

[0242] In some embodiments, a galvanizing cell catholyte may include one or more additives configured to improve galvanizing efficiency, such as a weak acid for pH buffering, including citric acid, boric acid, and / or a surfactant, including low-foaming nonionic surfactants such as Hopax EN 16-80, EA 15-90 and typical additives used in the galvanizing industry. GENERAL PROCESS EXAMPLES

[0243] Figure 4, Figure 6 and Figure 9 provide several schematic illustrations of exemplary iron conversion processes, as described in this document.

[0244] Figure 11 illustrates, for example, a complete process 1100 for converting an iron feedstock into pure iron while recycling a process solution, including several optional intermediate steps. In 1102, process 1100 may optionally comprise grinding a feedstock to a desired particle size. In 1104, the process may comprise a heat treatment, which may include air roasting and / or thermal reduction of the iron feedstock in the presence of hydrogen (e.g., including hydrogen produced in one or more process steps in process 1100). The heat treatment step 1104 may optionally be omitted if the feedstock is suitable for direct dissolution without such processing. In 1106, the feedstock may be added to a dissolution tank connected to an acid regenerator. In 1108, the feedstock may be dissolved in the dissolution tank with the acid and solution. Petition 870260045431, dated 05 / 13 / 2026, p. 101 / 460 93 / 200 of ferrous iron produced by the acid regenerator. After the iron concentration reaches a desired value, the now ferrous iron solution in the dissolution tank can be treated with iron (e.g., an accessory iron treatment, as described elsewhere in this document) to increase the pH and further convert any remaining ferric iron to ferrous iron in 1110. In 1112, the ferrous iron solution can be transferred to the catholyte and anolyte tanks associated with a galvanizing cell. In 1114, the galvanizing cell can be operated to galvanize metallic iron while producing ferric iron in the anolyte. In 1115, the deposited metallic iron can be removed from the cell, such as by removing the cathodic electrode.In 1116, the ferric galvanizing anolyte solution can return from the galvanizing system to a dissolving tank of the acid regenerator system, where it can be recycled to produce at least some ferrous iron before the feedstock is added to the dissolving tank in a subsequent cycle in 1106. In some embodiments, in 1120, a supporting salt can optionally be added to the electrolyte. Alternatively, a supporting salt can be added to an electrolyte at any other point in the process (e.g., in the electrolyte or added to the feedstock). In some embodiments, the supporting salt is not added in all cycles, for example, because it may not be consumed (or consumed significantly) in the process.

[0245] In some respects, the embodiments described in this document include: a method for producing high-purity iron from an iron oxide feedstock, the method comprising two subsystems, including a dissolution subsystem configured to form a solution containing ferrous salt (ferrous transfer solution) by: feeding a dissolution tank; feeding a first electrochemical cell (e.g., a regeneration cell). Petition 870260045431, dated 05 / 13 / 2026, page 102 / 460 94 / 200 acidic) having a cathode, a membrane and an anode; dissolving the raw material in the dissolution tank in an acidic solution, wherein the dissolution reaction releases Fe3+ into the solution while consuming protons; and circulating the solution to the cathode of the first electrochemical cell to convert Fe3+ to Fe2+ and simultaneously generate protons; wherein the circulation step comprises returning the reduced and acidified solution comprising the acid and Fe2+ ions to the dissolution tank to dissolve more iron oxide materials; and further comprising an iron galvanizing subsystem configured to produce metallic iron from the ferrous solution produced in the dissolution subsystem by: splitting the ferrous solution from the dissolution tank of the dissolution subsystem into two streams to be stored in two separate tanks for anolyte galvanizing and catholyte galvanizing; feeding a second electrochemical cell (e.g., a galvanizing cell);Circulate the solution from the catholyte tank to the cathode of the second electrochemical cell and circulate the anolyte from the anolyte tank to the anode of the second electrochemical cell, reducing Fe2+ ions to galvanized solid metallic iron at the cathode of the second electrochemical cell while simultaneously oxidizing Fe2+ ions to Fe3+ at the anode of the second electrochemical cell; remove the galvanized metallic iron; and return a ferric solution containing Fe3+ ions to the dissolution tank or the acid regeneration cell of the dissolution subsystem.

[0246] In some additional aspects, the catholyte and anolyte solutions on the cathode and anode sides of the electroplating cell can optionally be combined to form a ferric return solution that is returned to the dissolution subsystem. In some embodiments, the acid regeneration cell can be operated for one or more cycles before adding the solid feedstock to the dissolution tank, thus allowing the generation of acid solution and Petition 870260045431, dated 05 / 13 / 2026, p. 103 / 460 95 / 200 ferrous (Fe2+) sufficient to initiate the dissolution of solid raw material.

[0247] Figure 18 schematically illustrates certain embodiments of a chemical process and a chemical plant configured to perform aspects of the methods and systems for iron production described in this document. For example, the Acid Regenerator + Fe3 Reducer corresponds to certain aspects of the dissolution subsystems described in this document. For example, Fe Galvanizing corresponds to certain aspects of the iron galvanizing subsystems described in this document. The diagram shows various embodiments of inputs, outputs, and communications between the dissolution subsystem and the galvanizing subsystem. Figure 18 also illustrates an example of a water management system for transferring water to the acid regenerator anolyte from the acid regenerator catholyte, including an alternative use for the hydrogen collected in the system (recombining with the collected oxygen to form water).The system in Figure 18 also illustrates an example of the use of a sodium chloride support salt in the galvanizing system. INDUSTRIAL AND MARKET USES OF WATER-BASED ELECTROFORMED IRON

[0248] In various embodiments, iron produced electrolytically by the systems, methods and processes described in this document can be used for many commercial purposes that are generally not economically viable for other sources of iron.

[0249] The various modalities described in this document are particularly compatible with intermittent energy sources (e.g., renewables) that may fluctuate in terms of available energy over time, since the acid regeneration cell, the galvanizing cell, and other support systems are generally capable Petition 870260045431, dated 05 / 13 / 2026, page 104 / 460 96 / 200 can be activated at higher or lower power levels in response to varying power availability. Therefore, in some embodiments, the current supplied to an acid regeneration cell, a galvanizing cell, or other system components can be varied in response to a measured or communicated decrease or increase (e.g., through any smart grid or demand response communication system or protocol) in available or usable power. Such increases or decreases in current (or power) can generally be made within the range of current densities described in this document; however, they can be made outside these ranges in some embodiments, including the selective shutdown of all power to one or more cells, stacks, subsystems, or the entire system.

[0250] Figure 22 illustrates a process 2200 for producing green steel and green steel products using iron produced by any embodiment of a system or process for producing pure iron as described herein. According to process 2200, iron ore can be converted in 2202 into green iron using substantially only renewable or zero-carbon energy (e.g., wind, solar, tidal, geothermal, or nuclear power). In 2204, green iron can be removed from a galvanizing cell as described herein.

[0251] In 2206, green iron can be smelted, preferably using substantially only renewable or zero-carbon energy (e.g., wind, solar, tidal, geothermal, or nuclear power). In various embodiments, iron can be smelted using only electrical energy using an induction furnace, microwave, an electric arc furnace, or other systems.In some methods, a conventional basic oxygen furnace can be used to melt the iron. Petition 870260045431, dated 05 / 13 / 2026, page 105 / 460 97 / 200

[0252] In 2208, cast iron can be blended with various additives and alloying materials to produce a desired grade of cast steel. Examples of such additive and / or alloying elements may include carbon, chromium, molybdenum, vanadium, manganese, nickel, cobalt, silicon, lead, boron, aluminum, copper, cerium, niobium, titanium, tungsten, tin, zinc, zirconium, or any combination thereof.

[0253] In 2210, molten steel can be transformed into a steel product or a product precursor by means of extrusion, molding, casting or other molten steel transformation step into solid. Additional manufacturing steps may also be used to manufacture steel products, including rolling, forging, welding, stamping, machining, etc., or any combination thereof.

[0254] The pure iron produced by the systems, methods and processes described in this document fundamentally represents an energy carrier (e.g., a form of metallic electricity) that can be used for various market purposes, such as producing dispatchable hydrogen, seasonal storage and metallic fuels to enable a circular economy of iron.

[0255] Dispatchable hydrogen refers to the on-site and on-demand distribution of hydrogen. In some embodiments, the iron produced by the systems and methods described herein can be distributed to a location where gaseous hydrogen is desired and reacted with water (e.g., at an elevated temperature) or an acid (which can be produced on-site by an acid generator or obtained otherwise). The reaction of the iron with the acid will spontaneously produce gaseous hydrogen while oxidizing the iron. The oxidized iron can then be returned and used as feedstock in one of the iron conversion processes described herein.

[0256] The iron produced by means of a conversion process described in this document can be used to manufacture batteries. Petition 870260045431, dated 05 / 13 / 2026, page 106 / 460 98 / 200 primary (single-discharge) or secondary (rechargeable) iron electrode batteries (e.g., nickel-iron batteries, iron-air batteries, all-iron flow batteries, or others) that can be used for seasonal storage (i.e., renewable energy with a time shift by weeks or months, from a high-generation season to a lower-generation season, such as summer to winter for solar energy) or daily storage (i.e., renewable energy with a time shift by hours, from high-generation times to low-generation times, such as midday to late, night, or morning for solar energy).

[0257] Iron produced by a conversion process described in this document can be transformed into sufficiently small particles and burned as a solid fuel in a furnace (e.g., a coal furnace). The combustion of the iron consumes oxygen to form iron oxide (typically hematite), but does not release greenhouse gases.

[0258] In any of the above applications, the consumed iron that has reached its useful life in these processes (typically after being oxidized into one or more oxide forms) can be returned to an iron conversion process, such as those described in this document, and converted back into metallic iron. REDOX MEDIATOR STRUCTURE FOR DISSOCIATION OF IRON REDUCTION STEPS

[0259] The dissociation of ferric-ferrous reduction from ferrous iron reduction in various forms and examples in this document can be theoretically understood as the use of a redox mediator pair that mediates iron reduction and oxygen evolution, as shown by the following equations: Acid regeneration anode: 3 / 2H2O ^ 3H++ 3 / 4U2 + 3e (EQ 17a) Acid regeneration cathode: 3Fe3++ 3e ^ 3Fe2+(EQ 17c) Petition 870260045431, dated 05 / 13 / 2026, page 107 / 460 99 / 200 Anode of the galvanizing cell: 2Fe2+ → 2Fe3++ 2e (EQ 18a) Cathode of galvanizing: Fe2++ 2e → Fe (EQ 18c)

[0260] The half-reaction at the anode of the galvanizing cell (22a) is exactly the reverse reaction of the acid regeneration cathode half-reaction (21c). In essence, the Fe3+ / Fe2+ redox pair plays a redox mediator role that allows the dissociation of the water oxidation reaction and the reduction of Fe3+ to Fe0 in two separate electrochemical cells, the first cell performing only the reduction of ferric to ferrous, while the second cell reduces ferrous iron to iron by means of galvanizing. In this way, the action of an Fe3+ / Fe2+ diverter is harnessed and used advantageously to create substantial practical benefits and cost savings, as well as improving overall efficiency and control over the total system reaction.Among many advantages, dissociation can allow the acid regeneration cell and the galvanizing cell to operate at substantially different current densities, which can be particularly advantageous considering the different economic and operational characteristics of the two cells.

[0261] Although the Fe3+ / Fe2+ pair serves as a redox mediator in the above embodiments and examples, a generic redox mediator pair illustrated, for example, in Figure 23, can be described as an oxidized mediator (MO) and a reduced mediator (MR): MO / MR with 1 electron for which the half-reaction is: MR^ MO+ 1e-(EQ 19)

[0262] A pair of redox mediators can be used to dissociate the iron galvanization and water oxidation reactions in two cells as follows: Cell 1: Anode: H2O^½O2 + 2H++2e (EQ 20) Cathode: 2 MO+ 2e-^ 2 MR(EQ 21) Petition 870260045431, dated 05 / 13 / 2026, page 108 / 460 100 / 200 Global: H2O + 2 MO A ½O2 + 2H+ + 2 MR(EQ 22) Cell 2:

[0263] Using the reduced MR mediator that was generated in the first cell: Anode: 2 MRA 2 MO + 2e-(EQ 23) Cathode: Fe2++2e- A Fe (EQ 24) Global: Fe2++ 2 MRA Fe + 2 MO (EQ 25)

[0264] Thus, an MO / MR pair can serve as a redox mediator to dissociate the iron raw material dissolution process from the iron galvanizing process, as illustrated in Figure 23. In various embodiments, other redox pairs can be used to achieve a similar functional dissociation through different electrochemical reactions. Several examples of alternative redox mediator pairs may include, but are not limited to: Cu27Cu0, V5+ / V4+, V37V2+, Zn2+ / Zn0, any other salt, any organic redox pair, such as quinone / hydroquinone, a gas, such as H+ / H2, and so on. In some embodiments, a metallic redox mediator can be fed into a solution via dissolution and can be extracted separately from the solution through galvanizing, solvent extraction, or other methods.

[0265] Several aspects are considered in this document, several of which are presented in the paragraphs below. It is explicitly considered that any aspect or part thereof may be combined to form an aspect. Furthermore, it is explicitly considered that: any reference to aspect A1 includes a reference to aspects A1a, A1b, A1c and / or A1d; any reference to aspect B1 includes a reference to aspects B1a, B1b, B1c and / or B1d; any reference to aspect C1 includes a reference to aspects C1a and / or C1b; and any reference to aspect D1 includes a reference to aspects D1a and / or D1b. In addition, although the aspects below are Petition 870260045431, dated 05 / 13 / 2026, p. 109 / 460 101 / 200 subdivided into aspects A, B, C, and D, it is explicitly considered that the aspects in each of the subdivisions A, B, C, and D can be combined in any way. Furthermore, the term "any previous aspect" means any aspect that appears before the aspect containing such a phrase (in other words, the phrase "Aspect B13: The method or system according to aspect B8 or any previous aspect..." means that any aspect prior to aspect B13 is cited, including aspects B1-12 and all aspects A, such as aspects A1-A97). For example, it is considered that, optionally, any system or method according to any of the aspects below can be useful or combined with any other aspect provided below. Furthermore, for example, it is considered that any modality described above can, optionally, be combined with any of the aspects listed below.

[0266] Aspect A1a: Method for processing and dissolving an ore containing iron, the method comprising: Thermally reduce one or more iron oxide materials other than magnetite in iron-containing ore to form magnetite in the presence of a reducing agent, thereby forming a thermally reduced ore; and dissolve at least part of the thermally reduced ore using an acid to form an acidic solution of iron salt; in which the acidic iron salt solution comprises electrochemically generated protons in an electrochemical cell.

[0267] Aspect A1 b: Method for processing and dissolving an ore containing iron, the method comprising: In a dissolving tank, place the iron-containing ore in contact with an acid to dissolve at least part of the iron-containing ore, thus forming an acidic solution of iron salt that has dissolved Fe3+ ions; Petition 870260045431, dated 05 / 13 / 2026, page 110 / 460 102 / 200 recirculating at least part of the acidic iron salt solution between the dissolving tank and a cathodic chamber of an electrochemical cell, the electrochemical cell comprising a cathode in the presence of at least part of the acidic iron salt solution serving as a catholyte in the cathodic chamber, an anode in the presence of an anolyte and a separator separating the catholyte from the anolyte; electrochemically reduce at least a portion of the dissolved Fe3+ ions from the catholyte at the cathode to form Fe2+ ions in the catholyte; and electrochemically generate protons in the electrochemical cell and feed the electrochemically generated protons to the catholyte; wherein the acidic solution of iron salt in the dissolution tank, in the presence of the iron-containing ore, is characterized by a steady-state concentration of free protons that is at least 0.2 M (optionally, for example, at least 0.2, 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4 or 5 M, optionally wherein the steady-state concentration of free protons is less than 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4, 5 or 6 M and these values ​​may be combined in any way to form a range, such as 0.2-6 M).

[0268] Aspect A1 c: A method for processing and dissolving an ore containing iron, the method comprising: To thermally reduce one or more iron oxide materials other than magnetite in iron-containing ore to form magnetite in the presence of a reducing agent, thereby forming a thermally reduced ore; wherein the reducing agent comprises gaseous H2; and wherein at least part of the gaseous H2 is chemically generated through a reaction of metallic iron with an acid and / or at least part of the gaseous H2 is electrochemically generated through a parasitic hydrogen evolution reaction of a process of Petition 870260045431, dated 05 / 13 / 2026, page 111 / 460 103 / 200 galvanizing of iron; and dissolving at least the thermally reduced ore using an acidic solution to form an iron salt solution; whereby the dissolution step involves dissolving the magnetite formed in said acidic solution.

[0269] Aspect A1d: System for processing and dissolving an ore containing iron, the system comprising: A first dissolving tank to dissolve a first ore containing iron using a first acid; wherein: The dissolution of the first ore in the first acid forms a first acidic solution of iron salt comprising Fe3+ ions dissolved in the first dissolution tank; an electrochemical cell fluidically connected to the first dissolution tank; wherein: The electrochemical cell comprises a cathodic chamber having a catholyte in the presence of a cathode, an anodic chamber having an anolyte in the presence of an anode, and a separator separating the catholyte and the anolyte; and a first circulation subsystem that circulates at least part of the first acidic iron salt solution from the first dissolution tank to the cathodic chamber and at least part of the electrochemical cell catholyte to the first dissolution tank; whereby at least some of the Fe3+ ions from the first acidic iron salt solution are electrochemically reduced at the cathode to Fe2+ ions at the catholyte, thereby consuming the Fe3+ ions from the first acidic iron salt solution.

[0270] Aspect A2: The method or system according to any previous aspect comprising feeding at least part of a catholyte having said protons electrochemically generated from the electrochemical cell into the acidic iron salt solution during the step Petition 870260045431, dated 05 / 13 / 2026, p. 112 / 460 104 / 200 of dissolution, thus feeding the electrochemically generated protons to the acidic iron salt solution in the presence of the thermally reduced ore.

[0271] Aspect A3: The method or system according to aspect A2 or any previous aspect, wherein the dissolution step is carried out in a dissolution tank; wherein the dissolution tank and the electrochemical cell are fluidically connected; and wherein the acidic iron salt solution circulates between the dissolution tank and the electrochemical cell.

[0272] Aspect A4: The method or system according to aspect A3 or any previous aspect, in which, during at least part of the dissolution step, the entire acidic iron salt solution circulates between the dissolution tanks and the electrochemical cell.

[0273] Aspect A5: The method or system according to any of aspects A2-A4 or any preceding aspect, wherein the reaction between the thermally reduced ore and the acidic iron salt solution during dissolution generates water, thereby consuming protons from the acidic iron salt solution; and wherein the electrochemically generated protons fed in replace at least a portion of the protons consumed in the acidic iron salt solution.

[0274] Aspect A6: The method or system according to any of aspects A2-A5 or any preceding aspect, in which electrochemically generated protons are continuously fed to the acidic iron salt solution during at least part of the dissolution step.

[0275] Aspect A7: The method or system according to any of aspects A2-A6 or any preceding aspect, wherein the acidic iron salt solution is characterized by a steady-state concentration of free protons of at least 0.2 M (for example, at least 0.2, 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4 or 5 M, optionally Petition 870260045431, dated 05 / 13 / 2026, p. 113 / 460 105 / 200 where the steady-state concentration of free protons is less than 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4, 5 or 6 M and such values ​​can be combined in any way to form a range, such as 0.2-6 M) during the dissolution of the thermally reduced ore.

[0276] Aspect A8: The method or system according to aspect A7 or any previous aspect, wherein the acidic iron salt solution is characterized by a steady-state concentration of free protons selected in the range of 0.2 M to 3 M (for example, 0.4-2.8 M, 0.6-2.6 M, 0.8-2.2 M, 1-2 M, 1.2-1.8 M, 0.2-0.8 M, 0.8-1.4 M, 1.4-2 M, 22.5 M or 2.5-3 M).

[0277] Aspect A9: The method or system according to aspect A7 or A8 or any preceding aspect, wherein the acidic iron salt solution is characterized by a steady-state pH less than 0.7 (for example, less than: 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.1, -0.5 or -1, optionally wherein the steady-state pH is at least 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.1, -0.1, -0.5 or -1 and these values ​​may be combined in any way to form a range, such as -1 to 0.7).

[0278] Aspect A10: The method or system according to any of the preceding aspects comprising generating electrochemically from Fe2+ ions by electrochemical reduction, in the same or a different electrochemical cell, Fe3+ ions from the acidic iron salt solution to the electrochemically generated Fe2+ ion solution.

[0279] Aspect A11: The method or system according to aspect A10 or any previous aspect comprising feeding electrochemically generated Fe2+ ions to an acidic iron salt solution in the presence of thermally reduced ore during the dissolution step.

[0280] Aspect A12: The method or system according to aspect A10 or A11 or any previous aspect, wherein the electrochemical cell generates both electrochemically generated protons and Fe2+ ions. Petition 870260045431, dated 05 / 13 / 2026, page 114 / 460 106 / 200 electrochemically generated; wherein the dissolution step is carried out in a dissolution tank; and wherein the dissolution tank and the electrochemical cell are fluidically connected and the acidic iron salt solution circulates between the dissolution tank and the electrochemical cell.

[0281] Aspect A13: The method or system according to the aspect A8 or any previous aspect, wherein the electrochemical cell comprises a cathode in the presence of a catholyte, an anode in the presence of an anolyte, and a separator that separates the catholyte from the anolyte; wherein the catholyte comprises an acidic solution of iron salt; wherein the electrochemical reduction of Fe3+ ions from the acidic iron salt solution is carried out at the cathode to form electrochemically generated Fe2+ ions at the catholyte; and wherein the method further comprises: to electrochemically generate the electrochemically generated protons in the electrochemical cell by feeding the electrochemically generated protons to the catholyte.

[0282] Aspect A14: The method or system according to aspect A13 or any previous aspect, wherein the electrochemical generation step of the electrochemically generated protons comprises electrochemically oxidizing water at the anode.

[0283] Aspect A15: The method or system according to the aspect A13 or any previous aspect, wherein the electrochemical generation step of the electrochemically generated protons comprises electrochemically oxidizing gaseous H2 at the anode.

[0284] Aspect A16: The method or system according to aspect A14 or A15 or any previous aspect, wherein the step of feeding the electrochemically generated protons comprises transporting the electrochemically generated protons through the anolyte separator to Petition 870260045431, dated 05 / 13 / 2026, page 115 / 460 107 / 200 the catholyte.

[0285] Aspect A17: The method or system according to any of aspects A13-A16 or any preceding aspect, wherein the electrochemical cell is characterized by a Coulombic efficiency greater than 80% (for example, greater than: 80%, 85%, 90%, 95% or 99%, optionally wherein the Coulombic efficiency is less than: 80%, 85%, 90%, 95%, 99% or 100% and such values ​​may be combined in any way to form a range, such as 80-100%).

[0286] Aspect A18: The method or system according to any of aspects A13-A17 or any preceding aspect, in which electrochemically generated protons form at least partially the acid in the catholyte.

[0287] Aspect A19: The method or system according to any of aspects A13-A18 or any previous aspect comprising feeding water from the catholyte to the anolyte.

[0288] Aspect A20: The method or system according to aspect 14 or 16 or any previous aspect, wherein the oxidized water at the anode comprises the water generated by the dissolution of the iron-containing ore during the dissolution step.

[0289] Aspect A21: The method or system according to aspect A19 or A20 or any previous aspect, in which water is fed from the catholyte to the anolyte through the separator via osmosis.

[0290] Aspect A22: The method or system according to any of aspects A13-A21 or any preceding aspect, wherein the anolyte is characterized by the fact that the total salt concentration is greater than that of the catholyte.

[0291] Aspect A23: The method or system according to any of aspects A13-A22 or any previous aspect comprising separating water from the catholyte by means of membrane distillation and feeding said separated water to the anolyte. Petition 870260045431, dated 05 / 13 / 2026, p. 116 / 460 108 / 200

[0292] Aspect A24: The method or system according to any of aspects A13-A23 or any previous aspect comprising separating water from the catholyte by means of rapid distillation and feeding said separated water to the anolyte.

[0293] Aspect A25: The method or system according to any of aspects A13-A24 or any previous aspect comprising separating water from the catholyte by means of reverse osmosis and feeding said separated water to the anolyte.

[0294] Aspect A26: The method or system according to any of aspects A13-A25 or any previous aspect, wherein the anolyte has a composition different from that of the catholyte.

[0295] Aspect A27: The method or system according to any of aspects A13-A26 or any previous aspect, wherein the first anolyte has a pH different from the first catholyte.

[0296] Aspect A28: The method or system according to any of aspects A13-A27 or any previous aspect, wherein the first catholyte has a pH lower than that of the first anolyte.

[0297] Aspect A29: The method or system according to any of aspects A13-A28 or any preceding aspect, wherein the first anolyte comprises a composition of dissolved salts different from that of the first catholyte.

[0298] Aspect A30: The method or system according to any of aspects A13-A29 or any preceding aspect, wherein the first anolyte contains one or more dissolved ferric iron salts; and wherein the first analyte is characterized by a total concentration of one or more dissolved ferric iron salts that is equal to or greater than the total concentration of iron ions in the first catholyte.

[0299] Aspect A31: The method or system according to any of aspects A13-A30 or any previous aspect, wherein the first catholyte comprises one or more supporting salts. Petition 870260045431, dated 05 / 13 / 2026, p. 117 / 460 109 / 200

[0300] Aspect A32: The method or system according to aspect A31 or any previous aspect, wherein the first catholyte comprises a concentration of one or more supporting salts that is selected in the range of 0.1 to 1M (for example, 0.2 to 0.8 M, 0.4 to 0.6 M, 0.1 to 0.4 M, 0.4 to 0.8 M or 0.8 to 1 M).

[0301] Aspect A33: The method or system according to aspect A31 or A32 or any previous aspect, wherein one or more supporting salts comprise one or more metal sulfate compounds and / or one or more metal chloride compounds.

[0302] Aspect A34: The method or system according to aspect A33 or any previous aspect, wherein one or more metal sulfate compounds comprise potassium sulfate, sodium sulfate, ammonium sulfate, lithium sulfate, potassium chloride, sodium chloride, ammonium chloride, lithium chloride or a combination thereof.

[0303] Aspect A35: The method or system according to any of aspects A13-A34 or any previous aspect, wherein the first anolyte is characterized by at least one redox pair that is different from the first catholyte.

[0304] Aspect A36: The method or system according to any of aspects A13-A35 or any preceding aspect, wherein the first anolyte comprises a higher total concentration of dissolved salts than the first catholyte.

[0305] Aspect A37: The method or system according to any of aspects A1-A21, A23-A29 or A31-35 or any preceding aspect, wherein the first anolyte comprises a lower total concentration of dissolved salts than the first catholyte.

[0306] Aspect A38: The method or system according to any of aspects A1-A29 or A31-A35 or any previous aspect, wherein the anolyte is essentially free of Fe2+ and Fe3+ ions.

[0307] Aspect A39: The method or system according to any Petition 870260045431, dated 05 / 13 / 2026, p. 118 / 460 110 / 200 one of aspects A13-A38 or any previous aspect, wherein the catholyte is characterized by a maximum salt concentration that is selected in the range of 1 to 8 M (for example, 1-5 M, 2-5 M, 1-8 M, 2-7 M, 3-6 M, 4-5 M, 1-3 M, 3-5 M, 5-8 M, 1-4 M, 3-5 M or 3-8 M).

[0308] Aspect A40: The method or system according to any of aspects A13-A39 or any preceding aspect, wherein the catholyte is characterized by a maximum concentration of iron ions that is selected in the range of 0.5 to 5 M (e.g., 1-5 M, 1-4 M, 13 M, 0.5-5 M, 0.5-4 M, 2-4 M, 2-5 M, 1-2 M).

[0309] Aspect A41: The method or system according to any of aspects A13-A40 or any previous aspect comprising generating oxygen (O2) electrochemically at the anode.

[0310] Aspect A42: The method or system according to any of aspects A13-A41 or any preceding aspect, in which the electrochemical reactions at the anode are characterized by means of one or more redox pairs selected from the group consisting of: O2 / H2O, H2O / H2, H2 / H+, H7H2O and any combination thereof.

[0311] Aspect A43: The method or system according to any of aspects A13-A42 or any previous aspect, wherein the first anolyte is ionically connected to the first catholyte through the first separator.

[0312] Aspect A44: The method or system according to aspect A43 or any previous aspect, in which the first anolyte is fluidically disconnected from the first catholyte.

[0313] Aspect A45: The method or system according to any of aspects A13-A44 or any previous aspect, wherein the separator is an ion-exchange membrane.

[0314] Aspect A46: The method or system according to aspect A45 or any previous aspect, wherein the separator is a proton exchange membrane (PEM). Petition 870260045431, dated 05 / 13 / 2026, p. 119 / 460 111 / 200

[0315] Aspect A47: The method or system according to any of the preceding aspects comprising producing an iron-rich solution having Fe2+ ions.

[0316] Aspect A48: The method or system according to aspect A47 or any previous aspect, wherein the iron-rich solution produced is characterized by a total iron ion concentration selected in the range of 0.5 to 5 M (for example, 1-4 M, 1-5 M, 0.5-4 M, 14 M, 1-3 M, 0.5-4 M, 2-4 M, 2-5 M or 1-2 M).

[0317] Aspect A49: The method or system according to aspect A47 or A48 or any previous aspect comprising removing the iron-rich solution produced from the electrochemical cell and / or from a container in which the dissolution step is carried out.

[0318] Aspect A50: The method or system according to any of aspects A3-A49 or any prior aspect comprising increasing the pH of the acidic iron salt solution by fluidically disconnecting the dissolution tank from the electrochemical cell and / or deactivating the electrochemical cell during and before completion of the dissolution step.

[0319] Aspect A51: The method or system according to any of aspects A47-A50 or any preceding aspect comprising raising the pH of the iron-rich solution produced to be selected in the range of 2 to 7 (for example, 2-6.5, 2-6, 2-5, 3-7, 3-6, 3-5, 34, 4-7, 4-6, 4-5, 5-7, 5-6 or 6-7) thereby producing an iron-rich solution with adjusted pH.

[0320] Aspect A52: The method or system according to any of aspects A47-A51 or any preceding aspect comprising raising the pH of the iron-rich solution produced to be selected in the range of 2 to less than 7 (for example, 2-6.5, 2-6, 2-5, 3 to less than 7, 3-6, 3-5, 3-4, 4 to less than 7, 4-6, 4-5, 5 to less than 7, 5-6 or 6 to less than 7), thereby producing a rich solution Petition 870260045431, dated 05 / 13 / 2026, pp. 120 / 460 112 / 200 in iron with adjusted pH.

[0321] Aspect A53: The method or system according to aspect A51 or A52 or any previous aspect, wherein the pH-raising step comprises feeding metallic iron and / or one or more iron oxide materials into the presence of the iron-rich solution produced.

[0322] Aspect A54: The method or system according to aspect A53 or any previous aspect, wherein the pH-raising step comprises supplying magnetite, metallic iron, or magnetite and metallic iron together in the presence of the iron-rich solution produced.

[0323] Aspect A55: The method or system according to aspect A54 or any previous aspect, wherein the pH raising step comprises supplying magnetite or magnetite and metallic iron together in the presence of the iron-rich solution produced.

[0324] Aspect A56: The method or system according to any of aspects A51-A55 or any preceding aspect, wherein the pH-raising step comprises providing a sufficient amount of metallic iron to raise the pH of the iron-rich solution produced to be selected in the range of 2 to 7 (for example, 2-6.5, 2-6, 2-5, 3-7, 3 to less than 7, 3-6, 3-5, 3-4, 4-7, 4 to less than 7, 4-6, 4-5, 5-7, 5 to less than 7, 5-6, 6-7 or 6 to less than 7); in some aspects, metallic iron is a material comprising metallic iron.

[0325] Aspect A57: The method or system according to any of aspects A47-A56 or any previous aspect, comprising precipitating or crystallizing one or more ferrous salts from the iron-rich solution produced.

[0326] Aspect A58: The method or system according to any of aspects A47-A57 or any preceding aspect, comprising removing one or more ferrous salts from the iron-rich solution produced by means of one or more different galvanizing processes.

[0327] Aspect A59: The method or system according to any Petition 870260045431, dated 05 / 13 / 2026, page 121 / 460 113 / 200 one of the preceding aspects, wherein the thermal reduction step comprises exposing one or more iron oxide materials other than magnetite from the iron-containing ore to a reducing agent at a selected elevated temperature in the range of 200 °C to 600 °C (for example, a temperature (°C) of 200-550, 200-500, 200-450, 200-400, 200-350, 200-300, 200-250, 250-600, 250-550, 250-500, 250-400, 300-600, 300-550, 300-500, 300-450, 300-400, 350-600, 350-550, 350-500, 350-450, 400-600, 400-550, 400-500, 450-600, 450-550 or 500-600), thus converting at least a portion of one or more iron oxide materials other than magnetite into magnetite.

[0328] Aspect A60: The method or system according to any of the preceding aspects, wherein the reducing agent comprises gaseous H2; and wherein at least part of the gaseous H2 is chemically generated through a reaction of metallic iron with an acid and / or at least part of the gaseous H2 is electrochemically generated through a parasitic hydrogen evolution reaction of an iron galvanizing process.

[0329] Aspect A61: The method or system according to aspect A59 or any previous aspect, wherein the iron-containing ore is exposed to elevated temperature during a heat treatment time during the thermal reduction stage and wherein the iron-containing ore is exposed to the reducing agent during the entire heat treatment time.

[0330] Aspect A62: The method or system according to aspect A59 or any previous aspect, wherein the iron-containing ore is exposed to elevated temperature during a heat treatment time during the thermal reduction stage and wherein the iron-containing ore is exposed to the reducing agent during a portion of the heat treatment time.

[0331] Aspect A63: The method or system according to the aspect Petition 870260045431, dated 05 / 13 / 2026, p. 122 / 460 114 / 200 A62 or any preceding aspect, comprising air-roasting the iron-containing ore, exposing the iron-containing ore to air during an initial portion of the heat treatment time.

[0332] Aspect A64: The method or system according to any of the preceding aspects, which further comprises air-roasting at least part of the iron-containing ore in the presence of air at a temperature selected in the range of 200 °C to 600 °C (for example, a temperature (°C) of 200-550, 200-500, 200-450, 200-400, 200-350, 200-300, 200-250, 250-600, 250-550, 250-500, 250-400, 300-600, 300-550, 300-500, 300-450, 300-400, 350-600, 350-550, 350-500, 350-450, 400-600, 400-550, 400-500, 450-600, 450-550 or 500-600) to form an air-roasted ore.

[0333] Aspect A65: The method or system according to aspect A64 or any previous aspect, wherein the air roasting step is carried out before or separately from the thermal reduction step, wherein the air-roasted ore has not been thermally reduced before air roasting.

[0334] Aspect A66: The method or system according to aspect A64 or A65 or any previous aspect, wherein the thermal reduction step comprises thermally reducing the air-roasted ore to form at least a portion of thermally reduced ore; wherein the air roasting comprises one or more iron oxide materials other than magnetite.

[0335] Aspect A67: The method or system according to aspect A64, A65 or A66 or any previous aspect, wherein the dissolution step comprises dissolving at least part of the air-roasted ore and at least part of the thermally reduced ore simultaneously and / or sequentially.

[0336] Aspect A68: The method or system according to the aspect Petition 870260045431, dated 05 / 13 / 2026, p. 123 / 460 115 / 200 A67 or any preceding aspect, wherein the dissolution step comprises dissolving at least part of the air-roasted ore in a dissolution tank separate from the thermally reduced ore during at least part of the dissolution step.

[0337] Aspect A69: The method or system according to any of aspects A64-A68 or any previous aspect, wherein the dissolution step comprises dissolving a mixture of ore; wherein the ore mixture comprises 0% by weight to 100% by weight (for example, a % by weight of 0-100, 1-100, 1-90, 1-80, 1-70, 1-60, 1-50, 1-40, 1-30, 1-20, 1-10, 5-100, 5-90, 5-80, 5-70, 5-60, 5-50, 5-40, 5-30, 5-20, 5-10, 10-100, 10-90, 10-80, 10-70, 10-60, 10-50, 10-40, 10-30, 10-20, 20-100, 20-90, 20-80, 20-70, 20-60, 20-50, 20-40, 20-30, 40-100, 40-80, 40-60, 50-100, 50-80, 50-60, 60-100, 60-80, 70-100, 70-80, 80-100) of thermally reduced ore, 5% by weight to 100% by weight (e.g., a % by weight of 5-100, 5-90, 5-80, 5-70, 5-60, 5-50, 5-40, 5-30, 5-20, 5-10, 10-100, 10-90, 10-80, 10-70, 10-60, 10-50, 10-40, 10-30, 10-20, 20-100, 20-90, 20-80, 20-70, 20-60, 20-50, 20-40, 20-30, 40-100, 40-80, 40-60, 50-100, 50-80, 50-60, 60-100, 60-80, 70-100, 70-8080-100) of roasted ore and 0% by weight to 90% by weight (for example, a % by weight of 0-90, 1-90, 1-80, 1-70, 1-60, 1-50, 1-40, 130, 1-20, 1-10, 5-90, 5-80, 5-70, 5-60, 5-50, 5-40, 5-30, 5-20, 5-10, 10-90, 10-80, 10-70, 10-60, 10-50, 10-40, 10-30, 10-20, 20-90, 20-80, 20-70, 20-60, 20-50, 20-40, 20-30, 40-90, 40-80, 40-60, 50-90, 50-80, 50-60, 60-90, 60-80, 70-90, 70-80, 80-90) of roasted ore containing magnetite.

[0338] Aspect A70: The method or system according to any of aspects A64-A69 or any preceding aspect, wherein the dissolution step comprises circulating a dissolution solution between the electrochemical cell and at least one of a first dissolution tank, a second dissolution tank and a third tank. Petition 870260045431, dated 05 / 13 / 2026, page 124 / 460 116 / 200 dissolution; wherein the first dissolution tank comprises at least part of thermally reduced ore, the second dissolution tank comprises air-roasted ore and the third dissolution tank comprises raw ore containing iron; wherein the raw ore is an iron-containing ore that has not been thermally reduced or air-roasted.

[0339] Aspect A71: The method or system according to aspect A70 or any previous aspect, wherein the circulation step comprises circulating the dissolution solution for a total circulation time or a total number of circulation cycles; where the dissolution solution circulates between the electrochemical cell and the third dissolution tank from 0 to 99% (e.g., a % of 0-95, 1-99, 1-95, 5-90, 10-85, 15-80, 20-75, 25-70, 30-65, 35-60, 40-55, 1-90, 1-80, 1-70, 1-60, 1-50, 1-20, 5-99, 5-80, 5-70, 5-60, 5-40, 5-20, 10-95, 10-80, 10-60, 20-95, 20-80, 20-60, 40-99, 40-80, 60-99, 60-80, 70-95 or 80-95) of the total circulation time or the total number of circulation cycles;where the dissolution solution circulates between the electrochemical cell and the second dissolution tank from 0 to 99% (e.g., a % of 0-95, 1-99, 1-95, 5-90, 10-85, 15-80, 20-75, 25-70, 30-65, 35-60, 40-55, 1-90, 1-80, 1-70, 1-60, 1-50, 1-20, 5-99, 5-80, 5-70, 5-60, 5-40, 5-20, 10-95, 10-80, 10-60, 20-95, 20-80, 20-60, 40-99, 40-80, 60-99, 60-80, 70-95 or 80-95) of the total circulation time or the total number of circulation cycles; and in which the dissolution solution is circulated between the electrochemical cell and the first dissolution tank from 1 to 100% (for example, 1-99%, 5-100%, 1-95%, 5-90%, 10-100%, 10-85%, 15-80%, 20-100%, 20-75%, 25-70%, 30-65%, 35-60%, 40-100%, 40-55%, 1-90%, 1-80%, 1-70%, 1-60%, 1-50%, 1-20%, 5-99%, 5-80%, 5-70%, 5-60%, 5-40%, 5-20%, 10-95%, 10-80%, 10-60%, 20-95%, 20-80%, 50-100, 20-60, 40-99, 70-100, 40-80, 60-99, 60-80, 70-95, 80-100 or 80-95) of the total circulation time or the total number of circulation cycles. Petition 870260045431, dated 05 / 13 / 2026, page 125 / 460 117 / 200

[0340] Aspect A72: The method or system according to aspect A70 or A71 or any previous aspect in which, during the circulation step, the dissolution solution is circulated sequentially in any order and / or simultaneously between the electrochemical cell and any two or between any three of the first, second and third dissolution tanks.

[0341] Aspect A73: The method or system according to aspect A72 or any previous aspect, wherein the circulation step comprises a first circulation of the dissolving solution between the electrochemical cell and the third dissolving tank containing the raw ore and then a second circulation of the dissolving solution between the electrochemical cell and the second dissolving tank containing the air-roasted ore, then a third circulation of the dissolving solution between the electrochemical cell and the first dissolving tank containing the thermally reduced ore.

[0342] Aspect A74: The method or system according to any of aspects A70-A73 or any preceding aspect, wherein the dissolution solution is or comprises an acidic solution of iron salt.

[0343] Aspect A75: The method or system according to any of aspects A64-A74 or any preceding aspect, wherein the first dissolution tank further comprises air-roasted ore, raw ore or both during any part of the dissolution stage.

[0344] Aspect A76: The method or system according to any of aspects A64-A75 or any preceding aspect, wherein the second dissolution tank further comprises thermally reduced ore, raw ore or both during any part of the dissolution stage.

[0345] Aspect A77: The method or system in accordance with any of aspects A64-A76 or any preceding aspect, where applicable. Petition 870260045431, dated 05 / 13 / 2026, pp. 126 / 460 118 / 200 The dissolution tank also comprises air-roasted ore, thermally reduced ore, or both during any part of the dissolution stage.

[0346] Aspect A78: The method or system according to any of the preceding aspects, wherein the dissolution step is carried out in at least one dissolution tank; and wherein the dissolution step further comprises introducing an air-roasted ore, a raw ore or both into the acidic iron salt solution in at least one dissolution tank in the presence of the thermally reduced ore.

[0347] Aspect A79: The method or system according to any of the preceding aspects, wherein one or more iron oxide materials other than magnetite comprise hematite and / or goethite.

[0348] Aspect A80: The method or system according to any of the preceding aspects, wherein the acid comprises hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, citric acid, oxalic acid, boric acid, methanesulfonic acid or any combination thereof.

[0349] Aspect A81: A method for processing and dissolving an ore containing iron, the method comprising: In a dissolving tank, place the iron-containing ore in contact with an acid to dissolve at least part of the iron-containing ore, thus forming an acidic solution of iron salt that has dissolved Fe3+ ions; to recirculate at least part of the acidic iron salt solution between the dissolution tank and a cathodic chamber of an electrochemical cell, the electrochemical cell comprising a cathode in the presence of at least part of the acidic iron salt solution that serves as a catholyte in the cathodic chamber, an anode in the presence of an anolyte, and a separator that separates the catholyte from the anolyte; electrochemically reduce at least a portion of the ions Petition 870260045431, dated 05 / 13 / 2026, page 127 / 460 119 / 200 Dissolved Fe3+ ions from the catholyte are transferred to the cathode to form Fe2+ ions in the catholyte; and protons are generated electrochemically in the electrochemical cell, and the electrochemically generated protons are fed back to the catholyte. wherein the acidic solution of iron salt in the dissolution tank, in the presence of the iron-containing ore, is characterized by a steady-state concentration of free protons that is at least 0.2 M (optionally, for example, at least 0.2, 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4 or 5 M, optionally wherein the steady-state concentration of free protons is less than 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4, 5 or 6 M and these values ​​may be combined in any way to form a range, such as 0.2-6 M).

[0350] Aspect A82: A method for processing and dissolving an ore containing iron, the method comprising: To thermally reduce one or more iron oxide materials other than magnetite in iron-containing ore to form magnetite in the presence of a reducing agent, thereby forming a thermally reduced ore; wherein the reducing agent comprises gaseous H2; and wherein at least part of the gaseous H2 is chemically generated through a reaction of metallic iron with an acid and / or at least part of the gaseous H2 is electrochemically generated through a parasitic hydrogen evolution reaction of an iron galvanizing process; and dissolving at least the thermally reduced ore using an acidic solution to form an iron salt solution; whereby the dissolution step involves dissolving the magnetite formed in said acidic solution.

[0351] Aspect A83: A system for processing and dissolving an iron-containing ore, the system comprising: Petition 870260045431, dated 05 / 13 / 2026, pp. 128 / 460 120 / 200 a first dissolving tank to dissolve a first ore containing iron using a first acid; wherein: The dissolution of the first ore in the first acid forms a first acidic solution of iron salt comprising Fe3+ ions dissolved in the first dissolution tank; an electrochemical cell fluidically connected to the first dissolution tank; wherein: The electrochemical cell comprises a cathodic chamber having a catholyte in the presence of a cathode, an anodic chamber having an anolyte in the presence of an anode, and a separator separating the catholyte and the anolyte; and a first circulation subsystem that circulates at least part of the first acidic iron salt solution from the first dissolution tank to the cathodic chamber and at least part of the electrochemical cell catholyte to the first dissolution tank; whereby at least some of the Fe3+ ions from the first acidic iron salt solution are electrochemically reduced at the cathode to Fe2+ ions at the catholyte, thereby consuming the Fe3+ ions from the first acidic iron salt solution.

[0352] Aspect A84: The method or system according to aspect A83 or any previous aspect, in which protons are electrochemically generated in the electrochemical cell and fed to the catholyte, thereby replenishing at least partially the acid consumed during dissolution.

[0353] Aspect A85: The method or system according to aspect A84 or any previous aspect, in which protons are electrochemically generated in the anolyte and pass through the separator to the catholyte.

[0354] Aspect A86: The method or system according to aspect A83, A84 or A85 or any previous aspect, in which the acidic solution Petition 870260045431, dated 05 / 13 / 2026, pp. 129 / 460 A 121 / 200 concentration of iron salt in the dissolution tank, in the presence of iron-containing ore, is characterized by a steady-state concentration of free protons that is at least 0.2 M (optionally, for example, at least 0.2, 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4 or 5 M, optionally wherein the steady-state concentration of free protons is less than 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4, 5 or 6 M and such values ​​may be combined in any way to form a range, such as 0.2-6 M) and / or has a steady-state pH that is equal to or less than 0.7 (for example, equal to or less than 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0, -0.1, -0.5 or -1, optionally wherein the steady-state pH is at least 0.5, 0.4, 0.3, 0.2, 0.1, 0, -0.1, -0.5 or -1 and these values ​​may be combined in any way to form a range, such as -1 to 0.7).

[0355] Aspect A87: The method or system according to any of the above aspects, wherein the anolyte comprises water or an aqueous saline solution; and wherein the water is electrochemically oxidized at the anode to generate protons at the anolyte; and wherein the generated protons are transported to the catholyte through the separator.

[0356] Aspect A88: The method or system according to any of the preceding aspects, in which the anolyte has a composition different from that of the catholyte.

[0357] Aspect A89: The method or system according to any of the preceding aspects, wherein the first iron-containing ore comprises a thermally reduced ore having magnetite.

[0358] Aspect A90: The method or system according to aspect A69 or any previous aspect further comprising a thermal reduction subsystem configured to form thermally reduced ore by converting materials other than magnetite into magnetite in the presence of a reducing agent and at a selected elevated temperature in the range of 200 °C to 600 °C (for example, a temperature Petition 870260045431, dated 05 / 13 / 2026, pp. 130 / 460 122 / 200 (oC) 200-550, 200-500, 200-450, 200-400, 200-350, 200-300, 200250, 250 -600, 250-550, 250-500, 250-400, 300-600, 300-550, 300-500, 300-450, 300-400, 350-600, 350-550, 350-500, 350-450, 400-600, 400550, 400-500, 450-600, 450-550 or 500-600); where thermally reduced ore is fed to the first dissolution tank of the thermal reduction subsystem.

[0359] Aspect A91: The method or system according to aspect A90 or any previous aspect comprising an air-roasting subsystem configured to form an air-roasted ore by air-roasting an iron-containing ore in the presence of air and at a selected elevated temperature in the range of 200 °C to 600 °C (for example, a temperature (°C) of 200-550, 200-500, 200-450, 200-400, 200-350, 200-300, 200-250, 250-600, 250-550, 250-500, 250-400, 300-600, 300-550, 300-500, 300-450, 300-400, 350-600, 350-550, 350-500, 350-450, 400-600, 400-550, 400-500, 450-600, 450-550 or 500-600).

[0360] Aspect A92: The method or system according to aspect A91 or any previous aspect, where the air torrefaction subsystem and the thermal reduction subsystem are the same.

[0361] Aspect A93: The method or system according to any of the preceding aspects comprising a second dissolution tank having an air-roasted ore; wherein the air-roasted ore is an iron-containing ore that has not been thermally reduced and has been exposed to air at a selected elevated temperature in the range of 200 °C to 600 °C (for example, a temperature (°C) of 200-550, 200-500, 200-450, 200-400, 200-350, 200-300, 200-250, 250-600, 250-550, 250-500, 250-400, 300-600, 300-550, 300-500, 300-450, 300-400, 350-600, 350-550, 350-500, 350-450, 400-600, 400-550, 400-500, 450-600, 450-550 or 500-600); Petition 870260045431, dated 05 / 13 / 2026, page 131 / 460 123 / 200 where the dissolution of the air-roasted ore occurs in the presence of a second acidic iron salt solution comprising Fe3+ ions dissolved in the second dissolution tank; wherein the system further comprises a second circulation subsystem that circulates at least part of the second acidic iron salt solution from the second dissolution tank to the cathodic chamber and at least part of the electrochemical cell catholyte to the second dissolution tank; and wherein at least part of the Fe3+ ions from the second acidic iron salt solution are electrochemically reduced at the cathode to Fe2+ ions at the catholyte, thereby consuming the Fe3+ ions from the second acidic iron salt solution.

[0362] Aspect A94: The method or system according to any of the preceding aspects comprising a third dissolution tank containing a raw ore; wherein the raw ore is an iron-containing ore that has not been thermally reduced or air-roasted; wherein the dissolution of the air-roasted ore takes place in the presence of a third acidic iron salt solution comprising Fe3+ ions dissolved in the third dissolution tank; wherein the system further comprises a third circulation subsystem that circulates at least part of the third acidic iron salt solution from the third dissolution tank to the cathodic chamber and at least part of the electrochemical cell catholyte to the third dissolution tank; and wherein at least part of the Fe3+ ions from the third acidic iron salt solution are electrochemically reduced at the cathode to Fe2+ ions at the catholyte, thereby consuming the Fe3+ ions from the third acidic iron salt solution.

[0363] Aspect A95: The method or system according to any of the previous aspects configured to produce a rich solution. Petition 870260045431, dated 05 / 13 / 2026, p. 132 / 460 124 / 200 in iron that has a selected iron ion concentration in the range of 1 M to 4 M (e.g., 1-3.5, 1-3, 1-2.5, 1-2, 1-1.5, 1.5-4, 1.5-3.5, 1.5-3, 1.5-2.5, 1.5-2, 2-4, 2-3.5, 2-3, 2-2.5, 2.5-4, 2.5-3.5, 2.5-3, 3-4 or 3-3.5).

[0364] Aspect A96: The method or system according to any of the aspects above or below, in which the dissolution step is terminated when the proton concentration (optionally, a steady-state proton concentration) in the acidic iron salt solution is equal to or less than 0.4 M (optionally 0.3 M, optionally 0.2 M, optionally 0.1 M) (optionally after being above this limit for most of the time the dissolution step is performed).

[0365] Aspect A97: The method or system according to any of the aspects above or below, wherein the dissolution step is terminated when the total concentration of iron ions in the first catholyte, in the acidic iron salt solution and / or in the iron-rich solution produced reaches a desired maximum value (optionally, a steady-state value) which is 1 M, optionally 2 M, optionally 3 M, optionally 4 M, optionally any value or range between 1 M and 4 M inclusive.

[0366] Aspect B1a: A method for producing iron, the method comprising: feeding a raw material containing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; and Petition 870260045431, dated 05 / 13 / 2026, page 133 / 460 125 / 200 where the first anolyte has a different composition from that of the first catholyte; Dissolve at least part of the iron-containing ore using an acid to form an acidic solution of iron salt that has dissolved Fe3+ ions first; feed at least part of the acidic iron salt solution containing at least some of the first Fe3+ ions to the first cathodic chamber; first, electrochemically reduce the aforementioned first Fe3+ ions in the first catholyte to form Fe2+ ions; Transfer the Fe2+ ions formed from the dissolution subsystem to an iron galvanizing subsystem that has a second electrochemical cell; Second, to electrochemically reduce at least a first portion of the Fe3+ ions formed into metallic Fe at a second cathode of the second electrochemical cell; and to remove the metallic Fe from the second electrochemical cell, thereby producing iron.

[0367] Aspect B1b: A method for producing iron, the method comprising: feeding a raw material containing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell; wherein the first electrochemical cell comprises a first anodic chamber containing gaseous H2 in the presence of a first anode, a first cathodic chamber containing a first catholyte in the presence of a first cathode, and a first separator separating the first anodic chamber from the first catholyte; and dissolving at least part of the iron-containing ore using an acid to form an acidic solution of iron salt containing Petition 870260045431, dated 05 / 13 / 2026, page 134 / 460 126 / 200 first dissolved Fe3+ ions; feed at least part of the acidic iron salt solution containing at least some of the first Fe3+ ions to the first cathodic chamber; first, electrochemically reduce the aforementioned first Fe3+ ions in the first catholyte to form Fe2+ ions; Transfer the Fe2+ ions formed from the dissolution subsystem to an iron galvanizing subsystem that has a second electrochemical cell; Second, to electrochemically reduce at least a first portion of the Fe2+ ions formed into metallic Fe at a second cathode of the second electrochemical cell; and to remove the metallic Fe from the second electrochemical cell, thereby producing iron.

[0368] Aspect B1c: A system for the production of iron, the system comprising: a dissolution subsystem that has a dissolution tank and a first electrochemical cell fluidically connected to the dissolution tank; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; and wherein the first anolyte has a composition different from that of the first catholyte; and an iron galvanizing subsystem fluidically connected to the dissolution subsystem and having a second electrochemical cell; and Petition 870260045431, dated 05 / 13 / 2026, pp. 135 / 460 127 / 200 a first intersubsystem fluid connection between the dissolution subsystem and the galvanizing subsystem; in which: The dissolving tank receives a raw material containing iron ore; The dissolving tank comprises an acidic solution of iron salt to dissolve at least part of the iron-containing ore to generate first dissolved Fe3+ ions; The first Fe3+ ions are electrochemically reduced at the first cathode to form Fe2+ ions at the first catholyte; The Fe2+ ions formed are transferred from the dissolution subsystem to the iron galvanizing subsystem through the first intersubsystem fluid connection; The second electrochemical cell comprises a second cathode to reduce at least a first part of the Fe2+ ions formed transferred into metallic Fe; and the metallic Fe is removed from the second electrochemical cell.

[0369] Aspect B1d: A system for the production of iron, the system comprising: a dissolution subsystem that has a dissolution tank and a first electrochemical cell fluidically connected to the dissolution tank; wherein the first electrochemical cell comprises a first anodic chamber containing gaseous H2 in the presence of a first anode, a first cathodic chamber containing a first catholyte in the presence of a first cathode, and a first separator separating the first anodic chamber from the first catholyte; and an iron galvanizing subsystem fluidically connected to the dissolution subsystem and containing a second electrochemical cell; and Petition 870260045431, dated 05 / 13 / 2026, page 136 / 460 128 / 200 a first intersubsystem fluid connection between the dissolution subsystem and the galvanizing subsystem; in which: The dissolving tank receives a raw material containing iron ore; The dissolving tank comprises an acidic solution of iron salt to dissolve at least part of the iron-containing ore to generate first dissolved Fe3+ ions; The first Fe3+ ions are electrochemically reduced at the first cathode to form Fe2+ ions at the first catholyte; The Fe2+ ions formed are transferred from the dissolution subsystem to the iron galvanizing subsystem through the first intersubsystem fluid connection; The second electrochemical cell comprises a second cathode to reduce at least a first part of the Fe2+ ions formed transferred to metallic Fe; and the metallic Fe is removed from the second electrochemical cell.

[0370] Aspect B2: The method or system according to any previous aspect comprising generating protons electrochemically in the first electrochemical cell and feeding the electrochemically generated protons to the acidic iron salt solution during the dissolution step.

[0371] Aspect B3: The method or system according to aspect B2 or any previous aspect, wherein electrochemically generated protons that are generated and fed to the acidic iron salt solution facilitate that the acidic iron salt solution is characterized by a steady-state pH that is equal to or less than 0.7 (for example, equal to or less than 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0, -0.1, -0.5 or -1, optionally where the steady-state pH is at least 0.5, 0.4, 0.3, 0.2, 0.1, 0, -0.1, -0.5 or -1 and such values ​​may be combined in any way to form a range, such as -1 to 0.7) during. Petition 870260045431, dated 05 / 13 / 2026, pp. 137 / 460 129 / 200 the dissolution stage.

[0372] Aspect B4: The method or system according to aspect B2 or aspect B3 or any preceding aspect, wherein electrochemically generated protons which are generated and fed to the acidic iron salt solution facilitate that the acidic iron salt solution be characterized by a steady-state free proton concentration which is equal to or greater than 0.2 M (for example, equal to or greater than 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4 or 5 M, optionally wherein the steady-state free proton concentration is less than 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4, 5 or 6 M and such values ​​may be combined in any manner to form a range, such as 0.2–6 M) during the step of dissolution.

[0373] Aspect B5: The method or system according to any of the preceding aspects comprising continuously removing Fe3+ ions from the acidic iron salt solution during the dissolution step to facilitate the dissolution of said iron-containing ore through the first electrochemical reduction step of said first Fe3+ ions in the first catholyte.

[0374] Aspect B6: The method or system according to any of the above aspects, wherein the first anolyte has a pH different from the first catholyte.

[0375] Aspect B7: The method or system according to any of the preceding aspects, wherein the first catholyte has a lower pH than the first anolyte.

[0376] Aspect B8: The method or system according to any of the preceding aspects, wherein the first anolyte comprises a composition of dissolved salts different from that of the first catholyte.

[0377] Aspect B9: The method or system according to any of the above aspects, wherein the first anolyte contains one or Petition 870260045431, dated 05 / 13 / 2026, pp. 138 / 460 130 / 200 plus dissolved ferric iron salts; and wherein the first analyte is characterized by a total concentration of one or more dissolved ferric iron salts that is equal to or greater than the total concentration of iron ions in the first catholyte.

[0378] Aspect B10: The method or system according to any of the preceding aspects, wherein the first catholyte comprises one or more supporting salts.

[0379] Aspect B11: The method or system according to aspect B10 or any previous aspect, wherein the first catholyte comprises a concentration of one or more supporting salts that is selected in the range of 0.1 to 1M (for example, 0.2 to 0.8 M, 0.4 to 0.6 M, 0.1 to 0.4 M, 0.4 to 0.8 M or 0.8 to 1 M).

[0380] Aspect B12: The method or system according to aspect B10 or B11 or any previous aspect, wherein one or more supporting salts comprise one or more metal sulfate compounds and / or one or more metal chloride compounds.

[0381] Aspect B13: The method or system according to aspect B12 or any previous aspect, wherein one or more metal sulfate compounds comprise potassium sulfate, sodium sulfate, ammonium sulfate, lithium sulfate, potassium chloride, sodium chloride, ammonium chloride, lithium chloride or a combination thereof.

[0382] Aspect B14: The method or system according to any of the preceding aspects, wherein the first anolyte is characterized by at least one redox pair that is different from the first catholyte.

[0383] Aspect B15: The method or system according to any of the preceding aspects, wherein the first anolyte comprises a higher total concentration of dissolved salts than the first catholyte.

[0384] Aspect B16: The method or system in accordance with any of aspects B1-B8 and B10-B14 or any previous aspect, in Petition 870260045431, dated 05 / 13 / 2026, pp. 139 / 460 131 / 200 that the first anolyte comprises a lower total concentration of dissolved salts than the first catholyte.

[0385] Aspect B17: The method or system according to any of the preceding aspects, wherein the first anolyte is ionically connected to the first catholyte through the first separator.

[0386] Aspect B18: The method or system according to aspect B17 or any previous aspect, in which the first anolyte is fluidically disconnected from the first catholyte.

[0387] Aspect B19: The method or system according to any of the preceding aspects, wherein the first separator is an ion-exchange membrane.

[0388] Aspect B20: The method or system according to aspect B19 or any previous aspect, wherein the first separator is a proton exchange membrane (PEM).

[0389] Aspect B21: The method or system according to any of the preceding aspects, wherein: The dissolution subsystem comprises a first dissolution tank fluidically connected to the first electrochemical cell; The dissolution step is carried out in the dissolution tank so that the first dissolved Fe3+ ions are generated in the dissolution tank; The method involves first circulating at least part of the acidic iron salt solution between the dissolution tank and the first electrochemical cell; The first circulation stage comprises feeding at least part of the acidic iron salt solution containing at least part of the initial Fe3+ ions from the dissolution tank to the first cathodic chamber, and the first circulation stage further comprises supplying the Fe2+ ions formed from the first catholyte to Petition 870260045431, dated 05 / 13 / 2026, pp. 140 / 460 132 / 200 first dissolving tank.

[0390] Aspect B22: The method or system according to aspect B21 or any previous aspect, wherein the portion of the acidic iron salt solution fed to the first cathodic chamber serves as at least a portion of the first catholyte, such that the first catholyte comprises at least a portion of the acidic iron salt solution.

[0391] Aspect B23: The method or system according to aspect B21 or B22 or any previous aspect, wherein the entire acidic iron salt solution circulates between the first dissolution tank and the first electrochemical cell.

[0392] Aspect B24: The method or system according to aspect B21, B22 or B23 or any previous aspect comprising oxidizing water in the first anolyte to electrochemically generate aqueous protons and feeding the electrochemically generated protons to the first catholyte; wherein the circulation step comprises feeding the electrochemically generated aqueous protons from the first catholyte to the dissolution tank, so that the acidic iron salt solution in the first dissolution tank comprises the electrochemically generated protons during the dissolution step.

[0393] Aspect B25: The method or system according to aspect B24 or any previous aspect, wherein the oxidized water in the first electrochemical cell is generated in the dissolution tank by dissolving the iron-containing ore; and wherein the circulation step comprises feeding the water generated from the first dissolution tank to the first catholyte.

[0394] Aspect B26: The method or system according to any of the preceding aspects comprising feeding water to the first anolyte from the first catholyte.

[0395] Aspect B27: The method or system according to any Petition 870260045431, dated 05 / 13 / 2026, pp. 141 / 460 133 / 200 one of the preceding aspects comprising producing an iron-rich solution having the Fe2+ ions formed in the dissolution subsystem; wherein the step of transferring the Fe2+ ions formed comprises removing at least a portion of the iron-rich solution from the dissolution subsystem and feeding a fed iron-rich solution to the iron galvanizing subsystem; wherein the fed iron-rich solution comprises at least a portion of the iron-rich solution removed.

[0396] Aspect B28: The method or system according to aspect B27 or any previous aspect in which the iron-rich solution fed having Fe2+ ions formed is characterized by a pH greater than 0.5 (for example, greater than: 0.5, 0.6, 0.7, 0.8, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 or 6, optionally in which the pH is less than: 0.6, 0.7, 0.8, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 or 6 and these pHs may be combined in any way to form a range, such as 0.5-6).

[0397] Aspect B29: The method or system according to aspect B28 or any previous aspect, wherein the iron-rich solution fed is characterized by a pH equal to or greater than 1 (for example, greater than: 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 or 6, optionally wherein the pH is less than: 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 or 6 and such pHs may be combined in any way to form a range, such as 1-6).

[0398] Aspect B30: The method or system according to aspect B29 or any previous aspect, wherein the iron-rich solution fed is characterized by a pH selected in the range of 2 to 6 (for example, greater than: 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 or 6, optionally wherein the pH is less than: 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 or 6 and such pHs may be combined in any way to form a range).

[0399] Aspect B31: The method or system according to any Petition 870260045431, dated 05 / 13 / 2026, pp. 142 / 460 134 / 200 one of aspects B27-B30 or any of the preceding aspects, wherein the iron-rich feed solution comprises a higher concentration of Fe2+ ions than of Fe3+ ions.

[0400] Aspect B32: The method or system according to any of aspects B27-B31 or any preceding aspect, wherein the iron-rich solution fed is characterized by a ratio of Fe3+ to Fe2+ ion concentrations that is equal to or less than 0.01 (for example, equal to or less than 0.01, 0.0075, 0.005, 0.0025 or 0.001, optionally wherein the ratio may be equal to or greater than 0.0075, 0.005, 0.0025 or 0.001 and such values ​​may be combined in any way to form a range, such as 0.001-0.01).

[0401] Aspect B33: The method or system according to any of aspects B27-B32 or any preceding aspect, wherein the iron-rich feed solution is fed directly or indirectly to a second cathodic chamber; wherein the second electrochemical cell comprises the second cathodic chamber having a second catholyte in the presence of the second cathode.

[0402] Aspect B34: The method or system according to aspect B33 or any previous aspect, wherein at least 70% of the iron-rich feed solution is fed directly or indirectly to a second cathodic chamber (for example, at least: 70%, 75%, 80%, 85%, 90%, 95%, 99% or 100%, optionally wherein such value is less than 75%, 80%, 85%, 90%, 95%, 99% or 100% and may be combined in any way to form a range, such as 70-99%).

[0403] Aspect B35: The method or system according to aspect B34 or any previous aspect, wherein at least 90% of the iron-rich feed solution is fed directly or indirectly to a second cathodic chamber.

[0404] Aspect B36: The method or system according to any Petition 870260045431, dated 05 / 13 / 2026, pp. 143 / 460 135 / 200 one of aspects B33-B35 or any previous aspect, wherein the second electrochemical reduction step forms a second consumed catholyte, the second consumed catholyte having a lower concentration of iron ions than that of the iron-rich solution fed; wherein at least part of the second consumed catholyte is fed to a second anodic chamber; wherein the second electrochemical cell comprises the second anodic chamber having a second anolyte in the presence of a second anode.

[0405] Aspect B37: The method or system according to aspect B36 or any previous aspect, in which the second consumed catholyte is formed when the second electrochemical reduction step is completed or is deactivated.

[0406] Aspect B38: The method or system according to aspect B36 or B37 or any previous aspect, wherein the second catholyte consumed is characterized by an iron ion concentration of 60% to 70% (for example, 62-68%, 64-66%, 60-65% or 65-70%) relative to the iron ion concentration in the iron-rich solution fed.

[0407] Aspect B39: The method or system according to aspect B37 or any previous aspect, wherein the second electrochemical reduction step is completed or is deactivated when the concentration of iron ions in the second catholyte decreases to 60% to 70% (for example, 62-68%, 64-66%, 60-65% or 65-70%) relative to the concentration of iron ions in the iron-rich feed solution.

[0408] Aspect B40: The method or system according to any of aspects B27-B33 or any preceding aspect, wherein a first part of the iron-rich feed solution is fed directly or indirectly to a second cathodic chamber; wherein a second part of the iron-rich feed solution is fed directly or indirectly to a second anodic chamber; and wherein the second Petition 870260045431, dated 05 / 13 / 2026, pp. 144 / 460 136 / 200 electrochemical cell comprises a second cathodic chamber having a second catholyte in the presence of a second cathode and a second electrochemical cell comprises a second anodic chamber having a second anolyte in the presence of a second anode.

[0409] Aspect B41: The method or system according to aspect B40 or any previous aspect, wherein the first part is from 25% by volume to 45% by volume (for example, 30-40% by volume, 32-38% by volume, 25-35% by volume or 35-45% by volume) of the iron-rich solution fed and the second part is from 55% by volume to 75% by volume (for example, 60-70% by volume, 62-68% by volume, 55-65% by volume or 65-75% by volume) of the iron-rich solution fed.

[0410] Aspect B42: The method or system according to aspect B40 or B41 or any previous aspect, wherein the first part comprises 25 molar to 45 molar (for example, 30-40 molar, 32-38 molar, 25-35 molar or 35-45 molar) of the Fe2+-rich solution fed and the second part comprises 55 molar to 75 molar (for example, 60-70 molar, 62-68 molar, 55-65 molar or 65-75 molar) of the Fe2+-rich solution fed.

[0411] Aspect B43: The method or system according to any of aspects B27-B42 or any preceding aspect, wherein the transfer step further comprises treating the portion of the iron-rich solution removed, thereby forming a treated iron-rich solution, before the feeding step; and wherein the iron-rich solution fed comprises at least a portion of the treated iron-rich solution.

[0412] Aspect B44: The method or system according to aspect B43 or any previous aspect, wherein the treatment step comprises: increasing the pH of the iron-rich portion of the solution that has been removed.

[0413] Aspect B45: The method or system according to the aspect Petition 870260045431, dated 05 / 13 / 2026, pp. 145 / 460 137 / 200 B43 or B44 or any preceding aspect, wherein the treatment step comprises increasing the pH of the iron-rich portion of the solution removed by feeding metallic iron into the presence of the iron-rich portion of the solution removed; and wherein a reaction between the iron-rich portion of the solution removed and the metallic iron fed consumes protons in the iron-rich portion of the solution removed.

[0414] Aspect B46: The method or system according to aspect B45 or any previous aspect, wherein increasing the pH of the iron-rich portion of the solution removed further comprises supplying magnetite in the presence of the iron-rich portion of the solution removed before and / or simultaneously with the supply of metallic iron in the presence of the iron-rich portion of the solution removed.

[0415] Aspect B47: The method or system according to aspect B45 or B46 or any previous aspect, wherein a reaction between the iron-rich portion of the solution removed and the metallic iron fed chemically generates gaseous H2; and wherein the method further comprises collecting the chemically generated gaseous H2.

[0416] Aspect B48: The method or system according to any of aspects B43-B47 or any preceding aspect, wherein the treated iron solution has a pH selected in the range of 2 to less than 7 (for example, 2-4, 4-6, 6 to less than 7, 3 to less than 7, 3-6 or 4-5).

[0417] Aspect B49: The method or system according to any of the preceding aspects comprising electrochemically oxidizing Fe2+ ions to form second Fe3+ ions in a second anolyte; wherein the second electrochemical cell comprises the second cathodic chamber having a second catholyte in the presence of the second cathode and the second electrochemical cell comprises a second anodic chamber having a second anolyte in the presence of a second anode.

[0418] Aspect B50: The method or system according to aspect B49 or any previous aspect that comprises recycling a first Petition 870260045431, dated 05 / 13 / 2026, pp. 146 / 460 138 / 200 recycling solution from the galvanizing subsystem to the dissolution subsystem; wherein the recycling solution comprises the second Fe3+ ions formed in the second anolyte.

[0419] Aspect B51: The method or system according to aspect B50 or any previous aspect, in which the recycling step is carried out after the second electrochemical reduction step is completed or deactivated.

[0420] Aspect B52: The method or system according to aspect B50 or B51 or any preceding aspect, wherein the first recycling solution is fed to a first dissolving tank; wherein the dissolving step is carried out in the first dissolving tank comprising the iron-containing ore and the acidic iron salt solution.

[0421] Aspect B53: The method or system according to aspect B50, B51 or B52 or any previous aspect, wherein the first recycling solution comprises at least a part of the second catholyte and the second anolyte of the second electrochemical cell.

[0422] Aspect B54: The method or system according to any of aspects B27-B53 or any preceding aspect, wherein the second electrochemical reduction step is completed or is deactivated when the second catholyte of the second electrochemical cell is characterized by a total concentration of iron ions that is 60% to 70% (optionally 50% to 80%; optionally 62-68%, 64-66%, 60-65% or 65-70%) of the iron ion concentration in (i) the iron-rich solution fed or (ii) the iron-rich solution produced.

[0423] Aspect B55: Any previous aspect.

[0424] Aspect B56: Any previous aspect.

[0425] Aspect B57: The method or system according to any of the preceding aspects, in which the second electrochemical reduction step is completed or deactivated when the average thickness Petition 870260045431, dated 05 / 13 / 2026, pp. 147 / 460 139 / 200 of the metallic Fe formed at a second cathode of the second electrochemical cell is selected in the range of 1 mm to 10 mm (e.g., an average thickness (mm) of 1-10, 1-8, 1-6, 1-4, 1-2, 2-10, 2-8, 2-6, 2-4, 4-10, 4-8, 4-6, 6-10, 6-8 or 8-10).

[0426] Aspect B58: Any previous aspect.

[0427] Aspect B59: The method or system according to any of the preceding aspects, wherein the iron galvanizing subsystem comprises a first circulation tank configured to circulate a second catholyte between a second cathodic chamber of the second electrochemical cell and the first circulation tank; and wherein the iron galvanizing subsystem comprises a second circulation tank configured to circulate a second anolyte between a second anodic chamber of the second electrochemical cell and the second circulation tank.

[0428] Aspect B60: The method or system according to aspect B59 or any previous aspect, wherein the iron-rich solution fed indirectly to the second cathodic chamber is fed to the first circulation tank.

[0429] Aspect B61: The method or system according to any of the preceding aspects, wherein the second electrochemical cell comprises a second catholyte and a second anolyte separated by a second separator.

[0430] Aspect B62: The method or system according to aspect B61, wherein the second separator is a PEM or an anion exchange membrane (AEM) or a microporous separator.

[0431] Aspect B63: The method or system according to any of the preceding aspects, in which the first electrochemical cell is operated at a current density different from that of the second electrochemical cell.

[0432] Aspect B64: The method or system according to any Petition 870260045431, dated 05 / 13 / 2026, pages 148 / 460 140 / 200 one of the previous aspects, in which the first electrochemical cell is operated simultaneously at a current density different from that of the second electrochemical cell.

[0433] Aspect B65: The method or system according to aspect B63 or B64 or any previous aspect, in which the first electrochemical cell is operated at a higher current density than that of the second electrochemical cell.

[0434] Aspect B66: The method or system according to aspect B63, B64 or B65 or any preceding aspect, wherein the first electrochemical cell is operated at a current density selected in the range of 0.1 to 2 A / cm2 (for example, a current density (A / cm2) of 0.1-2, 0.1-1.5, 0.1-1, 0.1-0.5, 0.5-2, 0.5-1.5, 0.5-1, 1-2, 1-1.5 or 1.52) and the second electrochemical cell is operated at a current density selected in the range of 20 to 300 mA / cm2 (for example, a current density (mA / cm2) of 20-300, 20-250, 20-200, 20-150, 20-100, 20-50, 50-300, 50-250, 50-200, 50-150, 50-100, 100-300, 100-250, 100-200, 100-150, 150-300, 150-250, 150-200, 200-300, 200-250 or 250-300).

[0435] Aspect B67: The method or system according to any of the preceding aspects comprising repeating the method for at least 5 cycles (for example, at least: 5, 6, 7, 8, 9, 10, 15, 20, 30, 50 or 100 cycles, optionally wherein the cycles are less than: 6, 7, 8, 9, 10, 15, 20, 30, 50, 100 or 150 and each of these values ​​may be combined in any way to form a range, as well as 5-150).

[0436] Aspect B68: The method or system according to any of the preceding aspects, wherein the iron-containing ore comprises one or more iron oxide materials.

[0437] Aspect B69: The method or system according to any of the above aspects, in which one or more oxide materials Petition 870260045431, dated 05 / 13 / 2026, pp. 149 / 460 141 / 200 iron compounds comprise hematite, magemite, ferrihydrite, magnetite, goethite, akaganite, lepidocrocite, ferroxite or any combination thereof.

[0438] Aspect B70: The method or system according to any of the preceding aspects, wherein the dissolution step comprises dissolving magnetite in iron-containing ore.

[0439] Aspect B71: The method or system according to any of the preceding aspects comprising generating gaseous H2 and collecting the generated gaseous H2.

[0440] Aspect B72: The method or system according to aspect B47 or B71 or any preceding aspect, in which at least a portion of the oxidized collected gaseous H2 is used as a reducing agent in a process for the thermal reduction of iron-containing ore.

[0441] Aspect B73: The method or system according to any of the preceding aspects comprising electrically controlling the first electrochemical cell to prevent galvanization of metallic Fe at the first cathode.

[0442] Aspect B74: The method or system according to any of the preceding aspects, wherein the second electrochemical cell is operating at a temperature selected in the range of 40 °C to 80 °C (for example, 45-75 °C, 50-70 °C, 55-65 °C, 40-55 °C, 55-70 °C, 40-70 °C or 50-80 °C).

[0443] Aspect B75: The method or system according to any of the preceding aspects, wherein the second electrochemical cell comprises a second catholyte and a second anolyte; and wherein the second anolyte has a pH lower than that of the second catholyte.

[0444] Aspect B76: The method or system according to aspect B75 or any preceding aspect, wherein the pH of the second anolyte is lower than the solubility limit of Fe(III)(OH)2.

[0445] Aspect B77: The method or system according to the aspect Petition 870260045431, dated 05 / 13 / 2026, pages 150 / 460 142 / 200 B75 or B76 or any of the preceding aspects, wherein the second catholyte has a pH less than 6 (for example, less than: 6, 5.5, 5, 4.5, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.5, 0, -0.5 or -1, optionally wherein the pH is at least 5.5, 5, 4.5, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.5, 0, -0.5 or -1 and any of these values ​​may be combined in any way to form a range, such as -1 to 6) during the second electrochemical reduction step.

[0446] Aspect B78: The method or system according to any of the preceding aspects, wherein the removed metallic Fe comprises at least 99% by weight of Fe (for example, at least: 99% by weight, at least 99.5% by weight, at least 99.9% by weight or 100% by weight).

[0447] Aspect B79: The method or system according to any of the preceding aspects, wherein the first anode has a composition comprising lead, lead oxide, manganese oxide, a mixed metal oxide, iridium oxide, ruthenium oxide or any combination thereof.

[0448] Aspect B80: The method or system according to any of the preceding aspects, wherein the first cathode has a composition comprising carbon, graphite, titanium, or any combination thereof.

[0449] Aspect B81: The method or system according to any of the preceding aspects, wherein the second anode has a composition comprising carbon, graphite, lead, lead oxide, a mixed metal oxide or any combination thereof.

[0450] Aspect B82: The method or system according to any of the preceding aspects, wherein the second cathode has a composition comprising steel, low carbon steel, stainless steel, copper, copper alloy or any combination thereof.

[0451] Aspect B83: A system for iron production, the system Petition 870260045431, dated 05 / 13 / 2026, pages 151 / 460 143 / 200 comprising: a dissolution subsystem that has a dissolution tank and a first electrochemical cell fluidically connected to the dissolution tank; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; and wherein the first anolyte has a composition different from that of the first catholyte; and an iron galvanizing subsystem fluidically connected to the dissolution subsystem and having a second electrochemical cell; and a first intersubsystem fluidic connection between the dissolution subsystem and the galvanizing subsystem; in which: The dissolving tank receives a raw material containing iron ore; The dissolving tank comprises an acidic solution of iron salt to dissolve at least part of the iron-containing ore to generate first dissolved Fe3+ ions; The first Fe3+ ions are electrochemically reduced at the first cathode to form Fe2+ ions at the first catholyte; The Fe2+ ions formed are transferred from the dissolution subsystem to the iron galvanizing subsystem through the first intersubsystem fluid connection; The second electrochemical cell comprises a second cathode to reduce at least a first portion of the Fe2+ ions formed by transferring them to metallic Fe; and Petition 870260045431, dated 05 / 13 / 2026, pp. 152 / 460 144 / 200 metallic Fe is removed from the second electrochemical cell.

[0452] Aspect B84: The method or system according to aspect B83 or any previous aspect, wherein the second electrochemical cell comprises a second cathodic chamber having a second catholyte in the presence of the second cathode and the second electrochemical cell comprises a second anodic chamber having a second anolyte in the presence of a second anode.

[0453] Aspect B85: The method or system according to aspect B84 or any previous aspect, in which Fe2+ ions are oxidized to Fe3+ ions in the second anolyte.

[0454] Aspect B86: The method or system according to any of aspects B83-B85 or any preceding aspect, wherein the dissolution subsystem produces an iron-rich solution having Fe2+ ions formed; wherein the system comprises a transition subsystem for removing at least part of the iron-rich solution produced and treating the removed part of the iron-rich solution, thereby forming a treated iron-rich solution.

[0455] Aspect B87: The method or system according to any of aspects B84-B87 or any prior aspect comprising a consumed electrolyte recycling system configured to recycle a first recycling solution from the second electrochemical cell to the dissolution subsystem.

[0456] Aspect B88: The method or system according to aspect B87 or any previous aspect, wherein the first recycling solution comprises at least a part of the second anolyte and at least a part of the second catholyte.

[0457] Aspect B89: The method or system according to aspect B87 or any previous aspect, wherein the first recycling solution is formed by mixing at least one part of the second anolyte and at least one part of the second catholyte after reduction of Petition 870260045431, dated 05 / 13 / 2026, pp. 153 / 460 145 / 200 Fe2+ ions formed in metallic Fe be completed or be deactivated.

[0458] Aspect B90: A method for producing iron, the method comprising: feeding a raw material containing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell; wherein the first electrochemical cell comprises a first anodic chamber containing gaseous H2 in the presence of a first anode, a first cathodic chamber containing a first catholyte in the presence of a first cathode, and a first separator separating the first anodic chamber from the first catholyte; and dissolving at least part of the iron-containing ore using an acid to form an acidic solution of iron salt containing dissolved first Fe3+ ions; feed at least part of the acidic iron salt solution containing at least some of the first Fe3+ ions to the first cathodic chamber; first, electrochemically reduce the aforementioned first Fe3+ ions in the first catholyte to form Fe2+ ions; Transfer the Fe2+ ions formed from the dissolution subsystem to an iron galvanizing subsystem that has a second electrochemical cell; Second, to electrochemically reduce at least a first portion of the Fe2+ ions formed into metallic Fe at a second cathode of the second electrochemical cell; and to remove the metallic Fe from the second electrochemical cell, thereby producing iron.

[0459] Aspect B91: The method or system according to aspect B90 or any previous aspect comprising oxidizing gaseous H2 at the first anode to generate protons electrochemically. Petition 870260045431, dated 05 / 13 / 2026, pp. 154 / 460 146 / 200

[0460] Aspect B92: The method or system according to any of the aspects above or below, in which the dissolution step is terminated when the proton concentration (optionally, a steady-state proton concentration) in the acidic iron salt solution is equal to or less than 0.4 M (optionally 0.3 M, optionally 0.2 M, optionally 0.1 M) (optionally after being above this limit for most of the time the dissolution step is performed).

[0461] Aspect B93: The method or system according to any of the aspects above or below, wherein the dissolution step is terminated when the total concentration of iron ions in the first catholyte, in the acidic iron salt solution and / or in the iron-rich solution produced reaches a desired maximum value (optionally, a steady-state value) which is 1 M, optionally 2 M, optionally 3 M, optionally 4 M, optionally any value or range between 1 M and 4 M inclusive.

[0462] Aspect C1a: A method for producing iron, the method comprising: feeding a raw material containing an iron-containing ore and one or more impurities to a dissolution subsystem comprising a first electrochemical cell; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; Dissolve at least part of the iron-containing ore using an acid to form an acidic solution of iron salt having first dissolved Fe3+ ions; feed at least part of the acidic salt solution Petition 870260045431, dated 05 / 13 / 2026, pp. 155 / 460 147 / 200 iron having at least a portion of the first Fe3+ ions at the first cathodic chamber; first, electrochemically reduce the aforementioned first Fe3+ ions in the first catholyte to form Fe2+ ions; to produce an iron-rich solution in the dissolution subsystem, the iron-rich solution having at least a portion of the formed Fe2+ ions and at least a portion of one or more impurities; Treat at least a portion of the iron-rich solution to remove at least some of one or more impurities from the iron-rich solution, thereby forming a treated iron-rich solution that has at least some of the Fe2+ ions formed; wherein the treatment step comprises increasing the pH of the iron-rich solution from an initial pH to an adjusted pH, thereby precipitating at least some of one or more impurities in the treated iron-rich solution; feed at least a first portion of the treated iron-rich solution to an iron galvanizing subsystem that has a second electrochemical cell; Second, to electrochemically reduce at least a first portion of the Fe2+ ions formed into metallic Fe at a second cathode of the second electrochemical cell; and to remove the metallic Fe from the second electrochemical cell, thereby producing iron.

[0463] Aspect C1b: A system for the production of iron, the system comprising: a dissolution subsystem that has a first dissolution tank and a first electrochemical cell fluidically connected to the first dissolution tank; wherein the first electrochemical cell comprises a first cathode chamber having a first anolyte in the presence of a Petition 870260045431, dated 05 / 13 / 2026, pp. 156 / 460 148 / 200 first anode, a second anodic chamber having a first catholyte in the presence of a first cathode and a first separator separating the first anolyte from the first catholyte; and an iron galvanizing subsystem fluidically connected to the dissolution subsystem and having a second electrochemical cell; and a first impurity removal subsystem; in which: The first dissolution tank receives a raw material containing one or more iron-bearing ores and one or more impurities; The first dissolution tank comprises an acidic solution of iron salt to dissolve at least part of one or more iron-containing ores to generate first Fe3+ ions dissolved in the acidic iron salt solution; at least a portion of the acidic iron salt solution containing at least some of the first Fe3+ ions is supplied to the first cathodic chamber; The first Fe3+ ions are electrochemically reduced at the first cathode to form Fe2+ ions at the first catholyte; An iron-rich solution is formed in the dissolution subsystem, the iron-rich solution having at least a portion of the formed Fe2+ ions and at least a portion of one or more impurities; At least a portion of the iron-rich solution is fed to the first descaling subsystem to remove at least a portion of one or more impurities from the iron-rich solution, thereby forming a treated iron-rich solution that has at least a portion of the Fe2+ ions formed; in which the pH of the iron-rich solution is increased, in the first impurity removal subsystem, from an initial pH to a Petition 870260045431, dated 05 / 13 / 2026, pp. 157 / 460 149 / 200 pH adjusted to precipitate the removed portion with one or more impurities; At least a portion of the treated iron-rich solution is fed from the first impurity removal subsystem to the iron galvanizing subsystem; The second electrochemical cell comprises a second cathode to reduce at least a portion of the transferred Fe2+ ions to metallic Fe; and the metallic Fe is removed from the second electrochemical cell.

[0464] Aspect C2: The method or system according to aspect C1a or C1b or any previous aspect, wherein the dissolution of at least a portion of the iron-containing ore generates insoluble impurities; and wherein the method further comprises separating and removing at least a portion of the insoluble impurities.

[0465] Aspect C3: The method or system according to aspect C2 or any previous aspect, in which the removal of at least some of the insoluble impurities is achieved through filtration and / or separation of the insoluble impurities.

[0466] Aspect C4: The method or system according to aspect C2 or C3 or any previous aspect, wherein the insoluble impurities comprise quartz, gypsum and any combination thereof.

[0467] Aspect C5a: The method or system according to any of the preceding aspects, wherein the adjusted pH is equal to or greater than a precipitation pH of one or more impurities and below a precipitation pH of Fe2+ ions, thereby precipitating at least part of one or more impurities.

[0468] Aspect C5b: The method or system according to any of the preceding aspects, in which the adjusted pH is equal to or greater than a solubility limit of one or more impurities and below a solubility limit of Fe2+ ions, thus precipitating by Petition 870260045431, dated 05 / 13 / 2026, pp. 158 / 460 150 / 200 minus one part of one or more impurities.

[0469] Aspect C6a: The method or system according to aspect C5a or C5b or any previous aspect, wherein the adjusted pH is equal to or greater than the precipitation pH of aluminum, titanium and phosphate ions and below the precipitation pH of Fe2+ ions, thereby precipitating at least a portion of the ions containing aluminum, titanium and phosphorus.

[0470] Aspect C6b: The method or system according to aspect C5a or C5b or any previous aspect, wherein the adjusted pH is equal to or greater than a solubility limit for aluminum, titanium and phosphate ions and below a solubility limit for Fe2+ ions, thereby precipitating at least a portion of the aluminum, titanium and phosphorus-containing ions.

[0471] Aspect C7: The method or system according to any of aspects C3-C6 or any previous aspect comprising precipitating titanium hydroxide, aluminum hydroxide, aluminum phosphate and / or iron phosphate.

[0472] Aspect C8: The method or system according to any of aspects C3-C7 or any previous aspect comprising removing at least a portion of the precipitated impurities.

[0473] Aspect C9: The method or system according to any of aspects C1-C8 or any preceding aspect, wherein the adjusted pH is selected in the range of 3 to 7 (e.g., 3-6.5, 3-6, 3-5.5, 3-5, 3-less than 7, 3-6, 3-5, 3-4, 4-7, 4-less than 7, 4-6, 4-5, 5-7, 5-less than 7, 5-6, 6-7 or 6-less than 7).

[0474] Aspect C10: The method or system according to aspect C9 or any previous aspect, wherein the adjusted pH is selected in the range of 4 to less than 7 (e.g., 4-6.5, 4-5.5, 4 to less than 7, 4-6, 4-5, 5 to less than 7, 5-6 or 6 to less than 7).

[0475] Aspect C11: The method or system according to any of the aspects C1-C10 or any previous aspect, where the pH Petition 870260045431, dated 05 / 13 / 2026, pp. 159 / 460 The adjusted 151 / 200 also results in the coagulation of colloidal silica caused by the precipitation of other impurities, and the method further comprises removing at least a portion of the colloidal silica.

[0476] Aspect C12: The method or system according to any of aspects C1-C11 or any previous aspect, wherein the pH-raising step comprises feeding metallic iron and / or an iron oxide material into the presence of the iron-rich solution; and wherein a reaction between the portion of the iron-rich solution removed and the fed metallic iron and / or iron oxide material consumes protons in the iron-rich solution, thereby raising its pH.

[0477] Aspect C13: The method or system according to aspect C12 or any previous aspect, wherein the pH-raising step comprises first feeding iron oxide material into the presence of the iron-rich solution and subsequently feeding metallic iron into the presence of the iron-rich solution.

[0478] Aspect C14: The method or system according to aspect C12 or any previous aspect, wherein the increase in pH of the removed iron-rich portion of the solution further comprises supplying the iron oxide material in the presence of the removed iron-rich portion of the solution before and / or simultaneously with the supply of metallic iron in the presence of the removed iron-rich portion of the solution.

[0479] Aspect C15: The method or system according to any of aspects C12-C14 or any previous aspect, wherein the iron oxide material comprises magnetite.

[0480] Aspect C16: The method or system according to any of aspects C12-C15 or any preceding aspect, wherein the supplied iron oxide material comprises an ore containing thermally reduced iron.

[0481] Aspect C17: The method or system according to any of aspects C12-C16 or any previous aspect, in which iron Petition 870260045431, dated 05 / 13 / 2026, pages 160 / 460 152 / 200 metallic is a part of metallic Fe formed during the second electrochemical reduction step.

[0482] Aspect C18: The method or system according to any of the preceding aspects, in which the treated iron solution is characterized by: an aluminum ion concentration less than 1 mM or 0.2 M (for example, less than: 0.2 M, 0.15 M, 0.12 M, 0.1 M, 80 mM, 60 mM, 50 mM, 20 mM, 10 mM, 5 mM, 1 mM, optionally where the aluminum ion concentration is 0 mM or at least: 0.15 M, 0.12 M, 0.1 M, 80 mM, 60 mM, 50 mM, 20 mM, 10 mM, 5 mM, 1 mM and each of these values ​​may be combined in any way to form a range, such as 0-0.2 M or 1 mM to 0.1 M); and / or a phosphorus ion concentration less than 1 mM or 0.2 M (for example, less than: 0.2 M, 0.15 M, 0.12 M, 0.1 M, 80 mM, 60 mM, 50 mM, 20 mM, 10 mM, 5 mM, 1 mM, optionally where the phosphorus ion concentration is 0 mM or at least: 0.15 M, 0.12 M, 0.1 M, 80 mM, 60 mM, 50 mM, 20 mM, 10 mM, 5 mM, 1 mM and each of these values ​​may be combined in any way to form a range, such as 0-0.2 M or 1 mM to 0.1 M).

[0483] Aspect C19: The method or system according to any of the preceding aspects, wherein the second electrochemical cell comprises a second cathodic chamber having a second catholyte in the presence of the second cathode, a second anodic chamber having a second anolyte in the presence of a second anode, and a second separator separating the second catholyte from the second anolyte.

[0484] Aspect C20: The method or system according to aspect C19 or any previous aspect, wherein the treated iron-rich solution is fed directly or indirectly to the second cathodic chamber.

[0485] Aspect C21: The method or system according to aspect Petition 870260045431, dated 05 / 13 / 2026, pp. 161 / 460 153 / 200 C20 or any previous aspect, where the treated iron-rich solution is not fed into the second anodic chamber.

[0486] Aspect C22: The method or system according to aspect C20 or C21 or any previous aspect comprising feeding a second part of the iron-rich solution produced directly or indirectly into the second anodic chamber; wherein the second part of the iron-rich solution is not treated or is subjected to a different treatment from the first part of the iron-rich solution.

[0487] Aspect C23: The method or system according to any of the preceding aspects, wherein the iron-rich solution comprises colloidal silica; and wherein the treatment step comprises removing at least part of the colloidal silica.

[0488] Aspect C24: The method or system according to aspect C23 or any previous aspect, wherein the removal of colloidal silica comprises flocculating at least a portion of the colloidal silica to generate flocculated colloidal silica.

[0489] Aspect C25: The method or system according to aspect C23 or C24 or any previous aspect, wherein the colloidal silica removal step comprises adding polyethylene oxide to the iron-rich solution to facilitate the flocculation of the colloidal silica, thereby generating flocculated colloidal silica.

[0490] Aspect C26: The method or system according to any of aspects C23-C25 or any previous aspect, in which the removal of colloidal silica is done by means of filtration, sedimentation and / or any solid-liquid separation process.

[0491] Aspect C27: The method or system according to any of the preceding aspects, wherein the treated iron-rich solution has a colloidal silica content equal to or less than 10 mM (for example, equal to or less than: 10 mM, 8 mM, 6 mM, 5 mM, 4 mM, 2 mM or 1 mM, optionally wherein the colloidal silica content is 0 mM or less). Petition 870260045431, dated 05 / 13 / 2026, pp. 162 / 460 154 / 200 minus 8 mM, 6 mM, 5 mM, 4 mM, 2 mM or 1 mM, and each of these values ​​can be combined in any way to form a range, such as 0-10 mM or 1-8 mM).

[0492] Aspect C28: The method or system according to any of the preceding aspects, wherein the initial pH is in the range of 0.5 to 1.5 (for example, 0.5-1, 1-1.5, 0.8-1.3 or 0.7-1.4).

[0493] Aspect C29: The method or system according to any of the preceding aspects, in which the iron-rich solution is characterized by the initial pH and also has a higher concentration of Fe2+ ions than of Fe3+ ions.

[0494] Aspect C30: The method or system according to any of the preceding aspects, wherein the iron-rich solution is characterized by a ratio of Fe3+ to Fe2+ ion concentrations that is equal to or less than 0.1 (for example, equal to or less than: 0.1, 0.09, 0.08, 0.07, 0.06, 0.05, 0.04, 0.03, 0.02, 0.01 or 0.005, optionally wherein the ratio is at least 0.09, 0.08, 0.07, 0.06, 0.05, 0.04, 0.03, 0.02, 0.01 or 0.005 and each of these values ​​may be combined in any way to form a range, such as 0.005-0.1 or 0.02 to 0.08).

[0495] Aspect C31: The method or system according to any of the above aspects, in which the pH of the treated iron-rich solution decreases during galvanizing.

[0496] Aspect C32: The method or system according to aspect C31, wherein the pH during galvanizing is in the range of 2 to 6 (for example, 2-6, 2-5, 2-4, 2-3, 3-6, 3-5, 3-4, 4-6 or 4-5).

[0497] Aspect C33: The method or system according to any of the preceding aspects, wherein the raw material comprises magnetite, hematite, goethite or any combination thereof.

[0498] Aspect C34: The method or system according to any Petition 870260045431, dated 05 / 13 / 2026, pp. 163 / 460 155 / 200 one of the preceding aspects, wherein one or more impurities comprise aluminum compounds, titanium compounds, phosphate compounds, silicon compounds or any combination thereof.

[0499] Aspect C35: The method or system according to any of the preceding aspects, wherein the raw material comprises one or more impurities at a concentration selected in the range of 1 to 50% by weight (for example, a % by weight of 1-50, 1-45, 1-40, 1-35, 1-30, 1-25, 1-20, 1-15, 1-10, 1-5, 5-50, 5-45, 5-40, 5-35, 5-30, 5-25, 5-20, 5-15, 5-10, 10-50, 10-45, 10-40, 10-35, 10-30, 10-25, 20-50, 20-40, 20-30, 30-50, 30-40 or 40-50).

[0500] Aspect C36: The method or system according to any of the preceding aspects comprising a second treatment step of the second anolyte and / or the second catholyte in the second electrochemical cell to adjust the pH, alter the composition and / or remove impurities.

[0501] Aspect C37: The method or system according to any of the preceding aspects, in which the second treatment step is carried out after the second electrochemical reduction step is completed or deactivated.

[0502] Aspect C38a: The method or system according to any of the preceding aspects, in which the removed metallic Fe is characterized by: an aluminum concentration that is less than 0.1% by weight or less than 0.5% by weight (for example, an aluminum weight percentage less than 0.5, 0.2, 0.1, 0.08, 0.06, 0.05, 0.02, 0.01 or 0.005, optionally wherein the weight percentage is at least 0.2, 0.1, 0.08, 0.06, 0.05, 0.02, 0.01 or 0.005 and such values ​​may be combined in any way to form a range, such as 0.005-0.5 or 0.01 to 0.1); and / or a phosphorus ion concentration less than 0.01%. Petition 870260045431, dated 05 / 13 / 2026, pp. 164 / 460 156 / 200 by weight or less than 0.5% by weight (optionally, a phosphorus % by weight less than 0.5, 0.2, 0.1, 0.08, 0.06, 0.05, 0.02, 0.01, 0.008, 0.006, 0.005, 0.002 or 0.001; optionally where the % by weight is at least 0.2, 0.1, 0.08, 0.06, 0.05, 0.02, 0.01, 0.008, 0.006, 0.005, 0.002, 0.001 or 0.0005 and such values ​​may be combined in any way to form a range, such as 0.0005-0.5 or 0.0010.01).

[0503] Aspect C38b: The method or system according to any of the preceding aspects, in which the removed metallic Fe is characterized by: an aluminum concentration that is less than 0.1% by weight or less than 0.5% by weight (for example, a weight % of aluminum less than 0.5, 0.2, 0.1, 0.08, 0.06, 0.05, 0.02, 0.01 or 0.005, optionally wherein the weight % is at least 0.2, 0.1, 0.08, 0.06, 0.05, 0.02, 0.01 or 0.005 and such values ​​may be combined in any way to form a range, such as 0.005-0.5 or 0.01 to 0.1); and / or a phosphorus ion concentration of less than 0.01% by weight or less than 0.5% by weight (optionally, a phosphorus % by weight of less than 0.5, 0.2, 0.1, 0.08, 0.06, 0.05, 0.02, 0.01, 0.008, 0.006, 0.005, 0.002 or 0.001; optionally where the % by weight is at least 0.2, 0.1, 0.08, 0.06, 0.05, 0.02, 0.01, 0.008, 0.006, 0.005, 0.002, 0.001 or 0.0005 and such values ​​may be combined in any way to form a range, such as 0.0005-0.5 or 0.0010.01);and / or a manganese ion concentration that is less than 1% by weight or less than 0.5% by weight (optionally, a manganese % by weight of less than 0.9, 0.8, 0.7, 0.6, 0.5, 0.2, 0.1, 0.08, 0.06, 0.05, 0.02, 0.01, 0.008, 0.006, 0.005, 0.002 or 0.001; optionally, where the % by weight is at least 0.2, 0.1, 0.08, 0.06, 0.05,; Petition 870260045431, dated 05 / 13 / 2026, pp. 165 / 460 157 / 200 0.02, 0.01, 0.008, 0.006, 0.005, 0.002, 0.001, or 0.0005, and these values ​​can be combined in any way to form a range, such as 0.0005-0.5 or 0.001-0.01.

[0504] Aspect C39: The method or system according to any of the preceding aspects, in which the first anolyte has a composition different from that of the first catholyte.

[0505] Aspect C40: A system for the production of iron, the system comprising: a dissolution subsystem that has a first dissolution tank and a first electrochemical cell fluidically connected to the first dissolution tank; wherein the first electrochemical cell comprises a first cathodic chamber having a first anolyte in the presence of a first anode, a second anodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; and an iron galvanizing subsystem fluidically connected to the dissolution subsystem and having a second electrochemical cell; and a first impurity removal subsystem; in which: The first dissolution tank receives a raw material containing one or more iron-bearing ores and one or more impurities; The first dissolution tank comprises an acidic solution of iron salt to dissolve at least part of one or more iron-containing ores to generate first Fe3+ ions dissolved in the acidic iron salt solution; at least part of the acidic iron salt solution that has at least part of the first Fe3+ ions is supplied to the first Petition 870260045431, dated 05 / 13 / 2026, pp. 166 / 460 158 / 200 cathode ray tube; The first Fe3+ ions are electrochemically reduced at the first cathode to form Fe2+ ions at the first catholyte; An iron-rich solution is formed in the dissolution subsystem, the iron-rich solution having at least a portion of the formed Fe2+ ions and at least a portion of one or more impurities; At least a portion of the iron-rich solution is supplied to the first descaling subsystem to remove at least a portion of one or more impurities from the iron-rich solution, thereby forming a treated iron-rich solution that has at least a portion of the Fe2+ ions formed; in which the pH of the iron-rich solution is increased, in the first impurity removal subsystem, from an initial pH to a pH adjusted to precipitate the removed portion with one or more impurities; At least a portion of the treated iron-rich solution is fed from the first impurity removal subsystem to the iron galvanizing subsystem; The second electrochemical cell comprises a second cathode for reducing at least part of the transferred Fe2+ ions to metallic Fe; and the metallic Fe is removed from the second electrochemical cell.

[0506] Aspect D1a: A method for producing iron, the method comprising: In a first dissolution tank, bring an initial ore containing iron into contact with an acid to dissolve at least part of the initial iron-containing ore, thus forming an acidic solution of iron salt that has dissolved Fe3+ ions; circulate at least part of the acidic salt solution Petition 870260045431, dated 05 / 13 / 2026, pp. 167 / 460 159 / 200 iron between the first dissolution tank and a first cathodic chamber of a first electrochemical cell, thus feeding at least a portion of the first Fe3+ ions to a first catholyte of the first cathodic chamber; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having the first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; first, electrochemically reduce at least some of the initial Fe3+ ions at the first cathode to form Fe2+ ions at the first catholyte; to generate protons electrochemically in the first electrochemical cell; wherein the circulation step comprises feeding at least a portion of the electrochemically generated protons and at least a portion of the Fe2+ ions formed from the first catholyte to the acidic iron salt solution; to produce a first iron-rich solution that has Fe2+ ions formed in a dissolution subsystem, the dissolution subsystem comprising the first dissolution tank and the first electrochemical cell; transfer at least part of the first iron-rich solution to an iron galvanizing subsystem, the iron galvanizing subsystem comprising a second electrochemical cell; Second, to electrochemically reduce a first portion of the Fe2+ ions formed into metallic Fe at a second cathode of the second electrochemical cell; Petition 870260045431, dated 05 / 13 / 2026, pp. 168 / 460 160 / 200 wherein the second electrochemical cell comprises a second cathodic chamber having a second catholyte in the presence of the second cathode; a second anodic chamber having a second anolyte in the presence of a second anode and a second separator separating the first anolyte from the first catholyte; and removing metallic Fe from the second electrochemical cell thereby producing iron.

[0507] Aspect D1b: A system for the production of iron, the system comprising: A dissolution subsystem for producing an iron-rich solution, wherein the dissolution subsystem comprises a first dissolution tank, a first electrochemical cell, and a first circulation subsystem; in which: In the first dissolution tank, an ore containing iron is brought into contact with an acid to dissolve at least part of the iron-containing ore, thereby forming an acidic solution of iron salt containing dissolved Fe3+ ions; The first circulation subsystem circulates at least part of the acidic iron salt solution between the first dissolution tank and a first cathodic chamber of the first electrochemical cell, thus feeding at least part of the first Fe3+ ions to a first catholyte of the first cathodic chamber; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having the first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; The first electrochemical cell electrochemically reduces at least a portion of the first Fe3+ ions at the first cathode to form Fe2+ ions at the first catholyte; Petition 870260045431, dated 05 / 13 / 2026, pp. 169 / 460 161 / 200 the first electrochemical cell generates protons electrochemically and feeds the electrochemically generated protons to the catholyte; wherein the first circulation system feeds the electrochemically generated protons from the first catholyte to the acidic iron salt solution; and the iron-rich solution produced in the first subsystem comprises the Fe2+ ions formed; a transition subsystem comprising an initial intersubsystem fluid connection to transfer at least a portion of the iron-rich solution to an iron galvanizing subsystem; the iron galvanizing subsystem comprising a second electrochemical cell; wherein the second electrochemical cell comprises a second cathodic chamber having a second catholyte in the presence of the second cathode; a second anodic chamber having a second anolyte in the presence of a second anode and a second separator separating the first anolyte from the first catholyte having a second catholyte in the presence of a second cathode; wherein at least a first part of the Fe2+ ions formed and transferred are electrochemically reduced to metallic Fe at the second cathode; and an iron removal subsystem to remove metallic Fe from the second electrochemical cell, thereby producing iron.

[0508] Aspect D2: The method or system according to aspect D1a or D1b or any preceding aspect comprising thermally reducing one or more iron oxide materials other than magnetite in iron-containing ore to form magnetite in the presence of a reducing agent, thereby forming a thermally reduced ore; wherein the first iron-containing ore in the first dissolving tank comprises the thermally reduced ore; and wherein the Petition 870260045431, dated 05 / 13 / 2026, pp. 170 / 460 The 162 / 200 dissolution step comprises dissolving at least part of the thermally reduced ore using an acid to form an acidic solution of iron salt.

[0509] Aspect D3: The method or system according to aspect D2 or any previous aspect comprising feeding at least part of a catholyte having said electrochemically generated protons from the electrochemical cell into the acidic iron salt solution during the dissolution step, thereby feeding the electrochemically generated protons into the acidic iron salt solution in the presence of the thermally reduced ore.

[0510] Aspect D4: The method or system according to aspect D3 or any previous aspect, wherein the dissolution step is carried out in a dissolution tank; wherein the dissolution tank and the electrochemical cell are fluidically connected; and wherein the acidic iron salt solution circulates between the dissolution tank and the electrochemical cell.

[0511] Aspect D5: The method or system according to aspect D4 or any previous aspect in which, during at least part of the dissolution step, the entire acidic iron salt solution circulates between the dissolution tanks and the electrochemical cell.

[0512] Aspect D6: The method or system according to any of aspects D2-D5 or any preceding aspect, wherein the reaction between the thermally reduced ore and the acidic iron salt solution during dissolution generates water, thereby consuming protons from the acidic iron salt solution; and wherein the electrochemically generated protons fed in replace at least a portion of the protons consumed in the acidic iron salt solution.

[0513] Aspect D7: The method or system in accordance with any of the aspects D2-D6 or any previous aspect, in which the pro Petition 870260045431, dated 05 / 13 / 2026, pp. 171 / 460 163 / 200 tons of electrochemically generated material are continuously fed to the acidic iron salt solution during at least part of the dissolution step.

[0514] Aspect D8: The method or system according to any of aspects D2-D7 or any preceding aspect, wherein the acidic iron salt solution is characterized by a steady-state concentration of free protons of at least 0.2 M (for example, at least 0.2, 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4 or 5 M, optionally wherein the steady-state concentration of free protons is less than 0.3, 0.4, 0.5, 0.8, 1, 1.2, 1.5, 2, 3, 4, 5 or 6 M and such values ​​may be combined in any way to form a range, such as 0.2-6 M) during the dissolution of the thermally reduced ore.

[0515] Aspect D9: The method or system according to aspect D8 or any previous aspect, wherein the acidic iron salt solution is characterized by a steady-state concentration of free protons selected in the range of 0.2 M to 3 M.

[0516] Aspect D10: The method or system according to aspect D8 or D9 or any preceding aspect, wherein the acidic iron salt solution is characterized by a steady-state pH less than 0.7 (for example, equal to or less than 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0, -0.1, -0.5 or -1, optionally wherein the steady-state pH is at least 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0, -0.1, -0.5 or -1 and these values ​​may be combined in any way to form a range, such as -1 to 0.7 or 0.1 to less than 0.7).

[0517] Aspect D11: The method or system according to any of the preceding aspects, in which the electrochemical generation step of the electrochemically generated protons comprises electrochemically oxidizing water at the first anode.

[0518] Aspect D12: The method or system according to any Petition 870260045431, dated 05 / 13 / 2026, pp. 172 / 460 164 / 200 one of the previous aspects, in which the step of feeding electrochemically generated protons comprises transporting the electrochemically generated protons through the anolyte separator to the catholyte.

[0519] Aspect D13: The method or system according to any of the preceding aspects, wherein the electrochemical cell is characterized by a Coulombic efficiency greater than 80% (for example, greater than: 80%, 85%, 90%, 95% or 99%, optionally wherein the Coulombic efficiency is less than: 85%, 90%, 95%, 99% or 100% and such values ​​may be combined in any way to form a range, such as 80-100%).

[0520] Aspect D14: The method or system according to any of the preceding aspects, in which electrochemically generated protons form, at least partially, acid in the first catholyte.

[0521] Aspect D15: The method or system according to any of the preceding aspects comprising feeding water from the first catholyte to the first anolyte.

[0522] Aspect D16: The method or system according to any of aspects D11-D15 or any preceding aspect, wherein the oxidized water at the first anode comprises the water generated by the dissolution of the iron-containing ore during the dissolution step.

[0523] Aspect D17: The method or system according to any of the preceding aspects comprising feeding water from the catholyte to the anolyte via osmosis through the first separator, membrane distillation; and / or rapid distillation.

[0524] Aspect D18: The method or system according to any of the preceding aspects, in which the anolyte has a composition different from that of the catholyte.

[0525] Aspect D19: The method or system according to any of the above aspects, wherein the first anolyte has a pH different from the first catholyte. Petition 870260045431, dated 05 / 13 / 2026, pp. 173 / 460 165 / 200

[0526] Aspect D20: The method or system according to any of the preceding aspects, in which the first catholyte has a pH lower than that of the first anolyte.

[0527] Aspect D21: The method or system according to any of the preceding aspects, wherein the first anolyte comprises a composition of dissolved salts different from that of the first catholyte.

[0528] Aspect D22: The method or system according to any of the preceding aspects, wherein the first anolyte contains one or more dissolved ferric iron salts; and wherein the first anolyte is characterized by a total concentration of one or more dissolved ferric iron salts that is equal to or greater than the total concentration of iron ions in the first catholyte.

[0529] Aspect D23: The method or system according to any of the preceding aspects, wherein the first catholyte comprises one or more supporting salts.

[0530] Aspect D24: The method or system according to aspect D23 or any previous aspect, wherein the first catholyte comprises a concentration of one or more supporting salts that is selected in the range of 0.1 to 1M (for example, 0.2 to 0.8 M, 0.4 to 0.6 M, 0.1 to 0.4 M, 0.4 to 0.8 M or 0.8 to 1 M).

[0531] Aspect D25: The method or system according to aspect D23 or D24 or any previous aspect, wherein one or more supporting salts comprise one or more metal sulfate compounds and / or one or more metal chloride compounds.

[0532] Aspect D26: The method or system according to aspect D25 or any previous aspect, wherein one or more metal sulfate compounds comprise potassium sulfate, sodium sulfate, ammonium sulfate, lithium sulfate, potassium chloride, sodium chloride, ammonium chloride, lithium chloride or a combination thereof.

[0533] Aspect D27: The method or system according to any Petition 870260045431, dated 05 / 13 / 2026, pp. 174 / 460 166 / 200 one of the previous aspects, in which the first anolyte is characterized by at least one redox pair that is different from the first catholyte.

[0534] Aspect D28: The method or system according to any of the preceding aspects, wherein the first anolyte comprises a higher total concentration of dissolved salts than the first catholyte.

[0535] Aspect D29: The method or system according to any of aspects D1-D21 and D23-D27 or any previous aspect, wherein the first anolyte comprises a total concentration of dissolved salts lower than the first catholyte.

[0536] Aspect D30: The method or system according to any of aspects D1-D21 and D23-D28 or any previous aspect, in which the anolyte is essentially free of Fe2+ and Fe3+ ions.

[0537] Aspect D31: The method or system according to any of the preceding aspects, wherein the catholyte is characterized by a maximum concentration of iron ions that is selected in the range of 0.5 to 5 M or 1 to 5 M (for example, 1-5 M, 1-4 M, 1-3 M, 0.5-5 M, 0.5-4 M, 2-4 M, 2-5 M, 1-2 M).

[0538] Aspect D32: The method or system according to any of the preceding aspects comprising generating oxygen (O2) electrochemically at the anode.

[0539] Aspect D33: The method or system according to any of the preceding aspects, in which the first anolyte is ionically connected to the first catholyte through the first separator.

[0540] Aspect D34: The method or system in accordance with aspect D33 or any previous aspect, in which the first anolyte is fluidically disconnected from the first catholyte.

[0541] Aspect D35: The method or system according to any of the preceding aspects, wherein the separator is an ion-exchange membrane. Petition 870260045431, dated 05 / 13 / 2026, pp. 175 / 460 167 / 200

[0542] Aspect D36: The method or system according to aspect D35 or any previous aspect, where the separator is a proton exchange membrane (PEM).

[0543] Aspect D37: The method or system according to any of the preceding aspects, wherein the iron-rich solution produced is characterized by a total iron ion concentration selected in the range of 0.5 to 5 M or 1 to 5 M (for example, 1-5 M, 1-4 M, 1-3 M, 0.55 M, 0.5-4 M, 2-4 M, 2-5 M, 1-2 M).

[0544] Aspect D38: The method or system according to any of aspects D2-D37 or any preceding aspect, wherein the thermal reduction step comprises exposing one or more iron oxide materials other than magnetite from iron-containing ore to a reducing agent at an elevated temperature selected in the range of 200 °C to 600 °C (for example, a temperature (°C) of 200-550, 200-500, 200-450, 200-400, 200-350, 200-300, 200-250, 250-600, 250-550, 250-500, 250-400, 300-600, 300-550, 300-500, 300-450, 300-400, 350-600, 350-550, 350-500, 350-450, 400-600, 400-550, 400-500, 450-600, 450-550 or 500-600), thus converting at least a portion of one or more iron oxide materials other than magnetite into magnetite.

[0545] Aspect D39: The method or system according to any of aspects D2-D38 or any preceding aspect, wherein the reducing agent comprises gaseous H2; and wherein at least part of the gaseous H2 is chemically generated through a reaction of metallic iron with an acid and / or at least part of the gaseous H2 is electrochemically generated through a parasitic hydrogen evolution reaction of an iron galvanizing process.

[0546] Aspect D40: The method or system according to aspect D38 or any previous aspect, wherein the iron-containing ore is exposed to elevated temperature for a heat treatment time during the thermal reduction step and wherein the ore containing Petition 870260045431, dated 05 / 13 / 2026, pp. 176 / 460 168 / 200 iron is exposed to the reducing agent for the entire heat treatment time.

[0547] Aspect D41: The method or system according to aspect D38 or any preceding aspect, wherein the iron-containing ore is exposed to elevated temperature for a heat treatment time during the thermal reduction stage and wherein the iron-containing ore is exposed to the reducing agent for a portion of the heat treatment time (for example, air roasting may be carried out during a temperature increase or an initial portion of the time during which the iron-containing ore is exposed to elevated temperatures of 200 °C to 600 °C (for example, any temperature range specified elsewhere in this document for this 200-600 °C range), followed by the introduction of gaseous H2 to switch from air roasting to thermal reduction).

[0548] Aspect D42: The method or system according to aspect D41 or any previous aspect comprising air-roasting the iron-containing ore, exposing the iron-containing ore to air during an initial part of the heat treatment time.

[0549] Aspect D43: The method or system according to any of the preceding aspects which further comprises air-roasting at least part of the iron-containing ore in the presence of air at a temperature selected in the range of 200 °C to 600 °C (for example, a temperature (°C) of 200-550, 200-500, 200-450, 200-400, 200-350, 200-300, 200-250, 250-600, 250-550, 250-500, 250-400, 300-600, 300-550, 300-500, 300-450, 300-400, 350-600, 350-550, 350-500, 350-450, 400-600, 400-550, 400-500, 450-600, 450-550 or 500-600) to form an air-roasted ore.

[0550] Aspect D44: The method or system according to aspect D43 or any previous aspect, in which the air roasting step is carried out before or separately from the thermal reduction step, in which Petition 870260045431, dated 05 / 13 / 2026, pp. 177 / 460 169 / 200 the air-roasted ore was not thermally reduced before air roasting.

[0551] Aspect D45: The method or system according to aspect D43 or D44 or any previous aspect, wherein the thermal reduction step comprises thermally reducing the air-roasted ore to form at least a portion of thermally reduced ore; wherein the air roasting comprises one or more iron oxide materials other than magnetite.

[0552] Aspect D46: The method or system according to aspect D43, D44 or D45 or any previous aspect, wherein the dissolution step comprises dissolving at least part of the air-roasted ore and at least part of the thermally reduced ore simultaneously and / or sequentially.

[0553] Aspect D47: The method or system according to aspect D46 or any previous aspect, wherein the dissolution step comprises dissolving at least part of the air-roasted ore in a dissolution tank separate from the thermally reduced ore during at least part of the dissolution step.

[0554] Aspect D48: The method or system according to any of aspects D43-D47 or any preceding aspect, wherein the dissolution step comprises dissolving an ore mixture; wherein the ore mixture comprises 0% by weight to 100% by weight of thermally reduced ore, 5% by weight to 100% by weight of roasted ore and 0% by weight to 90% by weight of roasted ore containing magnetite (the % by weight ranges for each of the ranges presented in aspect A69 are equally applicable to the corresponding % by weight ranges in this aspect D48).

[0555] Aspect D49: The method or system according to any of aspects D43-D48 or any preceding aspect, wherein the dissolution step comprises circulating a dissolution solution between the Petition 870260045431, dated 05 / 13 / 2026, pp. 178 / 460 170 / 200 first electrochemical cell and at least one of a first dissolving tank, a second dissolving tank and a third dissolving tank; wherein the first dissolving tank comprises at least part of thermally reduced ore, the second dissolving tank comprises air-roasted ore and the third dissolving tank comprises a raw ore containing iron; wherein the...

Claims

1. A method for producing iron, characterized in that it comprises: supplying a raw material having an ore containing iron and one or more impurities to a dissolution subsystem comprising a first electrochemical cell; wherein the first electrochemical cell comprises a first anodic chamber having a first anolyte in the presence of a first anode, a first cathodic chamber having a first catholyte in the presence of a first cathode, and a first separator separating the first anolyte from the first catholyte; dissolving at least a portion of the iron-containing ore using an acid to form an acidic solution of iron salt having dissolved the first Fe3+ ions; supplying at least a portion of the acidic solution of iron salt, having at least a portion of the first Fe3+ ions, to the first cathodic chamber; first electrochemically reducing said first Fe3+ ions in the first catholyte to form Fe2+ ions;to produce an iron-rich solution in the dissolution subsystem, the iron-rich solution having at least a portion of the formed Fe2+ ions and at least a portion of one or more impurities; to treat at least a first portion of the iron-rich solution to remove at least a portion of one or more impurities from the iron-rich solution, thus forming a treated iron-rich solution having at least a portion of formed Fe2+ ions; wherein the treatment step comprises increasing the pH of the iron-rich solution from an initial pH to an adjusted pH, thus precipitating at least a portion of one or more impurities in the treated iron-rich solution; Petition 870260045431, dated 05 / 13 / 2026, page 210 / 460 2 / 10 to distribute at least a first portion of the treated iron-rich solution to an iron galvanizing subsystem having a second electrochemical cell;second, electrochemically reduce at least a first portion of the Fe2+ ions formed, transferring them to metallic Fe at a second cathode of the second electrochemical cell; and remove the Fe metal from the second electrochemical cell, thus producing iron.

2. A method according to claim 1, characterized in that the dissolution of at least a portion of the iron-containing ore generates insoluble impurities; and wherein the method further comprises separating and removing at least a portion of the insoluble impurities.

3. Method according to claim 2, characterized in that the removal of at least a portion of the insoluble impurities is done by filtration and / or separation of the insoluble impurities.

4. A method according to claim 2 or 3, characterized in that the insoluble impurities comprise quartz, gypsum, and any combination thereof.

5. A method, according to any of the preceding claims, characterized in that the adjusted pH is equal to or greater than the precipitation pH of one or more impurities and below the precipitation pH of Fe2+ ions, thereby precipitating at least a portion of one or more impurities.

6. Method, according to claim 5, characterized in that the adjusted pH is equal to or greater than the precipitation pH of aluminum, titanium and phosphate ions and below the precipitation pH of Fe2+ ions, thus precipitating at least a portion containing aluminum, titanium and phosphorus.

7. Method, according to any of the claims in Petition 870260045431, dated 05 / 13 / 2026, page 211 / 460 3 / 10 3 to 6, characterized in that it comprises the precipitation of titanium hydroxide, aluminum hydroxide, aluminum phosphate and / or iron phosphate.

8. A method according to any one of claims 3 to 7, characterized in that it comprises removing at least a portion of precipitated impurities.

9. Method, according to any one of claims 1 to 8, characterized in that the adjusted pH is selected in the range of 3 to 7.

10. Method according to claim 9, characterized in that the adjusted pH is selected in the range of 4 to less than 7.

11. A method according to any one of claims 1 to 10, characterized in that the adjusted pH also results in the coagulation of colloidal silica caused by the precipitation of other impurities; the method further comprises the removal of at least a portion of the colloidal silica.

12. A method according to any one of claims 1 to 11, characterized in that the pH-raising step comprises supplying metallic iron and / or an iron oxide material in the presence of the iron-rich solution; and in that a reaction between the removed portion of the iron-rich solution and the supplied metallic iron and / or iron oxide material consumes protons in the iron-rich solution, thereby raising its pH.

13. Method according to claim 12, characterized in that: the pH increase step comprises first supplying the iron oxide material in the presence of the iron-rich solution and subsequently supplying metallic iron in the presence of the iron-rich solution; and / or Petition 870260045431, dated 05 / 13 / 2026, page 212 / 460 4 / 10 the pH increase of the portion removed from the iron-rich solution further comprises supplying the iron oxide material in the presence of the portion removed from the iron-rich solution before and / or simultaneously with supplying the metallic iron material in the presence of the portion removed from the iron-rich solution; and / or wherein the iron oxide material comprises magnetite; and / or wherein the supplied iron oxide material comprises a thermally reduced iron-containing ore; and / or wherein the metallic iron is a portion of the Fe metal formed during the second electrochemical reduction step.

14. A method, according to any of the preceding claims, characterized in that the treated ferrous product solution has: an aluminum ion concentration of less than 1 mM; and / or a phosphorus-containing ion concentration of less than 1 mM.

15. A method, according to any of the preceding claims, characterized in that the second electrochemical cell comprises a second cathodic chamber having a second catholyte in the presence of the second cathode, a second anodic chamber having a second anolyte in the presence of a second anode, and a second separator separating the second catholyte from the second anolyte.

16. Method according to claim 15, characterized in that the treated iron-rich solution is distributed directly or indirectly to the second cathodic chamber.

17. Method according to claim 16, characterized in that: the treated iron-rich solution is not distributed to the second anodic chamber; and / or comprises distributing a second portion of the iron-rich solution produced directly or indirectly to the second anodic chamber; wherein the second portion of the iron-rich solution is not treated or is subjected to a different treatment than the first portion of the iron-rich solution.

18. A method, according to any of the preceding claims, characterized in that the iron-rich solution comprises colloidal silica; and in which the treatment step comprises the removal of at least a portion of the colloidal silica.

19. Method according to claim 18, characterized in that: the removal of colloidal silica comprises flocculating at least a portion of the colloidal silica to generate flocculated colloidal silica; and / or the colloidal silica removal step comprises adding polyethylene oxide to the iron-rich solution to facilitate the flocculation of the colloidal silica, thus generating flocculated colloidal silica; and / or the removal of colloidal silica is done by filtration, sedimentation and / or any solid-liquid separation process.

20. A method, according to any of the preceding claims, characterized in that: the treated iron-rich solution has a colloidal silica content of less than or equal to 10 mM; and / or the initial pH is in the range of 0.5 to 1.5; and / or the iron-rich solution is defined by the initial pH and also has a higher concentration of Fe2+ ions than Fe3+ ions; and / or the iron-rich solution is defined by a ratio of Fe3+ ion concentrations to Fe2+ ions being less than or equal to 0.1; and / or the pH of the treated iron-rich solution decreases during plating.

21. Method according to claim 20, characterized in that the pH during plating is in the range of 2 to 6.

22. A method, according to any of the preceding claims, characterized in that: the raw material comprises magnetite, hematite, goethite and any combination thereof; and / or in which one or more impurities comprise aluminum compounds, titanium compounds, phosphate compounds, silicon compounds or any combination thereof; and / or in which the raw material comprises one or more impurities in a concentration selected in the range of 1 to 50% by weight; and / or that it comprises a second treatment step of the second anolyte and / or the second catholyte of the second electrochemical cell to adjust the pH, alter the composition and / or remove impurities; and / or in which the second treatment step is carried out after the second electrochemical reduction step is completed or switched off.

23. A method, according to any of the preceding claims, characterized in that the removed Fe metal is defined by: an aluminum concentration of less than 0.1% by weight; and / or a phosphorus ion concentration of less than 0.01% by weight.

24. Method, according to any of the preceding claims, characterized in that the first anolyte has a composition different from the first catholyte.

25. System for the production of iron, characterized in that it comprises: a dissolution subsystem having a first dissolution tank and a first electrochemical cell fluidly connected to the first dissolution tank; wherein the first electrochemical cell comprises a first cathodic chamber having a first anolyte in the presence of a first anode, a second anodic chamber having a first catholyte in the presence of a first cathode and a first separator separating the first anolyte from the first catholyte; and an iron galvanizing subsystem fluidly connected to the dissolution subsystem and having a second electrochemical cell; and a first impurity removal subsystem; wherein: the first dissolution tank receives a raw material having one or more ores containing iron and one or more impurities;The first dissolution tank comprises an acidic iron salt solution to dissolve at least a portion of one or more iron-containing ores to generate first Fe3+ ions dissolved in the acidic iron salt solution; at least a portion of the acidic iron salt solution, having at least a portion of the first Fe3+ ions, is supplied to the first cathodic chamber; the first Fe3+ ions are electrochemically reduced at the first cathode to form Fe2+ ions at the first catholyte; an iron-rich solution is formed in the dissolution subsystem, the iron-rich solution having at least a portion of the Fe2+ ions formed and at least a portion of one or more impurities;Petition 870260045431, dated 05 / 13 / 2026, page 216 / 460 8 / 10 at least a portion of the iron-rich solution is supplied to the first impurity removal subsystem to remove at least a portion of one or more impurities from the iron-rich solution, thus forming a treated iron-rich solution having at least a portion of the Fe2+ ions formed; wherein the pH of the iron-rich solution is increased, in the first impurity removal subsystem, from an initial pH to an adjusted pH to precipitate the removed portion with one or more impurities; at least a first portion of the treated iron-rich solution is distributed from the first impurity removal subsystem to the iron galvanizing subsystem; the second electrochemical cell comprises a second cathode to reduce at least a portion of the Fe2+ ions transferred to Fe metal; and the Fe metal is removed from the second electrochemical cell.

26. Method for producing iron, characterized in that it comprises: supplying a solid raw material having an ore containing iron and one or more non-iron impurities to a dissolution subsystem; dissolving at least a portion of the iron-containing ore using an acid to form an acidic solution of iron salt having dissolved the first Fe3+ ions; reducing said first Fe3+ ions to form Fe2+ ions; producing an iron-rich solution in the dissolution subsystem, the iron-rich solution having at least a portion of the Fe2+ ions formed and at least a portion of one or more non-iron impurities; treating at least a first portion of the iron-rich solution in Petition 870260045431, dated 05 / 13 / 2026, page 1.217 / 460 9 / 10 iron to remove at least a portion of one or more non-iron impurities from the iron-rich solution, thus forming a treated iron-rich solution having at least a portion of formed Fe2+ ions; wherein the treatment step comprises raising the pH of the iron-rich solution from an initial pH to an adjusted pH, thus precipitating at least a portion of one or more non-iron impurities from the treated iron-rich solution; distributing at least a first portion of the treated iron-rich solution to an iron galvanizing subsystem having an electrochemical coating cell; iron electroplating by electrochemical reduction of at least a first portion of the distributed formed Fe2+ ions to metallic Fe at a coating cathode of the electrochemical coating cell; and removing the Fe metal from the electrochemical coating cell thus producing iron.

27. Method according to claim 26, characterized in that the reduction step comprises providing a metallic iron in contact with the acidic solution of salt and iron to chemically convert at least a portion of the first Fe3+ ions into at least a portion of the Fe2+ ions formed.

28. Method according to claim 26, characterized in that it comprises supplying at least a portion of the acidic salt and iron solution, with at least a portion of the first Fe3+ ions, to a first cathodic chamber of a first electrochemical cell; wherein the first electrochemical cell comprises a first anodic chamber with a first anolyte in the presence of a first anode, the first cathodic chamber with a first catholyte in the presence of a first cathode and a first separator that separates the first anolyte from the first cathode; and wherein the reduction step comprises the first electrochemical reduction of the first Fe3+ ions in the first catholyte to at least a portion of the Fe2+ ions formed in the first catholyte.

29. Method according to claim 26, characterized in that the iron electroplating step comprises the electrochemical oxidation of ferrous ions to ferric ions at an anode of the electrochemical electroplating cell.

30. Method according to claim 26, characterized in that the iron electroplating step comprises an oxygen evolution reaction at an anode of the electrochemical galvanizing cell.

Images