Process and system for electrolytically producing an iron-bearing product from iron ore particles.

Abstract

A continuous process for electrolytically producing solid particles of an iron-bearing product from iron ore particles is disclosed. The process is performed in an electrochemical flow reactor provided with an electrochemical cell comprising a cathodic compartment and an anodic compartment separated by a separator, wherein the cathodic compartment houses a cathode and the anodic compartment houses an anode at least partially in contact with an anolyte. A catholyte comprising iron ore particles having a particle size P80 greater than 20 µm suspended in an alkaline electrolyte is circulated through the cathodic compartment and an electrical potentiel greater than 1.4V is applied between the cathode and the anode in the electrochemical cell and electrolytically reduce the iron ore particles to solid particles of the iron-bearing product suspended in the alkaline electrolyte (spent catholyte). The spent catholyte is then circulated to a séparation means whereby the iron-bearing product particles are separated from the spent catholyte resulting in a depleted catholyte. Iron ore particles may then be introduced into the depleted catholyte and the resulting replenished catholyte is recirculated to the cathodic chamber.