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    IMPURITY REMOVAL IN AN IRON CONVERSION SYSTEM
    4.
    发明公开
    IMPURITY REMOVAL IN AN IRON CONVERSION SYSTEM 审中-公开

    公开(公告)号：US20240158939A1

    公开(公告)日：2024-05-16

    申请号：US18550189

    申请日：2022-03-24

    Applicant: ELECTRASTEEL, INC.

    Inventor： Ai Quoc PHAM ,  Sandeep NIJHAWAN ,  Adolfredo ALVAREZ ,  Steven FATUR

    IPC: C25C1/06 ,  C25C7/04

    CPC classification number: C25C1/06 ,  C25C7/04

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

    2-STEP IRON CONVERSION SYSTEM
    6.
    发明申请
    2-STEP IRON CONVERSION SYSTEM 有权

    公开(公告)号：US20220380919A1

    公开(公告)日：2022-12-01

    申请号：US17884260

    申请日：2022-08-09

    Applicant: ELECTRASTEEL, INC.

    Inventor： Ai Quoc PHAM ,  Sandeep NIJHAWAN ,  Adolfredo ALVAREZ ,  Colleen WALLACE ,  Steven FATUR

    IPC: C25C1/06 ,  C25C7/04

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

    ORE DISSOLUTION AND IRON CONVERSION SYSTEM
    7.
    发明申请
    ORE DISSOLUTION AND IRON CONVERSION SYSTEM 有权

    公开(公告)号：US20240368788A1

    公开(公告)日：2024-11-07

    申请号：US18758256

    申请日：2024-06-28

    Applicant: ELECTRASTEEL, INC.

    Inventor： Ai Quoc PHAM ,  Sandeep NIJHAWAN ,  Adolfredo ALVAREZ ,  Steven FATUR

    IPC: C25C1/06 ,  C22B3/06 ,  C22B5/00 ,  C25C7/02 ,  C25C7/04

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

    2-step iron conversion system
    8.
    发明授权
    2-step iron conversion system 有权

    公开(公告)号：US12065749B2

    公开(公告)日：2024-08-20

    申请号：US18226626

    申请日：2023-07-26

    Applicant: ELECTRASTEEL, INC.

    Inventor： Ai Quoc Pham ,  Sandeep Nijhawan ,  Adolfredo Alvarez ,  Colleen Wallace ,  Steven Fatur

    IPC: C25C1/06 ,  C22B3/06 ,  C22B5/00 ,  C25C7/02 ,  C25C7/04

    CPC classification number: C25C1/06 ,  C22B3/06 ,  C22B5/00 ,  C25C7/02 ,  C25C7/04

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

    Carbon Capture Using Electrochemically-Produced Acid and Base
    10.
    发明申请
    Carbon Capture Using Electrochemically-Produced Acid and Base 有权

    公开(公告)号：US20240425994A1

    公开(公告)日：2024-12-26

    申请号：US18825688

    申请日：2024-09-05

    Applicant: ELECTRASTEEL, INC.

    Inventor： Ai Quoc PHAM ,  Sandeep NIJHAWAN ,  Kevin GALLOWAY ,  Adolfredo ALVAREZ ,  Philip WAGNER ,  Steven FATUR

    IPC: C25B1/20 ,  C02F1/461 ,  C02F101/10 ,  C02F103/08 ,  C25B1/22 ,  C25B9/19 ,  C25B9/70 ,  C25B15/08

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

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