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公开(公告)号：US20240263333A1
公开(公告)日：2024-08-08
申请号：US18550195
申请日：2022-03-24
Applicant: ELECTRASTEEL, INC.
Inventor： Ai Quoc PHAM , Sandeep NIJHAWAN , Adolfredo ALVAREZ , Colleen WALLACE , Steven FATUR
IPC: C25C1/06 , C21B13/00 , C21C5/52 , C22B3/06 , C22B5/00 , C25B1/04 , C25B15/08 , C25C7/04 , C25C7/08 , C25D3/20
CPC classification number: C25C1/06 , C21B13/0073 , C21C5/5241 , C22B3/06 , C22B5/00 , C25B1/04 , C25B15/081 , C25B15/087 , C25C7/04 , C25C7/08 , C25D3/20
Abstract: Methods and systems for producing iron from an iron-containing ore are disclosed. For example, a method for producing iron comprises: providing an iron-containing ore to a dissolution subsystem comprising a first electrochemical cell and a dissolution tank; dissolving the iron-containing ore to form an acidic iron-salt solution; reducing Fe3+ ions to form Fe2+ ions and electrochemically generating protons in the first electrochemical cell; circulating solution between the dissolution tank and the first electrochemical cell; transferring formed Fe2+ ions from the dissolution subsystem to an iron-plating subsystem having a second electrochemical cell; second electrochemically reducing a first portion of the transferred formed Fe2+ ions to Fe metal at a second cathode of the second electrochemical cell; and removing the Fe metal. The methods and systems optionally include removing one or more impurities found in the feedstock.
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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
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.
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公开(公告)号：US20240141510A1
公开(公告)日：2024-05-02
申请号：US18548303
申请日：2022-03-17
Applicant: ELECTRASTEEL, INC.
Inventor： Ai Quoc PHAM , Sandeep NIJHAWAN , Kevin GALLOWAY , Adolfredo ALVAREZ , Philip WAGNER , Steven FATUR
IPC: C25B1/20 , C02F1/461 , C25B1/22 , C25B9/19 , C25B9/70 , C25B15/08 , C02F101/10 , C02F103/08
CPC classification number: C25B1/20 , C02F1/46104 , C25B1/22 , C25B9/19 , C25B9/70 , C25B15/083 , C02F2101/10 , C02F2103/08
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
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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
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.
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公开(公告)号：US20230374683A1
公开(公告)日：2023-11-23
申请号：US18226604
申请日：2023-07-26
Applicant: ELECTRASTEEL, INC.
Inventor： Ai Quoc PHAM , Sandeep NIJHAWAN , Adolfredo ALVAREZ , Steven FATUR
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.
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Patent Agency Ranking
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
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.
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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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公开(公告)号：US20240368789A1
公开(公告)日：2024-11-07
申请号：US18758821
申请日：2024-06-28
Applicant: ELECTRASTEEL, INC.
Inventor： Ai Quoc PHAM , Sandeep NIJHAWAN , Adolfredo ALVAREZ , Colleen WALLACE , Steven FATUR
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.
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公开(公告)号：US20230366115A1
公开(公告)日：2023-11-16
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
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.
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公开(公告)号：US20220380918A1
公开(公告)日：2022-12-01
申请号：US17884198
申请日：2022-08-09
Applicant: ELECTRASTEEL, INC.
Inventor： Ai Quoc PHAM , Sandeep NIJHAWAN , Adolfredo ALVAREZ , Steven FATUR
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.
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