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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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First Claim