A method for separating an amount of osmium from a mixture containing the osmium and at least one other additional metal is provided. In particular, method for forming and trapping OsO.sub.4 to separate the osmium from a mixture containing the osmium and at least one other additional metal is provided.

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 Fe.sup.2+ ions to Fe metal; and removing the Fe metal from the second electrochemical cell thereby producing iron.

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 Fe.sup.2+ ions to Fe metal; and removing the Fe metal from the second electrochemical cell thereby producing iron.

Production of high purity iron powder employs high efficiency low temperature electrolysis resulting in a process requiring substantially less energy with no CO.sub.2 gas and has high energy reduction. Configurations provide a renewable electricity supply that is environmental benign with low energy consumption. A hematite (Fe.sub.2O.sub.3), carbon and highly concentrated NaOH combine to form an electronically and ionically conductive suspension for iron production. The suspension is flowable which can also be applied to a flow electrolysis system. High purity iron powder is produced at the cathode side while the anode side can produce O.sub.2 gas as a byproduct.

Production of high purity iron powder employs high efficiency low temperature electrolysis resulting in a process requiring substantially less energy with no CO.sub.2 gas and has high energy reduction. Configurations provide a renewable electricity supply that is environmental benign with low energy consumption. A hematite (Fe.sub.2O.sub.3), carbon and highly concentrated NaOH combine to form an electronically and ionically conductive suspension for iron production. The suspension is flowable which can also be applied to a flow electrolysis system. High purity iron powder is produced at the cathode side while the anode side can produce O.sub.2 gas as a byproduct.

An electrochemical reactor system includes: an electrochemical cell, having: an anode; a cathode; an electrolyte stream including an electrolyte and an iron-containing feedstock containing feedstock particles; and a channel that contains the electrolyte stream; and a magnetic field source positioned to provide a magnetic field at the surface of the cathode. The electrochemical cell electrochemically reduces the iron-containing feedstock to form iron particles at a surface of the cathode and in the magnetic field. The feedstock particles have an average particle size in at least one dimension of 10 micrometers or less, and the iron particles have an average particle size in at least one dimension of 50 to 1,000 micrometers, or the feedstock particles have an average particle size in at least one dimension of 25 micrometers or greater, and the iron particles have an average particle size in at least one dimension of 0.1 to 20 micrometers.

An electrochemical reactor system includes: an electrochemical cell, having: an anode; a cathode; an electrolyte stream including an electrolyte and an iron-containing feedstock containing feedstock particles; and a channel that contains the electrolyte stream; and a magnetic field source positioned to provide a magnetic field at the surface of the cathode. The electrochemical cell electrochemically reduces the iron-containing feedstock to form iron particles at a surface of the cathode and in the magnetic field. The feedstock particles have an average particle size in at least one dimension of 10 micrometers or less, and the iron particles have an average particle size in at least one dimension of 50 to 1,000 micrometers, or the feedstock particles have an average particle size in at least one dimension of 25 micrometers or greater, and the iron particles have an average particle size in at least one dimension of 0.1 to 20 micrometers.

A method of removing one or more impurities from an iron-containing feedstock includes grinding the iron-containing feedstock in the presence of a grinding aid to form a pretreated iron-containing feedstock, the grinding aid including an alkali metal chloride, a fluoride salt, or a combination thereof; contacting the pretreated iron-containing feedstock with a flux comprising a metal borate; fusing the pretreated iron-containing feedstock and the flux to form a fused mixture; treating the fused mixture with a leaching solution to form a purified iron-containing feedstock and a used leaching solution; and solid-liquid separating the purified iron-containing feedstock from the used leaching solution, wherein an amount of aluminum, silicon, or a combination thereof is less in the purified iron-containing feedstock than in the iron-containing feedstock. Methods of removing one or more impurities from an iron-containing feedstock also include leaching the pretreated iron-containing feedstock with acid or base without fusion.

A method of removing one or more impurities from an iron-containing feedstock includes grinding the iron-containing feedstock in the presence of a grinding aid to form a pretreated iron-containing feedstock, the grinding aid including an alkali metal chloride, a fluoride salt, or a combination thereof; contacting the pretreated iron-containing feedstock with a flux comprising a metal borate; fusing the pretreated iron-containing feedstock and the flux to form a fused mixture; treating the fused mixture with a leaching solution to form a purified iron-containing feedstock and a used leaching solution; and solid-liquid separating the purified iron-containing feedstock from the used leaching solution, wherein an amount of aluminum, silicon, or a combination thereof is less in the purified iron-containing feedstock than in the iron-containing feedstock. Methods of removing one or more impurities from an iron-containing feedstock also include leaching the pretreated iron-containing feedstock with acid or base without fusion.

A method of purifying an alkaline electrolyte includes contacting the alkaline electrolyte with an aluminum compound to provide a purified alkaline electrolyte. The alkaline electrolyte includes a metal hydroxide, a compound comprising aluminum, silicon, or a combination thereof, and a solvent. The method can be particularly advantageous when used with a method of processing an iron-containing feedstock.