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.

A method of recovering metals from electronic waste comprises providing a powder comprising electronic waste in at least a first reactor and a second reactor and providing an electrolyte comprising at least ferric ions in an electrochemical cell in fluid communication with the first reactor and the second reactor. The method further includes contacting the powders within the first reactor and the second reactor with the electrolyte to dissolve at least one base metal from each reactor into the electrolyte and reduce at least some of the ferric ions to ferrous ions. The ferrous ions are oxidized at an anode of the electrochemical cell to regenerate the ferric ions. The powder within the second reactor comprises a higher weight percent of the at least one base metal than the powder in the first reactor. Additional methods of recovering metals from electronic waste are also described, as well as an apparatus of recovering metals from electronic waste.

A method of recovering metals from electronic waste comprises providing a powder comprising electronic waste in at least a first reactor and a second reactor and providing an electrolyte comprising at least ferric ions in an electrochemical cell in fluid communication with the first reactor and the second reactor. The method further includes contacting the powders within the first reactor and the second reactor with the electrolyte to dissolve at least one base metal from each reactor into the electrolyte and reduce at least some of the ferric ions to ferrous ions. The ferrous ions are oxidized at an anode of the electrochemical cell to regenerate the ferric ions. The powder within the second reactor comprises a higher weight percent of the at least one base metal than the powder in the first reactor. Additional methods of recovering metals from electronic waste are also described, as well as an apparatus of recovering metals from electronic waste.

The present invention relates to processes including the step of electrochemically treating an iron mineral. The processes are for improving the grade of iron, producing a magnetic iron mineral, or producing an iron oxide. In one aspect, the process for improving the grade of iron includes electrochemically treating a slurry including at least one iron mineral to thereby improve the grade of the iron in the slurry.

The present invention relates to processes including the step of electrochemically treating an iron mineral. The processes are for improving the grade of iron, producing a magnetic iron mineral, or producing an iron oxide. In one aspect, the process for improving the grade of iron includes electrochemically treating a slurry including at least one iron mineral to thereby improve the grade of the iron in the slurry.

An electrochemical cell and process for producing metal and a co-product from metal ore and an aqueous halide salt are described. The co-product may be a metal hydroxide, halogen, oxygen, and/or a hypohalite. The cell includes a cathode, an anode, and a separator. A catholyte includes (i) water, (ii) a metal hydroxide comprising Q, where Q is an alkali metal, an alkaline earth metal, or a combination thereof, and (iii) suspended metal ore particles comprising M.sub.xO.sub.y where M is a metal and x and y are integers. An anolyte includes (i) water and (ii) a halide salt comprising Q and X where X is Cl or Br. A process for producing metal includes applying a voltage across the electrochemical cell to effect reduction of the M.sub.xO.sub.y in the cathode compartment to provide the metal M and a hydroxide comprising Q. X.sub.2, O.sub.2, and/or XO.sup.? is formed in the anode compartment.

An electrochemical cell and process for producing metal and a co-product from metal ore and an aqueous halide salt are described. The co-product may be a metal hydroxide, halogen, oxygen, and/or a hypohalite. The cell includes a cathode, an anode, and a separator. A catholyte includes (i) water, (ii) a metal hydroxide comprising Q, where Q is an alkali metal, an alkaline earth metal, or a combination thereof, and (iii) suspended metal ore particles comprising M.sub.xO.sub.y where M is a metal and x and y are integers. An anolyte includes (i) water and (ii) a halide salt comprising Q and X where X is Cl or Br. A process for producing metal includes applying a voltage across the electrochemical cell to effect reduction of the M.sub.xO.sub.y in the cathode compartment to provide the metal M and a hydroxide comprising Q. X.sub.2, O.sub.2, and/or XO.sup.? is formed in the anode compartment.

A method of making a graphene-containing material comprising the steps of: electrolytically reducing a transition metal oxide to a transition metal in an electrolytic cell using a molten salt electrolyte and a carbon anode; followed by extracting a dry graphene material from the electrolytic cell. Also provided is a graphene-containing material obtainable by the method of the invention.

A method of making a graphene-containing material comprising the steps of: electrolytically reducing a transition metal oxide to a transition metal in an electrolytic cell using a molten salt electrolyte and a carbon anode; followed by extracting a dry graphene material from the electrolytic cell. Also provided is a graphene-containing material obtainable by the method of the invention.

Provided is a method for efficiently producing tungsten carbide from a raw material mixture comprising at least one valuable containing tungsten. The present invention relates to a method for producing tungsten carbide, comprising the steps of subjecting a raw material mixture comprising at least one valuable containing tungsten to electrolysis using an organic electrolytic solution to dissolve tungsten in the electrolytic solution; and calcining the electrolytic solution containing dissolved tungsten at a temperature of 800 C. or more to obtain tungsten carbide.