Recovery of spent pickle liquor and iron metal

Claim 2

A process for regenerating spent sulfuric acid pickle liquor and recovering iron therefrom, which comprises; introducing an aqueous catholyte containing dissolved ferrous sulfate into the cathode chamber of an electrolytic cell having a cathode in a cathode chamber, an anode in an anode chamber, and a cation-selective membrane separating the anode and cathode chambers; introducing an aqueous anolyte containing dissolved ammonium sulfate into the anode chamber of the cell; passing a direct electric current through the cell for depositing iron metal on the cathode and for transporting ammonium ion from the anolyte through the membrane into the catholyte, whereby the sulfuric acid content of the anolyte is increased and the ammonium sulfate content of the catholyte is increased; and withdrawing anolyte having an increased sulfuric acid content from the anode chamber.

Claim 3

The process of claim 1 wherein the membrane is formed of a perfluorocarbon polymer having pendant sulfonic acid groups.

Claim 4

The process of claim 2 wherein the membrane can transport ammonium ion with an efficiency of at least about 0.6 grams of ammonium ion per ampere hour of current passing through the membrane.

Claim 5

The process of claim 2 wherein the polymer is a copolymer of tetrafluoroethylene and a perfluorocarbon vinyl ether having a sulfonyl functional group.

Claim 6

The process of claim 1 wherein the total sulfate content of the anolyte and the total sulfate content of the catholyte are about equal.

Claim 7

The process of claim 1 wherein the ammonium ion content of the anolyte is at least electrochemically equivalent to the ferrous ion content of the catholyte.

Claim 8

A cyclic process for regenerating spent sulfuric acid pickle liquor and for recovering iron metal therefrom, which comprises: introducing spent sulfuric acid pickle liquor containing dissolved ferrous sulfate as catholyte into the cathode chamber of an electrolytic cell having a cathode in a cathode chamber, an anode in an anode chamber, and a cation-selective membrane separating the anode and cathode chambers; introducing an aqueous anolyte containing dissolved ammonium sulfate into the anode chamber of the cell; passing a direct electric current through the cell for depositing iron metal on the cathode and for transporting ammonium ion from the anolyte through the membrane into the catholyte, whereby the anolyte is substantially converted to regenerated sulfuric acid solution and the catholyte is substantially converted to ammonium sulfate solution; withdrawing regenerated sulfuric acid solution from the anode chamber; transferring catholyte from the cathode chamber to the anode chamber; and introducing spent sulfuric acid pickle liquor containing dissolved ferrous sulfate into the cathode chamber.

Claim 9

A cyclic process for regenerating spent sulfuric acid pickle liquor and for recovering iron metal therefrom, which comprises: introducing spent sulfuric acid pickle liquor containing dissolved ferrous sulfate as catholyte into the cathode chamber of an electrolytic cell having a cathode in a cathode chamber, an anode in an anode chamber, and a cation-selective membrane separating the anode and cathode chambers; introducing an aqueous anolyte containing dissolved ammonium sulfate into the anode chamber of the cell; passing a direct electric current through the cell for depositing iron metal on the cathode and for transporting ammonium ion from the anolyte through the membrane into the catholyte, whereby the anolyte is substantially converted to regenerated sulfuric acid solution and the catholyte is substantially converted to ammonium sulfate solution; withdrawing regenerated sulfuric acid solution from the anode chamber; transferring catholyte from the cathode chamber to the anode chamber; and introducing spent sulfuric acid pickle liquor containing dissolved ferrous sulfate into the cathode chamber.

Claim 10

The process of claim 7 wherein the membrane is formed of a perfluorocarbon polymer having pendant sulfonic acid groups.

Claim 11

The process of claim 8 wherein the membrane can transport ammonium ion with an efficiency of at least about 0.6 grams of ammonium ion per ampere hour of current passing through the membrane.

Claim 12

The process of claim 8 wherein the polymer is a copolymer of tetrafluoroethylene and a perfluorocarbon vinyl ether having a sulfonyl functional group.

Claim 13

The process of claim 7 wherein the ammonium ion content of the anolyte is at least electrochemically equivalent to the ferrous ion content of the catholyte.

Claim 14

A process for regenerating spent sulfuric acid pickle liquor and for recovering iron metal therefrom, which comprises: introducing spent sulfuric acid pickle liquor containing dissolved ferrous sulfate and dissolved ammonium sulfate as catholyte into the cathode chamber of an electrolytic cell having a cathode in a cathode chamber, an anode in an anode chamber, and a perfluorocarbon cation-selective membrane having pendant sulfonic acid groups separating the anode and cathode chambers; introducing an aqueous anolyte containing dissolved ammonium sulfate into the anode chamber of the cell, the ammonium ion content of the anolyte being at least electrochemically equivalent to the ferrous ion content plus the ammonium ion content of the catholyte; the total sulfate content of the anolyte being about equal to the total sulfate content of the catholyte; passing a direct electric current through the cell for depositing iron metal on the cathode and for transporting ammonium ion from the anolyte through the membrane into the catholyte; continuing the passage of current until the ammonium ion content of the anolyte is lowered to about the ammonium ion content of the spent sulfuric acid pickle liquor as introduced into the cathode chamber, whereby the anolyte is substantially converted to regenerated sulfuric acid solution; withdrawing regenerated sulfuric acid solution from the anode chamber; and transferring catholyte from the cathode chamber to the anode chamber.

Claim 15

A process for regenerating spent sulfuric acid pickle liquor and for recovering iron metal therefrom, which comprises: introducing spent sulfuric acid pickle liquor containing dissolved ferrous sulfate and dissolved ammonium sulfate as catholyte into the cathode chamber of an electrolytic cell having a cathode in a cathode chamber, an anode in an anode chamber, and a perfluorocarbon cation-selective membrane having pendant sulfonic acid groups separating the anode and cathode chambers; introducing an aqueous anolyte containing dissolved ammonium sulfate into the anode chamber of the cell, the ammonium ion content of the anolyte being at least electrochemically equivalent to the ferrous ion content plus the ammonium ion content of the catholyte; the total sulfate content of the anolyte being about equal to the total sulfate content of the catholyte; passing a direct electric current through the cell for depositing iron metal on the cathode and for transporting ammonium ion from the anolyte through the membrane into the catholyte; continuing the passage of current until the ammonium ion content of the anolyte is lowered to about the ammonium ion content of the spent sulfuric acid pickle liquor as introduced into the cathode chamber, whereby the anolyte is substantially converted to regenerated sulfuric acid solution; withdrawing regenerated sulfuric acid solution from the anode chamber; and transferring catholyte from the cathode chamber to the anode chamber.

Claim 16

The process of claim 12 wherein the membrane can transport ammonium ion with an efficiency of at least about 0.6 grams per ampere hour of current passing through the membrane.

Claim 17

The process of claim 13 wherein the polymer is a copolymer of tetrafluoroethylene and a perfluorocarbon vinyl ether having a sulfonyl functional group.

Claim 18

The process of claim 12 wherein a plurality of such electrolytic cells including a first cell and a last cell are employed, and which comprises the steps of: continuously introducing spent sulfuric acid pickle as catholyte liquor into the cathode chamber of the first cell; passing the catholyte in series through the cathode chambers of the cells; continuously transferring catholyte from the last cell to the anode chamber of the first cell as anolyte; passing the anolyte in series through the anode chambers of the cells; and continuously withdrawing regenerated sulfuric acid solution from the anode chamber of the last cell.