Production of chromic acid using two-compartment and three-compartment cells

Claim 2

In the process of producing chromic acid from chrome ore wherein the ore is roasted, solids are removed, and processing provides intermediate alkali metal chromate, the improvement which comprises: (A) introducing alkali metal chromate to the anolyte compartment of a two-compartment electrolytic cell, said chromate containing reduced forms of chromium, if such exist, at substantially below about 2 percent of the dichromate hexavalent chromium, said cell having substantially hydraulically impermeable cation-exchange membrane means separating said anolyte compartment from a cathode compartment; (B) introducing electrolyte to said cathode compartment; (C) applying electrolyzing current to said two-compartment electrolytic cell; (D) withdrawing from said cathode compartment electrolyzed catholyte solution containing alkali product; (E) withdrawing from said anolyte compartment electrolyzed anolyte solution containing alkali metal dichromate; (F) introducing alkali metal dichromate solution to the center compartment of a three-compartment electrolytic cell, said center compartment having porous diaphragm means separating same from an anode compartment and further having substantially hydraulically impermeable cation-exchange membrane means separating said center compartment from the cathode compartment; (G) permitting center compartment solution flow through said porous diaphragm to the anode compartment; (H) introducing electrolyte to the cathode compartment of the three-compartment cell; (I) applying electrolyzing current to said three-compartment electrolytic cell; (J) withdrawing electrolyzed catholyte solution containing alkali product from said cathode compartment of the three-compartment cell; and (K) withdrawing electrolyzed anolyte solution containing chromic acid from said anode compartment for downstream recovery of chromic acid.

Claim 3

The process of claim 1 further characterized by withdrawing cell solution, depleted in alkali metal dichromate, from the center compartment of said three-compartment cell and recycling same to combine with alkali metal dichromate feed introduced in step (F).

Claim 4

The process of claim 2 further characterized by passing at least a portion of said withdrawn cell solution to a mix tank.

Claim 5

The process of claim 3 wherein at least a portion of electrolyzed catholyte solution is fed to said mix tank.

Claim 6

The process of claim 3 further characterized by crystallizing chromic acid crystals, in the downstream recovery of chromic acid, and introducing chromic-acid-containing liquor separated from said crystals into said mix tank.

Claim 7

The process of claims 3, 4, or 5 wherein solution is withdrawn from said mix tank and introduced in step (F) to said three-compartment electrolytic cell.

Claim 8

The process of claim 1 wherein for each electrolytic cell said electrolyzing current is direct electrolyzing current applied across the anode and cathode of the cell and, in electrolyzing said two-compartment cell, any halide impurity in the chromate solution is reduced with commensurate evolution of halogen at the anode.

Claim 9

The process of claim 1 further characterized by introducing carbon dioxide into the catholyte of at least one of said electrolytic cells, or into catholyte being recirculated outside at least one of said electrolytic cells, thereby preparing carbonate product in the catholyte, and the carbonate product is removed from the cathode compartment or from recirculating catholyte.

Claim 10

The process of claim 1 wherein said dichromate solution introduced to the cell in step (F) is at a temperature within the range from about 15° C. to about 95° C. and a pressure differential enhances solution flow in step (G) from said center compartment through said porous diaphragm.

Claim 11

The process of claim 1 wherein for each cell said electrolyzing current provides a current density of above 0 to about 10 amperes per square inch and the electrolyzed anolyte solution of step (K) is at a temperature within the range from about 40° C. to about boiling.

Claim 12

The process of claim 1 further characterized by introducing in step (A) alkali metal chromate containing metallic ion impurity to said two-compartment electrolytic cell and reducing said impurity content in solution by attracting said impurity to the cation-exchange membrane of said cell.

Claim 13

The process of claim 1 further characterized by withdrawing electrolyzed anolyte solution from said two-compartment cell, and feeding same to evaporator means, thereby preparing a concentrated alkali metal dichromate solution, and in step (F) introducing said concentrated alkali metal dichromate solution from said evaporator means to the center compartment of the three-compartment electrolytic cell.

Claim 14

The process of claim 1 wherein at least a portion of said alkali product is recycled for use in chrome ore roasting.

Claim 15

The process of claim 1 wherein the alkali product concentration in the cathode compartment of each cell is at least partially controlled during electrolysis by water addition thereto or by water addition to catholyte being recirculated outside the cell.

Claim 16

The process of claim 1 wherein the alkali metal dichromate solution introduced to the cell in step (F) is substantially free from chromic acid.

Claim 17

The process of claim 1 wherein a hydrostatic head of pressure is present on said center compartment solution of the three-compartment electrolytic cell, and said pressure is maintained within the range from above 0 psig to about 2 psig.

Claim 18

The process of claim 1 further characterized by maintaining in the anode compartment of said three-compartment electrolytic cell aqueous sodium-dichromate-containing anolyte having an anolyte ratio between about 3 and 20.8 percent.

Claim 19

The process of claim 1 further characterized by maintaining in the anode compartment of said three-compartment electrolytic cell aqueous potassium-dichromate-containing anolyte having an anolyte ratio below 31.95 percent.

Claim 20

In the process of producing chromic acid from chrome ore wherein the ore is roasted, solids are removed, and processing provides intermediate alkali metal chromate, the improvement which comprises: (A) introducing alkali metal chromate to the center compartment of a first three-compartment electrolytic cell, said chromate containing reduced forms of chromium, if such exist, at substantially below about 2 percent of the dichromate hexavalent chromium, said center compartment having porous diaphragm means separating same from an anode compartment and further having substantially hydraulically impermeable cation-exchange membrane means separating said center compartment from the cathode compartment; (B) permitting center compartment solution flow through said porous diaphragm to the anode compartment; (C) introducing electrolyte to said cathode compartment; (D) applying electrolyzing current to said electrolytic cell; (E) withdrawing from said cathode compartment electrolyzed catholyte solution containing alkali product; (F) withdrawing from said anolyte compartment electrolyzed anolyte solution containing alkali metal dichromate; (G) introducing alkali metal dichromate solution to the center compartment of a second three-component electrolytic cell, said center compartment having porous diaphragm means separating same from an anode compartment and further having substantially hydraulically impermeable cation-exchange membrane means separating said center compartment from the cathode compartment; (H) permitting center compartment solution in step (G) to flow through said porous diaphragm to the anode compartment; (I) introducing electrolyte to said cathode compartment of said second electrolytic cell; (J) applying electrolyzing current to said second electrolytic cell; (K) withdrawing electrolyzed catholyte solution containing alkali product from said cathode compartment in step (G); and (L) withdrawing electrolyzed anolyte solution containing chromic acid from said anode compartment of the second three-compartment cell for downstream recovery of chromic acid.

Claim 21

In the process of producing chromic acid from chrome ore wherein the ore is roasted, solids are removed, and processing provides intermediate alkali metal chromate, the improvement which comprises: (A) introducing alkali metal chromate to the center compartment of a first three-compartment electrolytic cell, said chromate containing reduced forms of chromium, if such exist, at substantially below about 2 percent of the dichromate hexavalent chromium, said center compartment having porous diaphragm means separating same from an anode compartment and further having substantially hydraulically impermeable cation-exchange membrane means separating said center compartment from the cathode compartment; (B) permitting center compartment solution flow through said porous diaphragm to the anode compartment; (C) introducing electrolyte to said cathode compartment; (D) applying electrolyzing current to said electrolytic cell; (E) withdrawing from said cathode compartment electrolyzed catholyte solution containing alkali product; (F) withdrawing from said anolyte compartment electrolyzed anolyte solution containing alkali metal dichromate; (G) introducing alkali metal dichromate solution to the center compartment of a second three-component electrolytic cell, said center compartment having porous diaphragm means separating same from an anode compartment and further having substantially hydraulically impermeable cation-exchange membrane means separating said center compartment from the cathode compartment; (H) permitting center compartment solution in step (G) to flow through said porous diaphragm to the anode compartment; (I) introducing electrolyte to said cathode compartment of said second electrolytic cell; (J) applying electrolyzing current to said second electrolytic cell; (K) withdrawing electrolyzed catholyte solution containing alkali product from said cathode compartment in step (G); and (L) withdrawing electrolyzed anolyte solution containing chromic acid from said anode compartment of the second three-compartment cell for downstream recovery of chromic acid.

Claim 22

The process of claim 19 further characterized by withdrawing cell solution, depleted in alkali metal dichromate, from the center compartment of said second three-compartment cell and recycling same to combine with alkali metal dichromate feed introduced in step (G).

Claim 23

The process of claim 20 further characterized by passing at least a portion of said withdrawn cell solution to a mix tank.

Claim 24

The process of claim 21 wherein at least a portion of electrolyzed cathode solution is fed to said mix tank.

Claim 25

The process of claim 21 further characterized by crystallizing chromic acid crystals, in the downstream recovery of chromic acid, and introducing chromic-acid-containing liquor separated from said crystals into said mix tank.

Claim 26

The process of claims 21, 22 or 23 wherein solution is withdrawn from said mix tank and introduced in step (G) to said second three-compartment electrolytic cell.

Claim 27

The process of claim 19 wherein for each electrolytic cell said electrolyzing current is direct electrolyzing current applied across the anode and cathode of the cell and, in electrolyzing said first three-compartment cell, any halide impurity in the chromate solution is reduced with commensurate evolution of halogen at the anode.

Claim 28

The process of claim 19 further characterized by introducing carbon dioxide into the catholyte of at least one of said electrolytic cells, or into catholyte being recirculated outside at least one of said electrolytic cells, thereby preparing carbonate product in the catholyte, and the carbonate product is removed from the cathode compartment or from recirculating catholyte.

Claim 29

The process of claim 19 wherein a pressure differential in each cell enhances solution flow in each of steps (B) and (H) from said center compartment through said porous diaphragm.

Claim 30

The process of claim 19 wherein for each cell said electrolyzing current provides a current density of above 0 to about 10 amperes per square inch.

Claim 31

The process of claim 19 further characterized by introducing in step (A) alkali metal chromate containing metallic ion impurity to said first three-compartment electrolytic cell and reducing said impurity content in solution by attracting said impurity to the cation-exchange membrane of said cell.

Claim 32

The process of claim 19 further characterized in step (F) by withdrawing electrolyzed anolyte solution from said first three-compartment cell, and feeding same to evaporator means, thereby preparing a concentrated alkali metal dichromate solution, and introducing in step (G) said concentrated alkali metal dichromate solution from said evaporator means to the center compartment of the second three-compartment electrolytic cell.

Claim 33

The process of claim 19 wherein at least a portion of said alkali product is recycled for use in chrome ore roasting.

Claim 34

The process of claim 19 further characterized by withdrawing cell solution, depleted in alkali metal chromate, from the center compartment of said first electrolytic cell and recycling same to combine with alkali metal chromate feed introduced in step (A).

Claim 35

The process of claim 19 wherein the alkali product concentration in the cathode compartment of each cell is at least partially controlled during electrolysis by water addition thereto or by water addition to catholyte being recirculated outside the cell.

Claim 36

The process of claim 19 wherein the alkali metal dichromate solution introduced to the cell in step (G) is substantially free from chromic acid.

Claim 37

The process of claim 19 wherein a hydrostatic head of pressure is present on the center compartment solution for each electrolytic cell, and said pressure is maintained within the range from above 0 psig to about 2 psig.

Claim 38

The process of claim 19 further characterized by maintaining in the anode compartment of said second three-compartment electrolytic cell aqueous sodium-dichromate-containing anolyte having an anolyte ratio between about 3 and 20.8 percent.

Claim 39

The process of claim 19 further characterized by maintaining in the anode compartment of said second three-compartment electrolytic cell aqueous potassium-dichromate-containing anolyte having an anolyte ratio below 31.95 percent.