Process for the electrochemical production of sodium ferrate [Fe(VI)]

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the production of sodium ferrate by an electrolytic process in a membrane-type electrolysis cell.
2. Description of the Prior Art
Alkali metal and alkaline earth metal ferrates resemble permanganate in having a purple color and, in acid solutions, they evolve oxygen very rapidly.
The prior art teaches two principal methods for making alkali metal and alkaline earth metal ferrates. One method of preparation has been by electrolysis either in unseparated cells or in diaphragm-type electrolytic cells (i.e., multi-chamber cells which have an anolyte separated from the catholyte by a gas-porous, hydraulically permeable separator).
Alkali metal and alkaline earth metal ferrates have also been produced by the reaction of inorganic hypochlorites with iron-containing compounds in aqueous alkaline solutions.
However, sodium ferrate produced by such prior art methods becomes unstable and tends to degrade almost immediately. This lack of stability is due to the hydrolysis of sodium ferrate with water in the cell or the atmosphere to form ferric hydroxide. Also, the prior art methods for making sodium ferrate by electrochemical means also have the problem of anode passivity, which is caused by the formation of ferric oxide film on the iron anode. Further, once formed, this film has been found to catalyze and thus speed up the rate of ferrate decomposition. To prevent such problems, it is necessary to either wash the anode with acid or reverse the current to remove such a ferric oxide film. However, these techniques are costly or time-consuming, or both.
The strong oxidizing properties of ferrates suggest that they may be useful for a variety of commercial uses (e.g., oxidation of chemical moieties in waste water streams). However, the aforesaid instability tends to severely limit such utility for commercial applications. Thus, there is a need at the present time to find a commercial process for producing ferrates.
OBJECTS
It is a primary object of this invention to provide an improved electrolytic process for preparing a sodium hydroxide solution containing a stable sodium ferrate.
It is another object of this invention to provide a process for stabilizing sodium ferrate against degrading.
A further object is to provide an improved electrolytic process for producing sodium ferrate for use in water treatment purification.
These and other objects of the present invention will become apparent from the following description and the appended claims.
BRIEF SUMMARY OF THE INVENTION
The present invention, therefore, is directed to a process for the production of sodium ferrate in an electrolytic cell having an anolyte chamber containing an anode, a catholyte chamber containing a cathode, and a gas and liquid impermeable membrane between the chambers, the process comprising the steps of:
(a) admixing sodium hydroxide containing less than about 0.02% by weight of sodium halide with sufficient sodium halide to increase the sodium halide concentration of the resulting mixture to between about 0.02% to about 4.0% by weight;
(b) electrolyzing said resulting mixture while in contact with ferric ions as the anolyte of an electrolysis process whereby sodium ferrate is formed in the anolyte; and
(c) recovering said sodium ferrate therefrom.

DETAILED DESCRIPTION
1. GENERAL CELL CONSTRUCTION
Electrolytic cells employed in this invention may be a commercially available or a custom built membrane-type electrolytic cell of a size and electrical capacity capable of economically producing the desired sodium ferrate product. Since the electrolytic cell contains a strong base throughout, it should be constructed of any material resistant to strong bases and strong oxidant chemicals. It may be desirable to line the inside surfaces of the cell with a plastic material resistant to NaOH solutions and sodium ferrate or the cell may be constructed entirely of plastic material.
A particularly advantageous membrane-type electrolytic cell which may be employed in the practice of this process has separate anolyte and catholyte chambers, using a permselective cation exchange membrane as a separator. Located on one side of the membrane partition, the anolyte chamber has an outlet for any oxygen gas generated, and an inlet and an outlet for charging, removing or circulating anolyte. On the opposite side of the membrane partition, the catholyte chamber has inlets and outlets for the sodium hydroxide solution and an outlet for hydrogen liberated at the cathode by the electrolysis of water.
Electrolytic cells employed in the present invention may be operated on a batch or flow-through system. In the latter system, either anolyte or catholyte, or both, may be continuously circulated to and from external solution storage vessels.
Hydrogen gas is removed from the catholyte chamber and collected for use as a fuel or otherwise disposed of. Any oxygen gas evolved is likewise removed from the anolyte chamber.
2. MEMBRANE CONSTRUCTION
Membrane material employed as a separator between the anolyte and catholyte chambers should be physically and chemically stable both to strong sodium hydroxide solutions and to strong oxidizing chemicals (e.g., sodium ferrate) before, during, and after cell operation. The membrane should also be ionically conductive and allow ion flow between the two chambers. However, the ionic transport of ferrate ion [FeO.sub.4.sup.-2 ] should be much lower than that of the sodium ion [Na.sup.+ ], hydroxide ion [OH.sup.- ] and hydrogen ion [H.sup.+ ].
For the purposes of this invention, suitable membrane materials are gas- and hydraulic-impermeable permselective cation-exchange materials including sulfonic acid substituted perfluorocarbon polymers of the type described in U.S. Pat. No. 4,036,714, which issued on July 19, 1977 to Robert Spitzer; primary amine substituted polymers such as those described in U.S. Pat. No. 4,085,071, which issued on Apr. 18, 1978 to Paul Raphael Resnick et al; polyamine substituted polymers of the type described in U.S. Pat. No. 4,030,988, which issued on June 21, 1977 to Walter Gustav Grot; and carboxylic acid substituted polymers such as those described in U.S. Pat. No. 4,065,366, which issued on December 27, 1977 to Yoshio Oda et al. All of the teachings of these patents are incorporated herein in their entirety by reference.
With respect to the sulfonic acid substituted polmyers of U.S. Pat. No 4,036,714, these membranes are preferably prepared by copolymerizing a vinyl ether having the formula FSO.sub.2 CF.sub.2 CF.sub.2 OCF(CF.sub.3)CF.sub.2 OCF.dbd.CF.sub.2 and tetrafluoroethylene followed by converting the FSO.sub.2 -group to a moiety selected from the group consisting of HSO.sub.3.sup.-, alkali metal sulfonate, and mixtures thereof. The equivalent weight of the preferred copolymers range from 950 to 1350 where equivalent weight is defined as the average molecular weight per sulfonyl group.
With reference to the primary amine substituted polymers of U.S. Pat. No. 4,085,071, the basic sulfonyl fluoride polymer of the U.S Pat. No. 4,036,714 above is first prepared and then reacted with a suitable primary amine wherein the pendant sulfonyl fluoride groups react to form N-monosubstituted sulfonamido groups or salts thereof. In preparing the polymer precursor, the preferred copolymers utilized in the film are fluoropolymers or polyfluorocarbons although others can be utilized as long as there is a fluoride atom attached to the carbon atom which is attached to the sulfonyl group of the polymer The most preferred copolymer is a copolymer of tetrafluoroethylene and perfluoro(3,6-dioxa-4-methyl- 7-octenesulfonyl fluoride) which comprises 10 to 60 percent, preferably 25 to 50 percent by weight of the latter. The sulfonyl groups are then converted to N-monosubstituted sulfonamido groups or salt thereof through the reaction of a primary amine.
Polymers similar to the above U.S Pat. No. 4,085,071 are prepared as described in U.S. Pat. No. 4,030,988 wherein the backbone sulfonated fluoride polymers are reacted with a di- or polyamine, with heat treatment of the converted polymer to form diamino and polyamino substituents on the sulfonyl fluoride sites of the copolymer.
The carboxylic acid substituted polymers of U.S. Pat. No. 4,065,366 are prepared by reacting a fluorinated olefin with a comonomer having a carboxylic acid group or a functional group which can be converted to a carboxylic acid group. It is preferred to use a fluorinated copolymer having a molecular weight to give the volumetric melt flow rate of 100 millimeters per second at a temperature of 250.degree. C. to 300.degree. C. Preferably, the membrane is prepared by copolymerizing tetrafluoroethylene with CF.sub.2 .dbd.CFO(CF.sub.2).sub.3 COOCH.sub.3. Such polymers are believed to prevent substantial diffusion of the divalent ferrate ion [FeO.sub.4.sup.-2 ] through them. Also, such membranes are generally water-saturated, and when coupled with a low membrane thickness, will produce very low voltages across the membrane.
The thickness of the membrane may be in the range from about 1 to about 20 mils, and preferably from about 2 to about 5 mils. For selected membranes, a laminated inert cloth supporting material for the membrane of polytetrafluoroethylene may be used.
3. ANODE CONSTRUCTION
At least one electrode is positioned within the anolyte chamber and one electrode within the catholyte chamber. For maximum exposure of the electrolytic surface, the face of each electrode should preferably be parallel to the plane of the membrane.
The anode may be made of any conventional iron-containing anode material or, if the ferric ion source in the anolyte is different than the anode, may be of any conventional non-iron anode material. While the anode configuration is not critical, it should be shaped such as to give minimal electrolyte resistance drop and the most uniform current and potential distribution across its surface. This is usually a flatplate, expanded mesh, particulate or porous electrode structure. High surface area anodes such as steel or iron wool are preferred because they will achieve a higher cell efficiency than plate anodes under the same operating conditions.
Preferred for said iron-containing anode material is pure iron since this tends to minimize the occurrence of heavy metal impurities known to adversely affect the stability of sodium ferrate. Other types of iron-containing materials that may be used to form an anode include cast iron, wrought iron and scrap iron materials with those highest in iron content such as cast iron and low-grade carbon steels being preferred.
Examples of non-iron materials which may be employed as the anode include commercially available platinized titanium, platinized tantalum, or platinized platinum electrodes, a deposit of platinum on titanium, platinum on tantalum, or platinum on platinum. Also, effective are anodes composed of graphite, lead dioxide, lead dioxide-coated carbon or metal substrates and the like. One skilled in the art will recognize, however, that any anode construction capable of effecting electrolytic production of sodium ferrate by the oxidation of iron species present in the anolyte to the Fe(VI) moiety (i.e., FeO.sub.4.sup.-2) while in an aqueous sodium hydroxide solution containing at least one sodium halide compound may be used in the process of this invention.
4. CATHODE CONSTRUCTION
Examples of materials which may be employed as the cathode are carbon steel, stainless steel, nickel, nickel-molybdenum alloys, nickel-vanadium alloys and others. Those skilled in the art will also recognize that any electronically-conducting material or substrate that is capable of effecting the electrolytic reduction of water to hydroxide with either high or low hydrogen overvoltage may be used as cathode construction material in the process of this invention.
5. ANOLYTE PARAMETERS
The anolyte is comprised of an aqueous solution of sodium hydroxide having at least a sodium ferrate-stabilizing amount of at least one sodium halide salt. The anolyte also contains ferric ions which are produced either from the iron anode or ferric salts, or both. The sodium halide salt or salts is necessary to increase the rate of corrosion of iron surfaces in the anolyte solution by permeating and weakening the oxide gel which forms thereon, thus aiding in the formation of ferric ions [Fe(III)] for conversion to ferrate ions [FeO.sub.4.sup.-2 ]. Further, it has been found that when the chloride content is kept above about 0.02% by weight in the sodium hydroxide dissolved in the anolyte, the rate of degradation of the resultant sodium ferrate formed is much lower than is the case when such a level of chloride is not used.
The sodium hydroxide concentrations maintained in the anolyte may range from about 20% to about 65% by weight of the aqueous solution in the anolyte. Preferably, NaOH concentrations in the range from about 40% to about 65% by weight of the aqueous solution are maintained. For the best efficiencies, the most preferred sodium hydroxide concentration is from about 50% to about 65% by weight of the aqueous solution. Generally, a suitable sodium hydroxide solution is charged into the anolyte chamber before electrolysis in order to maintain the above ranges of concentration throughout the operation.
The preferred sodium halide salts that may be added to the anolyte are sodium chloride, sodium hypochlorite, sodium bromide, sodium hypobromite and mixtures thereof. Alternatively, such sodium halide or hypohalite salts may be made in situ by the addition of Cl.sub.2 or Br.sub.2 to the sodium hydroxide anolyte solution, thus forming NaCl, NaOCl, NaBr or NaOBr. Fluoride and iodide salts may also be used, but are believed to be less desirable from a cost standpoint. The most preferred sodium halide salt is NaCl.
Any proportion of sodium halide salt or salts capable of effecting stabilization of sodium ferrate without adversely diluting the sodium ferrate product may be employed. The weight ratio of sodium hydroxide to sodium halide salt ranges from about 25:1 to about 5,000:1 and preferably from about 50:1 to about 1,000:1. Expressed another way, the halide ranges are from about 0.02% to about 4.0% and preferably from about 0.01% to about 2.0% by weight of the total weight of halide/hydroxide mixture used in the anolyte solution.
When employing sodium chloride as the sodium halide salt, its concentration in the anolyte is preferably maintained in the range from about 100 parts to about 15,000 parts per million parts by weight of the anolyte. More preferably, its concentration is from about 500 parts to about 10,000 parts per million parts by weight of the anolyte. Equivalent amounts of other sodium halide salts may be employed. Expressed another way, the preferred operating range for NaCl would be from about 0.01% to about 1.5% and more preferably from about 0.05% to about 1.0%, by weight of the anolyte solution.
The anolyte pH is maintained during the operation in the range from about 10 to greater than 14 and preferably at least about 14 because of the stability of the sodium ferrate product in any aqueous solution is extremely sensitive to the pH. With a pH below 10, the ferrate product may begin to decompose to liberate oxygen and form Fe.sub.2 O.sub.3.
If the anode is made of non-ferrous material, it is necessary that the anolyte contain a source of ferric ions from which the sodium ferrate may be produced. Ferric ion sources include ferric salts such as ferric chloride and ferric sulfate or sources of pure iron such as iron particles, iron scraps and the like. If such ferric ion sources are employed instead of or concurrently with an iron anode, their amounts used in the anolyte would mainly depend upon the final concentration of sodium ferrate desired in the product after electrolysis.
Generally, the range of ferric ion concentration in the anolyte is from about 0.001% to about 12% of the anolyte. The preferable concentration range of ferric ion is from about 0.1% to about 10% by weight. It should be noted that the ferric ion concentration may be less or greater than the above recited range during startup and shutdown of the cell; however, at equilibrium, the concentration is preferably within these ranges.
6. CATHOLYTE PARAMETERS
The catholyte of the present invention, like the anolyte, is maintained during operation as aqueous sodium hydroxide solution. Generally, the NaOH concentration may range from about 20% to about 65% by weight in the catholyte. Preferably, this NaOH concentration is from about 40% to about 65% by weight, and most preferably, from about 45% to about 65% by weight of the catholyte. However, unlike the anolyte, the catholyte may be initially charged with pure H.sub.2 O before operation. Through the electrolysis operation, NaOH will be formed in the catholyte by the transport of Na.sup.+ ions to the catholyte chamber and by their reaction therein with OH.sup.- ions. Water may be added to the catholyte during or after electrolysis to replenish the water consumed during the operation. Since the concentration of NaOH will be increasing in the catholyte, it may also be necessary to withdraw some concentrated NaOH solution in order to maintain the concentration of sodium hydroxide solution in the preferred range.
7. ELECTRTOLYSIS OPERATING PARAMETERS
The electrolysis step of this invention is performed by supplying a direct current to the cell and impressing a voltage across the cell terminals. Without being bound by any theory, it is believed that during the operation of this step, a direct current flows to activate an electrochemical charge transfer directly at the anode, thereby converting Fe(0) atoms to Fe.sup.+3 ions. Then the Fe.sup.+3 ions are converted to FeO.sub.4.sup.-2 ions by further electrochemical charge transfer. In the case where Fe.sup.+3 ions are added to the anolyte in salt form, rather than employing a Fe(0) anode, these Fe.sup.+3 are also converted to FeO.sub.4.sup.-2 ions by electrochemical charge transfer.
The operating range for the current density of a membrane-type cell is from about 0.01 to about 5.0 kiloamperes per square meter (kA/m.sup.2), with current densities from about 0.01 to about 1.0 kA/m.sup.2 being preferred. The cell potential can range from about 1.5 to about 10 volts, with the preferred range of cell voltage being from about 1.5 to about 4.0 volts. The most preferred ranges for these parameters are from about 1.5 to about 3.5 volts and from about 0.03 to about 0.5 kA/m.sup.2.
With the anolyte being composed of an aqueous solution of sodium hydroxide and a sodium halide salt, the preferable anode to membrane gap distance is in the range from 0 to about 1 inch, and the preferable cathode to membrane gap distance is in the range from about 0 to about 1/2 inch. The current efficiency may be optimized by the employment of an anolyte pH of about 14. The pH may be adjusted by periodic addition of sodium hydroxide to the anolyte solution during electrolysis.
The operating temperature of a membrane cell is in the range from about 10.degree. C. to about 80.degree. C. with an operating temperature in the range of about 20.degree. C. to about 60.degree. C. and from about 35.degree. C. to above 50.degree. C. being most preferred for fastest reaction with minimum product degradation for highest yields.
The operating pressure of the cell is essentially atmospheric. However, sub- or superatmospheric pressure may be used, if desired.
Sodium ferrate may be made in concentrations in the aqueous sodium hydroxide solution which range from trace amounts of about 0.001% to about 1.4% by weight of the anolyte. However, at the higher concentrations, sodium ferrate might begin to precipitate or crystallize out of the anolyte solution and collect in the bottom of the anolyte chamber. The preferred sodium ferrate concentrations are generally in the range from about 0.1% to about 1.0% by weight of the anolyte.
It is not certain exactly how sodium ferrate is produced by the electrolysis process. However, without being bound by a theory, it is thought that the ferric ion source in either the iron anode or iron salt in the anolyte, or their combination, is converted by electrolysis, or by bulk reaction with OH.sup.- ions, respectively, into ferric oxy-hydroxide complexes [e.g., Fe.sub.x O.sub.y .multidot.nH.sub.2 O where n is at least one]. These complexes are next converted electrochemically in the presence of the halide ion to ferrate ions, which combines with Na.sup.+ ions to form sodium ferrate. This theory is illustrated by equations (1) and (2) wherein the ferric ion source is metallic Fe (such as iron anode) or ferric chloride (such as added to the anolyte) and chloride ion is also present: ##EQU1##
The main advantages of the use of a membrane-type electrolysis cell are the greatly increased current efficiency and lower power consumption. This is due to the elimination of two effects:
(a) electrochemical reduction of the ferrate ion at the cathode; and
(b) chemical reduction of the ferrate ion by molecular hydrogen made at the cathode as illustrated in equation (3):
2FeO.sub.4.sup..dbd. +5H.sub.2 .fwdarw.Fe.sub.2 O.sub.3 +5H.sub.2 O (3)
Another advantage of the present invention is that the hydrogen gas discharged from the catholyte chamber is isolated from any oxygen gas produced in the anolyte chamber by the competing reaction of H.sub.2 O electrolysis in the anolyte. Because of this separation of chambers, the danger of forming explosive mixtures of hydrogen and residual oxygen gas is thereby minimized. Thus, the process of this invention eliminates the need for an inert gas purge such as would be required in an undivided or diaphragm cell.
8. RECOVERY OF SODIUM FERRATE FROM ANOLYTE CHAMBER
Upon the formation of a suitable amount of sodium ferrate in anolyte chamber, the sodium ferrate product is then preferably recovered by removing the anolyte from the anolyte chamber. The sodium ferrate/sodium hydroxide anolyte (which is still in the presence of a stabilizing proportion of at least one sodium halide salt) is chilled to a temperature from about 5.degree. C. to about 18.degree. C. and then subjected to conventional solid/liquid separation technique (e.g., centrifugal filtration) to remove the stabilized solid sodium ferrate from liquid sodium hydroxide solution. This solid product is stable and has good shipping and storage properties.
After the solid product is removed, the filtrate may be recycled back to the anolyte chamber.
If filtration is the technique employed for separating the solid sodium ferrate product from the sodium hydroxide solution, a filter aid may be used to increase the filtering efficiency. Of course, the present invention intends to encompass other solid/liquid separation techniques besides filtration. Accordingly, this invention should not be limited to any particular steps or step for recovering the stabilizing sodium ferrate product from the anolyte chamber.
If the operating temperature of the cell is relatively low, it may be possible that sodium ferrate will precipitate out of the anolyte without further cooling. In that situation, more complicated recovery procedures will be required.
In any event, the separated solid and stabilized sodium ferrate product is then dried, preferably after a washing operation to dissolve and remove any sodium hydroxide still attached to the product. The dried product is a purple powder.
An alcohol extraction agent may be employed to wash and remove the water and at least a portion of the NaOH, KOH and halide salts from the precipitated and separated potassium ferrate product. This may be done in any conventional leaching extraction equipment. The alcohol, salt and water mixture may be then flash distilled to separate a substantially anhydrous alcohol vapor stream from an aqueous sodium hydroxide residue. The alcohol stream may be recycled back to the leaching step so that the amount of alcohol continuously added to the process may be minimized. Further, the aqueous residue may be utilized as makeup for the anolyte solution in the cell.
The preferred alcohols for extraction of sodium hydroxide and water from potassium ferrate are low-molecular weight secondary alcohols; specifically, isopropyl or sec-butyl alcohols, or mixtures thereof. Methanol and ethanol and other related primary alcohols are oxidized quickly at room temperature by sodium and potassium ferrate. Alcohols having higher molecular weights than the first-named alcohols have very low sodium hydroxide solubilities which make them poor extraction agents.
Continuous extraction may be carried out under vacuum to avoid filtration and air exposure. This will improve the storage stability of the alkaline earth metal ferrate product.
If an alcohol is utilized to leach the separated solids, it is preferred that the weight ratio of alcohol, in the case of isopropyl alcohol, to the total separated solids is from about 1:1 to about 500:1. More preferably, this weight ratio is from about 2:1 to about 120:1. In general, the weight ratio of alcohol, in the case of isopropyl alcohol, to Na.sub.2 FeO.sub.4 in the solids is preferably about 10:1 to about 10,000:1. More preferably, this weight ratio ranges from about 100:1 to about 500:1. If other alcohols are used, generally the same ratios are employed.
It should be realized that these extraction weight ratios are based on single contact extractions with no extractant or raffinate recycle. Much less alcohol overall is used if the alcohol is recovered from the filtrate and recycled.
9. OTHER PREFERRED EMBODIMENTS AND UTILITY
In another preferred operation, the membrane cell contains means to recycle the sodium hydroxide solution used in the catholyte chamber to the anolyte chamber where it is employed as part of the anolyte.
As mentioned above, the anolyte, after removal from the cell, is treated to separate the sodium ferrate salt from the sodium hydroxide solution and then the sodium hydroxide solution is recycled back to the anolyte chamber.
In a second preferred operation, both recycle streams of these preferred operations are combined together and recycled back to the anolyte chamber. Any conventional means for pumping and the like may be used for these recycle operations.
Another preferred embodiment is to pretreat any ferric salts used as the ferric ion source in the anolyte chamber in order to convert any ferrous (Fe.sup.+2) impurities therein to ferric (Fe.sup.+3) ions. Such pretreatment may be carried out by either heating the ferric salt themselves or the anolyte containing these to about 70.degree. C. t610000000000000000000000000000000000000000000000000000000000000000

Number	Name	Date
669441	Frasch	Mar 1901
2275223	Hardoen	Mar 1942
2455696	Mosesman	Dec 1948
2758090	Mills et al.	Aug 1956
2835553	Harrison et al.	May 1958
2967807	Osborne et al.	Jan 1961
3632802	De Miller et al.	Jan 1972
3904496	Harke et al.	Sep 1975
4036714	Spitzer	Jul 1977
4201637	Peterson	May 1980

Process for the electrochemical production of sodium ferrate [Fe(VI)]

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Entry
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