Process and system for electrolytically producing an iron-bearing product from iron ore particles

A system for electrolytically producing solid particles of an iron-bearing product from iron ore particles, said system comprising:

• an electrochemical flow reactor provided with an electrochemical cell comprising a cathodic compartment and an anodic compartment separated by a separator, wherein the cathodic compartment houses a cathode at least partially in contact with an alkaline catholyte and the anodic compartment houses an anode at least partially in contact with an alkaline anolyte;
• the alkaline catholyte comprising iron ore particles having a particle size P80 of greater than 20 μm suspended therein;
• a voltage source configured to apply an electrical potential greater than 1.4V between the cathode and the anode in the electrochemical cell and electrolytically reduce the iron ore particles to solid particles of the iron-bearing product suspended in the alkaline solution thereby producing a spent catholyte;
• a separation means in fluid communication with the cathodic compartment to separate the iron-bearing product particles from the spent catholyte and produce a depleted catholyte;
• and,
• a means to introduce said iron ore particles into the depleted catholyte and thereby replenish said catholyte;
• wherein said means is in fluid communication with the cathodic compartment in an arrangement whereby replenished catholyte is re-circulated to the cathodic compartment.