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Journal of Industrial and Engineering Chemistry 18 (2012) 1931–1936

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Journal of Industrial and Engineering Chemistry


journal homepage: www.elsevier.com/locate/jiec

A comparative study of iron-containing anodes and their influence on


electrochemical synthesis of ferrate(VI)
Ljiljana Nikolić-Bujanović a,*, Milan Čekerevac a,1, Mirjana Vojinović-Miloradov b,2,
Anja Jokić c,3, Miloš Simičić a,1
a
IHIS Techno-experts d.o.o., Research and Development Center, Batajnicki put 23, Belgrade, Serbia
b
Faculty of Technical Sciences, University of Novi Sad, Novi Sad, Serbia
c
Faculty of Sciences, University of Priština, Kosovska Mitrovica, Serbia

A R T I C L E I N F O A B S T R A C T

Article history: The influence of anode composition and temperature on the anode electrochemical activity and
Received 7 February 2012 subsequent ferrate(VI) production in 10 M NaOH solution has been studied. Results obtained from the
Accepted 16 May 2012 pure iron, gray and white cast iron were compared to establish the most promising anode in terms of
Available online 24 May 2012
ferrate production efficiency. The cyclic voltammetry measurements associated with the potentiody-
namic polarization results induce that the pure iron has the lowest electrochemical activity. Presence of
Keywords: silicon in outer layer was confirmed by X-ray diffraction of reaction products on WCI and GCI in the form
Ferrate(VI)
of iron(II)iron(III) silicon oxide–hydroxide.
Electrochemical synthesis
Cast iron
ß 2012 The Korean Society of Industrial and Engineering Chemistry. Published by Elsevier B.V. All rights
reserved.

1. Introduction process of chemical synthesis of ferrate(VI) must be conducted


under strictly controlled conditions in consideration of the danger
Ferrate(VI) salts have a wide range of potential applications due of poisoning and explosion. The additional problem arises in
to their high efficient oxidation performance. In the area of separation and purification of obtained ferrate(VI) because there
environmental application, ferrate has been considered for water are, as the associated primes, always present toxic oxy-chlorine
and wastewater treatment because of its environmental friendly compounds, which contaminate environment, especially water
properties without a hazard compounds forming such as chlorine [7,8]. Ferrate obtained by electrochemical synthesis has many
or bromine carcinogenic organic pollutants [1–3]. Due to fact that advantages compared to chemically synthesized ferrate [8–11],
Fe(III), generated during the oxidation by ferrate, exhibits valuable such as: simplicity, lower consumption of chemicals, non-toxic
coagulating properties, it makes an additional contribution to products and exceptional purity of obtained ferrate. Method of
water treatment processes. Oxidation of a variety of pollutants in electrochemical synthesis of ferrates has been recently developed
industrial wastewaters by ferrates including inorganic contami- by anodic dissolution of iron in transpassive region in highly
nants, nitrogen-containing pollutants and organosulfur com- alkaline solvents [12,13]. During the anodic dissolution of iron in
pounds are widely investigated in literature [4–6]. transpassive region, the surface of the anode becomes increasingly
Ferrate(VI) can be obtained by chemical or electrochemical covered with iron oxide/hydroxide species. The local disruption of
synthesis: (1) in aqueous solution by oxidation of ferric the passive layer and formation of a porous oxide–hydroxide layer
compounds by hypochlorite in highly alkaline solvents, (2) in enhance ferrate formation at potentials close to the competing
melts, by oxidation of ferric compounds with alkaline peroxides, oxygen evolution. Formed Fe(V) goes through decomposition
and (3) in electrochemical process, by anodic dissolution of iron in forming Fe(III) and Fe(VI). The efficiency of synthesis depends on
strongly alkaline solution (pH > 10) in the transpassive region. The the resistance of the oxide–hydroxide layer to the synthesis
conditions: electrolyte composition, electrode composition and
the temperature at which the synthesis is done. It was reported
* Corresponding author. Tel.: +381 11 3160 772; fax: +381 11 2194 991. that the optimum concentration for the ferrate synthesis is in the
E-mail addresses: mimosa@eunet.rs, ihis@eunet.rs (Lj. Nikolić-Bujanović), range of 10–15 M NaOH [10,14,15]. Through a detailed analysis of
ihis@eunet.rs (M. Čekerevac), miloradov@uns.ac.rs (M. Vojinović-Miloradov), the impact of NaOH, KOH and LiOH at various temperatures (20 8C,
profanjaj@yahoo.com (A. Jokić), ihis@eunet.rs (M. Simičić).
1 30 8C and 40 8C) on the ferrate synthesis, NaOH was shown to be
Tel.: +381 11 3160 772; fax: +381 11 2194 991.
2
Tel.: +381 21 485 2405. the most promising option that provides the highest current yields
3
Tel.: +381 64 6710 398. [16]. This is caused by individual products (FeO42 and its

1226-086X/$ – see front matter ß 2012 The Korean Society of Industrial and Engineering Chemistry. Published by Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.jiec.2012.05.007
1932 L. Nikolić-Bujanović et al. / Journal of Industrial and Engineering Chemistry 18 (2012) 1931–1936

intermediates) solubility within electrolysis process and impact of Cyclic voltammetry and polarization experiments were per-
the individual cations on the structure of surface layers, and their formed using a PC controlled Gamry G300 PC series potentiostat/
protective properties. Importance of the anode material composi- galvanostat. In this work the X-ray diffraction patterns were
tion was recognized in the early works [10,11,14,15]. Carbon conducted by diffractometer ‘‘Ital Structures’’ APD2000 using
content in the anode active material received the most attention, monochromatic Cu-Ka radiation (l = 1.5418 Å) in 0.2 degrees
most likely because carbon is a typical component in iron steps recording and retention of 0.5 s/step.
commonly available materials. The content of carbon in the anode
material has a crucial impact on the anode dissolution process. 3. Results and discussion
There is general agreement here that the presence of carbon
positively influence the anode material dissolution. A detailed 3.1. Voltammetric analysis
description of this phenomenon was given by Bouzek et al.
[10,11,15] who found that only carbon in the form of iron carbide Comparison of anodic cyclic voltammograms of the
(Fe3C) leads to the desired enhancement. However, Lescuras- tested materials (WCI, GCI, Fe) in 10 M NaOH, at different
Darrou et al. [17] claimed that silicon (Si) shows an enhancement temperature conditions is given in Fig. 1. Voltammetric studies
similar to carbon, by suppression of anode surface passivation. of iron behavior in alkaline media exhibit several peaks and
Besides the evident influence of Si presence to process of synthesis shoulders in the potential region of active anodic dissolution
ferrates, and theory that silicon may depress the inhibition of [11,12,20,21]. The anodic current peak a1 corresponds to the active
surface dissolution in the same way as (Fe3C), the mechanism of iron dissolution to Fe2+ according to Eq. (1) within the potential
action has not been explained.
The objective of this work is the optimization of conditions for
electrochemical synthesis of ferrates: composition and structure of
the anode material and temperature conditions. We initially
studied a comparison of the kinetic conditions of dissolving two
materials so far described in literature as the most suitable for the
synthesis of ferrate, white and gray cast iron. The anode of pure
iron served as reference material. The influence of components
present in the anode material (Fe3C and Si), which proved a
decisive influence on the formation and behavior of oxy-hydroxide
layer on the anode was examined.

2. Experimental details

All experiments were carried out in non-deaerated 10 M NaOH


solution (analytical reagent grade). Concentration NaOH was
chosen based on earlier studies of anodic dissolution of iron and its
alloys in alkaline solvents [18,19]. The white cast iron (WCI), gray
cast iron (GCI) and pure iron 99.99% (Fe) were tested as the anode
materials for electrochemical synthesis of ferrate. Their chemical
compositions have been evidenced with optical emission spec-
troscopy and shown in Table 1. All the carbon in white cast iron is
in the form of carbide (Fe3C), while in the gray cast iron is in the
form of graphite.
The surface of electrode processes and products were charac-
terized by different research methods and techniques: polariza-
tion, cyclic voltammetry and X-ray diffraction. Electrochemical
measurements were carried out in a classical three-electrode cell.
The working electrodes were iron-containing anodes previously
polished with very fine (600) grit, and then flushed with distilled
water and ethyl alcohol. The counter electrode was a platinum
gauze and Hg/HgO electrode in a 10 M NaOH solution served as a
reference. The electrolyte temperatures were thermostatically
controlled and fixed at following temperatures: 25 8C, 35 8C, and
55 8C. Working electrodes had the following active areas: WCI-
0.2 cm2, GCI-0.25 cm2 and Fe-0.28 cm2. The same electrodes were
subjected to polarization at constant potential (E = 590 mV vs. Hg/
HgO) for 1 h in order to examine electrode surface layer in the
transpassive region through X-ray diffraction analysis.

Table 1
Composition of cast irons (wt%, balance Fe)a.

Material Composition wt%

C Si Mn P S

WCI 3.25  0.05 1.79  0.09 0.66  0.06 0.29  0.005 0.08  0.006
Fig. 1. Cyclic voltammograms recorded in 10 M NaOH solution at potential scan rate
GCI 3.50  0.05 1.60  0.09 0.50  0.06 0.25  0.005 0.09  0.006
n = 100 mV s1 for anode materials: WCI (- - -), GCI (. . .), and Fe (–) at temperatures
a
Data are presented as mean  standard deviation. 20 8C, 35 8C, and 55 8C.
L. Nikolić-Bujanović et al. / Journal of Industrial and Engineering Chemistry 18 (2012) 1931–1936 1933

region, E(a1) = (1008 mV)–(1000 mV) depends on electrolysis The cathodic peak c2 is associated with the further reduction of
condition and composition of materials [11,20,21]. Fe3+ to Fe2+ ions according to reactions (14) and (15) within the
Peak-a1: potential region, E(c2) = (1080 mV)–(1010 mV) [25,26].
Peak-c2:
Fe þ 2OH ! FeðOHÞ2 þ 2e (1)
Fe3 O4 þ 4H2 O þ 2e ! 3FeðOHÞ2 þ 2OH (14)
In the potential region of peak a1, a simultaneous oxidation
reactions described by Eqs. (2) and (3) occur [22,23]:
Fe3 O4 þ H2 O þ 2e ! 3FeO þ 2OH (15)
 
3Fe þ 8OH ! Fe3 O4 þ 4H2 O þ 8e (2)
The peak c1 corresponds to the reduction of Fe(OH)2 to iron
  by Eq. (16) within the potential region, E(c1) = (1120 mV)–
Fe þ 2OH ! FeO þ H2 O þ 2e (3)
(1180 mV) [11].
The anodic current peak a2 corresponds, to the most probable Peak-c1:
continuous oxidation of Fe(OH)2 to Fe3O4 according to Eq. (4)
FeðOHÞ2 þ 2e ! Fe þ 2OH (16)
within the potential region, E(a2) = (980 mV)–(840 mV) [21].
Peak-a2: The cyclic voltammograms showed typical oxidation and

3FeðOHÞ2 þ 2OH ! Fe3 O4 þ 4H2 O þ 2e 
(4) reduction peaks essentially similar to those previously reported
in the literature but some points must be emphasized from Fig. 1.
At the potential of peak a2, whose shape and charge value again Firstly, current densities corresponding to peaks of anodic
depends on conditions applied, the reaction (4) could be assumed dissolution of WCI are one order of magnitude larger than for
to run in parallel with the reaction (5) [22]. GCI and pure iron at 20 8C. The situation has significantly changed
with increasing temperature, especially for GCI. With increasing
Fe3 O4 þ 2H2 O ! 3FeOOH þ Hþ þ e (5)
temperature the activity of OH ions increases which favors the
The anodic current peak a3 corresponds to the anodic reaction in depassivation process of anode [16]. Secondly, the peaks denoted
Eqs. (6)–(8) [21]. The solid oxides and hydroxides formed on the by a1 and a2 representing transition of Fe to Fe2+ are overlapping
surface of the anode are dissolved in the interaction with the due to the simultaneous reactions at higher temperatures. Finally,
hydroxyl ions within the potential region E(a3) = (644 mV)– the cathodic peak c4 that follows anodic peak a4, which appears
(580 mV) causing the iron surface to break down. only as a shoulder on CV curve, has been attributed to the reduction
Peak-a3: Fe(VI) to Fe(III) [9,11] and considered as a measure of the amount
of Fe(VI) species reminded in oxide layer. This is quite prominent
FeðOHÞ2 þ 2OH ! FeO2 2 þ 2H2 O (6)
for the WCI anode proving the high efficiency of WCI as an anode
material in the ferrate(VI) synthesis process at 20 8C. On the other
Fe3 O4 þ 4OH ! 3FeO2  þ 2H2 O þ e (7)
hand, the associated charge for GCI is very small and coincided
with the cathodic peak c4 for pure iron. However, at elevated
Fe2 O3 þ 2OH ! 2FeO2  þ H2 O (8)
temperatures cathodic peak c4 for GCI increases and even exceeds
After the active dissolution region, a broad plateau follows the value for the WCI anode at 55 8C.
passivity and subsequently an intensive oxygen evolution reaction
overlapping the transpassive iron dissolution, including ferrate(VI) 3.2. The XRD analysis
formation [21]. Noteworthy is that shoulder attached to the
current peak a4, which represents ferrate(VI) formation, is slightly Figs. 2 and 3 illustrate the XRD patterns of WCI and GCI
visible without curves magnification because it is overlapped to a electrodes subjected to polarization at constant potential
significant degree by the oxygen evolution. The last anodic peak a4, (E = 590 mV vs. Hg/HgO) for 1 h in 10 M NaOH solution at room
within the potential region E(a4) = 500–700 mV, which cannot temperature in order to examine electrode surface layer in the
always be observed, is identified to correspond to the reactions in transpassive region. XRD analysis of both anodes show that
Eqs. (9)–(11) [20]. The reaction (9) is followed by the subsequent consists of amorphous phase and trace of crystalline phase
disproportionation reaction described by Eq. (10). dispersed in amorphous matrix. All diffraction peaks of the
Peak-a4: samples can be indexed to Fe3(Si1.32Fe0.68)O5(OH)4, and the most

FeOOH þ 3OH ! FeO3 2 þ 2H2 O þ e (9)

3FeO3 2 þ H2 O ! 2FeO2  þ FeO4 2 þ 2OH (10)

2OH ! H2 O þ ð1=2ÞO2 þ 2e (11)


During the negative scan of the potential, the voltammograms
exhibit one shoulder and three different peaks.The cathodic
current shoulder c4 corresponds to the reduction of ferrate(VI)
ions to Fe3+ by Eq. (12) within the potential region,
E(c4) = (100 mV)–(300 mV) [9,24].
Peak-c4:

FeO4 2 þ 2H2 O þ 3e ! 4OH þ FeO2  (12)

The cathodic peak c3 is observed and attributed to reduction


reaction of Fe3+ to Fe2+ ions according to Eq. (13) within the
potential region, E(c3) = (890 mV)–(900 mV) [25,26].
Peak-c3:
FeOOH þ H2 O þ e ! FeðOHÞ2 þ OH (13) Fig. 2. XRD surface analysis of WCI anode.
1934 L. Nikolić-Bujanović et al. / Journal of Industrial and Engineering Chemistry 18 (2012) 1931–1936

Fig. 3. XRD surface analysis of GCI anode.

intensive peaks at 2u  458 may be assigned to FexSiy. No


diffraction peaks related to ferric oxy-hydroxide can be detected,
indicating its amorphous nature.

3.3. Anodic polarization curves

Potentiodynamic studies of WCI, GCI and Fe (Fig. 4) were


performed to evaluate the effect of temperature on the general
passivation behavior of anode materials. Potentiodynamic curves
were measured with a potential sweep rate of 2 mV s1 in 10 M
NaOH solution at the room temperature. The potential was swept
from the corrosion potential to the oxygen evolution potential. It is
noticeable that the most negative electrode potential at which a
passivating film is electrochemically formed for all anode materials
is very close to 600 mV and that overpotential values for oxygen
evolution reaction is about 100 mV lower for the WCI and the GCI
anode compared to Fe, especially at elevated temperatures. Also,
the corrosion potential values for Fe were more negative than
those obtained for GCI and WCI. With respect to the passive
behavior, the three studied materials exhibited a similar passive
behavior at all temperatures. Passivation current densities of all
the materials represented almost stable current density values
during the whole passivation range. The current density at the
beginning of passivation is different for different anode materials:
for WCI 0.9 mA cm2, GCI 0.45 mA cm2 and Fe 0.045 mA cm2, at
20 8C. The average current density in passive region is also different
for different anode materials: for WCI 0.7 mA cm2, GCI
0.2 mA cm2 and Fe 0.03 mA cm2, at 20 8C. Fig. 4 clearly shows
that the passivation current density is significantly increased with Fig. 4. Anodic polarization curves for anode materials Fe, GCI, and WCI in 10 M
an increase in temperature, especially for GCI it is several times NaOH solution at temperatures: 20 8C (–), 35 8C (. . .), 55 8C (- - -).
enlarged. The reasons for this behavior are the different properties
(porosity, compactness etc.) of the oxy-hydroxide layer covering
the electrode surface [20,21,27]. The formation of anodic films is a and chemical composition (e.g. variations in the water content of
complex which are little understood in spite of its great practical hydroxide films, or the oxidation of the cation to a higher valency
significance. Pore-free and porous films may be formed together in state) may also change.
a layer-like fashion. It is also a fact that some layer can decline from This complexity was confirmed by activation energies (Ea)
stoichiometry and no sharp transition between the layers exists. analysis from Arrhenius plots. The different influences of
Iron hydroxide Fe(OH)2 forms passive film on iron in alkaline temperature in different potential regions can be interpreted by
solution and Fe3O4 formation preferentially occurs from metallic plotting Arrhenius equation for reaction rates expressed as current
iron at the metal/Fe(OH)2 interface and at the same time the densities at different potentials [27]. Fig. 5 shows the Arrhenius
oxidation of pre-existent Fe(OH)2 to Fe3O4 at the Fe(OH)2/solution plots for a potential in the perfect passive region (0 mV vs. Hg/HgO)
interface. This Fe3O4 layer formed from Fe(OH)2 is subjected to and for ferrate production potential in the transpassive region
oxidation forming FeOOH outer film or a-Fe2O3. Anodic films may (585 mV vs. Hg/HgO). This potential was chosen because the pink-
undergo various secondary transformations which are possibly violet color indicated intensive ferrate(VI) formation and not yet
related to fluctuations of the current and potential. In addition to oxygen evolution evidenced by the bubbling, assuming that
being transformed to porous highly disordered films, their oxygen evolution is negligible. The activation energies (Ea) are
structure (e.g. amorphous films are converted to crystalline ones) derived from the slope of ln j vs. 1/T plots and represents the
L. Nikolić-Bujanović et al. / Journal of Industrial and Engineering Chemistry 18 (2012) 1931–1936 1935

and oxidized. Under such conditions, ions removed from the metal
lattice move across the film almost unhindered, i.e. the activation
energy of ion migration is negligible in the film providing the
highest current yields for the desired electrode reaction. On the
other hand, comparing results for GCI and Fe, the inner film (barrier
layer) of Fe3O4 oxidize to a smaller intensity and becomes thicker
in the presence of silicate than in absence of silicate [30]. During
thickening of the film, the physical properties (specific volume,
elasticity, thermal expansion, etc.) of the metal oxide (or any other
insoluble oxidation product of the metal) different from those of
the metal will result in mechanical strain. It is plausible that GCI
forms a thick compact inner layer causing the higher activation
energy and a stronger temperature dependency of current density.
The most interesting results of this study can be drawn from the
activation energies (Ea) for investigated anode materials at the
ferrate production potential. WCI and GCI presented almost the
same values of activation energy at the ferrate production
potential (Fig. 5). It probably means that the mechanism of the
corresponding reactions processes is the same and electrochemical
reaction described by Eq. (9) and subsequent disproportionation
reaction described by Eq. (10) are strongly affected by morphology
and composition of the oxy-hydroxide layer. These similarities in
activation energies may be attributed to a gradual silicon
incorporation in the outer film which may modify the film
composition and structure of oxy-hydroxide in both silicon-rich
materials. This results are in agreement with a results demon-
strated by X-rays diffraction of reaction products on WCI and GCI in
form of the iron(II)iron(III) silicon oxide–hydroxide.

4. Conclusion

The cyclic voltammetry measurements associated with the


potentiodynamic polarization results induce that the Fe has the
lowest electrochemical activity. A current densities corresponding
to peaks of anodic dissolution of WCI are one order of magnitude
larger than for GCI and Fe at 20 8C. The situation has significantly
changed with increasing temperature, especially for GCI.
The conjugated cathodic peak attributed to the reduction Fe(VI)
to Fe(III) and considered as a measure of the amount of Fe(VI)
species, is quite prominent for the WCI anode proving the high
efficiency of WCI as an anode material in the ferrate(VI) synthesis
process at 20 8C. On the other hand, the associated charge for GCI is
very small and coincided with the cathodic peak for Fe. However, at
elevated temperatures cathodic peak attributed to the reduction
Fe(VI) to Fe(III) for GCI increases and even exceeds the value for the
WCI anode at 55 8C.
Fig. 5. Arrhenius plots of anode materials: Fe, GCI, and WCI at the potentials 0 mV
(&) and 585 mV (*) vs. Hg/HgO of anodic polarization curves. It has been shown that WCI provides high porosity and multi-
pore an oxy-hydroxide passive layer on the surface of the anode
enabling the anode material to be continuously dissolved and
necessary energy for the anodic polarization process at which
oxidized. It is plausible that GCI forms a thick compact inner layer
formation of the passive film (0 mV vs. Hg/HgO) or ferrate
causing the higher activation energy and a stronger temperature
production occur (585 mV vs. Hg/HgO). The higher activation
dependency of current density.
energy exhibits a stronger temperature dependency of current
The similarities in values of activation energy may be attributed
density. From the slopes of the plots shown in Fig. 5 values for the
to a gradual silicon incorporation in the outer film which may
activation energy of 12.6, 30.6 and 1.9 kJ mol1 in the perfect
modify the film composition and structure of oxy-hydroxide in
passive region, and 17.3, 33.7 and 34.3 kJ mol1 for ferrate
both silicon-rich materials: WCI and GCI. This results are in
production potential in the transpassive region are determined
agreement with the experimental confirmation demonstrated by
for Fe, GCI and WCI respectively.
X-ray diffraction of reaction products on WCI and GCI in form of
The differences in the perfect passive region among the values
iron(II)iron(III) silicon oxide–hydroxide.
given above can be caused by the fact that reactions through inner
barrier films in the passive region are controlled by structure or
chemical composition defects through the passive film at the Acknowledgement
metal/oxide interface. Indeed, it has been shown that WCI contains
carbon in the form of cementite, or iron carbide, provides high This study is supported by the Ministry of Education and
porosity and multi-pore a passive layer on the surface of the anode Science of the Republic of Serbia, through technology development
[27–29] enabling the anode material to be continuously dissolved project TR34025.
1936 L. Nikolić-Bujanović et al. / Journal of Industrial and Engineering Chemistry 18 (2012) 1931–1936

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