AbstractFerrate (Fe(VI)) is of great interest in energy storage solutions, organic synthesis, and wastewater treatment due to its decent oxidation potential and non‐toxic end‐product formation, making it a green oxidizer. The electrochemical generation of ferrate in NaOH at current densities of j ≥ 100 mA cm−2 is presented using low‐cost sacrificial iron anodes, mild steel, and spheroidal graphite cast iron (ductile iron). Under optimized reaction parameters with 40 wt.% (14 m) NaOH and a ZrO2‐based diaphragm, spheroidal graphite cast iron shows no signs of passivation in 5 h experiments even at j = 150 mA cm−2. The results are used in a novel electrolysis cell with a combined geometric anode surface area of 230 cm2, incorporated in a mini‐plant suitable for continuous synthesis. This setup produces a peak ferrate concentration of 10.1 g L−1 (84 mm) after 5 h in 1.6 L anolyte volume, resulting in a total ferrate mass of 16.2 g. Optimal electrolysis temperatures are between 35 and 50 °C. The highest current efficiency is 63.0%, and the lowest specific energy consumption is 9.2 kWh kg−1 ferrate. The presented work is an essential step toward the continuous electrochemical synthesis of ferrate using sacrificial anodes under basic conditions.
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