Abstract: The invention provides a process for preparing a crystalline vanadyl sulphate/vanadous sulphate material, the process including the steps of providing a mixture of vanadium pentoxide (V2O5) and vanadium trioxide (V2O3); adding to the mixture a predetermined volume of a sulphuric acid solution to produce a powder slurry; and heating the slurry at a temperature and for a time sufficient to form a crystalline vanadyl sulphate/vanadous sulphate material. The invention extends to a process for preparing an electrolyte from such a crystalline vanadyl/vanadous sulphate material, including the steps of dissolving the crystalline material in boiling water and adding a stabilising agent, typically phosphoric acid, to stabilise the electrolyte.

Abstract: A process for producing a vanadyl sulphate solution (VOSO4) comprises forming a suspension of vanadium trioxide (V2O3) in a sulphuric acid solution and contacting the V2O3 suspension with a strong oxidising agent under controlled conditions to produce the VOSO4 solution. A preferred oxidising agent is hydrogen peroxide, which is added very slowly to the V2O3 suspension due to the violent nature of the reaction.

Abstract: A process for preparing a reconstituted vanadyl sulphate/vanadous sulphate solution for use as an electrolyte in a vanadium redox battery is disclosed. The process includes preparing a starting material including a vanadyl sulphate/vanadous sulphate solution, evaporating the starting material by applying heat to form vanadyl sulphate/vanadous sulphate crystals, and re-dissolving the vanadyl sulphate/vanadous sulphate crystals with a volume of de-ionized water to form a reconstituted vanadyl sulphate/vanadous sulphate solution having substantially the same chemical composition at the starting material. A process for preparing a vanadyl sulphate/vanadous sulphate starting material from a vanadium bearing ore material, particularly a titaniferous magnetite ore material is also disclosed.

Abstract: A process for the crystallization and re-establishment of a vanadyl/vanadous sulphate solution to its original chemical composition, and the use of a vanadium bearing ore material, in particular a titaniferous magnetite ore material, for producing the vanadyl/vanadous sulphate solution or crystals, particularly for use as an electrolyte in a vanadium redox battery.