This study focuses on the removal of metallic impurities such as Fe͑II͒, Fe͑III͒, and Cr͑III͒ from spent plating solutions via electrolytic separation. A two-chamber electrolytic cell separated by a ceramic membrane was used. The choice of the catholyte affected the removal rate of iron. As compared to chromic acid, sodium monophosphate was found to provide the maximum removal rates for iron ͑5.89 mM h Ϫ1 ͒. The main modes of mass transfer across the ceramic membrane were diffusion driven by concentration gradient and cation migration. Subsequent removal of the impurity from the cathode compartment was achieved via electrodeposition and precipitation as sludge. The iron removal increased 69% when the applied potential was increased from 5 to 7.5 V, while an increase in temperature from 45 to 55°C resulted in a 33% decrease in impurity removal. In addition, regeneration of Cr͑VI͒ occurred simultaneously due to the anodic oxidation of Cr͑III͒. The rate of regeneration was found to depend on the applied potential and the concentration of the Cr͑III͒ species in the anode chamber. A mathematical model describing the process was developed and validated. Modeling results indicate that a greater iron removal could be obtained if the impurities transported to the catholyte are deposited or precipitated at a faster rate. The estimated mobilities, diffusivities are in good agreement with those reported in the literature.Hexavalent ͑hard͒ chromium plating solutions consist of chromate anions (Cr x O y 2Ϫ ) as a source of chromium. During electrodeposition, the electrolyte is contaminated with metallic impurities such as trivalent chromium ͓Cr͑III͔͒, iron ͓Fe͑II͒ and Fe͑III͔͒, nickel ͓Ni͑II͔͒, and copper ͓Cu͑II͔͒ due to the incomplete reduction of polychromates and reverse etching of the metal substrates into the corrosive chromic acid solution. 1 Depending upon the concentration, the impurities in chromium plating baths affect the efficiency of the plating process and the quality of deposits produced. 2,3 Despite its high chromate content, the electrolyte needs to be discarded or processed to recover the metal impurities usually by high cost smelting operations. It is, therefore, desirable to regenerate the waste chromium liquors by continuously removing the impurities from the plating baths.The most commonly used regeneration technique is electrolytic separation. In this process, a two-compartment electrolytic cell divided by a cation exchange or a porous ceramic membrane for the separation of the purified and contaminated solution is used. 4 Upon the application of electric voltage across the electrodes, metal cations in the contaminated solution migrate from the anode to the cathode compartment through the porous membrane where they are concentrated. Subsequent precipitation as sludge or electrodeposition occurs in the cathode compartment depending on the applied potential and the pH of the catholyte. This technique is known to simultaneously remove contaminants such as Cu͑II͒, Ni͑II͒, and Fe͑III͒, and oxidize Cr͑III͒ to ...