Abstract: The present invention discloses a molten salt ultrasonic cleaning machine. The molten salt ultrasonic cleaning machine includes a tank body, a molten salt heating system, an ultrasonic application system and a stirring system, wherein the tank body is configured to accommodate molten salt and a to-be-cleaned workpiece; the tank body includes a bottom wall, and a side wall arranged circumferentially in a surrounding way; the molten salt heating system is configured to heat the molten salt in the tank body; the ultrasonic application system is configured to apply ultrasonic impact to the to-be-cleaned workpiece in the tank body; and the stirring system includes a stirring rod which is rotatably arranged in the tank body. When the molten salt ultrasonic cleaning machine provided by the present invention cleans a workpiece, the stirring rod rotates to improve the flowability of the molten salt.

Abstract: Certain systems comprise a reactor (e.g., a reduction cell such as an electrolytic cell comprising an anode, a cathode, and an electrolyte) comprising molten metal within a container; and a collection vessel at least partially contained within the container of the reactor, the collection vessel comprising an opening fluidically connected to the container of the reactor. Some systems comprise a reactor; and a collection vessel comprising a first opening fluidically connected to the reactor and a second opening fluidically connected to a source of gas (e.g., inert gas) and to a source of negative pressure.

Abstract: The present invention addresses the problem of providing a technique capable of efficiently and stably providing a method for producing high-purity lanthanum, the method characterized in that: a crude lanthanum oxide starting material having a purity of 2N-3N, excluding gas components, is used; the material is subjected to molten salt electrolysis at a bath temperature of 450-700° C. to produce lanthanum crystals; the lanthanum crystals are subsequently desalted: and electron beam melting is then performed to remove volatile substances. The present invention also addresses the problem of providing a technique capable of efficiently and stably providing high-purity lanthanum, high-purity lanthanum itself, a sputtering target formed from high-purity material lanthanum; and a thin film for metal gates that has high purity lanthanum as the main component.

Abstract: According to one embodiment, a process for producing rare metals includes the steps of: recovering a first-residue solution through a primary target metal extracted by leaching a mineral resource; extracting a perrhenic acid ion contained in the first-residue solution with at least one of an anion exchange resin and a first-organic solvent; back extracting the perrhenic acid ion contained in the anion exchange resin or the first-organic solvent to a first-eluant; and electrolyzing the back extracted first-eluant to collect a rhenium at a cathode.

Abstract: Provided is a method for obtaining a particular metal at high purity, with safety, and at low cost, from a treatment object containing two or more metal elements. The present invention provides a method for producing a metal by molten salt electrolysis, the method including a step of dissolving, in a molten salt, a metal element contained in a treatment object containing two or more metal elements; and a step of depositing or alloying a particular metal present in the molten salt, on one of a pair of electrode members disposed in the molten salt containing the dissolved metal element, by controlling a potential of the electrode members to a predetermined value.

Abstract: The present invention addresses the problem of providing a technique capable of efficiently and stably providing a method for producing high-purity lanthanum, the method characterized in that: a crude lanthanum oxide starting material having a purity of 2N-5N, excluding gas components, is used; the material is subjected to molten salt electrolysis at a bath temperature of 450-700° C. to produce lanthanum crystals; the lanthanum crystals are subsequently desalted: and electron beam melting is then performed to remove volatile substances. The present invention also addresses the problem of providing a technique capable of efficiently and stably providing high-purity lanthanum, high-purity lanthanum itself, a sputtering target formed from high-purity material lanthanum; and a thin film for metal gates that has high purity lanthanum as the main component.

Abstract: According to one embodiment, a process for producing rare metals includes the steps of: recovering a first-residue solution through a primary target metal extracted by leaching a mineral resource; extracting a perrhenic acid ion contained in the first-residue solution with at least one of an anion exchange resin and a first-organic solvent; back extracting the perrhenic acid ion contained in the anion exchange resin or the first-organic solvent to a first-eluant; and electrolyzing the back extracted first-eluant to collect a rhenium at a cathode.

Abstract: In one aspect, the present invention is directed to methods for extracting rare earth metals from ores comprising reduction of rare earth metal oxyfluorides. In another aspect, the invention relates to an apparatus for extracting rare earth metals from ores comprising reduction of rare earth metal oxyfluorides. The methods and apparatuses described herein generate rare earth metals from ores with reduced requisite pre-removal of metal oxides found as natural impurities in ores.

Abstract: A method for recovering at least one rare earth element from a phosphor is presented. The method includes a halogenation step (a) and a reduction step (b). The phosphor is first halogenated in a molten salt to convert at least one rare earth constituent contained therein to a soluble rare earth halide. Then, the rare earth halide in the molten salt can be reduced, to convert the rare earth halide to a rare earth element in its elemental state. A method for individually recovering multiple rare earth elements from a phosphor is also presented.

Abstract: According to one embodiment, a process for producing rare metals includes the steps of: electrolyzing an electrolytic solution to extract a Re oxide at a cathode; recovering the Re oxide, and electrolyzing the Re oxide in a molten salt electrolyte to extract metallic Re; recovering a Nd containing residue solution; treating the Nd containing residue solution to produce Nd oxide; electrolyzing the Nd oxide in a molten salt electrolyte to extract metallic Nd; recovering a Dy containing residue solution; treating the Dy containing residue solution to produce Dy oxide; and electrolyzing the Dy oxide in a molten salt electrolyte to extract metallic Dy.

Abstract: A method of electrochemically reducing a metal oxide to the metal in an electrochemical cell is disclosed along with the cell. Each of the anode and cathode operate at their respective maximum reaction rates. An electrolyte and an anode at which oxygen can be evolved, and a cathode including a metal oxide to be reduced are included as is a third electrode with independent power supplies connecting the anode and the third electrode and the cathode and the third electrode.

Abstract: A low temperature method for reducing and purifying refractory metals, metal compounds, and semi-metals using a catalyst. Using this invention, TiO2 can be reduced directly to Ti metal at room temperature. The catalyst is an ion in an electrolyte that catalyzes the rate of the reduction of a compound MX to M, wherein M is a metal or a semi-metal; MX is a metal compound, a semi-metal compound, or a metal or semi-metal dissolved as an impurity in M; and X is an element chemically combined with or dissolved in M.

Abstract: This invention discloses and claims the low temperature reduction and purification of refractory metals, metal compounds, and semi-metals. The reduction is accomplished using non-aqueous ionic solvents in an electrochemical cell with the metal entity to be reduced. Using this invention, TiO2 is reduced directly to Ti metal at room temperature.

Abstract: A method of removing oxygen from a solid metal, metal compound or semi-metal M1O by electrolysis in a fused salt of M2Y or a mixture of salts, which comprises conducting electrolysis under conditions such that reaction of oxygen rather than M2 deposition occurs at an electrode surface and that oxygen dissolves in the electrolyte M2Y and wherein, M1O is in the form of (sintered) granules or is in the form of a powder which is continuously fed into the fused salt. Also disclosed is a method of producing a metal foam comprising the steps of fabricating a foam-like metal oxide preform, removing oxygen from said foam structured metal oxide preform by electrolysis in a fused salt of M2Y or a mixture of salts, which comprises conducting electrolysis under conditions such that reaction of oxygen rather than M2 deposition occurs at an electrode surface. The method is advantageously applied for the production of titanium from Ti-dioxide.

Abstract: A method of electrochemically reducing a metal oxide to the metal in an electrochemical cell is disclosed along with the cell. Each of the anode and cathode operate at their respective maximum reaction rates. An electrolyte and an anode at which oxygen can be evolved, and a cathode including a metal oxide to be reduced are included as is a third electrode with independent power supplies connecting the anode and the third electrode and the cathode and the third electrode.

Abstract: A method of controlling the direct electrolytic reduction of a metal oxide or mixtures of metal oxides to the corresponding metal or metals. A non-consumable anode and a cathode and a salt electrolyte with a first reference electrode near the non-consumable anode and a second reference electrode near the cathode are used. Oxygen gas is produced and removed from the cell. The anode potential is compared to the first reference electrode to prevent anode dissolution and gas evolution other than oxygen, and the cathode potential is compared to the second reference electrode to prevent production of reductant metal from ions in the electrolyte.

Abstract: An amperometric in situ apparatus and technique for measuring the concentrations and transport properties of easily dissociable oxides in slags is described. The technique consists of a combination of different measurements utilizing an electrolyte to separate a reference-gas compartment from the slag of interest. A method and apparatus for metals extraction is also described which includes a vessel for holding a molten electrolyte, the electrolyte comprising a mobile metallic species and an anionic species having a diffusivity greater than about 10−5 cm2/sec; a cathode and an anode, the cathode in electrical contact with the molten metal electrolyte, the cathode and molten electrolyte separated from the anode by an ionic membrane capable of transporting the anionic species of the electrolyte into the membrane; and a power source for generating a potential between the cathode and the anode.

Abstract: An amperometric in situ apparatus and technique for measuring the concentrations and transport properties of easily dissociable oxides in slags is described. The technique consists of a combination of different measurements utilizing an electrolyte to separate a reference-gas compartment from the slag of interest. A potentiometric measurement (type I) provides information on the thermodynamic properties of the slag; an amperometric measurement (type II) yields information concerning the type and transport properties of dissociable oxides; an electrolysis measurement (type III) determines the concentration of dissociable oxides. A method and apparatus for metals extraction is also described which includes a vessel for holding a molten electrolyte, the electrolyte comprising a mobile metallic species and an anionic species having a diffusivity greater than about 10.sup.-5 cm.sup.

Abstract: A process for producing rare earth metals including the step of electrolyzing a starting material containing rare earth carbonates as main ingredients in a molten salt electrolytic bath containing rare earth fluorides, lithium fluoride, and barium fluoride at a bath temperature of 750 to 950.degree. C. while adjusting an anode potential to an electrolytic potential of fluorides. This method allows production of rare earth metals at a high current density and a high current efficiency, while ensuring prolongation of life time of an electrolytic cell and electrodes by performing the electrolysis at a lower bath temperature, and suppressing generation of toxic fluorine-containing gases.

Abstract: A method of producing neodymium in an electrolytic cell without formation of perfluorinated carbon gases (PFCs), the method comprising the steps of providing an electrolyte in the electrolytic cell and providing an anode in an anode region of the electrolyte and providing a cathode in a cathode region of the electrolytic cell. Dissolving an oxygen-containing neodymium compound in the electrolyte in the anode region and maintaining a more intense electrolyte circulation in the anode region than in the cathode region. Passing an electrolytic current between said anode and said cathode and depositing neodymium metal at the cathode, preventing the formation of perfluorinated carbon gases by limiting anode over voltage.