Abstract: An electrochemical cell is provided which has a liquid anode. Preferably the liquid anode comprises molten salt and a fuel, which preferably has a significant elemental carbon content. The supply of fuel is preferably continuously replenished in the anode. Where the fuel contains or pyrolizes to elemental carbon, the reaction C+2O2??CO2+4e? may occur at the anode. The electrochemical cell preferably has a solid electrolyte, which may be yttrium stabilized zirconia (YSZ). The electrolyte is connected to a solid or liquid cathode, which is given a supply of an oxidizer such as air. An ion such as O2? passes through the electrolyte. If O2? passes through the electrolyte from the anode to the cathode, a possible reaction at the cathode may be O2+4e??2O2?. The electrochemical cell of the invention is preferably operated as a fuel cell, consuming fuel and producing electrical current.

Abstract: In one embodiment, the present disclosure relates generally to a method for thermally decomposing a complex precursor salt. In one embodiment, the method includes heating a salt in a reactor until a molten salt is formed, adding the complex precursor salt to the molten salt in the reactor and removing a volatile precursor halide formed from thermal decomposition of the complex precursor salt from the reactor.

Abstract: In one embodiment, the present disclosure relates generally to a method for recovering an element from a mixture of the element with an ionic halide. In one embodiment, the method includes treating the mixture of the element and the ionic halide with an acidic solution to dissolve the ionic halide, wherein the acidic solution comprises water and an acid and has a pH of less than 1.0 and removing the element from an aqueous solution that results after the treating step.

Abstract: Aspects of the invention include methods for depositing silicon on a substrate. In certain embodiments, the methods include exposing a substrate containing silicon to a halogenated silane in a manner sufficient to deposit the silicon on the substrate. In certain embodiments, the method includes providing a substrate, one or more sources of gas, and a reaction vessel that is in fluid communication with the substrate and the one or more sources of gas. In certain embodiments, the substrate is a low or metallurgical grade silicon which may be subjected to a purification process. In certain embodiments, the reaction vessel is a particle bed reaction vessel that includes a moving bed, such as a fluidized bed which contains silicon and the gas includes a halide.

Abstract: Aspects of the invention include methods for producing purified semiconductor or metallic materials. In one embodiment, the methods include admixing a particulate composition of a material, for instance, a metal, with a metal halide to produce a metal-metal halide admixture. The admixture is then heated to a temperature that is above the material's melting point in a container that is chemically and physically stable at that temperature. The molten admixture is allowed to segregate into a lower of the material and an layer of the metal halide and cooled. The metal halide is then separated from the material and a purified semiconductor or metallic material is thereby produced. Also provided are purified material crystals, shaped ingots and/or taper, sheet, or ribbons produced by such methods, as well as the silicon chips and solar panels in which such products are employed.

Abstract: In one embodiment, the present invention relates generally to a multi-stage system for performing melt coalescence and separation, the multi-stage system. In one embodiment, the multi-stage system includes a first container for mixing a powder with a salt, the first container having an opening, a heating means coupled to the first container for heating the first container and a second container coupled to the first container.

Abstract: In one embodiment, the present invention relates generally to a method for reutilizing ionic halides in a production of an elemental material. In one embodiment, the method includes reacting a mixture of an ionic halide, at least one of: an oxide, suboxide or an oxyhalide of an element to be produced and an aqueous acid solution at moderate temperature to form a complex precursor salt and a salt, forming a precursor halide from the complex precursor salt, reducing the precursor halide into the element to be produced and the ionic halide and returning the ionic halide into the mixture of the reacting step.

Abstract: The present invention relates generally to a liquid injector for silicon production. In one embodiment, the injector includes a tube having at least one opening at a first end of said tube, a moveable sealing means disposed inside the tube for sealing the at least one opening and a heating means coupled to the tube for controlling a temperature of a liquid exiting the tube through the at least one opening.

Abstract: The present invention relates generally to production of photoelectric grade films or cells from semiconductor powders or dust. In one embodiment, the present invention provides a method for producing a photoelectric grade film from a semiconductor powder. The method includes providing a substrate, coating the substrate with a layer of the semiconductor powder and moving the substrate with the layer of the semiconductor powder under an energy source at a predefined rate, wherein the predefined rate is sufficient to melt the semiconductor powder by the energy source and to cool the substrate such that substantially all impurities are moved to an edge of the substrate.

Abstract: The present invention relates generally to production of a fluoride gas and equivalents thereof, and fluorine-doped sodium silicate glass, glass ceramics, vitro ceramics and equivalents thereof. In one embodiment, the method includes providing a salt and an oxide in a reactor, heating the reactor to produce a vapor and the vitro ceramic and removing the vapor.

Abstract: A moving bed reactor system is provided. The system comprises at least one gas inlet, a distributor, a temperature control, a plurality of electrodes, and a spark control circuit. The spark control circuit drives the electrodes and generates a multi-arc discharge when the system is loaded with particles and a gas at approximately atmospheric pressure or greater is being pumped through the system. The multi-arc discharge is useful to create activated species which may improve the rate of a chemical reaction taking place in the moving bed reactor system.

Abstract: Aspects of the invention include methods for depositing silicon on a substrate. In certain embodiments, the methods include exposing a substrate containing silicon to a halogenated silane in a manner sufficient to deposit the silicon on the substrate. In certain embodiments, the method includes providing a substrate, one or more sources of gas, and a reaction vessel that is in fluid communication with the substrate and the one or more sources of gas. In certain embodiments, the substrate is a low or metallurgical grade silicon which may be subjected to a purification process. In certain embodiments, the reaction vessel is a particle bed reaction vessel that includes a moving bed, such as a fluidized bed which contains silicon and the gas includes a halide.

Abstract: The present invention is generally directed towards a method for producing a solid metallic composition by reacting a gaseous metal halide with a reducing agent are described. In one embodiment, the method includes reacting a gaseous metal halide with a reducing agent in a manner effective to form a nonsolid reaction product, wherein the metal halide has the formula MXi, in which M is a metal selected from a transition metal of the periodic table, aluminum, silicon, boron, and combinations thereof, X is a halogen, i is greater than 0, and the reducing agent is a gaseous reducing agent selected from hydrogen and a compound that releases hydrogen, and combinations thereof; and solidifying the reaction product, thereby forming a metallic composition comprising M that is substantially free from halides. The invention may be used to produce high-purity metallic compositions, particularly titanium particles and alloys thereof for use in powder metallurgy applications.

Abstract: Aspects of the invention include methods for producing purified semiconductor or metallic materials. In one embodiment, the methods include admixing a particulate composition of a material, for instance, a metal, with a metal halide to produce a metal-metal halide admixture. The admixture is then heated to a temperature that is above the material's melting point in a container that is chemically and physically stable at that temperature. The molten admixture is allowed to segregate into a lower of the material and an layer of the metal halide and cooled. The metal halide is then separated from the material and a purified semiconductor or metallic material is thereby produced. Also provided are purified material crystals, shaped ingots and/or taper, sheet, or ribbons produced by such methods, as well as the silicon chips and solar panels in which such products are employed.

Abstract: An electrochemical cell is provided which has a liquid anode. Preferably the liquid anode comprises molten salt and a fuel, which preferably has a significant elemental carbon content. The supply of fuel is preferably continuously replenished in the anode. Where the fuel contains or pyrolizes to elemental carbon, the reaction C+2O2??CO2+4e? may occur at the anode. The electrochemical cell preferably has a solid electrolyte, which may be yttrium stabilized zirconia (YSZ). The electrolyte is connected to a solid or liquid cathode, which is given a supply of an oxidizer such as air. An ion such as O2? passes through the electrolyte. If O2? passes through the electrolyte from the anode to the cathode, a possible reaction at the cathode may be O2+4e??2O2?. The electrochemical cell of the invention is preferably operated as a fuel cell, consuming fuel and producing electrical current.

Abstract: An electrochemical cell is provided which has a liquid anode. Preferably the liquid anode comprises molten salt and a fuel, which preferably has a significant elemental carbon content. The supply of fuel is preferably continuously replenished in the anode. Where the fuel contains or pyrolizes to elemental carbon, the reaction C+2O2??CO2+4e? may occur at the anode. The electrochemical cell preferably has a solid electrolyte, which may be yttrium stabilized zirconia (YSZ). The electrolyte is connected to a solid or liquid cathode, which is given a supply of an oxidizer such as air. An ion such as O2? passes through the electrolyte. If O2? passes through the electrolyte from the anode to the cathode, a possible reaction at the cathode may be O2+4e??2O2?. The electrochemical cell of the invention is preferably operated as a fuel cell, consuming fuel and producing electrical current.

Abstract: Methods and apparatuses for producing a solid metallic composition by reacting a gaseous metal halide with a reducing agent are described. The method generally includes reacting a gaseous metal halide with a reducing agent in a manner effective to form a nonsolid reaction product, wherein the metal halide has the formula MXi, in which M is a metal selected from a transition metal of the periodic table, aluminum, silicon, boron, and combinations thereof, X is a halogen, i is greater than 0, and the reducing agent is a gaseous reducing agent selected from hydrogen and a compound that releases hydrogen, and combinations thereof; and solidifying the reaction product, thereby forming a metallic composition comprising M that is substantially free from halides.

Abstract: A condensing heat exchanger structure in contact with a combustion environment and which structure includes a ferrous substrate is provided with a corrosion resistant diffusion coating applied to the ferrous substrate via a fluidized bed application. Also provided is a method for improving the corrosion resistance of a condensing heat exchanger structure which includes a ferrous substrate and a surface portion at least partially exposed to a combustion product-containing environment. In such method, a corrosion resistant diffusion coating is applied onto the ferrous substrate via a fluidized bed application.

Abstract: A condensing heat exchanger structure in contact with a combustion environment and which structure includes a ferrous substrate is provided with a corrosion resistant diffusion coating applied to the ferrous substrate via a fluidized bed application. Also provided is a method for improving the corrosion resistance of a condensing heat exchanger structure which includes a ferrous substrate and a surface portion at least partially exposed to a combustion product-containing environment. In such method, a corrosion resistant diffusion coating is applied onto the ferrous substrate via a fluidized bed application.

Abstract: Fluidized bed reactors having centrally positioned heating means, as well as methods for their use, are provided. The subject reactors comprise a centrally positioned heating means (e.g. a susceptor rod) that, during operation, is at least partially immersed in a fluidized bed of particles. The subject reactors are further characterized in that, during use, a temperature gradient is produced within the reactor. The subject reactors find use in a variety of applications.