Abstract: A method of reducing a titanium oxide in a solid state in an electrolytic cell which includes an anode, a cathode formed at least in part from the titanium oxide, and a molten electrolyte which includes cations of a metal that is capable of chemically reducing the cathode titanium oxide, which method includes operating the cell at a potential that is above a potential at which cations of the metal that is capable of chemically reducing the cathode titanium oxide deposit as the metal on the cathode, whereby the metal chemically reduces the cathode titanium oxide, and which method is characterised by refreshing the electrolyte and/or changing the cell potential in later stages of the operation of the cell as required having regard to the reactions occurring in the cell and the concentration of oxygen in the titanium oxide in the cell in order to produce high purity titanium.

Abstract: A method of reducing a titanium oxide in a solid state in an electrolytic cell which includes an anode, a cathode formed at least in part from the titanium oxide, and a molten electrolyte which includes cations of a metal that is capable of chemically reducing the cathode titanium oxide, which method includes operating the cell at a potential that is above a potential at which cations of the metal that is capable of chemically reducing the cathode titanium oxide deposit as the metal on the cathode, whereby the metal chemically reduces the cathode titanium oxide, and which method is characterized by refreshing the electrolyte and/or changing the cell potential in later stages of the operation of the cell as required having regard to the reactions occurring in the cell and the concentration of oxygen in the titanium oxide in the cell in order to produce high purity titanium.

Abstract: An electrochemical cell for electrochemical reduction of a metal oxide in a solid state is disclosed. The cell includes a molten electrolyte (14), an anode (10) formed from carbon in contact with the electrolyte, a cathode (20) formed at least in part from the metal oxide in contact with the electrolyte, and a membrane (28) that is permeable to oxygen anions and is impermeable to carbon in ionic and non-ionic forms positioned between the cathode and the anode to thereby prevent migration of carbon from the anode to the cathode. The membrane includes a body (32) and a lining (34) on the surface of the body on the cathode side of the membrane. The lining is formed from a material that is inert with respect to dissolved metal in the electrolyte and is impermeable to the dissolved metal. An electrochemical method based on the cell is also disclosed.

Abstract: A process for electrochemically reducing a metal oxide, such as titania, in a solid state in an electrochemical cell that includes a bath of molten electrolyte, a cathode, and an anode, which process includes the steps of: a) applying a cell potential across the anode and the cathode that is capable of electrochemically reducing the metal oxide supplied to the molten electrolyte bath, b) continuously or semi-continuously feeding the metal oxide in powder and/or pellet form into the molten electrolyte bath, c) transporting the powders and/or pellets along a path within the molten electrolyte bath and reducing the metal oxide as the metal oxide powders and/or pellets move along the path, and d) continuously or semi-continuously removing metal from the molten electrolyte bath. Also disclosed and claims is an electrochemical cell for carrying out this process.

Abstract: A method of manufacturing titanium or titanium alloy semi-finished or ready-to-use products is disclosed. The method includes forming shaped bodies of titanium oxide particles and positioning the shaped bodies is an electrolytic cell which includes: an anode, a cathode, and a molten electrolyte. The shaped bodies are positioned to form at least a part of the cathode. The electrolyte includes cations of a metal that is capable of chemically reducing titanium oxide. The method further includes reducing the titanium oxide to titanium in a solid state in the electrolytic cell so that the shaped bodies become shaped bodies of titanium sponge. Finally, the method includes processing the shaped bodies of titanium sponge to reduce the volume or at least one of the dimensions of the bodies thereby to form the semi-finished or ready-to-use products.

Abstract: An electrochemical cell for electrochemical reduction of a metal oxide, such as titania, in a solid state, is disclosed. The cell includes (a) a molten electrolyte (18), (b) a cathode (20) formed at least in part from the metal oxide in contact with the electrolyte, (c) an anode (14), and (d) a membrane (16) that separates the electrolyte and the anode. The membrane is permeable to oxygen cations and is impermeable to dissolved metal in the electrolyte. Optionally, the membrane is impermeable to any one or more of (i) electrolyte anions other that oxygen anions, (ii) anode metal cations, and (iii) any other ions and atoms. An electrochemical method based on the above cell is also disclosed.

Abstract: An electrochemical cell for electrochemical reduction of a metal oxide in a solid state is disclosed. The cell includes a molten electrolyte (14), an anode (10) formed from carbon in contact with the electrolyte, a cathode (20) formed at least in part from the metal oxide in contact with the electrolyte, and a membrane (28) that is permeable to oxygen anions and is impermeable to carbon in ionic and non-ionic forms positioned between the cathode and the anode to thereby prevent migration of carbon from the anode to the cathode. The membrane includes a body (32) and a lining (34) on the surface of the body on the cathode side of the membrane. The lining is formed from a material that is inert with respect to dissolved metal in the electrolyte and is impermeable to the dissolved metal. An electrochemical method based on the cell is also disclosed.

Abstract: A method of manufacturing titanium or titanium alloy semi-finished or ready-to-use products is disclosed. The method includes forming shaped bodies of titanium oxide particles and positioning the shaped bodies in an electrolytic cell which includes: an anode, a cathode, and a molten electrolyte. The shaped bodies are positioned to form at least a part of the cathode. The electrolyte includes cations of a metal that is capable of chemically reducing titanium oxide. The method further includes reducing the titanium oxide to titanium in a solid state in the electrolytic cell so that the shaped bodies become shaped bodies of titanium sponge. Finally, the method includes processing the shaped bodies of titanium sponge to reduce the volume or at least one of the dimensions of the bodies thereby to form the semi-finished or ready-to-use products.

Abstract: An electrolytic cell for reducing a metal oxide, such as titania, in a solid state is disclosed. The electrolytic cell includes an anode formed from carbon and a cathode formed at least in part from the metal oxide. The electrolytic cell also includes a membrane that is permeable to oxygen anions and is impermeable to carbon in ionic and non-ionic forms positioned between the cathode and the anode to thereby prevent migration of carbon to the cathode.

Abstract: A process for electrochemically reducing a metal oxide, such as titania, in a solid state in an electrochemical cell that includes a bath of molten electrolyte, a cathode, and an anode, which process includes the steps of: a) applying a cell potential across the anode and the cathode that is capable of electrochemically reducing the metal oxide supplied to the molten electrolyte bath, b) continuously or semi-continuously feeding the metal oxide in powder and/or pellet form into the molten electrolyte bath, c) transporting the powders and/or pellets along a path within the molten electrolyte bath and reducing the metal oxide as the metal oxide powders and/or pellets move along the path, and d) continuously or semi-continuously removing metal from the molten electrolyte bath. Also disclosed and claims is an electrochemical cell for carrying out this process.

Abstract: A method of manufacturing titanium or titanium alloy semi-finished or ready-to-use products is disclosed. The method includes forming shaped bodies of titanium oxide particles and positioning the shaped bodies in an electrolytic cell which includes: an anode, a cathode, and a molten electrolyte. The shaped bodies are positioned to form at least a part of the cathode. The electrolyte includes cations of a metal that is capable of chemically reducing titanium oxide. The method further includes reducing the titanium oxide to titanium in a solid state in the electrolytic cell so that the shaped bodies become shaped bodies of titanium sponge. Finally, the method includes processing the shaped bodies of titanium sponge to reduce the volume or at least one of the dimensions of the bodies thereby to form the semi-finished or ready-to-use products.

Abstract: A method of reducing a titanium oxide in a solid state in an electrolytic cell which includes an anode, a cathode formed at least in part from the titanium oxide, and a molten electrolyte which includes cations of a metal that is capable of chemically reducing the cathode titanium oxide, which method includes operating the cell at a potential that is above a potential at which cations of the metal that is capable of chemically reducing the cathode titanium oxide deposit as the metal on the cathod, whereby the metal chemically reduces the cathode titanium oxide, and which method is characterised by refreshing the electrolyte and/or changing the cell potential in later stages of the operation of the cell as required having regard to the reactions occurring in the cell and the concentration of oxygen in the titanium oxide in the cell in order to produce high purity titanium.