Abstract: Systems and processes for the production of lithium metal from molten salts. Systems can include a ceramic tube affixed by or to a freeze-composite. The freeze-composite includes a matrix, of a salt and a dispersed phase. The freeze is maintained with a cooling collar to maintain a temperature below the melting point of the salt. Systems can include a molten-catholyte and a molten-anolyte each adjacent to separate surfaces of the ceramic tube. The freeze-composite forms a fluidic and non-conductive barrier between the molten-catholyte and the molten-anolyte. Processes include a freeze-composite affixed to the ceramic tube. The ceramic tube is adjacent to a composite collar which is adjacent to a cooling collar; The cooling fluid is passed through the cooling collar. A molten-catholyte is passed along a first surface of the ceramic tube. A molten-anolyte is passed along to a second surface of the ceramic tube.

Abstract: A process for producing refined lithium metal can include: a) processing a lithium chemical feedstock material using an electrowinning apparatus to produce a crude lithium metal having a first purity; b) combining the crude lithium metal with a carrier material to create a lithium-rich feed alloy; c) introducing the lithium-rich feed alloy as a feedstock material to an electrorefining apparatus and processing the lithium-rich feed alloy using the electrorefining apparatus to separate lithium metal from the carrier material thereby producing i) a refined lithium metal having a second purity that is greater than the first purity and ii) a lithium-depleted alloy that comprises the carrier material and less lithium metal than the lithium-rich feed alloy; and d) extracting the lithium-depleted alloy from the electrorefining apparatus and recycling at least a portion of the lithium-depleted alloy to provide at least a portion of the carrier material used in step b).

Abstract: A process for producing refined lithium metal can include: a) processing a lithium chemical feedstock material using an electrowinning apparatus to produce a crude lithium metal having a first purity; b) combining the crude lithium metal with a carrier material to create a lithium-rich feed alloy; c) introducing the lithium-rich feed alloy as a feedstock material to an electrorefining apparatus and processing the lithium-rich feed alloy using the electrorefining apparatus to separate lithium metal from the carrier material thereby producing i) a refined lithium metal having a second purity that is greater than the first purity and ii) a lithium-depleted alloy that comprises the carrier material and less lithium metal than the lithium-rich feed alloy; and d) extracting the lithium-depleted alloy from the electrorefining apparatus and recycling at least a portion of the lithium-depleted alloy to provide at least a portion of the carrier material used in step b).

Abstract: A process for electrowinning a metal can include the steps of: a) conveying an anolyte material and a metal chemical feedstock material along an anolyte flow path within an anolyte chamber; b) conveying catholyte material along a catholyte flow path within a catholyte chamber that has a cathode; c) applying an activation electric potential between the anode and a cathode that is sufficient to electrolyze and liberate metal ions from the metal chemical feedstock material in the anolyte chamber, thereby causing a flux of metal ions to migrate through a porous membrane from the anolyte chamber to the catholyte chamber and a metal product to be formed in the catholyte chamber; and while applying the activation electric potential, extracting a feedstock-depleted anolyte material from the anolyte chamber; and extracting an outlet material comprising the catholyte material and the metal product from the catholyte chamber via a catholyte outlet.

Abstract: An electrorefining process for refining relatively purer lithium metal from a lithium-alloy feedstock material using a three-layer electrorefining apparatus can include a) providing an anode layer comprising a molten, lithium-alloy feedstock material that includes a combination of lithium metal having a first purity and a carrier material; b) providing an electrolyte layer comprising a molten salt electrolyte material; c) providing a product layer comprising molten lithium metal having a second purity that is greater than the first purity above the electrolyte layer; and d) applying an activation electric potential that is sufficient to electrolyze the lithium-alloy feedstock material between an anode layer and the product layer that is electrically isolated from the anode layer, whereby lithium metal is liberated from the lithium-alloy feedstock material, migrates through the electrolyte layer and collects in the product layer.

Abstract: A process for electrowinning a metal using a flow-through electrowinning apparatus can include the steps of: a) conveying an anolyte material and a metal chemical feedstock material along an anolyte flow path within an anolyte chamber; b) conveying catholyte material along a catholyte flow path within a catholyte chamber that has a cathode; c) applying an activation electric potential between the anode and a cathode that is sufficient to electrolyze and liberate metal ions from the metal chemical feedstock material in the anolyte chamber, thereby causing a flux of metal ions to migrate through a porous membrane from the anolyte chamber to the catholyte chamber and a metal product to be formed in the catholyte chamber; and while applying the activation electric potential, extracting a feedstock-depleted anolyte material from the anolyte chamber; and extracting an outlet material comprising the catholyte material and the metal product from the catholyte chamber via a catholyte outlet.

Abstract: An anode assembly for use in a lithium-based battery may include a current collector comprising aluminum, at least a first protective layer bonded to and covering a portion of the collector and being formed from a protective metal that is electrically conductive, and at least a first reactive layer comprising lithium metal bonded to the protective. The first protective layer can be disposed between the support surface and the reactive layer so that electrons can travel from the first reactive layer to the current collector and the first reactive layer is spaced from and at least substantially ionically isolated from the support surface, and whereby diffusion of the reactive layer to the current collector is substantially prevented, by the first protective layer thereby inhibiting reactions between the lithium metal and the current collector.

Abstract: A flexible electrical connector assembly is adapted to connect a bus bar of an electrolytic cell to a collector bar of the electrolytic cell. The assembly includes an electrical connector including a plurality of conductive metal sheets, the electrical connector having a collector bar end and a bus bar end. The electrical connector may be adapted for being joined, at the collector bar end, to the collector bar and, at the bus bar end, to the bus bar. The electrical connector may be adapted to implement a change in direction, at a bend along a current-carrying path between the bus bar end and the collector bar end, the bend assisting to define the change in direction as greater than 90 degrees.

Abstract: A flexible electrical connector assembly is adapted to connect a bus bar of an electrolytic cell to a collector bar of the electrolytic cell. The assembly includes an electrical connector including a plurality of conductive metal sheets, the electrical connector having a collector bar end and a bus bar end. The electrical connector may be adapted for being joined, at the collector bar end, to the collector bar and, at the bus bar end, to the bus bar. The electrical connector may be adapted to implement a change in direction, at a bend along a current-carrying path between the bus bar end and the collector bar end, the bend assisting to define the change in direction as greater than 90 degrees.

Abstract: A furnace is provided suitable for metallurgical processes, comprising at least one section comprised of refractory bricks with an outer shell plate adjacent to the refractory bricks, including exterior bricks whose external faces adjacent the shell plate define gaseous media cooling channels extending along the exterior of the refractory bricks between them and the shell plate. The furnace further comprises cooling plates within the cooling channels and joints between the successive courses of bricks. Advantageously, the conductivity of the cooling plates is at least 5 times the conductivity of the refractory lining into which it is inserted. Suitable materials include copper and copper-based alloys, brasses, bronzes, cast irons, aluminum alloys, silver, high-temperature steels, refractory metals and their alloys, graphite, silicon carbide, and aluminum nitride.

Abstract: A feed charging device comprises a holding vessel having an interior chamber for holding a reserve of a solid particulate feed material in a fluidized state, wherein the feed material is held in said fluidized state in a lower zone of the interior chamber. The feed material is supplied to the interior chamber through at least one outlet opening, and is discharged from the interior chamber through at least one outlet opening. The at least one outlet opening is in flow communication with the lower zone of the interior chamber. A gas supply means supplies a fluidizing gas to the lower zone of the interior chamber, and an outlet conduit in flow communication with the at least one outlet opening receives said feed material discharged from the interior chamber.

Abstract: A burner is provided for a pulverous feed material. The burner has a structure that integrates the burner with a reaction vessel, and has an opening that communicates with the interior of the reaction vessel. The burner also has a gas supply channel to supply reaction gas through the opening into the reaction vessel, and a feed supply for delivering pulverous material to the reaction vessel. The burner also has a fluidic control system having at least one port capable of directing a stream of fluid at an angle to the direction of flow of the reaction gas so as to modify the flow of the reaction gas. In addition, components are provided to modify the swirl intensity and turbulence intensity of the reaction gas independently of the exit velocity.

Abstract: A furnace is provided suitable for metallurgical processes, comprising at least one section comprised of refractory bricks with an outer shell plate adjacent to the refractory bricks, including exterior bricks whose external faces adjacent the shell plate define gaseous media cooling channels extending along the exterior of the refractory bricks between them and the shell plate. The furnace further comprises cooling plates within the cooling channels and joints between the successive courses of bricks. Advantageously, the conductivity of the cooling plates is at least 5 times the conductivity of the refractory lining into which it is inserted. Suitable materials include copper and copper-based alloys, brasses, bronzes, cast irons, aluminum alloys, silver, high-temperature steels, refractory metals and their alloys, graphite, silicon carbide, and aluminum nitride.

Abstract: A furnace is provided suitable for metallurgical processes, comprising at least one section comprised of refractory bricks with an outer shell plate adjacent to the refractory bricks, including exterior bricks whose external faces adjacent the shell plate define gaseous media cooling channels extending along the exterior of the refractory bricks between them and the shell plate. The furnace further comprises cooling plates within the cooling channels and joints between the successive courses of bricks. Advantageously, the conductivity of the cooling plates is at least 5 times the conductivity of the refractory lining into which it is inserted. Suitable materials include copper and copper-based alloys, brasses, bronzes, cast irons, aluminum alloys, silver, high-temperature steels, refractory metals and their alloys, graphite, silicon carbide, and aluminum nitride.

Abstract: A feed charging device comprises a holding vessel having an interior chamber for holding a reserve of a solid particulate feed material in a fluidized state, wherein the feed material is held in said fluidized state in a lower zone of the interior chamber. The feed material is supplied to the interior chamber through at least one outlet opening, and is discharged from the interior chamber through at least one outlet opening. The at least one outlet opening is in flow communication with the lower zone of the interior chamber. A gas supply means supplies a fluidizing gas to the lower zone of the interior chamber, and an outlet conduit in flow communication with the at least one outlet opening receives said feed material discharged from the interior chamber.

Abstract: A burner is provided for a pulverous feed material. The burner has a structure that integrates the burner with a reaction vessel, and has an opening that communicates with the interior of the reaction vessel. The burner also has a gas supply channel to supply reaction gas through the opening into the reaction vessel, and a feed supply for delivering pulverous material to the reaction vessel. The burner also has a fluidic control system having at least one port capable of directing a stream of fluid at an angle to the direction of flow of the reaction gas so as to modify the flow of the reaction gas. In addition, components are provided to modify the swirl intensity and turbulence intensity of the reaction gas independently of the exit velocity.

Abstract: A furnace is provided suitable for metallurgical processes, comprising at least one section comprised of refractory bricks with an outer shell plate adjacent to the refractory bricks, including exterior bricks whose external faces adjacent the shell plate define gaseous media cooling channels extending along the exterior of the refractory bricks between them and the shell plate. The furnace further comprises cooling plates within the cooling channels and joints between the successive courses of bricks. Advantageously, the conductivity of the cooling plates is at least 5 times the conductivity of the refractory lining into which it is inserted. Suitable materials include copper and copper-based alloys, brasses, bronzes, cast irons, aluminum alloys, silver, high-temperature steels, refractory metals and their alloys, graphite, silicon carbide, and aluminum nitride.

Abstract: An ultrasonic measurement system comprises a processor configured for enhancing a received ultrasonic signal, where the received ultrasonic signal is a frequency domain signal. The enhancing involves deconvolving the received ultrasonic signal to yield a filtered signal, determining autoregressive extrapolation parameters based on frequency amplitude fluctuations of the filtered signal within a frequency range over which a corresponding reference signal has a high signal-to-noise ratio, and carrying out an autoregressive spectral extrapolation of the filtered signal using the autoregressive extrapolation parameters to yield an enhanced ultrasonic signal.