Abstract: Provided are a method and to an arrangement for monitoring characteristics of a furnace process in a furnace space limited by a furnace shell of a metallurgical furnace. The arrangement comprises a process monitoring unit having a frame mounted by means of a mounting means on the metallurgical furnace outside the furnace space of the furnace shell. Also provided is a process monitoring unit for use in the method and/or in the arrangement.

Abstract: A process for recovering at least one metal from a metal containing resource, in particular containing at least one metal oxide. The process including the step: providing a crucible containing a chloride salt melt, at least one cathode and an anode connected to the salt melt, heating means for heating the salt melt, and an aluminum melt present at the bottom of the crucible, said aluminum melt forming a part of the anode.

Abstract: A series of inventions leading to the production of specific aluminum alloys (especially aluminum beverage can sheet product) through novel approach of introducing, selectively partitioning and managing alloying elements. This invention also enables manufacturing practices to enhance the performance characteristics of aluminum alloys produced. The selected elements can be derived from carbon anodes made from calcined petroleum coke with high metallic contents (such as nickel and vanadium). Alloying elements can also be introduced and managed from other raw material such as alumina and bath constituents added during aluminum smelting process. Additionally, cell operating parameters, such as cell temperature, off gas flow rate, aluminum tapping rate and impurity partition characteristics can also be manipulated to produce low cost aluminum alloys and facilitate utilization of high metallic content calcined petroleum coke.

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 invention relates to a ceramic implant, especially a dental implant, comprising a structured or porous surface for at least partially inserting into a bone. An especially advantageous surface is obtained when it is at least partially modified by a salt melt. These excellent osteointegration properties can be obtained by a method whereby the surface is modified in a salt melt at least in the regions exposed to the bones and/or soft tissue, optionally following a previous modification of the surface whereby material has been removed.

Abstract: Nanopatterned substrates can be prepared by a method that includes forming a block copolymer film on a substrate, annealing the block copolymer film, surface reconstructing the annealed block copolymer film, coating an etch-resistant layer on the surface reconstructed block copolymer film, etching the resist-coated block copolymer film to create an etched article comprising a nanopatterned substrate, and separating the etch-resistant layer and the block copolymer film from the nanopatterned substrate. The method is applicable to a wide variety of substrate materials, avoids any requirement for complicated procedures to produce long-range order in the block copolymer film, and avoids any requirement for metal functionalization of the block copolymer.

Abstract: The present invention provides a process for preparing lithium alloy or lithium metal from lithium carbonate or its equivalent lithium ion source such as spudomene ore without creating toxic byproducts such as halogen gases and a system adopted for such a process.

Abstract: A method of taking inoperative pot online using fuse in an aluminium manufacturing plant operating on electrolysis process is disclosed. The manufacturing plant comprises of plurality of electrolysis cells or pots connected in series. Some of the pots are kept off line during start up of the plant by shorting the risers of the non running pots to the cathode bus bar (31) by shorted joints (II). The method comprises, connecting fuse assemblies in parallel with the shorted joints; inserting insulating insert plates between the risers and the short circuit bus bars and securing the insulating insert plates to isolate the short circuit bus bars from the risers (14) such that the total rated current passes through the fuse assemblies. The fuse elements in the fuse assemblies melt within about 8 to 10 minutes, completely isolating the short circuit bus bars from the risers such that the risers now feed the current to the anode assemblies of the non running pot.

Abstract: The subject invention pertains to methods for processing a solid material (M1X) comprising a solid solution of a non-metal species (X) in a metal or semi-metal (M1) or a compound between the non-metal species and the metal or semi-metal is immersed in a molten salt (M2Y). A cathodic potential is applied to the material to remove a portion of the non-metal species by electro-deoxidation. To remove the non-metal species at lower concentrations, a source of a reactive metal (M3) is immersed in the molten salt and is electronically connected to the material. Reactions occur at the material, where the non-metal species dissolves in the salt, and at the reactive metal, which reacts with the non-metal species dissolved in the salt to form a reaction product more stable than a compound between the non-metal species and the metal or semi-metal (M1). The non-metal species is thus removed from the solid material.

Abstract: The present invention pertains to a method for removing a substance (X) from a solid metal or semi-metal compound (M1X) by electrolysis in a melt of M2Y, which comprises conducting the electrolysis under conditions such that reaction of X rather than M2 deposition occurs at a electrode surface, and that X dissolves in the electrolyte M2Y. The substance X is either removed from the surface (i.e., M1X) or by means of diffusion extracted from the case material. The temperature of the fused salt is chosen below the melting temperature of the metal M1. The potential is chosen below the decomposition potential of the electrolyte.

Abstract: A method of rapidly cooling molten mixtures of alkali metal alloys in which the metal components of said alloys have a wide divergence of melting points that result in separation of the alkali metals during cool down. A calcium-sodium alloy is produced in an electrolysis cell. A method of high pressure atomization of the calcium-sodium alloy and its subsequent rapid cooling produces a calcium nodular particulate that is encased in a sodium flocculant. The material manufactured is used as a nodular electrolytic flocculant reactant in the electrolyte of an alkaline battery.

Abstract: This invention describes a method of producing a metal, M1, in an electrolytic cell consisting of a molten electrolyte, MZY-MZO, at least one anode and at least one cathode, characterised in that the passage of current between said anode(s) and cathode(s) through said electrolyte, produces a metal, M1, from a raw material, M1X, containing a non-metallic species, X, under conditions such that the potential at the cathode causes the reduction of the MZ cation and the formation of MZ at activities less than one, and the potential at the cathode is insufficient to cause formation of MZ metal as a discrete solid or liquid phase, and the MZ so produced reduces the raw material, M1X, at the cathode, to M1.

Abstract: A series of inventions leading to the production of specific aluminum alloys (especially aluminum beverage can sheet product) through novel approach of introducing, selectively partitioning and managing alloying elements. This invention also enables manufacturing practices to enhance the performance characteristics of aluminum alloys produced. The selected elements can be derived from carbon anodes made from calcined petroleum coke with high metallic contents (such as nickel and vanadium). Alloying elements can also be introduced and managed from other raw material such as alumina and bath constituents added during aluminum smelting process. Additionally, cell operating parameters, such as cell temperature, off gas flow rate, aluminum tapping rate and impurity partition characteristics can also be manipulated to produce low cost aluminum alloys and facilitate utilization of high metallic content calcined petroleum coke.

Abstract: The present invention relates to a method for electrolytic production and refining of metals having a melting point above about 1000° C., particularly silicon, where there is provided a first electrolytic cell having an upper molten electrolyte layer of a first electrolyte, a lower molten alloy layer of an alloy of the metal to be refined and at least one metal more noble than the metal to be refined. The lower alloy layer is the cathode in the first cell and an anode is positioned in the upper molten electrolyte layer. A second electrolytic cell is also provided with an upper molten metal layer of the same metal as the metal to be refined, said layer constituting a cathode, a lower molten alloy layer, said lower layer constituting an anode, said alloy having a higher density than the metal to be refined, and an intermediate molten electrolyte layer having a density between the density of the upper and lower molten layers.

Abstract: The invention includes a method of forming a material which comprises at least two elements. More specifically, the method comprises providing an electrolytic cell comprising a cathode, an anode, and an electrolytic solution extending between the cathode and anode. A metallic product is electrolytically formed within the electrolytic cell. The forming of the metallic product comprises primarily electrorefining of a first element of the at least two elements and primarily electrowinning of a second element of the at least two elements. The invention also includes a mixed metal product comprising at least two elements, such as a product comprising tantalum and titanium.

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: The invention provides a method of forming an inorganic porous membrane that includes forming an inorganic membrane material on a substrate, forming a porous self-assembled material on the inorganic membrane material, and patterning the membrane material using the porous self-assembled material as a mask.

Abstract: A method for the production of an intermetallic compound (M1Z) involves treating a solid precursor material comprising three or more species, including first and second metal or metalloid species (M1, Z) and a non-metal species (X), by electro-deoxidation in contact with a melt comprising a fused salt (M2Y) under conditions whereby the non-metal species dissolves in the melt. The first and second metal or metalloid species form an intermetallic compound. The method is performed in a cell comprising a cathode of the precursor material (2), which is immersed in a melt (8) contained in a crucible (6) for electro-deoxidation.

Abstract: A method of producing a metal or an alloy from metalliferous material by removing O,S, or N from a solid body of metalliferous material by electrolysis in an electrolytic cell is disclosed. The cell includes a molten halide salt or mixture of halide salts as an electrolyte. The cation of the salt is selected from the group that includes Ca, Ba, Li, Na, K, Mg, Sr, Cs and Y. In one aspect of the invention the method includes conducting the electrolysis under conditions wherein the solid body of metalliferous material is made part of a cathode of the electrolytic cell, the cathode includes a conductor for electrically connecting the cathode with an electrical potential, the conductor has high resistance to chemical attack by the electrolyte at high temperatures, and the conductor is at least partly immersed in the electrolyte.

Abstract: The present invention pertains to a method for removing a substance (X) from a solid metal or semi-metal compound (M1X) by electrolysis in a melt of M2Y, which comprises conducting the electrolysis under conditions such that reaction of X rather than M2 deposition occurs at a electrode surface, and that X dissolves in the electrolyte M2Y. The substance X is either removed from the surface (i.e., M1X) or by means of diffusion extracted from the case material. The temperature of the fused salt is chosen below the melting temperature of the metal M1. The potential is chosen below the decomposition potential of the electrolyte.

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: A method for the manufacture of a foamed metal or alloy article including the steps of: A) selecting a particulate feedstock having suitable proportions of a metal element or combination of metal elements M1 contaminated by one or more contaminants X to form an alloy suitable for the foamed article; B) mixing the feedstock with a binder to form a slurry; C) preforming the slurry into a near net shape of the desired article and drying the preform to remove the binder; D) sintering the dried preform to provide a bonded foamed article; E) introducing the sintered article into an electrochemical cell, the cell containing a liquid electrolyte comprising a fused salt or mixture of salts generally designated as M2Y in which contaminant(s) X is soluble, and a relatively inert anode; F) conducting electrolysis under conditions favourable to the selective dissolution of the contaminant(s) X in preference to the M2 cation; and G) following electrolysis reclaiming the purified foam article from the cathode.

Abstract: The invention provides a method for producing a sputtering target material including electrolyzing a molten salt mixture containing a precious metal salt and a solvent salt, to thereby deposit a precious metal or a precious metal alloy. The method enables simplification of production steps and produces high-purity target materials. In addition, the electrodeposited precious metal or precious metal alloy is heat-treated at a temperature of at least 800° C. but lower than the melting point of the precious metal, to thereby produce a target material of higher purity.

Abstract: A Process for the electrolytic production of metals particularly titanium and alloys starting from the corresponding compounds is disclosed, by means of an apparatus for the electrochemical extraction including: (1) a cathode-crucible containing a mass of solidified metal, a liquid electrolyte with a density which is lower than that of the metal and a pool of liquid metal produced; (2) one or more non-consumable anodes particularly immersed in the electrolyte with means for regulating their distance from the cathodic surface; (3) a feeding system to the electrolyte of the compounds of the metals, of the electrolyte constituents and of alloying materials; (4) a power supply which feeds direct current to the liquid metal, and through the electrolyte, to the anodes, and causes the cathodic reduction of the metal in liquid form and the evolution of anodic gas, with the heat generation which maintains the electrolyte in the molten state; and (5) an air-tight containment structure in which the anodic gases generate

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.

Abstract: A process is disclosed for the electrolytic production of magnesium utilizing magnesium oxide and/or partially dehydrated magnesium chloride as a feedstock. An electrolyte containing magnesium chloride, potassium chloride and optionally sodium chloride is employed so that magnesium is produced. The magnesium is absorbed into a molten magnesium alloy cathode layer underlying the MgCl.sub.2 -KCl electrolyte. In a bipolar embodiment, pure magnesium is electrolytically transported from the magnesium alloy through a second molten salt electrolyte to an overlying electrode where the magnesium collects as a pool on the second electrolyte.