Abstract: A system for the production of molten salt. The system can have a preparation tank configured to melt raw salts, and a bubbler system in communication with the preparation tank. The bubbler can be configured to maintain vacuum conditions within the preparation tank and to remove gases from the preparation tank. A method for producing molten salt includes a step of providing a system for the production of molten salt. The system can have a preparation tank configured to melt raw salts, and a bubbler system in communication with the preparation tank. The bubbler can be configured to maintain vacuum conditions within the preparation tank and to remove gases from the preparation tank. Then, the method can include inserting raw salt into the preparation tank, and heating the raw salt to form molten salt. Then filtering the molten salt, and storing the molten salt.

Abstract: A method of fabricating metallic fuel from surplus plutonium may include combining plutonium oxide powder and uranium oxide powder to obtain a mixed powder with reduced proliferation potential. The mixed powder may be electroreduced in a bath of molten salt so as to convert the mixed powder to a first alloy. The first alloy may be pressed to remove a majority of the molten salt adhered to the first alloy to form a pressed alloy-salt mixture. The first alloy may be isolated from the salt by melting the pressed alloy-salt mixture. The first alloy may be further processed to fabricate a fuel rod. Accordingly, the metallic fuel produced may be used in a fast reactor system, such as a Power Reactor Innovative Small Module (PRISM).

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: A method of producing metallic powder for use in the manufacture of a capacitor comprises the step of reducing a non-metallic compound to metal in contact with a molten salt. The salt comprises, for at least a portion of the process, a dopant element that acts as a sinter retardant in the metal. In preferred examples, the metallic powder is Ta or Nb powder produced by the reduction of a Ta or Nb oxide and the dopant is boron, nitrogen, or phosphorous.

Abstract: An electrolysis system for generating a metal and molecular oxygen includes a container for receiving a metal oxide containing a metallic species to be extracted, a cathode positioned to contact a metal oxide housed within the container; an oxygen-ion-conducting membrane positioned to contact a metal oxide housed within the container; an anode in contact with the oxygen-ion-conducting membrane and spaced apart from a metal oxide housed within the container, said anode selected from the group consisting of liquid metal silver, oxygen stable electronic oxides, oxygen stable crucible cermets, and stabilized zirconia composites with oxygen stable electronic oxides.

Abstract: Provided is a method for producing fine metal particles, wherein metal oxide powders can be used as a source of fine metal particles, and a method for producing fine metal particles can be provided avoiding the contamination of the molten salt electrolyte bath and the produced fine metal particles. A method for producing fine metal particles (112) is provided which comprises generating cathodic discharge outside and over the surface of an electrolyte bath (100) comprising metal oxide powders (110) suspended therein, whereby the metal oxide powders (110) are electrochemically reduced into the fine metal particles (112).

Abstract: A method for producing metal powder is provided the comprising supplying a molten bath containing a reducing agent, contacting a metal oxide with the molten bath for a time and at a temperature sufficient to reduce the metal in the metal oxide to elemental metal and produce free oxygen; and isolating the elemental metal from the molten bath.

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: A molten salt electrolyzer for reducing metal comprises an electrolytic cell filled with a molten salt composed of a reducing metal chloride, an anode immersed in the molten salt of the electrolytic cell and surrounded by a first wall at the periphery thereof, and a cathode immersed in the molten salt of the electrolytic cell and surrounded by a second wall at the periphery thereof.

Abstract: An electrolysis system for generating a metal and molecular oxygen includes a container for receiving a metal oxide containing a metallic species to be extracted, a cathode positioned to contact a metal oxide housed within the container; an oxygen-ion-conducting membrane positioned to contact a metal oxide housed within the container; an anode in contact with the oxygen-ion-conducting membrane and spaced apart from a metal oxide housed within the container, said anode selected from the group consisting of liquid metal silver, oxygen stable electronic oxides, oxygen stable crucible cermets, and stabilized zirconia composites with oxygen stable electronic oxides.

Abstract: Disclosed relates to a method for preparing tantalum or niobium powders used for manufacturing capacitors in an electrolytic reducing reactor including an anode, a cathode and a molten salt, the method comprising: obtaining a tantalum or niobium oxide, expressed by Ta2O(5-y) or Nb2O(5-y) where y=2.5 to 4.

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 cermet inert anode having a reduced level of contaminating surface metal is disclosed. Methods for preparing cermet inert anodes and methods for treating cermet inert anodes are also disclosed. The methods generally use an oxidizing agent to convert metals on the surface of the anode to inert oxides and/or to otherwise remove the metal contaminants. The inert anodes of the present invention may be used in electrolytic reduction cells for the production of commercial purity aluminum, as well as other metals.

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: The present invention includes uranium-bearing ceramic phase electrodes and electrolysis apparatus and electrolysis methods featuring same, including methods of metal production and the like by the electrolytic reduction of oxides or salts of the respective metals. More particularly, the invention relates to an inert type electrode composition, and methods for fabricating electrode compositions, useful in the electrolytic production of such metals. The present invention also includes an inert-type electrode composition, and methods for fabricating electrode compositions, used in processes for generating energy from fossil fuels.

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: 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.