US20040237710A1 - Electrolytic reducion of metal oxides - Google Patents

Electrolytic reducion of metal oxides Download PDF

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Publication number
US20040237710A1
US20040237710A1 US10/474,746 US47474604A US2004237710A1 US 20040237710 A1 US20040237710 A1 US 20040237710A1 US 47474604 A US47474604 A US 47474604A US 2004237710 A1 US2004237710 A1 US 2004237710A1
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US
United States
Prior art keywords
metal
electrolyte
cell
metal oxide
method defined
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/474,746
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English (en)
Inventor
Lazar Strezov
Ivan Ratchev
Steve Osborn
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BHP Billiton Innovation Pty Ltd
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BHP Billiton Innovation Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BHP Billiton Innovation Pty Ltd filed Critical BHP Billiton Innovation Pty Ltd
Assigned to BHP BILLITON INNOVATION PTY LTD. reassignment BHP BILLITON INNOVATION PTY LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OSBORN, STEVE, RATCHEV, IVAN, STREZOV, LAZAR
Assigned to BHP BILLITON INNOVATION PTY LTD. reassignment BHP BILLITON INNOVATION PTY LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OSBORN, STEVE, RATCHEV, IVAN, STREZOV, LAZAR
Publication of US20040237710A1 publication Critical patent/US20040237710A1/en
Priority to US11/924,808 priority Critical patent/US20080110764A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
    • C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
    • C25C3/06—Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
    • C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
    • C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
    • C25C3/04—Electrolytic production, recovery or refining of metals by electrolysis of melts of magnesium

Definitions

  • the present invention relates to electrolytic reduction of metal oxides to produce substantially pure metals.
  • the present invention relates to electrolytic reduction of aluminium and magnesium oxides using a CaCl 2 electrolyte.
  • the present invention was made during the course of an on-going research project on the electrolytic reduction of metal oxides using CaCl 2 -based electrolyte being carried out by the applicant.
  • the research project investigated electrolytic reduction of a range of metal oxides in electrolyte cells based on the use of using CaCl 2 electrolyte.
  • the CaCl 2 electrolyte was a commercially available source of CaCl 2 , namely calcium chloride dihydrate, that decomposed on heating and produced a very small amount of CaO.
  • the applicant operated the electrolytic cells at a potential above the decomposition potential of CaO and below the decomposition potential of CaCl 2 .
  • the present invention provides, in broad terms, a method of electrolytically reducing a metal oxide to produce a metal in an electrolytic cell, which method includes electrolytically reducing the metal oxide in an electrolytic cell that includes (a) a pool of molten metal, the metal being the metal of the metal oxide to be reduced, the molten metal pool forming a cathode of the cell, (b) a pool of molten electrolyte in contact with the molten metal, the electrolyte containing alkali and/or alkaline earth halides, (c) an anode extending into the electrolyte, and (d) a body of metal oxide to reduced in contact with the molten metal and the electrolyte.
  • the metal oxide body has a geometric shape that maximizes contact between (i) the molten metal, (ii) the metal oxide, and (iii) the electrolyte.
  • the method includes feeding the metal oxide body into the electrolytic cell to maintain contact of the metal oxide and the molten metal.
  • the metal oxide body may be in many forms, including rods, plates, blocks and the like, which can be readily immersed into the electrolyte and brought into contact with the molten metal.
  • the method includes maintaining the cell temperature above the melting points of the electrolyte and the metal of the metal oxide to be reduced.
  • the method includes operating the cell at a potential that is above a decomposition potential of at least one constituent of the electrolyte so that there are cations of a metal other than that of the cathode metal oxide in the electrolyte.
  • the metal oxide is an aluminium oxide or a magnesium oxide.
  • the electrolyte be a CaCl 2 -based electrolyte that includes CaO as one of the constituents.
  • the cell potential be above the decomposition potential for CaO.
  • the cell potential be below the decomposition potential for CaCl 2 .
  • the cell potential be less than 3.0V.
  • the cell potential be below 2.5V.
  • the cell potential be below 2.0V.
  • the cell potential be at least 1.5V.
  • the CaCl 2 -based electrolyte may be a commercially available source of CaCl 2 , such as calcium chloride dihydrate, that partially decomposes on heating and produces CaO or otherwise includes CaO.
  • the CaCl 2 -based electrolyte may include CaCl 2 and CaO that are added separately or pre-mised to form the electrolyte.
  • the applicant also believes that the O ⁇ anions, once extracted from the metal oxide, migrate to the anode and react with anode carbon and produce CO and release electrons that facilitate electrolytic reduction of metal oxide to metal.
  • the experimental work carried out by the applicant produced evidence of Ca metal in the electrolyte.
  • the applicant believes that the Ca metal was the result of electrodeposition of Ca ++ cations as Ca metal on electrically conductive sections of the cathode and that at least part of the Ca metal dissolved in the electrolyte and migrated to the vicinity of the metal oxide in the cathode and participated in chemical reduction of oxides.
  • the anode be graphite.
  • the cell includes a base and side walls extending upwardly from the base formed from graphite.
  • the cell includes at least one tap hole for molten metal in one of the side walls and the method includes removing molten metal continuously or periodically.
  • One option is to introduce the (pure) metal and the electrolyte in solid state into the cell and subsequently heat the entire system to melt the metal and the electrolyte.
  • Another option is to introduce molten metal and molten electrolyte separately into the cell.
  • FIG. 1 is a schematic illustration of an electrolytic cell 5 that can be scaled-up in application of the present invention.
  • the electrolytic cell 5 of FIG. 1 includes a graphite crucible 10 that has a base 21 , side walls 31 , and a tapping/discharge opening indicated as 12 in one of the side walls 31 .
  • the electrolytic cell 5 further includes a bath of molten CaCl 2 electrolyte 13 in the crucible and a graphite electrode 11 immersed in the molten electrolyte 13 .
  • the graphite electrode 11 forms the anode of the cell 5 .
  • the electrolytic cell 5 further includes a pool 15 of molten aluminium in a lower section of the crucible 10 .
  • the molten aluminium pool 15 forms the cathode of the cell.
  • the electrolytic cell further includes a body 14 that consists of or incorporates alumina (Al 2 O 3 ) to be reduced and extends into the electrolyte 13 and contacts the molten aluminium cathode 15 .
  • the alumina is shaped as a rod, sheet or prismatic body. Alumina body 14 is held in an appropriate manner to allow controlled movement into and away from the crucible interior as indicated by the arrow 16 .
  • the electrolytic cell 5 further includes a suitable power source 18 connected to the anode 11 and to the molten aluminium cathode 15 .
  • the molten aluminium cathode 15 is required in order to initiate electrolytic reduction of the alumina in the alumina body 14 to aluminium.
  • the electrolytic reduction process is carried out at an elevated temperature of around 950° C. at which the CaCl 2 electrolyte is and remains molten.
  • reduction of the alumina takes place. Since the process temperatures are above the melting point of aluminium, the latter will melt into the bath 15 and the bath level within crucible 10 will tend to rise.
  • the alumina body 14 is moved at a rate commensurate with the melting-off rate of aluminium from the alumina body 14 and the build-up of aluminium so that immersion of the alumina body 14 in the molten aluminium is kept at a minimum.
  • the process may be operated in a continuous mode by removing molten aluminium through tap hole 12 and positioning additional alumina bodies 14 in the electrolyte 13 to replace bodies 14 that are consumed in the reduction process.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electrolytic Production Of Metals (AREA)
US10/474,746 2001-04-10 2002-04-10 Electrolytic reducion of metal oxides Abandoned US20040237710A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/924,808 US20080110764A1 (en) 2001-04-10 2007-10-26 Electrolytic Reduction of Metal Oxides

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AUPR4439 2001-04-10
AUPR4439A AUPR443901A0 (en) 2001-04-10 2001-04-10 Method for reduction of metal oxides to pure metals
PCT/AU2002/000456 WO2002083989A1 (fr) 2001-04-10 2002-04-10 Reduction electrolytique d'oxydes metalliques

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US11/924,808 Continuation US20080110764A1 (en) 2001-04-10 2007-10-26 Electrolytic Reduction of Metal Oxides

Publications (1)

Publication Number Publication Date
US20040237710A1 true US20040237710A1 (en) 2004-12-02

Family

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Family Applications (2)

Application Number Title Priority Date Filing Date
US10/474,746 Abandoned US20040237710A1 (en) 2001-04-10 2002-04-10 Electrolytic reducion of metal oxides
US11/924,808 Abandoned US20080110764A1 (en) 2001-04-10 2007-10-26 Electrolytic Reduction of Metal Oxides

Family Applications After (1)

Application Number Title Priority Date Filing Date
US11/924,808 Abandoned US20080110764A1 (en) 2001-04-10 2007-10-26 Electrolytic Reduction of Metal Oxides

Country Status (9)

Country Link
US (2) US20040237710A1 (fr)
EP (1) EP1392890A4 (fr)
JP (1) JP2004523662A (fr)
CN (1) CN1509346A (fr)
AU (1) AUPR443901A0 (fr)
CA (1) CA2443953A1 (fr)
NO (1) NO20034548L (fr)
WO (1) WO2002083989A1 (fr)
ZA (1) ZA200307978B (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100323253A1 (en) * 2006-02-22 2010-12-23 University Of Utah Resarch Foundation Systems and Methods for Hydrogen Storage and Generation from Water Using Lithium Based Materials

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU2002951962A0 (en) * 2002-10-09 2002-10-24 Bhp Billiton Innovation Pty Ltd Electrolytic reduction of metal oxides
AU2002952083A0 (en) 2002-10-16 2002-10-31 Bhp Billiton Innovation Pty Ltd Minimising carbon transfer in an electrolytic cell
US8152895B2 (en) * 2003-04-23 2012-04-10 Ut-Battelle, Llc Production of magnesium metal
EP2469969A1 (fr) * 2010-12-24 2012-06-27 Philip Morris Products S.A. Élément de chauffage de céramique réduit
KR101655143B1 (ko) * 2013-12-20 2016-09-07 현대자동차 주식회사 연료 전지 수소 공급 시스템의 원료 재생 방법
CN109055985B (zh) * 2018-09-12 2019-09-27 郑州大学 一种电解氧化镁用熔盐体系、制备方法及其应用
KR102004920B1 (ko) * 2019-01-28 2019-07-29 한국지질자원연구원 액체금속 음극을 이용한 금속 제련 방법
CN110219021B (zh) * 2019-06-19 2024-05-24 陕西均健佳实业有限公司 一种镁电解槽及镁电解工艺

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3951763A (en) * 1973-06-28 1976-04-20 Aluminum Company Of America Aluminum smelting temperature selection
US4455202A (en) * 1982-08-02 1984-06-19 Standard Oil Company (Indiana) Electrolytic production of lithium metal
US4973390A (en) * 1988-07-11 1990-11-27 Aluminum Company Of America Process and apparatus for producing lithium from aluminum-lithium alloy scrap in a three-layered lithium transport cell
US5378325A (en) * 1991-09-17 1995-01-03 Aluminum Company Of America Process for low temperature electrolysis of metals in a chloride salt bath
US5593566A (en) * 1995-06-09 1997-01-14 General Motors Corporation Electrolytic production process for magnesium and its alloys

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2487386A1 (fr) * 1980-07-23 1982-01-29 Pechiney Aluminium Procede et appareillage pour reguler de facon precise la cadence d'introduction et la teneur en alumine d'une cuve d'electrolyse ignee, et application a la production d'aluminium
BR8207776A (pt) * 1981-07-01 1983-05-31 Diamond Shamrock Corp Producao eletrolitica de aluminio
US4597839A (en) * 1983-12-14 1986-07-01 Atlantic Richfield Company Method and apparatus for production of a metal from metallic oxide ore
GB8707781D0 (en) * 1987-04-01 1987-05-07 Shell Int Research Electrolytic production of metals
US5279715A (en) * 1991-09-17 1994-01-18 Aluminum Company Of America Process and apparatus for low temperature electrolysis of oxides
AU2002349216B2 (en) * 2001-11-22 2006-04-27 Qit-Fer Et Titane Inc. A method for electrowinning of titanium metal or alloy from titanium oxide containing compound in the liquid state

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3951763A (en) * 1973-06-28 1976-04-20 Aluminum Company Of America Aluminum smelting temperature selection
US4455202A (en) * 1982-08-02 1984-06-19 Standard Oil Company (Indiana) Electrolytic production of lithium metal
US4973390A (en) * 1988-07-11 1990-11-27 Aluminum Company Of America Process and apparatus for producing lithium from aluminum-lithium alloy scrap in a three-layered lithium transport cell
US5378325A (en) * 1991-09-17 1995-01-03 Aluminum Company Of America Process for low temperature electrolysis of metals in a chloride salt bath
US5593566A (en) * 1995-06-09 1997-01-14 General Motors Corporation Electrolytic production process for magnesium and its alloys

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100323253A1 (en) * 2006-02-22 2010-12-23 University Of Utah Resarch Foundation Systems and Methods for Hydrogen Storage and Generation from Water Using Lithium Based Materials

Also Published As

Publication number Publication date
CA2443953A1 (fr) 2002-10-24
NO20034548D0 (no) 2003-10-09
AUPR443901A0 (en) 2001-05-17
EP1392890A1 (fr) 2004-03-03
US20080110764A1 (en) 2008-05-15
CN1509346A (zh) 2004-06-30
NO20034548L (no) 2003-12-01
JP2004523662A (ja) 2004-08-05
EP1392890A4 (fr) 2004-10-06
WO2002083989A1 (fr) 2002-10-24
ZA200307978B (en) 2004-09-03

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AS Assignment

Owner name: BHP BILLITON INNOVATION PTY LTD., AUSTRALIA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:STREZOV, LAZAR;RATCHEV, IVAN;OSBORN, STEVE;REEL/FRAME:015486/0061

Effective date: 20040326

AS Assignment

Owner name: BHP BILLITON INNOVATION PTY LTD., AUSTRALIA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:STREZOV, LAZAR;RATCHEV, IVAN;OSBORN, STEVE;REEL/FRAME:015691/0388

Effective date: 20040326

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION