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MOLTEN SALT ELECTROLYSIS

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MOLTEN SALT ELECTROLYSIS ( molten-salt-electrolysis )

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26 Xiao Y. Yan and Derek J. Fray The FFC Cambridge process, patented globally in 1998, is a novel electrolytic method for removing oxygen from a metal (or an alloy) dissolved with oxygen or reducing metal oxide to metal in a molten salt or salt mixture, such as CaCl2, that have appreciable solubilities for oxide ion (O2-) [65]. Shown in figure 9 is the schematic representation of the FFC-Cambridge Process. Although originally developed for titanium, there are indications that the process is also able to produce other metals, alloys and intermetallic compounds in the form of powders or bulk materials at a fraction of the current costs [67, 78]. Figure 9. Schematic representation of the FFC-Cambridge Process [65, 66]. The FFC-Cambridge Process is based on the concept of cathodic ionisation. In this process, a metal or alloy dissolved with oxygen and metal or semi-metal oxides is immersed in molten salt bath and is acted as the cathode. On application of cathodic potentials more negative than oxygen ionisation potentials of the oxygen-containing cathode materials but less cathodic than cathodic depositions of cations from the electrolytes, the cathodic reaction is simply: O (metal or oxide) + 2e = O2- (molten salt) (23) This novel cathodic process is termed electro-deoxidation [69]. The overall reaction is much more complicated as the metal oxide does not normally go directly to the metal but through a series of suboxides and compounds between the oxide and calcium oxide. The metal is left behind at the cathode. An alloy or intermetallic compound can form when cathode materials are an oxide mixtures or complex metal oxide. At the carbon anode, ionized O2- ions are removed as CO or CO2 gas: xO2- (molten salt) + C = COx (gas) + 2xe (24)

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