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Molten Salt Electrolysis for Sustainable Metals Extraction and Materials Processing 27 The FFC-Cambridge Process is much simpler, in principle, in operation and uses less energy than many current industrial technologies, such as the Kroll process, and promises a great potential for cheap production of useful reactive metals such as titanium, niobium, and tantalum. Its other advantage is to produce various metal alloys directly from mixed metal oxide powders, including TiNb, TiNi and niobium aluminides. This will offer more savings in energy and operation cost. It is also scientifically interesting because the electrolysis can be carried out on an insulating oxide, such as alumina and silica where the electro-deoxidation reaction starts at the three phase boundary between the salt, the insulating oxide and the connecting lead. As the conducting reduced phase forms, the reaction is able to occur over the surface of the pellets and gradually penetrates inside the pellet. Varous oxides have been reduced by this technique and these include, amongst others, TiO2 [66, 70], ZrO2 [71], Ta2O5 [72], Nb2O5 [73-76], Cr2O3 [77], PuO2 [78], and UO2 [79]. It should be noted that the only species that are removed are the anionic species so there is no refining of the cationic species. However, this can be used to advantage as it means that it is possible to produce alloys from mixtures of metal oxides. The oxides need not be in solid solution but simply in intimate contact. These alloys include Nb-Ti and Nb-Sn, Ti-Mo, Ti-Ni, Ti-W, Fe-Ti, Al-Sc, Ce-Ni, zirconium alloys, and niobium aluminides [80-88]. As well as metallic alloys, it is also possible to produce carbides, borides and silicides [89-91]. The overall cathodic reactions are: SiO2 +C+4e=SiC+2O2- (25) TiO2 +2B+4e=TiB2 +2O2- (26) TiO2 + B2O3 +10e = TiB2 + 5O2- (27) MoO2 +2Si+4e=MoSi2 +2O2- (28) MoO2 + 2SiO2 + 12e = MoSi2 + 6O2- (29) It is also possible to prepare coatings of metals, alloys and compounds by electro-deoxidising mixed layers of oxides or oxides and the metalloids on the surface of a substrate [91, 93]. 3.1.2. Applications of the FFC-Cambridge Process Fray has recently published several overview articles on novel molten salt electrochemical processes for sustainable production of metals and materials [93-96]. Apart from many of other metals, alloys, and intermetallics described above, the FFC-Cambridge Process has been applied to produce directly aluminium, magnesium, and silicon from Al2O3, MgO, and SiO2, respectively [54, 97, 98]. CaCl2-based electrolytes were used as the electrolytes and, thus, it would be much easily to incorporate O2-evolving inert anodes into the electrolytic cells, potentially making these alternative reduction processes “greener processes” [72, 99].PDF Image | MOLTEN SALT ELECTROLYSIS
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