Electrorefining apparatus and process for refining lithium metal

A three-layer electrorefining apparatus for refining relatively purer lithium metal from a lithium-alloy feedstock material, the apparatus comprising:

• a housing defining an interior chamber at least partially bounded by a housing sidewall and containing;
• an anode layer comprising a molten, lithium-alloy feedstock material that includes a combination lithium metal having a first purity and a carrier material that includes at least two of bismuth, indium, and tin;
• an electrolyte layer above the anode layer and comprising a molten salt electrolyte material;
• and
• a product layer above the electrolyte layer comprising molten lithium metal having a second purity that is greater than the first purity;
• an anode conductor member connectable to a power source and in contact with the lithium-alloy feedstock material in the anode layer;
• a cathode conductor member connectable to the power source, electrically isolated from the anode conductor member and in contact with the lithium metal in the product layer;
• a molten salt electrolyte inlet at a first end of the housing for introducing a flow of the molten salt electrolyte material into the interior chamber during operation;
• and
• a molten salt electrolyte outlet at a second end of the housing for allowing the molten salt electrolyte material to be withdrawn from the interior chamber during operation, the second end being spaced from the first end,
• whereby, when an activation electric potential that is sufficient to electrolyze the lithium-alloy feedstock material is applied between the anode layer and the product layer lithium metal is liberated from the lithium-alloy feedstock material, migrates through the electrolyte layer and collects in the product layer.