Removal of substances from metal and semi-metal compounds
AssigneeMetalysis Limited
InventorsDerek John Fray, Thomas William Farthing, Zheng Chen
Life of this patent
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Abstract
The present invention pertains to a method for removing a substance (X) from a solid metal or semi-metal compound (M1X) by electrolysis in a melt of M2Y, which comprises conducting the electrolysis under conditions such that reaction of X rather than M2 deposition occurs at a electrode surface, and that X dissolves in the electrolyte M2Y. The substance X is either removed from the surface (i.e., M1X) or by means of diffusion extracted from the case material. The temperature of the fused salt is chosen below the melting temperature of the metal M1. The potential is chosen below the decomposition potential of the electrolyte.
Claims73
A method for decomposing a solid compound by removing a substance (X) from the solid compound (M1X) between the substance and a metal or semi-metal (M1), comprising the steps of:
- (a) providing the solid compound in the form of a powder and forming the powder into a predetermined shape;
- (b) arranging a cathode comprising the solid compound, in the predetermined shape, in contact with an electrolyte (M2Y) comprising a fused salt;
- (c) arranging an anode in contact with the electrolyte;
- and
- (d) decomposing said solid compound by applying a cell potential of 3.5V or less between the cathode and the anode such that the substance dissolves in the electrolyte.
A method for decomposing a solid compound by removing a substance (X) from the solid compound (M1X) between the substance and a metal or semi-metal (M1), wherein the solid compound is an insulator, comprising the steps of:
- (a) providing the solid compound in the form of a powder and forming the powder into a predetermined shape;
- (b) arranging a cathode comprising the solid compound, in the predetermined shape, in contact with an electrolyte (M2Y) comprising a fused salt;
- (c) arranging an anode in contact with the electrolyte;
- and
- (d) decomposing said solid compound by applying a voltage between the cathode and the anode such that the substance dissolves in the electrolyte.
A method for decomposing a solid compound by removing a substance (X) from the solid compound (M1X) between the substance and a metal or semi-metal (M1), comprising the steps of:
- (a) providing the solid compound in the form of a powder and forming the powder into a predetermined shape;
- (b) arranging a cathode comprising the solid compound, in the predetermined shape, in contact with an electrolyte (M2Y) comprising a fused salt, the electrolyte comprising a cation (M2);
- (c) arranging an anode in contact with the electrolyte;
- and
- (d) decomposing said solid compound by applying a voltage between the cathode and the anode such that the substance dissolves in the electrolyte and such that the metal or semi-metal produced by the method contains substantially no deposit of metal from the discharge of the cation from the electrolyte.
A method for decomposing a solid compound by removing a substance (X) from the solid compound (M1X) between the substance and a metal or semi-metal (M1), comprising the steps of:
- (a) arranging a cathode, comprising the solid compound in sintered form, in contact with an electrolyte (M2Y) comprising a fused salt;
- (b) arranging an anode in contact with the electrolyte;
- and
- (c) decomposing said solid compound by applying a voltage between the cathode and the anode such that the substance dissolves in the electrolyte.
A method for forming an alloy of two or more metal or semi-metal components (M1, MN) comprising the steps of:
- (a) providing solid compounds (M1X, MNZ) of each of the components with another substance or substances (X, Z), each solid compound being in the form of a powder;
- (b) mixing the powders of the solid compounds together;
- (c) providing an electrolyte (M2Y) comprising a fused salt;
- (d) arranging a cathode comprising the mixed powders of the solid compounds in contact with the electrolyte;
- (e) arranging an anode in contact with the electrolyte;
- and
- (f) applying a voltage between the cathode and the anode such that the substance or substances dissolve(s) in the electrolyte.
A method for forming an alloy of two or more metal or semi-metal components (M1, MN), comprising the steps of:
- (a) providing solid compounds (M1X, MNZ) of each of the components with another substance or substances (X, Z), each solid compound being in the form of a powder, at least one of the compounds being an insulator;
- (b) mixing the powders of the solid compounds together;
- (c) providing an electrolyte (M2Y) comprising a fused salt;
- (d) arranging a cathode comprising the mixed powders of the solid compounds in contact with the electrolyte;
- (e) arranging an anode in contact with the electrolyte;
- and
- (f) applying a voltage between the cathode and the anode such that the substance or substances dissolve(s) in the electrolyte.
A method for forming an alloy of two or more metal or semi-metal components (M1, MN), comprising the steps of:
- (a) providing solid compounds (M1X, MNZ) of each of the components with another substance or substances (X, Z), each solid compound being in the form of a powder;
- (b) mixing and sintering the powders of the solid compounds together;
- (c) providing an electrolyte (M2Y) comprising a fused salt;
- (d) arranging a cathode, comprising the sintered powders of the solid compounds held in or by a conductor, in contact with an electrolyte;
- (e) arranging an anode in contact with the electrolyte;
- and
- (f) applying a voltage between the cathode and the anode such that the substance or substances dissolve(s) in the electrolyte.
A method for fabricating a product, comprising the steps of:
- (a) providing a solid compound between a substance (X) and a metal or semi-metal (M1), the solid compound being in the form of a powder;
- (b) forming from said powder an artefact of a predetermined shape for treatment by electrolysis to produce an electrolysis product;
- and
- (c) conducting the electrolysis by arranging a cathode comprising the artefact in contact with an electrolyte (M2Y) comprising a fused salt, arranging an anode in contact with the electrolyte and applying a voltage between the cathode and the anode such that the substance dissolves in the electrolyte, the electrolysis product remaining in the original shape.
A method for fabricating a product, comprising the steps of:
- (a) providing a solid compound between a substance (X) and a metal or semi-metal (M1), the solid compound being in the form of a powder;
- (b) forming from said powder an electrode with a desired or predetermined shape for treatment by electrolysis to produce an electrolysis product;
- and
- (c) conducting the electrolysis by arranging the electrode in contact with an electrolyte (M2Y) comprising a fused salt, arranging an anode in contact with the electrolyte and applying a voltage between the electrode and the anode such that the substance dissolves in the electrolyte, the electrolysis product remaining in the original shape.
Dependencies are inferred from the claim text.