The embodiments herein relate to methods, apparatus, and systems for forming and purifying solid carbon material from a molten carbonate salt electrolyte. Various embodiments also provide methods, apparatus, and systems for recycling certain materials including the carbonate salt electrolyte, carbon dioxide, water, etc. Advantageously, the system utilizes carbon dioxide in one or more processes, for example to purify the solid carbon and regenerate the carbonate salt electrolyte. These methods, apparatus, and systems provide an efficient technique to consume carbon dioxide in the production of solid carbon, with substantial advantages over systems that attempt to form solid carbon from a stream of carbon dioxide provided directly to an electrolysis reactor.

Disclosed is an electrochemical method for high-temperature molten salt electrolysis in humid atmosphere. The method involves preparing hydrogen gas, metals/alloys, metal oxide compounds and metal hydrides in humid high-temperature molten salt environment. Hydrogen gas is generated by electrolyzing water in a molten salt electrolyte at above 100 C., and with a working cathode being a solid-state oxide pellet and a voltage applied to the electrolyzing cell being far lower than that in a direct electro-deoxidation process, the hydrogen gas generated reduces solid-state oxide cathodes to produce metals. The hydrogen ions in the molten salt can be prepared by hydrolysis reaction of the molten salt in a water vapor containing atmosphere. Corresponding metals or alloys or metal oxide compounds can be prepared by reducing iron oxide, molybdenum oxide, tantalum oxide, nickel oxide, copper oxide, titanium oxide or corresponding compound oxides and the like.

Systems and methods for extracting lithium metal ions from a lithium containing ore such as spodumene or lithium salts are provided. The lithium ore or salt is suspended in a hydroxide salt or eutectic and heated to produce a molten salt suspension that is used to electroplate lithiated transition metal oxides on an electrode. Lithium metal or lithium ions can be isolated from the deposited lithiated transition metal oxides. A second metal ore may be included in the suspension and processed with the lithium ore.

The present invention relates to the production of graphene from CO.sub.2 through electrolysis and exfoliation processes. One embodiment is a method for producing graphene comprising (i) performing electrolysis between an electrolysis anode and an electrolysis cathode in a molten carbonate electrolyte to generate carbon nanomaterial on the cathode, and (ii) electrochemically exfoliating the carbon nanomaterial from a second anode to produce graphene. The exfoliating step produces graphene in high yield than thicker, conventional graphite exfoliation reactions. CO.sub.2 can be the sole reactant used to produce the valuable product as graphene. This can incentivize utilization of CO.sub.2, and unlike alternative products made from CO.sub.2 such as carbon monoxide or other fuels such as methane, use of the graphene product does not release this greenhouse gas back into the atmosphere.

A system and process for producing carbon nano-materials is disclosed. A carbonate material such as Li.sub.2CO.sub.3 is heated via a furnace to transform into molten carbonate. CO.sub.2 is bubbled into the molten carbonate. The molten carbonate is subjected to electrolysis by passing current from an anode to a cathode. A transition metal nucleation agent is added to result in nucleation sites that grow carbon nano-materials at the cathode. This process separates oxygen at the anode and carbon nano-materials at the cathode. The characteristics of the carbon nano-material may be controlled by varying current density, feed gas, transition metal composition, temperature, viscosity and electrolyte composition.

According to one embodiment, a system includes an electrochemical cell that includes a crucible having a molten CaCO.sub.3:CaCl.sub.2:CaO mixture therein, where a cathode and an inert anode are positioned in the molten CaCO.sub.3:CaCl.sub.2:CaO mixture, and an inlet for feeding carbon dioxide gas into the molten CaCO.sub.3:CaCl.sub.2:CaO mixture. In addition, the system includes a furnace having an inert atmosphere therein, where the electrochemical cell is sealed in the furnace having the inert atmosphere.

The embodiments of the present disclosure relate to a method and apparatus for producing a carbon nanomaterial product (CNM) product that may comprise carbon nanotubes and various other allotropes of nanocarbon. The method and apparatus employ a consumable carbon dioxide (CO.sub.2) and a renewable carbonate electrolyte as reactants in an electrolysis reaction in order to make CNTs. In some embodiments of the present disclosure, operational conditions of the electrolysis reaction may be varied in order to produce the CNM product with a greater incidence of a desired allotrope of nanocarbon or a desired combination of two or more allotropes.

The embodiments of the present disclosure relate to a method and apparatus for producing a carbon nanomaterial product (CNM) product that may comprise carbon nanotubes and various other allotropes of nanocarbon. The method and apparatus employ a consumable carbon dioxide (CO.sub.2) and a renewable carbonate electrolyte as reactants in an electrolysis reaction in order to make CNTs. In some embodiments of the present disclosure, operational conditions of the electrolysis reaction may be varied in order to produce the CNM product with a greater incidence of a desired allotrope of nanocarbon or a desired combination of two or more allotropes.

Embodiments of the present disclosure relate to an apparatus, system and method for making an admixture of a polymer and carbon nanomaterials (CNM). The admixture of such embodiments comprise about 10% or less by weight (wt %) of CNMs. The CNM content of such admixture may impart new or enhanced properties to the admix and to materials and products made therefrom. Such new or enhanced products may include enhanced tensile strength, new or enhanced electronic medical, structural thermal, catalytic properties or any combination thereof.

Disclosed is an electrochemical method for high-temperature molten salt electrolysis in humid atmosphere. The method involves preparing hydrogen gas, metals/alloys, metal oxide compounds and metal hydrides in humid high-temperature molten salt environment. Hydrogen gas is generated by electrolyzing water in a molten salt electrolyte at above 100 C., and with a working cathode being a solid-state oxide pellet and a voltage applied to the electrolyzing cell being far lower than that in a direct electro-deoxidation process, the hydrogen gas generated reduces solid-state oxide cathodes to produce metals. The hydrogen ions in the molten salt can be prepared by hydrolysis reaction of the molten salt in a water vapor containing atmosphere. Corresponding metals or alloys or metal oxide compounds can be prepared by reducing iron oxide, molybdenum oxide, tantalum oxide, nickel oxide, copper oxide, titanium oxide or corresponding compound oxides and the like.