The invention generally relates to systems and methods for producing metal clusters; functionalized surfaces; and droplets including solvated metal ions. In certain aspects, the invention provides methods that involve providing a metal and a solvent. The methods additionally involve applying voltage to the solvated metal to thereby produce solvent droplets including ions of the metal containing compound, and directing the solvent droplets including the metal ions to a target. In certain embodiments, once at the target, the metal ions can react directly or catalyze reactions.

The invention generally relates to systems and methods for producing metal clusters; functionalized surfaces; and droplets including solvated metal ions. In certain aspects, the invention provides methods that involve providing a metal and a solvent. The methods additionally involve applying voltage to the solvated metal to thereby produce solvent droplets including ions of the metal containing compound, and directing the solvent droplets including the metal ions to a target. In certain embodiments, once at the target, the metal ions can react directly or catalyze reactions.

The invention generally relates to systems and methods for producing metal clusters; functionalized surfaces; and droplets including solvated metal ions. In certain aspects, the invention provides methods that involve providing a metal and a solvent. The methods additionally involve applying voltage to the solvated metal to thereby produce solvent droplets including ions of the metal containing compound, and directing the solvent droplets including the metal ions to a target. In certain embodiments, once at the target, the metal ions can react directly or catalyze reactions.

Provided is a tungsten electrode for molten salt electrolysis for rare earth metals preparation, including an open tungsten shell and a copper alloy body; wherein the copper alloy body is arranged inside the open tungsten shell; a tungsten buffer layer is provided between a side wall of the copper alloy body and the open tungsten shell; and a bottom of the copper alloy body is in contact with an inner bottom of the open tungsten shell.

Provided is a tungsten electrode for molten salt electrolysis for rare earth metals preparation, including an open tungsten shell and a copper alloy body; wherein the copper alloy body is arranged inside the open tungsten shell; a tungsten buffer layer is provided between a side wall of the copper alloy body and the open tungsten shell; and a bottom of the copper alloy body is in contact with an inner bottom of the open tungsten shell.

Electrochemically reacting a lanthanide or actinide in solvent at a working electrode; wherein the solvent comprises an organic solvent such as acetonitrile which have a dielectric constant of at least three; wherein the solvent system further comprises an electrolyte; wherein the working electrode comprises an ionically conducting or permeable film such as a fluorosulfonate film; wherein at least one ligand such as triflate distinct from the ionically conducting or permeable film is present; wherein the ligand is chemically similar to a structure in the ionically conducting or ionically permeable film; and optionally wherein the electrochemical oxidation or reduction is carried out under the influence of a magnetic field which favorably enhances the reaction. Improved electrochemical methods, identification, and separation can be achieved. Also, an electrochemical device, wherein the device is adapted to employ the oxygen reduction reaction (ORR) at the cathode, wherein the cathode is magnetically modified, or the electrolyte comprises at least one lanthanide or actinide, or both.

Electrochemically reacting a lanthanide or actinide in solvent at a working electrode; wherein the solvent comprises an organic solvent such as acetonitrile which have a dielectric constant of at least three; wherein the solvent system further comprises an electrolyte; wherein the working electrode comprises an ionically conducting or permeable film such as a fluorosulfonate film; wherein at least one ligand such as triflate distinct from the ionically conducting or permeable film is present; wherein the ligand is chemically similar to a structure in the ionically conducting or ionically permeable film; and optionally wherein the electrochemical oxidation or reduction is carried out under the influence of a magnetic field which favorably enhances the reaction. Improved electrochemical methods, identification, and separation can be achieved. Also, an electrochemical device, wherein the device is adapted to employ the oxygen reduction reaction (ORR) at the cathode, wherein the cathode is magnetically modified, or the electrolyte comprises at least one lanthanide or actinide, or both.

Provided herein is an electrodialysis metathesis system that has at least one stack or quad of compartments arranged so each compartment is in fluid communication with its adjacent compartment via alternating cation- and anion-exchange membranes. The compartments in a stack are a feed compartment, a substitution salt solution compartment, a first concentrated compartment and a second concentrated compartment. Also provided are processes and methods for separating or recovering a metal, for example, a rare earth element, or a salt or a combination thereof from a salt-containing water. Simultaneous metathesis reactions and electrodialysis across the stack recovers one or more metal or salts from the salt-containing water which desalinates the salt-containing water.

Provided herein is an electrodialysis metathesis system that has at least one stack or quad of compartments arranged so each compartment is in fluid communication with its adjacent compartment via alternating cation- and anion-exchange membranes. The compartments in a stack are a feed compartment, a substitution salt solution compartment, a first concentrated compartment and a second concentrated compartment. Also provided are processes and methods for separating or recovering a metal, for example, a rare earth element, or a salt or a combination thereof from a salt-containing water. Simultaneous metathesis reactions and electrodialysis across the stack recovers one or more metal or salts from the salt-containing water which desalinates the salt-containing water.

The present invention provides a method for recovery, extraction and separation of rare earth elements from rare earth containing materials such as ore and tailings. In accordance with preferred embodiments, the method of the present invention includes grinding rare earth-containing ores to form ore powder and leaching the powered ore with at least one mineral acid. Further, the method of the present invention includes forming a leach solution of metal ions, forming an aqueous-metal concentrate, and precipitating the aqueous-metal concentrate to selectively remove the metal ions from the leach solution. Further, the method of present invention includes the steps of obtaining a precipitate of the rare earth elements, mixing the precipitate with ammonium salt and subjected the mixture to an electrowinning process.