The present disclosure provides an electrochemical method for the separation of zirconium and hafnium, using an electrolytic cell equipped with an anode chamber and a cathode chamber, wherein the anode chamber and the cathode chamber are separated by a liquid alloy. In particular, the liquid alloy comprises a crude zirconium and a matrix metal with the metal activity lower than zirconium. After the electrolysis reaction is started, since the metal activity series in the liquid alloy is: hafnium>zirconium>>matrix metal, the hafnium in the liquid alloy is oxidized prior to the zirconium, the hafnium in ionic form migrates into the cathode electrolyte in the cathode chamber, leading to a continuous decrease of hafnium content in the liquid alloy, whereas the zirconium remains in the liquid alloy. Accordingly, deep separation of zirconium from hafnium is achieved, and therefore, nuclear-grade zirconium products can be prepared.

A method for separating metal components from a treatment material containing a silicate and metal elements includes: a reaction step of reacting the treatment material and a molten alkali hydroxide in which bubbles due to water vapor derived from water are generated by heating a hydroxide of an alkali metal or an alkaline-earth metal and the water in a state where the hydroxide and the water coexist, to obtain a reaction product; and a first precipitation step of dissolving the reaction product of the treatment material and the molten alkali hydroxide after the reaction step in water, thereby generating a precipitate containing the metal elements.

This invention provides an electrolyte salt for use in an electrodeposition process for depositing Zirconium metal on a thin foil substrate. The prior art electrochemical process causes a reaction between a uranium substrate and ZrF.sub.4 species in the electrolyte that causes the formation of UF.sub.x at the substrate surface that prevents the formation of a dense uniform zirconium coating. This problem is solved by using an electrolyte salt in an electrodeposition process consisting of lithium fluoride (LiF) in a concentration ranging between about 11.5 molar percent and about 61 molar percent and one or more salts selected from the group consisting of sodium fluoride (NaF), potassium fluoride (KF), cesium fluoride (CsF), or cesium chloride (CsCL). Zirconium is added to the electrolyte salt through an addition of zirconium fluoride (ZrF.sub.4) in the range of about 1 to about 5 mass percent (w/w %). The Zr coating is of at least 98% pure Zr with a density of at least 98%.

This invention provides an electrolyte salt for use in an electrodeposition process for depositing Zirconium metal on a thin foil substrate. The prior art electrochemical process causes a reaction between a uranium substrate and ZrF.sub.4 species in the electrolyte that causes the formation of UF.sub.x at the substrate surface that prevents the formation of a dense uniform zirconium coating. This problem is solved by using an electrolyte salt in an electrodeposition process consisting of lithium fluoride (LiF) in a concentration ranging between about 11.5 molar percent and about 61 molar percent and one or more salts selected from the group consisting of sodium fluoride (NaF), potassium fluoride (KF), cesium fluoride (CsF), or cesium chloride (CsCL). Zirconium is added to the electrolyte salt through an addition of zirconium fluoride (ZrF.sub.4) in the range of about 1 to about 5 mass percent (w/w %). The Zr coating is of at least 98% pure Zr with a density of at least 98%.

A method of refining a metal (e.g. titanium), comprising the following steps: (a) providing (10) an oxide of the metal having a level of impurities of at least 1.0 wt %; (b) reacting (12) the oxide of the metal to form an oxycarbide by providing an electrode comprising the oxide of the metal including calcium oxide and iron oxide. and carbon, and electrolytically reducing the electrode in a molten calcium chloride electrolyte; (c) electrolysing (14) the oxycarbide in an electrolyte, with the oxycarbide configured as an anode; and (d) recovering (16) a refined form of the metal from a cathode in the electrolyte.

A method of refining a metal (e.g. titanium), comprising the following steps: (a) providing (10) an oxide of the metal having a level of impurities of at least 1.0 wt %; (b) reacting (12) the oxide of the metal to form an oxycarbide by providing an electrode comprising the oxide of the metal including calcium oxide and iron oxide. and carbon, and electrolytically reducing the electrode in a molten calcium chloride electrolyte; (c) electrolysing (14) the oxycarbide in an electrolyte, with the oxycarbide configured as an anode; and (d) recovering (16) a refined form of the metal from a cathode in the electrolyte.

Provided is a method for producing metal by molten salt electrolysis, by which the metal can be efficiently produced. A method for producing metal by using an apparatus for molten salt electrolysis having an electrolytic cell and an electrode pair, wherein the molten salt electrolysis in the electrolytic cell and heating of the molten salt by a Joule heat generation between a pair of electrodes for electrolysis are simultaneously performed; and wherein the apparatus for molten salt electrolysis has at least two sets of electrode pair, and at least one set of the electrode pairs is electrically opened.

Provided is a method for producing metal by molten salt electrolysis, by which the metal can be efficiently produced. A method for producing metal by using an apparatus for molten salt electrolysis having an electrolytic cell and an electrode pair, wherein the molten salt electrolysis in the electrolytic cell and heating of the molten salt by a Joule heat generation between a pair of electrodes for electrolysis are simultaneously performed; and wherein the apparatus for molten salt electrolysis has at least two sets of electrode pair, and at least one set of the electrode pairs is electrically opened.

In a method for removing a substance from a feedstock comprising a solid metal or a solid metal compound, the feedstock is contacted with a fused-salt melt. The fused-salt melt contains a fused salt, a reactive-metal compound, and a reactive metal. The fused salt comprises an anion species which is different from the substance, the reactive-metal compound comprises the reactive metal and the substance, and the reactive metal is capable of reaction to remove at least some of the substance from the feedstock. A cathode and an anode contact the melt, and the feedstock contacts the cathode. An electrical current is applied between the cathode and the anode such that at least a portion of the substance is removed from the feedstock. During the application of the current, a quantity of the reactive metal in the melt is maintained sufficient to prevent oxidation of the anion species of the fused salt at the anode. The method may advantageously be usable for removing the substance from successive batches of the feedstock, where the applied current is controlled such that the fused-salt melt after processing a batch contains the quantity of the reactive metal sufficient to prevent oxidation of the anion species at the anode.

In a method for removing a substance from a feedstock comprising a solid metal or a solid metal compound, the feedstock is contacted with a fused-salt melt. The fused-salt melt contains a fused salt, a reactive-metal compound, and a reactive metal. The fused salt comprises an anion species which is different from the substance, the reactive-metal compound comprises the reactive metal and the substance, and the reactive metal is capable of reaction to remove at least some of the substance from the feedstock. A cathode and an anode contact the melt, and the feedstock contacts the cathode. An electrical current is applied between the cathode and the anode such that at least a portion of the substance is removed from the feedstock. During the application of the current, a quantity of the reactive metal in the melt is maintained sufficient to prevent oxidation of the anion species of the fused salt at the anode. The method may advantageously be usable for removing the substance from successive batches of the feedstock, where the applied current is controlled such that the fused-salt melt after processing a batch contains the quantity of the reactive metal sufficient to prevent oxidation of the anion species at the anode.