Methods are proposed for extracting transition metal oxides from scrap batteries by dissolving the metal oxides in a glass-forming oxide melt, followed by electrolytic reduction of the transition metal onto the cathode of an electrolytic cell. Suitable glass-forming oxide melts include borate and pyrophosphate melts with added Na.sub.2O or NaF. The method is particularly suited to the recovery of cobalt, nickel, and manganese from scrap battery and electronic materials. A preferred recycling process includes first recovering lithium metal from scrap battery material, and then extracting transition metal oxides from the lithium-depleted material.

A method for recycling molten salt from electrorefining processes, the method having the steps of collecting actinide metal using a first plurality of cathodes from an electrolyte bath, collecting rare earths metal using a second plurality of cathodes from the electrolyte bath, inserting the collected actinide metal and uranium into the bath, and chlorinating the inserted actinide metal and uranium. Also provided is a system for recycling molten salt, the system having a vessel adapted to receive and heat electrolyte salt, a first plurality of cathodes adapted to be removably inserted into the vessel, a second plurality of cathodes adapted to be removably inserted into the vessel, an anode positioned within the vessel so as to be coaxially aligned with the vessel, and a vehicle for inserting uranium into the salt.

A method for recycling molten salt from electrorefining processes, the method having the steps of collecting actinide metal using a first plurality of cathodes from an electrolyte bath, collecting rare earths metal using a second plurality of cathodes from the electrolyte bath, inserting the collected actinide metal and uranium into the bath, and chlorinating the inserted actinide metal and uranium. Also provided is a system for recycling molten salt, the system having a vessel adapted to receive and heat electrolyte salt, a first plurality of cathodes adapted to be removably inserted into the vessel, a second plurality of cathodes adapted to be removably inserted into the vessel, an anode positioned within the vessel so as to be coaxially aligned with the vessel, and a vehicle for inserting uranium into the salt.

It is the object of the present invention to present a cell for extracting oxygen from lunar regolith via Molten Oxide Electrolysis, comprising (i) a cathode, (ii) an anode and (iii) a crucible, wherein the anode is characterized as at least partially liquid. The anode may be constructed from palladium, lead, silver, gold, platinum tantalum, or from a mixture.

A system for extracting oxygen from powdered metal oxides, the system comprising a container comprising an electrolyte in the form of meltable or molten salt, at least one cathode, at least one anode, a power supply, and a conducting structure, wherein the cathode is shaped as a receptacle having a porous shell, which has an upper opening, the cathode being arranged in the electrolyte with the opening protruding over the electrolyte, wherein the conducting structure comprises a plurality of conducting elements and gaps between the conducting elements, wherein the power supply is connectable to the at least one cathode and the at least one anode to selectively apply an electric potential across the cathode and the anode, wherein the conducting structure is insertable into the cathode, such that the conducting elements reach into an inner space of the cathode, wherein the conducting structure is electrically connectable to the cathode, and wherein the system is adapted for reducing at least one respective metallic species of at least one metal oxide of feedstock inside the shell of the cathode with inserted conducting structure by applying the electric potential, wherein the potential is greater than the dissociation potential of the at least one metal oxide.

Methods for electrochemical extraction of metals, and methods for determining electrolyte fluids suitable therefor. A method of extracting, separating, and/or purifying a method includes immersing an electrochemical cell including an anode and a cathode in a liquid including the metal to form a layer including the metal on the cathode. The immersing includes applying an electrochemical potential across the anode and cathode.

According to an embodiment, a nuclear fuel material recovery method of recovering a nuclear fuel material containing thorium metal by reprocessing an oxide of a nuclear fuel material containing thorium oxide in a spent fuel is provided. The method has: a first electrolytic reduction step of electrolytically reducing thorium oxide in a first molten salt of alkaline-earth metal halide; a first reduction product washing step of washing a reduction product; and a main electrolytic separation step of separating the reduction product. The first molten salt further contains alkali metal halide, and contains at least one out of a group consisting of calcium chloride, magnesium chloride, calcium fluoride and magnesium fluoride. The method may further has a second electrolytic reduction step of electrolytically reducing uranium oxide, plutonium oxide, and minor actinoid oxide in a second molten salt of alkali metal halide.

According to an embodiment, a nuclear fuel material recovery method of recovering a nuclear fuel material containing thorium metal by reprocessing an oxide of a nuclear fuel material containing thorium oxide in a spent fuel is provided. The method has: a first electrolytic reduction step of electrolytically reducing thorium oxide in a first molten salt of alkaline-earth metal halide; a first reduction product washing step of washing a reduction product; and a main electrolytic separation step of separating the reduction product. The first molten salt further contains alkali metal halide, and contains at least one out of a group consisting of calcium chloride, magnesium chloride, calcium fluoride and magnesium fluoride. The method may further has a second electrolytic reduction step of electrolytically reducing uranium oxide, plutonium oxide, and minor actinoid oxide in a second molten salt of alkali metal halide.

The invention provides a system for collecting metal in an electrorefining process, the system having a hollow cathode; and a container defining an upwardly extending surface adapted to be received by the hollow cathode. An embodiment of the invention provides for metal reduction to occur on laterally facing and medially facing surfaces of the cathode such that electrolyte resides between surfaces of the cathode. Also provided is a metal electrorefining process having the steps of subjecting molten salt containing metal moieties to electrolysis wherein reduced metal accumulates in a cathode-cup construct in a first position; raising the construct to a second position above the molten salt while subjecting the construct to heat from the molten salt; withdrawing the cathode from the construct into a vestibule to the electrorefiner to a third position; and removing the cathode and cup from the electrorefiner to a fourth position.

The invention provides a system for collecting metal in an electrorefining process, the system having a hollow cathode; and a container defining an upwardly extending surface adapted to be received by the hollow cathode. An embodiment of the invention provides for metal reduction to occur on laterally facing and medially facing surfaces of the cathode such that electrolyte resides between surfaces of the cathode. Also provided is a metal electrorefining process having the steps of subjecting molten salt containing metal moieties to electrolysis wherein reduced metal accumulates in a cathode-cup construct in a first position; raising the construct to a second position above the molten salt while subjecting the construct to heat from the molten salt; withdrawing the cathode from the construct into a vestibule to the electrorefiner to a third position; and removing the cathode and cup from the electrorefiner to a fourth position.