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.

A method of removing of recovering an elemental rare earth metal comprises placing a rare earth-containing material comprising a rare earth metal in a reaction solution comprising a reducing agent and a non-aqueous solvent comprising an ionic liquid or a eutectic mixture, reducing the rare earth metal with the reducing agent to form a metallic rare earth metal and cations of the reducing agent, transferring the cations of the reducing agent from the reaction solution to an electrochemical cell through an ion exchange membrane, and reducing the cations of the reducing agent in the electrochemical cell. Related methods of forming an elemental rare earth metal, and related systems are disclosed.

A method of producing uranium halides is disclosed in which chlorine gas is introduced into a liquid uranium-nickel alloy. NaCl salt is surrounding the crucible containing the liquid uranium-nickel alloy, producing a eutectic mixture of NaCl—UCl.sub.3. Upon chlorination, the metal halide dissolves in the matrix salt forming a solution. Adding the reactant metal, uranium to the nickel, the alloy is able to remain molten throughout processing. The liquid metal alloy may be removed from the salt bath, while the halogen gas continues to enter the system through the sparge until the desired composition of NaCl—UCl.sub.3—UCl.sub.4 is achieved. The method and system can be used to produce other metal halide salts such as actinide, lanthanide or transition metal halides contained in a matrix salt consisting of alkali and/or alkaline earth halides.

A method of producing uranium halides is disclosed in which chlorine gas is introduced into a liquid uranium-nickel alloy. NaCl salt is surrounding the crucible containing the liquid uranium-nickel alloy, producing a eutectic mixture of NaCl—UCl.sub.3. Upon chlorination, the metal halide dissolves in the matrix salt forming a solution. Adding the reactant metal, uranium to the nickel, the alloy is able to remain molten throughout processing. The liquid metal alloy may be removed from the salt bath, while the halogen gas continues to enter the system through the sparge until the desired composition of NaCl—UCl.sub.3—UCl.sub.4 is achieved. The method and system can be used to produce other metal halide salts such as actinide, lanthanide or transition metal halides contained in a matrix salt consisting of alkali and/or alkaline earth halides.

Various embodiments utilize selective sulfidation and/or desulfidation for such things as ore and concentrate cracking, metal separation, compound production, and recycling. Selective sulfidation can be used to selectively convert an oxide or other material in a feedstock to a sulfide or other sulfur-containing material, and selective desulfidation can be used to selectively convert a sulfide or other sulfur-containing material in a feedstock to an oxide or other material. In some cases, the material produced by such selective sulfidation/desulfidation of the feedstock can itself be novel and/or commercially valuable, while in other cases, such selective sulfidation/desulfidation can be followed by one or more processes to extract, isolate, or concentrate the converted material.

Various embodiments utilize selective sulfidation and/or desulfidation for such things as ore and concentrate cracking, metal separation, compound production, and recycling. Selective sulfidation can be used to selectively convert an oxide or other material in a feedstock to a sulfide or other sulfur-containing material, and selective desulfidation can be used to selectively convert a sulfide or other sulfur-containing material in a feedstock to an oxide or other material. In some cases, the material produced by such selective sulfidation/desulfidation of the feedstock can itself be novel and/or commercially valuable, while in other cases, such selective sulfidation/desulfidation can be followed by one or more processes to extract, isolate, or concentrate the converted material.

A method of direct oxide reduction includes forming a molten salt electrolyte in an electrochemical cell, disposing at least one metal oxide in the electrochemical cell, disposing a counter electrode comprising a material selected from the group consisting of osmium, ruthenium, rhodium, iridium, palladium, platinum, silver, gold, lithium iridate, lithium ruthenate, a lithium rhodate, a lithium tin oxygen compound, a lithium manganese compound, strontium ruthenium ternary compounds, calcium iridate, strontium iridate, calcium platinate, strontium platinate, magnesium ruthenate, magnesium iridate, sodium ruthenate, sodium iridate, potassium iridate, and potassium ruthenate in the electrochemical cell, and applying a current between the counter electrode and the at least one metal oxide to reduce the at least one metal oxide. Related methods of direct oxide reduction and related electrochemical cells are also disclosed.

A method of direct oxide reduction includes forming a molten salt electrolyte in an electrochemical cell, disposing at least one metal oxide in the electrochemical cell, disposing a counter electrode comprising a material selected from the group consisting of osmium, ruthenium, rhodium, iridium, palladium, platinum, silver, gold, lithium iridate, lithium ruthenate, a lithium rhodate, a lithium tin oxygen compound, a lithium manganese compound, strontium ruthenium ternary compounds, calcium iridate, strontium iridate, calcium platinate, strontium platinate, magnesium ruthenate, magnesium iridate, sodium ruthenate, sodium iridate, potassium iridate, and potassium ruthenate in the electrochemical cell, and applying a current between the counter electrode and the at least one metal oxide to reduce the at least one metal oxide. Related methods of direct oxide reduction and related electrochemical cells are also disclosed.

The following describes a reconfigurable set of industrial processing techniques which, when appropriately combined, enable zero-emissions reforming, utilizing a wide range of conventional and unconventional feedstocks. Hydrocarbons, harvested or refuse biomass, as well as assorted byproducts and wastes are reformed through tightly integrated processing. The system is designed to incorporate alternative energy sources such as renewables or nuclear for high-density energy utilization and storage. Central to the processing methodology is a novel molten salt electrochemical reactor designed as a modular system for high-throughput carbochlorination and resource recovery. Such a configuration drastically reduces or eliminates waste while improving efficiency and realizing vast new economic incentives.

The following describes a reconfigurable set of industrial processing techniques which, when appropriately combined, enable zero-emissions reforming, utilizing a wide range of conventional and unconventional feedstocks. Hydrocarbons, harvested or refuse biomass, as well as assorted byproducts and wastes are reformed through tightly integrated processing. The system is designed to incorporate alternative energy sources such as renewables or nuclear for high-density energy utilization and storage. Central to the processing methodology is a novel molten salt electrochemical reactor designed as a modular system for high-throughput carbochlorination and resource recovery. Such a configuration drastically reduces or eliminates waste while improving efficiency and realizing vast new economic incentives.