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 present invention provides a molten-salt electrolytic refining apparatus for refining a raw-material alloy containing indium using a molten-salt electrolytic refining method. The molten-salt electrolytic refining apparatus includes a reaction crucible provided in a reaction container so as to be filled with a molten-salt electrolytic solution, an anode and a cathode immersed in the molten-salt electrolytic solution, an anode crucible in which a liquid raw-material alloy is contained, a cathode crucible in which at least one raw-material metal included in the raw-material alloy is recovered in a liquid phase, and a heater provided so that the temperature of the molten-salt electrolytic solution is adjusted to be equal to or greater than the melting temperature of the raw-material alloy. The present invention also provides a molten-salt electrolytic refining method which includes recovering indium (In) from an indium-tin (InSn) alloy using a molten-salt electrolytic solution containing fluoride.

The present invention provides a molten-salt electrolytic refining apparatus for refining a raw-material alloy containing indium using a molten-salt electrolytic refining method. The molten-salt electrolytic refining apparatus includes a reaction crucible provided in a reaction container so as to be filled with a molten-salt electrolytic solution, an anode and a cathode immersed in the molten-salt electrolytic solution, an anode crucible in which a liquid raw-material alloy is contained, a cathode crucible in which at least one raw-material metal included in the raw-material alloy is recovered in a liquid phase, and a heater provided so that the temperature of the molten-salt electrolytic solution is adjusted to be equal to or greater than the melting temperature of the raw-material alloy. The present invention also provides a molten-salt electrolytic refining method which includes recovering indium (In) from an indium-tin (InSn) alloy using a molten-salt electrolytic solution containing fluoride.

A method of and system for electrolytic production of reactive metals is presented. The method includes providing a molten oxide electrolytic cell including a container, an anode, and a current collector and disposing a molten oxide electrolyte within the container and in ion conducting contact with the anode and the current collector. The electrolyte includes a mixture of at least one alkaline earth oxide and at least one rare earth oxide. The method also includes providing a metal oxide feedstock including at least one target metal species into the molten oxide electrolyte and applying a current between the anode and the current collector, thereby reducing the target metal species to form at least one molten target metal in the container.

A method of and system for electrolytic production of reactive metals is presented. The method includes providing a molten oxide electrolytic cell including a container, an anode, and a current collector and disposing a molten oxide electrolyte within the container and in ion conducting contact with the anode and the current collector. The electrolyte includes a mixture of at least one alkaline earth oxide and at least one rare earth oxide. The method also includes providing a metal oxide feedstock including at least one target metal species into the molten oxide electrolyte and applying a current between the anode and the current collector, thereby reducing the target metal species to form at least one molten target metal in the container.

A reduced iron production method using an electrowinning method and reduced iron is provided. The method includes, preparing a mixture by mixing, a solid electrolyte containing sodium peroxide (Na.sub.2O.sub.2) and boron oxide (B.sub.2O.sub.3), with iron oxide (Fe.sub.2O.sub.3); and putting the mixture in an electrowinning device provided with an anode and an insoluble cathode and heating to form a molten oxide and then applying a voltage to the anode and the cathode to form iron on the cathode. Therefore, by reducing iron oxide through an electrowinning method, a reduced iron in a pure iron state can be obtained. Although it is very difficult to obtain pure iron by refining an iron ore, by using the electrowinning method in which the composition of an electrolyte is controlled and electrolysis conditions are controlled, reduced iron that is pure can be obtained.

A reduced iron production method using an electrowinning method and reduced iron is provided. The method includes, preparing a mixture by mixing, a solid electrolyte containing sodium peroxide (Na.sub.2O.sub.2) and boron oxide (B.sub.2O.sub.3), with iron oxide (Fe.sub.2O.sub.3); and putting the mixture in an electrowinning device provided with an anode and an insoluble cathode and heating to form a molten oxide and then applying a voltage to the anode and the cathode to form iron on the cathode. Therefore, by reducing iron oxide through an electrowinning method, a reduced iron in a pure iron state can be obtained. Although it is very difficult to obtain pure iron by refining an iron ore, by using the electrowinning method in which the composition of an electrolyte is controlled and electrolysis conditions are controlled, reduced iron that is pure can be obtained.

Systems and methods for producing metal chloride M.sup.ICl.sub.x from metal M.sup.I without the use of HCl and/or Cl.sub.2 gases, including: a bath vessel holding conductive fluid; an anode disposed in the conductive fluid, the anode including metal M.sup.I; a cathode assembly disposed in the conductive fluid, the cathode assembly including a cathode vessel including porous and non-porous portions, the non-porous portion holding sacrificial metal chloride M.sup.IICl.sub.y substantially separate from metal chloride M.sup.ICl.sub.x, wherein the cathode assembly includes a center lead disposed within the cathode vessel operable for delivering charge to sacrificial metal chloride M.sup.IICl.sub.y; and a power supply coupling the anode and the cathode assembly, the power supply polarized to produce current flow in a direction that causes anodic dissolution of metal M.sup.I into the conductive fluid and deposition of metal M.sup.II within the cathode vessel. The systems and methods apply equally to producing metal halide M.sup.IX.sub.x.

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.