A method and an apparatus for manufacturing a metallic article involve providing a non-metallic feedstock, for example in the form of an oxide of a desired metal or a mixture of oxides of the components of a desired metal alloy. A manufacturing apparatus has a reduction apparatus for electrochemically reducing the feedstock to a metallic product and a processor for converting the metallic product to a metallic powder. The powder is fed into an additive-manufacturing apparatus for fabricating the metallic article from the metallic powder. At least the reduction apparatus and the processor, and preferably also the additive-manufacturing apparatus, are collocated, or located in the same container, or in the same building, or on the same site.
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
B33Y 50/02 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
B22D 23/00 - Procédés de coulée non prévus dans les groupes
B22F 3/115 - Fabrication de pièces ou d'objets à partir de poudres métalliques, caractérisée par le mode de compactage ou de frittageAppareils spécialement adaptés à cet effet par pulvérisation de métal fondu, c.-à-d. frittage par pulvérisation, moulage par pulvérisation
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
C25C 5/04 - Production, récupération ou affinage de poudres métalliques ou de métaux poreux à partir de bains fondus
B22F 1/052 - Poudres métalliques caractérisées par la dimension ou la surface spécifique des particules caractérisées par un mélange de particules de dimensions différentes ou par la distribution granulométrique des particules
A method of making a graphene-containing material comprising the steps of: electrolytically reducing a transition metal oxide to a transition metal in an electrolytic cell using a molten salt electrolyte and a carbon anode; followed by extracting a dry graphene material from the electrolytic cell. Also provided is a graphene-containing material obtainable by the method of the invention.
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
C25C 1/06 - Production, récupération ou affinage électrolytique des métaux par électrolyse de solutions des métaux du groupe du fer, de métaux réfractaires ou du manganèse
A method of forming a powder of a composite material is provided, each composite powder particle comprising both a matrix phase and a reinforcement phase distributed within the matrix phase. The method comprises the step of forming a precursor powder (190) with an average particle size of less than 150 micrometres, each precursor powder particle comprising a matrix precursor material and a reinforcement precursor material. The matrix precursor material comprises a reducible compound comprising a first metal and oxygen. The precursor powder is reduced under conditions in which oxygen is removed from the matrix precursor material. The matrix phase of the composite thus comprises the first metal. The reinforcement phase of the composite derives from a reaction of the reinforcement precursor material. A precursor powder (190) and a powder of a composite material are also provided.
B22F 1/02 - Traitement particulier des poudres métalliques, p.ex. en vue de faciliter leur mise en œuvre, d'améliorer leurs propriétés; Poudres métalliques en soi, p.ex. mélanges de particules de compositions différentes comportant un enrobage des particules
B22F 9/02 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par des procédés physiques
B22F 9/18 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
B22F 9/22 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides utilisant des réducteurs gazeux
C22C 1/05 - Mélanges de poudre métallique et de poudre non métallique
C22C 29/00 - Alliages à base de carbures, oxydes, borures, nitrures ou siliciures, p. ex. cermets, ou d'autres composés métalliques, p. ex. oxynitrures, sulfures
C22C 32/00 - Alliages non ferreux contenant entre 5 et 50% en poids d'oxydes, de carbures, de borures, de nitrures, de siliciures ou d'autres composés métalliques, p. ex. oxynitrures, sulfures, qu'ils soient soient ajoutés comme tels ou formés in situ
4.
COMPOSITE POWDER AND METHOD OF PRODUCING COMPOSITE POWDER
A method of forming a powder of a composite material is provided, each composite powder particle comprising both a matrix phase and a reinforcement phase distributed within the matrix phase. The method comprises the step of forming a precursor powder (190) with an average particle size of less than 150 micrometres, each precursor powder particle comprising a matrix precursor material and a reinforcement precursor material. The matrix precursor material comprises a reducible compound comprising a first metal and oxygen. The precursor powder is reduced under conditions in which oxygen is removed from the matrix precursor material, but in which the reinforcement precursor material does not react. Thus, the matrix phase of the composite comprises the first metal, and the reinforcement phase of the composite consists of the reinforcement precursor material. A precursor powder (190) and a powder of a composite material are also provided.
B22F 1/00 - Poudres métalliquesTraitement des poudres métalliques, p. ex. en vue de faciliter leur mise en œuvre ou d'améliorer leurs propriétés
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
C22C 32/00 - Alliages non ferreux contenant entre 5 et 50% en poids d'oxydes, de carbures, de borures, de nitrures, de siliciures ou d'autres composés métalliques, p. ex. oxynitrures, sulfures, qu'ils soient soient ajoutés comme tels ou formés in situ
Method of Producing a Composite Material A method of forming a composite material comprising a matrix phase and a reinforcement phase distributed within the matrix phasecomprises the step of growing a plurality of precursor particles comprising a matrix precursor material and a reinforcement precursor material using a fluidised-bed spray granulation process, thereby forming a precursor powder (190).The matrix precursor material comprisesa reducible compound comprising a first metal and oxygen. The precursor powder is reduced under conditions in which oxygen is removed from the matrix precursor material.The matrix phase of the composite comprises the first metal, and the reinforcement phase of the composite either consists of the reinforcement precursor material or derives from a reaction of the reinforcement precursor material.A precursor powder (190) and a composite material are also provided. (Figure4)
B22F 1/02 - Traitement particulier des poudres métalliques, p.ex. en vue de faciliter leur mise en œuvre, d'améliorer leurs propriétés; Poudres métalliques en soi, p.ex. mélanges de particules de compositions différentes comportant un enrobage des particules
B22F 9/02 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par des procédés physiques
B22F 9/18 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
B22F 9/22 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides utilisant des réducteurs gazeux
C22C 1/05 - Mélanges de poudre métallique et de poudre non métallique
C22C 29/00 - Alliages à base de carbures, oxydes, borures, nitrures ou siliciures, p. ex. cermets, ou d'autres composés métalliques, p. ex. oxynitrures, sulfures
C22C 32/00 - Alliages non ferreux contenant entre 5 et 50% en poids d'oxydes, de carbures, de borures, de nitrures, de siliciures ou d'autres composés métalliques, p. ex. oxynitrures, sulfures, qu'ils soient soient ajoutés comme tels ou formés in situ
6.
APPARATUS FOR MANUFACTURING A METALLIC ARTICLE AND METHOD FOR MANUFACTURING A METALLIC ARTICLE FROM A POWDER FEEDSTOCK
A method and an apparatus for manufacturing a metallic article involve providing a non- metallic feedstock, for example in the form of an oxide of a desired metal or a mixture of oxides of the components of a desired metal alloy. A manufacturing apparatus has a reduction apparatus for electrochemically reducing the feedstock to a metallic product and a processor for converting the metallic product to a metallic powder. The powder is fed into an additive-manufacturing apparatus for fabricating the metallic article from the metallic powder. At least the reduction apparatus and the processor, and preferably also the additive-manufacturing apparatus, are collocated, or located in the same container, or in the same building, or on the same site.
A method and an apparatus for manufacturing a metallic article involve providing a non- metallic feedstock, for example in the form of an oxide of a desired metal or a mixture of oxides of the components of a desired metal alloy. A manufacturing apparatus has a reduction apparatus for electrochemically reducing the feedstock to a metallic product and a processor for converting the metallic product to a metallic powder. The powder is fed into an additive-manufacturing apparatus for fabricating the metallic article from the metallic powder. At least the reduction apparatus and the processor, and preferably also the additive-manufacturing apparatus, are collocated, or located in the same container, or in the same building, or on the same site.
A method of making a graphene-containing material comprising the steps of: electrolytically reducing a transition metal oxide to a transition metal in an electrolytic cell using a molten salt electrolyte and a carbon anode; followed by extracting a dry graphene material from the electrolytic cell. Also provided is a graphene-containing material obtainable by the method of the invention.
A method of producing metallic tantalum comprises the steps of providing a precursor comprising a tantalate of a first metal, arranging the precursor material in contact with a molten salt in an electrolytic cell, the electrolysis cell further comprising an anode and a cathode arranged in contact with the molten salt, and applying a potential between the anode and the cathode such that the precursor material is reduced to tantalum. The first metal is an alkali metal or an alkaline earth metal. The anode does not comprise a carbon material, which prevents contamination of the tantalum and improves current efficiency of the process.
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
H01G 9/00 - Condensateurs électrolytiques, redresseurs électrolytiques, détecteurs électrolytiques, dispositifs de commutation électrolytiques, dispositifs électrolytiques photosensibles ou sensibles à la températureProcédés pour leur fabrication
A method of producing a non-metallic feedstock powder suitable for reduction to metal comprises the steps of combining a liquid with solid metal oxide particles to form a mixture, subjecting the mixture to high-shear mixing to form a liquid suspension of metal oxide and the liquid, and drying the liquid suspension using a fluidised-bed spray-granulation process to grow a plurality particles to form the non-metallic feedstock powder. The method allows feedstock powders to be grown to desired particle sizes. The method allows production of feedstock powders having controlled compositions.
B01J 2/04 - Procédés ou dispositifs pour la granulation de substances, en généralTraitement de matériaux particulaires leur permettant de s'écouler librement, en général, p. ex. en les rendant hydrophobes par division du produit liquide en gouttelettes, p. ex. par pulvérisation, et solidification des gouttelettes en milieu gazeux
B01J 2/16 - Procédés ou dispositifs pour la granulation de substances, en généralTraitement de matériaux particulaires leur permettant de s'écouler librement, en général, p. ex. en les rendant hydrophobes par suspension de la substance en poudre dans un gaz, p. ex. sous forme de "lits fluidisés" ou de rideau
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
C22B 5/02 - Procédés généraux de réduction appliqués aux métaux par voie sèche
C25C 3/36 - Alliages obtenus par réduction cathodique de tous leurs ions
A method of producing a non-metallic feedstock powder suitable for reduction to metal comprises the steps of combining a liquid with solid metal oxide particles to form a mixture, subjecting the mixture to high-shear mixing to form a liquid suspension of metal oxide and the liquid, and drying the liquid suspension using a fluidised-bed spray-granulation process to grow a plurality particles to form the non-metallic feedstock powder. The method allows feedstock powders to be grown to desired particle sizes. The method allows production of feedstock powders having controlled compositions.
C25C 3/36 - Alliages obtenus par réduction cathodique de tous leurs ions
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
B01J 2/00 - Procédés ou dispositifs pour la granulation de substances, en généralTraitement de matériaux particulaires leur permettant de s'écouler librement, en général, p. ex. en les rendant hydrophobes
A method is provided for producing metal by electrolytic reduction of a feedstock comprising an oxide of a first metal. The method comprises the steps of arranging the feedstock in contact with a cathode and a molten salt within an electrolysis cell, arranging an anode in contact with the molten salt within the electrolysis cell, and applying a potential between the anode and the cathode such that oxygen is removed from the feedstock. The anode comprises a second metal, which at the temperature of electrolysis within the cell is a molten metal. The second metal is a different metal to the first metal. Oxygen removed from the feedstock during electrolysis reacts with the molten second metal to form an oxide comprising the second metal. Thus, oxygen is not evolved as a gas at the molten anode.
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
C25C 3/00 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus
A method of electrolytic reduction of a feedstock comprising oxygen and a first metal comprises the steps of, arranging the feedstock in contact with a cathode and a molten salt within an electrolysis cell, arranging an anode in contact with the molten salt within the electrolysis cell, the anode comprising a molten second metal and applying a potential between the anode and the cathode such that oxygen is removed from the feedstock to form a reduced feedstock. The oxygen removed from the feedstock reacts with the molten second metal to form an oxide comprising the second metal. The second metal is aluminium. The reduced feedstock may comprise a proportion of aluminium.
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
C25C 5/04 - Production, récupération ou affinage de poudres métalliques ou de métaux poreux à partir de bains fondus
A method of producing metallic tantalum comprises the steps of providing a precursor comprising a tantalate of a first metal, arranging the precursor material in contact with a molten salt in an electrolytic cell, the electrolysis cell further comprising an anode and a cathode arranged in contact with the molten salt, and applying a potential between the anode and the cathode such that the precursor material is reduced to tantalum. The first metal is an alkali metal or an alkaline earth metal. The anode does not comprise a carbon material, which prevents contamination of the tantalum and improves current efficiency of the process.
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
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.
C25C 3/00 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus
C25C 3/02 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus des métaux alcalins ou alcalino-terreux
C25C 3/04 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du magnésium
C25C 3/06 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus de l'aluminium
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
C25C 3/30 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du manganèse
C25C 3/32 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du chrome
C25C 3/34 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus des métaux non prévus dans les groupes
A method of producing metallic powder comprises steps of arranging a volume of feedstock comprising a plurality of non-metallic particles within an electrolysis cell, causing a molten salt to flow through the volume of feedstock, and applying a potential between a cathode and an anode such that the feedstock is reduced to metal. In preferred embodiments the feedstock is a plurality of discrete powder particles and these particles are reduced to a corresponding plurality of discrete metallic particles. In advantageous embodiments, the feedstock may be sand.
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
C25C 5/04 - Production, récupération ou affinage de poudres métalliques ou de métaux poreux à partir de bains fondus
A method is provided for producing metal by electrolytic reduction of a feedstock comprising an oxide of a first metal. The method comprises the steps of arranging the feedstock in contact with a cathode and a molten salt within an electrolysis cell, arranging an anode in contact with the molten salt within the electrolysis cell, and applying a potential between the anode and the cathode such that oxygen is removed from the feedstock. The anode comprises a second metal, which at the temperature of electrolysis within the cell is a molten metal. The second metal is a different metal to the first metal. Oxygen removed from the feedstock during electrolysis reacts with the molten second metal to form an oxide comprising the second metal. Thus, oxygen is not evolved as a gas at the molten anode.
C25C 3/00 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
A method of producing metallic powder for use in the manufacture of a capacitor comprises the step of reducing a non-metallic compound to metal in contact with a molten salt. The salt comprises, for at least a portion of the process, a dopant element that acts as a sinter retardant in the metal. In preferred examples, the metallic powder is Ta or Nb powder produced by the reduction of a Ta or Nb oxide and the dopant is boron, nitrogen, or phosphorous.
C25C 3/34 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus des métaux non prévus dans les groupes
C25C 3/04 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du magnésium
B22F 9/18 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
C22B 5/02 - Procédés généraux de réduction appliqués aux métaux par voie sèche
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
C25C 5/04 - Production, récupération ou affinage de poudres métalliques ou de métaux poreux à partir de bains fondus
A method is provided for producing a metal powder suitable for a powder metallurgy process. The method involves steps of identifying a first set of powder size characteristics that define a metal powder suitable for use in a powder metallurgy process, obtaining a non-metallic powder comprising a plurality of non-metallic particles, selecting a fraction of the non-metallic particles having a second set of powder size characteristics, and reducing the selected fraction of non-metallic particles to a metal powder. The metal powder formed by the reduction has powder size characteristics approximating the first set of powder size characteristics and is suitable for use in the powder metallurgy process. The method preferably allows the reduction of a non-metallic feedstock directly to a powder having desired powder size characteristics, such as a desired particle size distribution, for use in a powder metallurgy process without need for any further processing.
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
20.
Method and apparatus for electrochemical reduction of a solid feedstock
The method, apparatus and product relate to the electrochemical reduction of a solid feedstock (20) to produce a product. A container (2) is filled with a fused salt (6), and one or more anodes (14) contact the fused salt. A cathode (18) is loaded with feedstock and engages with a transport apparatus (22, 36, 40) which locates and moves the cathode past the anodes(s), while the cathode and the feedstock contact the fused salt. As the cathode moves past the anodes(s), a voltage applied between the cathode and the anode(s) electrochemically reduces the solid feedstock to form the product.
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.
C25C 3/00 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
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.
C25C 3/00 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
A removable electrode module for engagement with an electrolysis chamber comprises a first electrode, a second electrode, and a suspension structure. The suspension structure comprises a suspension rod coupled to the first electrode. The second electrode is suspended or supported by the suspension structure, which comprises at least one electrically-insulating spacer element for retaining the second electrode in spatial separation from the first electrode.
A method of producing metallic powder comprises steps of arranging a volume of feedstock comprising a plurality of non-metallic particles within an electrolysis cell, causing a molten salt to flow through the volume of feedstock, and applying a potential between a cathode and an anode such that the feedstock is reduced to metal. In preferred embodiments the feedstock is a plurality of discrete powder particles and these particles are reduced to a corresponding plurality of discrete metallic particles. In advantageous embodiments the feedstock may be sand.
A method of producing metallic powder comprises steps of arranging a volume of feedstock comprising a plurality of non-metallic particles within an electrolysis cell, causing a molten salt to flow through the volume of feedstock, and applying a potential between a cathode and an anode such that the feedstock is reduced to metal. In preferred embodiments the feedstock is a plurality of discrete powder particles and these particles are reduced to a corresponding plurality of discrete metallic particles. In advantageous embodiments the feedstock may be sand.
The method, apparatus and product relate to the electrochemical reduction of a solid feedstock (20) to produce a product. A container (2) is filled with a fused salt (6), and one or more anodes (14) contact the fused salt. A cathode (18) is loaded with feedstock and engages with a transport apparatus (22, 36, 40) which locates and moves the cathode past the anodes(s), while the cathode and the feedstock contact the fused salt. As the cathode moves past the anodes(s), a voltage applied between the cathode and the anode(s) electrochemically reduces the solid feedstock to form the product.
The method, apparatus and product relate to the electrochemical reduction of a solid feedstock (20) to produce a product. A container (2) is filled with a fused salt (6), and one or more anodes (14) contact the fused salt. A cathode (18) is loaded with feedstock and engages with a transport apparatus (22, 36, 40) which locates and moves the cathode past the anodes(s), while the cathode and the feedstock contact the fused salt. As the cathode moves past the anodes(s), a voltage applied between the cathode and the anode(s) electrochemically reduces the solid feedstock to form the product.
In a method for reducing a solid feedstock (110), such as a solid metal compound, feedstock is arranged on upper surfaces of elements (60, 80, 81) in a bipolar cell stack contained within a housing (25). A molten salt electrolyte is circulated through the housing so that it contacts the elements of the bipolar stack and the feedstock. A potential is applied to terminal electrodes (50, 60) of the bipolar stack such that the upper surfaces of the elements become cathodic and the lower surfaces of the elements become anodic. The applied potential is sufficient to cause reduction of the feedstock. The invention also provides an apparatus for implementing the method.
In a method for reduction of a solid feedstock, such as a solid metal compound, in an electrolytic apparatus a portion of the feedstock is arranged in each of two or more electrolytic cells (50, 60, 70, 80). A molten salt is provided as an electrolyte in each cell. The molten salt is circulated from a molten salt reservoir (10) such that salt flows through each of the cells. Feedstock is reduced in each cell by applying a potential across electrodes in each cell, the potential being sufficient to cause reduction of the feedstock. The invention also provides an apparatus for implementing the method.
C25C 7/00 - Éléments structurels, ou leur assemblage, des cellulesEntretien ou conduite des cellules
C25C 3/00 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
A removable electrode module for engagement with an electrolysis chamber comprises a first electrode (20), a second electrode (30), and a suspension structure. The suspension structure comprises a suspension rod (110) coupled to the first electrode. The second electrode is suspended or supported by the suspension structure, which comprises at least one electrically-insulating spacer element (60) for retaining the second electrode in spatial separation from the first electrode.
An apparatus for reduction of a solid feedstock has a first electrode (20) and second electrode (30) located within an electrolysis chamber, the second electrode being disposed above an upper surface of the first electrode. A retaining barrier acts (70) to retain solid feedstock within an area of the upper surface of the first electrode. The retaining barrier is formed from an electrically insulating material.
C25C 3/00 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
C25C 7/00 - Éléments structurels, ou leur assemblage, des cellulesEntretien ou conduite des cellules
In a method of electrolytically reducing a solid feedstock, for example a solid metal oxide feedstock, an electrode module (10) is positioned in a first position to be loaded with the feedstock. The loaded module is then transferred from the first position and engaged with an electrolysis chamber (220) containing a molten salt. A voltage is applied to the electrode module to reduce the solid feedstock. The loaded module may be transferred within a transfer module.
A method of producing metallic powder for use in the manufacture of a capacitor comprises the step of reducing a non-metallic compound to metal in contact with a molten salt. The salt comprises, for at least a portion of the process, a dopant element that acts as a sinter retardant in the metal. In preferred examples, the metallic powder is Ta or Nb powder produced by the reduction of a Ta or Nb oxide and the dopant is boron, nitrogen, or phosphorous.
C25C 3/34 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus des métaux non prévus dans les groupes
C25C 5/04 - Production, récupération ou affinage de poudres métalliques ou de métaux poreux à partir de bains fondus
B22F 9/18 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
C22B 5/02 - Procédés généraux de réduction appliqués aux métaux par voie sèche
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
The invention relates to a feedstock for reduction in an electrolytic cell, for example a non-metallic feedstock that can be reduced to metal on a commercial scale. The feedstock comprises a plurality of three-dimensional elements which are shaped such that a volume of the feedstock has between 35% and 90% free space (not including any microscopic porosity of the elements). The elements are also shaped as randomly-packable elements to minimise any settling, ordering or alignment of the feedstock, which would otherwise hinder or prevent fluid flow and/or current flow through the feedstock.
B01J 19/30 - Éléments de remplissage non agglomérés ou en forme, p. ex. anneaux de Raschig ou éléments de Berl en forme de selle, destinés à être versés dans l'appareil de transfert de chaleur ou de matière
C25C 3/00 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
C25C 7/00 - Éléments structurels, ou leur assemblage, des cellulesEntretien ou conduite des cellules
The invention relates to a feedstock for reduction in an electrolytic cell, for example a non-metallic feedstock that can be reduced to metal on a commercial scale. The feedstock comprises a plurality of three-dimensional elements which are shaped such that a volume of the feedstock has between 35% and 90% free space (not including any microscopic porosity of the elements). The elements are also shaped as randomly-packable elements to minimise any settling, ordering or alignment of the feedstock, which would otherwise hinder or prevent fluid flow and/or current flow through the feedstock.
C25C 3/00 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
C25C 7/00 - Éléments structurels, ou leur assemblage, des cellulesEntretien ou conduite des cellules
B01J 19/30 - Éléments de remplissage non agglomérés ou en forme, p. ex. anneaux de Raschig ou éléments de Berl en forme de selle, destinés à être versés dans l'appareil de transfert de chaleur ou de matière
36.
APPARATUS AND METHOD FOR REDUCTION OF A SOLID FEEDSTOCK
In a method for reduction of a solid feedstock, such as a solid metal compound, in an electrolytic apparatus a portion of the feedstock is arranged in each of two or more electrolytic cells (50, 60, 70, 80). A molten salt is provided as an electrolyte in each cell. The molten salt is circulated from a molten salt reservoir (10) such that salt flows through each of the cells. Feedstock is reduced in each cell by applying a potential across electrodes in each cell, the potential being sufficient to cause reduction of the feedstock. The invention also provides an apparatus for implementing the method.
In a method for reducing a solid feedstock (110), such as a solid metal compound, feedstock is arranged on upper surfaces of elements (60, 80, 81 ) in a bipolar cell stack contained within a housing (25). A molten salt electrolyte is circulated through the housing so that it contacts the elements of the bipolar stack and the feedstock. A potential is applied to terminal electrodes (50, 60) of the bipolar stack such that the upper surfaces of the elements become cathodic and the lower surfaces of the elements become anodic. The applied potential is sufficient to cause reduction of the feedstock. The invention also provides an apparatus for implementing the method.
In a method for reducing a solid feedstock (110), such as a solid metal compound, feedstock is arranged on upper surfaces of elements (60, 80, 81 ) in a bipolar cell stack contained within a housing (25). A molten salt electrolyte is circulated through the housing so that it contacts the elements of the bipolar stack and the feedstock. A potential is applied to terminal electrodes (50, 60) of the bipolar stack such that the upper surfaces of the elements become cathodic and the lower surfaces of the elements become anodic. The applied potential is sufficient to cause reduction of the feedstock. The invention also provides an apparatus for implementing the method.
In a method for reduction of a solid feedstock, such as a solid metal compound, in an electrolytic apparatus a portion of the feedstock is arranged in each of two or more electrolytic cells (50, 60, 70, 80). A molten salt is provided as an electrolyte in each cell. The molten salt is circulated from a molten salt reservoir (10) such that salt flows through each of the cells. Feedstock is reduced in each cell by applying a potential across electrodes in each cell, the potential being sufficient to cause reduction of the feedstock. The invention also provides an apparatus for implementing the method.
A method of producing metallic powder for use in the manufacture of a capacitor comprises the step of reducing a non-metallic compound to metal in contact with a molten salt. The salt comprises, for at least a portion of the process, a dopant element that acts as a sinter retardant in the metal. In preferred examples, the metallic powder is Ta or Nb powder produced by the reduction of a Ta or Nb oxide and the dopant is boron, nitrogen or phosphorous.
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
C25C 3/26 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium
C25C 5/04 - Production, récupération ou affinage de poudres métalliques ou de métaux poreux à partir de bains fondus
A commercial scale electrochemical cell for carrying out an electrochemical process for reducing a metal oxide such as a titanium oxide in a solid state is disclosed. The cell includes a plurality of cathodes that are formed at least in part from the metal oxide and can be removed from the cell and replaced by other such cathodes as the process continues to operate in the cell and thereby continues to reduce the metal oxide in the cell.
C25C 3/28 - Production, récupération ou affinage électrolytique de métaux par électrolyse de bains fondus du titane, du zirconium, de l'hafnium, du tantale ou du vanadium du titane
C25C 7/00 - Éléments structurels, ou leur assemblage, des cellulesEntretien ou conduite des cellules
A cathode element for use in an electrochemical cell for carrying out an electrochemical process for reducing a metal oxide such as a titanium oxide in a solid state is disclosed. The cathode element includes a honeycomb-shaped structure that includes a series of interconnected walls (103) that define a plurality of passages (97) for an electrolyte in the cell to penetrate the structure to contact internal exposed surfaces of the structure.
In a method for fabricating an aggregate of Ta, Nb, or an alloy comprising Ta or Nb, a precursor material is produced by sintering a powder of a compound of the metal or a mixture of compounds of the metals for forming an alloy, the sintering is performed at a first temperature. The precursor is then made the cathode in a fused salt melt at a second temperature, lower than the first temperature, and reduced to form a metal or alloy product. The second temperature is predetermined so as not to decrease substantially the porosity of the precursor material or, after reduction, the metal or alloy.
B22F 9/20 - Fabrication des poudres métalliques ou de leurs suspensionsAppareils ou dispositifs spécialement adaptés à cet effet par un procédé chimique avec réduction de mélanges métalliques à partir de mélanges métalliques solides
42 - Services scientifiques, technologiques et industriels, recherche et conception
Produits et services
Metals and metal products; metals and metal alloys; goods
made of common metal. Machines for the production and processing of metals; metal
processing apparatus and equipment; metal pressing
apparatus; washing machines and apparatus; drying machines;
apparatus for the separation of metals and metal powders;
centrifugal apparatus; filters being parts of machines;
hydrocyclones; parts and fittings for the aforesaid goods. Scientific and technological services and research and
design relating thereto; industrial analysis and research
services; licensing services; licensing of technology and of
patents.
42 - Services scientifiques, technologiques et industriels, recherche et conception
Produits et services
Base metals; Minor metals, namely, [ beryllium, ] tantalum and niobium [ zirconium; ] [ Refractory blocks of metal; Refractory bricks of metal; Refractory castable mixes of metal; Refractory construction materials of metal; Refractory furnace linings of metal; Refractory shapes of metal; Semi-refractory bricks of metal; Single crystal source materials, namely, refractory metals; Common metals, unwrought and semi-worked, for further manufacture; Semi-refractory bricks of metal; Metal alloys for further manufacturing; Metal bars for further manufacture; Metal billets ] ; Metal in powdered form; and alloys for these metals [ Machines for modifying the size of metal particles; industrial machinery, namely, metal processing apparatus and equipment, namely, machines for rolling metal sheet and plate from metal and alloy powders and parts and fittings therefore; washing machines and drying machines used in the processing and manufacturing of metals, metal powders, and alloys, and parts and fittings therefore ] [ Scientific and technical services and research and design services relating to the manufacture and processing of metals and alloys, namely, material testing, and research services in the field of electrochemical reduction of metal oxides; research services in the field of reduction of metals by electrolysis in a molten salt; research services in the field of the production of metals from metal oxides; industrial analysis of metals and metal oxides and research relating to metals and metal oxides; licensing of intellectual property and of patents ]
