METHODS OF FORMING ALLOYS BY REDUCING METAL OXIDES

• US 20190323135A1
• Filed: 04/18/2019
• Published: 10/24/2019
• Est. Priority Date: 04/24/2018
• Status: Active Application

• Current Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Original Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Inventors: Tripathy, Prabhat K.
• Application Number:
  US16/388,272
• Publication Number:
  US 20190323135A1
• Time in Patent Office: Days
• CPC Class Codes: C25C 3/36 Alloys obtained by cathodic reduction of all their ions
• CPC Class Codes: C25C 5/04 from melts
• CPC Class Codes: C25C 7/025 used in cells for the electrolysis of melts

Abstract

A method of forming an alloy includes disposing a first metal oxide and a second metal oxide in a molten salt. The molten salt is in contact with a working electrode and a counter electrode. An electrical potential is applied between the counter electrode and the working electrode to co-reduce the first metal oxide and the second metal oxide to form a first metal and a second metal, respectively.

Claims

1. A method of forming an alloy, the method comprising:

disposing a first metal oxide and a second metal oxide in a molten salt, the molten salt in contact with a working electrode and a counter electrode;

applying an electrical potential between the counter electrode and the working electrode to co-reduce the first metal oxide and the second metal oxide to form a first metal and a second metal, respectively.

2. The method of claim 1, further comprising selecting the counter electrode to comprise a platinum-group metal.

3. The method of claim 2, further comprising selecting the counter electrode to comprise the platinum-group metal over a base material.

4. The method of claim 1, Wherein disposing the first metal oxide and the second metal oxide in the molten salt comprises disposing Sm₂O₃ in the molten salt.

5. The method of claim 1, wherein disposing the first metal oxide and the second metal oxide in the molten salt comprises disposing CoO in the molten salt.

6. The method of claim 1, wherein disposing the first metal oxide and the second metal oxide in the molten salt comprises disposing NiO in the molten salt.

7. The method of claim 1, wherein disposing the first metal oxide and the second metal oxide in the molten salt comprises disposing Nd₂O₃ in the molten salt.

8. The method of claim 1, wherein disposing the first metal oxide and the second metal oxide in the molten salt comprises disposing Fe₂O₃ in the molten salt.

9. The method of claim 1, further comprising maintaining the molten salt at a temperature of at least 750°

C.

10. The method of claim 1, wherein applying the electrical potential between the counter electrode and the working electrode comprises maintaining the molten salt under an inert atmosphere.

11. The method of claim 10, wherein maintaining the molten salt under the inert atmosphere comprises maintaining the molten salt under an atmosphere consisting essentially of argon.

12. The method of claim 1, further comprising disposing a reference electrode in contact with the molten salt.

13. The method of claim 12, further comprising selecting the reference electrode to comprise glassy carbon.

14. The method of claim 1, further comprising selecting the working electrode to comprise nickel.

15. The method of claim 1, further comprising selecting the molten salt to comprise calcium chloride.

16. The method of claim 1, wherein applying an electrical potential between the counter electrode and the working electrode comprises forming a nickel-rich alloy.

17. The method of claim 1, wherein applying an electrical potential between the counter electrode and the working electrode comprises transferring a metal from the working electrode to the alloy.

18. A method of reducing metal oxides, the method comprising:

providing an electrochemical cell comprising a working electrode, a counter electrode comprising a platinum-group metal, and a molten salt in contact with the working electrode and the counter electrode;

disposing a material comprising at least two metal oxides in contact with the molten salt and the working electrode; and

providing an electric current between the counter electrode and the working electrode to reduce the at least two metal oxides to form an alloy comprising at least two metals formed by reduction of the at least two metal oxides.

19. The method of claim 18, further comprising selecting the counter electrode to comprise a metal selected from the group consisting of iridium, ruthenium, and platinum.

20. The method of claim 18, further comprising selecting the counter electrode to comprise a substrate material selected from the group consisting of high-density graphite, molybdenum, tantalum, titanium, nickel, chromium, tungsten, and combinations thereof, wherein the substrate material is coated with the platinum-group metal.

21. The method of claim 18, further comprising selecting the counter electrode to comprise a substrate material coated with a coating material comprising the platinum-group metal and having a thickness between about 3.0 mm and about 5.0 mm.

22. The method of claim 18, further comprising selecting the working electrode to comprise nickel.

23. The method of claim 18, further comprising selecting the molten salt to comprise calcium chloride.

24. The method of claim 18, wherein disposing a material comprising at least two metal oxides in contact with the molten salt and the working electrode comprises disposing cobalt oxide in contact with the molten salt and the working electrode.

25. The method of claim 18, wherein disposing a material comprising at least two metal oxides in contact with the molten salt and the working electrode comprises disposing samarium oxide in contact with the molten salt and the working electrode.

26. The method of claim 18, wherein disposing a material comprising at least two metal oxides in contact with the molten salt and the working electrode comprises disposing nickel oxide in contact with the molten salt and the working electrode.