Fracture Resistant Ceramic Piping Mount for Molten Salt Electrolysis
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Solution Overview
Problem
Commercial-scale molten salt electrolytic processes face challenges due to undesirable properties of electrolytes and products, such as toxicity, corrosiveness, and cost, which affect the efficiency and safety of metal production, particularly in the Hall-Heroult and Dow processes for aluminum and magnesium.
Innovation Solution
The implementation of a ceramic tube electrolytic system with a freeze-composite matrix, comprising a salt and a dispersed phase, which forms a fluidic and non-conductive barrier between molten catholyte and anolyte, maintaining a temperature below the melting point of the salt to prevent ionic and electronic conductivity and ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic tube is used as a membrane in molten salt electrolysis, then ionic conductivity is maintained, but the ceramic material is susceptible to fracture and mechanical failure
Solution Approach 1:
The patent applies composite materials by combining ceramic tube with external reinforcement structures (metallic cages or braided mesh) and support matrices (rigid or flexible). This creates a composite system where the ceramic provides ionic conductivity while the surrounding materials provide mechanical strength and fracture resistance, resolving the contradiction between maintaining ceramic integrity and preventing mechanical failure.
2Productivity
If traditional chloride or fluoride electrolytes are used, then metal electrowinning is facilitated, but toxicity and corrosiveness increase
Solution Approach 1:
The patent changes the chemical composition parameters of the electrolyte by substituting traditional chloride or fluoride electrolytes with alternative molten salt compositions. This parameter change maintains the electrolyte's ability to facilitate metal electrowinning while reducing harmful properties such as toxicity and corrosiveness, thereby resolving the technical contradiction between productivity and safety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances the separation of molten catholyte and anolyte, preventing fluidic conductivity and allowing for the efficient production of lithium metal while addressing the issues of toxicity and cost associated with traditional electrolytes, thereby improving the safety and efficiency of the electrolytic process.
Implementation Method 1
A cooling collar is disposed about and spaced apart from a portion of the ceramic tube. A freeze-composite matrix that includes a salt and a dispersed phase is disposed between and in contact with the ceramic tube and the cooling collar. The cooling collar causes the freeze-composite matrix to form a barrier between the cooling collar and the ceramic tube.
Implementation Method 2
the freeze-composite matrix, when cooled, forms a fluidic and non-conductive barrier between the molten-catholyte and the molten-anolyte
Data Source
AI summary
Systems and processes for the production of lithium metal from molten salts. Systems can include a ceramic tube affixed by or to a freeze-composite. The freeze-composite includes a matrix, of a salt and a dispersed phase. The freeze is maintained with a cooling collar to maintain a temperature below the melting point of the salt. Systems can include a molten-catholyte and a molten-anolyte each adjacent to separate surfaces of the ceramic tube. The freeze-composite forms a fluidic and non-conductive barrier between the molten-catholyte and the molten-anolyte. Processes include a freeze-composite affixed to the ceramic tube. The ceramic tube is adjacent to a composite collar which is adjacent to a cooling collar; The cooling fluid is passed through the cooling collar. A molten-catholyte is passed along a first surface of the ceramic tube. A molten-anolyte is passed along to a second surface of the ceramic tube.