Composition for inert electrodes

Claim 2

A composition for fabricating into an inert electrode for use in the electrolytic production of metal from a metal compound dissolved in a molten salt, the electrode comprising: two metal compounds combined to provide a combination metal compound having a first phase and a second phase, the first phase consisting essentially of a composition defined by the formula M(M' y M 1-y ) z X K , and the second phase containing one of said metal compounds, in the formula, y is a number in the range of 0.1≦y≦0.45 and 0.55≦y≦0.9 and M is a metal having a valence selected from the group consisting of 1, 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, z is a number selected from the group consisting of 2, 3 and 4, X is at least one material selected from the group consisting of O, F, N, S, C and B, and K is a number in the range of 2 to 4.4, the electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 3

The composition in accordance with claim 1 wherein K is in the range of 3.9 to 4.4.

Claim 4

The composition in accordance with claim 1 wherein X is oxygen.

Claim 5

The composition in accordance with claim 1 wherein the metal compounds aremetal oxides.

Claim 6

The composition in accordance with claim 1 wherein M is a metal selected from the group consisting of Ni, Sn, Zr, Zn, Co, Mn, Ti, Nb, Ta, Fe, Hf and Li.

Claim 7

The composition in accordance with claim 1 wherein M' is a metal selected from the group consisting of Fe, V, Cr, Mn, Al, Nb, Ta, Sn, Zn, Co, Ni, Hf and Y.

Claim 8

The composition in accordance with claim 1 wherein M is a metal selected from the group consisting of Ni, Sn, Mn, Ti, Zr and Zn.

Claim 9

The composition in accordance with claim 1 wherein M' is a metal selected from the group consisting of Fe, Cr and V.

Claim 10

The composition in accordance with claim 1 wherein M is formulated from NiO.

Claim 11

The composition in accordance with claim 1 wherein M' is formulated from Fe 2 O 3 .

Claim 12

The composition in accordance with claim 1 wherein the metal compounds are NiO and Fe 2 O 3 .

Claim 13

The composition in accordance with claim 1 wherein the metal compounds are SnO 2 and Cr 2 O 3 .

Claim 14

The composition in accordance with claim 1 wherein the metal compounds are Fe 2 O 3 and Co 3 O 4 .

Claim 15

The composition in accordance with claim 1 wherein the electrode is an anode.

Claim 16

A metal oxide composition for use as an inert electrode in the electrolytic production of metal from a metal compound in a molten salt, the electrode comprising: two metal oxides combined to provide a metal oxide composition having a first and second phase, the first phase having the formula M(M' y M 1-y ) z O K , the second phase having one of said metal oxides, in the formula y is a number from 0.1≦y≦0.45 and 0.55≦y≦0.9, O is oxygen, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 3.9 to 4.4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 17

A metal oxide composition for use as an inert electrode in the electrolytic production of metal from a metal compound in a molten salt, the electrode comprising: two metal oxides combined to provide a metal oxide composition having a first and second phase, the first phase having the formula M(M' y M 1-y ) z O K , the second phase having one of said metal oxides, in the formula y is a number from 0.1≦y≦0.45 and 0.55≦y≦0.9, O is oxygen, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 3.9 to 4.4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 18

A metal oxide composition for use as an inert electrode in the electrolytic production of metal from at least one of the metal oxide and metal salt dissolved in a molten salt, the electrode having a composition comprising: two metal oxides which are combined to provide an electrode metal oxide composition having a first phase and a second phase, the first phase consisting essentially of a material having the formula M(M' y M 1-y ) z O K and the second phase containing one of said metal oxides in the formula, y is a number in the range of 0.1≦y≦0.45 and 0.55≦y≦0.9, O is oxygen, M is a metal selected from the group consisting of Ni, Sn, Zr, Zn, Co, Mn, Ti, Nb and Ta, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 19

A metal oxide composition for use as an inert electrode in the electrolytic production of metal from at least one of the metal oxide and metal salt dissolved in a molten salt, the electrode having a composition comprising: two metal oxides which are combined to provide an electrode metal oxide composition having a first phase and a second phase, the first phase consisting essentially of a material having the formula M(M' y M 1-y ) z O K and the second phase containing one of said metal oxides in the formula, y is a number in the range of 0.1≦y≦0.45 and 0.55≦y≦0.9, O is oxygen, M is a metal selected from the group consisting of Ni, Sn, Zr, Zn, Co, Mn, Ti, Nb and Ta, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 20

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal compounds combined to provide a combination metal compound consisting essentially of a composition defined by the formula M(M' y M 1-y ) z X K where y is a number in the range of 0.1≦y≦0.45 and 0.55≦y≦0.9, M is a metal having a valence selected from the group consisting of 1, 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, z is a number selected from the group consisting of 2, 3 and 4, X is at least one material selected from the group consisting of O, F, N, S, C and B, and K is a number in the range of 2 to 4.4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 21

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal compounds combined to provide a combination metal compound consisting essentially of a composition defined by the formula M(M' y M 1-y ) z X K where y is a number in the range of 0.1≦y≦0.45 and 0.55≦y≦0.9, M is a metal having a valence selected from the group consisting of 1, 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, z is a number selected from the group consisting of 2, 3 and 4, X is at least one material selected from the group consisting of O, F, N, S, C and B, and K is a number in the range of 2 to 4.4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 22

The composition in accordance with claim 17 wherein K is in the range of 3.9 to 4.4.

Claim 23

The composition in accordance with claim 17 wherein the composition is comprised of a first phase and a second phase, the first phase having the formula of claim 17.

Claim 24

The composition in accordance with claim 19 wherein the second phase has the formula MO.

Claim 25

The composition in accordance with claim 19 wherein the second hase is comprised of at least one of the metal oxides used to provide the electrode composition.

Claim 26

The composition in accordance with claim 17 wherein X is oxygen.

Claim 27

The composition in accordance with claim 17 wherein the metal compounds are metal oxides.

Claim 28

The composition in accordance with claim 17 wherein the metal compounds are metal oxides and the oxides are combined to provide a combination metal oxide having a first phase and a second phase, the first phase consisting essentially of a composition defined by the formula M(M' y M 1-y ) z O K and the second phase containing at least one of said metal oxides, in the formula, y is a number in the range of 0.1≦y≦0.45 and 0.55≦y≦0.9, M is a metal having a valence selected from the group consisting of 1, 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4.4.

Claim 29

The composition in accordance with claim 17 wherein M is a metal selected from the group consisting of Ni, Sn, Zr, Zn, Co, Mn, Ti, Nb, Ta, Fe, Hf and Li.

Claim 30

The composition in accordance with claim 17 wherein M' is a metal selected from the group consisting of Fe, V, Cr, Mn, Al, Nb, Ta, Sn, Zn, Co, Ni, Hf and Y.

Claim 31

The composition in accordance with claim 17 wherein M is a metal selected from the group consisting of Ni, Sn, Mn, Ti, Zr and Zn.

Claim 32

The composition in accordance with claim 17 wherein M' is a metal selected from the group consisting of Fe, Cr and V.

Claim 33

The composition in accordance with claim 17 wherein M is formulated from NiO.

Claim 34

The composition in accordance with claim 17 wherein M' is formulated from Fe 2 O 3 .

Claim 35

The composition in accordance with claim 17 wherein the metal compounds are NiO and Fe 2 O 3 .

Claim 36

The composition in accordance with claim 17 wherein the metal compounds are SnO 2 and Cr 2 O 3 .

Claim 37

The composition in accordance with claim 17 wherein the metal compounds are Fe 2 O 3 and Co 3 O 4 .

Claim 38

The composition in accordance with claim 17 wherein the metal produced from the metal compound electrolysis is aluminum.

Claim 39

The composition in accordance with claim 17 wherein the metal compound dissolved in the molten salt is alumina.

Claim 40

The composition in accordance with claim 17 wherein the electrode is an anode.

Claim 41

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal oxides combined to provide an anode metal oxide composition wherein one of the two metal oxides is selected from the group consisting of NiO, SnO 2 , ZrO 2 , ZnO, CoO, MnO, TiO 2 and Ta 2 O 5 , the composition containing a material having the formula M(M' y M 1-y ) z O K where y is a number in the range of about 0.1≦y≦0.4 and 0.6≦y≦0.9, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4.4, an anode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 42

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal oxides combined to provide an anode metal oxide composition wherein one of the two metal oxides is selected from the group consisting of NiO, SnO 2 , ZrO 2 , ZnO, CoO, MnO, TiO 2 and Ta 2 O 5 , the composition containing a material having the formula M(M' y M 1-y ) z O K where y is a number in the range of about 0.1≦y≦0.4 and 0.6≦y≦0.9, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4.4, an anode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 43

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal oxides combined to provide an anode metal oxide composition wherein one of the two metal oxides is selected from the group consisting of Fe 2 O 3 , Cr 2 O 3 , Mn 2 O 3 , and Y 2 O 3 , the composition containing a material having the formula M(M' y M 1-y ) z O K where y is number in the range of 0.1≦y≦0.4 and 0.6≦y≦0.9, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being two different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4.4, an anode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 44

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal oxides combined to provide an anode metal oxide composition wherein one of the two metal oxides is selected from the group consisting of Fe 2 O 3 , Cr 2 O 3 , Mn 2 O 3 , and Y 2 O 3 , the composition containing a material having the formula M(M' y M 1-y ) z O K where y is number in the range of 0.1≦y≦0.4 and 0.6≦y≦0.9, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being two different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4.4, an anode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 45

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal oxides combined to provide a metal oxide composition wherein one of the two metal oxides is selected from the group consisting of NiO, SnO 2 , ZrO 2 , ZnO, CoO, MnO and TiO 2 , the other metal oxide is selected from the group consisting of Fe 2 O 3 , Cr 2 O 3 , Mn 2 O 3 , and Y 2 O 3 , the composition containing a material having the formula M(M' y M 1-y ) z O K where y is a number in the range of 0.1≦y≦0.4 and 0.6≦y≦0.9, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being two different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4.4, an anode formulated from the composition being highly conductive and being inert with respect to said molten salt.

Claim 46

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal oxides combined to provide a metal oxide composition wherein one of the two metal oxides is selected from the group consisting of NiO, SnO 2 , ZrO 2 , ZnO, CoO, MnO and TiO 2 , the other metal oxide is selected from the group consisting of Fe 2 O 3 , Cr 2 O 3 , Mn 2 O 3 , and Y 2 O 3 , the composition containing a material having the formula M(M' y M 1-y ) z O K where y is a number in the range of 0.1≦y≦0.4 and 0.6≦y≦0.9, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being two different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4.4, an anode formulated from the composition being highly conductive and being inert with respect to said molten salt.

Claim 47

In an improved process for the electrolytic production of metal from a metal compound dissolved in a motion salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal oxides combined to provide a metal oxide composition having a first and second phase, the first phase having the formula M(M'hd yM 1-y ) z O K , the second phase containing one of said metal oxides, in the formula, y is a number from 0.1≦y≦0.45 and 0.55≦y≦0.9, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 3.9 to 4.4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 48

In an improved process for the electrolytic production of metal from a metal compound dissolved in a motion salt using an inert electrode, the improvement comprising: electrolyzing the metal compound using an inert electrode fabricated from two metal oxides combined to provide a metal oxide composition having a first and second phase, the first phase having the formula M(M'hd yM 1-y ) z O K , the second phase containing one of said metal oxides, in the formula, y is a number from 0.1≦y≦0.45 and 0.55≦y≦0.9, M is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 3.9 to 4.4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 49

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: two metal oxides which are combined to provide an electrode metal oxide composition having a first phase and a second phase, the first phase consisting essentially of a material having the formula M(M' y M 1-y ) z O K , the second phase containing one of said metal oxides, in the formula, y is a number in the range of 0.1≦y≦0.45 and 0.55≦y≦0.9, M is a metal selected from the group consisting of Ni, Sn, Zr, Zn, Co, Mn, Ti, Nb and Ta, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.

Claim 50

In an improved process for the electrolytic production of metal from a metal compound dissolved in a molten salt using an inert electrode, the improvement comprising: two metal oxides which are combined to provide an electrode metal oxide composition having a first phase and a second phase, the first phase consisting essentially of a material having the formula M(M' y M 1-y ) z O K , the second phase containing one of said metal oxides, in the formula, y is a number in the range of 0.1≦y≦0.45 and 0.55≦y≦0.9, M is a metal selected from the group consisting of Ni, Sn, Zr, Zn, Co, Mn, Ti, Nb and Ta, M' is a metal having a valence selected from the group consisting of 2, 3, 4 and 5, M and M' being different metals, O is oxygen, z is a number selected from the group consisting of 2, 3 and 4, and K is a number in the range of 2 to 4, an electrode formulated from said composition being highly conductive and being inert with respect to said molten salt.