Method of manufacture for ferro-titanium and other metal alloys electrolytic reduction

Abstract

A method for the production of a master alloy including the steps of; introducing mixed ores comprising the metals of the alloy; introducing the mixed ores into an electrochemical cell, the cell containing a liquid electrolyte comprising a fused salt or mixture of salts generally designated as M 2 Y in which contaminants X contained in the mixed ores are soluble, and a relatively inert anode; conducting electrolysis under conditions favourable to the selective dissolution of contaminants contained in the mixed ores in preference to the deposition of the M 2 cation; and following electrolysis, reclaiming the purified mixed ore form the cathode.

1 . A method for the production of an alloy from a mixed metal oxide feedstock, by electrolysis in a fused salt of M 2 Y or a mixture of such salts under conditions such that ionisation of oxygen rather than M 2  deposition occurs and that oxygen dissolves in the electrolyte M 2 Y, characterised in that the feedstock comprises a combination of naturally occurring ores wherein the ores are mixed in proportions suitable for forming an alloy of the required stoichiometry.  
     
     
         2 . A method as claimed in  claim 1  wherein the alloy is Ferro-titanium.  
     
     
         3 . A method as claimed in any preceding claim wherein the selected ores include ilmenite.  
     
     
         4 . A method as claimed in any preceding claim wherein the selected ores include rutile.  
     
     
         5 . A method as claimed in any preceding claim wherein the ores comprise iron and titanium and are mixed in proportions suitable to provide a eutectic Ferro-titanium alloy comprising about 70% Ti to about 30% Fe by weight.  
     
     
         6 . A method as claimed in any preceding claim wherein the ores are crushed, ground or powdered prior to mixing.  
     
     
         7 . A method as claimed in  claim 6  wherein the particle size of the crushed, ground or powdered ores are in the range 100-600 microns.  
     
     
         8 . A method as claimed in  claim 6  wherein the particle size of the crushed, ground or powdered ores is a few millimeters.  
     
     
         9 . A method as claimed in any of  claims 6  to  8  wherein the crushed, ground or powdered particles are preformed to a near net shape of the end product prior to electrolysis.  
     
     
         10 . A method as claimed in any preceding claim, wherein the electrochemical reduction is halted when the quantity of oxygen in the feedstock has been reduced to a predetermined acceptable maximum level which is greater than the minimum level achievable if reduction is completed.  
     
     
         11 . A method for the production of a master alloy substantially as described herein.