Method and system for electrolytically reducing a solid feedstock

Abstract

In a method of electrolytically reducing a solid feedstock, for example a solid metal oxide feedstock, an electrode module 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 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.

We claim: 
     
         1 . A method of electrolytically reducing a solid feedstock, comprising the steps of;
 positioning an electrode module comprising at least one electrode in a first position for loading of feedstock,   loading solid feedstock onto the electrode module,   moving the electrode module from the first position and engaging the electrode module with an electrolysis chamber such that the feedstock is in contact with a molten salt within the electrolysis chamber, and   applying a voltage to the electrode module such that the solid feedstock is reduced.   
     
     
         2 . The method according to  claim 1 , in which the electrode module is transferred from the first position within a transfer module. 
     
     
         3 . The method according to  claim 1 , in which the electrode module is heated to a predetermined temperature prior to engaging with the electrolysis chamber. 
     
     
         4 . The method according to  claim 3 , in which the electrode module is heated under an inert atmosphere within the transfer module. 
     
     
         5 . The method according to  claim 3 , in which the electrode module is transferred from the transfer module to a heating station to be heated to the predetermined temperature. 
     
     
         6 . The method according to  claim 5 , in which the electrode module is transferred from the loading station within the transfer module, lowered into the heating station, heated to the predetermined temperature, and raised back into the transfer module to be transferred to the electrolysis chamber. 
     
     
         7 . The method according to  claim 2 , in which the electrode module is sealed within the transfer chamber by closing a closure, preferably in which the closure is a gate-valve. 
     
     
         8 . The method according to  claim 1 , in which an opening of the electrolysis chamber is closed by an openable closure. 
     
     
         9 . The method according to  claim 1 , further comprising the step of removing the electrode module from the electrolysis chamber after electrolysis to recover the reduced feedstock. 
     
     
         10 . The method according to  claim 9 , in which the electrode module is lifted from the electrolysis chamber into the transfer module. 
     
     
         11 . The method according to  claim 10 , in which the electrode module is cooled under an inert atmosphere within the transfer module after being removed from the electrolysis chamber. 
     
     
         12 . The method according to  claim 10 , in which the electrode module is transferred to a cooling station to be cooled to a predetermined temperature. 
     
     
         13 . The method according to  claim 12 , in which the electrode module is transferred to the cooling station within a transfer module, lowered into the cooling station, cooled to the predetermined temperature, and raised back into the transfer module to be transferred away from the cooling station. 
     
     
         14 . The method according to  claim 9 , in which the electrode module is further transferred to a washing station for washing salt from the reduced feedstock. 
     
     
         15 . The method according to  claim 9 , in which the electrode module is further transferred to an unloading station for unloading the reduced feedstock. 
     
     
         16 . The method according to  claim 1 , in which solid feedstock is loaded onto removable trays separate from the electrode module, the removable trays then being coupled to the electrode module to load feedstock onto the electrode module. 
     
     
         17 . The method according to  claim 1 , in which the feedstock is loaded such that it contacts a cathode structure of the electrode module. 
     
     
         18 . The method according to  claim 1 , in which the electrode module comprises one or more bipolar electrodes, and feedstock is loaded in contact with a cathodic surface of each bipolar electrode. 
     
     
         19 . The method according to  claim 1 , that proceeds by the electro-deoxidation of the solid feedstock. 
     
     
         20 . (canceled) 
     
     
         21 . An electrolysis system comprising an electrode module, a transfer module, a heating station, an electrolysis chamber, and a cooling station. 
     
     
         22 . (canceled) 
     
     
         23 . The method according to  claim 8 , in which the openable closure is a gate-valve openable to allow the electrode module to pass into the electrolysis chamber.