Electroreduction, or electrodeoxidation, of pelleted SiO2 powder (left image) or its mixture with other metal oxide powders in molten CaCl2 produces pure Si powder (right image), or the respective silicon alloy powder. Being advantageous by simplicity and resulting in less CO2 emission, the electrochemical approach has an energy consumption that is below 13 kWh (kg of Si)−1.
Solid electrode processes fall in the central focus of electrochemistry due to their broad-based applications in electrochemical energy storage/conversion devices, sensors and electrochemical preparation. The electrolytic production of metals, alloys, semiconductors and oxides via the electrochemical reduction of solid compounds (especially solid oxides) in high temperature molten salts has been well demonstrated to be an effective and environmentally friendly process for refractory metal extraction, functional materials preparation as well as spent fuel reprocessing. The (electro)chemical reduction of solid compounds under cathodic polarizations generally accompanies a variety of changes at the cathode/melt electrochemical interface which result in diverse electrolytic products with different compositions, morphologies and microstructures. This report summarizes various (electro)chemical reactions taking place at the compound cathode/melt interface during the electrochemical reduction of solid compounds in molten salts, which mainly include: (1) the direct electro-deoxidation of solid oxides; (2) the deposition of the active metal together with the electrochemical reduction of solid oxides; (3) the electro-inclusion of cations from molten salts; (4) the dissolution-electrodeposition process, and (5) the electron hopping process and carbon deposition with the utilization of carbon-based anodes. The implications of the forenamed cathodic reactions on the energy efficiency, chemical compositions and microstructures of the electrolytic products are also discussed. We hope that a comprehensive understanding of the cathodic processes during the electrochemical reduction of solid compounds in molten salts could form a basis for developing a clean, energy efficient and affordable production process for advanced/engineering materials.
Efficient water electrolyzers are constrained by the lack of low-cost and earth-abundant hydrogen evolution reaction (HER) catalysts that can operate at industry-level conditions and be prepared with a facile process. Here we report a self-standing MoC–Mo2C catalytic electrode prepared via a one-step electro-carbiding approach using CO2 as the feedstock. The outstanding HER performances of the MoC–Mo2C electrode with low overpotentials at 500 mA cm−2 in both acidic (256 mV) and alkaline electrolytes (292 mV), long-lasting lifetime of over 2400 h (100 d), and high-temperature performance (70 oC) are due to the self-standing hydrophilic porous surface, intrinsic mechanical strength and self-grown MoC (001)–Mo2C (101) heterojunctions that have a ΔGH* value of −0.13 eV in acidic condition, and the energy barrier of 1.15 eV for water dissociation in alkaline solution. The preparation of a large electrode (3 cm × 11.5 cm) demonstrates the possibility of scaling up this process to prepare various carbide electrodes with rationally designed structures, tunable compositions, and favorable properties.
The electrochemical reduction of solid SiO2 (quartz) to Si is studied in molten CaCl2 at 1173 K. Experimental observations are compared and agree well with a novel penetration model in relation with electrochemistry at the dynamic conductor|insulator|electrolyte three-phase interlines. The findings show that the reduction of a cylindrical quartz pellet at certain potentials is mainly determined by the diffusion of the O(2-) ions and also the ohmic polarisation in the reduction-generated porous silicon layer. The reduction rate increases with the overpotential to a maximum after which the process is retarded, most likely due to precipitation of CaO in the reaction region (cathodic passivation). Data are reported on the reduction rate, current efficiency and energy consumption during the electroreduction of quartz under potentiostatic conditions. These theoretical and experimental findings form the basis for an in-depth discussion on the optimisation of the electroreduction method for the production of silicon.
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