IP Library › Granted Patent US 12,357,945
Granted Patent B2
US 12,357,945 · App. 18/463,495 · Granted Jul 15, 2025

Systems and methods for recovery of substances from molten salt electrolysis

Inventors: Thomas Anthony Villalon, Jr. (Boston, MA); Richard Robert Salvucci (Quincy, MA); Henry Chase Hutcheson (Malden, MA)
Assignee: Phoenix Tailings, Inc.
B01D53/78B01D39/12B01D53/002B01D53/1418B01D53/18B01D53/68B01D53/75C25C3/34B01D2251/304B01D2251/604B01D2252/103B01D2257/204B01D2258/025
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Quick Facts
Patent No.
US 12,357,945
App. No.
18/463,495
Granted
Jul 15, 2025
Kind
B2
Abstract

Systems and methods for recovery of gaseous substances from molten salt electrolysis are generally described. Certain systems comprise a cell configured for molten salt electrolysis; a collector fluidically connected to the cell and configured to collect volatilized molten salt from the cell; and a gas scrubber fluidically connected to the collector and configured to at least partially remove a gas from an effluent stream of the cell. Some methods comprise, using a pressure gradient: transporting a gas comprising molten salt vapor from an electrolytic cell to and through a collector such that at least a portion of the molten salt vapor forms a solid within the collector; and transporting some or all of the gas from the collector through a gas scrubber.

Claims (26)

1. A system, comprising:

a cell configured for molten salt electrolysis;

a collector fluidically connected to the cell, the collector configured to collect volatilized molten salt from the cell; and

a gas scrubber fluidically connected to the collector, the gas scrubber configured to at least partially remove a gas from an effluent stream of the cell,

wherein the system is configured to replenish the cell with the salt collected in the collector.

2. The system of claim 1 , further comprising a conduit in fluidic communication with the cell, the conduit configured to introduce salt collected in the collector into the cell.

3. The system of claim 1 , wherein the gas scrubber comprises a divider configured to separate scrubbing agent excess from precipitate formed from incoming gas.

4. The system of claim 1 , further comprising a pump configured to create a pressure drop resulting in the transport of gas into the cell.

5. The system of claim 1 , wherein the gas scrubber is a first gas scrubber configured to remove a first gas from the effluent stream of the cell, and the system further comprises a second gas scrubber fluidically connected to the first gas scrubber, wherein the second gas scrubber is configured to at least partially remove the first gas and/or a second gas from an effluent stream of the first gas scrubber.

6. The system of claim 1 , further comprising a solution in the gas scrubber, the solution comprising a scrubbing agent.

7. The system of claim 1 , further comprising a thermal oxidizer fluidically connected to and between the cell and the gas scrubber.

8. The system of claim 1 , wherein the collector comprises a porous medium.

9. The system of claim 1 , wherein the collector comprises a door configured for recovering salt collected in the collector.

10. The system of claim 5 , wherein the second gas scrubber comprises a divider configured to separate scrubbing agent excess from precipitate formed from incoming gas.

11. The system of claim 8 , wherein the porous medium has an average pore size of greater than or equal to 0.5 microns and less than or equal to 1 millimeter as measured by porosimetry.

12. The system of claim 8 , wherein the porous medium comprises an electronically conductive material.

13. The system of claim 8 , wherein the porous medium comprises a metal.

14. The system of claim 8 , wherein the porous medium comprises stainless steel.

15. The system of claim 8 , wherein the porous medium comprises steel wool.

16. The system of claim 7 , wherein the thermal oxidizer is configured to oxidize at least one component of the gas.

17. The system of claim 6 , wherein the gas scrubber comprises a cleaning port configured for retrieval of solid formed from reaction of the gas and the scrubbing agent.

18. The system of claim 5 , wherein the second gas scrubber comprises an outlet in fluidic communication with the cell.

19. The system of claim 1 , wherein the cell comprises molten salt.

20. The system of claim 19 , wherein the molten salt comprises a rare earth metal halide, oxide, and/or oxyhalide.

21. The system of claim 1 , further comprising a heat exchanger in thermal communication with the collector.

22. The system of claim 1 , wherein the gas scrubber is fluidically connected to the collector by a sparger facing an interior of the gas scrubber.

Assignments (2)
SECURITY INTEREST Recorded Jan 20, 2026
From: PHOENIX TAILINGS, INC.
To: NOMURA STRATEGIC VENTURES FUND 1, LP
Reel/Frame 073513/0882 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 2, 2025
From: VILLALON, THOMAS ANTHONY, JR.; SALVUCCI, RICHARD ROBERT; HUTCHESON, HENRY CHASE
To: PHOENIX TAILINGS, INC.
Reel/Frame 069723/0040 →
Continuity (2)
Provisional Application 63405010 · Sep 9, 2022
Related Publication 20240082783A1 · Mar 14, 2024
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