IP Library › Granted Patent US 12,540,413
Granted Patent B2
US 12,540,413 · App. 18/594,216 · Granted Feb 3, 2026

Systems and methods for recovery of molten metal

Inventors: Thomas Anthony Villalon, Jr. (Boston, MA); Benjamin David Brakenwagen (Narragansett, RI); Richard Robert Salvucci (Quincy, MA)
Assignee: Phoenix Tailings, Inc.
C25C3/34
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Quick Facts
Patent No.
US 12,540,413
App. No.
18/594,216
Granted
Feb 3, 2026
Kind
B2
Abstract

Systems and methods for recovery of molten metal are generally described. Certain systems comprise a reactor (e.g., a reduction cell such as an electrolytic cell comprising an anode, a cathode, and an electrolyte) comprising molten metal within a container; and a collection vessel at least partially contained within the container of the reactor, the collection vessel comprising an opening fluidically connected to the container of the reactor. Some systems comprise a reactor; and a collection vessel comprising a first opening fluidically connected to the reactor and a second opening fluidically connected to a source of gas (e.g., inert gas) and to a source of negative pressure.

Claims (47)

1 . A system, comprising:

a reactor; and

a collection vessel comprising:

a first opening fluidically connected to the reactor, and

a second opening fluidically connected to a source of gas and to a source of negative pressure,

wherein the collection vessel is in fluidic communication with a bottom half of an interior volume of the reactor.

2 . A system, comprising:

a reactor; and

a collection vessel;

wherein the collection vessel is fluidically connected to the reactor, a source of gas, and a source of negative pressure, and

wherein the collection vessel is in fluidic communication with a bottom half of an interior volume of the reactor.

3 . The system of claim 2 , wherein the source of the negative pressure is a vacuum pump.

4 . The system of claim 2 , wherein the reactor is a reduction cell.

5 . The system of claim 4 , wherein the reduction cell is an electrolytic cell.

6 . The system of claim 5 , wherein the electrolytic cell comprises an anode, a cathode, and an electrolyte.

7 . The system of claim 2 , wherein the reactor comprises a molten metal within a container.

8 . The system of claim 7 , wherein the molten metal comprises a molten rare earth metal.

9 . The system of claim 7 , wherein the container is thermally insulated.

10 . The system of claim 7 , wherein a spatially averaged temperature within the container is at least 675° C.

11 . The system of claim 2 , wherein the collection vessel has a volume of at least 180 cm 3 .

12 . The system of claim 2 , wherein walls of the collection vessel comprise a refractory metal and/or a ceramic.

13 . The system of claim 2 , wherein the source of gas is a source of inert gas.

14 . The system of claim 13 , wherein the inert gas comprises a noble gas.

15 . The system of claim 2 , further comprising valving, wherein:

the valving is positioned between the source of gas and the collection vessel;

the valving is positioned between the source of negative pressure and the collection vessel,

the valving is configured to assume a first position in which the collection vessel is in fluidic communication with the source of gas but not in fluidic communication with the source of negative pressure, and

the valving is configured to assume a second position in which the collection vessel is in fluidic communication with the source of negative pressure but not in fluidic communication with the source of gas.

16 . The system of claim 7 , wherein the molten metal forms a first liquid phase, wherein the reactor is an electrolytic cell, wherein a second liquid phase is present in the reactor, wherein the second liquid phase comprises a molten salt electrolyte, and wherein the molten metal comprises a molten rare earth metal.

17 . The system of claim 1 , wherein the source of the negative pressure is a vacuum pump.

18 . The system of claim 1 , wherein the reactor is a reduction cell.

19 . The system of claim 18 , wherein the reduction cell is an electrolytic cell.

20 . The system of claim 19 , wherein the electrolytic cell comprises an anode, a cathode, and an electrolyte.

21 . The system of claim 1 , wherein the reactor comprises a molten metal within a container.

22 . The system of claim 21 , wherein the molten metal comprises a molten rare earth metal.

23 . The system of claim 21 , wherein the container is thermally insulated.

24 . The system of claim 21 , wherein a spatially averaged temperature within the container is at least 675° C.

25 . The system of claim 1 , wherein the collection vessel has a volume of at least 180 cm 3 .

26 . The system of claim 1 , wherein walls of the collection vessel comprise a refractory metal and/or a ceramic.

27 . The system of claim 1 , wherein the source of gas is a source of inert gas.

28 . The system of claim 27 , wherein the inert gas comprises a noble gas.

29 . The system of claim 1 , further comprising valving, wherein:

the valving is positioned between the source of gas and the second opening;

the valving is positioned between the source of negative pressure and the second opening,

the valving is configured to assume a first position in which the second opening is in fluidic communication with the source of gas but not in fluidic communication with the source of negative pressure, and

the valving is configured to assume a second position in which the second opening is in fluidic communication with the source of negative pressure but not in fluidic communication with the source of gas.

30 . The system of claim 21 , wherein the molten metal forms a first liquid phase, wherein the reactor is an electrolytic cell, wherein a second liquid phase is present in the reactor, wherein the second liquid phase comprises a molten salt electrolyte, and wherein the molten metal comprises a molten rare earth metal.

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 Jul 8, 2024
From: VILLALON, THOMAS ANTHONY, JR.; BRAKENWAGEN, BENJAMIN DAVID; SALVUCCI, RICHARD ROBERT
To: PHOENIX TAILINGS, INC.
Reel/Frame 068217/0125 →
Continuity (4)
Continuation 18363257 · Aug 1, 2023
Division 18174330 · Feb 24, 2023
Provisional Application 63334371 · Apr 25, 2022
Related Publication 20250075358A1 · Mar 6, 2025
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