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Preparation of Zirconium and Hafnium Metal Powders Using Fused Salt Electrolysis

The paper describes the preparation of zirconium and hafnium metal powders from their respective secondary resources, such as zircaloy-2 scrap and calcium reduced off-grade hafnium powder by a fused salt electrorefining process. The effect of the various experimental variables, such as temperature of electrolysis, current density and concentration of soluble metal in the bath, has been optimised to recover these metals in a state of right purity and with good yield. The metal powders so prepared meet the specification for fabrication. The paper also incorporates the results on electrolytic processing of zircaloy scrap on a 10-kg batch scale to optimise the cell design, with respect to space time yield and specific energy consumption.