Effect of Halide Flux on Physicochemical Properties of MgCl2-Based Molten Salts for Accelerating Zirconium Production: Thermodynamic Assessment

Abstract

The effective halide flux additive for increasing the density of MgCl2 mixture and for decreasing the activity of MgCl2 was investigated in order to improve the reaction efficiency between gaseous ZrCl4 and fresh Mg melt to produce zirconium sponge. Thermochemical computation using FactSageTM software was primarily carried out, followed by the experimental confirmation. The addition of CaCl2, BaCl2, MgF2, and CaF2 to the molten MgCl2 increases the density of the melts, indicating that these halide additives can be a candidate to increase the density of the MgCl2-based molten salts. Among them, BaCl2, MgF2, and CaF2 are the useful additives. The activity of MgCl2 can be reduced by the addition of BaCl2, KCl, NaCl, MgF2, and CaF2, among which the CaF2 is the most effective additive to reduce the activity of MgCl2 with the strongest negative deviation from an ideality. Thus, the addition of CaF2 to the MgCl2, forming the MgCl2-CaF2 binary melt, is the most effective way not only to increase the density of the melt but also to decrease the activity of MgCl2, which was experimentally confirmed. Consequently, the production rate of zirconium sponge by magnesiothermic reduction process can be accelerated by the addition of CaF2.