Abstract
The Fray–Farthing–Chen (FFC) Cambridge process was patented in 1998 for low cost and clean electrochemical extraction of metals and synthesis of alloys directly from the mineral precursors, particularly oxides (including slags) and sulfides, with the aid of molten salts. In this paper, the technical success of this unique method is explained from the basic electrode reaction thermodynamics and mechanisms at the compound/metal/electrolyte three-phase interlines (boundaries). Selected recent innovations are then introduced towards more efficient cathode design and practices. Finally, the prospects of the FFC Cambridge process are discussed for processing the ilmenite ore and the so-called titanium-rich slag to produce Fe–Ti alloys and its commercial potential in the future titanium industry.
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