A System Design for Large Scale Production of Elemental Boron by Electrochemical Deposition

In this study, a new electrolysis melt reactor for large-scale and low-temperature production amorphous elemental boron powders (ABP) equipped with a rotating star cathode electrode in a graphite crucible, which decreases the homogenization time of the boron salts is reported. The electrochemical deposition system has designed to produce high-purity ABP up to 25 kg capacity for a different combination of various salts in different percentage ranges in accordance with commercial production. One of the innovations of the system, the star type iron cathode is rotated bidirectionally and positioned up and down when desired, thanks to the movement transmission shaft. After the design of the melted reactor, ABP has produced using certain proportions of KCl, KBF 4 , and B 2 O 3 salts. As a result, the melting time of KCl, KBF 4 , and B 2 O 3 mixed salts was 3.7 h, and the production took place at a low temperature of 480 degrees. The highest cathode current density in production was measured as 1.083 A cm −2 . The analyses revealed that an amorphous structured high purity (95.6%) elemental boron (B) particles were produced. The morphology and chemical composition of the highest purity B has characterized using XRD, SEM, EDS, and FTIR analysis.