To
recover zirconium (Zr) from LiCl-KCl molten salt, the electro-reduction
mechanisms and dynamic and thermodynamic properties of Zr(IV) on W
and Fe electrodes were investigated using a series of electrochemical
techniques. Zr(IV) was reduced by a continuous two-step process to
form metallic Zr on the W electrode and a one-step process to form
various Zr–Fe alloy compounds on the Fe film electrode. The
deposition potentials pertaining to the formation of various Zr–Fe
intermetallics were found more positive than those of Zr(II)/Zr and
Zr(IV)/Zr(II)pairs. Furthermore, the dynamic data of the Zr(II)/Zr
pair on the W electrode and the ZrFe3/Zr(IV) pair on the
Fe film electrode were measured by linear polarization and Tafel methods.
The results indicated that, with an increasing temperature, the value
of the exchange current density for the two pairs increased, while
the charge transfer resistance and transfer coefficient of the two
pairs decreased. The thermodynamic data, for instance, the activities
of Zr in Zr–Fe alloys and Gibbs free energies of the formation
of Zr–Fe intermetallic compounds, were estimated using open-circuit
chronopotentiometry. Furthermore, electrochemical recovering Zr was
conducted using an Fe electrode by potentiostatic and galvanostatic
electrolysis, which proved that the products were only ZrFe2 intermetallic compounds. The recovery efficiencies were 98.05% and
98.97%, respectively.