Novel process for preparing zirconium by coupling CO2 capture and consumable anode electrolysis

The intensifying global climate threat is predominantly fueled by carbon dioxide (CO₂) emissions from human activities. Although traditional carbon capture methods have advanced, they face significant challenges including high energy demands and secondary pollution risks, thus limiting their scalability. This study proposes a novel approach that integrates CO₂ capture with molten salt electrolysis for the preparation of zirconium (Zr). Using cyclic voltammetry (CV) and square wave voltammetry (SWV), we investigated the electrochemical reduction mechanism of CO₂ in a CaCl₂-CaO molten salt system. The phase transitions and controlled carbonization during the conversion of ZrO₂ to Zr-C-O composite product were carried out at various voltages (3.0–2.5 V for 8 h), and zirconium carboxide (ZrC_xO_y) were obtained at 3 V for 8 h. Electrolysis using ZrC_xO_y as the consumable anode yielded metallic Zr at 2.9 V for 8 h, displaying the potential of this dual approach to address both metal production and carbon capture.