Metal Smelting & Extraction
metal_smelting_extraction_system
The metal smelting and extraction system converts beneficiated lunar regolith into refined titanium, aluminum, iron, and silicon ingots and powders for downstream manufacturing. Primary extraction relies on molten regolith electrolysis at 1600 to 1700 °C using iridium anodes, alongside FFC Cambridge electrochemical reduction in molten calcium chloride at 900 to 1000 °C. Operating in the lunar environment alters process fluid mechanics, as reduced gravity changes natural convection patterns within the molten pools, though the surrounding vacuum prevents reoxidation of the extracted metals. Delivering structural alloy purities exceeding 99%, the system consumes 14.5 kWh per kilogram of refined titanium while capturing over 98% of liberated oxygen byproduct.
Extracts pure metals from beneficiated lunar regolith using molten regolith electrolysis (MRE) and FFC Cambridge electrochemical processes.
Purpose
Convert raw mineral feedstock into refined metal ingots and powders suitable for downstream manufacturing processes.
Context
First step in the manufacturing chain, receiving processed regolith from mining subsystems and outputting feedstock metals (Ti, Al, Fe, Si) to additive, subtractive, and casting processes.
Principles
- ▸Molten regolith electrolysis decomposes metal oxides by passing current through molten regolith at 1600-1700 C
- ▸FFC Cambridge process reduces solid metal oxides electrochemically in molten calcium chloride salt at 900-1000 C
- ▸Oxygen is liberated as a valuable byproduct at the anode
- ▸Multiple extraction stages allow separation of iron, titanium, aluminum, and silicon
- ▸Energy input for titanium extraction approximately 14.5 kWh/kg
Typical implementations
- ▸Iridium or platinum-group anode materials for MRE
- ▸Graphite or inert ceramic anodes for FFC Cambridge
- ▸Molten salt electrolyte containment in stabilized zirconia crucibles
- ▸Electromagnetic stirring for melt homogeneity
- ▸Cascaded electrolysis cells for sequential metal recovery
Lunar considerations
- ▸Vacuum environment prevents reoxidation of extracted metals
- ▸Reduced gravity affects convection patterns in molten pools
- ▸Abundant ilmenite in lunar highlands provides titanium-rich feedstock
- ▸Oxygen byproduct captured for life support and propellant
- ▸Thermal management of 1700 C process in vacuum requires radiation cooling
Specifications
Functional
| primary function | Electrochemically reduce lunar regolith metal oxides into pure metal ingots and powders |
| inputs | beneficiated_regolith, electrical_power, electrolyte_salts |
| outputs | titanium_metal, aluminum_metal, iron_metal, silicon_metal, oxygen_gas, slag |
| titanium energy cost | 14.5 kWh/kg |
| metal purity | >99% for structural alloys |
| oxygen recovery | >98% of liberated O2 captured |
| throughput | scalable to Ark replacement part demand |
Physical
| materials | iridium_anodes, stabilized_zirconia_crucibles, refractory_ceramics, high_temperature_insulation |
| operating temperature | 900-1700 C at process zone |
| containment | refractory-lined electrolysis cells |
| atmosphere | vacuum or inert gas blanket |
Operational
| thermal range c | -173, 127 |
| lifetime years | 100 |
Interfaces
Provides
- Atomized metal powders for additive manufacturing
- Refined metal ingots for casting and forming
- Solid metal stock for CNC machining
- Byproduct oxygen for life support and storage
Requires
- High-current DC power for electrolysis cells
- Mineral-sorted regolith feedstock from mining
- Composition verification of extracted metals
Decomposes into
Cite this entry
Lunar Ark Codex. "Metal Smelting & Extraction" (L2-MFG-SMELT). Retrieved 10 September 2026, from https://lunarark.com/entry/L2-MFG-SMELT
Licensed CC-BY-SA 4.0. You may reuse and adapt this entry with attribution, under the same licence.