JPWO2019232276A5 - - Google Patents

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JPWO2019232276A5
JPWO2019232276A5 JP2021516852A JP2021516852A JPWO2019232276A5 JP WO2019232276 A5 JPWO2019232276 A5 JP WO2019232276A5 JP 2021516852 A JP2021516852 A JP 2021516852A JP 2021516852 A JP2021516852 A JP 2021516852A JP WO2019232276 A5 JPWO2019232276 A5 JP WO2019232276A5
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金属化合物粒子から少なくとも第１の希土類金属を含む微細金属粉末を製造するための方法において、
少なくとも第１の希土類金属の金属シュウ酸塩化合物の粒子を含む無水金属シュウ酸塩化合物粒子を分解温度に少なくとも２バールの分解圧力下で加熱し、前記無水金属シュウ酸塩化合物粒子を分解ガス下に保持する工程であって、前記分解ガス及び前記分解温度は、前記無水金属シュウ酸塩化合物粒子を分解し、気体状シュウ酸塩副生成物を形成するのに十分である工程と、
前記気体状シュウ酸塩副生成物が形成されているときに、前記気体状シュウ酸塩副生成物を前記無水金属シュウ酸塩化合物粒子から分離し、それによって中間金属生成物粒子が形成される工程と、
前記中間金属生成物粒子を前記分解温度よりも高く少なくとも約７５０℃である精製温度に加熱し、前記中間金属生成物粒子を前記精製温度及び精製ガス組成物下に保持する工程であって、前記中間金属生成物粒子中の不純物の濃度を低減し、前記少なくとも第１の希土類金属を含む微細金属粉末を形成する工程と、を備える、方法。 In a method for producing a fine metal powder containing at least a first rare earth metal from metal compound particles.
Anhydrous metal oxalate compound particles containing at least particles of the first rare earth metal metal oxalate compound are heated to a decomposition temperature under a decomposition pressure of at least 2 bar to decompose the anhydrous metal oxalate compound particles. The step of holding underneath is that the decomposition gas and the decomposition temperature are sufficient to decompose the anhydrous metal oxalate compound particles to form gaseous oxalate by-products. ,
When the gaseous oxalate by-product is formed, the gaseous oxalate by-product is separated from the anhydrous metal oxalate compound particles, thereby forming intermediate metal product particles . Process and
The step of heating the intermediate metal product particles to a purification temperature higher than the decomposition temperature and at least about 750 ° C., and holding the intermediate metal product particles under the purification temperature and the purification gas composition. A method comprising a step of reducing the concentration of impurities in the intermediate metal product particles to form a fine metal powder containing the at least the first rare earth metal . 水和金属シュウ酸塩化合物粒子から水和水を除去すべく前記水和金属シュウ酸塩化合物粒子を脱水し、前記無水金属シュウ酸塩化合物粒子及び水蒸気を形成する工程をさらに備える、請求項１に記載の方法。 Claimed further comprising a step of dehydrating the hydrated metal oxalate compound particles to remove hydrated water from the hydrated metal oxalate compound particles to form the anhydrous metal oxalate compound particles and water vapor. Item 1. The method according to Item 1. 前記水和金属シュウ酸塩化合物粒子を脱水する工程が、前記水和金属シュウ酸塩化合物粒子を脱水温度に加熱する工程を備える、請求項２に記載の方法。 The method according to claim 2, wherein the step of dehydrating the hydrated metal oxalate compound particles comprises a step of heating the hydrated metal oxalate compound particles to a dehydration temperature. 前記脱水温度が少なくとも約２４０℃である、請求項３に記載の方法。 The method of claim 3, wherein the dehydration temperature is at least about 240 ° C. 前記脱水温度が約３４０℃以下である、請求項３又は４に記載の方法。 The method according to claim 3 or 4, wherein the dehydration temperature is about 340 ° C. or lower. 前記水和金属シュウ酸塩化合物粒子を脱水する工程の間に、前記水和金属シュウ酸塩化合物粒子から前記水蒸気を分離する工程をさらに備える、請求項２～５のいずれか一項に記載の方法。 Any one of claims 2 to 5, further comprising a step of separating the water vapor from the hydrated metal oxalate compound particles during the step of dehydrating the hydrated metal oxalate compound particles. The method described in. 前記水和金属シュウ酸塩化合物粒子から前記水蒸気を分離する工程が、前記水和金属シュウ酸塩化合物粒子を通して脱水ガスを移動させて、前記水和金属シュウ酸塩化合物粒子から前記水蒸気を分離する工程を備える、請求項６に記載の方法。 The step of separating the water vapor from the hydrated metal oxalate compound particles moves the dehydration gas through the hydrated metal oxalate compound particles to separate the water vapor from the hydrated metal oxalate compound particles. The method of claim 6, comprising a step. 前記脱水ガスが窒素を含有する、請求項７に記載の方法。 The method according to claim 7, wherein the dehydrated gas contains nitrogen. 前記脱水ガスが約０．１％以下の酸素を含有する、請求項７又は８に記載の方法。 The method according to claim 7 or 8, wherein the dehydrated gas contains oxygen of about 0.1% or less. 前記水和金属シュウ酸塩化合物粒子を脱水する工程が、前記水和金属シュウ酸塩化合物粒子から前記水和水の少なくとも約９９．９％を除去する、請求項２～９のいずれか一項に記載の方法。 One of claims 2 to 9, wherein the step of dehydrating the hydrated metal oxalate compound particles removes at least about 99.9% of the hydrated water from the hydrated metal oxalate compound particles. The method described in. 前記分解温度が少なくとも約３６０℃である、請求項１～１０のいずれか一項に記載の方法。 The method according to any one of claims 1 to 10, wherein the decomposition temperature is at least about 360 ° C. 前記分解温度が約７００℃以下である、請求項１～１１のいずれか一項に記載の方法。 The method according to any one of claims 1 to 11, wherein the decomposition temperature is about 700 ° C. or lower. 前記分解ガスが約０．０１％以下の酸素を含有する、請求項１～１２のいずれか一項に記載の方法。 The method according to any one of claims 1 to 12, wherein the decomposition gas contains oxygen of about 0.01% or less. 前記分解ガスが少なくとも約５０％の窒素を含有する、請求項１～１３のいずれか一項に記載の方法。 The method according to any one of claims 1 to 13, wherein the decomposition gas contains at least about 50% nitrogen. 前記分解ガスが水素を含有する、請求項１～１４のいずれか一項に記載の方法。 The method according to any one of claims 1 to 14, wherein the decomposition gas contains hydrogen. 前記分解ガスが約２０％以下の水素を含有する、請求項１５に記載の方法。 The method according to claim 15, wherein the decomposition gas contains about 20% or less of hydrogen. 前記分解ガスが一酸化炭素を含有する、請求項１～１６のいずれか一項に記載の方法。 The method according to any one of claims 1 to 16, wherein the decomposition gas contains carbon monoxide. 前記分解ガスが少なくとも約２％の一酸化炭素を含有し、約２０％以下の一酸化炭素を含有する、請求項１７に記載の方法。 17. The method of claim 17, wherein the decomposition gas contains at least about 2% carbon monoxide and about 20% or less carbon monoxide. 前記分解ガスが窒素、水素及び一酸化炭素を含有する、請求項１～１８のいずれか一項に記載の方法。 The method according to any one of claims 1 to 18, wherein the decomposition gas contains nitrogen, hydrogen and carbon monoxide. 前記分解ガスがアンモニアを含有する、請求項１～１９のいずれか一項に記載の方法。 The method according to any one of claims 1 to 19, wherein the decomposition gas contains ammonia. 前記分解ガスがアンモニア、一酸化炭素及び窒素を含有する、請求項２０に記載の方法。 The method according to claim 20, wherein the decomposition gas contains ammonia, carbon monoxide and nitrogen. 前記分解圧力が約６バール以下である、請求項１～２１のいずれか一項に記載の方法。 The method according to any one of claims 1 to 21 , wherein the decomposition pressure is about 6 bar or less. 前記気体状シュウ酸塩副生成物を前記無水金属シュウ酸塩化合物粒子から分離する工程が、前記無水金属シュウ酸塩化合物粒子を通して前記分解ガスを移動させる工程を備える、請求項１～２２のいずれか一項に記載の方法。 Any of claims 1 to 22 , wherein the step of separating the gaseous oxalate by-product from the anhydrous metal oxalate compound particles comprises the step of moving the decomposition gas through the anhydrous metal oxalate compound particles. The method described in item 1 . 前記精製温度が少なくとも約８００℃である、請求項１～２３のいずれか一項に記載の方法。 The method according to any one of claims 1 to 23 , wherein the purification temperature is at least about 800 ° C. 前記精製温度が約１３００℃以下である、請求項１～２４のいずれか一項に記載の方法。 The method according to any one of claims 1 to 24 , wherein the purification temperature is about 1300 ° C. or lower . 前記精製ガス組成物が約０．０１％以下の酸素を含有する、請求項１～２５のいずれか一項に記載の方法。 The method according to any one of claims 1 to 25, wherein the purified gas composition contains about 0.01% or less oxygen. 前記精製ガス組成物が少なくとも約５０％の窒素を含有する、請求項１～２６のいずれか一項に記載の方法。 The method according to any one of claims 1 to 26, wherein the purified gas composition contains at least about 50% nitrogen. 前記精製ガス組成物が水素を含有する、請求項１～２７のいずれか一項に記載の方法。 The method according to any one of claims 1 to 27 , wherein the purified gas composition contains hydrogen. 前記精製ガス組成物が約２０％以下の水素を含有する、請求項２８に記載の方法。 28. The method of claim 28 , wherein the purified gas composition contains about 20% or less hydrogen. 前記精製ガス組成物が一酸化炭素を含有する、請求項１～２９のいずれか一項に記載の方法。 The method according to any one of claims 1 to 29 , wherein the purified gas composition contains carbon monoxide. 前記精製ガス組成物が少なくとも約２％の一酸化炭素を含有し、約２０％以下の一酸化炭素を含有する、請求項３０に記載の方法。 30. The method of claim 30 , wherein the purified gas composition contains at least about 2% carbon monoxide and about 20% or less carbon monoxide. 前記精製ガス組成物が窒素、水素及び一酸化炭素を含有する、請求項１～３１のいずれか一項に記載の方法。 The method according to any one of claims 1 to 31, wherein the purified gas composition contains nitrogen, hydrogen and carbon monoxide. 前記精製ガス組成物がアンモニアを含有する、請求項１～３２のいずれか一項に記載の方法。 The method according to any one of claims 1 to 32 , wherein the purified gas composition contains ammonia. 前記精製ガス組成物がアンモニア、一酸化炭素及び窒素を含む、請求項３３に記載の方法。 33. The method of claim 33 , wherein the purified gas composition comprises ammonia, carbon monoxide and nitrogen. 精製組成物は、前記分解ガスと実質的に同じである、請求項１～３４のいずれか一項に記載の方法。 The method according to any one of claims 1 to 34 , wherein the purified composition is substantially the same as the decomposition gas. 前記中間金属生成物粒子を加熱する工程が、高い精製圧力で実施される、請求項１～３５のいずれか一項に記載の方法。 The method according to any one of claims 1 to 35, wherein the step of heating the intermediate metal product particles is carried out at a high purification pressure. 前記精製圧力が少なくとも約２バールである、請求項３６に記載の方法。 36. The method of claim 36 , wherein the purification pressure is at least about 2 bar. 前記精製圧力が約６バール以下である、請求項３６又は３７に記載の方法。 36 or 37. The method of claim 36 or 37 , wherein the purification pressure is about 6 bar or less. 前記微細金属粉末が約２％以下の非金属不純物を含有する、請求項１～３８のいずれか一項に記載の方法。 The method according to any one of claims 1 to 38, wherein the fine metal powder contains about 2% or less of non-metal impurities. 前記微細金属粉末が約１％以下の非金属不純物を含有する、請求項３９に記載の方法。 39. The method of claim 39 , wherein the fine metal powder contains about 1% or less of non-metal impurities. 前記微細金属粉末が約０．１％以下の酸素を含有する、請求項１～４０のいずれか一項に記載の方法。 The method according to any one of claims 1 to 40, wherein the fine metal powder contains about 0.1% or less oxygen. 前記金属シュウ酸塩化合物の粒子は少なくとも第２の希土類金属の金属シュウ酸塩化合物の粒子を含み、前記微細金属粉末はさらに、少なくとも前記第２の希土類金属を含有する、請求項１～４１のいずれか一項に記載の方法。 The particles of the metal oxalate compound include at least particles of the metal oxalate compound of the second rare earth metal, and the fine metal powder further contains at least the second rare earth metal . The method described in any one of the items . 前記金属シュウ酸塩化合物の粒子は少なくとも第１の卑金属の金属シュウ酸塩化合物の粒子を含み、前記微細金属粉末は少なくとも前記第１の卑金属を含有する、請求項１～４２のいずれか一項に記載の方法。 One of claims 1 to 42 , wherein the particles of the metal oxalate compound contain at least particles of the metal oxalate compound of the first base metal, and the fine metal powder contains at least the first base metal . The method described in. 前記第１の希土類金属はネオジムであり、前記微細金属粉末はさらに鉄及びホウ素を含有する、請求項４３に記載の方法。 The method of claim 43 , wherein the first rare earth metal is neodymium , and the fine metal powder further contains iron and boron. 前記第１の希土類金属はサマリウムであり、前記微細金属粉末はさらにコバルトを含有する、請求項４３に記載の方法。 The method according to claim 43 , wherein the first rare earth metal is samarium , and the fine metal powder further contains cobalt. 前記第１の希土類金属はジスプロシウムであり、前記微細金属粉末はさらに鉄を含有する、請求項１～４１のいずれか一項に記載の方法。 The method according to any one of claims 1 to 41, wherein the first rare earth metal is dysprosium , and the fine metal powder further contains iron. 前記第１の希土類金属はニオブであり、前記微細金属粉末はさらに鉄を含有する、請求項１～４１のいずれか一項に記載の方法。 The method according to any one of claims 1 to 41, wherein the first rare earth metal is niobium , and the fine metal powder further contains iron. 前記第１の希土類金属はスカンジウムであり、前記微細金属粉末はさらにアルミニウムを含有する、請求項１～４１のいずれか一項に記載の方法。 The method according to any one of claims 1 to 41, wherein the first rare earth metal is scandium , and the fine metal powder further contains aluminum. 前記微細金属粉末が、約１０μｍ以下のメジアン（Ｄ５０）粒子サイズを有する、請求項１～４８のいずれか一項に記載の方法。 The method according to any one of claims 1 to 48, wherein the fine metal powder has a median (D50) particle size of about 10 μm or less. 前記微細金属粉末が、約５μｍ以下のメジアン（Ｄ５０）粒子サイズを有する、請求項４９に記載の方法。 49. The method of claim 49 , wherein the fine metal powder has a median (D50) particle size of about 5 μm or less . 前記微細金属粉末が、少なくとも約１μｍのメジアン（Ｄ５０）粒子サイズを有する、請求項１～５０のいずれか一項に記載の方法。 The method according to any one of claims 1 to 50, wherein the fine metal powder has a median (D50) particle size of at least about 1 μm. 少なくとも、前記無水金属シュウ酸塩化合物粒子を加熱する工程と、前記気体状シュウ酸塩副生成物を分離する工程と、前記中間金属生成物粒子を加熱する工程とが、前記無水金属シュウ酸塩化合物粒子及び前記中間金属生成物粒子を攪拌しながら実施される、請求項１～５１のいずれか一項に記載の方法。 At least, the step of heating the anhydrous metal oxalate compound particles, the step of separating the gaseous oxalate by-product, and the step of heating the intermediate metal product particles are the steps of forming the anhydrous metal oxalate. The method according to any one of claims 1 to 51, which is carried out while stirring the compound particles and the intermediate metal product particles . 前記無水金属シュウ酸塩化合物粒子及び前記中間金属生成物粒子の攪拌が流動床反応器内で行われる、請求項５２に記載の方法。 52. The method of claim 52 , wherein the anhydrous metal oxalate compound particles and the intermediate metal product particles are stirred in a fluidized bed reactor. 前記無水金属シュウ酸塩化合物粒子から分離された前記気体状シュウ酸塩副生成物が回収され、再利用される、請求項１～５３のいずれか一項に記載の方法。 The method according to any one of claims 1 to 53, wherein the gaseous oxalate by-product separated from the anhydrous metal oxalate compound particles is recovered and reused. 前記気体状シュウ酸塩副生成物がシュウ酸を含有する、請求項１～５４のいずれか一項に記載の方法。 The method according to any one of claims 1 to 54, wherein the gaseous oxalate by -product contains oxalic acid. 前記気体状シュウ酸塩副生成物がシュウ酸アンモニウムを含有する、請求項１～５５のいずれか一項に記載の方法。 The method according to any one of claims 1 to 55, wherein the gaseous oxalate by -product contains ammonium oxalate. 捕捉された前記気体状シュウ酸塩副生成物が凝縮及び結晶化され、次いで非シュウ酸塩金属化合物粒子と接触して金属シュウ酸塩化合物粒子を形成する、請求項５４～５６のいずれか一項に記載の方法。 Any one of claims 54-56 , wherein the captured gaseous oxalate by-product is condensed and crystallized and then contacted with the non-oxalate metal compound particles to form metal oxalate compound particles. The method described in the section . 前記非シュウ酸塩金属化合物粒子が、金属塩化物化合物、金属酸化物化合物、金属硫酸塩化合物及び金属炭酸塩化合物からなる群から選択される金属化合物を含有する、請求項５７に記載の方法。 58. The method of claim 57 , wherein the non-oxalate metal compound particles contain a metal compound selected from the group consisting of metal chloride compounds, metal oxide compounds, metal sulfate compounds and metal carbonate compounds. 酸素が実質的に存在しない状態で前記微細金属粉末を冷却する工程を備える、請求項１～５８のいずれか一項に記載の方法。 The method according to any one of claims 1 to 58 , comprising a step of cooling the fine metal powder in a state where oxygen is substantially absent. 前記微細金属粉末が約０．１重量％以下の炭素不純物を含有する、請求項１～５９のいずれか一項に記載の方法。 The method according to any one of claims 1 to 59, wherein the fine metal powder contains carbon impurities of about 0.1% by weight or less.
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