WO2001034858A9 - Carbothermic process for production of metals - Google Patents
Carbothermic process for production of metalsInfo
- Publication number
- WO2001034858A9 WO2001034858A9 PCT/NO2000/000379 NO0000379W WO0134858A9 WO 2001034858 A9 WO2001034858 A9 WO 2001034858A9 NO 0000379 W NO0000379 W NO 0000379W WO 0134858 A9 WO0134858 A9 WO 0134858A9
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- aluminium
- water
- reactor
- metal
- chamber
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B33/00—Silicon; Compounds thereof
- C01B33/02—Silicon
- C01B33/021—Preparation
- C01B33/023—Preparation by reduction of silica or free silica-containing material
- C01B33/025—Preparation by reduction of silica or free silica-containing material with carbon or a solid carbonaceous material, i.e. carbo-thermal process
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B21/00—Obtaining aluminium
- C22B21/0038—Obtaining aluminium by other processes
- C22B21/0053—Obtaining aluminium by other processes from other aluminium compounds
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B26/00—Obtaining alkali, alkaline earth metals or magnesium
- C22B26/20—Obtaining alkaline earth metals or magnesium
- C22B26/22—Obtaining magnesium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B5/00—General methods of reducing to metals
- C22B5/02—Dry methods smelting of sulfides or formation of mattes
- C22B5/10—Dry methods smelting of sulfides or formation of mattes by solid carbonaceous reducing agents
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B5/00—General methods of reducing to metals
- C22B5/02—Dry methods smelting of sulfides or formation of mattes
- C22B5/12—Dry methods smelting of sulfides or formation of mattes by gases
- C22B5/14—Dry methods smelting of sulfides or formation of mattes by gases fluidised material
Definitions
- This invention is related to a new process in carbothermal production of metal such as aluminium, silicon, magnesium and the like means.
- the process takes place within a reactor chamber where metal-oxides or compounds of these are subject to intense jet streams of hot combustion gases.
- the hot gases are delivering heat to the materials and putting them into an intense rotating motion which creates and artificial centrifugal force and generates frictional forces between the particles which generates additional heat to the process.
- the present invention will discuss the process utilised in the production of aluminium and to some extent silicon.
- Aluminium is at present produced in large-scale facilities throughout the world by the electrolytical Hall-Heroult process.
- the electrolyte bath contains aluminium oxide, cryolite and other additives.
- the electrolysis temperature is about 1000°C. Carbon is used as electrode material.
- the main advantage with this the method is that it is well developed and operates under stabile conditions. It is further more regarded as the cheapest way to produce aluminium from aluminium oxide (Al 2 O 3 ) which is upgraded from bauxite by the Bayer-process.
- the Hall-Heroult process is a very energy consuming process.
- Theoretically energy consumption is approx. 11 kWh per kg produced aluminium.
- To day's production technology operates at the level of 13-14 kWh per kg aluminium produced.
- Intensive research is going on all over the world to improve to day's technology in order to decrease the energy consumption.
- the cost of aluminium is also affected by the costs of the materials utilised and gas cleaning facilities in order to comply environmental requirements.
- Aluminium has been produced by direct reduction with carbon. All these carbothermal production processes are static processes. Temperatures in the processes are above 2000°C.
- the present invention however, both materials can be used to produce aluminium or an aluminium alloy.
- the present invention describes methods to produce aluminium, silicon and similar metals from metal by the carbon reduction process.
- this process also allows the use of aluminium hydroxide Al(OH) 3 .
- the present process is a high-efficiency cracking process of the aluminium compounds into aluminium, water and CO at low pressure and temperature. The energy-requirement is less than any other known method and uses no use of cryolite and has limited emission of toxic gases.
- Al 4 O 4 C + C 2 Al 2 O (g) + 2 CO (g) (6)
- Al 2 O 2 + 3 C 2 Al (g) + 3 CO (g) (7)
- Al 4 O C + 3 C 4 Al (g) + 4 CO (g) (8)
- JCP Jet Cracking Process
- the fluidised bed that takes place in a reactor chamber by jet streams of combustion gases, which are injected tangentially into the reactor chamber.
- the energy for the process is delivered from combustion gases - bot thermal and kinetic. This is achieved by pressurised combustion, where the combustion gases are injected into the reactor in such a manner that it generates a rotating motion of the material in the reactor.
- the energy converted to the material will be a combination of the heat in the gases and motion of particles in the reactor.
- the rotation of the particles in the reactor will generate shear-forces between the particles, which generates peak temperatures and a centrifugal force, which will separate different phases in the reactor.
- Aluminium compound is delivered into the process chamber together with the correct molar quantity of carbon correctly balanced to the energy input. Carbon can also be be delivered from the combustion gas.
- the water When the raw material is aluminium hydroxide instead of alumina, the water will be be evaporated after the so-called “flashevaporation". During the evaporation it will be generated ultrasonic vibration in the steam caused by the moving particles and the pressure in the front of the gas jets. Because of the extreme separation of the fluids in the solids that takes place before they are evaporated, the separation in addition to the vibration, generates micro-bubbles in the fluidised bed with extreme temperatures and pressure of several thousands of degree Kelvin and atmospheres whereby water is cracked into hydrogen and oxygen radicals.
- hydrogen radicals will react with the oxygen in alumina and forms water. Hydroxyl radicals (OH 4 ) who may be formed will react back into water and oxygen.
- OH 4 Hydroxyl radicals
- To the process can be added so-called hydrogen delivering materials other than water such as natural gas or oil. Alternatively, carbon can be delivered and thus oxygen will react with carbon into CO.
- the oxygen will react into CO or CO 2 by adding carbon.
- Each mol of Al(OH) 3 (molecular weight 77,99) gives one mol of Al with molecular weight of 27.
- 4 mols of Al(OH) 3 give 4 mols of Al and requires 3 mols of C with molecular weight of 12.
- SiO2 + 3 C SiC + 2CO (g).
- the oxycarbide will be more or less completely in the molte phase.
- the metal producing reaction may then be written:
- discharge of aluminium is done via a discharge arrangement that can be a rotating valve, pump or other practical means.
- a discharge arrangement that can be a rotating valve, pump or other practical means.
- the gas reaction products from the process, steam and CO is removed from the reactor via a pipe arrangement to heat recovery and gas cleaning system, which preheat the combustion air.
- over-saturated steam can be utilised to preheat the material to reduce the energy consumption.
- the energy consumption is the sum of the energy required to heat the oxide to the process temperature, to heat and evaporate the water the same temperature and the energy required for the chemical reactions.
- the energy utilised to crack the water is recovered by the exothermic reaction that takes place when reacting back to water.
- the produced aluminium from the reactor can be discharged either as aluminium powder into a neutral atmosphere or as melted aluminium.
- the novelty of the present invention is a kinetic and dynamic reaction process where all parameters can be controlled such as temperature, retention time, pressure and the velocity and the temperature of the combustion gases.
- the reactor is characterised by that it has no moving parts and that it can be isolated to withstand the operating temperatures which is in the range of 1000 - 2500 °C depending of the metals to be produced.
- the energy is delivered to the reactor from pressurised combustion gases, which is combusted under pressure in a separate combustion chamber.
- the gases leave the combustion chamber and enter the reactor through one or more tangentially oriented slots in the reactor.
- the process can have different arrangements and lay-out of the reactor - either vertical or horizontal and can take any shape where the principle can apply. In the following description is shown one preferred embodiment.
- Fig. 1 shows a simplified flow diagram of the process with the following main elements:
- a) is a hopper with an internal mixer for receiving of the reactants, fore example alumina, carbon and water.
- a screw conveyor b) driven by a variable motor c) which delivers the material to the reactor chamber d).
- the gases are passed to a heat-exchanger i) where pressurised combustion air from the compressor j) is pre-heat before entering the combustion chamber f). From the heat exchanger i) the gases are passed to a condenser k) where steam is condensed.
- Fig. 2 shows one embodiment of the reactor chamber d), the combustion chamber extension e) surrounding the reactor chamber d).
- the dashed lines of the reactor show the heat resistance coating.
- a step n) is arranged above the conical part o).
- a gas exit pipe p In the centre of the reaction chamber is arranged a gas exit pipe p).
- the isolated metal collecting tank m) is located at the base of the conical part o).
- the metal is supposed to flow from the reaction chamber directly to the collector tank m) but depending upon the operating conditions and metal produced, a valve arrangement can be located between the base of the conical part o and the tank m).
- the reactor has a shape of a vertical cyclone.
- the jet gases enters the reaction chamber and put the material in rotation similar to an cyclone, a layer of material will built up due to the step n) which establish a fluidised bed in the reaction zone.
- Fig 3 shows a cross section of the reactor d) with the extension e) and the combustion chamber f).
- the fuel gas and air is delivered to the combustion chamber via the pipe arrangement q).
- the combustion gases enters the reaction chamber d) via the slots r) which is designed to give the correct velocity of the gases into the reactor.
- Fig. 4 shows a layout of a 1000 kW unit designed to produce 50 kg aluminium each hour. With the following elements:
- the material is brought to the hopper a) and is passed to the reactor d) by a screw-conveyor b) driven by a variable drive c).
- the compressor at ratted pressure delivers the combustion air by the line s) to the heat exchanger i).
- the preheated air is then passed to the pipe arrangement g) where it mixes with gas delivered from a gas compressor t).
- the combustion gases are injected into the reactor via the extension e).
- the off gases from the reactor are discharged by the exit pipe h to the heat exchanger from where it is passed to a condenser k).
- the non-condensable gas CO is passed further to a CO burner.
- the produced metal is collected in the tank m) where it is sucked off.
- the entire unit is controlled from the control-unit u).
- Fig. 5 and 6 shows a simplified illustration of the process.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Environmental & Geological Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Inorganic Chemistry (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Physical Or Chemical Processes And Apparatus (AREA)
- Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)
- Forging (AREA)
- Chemically Coating (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002390943A CA2390943A1 (en) | 1999-11-11 | 2000-11-10 | Carbothermic process for production of metals |
AU14227/01A AU777662B2 (en) | 1999-11-11 | 2000-11-10 | Carbothermic process for production of metals |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NO19995514 | 1999-11-11 | ||
NO19995514A NO310426B1 (en) | 1999-11-11 | 1999-11-11 | Carbothermal process for the manufacture of metal |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2001034858A1 WO2001034858A1 (en) | 2001-05-17 |
WO2001034858A9 true WO2001034858A9 (en) | 2004-11-18 |
Family
ID=19903969
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/NO2000/000379 WO2001034858A1 (en) | 1999-11-11 | 2000-11-10 | Carbothermic process for production of metals |
Country Status (4)
Country | Link |
---|---|
AU (1) | AU777662B2 (en) |
CA (1) | CA2390943A1 (en) |
NO (1) | NO310426B1 (en) |
WO (1) | WO2001034858A1 (en) |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1529526A (en) * | 1976-08-27 | 1978-10-25 | Tetronics Res & Dev Co Ltd | Apparatus and procedure for reduction of metal oxides |
US4146389A (en) * | 1977-10-18 | 1979-03-27 | Bela Karlovitz | Thermal reduction process of aluminium |
DE3335859A1 (en) * | 1983-10-03 | 1985-04-18 | Klöckner-Humboldt-Deutz AG, 5000 Köln | METHOD AND DEVICE FOR THE PYROMETALLURGICAL TREATMENT OF FINE-GRAINED SOLIDS, WHICH RESULTS MELT-LIQUID PRODUCTS AT TREATMENT TEMPERATURES |
NO300600B1 (en) * | 1995-11-02 | 1997-06-23 | Ellingsen O & Co | Manufacture of aluminum |
-
1999
- 1999-11-11 NO NO19995514A patent/NO310426B1/en unknown
-
2000
- 2000-11-10 AU AU14227/01A patent/AU777662B2/en not_active Ceased
- 2000-11-10 WO PCT/NO2000/000379 patent/WO2001034858A1/en active IP Right Grant
- 2000-11-10 CA CA002390943A patent/CA2390943A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
NO310426B1 (en) | 2001-07-02 |
NO995514D0 (en) | 1999-11-11 |
AU1422701A (en) | 2001-06-06 |
WO2001034858A1 (en) | 2001-05-17 |
AU777662B2 (en) | 2004-10-28 |
NO995514L (en) | 2001-05-14 |
CA2390943A1 (en) | 2001-05-17 |
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