Fusion process using an alkali metal metalate

摘要

The product of a molten alkali metal metalate phase separation can be processed into a purified metal from a metal source. Metal sources include native ores, recycled metal, metal alloys, impure metal stock, recycle materials, etc. The method uses a molten alkali metal metalate as a process medium or solvent in purifying or extracting high value metal or metal oxides from metal sources. Vitrification methods using the silicate glass separation phase can be prepared as is or can be prepared with a particulate phase distributed throughout the silica glass phase and encapsulated and fixed within the continuous glass phase. Tungsten metal can be obtained from an alkali metal tungstate. A typically finely divided tungsten metal powder can be obtained from a variety of tungsten sources including recycled tungsten scrap, tungsten carbide scrap, low grade tungsten ore typically comprising tungsten oxide or other form of tungsten in a variety of oxidation states.

主权项

1. A reactor structure comprising a flow-through reactor for forming a purified sodium tungstate salt phase and separating the salt phase from a glass flux phase, the reactor structure comprising:
(a) an induction coil and a reactor vessel, the reactor vessel free of electrical heating positioned in the interior of the induction coil, the reactor vessel having a stand pipe used to control flow-through reaction time by accumulating and then permitting a flow of the purified sodium tungstate, the stand pipe having a circular diameter of about 1 to about 10 centimeters; (b) a heating component consisting of a conductive graphite or graphite composite reactor core positioned within the reactor vessel, the conductive reactor core comprising a top portion and extending downward from the top portion, a substantially cylindrical wall defining an internal void volume, the conductive reactor core structure having a height of about 20 to about 200 centimeters and an internal space having a radius of about 25 to about 130 centimeters, the downwardly extending cylindrical walls having an annular thickness of about 2 to about 10 centimeters; (c) the reactor structure comprises a reactor-flow space positioned between the reactor core and the interior surface of the reactor vessel and the reactor-flow space having an annular thickness of about 2 to about 10 centimeters and is less than 10% of the outside diameter of the vessel; and (d) a charge of reagents comprising a source of tungsten comprising an ore having a particle size of about 10 to 300 microns and an alkali metal metalate in particulate form at the top of the reactor vessel;wherein the charge of reagents and the reactor vessel are inductively heated by the conductive reactor core with power from the induction coil to a temperature greater than about 700° C. sufficient to produce an alkaline micro-corrosion of the source of tungsten resulting in a liquid glass flux phase separate from a phase comprising greater than 90% purified liquid sodium tungstate salt, substantially free of soluble sulfur that flows through the reactor and exits the reactor vessel.