Methods and reactor systems are provided for extracting metals, such as
nickel,
cobalt, and iron, from reduced, activated
metal compounds (“feed materials”). Feed materials may be derived from mixed
hydroxide precipitate. Feed materials and
carbon monoxide gas are delivered into an extraction reactor of a
reactor system, such as a shell tube
heat exchanger. A flow path therein directs the feed material downward and the
carbon monoxide gas upward, enabling contact therebetween, forming at least one
metal carbonyl gas and a
solid residue therein. The flow path further directs the upward flow of
metal carbonyl gases, and the downward flow of the residue. Methods and reactor systems may further purge the residue: using
nitric oxide to convert any remaining dicobalt octacarbonyl therein to
cobalt tricarbonyl nitrosyl gas; using an
inert gas to removing any
cobalt tricarbonyl nitrosyl therein; and using an
inert gas-
oxygen mixture, to form a passivated residue.