Sodium-based metal production system

Abstract

A sodium-based metal production system constituted of: a reactor comprising at least one chamber and at least one heat source; a first inlet subsystem; a sodium oxide dissociation unit; a control circuitry configured to: control the first inlet subsystem to feed a respective predetermined amount of a first material into the at least one chamber; control the first inlet subsystem to feed a respective predetermined amount of sodium into the at least one chamber; and control the at least one heat source to heat the at least one chamber, wherein the sodium oxide dissociation unit is configured to dissociate sodium oxide output from the reactor to produce sodium and oxygen, and wherein the produced sodium is output through the first outlet of the sodium oxide dissociation unit.

Description

SODIUM-BASED METAL PRODUCTION SYSTEMTECHNICAL FIELD

[0001] The present disclosure relates substantially to the field of metal production, and more particularly to a sodium-based metal production system.BACKGROUND

[0002] Iron ores are rocks and minerals from which metallic iron can be extracted. Typically, the ore is refined and then placed in a blast furnace, which is a tower-shaped structure, made of steel, and lined with refractory, or heat-resistant bricks. The mixture of raw material, or charge, enters at the top of the blast furnace. At the bottom of the furnace, very hot air is blown, or blasted, in through nozzles called tuye'res. The coke burns in the presence of the hot air. The oxygen in the air reacts with the carbon in the coke to form carbon monoxide. The carbon monoxide then reacts with the iron ore to form carbon dioxide and iron.

[0003] The melted iron then sinks to the bottom of the furnace. The limestone combines with the rock and other impurities in the ore to form a slag which is lighter than the iron and floats on top. As the volume of the charge is reduced, more is continually added at the top of the furnace. The iron and slag are then drawn off separately from the bottom of the furnace.SUMMARY

[0004] It is a principal object of the present invention to overcome at least some of the disadvantages of prior art metal production systems. In some examples, this is provided by a metal production system comprising: a reactor comprising at least one chamber and at least one heat source.

[0005] In some examples, the metal production system comprises a first inlet subsystem. In some examples, the metal production system comprises a separation unit. In some examples, an outlet of the reactor is fed into the separation unit.

[0006] In some examples, the metal production system comprises a sodium oxide dissociation unit. In some examples, a first outlet of the separation unit is fed into a first inlet of the sodium oxide dissociation unit and a first outlet of the sodium oxide dissociation unit is fed into the first inlet subsystem.

[0007] In some examples, the metal production system comprises a control circuitry configured to: control the first inlet subsystem to feed a respective predetermined amount of a first material into the at least one chamber; control the first inlet subsystem to feed a respective predetermined amount of sodium into the at least one chamber; and control the at least one heat source to heat the at least one chamber.

[0008] In some examples, the separation unit is configured to separate sodium oxide from a metal produced in the reactor, the sodium oxide output through the first outlet of the separation unit.

[0009] In some examples, the sodium oxide dissociation unit is configured to dissociate the sodium oxide to produce sodium and oxygen, wherein the produced sodium is output through the first outlet of the sodium oxide dissociation unit.

[0010] Additional features and advantages of the invention will become apparent from the following drawings and description.

[0011] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In case of conflict, the patent specification, including definitions, governs. As used herein, the articles "a" and "an" mean "at least one" or "one or more" unless the context clearly dictates otherwise. As utilized herein, “and / or” means any one or more of the items in the list joined by “and / or”. As an example, “x and / or y” means any element of the three-element set {(x), (y), (x, y) } . In other words, “x and / or y” means “x, y or both of x and y”. As another example, “x, y, and / or z” means any element of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}.

[0012] Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by anyone of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0013] In addition, use of the “a” or “an” are employed to describe elements and components of embodiments of the instant inventive concepts. This is done merely for convenience and to give a general sense of the inventive concepts, and “a” and “an” are intended to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

[0014] As used herein, the term "about", when referring to a measurable value such as an amount, a temporal duration, and the like, is meant to encompass variations of + / -10%, more preferably + / -5%, even more preferably + / -1%, and still more preferably + / -0.1% from the specified value, as such variations are appropriate to perform the disclosed devices and / or methods.

[0015] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, but not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other advantages or improvements.BRIEF DESCRIPTION OF DRAWINGS

[0016] For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings in which like numerals designate corresponding sections or elements throughout.

[0017] With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how several forms of the invention may be embodied in practice. In the accompanying drawings:

[0018] FIG. 1A illustrates a high-level schematic diagram of an example of a metal production system, in accordance with some examples of the disclosure;

[0019] FIG. IB illustrates a high-level illustration of an agitator of the metal production system of FIG. 1A;

[0020] FIG. 2 illustrates a high-level schematic diagram of a more detailed example of the metal production system of FIG. 1A;

[0021] FIG. 3 illustrates a high-level schematic diagram of a more detailed example of the metal production system of FIG. 2;

[0022] FIGs. 4A - 4B illustrate high-level schematic diagrams of various examples of an inlet subsystem of the metal production system of FIG. 3; and

[0023] FIGs. 5A - 5C illustrate high-level schematic diagrams of a sodium-based metal production system, with sodium recycling, in accordance with some examples of the disclosure.DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0024] In the following description, various aspects of the disclosure will be described. For the purpose of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the different aspects of the disclosure. However, it will also be apparent to one skilled in the art that the disclosure may be practiced without specific details being presented herein. Furthermore, well-known features may be omitted or simplified in order not to obscure the disclosure. In the figures, like reference numerals refer to like parts throughout. In order to avoid undue clutter from having too many reference numbers and lead lines on a particular drawing, some components will be introduced via one or more drawings and not explicitly identified in every subsequent drawing that contains that component.

[0025] FIG. 1 A illustrates a high-level schematic diagram of a metal production system 10. In some examples, metal production system 10 comprises: a reactor 20 defining a chamber 25, reactor 20 extending from a first end 21 to a second end 22, and exhibiting an inlet opening 23 and an outlet opening 24 providing access to chamber 25; a mixer 30 defining a chamber 25, mixer 30 extending from a first end 31 to a second end 32, and exhibiting an inlet opening 33 and an outlet opening 34 providing access to chamber 35; a passage unit 40 extending from afirst end 41 to a second end 42; a first heat source 50; a second heat source 52 and a control circuitry 54.

[0026] In some examples, system 10 comprises: an agitator 60 exhibiting a longitudinal axis 65, situated within reactor 20 and extending between first end 21 and second end 22 of reactor 20; and a motor 70. A shaft of motor 70 is mechanically coupled to rotational member60 such that a rotation of motor 70 rotates rotational member 60 about longitudinal axis 65 thereof to thereby provide agitation within chamber 25.

[0027] In some examples, system 10 comprises: an agitator 80 exhibiting a longitudinal axis 85 and situated within mixer 30; and a motor 90. A shaft of motor 90 is mechanically coupled to agitator 80 such that when motor 90 is rotated agitator 80 rotates about longitudinal axis 85 to thereby provide agitation within chamber 35. Although system 10 is illustrated and described in an example where separate motors 70 and 90 are provided, this is not meant to be limiting in any way. In some examples (not shown), the shaft of motor 70 is mechanically coupled to both agitator 60 and agitator 80 such that the rotation of motor 70 rotates both agitator 60 and agitator 80.

[0028] In some examples, as illustrated in FIG. IB, agitator 60 comprises a screw impeller. Particularly, in some examples, agitator 60 comprises: a central elongated member 61 extending from a first end 62 to a second end 63 along longitudinal axis 65; and a generally helically shaped thread 64 wrapped around central elongated member 61 between first end 62 and second end 63 such that central elongated member 61 extends through thread 64. Particularly, in some examples, the longitudinal axis of thread 64 coincides with longitudinal axis 65 of agitator 60. In some examples, first end 62 of central elongated member 61 is mechanically coupled to motor 70 such that a rotation of motor 70 rotates central elongated member 61.

[0029] Although a single motor 70 is illustrated, mechanically coupled to a single end of agitator 60, this is not meant to be limiting in any way. In some examples (not shown), a pair of motors 70 are provided, each mechanically coupled to a respective end of agitator 60.

[0030] Agitator 60 is illustrated in FIG. IB in an example where a first end of thread 64 is spaced apart from first end 62 of central elongated member 61 by a first distance (denoted DI) and a second end of thread 64 is spaced apart from second end 64 of central elongated member61 by a second distance (denoted D2), DI being greater than D2. However, this is not meantto be limiting in any way, and DI and D2 can be provided at any appropriate values, without exceeding the scope of the disclosure.

[0031] Although agitator 60 is illustrated and described herein in an example where thread 64 is adjacent to central elongated member 61, this is not meant to be limiting in any way. In some examples, thread 64 exhibits a predetermined, non-zero, radial distance from central elongated member 61. Particularly, in some examples, agitator 60 comprises a helical ribbon impeller. Although agitator 60 is illustrated and described herein as comprising a single thread 64, this is not meant to be limiting in any way. In some examples, thread 64 comprises a plurality of threads 64. Particularly, in some examples, agitator 60 comprises a double helical ribbon impeller.

[0032] In some examples, agitator 80 comprises a screw impeller or helical ribbon impeller, as described above in relation to agitator 80. In some examples, agitator 80 comprises a paddle impeller.

[0033] Although the above has been described in relation to examples where reactor 20 and mixer 30 each comprise a respective agitator situated therewithin, this is not meant to be limiting in any way. In some examples, agitator 60 and / or agitator 80 are not provided. In some examples, reactor 20 is rotatable about its longitudinal axis. Particularly, in some examples motor 70 rotates reactor 20 to thereby provide agitation within chamber 25. In some examples, mixer 30 is rotatable about its longitudinal axis. In some examples, motor 90 rotates mixer 30 to thereby provide agitation within chamber 35.

[0034] In some examples, an inner wall of reactor 20, defining chamber 25, is composed of silicon-carbide (SiC). In some examples, an inner wall of mixer 30, defining chamber 35, is composed of SiC. In some examples, the inner wall of reactor 20 is composed of stainless- steel. In some examples, the inner wall of mixer 30 is composed of stainless-steel.

[0035] In some examples, passage unit 40 is at least partially hollow and at least partially open at both ends 41 and 42 such that material can pass therethrough from first end 41 to second end 42. In some examples, first end 41 of passage unit 40 faces outlet opening 24 of reactor 20, and is in contact therewith, such that material within chamber 25 can exit through outlet opening 24 into passage unit 40. In some examples, second end 42 of passage unit 40 faces inlet opening 33 of mixer 30, and is in contact therewith, such that material within passage unit 40 can exit through second end 42 into chamber 35. In some examples, each of reactor 20,mixer 30 and passage unit 40 are generally cylindrical shaped, however this is not meant to be limiting in any way.

[0036] In some examples, as illustrated in FIG. 1A, reactor 20 and mixer 30 are separated by a predetermined distance, however this is not meant to be limiting in any way. In some examples, reactor 20 and mixer 30 are adjacent to each other, and passage unit 40 is composed of outlet opening 24 of reactor 20 and of inlet opening 33 of mixer 30. In some examples, as illustrated in FIG. 1A, reactor 20 and mixer 30 are constructed as two separate units, however this is not meant to be limiting in any way. In some examples, reactor 20 and mixer 30 form a single unit, such that chamber 25 and chamber 35 are separated by a single wall, the single wall defining second end 22 of reactor 20 and second end 32 of mixer 30.

[0037] In some examples, heat source 50 and heat source 52 each comprise a furnace. In some examples, heat source 50 is juxtaposed with reactor 20 and heat source 52 is juxtaposed with mixer 30. In some examples, heat source 50 surrounds reactor 20 and heat source 52 surrounds mixer 30.

[0038] Although heat source 50 is illustrated and described herein as a single unit, this is not meant to be limiting in any way. In some examples, heat source 50 comprises a plurality of heating units (e.g., furnaces), each juxtaposed with a respective portion of reactor 20. Although heat source 52 is illustrated and described herein as a single unit, this is not meant to be limiting in any way. In some examples, heat source 52 comprises a plurality of heating units (e.g., furnaces), each juxtaposed with a respective portion of mixer 30.

[0039] Although system 10 is illustrated and described herein as comprises a heat source 50 and a heat source 52, this is not meant to be limiting in any way. In some examples (not shown), a single heat source is provided for heating both chamber 25 and chamber 35.

[0040] In some examples, heat source 50 is designed and constructed to generate sufficient heat such that the temperature of chamber 25 reaches up to about 500° C. In some examples, heat source 50 is designed and constructed to generate heat at a greater temperature, and is controlled by control circuitry 54 to generate heat such that the temperature of chamber 25 reaches up to about 500° C. In some examples, heat source 52 is designed and constructed to generate sufficient heat such that the temperature of chamber 35 reaches up to about 600° C. In some examples, heat source 52 is designed and constructed to generate heat at a greatertemperature, and is controlled by control circuitry 54 to generate heat such that the temperature of chamber 35 reaches up to about 600° C.

[0041] As described above, in some examples as single heat source is provided. In such examples, control circuitry 54 controls the heat source to alternately: generate heat at a first temperature such that chamber 25 is heated to a temperature of about 350 - 450° C; and generate heat at a second temperature such that chamber 35 is heated to a temperature of about 600 - 900° C.

[0042] In some examples, control circuitry 54 controls heat source 50 to generate sufficient heat such that the temperature of chamber 25 reaches a first predetermined temperature for a first predetermined time period and controls heat source 52 to generate sufficient heat such that the temperature of chamber 35 reaches a second predetermined temperature for a second predetermined time period. In some examples, the first predetermined temperature is about 500° C and the second predetermined temperature is about 600° C. In some examples, the second predetermined time period is at least 1 hour. In some examples, the second predetermined time period is at least 5 times the first predetermined time period. In some examples, the first predetermined time period is less than 10 minutes.

[0043] In some examples, agitator 80 separates iron from sodium oxide that is generated in chamber 35, to thereby prevent the formation of sodium ferrites. Sodium ferrites reduce the yield of the produced iron.

[0044] Although the above has been described in relation to examples where a first reaction chamber 25 is heated to a first predetermined temperature for a first predetermined time period and a second reaction chamber 35 is heated to a second predetermined temperature for a second predetermined time period, this is not meant to be limiting in any way. In some examples (not shown), a single reaction chamber is provided, and one or more heat source are controlled to heat the single reaction chamber to the first predetermined temperature for the first predetermined time period and then heat the single reaction chamber to the second predetermined temperature for the second predetermined time period.

[0045] Although the above has been described in relation to a reactor 20 comprising an agitator 60, this is not meant to be limiting in any way. In some examples, motor 70 is configured to rotate chamber 25 about a longitudinal axis 65. In some examples, this is either in addition to the rotation of an agitator 60 or instead of the rotation of an agitator 60.

[0046] FIG. 2 illustrates a high-level schematic diagram of a more detailed examples of system 10. Particularly, in some examples, system 10 further comprises: a first inert gas source 100; a second inert gas source 110; and a third inert gas source 120. In some examples, reactor 20 exhibits: a first gas inlet opening 101 in fluid communication with first inert gas source 100; and a second gas inlet opening 111 in fluid communication with second inert gas source 110. The term "fluid communication", as used herein, means that the two elements are connected by an enclosed path that allows fluid to pass through, such as a tubular shaped element. Particularly, a fluid path 102 is provided, first inert gas source 100 and first gas inlet opening 101 being connected via fluid path 102. Similarly, a fluid path 112 is provided, second inert gas source 110 and second gas inlet opening 111 being connected via fluid path 112.

[0047] In some examples, a heat source 103 is provided within fluid path 102, or juxtaposed therewith, and a heat source 113 is provided within fluid path 112, or juxtaposed therewith. In some examples, heat source 103 heats the gas within fluid path 102 to a respective predetermined temperature, optionally about 100 degrees. In some examples, heat source 113 heats the gas within fluid path 112 to a respective predetermined temperature, optionally about 100 degrees.

[0048] Although reactor 20 is described herein as comprising a pair of gas inlet openings, receiving gas from a pair of gas sources this is not meant to be limiting in any way. In some examples (not shown), a single gas source and a single gas inlet opening is provided for reactor 20.

[0049] In some examples, first inert gas source 100 comprises nitrogen. In some examples, second inert gas source 110 comprises nitrogen or argon.

[0050] In some examples, mixer 30 exhibits a gas inlet opening 121 in fluid communication with third inert gas source 120, via a fluid path 122. In some examples, third inert gas source 120 comprises nitrogen. In some examples, a heat source 123 is provided within fluid path 122, or juxtaposed therewith. In some examples, heat source 123 heats the gas within fluid path 122 to a respective predetermined temperature, optionally about 100 degrees.

[0051] In some examples, system 10 further comprises an output unit 130 extending from a first end 131 to a second end 132. In some examples, output unit 130 is generally cylindrical, however this is not meant to be limiting in any way. In some examples, output unit 130 is at least partially hollow and at least partially open at both ends 131 and 132 such that materialcan pass therethrough from first end 131 to second 132. In some examples, first end 131 of output unit 130 faces outlet opening 34, and is in contact therewith, such that material within chamber 35 can exit through outlet opening 34 into output unit 130. In some examples, second end 132 of output unit 130 faces a collection tank 140, and is in contact therewith, such that material within output unit 130 can exit through second end 132 into collection tank 140.

[0052] In some examples, system 10 further comprises a heat source 150 juxtaposed with output unit 130. In some examples, heat source 150 is designed and constructed to generate sufficient heat such that the temperature of output unit 130 the second predetermined temperature. In some examples, heat sources 103, 113, 123 and 150 are each controlled by a respective output of control circuitry 54.

[0053] FIG. 3 illustrates a high-level schematic diagram of a more detailed examples of system 10. In some examples, as illustrated in FIG. 3, system 10 further comprises a trap subsystem 200. In some examples, trap subsystem 200 comprises: a suction mechanism 210; a gas output unit 220 extending from a first end 221 to a second end 222; and a trap 230. In some examples, suction mechanism 210 comprises: an evacuation unit 211, extending from a first end 212 to a second end 213; and a suction pump 214 configured to create suction within evacuation unit 211. In some examples, suction pump 212 is implemented as a vacuum pump. In some examples, such pump 212 is implemented as a rotary vane pump.

[0054] In some examples, evacuation unit 211 is generally cylindrical, however this is not meant to be limiting in any way. In some examples, evacuation unit 211 is at least partially hollow and at least partially open at both ends 212 and 213 such that material can pass therethrough from first end 212 to second end 213, responsive to the suction action of suction pump 214. In some examples, first end 212 of evacuation unit 211 faces an evacuation outlet 240 of chamber 35, and is in contact therewith, such that certain materials within chamber 35 can exit through evacuation outlet 240 into evacuation unit 211, responsive to the suction action of suction pump 214. In some examples, suction pump 214 operates at a capacity of 0.5 - 12 m3 / h. In some examples, second end 213 of evacuation unit 211 faces trap 230, and is in contact therewith, such that material within evacuation unit 211 can exit through second end 213 into trap 230.

[0055] In some examples, trap 230 comprises one or more vents 235. In some examples, vent / s 235 are designed to allow the gasses trapped in trap 230 to be vented.

[0056] In some examples, gas output unit 220 is generally cylindrical, however this is not meant to be limiting in any way. In some examples, gas output unit 220 is at least partially hollow and at least partially open at both ends 221 and 222 such that gas can pass therethrough from first end 221 to second end 222. In some examples, first end 221 of gas output unit 220 faces a gas outlet 250 of chamber 35, and is in contact therewith, such that gasses within chamber 35 can exit through gas outlet 250 into gas output unit 220. Particularly, in some examples, during operation chamber 35 is completely sealed, with the exception of gas outlet 250, thereby allowing the gas to escape therethrough. In some examples, second end 222 of gas output unit 220 faces trap 230, and is in contact therewith, such that gas within gas output unit 220 can exit through second end 222 into trap 230.

[0057] In some examples, system 10 further comprises an inlet subsystem 300, as will be described below. In some examples, inlet subsystem 300 comprises an output 310 coupled to inlet opening 23 of reactor 20.

[0058] FIG. 4A illustrates a high-level schematic diagram of a first example of an inlet subsystem 300, denoted inlet subsystem 300A. In some examples, inlet subsystem 300A feeds material from a reservoir 320 and a reservoir 325 to reactor 20, as will be described below. In some examples, reservoir 320 exhibits a gas inlet opening 321 and an output opening 322. In some examples, reservoir 325 exhibits an output opening 326.

[0059] In some examples, inlet subsystem 300A comprises: a heat source 330; an inert gas source 340; a reservoir output unit 350 extending from a first end 351 to a second end 352; an electronically controlled valve 360; a measurement input unit 370 extending from a first end 371 to a second end 372; a weighing container 380 exhibiting an inlet opening 381, an outlet opening 382 and a gas opening 383; a scale 390; a scale output unit 400 extending from a first end 401 to a second end 402; an inert gas source 430; and a feeder 440 exhibiting an inlet opening 441 and an outlet opening 442..

[0060] In some examples, reservoir 320 is configured to comprise a predetermined amount of sodium. In some examples, gas source 340 comprises nitrogen. In some examples, gas source 340 outputs gas at a predetermined pressure. In some examples, gas source 430 comprises nitrogen. In some examples, gas source 340 outputs gas at predetermined pressure. In some examples, the predetermined pressure is 1.01 - 3 atm.

[0061] In some examples, gas inlet opening 321 of reservoir 320 is in fluid communication with an output of gas source 340. In some examples, heat source 350 is controlled responsive to an output of control circuitry 54. In some examples, heat source 350 is controlled to generate sufficient heat such that the temperature of reservoir 320 reaches a respective predetermined temperature for a respective predetermined time period. In some examples, the respective predetermined temperature is at least 100° C. In some examples, the respective predetermined temperature is about 150° C.

[0062] In some examples, reservoir output unit 350 is generally cylindrical, however this is not meant to be limiting in any way. In some examples, reservoir output unit 350 is at least partially hollow and at least partially open at both ends 351 and 352 such that material can pass therethrough from first end 351 to second end 352. In some examples, first end 351 of reservoir output unit 350 is inserted within reservoir 320, via output opening 322, such that material within reservoir 320 can exit through reservoir output unit, responsive to a predetermined pressure provided by the gas output from gas source 340.

[0063] In some examples, second end 352 of reservoir output unit 350 faces an inlet of electronically controlled valve 360 and an outlet of electronically controlled valve 360 faces first end 371 of measurement input unit 370 such that material passes from reservoir output unit 350 to measurement input unit 370 via electronically controlled valve 360. In some examples, electronically controlled valve 360 is controlled responsive to an output of control circuitry 54 and a respective input of control circuitry 54 is in communication with an output of scale 390.

[0064] In some examples, measurement input unit 370 is generally cylindrical, however this is not meant to be limiting in any way. In some examples, measurement input unit 370 is at least partially hollow and at least partially open at both ends 371 and 372 such that material can pass therethrough from first end 371 to second end 372. In some examples, second end 372 of measurement input unit 370 is inserted within weighing container 380, via inlet opening 381, such that material within measurement input unit 370 can enter weighing container 380.

[0065] In some examples, weighing container 380 is positioned on scale 390, however this is not meant to be limiting in any way. In some examples, scale 390 is embedded within a floor of weighing container 380. In some examples, scale 390 weighs the contents of weighingcontainer 380. In some examples, gas opening 383 of weighing container 380 is in fluid communication with an outlet of gas source 430.

[0066] In some examples, scale output unit 400 is generally cylindrical, however this is not meant to be limiting in any way. In some examples, scale output unit 400 is at least partially hollow and at least partially open at both ends 401 and 402 such that material can pass therethrough from first end 401 to second end 402. In some examples, first end 401 of scale output unit 400 is inserted within weighing container 380, via outlet opening 382, such that material within weighing container 380 can exit via scale output unit 400, responsive to the pressure provided by the gas of gas source 430. In some examples, second end 402 of scale output unit 400 is inserted within chamber 25 via inlet opening 23 (not shown in FIG. 4A), or faces inlet opening 23, such that material within weighing container 380 can enter chamber 25 via scale output unit 400.

[0067] In some examples, control circuitry 54 control electronically controlled valve 360 to control the amount of material from reservoir 320 entering weighing container 380 responsive to an output of scale 390. Particularly, electronically controlled valve 360 is controlled such that a predetermined amount of the material is measured by determining the weight thereof. The predetermined amount of the material is output to chamber 25.

[0068] In some examples, a predetermined amount of a second material is contained within reservoir 225. In some examples, the second material comprises iron ore or iron oxide. In some examples, inlet opening 441 of feeder 440 is in fluid communication with output opening 326 of reservoir 325. In some examples, outlet opening 442 of feeder 440 is in inserted within chamber 25 via inlet opening 23, or faces inlet opening 23, such that material within feeder 440 can enter chamber 25. In some examples, feeder 440 comprises a screw feeder. In some examples, control circuitry 54 controls feeder 440 to feed the second material to chamber 25 at a predetermined rate. In some examples, the second material is fed to chamber 25 in an inert environment (e.g., with an inert gas, and / or in vacuum).

[0069] FIG. 4B illustrates a high-level schematic diagram of a second example of an inlet subsystem 300, denoted inlet subsystem 300B. In some examples, inlet subsystem 300B feeds material from a reservoir 320 and a reservoir 325 to reactor 20, as will be described below. In some examples, reservoir 320 exhibits a gas inlet opening 321 and an output opening 322. In some examples, reservoir 325 exhibits aN output opening 326.

[0070] In some examples, inlet subsystem 300B comprises: a heat source 330; an inert gas source 340; a reservoir output unit 350 extending from a first end 351 to a second end 352; a splitting unit 450 extending from a first end 451 to a second end 452, and exhibiting an outlet opening 453; a volume measurement container 455 extending from a first end 456 to a second end 457; a translation member 460 extending from a first end to a second end; a volume measurement sensor 470; a translation mechanism 480; a first electronically controlled switch 490; a second electronically controlled switch 500; a measurement output unit 510 extending from a first end 511 to a second end; and a feeder 440 exhibiting an inlet opening 441 and an outlet opening 442.

[0071] In some examples, as described above in relation to inlet subsystem 300A, reservoir 320 is configured to comprises a predetermined amount of sodium. In some examples, as described above in relation to inlet subsystem 300A, gas source 340 comprises nitrogen. In some examples, as described above in relation to inlet subsystem 300A, gas source 340 outputs gas at a predetermined pressure. In some examples, as described above in relation to inlet subsystem 300A, gas source 430 comprises nitrogen. In some examples, as described above in relation to inlet subsystem 300A, gas source 340 outputs gas at predetermined pressure. In some examples, the predetermined pressure is 1.01 - 3 atm.

[0072] In some examples, gas inlet opening 321 of reservoir 320 is in fluid communication with an output of gas source 340. In some examples, heat source 350 is controlled responsive to an output of control circuitry 54. In some examples, as described above in relation to inlet subsystem 300A, heat source 350 is controlled to generate sufficient heat such that the temperature of reservoir 320 reaches a respective predetermined temperature for a respective predetermined time period. In some examples, as described above in relation to inlet subsystem 300A, the respective predetermined temperature is at least 100° C. In some examples, the respective predetermined temperature is about 150° C.

[0073] In some examples, reservoir output unit 350 is generally cylindrical, however this is not meant to be limiting in any way. In some examples, reservoir output unit 350 is at least partially hollow and at least partially open at both ends 351 and 352 such that material can pass therethrough from first end 351 to second end 352. In some examples, first end 351 of reservoir output unit 350 is inserted within reservoir 320, via output opening 322, such that materialwithin reservoir 320 can exit through reservoir output unit, responsive to a predetermined pressure provided by the gas output from gas source 340, as described above in relation to inlet subsystem 300A.

[0074] In some examples, second end 352 of reservoir output unit 350 is in fluid communication with first end 451 of splitting unit 450 and second end 452 of splitting unit 450 is in fluid communication with first end 456 of volume measurement container 455, such that fluid flowing from reservoir 320 flows to volume measurement container 455 via splitting unit 450.

[0075] In some examples, electronically controlled switch 490 is positioned over first end 451 of splitting unit 450. In a first position of electronically controlled switch 490, a fluid path is provided from reservoir output unit 320 into splitting unit 450. In a second position of electronically controlled switch 490, the fluid path from reservoir output unit 320 into splitting unit 450 is blocked by electronically controlled switch 490.

[0076] In some examples, outlet opening 453 of splitting unit 450 is in fluid communication with first end 511 of measurement output unit 510. In some examples, electronically controlled switch 500 is positioned over outlet opening 453 of splitting unit 450. In a first position of electronically controlled switch 500, a fluid path is provided from volume measurement container 455 to measurement output unit 510. In a second position of electronically controlled switch 500, the fluid path from volume measurement container 455 to measurement output unit 510 is blocked by electronically controlled switch 500.

[0077] In some examples, volume measurement container 455 is generally cylindrical, however this is not meant to be limiting in any way. In some examples, translation member 460 comprises a piston. In some examples, volume measurement sensor 470 comprises a contact sensor. Although volume measurement sensor 470 is described herein, this is not meant to be limiting in any way, and any type of sensor for measuring the volume of material within volume measurement container 455 can be provided (e.g., a camera) without exceeding the scope of the disclosure. In some examples, translation mechanism 480 comprises a motor, a shaft of the motor coupled to translation member 460.

[0078] In some examples, first end 461 of translation member 460 is positioned within volume measurement container 455 and second end 462 of translation member 460 faces volume measurement sensor 470. In some examples, when volume measurement container 455is full, and / or has been filled by a predetermined volume of fluid, second end 462 of translation member 460 becomes in contact with contact sensor 470.

[0079] Particularly, in some examples, electronically controlled switch 490 is in set in the first position and fluid from reservoir 320 enters volume measurement container 455, responsive to the pressurized gas of gas source 340, and pushes translation member towards volume measurement sensor 470. In some examples, electronically controlled switch 500 is set in the second position, such that the fluid does not enter measurement output unit 510. When second end 462 of translation member 460 contacts contact sensor 470, electronically controlled switch 500 is set to the first position (to provide a fluid flow path to measurement output unit 510. In some examples, electronically controlled switch 490 is set to the second position (to block the fluid flow path to reservoir 320). In some examples, translation mechanism 480 translates translation member 460 towards measurement output unit 510 such that the measured volume of material is fed to chamber 25, as described above.

[0080] In some examples, measurement output unit 510 is generally cylindrical, however this is not meant to be limiting in any way. In some examples, measurement output unit 510 is at least partially hollow and at least partially open at both ends 511 and 512 such that material can pass therethrough from first end 511 to second end 512. In some examples, second end 512 of measurement output unit 510 is inserted within chamber 25 via inlet opening 23 (not shown in FIG. 4B), or faces inlet opening 23, such that material within volume measurement container 350 can enter chamber 25 via measurement output unit 510.

[0081] In some examples, a predetermined amount of a second material is contained within reservoir 225. In some examples, the second material comprises iron ore. In some examples, inlet opening 441 of feeder 440 is in fluid communication with output opening 326 of reservoir 325. In some examples, outlet opening 442 of feeder 440 is in inserted within chamber 25 via inlet opening 23, or faces inlet opening 23, such that material within feeder 440 can enter chamber 25. In some examples, feeder 440 comprises a screw feeder.

[0082] Although inlet subsystem is illustrated and described herein as comprising a single volume measurement container 510, this is not meant to be limiting in any way. In some examples, a plurality of volume measurement containers 510 are provided, preferably in parallel.

[0083] FIG. 5A illustrates a high-level schematic diagram of a sodium-based metal production system 600, in accordance with some examples of the disclosure. In some examples, system 600 comprises: a reactor 610; a separation unit 620; and a sodium oxide dissociation unit 630. In some examples, system 600 further comprises a sodium reservoir 640.

[0084] In some examples, reactor 610 comprises at least one chamber and at least one heat source, as described above in relation to reactor 20. In some examples, reactor 610 further comprises a motor, as described above in relation to motor 70. In some examples, reactor 610 further comprises an agitator, as described above in relation to agitator 60. In some examples, reactor 610 comprises reactor 20. In some examples, reactor 610 is implemented as reactor 20. As described above, in some examples, the motor is configured to rotate a chamber of reactor 610 and / or to operate the agitator.

[0085] In some examples, system 600 further comprises an inlet subsystem 650. In some examples, inlet subsystem 650 comprises one of inlet subsystem 300A or 300B, however this is not meant to be limiting in any way. In some examples, system 600 further comprises a control circuitry 660.

[0086] In some examples, reactor 610 comprises: an inlet 611; and an outlet 612. In some examples, separation unit 620 comprises: an inlet 621; a first outlet 622; and a second outlet 623. In some examples, sodium oxide dissociation unit 630 comprises: an inlet 631; a first outlet 632; and a second outlet 633. In some examples, sodium reservoir 640 comprises: an inlet 641; and an outlet 642.

[0087] In some examples, inlet 611 of reactor 610 is fed from inlet subsystem 650. Although a single inlet 611 is illustrated and described herein, this is not meant to be limiting in any way, and reactor 610 may contain a plurality of inlets, without exceeding the scope of the disclosure. As described above in relation to inlet subsystems 300A and 300B, in some examples, control circuitry 660 controls inlet subsystem 650 to feed reactor 610 a predetermined amount of sodium and a predetermined amount of a predetermined material. In some examples, the predetermined material is iron oxide. In some examples, the iron oxide is contained within ore. In some examples, reactor 610 is controlled by control circuitry 660 to be heated to a temperature of 100 - 500 degrees Celsius, as described above.

[0088] In some examples, separation unit 620 is configured to separate sodium oxide from a metal produced in reactor 610. In some examples, the metal is iron. In some examples, inlet621 of separation unit 620 is fed from outlet 612 of reactor 610, either directly or through one or more intervening units. Moreover, all connections between elements and units described herein can be direct, or through additional elements and units.

[0089] In some examples, separation unit 620 comprises a magnetized element that draws the metal thereto, thereby separating the metal from the sodium oxide. It is noted however that any method of separation of the metal and the sodium oxide can be used, as known to those skilled in the art. For example, a heat source can be provided to apply heat at a predetermined temperature to evaporate the sodium oxide, thereby separating the sodium oxide from the iron. The evaporated sodium oxide can then be condensed.

[0090] In some examples, separation unit 620 further comprises a translation mechanism configured to translate iron out through outlet 622 and to translate sodium oxide through outlet 623. In some examples, the translation mechanism is mechanical. In some examples, the translation mechanism is pressure based, and utilizes a predetermined pressure to translate the iron through outlet 622 and to translate the sodium oxide through outlet 623.

[0091] It is noted that in some examples iron is output through outlet 622 along with: ferrites; gangue; and / or a certain amount of sodium oxide.

[0092] In some examples, as will be described below, separation unit 620 is split into two separate sub-units. It is noted that separation unit 620 and reactor 610 are illustrated and described herein as separate units, however this is not meant to be limiting in any way. In some examples, separation unit 620 can be implemented within a chamber of reactor 610.

[0093] It is noted that separation unit 620 and sodium oxide dissociation unit 630 are described as separate units, however this is not meant to be limiting in any way, and in some examples separation unit 620 and sodium oxide dissociation unit 630 are a single unit configured to operate in two separate modes of operation, optionally at different times. In some examples, outlet 623 of separation unit 620 is fed into inlet 631 of sodium oxide dissociation unit 630.

[0094] In some examples, sodium oxide dissociation unit 630 is configured to dissociate sodium oxide to produce sodium and oxygen. In some examples, sodium oxide dissociation unit 630 comprises a heat source configured to heat sodium oxide therewithin to a predetermined temperature. In some examples, sodium oxide dissociation unit 630 furthercomprises a vacuum pump configured to provide a vacuum environment within sodium oxide dissociation unit 630. In some examples, sodium oxide dissociation unit 630 dissociates the sodium dioxide to produce sodium and oxygen by heating the sodium oxide to a predetermined temperature, under a predetermined pressure, as known to those skilled in the art. In some examples, the predetermined temperature is greater than the temperature of the heat applied in reactor 610. In some examples, the predetermined temperature is at least 50°C higher than the temperature of the heat applied in reactor 610. In some examples, the predetermined temperature is in the range of 400°C to 800°C and the predetermined pressure is in the range of 0.001 Bar to 0.5 Bar. In some examples, the heat is applied to evaporate the sodium. In some examples, sodium oxide dissociation unit 630 is further configured to condense the evaporated sodium. In some examples, the sodium is condensed at a lower temperature than the temperature at which the sodium was evaporated, and is optionally condensed within a dedicated container. Although the above is described in relation to an example where the sodium is evaporated and condensed, this is not meant to be limiting in any way, and dissociation of the sodium oxide, and the preparation thereof for transfer to sodium reservoir 640, can be performed utilizing any suitable method, as known to those skilled in the art.

[0095] In some examples, sodium oxide dissociation unit 630 further comprises a translation mechanism configured to translate the sodium out through outlet 632. In some examples, the translation mechanism is mechanical. In some examples, the translation mechanism is pressure based, and utilizes a predetermined pressure to translate the sodium through outlet 632. In some examples, outlet 632 of sodium oxide dissociation unit 630 is fed into inlet subsystem 650, optionally via sodium reservoir 640. Particularly, in some examples, outlet 632 of sodium oxide dissociation unit 630 is fed into inlet 641 of sodium reservoir 640. In some examples, the produced oxygen is output through outlet 633 of sodium oxide dissociation unit 630.

[0096] In some examples, as described above, control circuitry 660 controls inlet subsystem 650 to: feed a respective predetermined amount of a first material into the at least one chamber of reactor 610, such as iron oxide; and to feed a respective predetermined amount of sodium into the at least one chamber of reactor 610. In some examples, the sodium is fed to inlet subsystem 650 from sodium reservoir 640, as described above. As further described above in relation to reactor 20, in some examples control circuitry 660 controls at least one heat sourceof reactor 610 to heat the at least one chamber thereof to produce iron from the iron oxide and sodium. As described above, sodium oxide is further produced as a byproduct.

[0097] As described above, in some examples the sodium based metal production system 600 provides for recycling of the used sodium, through separation unit 620 and sodium oxide dissociation unit 630. Although the above has been described in relation to examples where sodium is recycled through both separation unit 620 and sodium oxide dissociation unit 630, this is not meant to be limiting in any way, and sodium oxide dissociation unit 630 can be provided without separation unit 620.

[0098] FIG. 5B illustrates a high-level schematic diagram of a more detailed example of system 600. In some examples, system 600 further comprises a sodium oxide generation unit 670. In some examples, sodium oxide generation unit 670 comprises: a first inlet 671; a second inlet 672; and an outlet 673. In some examples, inlet 671 is fed from sodium reservoir 640. In some examples (not shown), inlet 671 is fed from sodium oxide dissociation unit 630. In some examples (not shown), a valve is provided that is fed from sodium reservoir 640, and control circuitry 660 controls the valve such that a portion of the output sodium is fed into inlet 671 of sodium oxide generation unit 670.

[0099] In some examples (not shown), a sensor is provided, the sensor configured to measure the amount of sodium output from sodium oxide dissociation unit 630, and the portion of sodium fed into inlet 671 of sodium oxide generation unit 670 is based at least in part on the measured amount of sodium. Particularly, in some examples, separation unit 620 and sodium oxide dissociation unit 630 are unable to recycle all of the sodium fed to reactor 610, and sodium oxide generation unit 670 is provided in order to generate additional sodium oxide that will be provided to sodium oxide dissociation unit 630 for dissociation. Thus, in some examples, the amount of sodium fed to sodium oxide generation unit 670 is based on the amount of sodium that wasn't recycled, which can be determined by control circuitry 660 based on the measured amount of sodium output by sodium oxide dissociation unit 630.

[0100] In some examples, system 600 further comprises a second inlet subsystem 680. In some examples, inlet subsystem 680 is implemented as inlet subsystem 300A or 300B, however this is not meant to be limiting in any way. In some examples, control circuitry 660 controls inlet subsystem 680 to feed a respective predetermined amount of a material into inlet 672 of sodium oxide generation unit 670. In some examples, the material is sodium hydroxide. Insome examples, sodium oxide generation unit 670 reacts the material (e.g., the sodium hydroxide) with the received portion of sodium to generate sodium oxide.

[0101] In some examples, sodium oxide generation unit 670 further comprises a translation mechanism configured to translate sodium oxide out through outlet 673 into an inlet 634 of sodium oxide dissociation unit 630. In some examples, the translation mechanism is mechanical. In some examples, the translation mechanism is pressure based, and utilizes a predetermined pressure to translate the sodium oxide through outlet 673.

[0102] FIG. 5C illustrates a high-level schematic diagram of a more detailed example of system 600. It is noted that the example shown in FIG. 5C is not meant to be limiting, and one or more of the additional units shown in FIG. 5C can be provided with or without the sodium oxide generation unit 670 presented in FIG. 5B. Additionally, each of the added units of FIG. 5C can be provided alone or in combination with each other.

[0103] In some examples, system 600 further comprises sodium removal unit 680. In some examples, system 600 further comprises: a pretreatment unit 690; and a post treatment unit 700. In some examples, separation unit 620 comprises: a first separation sub-unit 710; and a second separation sub-unit 720.

[0104] In some examples, sodium removal unit 680 comprises an inlet 681 and an outlet 682. In some examples, inlet 681 is fed from reactor 610 and outlet 682 feeds separation unit 620. Thus, separation unit 620 is fed from reactor 610 via sodium removal unit 680. Although sodium removal unit 680 is shown and described as being separate from reactor 610, this is not meant to be limiting in any way. In some examples, sodium removal unit 680 is implemented within reactor 610, as will be described below.

[0105] In some examples, sodium removal unit 680 isolates sodium that is present in the output from reactor 610 and removes it therefrom. In some examples, the sodium is isolated by evaporating it at a predetermined temperature. In some examples, the predetermined temperature is in the range of 400° - 800° C. In some examples, this evaporation is performed within reactor 610, or in a separate sodium removal unit 680 comprises a dedicated heat source, optionally controlled by control circuitry 660. In some examples, sodium removal unit 680 further comprises a translation mechanism configured to translate the removed sodium to sodium reservoir 640. In some examples, the translation mechanism is mechanical. In some examples, the translation mechanism is pressure based, and utilizes a predetermined pressureto translate the sodium oxide through outlet 683 of sodium removal unit 680. In some examples, sodium removal unit 680 is further configured to condense the evaporated sodium to be transferred to sodium reservoir 640. In some examples, the sodium is condensed at a lower temperature than the temperature at which the sodium was evaporated, and is optionally condensed within a dedicated container.

[0106] Although the above is described in relation to an example where the sodium is evaporated and condensed, this is not meant to be limiting in any way, and removal of the sodium, and the preparation thereof for transfer to sodium reservoir 640, can be performed utilizing any suitable method, as known to those skilled in the art.

[0107] In some examples, pretreatment unit 690 is configured to refine input thereto, as known to those skilled in the art, and output iron oxide from the ore. The output iron oxide is fed into reactor 610. In some examples, post treatment unit 700 receives an output of separator 620 comprising: iron; ferrites; gangue; and sodium oxide. In some examples, post treatment unit 700 treats the output to isolate the iron, as known to those skilled in the art.

[0108] In some examples, separation sub-unit 710 comprises: an inlet 711; a first outlet 712; and a second outlet 713. In some examples, inlet 711 is fed from outlet 682 of sodium removal unit 680. As described above, sodium removal unit 680 can be implemented within reactor 610. In such examples, inlet 711 is fed from reactor 610. In some examples, second outlet 713 is fed to post treatment unit 700.

[0109] In some examples, separation sub-unit 720 comprises: an inlet 721 fed from outlet 712 of separation sub-unit 710; and an outlet 722, inlet 731 of sodium oxide dissociation unit 630 fed from outlet 722. In some examples, separation sub-unit 710 and separation sub-unit 720 each comprise the above described separation of sodium oxide and iron. In some examples, performing the separation twice provides improved separation thereof.Additional Examples of the Disclosed Technology

[0110] In view of the above described implementations of the disclosed subject matter, this application discloses the additional examples enumerated below. It should be noted that one feature of an example in isolation or more than one feature of the example taken in combination and, optionally, in combination with one or more features of one or more further examples are further examples also falling within the disclosure of this application.

[0111] Example 1. A sodium-based metal production system comprising: a reactor comprising at least one chamber and at least one heat source; a first inlet subsystem; a sodium oxide dissociation unit; and a control circuitry configured to: control the first inlet subsystem to feed a respective predetermined amount of a first material into the at least one chamber; control the first inlet subsystem to feed a respective predetermined amount of sodium into the at least one chamber; and control the at least one heat source to heat the at least one chamber, wherein the sodium oxide dissociation unit is configured to dissociate the sodium oxide to produce sodium and oxygen, and wherein the produced sodium is output through the first outlet of the sodium oxide dissociation unit.

[0112] Example 2. The system of any example herein, particularly example 1, wherein the first material comprises iron oxide and the metal is iron.

[0113] Example 3. The system of any example herein, particularly example 1 or 2, wherein the produced sodium is input into the first inlet subsystem.

[0114] Example 4. The system of any example herein, particularly any one of examples 1- 3, further comprising a separation unit, wherein an outlet of the reactor is fed into the separation unit, wherein a first outlet of the separation unit is fed into a first inlet of the sodium oxide dissociation unit and a first outlet of the sodium oxide dissociation unit is fed into the first inlet subsystem, and wherein the separation unit is configured to separate sodium oxide from a metal produced in the reactor, the sodium oxide output through the first outlet of the separation unit.

[0115] Example 5. The system of any example herein, particularly any one of examples 1- 4, further comprising a sodium oxide generation unit, wherein a first inlet of the sodium oxide generation unit is configured to receive a portion of the produced sodium output from the sodium oxide dissociation unit, wherein the sodium oxide generation unit is configured to generate sodium oxide using the received portion of the produced sodium, wherein an outlet of the sodium oxide generation unit is fed into a second inlet of the sodium oxide dissociation unit.

[0116] Example 6. The system of any example herein, particularly example 5, further comprising a second inlet subsystem, wherein the control circuitry is configured to control the second inlet subsystem to feed a respective predetermined amount of a second material into the sodium oxide generation unit.

[0117] Example 7. The system of any example herein, particularly example 6, wherein the second material is sodium hydroxide, and wherein the sodium oxide generation unit is configured to react the sodium hydroxide with the received portion of the produced sodium to generate the sodium oxide.

[0118] Example 8. The system of any example herein, particularly any one of examples 1- 7, further comprising a sodium removal unit, wherein the sodium removal unit is configured to: remove sodium output from the reactor; and input the removed sodium into the first inlet subsystem.

[0119] Example 9. The system of any example herein, particularly any one of examples 1- 8, further comprising at least one motor configured to provide agitation within each of the at least one chamber.

[0120] Example 10. The system of any example herein, particularly example 9, further comprising at least one agitator positioned within the at least one chamber, the agitation provided by the at least one motor generated by rotation of the at least one agitator.

[0121] Example 11. The system of any example herein, particularly example 10, wherein the at least one chamber comprises a first chamber and a second chamber, wherein the at least one agitator comprises a first agitator positioned within the first chamber and a second agitator positioned within the second chamber.

[0122] Example 12. The system of any example herein, particularly example 11, wherein the first agitator comprises a screw impeller and the second agitator comprises a paddle impeller.

[0123] Example 13. The system of any example herein, particularly any one of examples 1 - 12, wherein the control circuitry is configured to: control the at least one heat source to heat the at least one chamber to a first predetermined temperature for a first predetermined time period; and following the first predetermined time period, control the at least heat source to heat the at least one chamber to a second predetermined temperature for a second predetermined time period.

[0124] Example 14. The system of any example herein, particularly example 13, wherein the second predetermined temperature is greater than the first predetermined temperature.

[0125] Example 15. The system of any example herein, particularly example 14, wherein the first predetermined temperature is 100 - 500 degrees Celsius.

[0126] Example 16. The system of any example herein, particularly any one of examples 13 - 15, wherein the second predetermined time period is greater than the first predetermined time period.

[0127] Example 17. The system of any example herein, particularly any one of examples 1 - 16, wherein the first inlet subsystem comprises: a weighing container; a scale configured to weigh contents of the weighing container; an electronically controlled valve; a first inert gas source in fluid communication with a first reservoir comprising the sodium; and a second inert gas source in fluid communication with the weighing container, wherein a gas flow output by the first inert gas source transfers the first predetermined material to the weighing container via the electronically controlled valve and a gas flow output by the second inert gas source transfers the sodium from the weighing container to the at least one chamber, and wherein the electronically controlled valve is controlled responsive to an output of the scale.

[0128] Example 18. The system of any example herein, particularly any one of examples 1 - 16, wherein the first inlet subsystem comprises: a volume measurement container; a volume measurement sensor configured to measure a volume of contents contained within the volume measurement container; an inert gas source in fluid communication with a first reservoir comprising the sodium; and at least one electronically controlled switch configured: in a first state, to provide a path from the first reservoir to the volume measurement container and block a path from the volume measurement container to the at least one chamber; and in a second state, to block the path from the first reservoir to the volume measurement container and provide the path from the volume measurement container to the at least one chamber, wherein a gas flow output by the inert gas source transfers the sodium to the volume measurement container.

[0129] Example 19. The system of any example herein, particularly any one of examples 1 - 18, further comprising: a trap; an evacuation unit extending from the at least one chamber to the trap; and a suction pump configured to create suction within the evacuation unit and the at least one chamber.

[0130] Example 20. The system of any example herein, particularly example 1, further comprising at least one inert gas source in fluid communication with the at least one chamber,the at least one inert gas source configured to provide a flow of inert gas into each of the at least one chamber.

[0131] Example 21. The system of any example herein, particularly any one of examples 1 - 8, further comprising at least one motor configured to rotate each of the at least one chamber.

[0132] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub combination.

[0133] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as are commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods are described herein.

[0134] All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the patent specification, including definitions, will prevail. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

[0135] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the appended claims and includes both combinations and subcombinations of the various features described hereinabove as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description.

Claims

CLAIMS1. A sodium-based metal production system comprising: a reactor comprising at least one chamber and at least one heat source; a first inlet subsystem; a sodium oxide dissociation unit; a control circuitry configured to: control the first inlet subsystem to feed a respective predetermined amount of a first material into the at least one chamber; control the first inlet subsystem to feed a respective predetermined amount of sodium into the at least one chamber; and control the at least one heat source to heat the at least one chamber, wherein the sodium oxide dissociation unit is configured to dissociate sodium oxide output from the reactor to produce sodium and oxygen, and wherein the produced sodium is output through the first outlet of the sodium oxide dissociation unit.

2. The system of claim 1, wherein the first material comprises iron oxide and the metal is iron.

3. The system of claim 1 or 2, wherein the produced sodium is input into the first inlet subsystem.

4. The system of any one of claims 1 - 3, further comprising a separation unit, wherein an outlet of the reactor is fed into the separation unit, wherein a first outlet of the separation unit is fed into a first inlet of the sodium oxide dissociation unit and a first outlet of the sodium oxide dissociation unit is fed into the first inlet subsystem, and wherein the separation unit is configured to separate sodium oxide from a metal produced in the reactor, the sodium oxide output through the first outlet of the separation unit.

5. The system of any one of claims 1 - 4, further comprising a sodium oxide generation unit, wherein a first inlet of the sodium oxide generation unit is configured to receive a portion of the produced sodium output from the sodium oxide dissociation unit,wherein the sodium oxide generation unit is configured to generate sodium oxide using the received portion of the produced sodium, wherein an outlet of the sodium oxide generation unit is fed into a second inlet of the sodium oxide dissociation unit.

6. The system of claim 5, further comprising a second inlet subsystem, wherein the control circuitry is configured to control the second inlet subsystem to feed a respective predetermined amount of a second material into the sodium oxide generation unit.

7. The system of claim 6, wherein the second material is sodium hydroxide, and wherein the sodium oxide generation unit is configured to react the sodium hydroxide with the received portion of the produced sodium to generate the sodium oxide.

8. The system of any one of claims 1 - 7, further comprising a sodium removal unit, wherein the sodium removal unit is configured to: remove sodium output from the reactor; and input the removed sodium into the first inlet subsystem.

9. The system of any one of claims 1 - 8, further comprising at least one motor configured to provide agitation within each of the at least one chamber.

10. The system of claim 9, further comprising at least one agitator positioned within the at least one chamber, the agitation provided by the at least one motor generated by rotation of the at least one agitator.

11. The system of claim 10, wherein the at least one chamber comprises a first chamber and a second chamber, wherein the at least one agitator comprises a first agitator positioned within the first chamber and a second agitator positioned within the second chamber.

12. The system of claim 11, wherein the first agitator comprises a screw impeller and the second agitator comprises a paddle impeller.

13. The system of any one of claims 1 - 12, wherein the control circuitry is configured to: control the at least one heat source to heat the at least one chamber to a first predetermined temperature for a first predetermined time period; and following the first predetermined time period, control the at least heat source to heat the at least one chamber to a second predetermined temperature for a second predetermined time period.

14. The system of claim 13, wherein the second predetermined temperature is greater than the first predetermined temperature.

15. The system of claim 13, wherein the first predetermined temperature is 100 - 500 degrees Celsius.

16. The system of any one of claims 13 - 15, wherein the second predetermined time period is greater than the first predetermined time period.

17. The system of any one of claims 1 - 16, wherein the first inlet subsystem comprises: a weighing container; a scale configured to weigh contents of the weighing container; an electronically controlled valve; a first inert gas source in fluid communication with a first reservoir comprising the sodium; and a second inert gas source in fluid communication with the weighing container, wherein a gas flow output by the first inert gas source transfers the first predetermined material to the weighing container via the electronically controlled valve and a gas flow output by the second inert gas source transfers the sodium from the weighing container to the at least one chamber, and wherein the electronically controlled valve is controlled responsive to an output of the scale.

18. The system of any one of claims 1 - 17, wherein the first inlet subsystem comprises: a volume measurement container; a volume measurement sensor configured to measure a volume of contents contained within the volume measurement container;an inert gas source in fluid communication with a first reservoir comprising the sodium; and at least one electronically controlled switch configured: in a first state, to provide a path from the first reservoir to the volume measurement container and block a path from the volume measurement container to the at least one chamber; and in a second state, to block the path from the first reservoir to the volume measurement container and provide the path from the volume measurement container to the at least one chamber, wherein a gas flow output by the inert gas source transfers the sodium to the volume measurement container.

19. The system of any one of claims 1 - 18, further comprising: a trap; an evacuation unit extending from the at least one chamber to the trap; and a suction pump configured to create suction within the evacuation unit and the at least one chamber.

20. The system of claim 1, further comprising at least one inert gas source in fluid communication with the at least one chamber, the at least one inert gas source configured to provide a flow of inert gas into each of the at least one chamber.

21. The system of any one of claims 1 - 8, further comprising at least one motor configured to rotate each of the at least one chamber.

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