Sodium-based metal production system

Abstract

1. A sodium-based metals production system comprising: a reactor having at least one chamber and at least one heat source; a first inlet subsystem; a sodium oxide dissociation unit; and control circuitry configured to control the first inlet subsystem to supply respective predetermined amounts of first materials to the at least one chamber, to control the first inlet subsystem to supply respective predetermined amounts of sodium to the at least one chamber, and to 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 the produced sodium is output through a first outlet of the sodium oxide dissociation unit.

Description

[Technical Field]

[0001] The present disclosure relates generally to the field of metal production, and more particularly to sodium-based metal production systems. [Background technology]

[0002] Iron ore is a rock and mineral from which metallic iron can be extracted. Typically, the ore is refined and then placed in a blast furnace, a tower-shaped structure made of steel and lined with refractory or heat-resistant bricks. A mixture of raw materials, or charge, enters the top of the blast furnace. At the bottom of the furnace, very hot air is blown or blasted through nozzles called tuyere nozzles. Coke burns in the presence of the hot air. Oxygen in the air reacts with 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 molten iron then sinks to the bottom of the furnace. The limestone combines with rock and other impurities in the ore to form slag, which is lighter than the iron and floats to the top. As the charge volume is reduced, more is continuously added at the top of the furnace. The iron and slag are then separately withdrawn from the bottom of the furnace. Summary of the Invention

[0004] Accordingly, it is a primary object of the present invention to overcome at least some of the disadvantages of prior art metal production systems. In some instances, 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 includes a first inlet subsystem. In some examples, the metal production system includes a separation unit. In some examples, the outlet of the reactor is fed to the separation unit.

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

[0007] In some examples, the metal production system includes a control circuit configured to control the first inlet subsystems to deliver respective predetermined amounts of a first material to the at least one chamber, control the first inlet subsystems to deliver respective predetermined amounts of sodium to 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 metals produced in the reactor, and the sodium oxide is output through a first outlet of the separation unit.

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

[0010] Additional features and advantages of the present 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, will control. As used herein, the articles "a" and "an" mean "at least one" or "one or more" unless the context clearly dictates otherwise. As used 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 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] Furthermore, unless expressly stated to the contrary, "or" refers to an inclusive "or," not an exclusive "or." For example, condition A or B is satisfied by any of the following: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0013] Furthermore, the use of "a" or "an" is used to describe elements and components of embodiments of the 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 clear that it is meant otherwise.

[0014] As used herein, the term "about," when referring to a measurable value such as an amount, temporal duration, etc., is meant to include a variation of + / - 10%, more preferably + / - 5%, even more preferably + / - 1%, and even more preferably + / - 0.1% from the specified value, which variation is suitable for performing the disclosed devices and / or methods.

[0015] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools, and methods that are intended to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the problems noted above are reduced or eliminated, while other embodiments aim to provide other advantages or improvements. [Brief explanation of the drawings]

[0016] For a better understanding of various embodiments of the present 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 reference numerals indicate corresponding sections or elements throughout.

[0017]

[0023] Referring now specifically to the drawings in detail, the details shown are by way of example only for the purpose of illustrative discussion of preferred embodiments of the invention and are presented for the reason of providing what is believed to be the most useful and readily understood explanation of the principles and conceptual aspects of the invention. In this regard, no attempt has been made to show more structural details of the invention than are necessary for a fundamental understanding of the invention, and the description taken together with the drawings will make clear to those skilled in the art how several forms of the invention may be embodied in practice. The accompanying drawings are as follows: [Figure 1A] 1 depicts a high-level schematic diagram of an example metal production system, in accordance with certain examples of the present disclosure. [Figure 1B] 1B shows a high-level view of the agitator of the metal production system of FIG. 1A. [Figure 2] 1B shows a high-level schematic diagram of a more detailed example of the metal production system of FIG. 1A. [Figure 3]3 shows a high-level schematic diagram of a more detailed example of the metal production system of FIG. 2. [Figure 4A] 4A-4C illustrate high-level schematic diagrams of various examples of inlet subsystems of the metal production system of FIG. 3. [Figure 4B] 4A-4C illustrate high-level schematic diagrams of various examples of inlet subsystems of the metal production system of FIG. 3. [Figure 5A] FIG. 1 depicts a high-level schematic diagram of a sodium-based metals production system with sodium recycle, according to some examples of the present disclosure. [Figure 5B] FIG. 1 depicts a high-level schematic diagram of a sodium-based metals production system with sodium recycle, according to some examples of the present disclosure. [Figure 5C] FIG. 1 depicts a high-level schematic diagram of a sodium-based metals production system with sodium recycle, according to some examples of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0018] In the following description, various aspects of the present disclosure are described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of different aspects of the present disclosure. However, it will be apparent to those skilled in the art that the present disclosure may be practiced without the specific details presented herein. Additionally, well-known features may be omitted or simplified so as not to obscure the disclosure. In the figures, like reference numbers refer to like parts throughout. To avoid undue confusion due to a proliferation of reference numbers and leads in a particular drawing, some components may be introduced through one or more drawings and not explicitly identified in all subsequent drawings that include that component.

[0019] 1A shows a high-level schematic diagram of a metal production system 10. In some examples, the metal production system 10 includes a reactor 20 defining a chamber 25, the 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 the chamber 25, a mixer 30 defining the chamber 25, the mixer 30 extending from the first end 31 to the second end 32 and exhibiting an inlet opening 33 and an outlet opening 34 providing access to the chamber 25, a passage unit 40 extending from a first end 41 to a second end 42, a first heat source 50, a second heat source 52, and control circuitry 54.

[0020] In some examples, system 10 includes an agitator 60 positioned within reactor 20 and exhibiting a longitudinal axis 65 extending between first end 21 and second end 22 of reactor 20, and a motor 70. The shaft of motor 70 is mechanically coupled to rotating member 60 such that rotation of motor 70 rotates rotating member 60 about its longitudinal axis 65, thereby providing agitation within chamber 25.

[0021] In some examples, system 10 includes an agitator 80 positioned within mixer 30 and exhibiting a longitudinal axis 85, and a motor 90. The shaft of motor 90 is mechanically coupled to agitator 80, such that rotation of motor 90 rotates agitator 80 about longitudinal axis 85, thereby providing agitation within chamber 35. While system 10 is shown and described in examples where separate motors 70 and 90 are provided, this is not intended 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 rotation of motor 70 rotates both agitator 60 and agitator 80.

[0022] 1B , the agitator 60 comprises a screw impeller. In particular, in some examples, the agitator 60 comprises a central elongated member 61 extending from a first end 62 to a second end 63 along a longitudinal axis 65, and a generally helical thread 64 wound around the central elongated member 61 between the first end 62 and the second end 63 such that the central elongated member 61 extends through the thread 64. In particular, in some examples, the longitudinal axis of the thread 64 coincides with the longitudinal axis 65 of the agitator 60. In some examples, the first end 62 of the central elongated member 61 is mechanically coupled to a motor 70 such that rotation of the motor 70 rotates the central elongated member 61.

[0023] Although a single motor 70 is shown mechanically coupled to a single end of the agitator 60, this is not intended 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 the agitator 60.

[0024] 1B is shown with an example in which a first end of the threads 64 is spaced a first distance (denoted D1) from a first end 62 of the central elongated member 61, and a second end of the threads 64 is spaced a second distance (denoted D2) from a second end 64 of the central elongated member 61, with D1 being greater than D2. However, this is not intended to be limiting in any way, and D1 and D2 may be provided with any suitable values ​​without departing from the scope of the present disclosure.

[0025] Although the agitator 60 is shown and described herein in examples where the threads 64 are adjacent to the central elongated member 61, this is not intended to be limiting in any way. In some examples, the threads 64 represent a predetermined non-zero radial distance from the central elongated member 61. In particular, in some examples, the agitator 60 comprises a helical ribbon impeller. Although the agitator 60 is shown and described herein as comprising a single thread 64, this is not intended to be limiting in any way. In some examples, the threads 64 comprise multiple threads 64. In particular, in some examples, the agitator 60 comprises a double helical ribbon impeller.

[0026] In some examples, the agitator 80 comprises a screw impeller or a helical ribbon impeller, as described above with respect to the agitator 80. In some examples, the agitator 80 comprises a paddle impeller.

[0027] Although the above has been described with respect to examples in which reactor 20 and mixer 30 each include a respective agitator disposed therein, this is not intended 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. In particular, in some examples, motor 70 rotates reactor 20, thereby providing agitation within chamber 25. In some examples, mixer 30 is rotatable about its longitudinal axis. In some examples, motor 90 rotates mixer 30, thereby providing agitation within chamber 35.

[0028] In some examples, the interior wall of reactor 20 that defines chamber 25 is made of silicon carbide (SiC). In some examples, the interior wall of mixer 30 that defines chamber 35 is made of SiC. In some examples, the interior wall of reactor 20 is made of stainless steel. In some examples, the interior wall of mixer 30 is made of stainless steel.

[0029] In some examples, the passage unit 40 is at least partially hollow and at least partially open at both ends 41 and 42, such that material can pass from the first end 41 to the second end 42. In some examples, the first end 41 of the passage unit 40 faces and contacts the outlet opening 24 of the reactor 20, such that material in the chamber 25 can exit through the outlet opening 24 into the passage unit 40. In some examples, the second end 42 of the passage unit 40 faces and contacts the inlet opening 33 of the mixer 30, such that material in the passage unit 40 can exit through the second end 42 into the chamber 35. In some examples, the reactor 20, the mixer 30, and the passage unit 40 each have a generally cylindrical shape, although this is not intended to be limiting in any way.

[0030] In some examples, as shown in FIG. 1A, the reactor 20 and the mixer 30 are separated by a predetermined distance, although this is not intended to be limiting in any way. In some examples, the reactor 20 and the mixer 30 are adjacent to one another, and the passage unit 40 is made up of the outlet opening 24 of the reactor 20 and the inlet opening 33 of the mixer 30. In some examples, as shown in FIG. 1A, the reactor 20 and the mixer 30 are constructed as two separate units, although this is not intended to be limiting in any way. In some examples, the reactor 20 and the mixer 30 form a single unit, such that the chamber 25 and the chamber 35 are separated by a single wall, which defines the second end 22 of the reactor 20 and the second end 32 of the mixer 30.

[0031] In some examples, heat source 50 and heat source 52 each comprise a furnace. In some examples, heat source 50 is collocated with reactor 20 and heat source 52 is collocated with mixer 30. In some examples, heat source 50 surrounds reactor 20 and heat source 52 surrounds mixer 30.

[0032] Although heat source 50 is shown and described herein as a single unit, this is not intended to be limiting in any way. In some examples, heat source 50 comprises multiple heating units (e.g., furnaces), each juxtaposed with a respective portion of reactor 20. Although heat source 52 is shown and described herein as a single unit, this is not intended to be limiting in any way. In some examples, heat source 52 comprises multiple heating units (e.g., furnaces), each juxtaposed with a respective portion of mixer 30.

[0033] Although system 10 is shown and described herein as including heat source 50 and heat source 52, this is not intended to be limiting in any way. In some examples (not shown), a single heat source is provided to heat both chamber 25 and chamber 35.

[0034] In some examples, heat source 50 is designed and constructed to generate sufficient heat to cause the temperature of chamber 25 to reach approximately 500°C. In some examples, heat source 50 is designed and constructed to generate heat at a higher temperature and is controlled by control circuitry 54 to generate heat to cause the temperature of chamber 25 to reach approximately 500°C. In some examples, heat source 52 is designed and constructed to generate sufficient heat to cause the temperature of chamber 35 to reach approximately 600°C. In some examples, heat source 52 is designed and constructed to generate heat at a higher temperature and is controlled by control circuitry 54 to generate heat to cause the temperature of chamber 35 to reach approximately 600°C.

[0035] As noted above, in some examples, a single heat source is provided, and in such examples, control circuitry 54 controls the heat source to alternate between generating heat at a first temperature such that chamber 25 is heated to a temperature of approximately 350-450°C and generating heat at a second temperature such that chamber 35 is heated to a temperature of approximately 600-900°C.

[0036] In some examples, control circuitry 54 controls heat source 50 to generate sufficient heat so that the temperature of chamber 25 reaches a first predetermined temperature over a first predetermined period of time and controls heat source 52 to generate sufficient heat so that the temperature of chamber 35 reaches a second predetermined temperature over a second predetermined period of time. In some examples, the first predetermined temperature is approximately 500°C and the second predetermined temperature is approximately 600°C. In some examples, the second predetermined period of time is at least 1 hour. In some examples, the second predetermined period of time is at least five times the first predetermined period of time. In some examples, the first predetermined period of time is less than 10 minutes.

[0037] In some instances, the agitator 80 separates the iron from the sodium oxide produced in the chamber 35, thereby preventing the formation of sodium ferrite, which reduces the yield of iron produced.

[0038] While the above has been described with respect to examples in which the first reaction chamber 25 is heated to a first predetermined temperature for a first predetermined period of time and the second reaction chamber 35 is heated to a second predetermined temperature for a second predetermined period of time, this is not intended to be limiting in any way. In some examples (not shown), a single reaction chamber is provided and one or more heat sources are controlled to heat the single reaction chamber to a first predetermined temperature for a first predetermined period of time and then to heat the single reaction chamber to a second predetermined temperature for a second predetermined period of time.

[0039] Although the above is described in the context of reactor 20 including agitator 60, this is not intended to be limiting in any way. In some examples, motor 70 is configured to rotate chamber 25 about longitudinal axis 65. In some examples, this is done in addition to or instead of rotating agitator 60.

[0040] FIG. 2 shows a high-level schematic diagram of a more detailed example of system 10. In particular, 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. As used herein, the term "fluid communication" means that two elements are connected by a sealed pathway that allows a fluid to pass through, such as a tubular element. Specifically, fluid pathway 102 is provided, connecting first inert gas source 100 and first gas inlet opening 101 via fluid pathway 102. Similarly, fluid pathway 112 is provided, connecting second inert gas source 110 and second gas inlet opening 111 via fluid pathway 112.

[0041] In some examples, heat source 103 is provided within or collocated with fluid path 102, and heat source 113 is provided within or collocated with fluid path 112. In some examples, heat source 103 heats the gas in fluid path 102 to a respective predetermined temperature, optionally about 100 degrees. In some examples, heat source 113 heats the gas in fluid path 112 to a respective predetermined temperature, optionally about 100 degrees.

[0042] Although reactor 20 is described herein as having a pair of gas inlet openings and receiving gas from a pair of gas sources, this is not intended to be limiting in any way. In some examples (not shown), reactor 20 is provided with a single gas source and a single gas inlet opening.

[0043] In some examples, the first inert gas source 100 comprises nitrogen, hi some examples, the second inert gas source 110 comprises nitrogen or argon.

[0044] In some examples, mixer 30 exhibits a gas inlet opening 121 in fluid communication with a 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 or juxtaposed with fluid path 122. In some examples, heat source 123 heats the gas in fluid path 122 to a respective predetermined temperature, optionally about 100 degrees.

[0045] In some examples, the system 10 further includes an output unit 130 extending from a first end 131 to a second end 132. In some examples, the output unit 130 is generally cylindrical in shape, although this is not intended to be limiting in any way. In some examples, the output unit 130 is at least partially hollow and at least partially open at both ends 131 and 132, such that material can pass from the first end 131 to the second end 132. In some examples, the first end 131 of the output unit 130 faces and contacts the outlet opening 34, such that material in the chamber 35 can exit the output unit 130 through the outlet opening 34. In some examples, the second end 132 of the output unit 130 faces and contacts the collection tank 140, such that material in the output unit 130 can exit the collection tank 140 through the second end 132.

[0046] In some examples, system 10 further includes a heat source 150 collocated with output unit 130. In some examples, heat source 150 is designed and constructed to generate sufficient heat so that the temperature of output unit 130 is at a second predetermined temperature. In some examples, heat sources 103, 113, 123, and 150 are each controlled by a respective output of control circuit 54.

[0047] FIG. 3 shows a high-level schematic diagram of a more detailed example of system 10. In some examples, as shown in FIG. 3, system 10 further includes a trapping subsystem 200. In some examples, trapping subsystem 200 includes 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 includes an exhaust unit 211 extending from a first end 212 to a second end 213, and a suction pump 214 configured to generate a suction force within exhaust 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.

[0048] In some examples, the discharge unit 211 is generally cylindrical in shape, although this is not intended to be limiting in any way. In some examples, the discharge unit 211 is at least partially hollow and at least partially open at both ends 212 and 213, such that material can pass from the first end 212 to the second end 213 in response to the suction action of the suction pump 214. In some examples, the first end 212 of the discharge unit 211 faces and contacts the discharge outlet 240 of the chamber 35, such that certain material within the chamber 35 can exit the discharge unit 211 through the discharge outlet 240 in response to the suction action of the suction pump 214. In some examples, the suction pump 214 is 0.5 to 12 m 3 / h capacity. In some examples, the second end 213 of the discharge unit 211 faces and contacts the trap 230, so that material in the discharge unit 211 can exit through the second end 213 into the trap 230.

[0049] In some examples, trap 230 includes one or more vents 235. In some examples, vents 235 are designed to allow gas trapped in trap 230 to be released.

[0050] In some examples, the gas output unit 220 has a generally cylindrical shape, although this is not intended to be limiting in any way. In some examples, the 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 from the first end 221 to the second end 222. In some examples, the first end 221 of the gas output unit 220 faces and contacts the gas outlet 250 of the chamber 35, such that gas within the chamber 35 can exit through the gas outlet 250 into the gas output unit 220. Notably, in some examples, during operation, the chamber 35 is completely sealed except for the gas outlet 250, thereby allowing gas to escape therethrough. In some examples, the second end 222 of the gas output unit 220 faces and contacts the trap 230, such that gas within the gas output unit 220 can exit through the second end 222 to the trap 230.

[0051] In some examples, system 10 further comprises an inlet subsystem 300, as described below. In some examples, inlet subsystem 300 comprises an output 310 coupled to inlet opening 23 of reactor 20.

[0052] 4A shows a high-level schematic diagram of a first example of inlet subsystem 300, designated inlet subsystem 300A. In some examples, inlet subsystem 300A supplies materials to reactor 20 from reservoir 320 and reservoir 325, as described below. In some examples, reservoir 320 exhibits gas inlet opening 321 and output opening 322. In some examples, reservoir 325 exhibits output opening 326.

[0053] In some examples, the inlet subsystem 300A includes 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 measuring container 380 having 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 having an inlet opening 441 and an outlet opening 442.

[0054] In some examples, reservoir 320 is configured to contain a predetermined amount of sodium. In some examples, gas source 340 contains nitrogen. In some examples, gas source 340 outputs gas at a predetermined pressure. In some examples, gas source 430 contains nitrogen. In some examples, gas source 340 outputs gas at a predetermined pressure. In some examples, the predetermined pressure is between 1.01 and 3 atm.

[0055] In some examples, the gas inlet opening 321 of the reservoir 320 is in fluid communication with the output of the gas source 340. In some examples, the heat source 350 is controlled in response to the output of the control circuit 54. In some examples, the heat source 350 is controlled to generate sufficient heat such that the temperature of the reservoir 320 reaches a respective predetermined temperature over a respective predetermined period of time. In some examples, the respective predetermined temperatures are at least 100°C. In some examples, the respective predetermined temperatures are approximately 150°C.

[0056] In some examples, reservoir output unit 350 is generally cylindrical in shape, although this is not intended to be limiting in any way. In some examples, reservoir output unit 350 is at least partially hollow and at least partially open at opposite ends 351 and 352, such that material can pass from first end 351 to second end 352. In some examples, first end 351 of reservoir output unit 350 is inserted into reservoir 320 via output opening 322, such that material within reservoir 320 can exit through reservoir output unit 350 in response to a predetermined pressure provided by gas output from gas source 340.

[0057] In some examples, a second end 352 of the reservoir output unit 350 faces an inlet of an electronically controlled valve 360, and an outlet of the electronically controlled valve 360 ​​faces a first end 371 of a measurement input unit 370, such that material passes from the reservoir output unit 350 through the electronically controlled valve 360 ​​to the measurement input unit 370. In some examples, the electronically controlled valve 360 ​​is controlled in response to an output of a control circuit 54, and a respective input of the control circuit 54 communicates with an output of a balance 390.

[0058] In some examples, measurement input unit 370 is generally cylindrical in shape, although this is not intended to be limiting in any way. In some examples, measurement input unit 370 is at least partially hollow and at least partially open at opposite ends 371 and 372, such that material can pass from first end 371 to second end 372. In some examples, second end 372 of measurement input unit 370 is inserted into metered vessel 380 via inlet opening 381, such that material in measurement input unit 370 can enter metered vessel 380.

[0059] In some examples, metered vessel 380 is positioned on scale 390, although this is not intended to be limiting in any way. In some examples, scale 390 is recessed into the floor of metered vessel 380. In some examples, scale 390 weighs the contents of metered vessel 380. In some examples, gas opening 383 of metered vessel 380 is in fluid communication with the outlet of gas source 430.

[0060] In some examples, scale output unit 400 is generally cylindrical in shape, although this is not intended to be limiting in any way. In some examples, scale output unit 400 is at least partially hollow and at least partially open at opposite ends 401 and 402, such that material can pass from first end 401 to second end 402. In some examples, first end 401 of scale output unit 400 is inserted into metered vessel 380 via outlet opening 382, ​​such that material in metered vessel 380 can exit via scale output unit 400 in response to pressure provided by gas from gas source 430. In some examples, second end 402 of scale output unit 400 is inserted into chamber 25 via or faces inlet opening 23 (not shown in FIG. 4A ), such that material in metered vessel 380 can enter chamber 25 via scale output unit 400.

[0061] In some examples, control circuit 54 controls electronically controlled valve 360 ​​to control the amount of material entering metered container 380 from reservoir 320 in response to the output of scale 390. In particular, electronically controlled valve 360 ​​is controlled such that a predetermined amount of material is measured out by determining the weight of the material. The predetermined amount of material is output to chamber 25.

[0062] In some examples, a predetermined amount of the second material is contained in reservoir 225. In some examples, the second material includes 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 inserted into chamber 25 through inlet opening 23 or faces inlet opening 23, such that material in feeder 440 can enter chamber 25. In some examples, feeder 440 comprises a screw feeder. In some examples, control circuit 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., using an inert gas and / or in a vacuum).

[0063] 4B shows a high-level schematic diagram of a second example of inlet subsystem 300, designated inlet subsystem 300B. In some examples, inlet subsystem 300B supplies materials to reactor 20 from reservoir 320 and reservoir 325, as described below. In some examples, reservoir 320 exhibits gas inlet opening 321 and output opening 322. In some examples, reservoir 325 exhibits output opening 326.

[0064] In some examples, the 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 dividing unit 450 extending from a first end 451 to a second end 452 and presenting an outlet opening 453, a volume measuring container 455 extending from a first end 456 to a second end 457, a moving member 460 extending from the first end to the second end, a volume measuring sensor 470, a moving 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 presenting an inlet opening 441 and an outlet opening 442.

[0065] In some examples, as described above with respect to inlet subsystem 300A, reservoir 320 is configured to contain a predetermined amount of sodium. In some examples, as described above with respect to inlet subsystem 300A, gas source 340 contains nitrogen. In some examples, as described above with respect to inlet subsystem 300A, gas source 340 outputs gas at a predetermined pressure. In some examples, as described above with respect to inlet subsystem 300A, gas source 430 contains nitrogen. In some examples, as described above with respect to inlet subsystem 300A, gas source 340 outputs gas at a predetermined pressure. In some examples, the predetermined pressure is between 1.01 and 3 atm.

[0066] In some examples, the gas inlet opening 321 of the reservoir 320 is in fluid communication with the output of the gas source 340. In some examples, the heat source 350 is controlled in response to the output of the control circuit 54. In some examples, as described above with respect to the inlet subsystem 300A, the heat source 350 is controlled to generate sufficient heat such that the temperature of the reservoir 320 reaches a respective predetermined temperature over a respective predetermined period of time. In some examples, as described above with respect to the inlet subsystem 300A, the respective predetermined temperatures are at least 100°C. In some examples, the respective predetermined temperatures are approximately 150°C.

[0067] In some examples, reservoir output unit 350 is generally cylindrical in shape, although this is not intended to be limiting in any way. In some examples, reservoir output unit 350 is at least partially hollow and at least partially open at opposite ends 351 and 352, such that material can pass from first end 351 to second end 352. In some examples, as described above with respect to inlet subsystem 300A, first end 351 of reservoir output unit 350 is inserted into reservoir 320 through output opening 322, such that material within reservoir 320 can exit through reservoir output unit 350 in response to a predetermined pressure provided by gas output from gas source 340.

[0068] In some examples, the second end 352 of the reservoir output unit 350 is fluidly connected to the first end 451 of the dividing unit 450, and the second end 452 of the dividing unit 450 is fluidly connected to the first end 456 of the volume measuring container 455, such that fluid flowing from the reservoir 320 flows through the dividing unit 450 into the volume measuring container 455.

[0069] In some examples, the electronically controlled switch 490 is positioned above the first end 451 of the dividing unit 450. In a first position of the electronically controlled switch 490, a fluid path is provided from the reservoir output unit 320 to the dividing unit 450. In a second position of the electronically controlled switch 490, the fluid path from the reservoir output unit 320 to the dividing unit 450 is blocked by the electronically controlled switch 490.

[0070] In some examples, the outlet opening 453 of the dividing unit 450 is in fluid communication with the first end 511 of the measurement output unit 510. In some examples, the electronically controlled switch 500 is positioned above the outlet opening 453 of the dividing unit 450. In a first position of the electronically controlled switch 500, a fluid path is provided from the volume measuring reservoir 455 to the measurement output unit 510. In a second position of the electronically controlled switch 500, the fluid path from the volume measuring reservoir 455 to the measurement output unit 510 is blocked by the electronically controlled switch 500.

[0071] In some examples, the volumetric container 455 is generally cylindrical, although this is not intended to be limiting in any way. In some examples, the moving member 460 comprises a piston. In some examples, the volumetric sensor 470 comprises a contact sensor. While the volumetric sensor 470 is described herein, this is not intended to be limiting in any way, and any type of sensor (e.g., a camera) can be provided to measure the volume of material in the volumetric container 455 without going beyond the scope of the present disclosure. In some examples, the moving mechanism 480 comprises a motor, and the shaft of the motor is coupled to the moving member 460.

[0072] In some examples, a first end 461 of the moving member 460 is positioned within the volumetric container 455, and a second end 462 of the moving member 460 faces the volumetric sensor 470. In some examples, when the volumetric container 455 is full and / or filled with a predetermined volume of fluid, the second end 462 of the moving member 460 contacts the contact sensor 470.

[0073] In particular, in some examples, the electronically controlled switch 490 is set to a first position, and fluid from the reservoir 320 enters the volumetric measuring container 455 in response to pressurized gas from the gas source 340, pushing the moving member toward the volumetric measuring sensor 470. In some examples, the electronically controlled switch 500 is set to a second position to prevent fluid from entering the measurement output unit 510. When the second end 462 of the moving member 460 contacts the contact sensor 470, the electronically controlled switch 500 is set to the first position (to provide a fluid flow path to the measurement output unit 510). In some examples, the electronically controlled switch 490 is set to the second position (to block the fluid flow path to the reservoir 320). In some examples, as described above, the moving mechanism 480 moves the moving member 460 toward the measurement output unit 510, resulting in a measured volume of material being delivered to the chamber 25.

[0074] In some examples, the measurement output unit 510 is generally cylindrical in shape, although this is not intended to be limiting in any way. In some examples, the 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 from the first end 511 to the second end 512. In some examples, the second end 512 of the measurement output unit 510 is inserted into or faces the inlet opening 23 (not shown in FIG. 4B ) in the chamber 25, such that material in the volumetric measuring container 350 can enter the chamber 25 through the measurement output unit 510.

[0075] In some examples, a predetermined amount of a second material is contained within reservoir 225. In some examples, the second material includes 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 inserted into chamber 25 through inlet opening 23 or faces inlet opening 23, such that material in feeder 440 can enter chamber 25. In some examples, feeder 440 comprises a screw feeder.

[0076] Although the inlet subsystem is shown and described herein as comprising a single volumetric reservoir 510, this is not intended to be limiting in any way. In some instances, multiple volumetric reservoirs 510 are provided, preferably in parallel.

[0077] 5A shows a high-level schematic diagram of a sodium-based metals production system 600 according to some examples of the present disclosure. In some examples, system 600 includes a reactor 610, a separation unit 620, and a sodium oxide dissociation unit 630. In some examples, system 600 further includes a sodium reservoir 640.

[0078] In some examples, reactor 610 comprises at least one chamber and at least one heat source, as described above with respect to reactor 20. In some examples, reactor 610 further comprises a motor, as described above with respect to motor 70. In some examples, reactor 610 further comprises an agitator, as described above with respect 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 operate the agitator.

[0079] In some examples, system 600 further comprises an inlet subsystem 650. In some examples, inlet subsystem 650 comprises one of inlet subsystems 300A or 300B, although this is not intended to be limiting in any way. In some examples, system 600 further comprises control circuitry 660.

[0080] 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.

[0081] In some examples, the inlet 611 of the reactor 610 is supplied from the inlet subsystem 650. While a single inlet 611 is shown and described herein, this is not intended to be limiting in any way, and the reactor 610 may include multiple inlets without exceeding the scope of this disclosure. As described above with respect to the inlet subsystems 300A and 300B, in some examples, the control circuit 660 controls the inlet subsystem 650 to supply a predetermined amount of sodium and a predetermined amount of a predetermined material to the reactor 610. In some examples, the predetermined material is iron oxide. In some examples, the iron oxide is contained within the ore. In some examples, the reactor 610 is controlled by the control circuit 660 to be heated to a temperature between 100°C and 500°C, as described above.

[0082] In some examples, separation unit 620 is configured to separate sodium oxide from the metal produced in reactor 610. In some examples, the metal is iron. In some examples, inlet 621 of separation unit 620 is fed from outlet 612 of reactor 610, either directly or through one or more intervening units. Furthermore, all connections between elements and units described herein can be made directly or through additional elements and units.

[0083] In some examples, separation unit 620 includes a magnetized element that attracts the metal thereto, thereby separating the metal from the sodium oxide. However, it should be noted that any method of separating the metal and 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 vaporize the sodium oxide, thereby separating the sodium oxide from the iron. The vaporized sodium oxide can then be condensed.

[0084] In some examples, separation unit 620 further comprises a transfer mechanism configured to move the iron out through outlet 622 and the sodium oxide out through outlet 623. In some examples, the transfer mechanism is mechanical. In some examples, the transfer mechanism is pressure-based, utilizing a predetermined pressure to move the iron out through outlet 622 and the sodium oxide out through outlet 623.

[0085] Note that in some instances, the iron is output through outlet 622 along with ferrite, gangue, and / or a certain amount of sodium oxide.

[0086] In some examples, as described below, separation unit 620 is split into two separate subunits. Note that while separation unit 620 and reactor 610 are shown and described herein as separate units, this is not intended to be limiting in any way. In some examples, separation unit 620 may be implemented within a chamber of reactor 610.

[0087] It is noted that although separation unit 620 and sodium oxide dissociation unit 630 are described as separate units, this is not intended 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 to inlet 631 of sodium oxide dissociation unit 630.

[0088] In some examples, the sodium oxide dissociation unit 630 is configured to dissociate sodium oxide to produce sodium and oxygen. In some examples, the sodium oxide dissociation unit 630 includes a heat source configured to heat the sodium oxide therein to a predetermined temperature. In some examples, the sodium oxide dissociation unit 630 further includes a vacuum pump configured to provide a vacuum environment within the sodium oxide dissociation unit 630. In some examples, the sodium oxide dissociation unit 630 dissociates 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 higher than the temperature of heat added to the reactor 610. In some examples, the predetermined temperature is at least 50°C higher than the temperature of heat added to the 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, heat is added to vaporize the sodium. In some examples, the sodium oxide dissociation unit 630 is further configured to condense the vaporized sodium. In some examples, the sodium is condensed at a temperature lower than the temperature at which the sodium was evaporated, optionally in a dedicated vessel. While the above is described with respect to examples of evaporating and condensing sodium, this is not intended to be limiting in any way, and dissociation of the sodium oxide and preparation thereof for transfer to sodium reservoir 640 can be carried out using any suitable method known to those skilled in the art.

[0089] In some examples, the sodium oxide dissociation unit 630 further comprises a transfer mechanism configured to transfer the sodium out through outlet 632. In some examples, the transfer mechanism is mechanical. In some examples, the transfer mechanism is pressure-based, utilizing a predetermined pressure to transfer the sodium through outlet 632. In some examples, outlet 632 of the sodium oxide dissociation unit 630 is fed to inlet subsystem 650, optionally via sodium reservoir 640. In particular, in some examples, outlet 632 of the sodium oxide dissociation unit 630 is fed to inlet 641 of sodium reservoir 640. In some examples, the produced oxygen is output through outlet 633 of the sodium oxide dissociation unit 630.

[0090] In some examples, as described above, control circuitry 660 controls inlet subsystem 650 to provide a respective predetermined amount of a first material, e.g., iron oxide, to at least one chamber of reactor 610 and a respective predetermined amount of sodium to at least one chamber of reactor 610. In some examples, sodium is provided to inlet subsystem 650 from sodium reservoir 640, as described above. As further described above in connection with reactor 20, in some examples, control circuitry 660 controls at least one heat source of reactor 610 to heat its at least one chamber and produce iron from the iron oxide and sodium. As described above, sodium oxide is also produced as a by-product.

[0091] As mentioned above, in some examples, sodium-based metals production system 600 provides for recycling of spent sodium through separation unit 620 and sodium oxide dissociation unit 630. While the above is described with respect to examples in which sodium is recycled through both separation unit 620 and sodium oxide dissociation unit 630, this is not intended to be limiting in any way, and sodium oxide dissociation unit 630 can be provided without separation unit 620.

[0092] 5B shows a high-level schematic diagram of a more detailed example of system 600. In some examples, system 600 further includes a sodium oxide generation unit 670. In some examples, sodium oxide generation unit 670 includes 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 fed from sodium reservoir 640 is provided, and control circuit 660 controls the valve such that a portion of the output sodium is fed to inlet 671 of sodium oxide generation unit 670.

[0093] In some examples (not shown), a sensor is provided and configured to measure the amount of sodium output from sodium oxide dissociation unit 630, and the portion of sodium provided to inlet 671 of sodium oxide generation unit 670 is based, at least in part, on the measured amount of sodium. Notably, in some examples, separation unit 620 and sodium oxide dissociation unit 630 are unable to recycle all of the sodium provided to reactor 610, and sodium oxide generation unit 670 is provided to generate additional sodium oxide that is provided to sodium oxide dissociation unit 630 for dissociation. Thus, in some examples, the amount of sodium provided to sodium oxide generation unit 670 is based on the amount of sodium that was not recycled, which can be determined by control circuit 660 based on the measured amount of sodium output by sodium oxide dissociation unit 630.

[0094] In some examples, system 600 further includes a second inlet subsystem 680. In some examples, inlet subsystem 680 is implemented as inlet subsystem 300A or 300B, although this is not intended to be limiting in any way. In some examples, control circuit 660 controls inlet subsystem 680 to provide a predetermined amount of each material to inlet 672 of sodium oxide generation unit 670. In some examples, the material is sodium hydroxide. In some examples, sodium oxide generation unit 670 reacts the material (e.g., sodium hydroxide) with a received portion of the sodium to produce sodium oxide.

[0095] In some examples, the sodium oxide generation unit 670 further comprises a transfer mechanism configured to transfer the sodium oxide through the outlet 673 to the inlet 634 of the sodium oxide dissociation unit 630. In some examples, the transfer mechanism is mechanical. In some examples, the transfer mechanism is pressure-based, utilizing a predetermined pressure to transfer the sodium oxide through the outlet 673.

[0096] Figure 5C shows a high-level schematic diagram of a more detailed example of system 600. Note that the example shown in Figure 5C is not intended to be limiting, and one or more of the additional units shown in Figure 5C may or may not include the sodium oxide generation unit 670 presented in Figure 5B. Furthermore, each of the additional units in Figure 5C may be provided alone or in combination with one another.

[0097] In some examples, system 600 further comprises a sodium removal unit 680. In some examples, system 600 further comprises a pre-treatment unit 690 and a post-treatment unit 700. In some examples, separation unit 620 comprises a first separation subunit 710 and a second separation subunit 720.

[0098] In some examples, sodium removal unit 680 comprises an inlet 681 and an outlet 682. In some examples, inlet 681 feeds 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 intended to be limiting in any way. In some examples, sodium removal unit 680 is implemented within reactor 610, as described below.

[0099] In some examples, sodium removal unit 680 isolates sodium 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°C to 800°C. In some examples, this evaporation is performed within reactor 610 or in a separate sodium removal unit 680 with a dedicated heat source, optionally controlled by control circuitry 660. In some examples, sodium removal unit 680 further comprises a transfer mechanism configured to transfer the removed sodium to sodium reservoir 640. In some examples, the transfer mechanism is mechanical. In some examples, the transfer mechanism is pressure-based, utilizing a predetermined pressure to transfer 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 and transfer it to sodium reservoir 640. In some examples, the sodium is condensed at a temperature lower than the temperature at which the sodium evaporated, optionally in a dedicated vessel.

[0100] Although the above is described with respect to the example of evaporating and condensing sodium, this is not intended to be limiting in any way, and removal of sodium and preparation thereof for transfer to sodium reservoir 640 can be accomplished using any suitable method known to those skilled in the art.

[0101] In some examples, pre-treatment unit 690 is configured to refine the pre-treatment unit input and output iron oxide from the ore, as known to those skilled in the art. The output iron oxide is provided to reactor 610. In some examples, post-treatment unit 700 receives the output of separator 620, which includes iron, ferrite, gangue, and sodium oxide. In some examples, post-treatment unit 700 processes the output to separate the iron, as known to those skilled in the art.

[0102] In some examples, separation subunit 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.

[0103] In some examples, separation subunit 720 includes an inlet 721 fed from outlet 712 of separation subunit 710, an outlet 722, and an inlet 731 of sodium oxide dissociation unit 630 fed from outlet 722. In some examples, separation subunit 710 and separation subunit 720 include the sodium oxide and iron separations described above, respectively. In some examples, performing the separation twice improves the separation.

[0104] Additional Examples of the Disclosed Technology In view of the above-described implementations of the disclosed subject matter, the present application discloses the following additional examples: It should be noted that one feature of an example alone, or two or more features of an example taken in combination, and optionally in combination with one or more features of one or more additional examples, are additional examples that also fall within the scope of the present application's disclosure.

[0105] Example 1. A sodium-based metals production system comprising: a reactor having at least one chamber and at least one heat source; a first inlet subsystem; a sodium oxide dissociation unit; and control circuitry configured to control the first inlet subsystem to supply respective predetermined amounts of a first material to the at least one chamber, control the first inlet subsystem to supply respective predetermined amounts of sodium to 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 the produced sodium is output through a first outlet of the sodium oxide dissociation unit.

[0106] Example 2. The system of any example described herein, particularly Example 1, wherein the first material comprises iron oxide and the metal is iron.

[0107] Example 3. Any example described herein, particularly a system described in Example 1 or 2, wherein the sodium produced is input into the first inlet subsystem.

[0108] Example 4. The system of any example described herein, particularly any one of Examples 1-3, further comprising a separation unit, wherein an outlet of the reactor is fed to the separation unit, a first outlet of the separation unit is fed to a first inlet of the sodium oxide dissociation unit, the first outlet of the sodium oxide dissociation unit is fed to the first inlet subsystem, the separation unit is configured to separate the sodium oxide from the metals produced in the reactor, and the sodium oxide is output through the first outlet of the separation unit.

[0109] Example 5. The system of any example described 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, the sodium oxide generation unit is configured to generate sodium oxide using the received portion of the produced sodium, and an outlet of the sodium oxide generation unit is fed to a second inlet of the sodium oxide dissociation unit.

[0110] Example 6. The system of any example described herein, particularly Example 5, further comprising a second inlet subsystem, wherein the control circuit is configured to control the second inlet subsystem to provide a respective predetermined amount of the second material to the sodium oxide generation unit.

[0111] Example 7. The system of any example described herein, particularly Example 6, wherein the second material is sodium hydroxide and the sodium oxide generation unit is configured to react the sodium hydroxide with a received portion of the produced sodium to generate sodium oxide.

[0112] Example 8. The system of any example described herein, particularly any one of Examples 1-7, further comprising a sodium removal unit configured to remove sodium output from the reactor and input the removed sodium to the first inlet subsystem.

[0113] Example 9. The system of any example described 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.

[0114] Example 10. The system of any example described herein, particularly Example 9, further comprising at least one agitator positioned within the at least one chamber, wherein the agitation provided by the at least one motor occurs through rotation of the at least one agitator.

[0115] Example 11. The system of any example described herein, particularly Example 10, wherein the at least one chamber comprises a first chamber and a second chamber, and the at least one agitator comprises a first agitator positioned in the first chamber and a second agitator positioned in the second chamber.

[0116] Example 12. The system of any example described herein, especially Example 11, wherein the first agitator comprises a screw impeller and the second agitator comprises a paddle impeller.

[0117] Example 13. A system, any example described 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 one heat source to heat the at least one chamber to a second predetermined temperature for a second predetermined time period.

[0118] Example 14. The system of any example described herein, particularly Example 13, wherein the second predetermined temperature is greater than the first predetermined temperature.

[0119] Example 15. The system of any example described herein, particularly Example 14, wherein the first predetermined temperature is between 100 and 500°C.

[0120] Example 16. The system of any example described herein, particularly any one of Examples 13-15, wherein the second predetermined period is longer than the first predetermined period.

[0121] Example 17. The system of any example described herein, particularly any one of Examples 1-16, wherein the first inlet subsystem comprises a metered vessel, a scale configured to meter the contents of the metered vessel, an electronically controlled valve, a first inert gas source in fluid communication with a first reservoir containing sodium, and a second inert gas source in fluid communication with the metered vessel, wherein a gas flow output by the first inert gas source transfers the first predetermined material into the metered vessel via the electronically controlled valve, and a gas flow output by the second inert gas source transfers sodium from the metered vessel to the at least one chamber, and wherein the electronically controlled valve is controlled in response to an output of the scale.

[0122] Example 18. The system of any example described herein, particularly any one of Examples 1-16, wherein the first inlet subsystem comprises: a volumetric container; a volumetric sensor configured to measure a volume of contents contained within the volumetric container; an inert gas source in fluid communication with a first reservoir containing sodium; and at least one electronically controlled switch configured to, in a first state, provide a path from the first reservoir to the volumetric container and block a path from the volumetric container to the at least one chamber, and to, in a second state, block the path from the first reservoir to the volumetric container and provide a path from the volumetric container to the at least one chamber, wherein a gas flow output by the inert gas source transfers sodium to the volumetric container.

[0123] Example 19. The system of any example described 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.

[0124] Example 20. The system of any example described 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.

[0125] Example 21. The system of any example described herein, particularly any one of Examples 1-8, further comprising at least one motor configured to rotate each of the at least one chamber.

[0126] It will be 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 subcombination.

[0127] Unless otherwise defined, all technical and / or scientific terms used herein have the same meaning as 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, the preferred methods are described herein.

[0128] All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present patent specification, including definitions, will control. Furthermore, the materials, methods, and examples are illustrative only and not intended to be limiting.

[0129] It will be appreciated by those skilled in the art that the present invention is not limited by what has been particularly shown and described above, but rather the scope of the present invention is defined by the appended claims and includes both combinations and subcombinations of the various features described above, as well as variations and modifications thereof which would occur to those skilled in the art upon reading the foregoing description.

Claims

1. 1. A sodium-based metals production system comprising: a reactor comprising at least one chamber and at least one heat source; a first inlet subsystem; and a sodium oxide dissociation unit; A control circuit comprising: controlling the first inlet subsystem to deliver a respective predetermined amount of a first material to the at least one chamber; controlling the first inlet subsystem to provide a respective predetermined amount of sodium to the at least one chamber; and a control circuit configured to control the at least one heat source to heat the at least one chamber; the sodium oxide dissociation unit is configured to dissociate the sodium oxide output from the reactor to produce sodium and oxygen; The system wherein the produced sodium is output through a 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. 3. The system of claim 1 or 2, wherein the produced sodium is input into the first inlet subsystem.

4. Further comprising a separation unit, wherein the outlet of the reactor is fed to the separation unit; a first outlet of the separation unit is fed to a first inlet of the sodium oxide dissociation unit, and a first outlet of the sodium oxide dissociation unit is fed to the first inlet subsystem; 4. The system of claim 1, wherein the separation unit is configured to separate sodium oxide from metals produced in the reactor, and the sodium oxide is output through the first outlet of the separation unit.

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

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

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

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

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

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

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

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

13. The control circuit controlling the at least one heat source to heat the at least one chamber to a first predetermined temperature for a first predetermined period of time; 13. The system of claim 1, configured to, following the first predetermined period of time, control at least a heat source to heat the at least one chamber to a second predetermined temperature for a second predetermined period of time.

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 between 100 and 500°C.

16. The system of any one of claims 13 to 15, wherein the second predetermined period is longer than the first predetermined period.

17. the first inlet subsystem comprising: A measuring container; a scale configured to weigh the contents of the measuring vessel; an electronic control valve; a first inert gas source in fluid communication with the first reservoir containing sodium; a second source of inert gas in fluid communication with the metered vessel; a gas flow output by the first inert gas source transfers the first predetermined material to the metered vessel via the electronically controlled valve, and a gas flow output by the second inert gas source transfers the sodium from the metered vessel to the at least one chamber; A system according to any preceding claim, wherein the electronically controlled valve is controlled in response to the output of the balance.

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

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

20. 10. 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 to 8, further comprising at least one motor configured to rotate each of the at least one chamber.

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