Crude Solder Composition Control for Clog-Free Vacuum Distillation
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Solution Overview
Problem
Existing processes for producing crude solder face issues such as the formation of high melting point intermetallic compounds during vacuum distillation, leading to equipment clogging and reduced operational efficiency, and require complex and expensive treatments like the cuprosilicon process to condition the solder for further purification.
Innovation Solution
A process that controls the concentration of metals like copper, nickel, iron, and zinc in the feedstock, allowing for the production of a crude solder suitable for trouble-free vacuum distillation without the need for the cuprosilicon process, using a smelter furnace and reducing agents like ferrosilicon to achieve the desired metal ratios and phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pyrometallurgical processes are used to produce crude solder from secondary feedstocks, then metal recovery is achieved, but high melting point intermetallic compounds form during vacuum distillation causing equipment clogging and operational issues
Solution Approach 1:
The patent applies preliminary action by controlling the composition of crude solder before vacuum distillation. Specifically, the crude solder is conditioned to contain copper at 0.5-5.0 wt%, nickel at 0.1-1.0 wt%, iron at 0.1-1.0 wt%, and zinc at 0.1-1.0 wt% (claim 1). This pre-conditioning prevents the formation of harmful intermetallic compounds during subsequent vacuum distillation, eliminating equipment clogging and operational reliability issues.
Solution Approach 2:
The patent applies parameter changes by precisely controlling the concentration parameters of metal components in crude solder. The copper content is maintained at 0.5-5.0 wt%, nickel at 0.1-1.0 wt%, iron at 0.1-1.0 wt%, and zinc at 0.1-1.0 wt% (claim 1). These parameter specifications transform the crude solder into a composition that is suitable for vacuum distillation without forming high melting point intermetallic compounds, thereby resolving the reliability issue.
2Reliability
If the cuprosilicon process is used to condition crude solder for purification, then intermetallic compound formation is reduced, but process complexity and cost increase
Solution Approach 1:
The patent applies the taking out principle by extracting and eliminating the complex cuprosilicon process from the production flow. Instead of using silicon-based conditioning treatments, the invention directly specifies controlled composition ranges for copper (0.5-5.0 wt%), nickel (0.1-1.0 wt%), iron (0.1-1.0 wt%), and zinc (0.1-1.0 wt%) in the crude solder (claim 1). This extraction of the complex intermediate process simplifies the overall production while maintaining reliability.
Solution Approach 2:
The patent applies self-service by enabling the crude solder to be directly suitable for vacuum distillation through inherent composition control rather than requiring external complex treatment processes. The specified metal concentration ranges (copper 0.5-5.0 wt%, nickel 0.1-1.0 wt%, iron 0.1-1.0 wt%, zinc 0.1-1.0 wt%) allow the material to self-condition for distillation suitability, eliminating the need for cuprosilicon treatment and reducing process complexity.
3Manufacturing precision
If complex conditioning processes are applied to crude solder, then purification quality improves, but production cost and waste generation increase
Solution Approach 1:
The patent applies the blessing in disguise principle by converting what would normally be harmful trace metals (copper, nickel, iron, zinc) into beneficial composition elements. By specifying controlled ranges for these metals (copper 0.5-5.0 wt%, nickel 0.1-1.0 wt%, iron 0.1-1.0 wt%, zinc 0.1-1.0 wt%), the invention transforms potential contaminants into composition parameters that ensure suitable crude solder for vacuum distillation (claim 1). This eliminates the need for complex waste-generating conditioning processes while achieving high purification quality.
4Productivity
If traditional smelting processes are used without composition control, then production speed is maintained, but crude solder requires expensive additional treatment
Solution Approach 1:
The patent applies preliminary action by implementing composition control during the smelting process itself. The crude solder is produced with predetermined metal content ranges (copper 0.5-5.0 wt%, nickel 0.1-1.0 wt%, iron 0.1-1.0 wt%, zinc 0.1-1.0 wt%) directly in the smelting stage (claim 1). This preliminary composition control eliminates the need for expensive additional treatment processes, maintaining both production efficiency and process simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process produces a crude solder that can be readily purified into high-purity tin and lead without equipment clogging, reducing operational costs and waste, and allows for the use of simpler, less expensive equipment like a smelter furnace.
Implementation Method 1
introducing at least one reducing agent into the furnace and reducing at least part of the oxidized valence form of tin and/or lead into tin and/or lead metal
Implementation Method 2
The non-ferrous metal production processes typically contain at least one and usually a plurality of pyrometallurgical process steps in which metals and metal oxides both occur in a liquid molten state, and wherein the metal oxides may be separated by gravity as a separate and typically lighter liquid slag from the usually heavier molten metal phase
Data Source
AI summary
Disclosed is a pyrometallurgical process for producing a crude solder from a feedstock selected in terms of its levels of Sn, Cu, Sb, Bi, Zn, As, Ni and Pb, the process comprising at least the steps of obtaining in a furnace a liquid bath of metal and slag, introducing a reducing agent and optionally also energy, separating the crude solder from the slag and removing liquid from the furnace. Further disclosed is a crude solder comprising at least 9.5-69%wt of tin and at least 25%wt lead, at least 80% tin and lead together, 0.08-12%wt of copper, 0.15-7%wt of antimony, 0.012- 1.5%wt of bismuth, 0.010-1.1%wt of zinc, at most 3%wt of arsenic, at most 2.8%wt of nickel, at most 0.7%wt of zinc, at most 7.5%wt of iron and at most 0.5%wt of aluminium. The crude solder may readily be further prepared to become suitable as feedstock for vacuum distillation.