Selective Chlorination of Metal Oxide Waste for High Purity Recovery
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Solution Overview
Problem
Current metal production methods from metal oxides with low content and mixed compositions, such as coal mine waste and industrial byproducts, are not economically viable due to high impurity levels and low metal oxide content, making them considered as waste rather than a valuable source for metal chlorides or metals.
Innovation Solution
A method and apparatus for producing metal chlorides and metals from metal oxide-containing materials, involving calcination and selective chlorination, with energy conservation and recycling, allowing the use of low-grade sources like coal mine waste and industrial byproducts, and separating metal chlorides through fractional condensation/distillation to achieve high purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If low-grade metal oxide containing materials (such as coal mine waste and industrial byproducts) are used as feedstock, then the availability and cost-effectiveness of raw materials improve, but the metal oxide content and purity deteriorate
Solution Approach 1:
The invention segments the complex metal oxide containing material into individual metal oxides through selective chlorination reactions. Each metal oxide reacts specifically with chlorine to form its corresponding metal chloride, allowing for separation and purification of individual metal components from the mixed waste material.
Solution Approach 2:
The invention introduces chlorine as an intermediary substance that facilitates the conversion of mixed metal oxides into separable metal chlorides. The chlorine selectively reacts with different metal oxides to form volatile metal chlorides that can be separated through condensation and distillation processes, thereby purifying the individual metal components.
2Ease of manufacture
If conventional metal production methods are applied to low-grade sources, then the process simplicity is maintained, but the economic viability and production efficiency deteriorate
Solution Approach 1:
The invention changes the chemical parameters of the feedstock by converting metal oxides into metal chlorides through chlorination. This parameter change enables the use of low-grade materials that would otherwise be unsuitable for conventional metal production, thereby improving economic viability while maintaining a relatively simple process flow.
Solution Approach 2:
The invention implements continuous processing where metal oxide containing materials are continuously converted to metal chlorides, separated through condensation, and then reduced to metals. This continuous operation improves productivity and economic viability compared to batch processing of low-grade materials.
3Productivity
If energy is consumed in the calcination and chlorination processes, then the metal chloride production increases, but the energy cost increases
Solution Approach 1:
The invention merges the calcination and chlorination steps into a unified process where both reactions occur in sequence or simultaneously in the same reactor system. This integration reduces overall energy consumption by eliminating the need for separate heating and reaction zones, while maintaining high metal chloride production efficiency.
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 enables the economical production of metal chlorides and metals from low-grade sources by conserving energy, reducing impurities, and achieving high purity separation, thereby revitalizing the use of previously considered waste materials.
Implementation Method 1
calcining the metal oxide containing material under temperature conditions sufficient to obtain a calcined product comprising at least one metal oxide
Implementation Method 2
selectively chlorinating the calcined product to form at least one metal chloride
Implementation Method 3
separating metal chlorides through fractional condensation/distillation to achieve high purity
Data Source
AI summary
Method and apparatus for preparing at least one metal chloride from metal oxide containing material comprising calcining the metal oxide containing material under temperature conditions sufficient to obtain a calcined product comprising at least one metal oxide; and selectively chlorinating the calcined product to form at least one metal chloride.