Rapid conversion of metal-containing compounds to form metals or metal oxides

• US 20030019328A1
• Filed: 02/22/2001
• Published: 01/30/2003
• Est. Priority Date: 02/22/2000
• Status: Active Grant

• Current Assignee: The Board of Regents of the University of Colorado (University of Colorado System)
• Original Assignee: OMG Americas A Delaware Corporation
• Inventors: Johnson, Jacob A., Dunmead, Stephen, Weimer, Alan W., Buechler, Karen J., Karpale, Kauko Johannes
• Granted Patent: US 6,689,191 B2
• Time in Patent Office: Days
• US Class Current: 75/392
• CPC Class Codes: B01J 2208/00557 controlling the residence time inside the reactor vessel
• CPC Class Codes: B01J 2219/0277 Metal based
• CPC Class Codes: B01J 23/70 of the iron group metals or copper
• CPC Class Codes: B01J 37/082 Decomposition and pyrolysis
• CPC Class Codes: B01J 37/12 Oxidising
• CPC Class Codes: B01J 37/16 Reducing
• CPC Class Codes: B01J 8/087 Heating or cooling the reactor
• CPC Class Codes: B01J 8/12 moved by gravity in a downward flow
• CPC Class Codes: B22F 9/16 using chemical processes
• CPC Class Codes: B22F 9/22 using gaseous reductors
• CPC Class Codes: B22F 9/30 with decomposition of metal compounds, e.g. by pyrolysis
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C01B 13/18 by thermal decomposition of compounds, e.g. of salts or hydroxides
• CPC Class Codes: C01F 17/224 Oxides or hydroxides of lanthanides
• CPC Class Codes: C01F 17/229 Lanthanum oxides or hydroxides
• CPC Class Codes: C01F 17/235 Cerium oxides or hydroxides
• CPC Class Codes: C01G 1/02 Oxides
• CPC Class Codes: C01G 3/02 Oxides; Hydroxides
• CPC Class Codes: C01G 51/04 Oxides; Hydroxides
• CPC Class Codes: C01G 53/04 Oxides; Hydroxides
• CPC Class Codes: C01P 2002/60 : Compounds characterised by their crystallite size
• CPC Class Codes: C01P 2002/88 : by thermal analysis data, e.g. TGA, DTA, DSC
• CPC Class Codes: C01P 2004/50 : Agglomerated particles
• CPC Class Codes: C01P 2004/61 : Micrometer sized, i.e. from 1-100 micrometer
• CPC Class Codes: C01P 2004/62 : Submicrometer sized, i.e. from 0.1-1 micrometer
• CPC Class Codes: C01P 2004/64 : Nanometer sized, i.e. from 1-100 nanometer
• CPC Class Codes: C01P 2006/10 : Solid density
• CPC Class Codes: C01P 2006/11 : Powder tap density
• CPC Class Codes: C01P 2006/12 : Surface area
• CPC Class Codes: C01P 2006/60 : Optical properties, e.g. expressed in CIELAB-values
• CPC Class Codes: C01P 2006/80 : Compositional purity

Abstract

A method of converting metal-containing compounds into a metal or metal oxide by rapidly heating the metal-containing compound to an elevated temperature to instigate conversion and holding the metal-containing compound at the elevated temperature for a time sufficient to effect formation of the metal or metal oxide is an efficient and economical method of producing metals and metal oxides.

Claims

1. A method for converting a metal-containing compound to form the metal or an oxide of the metal of the metal-containing compound, comprising:

heating the metal-containing compound at a rate of between about 100°

C./second to about 100,000,000°

C./second to an elevated temperature that makes the conversion of the metal-containing compound thermodynamically favorable, and

holding the metal-containing compound at the elevated temperature for a residence time sufficient to convert the metal-containing compound into at least one product selected from the group consisting of (i) the metal and (ii) oxides of the metal.

2. The method of claim 1, wherein the residence time is from about 0.1 to about 60 seconds.

3. The method of claim 1, wherein the conversion is by decomposition.

4. The method of claim 1, wherein the conversion is by oxidation.

5. The method of claim 1, wherein the conversion is by reduction.

6. The method of claim 1, wherein the conversion is by substantially simultaneous decomposition and reduction.

7. The method of claim 1, wherein the conversion is by substantially simultaneous decomposition and oxidation.

8. The method of claim 1, wherein the residence time is from about 0.1 second to 30 seconds.

9. The method of claim 1, wherein the residence time is from about 0.1 second to 10 seconds.

10. The method of claim 1, wherein the heating rate is from about 100 to about 100,000,000°

C./second.

11. The method of claim 1, wherein the heating rate is from about 1,000 to about 1,000,000°

C./second.

12. The method of claim 1, wherein the heating rate is from about 10,000 to about 100,000°

C./second.

16. The method of claim 1, wherein the metal-containing compound is a metallic oxalate selected from the group consisting of the Group VIII (Ni, Co, Fe), Group IVA (Sn, Pb), Group IVB (Hi), Group VB(Ta), Group VIB (Cr, W), and combinations thereof, and the heating of the metal-containing compound is in a substantially non-oxidizing atmosphere.

17. The method of claim 16, wherein the at least one product is a metal selected from the group consisting of nickel, cobalt, lead and tin.

18. The method of claim 17, wherein the elevated temperature is between approximately 600°

C. and 1300°

C.

19. The method of claim 17, wherein the residence time is from about 0.1 second to about 30 minutes.

20. The method of claim 17, wherein the residence time is from about 0.1 second to about 30 seconds.

21. The method of claim 17, wherein the residence time is from about 0.1 second to about 10 seconds.

13. A method for converting a metal-containing compound to form the metal or an oxide of the metal of the metal-containing compound, comprising:

heating the metal-containing compound at a rate of between about 100°

C./second to about 100,000,000°

C./second to an elevated temperature that makes the conversion of the metal-containing compound thermodynamically favorable;

holding the metal-containing compound at the elevated temperature for a residence time sufficient to convert a portion of the metal-containing compound into at least one precursor selected from the group consisting of (i) the metal and (ii) oxides of the metal;

heating the precursor to a second elevated temperature that makes the conversion of the precursor thermodynamically favorable; and

holding the precursor at the second elevated temperature to convert substantially all of the precursor into at least one product selected from the group consisting of (i) the metal and (ii) oxides of the metal.

14. A method for converting a metal-containing compound to form the metal or an oxide of the metal of the metal-containing compound, comprising:

heating the metal-containing compound at a rate of between about 100°

C./second to about 100,000,000°

C./second to an elevated temperature that makes the conversion of the metal-containing compound thermodynamically favorable;

holding the metal-containing compound at the elevated temperature for a residence time sufficient to convert the metal-containing compound into at least one precursor selected from the group consisting of (i) the metal and (ii) a precursor oxide of the metal;

heating the metal or precursor oxide to a second elevated temperature that makes the conversion of the metal or precursor oxide thermodynamically favorable; and

holding the metal or precursor oxide at the second elevated temperature to convert substantially all of the metal or precursor oxide into the oxide of the metal.

15. A method for converting a metal-containing compound to form the metal of the metal-containing compound, comprising:

heating the metal-containing compound at a rate of between about 100°

C./second to about 100,000,000°

C./second to an elevated temperature that makes the conversion of the metal-containing compound thermodynamically favorable;

holding the metal-containing compound at the elevated temperature for a residence time sufficient to convert the metal-containing compound into at least one precursor metal-containing compound;

heating the precursor metal-containing compound to a second elevated temperature that makes the conversion of the precursor metal-containing thermodynamically favorable; and

holding the precursor metal-containing compound at the second elevated temperature to convert the precursor metal-containing compound into the metal.