Metal reduction process

Claim 2

The process of claim 1 wherein the reducing metal is selected from the group consisting of sodium, potassium, sodium mixed with barium, and sodium mixed with calcium.

Claim 3

The process of claim 1 wherein the reducible metal halide is selected from the group consisting of halide of titanium and zirconium.

Claim 4

The process of claim 4 wherein the reducing metal is an alkali metal selected from the group consisting of sodium, potassium and lithium.

Claim 5

The process of claim 4 wherein the reducing metal is selected from the group consisting of sodium, potassium, sodium mixed with barium, and sodium mixed with calcium.

Claim 6

The process of claim 6 wherein the reducible metal halide is selected from the group consisting of titanium tetrachloride and zirconium tetrachloride.

Claim 7

A reduction process for the production of metal, which process includes the steps of a. introducing into a reaction zone without premixing molybdenum sulfide and a reducing metal selected from the group consisting of sodium, potassium and lithium and mixtures thereof, said molybdenum sulfide and said reducing metal being introduced in amounts providing not more than 10 percent excess of either reactant over stoichiometric requirements for complete reduction of the molybdenum sulfide to molybdenum metal, b. sealing the reaction zone, c. heating the reactants without substantial agitation from a temperature below the melting point of the reducing metal to a temperature which is both above the melting point of the reducing metal and below the temperature at which a reduction reaction between the molybdenum sulfide and the molten reducing metal will proceed spontaneously, d. initiating a reducing reaction between the molybdenum sulfide and the molten reducing metal by suddenly disrupting the surface of the molten reducing metal by means of a mechanical force sufficient to provide a dispersion of the reducing metal in initmate contact with the molybdenum sulfide, e. permitting the reduction reaction to continue to thereby produce molybdenum metal, f. thereafter removing said molybdenum metal from the reduction zone.

Claim 8

The process of producing titanium metal which comprises: a. introducing titanium halide and sodium into a reaction zone without pre-mixing and in amounts providing not more than 10 percent excess of either reactant over stoichiometric requirements for complete reduction of the titanium halide to titanium metal; b. sealing the reaction zone; c. heating the reactants without substantial agitation from a temperature below the melting point of sodium to a temperature which is both above the melting point of sodium and below the temperature at which a reduction reaction between the titanium halide and molten sodium will proceed spontaneously; D. initiating a reduction reaction between the titanium halide and molten sodium by suddenly disrupting the surface of the molten sodium; e. permitting the reduction reaction to continue to thereby produce titanium metal; and f. thereafter removing consolidated titanium metal from the reaction zone.

Claim 9

The process of claim 9 wherein the titanium halide comprises titanium tetrachloride and wherein the titanium halide and sodium are present in amounts providing not more than 5 percent excess of either reactant.

Claim 10

The process of claim 9 wherein the titanium halide comprises titanium tetrachloride and wherein the titanium halide and sodium are present in substantially stoichiometric proportions.

Claim 11

The process of claim 11 wherein the maximum temperature of step (c) is between 120* and 400* C.

Claim 12

The process of claim 11 wherein the disruption of step (d) is caused by sudden vertical shaking of the molten sodium.

Claim 13

The process of producing zirconium metal which comprises: a. introducing zirconium halide and sodium or mixtures of sodium and calcium into a reaction zone without pre-mixing and in amounts providing not more than 10 percent excess of either reactnat over stoichiometric requirements for compelte reduction of the zirconium halide to zirconium metal; b. sealing the reaction zone; c. heating the reactants without substantial agitation from a temperature below the melting point of sodium or the mixture of sodium and calcium to a temperature which is both above the melting point of sodium or the mixture of sodium and calcium and below the temperature at which a reduction reaction between the zirconium halide and molten sodium or mixture of sodium and calcium will proceed spontaneously; d. initiating a reduction reaction between the zirconium halide and molten sodium or the mixture of sodium and calcium by suddenly disrupting the surface of the molten sodium or the mixture of sodium and calcium; e. permitting the reduction reaction to continue to thereby produce zirconium metal; and f. thereafter removing consolidated zirconium metal from the reaction zone.

Claim 14

The process of claim 9 wherein the zirconium halide comprises zirconium tetrachloride and wherein the zirconium halide and sodium or mixtures of sodium and calcium are present in amounts providing not more than 5 percent excess of either reactant.