Thermal upgrading of sea nodules

Claim 2

A process for recovering a concentrate of at least one non-ferrous metal value selected from the group consisting of nickel, cobalt, copper and molybdenum from manganiferous oxide minerals which comprises heating agglomerates of manganiferous oxide minerals containing the non-ferrous metal value and a reductant to a temperature of at least about 1100°C. to reduce a preponderant part of said non-ferrous values and iron values to metal and only minor amounts of manganese values to metallic manganese and leaving an unreduced portion of said agglomerates and to coalesce the reduced metal values into discrete metallic particles within said agglomerates, cooling the thermally treated agglomerates under conditions non-oxidizing to the reduced non-ferrous metals, comminuting the resultant cooled agglomerates to liberate the discrete metal particles from the bulk of the unreduced portion, and then by a physical means separating the coalesced discrete metallic particles from the unreduced portion of the agglomerates to recover the discrete metal particles as a concentrate of the reduced metal values.

Claim 3

The process as described in claim 1 wherein the reductant is added in an amount sufficient to insure the reduction of a preponderant part of the metal value and only minor amounts of manganese.

Claim 4

The process as described in claim 1 wherein the manganiferous oxide minerals and the reductant are heated to a temperature above about 1200°C.

Claim 5

The process as described in claim 1 wherein the manganiferous oxide minerals are deep sea nodules.

Claim 6

The process as described in claim 4 wherein the deep sea nodules are comminuted, mixed with the reductant and the mixture is then agglomerated prior to being heated to temperature.

Claim 7

The process as described in claim 5 wherein the reductant is added to the comminuted deep sea nodules in an amount between about 5% and 15%, based on the weight of the deep sea nodules.

Claim 8

The process as described in claim 5 wherein the reductant is added to the comminuted deep sea nodules in an amount between about 8% and 12%, based on the weight of the deep sea nodules.

Claim 9

The process as described in claim 6 wherein the reductant is a liquid hydrocarbon.

Claim 10

The process as described in claim 6 wherein at least one additive selected from the group consisting of elemental sulfur, iron pyrites, pyrrhotite, sodium sulfate or calcium sulfate is added to the comminuted deep sea nodules in small but effective amounts to catalyze reduction and to promote coalescence of the reduced metal values.

Claim 11

The process as described in claim 9 wherein the addition is added in amounts to provide the agglomerates with a sulfur content between about 0.2% and 2%.

Claim 12

The process as described in claim 9 wherein the addition is added in amounts to provide the agglomerates with a sulfur content between about 0.5% and 1%.

Claim 13

The process as described in claim 6 wherein at least one flux selected from the group consisting of silica, calcium oxide, limestone, sodium chloride or calcium chloride is added to the comminuted sea nodules to promote coalescence of the reduced metal value.

Claim 14

The process as described in claim 12 wherein the flux is added in an amount of up to about 10%, based on the weight of the nodules.

Claim 15

The process as described in claim 6 wherein the agglomerated mixture is heated to a temperature between about 1100°C. and 1300°C.

Claim 16

The process as described in claim 6 wherein the agglomerated mixture is heated to a temperature between about 1150°C. and 1250°C.

Claim 17

The process as described in claim 6 wherein the coalesced metal values are recovered by flotation, tabling, or magnetic separation.

Claim 18

The process as described in claim 1, in which the reduction is carried in a temperature range of from about 1120°C to about 1160°C.

Claim 19

the process as described in claim 1, in which the reduction is carried out in a temperature range of from about 1130°C to about 1150°C.

Claim 20

The process as described in claim 1, in which the reduction is carried out at a temperature of about 1140°C.

Claim 21

The process as described in claim 4, in which the reduction is carried out in a temperature range of from about 1120°C to about 1160°C.

Claim 22

The process as described in claim 1 in which the reduction is carried out by feeding the agglomerates as a static bed through a rotary hearth furnace.

Claim 23

A process for recovering a concentrate of at least one non-ferrous value selected from the group consisting of nickel, cobalt, copper and molybdenum from manganiferous oxide minerals which comprises heating agglomerates of manganiferous oxide minerals containing the non-ferrous metal value and a reductant at a temperature of at least about 1100°C. to reduce a preponderant part of said non-ferrous values and iron values to metal and only minor amounts of manganese values to metallic manganese and leaving an unreduced portion of said agglomerates and to coalesce the reduced metal values into discrete metallic particles, said temperature for reducing the agglomerates and coalescing the reduced metal values being substantially the incipient fusion temperature of the unreduced portion of said agglomerates, cooling the thermally treated agglomerates under conditions non-oxidizing to the reduced non-ferrous metals, comminuting the resultant cooled agglomerates to liberate the discrete metal particles from the bulk of the unreduced portion, and then by a physical means separating the coalesced discrete metallic particles from the unreduced portion of the agglomerates to recover the discrete metal particles as a concentrate of the reduced metal values.

Claim 24

A process for recovering a concentrate of at least one non-ferrous value selected from the group consisting of nickel, cobalt, copper and molybdenum from manganiferous oxide minerals which comprises heating agglomerates of manganiferous oxide minerals containing the non-ferrous metal value and a reductant at a temperature of at least about 1100°C. to reduce a preponderant part of said non-ferrous values and iron values to metal and only minor amounts of manganese values to metallic manganese and leaving an unreduced portion of said agglomerates and to coalesce the reduced metal values into discrete metallic particles, said temperature for reducing the agglomerates and coalescing the reduced metal values being substantially the incipient fusion temperature of the unreduced portion of said agglomerates, cooling the thermally treated agglomerates under conditions non-oxidizing to the reduced non-ferrous metals, comminuting the resultant cooled agglomerates to liberate the discrete metal particles from the bulk of the unreduced portion, and then by a physical means separating the coalesced discrete metallic particles from the unreduced portion of the agglomerates to recover the discrete metal particles as a concentrate of the reduced metal values.

Claim 25

The process as described in claim 22 in which the reduction is carried out by feeding the agglomerates as a static bed through a rotary hearth furnace.

Claim 26

The process as described in claim 22 wherein sulfur is provided in the agglomerates in an amount of up to about 10%.

Claim 27

The process as described in claim 1 wherein said unreduced portion of the agglomerates separated from the coalesced particles contains a preponderant part of the manganese values.