Hydrometallurgical process for the production of antimony

Claim 2

A chemical, electro-chemical process for the production of metallic antimony comprising: a first solution reduction stage in which antimony-containing materials are oxidized in a solution containing ferric chloride and hydrochloric acid until there is substantial solubilization of the antimony content of the said materials in the form of antimony (III) chloride and reduction of part of the ferric chloride to ferrous chloride; a second solution reduction stage, separate from the first solution reduction stage, in which at least a substantial portion of the ferric chloride in the solution from the first solution reduction stage is reduced to ferrous chloride; and an electrolysis stage in which metallic antimony is recovered and ferric chloride is regenerated by electrolysis of the ferrous chloride solution from the metal recovery stage.

Claim 3

The process of claim 1 in which a substantial portion of the ferric chloride is reduced to ferrous chloride in the second solution reduction stage by reaction with antimony sulfide ore or ore concentrates.

Claim 4

The process of claim 2 in which the substantially reduced ferric chloride solution is further reacted with hydrogen sulfide in an amount required to reduce essentially all the ferric chloride to ferrous chloride, said hydrogen sulfide being formed in situ by the reaction of antimony sulfide containing materials with a portion of the excess hydrochloric acid in the solution.

Claim 5

The process of claim 3 in which formation of hydrogen sulfide by reaction of antimony sulfide containing materials with a portion of the hydrochloric acid in the solution is obtaned by introducing antimony sulfide containing materials until an excess quantity above and beyond that required to reduce essentially all the ferric chloride to ferrous chloride is produced in the second solution reduction stage.

Claim 6

The process of claim 4 in which the excess hydrogen sulfide is used to partially reduce the ferric chloride in the electrolysis step to prevent overoxidation.

Claim 7

The process of claim 4 in which the excess hydrogen sulfide is reacted with liquor in the first solution reduction stage to reduce the loss of hydrogen sulfide vapor.

Claim 8

The process of claim 2 in which the first solution reduction stage is conducted on materials which include antimony sulfide ore or ore concentrates previously reacted with ferric chloride in the second solution reduction stage.

Claim 9

The process of claim 1 in which the reaction temperature in the first solution reduction stage is maintained in the range from about 115° C to about 159° C.

Claim 10

The process of claim 8 in which the reaction temperature in the first solution reduction stage is maintained at about 140° C.

Claim 11

The process of claim 9 in which the second solution reduction stage is conducted at a reaction temperature of about 105° C, with said reduction stage closed to the atmosphere to minimize loss of chloride vapor, whereby substantial reduction of the ferric chloride to ferrous chloride is achieved with minimal loss of antimony from the solution.

Claim 12

The process of claim 10 in which the first solution reduction stage is conducted on materials containing partially reacted stibnite ore or ore concentrates from the second solution reduction stage.

Claim 13

The process of claim 10 in which the substantially reduced ferric chloride solution is further reacted with materials containing metallic antimony to form ferrous chloride.

Claim 14

The process of claim 1 in which excess water in the process solution is removed by distillation to minimize dilution.

Claim 15

The process of claim 13 in which the hydrogen chloride content of the water removed by distillation is substantially reduced by fractionation, such fractionation being accomplished by the use of controlled reflux and contacting devices such as packed columns.

Claim 16

The process of claim 14 in which a portion of the concentrated process solution stream leaving the water removal system is available for treatment to remove undesirable soluble contaminants prior to returning it to the main process stream.

Claim 17

The process of claim 1 in which a portion of the ferric chloride in the regenerated ferric chloride solution is reduced or partially reduced by contacting with a reducing gas.

Claim 18

The process of claim 16 wherein the said reducing gas is hydrogen sulfide.

Claim 19

The process of claim 17 in which a substantial portion of the elemental sulfur formed is removed from the process circuit as a product.

Claim 20

The process of claim 1 in which said antimony-containing materials consist primarily of antimony mixed oxide - sulfide ores or ore concentrates.

Claim 21

The process of claim 19 in which additional hydrochloric acid is added to the system and the formation of free chlorine gas is obtained in the electrolysis stage.

Claim 22

The process of claim 1 in which said antimony-containing materials consist primarily of antimony oxide ores or ore concentrates.

Claim 23

The process of claim 21 in which additional hydrochloric acid is added to the system and the formation of free chlorine gas is obtained in the electrolysis stage.

Claim 24

The process of claim 1 in which the hydrochloric acid content is maintained in the solution throughout the process at a concentration above that required to avoid precipitation of any antimony chloride in solution by hydrolysis.

Claim 25

The process of claim 23 in which said second solution reduction stage is conducted in three steps, comprising: a. a first step in which antimony containing materials are introduced in an amount insufficient to reduce all of the ferric chloride to ferrous chloride, b. a second step in which the solution from the first step is reacted with hydrogen sulfide gas to reduce essentially all of the ferric chloride to ferrous chloride and to precipitate arsenic sulfide, and c. a third step in which the solution from the second step is contacted with antimony sulfide containing materials to react a portion of the antimony sulphide content of said material with the excess hydrochloric acid to produce hydrogen sulfide gas.

Claim 26

The process of claim 1 in which the reaction temperature in the first solution reduction stage is maintained at about 105° C.

Claim 27

The process of claim 25 in which the first solution reduction stage is closed to the atmosphere to minimize the loss of vapor.

Claim 28

The process of claim 1 in which the reaction temperature in the first solution reduction stage is maintained above the melting point of sulfur and below the temperature at which the viscosity of sulfur rises abruptly, in order to accelerate the reaction rate to produce a reaction slurry containing sulfur released from the sulfide ore concentrates essentially in elemental form.

Claim 29

The process of claim 27 in which the sulfur in the final reacted slurry of the first solution reduction stage is crystallized by cooling the slurry to a temperature below the melting point of sulfur so as to cause the crystallization of the sulfur into a form that will improve subsequent liquid-solids separation.

Claim 30

The process of claim 27 in which the finally reacted slurry of the first solution reduction stage is subjected to a phase separation, said phase separation comprising separating the aqueous solution, which includes the antimony chloride, from the molten sulfur and the insoluble residues, and thereafter further separating the insoluble residues from the molten elemental sulfur.

Claim 31

The process of claim 1 in which the metallic antimony produced at the cathodes is not more than about one half on the antimony in solution feed to the electrolytic cells to reduce the possibility of formation of hydrogen and/or stibine gases at the cathode.

Claim 32

The process of claim 30 in which the solution in contact with the anodes in the electrolytic cells is maintained physically separated from the solution in contact with the cathodes by diaphragms formed of material substantially inert to the environment of the electrolysis and having limited permeability to hydraulic flow together with minimal electrical resistance, and in which each said solution is separately mixed to maintain homogeneity.

Claim 33

The process of claim 1 in which a portion of the ferrous chloride is oxidized to ferric chloride by use of oxygen or oxygen-containing gases.

Claim 34

The process of claim 32 in which the oxygen-containing gas is air.

Claim 35

The process of claim 1 wherein the product antimony metal is oxidized in the presence of oxygen or oxygen-containing gases to form antimony oxide as a product.

Claim 36

The process of claim 34 in which the oxygen-containing gas is air.

Claim 37

The process of claim 1 in which a substantial portion of the ferric chloride is reduced to ferrous chloride in the second solution reduction stage by reaction with antimony-containing materials.

Claim 38

The process of claim 1 in which said antimony-containing materials consist primarily of metallic antimony.

Claim 39

The process of claim 1 in which the hydrochloric acid content is maintained in the solution throughout the process in a concentration sufficient to avoid loss by hydrolysis of any antimony chloride in the solution.

Claim 40

The process of claim 1 in which the reduced antimony chloride containing solution is electrolyzed at a temperature in the range between about 30° C and 60° C.

Claim 41

The process of claim 1 in which the reaction temperature in the second solution reduction stage is maintained at below the atmospheric boiling temperature but above 40° C.

Claim 42

The process of claim 1 in which the reaction temperature in the first solution reduction stage is maintained at below the atmospheric boiling temperature but above 40° C.

Claim 43

A chemical, electro-chemical process for the recovery of electrolytic antimony from antimony-containing materials, such as antimony ore concentrates containing sulfides or mixtures thereof with antimony oxides or metallic antimony, comprising a reduction stage into which said antimony-containing materials are introduced into a solution containing hydrochloric acid and ferric chloride to solubilize a part of the antimony in said antimony-containing materials in the form of antimony (III) chloride and to reduce essentially all of said ferric chloride in said solution to ferrous chloride and to form additionally hydrogen sulfide gas with concurrent solubilization of additional antimony values in the form of antimony (III) chloride; an antimony recovery stage in which the antimony chloride solution from said reduction stage is electrolyzed in an electrolytic cell to produce metallic antimony at the cathodes and to regenerate ferric chloride at the anodes; a ferric chloride reduction step in closed circuit with the ferric chloride regeneration step of said antimony recovery stage to prevent overoxidation of the process solution; and an additional solution reduction stage in which the solids from the other solution reduction stage are introduced into the solution leaving the electrolytic cell to solubilize essentially all remaining antimony in the solids in the form of antimony (III) chloride in solution; and recycling the resulting solution containing ferric chloride to said other solution reduction stage.

Claim 44

A chemical, electro-chemical process for the recovery of electrolytic antimony from antimony-containing materials, such as antimony ore concentrates containing sulfides or mixtures thereof with antimony oxides or metallic antimony, comprising a reduction stage into which said antimony-containing materials are introduced into a solution containing hydrochloric acid and ferric chloride to solubilize a part of the antimony in said antimony-containing materials in the form of antimony (III) chloride and to reduce essentially all of said ferric chloride in said solution to ferrous chloride and to form additionally hydrogen sulfide gas with concurrent solubilization of additional antimony values in the form of antimony (III) chloride; an antimony recovery stage in which the antimony chloride solution from said reduction stage is electrolyzed in an electrolytic cell to produce metallic antimony at the cathodes and to regenerate ferric chloride at the anodes; a ferric chloride reduction step in closed circuit with the ferric chloride regeneration step of said antimony recovery stage to prevent overoxidation of the process solution; and an additional solution reduction stage in which the solids from the other solution reduction stage are introduced into the solution leaving the electrolytic cell to solubilize essentially all remaining antimony in the solids in the form of antimony (III) chloride in solution; and recycling the resulting solution containing ferric chloride to said other solution reduction stage.

Claim 45

The process of claim 42 in which said antimony-containing materials include impure antimony metal to be processed for the production of electrolytic grade material.

Claim 46

The process of claim 42 in which said antimony-containing materials include scrap antimony metal.

Claim 47

A cyclic chemical, electro-chemical process for the production of metallic antimony comprising: A. introducing materials containing principally stibnite ore or concentrates thereof into a solution containing ferric chloride and hydrochloric acid at a temperature of at or slightly below the atmospheric boiling temperature of 107° C but not below 40° C in containers essentially closed to the atmosphere for such a period of time as to achieve substantial solubilization of the antimony content of the materials, thereby forming a solution containing antimony (III) chloride, ferric chloride and ferrous chloride. B. essentially reducing the ferric chloride in the solution from step (A) by reaction of the solution with materials containing fresh stibnite ore or concentrate in containers essentially closed to the atmosphere at about the atmospheric boiling point of 107° C, but not below 40° C. C. continuing to contact the reacting slurry from step (B) to complete the reduction of the ferric chloride in solution and to promote the production of hydrogen sulfide, thereby forming a feed solution for electrolysis containing ferrous chloride, antimony (III) chloride and hydrochloric acid. D. electrolyzing the solution from step (B) or step (C) in the catholyte compartment of a diaphragm equipped electrolytic cell to produce metallic antimony at the cathode. E. electrolyzing the solution from step (D) in the anolyte compartment of the diaphragm equipped electrolytic cell to regenerate the ferric chloride in the solution. F. withdrawing a portion of the anolyte solution and reacting it with a reducing gas such as hydrogen sulfide to partially reduce the ferric chloride in solution, thereby preventing overoxidation of said solution, and reintroducing the partially reduced solution into the circulating anolyte stream. G. returning the solution from step (F) to step (A), thus completing the cyclic process loop.

Claim 48

A cyclic chemical, electro-chemical process for the production of metallic antimony comprising: A. introducing materials containing principally stibnite ore or concentrates thereof into a solution containing ferric chloride and hydrochloric acid at a temperature of at or slightly below the atmospheric boiling temperature of 107° C but not below 40° C in containers essentially closed to the atmosphere for such a period of time as to achieve substantial solubilization of the antimony content of the materials, thereby forming a solution containing antimony (III) chloride, ferric chloride and ferrous chloride. B. essentially reducing the ferric chloride in the solution from step (A) by reaction of the solution with materials containing fresh stibnite ore or concentrate in containers essentially closed to the atmosphere at about the atmospheric boiling point of 107° C, but not below 40° C. C. continuing to contact the reacting slurry from step (B) to complete the reduction of the ferric chloride in solution and to promote the production of hydrogen sulfide, thereby forming a feed solution for electrolysis containing ferrous chloride, antimony (III) chloride and hydrochloric acid. D. electrolyzing the solution from step (B) or step (C) in the catholyte compartment of a diaphragm equipped electrolytic cell to produce metallic antimony at the cathode. E. electrolyzing the solution from step (D) in the anolyte compartment of the diaphragm equipped electrolytic cell to regenerate the ferric chloride in the solution. F. withdrawing a portion of the anolyte solution and reacting it with a reducing gas such as hydrogen sulfide to partially reduce the ferric chloride in solution, thereby preventing overoxidation of said solution, and reintroducing the partially reduced solution into the circulating anolyte stream. G. returning the solution from step (F) to step (A), thus completing the cyclic process loop.