Non-ferrous metal recovery from deep sea nodules

Claim 2

A process for recovering at least one non-ferrous metal value selected from the group consisting of nickel, cobalt, copper or molybdenum, which non-ferrous metal value is present as an oxide, from a manganiferous oxide material which process comprises selectively reducing said non-ferrous metal values and then smelting the manganiferous oxide material to produce a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating the first molten alloy from the first manganese-containing slag, blowing the separated molten first alloy with a free-oxygen-containing gas to oxidize and slag most of the manganese contained in the first molten alloy and to form a second molten alloy further depleted in manganese and a second manganese-containing slag, separating the second molten alloy from the second manganese-containing slag, and then sulfiding the second molten alloy to facilitate separation and recovery of the non-ferrous metal values.

Claim 3

The process as described in claim 1 wherein the manganiferous oxide material is heated to a temperature of at least about 750° C. but below about 1100° C. in an atmosphere reducing to oxides of the non-ferrous metal values but substantially not to manganous oxide to reduce a preponderant part of the non-ferrous metal value to the metallic state and a preponderant part of the manganese to manganous oxide and only minor amounts to the metallic manganese state.

Claim 4

The process as described in claim 2 wherein the manganiferous oxide material is reduced at temperatures between about 800° C. and 1000° C.

Claim 5

The process as described in claim 2 wherein at least about 70% of any nickel and copper and at least bout 60% of any cobalt contained in the manganiferous oxide is reduced to the metallic state.

Claim 6

The process as described in claim 2 wherein smelting is conducted at a temperature between about 1250° C. and 1600° C.

Claim 7

The process as described in claim 2 wherein the first molten alloy contains at least about 50% iron and less than about 5% manganese.

Claim 8

The process as described in claim 2 wherein at least one of the slags containing manganese is treated with at least one reducing agent selected from the group consisting of coal, coke, ferrosilicon, or silicomanganese at a temperature in excess of about 1350° C. to reduce the manganese value in the slag and to form a molten manganese metal bath.

Claim 9

The process according to claim 7 wherein said manganese-containing slag is treated without soidification at a temperature of about 1500° to 1700° C.

Claim 10

The process as described in claim 2 wherein the molten alloy is blown to reduce the manganese content thereof below about 0.7% sulfided by addition thereto of at least one sulfur-bearing material selected from the group consisting of elemental sulfur, pyrites, or pyrrhotite.

Claim 11

The process as described in claim 1 wherein the manganiferous oxide material is sea nodules.

Claim 12

A process for recovering at least one non-ferrous metal value selected from the group consisting of nickel, cobalt, copper or molybdenum, which non-ferrous metal value is present as an oxide, from a manganiferous oxide material which process comprises selectively reducing said non-ferrous metal values at a temperature of at least about 750° C. but below about 1100° C. in an atmosphere reducing to oxides of the non-ferrous metal values but substantially nonreducing to manganous oxide to reduce a preponderant part of the non-ferrous metal values to the metallic state and a preponderant part of the manganese to manganous oxide and only minor amounts to the metallic manganese state, smelting the selectively reduced manganiferous oxide material to produce a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag most of the manganese contained in the first molten alloy and to form a second molten alloy further depleted in manganese and a second manganese-containing slag, separating the second molten alloy from the second manganese-containing slag, sulfiding the second molten alloy to produce a matte, and then blowing the matte said matte containing iron values in the molten condition with a free-oxygen-containing gas to slag iron.

Claim 13

A process for recovering at least one non-ferrous metal value selected from the group consisting of nickel, cobalt, copper or molybdenum, which non-ferrous metal value is present as an oxide, from a manganiferous oxide material which process comprises selectively reducing said non-ferrous metal values at a temperature of at least about 750° C. but below about 1100° C. in an atmosphere reducing to oxides of the non-ferrous metal values but substantially nonreducing to manganous oxide to reduce a preponderant part of the non-ferrous metal values to the metallic state and a preponderant part of the manganese to manganous oxide and only minor amounts to the metallic manganese state, smelting the selectively reduced manganiferous oxide material to produce a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag most of the manganese contained in the first molten alloy and to form a second molten alloy further depleted in manganese and a second manganese-containing slag, separating the second molten alloy from the second manganese-containing slag, sulfiding the second molten alloy to produce a matte, and then blowing the matte said matte containing iron values in the molten condition with a free-oxygen-containing gas to slag iron.

Claim 14

The process as described in claim 11 wherein iron slagging is continued until the iron content of the molten matte is lowered to between about 0.2% and 1%.

Claim 15

The process according to as described in claim 11 wherein the matte after iron removal contains nickel, copper, less than 1% iron, and about 20% to 26% sulfur and the matte is slowly cooled to provide separately crystallized nickel and copper phases.

Claim 16

The process as described in claim 11 wherein the matte contains, after iron removal, sufficient sulfur to tie up copper, cobalt and iron as Cu 2 S, CoS and FeS, the matte is granulated and the resulting granules are carbonylated to recover nickel as nickel carbonyl.

Claim 17

The process according to as described in claim 11 wherein the matte contains, after iron removal, sufficient sulfur that, upon oxidation leaching a solution pH less than 3 is generated, and the matte is subjected to oxidation leaching to recover metal values in solution.

Claim 18

The process as described in claim 11 wherein iron slagging is terminated before the iron content of the molten matte falls below 5% to minimize cobalt losses.

Claim 19

A process for recovering from sea nodules at least one non-ferrous metal selected from the group consisting of nickel, cobalt, copper and molybdenum, said sea nodules being an oxidic material containing a major amount of manganese and iron and at least one of said non-ferrous metal values; comprising selectively reducing the sea nodules at a temperature of at least about 750° C. to below about 1100° C. in an atmosphere reducing to oxides of non-ferrous metal values but substantially not reducing to manganous oxide to reduce a preponderant part of the non-ferrous metal values to the metallic state and a preponderant part of the manganese values having an oxidation state greater than plus 2 to manganous oxide, smelting the selectively reduced material at a temperature of from about 1250° to about 1600° C. to form a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize manganese in the molten alloy and produce a second molten alloy and a second manganese-containing slag, separating said second manganese-containing slag from the second molten alloy to produce a second molten non-ferrous metal-containing alloy further depleted in manganese.

Claim 20

A process for recovering from sea nodules at least one non-ferrous metal selected from the group consisting of nickel, cobalt, copper and molybdenum, said sea nodules being an oxidic material containing a major amount of manganese and iron and at least one of said non-ferrous metal values; comprising selectively reducing the sea nodules at a temperature of at least about 750° C. to below about 1100° C. in an atmosphere reducing to oxides of non-ferrous metal values but substantially not reducing to manganous oxide to reduce a preponderant part of the non-ferrous metal values to the metallic state and a preponderant part of the manganese values having an oxidation state greater than plus 2 to manganous oxide, smelting the selectively reduced material at a temperature of from about 1250° to about 1600° C. to form a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize manganese in the molten alloy and produce a second molten alloy and a second manganese-containing slag, separating said second manganese-containing slag from the second molten alloy to produce a second molten non-ferrous metal-containing alloy further depleted in manganese.

Claim 21

The process as described in claim 17 wherein the sea nodules are reduced at temperatures between about 800° C. and 1000° C.

Claim 22

The process as described in claim 17 wherein at least about 70% of any nickel and copper and at least about 60% of any cobalt contained in the sea nodules are reduced to the metallic state.

Claim 23

The process as described in claim 17 wherein the first molten alloy contains at least about 50% iron and less than about 5% manganese.

Claim 24

The process as described in claim 17 wherein at least one of the slags containing manganese is treated with at least one reducing agent selected from the group consisting of coal, coke, ferrosilicon, or silicomanganese at a temperature in excess of about 1350° C. to reduce the manganese value in the slag and to form a molten manganese metal bath.

Claim 25

The process according to claim 21 wherein said manganese-containing slag is treated without solidification at a temperature of about 1500° to 1700° C.

Claim 26

The process as described in claim 17 wherein the first molten alloy is blown to reduce the manganese content thereof below about 0.7%, and the second molten alloy is sulfided by addition thereto of at least one sulfur-bearing material selected from the group consisting of elemental sulfur, pyrites, or pyrrhotite.

Claim 27

A process for recovering from sea nodules at least one non-ferrous metal selected from the group consisting of nickel, cobalt, copper and molybdenum, said sea nodules being an oxidic material containing a major amount of manganese and iron and at least one of said non-ferrous metal values; comprising selectively reducing the sea nodules at a temperature of at least about 750° C. to below about 1100° C. in an atmosphere reducing to oxides of non-ferrous metal values but substantially non-reducing to manganous oxide to reduce a preponderant part of the non-ferrous metal values to the metallic state and a preponderant part of the manganese values to manganous oxide, smelting the selectively reduced material at a temperature of from about 1250° to about 1600° C. to form a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag manganese contained in the first molten alloy and to form a second molten alloy further depleted in manganese and a second manganese-containing slag separating said second manganese-containing slag from the second molten alloy, sulfiding said second molten alloy to produce a matte, said matte containing iron values, and blowing the matte in the molten condition with a free-oxygen-containing gas to slag iron.

Claim 28

A process for recovering from sea nodules at least one non-ferrous metal selected from the group consisting of nickel, cobalt, copper and molybdenum, said sea nodules being an oxidic material containing a major amount of manganese and iron and at least one of said non-ferrous metal values; comprising selectively reducing the sea nodules at a temperature of at least about 750° C. to below about 1100° C. in an atmosphere reducing to oxides of non-ferrous metal values but substantially non-reducing to manganous oxide to reduce a preponderant part of the non-ferrous metal values to the metallic state and a preponderant part of the manganese values to manganous oxide, smelting the selectively reduced material at a temperature of from about 1250° to about 1600° C. to form a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag manganese contained in the first molten alloy and to form a second molten alloy further depleted in manganese and a second manganese-containing slag separating said second manganese-containing slag from the second molten alloy, sulfiding said second molten alloy to produce a matte, said matte containing iron values, and blowing the matte in the molten condition with a free-oxygen-containing gas to slag iron.

Claim 29

The process as described in claim 24 wherein iron slagging is terminated before the iron content of the molten matte falls below 5% to minimize cobalt losses.

Claim 30

The process as described in claim 24 wherein iron slagging is continued until the iron content of the molten matte is lowered to between about 0.2% and 1%.

Claim 31

The process as described in claim 24 wherein cobalt values are present in the matte and wherein said iron slagging is terminated before the iron content of the molten matte falls below 5% to minimize cobalt losses.

Claim 32

The process as described in claim 24 wherein said iron slagging is continued until the iron content of the molten matte is lowered to between about 0.2% and 1%.

Claim 33

A process for recovering at least one non-ferrous metal value selected from the group consisting of nickel, cobalt, copper or molybdenum, which non-ferrous metal value is present as an oxide, from a manganiferous oxide material which process comprises selectively reducing and smelting the manganiferous oxide material to produce a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag most of the manganese contained in the first molten alloy to form a second molten non-ferrous metal-containing alloy and a second manganese-containing slag, separating the second molten alloy from the second manganese-containing slag, and then sulfiding the second molten alloy to facilitate separation and recovery of the non-ferrous metal values.

Claim 34

A process for recovering at least one non-ferrous metal value selected from the group consisting of nickel, cobalt, copper or molybdenum, which non-ferrous metal value is present as an oxide, from a manganiferous oxide material which process comprises selectively reducing and smelting the manganiferous oxide material to produce a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag most of the manganese contained in the first molten alloy to form a second molten non-ferrous metal-containing alloy and a second manganese-containing slag, separating the second molten alloy from the second manganese-containing slag, and then sulfiding the second molten alloy to facilitate separation and recovery of the non-ferrous metal values.

Claim 35

A process for recovering from sea nodules at least one non-ferrous metal selected from the group consisting of nickel, cobalt, copper and molybdenum, said sea nodules being an oxidic material containing a major amount of manganese and iron and at least one of said non-ferrous metal values comprising treating the sea nodules at a temperature of at least about 750° C. to below about 1100° C. to reduce selectively a preponderant part of the non-ferrous metal values to the metallic state and only minor amounts of manganese values to the metallic state, smelting the selectively reduced material at a temperature of from about 1250° to about 1600° C. to form a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating and removing the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag manganese contained in the first molten alloy and to form a second molten alloy further depleted in manganese and a second manganese-containing slag, separating and removing the second manganese-containing slag from the second molten alloy sulfiding said second molten alloy to produce a matte, said matte containing iron values, and blowing the matte in the molten condition with a free-oxygen-containing gas to slag iron.

Claim 36

A process for recovering from sea nodules at least one non-ferrous metal selected from the group consisting of nickel, cobalt, copper and molybdenum, said sea nodules being an oxidic material containing a major amount of manganese and iron and at least one of said non-ferrous metal values comprising treating the sea nodules at a temperature of at least about 750° C. to below about 1100° C. to reduce selectively a preponderant part of the non-ferrous metal values to the metallic state and only minor amounts of manganese values to the metallic state, smelting the selectively reduced material at a temperature of from about 1250° to about 1600° C. to form a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating and removing the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag manganese contained in the first molten alloy and to form a second molten alloy further depleted in manganese and a second manganese-containing slag, separating and removing the second manganese-containing slag from the second molten alloy sulfiding said second molten alloy to produce a matte, said matte containing iron values, and blowing the matte in the molten condition with a free-oxygen-containing gas to slag iron.

Claim 37

A process for recovering at least one non-ferrous metal value selected from the group consisting of nickel, cobalt, copper or molybdenum, which non-ferrous metal value is present as an oxide, from a manganiferous oxide material which process comprises treating said manganiferous oxide material at a temperature of at least about 750° C. but below about 1100° C. to reduce selectively a preponderant part of the non-ferrous metal values to the metallic state and only minor amounts of manganese values to the metallic manganese state, smelting the selectively reduced manganiferous oxide material to produce a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating and removing the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag manganese contained in the first molten alloy and to form a second molten alloy further depleted in manganese and a second manganese-containing slag, separating and removing the second maganese-containing slag from the second molten alloy, sulfiding the second molten alloy to produce a matte, said matte containing iron values, and then blowing the matte in the molten condition with a free-oxygen-containing gas to slag iron.

Claim 38

A process for recovering at least one non-ferrous metal value selected from the group consisting of nickel, cobalt, copper or molybdenum, which non-ferrous metal value is present as an oxide, from a manganiferous oxide material which process comprises treating said manganiferous oxide material at a temperature of at least about 750° C. but below about 1100° C. to reduce selectively a preponderant part of the non-ferrous metal values to the metallic state and only minor amounts of manganese values to the metallic manganese state, smelting the selectively reduced manganiferous oxide material to produce a first molten alloy containing a preponderant part of the non-ferrous metal values and a first manganese-containing slag, separating and removing the first molten alloy from the first manganese-containing slag, blowing the separated first molten alloy with a free-oxygen-containing gas to oxidize and slag manganese contained in the first molten alloy and to form a second molten alloy further depleted in manganese and a second manganese-containing slag, separating and removing the second maganese-containing slag from the second molten alloy, sulfiding the second molten alloy to produce a matte, said matte containing iron values, and then blowing the matte in the molten condition with a free-oxygen-containing gas to slag iron.