Process for preparing metallic sulphates

Claim 2

In a process for producing metallic sulfates of metals selected from the group consisting of zinc, copper, iron and cadmium, which process comprises forming a mixture of the corresponding metallic sulfide concentrates and ammonium sulfate, heating said mixture in a non-oxidizing atmosphere of temperatures of between about 150° C. to 480° C. to convert said mixture into said metallic sulfate, ammonia, sulfur and sulfur dioxide, removing said metallic sulfate from the heating zone and quenching said metallic sulfate in water, passing the volatile products of the reaction consisting essentially of ammonia, sulfur vapor, sulfur dioxide and water into a first absorption zone at temperatures of between about 100° C. and 150° C. to form ammonium thiosulfate, passing the residual gases from said first zone into a second zone where the residual ammonia is absorbed in water, the improvement comprising, converting at least about 95% wt. of said sulfide to said sulfate by (a) adding to said mixture of ammonium sulfate and metallic sulfide, a quantity of the corresponding metallic sulfate to inhibit the development of agglomerating conditions in the reaction of said metallic sulfide concentrates with said ammonium sulfate and to form a resulting feed mixture consisting of about 25-75% wt. of said metallic sulfide, 23-73% wt. of said ammonium sulfate, and 2-14% wt. of said metallic sulfate; (b) introducing said resulting feed mixture into the upper portion of a fluidized bed reactor; (c) directly heating said resulting feed mixture to a temperature of about 150-480° C. with the products of combustion of a heating fuel selected from the group consisting of water gas, producer gas, natural gas, and mixtures thereof, said products of combustion comprising between about 1.0% by volume to about 6.0% by volume of reducing gases selected from the group consisting of hydrogen, carbon monoxide, and mixtures thereof, to convert said resultant feed mixture to metallic sulfate, ammonia, sulfur, sulfur dioxide and water, while maintaining evolved sulfur and sulfur dioxide in a molar ratio of about 1 to 1 and to maintain evolved ammonia and produced metallic sulfate in a molar ration of about 1 to 1; (d) removing the metallic sulfate from the lower portion of said reactor and passing said removed metallic sulfate to a quench zone where the sulfate is dissolved in water to form a metallic sulfate solution; (e) sweeping carbon dioxide, evolved sulfur, sulfur dioxide, and ammonia out of the upper portion of said reactor; (f) passing the swept out gases into a first absorption zone where the sulfur dioxide and a portion of the ammonia are dissolved and reacted to form an ammonium thiosulfate solution; and (g) passing the remaining gases from the first absorption zone to a second absorption zone where the remaining ammonia and the carbon dioxide are scrubbed with water and react to form an ammonium carbonate solution.

Claim 3

The process of claim 1 wherein said metallic sulphate is zinc sulphate and said resulting feed mixture includes a bulk density in the fluidized bed between about 50 and 90 pounds per cubic foot and particulate matter size ranging between about 10 mesh to 60 mesh.

Claim 4

The process of claim 2 wherein said mixture of ammonium sulphate, zinc sulphide concentrates and zinc sulphate comprises about 42% weight ammonium sulphate, about 50% weight zinc sulphide concentrates and about 8% weight zinc sulphate.

Claim 5

The process of claim 1 wherein said quantity of said resulting feed mixture is continuously added at a rate of between about 80 and 120 pounds per hour for every about 400 pounds of reaction mixture in said reactor

Claim 6

The process of claim 4 wherein said quantity of said resulting feed mixture is added at a rate of about 100 pounds per hour for every about 400 pounds of the reactor mixture in said reactor.

Claim 7

The process of claim 1 additionally including diluting said products of combustion with a quantity of a diluting neutral gas to adjust the temperature of said products of combustion.

Claim 8

The process of claim 6 wherein said diluting fluid is selected from the group consisting of steam, nitrogen, ammonia and carbon dioxide.

Claim 9

The process of claim 1 wherein said first absorption zone is maintained between a temperature of about 80° C. and 98° C.

Claim 10

The process of claim 1 wherein said metallic sulphate is zinc sulphate and said produced ammonium thiosulphate comprises a concentration range of between about 750 to 850 grams per liter.

Claim 11

The process of claim 1 wherein said second absorption zone is maintained between a temperature of about 23° C. and 30° C.

Claim 12

The process of claim 1 wherein said quenched metallic sulphate includes unreacted corresponding metallic sulphide concentrates.

Claim 13

The process of claim 11 additionally including separating off said unreacted corresponding metallic sulphide concentrates and said mixture of quenched metallic sulphate and unreacted corresponding metallic sulphide concentrates and recycling said separated corresponding metallic sulphide concentrates to said upper portion of said fluidized bed reactor for further production of said metallic sulphate.

Claim 14

The process of claim 12 additionally including removing said metallic sulphate and purifying said removed metallic sulphate by filtering.

Claim 15

An process of claim 12 wherein said metallic sulphate is zinc sulphate solution and said zinc sulphate within said quench zone includes a concentration of between about 160 to 200 grams of zinc ions per liter.

Claim 16

The process of claim 1 wherein a quantity of said produced metallic sulphate is recycled directly from said reactor for admixing with said mixture of said corresponding metallic sulphide concentrates and said ammonium sulphate for further production of said metallic sulphate.

Claim 17

The process of claim 15 wherein said quantity of said produced metallic sulphate includes unreacted corresponding metallic sulphide concentrates.

Claim 18

In a process for producing metallic sulfates of metals selected from the group consisting of zinc, copper, iron and cadmium, which process comprises forming a mixture of the corresponding metallic sulfide concentrates and ammonium sulfate, heating said mixture in a non-oxidizing atmosphere of temperatures of between about 150° to 480° C. to convert said mixture into said metallic sulfate, ammonia, sulfur and sulfur dioxide, removing said metallic sulfate from the heating zone and quenching said metallic sulfate in water, passing the volatile products of the reaction consisting essentially of ammonia sulfur vapor, sulfur dioxide and water into a first absorption zone at temperatures of between about 100° C. and 150° C. to form ammonium thiosulfate, passing the residual gases from said first zone into a second zone where the residual ammonia is absorbed in water, the improvement comprising, converting at least about 95% wt. of said sulfide to said sulfate by (a) adding to said mixture of ammonium sulfate and metallic sulfide, a quantity of the corresponding metallic sulfate to inhibit the development of agglomerating conditions in the reaction of said metallic sulfide concentrates with said ammonium sulfate and to form a resulting feed mixture consisting of about 25-75% wt. of said metallic sulfide, 23-73% wt. of said ammonium sulfate, and 2-14% wt. of said metallic sulfate; (b) introducing said resulting feed mixture into the upper portion of a fluidized bed reactor; (c) directly heating said resulting feed mixture to a temperature of about 150° C. to 480° C. with the products of combustion of a heating fuel selected from the group consisting of water gas, producer gas, natural gas and mixtures thereof, said products of combustion being neutral, adding at a rate of between about 1.0% and 10.0% of the rate of which said products of combustion contact said mixture a quantity of a fuel gas, said fuel gas being added to said evolved sulfur, said sulfur dioxide, said ammonia and water, to convert said resultant feed mixture to metallic sulfate, ammonia, sulfur, sulfur dioxide and water, while maintaining evolved sulfur and sulfur dioxide in a molar ratio of about 1 to 1 and to maintain evolved ammonia and produced metallic sulfate in a molar ratio of about 1 to 1; (d) removing the metallic sulfate from the lower portion of said reactor and passing said removed metallic sulfate to a quench zone where the sulfate is dissolved in water to form a metallic sulfate solution; (e) sweeping carbon dioxide, evolved sulfur, sulfur dioxide and ammonia out of the upper portion of said reactor; (f) passing the swept out gases into a first absorption zone where the sulfur dioxide and a portion of the ammonia are dissolved and reacted to form an ammonium thiosulfate solution; and (g) passing the remaining gases from the first absorption zone to a second absorption zone where the remaining ammonia and the carbon dioxide are scrubbed with water and react to form an ammonium carbonate solution.

Claim 19

In a process for producing metallic sulfates of metals selected from the group consisting of zinc, copper, iron and cadmium, which process comprises forming a mixture of the corresponding metallic sulfide concentrates and ammonium sulfate, heating said mixture in a non-oxidizing atmosphere of temperatures of between about 150° to 480° C. to convert said mixture into said metallic sulfate, ammonia, sulfur and sulfur dioxide, removing said metallic sulfate from the heating zone and quenching said metallic sulfate in water, passing the volatile products of the reaction consisting essentially of ammonia sulfur vapor, sulfur dioxide and water into a first absorption zone at temperatures of between about 100° C. and 150° C. to form ammonium thiosulfate, passing the residual gases from said first zone into a second zone where the residual ammonia is absorbed in water, the improvement comprising, converting at least about 95% wt. of said sulfide to said sulfate by (a) adding to said mixture of ammonium sulfate and metallic sulfide, a quantity of the corresponding metallic sulfate to inhibit the development of agglomerating conditions in the reaction of said metallic sulfide concentrates with said ammonium sulfate and to form a resulting feed mixture consisting of about 25-75% wt. of said metallic sulfide, 23-73% wt. of said ammonium sulfate, and 2-14% wt. of said metallic sulfate; (b) introducing said resulting feed mixture into the upper portion of a fluidized bed reactor; (c) directly heating said resulting feed mixture to a temperature of about 150° C. to 480° C. with the products of combustion of a heating fuel selected from the group consisting of water gas, producer gas, natural gas and mixtures thereof, said products of combustion being neutral, adding at a rate of between about 1.0% and 10.0% of the rate of which said products of combustion contact said mixture a quantity of a fuel gas, said fuel gas being added to said evolved sulfur, said sulfur dioxide, said ammonia and water, to convert said resultant feed mixture to metallic sulfate, ammonia, sulfur, sulfur dioxide and water, while maintaining evolved sulfur and sulfur dioxide in a molar ratio of about 1 to 1 and to maintain evolved ammonia and produced metallic sulfate in a molar ratio of about 1 to 1; (d) removing the metallic sulfate from the lower portion of said reactor and passing said removed metallic sulfate to a quench zone where the sulfate is dissolved in water to form a metallic sulfate solution; (e) sweeping carbon dioxide, evolved sulfur, sulfur dioxide and ammonia out of the upper portion of said reactor; (f) passing the swept out gases into a first absorption zone where the sulfur dioxide and a portion of the ammonia are dissolved and reacted to form an ammonium thiosulfate solution; and (g) passing the remaining gases from the first absorption zone to a second absorption zone where the remaining ammonia and the carbon dioxide are scrubbed with water and react to form an ammonium carbonate solution.

Claim 20

In a process for producing metallic sulfates of metals selected from the group consisting of zinc, copper, iron and cadmium, which process comprises forming a mixture of the corresponding metallic sulfide concentrates and ammonium sulfate, heating said mixture in a non-oxidizing atmosphere of temperatures of between about 150° C. to 480° C. to convert said mixture into said metallic sulfate, ammonia, sulfur and sulfur dioxide removing said metallic sulfate from the heating zone and quenching said metallic sulfate in water, passing the volatile products of the reaction consisting essentially of ammonia sulfur vapor, sulfur dioxide and water into a first absorption zone at temperatures of between about 100° C. and 150° C. to form ammonium thiosulfate, passing the residual gases from said irst zone into a second zone where the residual ammonia is absorbed in water, the improvement comprising, converting at least about 95% wt. of said sulfide to said sulfate by (a) adding to said mixture of ammonium sulfate and metallic sulfide, a quantity of the corresponding metallic calcine which initially reacts to form the corresponding metallic sulfate to inhibit the development of agglomerating conditions in the reaction of said metallic sulfide concentrates with said ammonium sulfate and to form a resulting feed mixture consisting of about 1-16% wt. of said metallic calcine, 30-84% wt. of said ammonium sulfate, and 15-65% wt. of said metallic sulfide; (b) introducing said resulting feed mixture into the upper portion of a fluidized bed reactor; (c) directly heating said resulting feed mixture to a temperature of about 150° C. to 480° C. with the products of combustion of a heating fuel selected from the group consisting of water gas, producer gas, natural gas and mixtures thereof, said products of combustion comprising between about 1.0% by volume to about 6.0% by volume of reducing gases selected from the group consisting of hydrogen, carbon monoxide, and mixtures thereof, to convert said resultant feed mixture to metallic sulfate, ammonia, sulfur, sulfur dioxide and water, while maintaining evolved sulfur and sulfur dioxide in a molar ratio of about 1 to 1 and to maintain evolved ammonia and produced metallic sulfate in a molar ratio of about 1 to 1; (d) removing the metallic sulfate from the lower portion of said reactor and passing said removed metallic sulfate to a quench zone where the sulfate is dissolved in water to form a metallic sulfate solution; (e) sweeping carbon dioxide, evolved sulfur, sulfur dioxide and ammonia out of the upper portion of said reactor; (f) passing the swept out gases into a first absorption zone where the sulfur dioxide and a portion of the ammonia are dissolved and reacted to form an ammonium thiosulfate solution; and (g) passing the remaining gases from the first absorption zone to a second absorption zone where the remaining ammonia and the carbon dioxide are scrubbed with water and react to form an ammonium carbonate solution.

Claim 21

In a process for producing metallic sulfates of metals selected from the group consisting of zinc, copper, iron and cadmium, which process comprises forming a mixture of the corresponding metallic sulfide concentrates and ammonium sulfate, heating said mixture in a non-oxidizing atmosphere of temperatures of between about 150° C. to 480° C. to convert said mixture into said metallic sulfate, ammonia, sulfur and sulfur dioxide removing said metallic sulfate from the heating zone and quenching said metallic sulfate in water, passing the volatile products of the reaction consisting essentially of ammonia sulfur vapor, sulfur dioxide and water into a first absorption zone at temperatures of between about 100° C. and 150° C. to form ammonium thiosulfate, passing the residual gases from said irst zone into a second zone where the residual ammonia is absorbed in water, the improvement comprising, converting at least about 95% wt. of said sulfide to said sulfate by (a) adding to said mixture of ammonium sulfate and metallic sulfide, a quantity of the corresponding metallic calcine which initially reacts to form the corresponding metallic sulfate to inhibit the development of agglomerating conditions in the reaction of said metallic sulfide concentrates with said ammonium sulfate and to form a resulting feed mixture consisting of about 1-16% wt. of said metallic calcine, 30-84% wt. of said ammonium sulfate, and 15-65% wt. of said metallic sulfide; (b) introducing said resulting feed mixture into the upper portion of a fluidized bed reactor; (c) directly heating said resulting feed mixture to a temperature of about 150° C. to 480° C. with the products of combustion of a heating fuel selected from the group consisting of water gas, producer gas, natural gas and mixtures thereof, said products of combustion comprising between about 1.0% by volume to about 6.0% by volume of reducing gases selected from the group consisting of hydrogen, carbon monoxide, and mixtures thereof, to convert said resultant feed mixture to metallic sulfate, ammonia, sulfur, sulfur dioxide and water, while maintaining evolved sulfur and sulfur dioxide in a molar ratio of about 1 to 1 and to maintain evolved ammonia and produced metallic sulfate in a molar ratio of about 1 to 1; (d) removing the metallic sulfate from the lower portion of said reactor and passing said removed metallic sulfate to a quench zone where the sulfate is dissolved in water to form a metallic sulfate solution; (e) sweeping carbon dioxide, evolved sulfur, sulfur dioxide and ammonia out of the upper portion of said reactor; (f) passing the swept out gases into a first absorption zone where the sulfur dioxide and a portion of the ammonia are dissolved and reacted to form an ammonium thiosulfate solution; and (g) passing the remaining gases from the first absorption zone to a second absorption zone where the remaining ammonia and the carbon dioxide are scrubbed with water and react to form an ammonium carbonate solution.