Process for reduction of zirconium, hafnium or titanium using a zinc or tin seal

Claim 2

In a process of the type wherein a chloride of zirconium, hafnium or titanium is reduced to produce a product metal, the improvement comprising: a. establishing a layer of a seal metal selected from the group consisting of zinc, zinc together with product metal, tin and tin together with product metal in a vessel, said seal metal layer having an upper molten portion and a lower solid portion, said lower solid portion being located adjacent to a cooling means; b. establishing a layer of molten magnesium chloride on top of said seal metal; c. establishing a layer of molten magnesium on top of said layer of magnesium chloride; d. introducing gaseous chloride of the product metal above said magnesium, thereby causing a reaction which produces product metal chunks which settle through said layers of molten magnesium, molten magnesium chloride and molten seal metal; e. withdrawing a lower part of said solid seal metal from said vessel and causing a portion of the molten seal metal to be relocated adjacent to said cooling means, whereby the portion of the molten seal metal relocated adjacent to the cooling means solidifies and maintains a seal at the bottom of the vessel while product metal chunks are trapped within the solidified seal metal and can be later withdrawn from said vessel together with solidified seal metal.

Claim 3

The process of claim 1, wherein at least a portion of seal metal which has been withdrawn from said vessel is separated from at least a portion of the product metal and is recycled to the vessel.

Claim 4

The process of claim 2, wherein the seal metal is zinc and product metal and zinc is separated from the product metal and zinc is recycled to the vessel.

Claim 5

The process of claim 2, wherein the seal metal is zinc and product metal and zinc and product metal are separated from the remainder of the product metal and zinc and product are recycled to the vessel.

Claim 6

The process of claim 2, wherein magnesium chloride is at least periodically withdrawn from said vessel.

Claim 7

The process of claim 5, wherein magnesium is at least periodically added to said vessel, whereby said process becomes a continuous process.

Claim 8

The process of claim 6, wherein said product metal is zirconium.

Claim 9

The process of claim 4, wherein seal metal containing product metal chunks which has been withdrawn is electron beam melted in a chamber, vaporizing the zinc and thereby separating said zinc from the product metal, and wherein the zinc vapor is condensed and recycled to the vessel.

Claim 10

In a process of the type wherein a chloride of zirconium, hafnium or titanium is reduced to produce a product metal, the improvement comprising: a. establishing a layer of a seal metal selected from the group consisting of zinc, zinc together with product metal, tin and tin together with product metal in a vessel, said seal metal layer having an upper molten portion and a lower solid portion, said lower solid portion being located adjacent to a cooling means; b. establishing a layer of molten reducing metal chloride on top of said seal metal; c. establishing a layer of molten reducing metal on top of said layer of reducing metal chloride; d. introducing gaseous chloride of the product metal above said reducing metal, thereby causing a reaction which produces product metal chunks which settle through said layers of molten reducing metal, reducing metal chloride and seal metal; e. withdrawing a lower part of said solid seal metal from said vessel and causing a portion of the molten seal metal to be relocated adjacent to said cooling means, whereby the portion of the molten seal metal relocated adjacent to the cooling means solidifies and maintains a seal at the bottom of the vessel while product metal chunks are trapped within the solidified seal metal and can be later withdrawn from said vessel together with solidified seal metal.

Claim 11

In a process of the type wherein a chloride of zirconium, hafnium or titanium is reduced to produce a product metal, the improvement comprising: a. establishing a layer of a seal metal selected from the group consisting of zinc, zinc together with product metal, tin and tin together with product metal in a vessel, said seal metal layer having an upper molten portion and a lower solid portion, said lower solid portion being located adjacent to a cooling means; b. establishing a layer of molten reducing metal chloride on top of said seal metal; c. establishing a layer of molten reducing metal on top of said layer of reducing metal chloride; d. introducing gaseous chloride of the product metal above said reducing metal, thereby causing a reaction which produces product metal chunks which settle through said layers of molten reducing metal, reducing metal chloride and seal metal; e. withdrawing a lower part of said solid seal metal from said vessel and causing a portion of the molten seal metal to be relocated adjacent to said cooling means, whereby the portion of the molten seal metal relocated adjacent to the cooling means solidifies and maintains a seal at the bottom of the vessel while product metal chunks are trapped within the solidified seal metal and can be later withdrawn from said vessel together with solidified seal metal.

Claim 12

The process of claim 9, wherein at least a portion of seal metal which has been withdrawn from said vessel is separated from at least a portion of the product metal and is recycled to the vessel.

Claim 13

The process of claim 10, wherein the seal metal is zinc and product metal and zinc is separated from the product metal and zinc is recycled to the vessel.

Claim 14

The process of claim 10, wherein the seal metal is zinc and product metal and zinc and product metal are separated from the remainder of the product metal and zinc and product metal are recycled to the vessel.

Claim 15

The process of claim 10, wherein reducing metal chloride is at least periodically withdrawn from said vessel.

Claim 16

The process of claim 13, wherein reducing metal is at least periodically added to said vessel, whereby said process becomes a continuous process.

Claim 17

The process of claim 14, wherein said product metal is zirconium.

Claim 18

The process of claim 10, wherein seal metal containing product metal chunks which has been withdrawn is electron beam melted in a chamber, vaporizing the zinc and thereby separating said zinc from the product metal, and wherein the zinc vapor is condensed and recycled to the vessel.

Claim 19

In a process of the type wherein a chloride of zirconium, hafnium or titanium is reduced to produce a product metal, the improvement comprising: a. establishing a layer of zinc together with product metal seal metal in a vessel, said seal metal layer having an upper molten portion and a lower solid portion, said lower solid portion being located adjacent to a cooling means; b. establishing a layer of molten magnesium chloride on top of said seal metal; c. establishing a layer of molten magnesium on top of said layer of magnesium chloride; d. introducing gaseous chloride of the product metal above said magnesium, thereby causing a reaction which produces product metal chunks which settle through said layers of molten magnesium, molten magnesium chloride and molten seal metal; e. withdrawing a lower part of said solid seal metal from said vessel and causing a portion of the molten metal to be relocated adjacent to said cooling means, causing the portion of the molten seal metal relocated adjacent to the cooling means to solidify and maintain a seal at the bottom of the vessel, whereby while product metal chunks are trapped within the solidified seal metal and can be later withdrawn from said vessel together with solidified seal metal; f. at least periodically withdrawing magnesium chloride from said vessel; g. at least periodically adding magnesium to said vessel; h. electron beam melting zinc containing product metal chunks in a chamber, vaporizing the zinc and thereby separating said zinc from the product metal; and i. condensing said zinc vapor and recycling zinc to said vessel.

Claim 20

In a process of the type wherein a chloride of zirconium, hafnium or titanium is reduced to produce a product metal, the improvement comprising: a. establishing a layer of zinc together with product metal seal metal in a vessel, said seal metal layer having an upper molten portion and a lower solid portion, said lower solid portion being located adjacent to a cooling means; b. establishing a layer of molten magnesium chloride on top of said seal metal; c. establishing a layer of molten magnesium on top of said layer of magnesium chloride; d. introducing gaseous chloride of the product metal above said magnesium, thereby causing a reaction which produces product metal chunks which settle through said layers of molten magnesium, molten magnesium chloride and molten seal metal; e. withdrawing a lower part of said solid seal metal from said vessel and causing a portion of the molten metal to be relocated adjacent to said cooling means, causing the portion of the molten seal metal relocated adjacent to the cooling means to solidify and maintain a seal at the bottom of the vessel, whereby while product metal chunks are trapped within the solidified seal metal and can be later withdrawn from said vessel together with solidified seal metal; f. at least periodically withdrawing magnesium chloride from said vessel; g. at least periodically adding magnesium to said vessel; h. electron beam melting zinc containing product metal chunks in a chamber, vaporizing the zinc and thereby separating said zinc from the product metal; and i. condensing said zinc vapor and recycling zinc to said vessel.