This invention refers to a process for the production of products in the form of commercial zinc oxide and iron ecosinter, which are important raw materials for the production of SHG zinc (a special quality product) and pig iron, with subsequent obtaining steel. The process for producing zinc oxide concentrate and iron ecosinter uses as raw material zinc ferrite residues, steelmaking co-products such as light mud, heavy mud, iron scale, pre-lime and yard cleaning materials rich in iron and, mainly, steel mill dust (class I) mixed with carbon sources, whose mixture is homogenized and pelletized, followed by reduction in a pot furnace fed by insufflated air in ascending flow with temperature ranging from 850 C. to 1,300 C.; being the volatilized metals and the gases generated sent to a cyclone and bag filter where the zinc oxide is retained; the iron ecosinter is poured from the pot at the end of the process.

Carbothermic reduction of magnesium oxide at approximately 2200 degrees Kelvin yields a high temperature mixture of magnesium vapors and carbon monoxide gas. Previous processes have sought to cool or alter the mixture to cause the yield of pure magnesium, which is then used in subsequent processes for its reducing properties. The present invention takes advantage of the stability and inertness of carbon monoxide at elevated temperatures enabling the magnesium vapor/carbon monoxide gas mixture from the carbothermic process to be used directly for the production of other metals at high temperatures. For example, Chromium oxide or chloride, manganese oxide or chloride, zinc oxide or chloride or sulfide, and several other metal compounds can be reduced by the magnesium vapor/carbon monoxide gas mixture at temperatures high enough to prevent the gas mixture from back-reacting to magnesium oxide and carbon.

Carbothermic reduction of magnesium oxide at approximately 2200 degrees Kelvin yields a high temperature mixture of magnesium vapors and carbon monoxide gas. Previous processes have sought to cool or alter the mixture to cause the yield of pure magnesium, which is then used in subsequent processes for its reducing properties. The present invention takes advantage of the stability and inertness of carbon monoxide at elevated temperatures enabling the magnesium vapor/carbon monoxide gas mixture from the carbothermic process to be used directly for the production of other metals at high temperatures. For example, Chromium oxide or chloride, manganese oxide or chloride, zinc oxide or chloride or sulfide, and several other metal compounds can be reduced by the magnesium vapor/carbon monoxide gas mixture at temperatures high enough to prevent the gas mixture from back-reacting to magnesium oxide and carbon.

A continuous process for converting metal compound particles into a mixture of elemental metals. Metal compound particles and a reductant are introduced into an ultra-high temperature reaction zone having a temperature greater than 2,700 C. and an oxygen content less than 3 vol. %. The metal compound particles have particle sizes of d90 500 m. The metal compound particles have a residence time less than 1 minute in the ultra-high temperature reaction zone sufficient to mix with and react with the reductant to reduce the metal compound particles to form a mixture of elemental metals. The mixture of elemental metals is removed from the ultra-high temperature reaction zone. One or more elemental metals are separated or concentrated from the mixture of elemental metals within one or more separation zones based on differential size and density of the one or more elemental metals and the remaining mixture of elemental metals.

A continuous process for converting metal compound particles into a mixture of elemental metals. Metal compound particles and a reductant are introduced into an ultra-high temperature reaction zone having a temperature greater than 2,700 C. and an oxygen content less than 3 vol. %. The metal compound particles have particle sizes of d90 500 m. The metal compound particles have a residence time less than 1 minute in the ultra-high temperature reaction zone sufficient to mix with and react with the reductant to reduce the metal compound particles to form a mixture of elemental metals. The mixture of elemental metals is removed from the ultra-high temperature reaction zone. One or more elemental metals are separated or concentrated from the mixture of elemental metals within one or more separation zones based on differential size and density of the one or more elemental metals and the remaining mixture of elemental metals.

A system and method for continuous production of Mg from metallothermic reduction of magnesium bearing ore from both the reactor side and condenser side of the system, using a separate collection vessel. The furnace is a heated tube through which a moving bed of tableted feed flows. The condenser is a common heat exchanger design (shell/tube, plate/plate, etc.) and uses a heat transfer liquid to cool and condense magnesium gas under vacuum or pressure conditions. The cooling medium can be molten salts or metals which are not in direct contact with the magnesium metal. Liquid magnesium flows from the condenser into a collection vessel for further processing. Continuous operation is achieved by supplying a constant feed of tablets into the furnace, producing a constant stream of Mg gas to the condenser. Magnesium liquid product is tapped periodically from the collection vessel.

A system and method for continuous production of Mg from metallothermic reduction of magnesium bearing ore from both the reactor side and condenser side of the system, using a separate collection vessel. The furnace is a heated tube through which a moving bed of tableted feed flows. The condenser is a common heat exchanger design (shell/tube, plate/plate, etc.) and uses a heat transfer liquid to cool and condense magnesium gas under vacuum or pressure conditions. The cooling medium can be molten salts or metals which are not in direct contact with the magnesium metal. Liquid magnesium flows from the condenser into a collection vessel for further processing. Continuous operation is achieved by supplying a constant feed of tablets into the furnace, producing a constant stream of Mg gas to the condenser. Magnesium liquid product is tapped periodically from the collection vessel.

A method for smelting magnesium quickly and continuously includes: preparing dolomite or magnesite with reductants and fluorite at a predetermined ratio, uniformly mixing the prepared ingredients to obtain pellets, and calcining the obtained pellets in an argon or nitrogen atmosphere; continuously feeding the high-temperature calcined pellets (without being cooled) under argon protection into a reduction furnace, and performing a high-temperature reduction reaction in a flowing argon atmosphere to obtain high-temperature magnesium steam; and enabling the high-temperature magnesium steam to be carried out of the high-temperature reduction furnace by an argon flow, and performing condensation to obtain metal magnesium. The present invention eliminates a vacuum system and a vacuum reduction tank, so that quick and continuous production of the metal magnesium is realized, the reduction time is shortened to 90 min or less, and the recovery rate of magnesium is increased to 88% or more.

A method for smelting magnesium quickly and continuously includes: preparing dolomite or magnesite with reductants and fluorite at a predetermined ratio, uniformly mixing the prepared ingredients to obtain pellets, and calcining the obtained pellets in an argon or nitrogen atmosphere; continuously feeding the high-temperature calcined pellets (without being cooled) under argon protection into a reduction furnace, and performing a high-temperature reduction reaction in a flowing argon atmosphere to obtain high-temperature magnesium steam; and enabling the high-temperature magnesium steam to be carried out of the high-temperature reduction furnace by an argon flow, and performing condensation to obtain metal magnesium. The present invention eliminates a vacuum system and a vacuum reduction tank, so that quick and continuous production of the metal magnesium is realized, the reduction time is shortened to 90 min or less, and the recovery rate of magnesium is increased to 88% or more.

Methods and systems for separating a first metal from a metal-containing feed stream are provided. The method can include applying solar energy, for example, by focusing one or more mirrors in one or more heliostats, to heat a metal-containing feed stream in a heating zone to a first temperature to produce a first vapor including the first metal. The first vapor can be condensed in a condensation zone to produce a first liquid including the first metal, and the first liquid can be collected. The system can include a separation unit include a heating zone in fluid communication with a condensation zone and a means for applying solar energy to heat a metal-containing feed stream disposed in the heating zone.