According to the present invention there is provided a method for treating a zinc leach residue comprising the steps of: adding the zinc leach residue and a sulfide material comprising copper and flux to a furnace having a molten bath therein; operating the furnace to produce a matte comprising copper and a slag comprising zinc; separating the matte from the slag; and recovering zinc from the slag. The method preferably comprises the additional step of recovering the copper and/or other precious metals such as silver and gold, from the matte.

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 phase change system comprising a reduction assembly, a cold sublimation assembly, and a hot sublimation assembly. The reduction assembly comprises a reduction crucible, a first modular crucible, and a reduction control nozzle and, when assembled, the reduction control nozzle is positioned between an open end of the reduction crucible and an open end of the first modular crucible and a protruding outlet of the reduction control nozzle extends into an activity chamber of the first modular crucible. The cold sublimation assembly comprises a collection crucible and a cold sublimation control nozzle and, when assembled, the cold sublimation control nozzle extends into an activity chamber of the collection crucible. In addition, the hot sublimation assembly comprises a hot sublimation crucible and a second modular crucible and, when assembled, the hot sublimation crucible is fluidly coupled to the second modular crucible.

A phase change system comprising a reduction assembly, a cold sublimation assembly, and a hot sublimation assembly. The reduction assembly comprises a reduction crucible, a first modular crucible, and a reduction control nozzle and, when assembled, the reduction control nozzle is positioned between an open end of the reduction crucible and an open end of the first modular crucible and a protruding outlet of the reduction control nozzle extends into an activity chamber of the first modular crucible. The cold sublimation assembly comprises a collection crucible and a cold sublimation control nozzle and, when assembled, the cold sublimation control nozzle extends into an activity chamber of the collection crucible. In addition, the hot sublimation assembly comprises a hot sublimation crucible and a second modular crucible and, when assembled, the hot sublimation crucible is fluidly coupled to the second modular crucible.

The present disclosure is a metal extraction process that includes preparing a homogeneous admixture of metal oxide powder, reducing agent powder, and catalyst powder, pelletizing the admixture to yield a plurality of pellets, positioning the plurality of pellets in a cartridge, positioning the cartridge in a reducing chamber and heating the reducing chamber to a reducing temperature, pulling a partial vacuum in the reducing chamber, vaporizing desired metal from the plurality of pellets, condensing vaporized metal on a condensation surface positioned in a condensation chamber in pneumatic communication with the reducing chamber, cooling the condensation surface outside the condensation chamber, and removing condensed metal bodies from the condensation surface.

The present disclosure is a metal extraction process that includes preparing a homogeneous admixture of metal oxide powder, reducing agent powder, and catalyst powder, pelletizing the admixture to yield a plurality of pellets, positioning the plurality of pellets in a cartridge, positioning the cartridge in a reducing chamber and heating the reducing chamber to a reducing temperature, pulling a partial vacuum in the reducing chamber, vaporizing desired metal from the plurality of pellets, condensing vaporized metal on a condensation surface positioned in a condensation chamber in pneumatic communication with the reducing chamber, cooling the condensation surface outside the condensation chamber, and removing condensed metal bodies from the condensation surface.

A process and system are disclosed for producing lithium oxide from lithium nitrate. In the process and system, the lithium nitrate is thermally decomposed in a manner such that a fraction of the lithium nitrate forms lithium oxide, and such that a remaining fraction of the lithium nitrate does not decompose to lithium oxide. The thermal decomposition may be terminated after a determined time period to ensure that there is a remaining fraction of lithium nitrate and to thereby produce a lithium oxide in lithium nitrate product. The lithium oxide in lithium nitrate product may have one or more transition-metal oxides, hydroxides, carbonates or nitrates added thereto to form a battery electrode. The lithium oxide in lithium nitrate product may alternatively be subjected to carbothermal reduction to produce lithium metal.

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.

A system and method that uses a high-temperature condenser to collect magnesium produced by thermal reduction, electrolysis, or distillation. The condenser is a common heat exchanger design (shell/tube, plate/plate, etc.) and uses a heat transfer fluid to cool and condense magnesium gas, e.g., to 200-900 C. under vacuum or pressure conditions. Solid or liquid magnesium is collected in the condenser along with any by-products or impurities at a purity greater than 35 wt-% Mg. Magnesium is subsequently liberated from the condenser by raising the temperature of the system, lowering the pressure, or both, to induce a phase change in the metal, such as melting or distillation, for further purification to, e.g., >90 wt-% Mg.