Processes for the production of tantalum alloys and niobium are disclosed. The processes use aluminothermic reactions to reduce tantalum pentoxide to tantalum metal or niobium pentoxide to niobium metal.

A method of separating a rare earth element from coal and clay ores includes subjecting a raw coal to a liquefaction process to form a pitch or a pitch resin and filtering the pitch or pitch resin to capture the rare earth element. The method further includes refining the pitch or pitch resin to produce a mesophase pitch. The method also includes subjecting the mesophase pitch or pitch resin to a low-crystallinity spinning process to form a carbon fiber.

A method of separating a rare earth element from coal and clay ores includes subjecting a raw coal to a liquefaction process to form a pitch or a pitch resin and filtering the pitch or pitch resin to capture the rare earth element. The method further includes refining the pitch or pitch resin to produce a mesophase pitch. The method also includes subjecting the mesophase pitch or pitch resin to a low-crystallinity spinning process to form a carbon fiber.

The present invention provides methods for recovering metals, including rare earth metals, from mixed metals. An example is the recovery of metals from electronic waste. The method of separation is based on the inversion and/or lowering of the thermodynamic energy barrier by using one or more stressors applied at appropriate ratios to create lower energy points in the thermodynamic energy landscape of the mixed metals. Example stressors include a) a chemical stress, b) a mechanical stress, c) a thermal stress, d) and electromagnetic radiation and/or light stress, an interfacial stress, and/or a magnetic flux gradient stress.

The present invention provides methods for recovering metals, including rare earth metals, from mixed metals. An example is the recovery of metals from electronic waste. The method of separation is based on the inversion and/or lowering of the thermodynamic energy barrier by using one or more stressors applied at appropriate ratios to create lower energy points in the thermodynamic energy landscape of the mixed metals. Example stressors include a) a chemical stress, b) a mechanical stress, c) a thermal stress, d) and electromagnetic radiation and/or light stress, an interfacial stress, and/or a magnetic flux gradient stress.

Systems and methods for recovery of molten metal are generally described. Certain systems comprise a reactor (e.g., a reduction cell such as an electrolytic cell comprising an anode, a cathode, and an electrolyte) comprising molten metal within a container; and a collection vessel at least partially contained within the container of the reactor, the collection vessel comprising an opening fluidically connected to the container of the reactor. Some systems comprise a reactor; and a collection vessel comprising a first opening fluidically connected to the reactor and a second opening fluidically connected to a source of gas (e.g., inert gas) and to a source of negative pressure.

The invention relates to a method and to an arrangement for refining copper concentrate. The arrangement includes a suspension smelting furnace comprising a reaction shaft, and a settler. The reaction shaft is provided with a concentrate burner for feeding copper concentrate such as copper sulfide concentrate and/or copper matte and additionally at least reaction gas into the reaction shaft to obtain a blister layer containing blister and a first slag layer containing slag on top of the blister layer in the settler, and a slag cleaning furnace. The arrangement includes a feeder configured for feeding blister from the blister layer in the settler and for feeding slag from the first slag layer in the settler into the slag cleaning furnace.

The invention relates to a method and to an arrangement for refining copper concentrate. The arrangement includes a suspension smelting furnace comprising a reaction shaft, and a settler. The reaction shaft is provided with a concentrate burner for feeding copper concentrate such as copper sulfide concentrate and/or copper matte and additionally at least reaction gas into the reaction shaft to obtain a blister layer containing blister and a first slag layer containing slag on top of the blister layer in the settler, and a slag cleaning furnace. The arrangement includes a feeder configured for feeding blister from the blister layer in the settler and for feeding slag from the first slag layer in the settler into the slag cleaning furnace.

Niobium and tantalum extraction industries heavily depend on fluoride chemistry for metal oxide production. A fluoride-free approach utilizes alkali treatment for selective dissolution of niobium and tantalum phases. The application of microwave heating in the alkali treatment of columbite significantly reduced the processing time, providing a higher reaction rate and recovery than furnace or convection heating. Purified oxides are recovered using either direct precipitation or solvent extraction.

Niobium and tantalum extraction industries heavily depend on fluoride chemistry for metal oxide production. A fluoride-free approach utilizes alkali treatment for selective dissolution of niobium and tantalum phases. The application of microwave heating in the alkali treatment of columbite significantly reduced the processing time, providing a higher reaction rate and recovery than furnace or convection heating. Purified oxides are recovered using either direct precipitation or solvent extraction.