Disclosed herein are methods of using reactor outputs to purify materials. For example, methods of using acid and/or base produced in a reactor to purify materials (e.g., limestone, dolomite, waste streams, and/or ash) are described herein. Related systems are also described.

A method is provided for recycling lithium-ion batteries containing plastics, electrolyte, carbon, metals, and lithium. The method includes: Lithium-ion batteries are ground to form ground battery material which is then pyrolyzed at a temperature between about 100° C. and 700° C. for a time sufficient to vaporize about 80 wt % to 100 wt % of electrolytes present in the ground battery material. The resulting material is further ground and screen classified to produce a screen oversize and a screen undersize. The screen oversize comprises metals and plastics, while the screen undersize comprises a black mass material. Lithium dissolution, triboelectric charging and electrostatic separation of the black mass material (not necessarily in that order) produces a liquid comprising dissolved lithium, a graphite product, and a concentrated metal fines product. Lithium is precipitated from the liquid comprising dissolved lithium, and the concentrated metal fines can be further treated by hydrometallurgy or pyrometallurgy processes.

A method is provided for recycling lithium-ion batteries containing plastics, electrolyte, carbon, metals, and lithium. The method includes: Lithium-ion batteries are ground to form ground battery material which is then pyrolyzed at a temperature between about 100° C. and 700° C. for a time sufficient to vaporize about 80 wt % to 100 wt % of electrolytes present in the ground battery material. The resulting material is further ground and screen classified to produce a screen oversize and a screen undersize. The screen oversize comprises metals and plastics, while the screen undersize comprises a black mass material. Lithium dissolution, triboelectric charging and electrostatic separation of the black mass material (not necessarily in that order) produces a liquid comprising dissolved lithium, a graphite product, and a concentrated metal fines product. Lithium is precipitated from the liquid comprising dissolved lithium, and the concentrated metal fines can be further treated by hydrometallurgy or pyrometallurgy processes.

A process for the production of a metal which comprises: carbothermal reduction of the corresponding metal oxide to produce a mixed gas stream comprising the metal and carbon monoxide; maintaining the mixed gas stream at a suitably elevated temperature to prevent reformation of the metal oxide; ejecting the mixed gas stream through a convergent-divergent nozzle in order to cool the mixed gas stream instantaneously to a temperature at which reformation of the metal oxide cannot take place; and separating and collecting the metal, wherein the nozzle is heated by means other than gas flow through the nozzle so that temperature of surfaces of the nozzle in contact with the mixed gas stream are maintained at a temperature sufficient to prevent deposition on the said surfaces of products from the gas stream.

A process for the production of a metal which comprises: carbothermal reduction of the corresponding metal oxide to produce a mixed gas stream comprising the metal and carbon monoxide; maintaining the mixed gas stream at a suitably elevated temperature to prevent reformation of the metal oxide; ejecting the mixed gas stream through a convergent-divergent nozzle in order to cool the mixed gas stream instantaneously to a temperature at which reformation of the metal oxide cannot take place; and separating and collecting the metal, wherein the nozzle is heated by means other than gas flow through the nozzle so that temperature of surfaces of the nozzle in contact with the mixed gas stream are maintained at a temperature sufficient to prevent deposition on the said surfaces of products from the gas stream.

The invention relates to a method for smelting non-ferrous metal sulfides (13) in a suspension smelting furnace and to a suspension smelting furnace. The suspension smelting furnace comprises at least one injection means (18) for injecting at least one of fluid (19) and pulverous matter (20) into a settler (2) of the suspension smelting furnace from at least one of a first side wall structure (8) and a second side wall structure (9) of the settler (2) so that fluid (19) and/or pulverous matter (20) is injected into the settler (2) above a top surface (16) of a layer of melt (15) in the settler (2).

The invention relates to a method for smelting non-ferrous metal sulfides (13) in a suspension smelting furnace and to a suspension smelting furnace. The suspension smelting furnace comprises at least one injection means (18) for injecting at least one of fluid (19) and pulverous matter (20) into a settler (2) of the suspension smelting furnace from at least one of a first side wall structure (8) and a second side wall structure (9) of the settler (2) so that fluid (19) and/or pulverous matter (20) is injected into the settler (2) above a top surface (16) of a layer of melt (15) in the settler (2).

This invention provides processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

This invention provides processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

Processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Pyrolysis in the presence of an inert gas is employed to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.