Method of Producing Metals and Alloys by Carbothermal Reduction of Metal Oxides

Abstract

A method of producing metals and alloys, the method comprising heating raw materials comprising at least one metal oxide, and agglomerates comprising a carbonaceous reducing agent and a cured binder to effect reduction of the metal oxide to the metal, wherein each agglomerate has at least one molded open channel, and an apparent density not greater than 99% of the apparent density of an identical agglomerate except without the channel.

1 . A method of producing a metal, the method comprising heating raw materials comprising at least one metal oxide, and agglomerates comprising a carbonaceous reducing agent and a cured binder to effect reduction of the metal oxide to the metal, wherein each agglomerate has at least one molded open channel, and an apparent density not greater than 99% of the apparent density of an identical agglomerate except without the channel. 
   
   
       2 . The method according to  claim 1 , wherein each agglomerate has an apparent density not greater than 80% of the apparent density of an identical agglomerate except without the channel. 
   
   
       3 . The method according to  claim 2  wherein each agglomerate has an apparent density not greater than 75% of the apparent density of an identical agglomerate except without the channel. 
   
   
       4 . The method according to  claim 1 , wherein the agglomerates are briquettes or pellets. 
   
   
       5 . The method according to  claim 4 , wherein the briquettes are honeycomb briquettes. 
   
   
       6 . The method according to  claim 1 , wherein the agglomerates have a cylindrical shape. 
   
   
       7 . The method according to  claim 1 , wherein the carbonaceous reducing agent is selected from carbon black and activated carbon. 
   
   
       8 . The method according to  claim 1 , wherein the cured binder is a cured product of sucrose and adipic acid. 
   
   
       9 . The method according to  claim 1 , wherein the agglomerates comprise at least a portion of the metal oxide in the raw materials. 
   
   
       10 . The method according to  claim 1 , wherein the raw materials further comprise wood chips. 
   
   
       11 . The method according to  claim 1 , wherein the raw materials are heated in an electric arc furnace. 
   
   
       12 . The method according to  claim 11 , further comprising recovering the metal from the furnace. 
   
   
       13 . The method according to any of the preceding claims, wherein the metal oxide is silicon dioxide.