Metal chlorides and metals obtained from metal oxide containing materials

Abstract

Method and apparatus for preparing at least one metal chloride from metal oxide containing material comprising calcining the metal oxide containing material under temperature conditions sufficient to obtain a calcined product comprising at least one metal oxide; and selectively chlorinating the calcined product to form at least one metal chloride.

What is claimed: 
     
         1 . A method for preparing at least one metal chloride from metal oxide containing material comprising:
 calcining the metal oxide containing material under temperature conditions sufficient to obtain a calcined product comprising at least one metal oxide; and   selectively chlorinating the calcined product to form at least one metal chloride.   
     
     
         2 . A method according to  claim 1 , further comprising drying the metal oxide containing material. 
     
     
         3 . A method according to  claim 1 , wherein the at least one metal oxide includes at least one oxide of a metal comprising alkaline and earth alkaline metals, main group III with the exception of boron, main group IV with the exception of carbon and silicon, all transition metals, all lanthanides and actinides. 
     
     
         4 . A method according to  claim 1 , wherein the calcining is performed at a temperature between about 1450 and 1750° F. 
     
     
         5 . A method according to  claim 1 , wherein heat for calcining is provided by a heat content present in the metal oxide containing material. 
     
     
         6 . A method according to  claim 1 , wherein the calcining includes addition of a heat source. 
     
     
         7 . A method according to  claim 1 , wherein the selectively chlorinating comprises carbochlorination. 
     
     
         8 . A method according to  claim 1 , wherein the selectively chlorinating includes determining a content of metal oxides in the metal oxide containing material and using an amount of a source of chlorine and an amount of carbon from a carbon source in the selectively chlorinating based upon the determining. 
     
     
         9 . A method according to  claim 8 , wherein the amount of chlorine source comprise an excess of 0.1 to 2 wt % based on the metal oxide content. 
     
     
         10 . A method according to  claim 1 , further comprising generating at least one metal from the at least one metal chloride. 
     
     
         11 . A method according to  claim 1 , wherein the at least one metal chloride comprises at least two metal chlorides and additionally comprises separating the at least two metal chlorides. 
     
     
         12 . A method according to  claim 11 , wherein the separating includes fractional condensation/distillation of the at least two metal chlorides at pressures and temperatures to fractionally separate the at least two metal chlorides. 
     
     
         13 . A method according to  claim 1 , wherein the at least one metal oxide containing material comprises coal mine waste. 
     
     
         14 . A method according to  claim 1 , wherein the at least one metal oxide containing material comprises solid industrial byproduct. 
     
     
         15 . A method according to  claim 1 , further including separating products after the selectively chlorinating comprising:
 separating solids from gases; and   separating the gaseous metal chlorides by fractional condensation/distillation.   
     
     
         16 . A method according to  claim 15 , wherein the separating solids from gases includes separating liquids from the solids. 
     
     
         17 . A method according to  claim 1 , wherein excess heat from at least one of the calcining and the selectively chlorinating is used in the process. 
     
     
         18 . A method according to  claim 15 , wherein the fractional condensation/distillation includes condensation and distillation of metal chlorides at pressures between atmospheric and 80 psig. 
     
     
         19 . A method according to  claim 15 , further comprising forming metals from the gaseous metal chlorides. 
     
     
         20 . A method for conserving energy in a metal chloride generating process comprising:
 combusting a heat source to calcine metal oxide containing material; and   chlorinating at least one metal oxide from the metal oxide containing material; and   diverting energy from at least one of the combusting and the chlorinating to other parts of the process.