Method for producing molybdenum metal and molybdenum metal

Abstract

Apparatus for producing molybdenum metal Apparatus includes a furnace that defines at least two heating zones of substantially equal length, the furnace maintaining each of the two heating zones at temperatures not greater than about 1200° C.; a supply of precursor material; a process tube extending through each of the two heating zones of the furnace, wherein the precursor material is introduced into the process tube and moved through the two heating zones of the furnace; a pressure regulator operatively associated with the process tube to maintain an interior region of the process tube at a substantially constant pressure greater than an ambient pressure; and a supply of process gas operatively associated with the process tube, whereby the process gas is introduced into the process tube such that the process gas reacts with the precursor material within the furnace to form the molybdenum metal.

1 . An apparatus for producing molybdenum metal, comprising: 
 a furnace, the furnace defining at least two heating zones of substantially equal length, the furnace maintaining each of the two heating zones at temperatures no greater than about 1200° C.;    a supply of precursor material;    a process tube extending through each of the at least two heating zones of the furnace, wherein the precursor material is introduced into the process tube and moved through each of the at least two heating zones of the furnace;    a pressure regulator operatively associated with the process tube, the pressure regulator maintaining an interior region of the process tube at a substantially constant pressure greater than an ambient pressure; and    a supply of process gas operatively associated with the process tube, whereby the process gas is introduced into the process tube such that the process gas reacts with the precursor material within the furnace to form the molybdenum metal.    
   
   
       2 . An apparatus as in  claim 1 , wherein the furnace comprises three heating zones of substantially equal length, the furnace maintaining the three heating zones at temperatures no greater than about 1200° C., and the process tube extending through each of the three heating zones.  
   
   
       3 . An apparatus as in  claim 1 , further comprising a feed system linked to the process tube for introducing the precursor material into the process tube at a substantially constant rate.  
   
   
       4 . An apparatus as in  claim 1 , wherein the supply of process gas comprises at least a reducing gas.  
   
   
       5 . An apparatus as in  claim 1 , wherein the supply of process gas comprises at least hydrogen.  
   
   
       6 . An apparatus as in  claim 1 , wherein the substantially constant pressure is in a range of about 9 to about 14 cm of water pressure (gauge).  
   
   
       7 . An apparatus as in  claim 1  further comprising a cooling zone connected to the second heating zone.  
   
   
       8 . An apparatus as in  claim 1  wherein the process tube is inclined at an angle in a range from about 0° to about 5°.  
   
   
       9 . An apparatus as in  claim 1  further comprising a scrubber operatively associated with the process tube.  
   
   
       10 . An apparatus as in  claim 9 , wherein the scrubber comprises: 
 a dry pot fluidically connected to the process tube; and    a wet pot fluidically connected to the dry pot, the wet pot containing water therein    
   
   
       11 . Apparatus for producing molybdenum metal, comprising: 
 a furnace defining a first heating zone and a second heating zone, the heating zones being of substantially equal length, the furnace maintaining the first heating zone at a temperature in a range of about 540° C. to about 600° C. and the furnace maintaining the second heating zone at a temperature in a range of about 980° C. to about 1050° C.;    a process tube having a proximal end and a distal end, the process tube extending through the first and second heating zones defined by the furnace, the distal end of the process tube extending beyond the second heating zone and comprising a cooling zone;    a supply of precursor material operatively associated with the process tube;    a supply of reducing gas operatively associated with the distal end of the process tube; and    a pressure regulator operatively associated with the process tube, the pressure regulator maintaining an interior region of the process tube at a substantially constant pressure, the substantially constant pressure being greater than an ambient pressure.    
   
   
       12 . Apparatus of  claim 11 , wherein the furnace defines an intermediate heating zone between the first and second heating zones, the heating zones being of substantially equal length, the furnace maintaining the intermediate heating zone at a temperature in a range of about 760° C. to about 820° C.  
   
   
       13 . Apparatus of  claim 11  wherein the supply of precursor material comprises a feed system operatively associated with the proximal end of the process tube, the feed system continuously feeding the precursor material to the proximal end of the process tube.  
   
   
       14 . Apparatus of  claim 11  further comprising a discharge hopper operatively associated with the distal end of the process tube, the discharge hopper collecting the molybdenum metal.  
   
   
       15 . An apparatus for producing molybdenum metal from a precursor material, comprising: 
 a furnace having at least two heating zones; a process tube extending through each of said at least two heating zones of said furnace, said process tube having an inclination in a range of about 0.2° to about 0.4°, said process tube having a substantially constant pressure, wherein said precursor material is introduced into said process tube and moved through each of said at least two heating zones of said furnace; and    a process gas introduced into said process tube, wherein said precursor material reacts with said process gas within said furnace to form said molybdenum metal.    
   
   
       16 . The apparatus of  claim 15 , wherein said process tube is at an inclination of about 0.3°.  
   
   
       17 . The apparatus of  claim 15 , further comprising a feed system linked to said process tube, wherein said precursor material is introduced into said process tube at a rate of about 9 grams per minute.  
   
   
       18 . The apparatus of  claim 15 , further comprising a feed system linked to said process tube, wherein said precursor material is introduced into said process tube at a rate of about 5 grams per minute.  
   
   
       19 . The apparatus of  claim 15 , further comprising a feed system linked to said process tube, wherein said precursor material is introduced into said process tube at a rate in a range of about 5 grams per minute to about 9 grams per minute.  
   
   
       20 . An apparatus for producing molybdenum metal from a precursor material, comprising: 
 a process tube having three heating zones and a cooling zone, said process tube having an inclination in a range of about 0.2° to about 0.4°, wherein said precursor material is introduced into said process tube and moves through said three heating zones; and    a process gas introduced into said process tube, wherein said precursor material reacts with said process gas to form said molybdenum metal in said three heating zones, said molybdenum metal cooling at a constant pressure in said cooling zone.    
   
   
       21 . The apparatus of  claim 20 , wherein said process tube is at an inclination of about 0.3°.  
   
   
       22 . The apparatus of  claim 20 , further comprising a feed system linked to said process tube, wherein said precursor material is introduced into said process tube at a rate of about 9 grams per minute.  
   
   
       23 . The apparatus of  claim 20 , further comprising a feed system linked to said process tube, wherein said precursor material is introduced into said process tube at a rate of about 5 grams per minute.  
   
   
       24 . The apparatus of  claim 20 , further comprising a feed system linked to said process tube, wherein said precursor material is introduced into said process tube at a rate in a range of about 5 grams per minute to about 9 grams per minute.