Continuous process

Abstract

A process for producing a metal from the corresponding metal halide by reaction of the metal halide at elevated temperature in a reactor comprising a fluidised bed, the fluidised bed comprising seed particles of an inert material that has a melting point higher than that of the metal.

1 . A process for producing a metal from the corresponding metal halide by reaction of the metal halide at elevated temperature in a reactor comprising a fluidised bed, the fluidised bed comprising seed particles of an inert material that has a melting point higher than that of the metal. 
   
   
       2 . A process according to  claim 1 , wherein the melting point of the inert material is at least 30° C. higher than the melting point of the metal to be produced. 
   
   
       3 . A process according to  claim 1 , wherein the inert material is selected from the group consisting of metal oxides, metal nitrides and metal silicates, metals, metal alloys and coke. 
   
   
       4 . A process according to  claim 3 , wherein the inert material is silica. 
   
   
       5 . A process according to  claim 1 , wherein the particle size of the seed particles is from 500 to 1000 μm. 
   
   
       6 . A process according to  claim 1 , wherein on start-up the fluidised bed comprises a mixture of seed particles of the inert material and of the metal to be produced. 
   
   
       7 . A process according to  claim 6 , wherein the weight ratio of seed particles of inert material to seed particles of metal is from 20:80 to 80:20. 
   
   
       8 . A process according to  claim 1 , wherein on start-up the fluidised bed consists solely of seed particles of the inert material. 
   
   
       9 . A process according to  claim 1 , which comprises continuously discharging particles from the reactor and sampling the particles to determine when seed particles and composite particles comprising the seed particles are no longer present in the fluidised bed and then isolating particles discharged subsequently from the reactor. 
   
   
       10 . A process according to  claim 9 , wherein the fluidised bed is replenished with seed particles formed from the metal.