Method for producing metal from metal oxide by carbothermic reduction and holed cake used therefor

Abstract

A high-efficiency method for producing metal from metal oxide by carbothermic reduction includes step in which a holed cake is provided, which has a composition comprising a metal oxide, a carbonaceous reducing agent, and a binder, and the holed cake has a plurality of holes. The method continues with step in which the holed cake is placed in a high-temperature furnace for carbothermic reduction, to reduce the metal oxide in the holed cake into a metal.

What is claimed is: 
     
         1 . A method for producing metal from metal oxide by carbothermic reduction, comprising:
 providing a holed cake having a composition comprising a metal oxide, a carbonaceous reducing agent, and a binder, and the holed cake having a plurality of holes; and   placing the holed cake in a high-temperature furnace for carbothermic reduction, to reduce the metal oxide in the holed cake into a metal.   
     
     
         2 . The method of  claim 1 , wherein the holed cake is prepared by the following steps: the metal oxide, the carbonaceous reducing agent and the binder are uniformly mixed to form a mixture; and then the mixture is disposed in a mold to form the holed cake. 
     
     
         3 . The method of  claim 1 , wherein the content of the metal oxide is 70 to 90 wt % inclusive. 
     
     
         4 . The method of  claim 1 , wherein the content of the carbonaceous reducing agent is 10 to 30 wt % inclusive. 
     
     
         5 . The method of  claim 1 , wherein the binder is added in an amount of 0.1 to 6% based on the total weight of the metal oxide and the carbonaceous reducing agent. 
     
     
         6 . The method of  claim 1 , wherein the metal oxide is iron oxide, nickel oxide, copper oxide, lead oxide, manganese oxide, tin oxide, potassium oxide, sodium oxide, zinc oxide, or a combination of at least two of the foregoing. 
     
     
         7 . The method of  claim 1 , wherein the carbonaceous reducing agent is carbon black, activated carbon, coal, coke, graphite, charcoal, or a combination of at least two of the foregoing. 
     
     
         8 . The method of  claim 1 , wherein each of the holes has a center, and a distance exists between the centers of two adjacent holes. 
     
     
         9 . The method of  claim 8 , wherein a to-be-reduced material portion is between two adjacent holes, the to-be-reduced material portion has a thickness, and the thickness of the to-be-reduced material portion is less than the distance. 
     
     
         10 . The method of  claim 1 , wherein a reaction temperature of the carbothermic reduction is 900 to 1600° C. inclusive. 
     
     
         11 . The method of  claim 1 , wherein a reaction time of the carbothermic reduction is 30 to 80 min inclusive. 
     
     
         12 . A holed cake has a composition comprising a metal oxide, a carbonaceous reducing agent, and a binder, and the holed cake has a plurality of holes. 
     
     
         13 . The holed cake of  claim 12 , wherein the content of the metal oxide is 70 to 90 wt % inclusive. 
     
     
         14 . The holed cake of  claim 12 , wherein the content of the carbonaceous reducing agent is 10 to 30 wt % inclusive. 
     
     
         15 . The holed cake of  claim 12 , wherein the binder is added in an amount of 0.1 to 6% based on the total weight of the metal oxide and the carbonaceous reducing agent. 
     
     
         16 . The holed cake of  claim 12 , wherein the metal oxide is iron oxide, nickel oxide, copper oxide, lead oxide, manganese oxide, tin oxide, potassium oxide, sodium oxide, zinc oxide, or a combination of at least two of the foregoing. 
     
     
         17 . The holed cake of  claim 12 , wherein the carbonaceous reducing agent is carbon black, activated carbon, coal, coke, graphite, charcoal, or a combination of at least two of the foregoing.