Molten Metal Reactors and Processes

Abstract

A molten metal reactor comprising at least the following components a) through c): a) a reactor vessel comprising a molten metal bath, b) an injection assembly, and c) a product removal assembly.

1 . A molten metal reactor comprising at least the following components a) through c):
 a) a reactor vessel comprising a molten metal bath,   b) an injection assembly, and   c) a product removal assembly.   
     
     
         2 . The molten metal reactor of  claim 1 , wherein the reactor further comprises a partition located within the reactor vessel. 
     
     
         3 . The molten metal reactor of  claim 1 , wherein the reactor further comprises ≥1 plug unit(s). 
     
     
         4 . The molten metal reactor of  claim 3 , wherein each plug unit is used to seal in a positive pressure, inert gas purge, to reduce the amount of oxygen that can leak into the reactor. 
     
     
         5 . The molten metal reactor of  claim 3 , wherein each plug unit is removable. 
     
     
         6 . The molten metal reactor of  claim 3 , wherein the bottom surface of each plug unit is inserted into the molten metal bath. 
     
     
         7 . The molten metal reactor of  claim 3 , wherein each plug unit is over an open surface of the reactor vessel when the reactor is in operation. 
     
     
         8 . The molten metal reactor of  claim 1  wherein the injection assembly is located on a plug unit. 
     
     
         9 . The molten metal reactor of  claim 1 , wherein the injection assembly comprises ≥1 injection device(s). 
     
     
         10 . The molten metal reactor of  claim 9 , wherein at least one injection device is used to inject at least one carbon source into the molten metal bath. 
     
     
         11 . The molten metal reactor of  claim 10 , wherein the at least one carbon source is at least one hydrocarbon. 
     
     
         12 . The molten metal reactor of  claim 9 , wherein at least one injection device is used to inject at least one inert gas into the molten metal bath. 
     
     
         13 . The molten metal reactor of  claim 12 , wherein the at least one inert gas is argon. 
     
     
         14 . The molten metal reactor of  claim 9 , wherein a portion of each injection device is inserted beneath the surface of the molten metal bath, at an angle relative to the base surface of a plug unit. 
     
     
         15 . The molten metal reactor of  claim 14 , wherein the angle is from 35 degrees to 60 degrees, relative to the base surface of the plug unit. 
     
     
         16 . The molten metal reactor of  claim 1 , wherein the molten metal of the molten metal bath comprises aluminum (Al), magnesium (Mg), lithium (Li), or any combination thereof. 
     
     
         17 . The molten metal reactor of  claim 1 , wherein the molten metal of the molten metal bath comprises aluminum (Al), magnesium (Mg) or any combination thereof. 
     
     
         18 . The molten metal reactor of  claim 1 , wherein the molten metal of the molten metal bath comprises aluminum (Al). 
     
     
         19 . The molten metal reactor of  claim 1 , wherein the reactor comprises a closed-circuit recirculating system. 
     
     
         20 . The molten metal reactor of  claim 1 , wherein the reactor further comprises from 1 to 25 electric resistance heaters. 
     
     
         21 . The molten metal reactor of  claim 20 , wherein the heating element of each heater is inserted vertically into the molten bath. 
     
     
         22 . The molten metal reactor of  claim 20 , wherein the electrical power generated by each heater is dissipated as heat into the molten metal bath.