Abstract: The invention provides a new method for casting alloys containing a finely divided phase. A bath of the molten metal having a melting point is provided. A finely divided solid metal having a melting point greater than the melting point of molten metal is introduced into the molten metal. The finely divided metal is reacted with the molten metal to form a solid phase within the molten metal. The molten bath is then mixed to distribute the solid phase within the molten metal. The molten alloy is then cast into a solid object containing the solid phase. The solid phase is insoluble in the matrix and has a size related to the initial size of the finely divided solid. The alloy of the invention advantageously consists essentially of, by weight percent, about 3 to 40 aluminum, about 0.8 to 25 nickel, about 0 to 12 copper and balance zinc and incidental impurities. The alloy has a zinc-containing matrix with nickel-containing aluminides distributed throughout the matrix.

Abstract: The invention provides a new method for casting alloys containing a finely divided phase. A bath of the molten metal having a melting point is provided. A finely divided solid metal having a melting point greater than the melting point of molten metal is introduced into the molten metal. The finely divided metal is reacted with the molten metal to form a solid phase within the molten metal. The molten bath is then mixed to distribute the solid phase within the molten metal. The molten alloy is then cast into a solid object containing the solid phase. The solid phase is insoluble in the matrix and has a size related to the initial size of the finely divided solid. The alloy of the invention advantageously consists essentially of, by weight percent, about 3 to 40 aluminum, about 0.8 to 25 nickel, about 0 to 12 copper and balance zinc and incidental impurities. The alloy has a zinc-containing matrix with nickel-containing aluminides distributed throughout the matrix.

Abstract: Manganiferous deep sea nodules containing non-ferrous metal values are selectively reduced to reduce manganic oxides to manganous oxide (MnO) and the non-ferrous metal values to the metallic state, and the selectively reduced nodules are then smelted to produce a molten metallic alloy containing the non-ferrous metal values and a slag containing most of the manganese. The molten alloy is blown with a free-oxygen-containing gas to eliminate most of the manganese, and the substantially manganese-free metal is then sulfided to produce a matte suitable for separation and recovery of the non-ferrous metal values. After sulfiding the matte can be blown with a free-oxygen-containing gas to lower the iron content thereof. Not all the iron is removed if it is advantageous to keep a high proportion of cobalt in the matte.

Abstract: Recovery, by thermal upgrading, of nickel values from nickeliferous lateritic ores containing a silicate fraction is improved by forming agglomerates of the ore, a reagent containing at least one member selected from the group consisting of alkali or alkaline earth metal compounds in a small but effective amount to increase nickel recovery from the silicate fraction and a liquid hydrocarbon in an amount between about 1 and 12%, based on the weight of the ore and heating a static, shallow bed of the agglomerates established on a moving bed to partially melt the agglomerates to reduce and coalesce the nickel values into easily recoverable ferronickel concentrate. The grade of the ferronickel concentrate can be increased by incorporating a sulfur-bearing material in the agglomerates.

Abstract: Base metal chlorides are recovered from fused alkali metal or alkaline earth metal halide salts by precipitation with at least one reagent selected from the group consisting of hydrogen, hydrogen sulfide or aluminum. Advantageously, the bulk of the base metals are precipitated by combinations of hydrogen sulfide and hydrogen to produce a precipitate having a controlled sulfur content that is molten at temperatures between about 750.degree. C. and 900.degree. C., and final salt cleaning is achieved by precipitating residual base metals with aluminum. The melting point of the precipitate is also controlled by the ratio of nickel to other base metals in the salt.

Abstract: Manganiferous oxide minerals, particularly sea nodules, containing at least one metal value selected from the group consisting of cobalt, copper, iron, molybdenum and nickel and a reductant are heated to a temperature above about 1100.degree.C. to selectively reduce the metal values to metal and only minor amounts of the manganese values to metal and to coalesce the reduced metal values. The coalesced metal values are recovered by techniques such as magnetic separation, flotation and tabling to produce a concentrate of the metal values.

Abstract: Nickel matte containing at least about 28% sulfur is refined with respect to arsenic, antimony or bismuth by contacting molten matte with gaseous chlorine to chlorinate and volatilize arsenic, antimony or bismuth from the nickel matte. Advantageously, the molten nickel matte is provided with a halide flux to minimize volatilization of any nickel chloride that is formed.