Abstract: A process for producing phosphorus pentoxide from phosphate ore includes the steps of mixing phosphate ore containing silica with solid carbonaceous material and a silica fluxing agent to form a feed mixture and thereafter forming the feed mixture into pellets. Alternatively, pellets may be formed using phosphate ore containing silica and carbonaceous material which are then coated with a silica fluxing agent. The pellets are heated by exposure to radiation eminating from an oxidation zone within a kiln to a temperature enabling the silica fluxing agent to promote melting of the silica proximate to surface areas of the pellet in order to seal internal portions of the pellet from the oxidizing zone and thereby reduce premature oxidation of the carbonaceous material in the pellet. Thereafter the pellets are heated to a temperature sufficient to reduce the phosphate in the pellets by reaction with the solid carbonaceous material to form elemental phosphorus vapor.

Abstract: The instant invention relates to a process for the preparation of titanium metal from an ore comprising titanium oxides which process comprises the steps of fluorinating the ore to convert the titanium oxides to titanium fluorides and then reducing the titanium fluorides to the metal. Such reduction may be carried out by contacting the titanium fluorides as a molten salt mixture with a molten alloy of zinc and aluminum at conditions whereby titanium is converted into a titanium-zinc alloy and the aluminum is converted into fluorides of aluminum. The titanium zinc alloy is separated from the fluorides of aluminum and the zinc is distilled from the alloy to leave behind titanium sponge. The ore may be an ilmenite ore and the fluorination may be carried out by contacting said ilmenite ore with a fluosilicate salt such as sodium fluosilicate.

Abstract: A process for producing phosphorus pentoxide from phosphorus ore includes formation of a feed with a phosphate ore, silica and solid carbonaceous material in amounts to produce a feed mixture having a CaO/SiO.sub.2 mole ratio of less than about 0.5. The feed mixture is formed into agglomerated feed particles and the particles are heated by exposure to radiation eminating from an oxidation zone to a temperature sufficient to reduce the phosphate by reaction from the solid carbonaceous material to form elemental phosphorus vapor without substantial melting of the agglomerated feed particles. Sufficient oxygen-containing gas is provided to cause oxidation of the elemental phosphorus vapor within the oxidation zone to produce phosphorus pentoxide.

Abstract: Method and apparatus for introducing finely divided gas bubbles into a lixiviant used for in-situ mining of minerals containing metal values, such as copper values. The lixiviant is supplied to a plurality of porous tubes formed of sintered powdered metal while a gas is supplied under pressure about the tubes to cause the gas to penetrate into the interior of the tubes in the form of fine bubbles which are wiped from the interior of the tubes by the lixiviant passing therethrough.The method and apparatus can be advantageously employed in situations where it is desirable to perform in-situ mining with an oxidizing lixiviant. In these cases oxygen is supplied under pressure about the tubes.

Abstract: The instant invention relates to a process for the preparation of titanium dioxide from an ore comprising titanium oxides which comprises the steps of fluorinating said ore to convert the titanium oxides to titanium fluorides; and, contacting said titanium fluorides with an alkaline material at conditions whereby said titanium fluorides are converted to titanium dioxide. The ore may be an ilmenite ore and the fluorination may be carried out by contacting said ilmenite ore with a fluosilicate salt as sodium fluosilicate.

Abstract: A process for producing phosphorus pentoxide from phosphate ores in a rotary-type kiln includes heating, by exposure to a flame, a porous bed comprising phosphate ore and solid carbonaceous material to a temperature sufficient to reduce the phosphorus pentoxide to phosphorus vapor. The phosphorus vapor is oxidized in an oxidation zone disposed over the porous bed to heat the porous bed. An inert gas is used to purge the porous bed of carbon monoxide formed during the reduction reaction to drive the reduction reaction more rapidly toward complete reduction of the phosphorus pentoxide and to inhibit oxidation of the phosphorus vapor and carbonaceous material within the porous bed.

Abstract: A process for reducing phosphate ore includes beneficiating phosphate ore to reduce alumina impurities while allowing fluoride impurities to remain in the beneficiated ore, mixing beneficiated ore with solid carbonaceous material to form a porous bed of agglomerated feed and heating the porous bed in a rotary-type kiln to produce elemental phosphorus and carbon monoxide. The elemental phosphorus may be burned within the kiln to provide heat to the porous bed and an inert gas may be purged through the porous bed to drive the reaction between the phosphate ore and the solid carbonaceous material towards complete reduction of the phosphate ore by removal of carbon monoxide from the porous bed.

Abstract: The instant invention relates to a method for making magnesium metal by reducing a magnesium metal precursor in an electrochemical cell wherein the cathode is a molten silicon alloy. Magnesium metal is formed at the interface of the silicon alloy and the magnesium metal precursor (or the molten salt if the magnesium metal precursor is suspended as finely divided particles in a molten salt) and subsequently combines with said silicon alloy. The silicon alloy containing combined magnesium metal is removed from said cell to a magnesium metal removal zone wherein an inert gas is passed through the alloy at a temperature and pressure sufficient to remove the magnesium metal as a vapor overhead. The magnesium metal is recovered and the silicon alloy, depleted in magnesium, is returned to the cell for further use as a cathode.

Abstract: Disclosed is a method of economically exploiting deep set porphyry ore bodies of the type containing metal values such as sulfidic copper nickel or uranium minerals and minerals capable of absorbing copper, uranium and nickel ions. The method involves establishing communication with the ore body through access and recovery wells and passing fluids sequentially therethrough. If necessary, thief zones of as low as 25 to 50 md in igneous rock of 1 to 5 md are prevented from distorting flow, by the injection of a polymeric solution of macromolecules with molecular weights of the order of 5 million along the entire wellbore, the higher permeability zones initially accepting the majority of the flow and being impaired at a much faster rate than the less permeable zones.

Abstract: A fragmented permeable mass of formation particles containing oil shale and carbonates of calcium and magnesium is formed in an in situ oil shale retort. A combustion zone is advanced through the fragmented mass, whereby kerogen in oil shale in the fragmented mass is decomposed in a retorting zone on the advancing side of the combustion zone to produce gaseous and liquid products including shale oil. The combustion zone also converts the magnesium values in the particles of retorted oil shale to a more leachable form such as magnesium oxide. Magnesium values are selectively leached from the combusted particles, with respect to calcium compounds, with an aqueous solution of a purgeable, acid-forming gas such as carbon dioxide and a minor amount of a polyelectrolyte such as polyacrylic acid, polysulfonic acid, polyphosphonic acid, or the salts thereof. An enriched solution containing magnesium values is withdrawn from the fragmented mass and magnesia is recovered from such enriched solution.

Abstract: A fragmented permeable mass of formation particles containing oil shale and carbonates of calcium and magnesium is formed in an in situ oil shale retort. A combustion zone is advanced through the fragmented mass, whereby kerogen in oil shale in the fragmented mass is decomposed in a retorting zone on the advancing side of the combustion zone to produce gaseous and liquid products including shale oil, and particles containing retorted oil shale are combusted for converting magnesium values to more leachable form such as magnesium oxide. Magnesium values are leached from the combusted particles selectively with respect to calcium compounds and silicates with aqueous solutions of a purgeable, acid-forming gas such as carbon dioxide or sulfur dioxide. An enriched solution containing magnesium values is withdrawn from the fragmented mass and magnesia is recovered from such enriched solution.

Abstract: An environmentally compatible, industrially safe, and potentially economic means for recovering copper and/or nickel from deep-seated deposits without resorting to extensive underground development. A two-phase ammoniacal leach solution containing oxygen bubbles is forced under high pressure through an injection hole several thousand feet deep into a leaching interval of a deep lying deposit containing copper or nickel or copper and nickel. The two-phase leach solution travels through the leaching interval of the deep lying deposit and is pumped out of withdrawal holes spaced apart from the injection hole.The two-phase leach solution under high pressure (more than 500 psi) penetrates the deposit through cracks, fissures and fractures, leaching copper and/or nickel along the way. Under a controlled pressure gradient, the leaching solution migrates over a period of time to receiving holes from which the pregnant leaching solution is withdrawn.

Abstract: A process is disclosed for in-situ mining of copper from a subterranean ore body characterized, at least in part, by the presence of a sulfidic ore and by natural, microscopic fracture openings. The process comprises forcing a stable, two-phase lixiviant comprising an aqueous phase, a multiplicity of gaseous, oxygen-containing bubbles having a size sufficient to pass through the natural fracture openings in the ore body, and a surfactant for enhancing the formation of the bubbles and for minimizing bubble coalescence through the ore body to leach copper.The aqueous and gaseous phases of the lixiviant are mixed at the surface and injected into the leaching interval through an injection hole, or preferably, are mixed in a subterranean sparger within the hole above the leaching interval. The pregnant liquor is recovered through one or more production holes and, after the copper is recovered, the lixiviant may be reconstituted and recirculated.