Abstract: A fluidized bed reactor (10) for chemically transforming reactants to generate a desired product, having a hollow, elongated, vertically oriented reactor housing (12) for confining the reaction and an unobstructed collection path (18) below the reaction zone for funneling the residue of the process to an exit port (32). A central gas inlet (22) proximate the bottom of the reaction zone within the housing directs gas parallel to the vertical axis of the housing to maintain the raw materials in suspension. A plurality of individually controlled peripheral gas jets (24) positioned at least two elevations along the elongated dimension of the reaction housing (12), and located circumferentially around the housing (12) at each elevation, introduce gas at an angle to promote mixing of the entrained materials in suspension. The clog-free collection path (18) below the reaction zone funnels the residue of the process to an exit port (32) where it is continuously removed by a screw feeder (34).

Abstract: A method and system for improved ion exchange chromatographic elemental separations of zirconium and hafnium elements and also, if desired, separations of the isotopes thereof from crude zirconium minerals by using improved crude aqueous zirconium (also containing hafnium) chloride feedstock solutions, aqueous chloride eluant solutions, cationic or anionic exchange resins, and reduced ion exchange chromatographic operating temperatures. The method and system of the invention provides improved crude aqueous zirconium chloride feedstock solutions by carbochlorinating zircon sand and hydrolyzing and dissolving the chlorination products under controlled conditions to substantially eliminate cross-polymerization of the carbochlorination products, which undesirably yield inseparable zirconium and hafnium co-polymers during hydrolysis, by inhibiting the hydrolysis exotherm and/or the free acid generation during hydrolysis.

Abstract: A method and system for improved continuous ion exchange chromatographic elemental separations of zirconium and hafnium and also for isotopic separations thereof from crude zirconium minerals by using zirconium (also containing hafnium) sulfate feedstock solutions, sulfate eluant solutions, anionic exchange resins, and reduced ion exchange column operating temperatures. The method and system of the invention provides sulfate feedstock solutions by completely converting the carbochlorination products of zircon sand to sulfate solutions prior to feeding to the ion exchange chromatographic column. The method and system of the invention is performed in a continuously operating continuous annular chromatograph (CAC). Nuclear grade substantially purified zirconium and hafnium metals are produced.

Abstract: Normally reject sponge metal fines, especially those produced by the crushing and screening of a regulus of zirconium and/or hafnium metal sponge, are added to the initial reduction charge of the metal tetrachloride and magnesium metal, and the so-modified charge is then passed through the conventional reduction and vacuum distillation steps to produce a regulus of the metal that has the reject fines incorporated therein by sintering.