Abstract: A method for preparing zircon powder, which comprises mixing (1) silica sol and (2) an aqueous zirconium oxychloride solution having a concentration which would be from 0.1 to 2 mols/l after mixed with the silica sol, in a SiO.sub.2 /ZrO.sub.2 molar ratio of from 0.95 to 1.10, heating the mixture to hydrolyze the zirconium oxychloride, followed by dehydration treatment to obtain a powder, heating the powder from room temperature to a calcination temperature over a period of from 0.7 to 30 hours and calcining the powder at a temperature of from 1,200.degree. to 1,400.degree. C. for a period of time satisfying the relation of:t.gtoreq.116-0.08Twhere t is the calcination time (hr) and T is the calcination temperature (.degree.C.), or heating the powder from room temperature to a calcination temperature over a period of from 0.8 to 70 hours and calcining the powder at a temperature higher than 1,400.degree. C. and not higher than 1,700.degree. C. for a period of time satisfying the relation of:t.gtoreq.18-0.

Abstract: The application relates to a process for the preparation of low-chloride aqueous solutions of titanyl nitrate which have a chloride content of less than 200 ppm by treatment with nitric acid and excess nitric acid and/or hydrogen peroxide.

Abstract: The thermal neutron capture cross-section of zirconium may be altered by altering its natural isotope distribution through a steady state chromatographic separation of these isotopes using an anion exchange resin as the stationary phase of the chromatographic column. Zirconium is dissolved in a very strong acid which causes the formation of a zirconium anion, such as the ZrOCl.sub.4.sup.-2 anion formed in six normal hydrochloric acid, and eluted off the column with a weaker acid. Distinct elution volumes representative of each isotope are collected. In a preferred embodiment, the process also separates the zirconium from hafnium and the other impurities normally present in the product obtained by chlorinating zircon sand and utilizes a continuous annular chromatograph.

Abstract: An improved halogenator process and system is provided which significantly and economically decreases the level of impurities in the processing of various refractory metals and their halides and particularly hafnium tetrachloride which is condensed from gases produced by the chlorination of Zircon.

Abstract: Process for the manufacture of a powder of mixed metal oxides by cohydrolysis of metal alcoholates in the presence of an acidic organic compound and mixed metal oxide powders in which the molar relationships R1 and R2 of a metal oxide to the sum of the metal oxides in the powder and in a particle of the powder are such that ##EQU1## The process applies especially well to powders of zirconia doped with yttrium oxide or other oxides.

Abstract: The isotopes of zirconium can be partially or completely separated by loading an aqueous solution of an ionic compound of zirconium onto a cationic exchange resin which serves as the stationary phase of a chromatograph, eluting the compound with an aqueous acid and collecting distinct elution volumes representative of each isotope. In a preferred embodiment, the eluant is a strong mineral acid, such as hydrochloric acid and the chromatograph is of a type, such as a continuous annular chromatograph that it can be operated in a continuous, steady state manner.

Abstract: Process for purifying TiO.sub.2 ore consisting essentially of subjecting the ore to two or more leaching treatments, said leaching treatments alternating between use of an aqueous solution of a mineral acid and an aqueous solution of an alkali metal compound selected from the group consisting essentially of alkali metal carbonates, hydroxides or mixtures thereof.

Abstract: A preparation method for zircon powder, which comprises heating a feed powder mixture comprising:(1) silica and zirconia obtained by subjecting a liquid having a pH of not higher than 8 and containing silica and zirconia in a SiO.sub.2 /ZrO.sub.2 molar ratio of substantially 1/1, to liquid-removing treatment, and(2) zircon in an amount of at least 0.1% by weight based on the total amount of said silica and zirconia,at a heating rate of not higher than 5.degree. C./min from 1,200.degree. C. to a calcination temperature, and maintaining it at a calcination temperature of from 1,300.degree. to 1,700.degree. C. for from 1.0 to 24 hours.

Abstract: The isotopes of zirconium can be partially or completely separated by loading an essentially anhydrous alcoholic solution of an ionic compound of zirconium onto a cationic exchange resin with pentavalent phosphorus derived active groups which serves as the stationary phase of a chromatograph, eluting the compound with an essentially anhydrous alcoholic solution of hydrogen chloride and collecting distinct elution volumes representative of each isotope. In a preferred embodiment, the active groups of the cation exchange resin are derived from di-2-ethylhexyl phosphoric acid, tri-n-octyl phosphine oxide or tributyl phosphate and the chromatograph is of a type, such as a continuous annular chromatograph that it can be operated in a continuous steady state manner.

Abstract: A synthetic rutile is prepared from a titaniferous slag, typically containing at least about 1.0 weight percent magnesium oxide and at least some portion of its titanium values as Ti.sub.2 O.sub.3, by a method comprising contacting the slag with chlorine gas at a temperature between about 400.degree. C.-800.degree. C., such that the magnesium oxide and chlorine gas react to form magnesium chloride, and then removing the magnesium chloride from the slag, typically by washing the slag with water. In one embodiment, the synthetic rutile can be further upgraded by subjecting it to either a caustic or acid leaching treatment.

Abstract: A ZrO.sub.2 powder of very fine particle size adapted especially for the making of high density ceramics is produced by chlorinating a zirconium source material, such as zircon sand, to produce crude ZrCl.sub.4 solids; the solids are dissolved to form a ZrOCl.sub.2 solution from which ZrOCl.sub.2 crystals are precipitated; the crystals are dried and milled to a desired particle size; and the crystal particles are subjected to direct oxidation under controlled conditions to produce a very fine ZrO.sub.2 powder especially adapted to the making of high density ceramics.

Abstract: Compositions comprising carbon-based supports and containing heteropolycyclic compounds such as bipyridyl, phenanthroline or derivatives thereof are used in separation of dissolved late transition metals such as Fe, Co, Ni and Cu from solutions, in particular when such solutions contain high concentrations of other dissolved metals such as Zr, Hf, La, Al and Ba. Such compositions are also used to separate late transition metals such as Pt group metals from each other.

Abstract: There is disclosed a process and an apparatus for beneficiating a mineral ore, such as phosphate-containing ore, in a substantially vertical column. The feed subjected to the benefication preferably has a particle size of less than 20 mesh. The feed is introduced into the column, containing at least one baffle, into which there is also introduced a gas at the bottom portion thereof and a liquid through at least one column inlet at the top of the column. The baffle and the rates of introduction of the feed, the gas, and the liquid are such as to create relatively high turbulence conditions within the column. The enriched, beneficiated product is removed at the top of the column, while the waste products, such as silica-containing material, in the case of a phosphate ore, are recovered at the bottom of the column.

Abstract: A process for the production of zirconium tetrachloride from dissociated zircon in which gaseous chlorine is passed through pellets consisting of ground dissociated zircon, carbon and a binder at a temperature in the range of from 450.degree. to 800.degree. C. The zirconium tetrachloride produced contains less than about 0.22% by weight, calculated as SiO.sub.2, of silicon tetrachloride.

Abstract: A method is provided of producing a self-supporting ceramic composite structure having one or more encasement members, such as an encasing steel sleeve, joined to it by growth of the ceramic material to engagement surface(s) of the encasement member(s). A parent metal is contacted with a body of filler which is encased by the encasement member(s). The resulting assembly is heated to melt and oxidize the parent metal, e.g., aluminum, to form a polycrystalline material comprising an oxidation reaction product which grows through the doby of filler and stops at the engagement surface(s) of the encasement member(s) which thereby determines the surface geometry of the grown ceramic matrix. Upon cooling, the encasement member(s) is shrink-fitted about the ceramic composite body. The invention also provides the resultant articles, for example, a ceramic composite body having a stainless steel member affixed thereto.

Abstract: A metal alcoholate is treated with a quantity of water such that the molar ratio of the quantity of water to the quantity of metal alcoholate is lower than the valency of the metal in the alcoholate.

Abstract: The beneficiation or upgrading of an iron-containing titaniferous ore to a synthetic rutile by subjecting the ore to reduction followed by acid leaching of the reduced ore is improved by forming a mixture of the ore and an aqueous sulfuric acid solution, adding a reducing agent to this mixture and then subjecting this mixture containing the reducing agent to reduction at elevated temperatures. The resulting reduced ore, which is characterized by an increase in the ferrous iron content thereof and an increase in its specific surface area, exhibits an enhanced response to subsequent acid leaching to provide a synthetic rutile of improved purity.

Abstract: The invention concerns a process for the production of metal Zr by means of molten Mg in a reactor (1) having a hearth plate (3), comprising separating the magnesium chloride formed in the reduction reaction from the metal Zr formed and the magnesium, then cooling, then extracting the sponge cake of metal Zr formed. The process is characterized by separating the magnesium chloride formed by tapping off towards the bottom of the reactor (1) by means of a chimney (6) whose bottom end portion (5) is fixed to an orifice (4) in the hearth plate (3) and whose transverse open top end (7) is above the portion of the metallic mass (Zr, Mg) which borders the chimney (6) at the end of the reduction reaction.The invention also concerns the corresponding apparatus for the production of metal zirconium.The invention provides a simplification in the operation of separating the MgCl.sub.

Abstract: A process for the production of high-purity zirconia from dissociated zircon or other zirconiferous material is disclosed. The process includes leaching of the zirconiferous material with concentrated sulphuric acid and continuously removing the water formed during leaching to maintain the concentration of sulphuric acid at a substantially constant level.

Abstract: Niobium (V) and tantalum (V) halides are converted to Nb.sub.2 O.sub.5 and Ta.sub.2 O.sub.5 that are free of detectable levels of halide in a two step process. In the first step, the metal halide is reacted with an alcohol and with a replacement species, such as ammonia, which reacts with the halide. This produces a metal alkoxide which is soluble and a halide salt of the replacement species which is insoluble in the alcohol and precipitates. After physically separating the alkoxide in alcohol solution from the precipitate, in a second step, the metal alkoxide is hydrolyzed with purified water to produce the oxide.

Abstract: This is a high quality zirconium or hafnium sponge, a fuel element cladding liner having material of the quality of this sponge and a process utilizing this quality sponge to fabricate liner material for lined fuel element cladding. The sponge contains 250-about 350 ppm of oxygen impurity, 50-300 ppm of iron impurity, and a total of 500-1,000 ppm of impurity. This material is much purer than conventional sponge and approaches the quality of crystal bar.

Abstract: Metal ions are reduced from a higher to a lower oxidation stage using ferrophosphorus as the reductant.

Abstract: This is a process for producing high quality zirconium or hafnium sponge. It is especially useful for producing the very high purity zirconium which may be used to line the inner surface zirconium of Zircaloy tubing for nuclear fuel rods. The process uses a combination reduction-distillation vessel which is directly fed with zirconium or hafnium tetrachloride from a molten salt sublimer. A precharge of magnesium chloride is used to prevent reduction of metal outside the inner liner, and thereby facilitate removal of the inner liner after reduction and distillation. The agitator for the molten salt sublimer preferably utilizes a molten metal seal around the agitator shaft.

Abstract: Ion exchange inorganic films made up of alpha-type or gamma-type layered structure insoluble acid salts of tetravalent metals or their salt forms, or their intercalated forms or their organic derivatives containing polar groups. A process for the preparation of said films.

Abstract: A coating comprising elemental silicon is electrodeposited on a substrate from an aqueous medium. The plating bath is a solution of what is described as one or more metal hydrides. The metal hydrides of the present invention are provided by combining stoichiometric amounts of metal, alkaline metal hydroxide and water in a preselected proportion by mole percent. The particular proportion is a function of the particular metal. A hydride concentrate is provided which is used in aqueous solution to provide a plating bath.

Abstract: The present invention provides novel amorphous phosphosilicates represented by the formulae Zr(PO.sub.4).sub.2y (SiO.sub.2).sub.z.n'H.sub.2 O (I) and M.sub.2/l Zr(PO.sub.4).sub.2y (SiO.sub.2).n'H.sub.2 O (III) and the processes for producing the same.

Abstract: Titanium and iron values are recovered from ores, concentrates and slags by effecting solid-state reduction and carburization to form titanium carbide and carburized iron, separation of the carburized iron, and low temperature chlorination of the titanium carbide to gaseous substantially pure titanium tetrachloride, which may be oxidized to pigmentary titanium dioxide.

Abstract: A process for producing titanium metal sponge within a closed cell system involving the electrical decomposition of molten magnesium chloride into magnesium metal and chlorine gas within a closed cell to form said magnesium metal as a molten layer upon said magnesium chloride; terminating said electrolytic decomposition, and subsequently; directly contacting titanium tetrachloride with said layer of magnesium metal for effecting a reduction reaction therebetween within the same closed cell to form titanium metal sponge and magnesium chloride and removing said titanium metal sponge from said closed cell. The chlorine gas by-product can be used to form titanium tetrachloride from a titanium ore/coke mixture.

Abstract: A process for recovering metallic values by putting the values into solution and separating undesired mineral matter from the solution using countercurrent flotation is provided. The process involves leaching metallic values from host rock, conditioning the resultant ore pulp with the required reagents to achieve selective flotation of mineral matter in the metallic values solution, introducing the conditioned ore pulp into flotation cells, along with counterflow of solution from an immediately subsequent flotation step, wherein simultaneous washing and flotation is achieved, and the mineral matter is removed leaving a solution of the metallic values. The resultant mineral matter froth product is subjected to subsequent stages of flotation and simultaneous washing with counterflow of solution removed from each subsequent stage of flotation, water and/or barren solution being used for washing in the final flotation stage.

Abstract: A process is described for reacting chlorinated hydrocarbons other than carbon tetrachloride with metal oxides so as to convert essentially all of the carbon atoms to oxides of carbon. This process provides an efficient and economical means for utilizing chlorinated hydrocarbons.

Abstract: Novel sequestering agents useful for the extraction of metal values and in various organic syntheses comprise a cross-linked organic polymeric substrate, said substrate having covalently coupled thereto a plurality of functional groups, the free valence of which having the structural formula: ##STR1## wherein R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.6 and R.sub.7, which are identical or different, each represents a hydrogen atom or an alkyl radical having 1 to 4 carbon atoms, R.sub.5 and R.sub.8, which are also identical or different, each represents a hydrogen atom, an alkyl or cycloalkyl radical having 1 to 12 carbon atoms, a phenyl radical, a --C.sub.g H.sub.2q --.phi. or C.sub.q H.sub.2+1 --.phi.-- radical, and further wherein q ranges from 1 to about 12, and n, m and p, which are also identical or different, range from 1 to 10, and .phi. is phenyl.

Abstract: Zircon, ZrSiO.sub.4, is retrieved from zircon sand comprised of ZrSiO.sub.4 crystals and contaminants including SiO.sub.2 and iron by comminuting an aqueous slurry of the sand with iron means exposing the contaminants, admixing the resulting comminuted sand slurry with concentrated nitric and hydrochloric acids producing ferric chloride in solution thereby removing its iron component, admixing the resulting suspension with a flocculating agent agglomerating the suspended particles, admixing the resulting agglomerated mass with concentrated hydrofluoric acid to dissolve its SiO.sub.2 component, recovering the resulting ZrSiO.sub.4, washing it with water and drying.

Abstract: In the process wherein a titanium-containing material is subjected to react with sulphuric acid to form a solid reaction mass from which the titanium values are recovered in solution by digestion with water or dilute sulphuric acid leaving behind a reaction residue and the reaction residue is thereafter treated to recover at least part of the titanium contained therein, the improvement wherein the treatment of the reaction residue is effected by contacting with sulphuric acid of a concentration greater than 86% a mixture by weight comprising about 5 to 95% of the reaction residue and 95 to 5% of a slag having a TiO.sub.2 content 60% by weight and a Ti(III) content of about 5 to 40% by weight, and thereafter eventually adding water, steam or dilute sulphuric acid to the mass to start the reaction.

Abstract: Significant enhancement of titanium dioxide recovery from a titaniferous ore is achieved by improving the efficiency of the comminution of the ore with the use of polyols of the formula:R--C--R'OH).sub.3wherein R is alkyl (C.sub.1 -C.sub.4), or hydroxyalkyl (C.sub.1 -C.sub.4) containing up to 3 hydroxy groups, and wherein R' is alkylene (C.sub.1 -C.sub.4).

Abstract: Process of extracting titanium values from titaniferous bearing material by circulating a reaction mixture containing titanium values in an agitation column located within a reaction vessel in a direction countercurrent to the flow of the reaction mixture in the annular space located between the agitation column and the inner reaction vessel wall, said circulation being done in a manner to maintain the titaniferous bearing material in a continuous turbulent suspension flow in the agitation column and discharging the reaction mixture from the reaction vessel and recovering the extracted titanium values.

Abstract: Metals in oxide, carbonate and/or hydroxide form in ores or ore concentrates are converted to the corresponding carbide by a solid state reaction with carbon. The carbide then is separated in substantially pure form from the gangue constituents and may be converted to the metal.

Abstract: To a coal-fired furnace that uses electrostatic precipitation or a mechanical collector to collect fly ash, a mix of magnesia-alumina or magnesia-talc is added above the fireball (2600.degree.-3300.degree. F.). The additive increases the mean particle size of the fly ash and reduces its surface resistivity, thereby causing improved collection in the electrostatic precipitators or mechanical collector. Fine particulates containing heavy metals tend to be agglomerated; thus the invention permits recovery of substantial amounts of heavy metal contaminants that would otherwise be lost as stack emission.

Abstract: Solid carbonaceous fossil fuels such as coal, lignite and peat are treated with an aqueous medium containing a novel catalyst to remove undesirable constituents and produce valuable products. The catalyst is prepared by steps including admixing a water soluble alkali metal silicate with an aqueous medium containing carefully controlled amounts of dissolved water soluble substances which are sources of calcium ion and magnesium ion, reacting the same to produce an aqueous colloidal suspension of the reaction product, admixing a micelle-forming surfactant with the aqueous medium, and agitating the aqueous medium containing the colloidal particles and surfactant to form catalyst-containing micelles. In one variant, particles of a fossil fuel containing metal values are treated with an aqueous medium in the presence of the catalyst, and thereafter the treated particles are separated from the aqueous medium and extracted with an aqueous leach solution in which the metal values are soluble.

Abstract: The titanium and zirconium-based minerals, present in the first stage centrifuge tailings from the hot water process for extraction of bitumen from bituminous sands, may be concentrated by a dry screening process. The tailings are burned off to provide a dry, essentially carbon-free, mineral mixture. By screening the mixture into three streams of different particle size range, silica and clays may be rejected as coarse and fine materials respectively, while titanium and zirconium minerals may be concentrated in the intermediate stream. The titanium and zirconium concentrate stream may be advanced to high tension and magnetic separation steps known in conventional processing of heavy minerals, for further beneficiation.

Abstract: Rutile, which has been obtained by precipitation from a hydrogen chloride solution will contain a relatively large amount of residual chlorine containing compounds such as the various forms of titanium chloride. These residual chlorine containing compounds may be removed in an economical way by treating the rutile with hydrogen peroxide in an acidic solution at relatively low temperatures to substantially reduce the chloride content of the product.

Abstract: A mass of fine particulates such as chlorinated by-products (often collected as "cyclone solids") from the chlorination of titaniferous material, said particulates comprising hydrolyzable metal halides, are converted to readily-handled granules by hydration and attendant agglomeration as heat and vapors evolve.

Abstract: Titanium metal values are recovered from a titanium bearing source such as an ilmenite ore by subjecting the source to a reductive roast and leaching the reduced source with a halogen-containing compound. Following this the soluble metal halides are separated from gangue and the pregnant leach liquor if treated with an iron oxide such as ferric oxide to precipitate titanium dioxide. The nucleation of the titanium dioxide may be improved by using a large excess of ferric oxide in the precipitation step. The improvement will thus result in an increased yield of the desired titanium dioxide.

Abstract: An oily mass of solids tailings is derived from flotation of bitumen during hot water extraction of bituminous sands, and subsequent separation of most of the bitumen from associated solids. This oily mass contains a high concentration of heavy minerals, in the order of 10% by weight titanium and 4% zirconium. The tailings are introduced into a hot reaction zone and contacted with oxygen while agitating the solids. The bitumen associated with the solids is burned, as is residual coke left from the combustion of the bitumen. The product particles are discrete, dry and clean. They can be slurried with water and passed through gravity concentrating means, such as a spiral, to produce a concentrate containing in the order of 18% titanium and 8% zirconium.

Abstract: An oily mass of solids tailings is derived from flotation of bitumen during hot water extraction of bituminous sands, and subsequent separation of most of the bitumen from associated solids. This oily mass contains a high concentration of heavy minerals, in the order of 10% by weight titanium and 4% zirconium. The tailings are introduced into a hot reaction zone and contacted with oxygen while agitating the solids. The bitumen associated with the solids is burned, as is residual coke left from the combustion of the bitumen. The product particles are discrete, dry and clean. They can be slurried with water and passed through gravity concentrating means, such as a spiral, to produce a concentrate containing in the order of 18% titanium and 8% zirconium.

Abstract: Titanium trichloride which is obtained during one step of a process for recovering titanium metal values from a titanium bearing source which still contains some impurities such as iron and vanadium compounds may be purified by drying the titanium compound in an air atmosphere, further drying under a carbon monoxide atmosphere and thereafter roasting the dried compound in the presence of chlorine at an elevated temperature to separate the impurities from the desired titanium compounds.

Abstract: A process for removing impurities from an oxide of titanium-bearing material such as a titania slag by treating the material with SO.sub.3 gas and subsequently leaching with a liquid. In particular a process for upgrading an ilmenite ore by preparing a titania slag therefrom and purifying the slag such that it may be used as a synthetic rutile suitable for use in a fluidized-bed chlorination reactor to produce titanium tetrachloride which can be reoxidized to TiO.sub.2.

Abstract: Ferric chloride from the selective chlorination of titaniferous material such as ilmenite is partially oxidized to obtain a chlorine-rich stream and byproduct iron oxide. Unreacted ferric chloride is separated as solid particles from said stream and at least a portion of said particles are returned to the chlorination operation for absorbing heat generated in such operation.

Abstract: This invention relates to a process for removing hydrogen chloride, chlorine, chlorides, oxychlorides and metal chlorides from a beneficiate produced by contacting a titaniferous ore with chlorine at high temperatures preferably in the presence of carbon wherein the beneficiate mixed with carbon is contacted at temperatures of about 1000.degree. C. with steam, moist air or moist inert gas. The beneficiate which is essentially titanium dioxide is useful as a starting material for the manufacture of titanium dioxide pigments.

Abstract: A method for separating niobium pentachloride and tantalum pentachloride contaminants from crude titanium chloride vehicle by addition of water to said vehicle to form substantially selectively solid hydration products of such contaminants which are readily separable.

Abstract: Minerals, for example, zirconium minerals, are subjected to a chemical process of comminution, in particular with the aid of strong acids. These acids dissolve the carbonatic and silicious cements which hold together the crystalline forms of different mineral species from one another, e.g., magnetic and non-magnetic species to render them amenable to further separation in a subsequent ore dressing stage, e.g., by high intensity magnetic separation. This process is operative as these cements dissolve in acid more readily than most of the other compounds of the ores. This separation was found to take place more effectively than by the usual methods of mechanical grinding and without the disadvantage of an unfavorable particle size distribution which results from grinding. It was found that the same process conditions also resulted in a particularly favorable removal of naturally occurring radioactive contaminants from the minerals, in particuar thorium and uranium.