Abstract: The present invention is directed to a method of manufacture of metal or alloy powders that uses liquid phase reduction of a metal halide, or a mixture of metal halides, to produce a metal particle coated in salts produced as a reaction byproduct. The reaction conditions can be chosen to select a range of metal particle sizes, and the salt coating prevents oxidation (or reaction with other atmospheric gases) and permits a range of applications hitherto difficult to achieve using metal powders.

Abstract: The invention relates to a process for producing sinterable molybdenum metal powder in a moving bed, sinterable molybdenum powder and its use.

Abstract: A low-temperature process of producing high-purity iron powder by feeding hematite and a reducing agent into a rotary reactor under pressure to form a mechanical fluid bed. The fluid bed is rotated at a particular speed within a rotary reactor. The fluid bed is simultaneously heated to a reaction temperature, and the pressure is then reduced within the rotary reactor to a pressure in a range of 0.01 bars to 2.0 bars, as a result reducing the reaction temperature to a temperature in a range of 600° C. to 850° C. Maintaining the pressure and the rotation results in the formation of a high-purity iron oxide without the requirement for post-grinding process steps because sintering is prevented by using a combination of pressure reduction and a rotary set at an optimum rotation speed, resulting in useful additives produced by a more environmentally-friendly process.

Abstract: A method for production of titanium particles or other metal of interest by a metallothermic reduction reaction of TiCl4 or other metal chloride in a reaction zone which comprises conducting the reaction in a fluidized bed reaction zone, and recycling particles to the reaction zone to build up particle size.

Abstract: A method of recovering silver from a silver chloride mixture in which hydrogen gas is passed through the mixture to produce a metal chloride hydride which is then heated to dissociate the metal and to release hydrogen chloride gas.

Abstract: This invention relates to a method for producing titanium by reaction of titanium tetrachloride with magnesium in a reactor, wherein the temperature in the reactor is above the melting point of magnesium and below the melting point of magnesium chloride, wherein the reaction results in formation of particles comprising titanium, and wherein the particles are removed from the reactor and processed in order to recover the titanium.

Abstract: This invention discloses a method of making an oxygen scavenging particle comprised of an activating component and an oxidizable component wherein one component is deposited upon the other component from a vapor phase and is particularly useful when the activating component is a protic solvent hydrolysable halogen compound and the oxygen scavenging particle is a reduced metal.

Abstract: An efficient oxygen scavenging composition for use in film forming polymers is disclosed wherein the oxygen scavenging composition comprises an oxidizable metal particle, such as elemental iron; a water hydrolysable Lewis acid, such as aluminum chloride; and an acidifying electrolyte such as sodium or potassium bisulfate.

Abstract: This invention relates to a method for purifying metal alloy and intermetallic powders. Particularly, the present invention relates to a method for the reduction or elimination of the content of the dissolved oxygen and to remove the metal oxide inclusions from metal alloy and intermetallic powders including the steps of: a) placing the metal in powder form into a reaction apparatus; b) introducing a suitable carrier substance to the metal powder; and c) introducing calcium vapour into the reaction apparatus to create a reaction between the metallic powder and calcium vapour thereby removing inclusions in the metal as shown in FIG. 11.

Abstract: The present invention relates to a process for producing metal oxide from metal compounds, in particular metal hydroxide or metal carbonate, in which the metal compound is conveyed into a reactor (25) with fluidized bed, heated there to a temperature of 650 15 to 1150° C. by combustion of fuel, and metal oxide is generated, as well as to a corresponding plant. To improve the utilization of energy, it is proposed to introduce a first gas or gas mixture from below through a gas supply tube (26) into a mixing chamber (20) of the reactor (25), the gas supply tube (26) being at least partly surrounded by a stationary annular fluidized bed (27) which is fluidized by supplying fluidizing gas, and 20 to adjust the gas velocities of the first gas or gas mixture and of the fluidizing gas for the annular fluidized bed (27) such that the Particle-Froude numbers in the gas supply tube (26) lie between 1 and 100, in the annular fluidized bed (27) between 0.02 and 2, and in the mixing chamber (20) between 0.3 and 30.

Abstract: This invention discloses a method of making an oxygen scavenging particle comprised of an activating component and an oxidizable component wherein one component is deposited upon the other component from a vapour phase and is particularly useful when the activating component is a protic solvent hydrolysable halogen compound and the oxygen scavenging particle is a reduced metal.

Abstract: A method of producing a refractory metal powder that includes providing a metal powder containing magnesium tantalate or magnesium niobate; and heating the powder in an inert atmosphere in the presence of magnesium, calcium and/or aluminum to a temperature sufficient to remove magnesium tantalate or magnesium niobate from the powder and/or heating the powder under vacuum to a temperature sufficient to remove magnesium tantalate or magnesium niobate from the powder, the heating steps being performed in any order. The metal powder can be formed into pellets at an appropriate sintering temperature, which can be formed into electrolytic capacitors.

Abstract: The present invention relates to a process for the production of an elemental material, comprising the step of reacting a halide of the elemental material with a reducing agent in solid form in a fluidized bed reactor at a reaction temperature which is below the melting temperature of the reducing agent. In a preferred embodiment of the present invention, the elemental material is titanium and the titanium is produced in powder form. The invention also relates to the production of alloys or intermetallics of the elemental materials.

Abstract: The present invention relates to a process for the production of an elemental material, comprising the step of reacting a halide of the elemental material with a reducing agent in solid form in a fluidized bed reactor at a reaction temperature which is below the melting temperature of the reducing agent. In a preferred embodiment of the present invention, the elemental material is titanium and the titanium is produced in powder form. The invention also relates to the production of alloys or intermetallics of the elemental materials.

Abstract: Apparatus and method for producing metallic flake having an environmental coating for use in oxidative and corrosive atmospheres. Fluidized bed techniques are utilized to perform a controlled oxidation of metallic particles that include aluminum. The fluidized techniques permit the formation of a thin, outer shell of alumina over the outer surface of the flake. Because the oxidation is controlled so that the selective oxidation produces a thin outer shell, the particle has good reflectance and the metallic core of the particle is unaffected by the oxidizing treatment. Although the techniques of the present invention are effective for producing a reflective surface on aluminum-containing iron alloys while the core particles can be either magnetically soft or hard, the techniques can be used to produce a reflective surface that is corrosion and oxidation resistant on any aluminum containing alloy. Apparatus that facilitates the controlled oxidation is also set forth.

Abstract: A process of producing granules of a reactive metal. The process comprises providing a source of molten reactive metal (41), forming discrete droplets (53) of the molten metal, contacting the droplets while still substantially molten with a fluidized bed of particles (12) maintained at a temperature substantially below the solidus temperature of the metal and freezing the droplets as discrete granules of the reactive metal in the fluidized bed. The invention also provides apparatus for carrying out the method and product produces by the method, including a magnesium-containing additive for aluminum alloying. The use of a fluidized bed for cooling and freezing the droplets avoids problems encountered in prior methods and also makes it possible to provide coatings of various kinds on the surfaces of the granules, if desired.

Abstract: Apparatus (1) and process for treating particulate material or powder (33) of a size capable of being fluidized in a retort (31) mounted for rotation on a pair of end axles (18, 41). Retort (31) is mounted on a tilt frame (5) for tilting movement in a vertical plane. Gas conduits (18A, 18B) are mounted within an axle (18) for the supply and exhaust of gas for retort (31). A conduit (55) mounted within the other axle (41) permits particulate material to be passed into or out of the retort (31) as shown in FIG. 1B. A removable injection assembly (90, FIG. 10) is utilized for the injection of additional particulate material. A removable sampling assembly (95, FIG. 11) is utilized for removing a sample of the particulate material from the retort (31). As the retort (31) is rotated, particles of the particulate material are constantly intermingled with each other and the walls of the retort (31).

Abstract: A process for making silver metal particles from silver salt particles having the same morphology. Precursor silver salt particles selected from the group consisting of silver acetate and silver sulfide having a selected morphology are contained in a reactor vessel having means for supporting the particles in an air suspension to prevent the agglomeration of the particles. Air is flowed through the reactor vessel at a flow rate sufficient to suspend the particles in the reactor vessel. The suspended precursor silver salt particles are heated to a processing temperature and at a heating rate below which the physical deterioration of the suspended precursor silver salt particles takes place. The suspended precursor silver salt particles are maintained at the processing temperature for a period of time sufficient to convert the particles into silver metal particles having the same morphology as the precursor silver salt particles.

Abstract: A process of producing granules of a reactive metal. The process comprises providing a source of molten reactive metal, forming discrete droplets of the molten metal, contacting the droplets while still substantially molten with a fluidized bed of particles maintained at a temperature substantially below the solidus temperature of the metal and freezing the droplets as discrete granules of the reactive metal in the fluidized bed. The invention also provides apparatus for carrying out the method and product produced by the method, including a magnesium-containing additive for aluminum alloying. The use of a fluidized bed for cooling and freezing the droplets avoids problems encountered in prior methods and also makes it possible to provide coatings of various kinds on the surfaces of the granules, if desired.

Abstract: A process is described for the production of composite powders with ultrafine microstructures. The process involves three coordinated steps:1) preparation and mixing of an appropriate starting solution;2) spray drying to form a chemically homogeneous precursor powder; and3) fluid bed thermochemical conversion of the precursor into the desired nanophase composite powder.Both spray drying and fluid bed conversion are scaleable technologies, and together provide the means for producing bulk quantities of nanophase composite powders at low manufacturing cost. Processing parameters are controlled to ensure maintenance of chemical and microstructural uniformity at the nanoscale (less than 0.1 micron) level.Spray conversion processing is a versatile technology, which can be applied to a variety of metal--metal (e.g. W--Cu), ceramic-metal (e.g. WC--Co), and ceramic--ceramic (e.g. Al.sub.2 O.sub.3 --SiO.sub.2) nanophase composite powders ceramic-metal (e.g. WC--Co), and ceramic--ceramic (e.g. Al.sub.2 O.sub.3 --SiO.

Abstract: A new carbothermic reaction process is described for the thermochemical processing of nanophase WC-Co powders. The process permits shorter reaction times, reduced temperatures, and finer microstructures compared to conventional processing methods.The process builds on our experience with spray conversion processing but involves 1) chemical vapor infiltration reaction of the carbon infiltrant using a carbon source gas at a carbon activity greater than or equal to 1.0 with the particle substrate to form WC-CO; and 2) removal of any excess (unreacted) carbon by controlled gasification using a gas with carbon activity less than 1.0. A feature of the carbothermic reaction process is its adaptability to conventional WC-Co processing technology, as well as to spray conversion processing technology.The resulting power particles consist of a network of fine grains, (less than 100 nm) of WC and Co with interconnected fine porosity.

Abstract: A low temperature process is described for forming a coating or powder comprising one or more metals or metal compounds by first reacting one or more metal reactants with a halide-containing reactant to form one or more reactive intermediates capable of reacting, disproportionating, or decomposing to form a coating or powder comprising the one or more metal reactants. When one or more metal compounds are formed, either as powders or as coatings, a third reactant may be injected into a second reaction zone in the reactor to contact the one or more reactive intermediates formed in the first reaction zone to thereby form one or more metal compounds such as metal nitrides, carbides, oxides, borides, or mixtures of same.

Abstract: Tungsten metal powder of controlled particle sizes is obtained in a fluid bed process by reducing particles of tungsten oxide having the formula WO.sub.X where x is from 2.5 to 3.0. The WO.sub.X powder particles are heated to and then maintained at a temperature between 650.degree. and 1000.degree. C. in a reducing atmosphere, which is maintained by passing a mixture of hydrogen gas, water and optionally nitrogen gas through a fluid bed of the tungsten oxide particles until substantially all of the powder solid is tungsten dioxide, WO.sub.2. The ratio of water partial pressure to hydrogen partial pressure in the feed gas is equal to or slightly higher than the equilibrium partial pressure ratio. The flow of water vapor is then discontinued, either gradually or instantaneously, while maintianing the flow of hydrogen gas to reduce the WO.sub.2 to tungsten metal. By maintaining the ratio of water partial pressure to hydrogen partial pressure above the equilibrium value until the original WO.sub.