METHODS FOR FORMING METAL-CONTAINING PARTICLES IN BARTON REACTORS AND FOR RETROFITTING BARTON REACTORS
According to one or more embodiments presently described, metal-containing particles may be formed by a method including forming a molten material from a solid supply material, introducing the molten material into a reaction zone of a Barton reactor, and contacting the molten material with a processing gas in the reaction zone to form solid metal-containing particles comprising solid metallic particles and solid metal oxide particles. The Barton reactor may include a reaction vessel which may include a top cover and sidewalls defining the reaction zone, an agitator, a processing gas inlet, and a product outlet. The molten material may be introduced to the reaction zone in a laminar flow or as atomized molten particles. Less than 99% of the particles may include metal oxide.
1 . A method for forming metal-containing particles, the method comprising:
forming a molten material from a solid supply material;
introducing the molten material into a reaction zone of a Barton reactor, the Barton reactor comprising a reaction vessel comprising a top cover and sidewalls defining the reaction zone, an agitator, a processing gas inlet, and a product outlet, wherein the molten material is introduced to the reaction zone in a laminar flow or as atomized molten particles; and
contacting the molten material with a processing gas in the reaction zone to form solid metal-containing particles comprising solid metallic particles and solid metal oxide particles, wherein less than 99% of the particles comprise metal oxide.
2 . The method of claim 1 , wherein the formed metal-containing particles include lead oxide particles and lead metal particles, and wherein the weight ratio of formed lead oxide particles to lead metal particles is less than 99:1
3 . The method of claim 2 , wherein the weight ratio of formed solid lead oxide particles to solid lead metal particles is from 50:50 to 90:10.
4 . The method of claim 2 , wherein the reaction zone has a temperature of from 621° F. to 880° F.
5 . The method of claim 2 , wherein the majority by weight of solid lead oxide particles comprise alpha lead oxide having a tetragonal crystal structure, and wherein the particles are suitable for lead acid battery manufacturing.
6 . The method of claim 1 , wherein the weight ratio of formed solid lead oxide particles to solid lead metal particles is from 50:50 to 90:10, and wherein the majority by weight of solid lead oxide particles comprise alpha lead oxide having a tetragonal crystal structure.
7 . The method of claim 1 , wherein at least 99% of the particles are non-oxidized metals, metalloids, or alloys.
8 . The method of claim 1 , wherein the molten metal lead material is introduced into the reaction zone in a hollow conical laminar spray.
9 . The method of claim 1 , wherein the molten metal lead material is introduced into the reaction zone in an atomized form.
10 . The method of claim 1 , wherein the molten metal lead material is introduced into the reaction zone through a nozzle.
11 . The method of claim 1 , wherein the processing gas is an oxidizing agent such as oxygen, air, or combinations thereof.
12 . The method of claim 1 , wherein the formed metal-containing particles include lead oxide particles and lead metal particles, and wherein the weight ratio of formed lead oxide particles to lead metal particles is from 50:50 to 90:10, and wherein at least 90 wt. % of solid lead oxide particles comprise alpha lead oxide having a tetragonal crystal structure.
13 . A method for retrofitting a Barton reactor, the method comprising:
replacing a conventional molten material inlet of a Barton reactor with an injector operable to receive molten material and inject the molten material into a reaction zone of the Barton reactor;
wherein the injector is operable to pass molten metal-containing material into the reaction zone with a laminar flow or in an atomized form.
14 . The method of claim 13 , wherein the conventional molten material inlet comprises a pipe.
15 . The method of claim 13 , wherein the conventional molten material inlet comprises a trough, dam, lip, or like device.
16 . The method of claim 13 , wherein the injector comprises a nozzle.
17 . the method of claim 13 , wherein the injector is operable to pass the molten metal-containing material into the reaction zone with a laminar flow.
18 . The method of claim 13 , wherein the injector is operable to pass the molten metal-containing material into the reaction zone in an atomized form.
19 . The method of claim 13 , further comprising operating the retrofitted Barton reactor to form lead metal particles, lead oxide particles, or a mixture thereof.
20 . The method of claim 19 , wherein the operation of the retrofitted Barton reactor forms a mixture of lead metal particles and lead oxide particles suitable for use in a lead acid battery, and wherein the retrofitted Barton reactor is operated at a temperature of from 621° F. to 880° F.