Methods and systems for making metal-containing particles
According to one or more embodiments presently described, metal-containing particles may be made by a method that includes introducing a molten material into a reaction zone of a reactor system, passing a process gas into the reaction zone in a direction substantially tangential to a sidewall of the reaction zone, and contacting the process gas with the molten material in the reaction zone to form metal-containing particles. The molten material may be introduced into an upper portion of the reaction zone The reaction zone may include a substantially circular cross-section, and the molten metal may be introduced into the reaction zone in a laminar flow or as atomized particles.
1. A method for making metal-containing particles, the method comprising:
introducing a molten material into a reaction zone of a reactor system, wherein the molten material is introduced into an upper portion of the reaction zone, wherein the reaction zone comprises a circular cross-section, and wherein the molten metal is introduced into the reaction zone in a laminar flow;
passing a process gas into the reaction zone in a direction substantially tangential to a sidewall of the reaction zone;
contacting the process gas with the molten material in the reaction zone to form metal-containing particles.
2. The method of claim 1 , wherein at least 99% of the particles are non-oxidized metals, metalloids or alloys.
3. The method of claim 2 , wherein at least 95% of the particles are pure lead metal particles.
4. The method of claim 1 , wherein the process gas is inert.
5. The method of claim 1 , wherein the reaction zone operates at a temperature of at least 621° F.
6. The method of claim 1 , further comprising separating the process gas from the formed metal-containing particles.
7. The method of claim 6 , wherein the separating occurs in a separation zone comprising a frustum.
8. The method of claim 7 , further comprising providing a cooling air supply to a separation section zone where separation of the metal-containing particles and process gas occurs.
9. The method of claim 7 , wherein the process gas flows upwardly to exit the separation zone.
10. The method of claim 7 , wherein the metal-containing particles flow downwardly to exit the separation zone.
11. The method of claim 1 , wherein the process gas is an oxidizing agent and metal oxide particles are formed.
12. The method of claim 1 , wherein a flow of gas impinges upon the laminar flow of molten material.
13. The method of claim 1 , wherein the molten metal is dispensed in a hollow conical pattern, which is contacted by a gas annulus.