Process for producing an aluminium-silicon alloy from leucite

Description

[0001] This invention relates to a process for producing an AI-Si alloy from leucite by reducing the corresponding oxides contained therein. In the case of leucites, of which there is a large availability in Italy, a large number of processes have been developed during the last 50 years for recovering alumina and alkalies, including experiments, in pilot plants and sometimes on an industrial scale.

[0002] The results have always been negative for technical or economical reasons. The known processes of the art are as follows:

-attacking with HN0₃+HCI (Italian patent 536,793), this being negative because of the high cost of the acid and because of material problems;

- attacking with CaO at 1000-1400°C (French patent 527,066);

-attacking with hot NaN0₃ in solution, under pressure;

- attacking with Ca(OH)₂ under pressure in order to recover KOH (French patent 556,994).

[0003] The most recent proposals relate to processes involving attack by H₂S0₄, HCI or alkali. However, at the same time the pyrometallurgical processes are making progress, these tending to recover the components of an alkaline (or alkaline earth) silico-aluminous concentrate in metal form as an Al-Si alloy, together with the alkaline oxide by virtue of its volatilisation. The use of conventional electric furnaces has not yet given promising technical and economical results because of the low metal recovery and high energy consumption.

[0004] From US―A―3661561 is known a process for producing, in a blast furnace, an aluminium-silicon alloy from a charge containing carbon, an aluminium-silicon ore and pure oxygen, where the temperature in the reduction zone of the furnace ranges from about 2050°C to about 2500°C.

[0005] It has surprisingly been found that the aforesaid difficulties and drawbacks can be obviated using the process according to the present invention, by which the oxides of AI and Si can be simultaneously reduced and the so obtained metals are alloyed into an alloy with high process yields, because of the high contact surface of the reaction phases.

[0006] With regard to the chemical reactions, the chemical-physical energy necessary to break the formation bond of leucite or AI and Si oxides is provided both by direct reduction with the carbon and by the energy associated with the AI-Si solution in liquid phase, which subtracts Si and AI as they become formed, thus lowering the activity of the reaction products.

[0007] The alkaline oxides contained in the silico-aluminous concentrates are recovered separately.

[0008] The present invention relates to a process for producing an aluminium-silicon alloy from an aluminium-silicon ore with a carbon-containing reducing material at a temperature of 2000°C and over, characterized in that the aluminium-silicon ore to be reduced is leucite and said ore is injected in particulate form into a plasma-arc burner positioned in the bottom section of a shaft-furnace filled with solid carbon-containing reducing material exclusively, the expected molten Si-Al alloy and the slags are separately collected at the bottom of said shaft furnace, the vapour of the unreacted alkali metal- and alkaline earth-metal oxides and the exhaust gases being vented at the top of said furnace.

[0009] The invention is described in greater detail hereinafter with reference to the accompanying drawing, which represents a sectional view of a shaft or reactor which can be used in accordance with the present invention.

[0010] On the accompanying drawing, a shaft reactor 1 is filled with a reducing agent 2, preferably coke.

[0011] A blast furnace charger 3 is mounted at the top of the reactor 1, directly above the reactor itself, and is arranged to be continuously filled with coke to a predetermined level. In order to automatically obtain this predetermined level in the mouth 4 of the blast furnace charger 3, two level indicators 5, 6 are installed, to interact with filling members, not shown. A pipe 7, connected to a condenser 8, emerges from the top of the reactor 1.

[0012] The material to be treated, containing silicon and aluminium oxide, is fed through the inlet 9 either alone or in combination with the reducing material.

[0013] There is also a plasma arc burner 11 with a feed pipe 12, and on the base of the reactor 1 there are mounted tapping means 13 for the slag, and tapping means 14 for the liquid metal.

[0014] The following occurs during operation. The material to be treated is subjected to air blasting in the reaction zone of the reactor 1, where together with the reducing agent it becomes rapidly heated and reacts to form the liquid and gaseous reduction products. The liquid products consist of an AI+Si alloy, and slag deriving from slagging agents either added separately during the operation or mixed with the material containing the metal oxides, a certain quantity of ash originating from the reducing agent also being produced. The gaseous product consists of unreacted alkaline oxides and reduction gas, of which the composition depends on the reducing agent used.

[0015] The liquid reduction products are collected on the base of the shaft and can be discharged through the tapping holes 13, 14, whereas the gaseous products, essentially alkaline oxides, rise upwards through the shaft and are extracted through the pipe 7.

[0016] The coke in the shaft forms a permeable layer, through which the reaction products pass respectively towards the base and towards the top of the shaft, and in this respect the coke has the following purposes:

a) to form a large reaction surface for the contact of all the reaction phases;

b) to hold back all the fine grain material which passes through this layer;

c) to act as a reducing agent and thus ensure that the reduction conditions exist from one end to the other of the shaft;

d) to prevent the evolved oxide vapours from becoming condensed, this being attained by virtue of the fact that the top of the shaft and the top of the blast furnace are protected by coke. To ensure that the condition of point (d) is satisfied, coke is fed into the reactor by way of level regulators 5, 6. Furthermore, as stated heretofore, the entire coke layer is maintained at a temperature of about 1000°C or higher.

[0017] The reaction gas which leaves the shaft is made to pass through the condenser 8, in which it is separated, and the metal oxides contained in it are condensed and discharged from 15.

[0018] The remaining gas, consisting mainly of carbon monoxide and gaseous hydrogen, leaves the condenser at 16 and can be used for various purposes.

[0019] The process according to the invention is further illustrated with reference to the following example, which is given by way of non-limiting example only.

Example

[0020] The material containing a leucite concentrate had the following composition: (in terms of its main elements)

20-23% AI₂0₃

50―53% SiO₂

20-21% K₂0
max. 0.80% as Fe

remainder: oxides of various metals.

[0021] The following consumption of reducing agent, slagging agents and electricity was determined per ton of treated material:

- reducing agent 100 kg of dried coke 300 kg of pit coal

- electricity 4 kWh.

[0022] The following products were obtained per ton of starting material:

-300 kg of alloy. containing 30-35% AI and 65-70% Si

-190 kg of potassium oxide.

Claims

A process for producing an aluminium-silicon alloy from an aluminium-silicon ore with a carbon-containing reducing material at a temperature of 2000°C and over, characterized in that the aluminium-silicon ore to be reduced is leucite and said ore is injected in particulate form into a plasma-arc burner positioned in the bottom section of shaft furnace filled with solid carbon-containing reducing material exclusively, the expected molten Si-Al alloy and the slags are separately collected at the bottom of said shaft furnace, the vapours of the unreacted alkali metal-and alkaline earth-metal oxides and the exhaust gases being vented at the top of said furnace.

Ansprüche

Verfahren zur Herstellung einer Aluminium-Silizium-Legierung aus einem Aluminium-Silizium-Erz mit einem kohlenstoffhaltigen Reduktionsmittel bei einer Temperatur von 2000°C und darüber, dadurch gekennzeichnet, daß das zu reduzierende Aluminium-Silizium-Erz Leucit ist und dieses Erz in Teilchenferm in einen Plasma-Bogenbrenner eingeführt wird, der im Bodenteil eines Schachtofens angeordnet ist, der ausschließlich mit festem, kohlstoffhaltigem Reduktionsmaterial gefüllt ist, wobei die angestrebte geschmolzene Si-AI-Legierung und die Schlacken getrennt am Boden dieses Schachtofens abgezogen werden und die Dämpfe der nicht umgesetzten Alkalimetall- und Erdalkalimetalloxide und die Abgase am Kopf dieses Ofens abgenommen werden.

Revendications

Procédé pour la fabrication d'un alliage d'aluminium et de silicium à partir d'un minerai d'aluminium-silicium avec une matière réductrice contenant du carbone, à une température de 2000°C et au-dessus, caractérisé par le fait que le minerai d'aluminium-silicium à réduire est de la leucite et ledit minerai est injecté sous forme particulaire dans un brûleur à arc-plasma disposé à la partie inférieure d'un four à cuve rempli exclusivement de matière réductrice solide contenant du carbone, l'alliage fondu de Si-AI recherché et les scories sont recueillis séparément au fond dudit four à curve, les vapeurs des oxydes de métaux alcalins et de métaux alcalino- terreux qui n'ont pas réagi et les gaz d'échappement étant expulsés. au sommet dudit four.

Drawing