A method and apparatus for germanium reclamation from chemical vapor deposition exhaust gas streams

Abstract: A continuous system recovers germanium (Ge) from a chemical vapor deposit. A chemical vapor deposit scrubber scrubs a chemical vapor deposit to form a chemical vapor deposit scrubber solution. An equalization and neutralization mixer adds a caustic soda to the chemical vapor deposit scrubber solution to form an equalization and neutralization mixer solution having a pH above 12.0 to maintain the solubility of silicon oxide (SiO 2 ) and hypochlorite (ClO - ). A hypochlorite reduction mixer adds a peroxide to the equalization and neutralization solution to form a hypochlorite reduction solution to reduce hypochlorites. A precipitant and neutralization mixer adds a metal cation such as Epsom Salts (MgSO 4 ) and a caustic soda (NAOH) to the hypochlorite reduction solution to form a precipitant and neutralization solution to precipitate magnesium germanate (MgGeO 3 ) and magnesium silicon trioxide (MgSiO 3 ). A reactor tank adds a cationic polymer to the precipitant and neutralization solution to flocculate the germanium (Ge) and silicon (Si) solids and form a flocculation solution. A plate clarifier collects the flocculation solution to form a flocculated material. A filter press and the dryer processes and drys the flocculated material to produce a dry sludge of germanium (Ge) within a range of 5%-10% by weight.

Description: FIELD OF INVENTION The invention provides a method and apparatus for reclaiming germanium (Ge) from chemical vapor deposition (CVD) exhaust. BACKGROUND OF THE INVENTION There are many known methods and apparatus for reclaiming germanium (Ge) from chemical vapor deposition (CVD) exhaust. For example, U.S. Patent No. 4,385,915 describes a batch process for the removal of germanium (Ge) from an effluent that is the result of processes used for the production of optical components. In the batch process, optical fiber reactors provide effluent to scrubbers, which processes the effluent and provides a basic aqueous output to a moving sandbag filter. A filtered aqueous medium having dissolved germanium is precipitated from a medium provided by the moving sandbag filter by a precipitator by the addition of a precipitating agent such as an aqueous magnesium sulfate solution. The process also includes providing the filtered aqueous medium to a holding tank, where a sodium hydroxide solution is added to bring the pH of the aqueous medium therein to a value of twelve, and recycling a medium back to the scrubbers for reprocessing. One problem with this process is that it is a batch process, and thus not continuous. Another problem is that the basic aqueous output from the scrubber is filtered before being equalized, neutralized, or the hypochlorites are reduced. Other methods and apparatus for reclaiming germanium (Ge) from chemical vapor deposition (CVD) exhaust include the following: U.S. Patent No. 2,827,361 describes a method of recovering germanium (Ge) which involves removing dissolved silicon contained in an aqueous solution having dissolved germanium (Ge) therein and having a pH value of at least seven. The method includes the step of adding soluble inorganic aluminum to the solution to precipitate insoluble silicon from the solution. The aqueous solution used is aqueous sodium hydroxide. U.S. Patent No. 2,929,677 describes a process for recovering germanium (Ge) from zinc oxide fume taken from furnace slag, using an aqueous sodium hydroxide solution to precipitate iron and germanium (Ge). U.S. Patent No. 4,367,085 describes a method of making optical fiber preforms using glass raw material gases. The apparatus used in the method incudes an exhaust gas cleaner to process the gases exiting the exhaust port. The cleaning process apparently includes the use of a water spray and a neutralizer NaOH. U.S. Patent No. 4,578,253 describes a method of recovering germanium (Ge) from the effluent of a vapor deposition process of making an optical fiber. This patent incorporates methods disclosed in the U.S. Patent No. 4,385,915. DE Patent No. 3,143,958 describes a method of forming optical fibers which includes steps of reclaiming the gases used as dopants. A water spray and fractional distillation process are used in the method of recovering germanium (Ge) for reuse. Moreover, Figure 1 of the present patent application shows a known continuous stirred tank reactor for waste treatment which includes the following steps: Providing a tube exhaust from a CVD lathes to a scrubber having a recirculation pump; scrubbing the tube exhaust and passing liquid waste from the scrubber to a pH neutralization reactor; combining the liquid waste with a polyflow, a water bath and a scrubber overclad, and providing a pH neutralization solution to a settling stage; providing a slurry to a filtration stage, which provides a filtered slurry back to the settling stage; and providing the slurry to a filter press which provides filter cakes for disposing in a landfill. SUMMARY OF THE INVENTION The present invention relates to a process for recovering of germanium (Ge) from a chemical vapor deposit, comprising the successive steps of : providing an effluent having gaseous and particulate germanium (Ge) material ; scrubbing said effluent to form a scrubber solution ; equalizing and neutralizing the scrubber solution to form an equalization and neutralization germanium (Ge) solution having a predetermined pH to maintain the solubility of silicon oxide (SiO 2 ) and hypochlorite (ClO - ) ; converting hypochlorites in the equalization and neutralization germanium (Ge) solution by adding hydrogen peroxyde to form a hypochlorite conversion germanium (Ge) solution ; precipitating the hypochlorite conversion germanium (Ge) solution by adding a precipitating agent to recover the germanium (Ge) ; and flocculating the precipitant solution to form a flocculation solution. The present invention also relates to a continuous system for recovering germanium (Ge) from a chemical vapor deposit, comprising : a chemical vapor deposit scrubber (10) for receiving a chemical vapor deposit, and scrubbing the chemical vapor deposit to form a chemical vapor deposit scrubber solution ; an equalization and neutralization mixer (12) connected to said chemical vapor deposit scrubber (10), for receiving said chemical vapor deposits scrubber solution, and adding a caustic soda thereto to form an equalization and neutralization mixer solution having a pH above 12.0 to maintain the solubility of silicon oxide (SiO 2 ) and hypochlorite (ClO - ) ; a hypochlorite reduction mixer (14) connected to said equalization and neutralization mixer (12) for receiving the equalization and neutralization mixer solution, and adding a peroxide to the equalization and neutralization solution to form a hypochlorite conversion solution to convert hypochlorites ; a precipitant and neutralization mixer (16) connected to said hypochlorite reduction mixer (14) for receiving the hypochlorite conversion solution, and adding a metal cation in the form of Epson Salts (MgSO 4 ), and adding a caustic soda (NaOH), to form a precipitant and neutralization solution to aid in the precipitation of magnesium germanate (MgGeO 3 ) and magnesium silicon trioxide (MgSiO 3 ) ; a reactor tank (17) connected to said precipitant and neutralization mixer (16), for receiving the precipitant and neutralization solution, and adding a cationic polymer to the precipitant and neutralization solution to aid in the flocculation of the germanium (Ge) and silicon (Si) solids and to form a flocculation solution ; a plate clarifier (18) connected to said reactor tank (17), for receiving the flocculation solution for collection to form a flocculated material, and a filter press (20) and dryer (22), connected to said plate clarifier (18), for receiving the flocculated material, and processing and drying the flocculated material to produce a dry sludge of germanium (Ge) within a range of 5%-10% by weight. BRIEF DESCRIPTION OF THE DRAWING The invention, both as to its organization and manner of operation, may be further understood by reference to a drawing (not drawn to scale) which includes Figure 1-3 taken in connection with the following description. Figure 1 illustrates a schematic diagram of a known continuous stirred tank reactor for germanium (Ge) reclamation. Figure 2 is a schematic diagram of a continuous stirred tank reactor for germanium (Ge) reclamation which is the subject matter of the present application. Figure 3 is a recovery data listing showing actual germanium (Ge) percentage and weight as a result of using the process of the present invention. BEST MODE OF THE INVENTION In Figure 2, an effluent from a modified chemical vapor deposition (MCVD) process for manufacturing optical fiber preforms is directed into a CVD scrubber 10. It is treated internally to the scrubber with an aqueous solution of sodium hydroxide maintaining a pH above 10.0. The slurry overflow from a scrubber sump is directed to a waste treatment system where it is treated to recover germanium (Ge). The steps involved in the treatment to participate germanium (Ge) are as follows : Step 1: Equalization and Neutralization - A CVD scrubber solution is provided from the CVD scrubber 10 to an equalization and neutralization mixer generally indicated as 12, where caustic soda is added to from an equalization and neutralization mixer solution having a pH above 12.0 to maintain the solubility of silicon oxide (SiO 2 ) and hypochlorite (ClO - ). Step 2 : Hypochlorite Conversion - The equalization and neutralization solution is provided from the equalization and neutralization mixer 12 to a hypochlorite conversion mixer generally indicated as 14, where a peroxide is added to form a hypochlorite conversion solution to reduce hypochlorites. Step 3 : Precipitant/Neutralization - The hypochlorite conversion solution is provided from the hypochlorite conversion mixer 14 to a precipitant/neutralization mixer generally indicated as 16, where a metal cation in the form of Epsom Salts (MgSO4) is added, and a caustic soda (NaOH) is also added, to form a precipitant/neutralization solution and to aid in the precipitation of magnesium germanate (MgGeO 3 ) and MgSiO 3 . Step 4: A cationic polymer is added to the precipitant/neutralization solution in a reactor tank 17 to aid in the flocculation of the germanium (Ge) and silicon (Si) solids which are provided to a plate clarifier 18 for collection to form flocculated material. Step 5: The flocculated material is then processed through a filter press 20 and a dryer 22 to produce a dry sludge of germanium (Ge) within a range of 5%-10% by weight which is formed into filter cake 24 for recycling. The drying step reduces the water to a range of 10%-15% by weight, and produces filter cakes of germanium (Ge) and results in recovery of germanium (Ge) from the MCVD process. The overall process recovers 98% of the scrubbed germanium (Ge). A maximum solid content of 85% was achieved when operating the dryer 22 at a standard operating temperature of 675 degrees Fahrenheit. When the operating temperature of the dryer 22 is maintained between 575 to 600 degrees, the method provides a maximum yield of germanium. Step 6: Supernate from a clarifier and excess water from the filter press 20 are recycled and returned to another system, such as an overclad scrubber (not shown). The scope of the invention is not intended to be limited to only the chemicals shown and described with respect to Figure 2. For example, embodiments are envisioned in which other reducing agents, such as metabisulites, are used in the Hypochlorite Reduction step. The following are advantages of the following germanium (Ge) reclamation design: a) Using a scrubber sump overflow instead of filtration system provides for a continuous process instead of a batch process. The continuous process ensures that a steady, relatively unchanging percentage of germanium (Ge) is flowing into the reclamation system. The scrubber sump acts as a buffer to the many MCVD batch process upstream of the scrubber. Therefore, the final product has substantially a constant percentage of germanium (Ge) by weight. This prevents an extra testing step of the product before shipping to a customer, thereby saving on operating costs 5 and allowing us more pricing leverage with the customer. Secondly, the expensive and difficult step of filtering the scrubber recirculation solution is eliminated. b) The flocculation step increases filter efficiency. By concentrating the particulate with a flocculation agent, 10. the filtering equipment can be sized smaller and recovers more of the desirable product. Extra filtration steps would be needed if flocculation was not used to recover the same amount of germanium (Ge). Thus, a cost savings is gained by eliminating equipment and operating costs. c) The drying step reduces operating and shipping costs. The dryer reduces the amount of water H 2 O in the product. Thus, the shipping weight is reduced and the product is easier to handle. d) Waste liquid from the process is of sufficient quality that it can be recycled in other processes or discharged to a sewer without further treatment. e) Product is directly added to the customer's normal feedstock for GeCl 4 production. No further treatment is required. The product has greater than 10-20 times the percentage of germanium (Ge) than the customer's normal feedstock. Figure 3 is a recovery data listing showing actual germanium (Ge) percentage and weight. It is also to be understood that the claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Claims: A process for recovering of germanium (Ge) from a chemical vapor deposit, comprising the successive steps of : providing an effluent having gaseous and particulate germanium (Ge) material ; scrubbing said effluent to form a scrubber solution ; equalizing and neutralizing the scrubber solution to form an equalization and neutralization germanium (Ge) solution having a predetermined pH to maintain the solubility of silicon oxide (SiO 2 ) and hypochlorite (ClO - ) ; converting hypochlorites in the equalization and neutralization germanium (Ge) solution by adding hydrogen peroxyde to form a hypochlorite conversion germanium (Ge) solution ; precipitating the hypochlorite conversion germanium (Ge) solution by adding a precipitating agent to recover the germanium (Ge) ; and flocculating the precipitant solution to form a flocculation solution. A process according to claim 1, wherein the effluent having gaseous and particulate germanium (Ge) material is a chemical vapor deposit. A process according to claims 1 or 2, wherein in the equalizing and neutralizing step, caustic soda is added to the scrubber solution. A process according to any one of claims 1 to 3, wherein the precipitating agent is a metal cation. A process according to any one of claims 1 to 4, wherein, in the flocculating step, a cationic polymer and caustic soda are added to form a flocculation solution. A process according to any one of claims 1 to 5, wherein the process further comprises the steps of: providing the flocculation solution to a plate clarifier for collection to form a flocculated material ; providing the flocculated material to a filter press and a dryer ; processing and drying the flocculated material to produce a dry sludge of germanium (Ge) within a range of 5%-10% by weight ; forming the dry sludge into filter cakes for recycling ; and recycling and returning supernate form the plate clarifier and excess water from the filter press to another system, such as an overclad scrubber. A process according to any one of claims 1 to 6, wherein the equalization and neutralization mixer solution has a pH above 12.0 to maintain the solubility of silicon dioxide (SiO 2 ) and hypochlorite (ClO - ). A process according to any one of claims 4 to 7, wherein the metal cation is in the form of Epsom Salts MgSO 4 and the caustic soda is sodium hydrate (NaOH). A process according to any one of claims 1 to 8, wherein the process is continuous. A continuous system for recovering germanium (Ge) from a chemical vapor deposit, comprising : a chemical vapor deposit scrubber (10) for receiving a chemical vapor deposit, and scrubbing the chemical vapor deposit to form a chemical vapor deposit scrubber solution ; an equalization and neutralization mixer (12) connected to said chemical vapor deposit scrubber (10), for receiving said chemical vapor deposits scrubber solution, and adding a caustic soda thereto to form an equalization and neutralization mixer solution having a pH above 12.0 to maintain the solubility of silicon oxide (SiO 2 ) and hypochlorite (ClO - ) ; a hypochlorite reduction mixer (14) connected to said equalization and neutralization mixer (12) for receiving the equalization and neutralization mixer solution, and adding a peroxide to the equalization and neutralization solution to form a hypochlorite conversion solution to convert hypochlorites ; a precipitant and neutralization mixer (16) connected to said hypochlorite reduction mixer (14) for receiving the hypochlorite conversion solution, and adding a metal cation in the form of Epson Salts (MgSO 4 ), and adding a caustic soda (NaOH), to form a precipitant and neutralization solution to aid in the precipitation of magnesium germanate (MgGeO 3 ) and magnesium silicon trioxide (MgSiO 3 ) ; a reactor tank (17) connected to said precipitant and neutralization mixer (16), for receiving the precipitant and neutralization solution, and adding a cationic polymer to the precipitant and neutralization solution to aid in the flocculation of the germanium (Ge) and silicon (Si) solids and to form a flocculation solution ; a plate clarifier (18) connected to said reactor tank (17), for receiving the flocculation solution for collection to form a flocculated material, and a filter press (20) and dryer (22), connected to said plate clarifier (18), for receiving the flocculated material, and processing and drying the flocculated material to produce a dry sludge of germanium (Ge) within a range of 5%-10% by weight. A continuous system according to claim 10, wherein the filter press (20) and the dryer (22) form the dry sludge into filter cakes (24) for recycling.

Inventors: LANKEWICZ DAVID W, REILLY BRUCE D, LANKEWICZ, DAVID W., REILLY, BRUCE D.
Applicants: CIT ALCATEL, ALCATEL
Application year: 1998
Main classification: C22B41
IPC codes: C22B7, C03B37, C01G17, B01D53, C22B41