Patent Publication Number: US-6221310-B1

Title: System for extracting sodium metal from sodium hydroxide with methane as a reductant

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     A system, apparatus and process for practice for the reduction of sodium hydroxide with natural gas in the presence of heat to produce, after quenching, sodium metal as a product of the thermodynamic reaction. 
     2. Prior Art 
     The invention is in a system and apparatus for practicing a process where separate flows of a heated liquid sodium hydroxide, oxygen and heated methane are sprayed through a mixing nozzle to strike one another and mix for burning in a burner area of a reactor vessel, with vaporous sodium metal, carbon monoxide and hydrogen gases, the product of that burning that is passed from the reactor vessel for quenching to rapidly cool and liquify the sodium into metal that is then passed to a storage vessel with the carbon monoxide and hydrogen gases passed for discharge or recycling in the system. 
     Apparatus and processes for refining sodium metal are old in the art, with a recent U.S. patent application Ser. No. 09/262,876 filed Mar. 5, 1997, by one of the inventors being an example of a new system to include a reactor vessel wherein a heated mixture of sodium hydroxide and methane is provided to vaporize the mix into sodium metal vapors, carbon monoxide and hydrogen gas, which mix is then quenched to separate out the liquid sodium metal from the gases, with the liquid sodium then passed for use. Unique therefrom, the present invention provides a nozzle arrangement for spraying separate flows of heated sodium hydroxide, oxygen and methane together in a burner area of a reactor vessel creating a chemical reaction that produces a sodium metal vapor, and carbon monoxide and hydrogen gases, which mix is passed to a quench chamber wherein vaporized sodium metal is condensed to a liquid that is drawn off for use. 
     Very earlier apparatus and processes are shown in U.S. Pat. No. 342,897 to Castner; U.S. Pat. Nos. 380,775 and 380,776 to Thowless; and U.S. Pat. No. 460,985 to Netto, as examples of systems that utilize a carbonaceous material as a reactive agent, usually carbon in powder form, that is to react with the compound containing sodium or potassium in the presence of high heat to produce free sodium. Such processes have, however, not only required that a number of complex steps be performed to finally produce sodium metal and, unlike the invention, they have generally been single batch processes only. 
     Additionally, a French Patent No. 603,825, shows sodium metal being reacted with iron in powder form by first vaporizing the mix and then condense out sodium vapor at temperatures below the sodium condensation temperature. Such process has, however, required that it be conducted in a vacuum and that sodium vapors as are produced be removed from a reaction zone and condensed. Further, in the &#39;825 patent, like a later U.S. Pat. No. 2,642,347 to Gilbert, sodium metal vapor is produced from a condensation of sodium carbonate that has been reacted with carbon at a heat of from 1000 degrees C to 1200 degrees C, which vaporization takes place after the sodium metal vapor has been conducted away from the reaction. Condensation in the Gilbert &#39;347 patent utilizes surfaces of steel balls that are maintained at a temperature below that required for sodium vaporization, with vapor contact with the steel ball surfaces condensing sodium metal. The above cited systems are each essentially a batch system, unlike the present invention, that is a continuous system where sodium metal is produced in liquid form and is continuously drawn from a bottom vessel of a quench chamber, and neither involves a use of sodium hydroxide and methane as reactants. Nor do the either of the systems of these patents proved, as does the invention, a novel mixing spray nozzle that directs individual flows of the heated reactants against one another to break the flows into fine particulates, mixing them together in a high heat atmosphere, to react and produce vaporous sodium metal, and carbon monoxide and hydrogen gasses, with the mix then quenched to liquify sodium metal that is then removed for use. With such quenching taken place in a vessel or vessels that maintain a cooled surface, such as a coil receiving a coolant liquid passed therethrough and/or may include spraying of a non-reactive coolant into the vaporous mix as it enters the quench cooler, which quenching condenses out sodium metal from the reactant vapors that is then drained into a storage vessel. 
     A U.S. Pat. No. 2,930,689 to McGriff teaches a submerged combustion of methane in molten sodium carbonate and includes a separation wall to prevent the combustion gases, water and carbon dioxide, from entering into the reaction of methane or carbon with sodium carbonate. The McGriff process requires an operating temperature of from 1150 to 1250 degrees C, with carbon or methane fed into the hot sodium carbonate, and with sodium carbonate continuously added. The process requires a continuous addition of carbon, preferably coke in powdered form, to perpetuate the reaction. In practice, handling of a solid material, such as carbon, is a disadvantage that is not present in a practice of the invention. Further, McGriff &#39;689 does not include a mixing nozzle or quenching arrangement like that of the present invention, but provides for an immediate reaction at high heat to produce vaporous sodium metal like that of the invention. 
     While McGriff &#39;689, like the invention, teaches a use of methane as one of the reactants for producing sodium metal, that production is from a molten sodium carbonate, and further, unlike the invention, it requires that carbon, in powdered form, be continuously passed into the reaction vessel. Also, unlike the invention, the McGriff &#39;689 patent provides for burning of the introduced methane producing a high heat in the presence of carbon, with methane fed into hot sodium carbonate and with carbon, as solid coke in powdered form, continuously added for the reaction to proceed. Further the McGriff &#39;689 patent does not deal with problems inherent in quenching sodium metal from a mix of gaseous carbon monoxide (CO) and sodium (Na), and fails to recognize and deal with a back reaction as will occur as the gases cool where sodium metal tends to react with carbon monoxide to produce sodium carbonate (Na 2 CO 3 ), which problem of back reaction the invention addresses and solves. 
     Further, a patent to Deyrup, U.S. Pat. No. 2,685,346, like the invention, incorporates a step of quenching of a hot vapor containing a free alkaline metal to cool the alkaline metal to a molten state, and deals with a handling of a back reaction as the sodium vapor is quenched from the carbon monoxide and sodium gases. Unlike the invention, however, the Deyrup &#39;346 patent involves a use of large amounts of tin, must be operated at high temperatures, and, of course, does not involve a mixing spray nozzle arrangement like that of the invention. Also, the Deyrup &#39;346 patent teaches a multi-step process to provide for a quenching of the sodium metal and accordingly, in its operation, it is likely that a large percentage of the collected sodium metal will be lost to back reaction, and further the system of the Deyrup &#39;346 patent is not continuous. 
     SUMMARY OF THE INVENTION 
     It is a principal object of the present invention to provide a system, apparatus and process for separating out sodium metal from a mixture of heated sodium hydroxide as a reactant with the sodium hydroxide, heated methane and oxygen sprayed together through a single nozzle apparatus into a high heat area of a reactor vessel to produce metal sodium in a vapor state along with carbon monoxide and hydrogen gases, with the vapor and gaseous mix then quenched to liquify sodium metal that is drawn off for use. 
     Another object of the present invention is to provide a system, apparatus and process for continuously producing sodium metal from a reaction of heated sodium hydroxide as the reactant with methane as a reductant in the presence of oxygen to produce high heat in a reactor vessel, forming a vapor and gaseous mix of sodium metal, carbon monoxide and hydrogen that is then rapidly quenched to produce liquid sodium metal, with carbon monoxide and hydrogen as off gases that are exhausted to atmosphere or are recycled into the system. 
     Another object of the present invention is to provide an nozzle apparatus and process to produce, from a reaction of hot sodium hydroxide as a reactant with methane as a reductant in the presence of oxygen combined as a mixture and injected into a reactor vessel burner zone to produce a temperature that is well above the vaporization temperature of sodium metal of approximately two thousand (2,000) to twenty-eight hundred (2800) degrees F., to vaporize sodium metal from the mixture and form carbon monoxide and hydrogen gases, the sodium metal vapors and gases to pass to a quench chamber for rapid cooling, precipitating sodium metal from the flow that is collected and passed from the quench unit for processing, with the gases passed for venting or recycling. 
     Another object of the present invention is to provide, for practicing the process of the invention, a quench apparatus arranged as primary and secondary, or first and second chambers that operate in series to receive and, in passage of the vapor and gaseous mix, to cool the mix to below the condensation temperature of sodium metal, condensing out sodium metal while discouraging a back reaction of the sodium metal. 
     Still another object of the present invention is to provide, in a quenching apparatus of the invention, for performing a rapid cooling of the vaporized and gaseous mix constituents, that is a two stage first and second vessel arrangement provided to efficiently precipitate of essentially all the available sodium metal from the vaporous and gaseous mix. 
     Still another object of the present invention is to provide a simple spray nozzle for spraying separate flows of the constituents of heated sodium hydroxide, methane and oxygen from the single nozzle that directs the flows together creating fine thoroughly mixed particulates in a burner portion or section of a reactor vessel, providing a rapid reaction of the constituents at high heat to form a flow of sodium metal vapors, and carbon monoxide and hydrogen gases, with that flow then passed through first and second quench chambers that cool the flow to condense sodium metal. 
     Still another object of the present invention is to prevent a back reactor of the condensed sodium metal during a continuous production of liquid sodium metal that can then drawn from the quench vessel as a continuous process. 
     Still another object of the present invention is to provide a reactor vessel and process for practice therein to efficiently produce sodium metal that is essentially automated and, except for a close monitoring or temperatures and pressures in a reactor vessel, requires little human involvement in a continuous refining of sodium metal from a liquid sodium hydroxide. 
     The system, apparatus and process of the invention is for processing sodium hydroxide (NaOH) as a reactant that is combined with, in a preferred embodiment, methane gas or other appropriate combustible hydrocarbon as a reductant, and reducing the mixture by high heat in the presence of oxygen to produce a combined flow of vaporized sodium metal and carbon monoxide and hydrogen gases. The system and apparatus includes a reactor nozzle wherethrough are simultaneously passed, preferably, separate flows of heated sodium hydroxide and methane and oxygen, with the nozzle directing the flows therefrom to impinge upon and mix with one another, forming fine particulates within a burn area of a reactor vessel, with the constituents in the combined flows immediately reacting producing vaporous sodium metal from the mix and forming carbon monoxide and hydrogen gasses. The sodium metal vapors and gases are then passed to a first of two quench coolers that, preferably, also receives a flow of a coolant liquid that is non-reactive with sodium metal directed therein, and thence to a second to further reduce the temperature of the vaporous and gaseous mix, to precipitate sodium metal therefrom. A back reaction of the liquid sodium metal to sodium carbonate (Na 2 CO 3 ) is discouraged by the injection of the coolant liquid and the speed of quenching and, along with the presence of an inert gas, preferably nitrogen, in the reactor vessel and quench cooler. The sodium metal is then passed to a holding vessel that contains a material that is non-reactive with and is lighter than sodium metal to float thereon that is preferably the coolant liquid as passed to the first quench cooler that is circulated from the holding vessel to the first quench cooler. The sodium metal is thereby contained in a non-reactive state until it is drawn off for use. The system is operated as a continuous process, with the temperature in the top or burner zone of the reaction vessel wherein the sodium hydroxide, oxygen and methane are sprayed from the single nozzle, maintained at from two thousand (2,000) to twenty eight hundred (2,800) degrees F., preferably approximately twenty-five hundred (2,500) degrees F., with the reaction to produce sodium metal, along with carbon monoxide and hydrogen gases taking place at approximately nineteen hundred (1,900) degrees F. The quenching process is preferably conducted in an inert atmosphere and at less than atmospheric pressure, minimizing the number of molecules as are present as could react with the sodium metal causing a back reaction producing sodium carbonate. In a practice of the process of the invention, the process constituents consisting of flows of heated sodium hydroxide and methane along with oxygen are separately and continuously passed through the nozzle of the invention, spraying against one another to mix and form fine particulates in a burner portion of the reactor vessel wherein a flame area is maintained. An immediate reaction thereby takes place that produces vaporous sodium metal along with carbon monoxide and hydrogen gases that are then passed to a quench assembly for rapid cooling. Sodium metal is thereby produced, with the carbon monoxide and hydrogen gases vented as waste or are for passed recycling to be burned for heating, as desired. Sodium hydroxide that is the reactant in a practice of the process of the invention may be a waste product, as is produced in a number of commercial processes, or may be supplied from any number of sources. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings that illustrate that which is presently regarded as the best mode for carrying out the invention: 
     FIG. 1 is a schematic of a sodium metal production facility of the invention where sodium metal is produced in a reaction of heated sodium hydroxide with heated methane in an oxygen environment and at a high heat, where the reaction constituents are separately sprayed from a single nozzle that directs the sprays against one another, forming a flow of well mixed fine particles within a burner area of a reactor vessel, thereby cracking the mixture to produce vaporous sodium metal along with carbon monoxide and hydrogen gases, with the vapor and gases then passed for rapid cooling in a two stage quenching apparatus, wherein sodium metal is condensed from the mix and is passed to a storage vessel wherein it is maintained beneath a non-reactive material to discourage any back reaction until drawn therefrom for use; 
     FIG. 2 is an enlarged sectional view taken along the line  2 — 2  of FIG. 1 of the reactor nozzle of the invention; 
     FIG. 2A shows a lower end plan view of the reactor nozzle of FIG. 2; 
     FIG. 3 shows an enlarged end view of the end of the nozzle of FIG. 2 showing the reactive materials being sprayed out of the nozzle end, striking one another forming fine mixed particles that provide a large surface area for reaction. 
    
    
     DETAILED DESCRIPTION 
     FIG. 1 shows a schematic of a plant  10  for refining sodium metal from a reactant of sodium hydroxide with, preferably, methane as a reductant in the presence of oxygen at a high or cracking heat in a reactor vessel  11 , shown herein as a cylinder, through it should be understood, another shape of vessel could be so used, to vaporize sodium metal from the constituent mix, and with the sodium metal then condensed from a vaporous and gaseous mix in a quench assembly  12 . 
     In the schematic of FIG. 1, the plant includes a single reactor vessel  11  along with a pair of separate serially connected chambers or coolers as the quench assembly  12 . The reactor vessel  11 , as shown in the drawings, incorporates a reactor nozzle  13  that is configured to have three separate longitudinal passages  14 ,  15  and  16 , respectively therethrough, with the individually passages for transporting, respectively, a sodium hydroxide solution that has been heated to approximately two thousand (2,000) degrees F. through the center passage  14 ; with oxygen gas passed through the middle passage  15 ; and with methane gas that has been heated to approximately fifteen hundred (1,500) degrees F. through the outer passage  16 , as shown in FIGS. 2 and 3. It should, however, be understood that, in practice, the oxygen flow can be a compressed air flow within the scope of this disclosure and can be combined with the sodium hydroxide flow, allowing for a use of a reactor nozzle  13  having only a center passage  14  and an outer passage  16 , within the scope of this disclosure and further than a hydrocarbon other than methane can be utilized as the reductant within the scope of this disclosure. The liquid and gaseous mix is thereby injected into a top section  11   a  of the reactor vessel  11  and into a burner area of the reactor vessel that receives a burnable material, preferably methane or natural gas, through a gas pilot  17  that extends into the vessel top section  11   a  or burner portion that is ignited to produce a hot fire, though another burnable material can be so used, or even an electric furnace arrangement can be so employed within the scope of this disclosure. So arranged, the oxygen flow that is injected through passage  15  promotes a high heat of burning in the top section  11   a  or burner portion that receives the heated fine particulate mixture of sodium hydroxide and methane and oxygen, providing a rapid temperature to the mixture to increase to approximately between two thousand (2,000) and twenty-eight (2,800) degrees F., to cause an immediate reaction or cracking of the mix into sodium metal vapor and carbon monoxide and hydrogen gases. At this high heat, the reaction will be almost instantaneous and the combined vapor and gaseous mix can then be passed to the quench assembly for rapid cooling, causing the sodium metal vapor to condense to a liquid that can then be drawn off, as set out and discussed in detail hereinbelow. 
     The plant  10  includes a caustic or sodium hydroxide (NaOH) tank  20  that receives, through a hinged top  21 , a supply of caustic sodium hydroxide  22  that is preferable an anhydrous NaOH caustic prills or beads though, it should be understood, such caustic can be a waste product from another manufacturing process, within the scope of this disclosure. A burner  23  receives a high pressure flow of methane gas from a source  24  for burning and directs the burner output, that is mixed with air from a blower  25 , through a line  26  that runs through the tank  20 , heating the sodium hydroxide  22 , to vent, through a line  27 , carbon dioxide, water vapor, nitrogen and oxygen. The caustic sodium hydroxide solution is initially heated in tank  20  to approximately seven hundred fifty (750) degrees F. and is then passed therefrom through a valve  28  and is pumped by pump  29  through line  30  into a heating coil  31  that is contained in vessel  32 . A burner  33  is mounted in the vessel  32  bottom to receive methane that is fed thereto through a feed line  33   a  that receives the flow of methane from a high pressure methane source  24 . The methane gas is mixed with air that is provided through a blower  34  and a burner control  35  provides a desired heat output, with the vessel  32  vented through line  36 . After passage of the sodium hydroxide solution through coil  31  it emerges into line  31   a  having a temperature that has been raised to approximately two thousand (2,000) degrees F. Additionally, methane gas, under pressure, is directed through a line  37  to pass through a valve  38  and is directed through a line  39  that parallels the coil  31 , to emerge from the vessel  32  as line  39   a  that contains the methane that has been heated to a temperature of approximately fifteen hundred (1,500) degrees F. The respective heated sodium hydroxide solution and methane gas travel through the separate passages through the nozzle  13  and are mixed together by spraying them through an injection plate  46 , the flows to strike one another in front of a nozzle face  13   a , and with oxygen or compressed air provided through a line  41  from a compressor  42  that draws fresh air through an inlet  42   a  that is also directed through the nozzle  13  from a tank  40  and through a line  40   a , wherein line  41  may be connected as an alternative or to augment the flow of oxygen from tank  40 . The respective gases and sodium hydroxide solution are injected under pressure from the reactor nozzle  13  striking one another apart from the nozzle face  13   a , as set out below. 
     The reactor nozzle  13  is mounted, as shown in FIG. 1, in the head or top end  11   a  of the reactor vessel  11  that preferably has ceramic walls  11   b , as the vessel liner, that will withstand the effects of the high heat atmosphere therein along with the effects of the heat stimulated reaction of the heated caustic solution and methane that produces a rapid vaporization of sodium metal, and the ceramic vessel walls are non-reactive with sodium metal to prevent any unwanted back reaction of the vaporized sodium metal to form sodium carbonate (Na 2 CO 3 ). The reactor nozzle  13  provides for separated passage of the heated methane and sodium hydroxide solutions along with oxygen or compressed air for mixing these constituents in front of its injection end  13   a , as shown in FIGS. 2 and 3. Preferably, the sodium hydroxide passage  14  is a center tube or pipe  45  that is open the length thereof and has its injection end covered with an injection plate  46  wherein a plurality of spaced holes or perforations  47  are formed, that pass the separate sodium hydroxide methane and oxygen flows. The spaced holes or perforations  47  act as nozzles for directing sodium hydroxide, methane and oxygen or compressed air sprays under pressure therethrough to impinge or strike one another so as to cause both a break up of the sprayed constituents into fine particulates and turbulence to thoroughly mix the respective flows together in the high heat environment as is present at the top  11   a  of the reactor vessel  11 . The combined fine particulate constituents provide a large surface area that will rapidly be heated to provide complete reaction of the sodium hydroxide and methane to form, respectively, sodium metal in vaporous form, along with carbon monoxide and hydrogen gases. The oxygen or compressed air as is passed through a nozzle chamber  48  is to promote combustion in the reactor vessel providing the preferred high heat of between two thousand (2,000) to twenty-eight (2,800) degrees F. and is approximately twenty-five (2,500) degrees F. that, in turn, provides for a rapid reaction or cracking of the constituents in the flows, producing sodium metal. Further, where compressed air is so used, a large volume of nitrogen (N) is thereby present that is, of course, inert and prevents an undesired back reaction of the sodium metal vapors into sodium carbonate (Na 2 CO 3 ). 
     The reactor nozzle  13 , in addition to its center pipe  45 , includes an inner sleeve  48  having an open annular space along its length, is closed across its upper end at  49  and includes a feed port  50  whereto the line  40   a  from the oxygen or compressed air source is connected. Oxygen or compressed air is passed through the feed port  50  and flows between the pipe  45  carry the heat sodium hydroxide solution and outer sleeve  51  that transports the heated methane with the oxygen or compressed air flow thereby heated by the pipe  45  and sleeve  51  walls which oxygen or compressed air flow is passed through holes or perforations  47  in the injection plate  46 , spraying into the sprays of sodium hydroxide and methane which sprayed flows are thereby broken into fine particulates with the fine particles presenting a large reaction surface and are thoroughly mixed with the oxygen presence to promote a rapid heating of the mixed flows in the flame area at the top  11   a  of reactor vessel  11  producing a rapid reaction or cracking. The reactor nozzle  13  further includes the outer sleeve  51  that has an open annular cavity therealong, is closed across its top end  52  and includes a feed port  53  whereto is connected line  39   a . Heated methane gas or other suitable hydrocarbon, such as heating oil, propane (C 2 H 6 ), or the like is passed from line  39   a  through feed port  53  to travel through the outer sleeve annular cavity and out the holes or perforations  47  formed in the injection plate, spraying therefrom into engagement with the sprays of sodium hydroxide and oxygen or compressed air, so as to thoroughly mix therewith and react with the sodium hydroxide in the high heat atmosphere. In FIG. 3 is shown the respective sprays as are sprayed out from holes or perforations  47  impinge or strike one another, providing fine thoroughly mixed flow of particles. 
     In FIG. 1 the sprays from reactor nozzle  13  are shown sprayed into the top area  11   a  of the reactor vessel  11 . A fuel flow is passed through the gas pilot  17  and is ignited within the top area  11   a  to provide a flame or burner area that receives the sprays from reactor nozzle  13 . So arranged, an immediate reaction of the sodium hydroxide and methane will take place in the reactor vessel top area  11   a , forming vaporized sodium metal and carbon monoxide and hydrogen gases by the reaction: 
     
       
         CH 4 +NaOH→CO+Na+2.5H 2    
       
     
     The vapor and gaseous mix are then passed from the reactor vessel  11  through a bottom vent  55  and into an inlet  57  of a first quench cooler  56  of the quench assembly  12 . 
     The first quench cooler  56 , as shown in FIG. 1, is a hollow vessel, identified as a tube or cylinder  58  though another shape of vessel could be so used, that connects at a vapor and gas inlet  57 , to bottom vent  55  of the reactor vessel to pass the flow from that reactor vessel  11  and into the cylinder  58 . The cylinder  58  is closed across end  59  wherethrough inlet and exhaust coolant lines  61   a  and  61   b , respectively are passed that connect into a chill coil  60  that is positioned within an open longitudinal center area of the cylinder  58 . Further, which cylinder  58  and end  59  adjacent to vapor and gas inlet  57 , can be connected to a spray end  90   a  of an inert fluid flow line  90  that connects at  90   b  into a liquid sodium tank  67  to drain an inert fluid  68  therefrom. So arranged, inert fluid  68  removed from tank  67  is pumped by pump  91  to pass through a valve  92  and be sprayed into the vapor and gaseous flow passed into the first quench cooler  56 . This spray of inert fluid  68  to provide, as a direct quench, for an initial cooling of the flow to initially lower the mix temperature and provides for a formulation of an envelope around the individual sodium particles, preventing an unwanted back reaction of sodium into sodium carbonate (Na 2 CO 3 ). The chill coil  60  to provide rapid cooling to the vapor and gas flow receives a coolant flow pumped therethrough, creating a cold outer surface that is contacted by the vapor and gas flow from the reactor chamber. So arranged, the vapor and gas flow is initially or further cooled and is then passed through a vent coupling  57   a  to a second quench cooler  62  of the quench assembly  12 . 
     The second quench cooler  62  is also shown as a cylinder  63 , though another vessel shape could be so used, and wherein a final chill coil  64  is fitted that is to receive the vapor and gaseous mixture flow thereover, cooling that flow to below the vaporization temperature of sodium metal. So arranged, sodium metal is thereby condensed out of the vapor and gaseous flow to a liquid state and falls through a discharge end  65  of the cylinder  63  to pass through a line  65   a  and into a liquid sodium holding tank  67 , shown as a volume  70 . In practice, the temperature of the vaporous and gaseous mix within the second quench cooler  62  is reduced to below three hundred (300) degrees F., whereat sodium metal vapors condenses into a liquid, with the carbon monoxide and hydrogen gases as remain in the flow, along with some carbon dioxide and water vapor, then exhausted through a cylinder vent end  66   a  and passed through an exhaust line or stack  66  to atmosphere or to a recycling line for reprocessing and use in a plant system, not shown, as is practical and profitable to the process, within the scope of this disclosure. In which passage through the stack  66  the gases are passed through a flame arrester  66   b  that is to eliminate a possibility of an unwanted ignition of the mix of gases, including the gaseous hydrogen. 
     Shown in FIG. 1, the line  65   a  extends into the liquid sodium tank  67  to just above the bottom thereof to discharge liquid sodium from the second quench cooler  62  through end  66   b  to below the level of the liquid sodium  70  maintained therein. Further, to maintain the integrity of the sodium metal  70 , precluding a back reaction thereof where the sodium metal reacts to form a sodium hydroxide, the sodium metal  70  is covered by a layer of an inert liquid  68 , such as kerosene, though other liquid could be so used within the scope of this disclosure. As set out above, the inert liquid  68  preferably kerosene or other appropriate liquid can be drawn out of the liquid sodium tank  67  to serve as an initial coolant for lowering the temperature and encapsulating sodium metal particles in the first quench cooler  56 . Such drawing off of inert fluid  68  should be limited so as not to uncover the liquid sodium to with, of course, the inert liquid  68  as is directed into the first quench cooler  56  to return to the liquid sodium tank  67  through the discharge end  65  of the second quench cooler  62 . 
     Like the coolant liquid supplied to the first quench cooler  56 , a refrigerant is supplied to and discharged from the second quench cooler  56  through branches of lines  61   a  and  61   b , respectively, Line  61   a  is connected to a refrigerant flow from a dowtherm cooler  71  that condenses the refrigerant by cooling it, as illustrated by a fan  72 , and directs that liquid refrigerant into a surge tank  73 . The liquid refrigerant, shown at  75 , is then passed through a valve  75  to a pump  76  into the line  61   a  that branches to flow to both the first and second quench coolers  56  and  62 . The discharge flow from each quench cooler then flows through branched return lines  61   b , with line  61   b  connected to an inlet side of the dowtherm cooler  71 . 
     To prohibit the occurrence of a back reaction in the reaction or cracking process as takes place in the reactor vessel, a nitrogen source, shown as a tank  80 , is linked through line  80   a  to a manifold  81  that is connected through line  81   a  into the top of sodium holding tank  67  to provide a nitrogen atmosphere above the kerosene  68  level. Further, a branch line  81   b  from the manifold  81  connects into the supply line  40   a  from the oxygen source tank  40  that passes nitrogen therethrough to control the volume of oxygen as is passed through nozzle  13  to a volume to support combustion in the top  11   a  or reactor vessel  11  only, to provide that essentially all of the oxygen as is supplied with the sodium hydroxide and methane into the reactor vessel will be consumed in the combustion taking place there or, as an alternative, with a use of compressed air, the flow into nozzle  13  will contain both oxygen and nitrogen without a need for a separate source of nitrogen gas. Sodium metal  70  is drawn from beneath the level in tank  67  from a discharge line  84 , through a valve  85  and pump  86  for use. 
     Hereinabove has been shown and described a preferred apparatus and system of my invention for producing sodium metal from sodium hydroxide reacted with methane in the presence of a high heat of approximately two thousand (2,000) to twenty-eight hundred (2,800) degrees F. to crack mixed sprays of sodium hydroxide and methane with oxygen alone or with oxygen in compressed air, to produce sodium metal vapors from the reaction sodium metal vapor with carbon monoxide and hydrogen gases, with the sodium metal vapors then condensed into a liquid by a rapid cooling of the vapor and gaseous mix, which sodium metal is then drained off in a continuous process. It should, however, be understood that the present disclosure is made by way of example only and that variations are possible without departing from the subject matter coming within the scope of the following claims and a reasonable equivalency thereof, which subject matter we regard as our invention.