Abstract: The invention comprises a process for the manufacture of metal chlorides by the double-decomposition reaction between a metal chlorinating agent and a metal oxide having greater affinity for chlorine than does the oxide of the metal chloride, and in the presence of small amounts of boron chloride or functionally equivalent boron compounds that increase the rate and degree of completion of the reaction.A major application of this invention is for the making by the chlorination of clay of aluminum chloride and alumina intermediates for the manufacture of aluminum metal.SiCl.sub.4 is formed in the carbo-chlorination of clay or other aluminous-siliceous ores. The SiCl.sub.4 by this invention is catalyzed with BCl.sub.3 and reacted with calcined clay to produce AlCl.sub.3 and SiO.sub.2. The practical use of SiCl.sub.4 to make AlCl.sub.3 thus eliminates the previous costly burden of waste SiCl.sub.4 production.

Abstract: A method for the consolidation of fine alumina particles, like those made by the dry oxidation of aluminum chloride, to produce a metallurgical grade alumina that resembles Bayer alumina in the following properties; dissolving as well in a Hall cell; absorption of water; absorption of hydrogen fluoride gas to eliminate that contaminant from the Hall cell offgases in a fluid bed; bulk density; particle size distribution; purity and handling.The method comprises the uniform admixture of caustic soda solution, compressing, autoclaving, then drying and calcining the mass; finally crushing and screening the solid product with recycling of the fines.

Abstract: The present invention provides a process for the production of aluminum chloride and alumina of metallurgical grade purity, and valuable by-products from aluminous ores like clay, bauxites and laterites. The process comprises carbo-chlorination of the ore to produce aluminum chloride and other metal chlorides. The aluminum chloride is separated, purified and utilized as such or oxidized to make alumina while the other metal chlorides are processed to recover maximum values.

Abstract: A process is disclosed for collecting and purifying aluminum chloride from gases like those produced from the chlorination of bauxite, clay and other aluminous ores. The method comprises first dissolving the aluminum chloride at about atmospheric pressure in a molten salt solvent in which most of the other principal metal chloride vapors, like SiCl.sub.4 and TiCl.sub.4, are substantially insoluble; then vaporizing and separating the AlCl.sub.3 to produce a purified liquid product. This process eliminates the previous use of costly and/or hazardous compressors and scraped-wall condensers and provides for economical recovery of purified liquid aluminum chloride.

Abstract: A process for purifying aluminum chloride gas such as that produced in the chlorination of bauxite, clay and other aluminous ores is disclosed. The method first selectively dissolves or liquefies AlCl.sub.3 from an anhydrous mixture of gaseous metal chlorides which may also include the chlorides of Si, Ti, Fe and other metals. More specifically, the method of the present invention provides for selectively dissolving AlCl.sub.3 vapor at substantially atmospheric pressure without the use of costly or hazardous compressors, or the scraped-wall condensers formerly required for this purpose. In addition, the present method allows for economical recovery of the liquefied AlCl.sub.3.

Abstract: A process of carbo-chlorination of AlPO.sub.4 wherein AlPO.sub.4 or AlPO.sub.4 -containing material is introduced into a reactor along with chlorinating agents and a source of carbon. The reactor is heated to approximately 600.degree. to 1200.degree.C and forms aluminum chlorides, phosphorous oxides, phosphorous chlorides, phosphorous oxychlorides and carbon oxides. These reaction products are then separated into three fractions by condensation, the first fraction being P.sub.2 O.sub.5, the second fraction being AlCl.sub.3 and AlCl.sub.3 .POCl.sub.3 and the third fraction being remaining gasses, namely PCl.sub.3, PCl.sub.5, P.sub.2 O.sub.3, CO and CO.sub.2. The second fraction is reacted in a further reactor to give AlCl.sub.3 and P.sub.2 O.sub.3 which are separated by distillation. The phosphorous chlorides from the third fraction are oxidized, along with the P.sub.2 O.sub.3 of the second fraction, to form P.sub.2 O.sub.5.