Abstract: An abrasive particle (01) having a shell (02) and a hollow space (03) arranged within the shell (02) is proposed.

Abstract: A process for extracting metal values from ores or residues is disclosed. The process mentioned above is mainly suitable for aluminoferrous ores such as bauxite, titanoferrous ores such as ilmenite, or residues such as red mud waste. The process involves pulverizing the ore and/or residue and mixing with a carbonaceous material, followed by smelting the iron values and slag in the mixture to yield molten iron and oxides of aluminum and titanium. The process is simple, cost-effective, and provides effective extraction of high purity metal values.

Abstract: A method for producing a GaN crystal capable of achieving at least one of the prevention of nucleation and the growth of a high-quality non-polar surface is provided. The production method of the present invention is a method for producing a GaN crystal in a melt containing at least an alkali metal and gallium, including an adjustment step of adjusting the carbon content of the melt, and a reaction step of causing the gallium and nitrogen to react with each other. According to the production method of the present invention, nucleation can be prevented, and as shown in FIG. 4, a non-polar surface can be grown.

Abstract: Disclosed is a method for preparing a lithium metal phosphate represented by the following Formula 1 by using a mixture of a metal (M) with a metal oxide containing the same metal: LixMyPO4??[Formula 1] wherein M is a transition metal element selected from Group 3 to 12 elements in the Periodic Table, Mg, Al, Ga and B; 0.05?x?1.2; and 0.8?y?1.2. Also, an electrode comprising the lithium metal phosphate as an electrode active material, and a secondary battery comprising the electrode are also disclosed.

Abstract: A mass of solid aluminium carbide containing product is produced by injecting particulate alumina into a bath (30) of molten aluminium metal; and injecting carbonaceous material, consisting of, containing or yielding carbon, into the bath (30). The bath (30) of molten aluminium metal is maintained at a superheated temperature to heat and react carbon with molten aluminium to produce solid aluminium carbide which mixes with alumina to form a mass (36) containing entrapped gas and entrapped molten aluminium metal and having a bulk or apparent density less than aluminium. The mass is allowed to accumulate as a mass of solid aluminium carbide containing product on the upper surface of the bath. The carbonaceous material is a hydrocarbon material or is produced by pyrolysis, decomposition or cracking of a hydrocarbon material.

Abstract: A carbothermic process for producing an aluminium carbide containing mass by injecting carbon and alumina into molten aluminium superheated above 1400° C. The carbon reacts with molten aluminium to produce an aluminium carbide and alumina mass. The mass can be heated in the range of 1700° C. to 2000° C. to produce aluminium metal and carbon monoxide.

Abstract: This invention discloses a type of improved graphite granules and the method for their fabrication. Each improved graphite granule includes an unimproved graphite granule whose electrochemical properties need to be improved, and a membrane of amorphous carbon enveloping said unimproved graphite granule forming the membrane. The thickness of said amorphous carbon membrane is between 0.05 &mgr;m and 1 &mgr;m. To fabricate said improved graphite granules, said unimproved graphite granules are immersed in a polymer surface modifying solution, stirred, separated, sifted, and then solidified and carbonized. Said improved graphite granules, when used as the negative electrode of a lithium ion rechargeable battery produces a battery with excellent high current characteristics, high reversible specific capacity, long cycle life, and can satisfy the performance demands on rechargeable batteries. The technology for the fabrication of this improved graphite granules is simple. Its cost of production is low.

Abstract: A process for producing unagglomerated single crystals of aluminum nitride having a size of at least 10 microns suitable for the reinforcement of metal and ceramic matrix composite materials. The process involves reacting alumina (or a precursor) with carbon under an atmosphere of nitrogen (or a precursor such as ammonia or an amine) at a temperature in the range of 1800.degree.-1950.degree. C. in the presence of an alkaki metal oxide (or precursor such as a carbonate) as a crystal growth promoter or catalyst. The alkali metal oxide is present in an amount required for the formation of crystals of the required size, preferably in the range of 10-60 microns. Particularly desirable crystals are produced if electrostatic precipitator dust is used as a source of the alumina, if petroleum coke or calcined anthracite coal is used as a source of the carbon and if the reaction is carried out in the presence of a porosity enhancer for the reaction mass, especially short cellulose fibres.

Abstract: A process for producing chlorides by the chlorination of a material selected from the group consisting of aluminous materials and metal and metalloid oxides in the presence of a reductant. The method comprises calcining a carbonaceous material with added steam to oxidize substantially all precursors of chlorinated hydrocarbons and to form a reductant; and chlorinating a material selected from the group consisting of aluminous materials and metal oxides in the presence of the reductant.

Abstract: The invention pertains to an entrained-downflow chlorination process of fine metalliferous ores particularly containing alkali and/or alkaline earth metals greater than about 0.3% by weight as the oxide. The process includes a quenching step following the chlorination step where the chlorinated products are quenched by liquid cooling fluid spray patterns adapted to prevent solidification of the alkali and/or alkaline earth materials onto the reactor walls. The chlorinator unit of this invention prevents disruption of the chlorination process due to presence of liquids or sticky particles and it contains a quenching spray means disposed below the chlorination zone in the entrained-downflow chlorinator unit, whereby the quenching sprays prevent reactor wall buildup.

Abstract: A process for the beneficiation of an iron-containing material is carried out by first chlorinating the iron-containing material. Oxidation of ferrous chloride in the effluent gas from the chlorination is carried out under controlled conditions of oxygen supply so that more than 50% but less than 100% of the ferrous chloride is oxidized. In this way chlorine gas is separated from the process stream in a relatively pure form which can be utilized in a continuous process by recycle to another chlorination.

Abstract: In preparing AlCl.sub.3 from Al.sub.2 O.sub.3 at about 750.degree.-950.degree. C. in a carbothermic process, the rate of the reaction is increased by adding a catalytically active amount of a catalyst selected from the group consisting of:alkali fluorides;alkaline earth fluorides;fused mixtures of alkali, alkaline earth, or alkali and alkaline earth fluorides;alkaline earth carbonates;fused mixtures of alkali, alkaline earth, or alkali and alkaline earth carbonates;alkaline earth chlorides;alkaline earth bromides;alkaline earth oxides;sources of alkaline earth oxides or alkaline earth halides in situ by decomposition upon heating at about 750.degree. C.; andmixtures thereof.

Abstract: A process for decomposing chlorinated hydrocarbon compounds wherein the compounds are heated to an elevated temperature of about 800.degree. to 1200.degree. C. and reacted with alumina and a reactive carbon source. A preferred operating temperature is about 800.degree. to 900.degree. C. and preferred carbon sources are activated carbon and coked alumina. The process is particularly useful for disposing of chlorinated organic compounds that are generated in the production of metal chlorides by chlorination of a metal oxide in the presence of carbon.

Abstract: The invention relates to a process for the recovery of valuable metals from sulfidic, silicate-containing raw materials by slurrying the raw material in water, by subjecting the slurry to a selective leach under atmospheric conditions and in an acidic milieu, and by separating the valuable-metal containing solution from the solid leach residue.When the leach is carried out by introducing an oxygen-bearing gas into the slurry which contains finely-divided sulfide and carbon, the acidity of the slurry drops in a controlled manner so that a high efficiency of oxygen, and a high selectivity of the leach as regards valuable metals, are obtained. Owing to the presence of carbon the oxygen is reduced very easily and so oxygen efficiency is high and the rate of dissolving of the valuable metals increases in the slurry mixture.

Abstract: An improved method of producing anhydrous aluminum chloride via aluminum chloride hexahydrate is provided. In a preferred embodiment the method is incorporated into a process for producing aluminum from aluminous ores, and particularly from domestic ore sources comprising (1) acid leaching an aluminous ore to produce aluminum chloride hexahydrate (ACH); (2) calcining the ACH to a specific temperature of above about 450.degree. C. to produce highly reactive aluminous particles containing high residual chloride and low residual hydrogen levels; (3) reductively chlorinating the calcined ACH at a low temperature to produce anhydrous aluminum chloride suitable for electrolytic reduction; and (4) electrolytically reducing the anhydrous aluminum chloride in a fused salt to produce aluminum metal and chlorine which is recycled to step (3).

Abstract: An improved solid carbon reductant comprising partially calcined carbonaceous materials such as petroleum coke, containing relatively low amounts of residual hydrocarbons and a relatively high surface area and thus increased activity as compared to known reductants is provided. This improved reductant is produced by a method comprising heating the carbonaceous material in an oxidizing atmosphere to a temperature of from about 650.degree. C. to about 950.degree. C., preferably from about 800.degree. C. to about 875.degree. C., and most preferably at a temperature about 850.degree. C. In addition, according to the present invention improved chlorination processes are provided using these reductants which result in reduced levels of chlorinated hydrocarbon (C.sub.x Cl.sub.y) production due to reduced residual hydrocarbons. In a preferred embodiment anhydrous aluminum chloride is produced by chlorination of aluminum hexahydrate using the improved reductant.

Abstract: A novel method of activating carbon is provided comprising contacting the carbon with low temperature aluminum chloride acid melts comprising at least 50 mole percent aluminum chloride and less than 50 mole percent of at least one halide salt capable of exhibiting a liquid state at atmospheric conditions, e.g., sodium chloride. Carbon activated according to the present invention is useful as a reductant of the chlorination of aluminous materials to produce anhydrous aluminum chloride.

Abstract: The efficiency of a given reactor for the conversion of aluminum oxide bearing starting material by means of reducing and chlorinating gases or of carbon coated aluminum oxide bearing starting material by means of chlorinating gases in a solid/gas fluidized bed to yield aluminum chloride is improved by the addition of an inert, solid dilution agent to the bed. Whereas, as a result of the chemical reaction, the average particle size and bulk density of the reagent decreases in a batch process, and in a continuous process an equilibrium value is reached, the average particle size and the bulk density of the inert material remains unchanged. An initial average particle size of 60-80 microns proved successful; quartz, corundum, magnesium oxide of similar particle size and bulk density was added as dilution agent, and a gas flow rate of 2 to 30 cm/sec was attained along with quantitative conversion of the gaseous reagent.

Abstract: The process is based on the series of halide-forming affinities. The oxides are passed through a series of zones equal in number to the plurality of halides or mixtures which are to be produced. A halide of an element of lower halide-forming affinity is fed counter-current to the oxides. The halide supply is in stoichiometric equivalent to the total content of halide to be extracted. The oxide of the said fed element is also extracted.

Abstract: Chlorination of aluminous materials such as alumina and bauxite is carried out at 575.degree. to 750.degree. C. in the presence of a solid reducing agent. The reducing agent is a green coke which has been calcined at a temperature between 650.degree. C. and 900.degree. C. for a period of from 10 to 120 minutes.

Abstract: A continuous process for recovering substantially pure aluminum chloride from chlorination products of aluminum ore. The chlorination products are contacted with a first selective solvent to dissolve a substantial portion of the aluminum chloride and some ferric chloride. The solvent is separated from the chlorides which then are treated to produce a ferric chloride-rich stream and an aluminum chloride-rich stream in which the aluminum chloride to ferric chloride ratio is higher than the ratio prior to solvent separation. The aluminum chloride-rich stream is contacted with a second solvent to dissolve any ferric chloride present and saturate the solution with aluminum chloride. Aluminum chloride in excess of that soluble in the second solvent separates as a substantially pure solid phase. The solution is separated from solid phase and recycled in process to recover additional aluminum chloride.

Abstract: When an alkali such as an alkali metal bicarbonate or carbonate is intimately mixed with bauxite or other alumina-containing raw material at an Al.sub.2 O.sub.3 /Na.sub.2 O molar ratio of from 1/1 to 1/3 and the mixture is molded into granules, then calcined and extracted with an aqueous medium, the alumina component can be recovered in a high yield in the form of an aqueous solution of an alkali metal aluminate. The alkali component is not substantially contained in the residue left after recovery of this aqueous solution.

Abstract: A method of producing aluminum chloride from aluminous materials containing compounds of iron, titanium and silicon comprising reacting the aluminous materials with carbon and a chlorine-containing gas at a temperature of about 900.degree. K. to form a gaseous mixture containing chlorides of aluminum, iron, titanium and silicon and oxides of carbon; cooling the gaseous mixture to a temperature of about 400.degree. K. or lower to condense the aluminum chlorides and iron chlorides while titanium chloride and silicon chloride remain in the gas phase to effect a separation thereof; heating the mixture of iron chlorides and aluminum chlorides to a temperature of about 800.degree. K. to form gaseous aluminum chlorides and iron chlorides; passing the heated gases into intimate contact with aluminum sulfide to precipitate solid iron sulfide and to form additional gaseous aluminum chlorides; and separating the gaseous aluminum chloride from the solid iron sulfide.

Abstract: A method of forming the chloride of a metal-oxygen-containing substance, including the steps of coating particles of such substance with green carbon, i.e. carbon which contains substances more volatile than carbon, heating the coated particles to drive off the volatile matter and produce openings such as pores and fissures, and then reacting the particles from the step of heating with a source of chlorine.

Abstract: Aluminum chloride is produced from clay containing aluminum oxide and silicon oxide by chlorinating clay in at least two stages with a mixture consisting of a chlorinating agent, a reducing agent, an alkali metal compound catalyst and silicon tetrachloride in which the proportions and amounts of the feed gases to each stage are separately regulated to suit the needs of the aluminum chloride production reaction in that stage. The effluent gases from the successive stages are collected and the silicon tetrachloride is separated from such gases and recycled back into the reactors to promote chlorination of the aluminum oxide in the clay while suppressing net chlorination of the silicon oxide fraction of the clay.

Abstract: In the conversion of a metal oxide to a metal chloride by reaction with chlorine and carbon monoxide wherein hydrogen chloride is produced as byproduct, the byproduct hydrogen chloride is contacted with a molten salt mixture containing the higher and lower valent chlorides of a multivalent metal and oxygen to recover the hydrogen chloride by enriching the salt in the higher valent metal chloride. Essentially all of the chlorine values are recovered from the salt by direct contact with all or a portion of the carbon monoxide fresh feed to the metal chloride production, with such carbon monoxide stripping gaseous chlorine from the salt, as well as combining with the chlorine to produce phosgene. The carbon monoxide, chlorine and phosgene are employed in the metal chloride production.

Abstract: A process is disclosed for recovering metallic constituents of spent or waste catalysts containing metallic compounds fixed on an aluminous support. The process is particularly applicable for the recovery of metals such as Al, Mo, V, Ni and Co, contained in spent catalyst. The process comprises transforming the metals to be recovered into volatile chlorides by carbochlorination and then separating the chlorides obtained by dry means and fixing them successively in a selective manner. The separation of AlCl.sub.3 is accomplished by passage through granules of anhydrous NaCl, and the separation of MoCl.sub.5 by passage through granules of crystallized KCl. The process is particularly suitable for the treatment of waste catalyst from the catalytic hydrocracking or hydrodesulfurization of oils.

Abstract: The present invention provides a novel process for the preferential chlorination of alumina over silica in the carbo-chlorination of kaolinitic ores to produce aluminum chloride. The process comprises introducing small amounts of alkali metal compounds with oxyanions into the carbo-chlorination process. Preferred embodiments are directed to particular compounds of alkali metals with oxyanions selected from the group consisting of carbonates, sulfates, hydroxides, oxides, phosphates, and the like. The present invention results in significantly reduced energy, manufacturing, and equipment costs and thus represents a breakthrough in the utilization of domestic ores such as kaolinitic clay for the production of aluminum chloride or alumina through oxidation of the aluminum chloride.

Abstract: A process for removing silicon from a silicate-bearing material. The silicate-bearing material is analyzed for its silicon content and mixed with a controlled quantity of carbon as indicated by the analysis. The carbon is limited to an amount less than the stoichiometric amount necessary to react with the silicon to form silicon carbide. The silicate-bearing material/carbon mixture is formed into a first phase and interposed with a second phase containing additional carbon to form a reaction mixture. The reaction mixture is subjected to a carbothermal reduction reaction to reduce silica in the silicate-bearing material to silicon monoxide. At the temperatures involved in the reaction, the silicon monoxide is in the gaseous phase and readily diffuses from the first phase into the second phase where the diffused silicon monoxide reacts with the additional carbon in the second phase to form silicon carbide.

Abstract: A process for the production of aluminum chloride comprises providing a mixture of high purity activated carbon and alumina and bubbling chlorine gas therethrough, the mixture being kept at a temperature in the range of 500.degree. to 775.degree. C. Aluminum chloride is removed from the mixture as a vapor and condensed.

Abstract: An improved process for the production of aluminum chloride from coked alumina and chlorine comprises providing a bed of coked alumina in a reaction vessel and introducing gaseous chlorine thereto in an amount sufficient to fluidize the bed, at least a portion of the vessel having a nitride-based refractory lining especially adjacent and bounding the lower part of the fluidized bed. Aluminum chloride formed is recovered as a gaseous effluent emmanating from the bed.

Abstract: A novel improvement in the process for the carbochlorination of kaolinitic ores is provided wherein the improvement comprises adding catalytic amounts of boron chloride to the carbo-chlorination step which results in the catalyzed and controlled chlorination of alumina and silica. Preferably, about 0.3 to 5.0 percent of boron chloride per volume of chlorine is added to the chlorination step and in combination with from 5 to 40 percent or more of reductant carbon to provide a conjoint action wherein preferential chlorination of alumina over silica is obtained at low levels of boron chloride and reductant and total chlorination of both alumina and silica are obtained at high boron chloride and reductant levels.

Abstract: One of the major obstacles toward the needed and economic production of alumina and other values from kaolinitic clay and other ores by chlorination has been the slow reaction rates and low yields of the metal values. The present information provides methods for improving reaction rates and/or yields in the halogenation of various ores which comprises the addition of sulfur and/or functionally equivalent sulfur containing compounds as an ore conditioning agent and/or reaction promoter. These improvements also permit operation at low temperatures with advantage of savings of energy and of equipment and maintenance costs. The invention is applicable to both displacement halogenation and carbo-halogenation processes. The sulfur and/or functionally equivalent sulfur containing compounds can be added to the reaction mass during pre-halogenation steps or to the halogenation step or to combinations of steps ordinarily with additional benefits.

Abstract: Multicourse liner construction for a fluidized bed reaction chamber for the chlorination of alumina bearing material including a reaction-chamber-defining inner course of essentially non-reactive carbon, an outer course of heat insulating refractory material, and an intermediate course of high density and essentially non-reactive material to minimize undesired flow of reactant chlorine externally of said reaction chamber.

Abstract: The invention provides a process for recovering aluminum values from aluminum-containing minerals, such as oxides of aluminum and aluminosilicates.The process involves heating an intimate mixture of an aluminum-containing mineral and a solid carbonizable organic material, preferably a fibrous cellulosic material, so as to carbonize the organic material, and chlorinating the solid residue from the carbonization step. The solid residue contains carbon in very finely divided form distributed throughout the aluminum-containing mineral. The surface area and reactivity of this carbon is much higher than that of powdered coal and the chlorination reaction thus takes place in a most efficient manner.

Abstract: Recovery of high purity aluminum chloride is achieved by use of a series of condensers wherein the first condenser is operated at a high temperature of 80.degree.-110.degree. C to insure minimum condensation of other metal chlorides such as titanium chloride, silicon chloride, or the like, while a second condenser operates at a much lower temperature of from 20.degree.-50.degree. C to trap all impurities while reducing the chloride losses to a minimum. The product of the first condenser may then be used as a feed for the electrolytic reduction of aluminum chloride to metallic aluminum.

Abstract: A process is disclosed for recovering the caustic and alumina values from high iron-containing Bayer red mud utilizing the so-called lime-soda-sinter process wherein a carbonaceous material such as coke is included in the sintering operation and leaching is carried out without any intermediate iron separation step.

Abstract: A method for producing aluminum chloride comprises contacting Al.sub.2 O.sub.3 with a reducing agent and chlorine in a bath of molten metal halides to form aluminum chloride and recovering the aluminum chloride by vaporization.

Abstract: An improved method is disclosed for producing aluminum chloride by contacting aluminum oxide, a reducing agent, and chlorine in a molten bath of aluminum chloride and metal halide to form aluminum chloride which is recovered from the bath by sublimation. The improvement comprises increasing the rate of formation of aluminum chloride by adding a source of metal selected from the group consisting of iron, chromium, copper, europium and cerium to the molten bath.

Abstract: A method of producing an alumina bearing product in which the alumina is substantially soluble in cold alkali including the steps of contacting an aluminium bearing material with concentrated sulphuric acid containing 30 to 100 weight percent sulphuric acid, heat treating the acid and material to cause the acid to react with the material to form a substantially anhydrous hard product and decomposing the product by heat treatment to produce the alumina bearing product. The alumina values may be recovered from the resulting alumina bearing product using the known Bayer process. The process has particular application to non-bauxitic ores.

Abstract: Multicourse liner construction for a fluidized bed reaction chamber for the chlorination of alumina bearing material including a reaction-chamber-defining inner course of essentially non-reactive carbon, an outer course of heat insulating refractory material, and an intermediate course of high density and essentially non-reactive material to minimize undesired flow of reactant chlorine externally of said reaction chamber.

Abstract: Recovery of selectively constituted high purity aluminum chloride from the gaseous effluent of the chlorination of sodium contaminated alumina including the steps of purifying such gaseous effluent to provide essentially contaminant-free aluminum chloride in gaseous form in a gaseous carrier through selectively cooling the hot gaseous effluent to a temperature range well below the chlorination temperature but above the ambient condition condensation temperature of aluminum chloride yet sufficient to condense a selective portion of the condensable constituents therein including substantially all of the sodium aluminum chloride values therein, intermediate the steps of passing such gaseous effluent through filtration media to effect the separation of the condensed sodium aluminum chloride values and entrained solid and liquid particles therefrom and condensing high purity aluminum chloride values from the purified residual gaseous effluent to selectively constituted solid form at controlled temperatures.

Abstract: The instant invention is particularly useful for using low-grade carbonaceous material to form aluminum-trichloride. Aluminous material and the carbonaceous material are comminuted either separately or together, and then the aluminous and carbonaceous materials are either compacted or mixed with a binder to form a doughlike paste. The compacting or mixing with the binder to form the dough-like paste is to insure that the particulate aluminous and carbonaceous materials have extremely close and intimate contact. The mixture is then calcined and chlorinated at an elevated temperature to form aluminum trichloride.

Abstract: A process for the production of aluminum chloride from raw materials such as coal slate or bituminous shale is disclosed. The raw material should preferably have an ash content of at least 30% by weight, and with the aluminum content of the ash being at least 20%, calculated as Al.sub.2 O.sub.3. The raw material is first calcined and then chlorinated with a gaseous stream containing chlorine and carbon monoxide to form the aluminum chloride product.

Abstract: A process for the production of aluminum chloride from raw materials such as coal slate or bituminous shale is disclosed. The raw material should preferably have an ash content of at least 30% by weight, and with the aluminum content of the ash being at least 20%, calculated as Al.sub.2 O.sub.3. The raw material is first calcined and then chlorinated with a gaseous stream containing chlorine and carbon monoxide to form the aluminum chloride product.