Abstract: A method for continuously casting lithium-containing alloys by a direct chill process includes cooling the alloy to form a continuous ingot having a solid shell and further cooling the ingot by direct chill with an organic coolant. The organic coolant in one aspect includes a modified hydrocarbon fluid, e.g., ethylene glycol, having less than a predetermined moisture content. The method includes recirculating coolant while controlling moisture content. An ingot formed by the present invention provides small dendrite arm spacing in a relatively large size ingot.

Abstract: A method for continuously casting lithium-containing alloys by a direct chill process includes cooling the alloy to form a continuous ingot having a solid shell and further cooling the ingot by direct chill with an organic coolant. The organic coolant in one aspect includes a modified hydrocarbon fluid, e.g., ethylene glycol, having less than a predetermined moisture content. The method includes recirculating coolant while controlling moisture content. An ingot formed by the present invention provides small dendrite arm spacing in a relatively large size ingot.

Abstract: The present invention provides heat exchanger apparatus and method including a tubular heat transfer surface, a heat transfer fluid which is made to pass along the surface, and a wire brush heat exchanger insert positioned to impinge the fluid flowing within the heat transfer surface. The brush heat exchange insert is composed of a ceramic material having a high absorptance and emittance.

Abstract: The process of the present invention for preparing granules of alumina includes pretreating an alumina powder by admixing with cold water in a mixer at a temperature below room temperature, e.g., such as below about 20.degree. C., to form a pretreated alumina having a pore volume saturated with water and further having a surface area of gel structure, and agglomerating the pretreated alumina in a fluidized bed to form granules sized in the range of about 1-3 mm. The process is particularly suited to producing activated alumina in macroporous granules. The process in one aspect further includes a cold hopper for cooling alumina powder prior to the pretreating step.

Abstract: The present invention provides heat exchanger apparatus and method for enhancing heat transfer between a fluid and a tubular heat exchanger surface. The invention involves a heat transfer surface, a heat transfer fluid passed along the surface, and a metal or ceramic thin rod packing positioned to impinge the fluid flowing within the heat transfer surface. The thin rod packing is established in the form of a screen heat exchange insert composed of a metal or ceramic material having a high adsorptance and emittance.

Abstract: The present invention provides heat transfer apparatus and method for enhancing the heat transfer of fluid passing along a tubular heat exchange surface including positioning a heat exchange insert of planar or, sheet-like shape to form an unobstructed area of about 20%-80% of the tubular cross section. The heat exchange insert is constructed of a material having an absorptance and emittance to provide high radiative heat transfer over a substantially unobstructed line of sight between the insert surface and the tubular surface. Heat exchange inserts are further positioned in the tube or pipe to increase the mass of fluid contacting the insert by alternating the position of insert in the tube.

Abstract: This invention includes apparatus and method for providing a support mechanism for electrode assemblies including positioning means of electrically nonconductive material having an inside surface forming an internal cavity, means for passing a heat transfer fluid through the cavity along the inside surface, and wire or fiber in the path of the fluid. The wire or fiber is positioned essentially normal to the flow of the fluid and is positioned to provide a substantially unobstructed line of sight between the wire or fiber and the inside surface, the wire or fiber having a high radiative absorptance and emittance.

Abstract: Disclosed are method and fluid lift pump for raising liquids through a bundle of substantially vertical lift tubes adapted to raise liquids even while submerged less than 50% of total lift height, the tubes having about the same length extending side by side, each tube having an inside diameter of less than about one inch. The lift tubes communicate at the lower end with a housing defining a chamber capable of being filled with liquid to be raised, and the lower portion of the housing includes means for injecting a lifting fluid into the liquid in the chamber. The injecting means comprise an injecting orifice, having an inside diameter no larger than about the largest lift tube inside diameter, positioned below the lower ends of the lift tubes by a specified distance depending on the cross-sectional area of the bundle and the number of injecting orifices. Bubbles of lifting fluid rise through the liquid in the chamber, enter the lift tubes, and form rising slugs of liquid separated by slugs of lifting fluid.

Abstract: Disclosed are electrolytic cell and method in which first and second electrodes are adapted to pass a current through an inter-electrode zone of specified dimension for containing electrolyte, wherein the first electrode is held free from support by internal cell surfaces, and one electrode is provided with electrical connection to a liquid pad, e.g., of molten metal product, having a higher electrical conductivity than cell electrolyte.A preferred embodiment includes channeling gas from the anode, facilitating run-off of product liquid from the cathode, and incorporating bipolar electrode assemblies. The cell and method of the present invention are suitable for the production of a metal, for example, aluminum, from a compound of the metal, e.g., alumina, dissolved in an electrolyte, e.g., cryolite.

Abstract: A process is disclosed for purifying gibbsitic alumina-rich ore of high silica content including admixing the ore with an aqueous digestion solution high in silica concentration. In one aspect the digestion is performed with high alumina and soda concentration at low temperature, e.g., such as by atmospheric digestion.

Abstract: Novel adsorbent and substrate compositions are formed by mixing activated aluminas and synthetic hydrotalcite produced by reacting activated magnesia with an aqueous solution containing aluminate, carbonate, and hydroxyl ions. Activated magnesia used in this method is formed by heating a magnesium compound such as magnesium carbonate or magnesium hydroxide to a temperature between about 500.degree.-900.degree. C. The method is suited to producing synthetic hydrotalcite from industrial Bayer liquor. The synthetic hydrotalcite so formed can be heated to a temperature of about 500.degree.-600.degree. C. to form a highly porous and adsorbent product either before or after mixing with activated aluminas to form the composite of the present invention.

Abstract: Disclosed are method and fluid lift pump for raising liquids through a bundle of substantially vertical lift tubes adapted to raise liquids even while submerged less than 50% of total lift height, the tubes having about the same length extending side by side, each tube having an inside diameter of less than about one inch. The lift tubes communicate at the lower end with a housing defining a chamber capable of being filled with liquid to be raised, and the lower portion of the housing includes means for injecting a lifting fluid into the liquid in the chamber. The injecting means comprise an injecting orifice, having an inside diameter no larger than about the largest lift tube inside diameter, positioned below the lower ends of the lift tubes by a specified distance depending on the cross-sectional area of the bundle and the number of injecting orifices. Bubbles of lifting fluid rise through the liquid in the chamber, enter the lift tubes, and form rising slugs of liquid separated by slugs of lifting fluid.

Abstract: A method is disclosed for controlling flow rates of a primary fluid including aspirating, mixing, and metering the primary fluid with a secondary fluid. The secondary fluid has a high relative vapor pressure to form a gaseous mixture consisting essentially of vapor at constant volume fraction of primary fluid independent of flow rates. In one aspect, the invention includes passing a secondary fluid of diluent gas through a venturi having specified proportions including discharge coefficient; and pumping primary fluid through venturi suction to pass through a primary fluid orifice of specified discharge coefficient wherein the venturi discharge coefficients of the venturi and the liquid orifice form a substantially linear proportionality over a wide range of flow rates through the venturi.

Abstract: An apparatus is disclosed for controlling flow rates of a primary fluid including aspirating, mixing, and metering the primary fluid with a secondary fluid. In one aspect, the invention includes means for passing a secondary fluid of diluent gas through a venturi having specified proportions including discharge coefficient; and means for pumping primary fluid through venturi suction to pass through a primary fluid orifice of specified discharge coefficient wherein the venturi discharge coefficients of the venturi and the liquid orifice form a substantially linear proportionality over a wide range of flow rates through the venturi.

Abstract: A process is disclosed for the continuous casting of a lithium-containing alloy including casting the alloy through a mold and applying alpha-olefin oligomer to the mold. In one aspect, the process includes a lubricant containing alpha-olefin oligomer, preferably having a viscosity in the range of about 1-3 cs at 450.degree. F. In another aspect, the process includes a lubricant containing less than the varnish-film forming amount of fatty ester, fatty acid, or fatty alcohol.

Abstract: Disclosed is an electrolytic cell including first and second inclined or nonhorizontal electrodes, means for holding the first electrode in position relative to the second electrode to form an inter-electrode zone of specified dimension, wherein the first electrode is held essentially free from support by the internal surfaces of the cell, and conductive means for electrically connecting one electrode to a separate liquid pad of higher conductivity than the electrolyte.Also disclosed is an electrolytic method including establishing first and second inclined or nonhorizontal electrodes in relative position in an electrolytic cell to form an inter-electrode zone of specified dimension for containing an electrolyte, supporting the first electrode essentially free from support by an internal cell surface, and connecting one electrode electrically with a separate liquid pad of higher conductivity than the electrolyte.

Abstract: Disclosed is a process for producing purified alumina from high-silica bauxite including separating alumina-rich ore containing high-silica content into a coarse fraction and a fines fraction; digesting the fines fraction in a sodium aluminate solution at low temperatures; digesting the coarse fraction in a sodium aluminate solution at higher temperatures under pressure; and precipitating out alumina from the digest solutions after the combined liquors are desilicated during clarification.

Abstract: A method for continuously casting lithium-containing alloys by a direct chill process includes cooling the alloy to form a continuous ingot having a solid shell and further cooling the ingot by direct chill with an organic coolant. The organic coolant in one aspect includes a modified hydrocarbon fluid, e.g., ethylene glycol, having less than a predetermined moisture content. The method includes recirculating coolant while controlling moisture content. An ingot formed by the disclosed method provides small dendrite arm spacing in a relatively large size ingot.

Abstract: The present invention involves a process for continuously casting a lithium-containing alloy by direct chill with a direct chill coolant and providing a moisture barrier liquid having a flash point higher than about 400.degree. F. to reduce water absorption in the coolant. The process in one aspect includes applying the moisture barrier liquid as a mold parting composition containing less than a varnish-film forming amount of fatty esters, fatty acids, or fatty alcohols. The process is particularly useful in the direct chill casting of aluminum-lithium alloy by direct chill with ethylene glycol coolant.

Abstract: A lubricating process is disclosed for continuously casting molten metal through a mold or header including applying a parting lubricant containing alpha-olefin oligomer to the mold or header. In one aspect, the process includes applying a parting lubricant containing alpha-olefin oligomer and fatty ester.