Abstract: A mass of solid aluminum carbide containing product is produced by a process in which a mixture is formed of an aluminum containing material and a carbonaceous material consisting of, containing or yielding carbon. Then the resulting mixture is heated to a temperature sufficient to react carbon of the carbonaceous material with the aluminum of the aluminum containing material to produce solid aluminum carbide. The solid aluminum carbide then is able to be heated with an aluminum compound selected from Al2O3, Al4CO4, AlO, Al2O and mixtures thereof, to produce aluminum metal and carbon monoxide.

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.