Abstract: A process for purifying solid crude aluminum chloride, containing iron impurities, includes the steps of mixing iron with the crude aluminum chloride and reactively subliming and desubliming the mixture.

Abstract: A process for producing alumina involving reacting anhydrous aluminum chloride with a oxidizing agent with a temperature within the range of from about 700.degree. C. to about 1200.degree. C. to form aluminum oxide and chlorine and separating the chlorine and mixing a portion thereof with the reacting aluminum chloride and oxidizing agent.

Abstract: A mixture of an aluminous ore and a carbon source is dried and calcined in the presence of a sulfur-containing compound. The mixture is then chlorinated to produce crude metal chlorides. Aluminum chloride is condensed and separated from the remaining metal chlorides, combined with sulfur and aluminum powder, and sublimated and desublimated so as to produce substantially pure aluminum chloride.

Abstract: The purification of aluminum chloride, with the crude aluminum chloride normally being obtained through a process of carbo-chlorination of metallic ores, in particularly aluminum bearing ores, to make the metallic chlorides, in particular aluminum chloride. In the present invention, if the crude aluminum chloride does not contain traces of sulfur, the crude aluminum chloride is blended with elemental sulfur or an equivalent sulfur containing compound and simultaneously elemental aluminum powder or an equivalent aluminum containing compound in the solid state is added to the crude aluminum chloride. This blend is kept at 180.degree. C. at one atmosphere of pressure and is fed into a screw-type sublimer wherein the substantially pure aluminum chloride undergoes sublimation in the presence of elemental nitrogen as a purging agent and under constant agitation. The sublimed aluminum chloride is streamed into a reaction ground bed containing aluminum granules at approximately 250.degree. C.

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 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: 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 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: The present invention provides a process for the catalytic reduction of aluminum chloride by manganese to form a high aluminum content alloy, separating the catalysis metal from the alloy, and separating the manganese in the alloy to produce essentially pure aluminum. As a preferred embodiment, liquid aluminum chloride is contacted with solid manganese metal in the presence of a Group IIB metal or compound thereof at a relatively low temperature and at a pressure to maintain the reactants in such phases.

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 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 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 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.