Abstract: Aluminum dross containing chlorides and combustible volatile material is agglomerated and sized to produce a compact which is then treated in a direct fired rotary kiln in excess of 1800.degree. F. to volatilize the chlorides and burn the combustible volatile material and to produce a refractory material. The flue gases containing the volatilized chlorides are then treated in a condenser where the chlorides are condensed out of the remaining flue gases. The refractory product from the kiln may be passed through a cooler wherein the heat is transferred to the combustion air.

Abstract: A dry, lightweight refractory mixture which can be shipped and stored in a dry form, but which becomes plasticized upon the addition of water to yield a moldable, air-setting, insulating refractory composition, the dry refractory mixture including from about 35 to about 70% by weight ceramic fiber; from about 10.5 to about 40% by weight setting agent, preferably a mixture of aluminum phosphate powder and calcined magnesia powder; from about 5 to about 20% by weight of dry, water-soluble, powdered resin binder prepared from urea formaldehyde or melamine formaldehyde, and from about 0.3 to about 2% by weight of dry, water-soluble, non-ionic, powdered organic polymer gelling and cohesion enhancing agent. The dry mixture also preferably includes from about 0.5 to about 2.0% by weight of a dry, water-soluble acidifying agent for catalyzing the air-setting of the plasticized composition.