Abstract: Disclosed is a method for the carbothermic reduction of aluminum oxide to form an aluminum alloy including producing silicon carbide by heating a first mix of carbon and silicon oxide in a combustion reactor to an elevated temperature sufficient to produce silicon carbide at an accelerated rate, the heating being provided by an in situ combustion with oxygen gas, and then admixing the silicon carbide with carbon and aluminum oxide to form a second mix and heating the second mix in a second reactor to an elevated metal-forming temperature sufficient to produce aluminum-silicon alloy. The prereduction step includes holding aluminum oxide substantially absent from the combustion reactor. The metal-forming step includes feeding silicon oxide in a preferred ratio with silicon carbide.

Abstract: Disclosed are apparatus and method of carbothermic direct reduction for producing an aluminum alloy from a raw material mix including aluminum oxide, silicon oxide, and carbon wherein parallel heat sources are provided by a combustion heat source and by an electrical heat source at essentially the same position in the reactor, e.g., such as at the same horizontal level in the path of a gravity-fed moving bed in a vertical reactor. The present invention includes providing at least 79% of the heat energy required in the process by the electrical heat source.