Abstract: A carbo-chlorination process is disclosed for selectively producing AlCl3 from an alumina-containing feedstock, comprising introducing the following into a fluidized bed reactor maintained at 600-700° C.: (a) dried and calcined feed stream comprising the alumina-containing feedstock and a carbon feed; (b) chlorinating agent; (c) selectivity agent; (d) dried air; and optionally (e) off-spec AlCl3. The process further includes removing a vapor stream from the reactor in which preferably about 75-80%, of the alumina present in the reactor is converted to AlCl3; and also removing a solid raw pozzolan stream from the reactor, wherein about 90-99% of the silica present in the reactor remains unconverted and exits the reactor through the solid raw pozzolan stream. The vapor stream comprising AlCl3 is purified to create an AlCl3 product stream comprising preferably greater than about 99.99% AlCl3.

Abstract: Method for directly desubliming gaseous aluminum chloride to solid form in a fluidized bed of solid particles of aluminum chloride at controlled temperatures for production of selectively constituted solid particulate aluminum chloride.

Abstract: A method for producing metal by electrolysis in a molten salt bath containing superimposed electrodes, at least one of which is a bipolar electrode. The arrangement of the electrodes creates interelectrode spaces between them. Bath is swept through these interelectrode spaces. This method is improved by providing circulation of the bath from one interelectrode space to the next at a location inwards of the outer peripheries of the electrodes. This can be accomplished e.g. by boring holes through the electrodes. It can also be accomplished by breaking the electrodes into individual, mutually separated stacks of electrodes, the circulation of the improvement then occurring e.g. in the space between the stacks.

Abstract: Method and apparatus for directly desubliming gaseous aluminum chloride to solid form in a fluidized bed of solid particles of aluminum chloride at controlled temperatures for production of selectively constituted solid particulate aluminum chloride.

Abstract: Methods of switching electrical current in the operation of an electrical load device such as an electrolytic cell having at least one anode and one cathode. At least one source of electrical current is connected to the anode and cathode at two spaced apart locations thereon. One method comprises the steps of disconnecting one of the locations on the anode and on the cathode from the source of electrical current, and connecting the disconnected locations of the anode and cathode directly together so that the path of current flow to and from the source of electrical current is limited to the anode and cathode. To reconnect the anode and cathode to the source of electrical current, the directly connected locations of the anode and cathode are unconnected from each other and reconnected to the source of electrical current. In addition, the invention includes the use of an anode or cathode, exclusive of the other, as means to heat an electrolytic cell.

Abstract: Recovery of selectively constituted high purity aluminum chloride from the gaseous effluent of the chlorination of sodium contaminated alumina including the steps of purifying such gaseous effluent to provide essentially contaminant-free aluminum chloride in gaseous form in a gaseous carrier through selectively cooling the hot gaseous effluent to a temperature range well below the chlorination temperature but above the ambient condition condensation temperature of aluminum chloride yet sufficient to condense a selective portion of the condensable constituents therein including substantially all of the sodium aluminum chloride values therein, intermediate the steps of passing such gaseous effluent through filtration media to effect the separation of the condensed sodium aluminum chloride values and entrained solid and liquid particles therefrom and condensing high purity aluminum chloride values from the purified residual gaseous effluent to selectively constituted solid form at controlled temperatures.

Abstract: Fluidized bed desubliming apparatus for directly desubliming gaseous aluminum chloride to solid form in a fluidized bed of solid particles of aluminum chloride in a chamber at controlled temperatures for production of selectively constituted solid particulate aluminum chloride, for example including cooling means within the bed for maintaining such controlled temperatures, means for introducing such gaseous aluminum chloride into the bed remote from all contact surfaces within the chamber which are below the ambient desublimation temperature, gas distribution inlet means, residual gaseous effluent outlet means and means for withdrawing aluminum chloride particles from the bed.