Abstract: A mass of solid aluminium carbide containing product is produced by a process in which a mixture is formed of an aluminium 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 aluminium of the aluminium containing material to produce solid aluminium carbide. The solid aluminium carbide then is able to be heated with an aluminium compound selected from AI2O3, AI4CO4, AIO, AI2O and mixtures thereof, to produce aluminium 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: Apparatus, systems and methods for carbothermically producing aluminum are disclosed. The systems may include a reactor and an electrical supply. The reactor may include a plurality of side-entering electrodes and a top-entering electrode. The electrical supply may be operable to supply multiphase current to the side-entering electrodes and/or the top-entering electrodes. The electrodes may be in communication with a molten bath of the reactor, and the multiphase current supplied thereto may be passed through the bath to heat the reactor. The amount of current supplied to various electrode sets may be adjusted to facilitate tailored heating of the molten bath.

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.

Abstract: An agglomerate comprising alumina, carbon, and a binder for use in a vapor recovery reactor of a carbothermic alumina reduction furnace is disclosed. A method for using alumina-carbon agglomerates to capture aluminum vapor species and utilize waste heat from off-gases in a vapor recovery reactor to form a recyclable material is also disclosed.

Abstract: Apparatus, systems and methods for carbothermically producing aluminum are disclosed. The systems may include a reactor and an electrical supply. The reactor may include a plurality of side-entering electrodes and a top-entering electrode. The electrical supply may be operable to supply multiphase current to the side-entering electrodes and/or the top-entering electrodes. The electrodes may be in communication with a molten bath of the reactor, and the multiphase current supplied thereto may be passed through the bath to heat the reactor. The amount of current supplied to various electrode sets may be adjusted to facilitate tailored heating of the molten bath.

Abstract: Graphite electrodes for the production of aluminum by carbothermic reduction of alumina are either submerged in the molten bath in the low temperature compartment or they are horizontally arranged in the side walls of the high temperature compartment. The electrodes are manufactured by using a mixture of coke particles covering the complete particle size range between 25 ?m to 3 mm and by using an intensive mixer to effectively wet all coke particles with pitch. The electrodes have a flexural strength of at least 20 N/mm2. By using a complete range (continuum) of particle sizes in conjunction with an intensive mixer, the geometric packing of the particles is significantly improved, hence the material density is increased and thus a higher mechanical strength as well as improved electrical conductivity in comparison to conventional graphite electrodes is achieved.

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 process for recycling composite materials includes the steps of feeding a quantity of composite material composed of at least one polymer and aluminum into at least one first reactor; heating the composite material in a non-oxidizing environment at a temperature sufficient to volatilize the at least one polymer and form a hydrocarbon by-product and aluminum in the at least one first reactor; feeding the aluminum free of the at least one polymer into a second reactor; and heating the aluminum in a non-oxidizing environment at a temperature sufficient to melt the aluminum in the second reactor.

Abstract: A batch process for producing low carbon aluminum using a single carbothermic reactor furnace is disclosed in which the slag making, metal making and carbon extraction is carried out in a single furnace, single compartment reactor. The Al2O and Al vapors generated in slag making and metal making steps are recovered in a vapor recovery reactor, and treated with a carbonaceous material to produce recyclable material comprising Al4C3. The recyclable material is used to assist with one or more subsequent slag making steps.

Abstract: Apparatus, systems and methods for carbothermically producing aluminum are disclosed. The systems may include a reactor and an electrical supply. The reactor may include a plurality of side-entering electrodes and a top-entering electrode. The electrical supply may be operable to supply multiphase current to the side-entering electrodes and/or the top-entering electrodes. The electrodes may be in communication with a molten bath of the reactor, and the multiphase current supplied thereto may be passed through the bath to heat the reactor. The amount of current supplied to various electrode sets may be adjusted to facilitate tailored heating of the molten bath.

Abstract: An agglomerate comprising alumina, carbon, and a binder for use in a vapor recovery reactor of a carbothermic alumina reduction furnace is disclosed. A method for using alumina-carbon agglomerates to capture aluminum vapor species and utilize waste heat from off-gases in a vapor recovery reactor to form a recyclable material is also disclosed.

Abstract: Graphite electrodes for the production of aluminum by carbothermic reduction of alumina are either submerged in the molten bath in the low temperature compartment or they are horizontally arranged in the side walls of the high temperature compartment. The electrodes are manufactured by using a mixture of coke particles covering the complete particle size range between 25 ?m to 3 mm and by using an intensive mixer to effectively wet all coke particles with pitch. The electrodes have a flexural strength of at least 20 N/mm2. By using a complete range (continuum) of particle sizes in conjunction with an intensive mixer, the geometric packing of the particles is significantly improved, hence the material density is increased and thus a higher mechanical strength as well as improved electrical conductivity in comparison to conventional graphite electrodes is achieved.

Abstract: A graphite electrode for an electrothermic reduction furnace is formed from anode grade coke and graphitized at a graphitization temperature below 2700° C. The resulting electrode is particularly suited for carbothermal reduction of alumina. It has an iron content of about 0.05% by weight, a specific electrical resistivity of above 5 ?Ohm·m, and a thermal conductivity of less than 150 W/m·K. The graphite electrode is manufactured by first mixing calcined anode coke with a coal-tar pitch binder, and a green electrode is formed from the mixture at a temperature close to the softening point of the pitch binder. The green electrode is then baked to carbonize the pitch binder to solid coke. The resultant carbonized electrode, after further optional processing is then graphitized at a temperature below 2700° C. for a time sufficient to cause the carbon atoms in the carbonized electrode to organize into the crystalline structure of graphite.

Abstract: A batch process for producing low carbon aluminum using a single carbothermic reactor furnace is disclosed in which the slag making, metal making and carbon extraction is carried out in a single furnace, single compartment reactor. The Al2O and Al vapors generated in slag making and metal making steps are recovered in a vapor recovery reactor, and treated with a carbonaceous material to produce recyclable material comprising Al4C3. The recyclable material is used to assist with one or more subsequent slag making steps.

Abstract: Systems and associated methods for carbothermically producing aluminum are provided, the systems generally including a reactor having a depth such that when the reactor contains molten liquid hydrostatic pressure of the molten liquid is at least about 0.5 atm as measured proximal the bottom of the reactor. A plurality of horizontally disposed electrodes, which may be offset from one another in a vertical and/or horizontal direction, may also be used in accordance with the system to provide selective heating gradients within the molten liquid.

Abstract: The device and method of the present invention employs a column having a gas inlet in its lower part and a gas outlet in its upper part. Carbon particles are introduced into the column through a supply pipe. The supply pipe is movable so that by manipulating the height of the supply pipe in conjunction with discharging particulate matter through the column, the height of the bed of particulate matter in the column can be adjusted so that the retention time of the off gas in the particulate bed is constant. By maintaining a constant retention time of the off gas in the bed, complete conversion of the off gas is achieved.

Abstract: In a method for recovering Al from an off-gas (3,4) produced during carbothermic reduction of aluminum utilizing at least one smelter (1,2), the off-gas (3,4) is directed to an enclosed reactor (5) which is fed a supply of wood charcoal (7) having a porosity of from about 50 vol. % to 85 vol. % and an average pore diameter of from about 0.05 ?m to about 2.00 ?m, where the wood charcoal (7) contacts the off-gas (3,4) to produce at least Al4C3 (6), which is passed back to the smelter (1,2).

Abstract: A hollow partition wall is employed to feed carbon material to an underflow of a carbothermic reduction furnace used to make aluminum. The partition wall divides a low temperature reaction zone where aluminum oxide is reacted with carbon to form aluminum carbide and a high temperature reaction zone where the aluminum carbide and remaining aluminum oxide are reacted to form aluminum and carbon monoxide.

Abstract: A hollow partition wall is employed to feed carbon material to an underflow of a carbothermic reduction furnace used to make aluminum. The partition wall divides a low temperature reaction zone where aluminum oxide is reacted with carbon to form aluminum carbide and a high temperature reaction zone where the aluminum carbide and remaining aluminum oxide are reacted to form aluminum and carbon monoxide.

Abstract: The invention relates to a method for producing high-performance Cr—Ti—V hydrogen storage alloys utilizing thermit process, whereby residence of adversely affecting impurities is inhibited, addition of not less than 10 at % of Ti as an alloy component is realized, and thermal burden on the crucible used in the method is reduced. The method includes the steps of: (A) providing an alloy material (1) comprising a Cr oxide, a V oxide, and a reducing agent Al, and an alloy material (2) comprising Ti; (B) placing said alloy materials in a crucible for thermit reduction so that the alloy material (1) is placed above the alloy material (2); (C) igniting the alloy material (1) placed in step (B) and melting all metal elements contained in the alloy materials with heat of thermit reaction of the alloy material (1); and (D) making an alloy melt obtained in step (C) into an alloy.

Abstract: A method for aluminum recovery during the carbothermic production of aluminum in a smelting furnace (1,2) is disclosed, where during carbothermic reduction of alumina, aluminum and aluminum suboxide vapors are produced (3, 4), which are reacting with carbon. Reactive carbon is generated in situ by the cracking of hydrocarbon compounds (6) in a separate closed reactor vessel (5) at a temperature greater than about 1955° C. Solid aluminum carbide that formed during the reaction can then be recycled by a conduit (8) to the primary reactor for reduction to aluminum, and reactor gas (10) can be fed to a cooler (9).

Abstract: A method for aluminum recovery during the carbothermic production of aluminum in a smelting furnace (1,2) is disclosed, where during carbothermic reduction of alumina, aluminum and aluminum suboxide vapors are produced (3, 4), which are reacting with carbon. Reactive carbon is generated in situ by the cracking of hydrocarbon compounds (6) in a separate closed reactor vessel (5) at a temperature greater than about 1955° C. Solid aluminum carbide that formed during the reaction can then be recycled by a conduit (8) to the primary reactor for reduction to aluminum, and reactor gas (10) can be fed to a cooler (9).

Abstract: A process for producing aluminum metal by carbothermic reduction of alumina ore. Alumina ore is heated in the presence of carbon at an elevated temperature to produce an aluminum metal body contaminated with about 10-30% by wt. aluminum carbide. Aluminum metal or aluminum alloy scrap then is added to bring the temperature to about 900-1000° C. and precipitate out aluminum carbide. The precipitated aluminum carbide is filtered, decanted, or fluxed with salt to form a molten body having reduced aluminum carbide content.

Abstract: The present invention relates to a process for carbothermic production of aluminum where molten bath aluminum carbide and aluminum oxide are produced in a low temperature compartment (2), and continuously flow into a high temperature compartment (3) where the aluminum carbide is reacted with alumina to produce a top aluminum layer (31), where the aluminum layer (31) forms a layer on the top of a molten slag layer and is tapped from the high temperature compartment (3) at outlet (5), and where off-gases from the two compartments are treated in reactors fed by one or more columns (9, 19). According to the invention the low temperature compartment (2) and the high temperature compartment (3) are located in a common reaction vessel (1) where the low temperature compartment is separated from the high temperature compartment by an underflow partition wall (4).

Abstract: A continuous process for the production of elemental aluminum is described. Aluminum is made from aluminum oxide and a reducing gas such as a light hydrocarbon gas or other reducing gas, for example hydrogen. In the process, a feed stream of the aluminum oxide and the reducing gas is continuously fed into a reaction zone. There the aluminum oxide and reducing gas are reacted at a temperature of about 1500° C. or greater in the reaction zone to provide a continuous product stream of reaction products, which include elemental aluminum. The product stream is continuously quenching after leaving the reaction zone, and the elemental aluminum is separated from the other reaction products.

Abstract: A process for producing aluminum metal by carbothermic reduction of alumina ore. Alumina ore is heated in the presence of carbon at an elevated temperature to produce an aluminum metal body contaminated with about 10-30% by wt. aluminum carbide. Aluminum metal or aluminum alloy scrap then is added to bring the temperature to about 900-1000° C. and precipitate out aluminum carbide. The precipitated aluminum carbide is filtered, decanted, or fluxed with salt to form a molten body having reduced aluminum carbide content.