Abstract: A method of reducing entrained aluminum oxides in aluminum castings. The method comprises preheating a furnace charge to remove moisture and contaminants. The furnace charge is then coated on all free surfaces with a layer of flux. Subsequently the furnace charge is melted in a furnace to form a melt bath of liquid aluminum suitable for casting. The flux layer removes the naturally occurring oxide film from the furnace charge surface as well as provides a cover flux to protect the melt bath from oxidation.

Abstract: Here, a method has been offered of aluminum reception by means of metallothermal magnesium recovery of aluminum trichloride in the flow of inactive gas at the temperature of 900-1150° C. and the total pressure of 0.01-5 atm., the mass correlation of aluminii chloride and magnesium in the parent mix being 3.69:1.00. The process is realized in a cylinder-shaped reactor with thin-walled attachments (6) made of ceramics and located inside the reactor. The latter is supplied with a cone-like bottom part. A cauldron-evaporator of magnesium into the flow of inactive gas is mounted in front of the reactor, while behind it there is a unit for separating liquid magnesium from the residual mix of magnesium and aluminii chloride, all the components of the device having been lined inside with fireproof materials. The technical result is growth of efficiency at the expense of guaranteed uninterrupted process of recovery and the best of ecological specifications.

Abstract: A tilting rotary furnace with a door assembly that seals against a furnace vessel. The seal between the door and the furnace vessel allows for regulation of the internal environment of the furnace and control over thermitting of the aluminum. As a result, aluminum recovery may be carried out without the use of salt. A portion of the door may rotate with the furnace vessel and a portion of the door may remain rotationally stationary with respect to the furnace vessel and the rotating portion of the door.

Abstract: Burner assembly for use in industrial heating and melting applications of material susceptible to oxidation at elevated temperatures is comprised of a flow passage of oxidant surrounded by an annular flow passage of fuel whereby the oxidant is substantially contained inside the fuel layer up to at least 5 oxidant nozzle diameters downstream of the burner outlet in order to minimize contact between the oxidant and the furnace load.

Abstract: By forming an aluminum nitride layer by a self-limiting process sequence, the interface characteristics of a copper-based metallization layer may be significantly enhanced while nevertheless maintaining the overall permittivity of the layer stack at a lower level.

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: A method is described for smelting fragmentized aluminum scrap, with the aluminum scrap to be smelted being molten in a furnace after thermal pre-treatment in a hot-gas stream. In order to provide advantageous process conditions it is proposed that the aluminum scrap is subjected at first in a continuous flow of material to the thermal treatment and is smelted thereafter, and that from the hot gas stream guided in a circulation for the thermal treatment of the aluminum scrap a partial stream is branched off and is guided into the furnace.

Abstract: Method for the production of primary aluminium from alumina comprising the step of converting alumina into aluminium sulfide (Al2S3) and subsequently the separation of aluminium from aluminium sulfide wherein the conversion of alumina into aluminium sulfide is performed by reacting alumina with CS2 containing gas at a temperature Tal whereby the alumina is mainly &ggr;-alumina.

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 thermo-mechanical process for producing aluminum or other metals from aluminium or metal compounds, is described, whereby aluminum oxide or similar aluminium compounds or similar other metal compounds, are heated by friction generated by mechanical forces from a rotating and/or agitating means within a process chamber together with either free water or waterforming constituents in the aluminium-or-metal compounds and a hydrogen- and carbon delivering material such as oil or natural gas, such as methane, and carbon in such a manner that material in the reactor chamber behaves like a hot mechanical fluidized bed whereby the water can be split into hydroxyl and hydrogen radicals making hydrogen radicals react, with the oxygen in the hot and now unstable aluminum or metal compound and thus releasing aluminum or metal atoms, and the hydroxyl radical reacting back to water and if carbon is used, the surplus of oxygen reacting with carbon to CO or CO.sub.2.

Abstract: A metal volatilization process is described in which metal oxide pieces in a reaction chamber are reduced to form reduced metal and at least a portion of that metal is volatilized and used for coating a variety of substrates, including those which are susceptible to heat damage. The metal oxides formed must have curved surfaces which maintain a non-zero contact angle with their support during reduction. Preferably the reduction phase is preceded by an oxidation phase which is conducted in the same chamber, and uses as the starting materials oxidizable metal pieces which also are curved to maintain a non-zero contact angle with the support, so that general curved shapes will be maintained throughout the oxidation and reduction phases of the process. Vacuum is unnecessary, and the process can be operated at ambient pressures.

Abstract: A method of treating spent potliner material from aluminum reduction cells is disclosed. The spent potliner material is introduced into a sulfuric acid digester to produce a gas component including hydrogen fluoride and hydrogen cyanide and a slurry component including carbon, silica, alumina, sodium sulfate, iron, calcium and magnesium. The gas component is recovered and heated an effective amount to eliminate hydrogen cyanide and produce a remaining gas component including CO.sub.2, H.sub.2 O, nitrogen oxides and HF. The remaining gas component is directed through a water scrubber to form hydrofluoric acid, and the hydrofluoric acid is admixed with aluminum hydroxide to create aluminum fluoride. The slurry component is rinsed with water to separate a first solid fraction containing carbon, alumina and silica from a second liquid faction. The pH of the liquid fraction is adjusted to first create and separate aluminum hydroxide and then to separate sodium sulfate.

Abstract: A method of smelting aluminum from aluminum ore wherein the powdered ore is mixed with a flux containing substantial amounts of borax, sodium bicarbonate and a copper compound, preferably copper sulphate. The mixture is placed in a suitable vessel, preferably with a rounded bottom, that can withstand high temperatures and that has an outlet hole in the bottom. The mixture of powdered ore and flux is heated to a temperature sufficient to melt the mixture and thereby produce a molten material containing aluminum. The molten material is allowed to flow out of the outlet hole and to cool outside by means of air cooling which results in the aluminum separating out. Preferably, the flux comprises about one third borax, one third sodium bicarbonate and about one third copper sulphate. A suitable ore for this method is nepheline syenite.

Abstract: An improved process for the removal of organic matter from bauxite ore containing gibbsite comprises heating the ore under roasting conditions including a roasting temperature of from about 400.degree. C. to about 600.degree. C. with oxygen-containing roasting gas having a moisture content of less than 1% by volume water until the water of crystallization of the alumina present in the treated product is less than 0.5 mole per mole of alumina.