Aluminum Technologies, LLC

Toth Aluminum Corporation

Charles Toth

Charles Ernest Toth, Iii

Caroline Toth Reily

Donald Ray Bradford

Larry George Boxall

Alfred Lippman

Roger Frank Sebenik

Lester L Knapp

A carbo-chlorination process is disclosed for selectively producing AlClfrom 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 AlCl. 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 AlCl; 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 AlClis purified to create an AlClproduct stream comprising preferably greater than about 99.99% AlCl. The raw pozzolan product is classified to remove coke and create a final pozzolan product having a strength activity index (SAI) in the range of 80-160, per ASTM 618.

Process for selective chlorination of aluminous ores for the preparation of aluminum

Reduction cell for producing aluminum

A process of carbo-chlorination of AlPO.sub.4 wherein AlPO.sub.4 or AlPO.sub.4 -containing material is introduced into a reactor along with chlorinating agents and a source of carbon. The reactor is heated to approximately 600.degree. to 1200.degree.C and forms aluminum chlorides, phosphorous oxides, phosphorous chlorides, phosphorous oxychlorides and carbon oxides. These reaction products are then separated into three fractions by condensation, the first fraction being P.sub.2 O.sub.5, the second fraction being AlCl.sub.3 and AlCl.sub.3 .POCl.sub.3 and the third fraction being remaining gasses, namely PCl.sub.3, PCl.sub.5, P.sub.2 O.sub.3, CO and CO.sub.2. The second fraction is reacted in a further reactor to give AlCl.sub.3 and P.sub.2 O.sub.3 which are separated by distillation. The phosphorous chlorides from the third fraction are oxidized, along with the P.sub.2 O.sub.3 of the second fraction, to form P.sub.2 O.sub.5.

Carbo chlorination of AlPO.sub.4

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New Orleans, LA, United States of America

Charles Toth