Polar Sapphire Ltd.

Daniel Smith

Scott Nichol

A method comprises reacting an aluminum feedstock with an acid in the presence of water to provide an aluminum salt solution comprising an aluminum salt in water, wherein the aluminum salt comprises a reaction product of the acid and aluminum, and spray roasting the aluminum salt solution at a temperature of at least about 450&#xb0; C. to provide an aluminum oxide powder, wherein the spray roasting is performed in a furnace lined with a refractory comprising alumina that is at least about 99.2% purity alumina, and wherein the aluminum oxide powder is 99.2% pure aluminum oxide or greater.

Process for making high-purity aluminum oxide

A method comprising (a) reacting aluminum metal with an acid in the presence of water to provide a first aluminum salt solution comprising an aluminum salt in water, wherein the aluminum salt comprises a reaction product of the acid and the aluminum metal, (b) heating the first aluminum salt solution to provide a mother liquor and solid aluminum salt, (c) optionally, separating the solid aluminum salt from the mother liquor, (d) optionally, dissolving at least a portion of the separated solid aluminum salt with water to provide a second aluminum salt solution, (e) spray roasting the first, or second (if produced), aluminum salt solution to provide an aluminum oxide powder, and (f) washing the aluminum oxide powder, wherein the washed aluminum oxide powder comprises less than about 30 ppmw total metallic and alkyl impurities.

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Brampton, Canada

Daniel Smith