Toth Aluminum Corporation

John Christopher Terry

Ronald Wyndham

Roger Frank Sebenik

The present invention provides a novel process for the preferential chlorination of alumina over silica in the carbo-chlorination of kaolinitic ores to produce aluminum chloride. The process comprises introducing small amounts of alkali metal compounds with oxyanions into the carbo-chlorination process. Preferred embodiments are directed to particular compounds of alkali metals with oxyanions selected from the group consisting of carbonates, sulfates, hydroxides, oxides, phosphates, and the like. The present invention results in significantly reduced energy, manufacturing, and equipment costs and thus represents a breakthrough in the utilization of domestic ores such as kaolinitic clay for the production of aluminum chloride or alumina through oxidation of the aluminum chloride.

Preferential chlorination of alumina in kaolinitic ores

One of the major obstacles toward the needed and economic production of alumina and other values from kaolinitic clay and other ores by chlorination has been the slow reaction rates and low yields of the metal values. The present information provides methods for improving reaction rates and/or yields in the halogenation of various ores which comprises the addition of sulfur and/or functionally equivalent sulfur containing compounds as an ore conditioning agent and/or reaction promoter. These improvements also permit operation at low temperatures with advantage of savings of energy and of equipment and maintenance costs. The invention is applicable to both displacement halogenation and carbo-halogenation processes. The sulfur and/or functionally equivalent sulfur containing compounds can be added to the reaction mass during pre-halogenation steps or to the halogenation step or to combinations of steps ordinarily with additional benefits. The preferred embodiments are directed toward the carbochlorination of ores with illustrative examples given for clay, bauxite, ilmenite and aluminum phosphate; and for displacement chlorination of ores with illustrative examples given for hematite and ilmenite.

Clay halogenation process

The present invention provides a process for the catalytic reduction of aluminum chloride by manganese to form a high aluminum content alloy, separating the catalysis metal from the alloy, and separating the manganese in the alloy to produce essentially pure aluminum. As a preferred embodiment, liquid aluminum chloride is contacted with solid manganese metal in the presence of a Group IIB metal or compound thereof at a relatively low temperature and at a pressure to maintain the reactants in such phases.

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Metairie, LA, United States of America

John Christopher Terry