Process for producing magnesium utilizing aluminum-silicon alloy reductant

Claim 2

A process for the production of magnesium in a reaction-condensation system having a reducing furnace zone and a condensation zone, comprising; reacting an aluminum-silicon alloy comprising by weight percent 15- 75 aluminum and 20- 80 silicon with a calcium magnesium aluminum silicate slag or magnesium oxide in the presence of said slag in the reducing furnace zone or reaction zone at a temperature of about 1400° - 1650° C. and a pressure of about 25- millimeters of mercury, the amount of magnesium oxide fed into the reaction zone being at least 101 percent of the amount theoretically required to react with the aluminum-silicon alloy fed into the reaction zone, maintaining the composition of the slag in amounts by weight percent of 42- 65 calcium oxide, 1- 11 magnesium oxide, 11- 38 aluminum oxide and 5- 19 silicon dioxide, evolving magnesium vapor from the reducing furnace zone or reaction zone to the condensation zone, and condensing and recovering the magnesium as a product.

Claim 3

The process of claim 1, wherein said temperature is about 1475°-1550° C.

Claim 4

The process of claim 1, wherein said temperature is about 1500° C.

Claim 5

The process of claim 1, wherein said pressure is about 50- 200 millimeters of mercury.

Claim 6

The process of claim 1, wherein the magnesium oxide is in the form of calcined dolime of the formula CaO.sup.. x MgO where 0.5≦ × ≦ 2.0.

Claim 7

The process of claim 1, wherein an inert gas is employed to prevent air from contacting the magnesium.

Claim 8

The process of claim 1, wherein said aluminum-silicon alloy comprises by weight percent the following ingredients: Aluminum (Al)-- 15- 75 Silicon (Si)-- 20- 80 Iron (Fe), Titanium (Ti), Carbon (C) and Oxygen (O) in Total-- 0-- 10 Carbon dioxide (CO 2 )-- < 0.5 Water (H 2 O)-- < 0.5.

Claim 9

The process of claim 1, wherein sufficient magnesium oxide is employed to provide that slag in the reaction zone contains 1- 5 weight percent magnesium oxide.

Claim 10

In a process for producing magnesium by reduction of magnesium oxide with aluminum-silicon alloy in a reaction-condensation system and utilizing a molten oxidic slag, the improvement therein, wherein said aluminum-silicon alloy comprises by weight percent 15- 75 aluminum and 20- 80 silicon, said magnesium oxide is fed into the reaction zone in an amount of at least 101 percent of the amount theoretically required to react with said aluminum-silicon alloy fed into the reaction zone and said slag comprises by weight percent the following ingredients: Calcium oxide (CaO)-- 42- 65 Magnesium oxide (MgO)-- 1- 11 Aluminum oxide (Al 2 O 3 )--11- 38 Silicon dioxide (SiO 2 )-- 5- 19.

Claim 11

In a process for producing magnesium by reduction of magnesium oxide with aluminum-silicon alloy in a reaction-condensation system and utilizing a molten oxidic slag, the improvement therein, wherein said aluminum-silicon alloy comprises by weight percent 15- 75 aluminum and 20- 80 silicon, said magnesium oxide is fed into the reaction zone in an amount of at least 101 percent of the amount theoretically required to react with said aluminum-silicon alloy fed into the reaction zone and said slag comprises by weight percent the following ingredients: Calcium oxide (CaO)-- 42- 65 Magnesium oxide (MgO)-- 1- 11 Aluminum oxide (Al 2 O 3 )--11- 38 Silicon dioxide (SiO 2 )-- 5- 19.

Claim 12

The process of claim 9, wherein said magnesium oxide is present in said slag in an amount of about 1- 5 weight percent.

Claim 13

A process for the production of magnesium metal in a reaction-condensation system having a reducing furnace zone and a condensation zone, comprising preparing and melting in the reaction zone a magnesium oxide slag of the following weight percent composition: Calcium oxide (CaO)-- 42- 65 Aluminum oxide (Al 2 O 3 )-- 11- 38 Magnesium oxide (MgO)-- 1- 11 Silicon dioxide (SiO 2 )-- 5- 19 reacting with the molten oxidic slag in the reaction zone an aluminum-silicon alloy of the following weight percent composition: Aluminum (Al)-- 15- 75 Silicon (Si)-- 20- 80 Iron (Fe), Titanium (Ti), Carbon (C) and Oxygen (O) in Total-- 0- 10 Carbon dioxide (CO 2 )-- < 0.5 Water (H 2 O)-- < 0.5 carrying out the reaction at a temperature of about 1400° - 1650° C. and at a pressure of about 25- 500 millimeters of mercury, adding magnesium oxide in the reaction zone as the reaction continues so that the amount thereof is at least 101 percent of the amount theoretically required to react with the aluminum-silicon alloy, periodically withdrawing molten oxidic slag from the reaction zone, maintaining the composition of the molten oxidic slag in the reaction zone in the amounts aforesaid, evolving magnesium vapor from the reaction zone to the condensation zone and recovering magnesium metal as a product.

Claim 14

A process for the production of magnesium metal in a reaction-condensation system having a reducing furnace zone and a condensation zone, comprising preparing and melting in the reaction zone a magnesium oxide slag of the following weight percent composition: Calcium oxide (CaO)-- 42- 65 Aluminum oxide (Al 2 O 3 )-- 11- 38 Magnesium oxide (MgO)-- 1- 11 Silicon dioxide (SiO 2 )-- 5- 19 reacting with the molten oxidic slag in the reaction zone an aluminum-silicon alloy of the following weight percent composition: Aluminum (Al)-- 15- 75 Silicon (Si)-- 20- 80 Iron (Fe), Titanium (Ti), Carbon (C) and Oxygen (O) in Total-- 0- 10 Carbon dioxide (CO 2 )-- < 0.5 Water (H 2 O)-- < 0.5 carrying out the reaction at a temperature of about 1400° - 1650° C. and at a pressure of about 25- 500 millimeters of mercury, adding magnesium oxide in the reaction zone as the reaction continues so that the amount thereof is at least 101 percent of the amount theoretically required to react with the aluminum-silicon alloy, periodically withdrawing molten oxidic slag from the reaction zone, maintaining the composition of the molten oxidic slag in the reaction zone in the amounts aforesaid, evolving magnesium vapor from the reaction zone to the condensation zone and recovering magnesium metal as a product.

Claim 15

The process of claim 11, wherein said magnesium oxide of said slag composition is maintained at a level of 1- 5% of said total slag composition.

Claim 16

The process of claim 11, wherein said temperature is about 1475° - 1550° C.

Claim 17

The process of claim 11, wherein said pressure is about 50- 200 millimeters of mercury.

Claim 18

The process of claim 11, wherein the melting in the reaction zone is conducted in the presence of an inert gas.

Claim 19

The process of claim 11, wherein the magnesium oxide is a calcined dolime of the formula CaO.sup. . × MgO where 0.5≦ × ≦ 2.0.