US4039648A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Production of aluminum chloride
Assignee: Alcoa Corp
•
Filing: 1975-12-12
•
Granted: 1977-08-02
•
Expires: 1995-12-12
Abstract
Abstract A method for producing aluminum chloride comprises contacting Al 2 O 3 with a reducing agent and chlorine in a bath of molten metal halides to form aluminum chloride and recovering the aluminum chloride by vaporization.
Inventors
- 👤 Warren E. Haupin
- 👤 John A. Remper
- 👤 M. Benjamin Dell
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 21:30
CPC Classifications
C; C01; C01F; C01F7/00; C01F7/48; C01F7/56; C01F7/58; C01F7/60; Y; Y10; Y10S; Y10S423/00; Y10S423/09; Y10S423/12
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
183 words
A method of producing AlCl 3 comprising: a. contacting alumina which has been extracted from its ore and which has a surface area in the range of 0.5 to 110 m 2 /g and a carbonaceous reducing agent with a source of Cl 2 in a molten bath containing at least 30% by weight AlCl 3 with the balance consisting essentially of at least one metal halide, said bath being at a temperature in the range of 150° to 1000° C., said method being capable of exothermically converting substantially 100% of said Cl 2 to AlCl 3 ; b. maintaining said carbonaceous reducing agent in said bath in an amount in the range of 0.05 to 0.5 lbs/lb of molten bath, further maintaining said alumina in said bath in an amount in the range of 0.05 to 0.5 lbs/lb of molten bath; c. adding the alumina, reducing agent and Cl 2 to said bath in stoichiometric amounts for purposes of said contacting thereby maintaining the reducing agent and the alumina in said ranges; and d. recovering AlCl 3 by vaporization from the bath.
Claim 2
Independent Claim
183 words
A method of producing AlCl 3 comprising: a. contacting alumina which has been extracted from its ore and which has a surface area in the range of 0.5 to 110 m 2 /g and a carbonaceous reducing agent with a source of Cl 2 in a molten bath containing at least 30% by weight AlCl 3 with the balance consisting essentially of at least one metal halide, said bath being at a temperature in the range of 150° to 1000° C., said method being capable of exothermically converting substantially 100% of said Cl 2 to AlCl 3 ; b. maintaining said carbonaceous reducing agent in said bath in an amount in the range of 0.05 to 0.5 lbs/lb of molten bath, further maintaining said alumina in said bath in an amount in the range of 0.05 to 0.5 lbs/lb of molten bath; c. adding the alumina, reducing agent and Cl 2 to said bath in stoichiometric amounts for purposes of said contacting thereby maintaining the reducing agent and the alumina in said ranges; and d. recovering AlCl 3 by vaporization from the bath.
Claim 3
Dependent Claim
18 words
The method of claim 1 wherein the reducing agent and the source of chlorine comprise a single compound.
Claim 4
Dependent Claim
22 words
The method of claim 2 wherein the single compound is selected from the group consisting of COCl 2 and CCl 4 .
Claim 5
Dependent Claim
17 words
The method of claim 1 wherein the reducing agent and the source of chlorine are separate compounds.
Claim 6
Dependent Claim
11 words
The method of claim 1 wherein the reducing agent is carbon.
Claim 7
Dependent Claim
14 words
The method of claim 1 wherein the source of Cl 2 is gaseous chlorine.
Claim 8
Dependent Claim
22 words
The method of claim 1 wherein the metal halide is selected from the group consisting of alkali and alkaline earth metal chloride.
Claim 9
Dependent Claim
19 words
The method of claim 1 wherein the molten bath temperature is in a range of 400° to 950° C.
Claim 10
Dependent Claim
24 words
The method of claim 1 wherein the reducing agent and the alumina each have a mesh size of less than 64 mesh (Tyler series).
Claim 11
Independent Claim
188 words
A method of producing AlCl 3 comprising: a. contacting alumina, which has been extracted from its ore and calcined at a temperature of at least 600° C., and solid carbon, both ground to a mesh size of less than 64 (Tyler series), with gaseous chlorine in a molten bath, the alumina having a surface area in the range of 0.5 to 110 m 2 /g, the molten bath containing 30% - 70% by weight AlCl 3 with the balance consisting essentially of NaCl at a temperature of 400° to 950° C., said bath capable of exothermically converting substantially 100% of said Cl 2 to AlCl 3 ; b. maintaining said carbon in said bath in an amount in the range of 0.05 to 0.5 lbs/lb of molten bath, and further maintaining said alumina in said bath in an amount in the range of 0.05 to 0.5 lbs/lb of molten bath; c. adding the alumina, carbon and Cl 2 to the bath in stoichiometric amounts for purposes of said contacting thereby maintaining the alumina and carbon in said ranges; and d. recovering AlCl 3 by vaporization from the bath.
Claim 12
Independent Claim
188 words
A method of producing AlCl 3 comprising: a. contacting alumina, which has been extracted from its ore and calcined at a temperature of at least 600° C., and solid carbon, both ground to a mesh size of less than 64 (Tyler series), with gaseous chlorine in a molten bath, the alumina having a surface area in the range of 0.5 to 110 m 2 /g, the molten bath containing 30% - 70% by weight AlCl 3 with the balance consisting essentially of NaCl at a temperature of 400° to 950° C., said bath capable of exothermically converting substantially 100% of said Cl 2 to AlCl 3 ; b. maintaining said carbon in said bath in an amount in the range of 0.05 to 0.5 lbs/lb of molten bath, and further maintaining said alumina in said bath in an amount in the range of 0.05 to 0.5 lbs/lb of molten bath; c. adding the alumina, carbon and Cl 2 to the bath in stoichiometric amounts for purposes of said contacting thereby maintaining the alumina and carbon in said ranges; and d. recovering AlCl 3 by vaporization from the bath.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-08-01 | 1981-01-31 | 1981-08-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-08-01 | 1985-01-31 | 1985-08-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-08-01 | 1989-01-31 | 1989-08-02 | $7700.00 | Window Closed / Lapsed |