Process for producing magnesium utilizing aluminum metal reductant

Claim 2

A process for production of magnesium in a reaction-condensation system having a reducing furnace zone and a condensation zone, comprising reacting in the reducing furnace zone aluminum metal containing at least 80 weight percent aluminum and a calcium magnesium aluminate slag or magnesium oxide in the presence of said slag containing not more than five weight percent silicon dioxide, the amount of aluminum metal fed into the reducing furnace zone being in excess of the stoichiometric amount of aluminum required to react with the magnesium oxide fed into the reaction zone, and slag removed therefrom contains about 6-16 weight percent magnesium oxide, carrying out the reaction at a temperature of about 1500°-1700° C at a pressure of about 0.5-2.0 atmospheres, maintaining the silicon dioxide content and the magnesium oxide content of the molten oxidic slag in the reaction zone at least as low as five weight percent and about 6-16 weight percent, respectively, evolving magnesium vapor from the reaction zone to the condensation zone, and condensing and recovering the magnesium as a product.

Claim 3

The process of claim 1, wherein the excess amount of aluminum metal fed into the reducing furnace zone is from five percent to 100 percent of the stoichiometric amount of aluminum required to react with the magnesium oxide fed into the reaction zone.

Claim 4

The process of claim 1, wherein the excess amount of aluminum metal fed into the reducing furnace zone is from 5 percent to 10 percent of the stoichiometric amount of aluminum required to react with the magnesium oxide fed into the reaction zone.

Claim 5

The process of claim 1, wherein the reaction is carried out at a temperature of 1550°-1600° C.

Claim 6

The process of claim 1, wherein the reaction is carried out at a pressure of about one atmosphere.

Claim 7

The process of claim 1, wherein the silicon dioxide content of the molten oxidic slag is maintained at least as low as two weight percent.

Claim 8

The process of claim 1, wherein said aluminum has a purity of at least 90 weight percent.

Claim 9

The process of claim 1, wherein as the reaction continues, and as magnesium oxide in the slag is consumed by reacting with the aluminum, additional oxides are added as necessary to maintain the composition of the slag in weight percent as follows: ______________________________________ calcium oxide (CaO) 30 - 65 aluminum oxide (Al.sub.2 O.sub.3) 28 - 64 magnesium oxide (MgO) 6 - 16 silicon dioxide (SiO.sub.2) ≦5 and other oxides, halides, sulfides ≦5 ______________________________________

Claim 10

The process of claim 8, wherein the magnesium oxide is in the form of calcined dolime of the formula T CaO.sup.. MgO where 0.5 ≦ T ≦ 2.0.

Claim 11

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

Claim 12

In a process for producing magnesium by reaction of magnesium oxide with aluminum in a reaction-condensation system and utilizing a molten oxidic slag, the improvement therein, wherein the aluminum has a purity of at least 80 weight percent, the amount of aluminum metal fed into the reaction zone is from 5 to 100 percent in excess of the stoichiometric amount of aluminum required to react with the magnesium oxide, the silicon dioxide content and the magnesium oxide content of the molten oxidic slag is maintained at less than about five weight percent of said slag and about 6-16 weight percent of said slag, respectively.

Claim 13

In a process for producing magnesium by reaction of magnesium oxide with aluminum in a reaction-condensation system and utilizing a molten oxidic slag, the improvement therein, wherein the aluminum has a purity of at least 80 weight percent, the amount of aluminum metal fed into the reaction zone is from 5 to 100 percent in excess of the stoichiometric amount of aluminum required to react with the magnesium oxide, the silicon dioxide content and the magnesium oxide content of the molten oxidic slag is maintained at less than about five weight percent of said slag and about 6-16 weight percent of said slag, respectively.

Claim 14

The process of claim 11, wherein the silicon dioxide content of the molten oxidic slag is maintained at less than about two weight percent of said slag.

Claim 15

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 calcium magnesium aluminum oxide slag of the following weight percent composition: ______________________________________ Calcium oxide (CaO) 30 - 65 Aluminum oxide (Al.sub.2 O.sub.3) 28 - 64 Magnesium oxide (MgO) 6 - 16 Silicon dioxide (SiO.sub.2) ≦5 ______________________________________ reacting with the molten oxidic slag in the reaction zone an aluminum metal of at least 80 weight percent purity, the amount of the aluminum metal being from five percent to 100 percent in excess of the amount of aluminum required to react stoichiometrically with the magnesium oxide, carrying out the reaction at a temperature of about 1500°-1700° C and at a pressure of about 0.5-2.0 atmospheres, periodically withdrawing molten oxidic slag from the reaction zone, maintaining the silicon dioxide content and the magnesium oxide content of the molten oxidic slag in the reaction zone and the molten oxidic slag withdrawn therefrom at five weight percent or less and about 6-16 weight percent, respectively, evolving magnesium vapor from the reaction zone to the condensation zone and recovering magnesium metal as a product.

Claim 16

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 calcium magnesium aluminum oxide slag of the following weight percent composition: ______________________________________ Calcium oxide (CaO) 30 - 65 Aluminum oxide (Al.sub.2 O.sub.3) 28 - 64 Magnesium oxide (MgO) 6 - 16 Silicon dioxide (SiO.sub.2) ≦5 ______________________________________ reacting with the molten oxidic slag in the reaction zone an aluminum metal of at least 80 weight percent purity, the amount of the aluminum metal being from five percent to 100 percent in excess of the amount of aluminum required to react stoichiometrically with the magnesium oxide, carrying out the reaction at a temperature of about 1500°-1700° C and at a pressure of about 0.5-2.0 atmospheres, periodically withdrawing molten oxidic slag from the reaction zone, maintaining the silicon dioxide content and the magnesium oxide content of the molten oxidic slag in the reaction zone and the molten oxidic slag withdrawn therefrom at five weight percent or less and about 6-16 weight percent, respectively, evolving magnesium vapor from the reaction zone to the condensation zone and recovering magnesium metal as a product.

Claim 17

The process of claim 13, wherein the silicon dioxide content of said slag is maintained at two weight percent or less.

Claim 18

The process of claim 13, wherein said temperature is about 1550°-1600° C.

Claim 19

The process of claim 13, wherein the excess amount of aluminum is from 5 percent to 10 percent of the stoichiometric amount of aluminum.

Claim 20

The process of claim 13, wherein said pressure is about one atmosphere.

Claim 21

The process of claim 13, wherein the melting in the reaction zone is conducted in an atmosphere of an inert gas.

Claim 22

The process of claim 13, wherein the aluminum metal is aluminum scrap.