US4252774A — Method of processing aluminous ores

Claim 1

Independent Claim 77 words

A method of producing aluminum chloride from aluminous materials containing iron comprising reacting said aluminous materials containing iron with carbon and a chlorine-containing gas at a temperature sufficient to form a gaseous mixture including chlorides of aluminum and iron and oxides of carbon, contacting the chlorides of aluminum and iron with aluminum sulfide at a temperature sufficient to precipitate iron sulfide and to form gaseous aluminum chloride, and separating aluminun chloride gas from the precipitated iron sulfide.

Claim 2

Independent Claim 77 words

A method of producing aluminum chloride from aluminous materials containing iron comprising reacting said aluminous materials containing iron with carbon and a chlorine-containing gas at a temperature sufficient to form a gaseous mixture including chlorides of aluminum and iron and oxides of carbon, contacting the chlorides of aluminum and iron with aluminum sulfide at a temperature sufficient to precipitate iron sulfide and to form gaseous aluminum chloride, and separating aluminun chloride gas from the precipitated iron sulfide.

Claim 3

Dependent Claim 38 words

The method of producing aluminum chloride set forth in claim 1, wherein the aluminous materials are reacted with carbon and the chlorine-containing gas at a temperature in the range of between about 900° K. and about 1200° K.

Claim 4

Dependent Claim 32 words

The method of producing aluminum chloride set forth in claim 1, wherein the reaction with aluminum sulfide takes place in the temperature range of between about 600° K. and about 1100° K.

Claim 5

Dependent Claim 38 words

The method of producing aluminum chloride set forth in claim 1, wherein the aluminum sulfide is present in an amount in excess of the stoichiometric quantity and the reaction takes place at a temperture of about 800° K.

Claim 6

Dependent Claim 39 words

The method of producing aluminum chloride set forth in claim 4, wherein the aluminum sulfide is in the form of a bed of particles at least partially fluidized by passage therethrough of the gaseous chlorides of aluminum and iron.

Claim 7

Dependent Claim 25 words

The method of producing aluminum chloride set forth in claim 1, wherein the aluminum sulfide is present as a solute in a molten salt bath.

Claim 8

Dependent Claim 20 words

The method of producing aluminum chloride set forth in claim 6, wherein said molten salt has an alkali metal cation.

Claim 9

Dependent Claim 23 words

The method of producing aluminum chloride set forth in claim 6, wherein the molten salt is sodium chloride, potassium chloride or mixtures thereof.

Claim 10

Dependent Claim 24 words

The method of producing aluminum chloride set forth in claim 6, wherein the molten salt is the eutectic of sodium chloride and potassium chloride.

Claim 11

Independent Claim 180 words

A method of producing aluminum chloride from aluminous materials containing minor amounts of compounds of iron, titanium and silicon comprising reacting said aluminous materials with carbon and a chlorine-containing gas in the temperature range of from about 900° K. to about 1200° K. to form a gaseous mixture containing chlorides of aluminum, iron, titanium and silicon and oxides of carbon, cooling said gaseous mixture to a temperature in the range below the boiling point of the aluminum chloride in the mixture and above the boiling point of the titanium chloride in the mixture to condense the aluminum chlorides and iron chlorides while titanium chloride and silicon chloride remain in the gas phase to effect a separation thereof; heating the mixture of iron chlorides and aluminum chlorides to a temperature in excess of the boiling point of the iron chlorides in the mixture to form gaseous aluminum chlorides and iron chlorides; passing the heated gases into intimate contact with aluminum sulfide to precipitate iron sulfide and to form gaseous aluminum chloride; and separating gaseous aluminum chloride from the precipitated iron sulfide.

Claim 12

Independent Claim 180 words

A method of producing aluminum chloride from aluminous materials containing minor amounts of compounds of iron, titanium and silicon comprising reacting said aluminous materials with carbon and a chlorine-containing gas in the temperature range of from about 900° K. to about 1200° K. to form a gaseous mixture containing chlorides of aluminum, iron, titanium and silicon and oxides of carbon, cooling said gaseous mixture to a temperature in the range below the boiling point of the aluminum chloride in the mixture and above the boiling point of the titanium chloride in the mixture to condense the aluminum chlorides and iron chlorides while titanium chloride and silicon chloride remain in the gas phase to effect a separation thereof; heating the mixture of iron chlorides and aluminum chlorides to a temperature in excess of the boiling point of the iron chlorides in the mixture to form gaseous aluminum chlorides and iron chlorides; passing the heated gases into intimate contact with aluminum sulfide to precipitate iron sulfide and to form gaseous aluminum chloride; and separating gaseous aluminum chloride from the precipitated iron sulfide.

Claim 13

Dependent Claim 38 words

The method of producing aluminum chloride set forth in claim 10, wherein the gaseous titanium chloride silicon chloride are separated from the aluminum chlorides and the iron chlorides by cooling the mixture to a temperature below 400° K.

Claim 14

Dependent Claim 35 words

The method of producing aluminum chloride set forth in claim 10, wherein the reaction of iron chlorides and aluminum sulfide takes place in the temperature range of between about 600° K. and about 1100° K.

Claim 15

Dependent Claim 43 words

The method of producing aluminum chloride set forth in claim 10, wherein the reaction of iron chlorides with aluminum sulfide takes place at a temperature of about 800° K. and the aluminum sulfide is present in an amount greater than the stoichiometric quantity.

Claim 16

Dependent Claim 41 words

The method of producing aluminum chloride set forth in claim 10, and further comprising separating the precipitated iron sulfide from the unreacted aluminum sulfide and recycling the aluminum sulfide for contact with the heated mixture of iron chlorides and aluminum chlorides.

Claim 17

Dependent Claim 31 words

The method of producing aluminum chloride set forth in claim 10, wherein the method is continuous and aluminum sulfide is continuously produced by the reaction of aluminum oxide and carbon disulfide.

Claim 18

Independent Claim 45 words

A method of separating gaseous mixtures of iron chlorides and aluminum chlorides comprising contacting said gaseous mixtures with aluminum sulfide at a temperature sufficient to precipitate iron sulfide and to form gaseous aluminum chlorides, and separating said gaseous aluminum chlorides from said precipitated iron sulfide.

Claim 19

Independent Claim 45 words

A method of separating gaseous mixtures of iron chlorides and aluminum chlorides comprising contacting said gaseous mixtures with aluminum sulfide at a temperature sufficient to precipitate iron sulfide and to form gaseous aluminum chlorides, and separating said gaseous aluminum chlorides from said precipitated iron sulfide.

Claim 20

Dependent Claim 34 words

The method of separating gaseous mixtures of iron chlorides and aluminum chlorides set forth in claim 16, wherein the temperature is greater than the boiling point of the iron chlorides in the gaseous mixture.

Claim 21

Dependent Claim 28 words

The method of separating gaseous mixtures of iron chloride and aluminum chloride set forth in claim 16, wherein the aluminum sulfide is in the form of solid particles.

Claim 22

Dependent Claim 44 words

The method of separating gaseous mixtures of iron chloride and aluminum chloride set forth in claim 18, wherein the aluminum sulfide is in a fluidized bed at least partially fluidized by the passage therethrough of the gaseous mixtures of aluminum chlorides and iron chlorides.

Claim 23

Dependent Claim 27 words

The method of separating gaseous mixtures of iron chlorides and aluminum chlorides set forth in claim 16, wherein aluminum sulfide is present in a molten salt bath.

Claim 24

Dependent Claim 32 words

The method of separating gaseous mixtures of iron chlorides and aluminum chlorides set forth in claim 16, wherein the aluminum sulfide is present as a solute in an alkali metal chloride bath.

Claim 25

Dependent Claim 33 words

The method of separating gaseous mixture of iron chlorides and aluminum chlorides set forth in claim 21, wherein said alkali metal chloride bath is a eutectic mixture of sodium chloride and potassium chloride.

Claim 26

Dependent Claim 47 words

The method of separating gaseous mixture of iron chlorides and aluminum chlorides set forth in claim 16, wherein the aluminum sulfide is present in an amount greater than the stoichiometric quantity and the temperature is in the range of from about 600° K. to about 1100° K.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1984-02-24	1984-08-25	1985-02-24	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1988-02-24	1988-08-25	1989-02-24	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1992-02-24	1992-08-25	1993-02-24	$7700.00	Window Closed / Lapsed

Method of processing aluminous ores

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