Production of a purified alumina-silica product and substantially pure aluminum trichloride from bauxites and clays

Claim 2

A process for the production of a substantially iron free alumina-silica product from the group of raw materials consisting of kaolinitic clays and bauxites wherein said kaolinitic clays contain at least kaolinite with the chemical analysis of Al 2 O 3 .2SiO 2 .2H 2 O and said bauxites contain at least one of the minerals with the chemical analysis of Al 2 O 3 .x2H 2 O and at least one silica mineral from the group consisting of Al 2 O 3 .2SiO 2 .2H 2 O and SiO 2 and said group of raw materials contain at least iron as iron mineral, the said process comprising: (a) subjecting the said raw material to at least a calcining stage wherein the said mineral is heated to within the temperature range of 625° C. to about 1150° C. to remove free moisture and water of crystallization combined in said minerals contained in the said material and to convert said Al 2 O 3 .2SiO 2 .2H 2 O and said Al 2 O 3 .xH 2 O to alumina and silica to produce a calcined solids alumina silica product containing said iron; (b) subsequently subjecting the said calcined product to a number one chlorination stage to differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is at least one member selected from the group consisting of Cl 2 , HCl, and COCl 2 and in the presence of at least CO and in the temperature range of about 750° C. to about 1150° C. and said chlorination agent forms less than about 21% of said gas stream to produce a said solids alumina-silica product impoverished in said iron; and (c) subsequently subjecting the said solids alumina-silica product to a number two chlorination stage to further differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is selected from the group consisting of SiCl 4 and AlCl 3 and in the presence of at least CO and in the temperature range of about 900° C. to about 1150° C. and said chlorination agent being present in minor amounts of said gas stream to produce a said solids alumina-silica product further impoverished in said iron.

Claim 3

The process of claim 1 wherein in the said number one chlorination stage the said chlorination agent is Cl 2 .

Claim 4

The process of claim 1 wherein in the said number one chlorination stage the said chlorination agent is Cl 2 and HCl.

Claim 5

A process for the production of a substantially iron free alumina-silica product from the group of raw materials consisting of kaolinitic clays and bauxites wherein said kaolinitic clays contain at least kaolinite with the chemical analysis of Al 2 O 3 .2SiO 2 .2H 2 O and said bauxites contain at least one of the minerals with the chemical analysis of Al 2 O 3 .xH 2 O and at least one silica mineral from the group consisting of Al 2 O 3 .2SiO 2 .2H 2 O and SiO 2 and said group of raw materials contain at least iron as iron mineral, the said process comprising: (a) subjecting the said raw material to at least a calcining stage wherein the said material is heated to within the temperature range of 625° C. to about 1150° C. to remove free moisture and water of crystallization combined in said minerals contained in the said material and to convert said Al 2 O 3 .2SiO 2 .2H 2 O and said Al 2 O 3 .xH 2 O to alumina and silica to produce a calcined solids alumina silica product containing said iron; (b) subsequently subjecting the said calcined product to a number one chlorination stage to differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is SiCl 4 and at least one member selected from the group consisting of Cl 2 , HCl, and COCl 2 and in the presence of at least CO and in the temperature range of 750° C. to about 1150° C. and said chlorination agents form less than about 21% of said gas stream to produce a said solids alumina-silica product impoverished in said iron; and (c) subsequently subjecting the said solids alumina-silica product to a number two chlorination stage to further differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is selected from the group consisting of SiCl 4 and AlCl 3 and in the presence of at least CO and in the temperature range of about 900° C. to about 1150° C. and said chlorination agent being present in minor amounts of said gas stream to produce a said solids alumina-silica product further impoverished in said iron.

Claim 6

A process for the production of a substantially iron free alumina-silica product from the group of raw materials consisting of kaolinitic clays and bauxites wherein said kaolinitic clays contain at least kaolinite with the chemical analysis of Al 2 O 3 .2SiO 2 .2H 2 O and said bauxites contain at least one of the minerals with the chemical analysis of Al 2 O 3 .xH 2 O and at least one silica mineral from the group consisting of Al 2 O 3 .2SiO 2 .2H 2 O and SiO 2 and said group of raw materials contain at least iron as iron mineral, the said process comprising: (a) subjecting the said raw material to at least a calcining stage wherein the said material is heated to within the temperature range of 625° C. to about 1150° C. to remove free moisture and water of crystallization combined in said minerals contained in the said material and to convert said Al 2 O 3 .2SiO 2 .2H 2 O and said Al 2 O 3 .xH 2 O to alumina and silica to produce a calcined solids alumina silica product containing said iron; (b) subsequently subjecting the said calcined product to a number one chlorination stage to differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is SiCl 4 and at least one member selected from the group consisting of Cl 2 , HCl, and COCl 2 and in the presence of at least CO and in the temperature range of 750° C. to about 1150° C. and said chlorination agents form less than about 21% of said gas stream to produce a said solids alumina-silica product impoverished in said iron; and (c) subsequently subjecting the said solids alumina-silica product to a number two chlorination stage to further differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is selected from the group consisting of SiCl 4 and AlCl 3 and in the presence of at least CO and in the temperature range of about 900° C. to about 1150° C. and said chlorination agent being present in minor amounts of said gas stream to produce a said solids alumina-silica product further impoverished in said iron.

Claim 7

The process of claim 4 wherein in the said number one chlorination stage the said chlorination agent is SiCl 4 and Cl 2 .

Claim 8

The process of claim 4 wherein in the said number one chlorination stage the said chlorination agent is SiCl 4 and HCl.

Claim 9

The process of claim 4 wherein in the said number one chlorination stage the said chlorination agent is SiCl 4 , Cl 2 and HCl.

Claim 10

A process for the production of a substantially iron free alumina-silica product from the group of raw materials consisting of kaolinitic clays and bauxites wherein said kaolinitic clays contain at least kaolinite with the chemical analysis of Al 2 O 3 .2SiO 2 .2H 2 O and said bauxites contain at least one of the minerals with the chemical analysis of Al 2 O 3 .xH 2 O and at least one silica mineral from the group consisting of Al 2 O 3 .2SiO 2 .2H 2 O and SiO 2 and said group of raw materials contain at least iron as iron mineral, the said process comprising: (a) subjecting the said raw material to at least a calcining stage wherein the said material is heated to within the temperature range of 625° C. to about 1150° C. to remove free moisture and water of crystallization combined in said minerals contained in the said material and to convert said Al 2 O 3 .2SiO 2 .2H 2 O and said Al 2 O 3 .xH 2 O to alumina and silica to produce a calcined solids alumina silica product containing said iron; (b) subsequently subjecting the said calcined product to a number one chlorination stage wherein the chlorination agent is SiCl 4 and wherein the said SiCl 4 forming part of the said chlorination stage gas stream is in the range of about 2% to 10% of said gas stream and in the presence of at least CO and in the temperature range of about 900° C. to 1150° C. to produce a chlorinated said solids alumina-silica product impoverished in said iron; (c) subsequently subjecting the said solids product to a number two chlorination stage wherein the chlorination agent is AlCl 3 and wherein the said AlCl 3 forming part of the said chlorination stage gas stream is in the range of about 5% to 20% of said gas stream and in the presence of at least CO and in the temperature range of about 900° C. to 1150° C. to produce a further chlorinated said solids alumina-silica product substantially free of said iron.

Claim 11

A process for the production of a substantially iron free alumina-silica product from the group of raw materials consisting of kaolinitic clays and bauxites wherein said kaolinitic clays contain at least kaolinite with the chemical analysis of Al 2 O 3 .2SiO 2 .2H 2 O and said bauxites contain at least one of the minerals with the chemical analysis of Al 2 O 3 .xH 2 O and at least one silica mineral from the group consisting of Al 2 O 3 .2SiO 2 .2H 2 O and SiO 2 and said group of raw materials contain at least iron as iron mineral, the said process comprising: (a) subjecting the said raw material to at least a calcining stage wherein the said material is heated to within the temperature range of 625° C. to about 1150° C. to remove free moisture and water of crystallization combined in said minerals contained in the said material and to convert said Al 2 O 3 .2SiO 2 .2H 2 O and said Al 2 O 3 .xH 2 O to alumina and silica to produce a calcined solids alumina silica product containing said iron; (b) subsequently subjecting the said calcined product to a number one chlorination stage wherein the chlorination agent is SiCl 4 and wherein the said SiCl 4 forming part of the said chlorination stage gas stream is in the range of about 2% to 10% of said gas stream and in the presence of at least CO and in the temperature range of about 900° C. to 1150° C. to produce a chlorinated said solids alumina-silica product impoverished in said iron; (c) subsequently subjecting the said solids product to a number two chlorination stage wherein the chlorination agent is AlCl 3 and wherein the said AlCl 3 forming part of the said chlorination stage gas stream is in the range of about 5% to 20% of said gas stream and in the presence of at least CO and in the temperature range of about 900° C. to 1150° C. to produce a further chlorinated said solids alumina-silica product substantially free of said iron.

Claim 12

The process of claim 1, 4 or 8 wherein subsequent to the said number two chlorination stage said solids alumina-silica product substantially free of iron is subjected to a number three chlorination stage wherein the said chlorination agent is at least selected from the group consisting of Cl 2 and COCl 2 and in the presence of reducing agent selected from the group consisting of C and CO and in the temperature range of about 750° C. to 1150° C. to chlorinate the said alumina and wherein the resultant gas stream following said chlorination stage is substantially free of said iron and the said C and CO is substantially converted to CO 2 , and the said alumina is substantially converted to aluminum chloride, and wherein in reducing the temperature of said gas stream to below 183° C. to condense the said aluminum chloride and produce a substantially iron free aluminum chloride product.

Claim 13

The process of claim 9 wherein the condensation of aluminum chloride is carried out between about 183° C. and above 137° C.

Claim 14

The process of claim 9 wherein the said resultant gas stream is passed through a bed selected from the group consisting of charcoal and devolatilized coke to convert the said CO 2 to CO.

Claim 15

The process of claim 9 wherein subsequent to the production of the said aluminum chloride product the remaining said gas stream is passed through a bed selected from the group consisting of charcoal and devolatilized coke to convert the said CO 2 to CO.

Claim 16

The process of claim 1, 4, or 8 wherein subsequent to the said number two chlorination stage said solids alumina-silica product substantially free of iron is subjected to a number three chlorination stage wherein the said chlorination agent is at least selected from the group consisting of Cl 2 and COCl 2 and in the presence of reducing agent selected from the group consisting of C and CO and in the temperature range of about 750° C. to 1150° C. and in the presence of at least one catalyst selected from the group consisting of NaCl, KCl, NaAlCl 4 and KAlCl 4 to chlorinate the said alumina and wherein the resultant gas stream following said chlorination stage is substantially free of said iron and the said C and CO is substantially converted to CO 2 and the said alumina is substantially converted to aluminum chloride, and wherein in reducing the temperature of said gas stream to below 183° C. to condense the said aluminum chloride and produce a substantially iron free aluminum chloride product.