Patent ID: 7896945
Filing Date: 2011-03-01
Classification: C22B

Abstract:
1. A process for producing a mass of solid aluminium carbide containing product, wherein the process includes the steps of: (a) injecting particulate alumina into a bath of molten aluminium metal; (b) injecting carbonaceous material consisting of, containing or yielding carbon, into the bath of molten aluminium metal; (c) maintaining the bath of molten aluminium metal at a superheated temperature sufficient to heat and react carbon of the carbonaceous material with molten aluminium of the bath to produce solid aluminium carbide which mixes with alumina to form a mass containing entrapped gas and entrapped molten aluminium metal and having a bulk or apparent density less than the aluminium of the bath; and (d) allowing the mass of solid aluminium carbide mixed with alumina, containing gas and aluminium metal, to accumulate as a mass of solid aluminium carbide containing product on the upper surface of the bath, wherein the carbonaceous material is a hydrocarbon material or is produced by pyrolysis, decomposition or cracking of a hydrocarbon material.