Improvements in the Manufacture or Production of Aluminium Alloys.
Year: 1891

page_text: PROVISIONAL SPECIFICATION.
Improvements in the Manufacture or Production of Aluminium
Alloys.
I, CAMILLE ALPHONSE FAURE of 15 Rue des Halles, Paris, France,
Electrical Engineer, do hereby declare the nature of this invention to be as
follows:-
:―
My invention more especially relates to a novel process of manufacturing
aluminium chloride and ferro-aluminium, and constitutes an improvement upon the
process secured to me by United States Letters Patent, 385,345 of July 3, 1888.
My improved process comprises the following successive steps
1. The manufacture of aluminium-chloride;
:-
2. The separation of said chloride from accompanying gases by condensation and.
the re-volatilization of said chloride;
3. Passing such re-volatilized aluminium-chloride vapors over or through red-hot
scrap iron, thus forming an alloy of aluminium and iron which melts and runs out
into a suitable receptacle.
In order to carry out my invention in the best way now known to me, I place a
mass of alumina-say about ten tons-mixed as usual with carbonaceous matter, in
a suitable furnace and heated up to redness by passing hot carbonic oxide gas
therethrough. This gas is obtained preferably by passing air over heated bricks
or similar material, as for instance in the well known Siemens regenerators used in
steel making. After leaving the regenerator, the hot air is passed through a mass
of hard coke, or other suitable material, whereby all the oxygen of the air is con-
verted into carbonic oxide; this being properly done, and no air being allowed
access afterwards to the alumina, none of the carbon mixed therewith will be
consumed.
This mode of operation enables me to dispense with the use of retorts in this
process.
When the alumina is sufficiently heated, I shut off the carbonic oxide flame and
pass through the heated alumina a current of hydro-chloric acid gas, or other gas
rich in chlorine, such as perchloride of iron, Fe,Cl, or even chlorine gas, with or
without a proper quantity of hydro carbon vapor the result being that, by the
effect of the stored up heat in the material, and the help of the carbon added to
the alumina or brought in by the carbonic oxide gaseous mixture, and the hydro-
chloric acid gas chloride of aluminium is produced, together with carbonic-oxide
gas and more or less hydrogen.
The above products being all in gaseous form, are then cooled by passing them
through pipes and other vessels constituting a condenser of usual construction,
which condenses the chloride of aluminium, while the carbonic oxide, hydrogen
and any other volatilized product, such as the chloride of silicon, which may arise
from any silica, in the alumina, pass off through the chimney shaft, as usual.
Fire being next applied under the vessel containing the condensed chloride of

page_text: aluminium, it is volatilized and brought into contact with red hot scrap-iron placed in
a furnace, preferably similar to that used for heating the alumina, as above described,
and in great mass-say ten tons and is heated up to red heat in a similar manner;
that is, by carbonic oxide, free from unburned air or carbonic acid. The white-hot
carbonic oxide employed is preferably obtained by the same means as above
described, so as to secure an absolutely reducing flame.
After the scrap iron has been properly heated, as above described, by this
reducing flame, the carbonic oxide gas is cut off and chloride of aluminium vapors
are then admitted under and into the heated scrap-iron until the iron melts into an
alloy of aluminium, and runs into a proper gutter.
The chloride of iron vapor arising during this step of the process is drawn into a
suitable shaft, and condensed in the usual way. Chloride of iron being oxidised in
a proper furnace, produces iron-oxide and perchloride of iron, which may be used
instead of hydro-chloric acid in the above process.
Dated this 10th Jan of Wah 1901
C. A. FAURE,
By L. W., per F. B.
COMPLETE SPECIFICATION.
Improvements in the Manufacture or Production of Aluminium
Alloys.
I, CAMILLE ALPHONSE FAURE of 15 Rue des Halles, Paris, France,
Electrical Engineer, do hereby declare the nature of this invention and in what
manner the same is to be performed to be particularly described and ascertained
in and by the following statement :-
My invention more especially relates to a novel process of manufacturing
aluminium chloride and ferro-aluminium, and constitutes an improvement upon the
process secured to me by United States Letters Patent 385,345 of July 3, 1888.
My improved process comprises the following successive steps
1. The manufacture of aluminium-chloride;
:-
2. The separation of said chloride from accompanying gases by condensation and
the re-volatilization of said chloride;
3. Passing such re-volatilized aluminium-chloride vapors over or through red-hot
scrap iron, thus forming an alloy of aluminium and iron which melts and runs out
into a suitable receptacle.
In order to carry out my invention in the best way now known to me, J. place a
mass of alumina-say about ten tons--mixed as usual with carbonaceous matter, in
a suitable furnace and heated up to redness by passing hot carbonic oxide gas
therethrough. This gas is obtained preferably by passing air over heated bricks or
similar material, as for instance in the well known Siemens regenerators used in
steel making. After leaving the regenerator, the hot air is passed through a mass
of hard coke, or other suitable material, whereby all the oxygen of the air is con-
verted into carbonic oxide; this being properly done, and no air being allowed
access afterwards to the alumina, none of the carbon mixed therewith will be
consumed.
This mode of operation enables me to dispense with the use of retorts in this
process.
j
When the alumina is sufficiently heated, I shut off the carbonic oxide flame and
pass through the heated alumina a current of hydro-chloric acid gas, or other gas
rich in chlorine, such as perchloride of iron, Fe, Cl, or even chlorine.
with or
gas,
without a proper quantity of hydrocarbon vapor; the result being that, by the
effect of the stored up heat in the material, and the help of the.carbon. added to the
alumina or brought in by the carbonic oxide gaseous.mixture, and the hydrochloric
acid gas, chloride of aluminium, is produced, together with carbonic oxide gas, and
more or less hydrogen.

page_text: The above products being all in gaseous form, are then cooled by passing them
through pipes and other vessels constituting a condenser of usual construction,
which condenses the chloride of aluminium, while the carbonic oxide, hydrogen and
any other volatilized product, such as the chloride of silicon, which may arise from
any silica in the alumina, pass off through the chimney shaft as usual.
Fire being next applied under the vessel containing the condensed chloride of
aluminium, it is volatilized and brought into contact with red hot scrap iron placed
in a furnace, preferably similar to that used for heating the alumina, as above
described, and in great mass-say ten tons--and is heated up to red heat in a
similar manner; that is, by carbonic oxide, free from unburned air or carbonic
acid. The white hot carbonic oxide flame employed is preferably obtained by
the same means as above described, so as to secure an absolutely reducing
flame.
After the scrap iron has been properly heated, as above described, by this
reducing flame, the carbonic oxide gas is cut off, and chloride of aluminium vapors
are then admitted under and into the heated scrap-iron until the iron melts into an
alloy of aluminium, and runs into a proper gutter.
The chloride of iron vapor arising during this step of the process is drawn into a
suitable shaft, and condensed in the usual way. Chloride of iron being oxidised in
a proper furnace, produces oxide of iron and perchloride of iron, which latter inay
be used instead of hydrochloric acid in the above process.
The accompanying drawings represent so much of an apparatus as is necessary
to illustrate the manner of carrying out my invention,
Fig. 1 being a vertical longitudinal section on the line 1-1 of Fig. 2;
Fig. 2 a vertical transverse section on the line 2-2 of Fig. 1 ;
Fig. 3 a vertical longitudinal section on the line 3-3 of Fig. 4;
Fig. 4 a transverse section on the line 4-4 of Fig. 3; and
Fig. 5 a side elevation of the condenser and its appurtenances, partly in
section.
The unfeathered darts indicate the direction in which the sections are seen, while
the feathered arrows indicate the direction of the air, the gases, and the products
of combustion.
The drawings shew a regenerative apparatus consisting of two recuperators, A A'
made like the ordinary Siemens' generator, but operated in a different manner, as
hereinafter explained. These regenerators are so constructed as to cause the air
to pass first through one, then through the other, as usual, being provided with
suitable valves for that purpose.
The air enters one (A) of these regenerators, (Fig. 3), through an opening a,
provided with a valve a', controlling the exit a³, and a valve a controlling the
entrance t. The hot air passes from the regenerator through an opening b, con-
trolled by a valve, into a furnace B, (Fig. 1) provided with an opening for
stirring the fuel therein, closed by a door. The ash pit C, of this furnace, is
likewise closed by a suitable door or valve c, or the same purpose may be served by
allowing ashes, c¹, to accumulate therein, so as to prevent access of air except
through the regenerator flues. The hot air admitted through these flues passes
up through a mass of hard coke contained in the fire-place, being supplied thereto
through an opening 63, closed by a stopper 6.
The flame and products of combustion pass over the bridge-wall d, of a
passage D, whence they escape through openings d', in an arch D', constituting
the bottom of a volatilizing chamber E, which contains the mixture of material to
be treated.
After passing through this chamber, the products of combustion escape into a
passage F, controlled by a suitable valve, where it is mingled with fresh air, thus
producing combustion and intense heat; these products of combustion pass through
the opposite regenerator to that through which the air first entered, and after
heating it escapes through the chimney.
The operation of this portion of my apparatus, it will be observed, differs from

page_text: the normal working of the Siemens regenerator, inasmuch as I pass the heated air
through the fuel before it passes through the material to be acted upon.
After the material in the volatilizing chamber E has been sufficiently heated, the
regenerator-flues are closed, and the gas or vapor with which the material is to be
treated is permitted to enter through an opening G, Fig. 1 in the top of the
furnace, whence it passes through the passage D, and its openings, into the
bottom of the volatilizing chamber E, rising through the material therein, and
finally escaping through the opening H, which is to be closed by a suitable
damper.
The material to be treated is fed into the volatilizing chamber through a suitable
opening e, provided with a cover or door E¹.
From the foregoing description it will be seen that the operation of the
apparatus is such that all air is excluded from the material to be treated, which
is only acted upon by the carbonic-oxide generated by the passage of the hot
air through the fuel. This keeps the material well deoxidized, and prevents the
active combustion of the carbon contained in the volatilizing chamber.
The gases and vapors which enter the opening or passage H, (Fig. 5) pass
through a tunnel H', or a series of tubes, wherein heavy particles, such as dust
and chlorate of iron impurities may be deposited. A valve ', and pan ³, permit.
of the removal of these particles from the tunnel.
The vapors and gases pass from this tunnel through a pipe H², to a condenser,
shewn as consisting of two parallel superposed horizontal cylindrical iron boilers
or shells. The vapors enter the lower one I, of these shells, and ascend through a
pipe, to the upper shell 1. The condensible portions of these vapors remain in
the condenser, while the uncondensible portions escape through a valve j, up the
chimney J. The condensible products, after the completion of the condensing
operation, are again volatilized by means of a furnace K, the products of com-
bustion from which pass around or through the condenser to the chimney. The
volatilized gases pass through a pipe M, "provided with a valve m to the place
where they are to be utilized, not shewn in the drawings. The contents of the
condenser may be drawn off when desired, through a pipe N, provided with a
stop-cock.
-
Having now particularly described and ascertained the nature of the said
invention and in what manner the same is to be performed I declare that
what I claim is :-
1. The hereinbefore described process of manufacturing aluminium-chloride by
passing hot carbonic oxide through a mixture of alumina and carbon, and then
passing through the mixture thus heated a gas rich in chlorine mixed with hydro-
carbon vapors, substantially as hereinbefore set forth.
2. The hereinbefore described process of manufacturing aluminium-chloride,
consisting in heating a mixture of alumina and carbon by passing hot carbonic
oxide therethrough then cutting off the carbonic oxide, and passing through the
mixture a gas rich in chlorine, such as hydrochloric acid gas or perchloride of iron
mixed with hydrocarbon vapors without contact with atmospheric air, substantially
as hereinbefore set forth.
3. The herein before described process of manufacturing aluminium-chloride by
passing hot carbonic oxide through a mixture of alumina and carbon; cutting off
the carbonic-oxide passing through the mixture a gas rich in chlorine mixed with
hydrocarbon vapors, and separating the aluminium-chloride therefrom by con-
densation, substantially as herein before set forth.
4. The hereinbefore described process of manufacturing aluminium-chloride, con-
sisting in heating alumina mixed with carbon by passing through the mixture a
current of carbonic oxide obtained by passing heated air through incandescent
carbon cutting off the carbonic oxide flame, and then passing through the heated
alumina, chlorine gas mixed with hydrocarbon vapors, substantially as herein before
set forth.

page_text: 5. The hereinbefore described process of manufacturing ferro-aluminium, which
consists in heating scrap iron by carbonic oxide gas; cutting off the carbonic
oxide gas flame, and passing aluminium chloride vapors through the mass of heated
scrap iron to melt the iron and form the alloy, substantially as herein before set
forth.
6. The hereinbefore described process of manufacturing an alloy of aluminium
and iron, which consists in heating scrap iron by passing therethrough a current of
hot carbonic oxide gas obtained by passing heated air through incandescent
carbon then cutting off the flame, and passing aluminium-chloride vapors through
the iron until the alloy runs out, substantially as hereinbefore set forth.
;
7. The hereinbefore described process of manufacturing ferro-aluminium, which
consists in passing hot carbonic oxide through a mixture of alumina and carbon;
subsequently passing through the mixture thus heated chlorine gas and hydrocarbon
vapors separating the aluminium chloride from the other volatilized products by
condensation; and then vaporizing it and passing it through hot scrap-iron which
it melts and with which it forms an alloy.
8. The herein before described process of manufacturing ferro-aluminium, which
consists in passing hot carbonic oxide through a mixture of alumina and carbon;
subsequently passing hydrocarbon vapors and chlorine gas through said heated
mixture; condensing the aluminium-chloride vapors thus produced; heating scrap-
iron by hot carbonic oxide; vaporizing the condensed aluminium-chloride, and
passing it through the heated scrap-iron until it melts the same and the aluminium
therein forms an alloy with the iron substantially as hereinbefore set forth.
9. The hereinbefore described process of manufacturing aluminium alloys, which
consists in heating a mixture of alumina and carbon without combustion of the
carbon, and then passing through said mixture a gas with which the aluminium
combines, forming a vapor or gas composed of vaporized aluminium and the gas
introduced, and then passing said vapors or gases through or over heated metal
substantially as described, thereby causing the aluminium to form an alloy
therewith.
Deted this 19th dox of November 1891
C. A. FAURE,
By L. W., per F. B.