Year: 1887

page_text: Date of Application, 20th Dec., 1887
Complete Specification Left, 20th Sept., 1888
Complete Specification Accepted, 20th Dec., 1888
I, HENRY HARRIS LAKE, of the firm of Haseltine, Lake & Co., Patent Agents,
Southampton Buildings, in the County of Middlesex, do hereby declare the nature
of this invention to be as follows:-
This invention consists in improvements in the process of manufacturing aluminium
and apparatus therefor described in the specification of a former application filed on
the 21st day of March 1887, No. 4228. The process therein described consists in
preparing aluminium from the compounds of the same with chlorine, bromine, fluorine
or the double compounds of aluminium with the aforesaid bodies and potassium and
sodium by means of the metals of the alkalies or alkaline earths in such a manner
that sodium in the solid state is introduced into the molten cryolite or other aluminium
72
"diver and an instantaneous decom-
compound by means of an apparatus termed a
position is effected. As soon as the decomposition has taken place and the reaction
has been completed a rapid cooling is effected by pouring out of the containing vessel
the molten mass, whereupon the aluminium separates from the rest of the slag and can
be readily obtained therefrom in the form of an ingot.
The present specification contains a description of apparatus which under certain
circumstances may be advantageously used in lieu of that described in my former
specification. In some cases also an alteration in the process may be desirable.
In order to introduce the sodium quickly into the molten aluminium compound and
to mix it rapidly and completely with the same, other devices can also be employed,
such as, for example, a smelting and reducing vessel which can be set in motion in
order to effect the quick and complete mixing of the sodium with the liquid aluminium
compound, which succeeds without difficulty, owing to the difference in the specific
weights of the lighter sodium and the molten mass,

page_text: A very simple process of this kind, which was often used for the trials relating to
this matter, consists in removing a crucible T Figure 1 after the fusion of its contents,
from the furnace and covering it with a well fitting cover D, which by means of pins
or projections arranged on its lower side, carries a sodium disc g, and is firmly
pressed upon the crucible by suitably shaped tongs k which embrace with one annular
claw the lower part of the crucible and with another annular claw the cylindrical
head of the cover D, the crucible being turned over as often as desired, any metallic
sodium present, by reason of its smaller specific gravity, ascending again and again
through the molten mass, until all the sodium is combined or used up.
This process, which effects the complete mixing without any loss of sodium through
volatilization, has beside this advantage, also a disadvantage inasmuch as, when earthen
crucibles are used, there is great difficulty in obtaining a tight joint between the
cover and crucible, whereas when iron vessels, are employed there will be an increased
quantity of iron in the aluminium.
For the production of large quantities of aluminium, and for such purposes in
which the presence of iron is not objectionable use can preferably be made of an iron
converter of the construction illustrated in Figure 2. The cylindrical iron vessel T
arranged upon the shaft æ, a is charged through the opening o with the aluminium
compound to be decomposed and the flux; the end of the heating tube is placed
in communication with the gas generator through the tube y and air is introduced
through p. As soon as the flame passing through the tube has caused the charge
to melt, solid or liquid metallic sodium is introduced through the opening which is
then closed, the connection of n with q is severed, and the converter T is set in rotation
by means of the pulley w. After the decomposition which will be terminated shortly
afterwards, the converter is placed in the vertical position, the outlet m is then
opened, and slag and aluminium are allowed to pass into a transportable tapping
crucible.
A lined converter can however he employed when a product as free as possible of
iron should be obtained.
In lieu of a rotating converter, a swinging or oscillating converter can also
be used.
It is known that steel may be produced from cast iron, by Heaton's process.
Aluminium may be extensively produced by a process similar to Heaton's process, in
which however metallic sodium is used in lieu of saltpetre, and a sieve made of
aluminium in lieu of the iron grate or perforated iron plate.
For the use of liquid sodium a diver cannot be very conveniently employed. For
this purpose a converter is especially well adapted.
With the crucible converter represented in Figure 1 it is then only necessary to
provide the cover with an opening which, after the liquid sodium has been poured in
through the same, is closed with an iron stopper.
With the rotating converter represented in Figure 2 the molten sodium is simply
poured in through the upper opening o, as described.
The sodium does not of course require to be always introduced from above but can
be introduced in any other suitable manner. Thus for instance, besides the above
described process similar to that of Heaton, use can be made of an apparatus which
is similar to Bessemer's converter and in which the liquid sodium is introduced in
proximity to the bottom, by the application of pressure. In some instances the
gaseous sodium given off from the retort in the manufacture of sodium may be
introduced directly into the molten cryolite or other aluminium compound.
Dated this 20th day of December 1887
HASELTINE, LAKE & Co.,
45, Southampton Buildings, London, W.C.,
Agents for the Applicant.

page_text: COMPLETE SPECIFICATION.
Improvements in the Manufacture of Aluminium and Apparatus
therefor.
T, HENRY HARRIS LAKE, of the firm of Haseltine, Lake & Co., Patent Agents,
Southampton Buildings, in the County of Middlesex, 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:-
This invention consists in improvements in the process and apparatus for the manu-
facture of aluminium described in the specification of former Letters Patent dated 21st
March A.D. 1887, No. 4228. The process therein described consists in preparing
aluminium from the compounds of the same with chlorine, bromine, fluorine, or from the
double compounds of aluminium with the aforesaid bodies and potassium and sodium, by
means of the metals of the alkalies or alkaline earths in the following manner, viz. :-the
decomposing metal, preferably in the solid state, is introduced into the molten cryolite
or other aluminium compound by means of an apparatus termed a "diver," and an
instantaneous decomposition is effected : or the molten aluminium compound is
introduced into the molten decomposing metal. As soon as the decomposition has
taken place and the reaction has been completed, a rapid cooling is effected by
pouring the molten mass out of the containing vessel, whereupon the aluminium
separates from the slag and can be readily obtained therefrom in the form of an
ingot.
The present invention comprises apparatus which, under certain circumstances, may
be advantageously used in lieu of that described in my said former specification; and
it also comprises various improvements in, or modifications of, the process described
in the said former specification.
In order to introduce the sodium quickly into the molten aluminium compound, and
to mix it rapidly and completely with the same, various devices can be employed,
such as, for example, a smelting and reducing vessel which can be set in motion in
order to effect the quick and complete mixing of the sodium with the liquid
aluminium compound.
I will now proceed to describe my present improvements with reference to the
accompanying drawings, in which
Figure 1 is a side elevation, partly in vertical section, showing one form of my
improved apparatus, and
Figure 2 is a vertical central section showing another forin or modification
thereof.
A very simple process of the kind above mentioned consists in first melting or
fusing the aluminium compound, together with the necessary flux, in a crucible A,
Figure 1, then removing the said crucible from the furnace, and covering or closing
it with a well-fitting cover B, which, by means of pins or projections arranged on

page_text: its underside, carries a sodium disc c, and which is firmly secured upon the crucible
by suitably shaped tongs d. These tongs embrace with one annular claw the lower
part of the crucible, and with another annular claw the cylindrical head of the
cover B. The crucible being repeatedly inverted or turned over as often as desired,
any metallic sodium present, by reason of its smaller specific gravity, will ascend
again and again through the molten mass, until all the sodium is combined or
used up.
This process, which effects the complete mixing without any loss of sodium through
volatilization, has, besides this advantage, also a slight disadvantage inasmuch as, when
earthen crucibles are used, there is great difficulty in obtaining a tight joint between
the cover and crucible.
When iron vessels are employed there will be an increased quantity of iron in the
aluminium.
For the production of large quantities of aluminium, and for purposes in which
the presence of iron is not objectionable, use is preferably made of an iron or steel
converter of the construction illustrated in Figure 2. The cylindrical iron vessel A
mounted upon the axles or trunnions a is charged through the opening a¹ with the
aluminium compound to be decomposed and with the flux; the end e¹ of the heating
tube e is placed in communication with the gas-generator through the tube, and air
is introduced through the branch-pipe g. As soon as the flame passing through the
tube e has melted the charge, solid or liquid metallic sodium is introduced through
the opening a¹ which is then closed, the connection of e¹ with fis cut off, and the
converter A is set in rotation by means of a pinion 7 or a pulley, or otherwise. After
the decomposition, which will be terminated shortly afterwards, the converter is placed
in the vertical position shown, the outlet is then opened, and the slag and aluminium
are allowed to pass into a transportable tapping crucible.
A lined converter can, however, be employed when it is desired to obtain a product
as free as possible from iron.
In lieu of a rotating converter, a swinging or oscillating converter can be used
if desired.
For the use of liquid sodium a diver cannot be very conveniently employed. For
this purpose a converter is especially well adapted. With the crucible-converter
represented in Figure 1, it is only necessary for this purpose to provide the cover with
an opening, which, after the liquid sodium has been poured in through the same, is
closed with an iron stopper.
With the rotating converter represented in Figure 2, the molten sodium is simply
poured in through the upper opening a' as above described.
According to another modification of my invention, I produce aluminium by a
process similar to Heaton's process of producing steel from cast iron by means of
saltpetre. In my process, however, metallic sodium is placed in the bottom of the
converter in lieu of saltpetre, and a sieve or grid made of aluminium, in lieu of the
iron grate or perforated iron plate, is placed over the sodium; the molten aluminium
compound is then poured into the converter, and the sodium gradually melting, rises
through the same, and decomposes it, thus reducing the aluminium, the said sieve or
grid being gradually fused so that the sodium is allowed to rise but not too
freely.
The sodium does not require to be always introduced from above; it can be
introduced in any other suitable manner. Thus, for instance, besides the above
described process similar to that of Heaton, use can be made of an apparatus which is
similar to Bessemer's converter, and in which the liquid sodium is introduced in
proximity to the bottom by the application of pressure.
Two convenient forms of apparatus for this purpose are shown in Figures 3 and 4,
which are vertical central sections.
A is the converter which is supported on trunnions B B. C is the sodium inlet
pipe which is passed through one of the trunnions B to permit the tipping of the
converter. The said pipe C (Figure 3) is provided with a stop-cock 1) for closing
the communication with the converter and the said pipe has attached thereto,-or-

page_text: formed therewith a conical or funnel-shaped piece E which is secured in any suitable
manner to the bottom of the converter. The said piece E is covered with a finely
perforated plate F through which the molten sodium rises in fine streams.
G is a
force-pump which draws the sodium from a containing tank H and forces it through
the pipe into the converter. I is a motor of any suitable construction for operating
the said force-pump, and K is a regulator. L is a heating chamber surrounding the
tank, pump, and regulator for the purpose of maintaining the same at a temperature of
about 203 degrees Fahrenheit. M is an ordinary stuffing-box around the pipe C,
and N indicates part of the gearing for tipping the converter in the usual
manner.
The stop-cock D being closed, the molten aluminium compound is poured into the
previously heated converter A. The stop-cock D is then opened and the molten
sodium is forced into the converter by means of the pump G through the finely
perforated plate F, and, by reason of the difference of specific gravity of the two
substances, rises through the molten aluminium bath, decomposing the aluminium
compound in its passage through the same. When any undecomposed sodium arrives
at the top of the molten bath, the operation is thus shown to be complete, whereupon
the stop-cock D is closed, the pump G stopped and the converter tipped to empty its
contents into a receiving vessel placed beneath it.
It is not essential that the sodium should be introduced through the bottom of the
converter as above described. It may be introduced near the bottom by means of a
pipe C, Figure 4, provided at its lower end with a conical or other suitable piece E
provided with a finely perforated plate F. The pipe C is connected with a force-pump
as in the arrangement last above described, and, after the molten aluminium compound
is poured into the converter, the pump is started and forces the sodium through the
bath, thus effecting the decomposition of the aluminium compound. The said pipe C
is removed prior to the tipping of the converter.
When the aluminium compound is to be introduced in a molten state into the
decomposing metal, I find it advantageous to proceed as follows, viz. ;-I melt or liquefy
the required quantity of sodium and place the same in a vessel of suitable form. The
aluminium compound is also fused and whilst in a liquid state is poured into the
liquid sodium in streams or jets or otherwise divided, so that a very large surface of
the aluminium compound comes into contact with the sodium. In order to divide
the aluminium compound I sometimes pass the same through a perforated vessel
similar to a colander.
As the molten aluminium compound sinks through the bath of metallic sodium by
reason of its greater specific gravity, its reduction is effected, the sodium combining
with the fluorine or chlorine and liberating the aluminium.
When the reduction is effected, the contents of the reducing vessel are poured into
a mould, at the bottom of which, after cooling, the metallic aluminium will be found.
Having now particularly described and ascertained the nature of the said invention
and in what manner the same is to be performed as communicated to me by my
foreign correspondent I wish it understood that I claim :-
First The improved process of manufacturing aluminium, wherein the aluminium
compound is first melted or fused in a crucible and the sodium is then introduced into
the same, which is then closed and repeatedly inverted, substantially as described.
Second The improved process of manufacturing aluminium, wherein the aluminium
compound is first melted or fused in an iron or steel vessel mounted upon axles or
trunnions and the sodium is then introduced and the vessel rotated or oscillated, sub-
stantially as described.
Third The improved process for the manufacture of aluminium, in which the
molten aluminium is allowed to fuse the sodium placed under an aluminium grid at
the bottom of the converter, substantially as described.
Fourth-The improved process of manufacturing aluminium, wherein the aluminium
compound is first melted or fused in an apparatus similar to a Bessemer Converter,

page_text: and the sodium is then introduced under pressure at, or near, the bottom thereof,
substantially as described.
Fifth The device comprising the crucible, the cover provided with the pins or
projections, and means whereby the said crucible may be kept closed and repeatedly
inverted, substantially as, and for the purpose, above specified.
Sixth The approved apparatus constructed substantially as described with reference
to Figure 2 of the drawings for the purpose specified.
Dated this 20th day of September 1888.
HASELTINE, LAKE & Co.,
45, Southampton Buildings, London,
Agents for the Applicant.