Production of aluminum--silicon alloy and ferrosilicon and commercial purity aluminum by the direct reduction process. First interim technical report, Phase B, September 1--November 30, 1978
The parameters of charge content, reaction temperatures and residence time were studied in a bench reactor concerning the production of Al--Si and Fe--Si alloys. Results confirmed that minimum final stage reaction temperature is 1950 to 2000/sup 0/C. Residence time varied with initial charge concentration. Fe/sub 2/O/sub 3/ additions to the charge produced a significant increase in metallic yield. A burden preparation procedure was developed for making acceptable agglomerates containing Fe/sub 2/O/sub 3/, bauxite, clay and coke. Particle size distribution of starting materials was correlated with agglomerate strength. A new bench scale reactor was designed and built to facilitate semi-continuous operation, using O/sub 2/ injection to burn coke supporting the burden, resulting in burden movement. In a number of runs bridging of the burden material occurred due to condensation of volatilized sub-oxides in the cooler zones of the reactor. The reactor operated smoothly as an iron blast furnace at 1500/sup 0/C, demonstrating the validity of the equipment and test procedures. Initial construction of pilot reactor VSR-1 was completed. Bench scale fractional crystallizer runs were continued to determine the impurity effects of Fe up to 6.9% and Ti up to 1.25% on alloy product concentration and yield. High levels of impurities formed intermetallic complexes with Al and reduced product yield.
- Research Organization:
- Aluminum Co. of America, Alcoa Center, PA. Alcoa Labs.
- DOE Contract Number:
- EC-77-C-01-5089
- OSTI ID:
- 6431940
- Report Number(s):
- CONS-5089-5
- Country of Publication:
- United States
- Language:
- English
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