Physical chemistry of carbothermic reduction of alumina

Production of aluminium, by means of carbothermic reduction of alumina, is discussed. By employing a solvent metal bath to absorb the alumina metal, carbothermic reduction of alumina was accomplished at temperatures 300/degree/C lower than the temperatures reported in the literature. Reduction occurred without the formation of intermediate compounds and without the high volatilization of aluminum bearing species. Reduction of alumina immersed in a solvent bath appeared to be rate limited by chemical reaction control. The rates seemed to be a function of the activity of aluminum in the solvent metal bath. Reduction of alumina particles, above the surface of the bath, seemed to occur via vapor transport with carbon in the particles or in the crucible walls. Mass transport in the gas phase appeared to be rate limiting. The rates seemed to be a function of the distance separating the alumina and carbon sources. With both submerged alumina and alumina particles, increasing the surface area of the alumina increased the rate of reduction. 58 refs., 65 figs., 9 tabs.