US3918960A - Method for the production of aluminum - Google Patents

Abstract

Counter-current method for producing aluminum in a reaction chamber from the reaction of aluminum trichloride and manganese including the steps of introducing manganese into an upper part of said reaction chamber, introducing aluminum trichloride into a lower part of said reaction chamber, and providing means causing said manganese and aluminum trichloride to travel in opposite directions within said reaction chamber producing a countercurrent flow of manganese with respect to aluminum chloride.

Description

United States Patent [191 Toth METHOD FOR THE PRODUCTION OF ALUMINUM {75] Inventor: Charles Toth, Westwego La.

[73] Assignee: Applied Aluminum Research Corporation, Westwego La 1 Filed: July 21, 1972 211 Appl No.: 273.700

Related US. Application Data [63] Continuation of Ser. No. 86!.98]. Sept 29. 1969. abandoned. which is a continuation-in-part of Ser. No. 692.036. Dec. 20. 1967. Pat. No 3.6|5 359Y [52] US. Cl 75/68 B [51] Int. Cl r 4 a 4 a 4 a a C22b 21/02 [58] Field of Search 75/68 B, 68 R [56] References Cited UNITED STATES PATENTS 2.451665 [H1948 Kroll et al r r a a r r t v 75/63 Nov. 11, 1975 2.625.472 l/l953 Scheuer N 75168 8 3.078159 2/1963 Hollingshead et all. a 5,118 8 3137.56? 6/l964 McGeer a 4 r a r r v v .a 75166 B Primary lid'uniiimr-L. Dewayne Rutledge Assistant E.\'amim'rM. J. Andrews Armrner. Agent, or FirmLane. Aitken. Dunner Lk Ziems [57] ABSTRACT 18 Claims. 6 Drawing Figures I AlCl U.S. Patant Nov. 11, 1975 Sheet2 012 3,918,960

16 52 FIG. 1.

METHOD FOR THE PRODUCTION OF ALUMINUM CROSS-REFERENCE TO RELATED APPLICATION This application is a continuation of application Ser. No. 86l.98l, filed Sept. 29, I969, which is now abandoned and which was a continuation-in-part of application Ser. No. 692,036, filed Dec. 20, I967, which issued on Oct. 26, 1971 as U.S. Pat. No. 3,6l5,359.

BACKGROUND OF THE INVENTION The production of aluminum from the reaction of manganese with aluminum trichloride is set forth in U.S. Pat. application Ser. No. 692,036 assigned to the assignee of the present application and of which the present application is a continuation-in-part. In application Ser. No. 692,036 a process is disclosed in which manganese is provided in a reaction chamber, such as a crucible, and aluminum trichloride is introduced into said reaction chamber under reaction conditions, intimately contacting manganese and resulting in the formation of aluminum.

In the reaction chamber the following principal reaction occurs:

2 AlCl -l- 3 Mn 3 MnCl +2 Al During the reaction, manganese is consumed while aluminum is produced in the reaction chamber. The reaction is continued until the reaction chamber contains a large amount of aluminum and a correspondingly small amount of manganese. Thus, the final product that is produced by the method disclosed in application Ser. No. 692 .036 is an aluminummanganese alloy with a high aluminum] manganese ratio.

In many applications, the final product resulting from the method of application Ser. No. 692,036 is satisfactory since it is well known in the art that manganese imparts desirable properties to aluminum. Thus, approximately 75 percent of all the aluminum sold contains 0.1 to 2 percent manganese. In fact, it is common practice in the aluminum art to add manganese to otherwise manganese-free aluminum to produce a "master alloy." Manganese is especially desirable in an aluminum alloy to be used in extrusion products which is only one of many uses for master alloys." However, in certain applications it is desirable to have available essentially pure aluminum.

Additionally, it is desirable to be able to produce essentially pure aluminum on a continuous production basis.

SUMMARY OF THE INVENTION In accordance with the present invention, a method for the continuous production of essentially manganese-free aluminum from the reaction of aluminum trichloride and manganese is provided. In one important embodiment of the invention reactants are brought into contact with one another in a counter-current manner.

It is accordingly an object of the present invention to provide a method for producing manganese-free aluminum from the reaction of manganese and aluminum trichloride.

It is a further object of the invention to provide an apparatus for the continuous production of essentially manganese-free aluminum.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a schematic diagram illustrating the counter-current operation of the process of the present invention.

FIG. 2 is an enlarged diagram of the reaction zone of FIG. 1.

FIG. 3 is a schematic diagram similar to FIG. 1, but also including a partial aluminum recycling system.

FIG. 4 is a graph showing the melting points of aluminum-manganese alloys.

FIG. 5 is a schematic diagram of a spray tower useful in practicing the process of the present invention.

FIG. 6 is a schematic diagram representing operation of the process of this invention with a series of countercurrent batch components.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The process of the present invention is illustrated schematically in FIG. I where a reaction chamber or column 10, containing a column of packing material 12, is shown. Reaction chamber I0 is comprised of conventional ceramic materials capable of withstanding the high temperatures normally present during reaction conditions. Packing material 12 is provided in the column in order to increase the interfacial areas where the reactants can contact each other and combine in accordance with the desired single replacement reaction. In one embodiment, the packing material is a fused alumina. It is to be understood, however, that any packing material is suitable so long as the material is inert to the system and capable of withstanding the high temperatures which are normally present during reaction conditions. In fact, a number of devices, such as bubble trays or sieve trays, can be employed in lieu of packing l2.

Substantially pure manganese is introduced into the top of the reaction chamber through conduit 16. Since the various reactions which take place throughout the process system are stoichiometric, the amount of one substance present, for example, manganese, will control the amount of other reactants which are required. Normally, manganese is fed into the reactor at a rate of about 25-300 lbs. per minute. It is to be understood, however, that the manganese feed rate can deviate from this range since as pointed out above the process involves a stoichiometric reaction.

It has been found that satisfactory results are obtained when manganese is fed into the reactor at a pressure anywhere between atmospheric pressure and up to psig. Normally, the manganese is maintained at a sufficiently high temperature (viz., l400-l 650 C.) so that the manganese is in a liquid phase at the time it enters the reaction chamber. This may be accomplished, for example, by using the residual heat in which the manganese is produced (i.e., by reduction of manganese chloride and/or manganese oxide) in order to maintain the manganese in the liquid phase. Although reference is made to reduction furnace for reducing manganese, a simple heating furnace where substantially pure, solid manganese is heated to about 1400 C. can also be employed. It is also possible, however, to utilize manganese as a solid by providing means (such as induction coils) at the top of chamber 10 which is capable of superheating soild manganese. With superheating techniques, solid manganese may be dumped into the top of chamber from a hopper or other device, superheated and liquified. Whichever of these approaches is employed, however, since the preferred embodiment of the invention involves counter-current flow the reactants should be present as fluids.

The temperature required to maintain manganese in the liquid phase is approximately 1400 C. In order to maintain this temperature, conduit 16 may be provided with heating coils (not shown). However, if the distance between the reduction furnace and the reaction chamber is short, such heating coils are not required.

During the operation of the reaction chamber, the liquid manganese flows in a downward direction as is shown in the drawing by arrows 18. Simultaneously, aluminum trichloride is introduced into chamber 10 through conduit 20.

The aluminum trichloride is maintained in the gaseous phase as it enters the column passing upward through the packing bed, as is indicated by arrows 24.

In order to maintain the aluminum trichloride as a gas, it is heated to a temperature between the ranges of 750-l 500 C. The aluminum trichloride is fed into the reactor at a pressure between the range of atmospheric pressure and 100 psig. The feed rate of the aluminum trichloride is controlled by the stoichiometric requirement of the system but is normally between the range of -500 lbs. per minute. The gaseous aluminum trichloride and liquid manganese flow in opposite direc tions, contact each other and result in the following principal reaction:

3 Mn 2 AlCl 3 MnCl, 2 Al.

By providing counter-current flow for the production of aluminum, as is shown in the drawing by arrows l8 and 24, significant advantages result. For example, at the bottom zone of chamber 10, represented in the drawing by bracket 26, substantially pure aluminum trichloride is present, while at the top of chamber 10, indicated in the drawing by bracket 28, substantially pure manganese is present. During normal operation of the cycle, the manganese-aluminum ratio decreases as the manganese travels from top to bottom and the aluminum trichloride travels from bottom to top of the column of chamber 10. Thus, at the bottom of chamber 10, substantially pure aluminum trichloride is in contact with the reaction product, aluminum, which contains low amounts of manganese alloyed therein. The result is that at the bottom of the chamber a large amount of aluminum trichloride is available for a small amount of manganese, a factor which tends to insure almost complete reaction of manganese. Thus, the counter-current flow effectively forces the above reaction to an equilibrium position most favorable to the production of aluminum.

in order to explain further the operation of the foregoing counter-current flow process, a reaction zone is shown in FIG. 1. (lt is to be understood that this reaction zone is included for illustrative purposes only; the actual reaction zone is present from top to bottom of the column of chamber 10.) As is shown in the drawing (FIG. 2), the rising aluminum trichloride contacts down-coming manganese. When a molecule of aluminum trichloride contacts a molecule of manganese, at the reaction conditions present in the reactor, a single replacement reaction occurs yielding manganese chloride and aluminum which are respectively a gas and a liquid at reaction conditions.

As is further shown diagrammatically in FIG. 2, the manganese chloride, since it is a gas. rise in the column, while the aluminum precipitates down. Normally, the process is run with an excess of aluminum chloride over the stoichiometric amount required. Thus, both aluminum trichloride and manganese chloride leave the top of the column via conduit 32.

The occurrence of manganese chloride and aluminum trichloride together in a batch operation tends to slow down the reaction, due to the presence of one of the desired reaction products, manganese chloride. However, in the disclosed counter-current method, the high manganese concentration at the top of the column overcomes the otherwise harmful equilibrium condition created by the presence of large manganese chloride concentration at the top of the column. The net result is that the reaction is forced in the direction of aluminum and manganese chloride at all points within the reaction chamber.

The presence of an overhead mixture of aluminum trichloride and manganese chloride gases is not inefficient, since the two gases are easily separated. Conduit 32 terminates at a condenser 40, which liquefies manganese chloride by lowering the gaseous mixture to a temperature of about 760 C. The aluminum trichloride leaves condenser 40 as a vapor at the top through conduit 42 and is recycled back into conduit 20 at 44 after being compressed by compressor 41 to a pressure between 2-l00 psig and heated by heater 43 to a temperature between l000-l 500 C. Although not shown, manganese chloride can be recycled by delivering it into a reduction furnace (for conversion to manganese) as discussed above.

In operation little attention need be given to the temperature of aluminum trichloride within the chamber since the aluminum trichloride is heated by the molten manganese as aluminum trichloride rises in the chamber. Thus, the temperature in the lower part of the reaction chamber can be maintained at a low level, at about the melting point of pure aluminum (above 650 C.). Although it is possible to operate at temperatures as low as 650 C., the preferred temperature is about 900 C. which can be maintained by induction heating coils (not shown) around reactor 10. It is to be understood unless specified otherwise that any temperatures given in this specification and claims are the temperatures which would be necessary at standard pressure (760 mm Hg).

In any embodiment of the process, it is important that both the temperature and pressure be properly maintained so that no manganese chloride condenses within the reaction chamber.

Should manganese chloride condense within the chamber, it would leave the reaction chamber with the aluminum and present contamination problems. Also, the presence of liquid manganese chloride would result in an undesirable reverse reaction between aluminum and manganese chloride, yielding manganese and aluminum chloride or aluminum monochloride. The presence of liquid manganese chloride would result in a reverse reaction at the most undesirable point in the system; that is, at the extraction point of aluminum.

Although high pressure systems are more costly, the use of high pressures becomes economical because high pressures improve the conversion of aluminum chloride and manganese to aluminum and manganese chloride. Pressures of up to psig are employed within reactor l since these pressures significantly improve yields without appreciably increasing production costs. It is to be understood. however, that the process can be successfully run at normal pressure.

Aluminum is withdrawn from the reactor at 50 at a rate of between 10-100 lbs. per minute depending upon the flow rates of the reactants.

The production of aluminum. in accordance with the present invention, is easily understood by reference to the following example:

EXAMPLE 1 Liquid manganese at a temperature of about l500 C and a pressure of psig is continuously fed to the top ofa packed reactor at a rate of 100 lbs. per minute. The reactor is 20 feet high and consists of a refractory lined vessel of 3 feet inside diameter packed with 1 inch diameter ceramic alumina Raschig rings. Gaseous aluminum trichloride preheated to about l000 C at a pressure of about 50 psig is introduced at the bottom of the tower at a rate of 200 lbs. per minute. The manganese dichloride produced, together with unreacted aluminum trichloride, is continuously removed from the top of the column. Approximately 20 percent (33 lbs. per minute) of the aluminum trichloride fee passes through the tower unreacted and mixes homogeneously with manganese dichloride. The manganese dichloride and aluminum trichloride gas mixture removed from the top of the tower is passed through a partial condensor which cools the gas mixture to about 750 C. At this temperature essentially all of the manganese dichloride is condensed without any considerable aluminum trichloride condensation. The aluminum trichloride is compressed to about 50 psig, reheated to about 1000 C and recycled back into the reactor. The manganese dichloride is treated in a reduction furnace to yield elemental manganese, which is fed back into the top of the reactor. High purity aluminum is withdrawn from the bottom of the column at a rate of about 33 lbs. per minute.

In lieu of the process shown schematically in FIG. I, it is also possible to employ a partial aluminum recycling operation which is shown in FIG. 3. The apparatus shown schematically in FIG. 3 is identical to the apparatus shown in FIG. I except for the partial aluminum recycling apparatus. All temperatures, pressures and flow rates are identical to those above. In FIG. 3 the aluminum outlet is connected to a recycling conduit 52. Thus, the reaction product, aluminum, is split into an aluminum product and recirculating aluminum. Between 560 percent of the product is put back into the reactor as recirculating aluminum and is pumped by pump 54 through conduit 52 into manganese inlet conduit 60 at a rate of about 2-50 lbs. per minute.

FIG. 4 is a graph showing the melting or freezing point of manganese-aluminum alloys of varying concentrations. By introducing a mixture of manganese and aluminum into the top of the reaction chamber, the temperature requirements of the system are greatly reduced. Thus, as is shown in FIG. 4, it is possible to operate the system of FIG. 3 at a low temperature while maintaining the constituents as fluids by diluting the manganese with aluminum. As is shown in FIG. 4, however. in order to be effective, the manganese must contain more than 20 percent aluminum by weight in order to appreciably lower the temperature below the normal melting point of manganese, since the highest melting point of an aluminum-manganese alloy (20 percent aluminum) is approximately the same as the melting point of manganese.

In addition to lowering the temperature of the system by a partial recycling of aluminum, an alloy flux. as is disclosed in patent application, Ser. No. 858,01 I. filed Sept. 15. 1969 and entitled Process for Producing Aluminum" which issued on Jan. 30, 1973 as U.S. Pat. No. 3,713,809. can be added to manganese before it enters the reaction chamber. The addition of an alloy flux material, such as bismuth, to either manganese or an aluminum manganese alloy results in the lowering of the freezing point of the mixture.

In addition to the methods shown in FIGS. I and 3, the invention may be practiced by providing a spray tower. as is shown in FIG. 5. When such a spray tower is utilized the temperature, pressures and flow rates may also be identical to those discussed in relation to the process of FIG. 1. In FIG. 5 a conduit 60 for introducing a stream of liquid manganese is shown. Also provided is a nozzle head 62 for producing a spray of manganese indicated by arrows 64. Provided in the bottom section of column 66 is conduit 68 for introducing a steady flow of aluminum trichloride gas indicated by arrows 70. The fluids within column 66 advance, contact each other and result in the formation of aluminum by the reaction previously discussed.

In this embodiment the flow rates of reactants may deviate from the flow rates discussed in connection with the process shown in FIG. 1 in that a large excess of aluminum trichloride (ten times the stoichiometric amount required) can be used in order to effect a substantially complete reaction of the manganese.

A mixture of aluminum trichloride and manganese chloride gases exits from column 66 by conduit 72. The mixture of gases is then separated by condensing manganese chloride in the manner previously discussed. The apparatus required is identical to that shown in FIG. 1. The aluminum trichloride is recycled back through conduit 68 by a suitable arrangement (not shown) which also can be identical to that shown in FIG. 1. The aluminum product is extracted as a liquid from the tower at 74. Since the arrangement in FIG. 5 operates as a spray tower, it is most efficient when its height greatly exceeds its width. A 20 foot column has a diameter of about 4 feet. Thus, the length to width ratio should be at least 5 to l.

The process may also be utilized by simply allowing the manganese to flow down the walls of a series of columns and thus effect the operation as a wetted-wall column, with the aluminum trichloride gas rising through the column in contact with the manganese.

It is also possible to utilize a series of batch components to produce a counter-current batch effect. This arrangement is shown schematically in FIG. 6. In FIG. 6 eight reactors are shown. At the start of the process liquid manganese at a temperature between l350l650 C is added to each reactor. The amount of manganese will, of course, depend on the size of the reactor. Aluminum trichloride at a temperature, pressure and flow rate described for the process shown in FIG. 1 is introduced into the molten manganese by a blow pipe 82. Aluminum trichloride and manganese chloride gases are extracted at 86. A condenser 88 which is identical to condenser 40 of FIG. I and operated at the same conditions removes manganese chloride before the gases enter the next reactor in the serics. A compressor and heater (not shown) similar to compressor 4] and heater 43 of FIG. 1 increase the pressure of the aluminum chloride to 2-l00 psig and the temperature to lO-l500 C. before entering each reactor in the series.

For illustration, eight reactors are shown, seven of which are utilized in series. At the start of the process the manganese in the first reactor in the series reacts almost completely with the incoming aluminum trichloride. As the aluminum concentration builds up within the reactor, the reaction is slowed down. However, the unreacted aluminum chloride is passed into a second reactor in the series where the reaction is very efficient since the manganese concentration in this reactor is large. This process is continued from reactor to reactor. Eventually the first reactor in the series contains an extremely high percentage of aluminum. When this occurs, a valve (not shown) switches off this component and the eighth reactor is connected to the series as its last member. The second reactor then becomes the first and the process is operated continuously.

The production of aluminum, in accordance with the present invention, is easily understood by reference to the following example:

EXAMPLE ll Seven, ton capacity, reactors are loaded to threefourths of their capacity with liquid manganese at a temperature of l500 C. The reactors are arranged in series and connected with conduits so that gases entering one reactor bubble through the manganese and leave that reactor through the unfilled upper portion to bubble into the manganese in second and subsequent reactors. Gaseous aluminum trichloride at a temperature of l300 C. and a pressure of 50 psig is introduced at a flow rate of 100 lbs. per minute into the first reactor in the series. Since the melting point of the manganese is lowered as aluminum is formed within a reactor, the residual heat of the aluminum trichloride and manganese is sufficient to maintain the component which remain in each reactor in a liquid phase.

For about the first half hour manganese chloride leaves the first rector as an overhead gas at the rate of about 160 lbs. per minute along with an insignificant quantity of aluminum trichloride. As the reaction continues the amount of manganese chloride in the overhead gas decreases and is replaced with a corresponding amount of pure aluminum trichloride. After about 24 hours of operation, the overhead gas in the first reactor is essentially lOO percent aluminum trichloride which bubbles into the manganese in the second reactor at the rate of about 100 lbs. per minute. Located between each reactor in the path of travel of the overhead gas is a condenser which cools the gaseous mixture to about 750 C., condensing the manganese chloride portion of the gaseous mixture which is passed out of the system while allowing the aluminum trichloride to pass on into the second and subsequent reactors as a gas. The aluminum trichloride before passing into the second and subsequent reactors is heated to about [300 C. and compressed to 50 psig. The process is continued for about 24 hours whereupon the first reactor in the series is disconnected and an eighth reactor filled with pure molten manganese is connected in place of the first reactor. When removed the first reactor contains essentially l00 percent pure aluminum. The process is then operated continuously, removing and replacing reactors as described above.

The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalencies of the claims are therefore intended to be embraced therein.

I claim:

I. A process for the continuous production of aluminum comprising the steps of: introducing gaseous aluminum trichloride at a bottom portion of a reaction chamber; providing manganese as liquid in an upper portion of said reaction chamber; allowing said gaseous aluminum trichloride to rise and said liquid manganese to flow downwardly in said reaction chamber thereby providing counter-current flow contact between said aluminum trichloride and said manganese within said reaction chamber; maintaining at least a portion of said reaction chamber at a temperature sufficient to react the aluminum trichloride with the manganese to yield liquid aluminum and gaseous manganese chloride, reacting said aluminum trichloride gas with said liquid manganese to form substantially manganese-free alu minum, and recovering said substantially manganesefree aluminum from said reaction chamber.

2. The process in claim I, wherein the step of providing manganese as a liquid includes introducing manganese as a solid at an upper portion of said reaction chamber and super-heating said solid manganese so that liquid manganese is provided.

3. The process in claim 1, wherein the step of introducing aluminum trichloride gas includes introducing said aluminum trichloride at about 750l500C and at the rate of between about 25-500 lbs. per minute.

4. The process of claim 1, wherein the step of providing liquid manganese includes spraying said liquid manganese into said reaction chamber.

5. The process of claim 1, wherein the step of providing manganese includes allowing the manganese to flow down the walls of said reaction chamber.

6. The process in claim 1 wherein the step of providing manganese as a liquid includes introducing manganese as a liquid at an upper portion of said reaction chamber.

7. The process in claim 6, wherein the step of introducing liquid manganese includes introducing said liquid manganese at a temperature of about l400-1650C and at a rate of between about 25-300 lbs. per minute.

8. The process in claim I, and further including the step of continuously extracting aluminum from a bottom portion of said reaction chamber.

9. The process in claim 8, and further including the step of recycling a portion of the extracted aluminum back into the liquid manganese at an upper portion of said reaction chamber.

10. The process in claim 1, and further including the step of withdrawing aluminum trichloride and manganese chloride as a mixed vapor from said reaction chamber.

1 l. The process in claim 10, and further including the step of condensing the manganese chloride from said aluminum trichloride and manganese chloride mixed vapor.

12. The process in claim 11 and further including the step of recycling the aluminum trichloride of said mixed vapor back into the reaction chamber.

13. The process in claim 1, wherein the step of providing manganese includes providing manganese as a liquid.

14. The process in claim 13, wherein the step of providing manganese as a liquid in an upper portion of a reaction chamber includes the step of providing a mixture of pure aluminum and manganese as said liquid.

15. The process in claim 14, wherein said pure aluminum is provided by recycling a portion of the liquid aluminum produced in said reaction chamber.

16. A process for the continuous production of alu minum, comprising the steps of: (a) providing a number of reactors in a series, each containing a quantity of molten manganese; (b) continuously introducing aluminum trichloride gas into the manganese within the first reactor in said series. said aluminum trichloride gas reacting with said manganese; (c) maintaining at least a portion of said reactor at a temperature sufficient to reduce the aluminum trichloride to produce liquid aluminum, reacting said aluminum trichloride gas with said liquid manganese to form substantially manganese-free aluminum; (d) withdrawing the resulting manganese chloride gas and unreacted aluminum trichloride gas as a mixture from said first reactor. (e) removing said unreacted aluminum trichloride from said mixture; (f) passing said removed aluminum trichloride into the manganese within the next reactor in said series; (g) and continuing steps (b) (f) until the first of said reactors contains substantially manganesefree aluminum.

17. The process in claim 16, and further including the steps of: (h) disconnecting the first reactor in said series after the reactor contains substantially manganesefree aluminum; (i) repeating steps (b) (f) except substituting the second reactor in said series for said first reactor; and (j) adding an additional reactor containing molten manganese as the last member of said series.

18. The process in claim 16, wherein step (a) includes providing each of said reactors with a quantity of molten manganese.

Claims (18)

1. A PROCESS FOR THE CONTINUOUS PRODUCTION OF ALUMINUM COMPRISING THE STEPS OF: INTRODUCING GASEOUS ALUMINUM TRICHLORIDE AT A BOTTOM PORTION OF A REACTION CHAMBER, PROVIDING MANGANESE AS LIQUID IN AN UPPER PORTION OF SAID REACTION CHAMBER, ALLOWING SAID GASEOUS ALUMINUM TRICHLORIDE TO RISE AND SAID LIQUID MANGANESE TO FLOW DOWNWARDLY IN SAID REACTION CHAMBER THEREBY PROVIDING COUNTER-CURRENT FLOW CONTACT BETWEEN SAID ALUMINUM TRICHLORIDE AND SAID MANGANESE WITHIN SAID REACTION CHAMBER, MAINTAINING AT LEAST PORTION OF SAID REACTION CHAMBER AT A TEMPERATURE SUFFICIENT TO REACT THE ALUMINUM TRICHLORIDE WITH THE MANGANESE TO YIELD LIQUID ALUMINUM AND GASEOUS MANGANESE CHLORIDE, REACTING SAID ALUMINUM TRICHLORIDE GAS WITH SAID LIQUID MANGANESE TO FORM SUBSTANTIALLY MANGANESE-FREE ALUMINUM, AND RECOVERING SAID SUBSTANTIALLY MANGANESE-FREE ALUMINUM FROM SAID REACTION CHAMBER.

2. The process in claim 1, wherein the step of providing manganese as a liquid includes introducing manganese as a solid at an upper portion of said reaction chamber and super-heating said solid manganese so that liquid manganese is provided.

3. The process in claim 1, wherein the step of introducing aluminum trichloride gas includes introducing said aluminum trichloride at about 750*-1500*C and at the rate of between about 25-500 lbs. per minute.

4. The process of claim 1, wherein the step of providing liquid manganese includes spraying said liquid manganese into said reaction chamber.

5. The process of claim 1, wherein the step of providing manganese includes allowing the manganese to flow down the walls of said reaction chamber.

6. The process in claim 1 wherein the step of providing manganese as a liquid includes introducing manganese as a liquid at an upper portion of said reaction chamber.

7. The process in claim 6, wherein the step of introducing liquid manganese includes introducing said liquid manganese at a temperature of about 1400*-1650*C and at a rate of between about 25-300 lbs. per minute.

8. The process in claim 1, and further including the step of continuously extracting aluminum from a bottom portion of said reaction chamber.

9. The process in claim 8, and further including the step of recycling a portion of the extracted aluminum back into the liquid Manganese at an upper portion of said reaction chamber.

10. The process in claim 1, and further including the step of withdrawing aluminum trichloride and manganese chloride as a mixed vapor from said reaction chamber.

11. The process in claim 10, and further including the step of condensing the manganese chloride from said aluminum trichloride and manganese chloride mixed vapor.

12. The process in claim 11 and further including the step of recycling the aluminum trichloride of said mixed vapor back into the reaction chamber.

13. The process in claim 1, wherein the step of providing manganese includes providing manganese as a liquid.

14. The process in claim 13, wherein the step of providing manganese as a liquid in an upper portion of a reaction chamber includes the step of providing a mixture of pure aluminum and manganese as said liquid.

15. The process in claim 14, wherein said pure aluminum is provided by recycling a portion of the liquid aluminum produced in said reaction chamber.

16. A process for the continuous production of aluminum, comprising the steps of: (a) providing a number of reactors in a series, each containing a quantity of molten manganese; (b) continuously introducing aluminum trichloride gas into the manganese within the first reactor in said series, said aluminum trichloride gas reacting with said manganese; (c) maintaining at least a portion of said reactor at a temperature sufficient to reduce the aluminum trichloride to produce liquid aluminum, reacting said aluminum trichloride gas with said liquid manganese to form substantially manganese-free aluminum; (d) withdrawing the resulting manganese chloride gas and unreacted aluminum trichloride gas as a mixture from said first reactor, (e) removing said unreacted aluminum trichloride from said mixture; (f) passing said removed aluminum trichloride into the manganese within the next reactor in said series; (g) and continuing steps (b) - (f) until the first of said reactors contains substantially manganese-free aluminum.

17. The process in claim 16, and further including the steps of: (h) disconnecting the first reactor in said series after the reactor contains substantially manganese-free aluminum; (i) repeating steps (b) - (f) except substituting the second reactor in said series for said first reactor; and (j) adding an additional reactor containing molten manganese as the last member of said series.

18. The process in claim 16, wherein step (a) includes providing each of said reactors with a quantity of molten manganese.

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