WO2009029279A2

WO2009029279A2 - Chemical synthesis and method to manufacture alkaline metal-aluminum phosphates

Info

Publication number: WO2009029279A2
Application number: PCT/US2008/010263
Authority: WO
Inventors: Daniel Eduardo Balzaretti
Original assignee: Daniel Eduardo Balzaretti
Priority date: 2007-08-31
Filing date: 2008-08-29
Publication date: 2009-03-05
Also published as: WO2009029279A3

Abstract

The subject of this invention is an environmentally friendly novel method to manufacture alkaline metal-aluminum phosphates with amorphous nano-size primary particles. The synthesis reactions take place by mixing and reacting an intermediate acidic solution of aluminum phosphate with a commercial or a prepared basic alkaline metal Aluminate solution. The synthesized alkaline metal-Aluminum Phosphate molecules can have any level of hydrated water. This novel manufacturing process is a chemical synthesis without generating any co-product or by-product other than water.

Description

Chemical synthesis and method to manufacture alkaline metal-Aluminum Phosphates

DESCRIPTION

FIELD OF THE INVENTION

The subjects provided herein are environmentally friendly chemical synthesis and processes for making and manufacturing compositions comprising alkaline metal-Aluminum Phosphates with amorphous nano-size particles.

Provided herein is a novel chemical process following a chemical synthesis without any chemical elements or compounds other than the chemicals comprised in the alkaline metal-Aluminum Phosphates molecule product, generating only the final product and water, but not other co- products or by-products. In certain embodiments, the final synthesized alkaline metal-aluminum phosphate molecules comprise hydrated and solvated Iigands such as water, Ammonium ions, alcohols and other polar compounds.

Also provided are the intermediate and final physical forms of the compositions of alkaline metal- Aluminum Phosphates, comprising colloidal solutions, amorphous solid suspensions, gel-like slurries, hydro-gels, amorphous solvated solids, amorphous hydrated solids and amorphous dried solids.

BACKGROUND OF THE INVENTION

The proposed new chemical route to synthesize and manufacture amorphous alkaline metal- Aluminum Phosphates with primary nano-size particles comprises only two chemical steps from the primary raw materials. Depending on the final chemical composition of the commercial product, the synthesis can be performed by only one chemical step. This environmentally friendly novel synthesis procedure does not require anymore as raw materials additional chemical elements and compounds not included in the final alkaline metal-Aluminum Phosphate molecules. The novel synthesis procedure does not generate any chemical co-products and byproducts.

Uses and marketing. Many alkaline metal-Aluminum Phosphates are in the market as commercial products. They have been used in different applications following their different chemical, physical and morphological properties. The current industrial uses are: Food additives, cosmetics, pulp and paper, plastic additives, ink additives, paints, lacquers and varnishes additives, catalyst support, pharmaceutical and chemical, ceramic bonding, dental cements, fire retardants materials, high temperature coating, electronic, polishing, etc. It is anticipated, due to their special properties and the new environmentally friendly manufacturing process to make these products, the use of alkaline metal- Aluminum Phosphates, will increase in those and other applications. Alkaline metal-Aluminum Phosphates, colloidal solutions, gel-like slurries, hydro-gels and amorphous solids, with primary nano-size spherical particles, have a wide range of applications, due the homogeneous size of the nano-particles and the special light back scattering properties of the product.

Literature, patent and application patent claims. Alkaline metal-Aluminum phosphates have many industrial applications as crystalline and amorphous solids. Also, amorphous alkaline metal- Aluminum Phosphates are used as colloidal solution, suspension, gel-like slurry, hydro-gel, solid amorphous hydrated and dried powders. There are several U.S.A. and foreign patents related to the production method and use of alkaline metal-Aluminum Phosphates with different compositions and kinds of properties; including different Phosphorus to Aluminum (P/Al) and alkaline metal to Aluminum molar ratios, produced in basic alkaline, or ammonia, or acidic environment, generating amorphous or crystalline solid particles, solid particles with high specific surface, particles with high open porosity, solid hollow particles, etc.

The literature shows two generic chemical synthesis methods to manufacture alkaline metal- Aluminum Phosphates: a-Mixing the three ions sources, alkaline metals (hydroxides or carbonates), Aluminum (hydroxides, Aluminum Phosphates or even metallic Aluminum) and Phosphates (alkaline metal Phosphates, Ammonium Phosphates or Phosphoric Acid) in water, creating a suspension, and then reacting these chemicals at temperatures from 70 ⁰C to 200 ⁰C. The syntheses occur at relatively high temperature and the product is a crystalline solid. When carbonates and ammonium ions are used, by-products like Carbon di-Oxide and/or Ammonia are present. These methods are described, with processes and product composition differences, in the US patents No. 4,704,211; 4,375,456; 4,347,325; and 4,289,739. b- The synthesis of alkaline metal-Aluminum Phosphate as result of exchange of metallic ions by mixing two salt solutions, one of them containing Aluminum positive ions and the other negative Phosphate ions from phosphate derivative salts or phosphoric acids. The resulting reacting solution, completed by adding simultaneously those described salt solutions, has very acidic pH, ranging from 0 to 3.5. To synthesize alkaline metal-Aluminum Phosphate, the acidity of the reacting solution must be adjusted by adding a basic solution, an alkaline metal hydroxide and/or Ammonium Hydroxide. As consequence, Aluminum Phosphates is synthesized with an alkaline metal ion or an Ammonium Hydroxide ion ((NH.sub.4).super.1+), or both, in the molecule and precipitate in a pH range from 3.5 to 7.5. Along with the production of Aluminum Phosphate, an alkaline metal and/or Ammonium salt, a by-product always results in all of these synthesis methods. The environmental impact of the by-products is the greatest inconvenience of this generic method, also associated with a higher raw material cost.

The U.S. patent No. 5,030,431 clearly describes this method using the following salts, and their hydrates, as the Aluminum positive ion source: Aluminum Nitrate, (Al(NO.sub.3)), Aluminum Chloride hydrate, (AlCl.sub.3).3.6(H.sub.2 O)) , Aluminum Bromide, (AlBr.sub.3).3.6(H.sub.2 O)), Aluminum Iodine hydrate, ((All.sub.3). 3.6(H.sub.2 O)), Aluminum Bromate, (Al(BrO.sub.3).3.9(H.sub.2 O)), Aluminum Chlorate, (Al(ClO.sub.3).3.6(H.sub.2 O)), etc. The Phosphate negative ion sources claimed are Ortho-Phosphoric Acid, (H.sub.3 (PO.sub.4)), Sodium Phosphate (Na.sub.2 (HPO.sub.4)), Ammonium Phosphate, (NH.sub.4), H.sub.2 PO.sub.4), di-Ammonium Phosphate, (NH.sub.4 H.sub.2 HPO.sub.4), or other double alkaline metal Phosphates. The preferred salts are Aluminum Nitrate and Ammonium Phosphate.

The US Patents Application Numbers: 20,060,045,831 (March 2, 2006); 20,060,211,798 (September 21, 2006), and in the Brazilian Patents Numbers: BR IP 9500522-6 (June 11, 2002); BR IP 9104581-9 (August 19, 2003); BR IP 9400746-2 (July 08, 2003) claim the synthesis of amorphous Aluminum Phosphate and poly-phosphates and Sodium Sulfate as by-products, by reacting an Aluminum Sulfate solution, Phosphoric Acid and Sodium Hydroxide. Also, these patents claim that the products have hollow solid particles, and they can be used as white pigment.

Alternatively, in the US Patent No. 6,022.513 (February 8, 2000), Pecoraro, et al, the reacting solution can be a basic solution of salts, such as a mixture of Sodium AIuminate (Na.sub.2 O.Al.sub.2 O.sub.3.3H.sub.2 O) and Sodium Phosphate (Na.sub.3 PO.sub.4.12H.sub.2 O), which is neutralized with an aqueous acidic solution with a pH lower than six (6), such as Hydrochloric Acid (HCl). The amount and concentration of Hydrochloric Acid should be sufficient to result in neutralization with formation of an Aluminum Phosphate precipitate. The range of acidity, pH, to employ for the Aluminum Phosphate synthesis is as set forth above. This last synthesis process seems practical, but it generates more than four moles of Sodium Chloride (NaCl) per mol of Aluminum Phosphate, following the same chemical path of the other synthesis processes and the final product become contaminated with Chlorine.

The U.S. patent No. 6,565,756 (May 20, 2003), Piesslinger-Schweiger, claims a method for the conditioning of Phosphoric Acid by adding Sodium Aluminate, forming an insoluble salt (Aluminum-Sodium Phosphate) and Sodium Phosphates water soluble by-products, but the claims are silent about these co-products and by-products. However, the claim is not the salt product itself, but a method to transform Phosphoric Acid from liquid to solid for its disposal.

Most of those synthesis methods are designed to synthesize alkaline metal-Aluminum Phosphates with specific composition and properties. Also, many of those methods use sizable amount of water and generate a large amount of co-products and by-products, with the associated negative environmental impact and high economical cost. However, the lack of flexibility to control and fine-tune the chemical reaction synthesis parameters to obtain a solid product, with almost spherical nano-size amorphous particles, is the main technical inconvenience to use them.

SUMMARY OF THE INVENTION

Provided herein are environmentally friendly chemical synthesis and processes for making and manufacturing alkaline metal-Aluminum Phosphates characterized by solid amorphous and almost spherical nano-size primary particles.

Provided herein is a novel chemical process following a chemical synthesis without any chemical elements or compounds other than the chemicals comprised in the alkaline metal-Aluminum Phosphates molecule product, generating the product and only water, but no other co-products or by-products. In certain embodiments, the final synthesized alkaline metal-aluminum phosphate molecules have hydrated and solvated Iigands comprising water, hydroxide ions, Hydrogen ions, Ammonium anions, alcohols and other polar compounds.

The denominate alkaline metals-Aluminum Phosphates product comprise mixed salts with alkaline metals-simple Aluminum Phosphates, alkaline metal-polyatomic Aluminum Phosphates, alkaline metal-Oxy-Aluminum Phosphates, alkaline metal-Aluminum ortho-Phosphates, alkaline metal-Aluminum pyro-Phosphates, alkaline metal-Aluminum meta-Phosphates, alkaline metal- Aluminum poly-Phosphates that comprise amorphous nano-size primary particles.

In certain embodiments, Aluminum ions in the synthesized alkaline metal-Aluminum phosphates molecules are simple trivalent ions, such as Aluminum III. In certain embodiments, the Aluminum ions in the synthesized alkaline metal-Aluminum phosphates molecules are complex ions, polyatomic ions, and polymer ions.

In certain embodiments, the alkaline metal-Aluminum Phosphates are characterized by compositions comprising molar ratios of Phosphorus to Aluminum (P/Al), from approximately 0.5 to greater than 2.0 and molar ratios of alkaline metal to Aluminum (alkaline metal/Al), from approximately 0.2 to greater than 1.2. In certain embodiments, the alkaline metal-Aluminum Phosphates comprise other ions, i.e. Ammonium ions, ((NH.sub.4).super.+).

In one embodiment, the amorphous solid Aluminum-Sodium Phosphates molecule has a molar ratio Phosphorus to Aluminum (P/Al), about 0.85 and a molar ratio Sodium to Aluminum (Na/Al), about 0.50, but molecules with other formulation ratios can be obtained by the same procedure.

In certain embodiments, the environmentally friendly chemical synthesis and process for amorphous alkaline metal-aluminum phosphates with these characteristic and properties result from chemical reactions among chemical compounds comprising Phosphoric Acids, Aluminum Hydroxides, alkaline metals Hydroxides and water.

In certain embodiments, the environmentally friendly chemical synthesis of the amorphous alkaline metal-aluminum phosphates with these characteristics and properties result from chemical reactions among chemical compounds comprising Phosphoric Acids, Aluminum Hydroxides, alkaline metals Aluminate, Aluminum-alkaline metal Hydroxides and water. In certain embodiments, the solution solvents are polar solvents comprising water, alcohols and other organic polar solvents or a mixture thereof.

In one embodiment, the environmentally friendly chemical synthesis and process to make amorphous alkaline metal-Aluminum Phosphates comprise reacting Aluminum Phosphates with alkaline metal Aluminate- Aluminum alkaline metal Hydroxides.

In another embodiment, those primary chemical compounds react in a first chemical step to form intermediate acidic water solutions comprising Aluminum ions, Hydrogen ions and Phosphate ions, and basic water solutions comprising simple and complex-poly atomic Aluminum ions, Aluminate ions and alkaline metal ions and, in a second chemical steps, both solutions mix and react to synthesize the final product, alkaline metal-Aluminum Phosphates.

In certain embodiments, the intermediate solutions comprise an acidic Aluminum Phosphate water solution and a basic solution comprising an alkaline metal Aluminate- Aluminum alkaline metal Hydroxide water solution.

In one embodiment, the alkaline metal-Aluminum Phosphates synthesis is the result of chemical reactions between intermediate solutions, an acidic water solution comprising Aluminum, Hydrogen and Phosphate ions and a basic water solution comprising Aluminum ions, Aluminate ions and alkaline metal ions solution comprising one or several process steps. In one embodiment, mixing the acidic and basic solutions generates the chemical reactions that precipitate amorphous alkaline metal-Aluminum Phosphates. In certain embodiments, these two described chemical synthesis steps can be integrated into only one step.

In certain embodiments, the chemical synthesis path of alkaline metal-Aluminum Phosphates comprises the chemical derivatives and precursors of the following raw materials and intermediate products: The Phosphorus source, generically called phosphoric acids, comprises Ortho-Phosphoric Acid, pure or a mixture with Meta-Phosphoric and/or Pyro-Phosphoric Acids, and/or any of many polymers phosphoric acids, Aluminum Phosphates, and other Phosphorus derivative acids. The Aluminum source, generically called Aluminum Hydroxide, comprises Aluminum tri-Hydroxide and other simple or complex polyatomic Aluminum Hydroxides, Aluminum Oxy-Hydroxides, Aluminum Oxide Hydrates, natural or purified Bauxite, alkaline metal Aluminates-Aluminum alkaline metal Hydroxides, Aluminum Phosphates, and even metallic Aluminum. The alkaline metal source, generically called alkaline metal hydroxide, comprises alkaline metal Hydroxides, alkaline metal oxides, alkaline metals and alkaline metals carbonates, and alkaline metal Aluminate-Aluminum alkaline metal Hydroxides. The preferred alkaline metals are Sodium, Potassium or Lithium or a mixture thereof. In one embodiment, Sodium is the alkaline metal used in the chemical synthesis reactions. In one embodiment, the chemical process to synthesize amorphous Sodium-Aluminum Phosphates comprise these process steps: a first step comprises reacting and dissolving solid Aluminum tri-Hydroxide in Ortho-Phosphoric acid solution making an acidic Aluminum Phosphate solution, and a second step comprises the chemical neutralization of the acidic solution with a basic solution of Sodium Aluminate Aluminum-Sodium Hydroxide generating amorphous nano-size and almost spherical particles.

In certain embodiments, in the second chemical step, the acidic Aluminum Phosphate water solution or dispersion from the first chemical step is reacted with an alkaline metal Aluminate- Aluminum alkaline metal Hydroxide solution, or any alkaline metal Aluminate solution and/or a mixture thereof.

In certain embodiments, the primary solid particles generated from the synthesis chemical reaction comprise amorphous nano-size and almost spherical particles. In certain embodiments, the almost spherical nano-size amorphous particles, generated by the chemical synthesis reactions, coalesce by adhering each others forming clusters of primary particles. Also, in certain embodiments, those primary particles clusters agglomerate each others forming irregular agglomeration of primary particles.

In certain embodiments, the reactor that performs the second reaction or the product synthesis reaction has a very high mixing and shear stress performance. This reactor performance is required to generate alkaline metal-Aluminum Phosphates characterized by amorphous primary almost spherical particles with the desired size distribution. These primary particles form from the reactor output colloidal solutions, amorphous solid suspensions and gel-like slurries. These physical states of the alkaline metal-Aluminum Phosphates products have the capability to form stable gel-like slurries and hydro-gels. In certain embodiments, the alkaline metal-Aluminum Phosphate products as colloidal solutions, amorphous solid suspensions and gel-like slurries generated from the rector are the commercial product formulation. In certain embodiments, the reactor output product concentrations and properties are adjusted for other process requirements. In one embodiment, the properties of the alkaline metal-Aluminum Phosphates from the reactor are adjusted to the requirement of the posterior drying process.

In certain embodiments, the synthesized alkaline metal-aluminum phosphates precipitate as hydrate with ligands comprising water, hydroxide ions and Hydrogen ions, alcohols and other polar solvents forming solvated amorphous primary almost spherical nano-size particles. In certain embodiments, the amorphous solvated and hydrated primary particles comprise colloidal solutions, amorphous solid suspensions, gel-like slurries and hydro-gels.

In certain embodiments, the physical forms of the alkaline metal-Aluminum Phosphates products comprising colloidal solutions, amorphous solid suspensions, gel-like slurries and hydro-gels are transformed into amorphous hydrated solids or amorphous dried solids by any state of the art liquid-solid separation and/or drying process.

In certain embodiments, the acidic Aluminum Phosphate solutions are prepared by dissolving anhydrous or hydrated Aluminum tri-Hydroxide in phosphoric acid solutions. In one embodiment, the acidic Aluminum Phosphate solution is prepared by dissolving Aluminum Phosphates in Phosphoric acid. In certain embodiments, the solid anhydrous or hydrated Aluminum Hydroxides are added to the Phosphoric Acid solution for the first step reaction to prepare the acidic solution. In certain embodiments, the solid anhydrous or hydrated Aluminum Hydroxide is partially added to the purified liquid alkaline metal Aluminate solution to reduce the molar ratio alkaline metal to Aluminum. In certain embodiments, an adjustment of the molar ratio of alkaline metal to Aluminum is required to form in the second reaction step products with the required compositions and properties.

In certain embodiments, the amount of Phosphoric Acid and Aluminum Hydroxide used and the molar ratio Phosphorus to Aluminum in the intermediate Aluminum Phosphates obtained in the acidic solution is determined by the final molar ratio Phosphorus to Aluminum, P/Al, and the molar ratio alkaline metal to Aluminum required in the final product alkaline metal-Aluminum Phosphates. In certain embodiments, this first step reaction is performed only to compensate for the high level of Sodium or other alkaline metal in the stabilized liquid saturated Sodium Aluminate - Sodium Aluminum Hydroxide solution used in the second or synthesis chemical reaction step.

In certain embodiments, the Phosphorus to Aluminum molar ratio in the acidic Aluminum Phosphates solutions is about 2 or greater than 2. In one embodiment, the Phosphorus to Aluminum molar ratio in the acidic Aluminum Phosphates solution and solid dispersion is about 2 and the acidity of the solution has a pH about 2. In one embodiment, the Phosphorus to Aluminum molar ratio in the acidic Aluminum Phosphates solutions is about 2.5 and the acidity of the solution about pH = 1.8.

In certain embodiments, the alkaline metal hydroxides and part of the Aluminum Hydroxides are used to create an intermediate chemical basic solution, which is the alkaline metal Aluminate Aluminum-alkaline metal Hydroxides solution. In certain embodiments, this step is avoided by using a commercial solution of alkaline metal Aluminate Aluminum-alkaline metal Hydroxide solid and/or solution as the additional source of Aluminum and alkaline metal.

In certain embodiments, the intermediate basic liquid Sodium Aluminate solutions or any basic liquid alkaline metal Aluminate-Aluminum alkaline metal Hydroxide solution used in the synthesis are standard commercial chemical products. In certain embodiments, the basic alkaline metal Aluminate-Aluminum alkaline metal Hydroxides solutions are prepared by dissolving commercial solid alkaline metal Aluminates-Aluminum alkaline metal Hydroxides in a polar solvent. In certain embodiments, the basic intermediate solutions are prepared by dissolving in an alkaline metal hydroxide solution Aluminum tri-Hydroxide obtaining a solution with alkaline metal to Aluminum molar ratio from approximately 1.0 to greater than 2.0. In certain embodiments, alkaline metal to Aluminum molar ratio from approximately 1.20 to about 1.35 is preferred. In one embodiment, Sodium is the alkaline metal used in these chemical reactions and synthesis.

In one embodiment, the alkaline metal Aluminate-Aluminum alkaline metal Hydroxides solution is prepared by adding and dissolving Aluminum Hydroxide, or any Aluminum compounds comprising in the Aluminum source list, in a liquid bath comprising melted alkaline metal hydroxides, alkaline metal oxides, alkaline metals, alkaline metal carbonates and bi-carbonates, or any alkaline metal compound comprising in the alkaline metal list, and then dissolving the products in solvents comprising water, alcohols, alkaline metal hydroxide solutions, and Ammonia solution or a mixture thereof. In certain embodiments, the Aluminum and alkaline metal source for the basic solution comprise an alkaline metal Aluminate-Aluminum alkaline metal Hydroxide, solid or solution, or a mixture of alkaline metals-Aluminum hydroxides solution.

In certain embodiments, purification processes are used to reduce the impurities from raw materials and intermediate products to minimize transferring these impurities to the final alkaline metal-Aluminum Phosphates product.

In certain embodiments, the liquid basic Sodium Aluminate and Sodium-Aluminum Hydroxides solutions are purified by polishing filtration in different steps or other physical and chemical methods to reduce the undesired impurities below the specification limits.

In certain embodiments, the alkaline metal, used in these chemical reactions and syntheses, is any alkaline metal, comprising Lithium, Sodium, Potassium or a mixture thereof. In one embodiment, Sodium is used in the synthesis chemical reactions.

Provided herein are some specifics properties of the alkaline metal-Aluminum Phosphates with solid amorphous nano-size particles comprising the capability to solvated by jointing as ligand polar solvents, form hydrated by water molecules, forming colloidal solutions, amorphous solid particles suspensions, gel-like slurries, hydro-gels, amorphous solvated solids, amorphous hydrated solids and amorphous dried solids. Also, the alkaline metal-Aluminum Phosphates with solid amorphous almost spherical nono-size particles has the remarkable physical property of back-scattering the light. Products with these properties have many applications.

DESCRIPTION OF THE EMBODIMENT OF THE INVENTION

In this description the disclosed the term "amorphous" refers to a solid material physical condition with lack of crystalline array. Amorphous, non-crystalline, solids do not have defined molecular stoichiometry as most of the crystalline chemical compounds do, for this reason, amorphous solids can cover a broad range of chemical compositions defined by the proposed range of molar ratios. In addition, this range of chemical composition includes the possibility to withstand a variable amount of hydrate water and also incorporate in the molecule other ionic constituents, like alkaline metal and ammonium ions, forming complex salts.

Amorphous hydro-gels expand or shrink by water absorption or de-sorption, when water is added or removed as hydrated ligand water to or from the molecule. When water is removed form the alkaline metal-Aluminum Phosphate gel-like slurries and hydro-gels, it forms an amorphous solid, but when water is added to the amorphous solid, it forms hydro-gel or gel-like slurry again.

In this description, the disclosed term "ligand" refers to atoms, molecules and ions attached by electrical polarity to other molecule or ion. The term "solvated" refers to molecules of the solvent of a solution that are attached by electrical polarity to the molecules or ions of the solute. The term "hydrate" refers to water molecules chemically attached to other molecules and ions in solution, or crystalline and amorphous solids.

In this description, the disclosed term "mother liquid" refers to the remained liquid after the solid had been removed from the original suspension. The disclosed term "primary particles" refers to the original particles formed as the result of the chemical reaction synthesis. Primary particles are only visible by electronic microscopes, such as Transmission Electronic Microscope (TEM), Scanning Electronic Microscope (SEM), and their chemical composition can be scanned by chemical microprobe. These devices are well known in the art and field of microscopy observation. The term "cluster" refers to a group of primary particles from the synthesis reactions formed by adherences among the particles. The term "agglomerate" refers to a group of clusters formed from primary particles attached each other to form a large irregular agglomerate of primary particles or macro-agglomerate particles. Most of the cluster agglomerations and macro- agglomerate particles are also visible with optical microscopes and standard devises that size and count particles.

Chemical analyses are performed by spectrometry, inductively coupled plasma optical emission spectrometry. Also in this description, the amount of solid in a solution, colloidal solution, suspension, gel-like slurries and hydro-gel, and the amount of water or humidity in solids are measured following the ASTM standards.

In these descriptions and examples, all numbers disclosed herein are approximate values, regardless whether the word "about" or "approximate" is used or not in connection therewith. They may vary by anywhere from 0.5 percent, 1 percent, 5 percent, 10 percent, to even 25 percent and sometimes more.

Provided herein are environmentally friendly chemical synthesis and processes for making and manufacturing alkaline metal-Aluminum Phosphate compounds characterized by solid amorphous and almost spherical nano-size primary particles.

Provided herein is a novel chemical process following a chemical synthesis without any reactive chemical elements or compounds other than the chemicals comprised in the alkaline metal- Aluminum Phosphates molecule product, generating only the product and water, but no other co- products or by-products. In certain embodiments, the final synthesized alkaline metal-aluminum phosphate molecules have hydrated and solvated ligands comprising water, hydroxide ions, Hydrogen ions, Ammonium anions, alcohols and other polar compounds.

Provided herein, the reactants chemical compound proportions, the chemical reactions and the synthesis processes are adjusted to synthesize alkaline metals-Aluminum Phosphates as an amorphous product with almost spherical nano-size primary solid particles. In certain embodiments, the synthesis chemical reaction allows obtaining the required morphological properties of the alkaline metal-Aluminum Phosphates during the synthesis process by controlling the reaction and process parameters.

Provided herein, the denominate alkaline metals-Aluminum Phosphate products comprise mixed salts with cathions comprising simple Aluminum (III), poly-atomic Aluminum, poly-Aluminum, and alkaline metal, and anions comprising Ortho-Phosphates ions and their chemical derivatives ions. In certain embodiments, the double salts present in the alkaline metal-Aluminum Phosphates comprise poly-Aluminum Phosphates, alkaline metal-Oxy-Aluminum Phosphates, alkaline metal-Aluminum ortho-Phosphates, alkaline metal-Aluminum pyro-Phosphates, alkaline metal-Aluminum meta-Phosphates and alkaline metal-Aluminum poly-Phosphates, and the final product is generically denominate alkaline metals-Aluminum Phosphates.

In one embodiment, the process to synthesize and make an amorphous alkaline metal-Aluminum Phosphates comprises reacting Aluminum tri-Hydroxide, Phosphoric acid and alkaline metal hydroxide. In one embodiment, the process to synthesize and make amorphous alkaline metal-Aluminum Phosphates comprise reacting acidic Aluminum Phosphate with alkaline metal Aluminates- Aluminum alkaline metal Hydroxides.

In one embodiment, the synthesis reactions to make alkaline metal-Aluminum Phosphates comprises two steps, the first step comprises preparing acidic Aluminum Phosphate solutions by dissolving and reacting Aluminum tri-Hydroxide and Phosphoric acid, and the second step comprises the product synthesis by the reacting acidic Aluminum Phosphates solutions and a basic alkaline metal Aluminates-Aluminum alkaline metal Hydroxide solutions.

In certain embodiments, the alkaline metal-Aluminum Phosphates are characterized by compositions comprising a molar ratio of Phosphorus to Aluminum (P/Al), of about 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.2, 1.5, also greater than 2.0, and a molar ratio of alkaline metal to Aluminum (alkaline metal/Al), of about 0.2, 0.3, 0.4, 05, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, also greater than 1.2. In certain embodiments, the alkaline metal-Aluminum Phosphates comprise other ions, i.e, Ammonium ions, ([NH.sub.4].super.l+).

In one embodiment, the process to synthesize and make amorphous alkaline metal-Aluminum Phosphates comprise reacting acidic Aluminum Phosphate solutions with basic alkaline metal Aluminate, Aluminum and alkaline metal Hydroxides solutions at approximately a neutralization pH of about 7 and temperatures of about 30 degrees Centigrade. In certain embodiments, the synthesis reactions progress in a basic environment at approximately constant acidity, comprising pHs of about 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 12, 13, and even more than 13.5.

In certain embodiments, the proportion of the ions of the elemental components Aluminum (Al), Phosphorus (P), and Sodium (Na), or any alkaline metal or mixture of alkaline metals in the reactant solutions, is carefully controlled to result in the neutral molecule alkaline metal- Aluminum Phosphates with the desired molar ratio composition in equilibrium with the solution acidity.

In certain embodiments, the reactants proportions synthesize neutral alkaline metal-Aluminum Phosphates molecules, but the composition molar ratios are not in equilibrium with the acidity or pH of the reaction solution, in this condition the alkaline metal-Aluminum Phosphate molecule adjusts to the equilibrium acidity originating a co-product. In certain embodiments, the Aluminum positive ion is in concentration deficiency, to create an electrically neutral molecule or the ions proportions in equilibrium with the reaction acidity, pH, the result of the reaction synthesis is not only a lower amount of the alkaline metal-Aluminum Phosphate, but also a mixture of Sodium Phosphates co-products, mainly di-Sodium Phosphate, to obtain the electrical equilibrium neutrality and equilibrium proportions of the final products. To avoid the generation of co-products and by-products the reactants proportions should be correctly adjusted.

In certain embodiments, alkaline metal-Aluminum Phosphates are synthesized with specified Phosphorus to Aluminum (P/Al), molar ratios comprise about 0.5 to molar ratios greater than 2 and Sodium to Aluminum (Na/Al), molar ratios comprise about 0.2 to greater than 1.2; every alkaline metal- Aluminum Phosphates composition precipitate at its own equilibrium pH, acidity or basic. In certain embodiments, amorphous alkaline metal-Aluminum Phosphates has Phosphorus to Aluminum (P/Al), molar ratio of about 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.5, 1.8, and greater than 2. In certain embodiments, amorphous alkaline metal-Aluminum Phosphates has alkaline metal to Aluminum molar ratio of about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, and greater than 1.2. In one embodiment, the solid Aluminum-Sodium Phosphate compound has a molar ratio Phosphorus to Aluminum (P/Al), of approximately 1.0 and a molar ratio Sodium to Aluminum (Na/Al), of approximately 0.8. In one embodiment, the solid Aluminum-Sodium Phosphate compound has a molar ratio Phosphorus to Aluminum (P/Al), approximately to 0.85 and a molar ratio Sodium to Aluminum (Na/Al), of approximately to 0.50. In certain embodiments, molecules of alkaline metal-Aluminum Phosphates with other formulation ratios can be obtained by the same chemical synthesis procedure.

In certain embodiments, the synthesis reactions take place in an open or closed batch reactor or any kind of continuous reactors, following the process and state of the art design. In certain embodiments, the synthesis reaction progresses in an acidic environment at approximately constant acidity, comprising pHs of about 4, 4.5, 5, 5.5, 6, and greater than 6.5. In certain embodiments, the temperature of the synthesis reaction is approximately constant, or increases slightly from the initial temperature, among values comprising of about 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 200, and greater than 220 degrees Centigrade, at any of these temperatures, the chemical kinetics of the reaction is very fast and the conversion is completed in only up to a few seconds to less than a second.

In certain embodiments, the process and reaction parameters to synthesize alkaline metal- Aluminum Phosphates are adjusted to obtain precipitated solid amorphous primary particles, almost spherical, with sizes comprising of about 10 nanometers to greater than 120 nanometers, during the reaction synthesis. In certain embodiments, primary particles sizes comprising of approximately 40 nanometers to about 80 nanometers are more frequent. In certain embodiments, the amorphous primary particles created by the synthesis reaction comprise sizes of approximately 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110 nanometers, and greater than 120 nanometers. In certain embodiments, the amorphous solid particles precipitate with a high content of hydrated and solvated ligands, comprising water, Hydroxide ions, Hydrogen ions, Ammonium ions, alcohols and other polar compounds.

In certain embodiments, primary particles from the synthesis reactions form clusters by adherences among the particles. In certain embodiments, clusters formed from primary particles have sizes of approximately four hundred (400) nanometers to greater than one thousand (1000) nanometers. In certain embodiments, those formed clusters from primary particles agglomerate to each other to form agglomerates of primary particles with sizes from approximately four hundred (400) nanometer to greater than fifty thousand (50,000) nanometer, identified as irregular forms of agglomerated primary particles or macro-agglomerate particles.

In certain embodiments, the primary particles form clusters and cluster agglomerates forming irregular macro-particles comprising diffuse clouds of non-uniform masses enclosing the small almost spherical primary particles. The sizes measured of these irregular agglomerated particles vary throughout different synthesis tests.

In certain embodiments, the primary particles inside clusters and agglomerates are chemically very homogeneous, analyses with electron beam (microprobe) indicate the small primary almost spherical particles have a fairly homogeneous distribution of Phosphorus and Aluminum, but part of the Sodium is concentrated in the border of each primary particle. Aluminum is not found outside of the almost spherical primary particles, in the cloud of no-uniform masses, but small amount of Phosphorus and part of the Sodium are in the no-uniform masses inside the agglomerates; some times, more in the no-uniform masses than the inside of the primary almost spherical particles. In certain embodiments, the intermediate acidic Aluminum Phosphate water solution or dispersion from the first chemical step is reacted with a Sodium Aluminate-Aluminum Sodium Hydroxide solution, any alkaline metal Aluminates solution or any mixture thereof. In one embodiment, the Sodium Aluminate solution used has a basic pH of about 12. In certain embodiments, when the molar ratios alkaline metals to Aluminum are higher than 1.2, the pH of the solution of Sodium Aluminate is greater than approximately 12, 13, or of about 14. In certain embodiments, when the molar ratios alkaline metals to Aluminum are lower than 1.2, the pH of the solution of Sodium Aluminate is about 9, 10, or greater than 11.

In one embodiment, solid amorphous alkaline metal-Aluminum Phosphates are precipitated by a neutralization reaction between the acidic Aluminum Phosphate solution and the basic solution comprising alkaline metal Aluminates Aluminum-alkaline metal Hydroxides solution comprising alkaline metal Aluminates, Aluminum Hydroxides, and alkaline metal Hydroxide in solution. In one embodiment, these neutralization and precipitation reactions take place at a pH of about 7. In certain embodiments, the precipitation reactions take place in a basic environment at a pH of approximately 7.5, 8, 9, or grater than 10. In certain embodiments, the precipitation synthesis reactions take place in an acidic environment at a pH of approximately 6.5, 6, 5, or lower than 4.

In one embodiment, the phosphoric acid used to prepare the intermediate acidic solution for these chemical reactions and syntheses is ortho-phosphoric acid (H.sub.3 (PO.sub.4)). In certain embodiments, the phosphoric acid used to prepare the acidic solution used for these chemical reactions and syntheses comprise any mixture of Phosphorus derivatives acids, such as ortho- phosphoric acid (H.sub.3 (PO.sub.4)), pyro-phosphoric (H.sub.4 P.sub.2 O.sub.7) acid, meta- phosphoric acid ((H P O.sub.3).sub.n) or, also, any of several other multiple poly-phosphoric acids and/or a mixture thereof.

In one embodiments, the aluminum hydroxide, used to prepare the intermediate acidic and the basic solutions, is Aluminum tri-Hydroxide ((Al(OH).sub3).(H.sub.2 O).sub.n). In certain embodiments, the aluminum hydroxide used to prepare the acidic and the basic solutions comprise Aluminum tri-Hydroxide ((Al(OH).sub3).(H.sub.2 O).sub.n), Aluminum oxy- hydroxides ((A1O(,OH)), ((Al.sub.2 O (OH).sub.4), any partially hydrated Aluminum oxide (Al.sub.2 O.sub3).(H.sub.2 O).sub.x, any natural, purified or synthesized complex Aluminum Oxy-Hydroxides (bohemite or diaspore), Aluminum Hydroxide (bayerite, hydreargillite or gibbsite, and novelstrandite), natural or purified Bauxite, metallic Aluminum, and other positive ions, or a mixture thereof. In one embodiment, Aluminum Phosphate is used as a source of Aluminum to prepare the intermediate acidic solution of Aluminum Phosphates.

In certain embodiments, the acidic Aluminum Phosphate water solution comprises the following ions: [Al.super 3+], [(AlOH).super 2+], [(Al(OH).sub 2).super 1+], [(AlO).super 1+], [(OH.sub 3) super 1+], [(PO.sub 4).super 3-], [(PO.sub 4 H).super 2-], [(PO.sub 4 H.sub 2).super 1-], complex, poly-atomic, and polymerized Aluminum ions, ortho-Phosphates ions, Phosphate derivative ions, polymer Phosphate ions, and impurity; water as hydrate and other ligands are normally part of those ions.

In certain embodiments, the primary reactant materials, comprising Aluminum Hydroxides, Phosphoric Acids, alkaline metals Hydroxides, are partially or totally replaced by their chemical precursors and chemical derivatives refer as the Aluminum source, the Phosphorus source and the alkaline metal source.

In certain embodiments, the Aluminum source comprises Aluminum tri-Hydroxide ((Al(OH).sub3).(H.sub.2 O).sub.n), or any Aluminum tri-Hydroxide ((AI(OH).sub3).(H.sub.2 O).sub.n), Aluminum oxy-hydroxides ((A1O(,OH)), ((Al.sub.2 O (OH).sub.4), partially hydrated Aluminum oxide (Al.sub.2 O.sub3).(H.sub.2 O).sub.x, complex Aluminum Oxy-Hydroxides (bohemite or diaspore), natural or purified Aluminum Hydroxides (bayerite, hydreargillite or gibbsite, and novelstrandite), natural or purified Bauxite, alkaline metals Aluminates, alkaline metal-Aluminum Hydroxides solutions, Aluminum-alkaline metal Carbonates and metallic Aluminum or a mixture thereof.

In certain embodiments, the Phosphorus source comprises phosphoric acid (H.sub.3 (PO.sub.4)), any mixture of Phosphorus derivatives acids, as ortho-phosphoric acid (H.sub.3 (PO.sub.4)), pyro-phosphoric (H.sub.4 P.sub.2 O.sub.7) acid, meta-phosphoric acid ((H P O.sub.3).sub.n), any of several other multiple poly-phosphoric acids, and other compatible acids and salts, or a mixture thereof; also in part Aluminum Phosphates, and Ammonium Phosphates.

In certain embodiments, the alkaline metal source comprises alkaline metal hydroxides, alkaline metal oxides, alkaline metals, alkaline metal Phosphates, alkaline metals Carbonates and bi~ Carbonates. In certain embodiments, the alkaline metal-Aluminum Phosphates comprise other ions, i.e, Ammonium ions, ((NH.sub.4).super.+).

In certain embodiments, the generic chemical formula of the alkaline metal-Aluminum Phosphate is represented with ligands comprising solvated water, hydroxide ions and Hydrogen ions. In certain embodiments, the generic chemical formula of alkaline metal-Aluminum Phosphate is represented with water as the only ligand.

In one embodiment, the generic chemical formula of the alkaline metal-Aluminum Ortho- Phosphate is represented by the following combination of ions and solvated water, hydroxide ions and Hydrogen ions ligands comprising:

(([AJ].super3+).sub.m) (([HO].super.l-).sub.r) (([Na].super.l+).sub.s) (([Hl.super.l+).sub.o) ((fPO.sub.4J.super.3-) .sub.p) . ((H.sub.2O)jsub.n)

In these embodiments, the aluminum ion is represented as simple Aluminum (III) ion, from Aluminum tri-Hydroxide, the phosphate is represented as ortho-phosphate and the ion the alkaline metal ion is represented by a Sodium ion. Hydroxide ions can be attached to cathions and Hydrogen ions can be attached to anions and water. Solvated water in different ions is represented as total water.

In certain embodiments, the sub-indexes ratio p/m, the molar ratio Phosphorus to Aluminum (P/Al), comprises a range from approximately 0.5 to greater than 2.0 and the ratio s/m, the molar ratio of alkaline metal/Aluminum (i.e. Na/Al), comprises a range from approximate 0.2 to greater than 1.2. In these embodiments, sub-indexes "r" and "o" are functions of the acidity (pH), of the synthesis solution and the sub-index "n", the solvated ligand level is a function of the concentration of the solution, physical form of the synthesis product and the posterior drying process. Also, in these embodiments, the charge balance equation of the cathions and anions of the generic chemical formula, are related to the chemical indexes, following this mathematical function: (3*m+s+o)-(3*p+r) = 0.

In certain embodiments, to synthesize stable alkaline metal-Aluminum Phosphates, the only possible molar relationship p/n between Phosphorus to Aluminum (P/Al), and s/m between alkaline metal to Aluminum are those that follow the charge balance equation; using other relationships generate undesirable co-products and by-products, i.e. Sodium Phosphates comprising mono-Sodium Phosphates, di-Sodium Phosphates, and any mixture of Phosphorus derivatives Phosphates and poly-Phosphates.

In certain embodiments, the chemical compositions of the solid amorphous alkaline metal Aluminum Phosphates nano-size primary particles are not completely electrically neutral, comprising a few negative electrical charges, these negative charges in the particles are neutralized by dissolved alkaline metals ions in solution, maintaining the particles in colloidal solutions, liquid dispersions, gel-like slurries, and hydro-gels.

In certain embodiments, the physical forms of the alkaline metal-Aluminum Phosphate products comprise colloidal solutions, amorphous solid suspensions, gel-like slurries, hydro-gels, amorphous hydrated solid powders, and amorphous dried solid powders. In certain embodiments, colloidal solutions and amorphous solid suspensions are transformed to gel-like slurries and hydro-gels by any state of the art process to concentrate colloidal solutions and amorphous solid suspensions or by any solid-liquid separation process and by any shear stress treatment application processes on the obtained amorphous solid.

I certain embodiments, gel-like slurries and hydro-gels, are transformed into amorphous hydrated solid powder by any state of the art drying process. I certain embodiments, gel-like slurries and hydro-gels, are transformed into amorphous dried solid powders by any state of the art spry drying process. In one embodiment, the composition of the suspension from the reactor is adjusted to the spray drying process. Also, the reactor is adjusted to obtain the specific composition and viscosity for the drying process, and the final particle size distribution of the powder. These characteristics are required for a fast re-dissolution to regenerate gel-like slurries and hydro-gel.

In certain embodiments, the amount of solids in the colloidal solutions and amorphous solid suspensions in water obtained by the synthesis chemical reactions are in a range comprising of approximately 0.5 percent by weight to greater than thirty (30) percent by weight. In certain embodiments, the amount of solids in the colloidal solutions and amorphous solid suspensions in water, obtained by the synthesis chemical reaction, comprise values of approximately 1, 2, 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, and greater than 30 thirty percent by weight.

In certain embodiments, gel-like slurries and hydro-gels obtained by the synthesis chemical reaction or by a concentration process comprise solvated, hydrated and free water, and the amount of beard solids are in a range comprising thirty (30) percent of solid by weight to seventy five (75) percent of solids by weight. In certain embodiments, the amounts of solid in the gel-like slurries obtained by the synthesis chemical reaction or by a concentration process or by any solid- liquid separation process comprise values of about 30, 35, and greater than 40 percent by weight.

In certain embodiments, the amounts of solid alkaline metal-Aluminum Phosphates in the hydro- gels obtained by a concentration process or by addition of amorphous hydrated or dried solid alkaline metal-Aluminum Phosphate powders comprise values of about 35, 40, 45, 50, 60, 70, and greater than 75 percent by weight.

In certain embodiments, the amorphous hydrated solid powders comprise solvated, hydrated and free water in a range comprising about five (5) percent by weight to greater than thirty five (35) percent by weight. In certain embodiments, the amount of solvated, hydrated and free water or volatile components in the amorphous hydrated solid alkaline metal-Aluminum Phosphate powders comprise values of approximately 6, 8, 10, 12, 14, 16, 18, 20, 22, 25, 30, and greater than 35 percent by weight. In certain embodiments, the amorphous dried solid alkaline metal-Aluminum Phosphate powders comprise solvated, hydrated and free water or volatile components comprising values of approximately 1, 2, 3, 4, and greater than 5 percent by weight. In one embodiment, the amorphous dried alkaline metal-Aluminum Phosphate solid powder is anhydrous.

Provided herein is the reversible characteristic property of the amorphous solvated, hydrated solids and amorphous dried solids alkaline metal-Aluminum Phosphate, to regenerate colloidal solutions, amorphous solid suspensions, gel-like slurries, and hydro-gels physical forms by adding polar solvents or polar solutions comprising water, alkaline metal Hydroxide water solutions, alkaline metal Phosphate solutions, Aluminum-alkaline metal Phosphates colloidal solutions, dispersions, gel-like slurries, and other polar solvents, i.e. alcohols. In certain embodiments, amorphous solvated and hydrated solids and amorphous dried alkaline metal- Aluminum Phosphates are re-dissolved in gel-like slurries to form gel-like slurries and hydro-gels with solid high concentration.

In certain embodiments, intermediate acidic Aluminum Phosphate solutions used in the synthesis reaction of alkaline metal-Aluminum Phosphates are prepared by dissolving chemical components comprising Aluminum Phosphates in Phosphoric Acid.

In one embodiment, intermediate acidic Aluminum Phosphates solutions used in the synthesis reaction of alkaline metal-Aluminum Phosphates are prepared by reacting and dissolving chemical components comprising solid Aluminum tri-Hydroxide and Phosphoric Acid.

In certain embodiments, the Aluminum source of the acidic Aluminum Phosphate solution comprises Aluminum tri-Hydroxide ((Al(OH).sub3).(H.sub.2 O).sub.n), any Aluminum tri- Hydroxide ((Al(OH).sub3).(H.sub.2 O).sub.n), Aluminum oxy-hydroxides ((A1O(,OH)), ((Al.sub.2 O (OH).sub.4), partially hydrated Aluminum oxide (Al.sub.2 O.sub3).(H.sub.2 O).sub.x, complex Aluminum Oxy-Hydroxides (bohemite or diaspore), natural or synthetic Aluminum Hydroxides (bayerite, hydreargillite or gibbsite and novelstrandite), natural or purified Bauxite, or a mixture thereof. In one embodiment, the Aluminum source of the acidic Aluminum Phosphate solution is metallic Aluminum.

In certain embodiments, the Phosphorus source comprises Aluminum Phosphates (Al.sub.2 (PO.sub.4) sub 3), phosphoric acid (H.sub.3 (PO.sub.4)), any mixture of Phosphorus derivatives acids, comprising ortho-phosphoric acid (H.sub.3 (PO.sub.4)), pyro-phosphoric (H.sub.4 P.sub.2 O.sub.7) acid, meta-phosphoric acid ((H P O.sub.3).sub.n), any of several multiple poly- phosphoric acids and/or a mixture thereof.

In certain embodiments, the chemical reactions between a Phosphoric Acid water solution and a solid hydrated Aluminum Hydroxide comprise the following chemical components and ions: a(H.sub.3 PO.sub.4)(aq) + b(Al(OH).sub.3).(OH.sub.2))(s) -»

(([Al].superJ+).sub.ml). (([HO] .super. l-).sub.r) (([H].super.l+).sub.ol)

(([PO.sub.4J.super.3-) .sub.pl) . (OH.sub.2).sub.nl).

In certain embodiments, the Phosphorus to Aluminum molar ratio (pl/ml), in the obtained intermediate acidic Aluminum Phosphate solution is of about 2 or higher than 2, and the acidic pH of the solution is of about 3.5 and below than 3.5. In one embodiment, the Phosphorus to Aluminum molar ratio, in the obtained acidic Aluminum Phosphate solution, is approximately 2.5 and the solution acidity has a pH of approximately 1.8. In one embodiment, the Phosphorus to Aluminum molar ratio in the obtained intermediate acidic Aluminum Phosphate solution is approximately 2 and the acidity of the solution has a pH of approximately 2.

In certain embodiments, the intermediate acidic Aluminum Phosphate solutions comprise pHs of about 0.1, 0.2, 0.4, 0.6, 0.8, 1, 1.2, 1.4, 1.6 and greater than 1.8. In certain embodiments, the amount of Aluminum Hydroxide added to the Phosphoric Acid generates a pH of approximately 2 or higher, at this acidic condition, some turbidity and fine precipitates are present in the solution, Aluminum Phosphate precipitation is not a problem if the resulting viscosity of this liquid-solid suspension is low enough, below 1000 cP. In certain embodiments, the final pH of the intermediate acidic solution is about 2, 2.5, 3.0 or 3.5.

In certain embodiments, a higher amount of Sodium or other alkaline metal is permitted in the final alkaline metal-Aluminum Phosphates molecules, and less Aluminum Hydroxide is required in the acidic Aluminum Phosphate solution of this first chemical step. In certain embodiments, an additional amount of Sodium or other alkaline metal in the alkaline metal-Aluminum Phosphates can act as gel-like slurry and hydro-gel stabilizer.

In certain embodiments, the reaction to form the intermediate acidic solution of Aluminum Phosphate takes place in an open or close batch reactor or any kind of continuous reactors, following the process and state of the art design. The reaction temperature can be set from of approximately 80 degrees centigrade (⁰C), to greater than 220 degrees centigrade, although a range of 95 degrees centigrade to 160 degrees centigrade is preferred, and the pressure is adjusted by equilibrium to the selected temperature. In certain embodiments, the reaction temperature is set at 90, 100, 110, 120, 130, 140, 150, 160, 180, 200, and greater than 220 degrees centigrade. The kinetics of the chemical reactions, to complete the dissolution of Aluminum tri-Hydroxide in Phosphoric acid, strongly depends on the reaction temperature selected, the grain size of the Aluminum tri-Hydroxide and the Aluminum source used.

In one embodiment, intermediate basic alkaline metal Alumiπate-Aluminum Hydroxide solutions used in the synthesis reaction of alkaline metal-Aluminum Phosphates are commercial products available in the market. In one embodiment, the commercial Sodium Aluminate solution has a molar ratio Sodium to Aluminum (Na/Al) of approximately 1.23 and a pH of approximately 12.

In one embodiment, intermediate basic alkaline metal Aluminate-Aluminum alkaline metal Hydroxide solutions used in the synthesis reaction of alkaline metal-Aluminum Phosphates are prepared by dissolving in water chemical components comprising Aluminum tri-Hydroxide in alkaline metal hydroxide, alkaline metal oxides, alkaline metals, alkaline metal carbonates, or mixtures thereof.

In certain embodiments, the intermediate basic alkaline metal Aluminate-Aluminum alkaline metal Hydroxides solutions comprise the following ions: ([AI(OH).sub 4] super 1-), ([AI(OH).sub 2] super 1+), ([AlO] super 1+), ([AlOH] super 2+), ([Al] super 3+), ([OH] super 1-), and other complex, polyatomic, and polymers Aluminum ions, Sodium ions ([Na] super 1+) and other alkaline metals ions, Ammonium ions, ([NH.sub.4].super.+) and other solution stabilizer ions, solvated ions, hydrated tons, and free water, the components and ions in chemical equilibrium in the solution are normally part of the solution. Also impurities can be present in the solution. Those comprised chemical components and ions in solution are generically denominated alkaline metal Aluminates. In one embodiment, those comprised chemical components and ions in solution are denominated Sodium Aluminates. hi certain embodiments, solvated and hydrated alkaline metals aluminates can be amorphous and crystalline solids and/or powders. In one embodiment, Sodium aluminates are solid powders. In certain embodiments, the intermediate basic liquid solution is prepared by dissolving solid alkaline metal Aluminates in a solvent, comprising water, any alkaline metal hydroxide solution, Ammonia solution, alcohol, and any solution stabilizer or a mixture thereof.

In certain embodiments, the intermediate basic liquid Sodium AIuminate solutions or any basic liquid alkaline metal AIuminate and Aluminum alkaline metal Hydroxide solutions are prepared by dissolving and reacting any Aluminum source, comprising metallic Aluminum, Aluminum tri- Hydroxide ((Al(OH).sub3).(H.sub.2 O).sub.n), any Aluminum tri-Hydroxide ((Al(OH).sub3).(H.sub.2 O).sub.n), Aluminum oxy-hydroxides ((A1O(,OH)), ((Al.sub.2 O (OH).sub.4), partially hydrated Aluminum oxide (Al.sub.2 O.sub3).(H.sub.2 O).sub.x, complex Aluminum Oxy-Hydroxides (bohemite or diaspore), natural or synthetic Aluminum Hydroxide (bayerite, hydreargillite or gibbsite and novelstrandite), natural or purified Bauxite, alkaline metals Aluminates, alkaline metal-Aluminum Hydroxides solutions, metallic Aluminum, solutions comprising Aluminum-alkaline metal hydroxide, carbonates, and bi-carbonates, or a mixture thereof.

In certain embodiments, the intermediate basic solutions are prepared by dissolving Aluminum tri-Hydroxide in an alkaline metal hydroxide solution, obtaining solutions with an alkaline metal to Aluminum molar ratio of approximately 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.8, and greater than 2. In certain embodiments, the basic intermediate solutions are prepared by dissolving Aluminum tri-Hydroxide, or any Aluminum source, in an alkaline metal hydroxide solution obtaining solutions with a preferable alkaline metal to Aluminum molar ratio of approximately 1.0, 1.05, 1.10, 1.15, 1.18, 1.20, 1.23, 1.25, 1.3, to 1.35. In one embodiment, Sodium is the alkaline metal used in these chemical reactions and synthesis.

In certain embodiments, the reactions to prepare the intermediate basic solution take place in an open or closed batch reactor or any kind of continuous reactors, following the process and state of the art design. In certain embodiments, the reaction temperatures is in a range of approximately 80 degrees centigrade to greater than 270 degrees centigrade, the range from approximately 95 degrees centigrade to greater than 160 degrees centigrade is more preferable, the pressure is adjusted by equilibrium to the selected temperature. In certain embodiments, the reaction temperature is set at about 90, 100, 110, 120, 130, 140, 150, 160, 180, 200, 220, 240, and greater than 270 degree centigrade. The kinetics of the chemical reaction to complete the dissolution of Aluminum tri-Hydroxide or any components of the Aluminum source list in alkaline metal Hydroxides strongly depends on the reaction temperature selected and the grain size of the Aluminum tri-Hydroxide used.

In certain embodiments, the intermediate basic solutions used in the synthesis reaction of alkaline metal-Aluminum Phosphates has an alkaline metal to Aluminum molar ratio of approximately 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.8, and greater than 2. In certain embodiments, the synthesis reactions take pace using commercial alkaline metal Aluminates solutions as intermediate basic solutions. Provided herein, the commercial liquid Sodium AIuminate water solutions, with different concentrations, are standard chemical products resulting from the first step in the Bayer process in the Alumina (Al.sub.2 O.sub.3) extraction from the Bauxite ore, often called "Purified Sodium AIuminate Pregnant solution". This liquid Sodium AIuminate water solution is saturated at ambient temperature and stabilized with Sodium Hydroxide (NaOH). Their typical compositions are: Sodium AIuminate, from approximately 58 percent by mass to greater than 65 percent by mass, equivalent to 25 and 28 percent of mass of Alumina, Al.sub.2 O.sub.3, and Sodium Hydroxide from approximately 3.5 percent by mass to greater than 5.5 percent by mass, equivalent to approximately 2.5 percent by mass to greater than 4 percent by mass of free Sodium oxide (Na.sub.2 O).

In certain embodiments, the commercial basic liquid stabilized Sodium Aluminate water solutions comprise molar ratios of Sodium to Aluminum comprising approximately 1.15 to greater than 1.45; the impurities amount are depending on the raw material origin. Iron (Fe), which is approximately 40 part per million by mass (ppm); heavy metals are about 20 part per million by mass (ppm), and small amount of anions, comprising Chlorine ion, ([Cl]. super.1-), and Sulfate ions, ([SO.sub.4].super.2-). In certain embodiments, the commercial Sodium AIuminates solutions are the color amber and their viscosity is approximately 770 centi-Poise (cP). In certain embodiments, stabilized basic solutions of alkaline metal Aluminates-Aluminum alkaline metal Hydroxides are prepared by dissolving commercial solid compounds comprising alkaline metal AIuminates, Aluminum and alkaline metal Hydroxides.

Provided herein is the commercial availability of the basic raw materials used in these proposed environmentally friendly chemical syntheses of amorphous alkaline metal-Aluminum Phosphate. Provided herein, the solid hydrated Aluminum Hydroxide (Al(OH).sub 3. x H2O), where "x" is of about 1.0 to greater than 1.5, and the denominated anhydrous Aluminum Hydroxide, (Al(OH).sub 3 . x H2O), where "x" is of approximately 0 (anhydrous) to of approximately 1.0, are also industrial chemical produced by the Bayer process in the Alumina, (Al sub.2 O sub.3), extraction from Bauxite ores. The solid hydrated Aluminum tri-Hydroxide is obtained from the "Purified Sodium Aluminate Pregnant solution" by precipitation which is accomplished via cooling the solution. The obtained hydrated Aluminum tri-Hydroxide also has a low level of impurities and a variable amount of humidity (cathions about 70 ppm, about 0.85 percent in mass of Chlorates and about 0.60 percent in mass of Sulfates; these impurities are determined by the purification level of the "Purified Sodium Aluminate pregnant solution"), and the total water, hydration and humidity, is approximately to 22.0 percent by mass to approximately 23.5 percent by mass.

Sodium Aluminate and Aluminum Hydroxide, both raw materials, are standard primary products, just first and second steps from the Bauxite processing, commodities, produced in huge amounts by the Bauxite processors and shipped in balk. Also in the market there are washed or purified Bauxite and other complex Aluminum Hydroxides that can be used as raw material in these chemical syntheses.

Provided herein, also Phosphoric Acid and many Phosphates are commercial chemical product produced in large amounts by the fertilizer industry, and high quality Phosphoric Acids are produced by the food industries and used in beverages.

Provided herein, Alkaline metal Hydroxides, alkaline metal oxides and Carbonates, especially Sodium Hydroxide, are standard commercial products. Also, Sodium Hydroxide is produced with different qualities; it is also produced with high purity as commodity for the textile industries.

In one embodiment, an approach to synthesize amorphous alkaline metal-Aluminum has been investigated by reacting Ortho-Phosphoric Acid water solution with a commercial or prepared basic solution of stabilized Sodium Aluminate. Following this procedure the molar ratio of Sodium to Aluminum (Na/Al), of the reactants is defined only by the Sodium, or any alkaline metal, amount in the Sodium Aluminate. The molar ratios of Sodium to Aluminum in the stabilized Sodium Aluminate solutions are normally higher than 1.2, usually from of approximately 1.2 to greater than 2.0. These values of Sodium to Aluminum molar ratio are higher than the required molar ratios of Sodium to Aluminum (Na/Al), from 0.2 to 1.2, in the final alkaline metal-Aluminum Phosphates product. As consequence, a co-product or by-product, such as di-Sodium Phosphate or a mixture of Sodium Phosphates, is formed and is present in the final solution together with the synthesized alkaline metal-Aluminum Phosphates.

In certain embodiments, the co-product and by-product salts, Sodium Phosphates, resulting from these synthesis methods, should be separated, treated, and reused or disposed to the environment. Also, these synthesis methods require a sizable additional amount of raw and intermediate materials, with the associated higher economical cost. These unnecessary chemical co-product or by-products, also difficult the separation processes, introduce a separation and a conversion cost, increase the use of process water, and if these Sodium Phosphates are disposed, create unnecessary impacts to the environment. In other embodiment, the synthesis method using Phosphoric Acid as acidic solution and commercial or prepared stabilized Sodium Aluminates or any stabilized alkaline metal Aluminates as basic solutions creates similar environmental and economical problems to all other analyzed synthesis methods of the second group described in the "Back ground of the invention."

Provided herein, the described synthesis method to synthesize alkaline metal-Aluminum Phosphates using Phosphoric Acid as acidic solution and commercial or prepared basic stabilized solution of Sodium Aluminates with Sodium to Aluminum molar ratio, Na/Al, from approximately 1.2 to greater than 2, composition that generate Sodium Phosphates and co- products and by-products, other than water, is disclosed here, but it is not part of this invention.

Provided herein are some specifics properties of the alkaline metal-Aluminum Phosphates with solid amorphous nano-size primary particles comprising the capability to form hydrates by jointing and absorbing water molecules, forming colloidal solutions, amorphous solid particles suspensions, gel-like slurries, hydro-gels, amorphous hydrated solids, amorphous hydrated- solvated solids, and amorphous dried solids. Also, the product becomes solvated by jointing polar solvents as ligand, and also absorbing the solvent into the amorphous structure.

Provided herein, the alkaline metal-Aluminum Phosphates with solid amorphous almost spherical nono-size primary particles has the remarkable physical property of back-scattering the light. This property opens the possibility of many applications.

EXAMPLES

In order to further illustrate the present invention and the advantages thereof, the following specific examples are given, it being understood that the same is intended only as illustrative and in nowise limitative.

The chemical analyses of Phosphorus, Aluminum, Sodium, and Potassium were performed by spectrometry, inductively coupled plasma optical emission spectrometry.

For the standard humidity test, the ASTM D-280 is used; the samples, usually 10 gram each, are heated at 105 degrees centigrade until constant weight, usually 30 minutes.

The particle size and morphology of solid products, such as gel-like slurries, hydro-gels, hydrated amorphous solid, etc., have been characterized and measured by observation with optical microscopy, scanning electronic microscopy, and electronic microprobe (element detection by electronic beam).

Example No 1.

An acidic Aluminum Phosphate solution is reacted with a Sodium Aluminate, solution obtaining 7.65 mol of Aluminum-Sodium Phosphate with molar ratios of P/Al = 1.0 and Na/Al = 0.8. These molar proportions create a stable alkaline metal-Aluminum Phosphate. For this test, Sodium is used as alkaline metal.

Reactants: a-Phosphoric Acid water solution at 80%mass (57.94 %mass as P.sub.2 O.sub.5), density: 1,564 kg/m3; Standard: food grade, clear transparent solution. b-Aluminum tri-Hydroxide, solid powder, 5.0 %mass hydrate water (ASTM-D280, at 105 degrees centigrade). Grain size distribution: from 0.1 to 0.8 mm average diameter. c-Stabilized Sodium Aluminate water solution. Concentration: 896.9 kg/m3 as (NaAl(HO).sub.4) at 37.8 ⁰C, density: 1556 kg/m3 at 25 degrees centigrade, molar ratio Na/Al = 1.316.

Concentration as Aluminum Oxide (Al.sub.2 O.sub.3): 25 %mass and as Sodium Oxide

(Na.sub.2 O): 20 %mass; as anhydrous Sodium Aluminate (Na.sub.2 Al.sub.2 O.sub.4): 40.20

%mass; free NaOH: 4.80 %mass as Sodium Oxide (Na.sub.2 O); color: Amber; NSF standard 60 and America Works Water Association (AWWA) standard B-405-00. i-Preparing the acidic Aluminum Phosphate solution.

To obtain a Sodium-Aluminum Phosphate with the specified molar ratios, using a common commercial Sodium Aluminate solution specified for this test, the molar ratio of P/Al required for the acidic Aluminum Phosphate is P/Al = 2.55. a-Phosphoric Acid solution: 1031.3 g (Phosphoric Acid: 750.0 g (7.65 mol), plus 75.0 g (0.765) to compensate evaporation losses; Water: 206.3 g (11.46 mol). Deionized water to obtain a dilution to 50.0 %mass solution: 450 g (25.0 mol), plus the water required to compensate the evaporation during the reaction. b-Aluminum tri-Hydroxide: 246.2 g ((Al(OH).sub.3): 234 g (3.00 mol); humidity water: 12.3 g (0.633 mol)). c- Water for final solution dilution: 2278 g (159.7 mol).

A batch stirred open reactor is used in this test. The Phosphoric Acid is diluted to 50%mass and poured into the reactor with agitation and heating. When temperature reaches 80 degrees centigrade, Aluminum tri-Hydroxide is slowly added during 10 minutes. When temperature reaches 100 degrees centigrade is maintained after total dissolution of the solid Aluminum Hydroxide, maintaining constant the liquid level by adding the evaporated water. The reaction is fairly completed in approximately one hour, but another 30 minutes is required to complete the dissolution of the coarse particles of Aluminum Hydroxides. Adding the dilution water dilutes this concentrate solution; the final diluted solution is cooled to ambient temperature. The final pH is approximately 1.8. A final solution weight of 4479 g (4510 g as balance) is obtained with a concentration of acidic Aluminum Phosphate approximately 20 %mass and a molar ratio of P/Al = 2.55. ii- Stabilized Sodium Aluminate water solution. The specified commercial solution is used in the amount of 948 g (Sodium Aluminate (Na Al (OH).sub.4): 548.7 g (4.65 mol), Free NaOH: 58.8 g (1.47 mol) and water: 340.5 g (18.91 mol)). iii-Sodium Aluminum Phosphate synthesis. The prepared acidic Aluminum Phosphate solution, 4479 g, and the commercial Stabilized Sodium Aluminate water solution, 948 g, have been maintained a 25 degrees centigrade. The solutions are added proportionally, continuously, and slowly during 15 minutes to a stirred batch reactor containing 2000 g (111.02 moles) of de- ionized water as ballast. The reaction progresses are at an approximately constant pH of 8.7, and the final reaction temperature is approximately 39 degrees centigrade. The final total reacting mass is 7395 g (7457.8 g as balance). A white gel-type precipitate forms from the beginning of the reaction. After the addition of the solutions is completed, the white precipitate is maintained in suspension by continuous agitation during 10 minutes. The final suspension has a milky aspect. After a liquid-solid separation by fine filtration, analyses indicate that the suspension has 1618 g, or 21.7 %mass, of solids dried at 80 degrees centigrade until constant mass (hydrated Sodium Aluminum Phosphate). The solid weight is reduced to 1342 g, or 18.0 % of the original reactor mass, when the solid is dried at 105 degrees centigrade until constant mass (measured by using the standard SSTM D-280), (partially hydrated Sodium Aluminum Phosphate). Drying the suspension at approximately 500 degrees centigrade, until constant mass (4 hours), the resulting solid does not contain any water and the weight is 1122 g, or 15.0 % of the original reactor mass; this amount of solid is an anhydrous Sodium Aluminum Phosphate.

The centrifugation and filtration of the mother liquid is mainly water. It does not have any appreciable amount of synthesis by-products, but impurities bearing by the raw materials.

Example No 2.

An acidic Aluminum Phosphate solution is reacted with an alkaline metal Aluminate solution, obtaining a product with a molar ratio of P/Al = 1.05 and alkaline metals/Al = 0.9. These molar proportions create a stable alkaline metal-Aluminum Phosphate. For this test, Sodium is used as alkaline metal.

Reactants: a-Phosphoric Acid water solution at 80%mass (57.94 %mass as P.sub.2 O.sub.5), density: 1564 kg/m3; Standard: food grade, clear transparent solution. b- Aluminum tri-Hydroxide, solid powder, 5.0 %mass hydrate water (measured following the

ASTM-D280 standard, at 105 degrees centigrade). Grain size distribution: from 0.1 to 0.8 mm. c-Stabilized Sodium Aluminate water solution. Concentration: 896.9 kg/m3 as NaAl(HO)4 at

37.8 degrees centigrade; Density: 1556 kg/m3 at 25 degrees centigrade; Molar Ratio Na/Al =

1.316;

%mass; free NaOH: 4.80 %mass as (Na.sub.2 O); color: Amber. i-Preparing the acidic Aluminum Phosphate solution.

To obtain a Sodium-Aluminum Phosphate with the specified molar ratios using a commercial

Sodium Aluminate specified for this test, the molar ratio P/Al required for the acidic Aluminum

Phosphate is P/Al = 3.32. a-Phosphoric Acid solution: 983.4 g (Phosphoric acid: 786.7 g (8.03 mol), water: 196.7 g (10.92 mol)), and deionized water to obtain a dilution to 50.0 % solution: 472.0 g (26.20mol). b- Aluminum tri-Hydroxide: 198.7 g (Aluminum tri-Hydroxide (Al(OH).sub.3): 188.8 g (2.42 mol); humidity Water: 9.9 g (0.55 mol)). c-Water for final solution dilution: 3000.0 g (166.5 mol).

Procedure. A batch-closed reactor is used in this test to avoid water and Phosphoric Acid evaporation. The Phosphoric Acid is diluted to 50%mass and poured into the reactor with all the

Aluminum tri-Hydroxide in suspension. The reactor is closed; the agitation and heating begin.

When temperature reaches approximately 100 degrees centigrade, it is maintained during 90 minutes to let the dissolution complete. After the heating is off, the reactor is opened when temperature reaches 50 degrees centigrade. The dissolution reaction is completed, including most of the coarse grains of the Aluminum Hydroxide. The dilution water is added and the solution is agitated well until it reaches ambient temperature. The final pH is 1.5. The final acidic Aluminum

Phosphate solution has a total weight 4643 g (4654 g as balance), a molar ratio P/Al = 3.32, and the concentration of the Aluminum Phosphate is approximately 20 %mass. ii- Stabilized Sodium Aluminate water solution. The specified commercial solution is used in the amount of 1066.3 g (Sodium Aluminate (NaAl(OH).sub.4): 617.O g (5.23mol), Free NaOH: 66.1 g (1.65 mol), and water: 383.2 g (21.27 mol)). iii-Sodium Aluminum Phosphate synthesis.

The prepared acidic Aluminum Phosphate solution, 4634 g, and the commercial stabilized

Sodium Aluminate water solution, 1066.3 g, have been maintained at 25 degrees centigrade. The solutions are added proportionally, continuously, and slowly during 15 minutes to an open stirred reactor containing 2000 g (111.02 mol) of deionized water as reaction ballast. The reaction progresses are at an approximately constant pH of 8.7, and the final reaction temperature is 41 degrees centigrade. The resulting total reacting mass is 7686 g (7720 g as balance). A white gel- type precipitate forms from the beginning of the reaction. After additions of the solutions are completed, the white precipitate is maintained in suspension by continuous agitation during 10 minute. The suspension has a milky aspect.

After a liquid-solid separation by centrifugation, analyses indicate that the suspension has 1672 g, or 21.6 %mass, of solids dried at 80 degrees centigrade until constant mass (hydrated Sodium Aluminum Phosphate). This solid weight is reduced to 1397 g, or 18.1 %mass of the original reacting solution, of solid dried at 105 degrees centigrade until constant mass (measured by using the standard ASTM D-280), (partially hydrated Sodium Aluminum Phosphate). Drying this solid at approximately 500 degrees centigrade, until constant mass (4 hours), the resulting solid does not contain any water, and the final weight is 1172 g, or 15.2 % of the original reactor mass; this amount of solid is anhydrous Sodium Aluminum Phosphate.

The centrifugation and filtration of "mother liquid" is mainly water. It does not have any appreciable amount of synthesis product and by-products, but impurities bearing by the raw materials.

Example No 3.

An acidic Aluminum Phosphate solution is reacted with alkaline metal aluminates with molar ratios of P/Al = 1.0 and alkaline metal/Al = 0.7, obtaining a final product with molar ratios of

P/Al = 0.96 and alkaline metals/Al = 0.6. This product molar proportion is a stable alkaline metal

Aluminum Phosphate that is different from the molar ratios of the reacting solutions. For this test,

Sodium is used as alkaline metal.

Reactants: a-Phosphoric Acid water solution at 80%mass (57.94 %mass as P.sub.2 O.sub.5), density: 1564 kg/m3; Standard: food grade, clear transparent solution. b- Aluminum tri-Hydroxide, solid powder, 5.0 %mass hydrate water (measured by using the standard ASTM-D280, at 105 degrees centigrade). Grain size distribution: from 0.1 to 0.8 mm. c-Stabilized Sodium Aluminate water solution. Concentration: 896.9 kg/m3 as (NaAl(HO).sub.4) at 37.8 degrees centigrade; Density: 1556 kg/m3 at 25 degrees centigrade; Molar Ratio Sodium to

Aluminum (Na/Al) = 1.316;

Concentration as Alumina (Al.sub.2 O.sub.3): 25 %mass and as Sodium Oxide (Na.sub.2 O): 20

%mass; Sodium Aluminate (Na.sub.2 Al.sub2.O.sub.4): 40.20 %mass; free Sodium Hydroxide,

NaOH: 4.80 %mass as Na.sub.2O; color: Amber. i-Preparing the acidic Aluminum Phosphate solution.

To obtain a Sodium-Aluminum Phosphate with the specified molar ratios of P/Al = 1.0, and

Na/Al = 0.7, using a commercial Sodium Aluminate solution specified for this test, the molar ratio of P/Al required for the acidic Aluminum Phosphate is P/Al = 2.13. a-Phosphoric Acid: 936.3 g (749.3 g (7.64 mol); water: 187.0 g (10.4 mol)) and deionized water to obtain a dilution to 50.0 % solution: 450.0 g (25.0 mol). b-Aluminum tri-Hydroxide: 293.9 g (Al(OH).sub.3): 279.2 g (3.58 mol); humidity water: 14.7 g

(0.82 mol)). c-Deionized water for final solution dilution: 3000.0 g (166.5 mol).

A batch-closed reactor is used in this test. The Phosphoric Acid is diluted to 50%mass and poured into the reactor with all the Aluminum tri-Hydroxide in suspension. The reactor is closed, the agitation, and heating begin. When temperature reaches 120 degrees centigrade, it is maintained during 60 minutes to let complete the dissolution. Heating is turn off; when temperature reaches 50 degrees centigrade, the reactor is opened. The dissolution reaction is completed, including most of the Aluminum Hydroxide coarse grains. The dilution water is added and the solution is agitated well until ambient temperature. The final pH is 2.0. The final acidic Aluminum Phosphate solution has a total weight 4660 g (4680 g as balance), a molar ratio P/Al = 2.14 and the concentration of the Aluminum Phosphate is approximately 20 %mass. ii- Stabilized Sodium Aluminate water solution. The specified commercial solution is used in the amount of 829.3 g ((NaAl(OH).sub.4): 480.0 g (4.07mol), Free NaOH: 51.4 g (1.29 mol) and water: 298.0 g (16.54 mol)). iii-Sodium Aluminum Phosphate synthesis.

The prepared acidic Aluminum Phosphate solution, 4660 g, and the commercial stabilized Sodium Aluminate water solution, 829.3 g, have been maintained a 25 degrees centigrade. The solutions are added proportionally, continuously and slowly during 15 minutes to a stirred reactor containing 2000 g (111.02 mol) of deionized water as reaction ballast. The reaction progresses are at an approximately constant pH of 8.8, and the final temperature of reaction is approximately 40 degrees centigrade. The final total reacting mass is 7466 g (7500 g as balance). A white gel-type precipitate forms from the beginning of the reaction. After the addition of reacting solutions is completed, the white precipitate is maintained in suspension by continuous agitation during 10 minute. The suspension has a milky aspect.

Analyses indicate that the milky suspension has 1542 g (1554 g as balance), or 20.7 %mass, of solids dried at 80 degrees centigrade until constant mass (hydrated Sodium Aluminum Phosphate).

After a liquid-solid separation by filtration, a white solid cake is separated and 4142 g of a clear mother liquid (8.6 %mass di-Sodium Phosphate, 1.6 %mass Sodium Aluminum Phosphate and water the remaining). The solid cake is washed with 1918 g of deionized water. The final washed solid cake has 3294 g and the washing liquid has 1932 g (0.42 %mass di-Sodium Phosphate and Sodium Phosphate (molar ration Na/P = 1.8), 0.8 %mass Sodium Aluminum Phosphate and water the remaining). The wet solid cake is Hydrated Sodium Aluminum Phosphate and has 36.4 %mass of solid (measured by using the standard ASTM D-280). More water can be separated from the wet solid cake by pressing the wet cake after washing and then blowing the pressed cake with air or Nitrogen.

The wet solid cake is kneaded and wet milled with a high shear stress process. Under shear stress, the wet hydro-gel solid cake release free and hydration water forming gel- like slurry. The Sodium Aluminum Phosphate in this gel-like slurry has a molar ratio P/AI = 0.96 and Na/AI = 0.6. This Sodium Aluminum Phosphate hydro-gels or gel-like slurries formed could be used as a moisturizing agent and a light back-scattering product. The obtained gel-like slurry is dried at 105 degrees centigrade until constant mass (measured by using the standard ASTM D-280), weight is reduced to 1269 g of solid (partially hydrated Sodium Aluminum Phosphate). Drying the slurry at approximately 500 degrees centigrade, until constant mass (4 hours), the resulting solid does not contain any water and the weight is 1045 g, or 14.0 % of the original reactor mass; this amount of solid is anhydrous Sodium Aluminum Phosphate.

The separated mother liquid has Sodium Phosphate with a molar ratio Na/P = 1.8. The presence of 364 g of Sodium Phosphate in the mother liquid indicates that the reaction molar ratios used does not match the equilibrium of a stable Sodium Aluminum Phosphate, as indicate the final molar ratios of the synthesized Sodium Aluminum Phosphate.

Example No 4.

An acidic Aluminum Phosphate solution is reacted with alkaline metal Aluminate with molar ratios of the mixture of P/Al = 0.98 and alkaline metal/Al = 0.7 obtaining a product with a molar ratio of P/Al = 0.98 and alkaline metals/Al = 0.7. This product molar proportion is a stable alkaline metal Aluminum Phosphate. For this test, Sodium is used as alkaline metal. Reactants: a-Phosphoric Acid water solution at 80%mass (57.94 %mass as P.sub.2 O.sub.5), density: 1564 kg/m3; Standard: food grade, clear transparent solution. b-Aluminum tri-Hydroxide, solid powder, 5.0 %mass hydrate water (measured following the

ASTM-D280 standard, at 105 degrees centigrade). Grain size distribution: from 0.1 to 0.8 mm. c-Stabilized Sodium Aluminate water solution. Concentration: 896.9 kg/m3 as NaAl(HO).sub.4 at

1.316;

(Na.sub.2 O): 20 %mass; anhydrous Sodium Aluminate (Na.sub.2 Al.sub.2 O.sub.4): 40.20

To obtain a Sodium-Aluminum Phosphate with the specified molar ratios, using a commercial

Sodium Aluminate specified for this test, the molar ratio of P/Al required for the intermediate acidic Aluminum Phosphate is P/Al = 2.10. a-Phosphoric Acid solution: 918 g (Phosphoric Acid: 734.4 g ((7.49 mol), water: 183.6 g (10.19 mol)) and deionized water to obtain a dilution to 50.0 % solution: 440.6 g (24.45 mol). b-Aluminum tri-Hydroxide: 294 g ((Al(OH).sub.3): 279.3 g (3.58 mol); humidity water: 14.7 g

A batch-closed reactor is used in this test. The Phosphoric Acid solution is diluted to 50%mass and poured into the reactor with all the Aluminum tri-Hydroxide in suspension. The reactor is closed and the agitation and heating begin. When temperature reaches of approximately 150 degrees centigrade (equilibrium pressure approximately 4.6 bar), it is maintained during 10 minutes to let complete the dissolution of the Aluminum tri-Hydroxide; this process can also be performed in a continuous reactor. After heating is turn off, the reactor is open when temperature reaches 50 degrees centigrade. The dissolution reaction is complete, including the coarse grains of the Aluminum Hydroxide are dissolved. The dilution water is added and the solution is agitated well until reaching ambient temperature. The final pH is 2.1. The final acidic Aluminum

Phosphate solution has a total weight 4647 g (4652.6 g as balance), a molar ratio P/Al = 2.09 and the concentration of the Aluminum Phosphate is approximately 20 %mass. ii-Preparation,of the diluted Sodium Aluminate.

To reach the desired molar ratios in the final Sodium Aluminum Phosphate solution, a commercial Sodium Aluminate solution is weighted and maintained a 25 degrees centigrade:

829.4 g ((NaAl(OH).sub.4): 480.0 g (4.07mol), Free NaOH: 51.4 g (1.29 mol) and water: 298.0 g

(16.54 mol)). This concentrate solution is diluted with 1300 g of deionized water at 25 degrees centigrade and mixed vigorously, obtaining 2120 g of a diluted Sodium Aluminate solution

(14.48 %mass of Sodium Aluminate plus the free Sodium Hydroxide). At the beginning, the diluted solution becomes turbid, but after a while turns again to a clear solution. This solution is very unstable at ambient temperatures; it should be used just after prepared. Overnight or in only a few hours could precipitate most of the Aluminum as Hydrated Aluminum tri-Hydroxide. iii-Sodium Aluminum Phosphate synthesis. The prepared acidic Aluminum Phosphate solution, 4647 g, and the diluted Sodium Aluminate solution, 212O g, have been maintained a 25 degrees centigrade. The solutions are continuously pumped in a flow rate proportion 2 to 1 (acidic Aluminum Phosphate solution / diluted basic Sodium Aluminate solution) to a continuous reactor with mixers. The flow rate of the mixed streams into the continuous reactor is approximately 100 g/s and the time of residence in the reactor is approximately 1.1 second. The reaction progresses are at an approximately constant pH of 8.5, at the reactor exit, the temperature of the reacted suspension is approximately 57 degrees centigrade. A white gel-like suspension exits the continuous reactor. The product is collected in a vessel. The pumps and the reactor are washed with 2000 g of deionized water. The final total reacting and washing mass is 6750 g (6767 g as balance). The immediate next step is to centrifuge the reacted milky dispersion, separating 3200 g (3235 g as balance) of clear mother liquid. The solid is a concentrated white gel-like suspension 3515 g, at 36 %mass of solid, measured by using the standard ASTM D-280 (at 105 degrees centigrade). This concentrate white suspension could be transformed in hydro-gel slurry, following the procedures of the example No. 3. However, the concentrated liquid dispersion is sent to a mini spray dry system. The liquid dispersion is dried to a solid powder. After drying the dispersion by spray draying, it is obtained 1512 g (1527 g by balance) of amorphous characteristics solid powder, containing 17.4 %mass of molecular water (measured by using the standard ASTM D-280, at 105 degrees centigrade). The solid powder is a hydrated Sodium Aluminum Phosphate. Drying this spray-dried powder at approximately 500 degrees centigrade, until constant mass (4 hours), the resulting solid does not contain any free or molecular water, and the final weight is 922 g; this solid is anhydrous Sodium Aluminum Phosphate.

All of these process and operations can be performed in batch or by continuous processes and operations, including the preparation of the acidic Aluminum Phosphate.

Example No 5.

An acidic Aluminum Phosphate solution is reacted with alkaline metal Aluminate solution, the reacting mixture has molar ratios P/Al = 1.16 and alkaline metal/ Al = 0.5, obtaining a product with a molar ratio P/Al = 1.16 and alkaline metals/Al = 0.5. This product molar proportion is a stable alkaline Aluminum Phosphate. For this test, Sodium is used as alkaline metal.

Reactants: a-Phosphoric Acid water solution at 80%mass (57.94 %mass as P.sub.2 O.sub.5), density: 1564 kg/m3; Standard: food grade, clear transparent solution. b-Aluminum tri-Hydroxide, solid powder, 5.0 %mass hydrate water (following the ASTM-D280 standard, at 105 degrees centigrade). Grain size distribution: from 0.1 to 0.8 mm. c-Sodium Hydroxide, NaOH. Solid pellets. d-deionized water. i-Preparing the acidic Aluminum Phosphate solution.

To obtain a Sodium Aluminum Phosphate with the specified molar ratios, the molar ratio of P/Al required for the intermediate acidic Aluminum Phosphate is P/Al = 2.0. The required Sodium

Aluminate molar ratio of Na/Al = 1.2, specified for this test, is not in the market, and the solution must be prepared. Both solutions have approximately the lower molar ratios to obtain stable solutions and should be used before a few hours after prepared. The acidic solution could precipitate Aluminum Phosphate and the basic solution could precipitate hydrated Aluminum

Hydroxide. a-Phosphoric Acid solution: 1087 g (Phosphoric Acid: 870 g (8.87 mol), water: 217 g (12.0 mol)) and deionized water to obtain a dilution to 50.0 % solution: 520 g (29.0 mol). b-Aluminum tri-Hydroxide: 367 g ((AI(OH).sub.3): 348.6 g (4.46 mol); humidity water: 18.4 g

(1.01 mol)). The Aluminum tri-Hydroxide powder is grinded to Mesh 120 to reduce the coarse particle sizes. c- Water for final solution dilution: 2000.0 g (111.0 mol).

A batch-closed reactor is used in this test. The Phosphoric Acid solution is diluted to 50%mass and poured into the reactor with all the Aluminum tri-Hydroxide in suspension. The reactor is closed; the agitation and heating begin. When temperature reaches of approximately 150 degrees centigrade (equilibrium pressure of 4.6 bar), it is maintained during 10 minutes at this temperature to let complete the dissolution of the Aluminum tri-Hydroxide, including the coarse grains. This process could also be performed in a continuous reactor. After heating is turn off; the reactor is open when temperature reaches 50 degrees centigrade. The dissolution reaction is completed, including all coarse grains of the Aluminum Hydroxide. The dilution water added and the solution is agitated well until it reaches ambient temperature. The final pH is 2.2. The final acidic Aluminum Phosphate solution has a total weight 3955 g (3974 g as balance), a molar ratio

P/Al = 2.0 and a concentration of the Aluminum Phosphate is approximately 30 %mass.

This solution could be unstable at long term; it should be used before a few hours of its preparation. Overnight or after a few hours, it could precipitate hydrated Aluminum Phosphates. ii-Preparation of the Sodium Hydroxide solution. a-Sodium Hydroxide pellets: 153 g (3.82 mol). b-Deionized Water: 245 g.

The Sodium Hydroxide pellets are added to the deionized water in a stirred glass vessel to obtain

398 g a solution with a concentration of 38.5 %mass of NaOH. The dissolution is exothermic. iii-Preparation of Sodium Aluminate. a- Sodium Hydroxide solution at 38.5 %mass of NaOH, 398 g. b- Aluminum tri-Hydroxide: 262 g. The powder is grinded to Mesh 120 to reduce the coarse particle sizes. c- Dilution de-Ionized water: 1327 g.

A batch-closed reactor is used for this reaction. The 398 g of prepared Sodium Hydroxide solution at 38.5%mass is poured into the reactor with all the 262 g Aluminum tri-Hydroxide in suspension. The reactor is closed; the agitation and heating begin. When temperature reaches approximately 150 degrees centigrade, it is maintained during 10 minutes at this temperature to let the complete dissolution of the Aluminum tri-Hydroxide, including the coarse grains; this reaction could also be performed in a continuous process. After heating is turn off; the reactor is open when temperature reaches approximately 50 degrees centigrade. The dissolution reaction is completed, also the coarse grains of the Aluminum Hydroxide. A small amount to the water dilution is used to wash the reactor and is added to the solution. The rest of the dilution water is added just before the use of the solution. The final pH is 13.2.

The final Sodium Aluminate solution has a total weight 1967 g (1987 g as balance), a molar ratio

Na/Al = 1.2 and the concentration of alkaline Sodium Aluminate is approximately 24.3 %mass.

This solution is unstable at low temperature; it could precipitate hydrated Aluminum Hydroxide

(Al(OH).sub.3 . H.sub.2 O). iv-Sodium Aluminum Phosphate synthesis.

The prepared acidic Aluminum Phosphate, 3955 g, and the diluted Sodium Aluminate, 1967 g, have been maintained a 25 degrees centigrade. The solutions are continuously pumped in flow rate proportion 2 to 1 (acidic Aluminum Phosphate solution / diluted Sodium Aluminate solution) to a continuous reactor with mixers. The mixed flow rate of both streams into the continuous reactor is approximately 100 g/s and the time of residence in the reactor approximately 1.5 second. The reaction progresses are at an approximately constant pH of 7.5, at the reactor exit, the temperature of the reacted suspension is approximately 78 degrees centigrade. White gel-type mass exits the continuous reactor, and it is collected in a vessel. The final total reacting mass is

5880 g (5922 g as balance) of a concentrated white dispersion (23.7 %mass of solid, measured by using the standard ASTM D-280 at 105 degrees centigrade. This gel-like dispersion can be homogenized as stable hydro-gel slurry by a high shear stress wet milling or drying to solid powders.

The concentrated gel-like liquid dispersion is sent to a mini spray dry system. After drying this dispersion by spray dry, it is obtained 1582 g (1621 g by balance) of a solid powder with amorphous characteristics, containing 16.3 %mass of water (measured by using the standard ASTM D-280, 105 degrees centigrade). The solid powder is a hydrated Sodium Aluminum Phosphate. Drying this spray-dried powder at approximately 500 degrees centigrade, until constant mass (4 hours), the resulting solid does not contain any free or molecular water, and the final weight is 992 g; this solid is an anhydrous Sodium Aluminum Phosphate.

Example No 6.

An acidic Aluminum Phosphate solution is reacted with alkaline metal Aluminate, the mixture has molar ratios P/Al = 0.945 and alkaline metal/Al = 0.7 and obtaining product with similar molar ratios, P/Al = 0.945 and alkaline metal/Al = 0.7. These product molar proportions synthesize a stable alkaline Aluminum Phosphate. For this test, Potassium is used as alkaline metal.

Reactants: a-Phosphoric Acid water solution at 80%mass (57.94 %mass as P.sub.2 O.sub.5), density: 1564 kg/m3; Standard: food grade, clear transparent solution. b- Aluminum tri-Hydroxide, solid powder, 5.0 %mass hydrate water (ASTM-D280, a 105 degrees centigrade). Grain size distribution: from 0.1 to 0.8 mm. c-Potassium Hydroxide, KOH. Solid pellets. d-Deionized water. i-Preparing the acidic Aluminum Phosphate solution.

To obtain a Potassium-Aluminum Phosphate with the specified molar ratios, the molar ratio of

P/Al required for the acidic Aluminum Phosphate is P/Al = 2.2. The required Potassium

Aluminate molar ratio specified for this test, K/Al = 1.2, is not found in the market and it is prepared. a-Phosphoric Acid solution: 885.0 g (Phosphoric Acid: 708.0 g((7.23 mol), water: 177.0 g (9.83 mol)) and deionized water to obtain a dilution to 50.0 % solution: 425.0 g (9.83 mol). b-Aluminum tri-Hydroxide: 268.5 g ((Al(OH).sub.3): 255.1 g (3.26 mol); humidity water: 13.4 g

(0.74 mol)). The Aluminum tri-Hydroxide powder is grinded to Mesh 400 to reduce the coarse particle sizes. c-Deionized water for final solution dilution: 2700.0 g.

A batch-closed reactor is used in this test. The Phosphoric Acid is diluted to 50%mass and poured into the reactor with all the milled Aluminum tri-Hydroxide in suspension. The reactor is closed; the agitation and heating begin. When in the reactor temperature reaches approximately 150 degrees centigrade (equilibrium pressure approximately 4.6 bar), temperature is maintained during 10 minutes to let complete the dissolution of the Aluminum tri-Hydroxide. This process could be performed in a continuous reactor. Heating is interrupted and the reactor is opened when temperature reaches approximately 50 degrees centigrade. The dissolution reaction is completed and no solid Aluminum Hydroxide is present. The dilution water added and solution is agitated well until ambient temperature. The final pH is 1,9.

The final acidic Aluminum Phosphate solution has a total weight 4220 g (4278.5 g as balance), a molar ratio of P/Al = 2.2 and a concentration of the Aluminum Phosphate is approximately 28

%mass. ii-Preparation of the Potassium Hydroxide solution. a-Sodium Hydroxide pellets: 300.0 g (5.35 mol). b-De-ionized Water: 500 g.

The Potassium Hydroxide pellets are added to the deionized water in a stirred glass vessel to obtaining 800 g solution with a concentration of 37.5 %mass of KOH. iii-Preparation of Potassium Aluminate, (K(Al(OH).sub.4)). a- Potassium Hydroxide: 800 g (Potassium Hydroxide: 5.35 mol or 300 g in solution at 37.5

%mass ofKOH). b- Aluminum tri-Hydroxide: 379 g (Aluminum tri-Hydroxide: 360 g or 4.39 mol, hydration water: 19 g). The powder is grinded to Mesh 400 to reduce the coarse particle sizes. c- Dilution deionized water: 960 g. A batch-closed reactor is used for this reaction. The 800 g of prepared Potassium Hydroxide solution at 37.5%mass is poured into the reactor with all the 360 g Aluminum tri-Hydroxide in suspension. The reactor is closed, the agitation and heating begin. When temperature reaches approximately 150 degrees centigrade, the reactor is maintained during 10 minutes at this temperature to let complete the dissolution of the Aluminum tri-Hydroxide. This process could be performed in a continuous reactor. After heating is interrupted, the reactor is opened when temperature reaches approximately 50 degrees centigrade. The dissolution reaction is completed. A small amount of the water for dilution is used to wash the reactor and is added to the solution. The rest of the dilution water is added just before the use of the solution. The final pH is 13.4. The final Potassium Aluminate solution has a total weight 21 15 g, (2139 g as balance) a molar ratio K/Al = 1.22 and the concentration of Potassium Aluminate is approximately 30 %mass. iv-Potassium Aluminum Phosphate synthesis.

The prepared acidic Aluminum Phosphate solution, 4220 g, and the prepared Potassium Aluminate solution, 2115 g, have been maintained a 25 degrees centigrade. The solutions are continuously pumped in flow rate proportion 2 to 1 (acidic Aluminum Phosphate solution / Potassium Aluminate solution) to a stirred batch reactor. The solutions are added continuously and slowly during 15 minutes to a stirred batch reactor containing 2000 g (111.02 mol) of deionized water as ballast. The reaction progresses are at an approximately constant pH of 8.4, creating a white foamy precipitate. The final reaction temperature is approximately 38 degrees centigrade. The final total reacting mass is 8290 g (8335 g as balance) of a concentrated white milky dispersion (19.0 %mass of solid, measured by using the standard ASTM D-280 atlO5 degrees centigrade.

The liquid suspension is filtered and washed, obtaining 4188 g (4257 g as balance) of a gel-like foamy solid cake, with approximately 37%mass of solid Potassium Aluminum Phosphate (measured by using the standard ASTM D-280). The cake is transformed into foamy hydro-ge! slurry of Potassium Aluminum Phosphate, following the procedure of the example No. 3.

All of these process and operations can be performed in batch or by continuous processes and operations, including the preparation of the acidic Aluminum Phosphate, the Sodium Aluminate, the Potassium Aluminate, the synthesis of alkaline metal-Aluminum Phosphates, etc.

While the invention has been described in terms of various preferred embodiments, a skilled person will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the present invention be limited solely by the scope of the following claims, including equivalents thereof.

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Claims

Chemical synthesis and method to manufacture alkaline metal-Aluminum PhosphatesCLAIMS

1. A process for making Sodium-Aluminum Phosphates or polyphosphates comprising reacting Phosphoric Acids, Aluminum Hydroxides and Sodium Aluminate. Wherein, the synthesized Sodium-Aluminum Phosphates or poly-phosphates comprise amorphous solid with nano-size primary particles.

2. A process for making Sodium-Aluminum Phosphates or polyphosphates comprising reacting aluminum phosphate and sodium aluminate. Wherein, the synthesized Sodium-Aluminum Phosphates comprise amorphous solid with nano-size primary particles.

3. A environmentally friendly chemical synthesis and process for making alkaline metal- Aluminum Phosphates comprising reacting Phosphoric acids, Aluminum Hydroxides, alkaline metal Hydroxides, Aluminum Phosphates, alkaline metal Aluminates in polar solvents and reacting in chemical reaction steps.

4. The process of claim 3, wherein one chemical step forms intermediate acidic Aluminum Phosphate solutions and basic alkaline metal Aluminate solutions. Wherein, the next chemical steps, the acidic and the basic solutions are mixed and reacted to synthesize the final product, solid amorphous alkaline metal-Aluminum Phosphates with almost spherical nano-size primary particles.

5. The process of claim 3, wherein the polar solvents comprise water, Ammonium solutions, alcohols, and other organic polar solvents or a mixture thereof.

6. The process of claim 3, wherein the intermediate acidic Aluminum Phosphate solutions comprise simple, poly-atomic, and solvated Aluminum ions, Hydrogen ions and Phosphates ions, and others negative anios, and the compounds and ions in chemical equilibrium. Wherein, the acidic Aluminum Phosphate solutions have molar ratios of Aluminum to Phosphorus from approximately 2 and greater than 2, and pH lower than 3.5.

7. The process of claim 3, wherein the intermediate basic alkaline metal Aluminate solutions comprise simple, poly-atomic, and solvated Aluminum ions, Aluminate ions, alkaline metal ions, and other positive anions, hydroxide ions, and compounds and ions in chemical equilibrium. Wherein, the basic alkaline metal Aluminate solutions have molar ratios of alkaline metal to Aluminum from approximately 1.0 to greater than 2.0, and pH grater than 11.

8. The process of claim 3, wherein the alkaline metals-Aluminum Phosphates product comprise salts with alkaline metals ions and simple, poly-atomic, and poly-Aluminum ions phosphates, alkaline metal-Oxy-Aluminum Phosphates, alkaline metal-Aluminum ortho-Phosphates, alkaline metal-Aluminum pyro-Phosphates, alkaline metal-Aluminum meta-Phosphates, alkaline metal- Aluminum poly-Phosphates, and other compatible salts, or a mixture thereof.

9. The process of claim 3, wherein the amorphous alkaline metal-Aluminum Phosphates further comprises alkaline metal ions and Ammonium ions. Wherein, the alkaline metals comprise Lithium, Sodium, Potassium, and the other alkaline metals, or a mixture thereof.

10. The process of claim 3, wherein the synthesis chemical reactions between the acidic solutions and the basic solutions that synthesize the final product, the solid amorphous alkaline metal- Aluminum Phosphates, takes place on a pH environment comprising from of approximately 3.5 to greater than 13.5. A more preferred pH environment comprises a range from of approximately 7 to greater than 12.

11. The process of claim 3, wherein the synthesized alkaline metal-Aluminum Phosphates are characterized by compositions comprising molar ratios of Phosphorus to Aluminum (P/Al), from approximately 0.5 to greater than 2.0 and molar ratios of alkaline metal to Aluminum (alkaline metal/ Al), from approximately 0.2 to greater than 1.2.

12. The process of claim 3, wherein the synthesized alkaline metal-Aluminum Phosphates molecules are solvated or hydrated by Iigands comprising water, hydroxide ions, Hydrogen ions, Ammonium ions, alcohols, other polar organic molecule, and a mixture of thereof.

13. The process of claim 3, wherein the final product generated by the synthesis reactions, comprise solid amorphous alkaline metal-Aluminum Phosphates with almost spherical primary particles with a size range comprising from approximately 10 nanometer to greater than 120 nanometer. Wherein, the almost spherical primary particles coalesce by adhering each others forming clusters of primary particles, and those primary particle clusters agglomerate forming irregular agglomerates or irregular macro-particles with sizes in a range comprising from of about 400 nanometers to greater than 50,000 nanometers.

14. The process of claim 3, wherein the alkaline metal-Aluminum phosphates product further comprising colloidal solutions, amorphous solid particles dispersions, amorphous gel-like slurries, amorphous hydro-gels, amorphous solvated powders, amorphous hydrated powders, and amorphous dried powders.

15. The process of claim 3, wherein the chemical synthesis of alkaline metal- Aluminum Phosphate takes place by reacting Aluminum Phosphates and alkaline metal Aluminate in one chemical step.

16. The process of claim 3, wherein the chemical synthesis of alkaline metal-Aluminum Phosphate takes place by reacting Phosphoric acid, Aluminum hydroxide and alkaline metal hydroxide and alkaline in one chemical step.

17. The process of claim 1, wherein the amorphous aluminum phosphate or polyphosphate further comprises any alkaline metal ions and/or Ammonium ions. Wherein, the alkaline metals comprise Lithium, Sodium, Potassium or a mixture thereof.

18. The process of claim 2, wherein the amorphous alkaline metal-aluminum phosphate or polyphosphate further comprises alkaline metal ions, Ammonium ions and other ions. Wherein, the alkaline metals comprise Lithium, Sodium, Potassium or a mixture thereof.

19. The process of claim 1, wherein the sodium aluminate solution is a water solution at pH grater than 12.

20. The process of claim 2, wherein the sodium aluminate solution is a water solution at pH grater than 12.