A system for producing particles of basic aluminum chloride includes a liquid feed system configured to have a liquid solution of aluminum chloride and configured to dispense droplets of the liquid solution, the droplets having an average size of about 0.5 mm to about 15 mm in diameter and spaced apart from one another, at least one conveyor belt having a surface configured to hold the droplets, a first heating zone having at least one radiant heat source configured to heat the liquid solution on the surface to concentrate the aluminum chloride, and a second heating zone having at least one radiant heat source configured to heat the concentrated aluminum chloride to decompose the aluminum chloride and produce the particles of basic aluminum chloride. The method includes dispensing and heating the droplets in a particular way to produce the particles of the basic aluminum chloride.

A system for producing particles of basic aluminum chloride includes a liquid feed system configured to have a liquid solution of aluminum chloride and configured to dispense droplets of the liquid solution, the droplets having an average size of about 0.5 mm to about 15 mm in diameter and spaced apart from one another, at least one conveyor belt having a surface configured to hold the droplets, a first heating zone having at least one radiant heat source configured to heat the liquid solution on the surface to concentrate the aluminum chloride, and a second heating zone having at least one radiant heat source configured to heat the concentrated aluminum chloride to decompose the aluminum chloride and produce the particles of basic aluminum chloride. The method includes dispensing and heating the droplets in a particular way to produce the particles of the basic aluminum chloride.

A method of producing aluminum chlorohydrate comprises adding small form aluminum metal pellets to a reactant receiving space of a reactor tank to form a pellet bed; adding aqueous hydrochloric acid to the reactant receiving space of the reactor tank; and continuously circulating the aqueous hydrochloric acid through the pellet bed. In some embodiments, the continuously circulating aqueous hydrochloric acid dispels reaction gases from the pellet bed. Methods described herein can, in some cases, further comprise consecutively adding additional small form aluminum metal pellets to the reactant receiving space of the reactor tank as the small form aluminum metal pellets are consumed in the pellet bed.

A method of producing aluminum chlorohydrate comprises adding small form aluminum metal pellets to a reactant receiving space of a reactor tank to form a pellet bed; adding aqueous hydrochloric acid to the reactant receiving space of the reactor tank; and continuously circulating the aqueous hydrochloric acid through the pellet bed. In some embodiments, the continuously circulating aqueous hydrochloric acid dispels reaction gases from the pellet bed. Methods described herein can, in some cases, further comprise consecutively adding additional small form aluminum metal pellets to the reactant receiving space of the reactor tank as the small form aluminum metal pellets are consumed in the pellet bed.

A method and system for batch manufacturing aluminum chlorohydrate (ACH) utilizing a reactor tank. The method comprises conducting two consecutive batch manufacturing processes, each batch manufacturing process producing aluminum chlorohydrate (ACH) by reacting solid-state aluminum metal pieces with an acid source in a reactor tank. Proximate the end of a first of the two batch manufacturing processes, after the aluminum chlorohydrate (ACH) being produced in that batch has reached a predetermined basicity level, a majority of the produced aluminum chlorohydrate (ACH) is withdrawn from the reactor tank but a heel-portion of the produced aluminum chlorohydrate (ACH) is retained in the reactor tank. The heel-portion comprises a sufficient amount of the produced aluminum chlorohydrate (ACH) to submerge therein a majority of unreacted solid-state aluminum metal pieces retained in the reactor tank at the time that produced aluminum chlorohydrate (ACH) is withdrawn from the reactor tank.

A method and system for batch manufacturing aluminum chlorohydrate (ACH) utilizing a reactor tank. The method comprises conducting two consecutive batch manufacturing processes, each batch manufacturing process producing aluminum chlorohydrate (ACH) by reacting solid-state aluminum metal pieces with an acid source in a reactor tank. Proximate the end of a first of the two batch manufacturing processes, after the aluminum chlorohydrate (ACH) being produced in that batch has reached a predetermined basicity level, a majority of the produced aluminum chlorohydrate (ACH) is withdrawn from the reactor tank but a heel-portion of the produced aluminum chlorohydrate (ACH) is retained in the reactor tank. The heel-portion comprises a sufficient amount of the produced aluminum chlorohydrate (ACH) to submerge therein a majority of unreacted solid-state aluminum metal pieces retained in the reactor tank at the time that produced aluminum chlorohydrate (ACH) is withdrawn from the reactor tank.