Disclosed herein is a method for reducing a metal oxide in a metal oxide containing precursor. The method comprises providing a reaction mixture comprising the metal oxide containing precursor and an aluminium reductant; heating the reaction mixture in the presence of solid or gaseous aluminium chloride to a temperature at which reactions that result in the metal oxide being reduced are initiated; controlling reaction conditions whereby the reaction mixture is prevented from reaching a temperature at which thermal runaway can occur; and isolating reaction products that include reduced metal oxide.

Disclosed herein is a method for reducing a metal oxide in a metal oxide containing precursor. The method comprises providing a reaction mixture comprising the metal oxide containing precursor and an aluminium reductant; heating the reaction mixture in the presence of solid or gaseous aluminium chloride to a temperature at which reactions that result in the metal oxide being reduced are initiated; controlling reaction conditions whereby the reaction mixture is prevented from reaching a temperature at which thermal runaway can occur; and isolating reaction products that include reduced metal oxide.

Activated aluminum sesquichlorohydrate (AASCH) powders and method of making are disclosed. The method of making the active comprises (a) diluting the concentrated aluminum sesquichlorohydrate (ASCH) solution to from about 10% to about 25% by weight and (b) heating the diluted solution to obtain a Band III polymer concentration of at least about 20% and a Band IV polymer concentration of at least about 15%, and (c) drying the heated solution to powders and (d) optionally screen or light mill the powders to free flowing spherical particles.

Activated aluminum sesquichlorohydrate (AASCH) powders and method of making are disclosed. The AASCH powder has Al:Cl atomic ratio of from about 1.60 to about 1.90 and Band III polymer concentration of at least about 20% and Band IV polymer concentration of at least about 15% when analyzed with Size Exclusion Chromatogram (SEC) operated by High Performance Liquid Chromatograph (HPLC). The method of making the active comprises (a) diluting the concentrated aluminum sesquichlorohydrate (ASCH) solution to from about 10% to about 25% by weight and (b) heating the diluted solution to obtain a Band III polymer concentration of at least about 20% and a Band IV polymer concentration of at least about 15%, and (c) drying the heated solution to powders having Al:Cl ratio of about 1.60 to about 1.90 and (d) optionally screen or light mill the powders to free flowing spherical particles.

Activated aluminum sesquichlorohydrate (AASCH) powders and method of making are disclosed. The AASCH powder has Al:Cl atomic ratio of from about 1.60 to about 1.90 and Band III polymer concentration of at least about 20% and Band IV polymer concentration of at least about 15% when analyzed with Size Exclusion Chromatogram (SEC) operated by High Performance Liquid Chromatograph (HPLC). The method of making the active comprises (a) diluting the concentrated aluminum sesquichlorohydrate (ASCH) solution to from about 10% to about 25% by weight and (b) heating the diluted solution to obtain a Band III polymer concentration of at least about 20% and a Band IV polymer concentration of at least about 15%, and (c) drying the heated solution to powders having Al:Cl ratio of about 1.60 to about 1.90 and (d) optionally screen or light mill the powders to free flowing spherical particles.

Disclosed herein is a method for reducing a metal oxide in a metal oxide containing precursor. The method comprises providing a reaction mixture comprising the metal oxide containing precursor and an aluminium reductant; heating the reaction mixture in the presence of solid or gaseous aluminium chloride to a temperature at which reactions that result in the metal oxide being reduced are initiated; controlling reaction conditions whereby the reaction mixture is prevented from reaching a temperature at which thermal runaway can occur; and isolating reaction products that include reduced metal oxide.

Disclosed herein is a method for reducing a metal oxide in a metal oxide containing precursor. The method comprises providing a reaction mixture comprising the metal oxide containing precursor and an aluminium reductant; heating the reaction mixture in the presence of solid or gaseous aluminium chloride to a temperature at which reactions that result in the metal oxide being reduced are initiated; controlling reaction conditions whereby the reaction mixture is prevented from reaching a temperature at which thermal runaway can occur; and isolating reaction products that include reduced metal oxide.

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.