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 particles of aluminum chlorohydrate includes (a) feeding a solution of aluminum chloride through an atomizer associated with a spray dryer, so that a spray of droplets of the solution is formed in the spray dryer, (b) operating the dryer at a temperature sufficient to cause transformation of the droplets into crystal particulates and to dry the crystal particulates, such dried crystal particulates being aluminum chlorohydrate, and (c) recovering the dried crystal particulates. A product produced by the process is also described.

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in that batch has reached a predetermined basicity level, a majority of the produced aluminum chlorohydrate (ACH) is withdrawn from the reactor tank but a heel-portion of the produced aluminum chlorohydrate (ACH) is retained in the reactor tank.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aluminum metal pieces retained in the reactor tank at the time that produced aluminum chlorohydrate (ACH) is withdrawn from the reactor tank.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 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.

An anhydrous antiperspirant stick or soft solid composition comprising an antiperspirant active system, thickening agent, and non-aqueous carrier oil, characterised in that the particulate antiperspirant active system comprises an aluminium sesquichlorohyrate of formula AI.sub.2OH.sub.44CI.sub.1.6 to AI.sub.2OH.sub.4.9CI.sub.1.1 activated with a water soluble calcium salt.

Aluminum chlorohydrate salts having an amount of Peak 1 material relative based on a total of Peaks 3, 4, and 5 of at least 20% as measured by size exclusion chromatography, together with water treatment compositions, antiperspirant compositions, and oral care compositions, comprising the same, and methods for making and using the same.

In one aspect, methods of producing polyaluminum chlorides are described herein which, in some embodiments, provide increased reaction rates and/or reductions in stoichiometric excesses of aluminum feedstock. In some embodiments, a method of producing polyaluminum chloride comprises providing a feedstock comprising aluminum, contacting the feedstock with a solution comprising hydrochloric acid and one or more transition metal compounds, and catalyzing formation of the polyaluminum chloride with the one or more transition metals. As described further herein, the one or more transition metal compounds can comprise a transition metal coordination complex, transition metal salt, or mixtures thereof.

In one aspect, methods of producing polyaluminum chlorides are described herein which, in some embodiments, provide increased reaction rates and/or reductions in stoichiometric excesses of aluminum feedstock. In some embodiments, a method of producing polyaluminum chloride comprises providing a feedstock comprising aluminum, contacting the feedstock with a solution comprising hydrochloric acid and one or more transition metal compounds, and catalyzing formation of the polyaluminum chloride with the one or more transition metals. As described further herein, the one or more transition metal compounds can comprise a transition metal coordination complex, transition metal salt, or mixtures thereof.

A chemical agent including a fluorine-containing polyaluminum chloride, wherein the chemical agent has 4,500 to 100,000 ppm by mass of fluorine per part by mass of aluminum. Also disclosed is a method for producing a fluorine-containing polyaluminum chloride.