A mass of solid aluminum carbide containing product is produced by a process in which a mixture is formed of an aluminum containing material and a carbonaceous material consisting of, containing or yielding carbon. Then the resulting mixture is heated to a temperature sufficient to react carbon of the carbonaceous material with the aluminum of the aluminum containing material to produce solid aluminum carbide. The solid aluminum carbide then is able to be heated with an aluminum compound selected from Al2O3, Al4CO4, AlO, Al2O and mixtures thereof, to produce aluminum metal and carbon monoxide.