Aluminum oxide Bayer process

There are several processes available for the manufacture of cryoHte. The choice is mainly dictated by the cost and quaUty of the available sources of soda, alumina, and fluoriae. Starting materials iaclude sodium aluminate from Bayer s alumina process hydrogen fluoride from kiln gases or aqueous hydrofluoric acid sodium fluoride ammonium bifluoride, fluorosiUcic acid, fluoroboric acid, sodium fluosiUcate, and aluminum fluorosiUcate aluminum oxide, aluminum sulfate, aluminum chloride, alumina hydrate and sodium hydroxide, sodium carbonate, sodium chloride, and sodium aluminate. 

A commercial process which uses hydrothermal leaching on a large scale is the Bayer process for production of aluminum oxide (see Aluminum compounds). This process is used to extract and precipitate high grade alurninum hydroxide (gibbsite [14762-49-3]) from bauxite [1318-16-7] ore. The hydrothermal process step is the extraction step in which concentrated sodium hydroxide is used to form a soluble sodium aluminate complex ... 

Aluminum. All primary aluminum as of 1995 is produced by molten salt electrolysis, which requires a feed of high purity alumina to the reduction cell. The Bayer process is a chemical purification of the bauxite ore by selective leaching of aluminum according to equation 35. Other oxide constituents of the ore, namely siUca, iron oxide, and titanium oxide remain in the residue, known as red mud. No solution purification is required and pure aluminum hydroxide is obtained by precipitation after reversing reaction 35 through a change in temperature or hydroxide concentration the precipitate is calcined to yield pure alumina. 

Small amounts of sodium aluminate are prepared in the lab by fusion of equimolar quantities of sodium carbonate [497-19-8] and aluminum acetate [139-12-8], A1(C2H202)3, at 800°C (4). Other methods involve reaction of sodium hycboxide with amorphous alumina or aluminum [7429-90-5] metal. Commercial quantities of sodium aluminate are made from hydrated alumina, in the form of aluminum hydroxy oxide [24623-77-6], AIO(OH), or aluminum hycboxide [21645-51 -2], Al(OH)3, a product of the Bayer process (5,6) which is used to refine bauxite [1318-16-7], the principal aluminum ore. 

Aluminum is the most abundant metallic element in the Earth s crust and, after oxygen and silicon, the third most abundant element (see Fig. 14.1). However, the aluminum content in most minerals is low, and the commercial source of aluminum, bauxite, is a hydrated, impure oxide, Al203-xH20, where x can range from 1 to 3. Bauxite ore, which is red from the iron oxides that it contains (Fig. 14.23), is processed to obtain alumina, A1203, in the Bayer process. In this process, the ore is first treated with aqueous sodium hydroxide, which dissolves the amphoteric alumina as the aluminate ion, Al(OH)4 (aq). Carbon dioxide is then bubbled through the solution to remove OH ions as HCO and to convert some of the aluminate ions into aluminum hydroxide, which precipitates. The aluminum hydroxide is removed and dehydrated to the oxide by heating to 1200°C. 

All the silica present in the bauxite was converted to insoluble sodium aluminosilicate, which represented a loss of sodium and aluminum. The aluminum hydroxide was calcined to the oxide, and the sodium carbonate solution was concentrated for re-use. The process was developed by H. E. St-Claire Deville in the 1860s the carbon dioxide stage had been invented earlier by H. L. Le Chatelier. It was superseded by the Bayer process. 

Bauxite is the most abundant ore of aluminum. The first step in extracting aluminum from bauxite is called the Bayer process. The Bayer process involves a fractional precipitation of impurities, including iron(lll) oxide and titanium dioxide. Search the Internet to find the history of the Bayer process and learn how it works. Present your findings as a poster. To start your search, go to the web site above and click on Web Links. 

The production of aluminum actually involves several steps. Bauxite is the ore that contains aluminum oxide (Al Oj) used to produce aluminum. Impurities of iron, sulfur, silicon and other elements are removed from bauxite using the Bayer process to produce purified alumina. The Bayer process, patented in 1887 by Austrian Karl Josef Bayer (1847-1904), involves pulverizing bauxite and treating it with a hot sodium hydroxide solution to produce sodium alu-minate (NaA102). Sodium aluminate is then placed in a reactor in which temperature and pressure can be varied to precipitate out impurities. The sodium aluminate solution is then hydrolyzed to produce purified alumina ... 

Iron(III) oxide or alumina is refined from bauxite. Approximately 175 million tons of bauxite are mined annually worldwide, with virtually all of this processed into alumina. Alumina is a white crystalline substance that resembles salt. Approximately 90% of all alumina is used for making aluminum, with the remainder used for abrasives and ceramics. Alumina is produced from bauxite using the Bayer process patented in 1887 by Austrian Karl Josef Bayer (1847-1904). The Bayer process begins by grinding the bauxite and mixing it with sodium hydroxide in a digester. The sodium hydroxide dissolves aluminum oxide components to produce aluminum hydroxide compounds. For gibbsite, the reaction is Al(OH)3 + NaOH —> Al(OH)4 + Na+. Insoluble impurities such as silicates, titanium oxides, and iron oxides are removed from the solution while sodium hydroxide is recovered and recycled. Reaction conditions are then... 

Alkali leach methods axe exemplified by the Bayer process for the preparation of pure a-A C for electrolysis (Section 17.5) from the mineral bauxite. Bauxite consists mainly of a-AlO(OH) (diaspore) and/or 7-A10(0H) (boehmite), the difference between these being essentially that the oxygen atoms form hep and ccp arrays, respectively. The chief contaminants are silica, some clay minerals, and iron(III) oxides/hydroxides, which impart a red-brown color to the mineral. Aluminum (III) is much more soluble than iron(III) or aluminosilicates in alkali, so that it can be leached out with aqueous NaOH (initially 10-15 mol L 1) at 165 °C under approximately 0.6 MPa pressure, leaving a red mud of iron (and other transition metal) oxides/hydroxides and aluminosilicates ... 

The high stability of the aluminate ion allows the production of concentrated solutions of aluminum with the virtual exclusion of the main metallic impurity, viz. iron as an oxide residue. The resultant impure aluminate solution is clarified and its temperature reduced when the reverse of the above reaction occurs with the formation of A1203,3H20 by a slow crystallization procedure. The high-purity alumina trihydrate product is calcined and then reduced electrochemically in a molten fluoride bath by the well-known Hall-Heroult process. The major problems in the Bayer process have their origin in the coordination chemistry of aluminum in alkaline solutions. The... 

Gallium is a minor constituent in bauxite, A1203 x H20, and like aluminum, forms an amphoteric oxide, Ga203. Explain how the Bayer process makes it possible to separate Ga203 from Fe203, which is also present in bauxite. Write a balanced net ionic equation for the reaction. 

Aluminum oxide is produced during the recovery of bauxite, which is crushed, ground, and kiln dried, followed by leaching with sodium hydroxide, forming sodium aluminate, from which alumina trihydrate is precipitated and calcined (Bayer process) (HSDB 1995). 

In the aluminum oxide system the precipitation pH is one of the variables which controls the nature of the phase eventually obtained. However, aging conditions of the initially formed amorphous precipitate are at least equally important. In general, it can be stated that precipitation above pH = 8 leads to the formation of bayerite, while precipitation under more acidic conditions favors the subsequent formation of boehmite. Hydrargillite is formed as the product of the Bayer process by seeding a supersaturated alkali containing aluminum solution. The formation of bayerite is strongly facilitated by the presence of alkali cations which stabilize the structure. 

Aluminum is the second most abundant metal on earth s crust. It is a common metal in tropical soils called laterites (red soils). It is extracted from bauxite that is a rich laterite by Bayer process that involves dissolution and separation of the oxide in caustic soda solution between 150 and 250°C and 20 atm of pressure. Though abundant and inexpensive, alumina based CBPCs are difficult to form because even in an acid solution the solubility of alumina is very low. This solubility, however, can be enhanced by a mUd thermal treatment and suitable CBPCs can be formed. Alumina is available commercially as calcined alumina called corundum, or as its hydrated forms such as aluminum hydroxide (Al(OH)3), as bohmite, (A1203-3H20), gibbsite (AI2O3 H2O) or in impure forms as in kaolin clay. These mineral forms and their use in ceramic formation are discussed in Chapter 11. 

One of the most important developments in the field of hydrometallurgy has been the application of elevated pressures and temperatures to complex sulfide and oxide ores (B21, F8, G8, M5, M6). The pressure-leaching of bauxite ores by the Bayer process (E3) is probably the first successful commercial application of this technique. The bauxite ore is leached with sodium hydroxide solution with a specific gravity of 1.36-1.4 at 160-170°C for 1 2 hr under a working pressure of 100 psig. The alumina is produced by calcining the aluminum hydrate precipitated from the leach liquor. 

In the first step in this process, aluminum oxide is separated from other oxides (such as oxides of iron) with which it also occurs by the Bayer process. In the Bayer process, the naturally occurring oxide mixture is added to sodium hydroxide, which dissolves out aluminum... 

Bayer process—process in which sodium hydroxide is added to a mixture of naturally occurring oxides so that aluminum oxide is dissolved out of the mixture. 

Aluminum production is a two-step process. First, aluminum oxide is separated from bauxite by the Bayer process. In this process, bauxite is mixed with sodium hydroxide (NaOH), which dissolves the aluminum oxide. The other compounds in bauxite are left behind. 

The industrial manufacture of aluminum hydroxide and aluminum oxide currently proceeds almost exclusively by the Bayer process i.e. by wet digestion of bauxite. The sinter- and melt-digestion processes with sodium carbonate and/or lime only have minor industrial importance. 

In the Bayer process, ground bauxite is digested with aqueous sodium hydroxide (200 to 350 g/L sodium hydroxide) at temperatures of 140 to 250°C in autoclaves or in continuous tube reactors, in which the hydrated aluminum hydroxide is dissolved as sodium aluminate. The iron-containing very finely divided so-called red mud is then separated in thickening and filter units and washed. Ca. 1 to 2 t of red mud is produced per t aluminum oxide. 

Sodium aluminate (theoretical formula NaA102) has a certain industrial importance not only as an intermediate in the digestion of bauxite in the Bayer process (see Section 3.2.4.2). USA production of sodium aluminate in 1993 was estimated to be 85 10- t/a. Sodium aluminate is produced by dissolving hydrated aluminum oxide in 50% sodium hydroxide. It is utilized in water purification, in the paper industry, for the post-treatment of Ti02-pigments, for the manufacture of aluminum-containing... 

Aluminum is the third most abundant element in the earth s crust (after oxygen and silicon), accounting for 8.2% of the total mass. It occurs most commonly in association with silicon in the aluminosilicates of feldspars and micas and in clays, the products of weathering of these rocks. The most important ore for aluminum production is bauxite, a hydrated aluminum oxide that contains 50% to 60% AI2O3 1% to 20% FeiOs 1% to 10% silica minor concentrations of titanium, zirconium, vanadium, and other transition-metal oxides and the balance (20% to 30%) water. Bauxite is purified via the Bayer process, which takes advantage of the fact that the amphoteric oxide alumina is soluble in strong bases but iron(III) oxide is not. Crude bauxite is dissolved in sodium hydroxide... 

The most common technique used to prepare the /i-type (i.e., or / ") alumina is to mechanically blend the component oxides or precursor compounds in powder form prior to a calcination or prereaction step at temperatures between 1000 and 1260°CT Commercially available aluminum oxide powders (0.3-0.5 pm average crystallite size) in the alpha (corundum) polymorph are typically usedT They are derived from three common sources decomposition of gibbsite [Al(OH)3], which is precipitated from soda liquors in the Bayer process preparation and decomposition of alum salts and preparation from aluminum chloride precursors NaaCOs is usually the source of Na20. Sources of Li20 have included Li2C03, LiNOs, and Li2C204- MgO is usually added as the commercially available oxide. 

Good descriptions of the production of aluminum can be found in the literature (Grjotheim etal. [7], Grjotheim and Welch [8], Grjotheim and Kvande [9], Burkin [10], and Peterson and Miller [11]). Referring to Fig. 2 [12], the first step in the production of aluminum from its ore ( bauxite ) is the selective leaching of the aluminum content (present as oxides/hy dr oxides of aluminum) into hot concentrated NaOH solution to form sodium aluminate in solution. After solution purification, very pure aluminum hydroxide is precipitated from the cooled, diluted solution by addition of seed particles to nucleate the precipitation. After solid-liquid separation the alumina is dried and calcined. These operations are the heart of the Bayer process and the alumina produced is shipped to a smelter where the alumina, dissolved in a molten salt electrolyte, is electrolyt-ically reduced to liquid aluminum in Hall- Heroult cells. This liquid aluminum,... 

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