Bayer process, alumina produced

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 ... 

The principal method used in producing aluminum metal involves three major steps refining of bauxite by the Bayer process to produce alumina, electrolytic reduction of alumina by the Hall-Heroult process to produce aluminum, and casting of aluminum into ingots (Browning 1969 Dinman 1983 IARC 1984). 

Chemical beneficiation includes processes of separating the desired mineral from unwanted waste products, for example, by dissolution in a suitable solvent followed by filtration. The Bayer process for producing alumina is also a good example of chemical beneficiation. Bauxite contains many impurities. 

Starch is a polysaccharide found in many plant species. Com and potatoes are two common sources of industrial starch. The composition of starch varies somewhat in terms of the amount of branching of the polymer chains (11). Its principal use as a flocculant is in the Bayer process for extracting aluminum from bauxite ore. The digestion of bauxite in sodium hydroxide solution produces a suspension of finely divided iron minerals and siUcates, called red mud, in a highly alkaline Hquor. Starch is used to settle the red mud so that relatively pure alumina can be produced from the clarified Hquor. It has been largely replaced by acryHc acid and acrylamide-based (11,12) polymers, although a number of plants stiH add some starch in addition to synthetic polymers to reduce the level of residual suspended soHds in the Hquor. Starch [9005-25-8] can be modified with various reagents to produce semisynthetic polymers. The principal one of these is cationic starch, which is used as a retention aid in paper production as a component of a dual system (13,14) or a microparticle system (15). 

Recovery from Bayer Liquor. The significant amount of primary gallium is recovered from the alumina industry. The main source is the sodium aluminate Hquor from Bayer-process plants that produce large quantities of alumina. Several methods have been developed to recover gallium from Bayer Hquor. 

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. 

Thus operating cells need aluminum fluoride [7784-18-17, AIF., rather than cryoHte. Much aluminum fluoride is produced in a fluidized bed by the reaction of hydrofluoric acid gas and activated alumina made by partially calcining the alumina hydrate from the Bayer process... 

Shaped products used for adsorbent purposes are generally less sophisticated and therefore less expensive than catalytic products. In 1985, it was reported that 10,000 t/yr of activated alumina adsorbents were produced in the United States. North American producers of Bayer process-based activated aluminas include Alcoa, La Roche (formerly Kaiser Chemicals), Discovery, and Alcan. Gel-based activated aluminas are produced by La Roche, Vista, and several of the major catalyst manufacturers. In Europe, principal sources of supply are Rhc ne-Poulenc and Condea. 

Purification. Alumina, AI2O3, is produced by the Bayer process (1,9) (see Aluminum COMPOUNDS) which involves digestion foUowed by precipitation and calcination. High purity magnesia is extracted from natural brines and seawater by precipitation and calcination (1,9). 

Alumina produced by the Bayer process is precipitated and then calcined [Krawczyk, Ceramic Forum International, 67(7-8), 342-8 (1990)]. Aggregates are typically 20 to 70 [Lm, and have to be reduced. The standard product is typically made in continuous dry ball or vibra-toiy mills to give a product d o size of 3-7 [Lm, 98 percent finer than 45 [Lm. The mills are lined with wear-resistant alumina blocks, and balls or cylinders are used with an alumina content of 80-92 percent. The products containing up to 96 percent AI9O3 are used for bricks, kiln furniture, grinding balls and liners, high voltage insulators, catalyst carriers, etc. 

The first production of aluminum was by the chemical reduction of aluminum chloride with sodium. The electrolytic process, based on the fused salt electrolysis of alumina dissolved in cryolite, was independently developed in 1886 by C. M. Hall in America and P. L. Heroult in France. Soon afterwards a chemical process for producing pure alumina from bauxite, the commercial source of aluminum, was developed by Bayer and this led to the commercial production of aluminum by a combination of the Bayer and the Hall-Heroult processes. At present this is the main method which supplies all the world s needs in primary aluminum. However, a few other processes also have been developed for the production of the metal. On account of problems still waiting to be solved none of these alternative methods has seen commercial exploitation. 

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... 

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). 

Aluminum hydroxide (Al(OH)3), also known as alumina trihydrate or ATH, is produced using the Bayer process from the mineral bauxite (a crude form of aluminum hydroxide containing 40%-70%... 

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. 

Caustic soda, which has much wider application than soda ash in the chemical industry, was not produced in India until about 1940, presumably because it was little needed in industry until that time. It was used chiefly by the textile and soap industries, for which 25,000 tons were imported in 1938-1939. The emergence of three major products in later years increased the demand for caustic soda. These were viscous rayon, paper pulp, and alumina from Bayer process extraction of bauxite. 

The Bayer Process produces a highly alkaline spent liquor which when treated with gaseous CO2 precipitates dawsonite, NaAlC03(0H)2 which can be recovered as a useful by-product or recycled into the Bayer Process. Na and Al MAS NMR, CP and DOR have been used to provide detailed structural information on dawsonite and on the X-ray amorphous phase which occurs as an intermediate in its thermal decomposition to NaA102 (Bastow et al. 1995). The Na and Al NMR spectra of dawsonite from Bayer liquor revealed the presence of the minor impurity phases NaHC03 and Al(OH)3 which were too amorphous to be detected by X-ray powder diffraction. The NMR spectra of dawsonite heated at 350°C for 16 h suggested the amorphous intermediate material contains a mixture of disordered phases related to NaHC03, NaAlOa and an amorphous alumina (Bastow et al. 1995). 

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,... 

However, as land and raw material costs rise, alumina producers are driven to seek ways to decrease the volume or eliminate this red mud waste. Alcoa has devised the Alcoa-Bayer process to recover the formerly... 

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