To maximize alumina production, it is vital that red mud be separated from sodium aluminate liquor. The following eight factors influence the effectiveness of separation and settling of red mud. Bauxite particle size varies from region to region.
To maximize alumina production, it is vital that red mud be separated from sodium aluminate liquor. The following eight factors influence the effectiveness of separation and settling of red mud. Bauxite particle size varies from region to region.
To maximize alumina production, it is vital that red mud be separated from sodium aluminate liquor. The following eight factors influence the effectiveness of separation and settling of red mud. Bauxite particle size varies from region to region.
To maximize alumina production, it is vital that red mud be separated from sodium aluminate liquor. The following eight factors influence the effectiveness of separation and settling of red mud. Bauxite particle size varies from region to region.
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TECHNOLOGY NOTE
Alumina
Factors affecting red mud
settling (Part I) To maximize alumina production, it is vital that red mud be Reactive Silica in Bauxite separated from sodium aluminate liquor to the fullest extent All bauxites contain silicates that are soluble in caustic. These possible. While many factors influence the effectiveness of silicates occur as separation and settling of red mud, Cytec’s experience has • Quartz (SiO2) shown that the following eight are the most common and • Kaolinite (Al2O3.2SiO2.2H2O) critical: • Halloysite (Al2O3.2SiO2.3H2O) and • Bauxite Particle Size • Kyanite (Al2O3.SiO2, found in Brazil). • Reactive Silica In Bauxite • Phosphorus Kyanite does not react with caustic. Kaolinite and Halloysite react • Goethite readily with caustic when digested under low temperatures, • Hematite to Goethite ratio while Quartz requires digestion temperatures above 200 ˚C. • High Slurry Feed Solids • Over-flocculation The reaction between silicates and caustic can be represented • Liquor Viscosity by the following equation:
This technology note, the first in a two-part series, discusses 6NaAlO2 + 6SiO2 g3(Na2O.Al2O3.2SiO2)X, the first three factors. The remainder are covered in the second part of the series. where X may be Na2CO3, NaCl, Na2SO4, or Na organics.
Bauxite Particle Size The compound formed by the reaction is called Bayer Sodalite The particle size of bauxite varies from region to region. or Desilication Product (DSP), and is eliminated from the Jamaican and Surinamese bauxite particles are typically of circuit with the red mud. As the level of reactive silica in finer size. As the particle size of bauxite decreases, the surface bauxite increases, so does the quantity of DSP. area of the mud generated grows larger. This increase in surface area results in a mud that does not compact well and DSP particles are fine and do not compact well. Mud that requires high doses of flocculants to settle at acceptable rates. contains high quantities of DSP therefore requires a high dose of flocculant to settle. However, despite high flocculant dosages, mud level control may be erratic and underflow densities poor.
All Rights Reserved Fax: 1(973) 357-3117 www.cytec.com US Toll Free: (800) 652-6013 Email: Cytec.mining@cytec.com When the level of reactive silica is below 3.5 percent, the problem of The reaction is not balanced, as apatite is variable. At low temper- inadequate settling is overcome by adding more flocculant. But as atures, carbonate apatite is formed, while at high temperatures, reactive silica exceeds 3.5 percent, the problem becomes difficult to hydroxy apatite is formed. Carbonate and hydroxy apatites are the manage. At this stage, polyacrylate/copolymer flocculants do not most insoluble calcium compounds in the Bayer Process. Their provide sufficient compaction of DSP particles. HXPAMs, such as insolubility results in a lack of Ca++ ions for bridging mud particles Cytec’s SUPERFLOC® HX flocculants, will settle mud containing high with flocculant, thus impeding settling. quantities of DSP but very high dosages will be required. Still, large amounts of HXPAM must be added to capture the fine DSP particles. To be continued in Part II of this series.
Phosphorus Cytec offers a range of technologies and products to
Phosphorus retards the flocculation of red mud by two main improve red mud settling in your plant. mechanisms: • In solution, phosphorus complexes with the mud surface and Your Cytec representative will be glad to evaluate your blocks the sites for flocculant attachment. processing operation and suggest reagent formulations that solve production problems, increase yields, cut costs and • Phosphorus consumes calcium, which is required for bridging increase overall efficiency. the negatively charged mud particles with the negatively charged flocculant. Updated 6/24/05 MCT-1075 Phosphorus can be controlled by the addition of lime or limestone. However, Cytec advises against using limestone, as it contributes to liquor carbonation. The reactions with limestone and lime can be represented by the following equations:
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