Sustainable utilization of Bauxite Residue (BR) is currently one of the greatest challenges being tackled by the alumina industry, due to its high production rates and limited reuse options. The present work is concerned with the use of BR as a candidate metallurgical raw material for iron (Fe) production and aluminum (Al) extraction. In more detail, at first, BR undergoes reductive smelting to extract its Fe content and produce a slag of mainly calcium aluminate composition. In a second step, Al contained in the calcium aluminate phases is extracted hydrometallurgically by leaching with a Na2CO3 aqueous solution. The focus of the current study is the optimization of this leaching process, and it was performed in two stages. The first was a laboratory scale investigation on the main parameters affecting the extraction rate of Al. The second stage was performed in pilot scale and incorporated observations and suggestions based on the laboratory scale investigation. Laboratory work showed that more than 50% of aluminum could be easily extracted in less than 1 h, in 5% S/L, at 70 °C and with an 20% excess of Na2CO3. Pilot scale work, by successfully applying the suggestions derived from laboratory scale work, achieved an average Al extraction of 68% from a 10% S/L pulp, with a slag of optimized composition in relation to the one used in the laboratory scale.
Leaching experiments were performed in calcium aluminate slag with a high-sodium carbonate adaptation of the Pedersen process. A theoretical thermodynamic study of the pregnant leaching solution was conducted to specify the thermodynamically favored species that exist within. Using the HSC 9.0 software, a carbonation process simulation (neutralization of the aluminate solution with CO2 gas) was simulated. Laboratory carbonation experiments were conducted to verify the theoretical predictions. According to the thermodynamic study, at temperatures below 50 °C gibbsite precipitates in the first stages of carbonation and then is transformed to dawsonite. Temperatures over 65 °C favor the direct precipitation of dawsonite. The same route (thermodynamic analysis, carbonation simulation, and experimental verification) was followed by a synthetic solution containing lower amount of sodium carbonate to prove that dawsonite precipitation occurred as a result of the high free carbonate content, to investigate the effect of temperature and to precipitate alumina hydrate phases.
Graphical Abstract
This study investigates applying the principles of the long-discontinued Pedersen process as a possible route for producing metallurgical grade alumina from low-grade and secondary feed materials. The investigation focused on the hydrometallurgical steps in the process, namely leaching, desilication, and precipitation, and adapting it to valorize bauxite residue. The test material used was a calcium–aluminate slag made by the smelting-reduction of a mixture of bauxite residue (dewatered red mud) and a calcium-rich bauxite beneficiation by-product. Samples of the slag were leached in a 1 L jacketed glass reactor with Na2CO3 solution, varying Na2CO3 concentration and leaching time. Additionally, different approaches to leaching involving mechanical treatment of the leached slag and re-leaching using either fresh or recycled solution were also explored. The desilication step was carried out by treating the leachate solution with powdered CaO, varying the amounts of CaO used. Finally, the desilicated leach solution was sparged with a CO2 gas mixture, after which the precipitate was allowed to age in the solution. The carbonation and aging temperatures and times were varied. As much as 67% of the Al was leached from the slag. The desilication process successfully removed 88% of the Si. The precipitation process produced a product composed mostly of bayerite [Al(OH)3], but some tests had considerable amounts of the unwanted phase dawsonite [NaAlCO3(OH)2]. The results indicated that the highest Al recovery was obtained using low concentrations of Na2CO3 solutions, and aluminum tri hydroxide is formed from these solutions at low temperatures at a fast rate compared to higher solution concentrations and temperatures.
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