An examination of the applicability of hydrotalcite for removing oxalate anions from Bayer process solutions

Hydrotalcite and thermally activated hydrotalcites were examined for their potential as methods for the removal of oxalate anions from Bayer Process liquors. Hydrotalcite was prepared and characterised by a number of methods, including X-ray diffraction, thermogravimetric analysis, nitrogen adsorption analysis and vibrational spectroscopy. Thermally activated hydrotalcites were prepared by a low temperature method and characterised using X-ray diffraction, nitrogen adsorption analysis and vibrational spectroscopy. Oxalate intercalated hydrotalcite was prepared by two methods and analysed with X-ray diffraction and for the first time thermogravimetric analysis, Raman spectroscopy and infrared emission spectroscopy. The adsorption of oxalate anions by hydrotalcite and thermally activated hydrotalcite was tested in a range of solutions using both batch and kinetic adsorption models.

Removing organic impurities from bayer process liquors

A process for treating a Bayer liquor by wet oxidn. to oxidize org. contaminants in the Bayer liquor in which the wet oxidn. process is conducted in the presence of a mixed Ce/Mn oxide. The catalyst may have nano-sized grains, and be supported on a mesoporous oxide support. The catalyst may also contain a platinum group metal. [on SciFinder(R)]

Determination of sodium oxalate in Bayer process liquors using flow analysis with tris(2,2'-bipyridyl)ruthenium(II) chemiluminescence detection

The research was a detailed investigation into a challenging analytical chemistry problem for the alumina industry. The successful outcomes were derived through innovative reagent chemistry and novel instrumental development. The resultant methodology and instrumentation deployed on this most demanding sample matrix is more robust, reliable and less expensive than anything currently used in this industry worldwide.

Stability of hydrotalcites formed from Bayer refinery environmental control processes

Bauxite refinery residues (red mud) are derived from the Bayer process by the digestion of crushed bauxite in concentrated sodium hydroxide at elevated temperatures and pressures. This slurry residue, if untreated, is unsuitable for discharge directly into the environment and is usually stored in tailing dams. The liquid portion has the potential for discharge, but requires pre-treatment before this can occur. The seawater neutralisation treatment facilitates a significant reduction in pH and dissolved metal concentrations, through the precipitation of hydrotalcite-like compounds and some other Mg, Ca, and Al hydroxide and carbonate minerals. The hydrotalcite-like compounds, precipitated during seawater neutralisation, also remove a range of transition metals, oxy-anions and other anionic species through a combination of intercalation and adsorption reactions: smaller anions are intercalated into the hydrotalcite matrix, while larger molecules are adsorbed on the particle surfaces. A phenomenon known as ‘reversion’ can occur if the seawater neutralisation process is not properly controlled. Reversion causes an increase in the pH and dissolved impurity levels of the neutralised effluent, rendering it unsuitable for discharge. It is believed that slow dissolution of components of the red mud residue and compounds formed during the neutralisation process are responsible for reversion. This investigation looked at characterising natural hydrotalcite (Mg6Al2(OH)16(CO3)∙4H2O) and ‘Bayer’ hydrotalcite (synthesised using the seawater neutralisation process) using a variety of techniques including X-ray diffraction, infrared and Raman spectroscopy, and thermogravimetric analysis. This investigation showed that Bayer hydrotalcite is comprised of a mixture of 3:1 and 4:1 hydrotalcite structures and exhibited similar chemical characteristic to the 4:1 synthetic hydrotalcite. Hydrotalcite formed from the seawater neutralisation of Bauxite refinery residues has been found not to cause reversion. Other components in red mud were investigated to determine the cause of reversion and this investigation found three components that contributed to reversion: 1) tricalcium aluminate, 2) hydrocalumite and 3) calcium hydroxide. Increasing the amount of magnesium in the neutralisation process has been found to be successful in reducing reversion.

Determination of sodium oxalate in Bayer liquor using flow-analysis incorporating an anion exchange column and tris(2,2`-bipyridyl)ruthenium(II) chemiluminescence detection

Semi-automated flow injection instrumentation, incorporating a small anion exchange column coupled with tris(2,2′-bipyridyl)ruthenium(II) (Ru(bipy)₃²⁺) chemiluminescence detection, was configured and utilised to develop rapid methodology for the determination of sodium oxalate in Bayer liquors. The elimination of both negative and positive interferences from aluminium(III) and, as yet, unknown concomitant organic species, respectively are discussed. The robustness of the methodology was considerably enhanced by using the temporally stable form of the chemiluminescence reagent, tris(2,2′-bipyridyl)ruthenium(III) perchlorate in dry acetonitrile. Real Bayer process samples were analysed and the results obtained compared well with those performed using standard methods within industrial laboratories.

Estudo hidrometalúrgico de compostos de titânio proveniente do resíduo do processo Bayer

Estudos realizados no resíduo do processo Bayer, lama vermelha, para reciclagem desse material têm sido intensificados por suas características físico-químicas. O resíduo é constituído por inúmeros óxidos, destes se destaca o óxido de ferro em teores acima de 30% em peso e óxido de titânio em concentrações acima de 5% em peso. Este trabalho estuda a possibilidade de extrair óxido de ferro, objetivando a concentração de compostos de titânio. A extração foi realizada através do processo de calcinação da lama vermelha a 900°C seguida de lixiviação ácida com concentração de H2SO4 a 20% e 30% em volume a 60°C, 80°C e 90°C, com retirada de uma alíquota a cada 30 minutos. Durante o processo de lixiviação, foi observada extração intensa dos compostos de ferro, resultando no aumento da concentração de titânio na lama vermelha, verificado em todos os experimentos, com destaque para os que foram realizados a 90°C e H2SO4 a 30% em v/v, onde houve extração de 95% de ferro e concentração de até 14% de titânio considerando o balanço de massa global. Diante dos dados obtidos, a lama vermelha torna-se um material interessante para ser utilizado como fonte alternativa para obtenção de minerais de titânio, os quais são encontrados na natureza com um percentual em torno de 8%.

Estudo e avaliação do uso de resíduos do processo Bayer como matéria-prima na produção de agregados sintéticos para a construção civil

A grande quantidade de resíduos sólidos, oriundos da indústria de mineração e metalurgia, constitui um sério problema sócio-ambiental. As características físicoquímicas destes resíduos despertam grande interesse para outras indústrias. A indústria cerâmica pode ser uma interessante consumidora da maioria deste material, para suprir a grande escassez das reservas de matérias-primas atual. Neste contexto, este trabalho mostra os estudos realizados para a reciclagem da lama vermelha, como matéria-prima na produção de agregado sintético, visando à construção civil. A lama vermelha, principal rejeito industrial da fabricação de alumina, mostrou-se um insumo de grande interesse na fabricação de diferentes tipos de agregado para ser utilizado na produção de concreto, para a construção civil. Pelas suas características físico-químicas e a grande quantidade que é produzida anualmente (cerca de 10.000.000 t em duas fábricas, só no Norte do Brasil). Estudos realizados neste trabalho mostram a possibilidade de fabricação de agregados, com diferentes propriedades e possibilidades de aplicação, na indústria da construção civil. Estas propriedades dependem do controle de parâmetros, como o teor de sílica livre e argila, a granulometria e a temperatura de sinterização. Tais variáveis permitem controlar perfeitamente a formação de fase vítrea que é a responsável pelas propriedades dos agregados como: porosidade, resistência mecânica e densidade. Este material pode ser utilizado em concreto convencional ou em concretos especiais, para atender a demanda da construção civil.

Minimization of bauxite residue neutralization products using nanofiltered seawater

Currently, open circuit Bayer refineries pump seawater directly into their operations to neutralize the caustic fraction of the Bayer residue. The resulting supernatant has a reduced pH and is pumped back to the marine environment. This investigation has assessed modified seawater sources generated from nanofiltration processes to compare their relative capacities to neutralize bauxite residues. An assessment of the chemical stability of the neutralization products, neutralization efficiency, discharge water quality, bauxite residue composition, and associated economic benefits have been considered to determine the most preferable seawater filtration process based on implementation costs, savings to operations and environmental benefits. The mechanism of neutralization for each technology was determined to be predominately due to the formation of Bayer hydrotalcite and calcium carbonate, however variations in neutralization capacity and efficiencies have been observed. The neutralization efficiency of each feed source has been found to be dependent on the concentration of magnesium, aluminium, calcium and carbonate. Nanofiltered seawater with approximately double the amount of magnesium and calcium required half the volume of seawater to achieve the same degree of neutralization. These studies have revealed that multiple neutralization steps occur throughout the process using characterization techniques such as X-ray diffraction (XRD), infrared (IR) spectroscopy and inductively coupled plasma optical emission spectroscopy (ICP-OES).

Characterisation of red mud and seawater neutralised red mud using vibrational spectroscopic techniques

Bauxite refinery residues are derived from the Bayer process by the digestion of crushed bauxite in concentrated caustic at elevated temperatures. Chemically, it comprises, in varying amounts (depending upon the composition of the starting bauxite), oxides of iron and titanium, residual alumina, sodalite, silica, and minor quantities of other metal oxides. Bauxite residues are being neutralised by seawater in recent years to reduce the alkalinity in bauxite residue, through the precipitation of hydrotalcite-like compounds and some other Mg, Ca, and Al hydroxide and carbonate minerals. A combination of X-ray diffraction (XRD) and vibrational spectroscopy techniques, including mid-infrared (IR), Raman, near-infrared (NIR), and UV-Visible, have been used to characterise bauxite residue and seawater neutralised bauxite residue. Both the ferrous (Fe2+) and ferric (Fe3+) ions within bauxite residue can be identified by their characteristic NIR bands, where ferrous ions produce a strong absorption band at around 9000 cm-1, while ferric ions produce two strong bands at 25000 and 14300 cm-1. The presence of adsorbed carbonate and hydroxide anions can be identified at around 5200 and 7000 cm-1, respectively, attributed to the 2nd overtone of the 1st fundamental overtones observed in the mid-IR spectra. The complex bands in the Raman and mid-IR spectra around 3500 cm-1 are assigned to the OH stretching vibrations of the various oxides present in bauxite residue, and water. The combination of carbonate and hydroxyl units and their fundamental overtones give rise to many of the features of the NIR spectra.

An investigation of goethite-seeded Al(OH)3 precipitation using in situ X-ray diffraction and Rietveld-based quantitative phase analysis

An in situ X-ray diffraction investigation of goethite-seeded Al(OH)3 precipitation from synthetic Bayer liquor at 343 K has been performed. The presence of iron oxides and oxyhydroxides in the Bayer process has implications for alumina reversion, which causes significant process losses through unwanted gibbsite precipitation, and is also relevant for the nucleation and growth of scale on mild steel process equipment. The gibbsite, bayerite and nordstrandite polymorphs of Al(OH)3 precipitated from the liquor; gibbsite appeared to precipitate first, with subsequent formation of bayerite and nordstrandite. A Rietveld-based approach to quantitative phase analysis was implemented for the determination of absolute phase abundances as a function of time, from which kinetic information for the formation of the Al(OH)3 phases was determined.

The roles of adsorption in hydrate precipitation

It has been well established that organic compounds with adjacent hydroxyl groups in Bayer process liquor can inhibit gibbsite precipitation by acting as seed poisons. The degree of inhibition is a function of the number and stereochemistry of the hydroxyl groups. Seed poisons generally adsorb strongly onto hydrate surfaces, implying that surface coverage is the mechanism for yield inhibition. There are examples however of organics that strongly adsorb but do not lead to yield inhibition. There is a possibility that this apparent contradiction may be an artifact of differences in conditions between the adsorption and precipitation experiments. The present work investigates the adsorption and inhibition effects of a range of compounds under strictly similar conditions to clarify the role of adsorption on yield inhibition.

Design and construction of geocell foundation to support the embankment on settled red mud

This paper presents the case history of the construction of a 3 m high embankment on the geocell foundation over the soft settled red mud. Red mud is a waste product from the Bayer process of Aluminum industry. Geotechnical problems of the site, the design of the geocell foundation based on experimental investigation and the construction sequences of the geocell foundations in the field are discussed in the paper. Based on the experimental studies, an analytical model was also developed to estimate the load carrying capacity of the soft clay bed reinforced with geocell and combination of geocell and geogrid. The results of the experimental and analytical studies revealed that the use of combination of geocell and the geogrid is always beneficial than using the geocell alone. Hence, the combination of geocell and geogrid was recommended to stabilize the embankment base. The reported embankment is located in Lanjigharh (Orissa) in India. Construction of the embankment on the geocell foundation has already been completed. The constructed embankmenthas already sustained two monsoon rains without any cracks and seepage. (C) 2013 Elsevier Ltd. All rights reserved.

拜耳法赤泥放射性特征及应用途径研究

赤泥是氧化铝生产过程中的工业固体废弃物,具有强碱性和高放射性两个特点。目前赤泥的处置方法主要是建设赤泥堆场，供长期堆放，尚没有对其进行大规模利用的成熟技术。 随着铝工业的发展，亟需开发赤泥处置与资源化利用的新工艺技术。本论文运用环境地球化学的理论方法，采用化学分析、选矿分离、放射性测试等技术手段，对贵州铝厂拜耳法赤泥的放射性特征进行了矿物学研究，并利用铁钛着色机理生产赤泥墙体装修材料进行了应用试验研究，指明了赤泥规模化综合利用的途径。 通过研究，得到以下主要结论： 1）初步确定了赤泥放射性元素主要来源于铝土矿原矿，并赋存于原矿残留的锆石和独居石中。 2) 贵州铝厂拜耳法赤泥所含放射性偏高，倘若利用赤泥制作建筑主体材料，需要慎重考虑。 3）探讨了不同选矿方法对赤泥放射性强度的变化情况，重选、磁选、加磁粉磁选所得赤泥组分与赤泥原样放射性相比较，没有显著性差异。采用现有选矿技术，难以达到分离富集赤泥中含放射性组分。 4）利用拜耳法赤泥中富含Fe2O3和TiO2的着色机理，加入一定量的页岩可以制得金红-褐色系列颜色的彩色墙体装修材料。采用现有烧结砖厂一般生产工艺，利用拜耳法赤泥生产烧结制品，是规模化处理赤泥的一条可行途径。 本论文的研究结果指明了赤泥可行的利用途径是用于建材领域，为制定赤泥大规模资源化利用的技术路线提供了一定的理论基础。

Effects of seawater-neutralised bauxite refinery residue on properties of concrete

Various industrial by-products, such as fly ash, ground granulated blast-furnace slag and silica fume, have been used in concrete to improve its properties. This also enables any environmental issues associated with their disposal. Another material that is available in large quantities and requiring alternative methods of disposal is the Bauxite Refinery Reside (BRR) from the Bayer process used to extract alumina from bauxite. As this is highly caustic and causes many health hazards, Virotec International Ltd. developed a patented technology to convert this into a material that can be used commercially, known as Bauxsol™, for various environmental remediation applications. This use is limited to small quantities of seawater-neutralised BRR and hence an investigation was carried out to establish its potential utilisation as a sand replacement material in concrete. In addition to fresh properties of concrete containing seawater-neutralised BRR up to 20% by mass of Portland cement, mechanical and durability properties were determined. These properties indicated that seawater-neutralised BRR can be used to replace natural sand up to 10% by mass of cement to improve the durability properties of concrete without detrimentally affecting their physical properties. Combining these beneficial effects with environmental remediation applications, it can be concluded that there are specific applications where concretes containing seawater-neutralised BRR could be used.