Digestion mechanism and crystal simulation of roasted low-grade high-sulfur bauxite

Low-grade high-sulfur bauxite was pretreated via suspension roasting and muffle furnace roasting to remove sulfur and enhance digestion properties.The results show that sulfur can be efficiently removed,and the alumina digestion properties are significantly improved after suspension roasting.Under optimal conditions(t=70 min,T=280°C,w(CaO)=8%and Nk=245 g/L),the digestion ratios are 94.45%and 92.08%for the suspension-roasted and muffle-roasted ore,respectively,and the apparent activation energies are 63.26 and 64.24 kJ/mol,respectively.Two crystal models were established by Materials Studio based on the XRD patterns.The DFT simulation shows that the existing Al—O bands after suspension roasting can improve alumina digestion.The(104)and(113)planes of Al2O3 after suspension roasting are found to combine with NaOH more easily than those of Al2O3 treated in a muffle furnace.

Removal and recovery of titanium(Ⅳ) from leach liquor of high-sulfur bauxite using calcium alginate microspheres impregnated with di-(2-ethylhexyl) phosphoric acid

In the leaching solution of high-sulfur bauxite roasted by sulfuric acid,a high concentration of aluminum presented along with titanium and iron.The present work was to remove Ti(IV)from the leach liquor by calcium alginate microsphere sorbent material(CA-P204)based on natural alginate impregnated with di-(2-ethylhexyl)phosphoric acid(D2EHPA)to purify leaching solution.Cation exchange and chelation make major contributions to the adsorption mechanism according to Fourier-transform infrared spectroscopy and X-ray photoelectron spectroscopy analysis.The results showed that Ti(IV)was successfully removed by the CA-P204 adsorbent from the Ti(IV)-Al(III)-Fe(III)ternary system with a dynamic column experiment.The removal rate of titanium was nearly 95%under optimal conditions and the maximum adsorption capacity was 66.79 mg/g at pH 1.0.Reusability of CA-P204 was evaluated over three consecutive adsorption/desorption cycles.The adsorption process was simple,low-cost,and had no waste discharge,suggesting that the CA-P204 was promising,efficient,and economical for removing Ti(IV)from high-sulfur bauxite leaching solution.

Research progress on desulfurization technology of high-sulfur bauxite

Bauxite is the main raw material of the alumina industry.However,high-sulfur bauxite constitutes a relatively large proportion of bauxite resource in China.Excessive sulfur impurities in bauxite have significant impact on the Bayer process,such as corrosion of equipment and pipelines,increased consumption of alkali,and difficulties in sedimentation of red mud particles after digestion.As the mainstreams of bauxite desulfurization technologies,the bauxite pre-desulfurization(roasting,electrochemistry,biology,flotation,etc)and Bayer process desulfurization(oxidation and precipitation)need to be fully understood for the further improvement of desulfurization performance.Here,an in-depth review on their mechanisms and advantages/disadvantages is presented.

Suspension calcination and alkali leaching of low-grade high-sulfur bauxite:Desulfurization, mineralogical evolution and desilication

To enable the utilization of low-grade and high-sulfur bauxite, the suspension calcination was used to remove the sulfur and the activate silica minerals, and the calcinated bauxite was subjected to a desilication process in Na OH solution under atmospheric pressure. The desulfurization and desilication properties and mineralogical evolution were studied by X-ray diffraction, thermogravimetry–differential thermal analysis, scanning electron microscopy, and FactSage methods. The results demonstrate that the suspension calcination method is efficient for sulfur removal: 84.21% of S was removed after calcination at 1000°C for 2 min. During the calcination process, diaspore and pyrite were transferred to α-Al2O3, magnetite, and hematite. The phase transformation of pyrite follows the order FeS2 → Fe3O4 → Fe2O3, and the iron oxides and silica were converted into iron silicate. In the alkali-soluble desilication process, the optimum condition was an alkali solution concentration of 110 g/L, a reaction time of 20 min, and a reaction temperature of 95°C. The corresponding desilication ratio and alumina loss ratio were 44.9% and 2.4%, respectively, and the alumina-to-silica mass ratio of the concentrate was 7.9. The Al2O3·2SiO2, SiO2, and Al2O3 formed during the calcination process could react with Na OH solution, and their activity decreased in the order of Al2O3·2 SiO2, SiO2, and Al2O3.

Reservoir characteristics and formation model of Upper Carboniferous bauxite series in eastern Ordos Basin,NW China

Through core observation,thin section identification,X-ray diffraction analysis,scanning electron microscopy,and low-temperature nitrogen adsorption and isothermal adsorption experiments,the lithology and pore characteristics of the Upper Carboniferous bauxite series in eastern Ordos Basin were analyzed to reveal the formation and evolution process of the bauxite reservoirs.A petrological nomenclature and classification scheme for bauxitic rocks based on three units(aluminum hydroxides,iron minerals and clay minerals)is proposed.It is found that bauxitic mudstone is in the form of dense massive and clastic structures,while the(clayey)bauxite is of dense massive,pisolite,oolite,porous soil and clastic structures.Both bauxitic mudstone and bauxite reservoirs develop dissolution pores,intercrystalline pores,and microfractures as the dominant gas storage space,with the porosity less than 10% and mesopores in dominance.The bauxite series in the North China Craton can be divided into five sections,i.e.,ferrilite(Shanxi-style iron ore,section A),bauxitic mudstone(section B),bauxite(section C),bauxite mudstone(debris-containing,section D)and dark mudstone-coal section(section E).The burrow/funnel filling,lenticular,layered/massive bauxite deposits occur separately in the karst platforms,gentle slopes and low-lying areas.The karst platforms and gentle slopes are conducive to surface water leaching,with strong karstification,well-developed pores,large reservoir thickness and good physical properties,but poor strata continuity.The low-lying areas have poor physical properties but relatively continuous and stable reservoirs.The gas enrichment in bauxites is jointly controlled by source rock,reservoir rock and fractures.This recognition provides geological basis for the exploration and development of natural gas in the Upper Carboniferous in the study area and similar bauxite systems.

Effect of integration of mechanical ball milling and flue gas desulfurization gypsum on dealkalization of bauxite residue

The synergistic impact of mechanical ball milling and flue gas desulfurization(FGD)gypsum on the dealkalization of bauxite residue was investigated through integrated analyses of solution chemistry,mineralogy,and microtopography.The results showed a significant decrease in Na_(2)O content(>30 wt.%)of FGD gypsum-treated bauxite residue after 30 min of mechanical ball milling.Mechanical ball milling resulted in differentiation of the elemental distribution,modification of the minerals in crystalline structure,and promotion in the dissolution of alkaline minerals,thus enhancing the acid neutralization capacity of bauxite residue.5 wt.%FGD gypsum combined with 30 min mechanical ball milling was optimal for the dealkalization of bauxite residue.

Synthesis and characterization of a novel collector for the desulfurization of fine high-sulfur bauxite via reverse flotation

Bauxite is one of the main raw materials in the alumina industry.Fine high-sulfur bauxite flotation desulfurization is a great challenge presently.This study aims to synthesize nanoparticle collectors(NPCs)by emulsion polymerization to improve the abovesaid flotation desulfurization process.The physicochemical properties of high-sulfur bauxite were analyzed,and the experimental conditions for the synthesis of NPCs were optimized.The interaction mechanism between NPCs and pyrite was studied via fundamental analyses including SEM(Scanning Electron Microscope),FT-IR(Fourier Transform Infrared spectoscopy),Zeta-potential,XPS(X-ray Photoelectron Spectroscopy),and wettability.Under the closed-circuit flotation flowsheet of"one roughing-two cleaning-three scavenging",aluminum concen-trate with a yield of 85.91%and sulfur content of 0.56%were obtained using a common collector.However,with the addition of the novel NPC,aluminum concentrate with a yield of 85.70%and sulfur content of 0.36%could be obtained by a simpler flowsheet of"one roughing-one cleaning-two scav-enging".The improvement in flotation performance is suggested to be contributed by the addition of spherical NPC,which induced a rougher and more hydrophobic pyrite surface.

Enhanced dealkalization of bauxite residue through calcium-activated desulfurization gypsum

A novel integrated approach to remove the free alkalis and stabilize solid-phase alkalinity by controlling the release of Ca from desulfurization gypsum was developed.The combination of recycled FeCl_(3)solution and EDTA activated desulfurization gypsum lowered the bauxite residue pH to 7.20.Moreover,it also improved the residual Ca state,with its contribution to the total exchangeable cations increased(68%-92%).Notably,the slow release of exchangeable Ca introduced through modified desulfurization gypsum induced a phase transition of the alkaline minerals.This treatment stabilized the dealkalization effect of bauxite residue via reducing its overall acid neutralization capacity in abating pH rebound.Hence,this approach can provide guidance for effectively utilizing desulfurization gypsum to achieve stable regulation of alkalinity in bauxite residue.

Study of the Chemical and Mineralogical Composition of Kindia Bauxite in the Republic of Guinea: The Case of the Saföfö Site

The chemical and mineralogical composition of bauxite deposits is a key factor in the profitability of refining processes. The study of bauxites from the Saföfö site has assessed variations in chemical and mineralogical composition under various conditions, as well as the optimum conditions for their exploitation. The methodologies used in this study include experimental methods for determining moisture content, chemical composition, mineralogical composition, and specific density of bauxite. The results show significant variation in moisture content among the bauxite samples, with values ranging from 2.90% to 17.80%. The silica percentages in the samples range from 1.69% to 8.14%, while alumina percentages vary from 36.81% to 54.03%. After calcination, alumina oxide percentages range from 40% to 75%. After chemical activation, alumina oxides Al2O3 range from 40% to over 50%. Gibbsite is the most abundant mineral, accounting for about 60% - 70% of the total composition of the bauxite samples. Samples A to F have bulk densities varying between approximately 3.6 and 3.9. Sample B has the highest density, around 3.9, while sample C has the lowest, at around 3.5. Bauxite mining at the Saföfö site offers significant potential for the alumina industry, provided appropriate processing methods are selected to maximize quality and profitability while minimizing environmental impact.

Petrological and Statistical Studies of the Limbiko Bauxite Deposit, Republic of Guinea

The increasing demand for Aluminium pushes the miners to multiply the research in order to answer this demand. The objective of this work is to characterize the bauxitic deposit of Limbiko. The methodology consists in collecting samples, and establishing stratigraphic logs, sections and geological maps. The analyses were carried out in the laboratory of the Company des Bauxites de Guinea. Statistical methods were used to process the geochemical data. The study area is characterized by sedimentary formations of the Devonian, in which the dolerites of the Mesozoic were injected. It is on these Devonian and Mesozoic formations that the Limbiko bauxite deposit was developed. The stratigraphic logs show the succession of formations. The parent rock is surmounted by an alteration crust. The petrographic study is based on the bauxitic and transitional zones characterized by ferruginous laterites. Both zones contain some ferriplantite. Mineralogical analysis shows the presence of gibbsite, goethite, alumogoethite, rutile and clay minerals. The geochemical study of the major elements shows that the more the contents of SiO2, Fe2O3 decrease, the more the content of Al2O3 increases and those of TiO2, Al2O3 increase in the same direction. The PCA confirms the mineralogical results by classifying the samples into clay, bauxite and ferrite.

Petrographic and Geochemical Characterization of Mayedo and Kinzoki Ranges (Sumbi Bauxite Region, Kongo Central/DR Congo)

The bauxitic region of Sumbi and its surroundings in Central Kongo (DR Congo) is located in an area corresponding to “bands” of basic rocks made up of microdolerites, basalts and andesites. The problem of this study is linked to the similarity of the phenomena that generated the depositional process of these ferruginous and aluminous formations. The aim of this article is to carry out a chemical and petrographic study of samples of bauxitic materials from the Mayedo and Kinzoki regions, with a view to their possible recovery. To this end, the chemical and petrographic analysis of the weathering formations outcropping in the study area was carried out using X-ray fluorescence and thin section methods. The latter revealed that two lithologies were detected in the healthy rocks: basalts with a mineralogical assemblage of plagioclase crystals, pyroxene microcrystals and oxide opaques;and dolerites represented by plagioclase crystals, pyroxenes and a few quartz crystals. X-ray fluorescence revealed high levels of Al2O3 (32.69%) in the Mayedo zone (MHb1). This visibly gibbsite-rich level corresponds to the zone of friable, homogeneous bauxite with a massive, blood-red texture, with an estimated gibbsite percentage of 55.50. The percentage of Fe2O3 is high in these zones at 42.77%, hence the dark red colour, reflecting a strong zone of ferruginasation. This horizon contains a high concentration of hematite and goethite minerals. Highly variable SiO2 contents ranging from 13.48% to 40.82%. These variations are essentially due to the dissolution of silica by leaching and resilification.

Radiological and X-Ray Diffraction Characterization of Bauxite and Rutile Ore Contaminated Environment in Kanam and Wase Mineral Exploration Sites, Plateau State-Nigeria

Two non-destructive analytical techniques (gamma spectrometer and X-ray diffractometer) were employed in the analysis of bauxite and rutile ore and their vicinity soil and control sourced within the Kanam and Wase mineral exploration sites. The activity concentrations of natural radionuclides 238U, 232Th, and 40K in the soil samples received from bauxite and rutile mineral mining vicinities revealed high concentrations of 238U, 232Th, and 40K compared to the control soil samples sourced 500 m away from the mineral exploration vicinities. Radiological detriments RLI, AUI, Hin and Hex unveiled values exceeding the radiation standard concentration (>1) for soil. X-ray diffraction characterization of bauxite ore revealed the interlocking minerals of Bauxite (18)%, Albite (11)%, Garnet (15)%, Illite (6)% and Muscovite (43)% in various proportions obtained within the 2θ range (9.18 to 64.4) and a peak value (intensity, cps) of 3400. Pure bauxite percentage in the ore meets metallurgical grade (15 - 25)%. X-ray diffraction of rutile ore revealed the minerals of rutile (40)%, quartz (21.4)%, ilmenite (27)% and garnet (11.8)% found within the 2θ range (27.5 to 35.6) and a peak value intensity of 31.1 - 100.0 cps also meeting the metallurgical grade of 15% - 25%. The major environmental concern associated with the mineral-sands industry is the radiation hazards, pollution of ground-water sources from heavy metals, mineral transport with heavy equipment’s, dredging operations in fragile coastal area and clearing of vegetation.

Upgraded Analytical Protocols in Bauxite Refining Industry Using Composite Sampling Approach to Minimize Laboratory Analysis Load

The laboratories in the bauxite processing industry are always under a heavy workload of sample collection, analysis, and compilation of the results. After size reduction from grinding mills, the samples of bauxite are collected after intervals of 3 to 4 hours. Large bauxite processing industries producing 1 million tons of pure aluminium can have three grinding mills. Thus, the total number of samples to be tested in one day reaches a figure of 18 to 24. The sample of bauxite ore coming from the grinding mill is tested for its particle size and composition. For testing the composition, the bauxite ore sample is first prepared by fusing it with X-ray flux. Then the sample is sent for X-ray fluorescence analysis. Afterwards, the crucibles are washed in ultrasonic baths to be used for the next testing. The whole procedure takes about 2 - 3 hours. With a large number of samples reaching the laboratory, the chances of error in composition analysis increase. In this study, we have used a composite sampling methodology to reduce the number of samples reaching the laboratory without compromising their validity. The results of the average composition of fifteen samples were measured against composite samples. The mean of difference was calculated. The standard deviation and paired t-test values were evaluated against predetermined critical values obtained using a two-tailed test. It was found from the results that paired test-t values were much lower than the critical values thus validating the composition attained through composite sampling. The composite sampling approach not only reduced the number of samples but also the chemicals used in the laboratory. The objective of improved analytical protocol to reduce the number of samples reaching the laboratory was successfully achieved without compromising the quality of analytical results.

Construction of a Gravel Road Using Bauxite Residue

Results from research efforts over many years by the Highway Laboratory of Civil Engineering Department of Aristotle University of Thessaloniki(AUTH)and other academic or research institutions on behalf of"Aluminium of Greece"have demonstrated the potential use of bauxite residue in the construction industry as bricks,in the ceramic industry,for restoring abandoned surface mines and road construction.This paper details the construction of a gravel road using bauxite residue on the road"St.Nikolas-Kiriaki"in the site of the"Aluminium of Greece".The final layer included the addition of bauxite aggregates to provide an additional road carrying capacity.The aim of the project was to construct a trafficable surface for trucks and other vehicles with adequate resistance to heavy traffic loads and external factors as changing climatic conditions or soil erosion due to the rain.The construction is the right balance between technically excellent result and economically feasible.The prospect of using bauxite residue for similar road construction,or in general road construction,remains open.

Mobility of Major and Trace Elements during the Bauxitization Processes in Ngaoundal Area (Adamawa Cameroon): Implication on Mining Perspectives

This study was focused to assess major and trace elements in bauxitic duricrusts from Ngaoundal and its surroundings in order to establish their mining interest. To this end, fieldworks, mineralogical and geochemical analyses were carried out. Four facies of duricrust were identified and characterized from the summit to the top of the slope of the Ngaoundal mountain: scoriaceous, pisolitic, nodular and massive. Mineralogical and geochemical analyses performed on 16 samples, revealed a significant concentration of Al2O3 mainly in the scoriaceous facies (over 45% in grade), moderate in Fe2O3 (averaging 23.69%) and SiO2 (averaging 21.7%). Trace elements were generally low, excluding Cr (421 ppm on average), Zr (327 ppm on average and V (213 ppm on average). In addition, the limited quantities of alkalis (Na2O, K2O) and alkaline earths metals (MgO, CaO) coupled with the very high values of Chemical Index of Alteration (CIA) and Mineralogical Index of Alteration (MIA), (more than 99%) attest to the intense weathering of the studied materials. Allitization and monosiallitization constituted the crystallochemical phenomena that have led to the development of bauxitic minerals. More than 90% of gibbsite in scoriaceous facies, 52.21% - 76.01% of kaolinite in pisolitic facies and more than 40% of hematite in nodular facies were quantified. The relationships between the constitutive components indicated their interdependency during the bauxitization phenomenon. The mineralogical and geochemical properties highlighted the mining interest of the studied duricrusts to be valorized.

Thermodynamics study on leaching process of gibbsitic bauxite by hydrochloric acid

For the low-grade gibbsitic bauxite,the leaching rate of alumina is very low during the Bayer process.The acid leaching method is attracting more attention,and the hydrochloric acid leaching was developed rapidly.The mineral composition and chemical composition were investigated by X-ray diffraction analysis and semi-quantitative analysis.The thermodynamics of leaching process was analyzed.The results show that the major minerals in the bauxite are gibbsite,secondly goethite and quartz,anatase and so on.The acid leaching reactions of the bauxite would be thermodynamically easy and completed.Under the conditions that ore granularity is less than-55 μm,the L/S ratio is 100：7,and the leaching temperature is 373-383 K,the leaching time is 120 min and the concentration of HCl is 10%,both the leaching rates of Al and Fe are over 95%.The main composition of leaching slag is SiO2 which is easy for comprehensive utilization.

Flotation of low-grade bauxite using organosilicon cationic collector and starch depressant

The flotation of diaspore and three kinds of silicate minerals, including kaolinite, illite and pyrophyllite, using an organosilicon cationic surfactant (TAS101) as collector and starch as depressant was investigated. The results show that both diaspore and aluminosilicate minerals float readily with organosilicon cationic collector TAS101 at pH values of 4 to 10. Starch has a strong depression effect for diaspore in the alkaline pH region but has little influence on the flotation of aluminosilicate minerals. It is possible to separate diaspore from aluminosilicate minerals using the organosilicon cationic collector and starch depressant. Further studies of bauxite ore flotation were also conducted, and the reverse flotation separation process was adopted. The concentrates with the mass ratio of Al2O3 to SiO2 of 9.58 and Al2O3 recovery of 83.34% are obtained from natural bauxite ore with the mass ratio of Al2O3 to SiO2 of 6.1 at pH value of 11 using the organosilicon cationic collector and starch depressant.

Sulfur phase and sulfur removal in high sulfur-containing bauxite

The sulfur phase in high sulfur-containing bauxite was studied by an X-ray diffraction analysis and a chemistry quantitative analysis.The methods for the removal of different shaped sulfur were also discussed.The results show that sulfur phases in high sulfur-containing bauxites exist in the main form of sulfide sulfur （pyrite） or sulfate sulfur,and the main sulfur forms of bauxites from different regions are not the same.Through a combination of an X-ray diffraction analysis and a chemistry quantitative analysis,the sulfur phases of high sulfur-containing bauxite could be accurately investigated.Deciding the main sulfur form of high sulfur-containing bauxite could provide theoretical instruction for choosing methods for the removal of sulfur from bauxite,and an oxidizing-roasting process is an effective way to remove sulfide sulfur from high sulfur-containing bauxite,the content of S^2-in crude ore in the digestion liquor is above 1.7 g/L,but in the roasted ore digestion liquor,it is below 0.18 g/L.Using the sodium carbonate solution washing technology to wash bauxite can effectively remove sulfate sulfur,the content of the total sulfur in ore is lowered to below 0.2% and can meet the production requirements for the sulfur content.

Three-dimensional orebody modelling and intellectualized longwall mining for stratiform bauxite deposits

Acoupled biharmonic spline and linear interpolation algorithm was proposed to create a three-dimensional smooth deposit model with minimal curvature containing grade and position data. To obtain the optimal technical parameters, such as cuttingheight and drum diameter, a virtual longwall mining procedure was modelled by simulating the actual fully mechanized longwall mining process. Based on the above work, a bauxite deposit in a longwall mining panel was modelled by scattered grade data from ores sampled on the entry wall. The deposit was then demarcated by industrial indexes and sliced according to the virtual longwallmining procedure. The results show that the proposed interpolation algorithm can depict the stratiform structure of bauxite depositsand that the uncovered bauxite deposit has high proportions of high-grade and rich ore. The ranges of optimal cutting height and drum diameters are 1.72-2.84 m and 1.42-1.72 m, respectively. Finally, an intellectualized longwall mining procedure was designed to guide the mining process with the lowest dilution and loss rates.

Effects of water hardness on selective flocculation of diasporic bauxite

The effect of electrolyte on settling behavior of kaolinite was studied. Effects of hard water on selective flocculation of diasporic bauxite was tested and the measures were taken to eliminate the effects of Ca2＋ and Mg2＋ in hard water. The results indicated that, not only the concentration of electrolyte ions but also the ionic valence of the electrolyte ions affects the settling behavior of kaolinite; hard water significantly affects its selective flocculation owing to Ca2＋ and Mg2＋; general dispersants could not eliminate the effects of Ca2＋ and Mg2＋. Self-made softening agent in our lab could weaken or eliminate the effects of hard water on flocculation processes. The results of molecular dynamics simulation show that softening agent molecules could restrict Ca2＋ and prevent them from playing their roles, so as to eliminate the effects. The continuous pilot experiment results of bauxite flocculation were even better than those obtained in laboratory.