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.

Application of suspension magnetization roasting as technology for high-efficiency separation of valuable iron minerals from high-iron bauxite

A technology for suspension magnetization roasting−magnetic separation was proposed to separate iron minerals for recovery.The optimum parameters were as follows:a roasting temperature of 650℃,a roasting time of 20 min,a CO concentration of 20%,and particles with a size less than 37μm accounting for 67.14%of the roasted product.The total iron content and iron recovery of the magnetic concentrate were 56.71%and 90.50%,respectively.The phase transformation,magnetic transition,and microstructure evolution were systematically characterized through iron chemical phase analysis,X-ray diffraction,vibrating sample magnetometry,X-ray photoelectron spectroscopy,and transmission electron microscopy.The results demonstrated the transformation of hematite to magnetite,with the iron content in magnetite increasing from 0.41%in the raw ore to 91.47%in the roasted product.

Extraction of iron and aluminum from high-iron bauxite by ammonium sulfate roasting and water leaching

High iron content is one of the challenges in utilizing the refractory bauxites in China. An improved method for treating the high-iron bauxite by roasting with (NH4)2SO4 was proposed, which offers a possible alternative method for utilizing the high-iron bauxite. The influences of the roasting time, roasting temperature, material ratio, and ore particle size on the extraction ratios of Fe and Al were studied, and the orthogonal test was used to optimize the reaction conditions. The optimized reaction conditions were proposed as follows: roasting temperature of 450 °C, roasting time of 120 min, material ratio of (NH4)2SO4 to ore of 2.5:1.0, and ore particle size below 80 jim. The roasting mechanism and kinetic parameters including the apparent activation energy and reaction rate constant were investigated. The results showed that the control step of the roasting process was the internal diffusion on the product layer and the apparent activation energy was 19.22 kJ mol-1 in the reaction temperature range. The kinetic equation was obtained finally.

Optimization of iron and aluminum recovery in bauxite

Recovering iron and aluminum efficiently is the key route to utilize low-grade high-iron bauxite.Aiming to optimize the iron separating process and elevate both Fe and Al recovery ratio,three different Fe-Al recovery processes with different magnetic roasting(R),Bayer leaching process(L)and magnetic separation(S)orders were investigated.The studied processes include bauxite leaching→red mud roasting→magnetic separation(L-R-S),bauxite roasting→magnetic separation→leaching(R-S-L)and bauxite roasting→leaching→magnetic separation(R-L-S).The iron recovery ratio,Fe2O3 content in iron concentration and the bauxite dissolution ratio of each process were investigated.Moreover,the optimizations of the leaching,roasting and magnetic separation conditions were studied.Results indicate that the R-S-L process should be an advisable order to recover both alumina and iron.In the three processes,the R-S-L route had the highest alumina dissolution ratio and iron recovery ratio,which was 86.20%and 69.58%,respectively,while the Fe2O3 content of the iron concentrate was 40.66%.

Progress on Preparation of Refractory Powder Using Nonmetallic Minerals and Its Applications

This review summarized the recent advances in the utilization of nonmetallic minerals and their applications for fabrication of unfired refractories.The preparation of refractory powder utilizing cheap nonmetallic minerals of zircon,low-grade bauxite and quartz was discussed,respectively.The preparation of three unfired SiC-based refractories：SiC-SiAlON-ZrN,Al2O3-SiC/β-SiAlON/Ti（C,N）-C,and Al2O3-SiC-Si3N4 using the as-prepared refractory powders was introduced.