Bayer Process Chemistry

Dr. M. Coley
 Course Structure
12 Lectures – Mondays, 1:00 pm
3 Tutorials –
Progress Tests -
Multiple choice, true & false, short answer

Final Exam:
- One 2-hr paper
- MCQs & Short Answer
 Course Objectives
to provide a working knowledge of the
processing of bauxite to alumina using the
Bayer process

to illustrate how various unit operations are

combined in industrial processes

to show the role of the chemist in managing,

monitoring and modifying industrial processes

to illustrate the application of chemistry to

manufacturing processes
 The Bayer Process
o hydrometallurgical process
 produces > 90% of Al2O3 used to make Al
 Process involves:
• dissolution of bauxite in NaOH

• separation & disposal of red mud

• seeding of supersaturated liquor

• precipitation of Al2O3.3H2O

• calcination to obtain Al2O3

• recycling of spent liquor

 The Bayer Process

Bauxite DIGESTION Mud

Spent Liquor Al2O3.3H2O Seed

PRECIPITATION

Al2O3.3H2O

CALCINATION

Al2O3
Calcined Al2O3
 Will not absorb moisture

 Suitable for Hall-Heroult Reduction process

 Requires 1.54 tonnes Al2O3.3H2O per tonne Al2O3

Cyclic Process impurities

Economic use of raw materials NaOH

Heat conservation
Greater equipment efficiency
Build up of soluble impurities
Sub-process contamination - additives
 Process Details
Bauxite characterized ground/
blended

Insoluble Dissolved in
residue Liquor
removed is flashed NaOH

Pregnant
liquor Clarification Seeding

Precipitation
Calcination Filtration/
Washing
Flow Diagram – Bayer Process
 Unit Operations – Bayer Process
1) Mining 5) mud separation
2) Crushing/blending 6) clarification
3) Pre-digestion 7) precipitation
4) Digestion 8) Calcination

Major Bayer Process Reactions

Al2O3.3H2O + 2OH- 2Al(OH)4-
Al2O3.H2O + 2OH- + 2H2O 2Al(OH)4-

2Al(OH)4- Al2O3.3H2O + 2OH-

Al2O3.3H2O Al2O3 + 3H2O

Windalco Processing Plant
Bayer Process Chemistry
Lecture 2:
Alumina: Uses, Production
Technologies & Heat exchange

Dr. M. Coley
Uses of Alumina & Aluminum
production of aluminum -
~ 90%

production of Alum –
Al2(SO4)3.14H2O

ceramics, cement

Refractory, ant-acids

paint, pharmaceuticals

packaging - utensils/food
containers

motor vehicle parts

Deodorants, medicines
Technologies for Al2O3 Production
American European
Digestion (oC) 140 – 145 200 – 250

Pressure (kg/cm2) 4 12 – 30

Caustic (g/L) 150 – 250 340 – 500

Precip Temp (oC) 65 – 77 50 - 60

Flows
better, less
Yield (g/L) 45 – 65 impurities, 60 - 70
less dusty
Calcination (oC) 1000 1200

Characteristics sandy, coarse floury, fine

 Al2O3 Production Costs

Energy Distribution
 Mining - 1%
 Bayer process - 20 %
 Shipping - 1%
 Al- smelting 78 %

Cost Structure
 Raw materials 52.4 %

 Energy 24.4 %

 Labour/overheads 23.2 %
 Product Specifications
Parameter Al2O3 Target % Bauxite %
Fe2O3 <0.012 20
SiO2 <0.012 <4

Na2O 0.30 trace

CaO 0.035 – 0.045 0.3

TiO2 <0.003 2-3
ZnO <0.008 trace
P2O5 <0.001 1-3
V2O5 <0.002 0.05

Gibbsite 0.1 – 0.20 35 - 50

L.O.I. 0.6 – 0.8 15 – 25

Thermal Economy & the Bayer Process
Objectives?
Heat Flow Diagram for the Bayer Process
 Thermal Economy
Objectives: Steam
condensate
 minimize heat loss used as wash
water for mud
 re-use heat to ensure maximum efficiency & Al2O3.3H2O

Details:
High T & P to ensure digestion process
Slurry flashed after digestion 143 107 oC
Flashed steam used to pre-heat entering bauxite slurry
DBO (107 oC) loses heat in the mud circuit (98 oC)
Heat lost is low grade and not recoverable
Clarified liquor (98 oC) cooled for precip. (65 – 80 oC)
Released energy used to pre-heat Evap Feed liquor
Heat lost during mud separation, precipitation, calcination
Heat is lost to mud, hydrate and alumina