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Bayer Process Chemistry: Dr. M. Coley
Bayer Process Chemistry: Dr. M. Coley
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
• precipitation of Al2O3.3H2O
PRECIPITATION
Al2O3.3H2O
CALCINATION
Al2O3
Calcined Al2O3
Will not absorb moisture
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
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
Deodorants, medicines
Technologies for Al2O3 Production
American European
Digestion (oC) 140 – 145 200 – 250
Pressure (kg/cm2) 4 12 – 30
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
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