Process Description

Bauxite raw material consists of 20 mm particles grounded with water in the

grinder (G-01) to reduce its particle size to 150 microns which are suitable enough for

reactive leaching. The grounded bauxite ore is directed to the digester (DG-01) wherein

NaOH is added to enhance the extraction process. The slurry mixture is pumped to the

digester in the reaction that took place. The reaction is carried out at a reaction

temperature of 141 ºC and a pressure of 4.1 atm. The reactions involved are as follows:

Al2O3(s) (in bauxite) + 2NaOH(aq) → 2NaAlO2(aq) + H2O(l) (Alumina Digestion)

The slurry produced in the digester (DG-01) as presented in the alumina

digestion main reaction is cooled (RC-01) which is operated at 67 ºC and atmospheric

pressure. The cooled slurry is pumped into the settling tank (SE-01) to separate solid

and aqueous solution and then, the aqueous solution are fed to the microfiltration unit

(F-01) to undergo filtration which further separates the bauxite residue from the

pregnant liquor (sodium aluminate solution).Consequently, the bauxite residue filtered

will undergo waste treatment to maximize the recovery of the inert metals in the

solution. The bauxite residue left after filtration will be directed to the bauxite residue

disposal area.

Now, the pregnant liquor is heated through a heat exchanger (HX-02) and fed to

the parallel single-stage precipitator (PR-01) having an overall temperature drop of 16.9

ºC. The feed stream temperature in the precipitator is 66.9 ºC and the outlet stream

temperature is 50 ºC. The precipitation is driven by progressively cooling of the

pregnant liquor which results in the formation of very small crystals of gibbsite, Al(OH)3.

The chemical reaction that occurs in the precipitation is given below.

2NaAlO2(aq) + H2O(l) → Al(OH)3(s) + NaOH(aq) (Gibbsite Precipitation Reaction)

The crystal obtained in the precipitation is classified according to their size ranges

through microfiltration. All the crystal obtained in the centrifuge unit (CF-01) undergoes

washing and drying steps to partially dry the crystal products before calcination. The

crystal is subjected to calcination carried out at 1100 ºC in a rotary kiln (RK-01) wherein

gibbsite crystal undergoes a series of changes in its crystal structure and finally, forms

alumina. The two decomposition reactions that occur in the calcination are as follows:

Reaction 1: 2Al(OH)3(s) → 2Al2O3(s) (refined) + 3H2O(v)

Reaction 2: CaCO3(s) → CaO(s) + CO2(g)

The alumina produced is fed to the electrolytic cell (EC-01) wherein it reacts with

the anodes. The electrolytic cell is operated with the aid of direct current and at a

temperature of 960 ºC. The electrolytic cell is composed of insulation to avoid heat

losses and carbon lining which acts as a cathode. Steel bars known as collectors are

utilized to conduct electric current from the cathode, subsequently, current enters the

cell through anodes. The alumina is dissolved in the molten cryolite bath inside the

electrolytic cell and undergoes electrolytic reduction to produce molten aluminum.

Finally, the molten aluminum is directed to a holding furnace and is suitable for metal

casting. The individual electrode reaction and overall reaction that happened in the

reduction cell are as follows:

At cathode: 4Al3+ + 12e- → 4Al

At anode: 2Al2O3 → 4Al3+ + 6O2-

3C + 6O2- → 3CO2 + 12e-

Overall Reaction at Anode: 2Al2O3 + 3C → 4Al3+ + 3CO2 + 12e-

Overall Reaction in the Cell: 2Al2O3 + 3C → 4Al3+ + 3CO2

Some other reactions also occur in the electrolytic cell which is due to the

impurities of alumina feed, anode used; such reactions are given below.

Reaction 2: 2Al2O3 + 3S → 3SO2 + 4Al

Reaction 3: C + CO2 → 2CO

Reaction 4: Fe2O3 +2Al → Al2O3 + 2Fe

The process produced some waste gasses, especially CO2 and SO2, hence,

waste gasses are scrubbed where fluorides are absorbed by some caustic soda

produced and stored. The SO2 components of waste gas are now then neutralized

before releasing it to the atmosphere.