High Purity Alumina

Alumina (Al2O3) is widely used in a variety of applications, because it has superior physical and
chemical properties which are high heat resistance, excellent electrical isolation, abrasion
resistance and high corrosion resistance. Generally, alumina is manufactured with a purity of
99.6–99.9% mainly by the Bayer’s process with bauxite as the starting material. It is used in
refractory-products, spark plugs. High purity alumina, which has a purity of more than 99.99%
and has a uniform fine particle has been widely used in translucent tubes for high-pressure
sodium lamps, single crystal materials such as sapphires for watch covers, high-strength
ceramic tools, abrasives for magnetic tape and the like. In recent years, the demand of high
purity alumina is expanding in fields which are expected to show a high growth rate in display
materials, energy, automobiles, semiconductors and computers.
There are a variety of different industrial methods for producing HPA, including hydrolysis of
aluminium alkoxide, thermal decomposition of ammonium alum, thermal decomposition of
ammonium aluminium carbonate hydroxide (AACH), underwater spark discharge with
aluminium, vapor-phase oxidation and the like.
Leucosapphire is single crystal aluminium oxide. It possesses a number of unique properties,
namely, high mechanical strength, chemical inertness, high hardness, low friction coefficient,
optical transparency in a wide range of wavelengths, high acoustic quality factor, and radiation
resistance. Due to the properties mentioned, leucosapphire is used in various fields of modern
technology: nuclear power engineering, laser technology, optics, lighting engineering, chemistry
and metallurgy of active substances, protective armor, electrical engineering and thermometry,
wear resistant mechanical elements equipment, oil and gas production, watch-making industry,
and mechanical engineering and instrumentation.
Methods of Production of Alumina:
Bayer’s Process for Alumina Production:
Alumina is primarily derived from bauxite ore through the Bayer process, in which a caustic
soda material, in combination with heat and pressure, is used to dissolve aluminium bearing
minerals from the bauxite. Bauxite residue is then separated from the sodium aluminate,
allowing alumina to be crystallized from the remaining solution. The crystallized alumina is
then thermally processed in a rotary kiln to remove bound moisture, creating the final pure
alumina product. A consequence of the Bayer process is the production of red mud – a caustic
by-product.

Bauxite Ore Crusher Grinding Mill Slurry Tank

Caustic Soda

Precipitators Filters Settling Tank Digester

Filtering Tanks Calcination Kiln Alumina Production

The extraction process converts the aluminium oxide in the ore to soluble sodium aluminate,
NaAlO2, according to the chemical equation:
Al2O3 + 2 NaOH → 2 NaAlO2 + H2O
This treatment also dissolves silica, forming sodium silicate;
2 NaOH + SiO2 → Na2SiO3 + H2O
The other components of Bauxite, however, do not dissolve. Sometimes, lime is added at this
stage to precipitate the silica as calcium silicate. The solution is clarified by filtering off the solid
impurities, commonly with a rotary sand trap and with the aid of a flocculant such as starch, to
remove the fine particles. The undissolved waste after the aluminium compounds are extracted,
bauxite tailings, contains iron oxides, silica, calcia, titania and some unreacted alumina. the
supersaturated solution with high-purity aluminium hydroxide (Al(OH)3) crystal, which
eliminated the need for cooling the liquid and was more economically feasible:
2 H2O + NaAlO2 → Al(OH)3 + NaOH
Some of the aluminium hydroxide produced is used in the manufacture of water treatment
chemicals such as aluminium sulfate, PAC (Poly-aluminium chloride) or sodium aluminate; a
significant amount is also used as a filler in rubber and plastics as a fire retardant. Some 90% of
the gibbsite produced is converted into aluminium oxide, Al2O3, by heating in rotary kilns or
fluid flash calciners to a temperature of about 1470 K.
2Al(OH)3 → Al2O3 + 3 H2O
The left-over, 'spent' sodium aluminate solution is then recycled. Apart from improving the
economy of the process, recycling accumulates gallium and vanadium impurities in the liquors,
so that they can be extracted profitably.
Red Mud: Red mud is the waste product that is produced in the digestion of bauxite with sodium
hydroxide. It has high calcium and sodium hydroxide content with a complex chemical
composition, and accordingly is very caustic and a potential source of pollution. Red mud dries
into a fine powder that contains iron, aluminium, calcium and sodium. Over 95% of the alumina
produced globally is through the Bayer process; for every tonne of alumina produced,
approximately 1 to 1.5 tonnes of red mud are also produced.

Hydrolysis of Aluminium Alkoxide:

The most common process used by major producers is the hydrolysis of aluminium alkoxide. In
this process, high purity aluminium alkoxide is synthesized from aluminium metal and alcohol,
and hydrated alumina is produced by hydrolysis of alkoxide. HPA is then obtained by
calcination.
Al + 3ROH Al (OR)3 + 3/2H2 ………(1)
2Al (OR)3 + 4H2O Al2O3 · H2O + 6ROH ……….(2)
Al2O3 · H2O Al2O3 + H2O ……….(3)
In this method, aluminium alkoxide is purified by distillation and so on. In addition, it is
important to control the conditions during hydrolysis and to avoid producing rigid
agglomerates during drying. Because the hydrolysis rate for aluminium alkoxide is extremely
fast, it produces fine particle hydrated alumina which easily become rigid agglomerates. α-
Al2O3, which is a stable phase at high temperatures, is obtained by calcination of hydrated
alumina (boehmite, for example) via γ, δ, θ-Al2O3. The various phases of alumina other than α-
Al2O3, which is a stable phase at high temperatures, are called intermediate alumina, and its
original particles are super fine particles of several tens of nano-meters.
The transition to α-Al2O3 from the intermediate alumina requires high temperatures of over
1200°C, because it needs rearrangements of the oxygen packing. The generation of α crystal
nuclei is a rate determining step for the α phase transition, and that the density of α crystal
nuclei is low. But once nuclei are generated, a sudden grain growth occurs because of mass
transfer from the surrounding intermediate alumina, and dendritic α-Al2O3 particles of micron
size are obtained. Therefore, in order to obtain α-Al2O3 particles which are fine and have a
uniform particle size distribution, it is important to eliminate factors such as inhomogeneous
generation of α-Al2O3 nuclei and to complete phase transition at as low a temperature as
possible in addition to strict control of the uniformity of temperature distribution during
calcination.
α-Al2O3 particles, which is obtained by strictly controlling the conditions for hydrolysis, drying
and calcination are in an agglomerate state, so deagglomeration process are necessary for
getting particles of narrow particle size distribution. A ball mill, vibration mill, jet mill, media
agitating mill or other type of mill can be used for the deagglomeration process.
In alumina ceramics applications, the presence of the agglomerates gives rise to local
nonuniformity in a green body, and it causes residual pores in a sintered body. Particularly in
translucent alumina ceramics applications for high pressure sodium lamps, the residual pores in
the sintered body reduce the translucency. And for magnetic tape application, the presence of
agglomerates makes for poor surface smoothness in the magnetic tape and causes damage to
magnetic heads while the tape is running and lowers the electromagnetic conversion
characteristics. By making refinement of various processes to reduce the agglomerates in high
purity alumina powder, we have developed alumina powders suitable for various applications.
Recently high-efficient jet mills and wet medium agitation mills for nanoparticles are developed.
According to the trend to get high-functional submicron particles and nano-meter particles.
Generally speaking, the process of deagglomeration of powders must be done with a great deal
of caution. Because the smaller the original particles are, the more necessity for avoiding both
regeneration of agglomerates and contamination are required.

PREPARATION OF ALUMINUM
OXIDE
OF SPECIAL QUALITY GRADE
FROM METAL ALUMINUM
In [11], combined production of
high-purity boeh-
mite and hydrogen was studied.
This requires the
aqueous aluminum slurry to be
treated in a high-pres-
sure reactor at a temperature of
200–400°C. A vapor-
hydrogen mixture was formed
which was separated
from boehmite and
accumulated, whereas
boehmite
was dried and calcined in a
vacuum oven at a tempera-
ture of 900–1900°C.
The electrochemical method for
the production of
aluminum oxide of special
quality grade [12] involves
the production of aluminum
hydroxide at the anode
during electrolysis at 25–90°C
using metallic alumi-
num plates with a purity of
99.996% as electrodes and
an electrolyte solution of
ammonium chloride. The
method makes it possible to
obtain aluminum hydrox-
ide as hydrargillite with a
maximum particle size of 8–
9 μm. Then, the precipitate is
calcined at 1000°C.
Using this method, γ-aluminum
oxide was obtained
with a purity of 99.995–
99.997%, which was success-
fully used for the growth of
leucosapphire by the Ver-
neuil method
PREPARATION OF ALUMINUM
OXIDE
OF SPECIAL QUALITY GRADE
FROM METAL ALUMINUM
In [11], combined production of
high-purity boeh-
mite and hydrogen was studied.
This requires the
aqueous aluminum slurry to be
treated in a high-pres-
sure reactor at a temperature of
200–400°C. A vapor-
hydrogen mixture was formed
which was separated
from boehmite and
accumulated, whereas
boehmite
was dried and calcined in a
vacuum oven at a tempera-
ture of 900–1900°C.
The electrochemical method for
the production of
aluminum oxide of special
quality grade [12] involves
the production of aluminum
hydroxide at the anode
during electrolysis at 25–90°C
using metallic alumi-
num plates with a purity of
99.996% as electrodes and
an electrolyte solution of
ammonium chloride. The
method makes it possible to
obtain aluminum hydrox-
ide as hydrargillite with a
maximum particle size of 8–
9 μm. Then, the precipitate is
calcined at 1000°C.
Using this method, γ-aluminum
oxide was obtained
with a purity of 99.995–
99.997%, which was success-
fully used for the growth of
leucosapphire by the Ver-
neuil method
PREPARATION OF ALUMINUM
OXIDE
OF SPECIAL QUALITY GRADE
FROM METAL ALUMINUM
In [11], combined production of
high-purity boeh-
mite and hydrogen was studied.
This requires the
aqueous aluminum slurry to be
treated in a high-pres-
sure reactor at a temperature of
200–400°C. A vapor-
hydrogen mixture was formed
which was separated
from boehmite and
accumulated, whereas
boehmite
was dried and calcined in a
vacuum oven at a tempera-
ture of 900–1900°C.
The electrochemical method for
the production of
aluminum oxide of special
quality grade [12] involves
the production of aluminum
hydroxide at the anode
during electrolysis at 25–90°C
using metallic alumi-
num plates with a purity of
99.996% as electrodes and
an electrolyte solution of
ammonium chloride. The
method makes it possible to
obtain aluminum hydrox-
ide as hydrargillite with a
maximum particle size of 8–
9 μm. Then, the precipitate is
calcined at 1000°C.
Using this method, γ-aluminum
oxide was obtained
with a purity of 99.995–
99.997%, which was success-
fully used for the growth of
leucosapphire by the Ver-
neuil method
Preparation of Aluminium Oxide of Special Quality Grade from Metal Aluminium:
In combined production of high-purity boehmite and hydrogen was studied. This requires the
aqueous aluminium slurry to be treated in a high-pressure reactor at a temperature of 200–
400°C. A vapor-hydrogen mixture was formed which was separated from boehmite and
accumulated, whereas boehmite was dried and calcined in a vacuum oven at a temperature of
900–1900°C. The electrochemical method for the production of aluminium oxide of special
quality grade involves the production of aluminium hydroxide at the anode during electrolysis
at 25–90°C using metallic aluminium plates with a purity of 99.996% as electrodes and an
electrolyte solution of ammonium chloride. The method makes it possible to obtain aluminium
hydroxide as hydrargillite with a maximum particle size of 8–9 μm. Then, the precipitate is
calcined at 1000°C. Using this method, γ-aluminium oxide was obtained with a purity of 99.995–
99.997.
The disadvantage of all these methods is the direct dependence of the purity of resulting
aluminium oxide on the purity of starting aluminium, since no additional purification is
provided during the synthesis of products. At the same time, the price of metal aluminium of
special quality grade is an order of magnitude higher than that of its compounds used as
starting materials in other methods developed for the production of aluminium oxide of special
quality grade.

Preparation of High-Purity Aluminium Oxide from Alum and Other Salts:

Recrystallization and decomposition of ammonia alum is a traditional method for the
preparation of aluminium oxide of special quality this material was used in the industrial
production of sapphire and ruby for precision instrumentation and production of watches.
Ammonium alum (NH4)⋅Al(SO4)2⋅12H2O is formed by the interaction between aqueous
solutions of aluminium sulfate and ammonium sulfate.
Aluminium oxide formed during the decomposition of ammonium alum is a mixture of
transitional modifications, which upon further heating are converted to α-Al2O3. After thermal
treatment at 1200°C for 2 h, the obtained powder oxide consisted predominantly of α-Al2O3.
Agglomerates of α-Al2O3 had an irregular shape and a vermicular structure. Transition
aluminium oxide obtained by decomposition of alums melted in crystallization water has a bulk
density of about 0.15 g/cm3. If decomposition is carried out without melting, the bulk density
can reach 0.35 g/cm3. When it has been transformed into the α-phase, the density of the
material increases by about one-and-a-half times. The aluminium oxide produced industrially
from ammonium alum includes powders with a bulk density increased to 0.7 g/cm3.

Transportation of Alumina:
Alumina is a white powder with a density generally between 0.85 to 1.05, very free flowing and
quite abrasive: its particle characteristics make its handling rather complex in order to achieve
optimum performances, in terms of quantity that can be conveyed, and the amount of dust and
spillage must also be taken into consideration during unloading operations. Alumina is a bauxite
having received a certain treatment. It is a dry, hygroscopic matter that is delivered in three
different categories;

 Standard variety
 Mineralized variety
 Variety resembling flour
Before loading ensure container, compartment is clean and dry. Alumina is a very dusty cargo
and should remain perfectly dry. Other cargo must also be protected against dust damage.
Because fine alumina penetrates everywhere and given the possibility of high loading
temperature (65-70°C), personal protection is to be maintained, safety glasses, goggles,
protective clothing. Risk factors include Moisture damage, Contamination/defilement, Toxic by
inhalation of dust.

Market Analysis:
The global high purity alumina market was valued at $1.3 billion in 2019, and is projected to
reach $4.8 billion by 2026, growing at a CAGR of 20.7% from 2020 to 2026. High purity alumina
(HPA) is a treated premium non-metallurgical form of aluminium categorized by its purity level.
It possesses characteristics such as chemical stability, high melting point, high electrical
resistance & insulation, and good thermal conductivity, which makes it an ideal choice for
engineering applications.
High purity alumina is widely used in manufacturing of LED bulbs, biomedical devices, and Li-
ion batteries. The demand for electric vehicles has been surged in recent years across the
developing economies such as India and China to curb the carbon emission and to reduce
dependency on the fossil fuels such as diesel and petrol. Due to this, the demand for Li-ion
batteries has been increased significantly to power the electric vehicles. This factor is likely to
increase the demand for high purity alumina. Due to growing number of patients affected form
the corona virus and other diseases that requires surgical treatments has led to surge in
demand for biomedical devices and is anticipated to drive the growth of high purity alumina
market. Furthermore, growing demand for smart lighting such LED bulbs due to its high energy
efficiency and ability to reduce the energy consumption has led to increase in its demand
globally.