Optimization of Hydrochemical Leaching Process of Kaolinite Fraction of Bauxite with Response Surface Methodology

• Published in: Processes 2024-07, Vol.12 (7), p.1440
• Main Authors: Abikak, Yerkezhan, Bakhshyan, Arina, Dyussenova, Symbat, Gladyshev, Sergey, Kassymzhanova, Asiya
• Format: Article
• Language: English
• Subjects: Alkaline leaching; Aluminum; Aluminum compounds; Aluminum oxide; Atmospheric pressure; Bauxite; Bayer process; Calcium oxide; Clay; Dawsonite; Design of experiments; Energy consumption; Fractions; High temperature; Kaolinite; Leaching; Lime; Methods; Particle size; Raw materials; Response surface methodology; Silicon dioxide; Sodium; Sodium bicarbonate; Sodium sulfate; Statistical analysis; Temperature; Variables
• ISSN: 2227-9717; 2227-9717
• DOI: 10.3390/pr12071440

A technology for the hydrochemical processing of the kaolinite fraction of bauxite has been developed, and it involves preliminary chemical activation in a sodium bicarbonate solution and alkaline leaching in a recycled high-modulus solution with the addition of an active form of calcium oxide. Chemical activation allows for the transformation of the difficult-to-explore kaolinite phase to form easily soluble phases of dawsonite, sodium hydroaluminosilicate and bemite. An active, finely dispersed form of calcium oxide was obtained as a result of CaO quenching in Na2SO4 solution at elevated temperature and pressure. Using a central composite design (CCD) via response surface methodology (RSM), the technological leaching mode was achieved. The influence on the leaching process was studied by adjusting the CaO/SiO2 ratio, temperature, alkaline solution concentration and duration. It was found that the determining factors are the concentration of the leaching solution and the temperature. At a stable CaO/SiO2 ratio, a combination of these two factors determines the duration of the process to achieve the predicted degree of recovery. The results of experiments carried out using the developed model of the leaching process confirmed the validity of the calculated indicators, with an error of 2.01%. In an optimal technological mode at a Na2O leaching solution concentration of 260 g/L, a temperature of 260 °C, a CaO/SiO2 ratio of 1.5 and a leaching time of 5 h, the extraction of Al2O3 into the solution was 89.7%, which is close to the value of 87.9% predicted by the model.