Abstract: Aluminous siliceous starting materials are mixed and ground with correction materials to produce a raw mixture comprising oxides of aluminium, silicon, calcium and alkali metal having certain mole ratios, preheating the raw mixture by suspending the raw mixture in a hot gas, and sintering the preheated material to clinker.

Abstract: A process for the production of alumina from aluminum-containing mineral ores, such as bauxite, comprising comminuting the aluminum-containing mineral ore, then reacting the comminuted mineral ore at an elevated temperature with an aqueous solution having at least 150 grams per liter of sodium bicarbonate which forms a solid reaction product containing dawsonite and impurities, and finally converting the dawsonite to alumina.

Abstract: The present invention relates to the production of alumina and, more specifically, to a process for desilication of aluminate solutions.The process of desilication according to the present invention comprises treatment of the aluminate solution first with a calcium-containing reagent "a" which is a product of the reaction of desilication of the aluminate solution; reagent "a" contains mainly calcium hydrogarnet of the formula:3CaO.Al.sub.2 O.sub.3.nSiO.sub.2 (6-2n)H.sub.2 Owherein n.ltoreq.1, and then with a reagent "b" of the formula:4CaO.Al.sub.2 O.sub.3 (0.1-0.6)X.mH.sub.2 Owherein X is CO.sub.2 and/or SO.sub.3 ; m=8 to 15. The treatment of the aluminate solution with reagent "a" is carried out for 0.5 to 2 hours at a temperature ranging from 40.degree. to 105.degree. C. Weight ratio of reagents "a" and "b" is maintained within the range of from 1:1 to 3:1.The process according to the present invention is useful in the manufacture of alumina.

Abstract: A method for recovery of fluoride values from spent potlining and fluoride containing insulating materials associated with the potlining is disclosed. Spent potlining and the insulating materials are reduced to a fine particle size and incinerated. The ash residue is leached with a dilute caustic and the leachate is treated with a calcium compound to precipitate calcium fluoride. The calcium fluoride is dried to a moisture content of less than 0.1 percent and is treated with about 93 to 99 percent concentration of sulfuric acid to produce hydrogen fluoride gas and a metal sulfate. The hydrogen fluoride gas is fed into an alumina dry scrubber to produce alumina with absorbed fluorides to be used as feed material to reduction cells used in the manufacture of aluminum by electrolytic reduction. The metal sulfate residue is treated with lime and constitutes an environmentally safe product which can be disposed of as landfill material.

Abstract: In the production of alumina from aluminous ores containing alumina trihydrate and alumina monohydrate comprising a first-stage digestion by digesting alumina trihydrate from a slurry of the ores and a caustic solution and separating the resulting slurry into a caustic aluminate solution and an insoluble residue, and a second-stage digestion by digesting alumina monohydrate from a slurry of the insoluble residue separated in the first-stage digestion and a caustic solution, the present invention provides an improvement wherein scale formation onto a preheater for the slurry in the second-stage digestion is completely or substantially prevented and reduction in heat transfer coefficient of heat transfer surface is remarkably lowered. The improvement is attained by setting up a desilication reaction zone in the course of the first-stage digestion, whereby the slurry introduced into said zone is subjected to desilication reaction treatment.

Abstract: An improvement in the lime-sinter process for recovering alumina from pulverized coal fly ash is disclosed. The addition of from 2 to 10 weight percent carbon and sulfur to the fly ash-calcium carbonate mixture increase alumina recovery at lower sintering temperatures.

Abstract: Flue gas containing sulfur dioxide is purified (and the sulfur content thereof is recovered in elemental form) by scrubbing the gas with aqueous sodium aluminate-sodium hydroxide solution thereby forming an underflow suspension consisting essentially of sodium and aluminum sulfites and sulfates and fly ash; oxidizing the sulfites to sulfates; evaporating the free water present; reducing the resulting apparently dry mixture of sodium and aluminum sulfates by the action of reactive hydrogen and a carbonaceous reducing agent thereby forming a solid mixture of a sodium oxide and sodium aluminate and a gaseous mixture comprising sulfur dioxide, sulfur, and hydrogen sulfide; condensing said sulfur; and inter-reacting said sulfur dioxide and hydrogen sulfide to provide elemental sulfur. The solid mixture is dissolved in water to regenerate the scrubbing solution, which is then recycled. The solution is filtered at any convenient point to remove fly ash and any other solids present.

Abstract: Cryolite (Na.sub.3 AlF.sub.6) as a source of aluminum is prepared from coal fly ash by reacting the aluminum oxide (Al.sub.2 O.sub.3) in fly ash with phosphoric acid to form aluminum phosphate, which is then converted to sodium aluminate by reaction with sodium hydroxide, and the sodium aluminate is converted to cryolite by reaction with hydrofluoric acid (HF), or equivalent reagent providing H.sup.+ and F.sup.- ions. Aluminum is thereby obtained from fly ash in a preferred form (as cryolite) for use in producing metallic aluminum.

Abstract: A process for obtaining solid alkali metal aluminates from an alkali metal aluminate aqueous solution by spray drying an alkali metal aluminate aqueous solution having an alkali metal oxide concentration of 1 to 6 mols per liter and an alkali metal oxide to alumina molar ratio of greater than 1. Also disclosed is an apparatus employed for effecting spray drying in which a spray drier of unidirectional flow is employed whose longitudinal axis is substantially horizontally disposed.

Abstract: Disclosed is a method for obtaining alumina from silicates by calcining a dry mixture of the silicate and an alkali metal or ammonium salt, such as the sulphate, bisulphate, sulphite, etc. and dissolving the reaction product in water or an aqueous alkali. Hydrated alumina is precipitated from the resulting solution and calcined to alumina.

Abstract: A process for extracting hydrogen fluoride from fluorine containing materials includes countercurrently contacting the materials with steam having a plane of rotation relatively perpendicular to the direction of flow of the material. An apparatus for the extraction of hydrogen fluoride from fluorine containing materials includes a rotary kiln having a first zone wherein a steam-air mixture countercurrently contacts the materials in an oxidation step, a second zone wherein an oxygen containing gas is tangentially injected into the kiln to provide complete combustion of carbon containing materials, a third zone wherein a steam stream countercurrently contacts the materials in a reducing step and means for providing a plane of rotation to the steam which is relatively perpendicular to the direction of flow of the material.

Abstract: In a process of the preparation of alumina from an alumina value containing material wherein a caustic sodium aluminate process liquor is subjected to a treatment to reduce the level of zinc impurity by the addition of ZnS seed in the presence of sulfide ion, the improvement comprising:(I) forming the zinc sulfide seed a by process comprising the steps of:(A) dissolving ZnO in NaOH to produce a caustic Na.sub.2 ZnO.sub.2 solution; and(B) reacting the solution of (A) with Na.sub.2 S to form ZnS, the Na.sub.2 S being present at a level sufficient to provide a concentration of Na.sub.2 S of at least about 0.150 g/l of Na.sub.2 S when the product of this step is added to the process liquor;(II) adding the product of step (B) to the process liquor to precipitate as ZnS, zinc contained as sodium zincate in the process liquor; and(III) filtering the process liquor to yield an NaAlO.sub.2 liquor containing less than 15 mg/l and preferably below about 10 mg/l zinc as ZnO.

Abstract: Bayer liquor containing carbon compounds is freed from the carbon compounds by a method which comprises adjusting the molar ratio of the aluminum component to the sodium component in the liquid to a value in the range of from 1 to 5 calculated as Al.sub.2 O.sub.3 /Na.sub.2 O and heating the resultant Bayer liquor.

Abstract: When an alkali such as an alkali metal bicarbonate or carbonate is intimately mixed with bauxite or other alumina-containing raw material at an Al.sub.2 O.sub.3 /Na.sub.2 O molar ratio of from 1/1 to 1/3 and the mixture is molded into granules, then calcined and extracted with an aqueous medium, the alumina component can be recovered in a high yield in the form of an aqueous solution of an alkali metal aluminate. The alkali component is not substantially contained in the residue left after recovery of this aqueous solution.

Abstract: A process and installation for the integrated treatment of concentrated residual solutions resulting from the anodization of aluminium parts is described, in which caustic soda is employed in the pickling process and sulphuric acid in the anodization bath.The process comprises three sets of operations:(1) Production of aluminium sulphate in concentrated solution or in hydrated crystals, by the treatment of part of the residual solution from the anodization.(2) Production of precipitated aluminium hydroxide and a solution of sodium sulphate from residual anodization and pickling solutions.(3) Production of sodium aluminate from residual pickling solutions and aluminium hydroxide producted in (2). (FIG. 1.

Abstract: An improved method for recovering aluminum values from alkaline aluminosilicate raw material by sintering a comminuted aqueous mixture of the alkaline aluminosilicate material, limestone and soda solution wherein the alumino-silicate material is first comminuted with the soda solution to form a mixture with a fraction of particles larger than 0.08 mm greater than 20 percent by weight, mixing limestone with the mixture and comminuting until the fraction of particles larger than 0.08 mm is between 2 and 15 percent by weight.

Abstract: A low grade aluminum and silicon containing starting material is intimately mixed with limestone and the resultant mixture is fluidized. The fluidized mixture is preheated to a temperature of 700.degree. to 900.degree. C., then held at sintering temperature for 5 to 10 minutes. Aluminum may be recovered by extraction of the sintered powder so produced.

Abstract: In the production of alumina from aluminous ores by the Bayer process, the present invention provides an improvement for effectively and economically recovering caustic components consisting essentially of sodium aluminate from aluminum hydroxide cakes as seed classified from the product aluminum hydroxide by washing the seed with a washing liquor having a substantially saturated concentration of sodium oxalate and little content of caustic and then removing organic substances such as sodium oxalate from the washed seed by secondly washing said seed with hot water, thereby recovering caustic components without the dissolution of sodium oxalate from the seed into the recovered caustic solution and attaining the removal of sodium oxalate contaminant with high efficiency.

Abstract: A method of fluidizing concentrated aqueous suspensions of red mud which comprises uniformly admixing with such suspensions at least 0.1 pound per metric ton of an acrylic acid polymer which has a molecular weight within the range of 5,000-30,000.

Abstract: An improved process is provided for the recovery of HF in increased yield from spent aluminum reduction cell linings. The spent linings are pyrohydrolyzed in a fluidized bed reactor and the generated Na-containing vapors and gases are then contacted with a relatively finely divided source of Al.sub.2 O.sub.3. Contacting is preferably accomplished in the close vicinity of the fluidized bed to obtain extended reaction between the Al.sub.2 O.sub.3 source and the vapors. This extended reaction allows conversion of the Na-containing compounds, such as NaF and Na.sub.2 O to HF and an Na.sub.2 OxAl.sub.2 O.sub.3 compound.

Abstract: Fluoridic spent and waste materials, such as are generated in electrolytic aluminum reduction systems, are pyrohydrolyzed in a fluidized bed reactor. For fluidization of these materials, as well as for the combustion of carbon present in the materials, an O.sub.2 -containing gas stream, containing at least about 90% by volume O.sub.2, is employed. This results in the generation of an HF-containing offgas of significantly increased HF level, which can be employed for the manufacture of an AlF.sub.3 product of at least about 85% by weight AlF.sub.3 content from hydrated alumina. The offgas having the increased HF content can also be employed for the production of highly concentrated HF acid with significantly lower energy requirement needed for concentration than in conventional systems.

Abstract: A pyrohydrolysis system is provided for the recovery of valuable components from waste and spent materials generated in electrolytic aluminum reduction facilities. The pyrohydrolysis system employs a dense phase fluidized bed reaction zone for the pyrohydrolysis of coarse feed, a dilute phase fluidized reaction zone for pyrohydrolyzing fine feed, this zone being superimposed and interconnected with the dense phase zone. The offgases, after removal of the solids, are contacted in a dilute phase fluidized zone, with a source of Al.sub.2 O.sub.3 to remove residual Na values and to produce Na-free HF. The solids from the first dilute zone, having a desired high Na:Al atom ratio, can be combined with the product clinker from the dense bed zone. The offgas, containing the source of Al.sub.2 O.sub.3, is subjected to solids separation, the solids-free and Na-free HF is utilized, while the solids of low Na:Al mole ratio are recycled to the residual Na conversion step.

Abstract: A method for sampling and controlling the addition of suspended gases, liquids and solids in a control stream to a process stream is disclosed wherein the surface area of the suspended material acts as the determining feature for control of the process. The measured surface area is compared with a preselected surface area to control the addition of the suspended material. This method is particularly useful for the control of particulate seed material to the process stream in the Bayer process for the production of alumina. The method is also broadly applicable to physical and/or chemical control means in an analytical scheme for controlling and monitoring any process.

Abstract: Red mud slurries can be solidified by adding thereto certain fatty substituted quaternary ammonium salts.

Abstract: In a process for extracting alumina from alumina-containing ores on a two-stream system by individually preheating a slurry of alumina-containing ores and an aqueous alkali solution each in preheaters of indirectly heating, mixing the preheated slurry with the preheated aqueous alkali solution, and extracting alumina from the ores in a digester of either the heating type involving the direct injection of live steam or the heat-insulated type, the alumina is extracted from the ores by preparing the slurry of alumina-containing ores with water or a diluted aqueous alkali solution, such as from the drain obtained by recovering steam from an evaporator for cooling the slurry resulting from extraction, and utilizing the recovered steam in preheating the slurry of the alumina-containing ores or decomposition solution or both, preheating the slurry of alumina-containing ores, and mixing the preheated slurry with an aqueous alkali solution preheated as another stream as the decomposition solution.

Abstract: The red mud by-product of the Bayer process by which aluminum oxide is reed from bauxite as an aluminate, is digested with concentrated sulfuric acid or with sulfur trioxide gas to produce sulfates that can be leached out to the resulting mass with water. The solution is then heated at a pH of 1 to precipitate titanium oxide hydrate by hydrolysis. The remaining sulfates of the solution are then obtained in solid form by evaporation, or by precipitation with acetone, and the solid is then roasted to convert the aluminum and iron to the oxide. After leaching out the sodium sulfate with water, the aluminum and iron oxide are separated by the Bayer process, which works in this case even though x-ray diffusion patterns show that the aluminum oxide is mainly .alpha.Al.sub.2 O.sub.3.

Abstract: An electrolyte compact for fuel cells includes a particulate support material of lithium aluminate that contains a mixture of alkali metal compounds, such as carbonates or hydroxides, as the active electrolyte material. The porous lithium aluminate support structure is formed by mixing alumina particles with a solution of lithium hydroxide and another alkali metal hydroxide, evaporating the solvent from the solution and heating to a temperature sufficient to react the lithium hydroxide with alumina to form lithium aluminate. Carbonates are formed by reacting the alkali metal hydroxides with carbon dioxide gas in an exothermic reaction which may proceed simultaneously with the formation with the lithium aluminate. The mixture of lithium aluminate and alkali metal in an electrolyte active material is pressed or otherwise processed to form the electrolyte structure for assembly into a fuel cell.

Abstract: A fully integrated process is provided for the recovery of valuable components from waste materials generated in electrolytic aluminum reduction systems. The waste materials, such as spent pot linings, channel and trench cleanings, floor sweepings and spent alumina from offgas purifying dry scrubbers, are combined, then pyrohydrolyzed at elevated temperature. Fluoridic values, such as NaF and HF can be recovered from the offgas generated by pyrohydrolysis, while alumina and Na.sub.2 O values, or if desired, sodium aluminate, is reclaimed from the solid residue of pyrohydrolysis.The fluoridic values from the pyrohydrolysis offgas can be used for the manufacture of both electrolytes for aluminum reduction cells and also for the production of anhydrous HF. The alumina from the pyrohydrolysis residue can be reclaimed by a Bayer process-type leach with a caustic solution and the recovered high purity alumina utilized, for example, as reduction cell feed and/or for scrubbing reduction cell offgases.

Abstract: Floride and aluminum values, as well as carbon, are recovered from waste cathode liner material from aluminum electrolytic cells by leaching of the liner at ambient temperature with a caustic solution, followed by precipitation of sodium fluoride by saturating the leach liquor with a compound which suppresses the solubility of sodium fluoride in the leach liquor. Ammonia is a preferred compound. Aluminum compounds, as well as the carbon values, are also recovered. Treating chemicals used in the process are recycled. The process is essentially a closed-cycle process with substantially no discharge of effluent.

Abstract: A pretreatment system is provided for transforming the goethite constituent [FeO(OH)] of goethitic bauxites to hematite and/or magnetite at high temperatures and pressures. The system employs a number of float-type, liquid displacement pressure pumps, both for charging caustic-containing bauxite slurries of high solids concentration to the system and for discharging the treated slurries. The system operates at temperatures in excess of 250.degree. C and up to temperatures required for the total conversion of the goethite content to hematite or magnetite which, in turn, significantly increases the yield of recoverable alumina. Since the slurry to be pretreated is of high solids concentration, e.g.

Abstract: Vanadium and molybdenum are recovered from a spent desulfurization catalyst containing the same by a process involving intimately admixing with comminuted catalyst an amount of a solid alkali metal carbonate, such as calcined sodium carbonate, sufficient to convert the vanadium and molybdenum present into water-soluble compounds, heating the mixture in the solid state in the presence of air at a temperature between about 650.degree. C and about 850.degree. C for a period of about 1 to 2 hours, and extracting the vanadium and molybdenum compounds with water.

Abstract: Gallium and other values are recovered from phosphorus-furnace flue-dust by treating dust with sulfuric acid to form a solution and a residue. The residue may be treated for recovery of values. Zinc is precipitated from the solution as zinc ammonium sulfate hexahydrate and an alkaline material is added to precipitate a gallium concentrate and to form a gallium-free solution, which may be treated for recovery of sulfate and phosphate values. The gallium concentrate may be upgraded by mixing concentrate with lime to precipitate calcium phosphate and by subsequently adding sodium hydroxide to redissolve coprecipitated gallium and aluminum compounds. Residual precipitate is recycled and the solution is neutralized to precipitate an upgraded concentrate. Aluminum may be removed as calcium aluminate. Upgraded concentrate may be dissolved in alkaline solution and the solution electrolyzed for deposition and recovery of gallium.

Abstract: A method is provided for removing harmful organic compounds from the aluminate liquor obtained in the production of alumina according to the Bayer process. A magnesium obtained is added to the aluminate liquor to form a hydroxide mixture containing magnesium hydroxide and aluminum hydroxide which precipitates from the aluminate liquor. The precipitated mixture is maintained in the aluminate liquor, while being stirred, until at least a part of the organic compounds have been eliminated from the aluminate liquor. The hydroxide mixture containing the organic compounds then is separated from the aluminate liquor.

Abstract: A process is disclosed for recovering the caustic and alumina values from high iron-containing Bayer red mud utilizing the so-called lime-soda-sinter process wherein a carbonaceous material such as coke is included in the sintering operation and leaching is carried out without any intermediate iron separation step.

Abstract: Back reactions of dissolved alumina from a high caustic-lime digest of anorthosite and other alumina-containing siliceous materials can be eliminated or mitigated by control of particle size of digestible material; and time and temperature of separation of the alumina-bearing liquid from the solid residues. In one embodiment the back reaction is further controlled by adjustment of the caustic concentration of the digest effluent.

Abstract: In order to control the sodium oxalate level in the liquor employed in the Bayer process for the production of alumina, a part of the spent liquor recovered from alumina trihydrate precipitation stage is concentrated by evaporation to render it supersaturated with respect to sodium oxalate. The thus concentrated liquor is then sprayed onto a packing in an enclosed space under conditions such that the supersaturation of the droplets at impact on the packing exceeds a critical supersaturation. The sprayed liquor deposits sodium oxalate on the packing and is recovered for recirculation to the process circuit.

Abstract: A process for the obtention of alumina and phosphate values by the alkaline decomposition of silica-containing aluminum phosphate ores comprises reducing the ore to a particle size of from about 6 to 13 mm; calcining the ore at a temperature of from 500.degree. to 750.degree. C in order to remove water of crystallization and combined water; grinding the calcined ore to a particle size of from 20 to 60 mesh (U. S. Sieve); treating the calcined and ground ore with an aqueous solution having a concentration of from 20 to 30% by weight caustic alkali at an initial temperature of from 65.degree. to 75.degree. C; quickly filtering the hot suspension thus obtained to remove the solid silica and heavy metal oxides; adding a 50% caustic alkali solution to the filtrate in an amount sufficient to obtain a total concentration of from 10 to 15% by weight of free caustic alkali; cooling the alkaline liquor accompanied by an elutriation action in an elutriator to a temperature of from 5.degree. to 10.degree.

Abstract: An improved process is provided for the recovery of sodium aluminate crystallized from a digest of caustic and lime with high-silica aluminous materials. The digest solution is concentrated by evaporation and then seeded with Na.sub.2 Al.sub.2 O.sub.4.2.5H.sub.2 O crystals to crystallize alumina from the solution as Na.sub.2 Al.sub.2 O.sub.4.2.5H.sub.2 O. The crystals are then separated from the mother liquor solution by filtration or centrifugation. The crystals are then washed with a solution having a lower caustic content than the mother liquor and an alumina concentration of about 50 grams per liter to remove any mother liquor remaining on the crystals. The sodium aluminate crystals are used as a feed for a subsequent Bayer processing step.

Abstract: In a process for extracting alumina from alumina-containing ores by individually preheating a slurry of alumina-containing ores in alkali solution, and an alkali solution, and feeding the preheated slurry and the preheated alkali solution to a digester maintained at a temperature of about 200.degree. to about 300.degree. C, thereby extracting alumina from the alumina-containing ore. The alumina extraction is carried out without any formation of scales on the inside surface of the preheater with a considerably prolonged operating duration by preparing a slurry having a molar ratio of Na.sub.2 O/Al.sub.2 O.sub.

Abstract: Disclosed is a method for the treatment of the red mud byproduct of the Bayer aluminum process, wherein limestone, hydrated lime or other CaO-containing material is added to the red mud in certain molar proportions to the ingredients of the red mud, then the mixture is further mixed with a reducing agent, and the entire mixture is subjected to a reducing heat treatment during the course of which the mix becomes softened or molten. The iron and the slag are separated from each other while the mix is still molten, or after it has been cooled, and then the Na and Al-content of the slag is extracted with a sodium carbonate solution containing a caustic, or with a sodium carbonate solution and a solution of a caustic in two steps.

Abstract: A method of producing an alumina bearing product in which the alumina is substantially soluble in cold alkali including the steps of contacting an aluminium bearing material with concentrated sulphuric acid containing 30 to 100 weight percent sulphuric acid, heat treating the acid and material to cause the acid to react with the material to form a substantially anhydrous hard product and decomposing the product by heat treatment to produce the alumina bearing product. The alumina values may be recovered from the resulting alumina bearing product using the known Bayer process. The process has particular application to non-bauxitic ores.