Abstract: Aluminum may be recovered from various raw materials including kaolinite, alunite, coal ash and slag, and both raw and spent oil shale, by contacting such materials with an aqueous solution of hydrofluoric acid, followed by removal of the insoluble residues remaining suspended in solution and the precipitation of hydrated aluminum hydroxide from the clear solution by basification with an alkaline agent.

Abstract: An improvement in the process for recovering aluminum from alunite ore disclosed in U.S. Pat. Nos. 3,890,425 and 3,890,426, the improvement being in the recovery of potassium sulfate by crystallization from the leaching solution resulting from potassium hydroxide leaching of the roasted ore, the improvement consisting of adding potassium hydroxide to the concentrated leach liquor prior to crystallization to increase the concentration of the potassium ion so that increased recoveries of potassium sulfate are obtained at a given temperature over those obtained when this procedure is not used. By this procedure a yield is obtained at a temperature below that which is required to obtain the same yield when potassium hydroxide is not used so that the high temperatures formerly necessary to hold enough potassium sulfate in solution for an economic crystallization are avoided.

Abstract: An improvement in the process for the recovery of aluminum from alunite in which the alunite in particulate form is dehydrated, sulfur and alkali metal compounds removed from the dehydrated ore leaving a particulate residue containing aluminum values, the residue digested with at least one alkali metal hydroxide to convert the aluminum values to soluble aluminates, silicon removed from the soluble aluminate solution, and aluminum values precipitated from the aluminate solution, the improvement comprising: multiple stage digestion of the particulate residue accomplished by dividing the particulate residue into two fractions, digesting one fraction first and using the first stage liquor from the first digestion step to digest the remaining fraction. The fraction digested first may be the one having the smaller particle size, or the one having the larger particle size.

Abstract: In a coal gasification operation or similar process carried out in the presence of an alkali metal-containing catalyst wherein spent solids containing ash and alkali metal catalyst residues are produced, alkali metal constituents are recovered from the spent solids by first removing magnetic constituents from the solids, contacting the solid particles from which magnetic constituents have been separated with an acid solution to extract alkali metal constituents from the solids and produce a spent acid solution enriched in alkali metal salts, raising the pH of the enriched solution sufficiently to precipitate aluminum from the solution as aluminum hydroxide, heating the remaining solution to precipitate silicon compounds, and recovering an enriched alkali metal solution from which aluminum and silicon compounds have been removed.

Abstract: Alumina dust, particularly partially calcined alumina dust, is coarsened by forming an aqueous admixture or slurry comprising the alumina dust and finely divided calcium carbonate and introducing the resulting aqueous admixture or slurry into Bayer pregnant liquor and precipitating alumina trihydrate from the resulting Bayer pregnant liquor.

Abstract: Aluminate mother liquor is passed countercurrent to the direction of feed of aluminum hydroxide crystals through at least two stages, each of which has a lower turbulent zone with a high suspension density and which is agitated under conditions which assure particle growth via crystal growth and an upper non-turbulent, stagnant liquid layer from which most crystals settle back into the respective lower turbulent zone. The suspension density in the stages is maintained at a constant level by sending crystal suspension from the lower turbulent zone in all the precipitation stages but the first to the preceding stage. Mother liquor is removed from the upper stagnant zone of all stages but the last stage and sent to the respective following stages. Coarse crystal suspension is removed from the turbulent zone of the first stage for separation of the crystals for further processing, while the mother liquor is returned to the system.

Abstract: The invention concerns a process for solubilizing alumina in minerals, rocks or industrial waste products, in which the starting material in finely divided form is mixed with lime in an amount 1 to 3 moles or more of lime (CaO or Ca(OH).sub.2) for each mole of alumina and optionally 1 mole for each mole of any silica present in the starting material, and at the same time or thereafter with water, the resulting mix is maintained under hydrothermal conditions until the alumina has become solubilized by reaction with the lime, and the product is if necessary comminuted to bring it to a form suitable for leaching out of the solubilized alumina.

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: Alumina monohydrate is produced by treating aluminum nitrate solution at a temperature of about 250.degree. to 350.degree. C and a pressure of about 500 to 2500 psig.

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 is provided which allows control of the impurity level of Bayer process streams with simultaneous generation of an environmentally acceptable effluent and recovery of valuable dissolved aluminum and sodium values. The process involves carbonation of a blow-down stream at 40.degree.-100.degree. C to produce sodium dawsonite [NaAl(OH).sub.2 CO.sub.2 ] and an effluent essentially free of dissolved alumina and significantly depleted in dissolved sodium. The sodium dawsonite can be used as such or returned to the Bayer process after thermal decomposition to sodium aluminate. The effluent can be directly discharged into natural receiving bodies without further treatment.

Abstract: A continuous process for the production by electrodialysis of monobasic potassium phosphate from phosphoric acid produced by the wet process and potassium sulfate produced as a by-product in processes for the recovery of aluminum from alunite.

Abstract: A process for recovering aluminum from alunite ore directed to providing a residue for the Bayer leach step substantially free of impurities so that a high A/C ratio Bayer leach liquor is produced, which comprises roasting the ore in particulate form to drive off water and sulfur as SO.sub.2 and to convert aluminum sulfate to alumina, leaching the residue containing aluminum values with water and filtering to remove potassium sulfate and other soluble sulfates, hot leaching the residue with sulfuric acid to convert the alumina therein to soluble aluminum sulfate followed by filtering to remove silicon dioxide and other solid impurities, crystallizing the aluminum sulfate to further remove impurities, heating the residue to convert the aluminum sulfate to alumina and drive off any remaining sulfur as SO.sub.2, and digesting the alumina calcine with sodium hydroxide under standard Bayer conditions at a high A/C ratio to provide a high A/C ratio solution from which a "sandy" aluminum hydroxide is precipitated.

Abstract: This invention relates to an improvement in the well known "Bayer" process. In particular, the invention describes a process for the recovery of gallium and alumina from bauxite including the steps of:A. dissolving the ore in caustic soda solution under pressure;B. precipitation of pure alumina from the remaining caustic soda solution by reduction of temperature and pressure;C. subjecting the resulting mother liquor from (b) to an elevated temperature of 60.degree. to 450.degree. C and a pressure of 2 to 100 atmos. in the presence of an oxygen-containing atmosphere; andD. cementation of the gallium remaining in solution by contact with metallic aluminium.Step (a) is preferably carried out at a pressure of 5 atmospheres and step (c) is carried out in the presence of an atmosphere consisting substantially of oxygen at a pressure within the range 20 to 50 atmospheres and a temperature within the range 150.degree. to 350.degree. C.

Abstract: This invention relates to a method for recovering aluminum hydroxide from alunite ore by roasting the ore to remove water of hydration, roasting it again in a reducing atmosphere to remove sulfate, roasting a third time in an oxidizing atmosphere to convert any sulfides formed in the second roast, leaching with a weak base, leaching with water to remove potassium and sulfate, extracting the aluminum content with a mixture of sodium hydroxide and potassium hydroxide, removing contaminant silica from the leach solution, and precipitating aluminum hydroxide by cooling and seeding the solution.

Abstract: Metal values are extracted from manganiferous ocean floor nodule ore by treating the ore with hydrochloric acid, thereby producing chlorine and a starting pulp containing a solution of the metal chlorides and a solid residue. The starting pulp is subjected to at least two subsequent acidifications with HCl, each acidification being followed by addition of fresh ore, thereby producing chlorine and a final pulp containing a concentrated solution of metal chlorides and a solid residue. The solid residue is separated from the concentrated solution and substantially all the metal values, except manganese and alkali and alkaline earth metals, are separated from the solution. The manganese is separated from the solution by treatment with chlorine, at least the major portion of which was produced in the preceding leaching steps, while maintaining the solution at a pH of between about 3 and 7 by addition of a neutralizing agent such as MgO or Mg(OH).sub.2 whereby the manganese is precipitated in the form of MnO.sub.

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: Ammonium hydroxide is added to a mixture of high-temperature, high-pressure geothermal steam and brine to raise the pH of the brine to between 6.0 and 7.0 and precipitate out a gelatinous sludge of aluminum and iron hydroxides. The hydroxide sludge is suspended in the brine and sweeps out enough dissolved silica so that the temperature and pressure of the brine can be reduced with little, if any, formation of silica scale. Various metals and ammonium hydroxide may then be recovered from the brine, the ammonium hydroxide being recycled in the process.

Abstract: Aluminum oxide having a sodium oxide content after calcination of less than 0.1% by weight is continuously precipitated as aluminum hydroxide from a Bayer process liquor by a controlled slow precipitation. The controlled, slow precipitation rate required to create a low soda product is achieved by controlling the residence time of liquor in the precipitation vessel so as to provide a constant, low ratio of aluminum oxide to sodium oxide. Residence time control in a Bayer process plant is achieved by controlling green liquor flow rate to the tank, or by sizing the tank for a constant flow. The use of heavy seed charges to increase the seed surface area permits the production of a low soda product at a faster precipitation rate.

Abstract: A process for the production of monobasic potassium phosphate from wet process phosphoric acid and potassium sulfate by ion exchange. The application of the process is the production of monobasic potassium phosphate by ion exchange from wet phosphoric acid produced by the reaction of sulfuric acid on apatite rock and by-product potassium sulfate from processes for the recovery of aluminum from alunite.

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: A method for dehydrating alunite ore prior to further processing to recover metals therefrom, comprising exposing the ore in particulate form to burning coal as the heat supply in a fluidized bed fluidized with an oxygen containing gas. The invention is illustrated by the removal of water from alunite ore prior to further processing the ore to recover aluminum.

Abstract: An improvement in processes for recovering aluminum from alunite ore which processes include roasting the ore to remove water of hydration, removing sulfur and potassium compounds from the roasted ore by a procedure including a final leaching step resulting in a residue and a solution containing potassium sulfate, effecting partial recovery of potassium sulfate from the solution by crystallization with some potassium sulfate being bled off from the mother liquor, converting aluminum values in the residue to alkali metal aluminates by digesting the residue with alkali metal hydroxide including a substantial amount of sodium hydroxide, removing silicon from the alkali metal aluminates leaving a waste desilication product, recovering aluminum values from the desilicated aluminates by precipitation, circulating the mother liquor from the precipitation step to digestion as contaminated sodium hydroxide is bled off, the improvement which comprises enhancing the economics of the overall process by introducing therei

Abstract: A process for the extraction of gallium from sodium aluminate liquors comprises extracting gallium from aluminate liquors by cementation with the aid of a liquid gallium-aluminum alloy. Aluminate liquors produced in the Bayer process, prior to cementation, are freed from various impurities. To this end, the recycle aluminate liquor is cooled to a temperature at which soda crystallizes and vanadium is retained in the liquor, whereupon the crystallized precipitate is separated, while the residual liquor is mixed with the mother aluminate liquor in the ratio of 0.1-1 to 1-0.1. The resultant liquor is cooled down to ambient temperature, and the vanadium precipitate is separated. The process is a major step towards a simpler technique of gallium extraction from aluminate liquors both high and low in gallium. Also, the process permits extracting, directly from aluminate liquors, gallium in a higher degree of purity than can be obtained in the prior art.

Abstract: A method for processing alunite consisting in that alunite ore is treated with a solution of caustic alkalis at a maximum temperature of 60.degree.C, and a solid residue resulting from the above operation and containing largely potassium and sodium sulphates, is washed with hot water. As a result, potassium and sodium sulphates are dissolved in the wash water, and potassium sulphate is isolated by the action of a caustic-potash solution. The method enables losses of alkalis and aluminium during processing alunite ores containing active forms of silicon compounds to be much reduced, which compound when treating alunite ores with a solution of caustic alkalis, are liable to form insoluble aluminosilicates which are discarded into slime and thus lost together therewith when the latter is separated from the process solution.

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.

Abstract: An improved process for preparing highly concentrated salt solutions of metals of high purity from waste metal sludges at superior dissolution rates is achieved by preparing, concentrating and washing the sludge containing insoluble metal hydroxide under specific conditions to safeguard against the solids being exposed to air or dried out. The wet sludge is then dissolved in a dilute acid. The resultant solution can be used directly e.g. as make up in many electrolytic metal finishing processes to compensate for drag out losses occurred, or as the primary metal source in electrolytic processes employing insoluble anodes. Other specific uses for the process include the preparation of aluminum sulfate coagulants.