Abstract: A process of producing a structure for molecular separations includes providing a plurality of template materials. The template materials are selected from biomolecules, biopolymers, polymers, or combinations thereof. A sieve material, suitable for producing a structure for molecular separations, is provided around the template materials. The template materials are positioned in an arrangement for leaving pores suitable for molecular separations. The template materials are removed to leave pores in the sieve material and produce the structure suitable for molecular separations. The structure so produced can be used for molecular separation. In some embodiments, methods for molecular separation include situating in a feed stream an array of pores each approximating a double-stranded DNA molecule; flowing the feed stream into the pores; and allowing the pores to transport therethrough molecules within the feed stream, so as to separate the molecules from the feed stream.

Abstract: Systems and methods for treating a fluid with a body are disclosed. Various aspects involve treating a fluid with a porous body. In select embodiments, a body comprises ash particles, and the ash particles used to form the body may be selected based on their providing one or more desired properties for a given treatment. Various bodies provide for the reaction and/or removal of a substance in a fluid, often using a porous body comprised of ash particles. Computer-operable methods for matching a source material to an application are disclosed. Certain aspects feature a porous body comprised of ash particles, the ash particles have a particle size distribution and interparticle connectivity that creates a plurality of pores having a pore size distribution and pore connectivity, and the pore size distribution and pore connectivity are such that a first fluid may substantially penetrate the pores.

Abstract: A system and method for treating tailings from a bitumen froth treatment process such as TSRU tailings. The tailings are dewatered and then combusted to convert kaolin in the tailings into metakaolin. Calcined fines and heavy minerals may be recovered from the combustion products, namely from the flue gas and bottom ash.

Abstract: A liquid phase that comprises an oxalate-extracting amount of an organic salt is useful as an extractant in a liquid/liquid extraction process for purifying Bayer process streams.

Abstract: The present invention relates ways to increase the output of a high quality product from the aluminum hydroxide recovery processes such as the Bayer process. The invention is a method of increasing the size of precipitated aluminum hydroxide while not reducing the total production amounts. The invention relates to the use of a crystal growth modifier compositions added to the precipitation liquor to increase the particle size distribution of the precipitated alumina trihydrate.

Abstract: A process for removing anionic impurities from a caustic aluminate solution having aqueous tetrahydroxy aluminate ions is described. A caustic aluminate solution is obtained such that anionic impurities are partially or substantially substituted into tetrahydroxy aluminate ions to form substituted aluminate ions. A suitable calcium compound, such as quicklime, is reacted in a conventional slaker (10) with a slaking solution, for example water, and stored in an agitated storage tank (12). The resulting slurry is pumped to a reaction vessel (14) where it is reacted with a caustic aluminate solution under appropriate conditions such that the calcium compound is converted into tricalcium aluminate (TCA) precipitate. Upon reaction substituted aluminate ions are substantially incorporated within the TCA precipitate to form a substituted TCA precipitate enabling the anionic impurities to be removed from the solution via the substituted TCA precipitate for disposal or recovery.

Abstract: The invention provides methods for purifying caustic feed streams using membranes that comprise polysulfonamide matrices.

Abstract: A liquid phase that comprises an oxalate-extracting amount of an organic salt is useful as an extractant in a liquid/liquid extraction process for purifying Bayer process streams.

Abstract: The Bayer process uses hot sodium hydroxide solution to obtain pure alumina from bauxite ore. Alumina dissolves, and is then precipitated, and the remaining caustic Bayer liquor can be recycled for use again. However sodium oxalate tends to build up in the recycled liquor, and causes problems. By removing a stream of the liquor, treating it so as to be supersaturated with sodium oxalate, and then subjecting it to ultrasonic irradiation, crystal nuclei are formed. The resultant crystals can then be separated from the liquor. Surprisingly, other organic compounds in solution do not prevent this crystallisation process from being effective.

Abstract: A process for the removal and causticisation of sodium oxalate and/or sodium sulphate from a Bayer process liquor containing sodium carbonate and one or both of sodium oxalate and sodium sulphate in an alumina refinery is described. The process is based on the observation that to efficiently causticise sodium oxalate solutions, it is first necessary to remove the aluminate ion from solution, optionally with recovery of the aluminate ion in some later step. This is effected by removing aluminate ions from the Bayer liquor through the formation of a carbonate bearing hydrocalumite and/or sulpha-bearing hydrocalumite. The liquor may then be treated with sufficient lime to remove and causticise any residual carbonate ions and some or all of the oxalate ions present so that any reacted lime solids thus formed can be separated and safely disposed of.

Abstract: A composition of matter which is aluminum hydroxide, produced using the Bayer Process, wherein the aluminum hydroxide produced has a Total Organic Carbon of less than about 0.5 milligrams Total Organic Carbon/gram aluminum hydroxide.

Abstract: The present invention provides methods for selectively removing organic compound from a nano-composite material which comprises the organic compound that is dispersed within a solid inorganic compound structure. In particular, methods of the present invention comprise irradiating the nano-composite material with electromagnetic radiation wavelength that is shorter than the wavelength of visible light.

Abstract: Disclosed is a process for the elimination of volatile, foul-smelling organic compounds which are liberated in a gas suspension calciner process utilized to manufacture alumina. The process comprises recirculating captured alumina dust on which undesirable volatile organic compounds are adsorbed to a location in the manufacturing process (1) at or upstream (based on the path of the conveying gases) from the gas suspension calciner and (2) which is operating at a temperature of about 700 ° C. or higher. The adsorbed organic compounds are stripped off the alumina dust and are subsequently directed by process air into the gas suspension calciner furnace which is operating above 1000 ° C. under oxidizing conditions. Under such conditions the organic compounds are oxidized to H2O vapor and CO2. It is a preferred feature that the volatilized organic compounds are adsorbed on the alumina dust in a baghouse.

Abstract: A process for the removal and causticisation of sodium oxalate and/or sodium sulphate from a Bayer process liquor containing sodium carbonate and one or both of sodium oxalate and sodium sulphate in an alumina refinery is described. The process is based on the observation that to efficiently causticise sodium oxalate solutions, it is first necessary to remove the aluminate ion from solution, optionally with recovery of the aluminate ion in some later step. This is effeeted by removing aluminate ions from the Bayer liquor through the formation of a carbonate bearing hydrocalumite and/or sulpha-bearing hydrocalumite. The liquor may then be treated with sufficient lime to remove and causticise any residual carbonate ions and some or all of the oxalate ions present so that any reacted lime solids thus formed can be separated and safely disposed of.

Abstract: A process for the removal and causticisation of sodium oxalate and/or sodium sulphate from a Bayer process liquor containing sodium carbonate and one or both of sodium oxalate and sodium sulphate in an alumina refinery is described. The process is based on the observation that to efficiently causticise sodium oxalate solutions, it is first necessary to remove the aluminate ion from solution, optionally with recovery of the aluminate ion in some later step. This is effected by removing aluminate ions from the Bayer liquor through the formation of a carbonate-bearing hydrocalumite and/or sulphate-hearing hydrocalumite. The liquor may then be treated with sufficient lime to remove and causticise any residual carbonate ions and some or all of the oxalate ions present so that any reacted lime solids thus formed can be separated and safely disposed of.

Abstract: A process is provided for removing organic contaminants from a bayer process stream using a nano-filtration membrane.

Abstract: A process is disclosed for the treatment of an alumina process feedstock prior to transferring the treated feedstock to an alumina process for extracting refined alumina from the treated feedstock. The treatment process includes the following steps: (a) heating the alumina process feedstock to a temperature of 400C. to 650C. by direct contact with combustion gases, and (b) cooling the heated feedstock to a temperature at which it can be handled and fed to the alumina process. The treatment process is characterised by controlling the contact time of the solid alumina process feedstock at temperatures in the above range in step (a) to less than 5 minutes.

Abstract: A process is provided for the treatment of an alumina process feedstock prior to transferring the treated feedstock to an alumina process for extracting refined alumina from the treated feedstock. The treatment process includes: (a) heating the alumina process feedstock to a temperature of 400° C. to 650° C. by direct contact with combustion gas, and (b) cooling the heated feedstock to a temperature at which it can be handled and fed to the alumina process. The treatment process also includes controlling the contact time of the alumina process feedstock at temperatures in step (a) to ensure decomposition of alumina trihydrate and alumina monohydrate. The process also includes: (i) limiting the maximum temperature of incoming gas to a stage of the process in which the alumina process feedstock reaches the above temperature range of 400° C. to 650° C.

Abstract: A process for the removal of organic impurities in a Bayer process liquor in which wet and dry oxidation processes are linked together in a complementary way, such that the weaknesses of each individual organic removal process become a strength of the combined process. An organics-rich liquor stream is fed to a wet oxidation process to produce a first processed liquor which is depleted in organic compounds, but enriched in sodium carbonate and/or sodium oxalate. A feed slurry is fed to the dry oxidation process, typically including a liquor burner, where sodium compounds react to produce a discharge product. The first processed liquor and discharge product are directed into a leach tank, resulting in the formation of precipitated products including sodium carbonate and/or sodium oxalate. The precipitated products are separated from the leach tank and recycled in a mix tank providing the feed slurry to the liquor burner.

Abstract: A process in which alumina is extracted from bauxite with an aqueous alkali solution, and a desilication product is precipitated such that the product is not contained in a bauxite residue and does not form a complex. The desilication product is mixed with a calcium compound, and the mixture is calcined, to thereby solubilize and recover an alkali component of the product. In addition, an alkali component is removed from a residue (a solid product), and the residue is effectively used as a resource.

Abstract: A process for producing alumina from bauxite is described in which bauxite is treated with an alkali to form a mixture comprising a solution of aluminum-containing ions and alumina trihydrate is precipitated from the solution. The process comprises treatment of the solution before or after the precipitation step with a layered double hydroxide in order to remove impurities from the solution by intercalation into the layers in the double hydroxide. The double hydroxide may contain layers of the formula: [LiAl2(OH)6]+.

Abstract: A method is disclosed for controlling the precipitation of soluble sodium oxalate in Bayer process liquor which comprises adding a surface active quaternary ammonium compound to the Bayer process liquor and then subsequently adding a mixture of a hydrophobic oil and at least one surfactant.

Abstract: The invention relates to a reactor for the treatment of wastewater solutions containing cyanide and other dissolved organic material, having an elongated tube having an entrance (28) and an exit (32), and an energy source (22) for the tube, preferably positioned adjacent the exit. The energy source generates intense energy such that a cyanide/organic material-containing solution can be treated by passing it through the tube to expose it to said energy so that the solution absorbs sufficient energy from the energy source to degrade the cyanide and/or dissolved organic material contained therein. The source of intense energy is preferably a plasma, e.g. a plasma generated by a plasma torch or a DC electric arc. The invention also relates to a process of treatment of such a wastewater solution by passing it through such a reactor.

Abstract: Spent potliners from the aluminum processing industry are destroyed by gasification technology to produce an inert vitreous frit and useful gases including hydrogen fluoride, hydrogen and carbon monoxide. In one embodiment, the potliner material is processed in a slagging gasification unit in which the potliner material a bed of coke or other particulate material moves down through a preheating zone, a reduction zone and an oxidation zone where oxygen is injected into the then-incandescent bed. In a second embodiment, particles of spent potliner material are entrained in two rotating gaseous streams which are tangentially introduced into upper and lower regions of a processing vessel. In a third embodiment, particles of spent potliner material are entrained in and reacted with a stream of gases which flows down from a burner through a processing vessel.

Abstract: The invention relates to a method for the treatment of an impure aluminium oxide so that the organic impurities present therein it are converted into an insoluble and easily separable substance. According to the invention, aluminium oxide which contains organic matter as impurities is finely ground, the finely ground aluminium oxide is dissolved at an elevated temperature in sulphuric acid which has a concentration of at minimum 90% by weight, the amount of the sulphuric acid being at least stoichiometric in relation to the amount of aluminium oxide, the organic matter being carbonized into an insoluble and easily separable substance, and, if desired, the obtained mixture is treated further in order to form a solution-form or solid chemical which contains aluminium.

Abstract: A new and improved method for inhibiting the precipitation of sodium oxalate crystals in a Bayer process liquor is provided. In an embodiment, the method comprises the step of adding to the Bayer process liquor, after red mud separation, a minor effective amount of a liquor oxalate stabilizer selected from hydrocarbon-substituted amine oxide compounds and/or hydrocarbon-substituted betaine compounds.

Abstract: Process of sodium oxalate purification of sodium aluminate solutions resulting from alkaline attack of bauxites according to the Bayer process, comprising:precipitation of said sodium oxalate in at least a fraction of the pre-decomposed sodium aluminate solution, by means of an agent that destabilizes the supersaturation state of the sodium oxalate, or deoxalation initiator,separation of the oxalate, precipitated with the destabilizing agent in the form of an insoluble residue, and the purified sodium aluminate solution which is then recycled as the leaching liquor, characterized in that the destabilizing agent or deoxalation initiator, placed in contact with the sodium aluminate solution, is a salt other than an oxalate, a metal oxide, a metal hydroxide, or a mixture thereof, said destabilizing agent remaining insoluble and chemically inert with respect to the reaction medium, and in that, after regeneration if any, it is recycled to the top of the process as the deoxalation initiator.

Abstract: A method for flocculation of red mud in Bayer Process streams utilizing a fatty acid or fatty acid ester free latex polymer flocculant. Preferred fatty acid free emulsifiers useful for the preparation of such flocculants are obtained by reacting ethylene and/or propylene oxide with a reagent selected from the group consisting of ethylene diamine, ethanol and ethylene glycol.

Abstract: Methods of reducing foam in Bayer process liquor are provided, said methods comprising adding a composition to the Bayer process liquor that comprises a tri(alkoxy alkyl) phosphate and a hydroxyl group containing carrier.

Abstract: Sodium oxalate is precipitated from spent Bayer process liquor by mixture with a low total alkalinity (TA) sodium oxalate seed solution that has been treated with two or more adsorbents to remove organic poisons from the sodium oxalate. The adsorbents are preferably two different adsorbents selected from activated carbon, ESP dust, calcium oxide and magnesium oxide. Surprisingly, combination treatments with activated carbon and ESP dust are most effective even though ESP dust alone has little effect on oxalate removal.

Abstract: Improved process for fluidifying flocculated aqueous suspensions of red muds in the production of alumina from bauxite by the Bayer process, which consists:in dissolving bauxite using sodium hydroxide;then, in decanting and in washing the red muds formed in order to separate them from the alumina in successive vats, while recycling the washing waters upstream;and finally, in eliminating the red muds thus treated;and in which a flocculant (F) consisting of a polyacrylamide of molecular weight greater than ten million is introduced into the suspension of one of the successive vats;wherein a dispersing agent (D) formed by an anionic acrylic acid polymer of molecular weight lower than fifty thousand is added simultaneously with said flocculant (F) to the suspension in the same vat.

Abstract: There is disclosed a method for improving the brightness level of aluminum hydroxide removed from a caustic solution. The method comprises:(a) pre-filtering the solution to remove contaminants therefrom; and (b) contacting the filtered solution with an adsorbent consisting essentially of a calcined compound having the formula: A.sub.w B.sub.x (OH).sub.y C.sub.z.nH.sub.2 O wherein A represents a divalent metal cation selected from the group consisting of: Mg.sup.2+, Ni.sup.2+, Fe.sup.2+, Ca.sub.2+ and Zn.sup.2+ ; B represents a trivalent metal cation selected from the group consisting of: Al.sup.3+, Fe.sup.3+ and Cu.sup.3+ ; C represents a mono- to tetravalent anion selected from the group consisting of: OH.sup.-, Cl.sup.-, Br.sup.-, NO.sub.3.sup.- CH.sub.3 COO.sup.-, C.sub.2 O.sub.4.sup.2-, CO.sub.3.sup.2-, SO.sub.4.sup.2-, PO.sub.4.sup.3-, Fe(CN).sub.6.sup.3- and Fe(CN).sub.6.sup.4- ; and w, x, y, z and n satisfy the following: 0<z.ltoreq.x.ltoreq.4.ltoreq.w.ltoreq. 1/2 y and 12.gtoreq.n.gtoreq.

Abstract: Bauxite that is to be used in the Bayer process for the recovery of alumina is washed with aqueous wash liquor having a caustic content of at least 50 g/l and which comprises aqueous caustic from the alumina recovery circuit of the Bayer process and, after removing organic material from the wash liquor, the wash liquor is included in the digestion stage, the separation stage or the alumina recovery circuit of the Bayer process.

Abstract: The use of a dewatering aid comprising a sulfosuccinate and an oil in the filtration of alumina trihydrate is disclosed.

Abstract: Organic impurities are removed from Bayer process liquors using a polymer which contains vinylamine and/or vinylformamide.

Abstract: Siliceous materials produced by thermally treating spent Bayer process liquors are obtained in modified form when produced in the presence of polymeric quaternary ammonium compounds, polyamine polymers, copolymers of acrylic acid and acrylamide, and polyacrylamides. These modified siliceous materials possess morphologies which confer upon them a reduced tendency to deposit on surfaces throughout the process.

Abstract: The invention purpose is a process to obtain gel to elaborate Zeolite 4A, to be used in detergents due to its capacity for calcium absortion; the process lies on the obtention of an alkaline aluminum solution starting from bauxite provided by tank 3 which is attacked in digestor 1 with sodium hydroxide provided by tank 4, with a concentration of 11% minimum, with a filtration of the reacting mass and a purification 13 before the gel formation step in whose reactor 14 is also introduced an alkaline solution of SiO2 to obtain by agitation and temperature a gel which is treated in a crystallizer 15, cooling and concentrating the crystalline mass in 16, filtered in 17, and passed to a dryer 20 from where the product Zeolite 4A passes to storage 21. Bauxite residues are attacked with boiling sulphuric acid in reactor 9, filtering the resulting mass in 11 to recycle the silica and to recover the metal sulphates in solution for using them in water treatments.

Abstract: A method for inhibiting the precipitation of sodium oxalate crystals in a Bayer process liquor. The method comprises the step of adding to the Bayer process liquor, after red mud separation and immediately prior to crystallization of alumina trihydrate, or during crystallization of alumina trihydrate, or during classification of alumina trihydrate, an effective amount of a cationic, surface active, alkylammonium salt compound.

Abstract: A process for heat treating spent pot linings from Hall-Heroult electrolytic cells which comprise carbon and silico-aluminous materials impregnated with fluorides. The pot linings are ground to a particle size less than 5 mm, and formed into an intimate mixture with calcium sulfate or calcium sulfate dihydrate having a particle size less than 1 mm. The mixture is injected into the center of a vortex formed by a flow of circulating hot gas at the top part of a reactor at a temperature between 700.degree. and 1100.degree. C., and extracted from the bottom part of the reaction at a temperature between 400.degree. and 750.degree. C. after a contact time of less than 2 seconds.

Abstract: A method for defoaming a Bayer process liquor, the method comprising the steps of adding to the Bayer process liquor an effective amount of an antifoam/defoamer composition comprising a polyether surfactant and a polyhydric alcohol fatty acid ester.

Abstract: Waste energetic compositions such as solid rocket propellant are treated to reclaim valuable aluminum particles and oxidizer in a form in which they can be reused, and to incinerate the remaining solids in a totally environmentally sound manner. An initial percentage (40-50% by weight) of the oxidizer is extracted during hydromining when the propellant is removed from the casing of a rocket motor. Additional oxidizer (35-45% by weight) is extracted from the propellant during subsequent underwater high speed maceration operations. The residual material containing mostly aluminum and binder matrix is thermally destroyed in a closed incinerator and the aluminum recovered as very high purity aluminum oxide.

Abstract: Bayer process liquors derived from the digestion of bauxites with a caustic solution are purified by removing the organic impurities present in the liquors. Removal of these impurities is accomplished by treating the liquor containing dispersed solids with a high viscosity polymer which includes diallyl dimethyl ammonium monomers.

Abstract: A method for defoaming a Bayer process liquor, the method comprising the steps of adding to the Bayer process liquor an effective amount of an antifoam/defoamer composition comprising a water-soluble polypropylene glycol having an average molecular weight of from about 200 to about 600 daltons.

Abstract: The invention relates to a thermal shock treatment in a reactor of ground spent pot linings, constituted both by carbon-containing products and silico-aluminous products impregnated with fluorine-containing mineral compounds, mixed with a pulverulent mineral additive able to combine hot, with or without melting or fusion, with the fluorine-containing impregnating compounds in order to form new stable and insoluble compounds such as CaF.sub.2, binary, ternary or quaternary compounds of NaF, CaF.sub.2, SiO.sub.2, Al.sub.2 O.sub.3, CaSO.sub.4, Na.sub.2 SO.sub.4, of the nephelite, hauynite or similar type.

Abstract: A process is disclosed for reducing the turbidity of a Bayer process liquor containing a cationic polymer-humate complex comprising adding to said liquor a higher molecular weight, cationic polymer.

Abstract: Disclosed is a method of manufacturing an oxide superconductor containing at least an alkaline earth metal and copper. This method comprises the steps of heating a material substance containing elements constituting the oxide superconductor, in an atmosphere having an oxygen partial pressure of at most 50 Torr at a temperature ranging from 500.degree. C. to 1000.degree. C., and then heating the material substance in an oxygen-containing atmosphere. Also disclosed herein is a method of manufacturing composite oxide powder which is the precursor of the oxide superconductor. This method comprises the steps of heating the material substance in an atmosphere having an oxygen partial pressure of at most 50 Torr at a temperature ranging from 500.degree. C. to 1000.degree. C., and crushing the material substance into powder.

Abstract: A method of modifying crystal structure of alumina trihydrate crystallizing from saturated Bayer liquors, which method includes the treatment of the saturated Bayer liquors with a crystal modifying amount of a polysaccharide, preferably a dextran.

Abstract: An economical process for the removal and destruction of organic impurities present in Bayer process liquor depends upon the use of a hybrid adsorbent. The hybrid adsorbent consists essentially of porous essentially anhydrous particles of alumina having deposited on the surfaces thereof including the pores, an ultrathin layer of carbon atoms which is essentially monomolecular. Such carbonization is effected by cracking a suitable hydrocarbon, preferably a gas, in contact with a hot turbulent fluidized bed of alumina particles. This layer has the unique property of adsorbing far more impurities than the equivalent weight of active carbon, and also oxalate ions which are known not to be adsorbed on carbon. As an ultrathin layer it is too thin to change either the average pore volume or the surface area of the alumina particles substantially, from before they are carbonized.

Abstract: In the Bayer process for producing alumina from bauxite of the type wherein the bauxite is added to a caustic solution to produce a soluble aluminate solution and an insoluble red mud fraction which is then subjected to one or more separation steps to produce a thickener overflow which is then subjected to a Kelly Filter Press to polish the thickener overflow the improvement which comprises treating the thickener overflow and the filter aid with a filtration improving amount of dextran.

Abstract: A process for treating spent potlining from the electrolytic smelting of aluminum in cryolite includes incinerating the potlining to combust carbonaceous material to form an ash at a temperature low enough to maintain low fluorine vapor pressures, admixing siliceous material with the potlining either before of after the ash-forming stage, and heating the ash and siliceous material to form a glassy residue.The residue formed by the process of the present invention produces a spent potlining suitable for landfill characterized by a low leachability of fluorine in water.