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DON DONALDSON, BS, has worked in all facets of the alumina industry for over sixty years. He was employed by Kaiser Aluminum and Chemical Corporation for thirty-four years and he continued working for twenty-seven years as an independent consultant. Mr. Donaldson has written several publications and holds a number of patents in alumina technology.
BENNY E. RAAHAUGE, MSc, is General Manager, Pyro & Alumina Technology for FLSmidth in Denmark. Prior to joining FLSmidth in 1974, he worked as plant engineer for the Danish Sugar Factories. Mr. Raahauge has more than thirty-six years of experience in the calcination of alumina hydrate to alumina, including research and development, process development and design, engineering, and dynamic simulation of gas suspension calciner.
Preface xvii
Lead Editors xxi
Editorial Team xxiii
Part 1: Bauxite
Section Introduction 1
L. Perander
Bauxite -Its Technical and Economical History During the Last Hundred Years 3
J. Régnier
Bauxite Mineralogy 21
H Hose
The Classification of Bauxites from the Bayer Plant Standpoint 30
V. Hill and R. Robson
Effect of Bauxite Microstracture on Beneficiation and Processing 37
K. Solymàr, F. Màdai, and D. Papanastassiou
Chinese Bauxite and Its Influences on Alumina Production in China 43
G. Songqing
Impact of Jamaican Bauxite Mineralogy on Plant Operations 48
D. Lawson, A. Rijkeboer, L. Andermann Jr., and A. Mooney
Sustainable Bauxite Mining: A Global Perspective 54
MI, BAC, and C. Wagner
Bauxite Mining Sustainability 60
P.Atkins, C. Bayliss, and S. Ward
Bauxite Mine Rehabilitation Programs: A Progress Report 66
P. Atkins
Cross-Country Bauxite Slurry Transportation 70
R. Gandhi, J. Norwood, and Y. Che
Design and Operation of the World's First Long Distance Bauxite Slurry Pipeline 75
PSI, R. Gandhi, M. Weston, M. Talavera, CVRD, G. Brittes, and E. Barbosa
Recommended Reading 81
Part 2: Bayer Process
Section Introduction 83
F. Williams
Bayer Process Design
A Hundred Years of the Bayer Process for Alumina Production 85
F. Habashi
The Alumina Industry Technology Roadmap 94
I. Anich, T. Bagshaw, N. Margolis, anclM. Skillingberg
Basic Principles of Bayer Process Design 100
A. Adamson, E. Bloore, and A. Carr
Chemical Reaction Engineering in the Bayer Process 118
D. Thomas and B. Pei
The Effect of Silica, Temperature, Velocity and Particulates on Heat Transfer to Spent Bayer Liquor 124
A. Duncan, M. Groemping, B. Welch, and H. Muller-Steinhagen
Physical Data
The Effect of Four Common Bayer Liquor Impurities on Alumina Solubility 132
R. Bird, H. Vance, and C. Fuhrman
Autoprecipitation of Gibbsite andBoehmite 141
T. Harato, T. Ishida, and K. Yamada
Equilibrium Composition of Sodium Aluminate Liquors 148
B. McCoy andJ. Dewey
Boiling Point Rise of Bayer Plant Liquors 155
J. Dewey
Viscosity, Specific Gravity, and Equilibrium Concentration of Sodium Aluminate Solutions 162
T. Ikkatai and N. Okada
The Heat of Dissolution of Gibbsite at Bayer Digestion Temperatures 170
J. Langa
Reactions of Iron Minerals in Sodium Aluminate Solutions 176
P. Basu
Identification of Organics in Bayer Liquor 184
G. Lever
Behavior of Radioactive Elements (Uranium and Thorium) in Bayer Process 191
C. Sato, S. Kazama, A. Sakamoto, and K. Hirayanagi
Solubility of Bayer Liquor Impurities in Evaporative Crystallization 198
E. Schiller
Calcium Chemistry
Reaction of Lime in Sodium Aluminate Liquors 202
N. Chaplin
Some Aspects of Calcium Chemistry in the Bayer Process 210
S. Rosenberg, D. Wilson, and C. Heath
Chemistry of Bayer Liquor Causticization 217
R. Young
The Equilibrium Approach to Causticization for Optimizing Liquor Causticity 228
G. Roach
Layered Double Hydroxides in the Bayer Process: Past, Present, and Future 235
S. Rosenberg and L. Armstrong
Silica Chemistry
Dissolution Kinetics of Kaolin in Caustic Liquors 240
G. Roach and A. White
Dissolution Rate of Quartz and the Rate of Desilication in the Bayer Liquor 247
T. Oku and K. Yamada
Mathematical Modeling of the Kinetics of Gibbsite Extraction and Kaolinite Dissolution/Desilication in the Bayer Process 255
N. Raghavan and G. Fulford
Autoclave Desilication of Digested Bauxite Slurry in The Flashing Circuit 263
A. Damaskin, A. Suss, A. Panov, I. Paromova, N. Kuznetzova, N. Kutkova, O. Shipova, and A. Kuvyrkina
Organic Removal
Characterization of Organics in Bayer Liquor 268
J. Guthrie, P. The, and W. Imbrogno
Review of Bayer Organics-Oxalate Control Processes 278
B. Gnyra and G. Lever
Sizing an Organic Control System for the Bayer Process 284
J. Pulpeiro, L. Fleming, B. Hiscox, J. Fenger, and B. Raahauge
Organic Control Technologies in Bayer Process 291
G. Soucy, J. Larocque, and G. Forte
Removal of HMW Organic Compounds by Partial Wet Oxidation 297
B. Foster andM. Roberson
Removal of Organic Carbon from Bayer Liquor by Wet Oxidation in Tube Digesters 304
W. Arnswald, H Kaltenberg, and E. Guhl
A Year of Operation of the Solid-Liquid Calcination (SLC) Process 309
J. Pulpeiro, M. Gayol, H. Boily, A. Carruthers, B. Hiscox, J. Fenger, andB. Raahauge
A Thermodynamically Based Model for Oxalate Solubility in Bayer Liquor 314
K Beckham and S. Grocott
Oxalate Removal by Occlusion in Hydrate 320
V. Esquerre, P. Clerin, and B. Cristol
Recommended Reading 325
Part 3: Digestion
Section Introduction 329
D. Donaldson
Bayer Digestion and Predigestion Desilication Reactor Design 331
J. Kotte
Digester Design Using CFD 350
J. Woloshyn, L. Oshinowo, anclJ. Rosten
Preheaters and Digesters in the Bayer Digestion Process 356
G. Songquing and Y. Zhonglin
The Improved Low Temperature Digestion (ILTD) Process: An Economic and Environmentally Sustainable Way of Processing Gibbsitic Bauxites 362
G. Bànvòlgyi and P. Siklósi
New Technology for Digestion of Bauxites 371
R. Kelly, M. Edwards, D. Deboer, and P. Mclntosh
Boehmitic Reversion in a Double Digestion Process on a Bauxite Containing Trihydrate and Monohydrate 377
J. Lamerant and Y. Perret
Mixer Design Optimization for High Solids Contents Media: Methodology and Application to the Pechiney's High Density
Predesilication Process 381
Robin Industries, F. Bouquet
Mechano-Activated Bauxite Behaviour 387
S. Fortin and G. Forte
Processing of Diaspore Bauxites 393
G. Wargalla and W. Brandt
On-Line Multivariable Control for Digestion A/C Analysis 402
M. Hardin
Recommended Reading 409
Part 4: Clarification, Red Mud Washing, and Liquor Filtration
Section Introduction 411
T. Laros
Selection of Sedimentation Equipment for the Bayer Process: An Overview of Past and Present Technology 413
TMS, T. Laros, and F. Baczek
Effect of Particle Characteristics on the Solids Density of Bayer Mud Slurries 417
G. Roach, E. Jamieson, N. Pearson, A. Yu
Red Mud Flocculants Used in the Bayer Process 425
F. Ballentine, M. Lewellyn, and S. Moffatt
Development of New Bayer Process Flocculants 431
D. Spitzer, A. Rothenberg, H. Heitner, M. Lewellyn, L. Laviolette, T. Foster, and P. Avotins
Effects of Temperature and Method of Solution Preparation on the Performance of a Typical Red Mud Flocculent 436
P. Ferland, J. Malito, and E. Phillips
Advanced Filtration Methods for Pregnant Liquor Purification 444
R. Bott, T. Langeloh, andJ. Hahn
Impact of Excess Synthetic Flocculent on Security Filtration 449
J. Rousseaux and P. Ferland
Hydroseparators, Hydrocyclones and Classifiers as Applied in the Bayer Process for Degritting (Desanding) of Digested Bauxite, and for Sand Washing to Recover Soda 454
F. Krause, N. Beaton, and K. Grüner
Development of a Self-Sluicing Pressure Leaf Filter 461
B. Cousineau andJ. Lumsden
Comparison of the Rheology of Bauxite Residue Suspensions 466
N. Pashias, D. Boger, J. Summers, and D. Glenister
Pressure Decantation at Gramercy Alumina 470
P. Landry and H. Edwards
The Manufacture of Tricalcium Aluminate 476
L. Andermann Jr. and G. Pollet
Recommended Reading 483
Part 5: Precipitation, Classification, and Seed Filtration
Section Introduction 485
C. Misra
Precipitation Technology 487
J. Anjier andM. Roberson
Some Studies in Alumina Trihydrate Precipitation Kinetics 492
W. King
Physical Chemistry Considerations in Aluminum Hydroxide Precipitation 499
M. Chaubal
Modeling Bayer Precipitation with Agglomeration 509
D. Ilievski and E. White
Gibbsite Growth History: Revelations of a New Scanning Electron Microscope Technique 516
G. Roach, J. Cornell, and B. Griffin
Alumina Yield in the Bayer Process 522
R. Hond
Alumina Yield in the Bayer Process - Past, Present and Prospects 528
R. Hond, I. Hiralal, and A. Rijkeboer
Improvements by the New Alusuisse Process for Producing Coarse Aluminum Hydrate in the Bayer Process 534
O. Tschamper
Agitation Effects in Precipitation 541
C. Misra
Hydrodynamics Effect on Precipitation Yield 550
B. Cristol, Y. Perret, and H. Santos-Cottin
Hydrodynamics of Hydrate Slurries inPrecipitators: Application to Precipitators Design 559
Y. Perret
Alumina Crystallizer Mixing Using CFD 563
J. Perron andJ. Larocque
Particle Strength of Bayer Hydrate 570
J. Anjier and D. Marten
The Effect of Glucoisosaccharinate on the Bayer Precipitation of Alumina Tnhydrate 576
P. The
Influence of Mineral and Organic Impurities on the Alumina Trihydrate Precipitation Yield in the Bayer Process 582
A. Lectard and F. Nicolas
Factors Affecting Residual NA20 in Precipitation Products 592
J. Sang
Soda Incorporation During Hydrate Precipitation 602
C. Vernon, J. Loh, D. Lau, and A. Stanley
A Method for Evaluating Seed Balance Parameters in Alumina Refinery Seed Classifications Systems 608
W. Bounds Jr.
Utilization of Horizontal Belt Filters for Washing Fine Alumina Seed and Kiln Feed Product 615
R. Crawford, D. Dahlstrom, and G. Minear
Recommended Reading 621
Part 6: Product Hydrate Filtration and Alumina Production by Calcination
Section Introduction 623
B. Raahauge
The World's Largest Hydrate Pan Filter: Engineering Improvements and Experiences 625
B. Peter sen, M. Bach, andR. Arpe
Utilization of Steam Hoods in Horizontal Table Filters 630
H. Serres and J. Sorrentino
Conversion of Conventional Rotary Kiln into Effective Sandy Alumina Calciner 636
M. Ishihara, T. Hirano, and H. Yajima
Application of Circulating Fluid Bed Calcinaters in Large-size Alumina Plants 641
L. Reh and H. Schmidt
Alumina Calcination in the Fluid-Flash Calciner 648
W. Fish
Industrial Prospects and Operational Experience with 32 Mtpd Stationary Alumina Calciner 653
B. Raahauge and J. Nickelsen
Experience with 3 X 4500 TPD Gas Suspension Calciners (GSC) for Alumina 664
J. Fenger, B. Raahauge, and C. Wind
Alcoa Pressure Calcination Process for Alumina 669
S. Sucech and C. Misra
Recommended Reading 675
Part 7: Water, Evaporation, and Energy
Section Introduction 677
F. Williams
Alumina Refinery Wastewater Management: When Zero Discharge Just Isn't Feasible 679
L. Martin and S. Howard
Wastewater Treatment Methods 685
D. Smith, F. Williams, and S. Moffatt
The Need for Energy Efficiency in Bayer Refining 691
L. Henrickson
Prediction of Heat Exchanger -Heat Transfer Coefficient Decay Due to Fouling 697
G. O'Neill
Heat Transfer in the Bayer Process 705
D. Thomas
Perspective on Bayer Process Energy 711
D. Donaldson
Recommended Reading 715
Part 8: Alumina Quality
Section Introduction 717
B. Raahauge
Dehydration Products of Gibbsite by Rotary Kiln and Stational Calciner 719
K. Yamada, T. Harato, S. Hamano, and K. Horinouchi
Morphological Analysis of Alumina and Its Trihydrate 727
H. Hsieh
Factors Affecting the Attrition Strength of Alumina Products 740
J. Sang
The Generation of Fines Due to Heating of Alumina Trihydrate 747
J. Zwicker
Development of Particle Breakdown and Alumina Strength During Calcination 757
S. Wind, C. Jensen-Holm, and B. Raahauge
Measurement of Sandy Alumina Dustiness 765
S. Perra
Alumina Handling Dustiness 774
M. Authier-Martin
The Influence of Alumina Properties on Its Dissolution in Smelting Electrolyte 783
A. Bagshaw and B. Welch
The Influence of Physical and Chemical Properties of Alumina on Hydrogen Fluoride Absorption 788
J. Coyne, M. Wainwright, M. Brungs, and A. Bagshaw
SGA Requirements in Coming Years 793
S. Lindsay
Recommended Reading 799
Part 9: Health, Safety, and Plant Maintenance
Section Introduction 801
D. Donaldson
Application of Operation Integrity Management in the Alumina Industry 803
C. Suarez, D. Welshons, J. McNerney, andJ. Webb
Management Methodology for Pressure Equipment 808
P. Bletchly
The Design of Pressure Safety Systems in the Alumina Industry 817
B. Haneman
Inspection Techniques for Digestion Pressure Relief System 823
W. Harrington, G. Harrell, and B. Cohea Jr.
Benefits of the Utilization of Cleaning Liquor in Red Side of CVG-Bauxllum 828
R. Galarraga andR. Diaz
MAX HT™ Sodalite Scale Inhibitor: Plant Experience and Impact on the Process 832
D. Spitzer, O. Chamberlain, C. Franz, M. Lewellyn, and Q. Dai
Recommended Reading 839
Part 10: Process Control/Simulation
Section Introduction 841
D. Donaldson
Modern Control Instrumentation and Process Management in Bayer Plants 843
P. Mclntosh and E. Barker
Process Control in Alumina Refining, Review and Prospects 849
J. Riffaud
Development of Automatic Control of Bayer Plant Digestion 852
J. Riffaud
Aspen Modeling of the Bayer Process 860
J. Langa, T. Russell, G. O'Neill, P. Gacka, V. Shah, J. Stephenson, andJ. Snyder
Bayer Digester Optimization Studies Using Computer Techniques 870
J. Kotte and V. Schleider
Equations for Calculating Recovery of Soluble Values in a Countercurrent Decantation Washing System 879
H. Scandrett
Simulation and Development of Internal Model Control Applications in the Bayer Process 885
P. Colombé, R. Dablainville, andJ. Vacarisas
Dynamic Modeling of Yield and Particle Size Distribution in Continuous Bayer Precipitation 891
J. Stephenson and C. Kapraun
Recommended Reading 899
Part 11: Red Mud Disposal and Other Environmental Concerns
Section Introduction 901
L. Perander
Opportunities for Improved Environmental Control in the Alumina Industry 903
R. Mimna, J. Kildea, E. Phillips, W. Carlson, B. Keiser, andJ. Meier
Ferrosilt (Red Mud): Geotechnical Properties and Soil Mechanical Considerations 909
F. Jenny
Correlation of Red Mud Consolidation with Its Soil Properties 915
J. Stinson
Mobility in Mud 922
D. Morin
Developments in the Disposal of Residue from the Alumina Refining Industry 927
D. Cooling
Thickened Tailing Disposal in Any Topography 933
E. Robinsky
Solar Drying of Red Mud 938
J. Chandler
Red Mud Stacking 944
M. Bélanger
Proposed Mechanism for the Formation of Dust Horizons on Bauxite Residue Disposal Area 951
C. Klauber, N. Harwood, R. Hockridge, and C. Middleton
Induction of Biological Activity in Bauxite Residue 957
F. Williams andM. Hamdy
The Conversion and Sustainable Use of Alumina Refinery Residues: Global Solution Examples 965
L. Fergusson
Recommended Reading 973
Part 12: Alternative Processes and Raw Materials
Section Introduction 975
L. Perander
Alumina Production by the Pedersen Process: History and Future 977
J. Miller and A. Irgens
Efficiency ofNepheline Ore Processing for Alumina Production 983
B. Arlyuk, D. Sc, and A. Pivnev
A Technological Comparison of Six Processes for the Production of Reduction-Grade Alumina from Non-Bauxitic Raw Materials 998
K. Bengston
The Comparative Economics of Producing Alumina from U.S. Non-Bauxitic Ores 1031
R. Nunn, P. Chuberka, L. Malm, A. San Jose
Recovery of Alumina from Non-Bauxite Aluminum-Bearing Raw Materials 1057
J. Cohen and H. Mercier
Alumina Extraction from a Pennsylvania Diaspore Clay by an Ammonium Sulfate Process 1065
J. Fetterman and S. Sun
Alumina From Clay: A Nitric Acid Process 1074
J. Dewey
The Ammonoalunite Process for Production of Alumina From Clay 1082
R. Bartlett, R. Wesely, and T. Bolles
Options in the HC1 Process for the Production of Alumina from Clay 1089
D. Shanks, D. Thompson, R. Arington, G. Dan, andJ. Eisele
The Leaching of Aluminium in Spanish Clays, Coal Mining Wastes and Coal Fly Ashes by Sulphuric Acid 1098
A. Fernandez, J. Ibanez, M. Llavona, and R. Zapico
Recommended Reading 1109
Part 13: Non-Metallurgical Uses of Bauxite, Hydrate, and Alumina
Section Introduction 1111
T. Laros
Non-Metallurgical Use of Alumina and Bauxite 1113
W. Sleppy, A. Pearson, C. Misra, and G. MacZura
The Grafting of Industrial Chemicals Operations onto the Bayer Process 1121
L. Chin
On Alumina Powders for Ceramics 1124
Y. Oda, H. Okamoto, and S. Shibusawa
Development of Alumina and Silica Based Products in Hungary 1129
G. Baksa, G. Szalay, and F. Valló
The Use of Bayer Alumina Fines for Other Industrial Purposes 1137
P. Garcia, R. Zapico, J. Ayala, andJ. Sancho
Aluminas in Air Pollution Control 1144
J. Murphy
Aluminium Fluoride Synthesis in Circulating Fluidbeds 1158
E. Bóhm and L. Plass
Recommended Reading 1165
Author Index 1167
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