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Concept
Bayer process
Summary
The Bayer process is the principal industrial means of refining bauxite to produce alumina (aluminium oxide) and was developed by Carl Josef Bayer. Bauxite, the most important ore of aluminium, contains only 30–60% aluminium oxide (Al2O3), the rest being a mixture of silica, various iron oxides, and titanium dioxide. The aluminium oxide must be further purified before it can be refined into aluminium metal.
The Bayer process is also the main source of gallium as a byproduct despite low extraction yields.
Bauxite ore is a mixture of hydrated aluminium oxides and compounds of other elements such as iron. The aluminium compounds in the bauxite may be present as gibbsite (Al(OH)3), böhmite (γ-AlO(OH)) or diaspore (α-AlO(OH)); the different forms of the aluminium component and the impurities dictate the extraction conditions. Aluminium oxides and hydroxides are amphoteric, meaning that they are both acidic and basic. The solubility of Al(III) in water is very low but increases substantially at either high or low pH. In the Bayer process, bauxite ore is heated in a pressure vessel along with a sodium hydroxide solution (caustic soda) at a temperature of 150 to 200 °C. At these temperatures, the aluminium is dissolved as sodium aluminate (primarily [Al(OH)4]−) in an extraction process. After separation of the residue by filtering, gibbsite is precipitated when the liquid is cooled and then seeded with fine-grained aluminium hydroxide crystals from previous extractions. The precipitation may take several days without addition of seed crystals.
The extraction process (digestion) converts the aluminium oxide in the ore to soluble sodium aluminate, NaAlO2, according to the chemical equation:
Al2O3 + 2 NaOH → 2 NaAlO2 + H2O
This treatment also dissolves silica, forming sodium silicate :
2 NaOH + SiO2 → Na2SiO3 + H2O
The other components of Bauxite, however, do not dissolve. Sometimes lime is added at this stage to precipitate the silica as calcium silicate.
Official source
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