An Invitation on Characterization of H2-Reduced Bauxite Residue and Recovering Iron through Wet Magnetic Separation Processes
Abstract
:1. Introduction
2. Materials and Methods
2.1. Sample Preparation
2.2. Characterisation Methods
2.2.1. XRD Measurements
2.2.2. XRF Analysis
2.2.3. ICP-MS Analysis
2.2.4. SEM-EDS Measurement
2.2.5. TMA Analysis
2.2.6. AM Analysis
2.3. Magnetic Separation Tests
2.3.1. Davis Tube Tests
2.3.2. Slon® Tests
2.3.3. LIMS Trials
3. Results and Discussions
3.1. Sample Characterization
3.2. Magnetic Separation
3.2.1. The Impact of Magnetic Intensity and Particle Size (Davis Tube and Slon® Tests)
3.2.2. Wet Low-Intensity Magnetic Separation (WLIMS)
4. Conclusions and Future Works
- Further experimental studies to acquire an in-depth understanding of the sample characterization using micro-computed tomography with respect to the significant difference in X-ray adsorption densities between Ti- and Fe-bearing phases and Na, Ca-embedded phases;
- Applying intensive grinding/ultrafine grinding to reach a reasonable liberation degree of magnetite at particle sizes below 20–10 µm;
- Using physicochemical-based approaches such as flocculation, flotation, and flocculation-flotation on ultrafine ground particles;
- Increasing the reduction temperature to above 900 °C in order to coarsen the Fe particles and potentially ease the downstream separation processes.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Appendix A
Component | Mg | S | Ca | Mn | Fe | Co | Ni | Cu | Zn | Sr |
---|---|---|---|---|---|---|---|---|---|---|
Concentration * (ng/mL) | 913.49 | 649.37 | 21566.67 | 0.15 | 110.67 | 0.07 | 1.29 | 14.72 | 1.32 | 52.97 |
Sample Type | Sample 01 | Sample 02 | Sample 03: Feed Sample | |||
---|---|---|---|---|---|---|
Element | pXRF * (wt%) | XRF (wt%) | pXRF * (wt%) | XRF (wt%) | pXRF * (wt%) | XRF (wt%) |
Th | 0.013 | 0.012 | 0.009 | 0.010 | 0.01 | 0.015 |
Zr | 0.076 | <0.050 | 0.079 | <0.050 | 0.079 | 0.075 |
Pb | 0.011 | 0.014 | 0.011 | 0.032 | 0.020 | 0.01 |
Zn | 0.0077 | 0.007 | 0.007 | 0.005 | 0.004 | 0.002 |
Cu | 0.005 | 0.009 | 0.055 | 0.007 | <LOD | 0.008 |
Ni | 0.077 | 0.077 | 0.059 | 0.070 | 0.060 | 0.05 |
Fe | 35.90 | 36.50 | 25.65 | 26.84 | 23.40 | 22.7 |
Cr | 0.22 | 0.160 | 0.179 | 0.147 | 0.156 | 0.18 |
Ti | 3.27 | 3.240 | 3.040 | 3.007 | 2.77 | 3.05 |
Ca | 6.47 | 7.190 | 6.313 | 6.953 | 5.46 | 5.93 |
Al | 6.8 | 7.319 | 7.900 | 9.052 | 7.31 | 12.48 |
Si | 3.185 | 4.730 | 2.970 | 4.140 | 2.40 | 3.51 |
Mg | 1.44 | 0.3 | 0.025 | 0.118 | <LOD ** | 0.12 |
Phase | Formula | Raw BR (wt%) |
---|---|---|
Hematite | Fe2O3 | 32.6 |
Goethite | FeOOH | 5.2 |
Cancrinite | Na₆Ca₂[(CO₃)₂|Al₆Si₆O₂₄]·2H₂O | 12.8 |
Gibbsite | γ-Al(OH)3 | 3.4 |
Perovskite | CaTiO3 | 2.2 |
Katoite | Ca3Al2(SiO4)3 | 12.7 |
Diaspore | α-AlOOH | 15.2 |
Calcite | CaCO3 | 6.0 |
Quartz | SiO2 | 0.3 |
Boehmite | γ-AlOOH | 2.7 |
Anatase | TiO2 | 0.9 |
Bayerite | α-Al(OH)3 | 1.4 |
Amorphous/not detected | - | 4.5 |
Phase | Formula | H2-Reduced BR (wt%) |
---|---|---|
Magnetic | Fe3O4 | 35.5 |
Quartz | SiO2 | 0.2 |
Perovskite | CaTiO3 | 5.9 |
Sodium aluminum silicate | Na12AlSiO5 | 11.9 |
Sodium aluminate | NaAlO2 | 29.5 |
Iron | Fe | 0.7 |
Sodium iron oxide | NaFeO2 | 6.6 |
Calcium iron silicate | Ca(Fe)SiO3 | 0.5 |
Sodium calcium silicate | (Na)CaSiO3 | 0.9 |
Calcium silicate | CaSiO3 | 1.5 |
Amorphous/not detected | - | 6.6 |
Phase | Formula | Magnetic Product (wt%) | Non-Magnetic Product (wt%) |
---|---|---|---|
Magnetite | Fe3O4 | 61.6 | 37.8 |
Perovskite | CaTiO3 | 12.4 | 18.9 |
Ilmenite | FeTiO3 | 3.9 | 4.1 |
Quartz | SiO2 | - | 7.5 |
Calcite | CaCO3 | - | 5.9 |
Amorphous/not detected | - | 22.1 | 25.8 |
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Method | XRF | pXRF | ICP-MS | QXRD |
---|---|---|---|---|
Fe (wt%) | 22 ± 2 | 23 ± 2 | 25 ± 1 | 25 ± 1 |
−100 + 75 µm | −75 µm | |||
---|---|---|---|---|
Stream | Mass (g) | Fe (%) | Mass (g) | Fe (%) |
MIMS Mag | 98.98 | 23 * | 117.25 | 24 * |
MIMS Non-Mag | 8.88 | 13 | 51.17 | 19 |
LIMS Mag | 70.11 | 32 | 68.83 | 36 |
LIMS Non-Mag | 23.89 | 26 | 43.88 | 29 |
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Hassanzadeh, A.; Pilla, G.; Kar, M.K.; Kowalczuk, P.B. An Invitation on Characterization of H2-Reduced Bauxite Residue and Recovering Iron through Wet Magnetic Separation Processes. Minerals 2023, 13, 728. https://doi.org/10.3390/min13060728
Hassanzadeh A, Pilla G, Kar MK, Kowalczuk PB. An Invitation on Characterization of H2-Reduced Bauxite Residue and Recovering Iron through Wet Magnetic Separation Processes. Minerals. 2023; 13(6):728. https://doi.org/10.3390/min13060728
Chicago/Turabian StyleHassanzadeh, Ahmad, Ganesh Pilla, Manish K. Kar, and Przemyslaw B. Kowalczuk. 2023. "An Invitation on Characterization of H2-Reduced Bauxite Residue and Recovering Iron through Wet Magnetic Separation Processes" Minerals 13, no. 6: 728. https://doi.org/10.3390/min13060728