Smelter Grade Alumina from Bauxite: History, Best Practices, and Future Challenges (2022)

1. Introduction: Primary Aluminium - Alumina - Bauxite (Benny E. Raahauge)i. Property Driven Applicationsii. Supply-Demand Balance and Forecastiii. Cost Drivers and Pricingiv. Environmental Footprints and Challenges
2. Bauxite Mineralogy, Classification and Beneficiation (Hydro/RTA?)i. Bauxite Resourcesii. Mineralogy and Chemistryiii. Classification from Bayer Process Perspectiveiv. Beneficiation Options
3. Bayer Process Design and Physical Chemistry (Steve Healy)i. Bayer Process Design Overviewii. Liquor Properties - Physio Chemical Dataiii. Lime (CaO) Chemistry
4. Bauxite Processing - Crushing/Grinding, De-silication and Digestion (CSIRO?)i. Crushing & Grindingii. Silica Chemistry, Desilication Kinetics and Reactor Designiii. Digestion Chemistry, Breakpoint and Kineticsa. Maximum Extractable Alumina (MEA) and Breakpointb. Digestion Modelsc. Degradation of Organicsiv. Digestion Conditions, Bauxite Mineralogy and Yielda. Effect of Lime additionb. Impact of impuritiesv. Applied Digestion Technology and Heat Consumptiona. Autoclavesb. Tube Digesterc. Double Digestionvi. Digester Mass and Heat Balancesa. Theoretical Heat of Digestionb. Boiling Point Elevationc. Steam Requirements
5. De-sanding - Floculation / Sedimentation - Liquor Filtration (Tim Laros)i. De-Sanding Equipmentii. Flocculation and Sedimentation Principlesiii. Mud Rheology, Rake Drives and Mud Pumpingiv. Decantation and Clarification Technologyv. Rise Rate and Tank Designvi. Pregnant/Green Liquor Filtration Options and Trends
6. Bauxite Residue: Washing - Dewatering (Tim Laros) and Disposal (Paul McGlade)i. Mud Washing - Recovery of Soda and Aluminaii. Dewatering Options: Filtration and Centrifuginga. Filtration Theory and Applicationsb. Filtration Pressure and Equipment Optionsc. Centrifuge Theory and Applicationsiii. Mud Cake Disposal Options and Principlea. Wet Disposal w/wo Neutralizationb. Dry Stacking w/wo Mud Farmingc. Dry Disposal 7. Hydrate Precipitation (Dennis R. Audet), Classification and Filtration (Manfred Bach)i. Hydrate Crystallization Fundamentalsa. Nucleation, Agglomeration, Breakage and Growthb. Crystallization Mechanism and Kineticsc. Heat of Crystallizationd. Control of Residual Sodae. Impact of Organics and other impurities on Yieldii. Precipitation Flow Sheets and Particle Morphologya. Retention Time and Temperature Profile impact on Yieldb. Modelling of Precipitation Flow sheetiii. Precipitator Tank Design Optionsa. Agitation and Mixingb. Hydrodynamic Effects on Yieldiv. Classification Options and Mass Balance Controla. Hydro Clonesb. Fine Seed Thickenerv. Seed and Product Hydrate Filtration Optionsa. Seed Preparationb. Washing Efficiency and Flow sheets
8. Liquor Purification and Impurity Control (Steve Healy)i. Organics removalii. Removal of Inorganic impuritiesa. Ironb. Phosphorc. Other...
9. Water Balance, Evaporation, Heat Exchange and Co-Generation (Daniel Thomas)i. Refinery Water Balanceii. Bayer Process Heat Balancea. Heat Transfer b. Inter-depa