Bauxite ore is used to make aluminum. It must first be refined into aluminum oxide, or alumina. The Bayer refining process used by alumina refineries worldwide involves four steps - digestion, clarification, precipitation and calcination. To refine bauxite into alumina, the ore is first ground and mixed with lime and caustic soda, this mixture is then pumped into high-pressure containers and heated. Under pressure, the aluminum oxide is dissolved by the caustic soda, then precipitated out of this solution, washed, and heated to drive off water. What's left is alumina in a white powder form, which is transformed into aluminum metal in the subsequent smelting process.
We offer a range of products for each stage of the Bayer Process.
In the Bayer process production of alumina, bauxite ore is digested in a high temperature, highly caustic solution. The remaining red mud residue, which does not digest in this first stage of processing, is left suspended in the resulting saturated sodium aluminate solution. This residue must be removed prior to further processing of the saturated solution to ultimately precipitate a purified alumina trihydrate product. Its removal requires the use of flocculants effective in bridging and entrapping fine red mud solids to rapidly separate the solids from the saturated liquor. This separation process occurs via decantation and subsequently in multiple counter current washing stages to reclaim the soluble alumina and soda.
The more efficient the flocculant is in performing its function, the lower the cost of red mud separation. The more effective the flocculant, the greater the potential for increased alumina recovery, reduction in valuable soda losses, and minimization of negative downstream effects.
We offer a variety of scale inhibitors to minimize or eliminate scale formation encountered in the mining industry. The scale control products are used to eliminate sodalite scale from heat exchangers throughout the Bayer Process.
Antifoams prevent foaming, while defoamers suppress existing foam. They are used to treat Bayer liquors in the alumina processing cycle, including in the digesters, precipitator trains, hydrate classifiers, mud washing circuits and cooling towers.
s a variety of defoamer/antifoam technologies to meet industry's needs across these processes.
Dewatering aids are used to reduce cake moisture in the filtration of mineral slurries, such as sulfide flotation concentrates, iron ore concentrates and coal concentrates and tailings and alumina trihydrate in the Bayer process. The main goal is to increase filtration throughput in mineral processing by reducing moisture content and improving release of the filter cake.
Dust control agent binders are a polymeric soil stabilizer and dust control agent. They function to reduce surface erosion caused by wind and rain, and also serve to suppress dust generated during the transport of materials during dry, windy conditions. It works as binding agent which also forms a surface film coating when used in higher concentrations.