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Phase stability and role of mechanical activation in the chemical beneficiation of red mud

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Abstract

This paper focuses on the carbothermic reduction of red mud in the presence of sodium carbonate. The emphasis is on the reduction step in the ‘Elgai process’ which is central to the chemical beneficiation and carried out in the temperature range where fusing of roasting mass is avoided. The research, aimed at developing a fundamental understanding of the roasting has three different facets: (a) calculation of phase equilibrium in Fe2O3–Al2O3–Na2CO3–C and related systems for the relevant compositions and temperature range (650–950 °C); (b) simultaneous thermal analysis (TG/DTA) studies based on phase stability; and (c) roasting and leaching of red mud-soda-carbon pellets. Red mud was used in the as-received condition and after mechanical activation in an attrition mill. Red mud and roasted products were characterised by X-ray powder diffraction (XRD) and scanning electron microscopy (SEM) with X-ray microanalysis (EDS). The reduction temperature and carbon requirement were found to depend on the Al2O3 content of red mud, notably the occurrence of aluminogoethite. The interdependence of the decomposition of sodium carbonate, metallisation of red mud, sodium aluminate formation, and alumina recovery are elucidated. Mechanical activation improves the degree of metallisation and alumina recovery. The significance of Ca(OH)2 addition as a way forward to reduce the decomposition temperature of sodium carbonate and the consequent reduction in the roasting temperature are highlighted.

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Acknowledgements

The red mud used in the study was received from National Aluminium Company (India). The authors sincerely acknowledge characterisation support received from Dr. S.K. Das (SEM-EDS), Dr. B Ravikumar (XRD), Dr. D. Mishra (analytical) and Dr. N. Randhawa (thermal analysis) (all from CSIR-NML). The authors would like to sincerely thank Prof. Rajiv Shekhar (Director, IIT(ISM) and Dr. Indranil Chattoraj (Director, CSIR-NML) for their encouragement and support for this work. The first author would also like to express his gratitude to Prof. Seshadri Seetharaman (Royal Institute of Technology, Stockholm, Sweden) for useful discussion and providing valuable ideas during his visit to IIT(ISM) in early 2020.

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The authors, individually or collectively, did not receive any funding to purse the work reported in this paper.

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  1. Indian Institute of Technology (IIT-ISM), Dhanbad, 826004, India

    Rakesh Kumar

  2. CSIR-National Metallurgical Laboratory, Jamshedpur, 831007, India

    Rakesh Kumar & Thomas C. Alex

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Conceptualization contributed by RK; methodology and experimental work contributed by TCA; formal analysis and investigation contributed by RK, TCA; writing—original draft preparation contributed by TCA; writing—review and editing contributed by RK. All authors read and approved the final manuscript.

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Kumar, R., Alex, T.C. Phase stability and role of mechanical activation in the chemical beneficiation of red mud. J Therm Anal Calorim 148, 9813–9827 (2023). https://doi.org/10.1007/s10973-023-12350-7

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