A study of iron mineral transformation to reduce red mud tailings.

This study examines the effects of iron mineral transformation in an aluminum extraction process on the settling behavior, and the physical and chemical properties of the resulting red mud slurry that must be disposed of. By producing a red mud with a higher solid content, the total volume of mud slurry will also be reduced for a given alumina production rate and more caustic soda will be recovered. The settling behavior and the mineralogical, physical, and physico-chemical properties of one bauxite and three red muds processed under varying conditions were analyzed based on examination of the iron mineral transformations. The properties of red muds derived from the same bauxite can differ markedly due to variations in operating conditions of the Bayer process, such as temperature and the addition of a reducing agent. The settling of red mud can be improved by converting goethite into hematite and/or magnetite to produce a mud of larger particle size, smaller specific surface area, and larger specific gravity, characteristics which reduce the total volume of mud slurry to be disposed of and which allow for less potential contamination from caustic soda. This study also found that the by-product--Bayer sodalite--has the high exchange capacity for Na+ that might contribute to the long-term environmental problems.