A novel utilization of high-Fe bauxite through co-roasting with coal gangue to separate iron and aluminum minerals

Abstract

High-Fe bauxite is a typical refractory bauxite with extensive resources, and coal gangue is a solid waste produced during coal preparation. In this study, the co-roasting of high-Fe bauxite with coal gangue for iron and aluminum recycling was explored. The optimum conditions for co-roasting were roasting at 750 °C for 50 min with 40% coal gangue, and 70.55% particles with size <37 µm. Through magnetic separation, iron ore concentrate with 55.09% TFe and a recycling rate of 82.73%, and aluminum-rich products with Al₂O₃ of 21.67% and a recycling rate of 75.55% were produced. Based on the analysis of materials, hematite was transformed into magnetite, and diaspore was transformed into Al₂O₃ through co-roasting. Therefore, the co-roasting of high-Fe bauxite and coal gangue is a promising process for recycling iron and aluminum.

Keywords

coal gangue / high-Fe bauxite / co-roasting / separation / iron ore concentrate

References

[1] ZhangT, YangH-f, ZhangH-b, et al. . Aluminum extraction from activated coal gangue with carbide slag [J]. Journal of Analytical and Applied Pyrolysis, 2022, 163: 105504

[2] ZhangL, ChenH-c, PanJ-h, et al. . Extraction of lithium from coal gangue by a roasting-leaching process [J]. International Journal of Coal Preparation and Utilization, 2023, 43(5): 863-878

[3] FuH-j, LvG-z, ZhangT-a, et al. . Study on iron extraction from high iron bauxite residue by pyrite reduction [J]. Bulletin of Environmental Contamination and Toxicology, 2022, 109(1): 149-154

[4] ValeevD, PankratovD, ShoppertA, et al. . Mechanism and kinetics of iron extraction from high silica boehmite-kaolinite bauxite by hydrochloric acid leaching [J]. Transactions of Nonferrous Metals Society of China, 2021, 31(10): 3128-3149

[5] CaiJ-p, ShenP-l, LiuD-w, et al. . Growth of covellite crystal onto azurite surface during sulfurization and its response to flotation behavior [J]. International Journal of Mining Science and Technology, 2021, 31(6): 1003-1012

[6] YangQ-c, ZhangF, DengX-j, et al. . Extraction of alumina from alumina rich coal gangue by a hydro-chemical process [J]. Royal Society Open Science, 2020, 7(4): 192132

[7] BaiZ, HanY-x, JinJ-p, et al. . Extraction of vanadium from black shale by novel two-step fluidized roasting process [J]. Powder Technology, 2022, 408117745

[8] XuY-j, XinH-x, DuanH-m, et al. . Reaction behavior of silicon-rich diasporic bauxite with ammonium sulfate during roasting [J]. Journal of Central South University, 2022, 29122-31

[9] BaiZ, HanY-x, JinJ-p, et al. . Crystal transformation of sericite during fluidized roasting: A study combining experiment and simulation [J]. Minerals, 2022, 12(10): 1223

[10] YuanS, XiaoH-x, YuT-y, et al. . Enhanced removal of iron minerals from high-iron bauxite with advanced roasting technology for enrichment of aluminum [J]. Powder Technology, 2020, 3721-7

[11] TianD, ShenX-y, ZhaiY-c, et al. . Extraction of iron and aluminum from high-iron bauxite by ammonium sulfate roasting and water leaching [J]. Journal of Iron and Steel Research International, 2019, 26(6): 578-584

[12] DengB-n, SiP-x, BaumanL, et al. . Photocatalytic activity of CaTiO₃ derived from roasting process of bauxite residue [J]. Journal of Cleaner Production, 2020, 244118598

[13] GuF-q, LiG-h, PengZ-w, et al. . Upgrading diasporic bauxite ores for iron and alumina enrichment based on reductive roasting [J]. JOM, 2018, 70(9): 1893-1901

[14] CaoJ-y, WuQ-h, LiH, et al. . Metallogenic mechanism of Pingguo bauxite deposit, western Guangxi, China: Constraints from REE geochemistry and multi-fractal characteristics of major elements in bauxite ore [J]. Journal of Central South University, 2017, 24(7): 1627-1636

[15] CaoY, SunY-s, GaoP, et al. . Mechanism for suspension magnetization roasting of iron ore using straw-type biomass reductant [J]. International Journal of Mining Science and Technology, 2021, 31(6): 1075-1083

[16] CardeniaC, BalomenosE, PaniasD. Iron recovery from bauxite residue through reductive roasting and wet magnetic separation [J]. Journal of Sustainable Metallurgy, 2019, 5(1): 9-19

[17] QinQ-z, DengJ-s, GengH-h, et al. . An exploratory study on strategic metal recovery of coal gangue and sustainable utilization potential of recovery residue [J]. Journal of Cleaner Production, 2022, 340130765

[18] BaiZ, HanY-x, SunY-s, et al. . Temperature variation of V-bearing stone coal during decarburization roasting and the effect of roasting conditions [J]. Journal of Central South University, 2023, 30(6): 1817-1830

[19] ZhengG-y, XiaJ-p, LiuC-l, et al. . Dissolution of aluminum and titanium during high-temperature acidification of coal gangues and relative kinetics [J]. Energy Sources, Part A: Recovery, Utilization, and Environmental Effects, 2023, 45(2): 5411-5424

[20] BaiZ, HanY-x, JinJ-p, et al. . Decarbonization kinetics for fluidized roasting of vanadium-bearing carbonaceous shale [J]. Journal of Thermal Analysis and Calorimetry, 2023, 1486873-6885

[21] ZhaoA-c, ZhangT-an. Study on extraction and separation performance of iron and aluminum from acid leaching solution of high-iron bauxite [J]. Russian Journal of Non-Ferrous Metals, 2022, 63(1): 37-45

[22] HeY-f, WangY-y, JinH, et al. Conversion behavior of iron-containing minerals in the process of dissolving high-iron bauxite by starch hydrothermal method [M], 2020, Cham, Springer International Publishing: 7284

[23] ZhouG-t, WangY-l, QiT-g, et al. . Cleaning disposal of high-iron bauxite residue using hydrothermal hydrogen reduction [J]. Bulletin of Environmental Contamination and Toxicology, 2022, 109(1): 163-168

[24] TianT, ZhangC-l, ZhuF, et al. . Effect of phosphogypsum on saline-alkalinity and aggregate stability of bauxite residue [J]. Transactions of Nonferrous Metals Society of China, 2021, 31(5): 1484-1495

[25] LiY-w, LuoX-h, LiC-x, et al. . Variation of alkaline characteristics in bauxite residue under phosphogypsum amendment [J]. Journal of Central South University, 2019, 26(2): 361-372

[26] YuanS, XiaoH-x, YuT-y, et al. . Enhanced removal of iron minerals from high-iron bauxite with advanced roasting technology for enrichment of aluminum [J]. Powder Technology, 2020, 372: 1-7

[27] RazmyslovI N, KotovaO B, SilaevV I, et al. . Microphase heterogenization of high-iron bauxite as a result of thermal radiation [J]. Journal of Mining Science, 2019, 55(5): 811-823

[28] LiX-f, ZhangT-a, WangK, et al. . Experimental research on vortex melting reduction of high-iron red mud (bauxite residue) [J]. Bulletin of Environmental Contamination and Toxicology, 2022, 109(1): 155-162

[29] YuanS, ZhouW-t, LiY-j, et al. . Efficient enrichment of nickel and iron in laterite nickel ore by deep reduction and magnetic separation [J]. Transactions of Nonferrous Metals Society of China, 2020, 30(3): 812-822

[30] LiX-b, WangH-y, ZhouQ-s, et al. . Reaction behavior of kaolinite with ferric oxide during reduction roasting [J]. Transactions of Nonferrous Metals Society of China, 2019, 29(1): 186-193

[31] ZhangL-j, HeY, LüP, et al. . Comparison of microwave and conventional heating routes for Kaolin thermal activation [J]. Journal of Central South University, 2020, 27(9): 2494-2506

[32] SunY-s, ZhouW-t, HanY-x, et al. . Effect of different additives on reaction characteristics of fluorapatite during coal-based reduction of iron ore [J]. Metals, 2019, 9(9): 923

[33] SunY-s, ZhuX-r, HanY-x, et al. . Iron recovery from refractory limonite ore using suspension magnetization roasting: A pilot-scale study [J]. Journal of Cleaner Production, 2020, 261: 121221

[34] ChenY F, WangM C, HonM H. Phase transformation and growth of mullite in Kaolin ceramics [J]. Journal of the European Ceramic Society, 2004, 2482389-2397

[35] SunY-s, ZhangQ, HanY-x, et al. . Comprehensive utilization of iron and phosphorus from high-phosphorus refractory iron ore [J]. JOM, 2018, 70(2): 144-149

[36] JORDÁN D, GONZÁLEZ-CHÁVEZ D, LAURA D, et al. Detection of magnetic moment in thin films with a homemade vibrating sample magnetometer [J]. Journal of Magnetism and Magnetic Materials, 2018, 456: 56–61. DOI: https://doi.org/10.1016/j.jmmm.2018.01.088.

[37] JacobJ, Abdul KhadarM. VSM and Mössbauer study of nanostructured hematite [J]. Journal of Magnetism and Magnetic Materials, 2010, 322(6): 614-621

[38] YamashitaT, HayesP. Analysis of XPS spectra of Fe²⁺ and Fe³⁺ ions in oxide materials [J]. Applied Surface Science, 2008, 254(8): 2441-2449

[39] FangS, XuL-h, WuH-q, et al. . Influence of surface dissolution on sodium oleate adsorption on ilmenite and its gangue minerals by ultrasonic treatment [J]. Applied Surface Science, 2020, 500144038

[40] SalamaW, ElA M, GauppR. Spectroscopic characterization of iron ores formed in different geological environments using FTIR, XPS, Mössbauer spectroscopy and thermoanalyses [J]. Spectrochimica Acta Part A: Molecular and Biomolecular Spectroscopy, 2015, 1361816-1826

[41] DingM-m, ChenW, XuH, et al. . Novel α-Fe₂O₃/MXene nanocomposite as heterogeneous activator of peroxymonosulfate for the degradation of salicylic acid [J]. Journal of Hazardous Materials, 2020, 382121064

[42] LeiY, DingJ-j, YuP-f, et al. . Low-temperature preparation of magnetically separable Fe₃O₄@ZnO-RGO for high-performance removal of methylene blue in visible light [J]. Journal of Alloys and Compounds, 2020, 821153366