The Alclar range of flocculants is designed specifically for the flocculation of red mud in the manufacturing of alumina by the alkaline digestion of bauxite (Bayer process). These high-performance flocculants enhance the efficiency of the alumina refining process by improving settling rates, optimizing clarity, and reducing chemical and energy consumption.
Applications
Alclar flocculants are used throughout the Bayer process to improve the efficiency of red mud separation, hydrate thickening and liquor clarification. These solutions are designed for use in:
- Clarification: Enhancing red mud separation from Bayer liquor, improving overflow clarity and underflow density.
- Red Mud Washing: Improving the performance of washers by accelerating red mud settling and providing clearer overflow liquor, enabling more efficient waste removal and higher alumina yield.
- Hydrate Thickening: Increasing the concentration of aluminum hydroxide crystals, optimizing precipitation and calcination steps.
- Green Liquor Filtration: Enhancing the filtration process, reducing impurities, and improving process efficiency.
About the Bayer Process
The Bayer process is the primary method used to refine bauxite into alumina (aluminum oxide), which serves as the raw material for aluminum production. This process is integral to the global aluminum industry and operates continuously in refineries worldwide.
The key stages of the Bayer process include:
- Digestion: Bauxite is mixed with a hot solution of sodium hydroxide under high pressure, dissolving aluminum-bearing minerals and forming sodium aluminate.
- Clarification: Insoluble impurities, known as red mud, are separated from the sodium aluminate solution. The red mud is washed in multiple stages using counter-current washers. Red mud flocculants are crucial at this stage to enhance settling.
- Precipitation: Aluminum hydroxide is precipitated from the alkaline solution when seeded with alumina hydrate to act as a nucleus.
- Calcination: The aluminum hydroxide is heated in kilns above 1,000°C to remove water, yielding pure crystalline alumina.
Each ton of alumina produced generates up to two tons of red mud, making effective flocculation essential for Bayer process optimization and environmental management.
Product Benefits
Alclar flocculants improve the efficiency of Bayer alumina refining, enabling:
- Lower energy and chemical consumption
- Faster settling rates for red mud
- Clearer overflow liquor, reducing impurities
- Higher underflow density for more effective waste management
- Enhanced overall productivity in alumina processing
Customized Flocculant Solutions
Solenis offers a comprehensive range of Alclar flocculants tailored to the unique conditions of each alumina refinery. Our solutions address:
- Declining Bauxite Quality: Alclar flocculants ensure effective red mud separation even with lower-grade bauxite.
- High-throughput Operations: Alumina plants operate 24/7, requiring reliable flocculation solutions to maintain efficiency.
- Sustainable Processing: Optimized flocculant performance reduces waste, water usage and chemical costs.
More Information
To learn more about Alclar flocculants for alumina refining and our other bauxite processing solutions, consult with a Solenis expert today.
