PROCESS FOR RECOVERY OF ALUMINA AND SILICA

Abstract: A process for the simultaneous recovery of substantially pure alumina and silica from an aluminosilicate. The process comprises the following steps: (i) heating the aluminosilicate with hydrated CaCl2 to obtain calcium-alumino-silicate and calcium-aluminate products, wherein the CaCl2 is substantially free of MgCl2; (ii) leaching the products with HCl to form a solution comprising AlCl3 and CaCl2, and insoluble silica; (iii) separating the insoluble silica from the solution; and (iv) crystallizing AlCl3 from the solution and recovering the alumina from the crystallized AlCl3. The process may further comprise the following steps: (v) substantially removing MgCl2 from the CaCl2 solution of step (iv); and (vi) recycling the CaCl2 solution for use in step (i).

Description: PROCESS FOR RECOVERY OF A UMIN A AND SILICA FIELD OF THE INVENTION The present invention relates to a process for the recovery of substantially pure alumina and silica from raw materials containing aluminosilicates, and particularly from waste products resulting from coal combustion. BACKGROUND OF THE INVENTION Coal combustion remains a major source of energy in many parts of the world. The solid waste remaining after the combustion is called coal ash, which comprises fly ash - the fine particles collected from the combustion-off gas by electrostatic precipitators - and the ash remaining at the bottom of the combustion vessels. The volume of coal ash resulting from coal combustion world-wide is constantly on the rise, resulting in an ever increasing problem of disposing the waste without damaging the environment. In addition, the availability of the waste products at no cost and their being adjacent to sources of power and transport make them attractive as raw material for the extraction of various chemical products. The chemical composition of coal ash varies as a function of the source and type of the coal. However, A1 2 0 3 and Si0 2 are almost always major components of the ash, usually in the form of aluminosilicates and quartz. It would therefore be advantageous to use coal ash as a source for alumina and silica. The major source of pure alumina today is bauxite, with the alumina generally being extracted by the Bayer process. As bauxite is in ample supply and the alumina can be extracted relatively easily and inexpensively, any alternate method for extracting alumina must be economically competi¬ tive with the Bayer process. In calculating the process cost, the savings in disposal and disposal site maintenance costs should be taken into account, as well as environmental considerations. A number of processes for recovering aluminum from coal ash have been reported (Seeley, F.G., Canon, R.M. and McDowell, W.J., "Chemical Development of New processes for the Recovery of Resource Materials from Coal Ash", Oak Ridge National Laboratory, Contract W-7405-eng-26; Felker, K., et al, "Aluminum from Fly Ash", Chemtech 12(2):123-8 (1982)). These include direct acid leach methods, lime-sinter and lime-soda- sinter methods, a salt-soda sinter process and the Calsinter process. Direct acid leaching (either single-stage or multi-stage) with HCl, HN0 3 , or H 2 S0 4 usually results in quite low recovery rates of Al (under 50%). Lime and lime/soda sinter processes involve sintering coal wastes at 1200-1300°C with powdered limestone (CaC0 3 ) or limestone and soda ash (Na 2 C0 3 ) to form calcium or sodium aluminates. The aluminates are then dissolved by leaching with Na 2 CO 3 . In the salt-soda sinter process, a NaCl-Na 2 C0 3 mixture is sintered with fly ash, quenched in a water leach, and then leached in a dilute HN0 3 or H 2 S0 4 solution. The Calsinter process (developed at Oak Ridge National Laboratory, Tennessee, U.S.A.) involves the combination of a CaSO 4 -CaCO 3 -fly ash sintering system and an acid leach with H 2 SO 4 . Recently, another method for recovery of alumina from alumino¬ silicates has been described in GB 2,205,558. In this method, the alumino¬ silicate is reacted with hydrated calcium and/or magnesium chloride, with or without a minor proportion of sodium chloride. A leached water- insoluble residue is obtained which is treated, preferably with the application of heat, with a mineral acid such as HCl which forms a water-soluble aluminum salt. The salt is then diluted with water to produce an aqueous solution of the aluminum salt and an insoluble residue comprising hydrated silica. The aluminum is then recovered from the salt solution. None of the above processes relates to the simultaneous extraction of silica from coal ash. U.S. 1,868,499 to Guertler describes a process for the recovery of alumina from silicious materials such as clay, leucite and silicious bauxite. The process comprises the steps of heating the silicious material with CaCl 2 at 650-900° C, treating the heated mixture with HCl to dissolve and separate CaCl 2 for reuse and conversion of the aluminum to A1C1 3 , separating the non-gelatinous silicic acid precipitate, and purifying the A1C1 3 solution and decomposing to form alumina. There is no indication of the purity of the extracted metal oxides, nor is there any indication that the recycled CaCl 2 undergoes treatment. BRIEF SUMMARY OF THE INVENTION It is an object of the present invention to provide a process for the simultaneous recovery of alumina and silica from various aluminosilicate- containing materials, and particularly from coal ash. It is a further object of the present invention to provide a high yield process which results in the recovery of substantially pure alumina and silica. It is a still further object of the invention to provide an extraction process which is economically competitive with known processes of alumina extraction. According to the present invention, there is provided a process for the simultaneous recovery of substantially pure alumina and silica from an aluminosilicate comprising the following steps: (i) heating the aluminosilicate with hydrated CaCl 2 to obtain calcium-alumino-silicate and calcium-aluminate products, wherein the CaCl 2 salt is substantially free of MgC ; (ii) leaching said products with HCl to form a solution comprising A1C1 3 and CaCl : and insoluble silica; (iii) separating the insoluble silica from the solution; and (iv) crystallizing A1C1 3 from the solution and recovering the alumina from the crystallized A1C1 3 . The term "substantially pure" as used in the present specification with respect to the alumina and silica products preferably relates to a purity of >97%, and most preferably to a purity of >99%. In a preferred embodiment of the present invention, the process comprises the following further steps: (v) substantially removing MgCl 2 from the CaCl 2 solution of step (iv); and (vi) recycling the CaCl 2 solution for use in step (i). The reuse of CaCl 2 contributes to the efficiency of the process. According to another preferred embodiment of the present invention, Fe is extracted from the A1C1 3 solution of step (ii) by either ion exchange or solvent extraction prior to or after the A1C1 3 crystallization of step (iv). The novel process of the present invention differs from previously described processes, such as those described in GB 2,205,558 and US- 1,868,499, in that MgGU is removed from the CaC salt prior to the heating step. Heating the aluminosilicate-containing material in the presence of MgCl 2 and A1C1 3 results in the formation of spinel MgO * Al 2 0 3 (71.8% A1 2 0 3 ). Spinel is insoluble in HCl and therefore precipitates with the silica together with the alumina contained in it, reducing the yield of alumina and contaminating the silica. The CaCl 2 which is recovered from the process for recycling must also be purified from MgCl 2 , since many sources of aluminosilicates contain small amounts of Mg impurities which dissolve in HCl during the leaching stage. Preferably, the MgCl 2 is removed by precipitation with Ca(OH) 2 . Thus, the use of CaCl which is substantially free of Mg in the heating step significantly contributes to the yield and purity of the products. This affects the efficiency and profitability of the process, making it economically competitive with respect to the Bayer process. BRIEF DESCRIPTION OF THE DRAWING The present invention will be better understood from the following detailed description of preferred embodiments, taken in conjunction with Fig. 1 which is a flow diagram of the process of the invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The process will now be described in a general manner. The raw materials which can be used in the process of the invention include coal reject, fly ash, collieries, kaolin, shale, clays, and other aluminosilicate containing materials. The hydrated CaCl 2 can be in either salt form or brine. In the first step of the process of the invention, hydrated CaCl 2 is reacted with a material containing aluminosilicates and at a temperature of between 900-1300°C, and preferably at a temperature of 1000-1100°C. This temperature is lower than the temperatures of previously described processes (1300-1400°C), but higher than the temperature used in the process described in the Guertler patent, supra. The CaCl 2 is added to the alumino- silicate-containing material at a weight ratio of 0.5:1 - 3:1 depending on the phase composition of the material and its relative alumina content, as well as on the concentrations of mullite and silica. Most preferably, the weight ratio is in the range of 0.5:1 - 2:1. Preferably, the mixture of alumino¬ silicate and CaCl 2 salt is dried at 200-250°C to obtain a solid mixture prior to heating (sintering). The aluminosilicate reacts with the CaCl 2 , for example according to the following reaction: Al fi Si 0 I3 + (Al 2 0 3 -SiOvCaO) + Si0 2 + xCaCl, + yH 2 0 — > 2CaO-Al 2 0 3 -Si0 2 + Al 2 0 3 -2Si0 2 -CaO + 12CaO-7Al 2 0 3 + 2yHCl where x and y = 2-4. The evolved HCl can be absorbed in a gas trap and used in the later steps. In the second step, the aluminum and calcium salts are leached from the calcium-alumino-silicate by HCl at a concentration of 2-8N. According to the previous example, the reaction is as follows: Ca 2 Al 2 SiO 7 + CaAl 2 Si 2 0 8 + Ca 12 Al 14 0 33 + 84HC1 — > I8AICI 3 + 15CaCl 2 + 42H 2 0 + 3Si0 2 The resulting solution may contain a number of salts in addition to A1C1 3 and CaCl 2 such as FeCl 3 , MgCl 2 and heavy metals. The Si0 2 residue can be separated from the salt solution by known methods such as filtration and decantation. The Si0 2 will usually be of greater than 97% purity and at a yield of >90%. In the final step of the process, the A1C1 3 is separated from the solution by concentration and crystallization in a strongly acidic environment (HCl). Due to differences in solubility in the presence of a high chloride ion concentration, the A1C1 3 crystallizes before the other salts in the solution. The A1C1 3 crystals are filtered out and alumina is recovered by hydrolytic decomposition according to the following reaction: I / heat ~ 2A1C1 3 + 3H 2 O > A1 2 0 3 + 6HC1 The HCl can be recovered for reuse. The A1 2 0 3 will usually be recovered at a purity of >99% and a yield of >95%. The Fe can also be recovered from the solution by either ion exchange or liquid extraction prior to or after the A1C1 3 crystallization. The remaining solution contains a high concentration of CaCl 2 which can be recovered for reuse in the first step of the process after removal of MgCl 2 , for example by precipitation with Ca(OH) 2 . Precipitation with Ca(OH) 2 also removes other metal chlorides present in the solution. Fig. 1 illustrates the complete process of the invention including the recycling of various components. The following examples illustrate various aspects of the invention. Example 1 50 parts by weight of fly ash were mixed with 50 parts by weight of calcium chloride dihydrate. The mixture was heated for 1 hour at 1100°C and then kept at 1100°C for an additional hour during which HCl vapors were released. The solid product was thoroughly leached with hot HCl 6N solution. 20 parts by weight of the product were leached for 2 hours with 100 ml of 6N HCl at 103°C. Analysis of the residue on a dry base was: weight % SiO, 98 Cad 0.5 Alkalies 0.2 Examination of the acid solution obtained by leaching showed that it contained more than 95% of the total content of Alumina in the fly ash used, and other metal chlorides in minor quantities. A1C1 3 *6H 2 0 was crystallized from the leaching solution by increasing the hydrochloric acid concentration to 30%. The crystals were filtered, washed with HCl and dissolved before being hydrolytically decomposed by heating at 400-600°C to produce pure alumina. Example 2 930 parts by weight of CaCl 2 *2H 2 0 were dissolved in 485 parts by weight of water. 790 parts by weight of fly ash were added to the solution. The mixture was dried for 3 hours at 230°C. The dry product was then heated at 1100°C for 1 hour and then kept at 1100°C for an additional hour during which HCl vapors were released. The product was thoroughly leached with a hot 6N HCl solution. 20 parts by weight of the product were leached for 2 hours with 100 ml of 6N HCl at 103°C. Silica content in the residue was 98.6% of the dry material. The yield was 95%. Examination of the acid solution obtained by leaching showed that it contained 98% of the total content of Alumina in the fly ash used. A1C1 3 *6H 2 0 was crystallized from the leaching solution by increasing the HC1 concentration to 30%. The crystals were filtered and dissolved before hydrolytic decomposition by heating at 400-600°C to produce pure alumina. Example 3 The composition of the acidic filtrate from the crystallization step of the AlCl 3 *6H 2 O of Example 2 was: weight % Aids 1.54 FeCl 3 1.38 CaC 14.4 MgCl-, 0.7 TiCl 4 0.41 Solubles 1.02 Sulfates 4.71 Fe ions were extracted from the above solution. 654 parts by weight of the solution were then treated with 7.35 parts by weight of CaC0 3 and subsequently with 20.5 parts by weight of Ca(OH) 2 to precipitate Mg(OH), and the insoluble metal hydroxides and gypsum. The composition of the purified solution is: weight % AICI 3 1.6 CaCl 2 35 Alkalies 1.5 other chlorides 0.7 FLO 6L2 total 100 420 parts by weight of the purified solution were mixed with 200 parts by weight of fly ash. The mixture was heated to dryness at 220°C. The dry product was than heated at 1100°C for 1 hour and then kept at 1100°C for an additional 30 minutes during which HCl vapors, NaCI, FeCl 3 , etc. were released. The product was thoroughly leached with a hot 6N HCl solution. 20 parts by weight of the product were leached for 2 hours with 200 ml of 3N HCl at 103°C. Silica content in the residue was 98.8% of the dry material. The yield was 95.5%. Examination of the acid solution obtained by leaching showed that it contained 97% of the total content of Alumina in the fly ash used. A1C1 3 *6H 2 0 was crystallized from the leaching solution by increasing the hydrochloric acid concentration to 30%. The crystals were filtered and dissolved prior to hydrolytic decomposition by heating at 400-600°C to produce pure alumina. While the present invention has been described in terms of several preferred embodiments, it is expected that various modifications and improvements will occur to those skilled in the art upon consideration of this disclosure. The scope of the invention is not to be construed as limited by the illustrative embodiments set forth herein, but is to be determined in accordance with the appended claims.

Claims: CLAIMS: 1. A process for the simultaneous recovery of substantially pure alumina and silica from an aluminosilicate comprising the following steps: (i) heating said aluminosilicate with hydrated CaCl 2 to obtain calcium-alumino-silicate and calcium-aluminate products, wherein said CaCl 2 is substantially free of MgCl 2 ; (ii) leaching said products with HCl to form a solution comprising A1C1 3 and CaCl 2 , and insoluble silica; (iii) separating said insoluble silica from said solution; and (iv) crystallizing A1C1 3 from said solution and recovering said alumina from said crystallized A1C1 3 . 2. A process according to claim 1 further comprising the following steps: (v) substantially removing MgCl 2 from the CaCl 2 solution of step (iv); and (vi) recycling the CaCl 2 solution for use in step (i). 3. A process according to claim 1 wherein said aluminosilicate is cr -tained in a material selected from the group comprising coal reject, fly aMi, kaolin, shale and clays. 4. A process according to claim 1 wherein said CaCl 2 is added to said aluminosilicate at a weight ratio of 0.5:1 - 3:1. 5. A process according to claim 1 wherein said insoluble silica is separated from said solution in step (iii) by filtration. 6. A process according to claim 1 wherein said insoluble silica is separated from said solution in step (iii) by decantation. 7. A process according to claim 1 wherein said alumina is recovered from said crystallized A1C1 3 in step (iv) by hydrolytic decomposition. 8. A process according to claim 2 wherein said Mg is removed from said salt by precipitation with Ca(OH) 2 . 9. A process according to claim 1 wherein said CaCl 2 salt used in step (i) is in the form of a brine. 10. A process according to claim 1 wherein the mixture of alumino¬ silicate and CaClo salt of step (i) is dried at 200-250°C prior to heating. 11. A process according to claim 1 wherein said heating is carried out at a temperature of 900-1300°C. 12. A process according to claim 11 wherein said heating is carried out at a temperature of 1000-1100°C. 13. A process according to claim 1 wherein Fe is extracted from said A1C1 3 solution of step (ii) by either ion exchange or liquid extraction prior to the A1C1 3 crystallization of step (iv). 14. A process according to claim 1 wherein Fe is extracted from said AICI 3 solution of step (ii) by either ion exchange or liquid extraction after the AICI 3 crystallization of step (iv).

Inventors: BERKOVICH AMOS, GORIN CHANOCH, LIN ISRAEL J, NEHARI SHLOMO, BERKOVICH, AMOS, GORIN, CHANOCH, LIN, ISRAEL, J., NEHARI, SHLOMO
Applicants: BERKOVICH AMOS, GORIN CHANOCH, LIN ISRAEL J, MASHAL ALUMINA IND LTD, NEHARI SHLOMO, BERKOVICH, AMOS, GORIN, CHANOCH, LIN, ISRAEL, J., MASHAL ALUMINA INDUSTRIES LTD., NEHARI, SHLOMO
Application year: 1996
Main classification: C01F7
IPC codes: C01B33, C01F7