Bauxite Beneficiation Solutions: Innovative Processes for Highly Efficient Aluminum Enhancement and Silicon Reduction

As the main raw material of aluminum metal, bauxite ore beneficiation process is crucial to improve the aluminum-silicon ratio and reduce the impurity content. This paper focuses on the core theme of "bauxite beneficiation solutions", systematically introduces the specialized beneficiation process for alumina trihydrate, soft alumina monohydrate and hard alumina monohydrate, including the core technologies of ore washing and grading, flotation desilication, magnetic separation and iron removal, as well as the configuration of ancillary equipment and technical advantages, to provide a comprehensive solution for the efficient utilization of bauxite resources.

I. Characteristics and challenges of bauxite ore dressing

Bauxite ore dressing faces the following technical challenges:

• Diverse types of ore: divided into three water alumina, soft alumina monohydrate and hard alumina monohydrate, treatment process varies greatly

• High impurity content: containing silicon, iron, titanium and other impurities, requiring multi-process joint processing

• Fine embedded particle size: aluminum minerals and chalcopyrite minerals have complex embedded relationships, requiring fine grinding and dissociation.

• High product quality requirements: electrolytic aluminum requires an aluminum-silicon ratio of more than 8, and refractory materials require more.

Second, differentiated bauxite beneficiation process scheme

1. Bauxite beneficiation process of trihydrate alumina type

• Washing process: High-pressure water gun washing to remove more than 80% of clay impurities.

• Classification process: spiral classifier classification, +0.5mm/-0.5mm are treated separately.

• Flotation process: flotation with oleic acid type of trapping agent to improve the ratio of aluminum to silicon.

• Technical characteristics: simple process, low investment cost, suitable for processing ores with high clay content.

2. High-silica bauxite beneficiation process

• Grinding process: Stage grinding to -0.074mm accounts for 85%, to ensure the dissociation of monomer.

• Flotation desiliconization: combined chemicals system (oleic acid:tar oil:motor oil=1:1:1)

• Application of dispersant: sodium hexametaphosphate as dispersant to improve sorting efficiency

• Technical characteristics: good desilication effect, significant improvement of aluminum-silicon ratio

3. High iron type bauxite beneficiation process

• Iron removal by magnetic separation: High gradient magnetic separator (1.0-1.5T) to remove iron impurities.

• Reverse flotation for desiliconization: sulfonate trap reverse flotation for desiliconization.

• Combined process: magnetic separation - flotation synergistic, simultaneous removal of iron and desiliconization

• Technical features: significant reduction of iron content, wide range of product applications

Third, bauxite beneficiation production line core equipment configuration

Fourth, bauxite beneficiation technology advantages

1. Advanced technology

• High-efficiency sorting index: Aluminum-Silicon ratio increased by 2-5 times, Al₂O₃ content ≥50%.

• Customized design: Configure exclusive process flow for different types of ores

• Strong adaptability: can process raw ore with Al₂O₃ content 30-55%.

2. Innovative technology

• Compound flotation chemicals system: improve flotation selectivity and recovery rate.

• Magnetic separation-flotation synergistic technology: synchronized desiliconization and iron removal, with remarkable effect.

• Ore washing water recycling system: high utilization rate of return water, environmental protection and energy saving.

3. Remarkable economic benefits

• Low processing cost: reduce the processing cost of tons of ore by 30%.

• Long equipment life: key equipment life is extended by 50%.

• Fast return on investment: payback period <2 years

V. Bauxite production line configuration scheme

Option 1: Sanshui Alumina Production Line

• Processing capacity: 1000t/d

• Core equipment: drum washing machine, flotation machine, dewatering equipment

• Process characteristics: washing - classification - flotation joint process

• Product index: Al₂O₃≥55%, aluminum-silicon ratio≥8

Scheme II: High Silicon Aluminum Ore Beneficiation Production Line

• Processing capacity: 500t/d

• Innovative technology: two-stage grinding and flotation process, intelligent dosing system

• Process characteristics: stage grinding-flotation desilication

• Product index: Aluminum-silicon ratio increased by 3-5 times

Scheme III: High iron type aluminum ore dressing production line

• Processing capacity: 800t/d

• Core process: magnetic separation-flotation combined process

• Equipment configuration: high gradient magnetic separator, reverse flotation system

• Product index: Fe₂O₃≤5%, aluminum-silicon ratio ≥7

VI. Professional Technical Services

1. Experimental research service

• Embedding characteristics study: detailed analysis of bauxite process mineralogy characteristics

• Laboratory flotation test: Determine the optimal process flow and pharmacy system.

• Expansion test: conduct continuous expansion test to verify the feasibility of the process.

2. Engineering Design Services

• Process design: customized bauxite beneficiation process flow

• Production Line Layout: Reasonable equipment layout and plant design

• Automation control design: realize intelligent control of production process.

3. Equipment Supply Service

• Equipment Selection Recommendation: Select the best equipment according to the ore characteristics.

• Equipment Manufacturing Supply: Provide high quality key equipment

• Spare parts supply guarantee: ensure the continuous and stable operation of the production line.

4. Production support services

• Installation and commissioning guidance: professional technical team on-site service

• Optimization of pharmaceutical formula: adjust and optimize according to the nature of the ore.

• Operator training: systematic training for production operators

Application Cases

Case 1: A three-water alumina mine project in Guangxi

• Properties of raw ore: Al₂O₃ content 42%, Al-Si ratio 3.5

• Adopted process: washing - classification - flotation process

• Production index: concentrate Al₂O₃ content 58%, aluminum-silicon ratio 9.2, recovery rate 85

Case 2: Henan a certain water duralumin project

• Properties of raw ore: high silica bauxite, Al-Si ratio 2.8

• Adopted process: stage grinding-flotation desilication process

• Production index: Al-Si ratio increased to 11.5, Al₂O₃ recovery rate 82%.

Bauxite beneficiation is a technology-intensive systematic project, which requires customized solutions according to the type and characteristics of the ore. Our bauxite beneficiation solutions are tailored to the different characteristics of alumina trihydrate, soft alumina monohydrate and hard alumina monohydrate, adopting advanced washing, classification, flotation and magnetic separation processes, and equipped with high efficiency and energy-saving equipments, to ensure the efficient utilization of bauxite resources.

We provide the whole process service from experimental research, engineering design, equipment supply to installation and commissioning to ensure that customers get the best technical index and economic benefits. Specific bauxite beneficiation solution parameters need to be determined according to the nature of the ore test, it is recommended to carry out beneficiation test research first.

Welcome to inquire for more technical information and personalized program design, our professional and technical team will provide you with the best quality bauxite beneficiation solutions.