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WO2025233969A1 - Low-temperature process for recovery of alumina from different sources - Google Patents

Low-temperature process for recovery of alumina from different sources

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Publication number
WO2025233969A1
WO2025233969A1 PCT/IN2025/050726 IN2025050726W WO2025233969A1 WO 2025233969 A1 WO2025233969 A1 WO 2025233969A1 IN 2025050726 W IN2025050726 W IN 2025050726W WO 2025233969 A1 WO2025233969 A1 WO 2025233969A1
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WO
WIPO (PCT)
Prior art keywords
alumina
temperature
water
naoh
sodium
Prior art date
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Pending
Application number
PCT/IN2025/050726
Other languages
French (fr)
Inventor
Prof. Chenna Rao BORRA
Dr. Prasanta JANA
Gautam Behera
Gutti Chinna Chandrudu
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Indian Institute of Technology Kharagpur
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Indian Institute of Technology Kharagpur
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Publication of WO2025233969A1 publication Critical patent/WO2025233969A1/en
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01FCOMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F7/00Compounds of aluminium
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01FCOMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F7/00Compounds of aluminium
    • C01F7/02Aluminium oxide; Aluminium hydroxide; Aluminates
    • C01F7/04Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01FCOMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F7/00Compounds of aluminium
    • C01F7/02Aluminium oxide; Aluminium hydroxide; Aluminates
    • C01F7/04Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom
    • C01F7/06Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom by treating aluminous minerals or waste-like raw materials with alkali hydroxide, e.g. leaching of bauxite according to the Bayer process
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01FCOMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F7/00Compounds of aluminium
    • C01F7/02Aluminium oxide; Aluminium hydroxide; Aluminates
    • C01F7/04Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom
    • C01F7/06Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom by treating aluminous minerals or waste-like raw materials with alkali hydroxide, e.g. leaching of bauxite according to the Bayer process
    • C01F7/0606Making-up the alkali hydroxide solution from recycled spent liquor
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01FCOMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F7/00Compounds of aluminium
    • C01F7/02Aluminium oxide; Aluminium hydroxide; Aluminates
    • C01F7/04Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom
    • C01F7/06Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom by treating aluminous minerals or waste-like raw materials with alkali hydroxide, e.g. leaching of bauxite according to the Bayer process
    • C01F7/0646Separation of the insoluble residue, e.g. of red mud
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01FCOMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F7/00Compounds of aluminium
    • C01F7/02Aluminium oxide; Aluminium hydroxide; Aluminates
    • C01F7/04Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom
    • C01F7/14Aluminium oxide or hydroxide from alkali metal aluminates

Definitions

  • Alumina Al 2 O 3
  • bauxite Primary ore of aluminium
  • alumina there are other areas of application of alumina such as ceramics, abrasive, catalyst flame retardant, and high- performance materials in electronics and aerospace.
  • Primary source of alumina is bauxite (30 – 40% alumina) and there are a lot of secondary resources of alumina such as Bauxite residue (Red Mud), low-grade iron ore, aluminium dross, overburden.
  • Bauxite residue contains 15 – 20% alumina, Low-grade iron ore 4 – 8% alumina, aluminium dross 50 – 75% and overburden and iron ore tailings have 5-10% alumina.
  • Bauxite residue contains 15 – 20% alumina
  • Low-grade iron ore 4 – 8% alumina aluminium dross 50 – 75% and overburden and iron ore tailings have 5-10% alumina.
  • Global alumina production reached approximately to 140 million metric tons in 2022.
  • Bayer process Conventional and current alumina production in world is mostly done by the Bayer process, developed in the late 19 th century, which involves refining bauxite through digestion, precipitation, and calcination.
  • Bayers process utilizes a temperature of around 150-270 degrees centigrade depending upon the types of alumina rich phase present in bauxite ore and also a pressure of around 25 atm is used.
  • Another limitation of this process is that it is not suitable for all the alumina resources such as aluminum dross and diasporic bauxite and low-grade ore or ore containing high silica due to the formation of sodium alumino silicate phase leading to loss of sodium hydroxide as well as alumina leading to less recovery.
  • Other conventional process for lean bauxite ore or ore with high silica content are soda sintering or lime soda sintering process which involves refining bauxite through sintering/roasting, leaching, and carbonizing. This process utilized a temperature of around 950-1050 °C which is extremely high so it is an energy-intensive process.
  • IN202021022813 discloses a method to selectively enriching and separating alumina and silica from clay minerals and alumino- siliceous industrial rejects using acid, which generates huge volumes of effluents. The reagents are consumed in this process.
  • US730952 discloses a method to recover the caustic and alumina values from Bayer Red mud. However, it’s worth noting that this process utilized a temperature of around 1050° C which is significantly high. And use of both lime stone (calcium carbonate) and NaOH and coke.
  • the present invention is directed to a low-temperature (T ⁇ 200° C) method of recovery of alumina from various alumina-containing resources.
  • the method comprises the steps of treating an alumina-containing resource with Sodium Hydroxide (NaOH) at a predefined temperature in presence of small amount (5-50%) of water, which helps in better reaction between alumina containing phases and NaOH, and leaching the treated alumina- containing resource with water to dissolve Sodium Aluminate (NaAlO2) and produce leachate.
  • the method includes performing filtration/clarification for separating the solid residues from the leachate.
  • the method further comprises causing precipitation of Aluminium Hydroxide (Al(OH)3) by reacting the leachate with CO2 so as to convert the Sodium Aluminate (NaAlO2) to Aluminium Hydroxide (Al(OH) 3 ), and performing calcination of the precipitated Aluminium Hydroxide (Al(OH)3) at a pre-defined temperature to obtain alumina.
  • the sodium carbonate generated after alumina is regenerated by treating the solution with lime/slaked lime (CaO/Ca(OH) 2 ) to convert sodium carbonate to sodium hydroxide. After solid/liquid separation, NaOH solution is evaporated and the solution or crystals containing NaOH.H2O is send back for the reuse in the treatment.
  • Figure 1 illustrates a flowchart for workflow a low-temperature method of recovery of alumina from various alumina-containing resources, in accordance with an embodiment of the present disclosure
  • Figure 2 illustrates exemplary XRD pattern of aluminum hydroxide produced from dross, in accordance with an embodiment of the present disclosure
  • Figure 3 illustrates exemplary XRD pattern of sodium aluminate, formed upon NaOH treatment with red mud at different low temperature with 20% water, in accordance with an embodiment of the present disclosure.
  • Alumina a versatile compound derived mostly from bauxite, finds wide-ranging applications, including as the main constituent for aluminium production and in ceramics, abrasives, catalysts, flame retardants, and high-performance materials in electronics and aerospace. While bauxite is the primary source of alumina, there are numerous secondary resources available, such as bauxite residue (red mud), low-grade iron ore, aluminium dross, and overburden.
  • Embodiments of the present disclosure provide a method for recovery of alumina from various alumina-containing resources as illustrated in Figure 1.
  • the various alumina-containing resources include but not limited to red mud, dross, iron ore slime, overburden, low-grade iron ore any industrial waste or natural source.
  • the size and configuration of the required set of machinery for accomplishing the method (100) may be variable in accordance with the requirement of the different types of installation environment. Any such variation/modification shall be construed to be within the scope of the present disclosure.
  • the method (100) comprises one or more blocks to be performed for recovery of alumina from various alumina containing resources.
  • an alumina-containing resource is treated with Sodium Hydroxide (NaOH).
  • the alumina-containing resource is treated with Sodium Hydroxide (NaOH) at a predefined temperature in the presence of water preferably below 1:1 ratio of the NaOH to water and most preferably below 1:0.5.
  • the amount of water can be in a range of 5% to 50% and the critical amount of water can be in a range of 10% – 20%.
  • Critical amount of water 10 – 20% relative to weight of alumina containing sources is beneficial for maximizing the alumina recovery at this low temperature treatment.
  • the alumina-containing resource can also be treated with other alkali hydroxides such as KOH, LiOH etc.
  • the predefined temperature for treating the alumina-containing resource is in a range of 60 – 200°C, most preferably below 150°C. Further, the alumina containing resource and the sodium hydroxide is in a ratio ranging from 1:0.1 to 1:2.
  • the alumina-containing resource is mixed with NaOH and treated at temperatures between 80- 140°C to convert the alumina into sodium aluminate, as depicted in equation 1: Al2O3+NaOH + H2O ⁇ 2NaAlO2.H2O (1) [0022]
  • the treated alumina-containing resource is leached with water.
  • the treated alumina-containing resource is leached with water to dissolve Sodium Aluminate (NaAlO2.xH2O) and produce leachate.
  • leaching the treated alumina-containing resource with water is carried out in temperature between room temperature to 100°C i.e., in a range of 25oC – 100oC.
  • filtration is carried out to separate NaAlO2.xH2O from the leached residue.
  • Aluminium Hydroxide (Al(OH) 3 ) is precipitated from the leachate using CO 2 gas.
  • the Aluminium Hydroxide (Al(OH) 3 ) is precipitated by reacting the leachate with CO2 gas so as to convert the Sodium Aluminate (NaAlO2) to Aluminium Hydroxide (Al(OH)3).
  • Al(OH)3 is precipitated by introducing CO2 into the sodium aluminate solution, as shown in equation 2.
  • filtration is performed. In an embodiment, filtration is performed for effectively separating the Al(OH) 3 from Na 2 CO 3 solution produced upon CO 2 purging.
  • calcination of the precipitated Aluminium Hydroxide (Al(OH) 3 ) is performed and Sodium Hydroxide is regenerated. In an embodiment, calcination of the precipitated Aluminium Hydroxide (Al(OH) 3 ) is performed at a pre-defined temperature to obtain alumina. Further, Alumina hydroxide is separated from sodium carbonate solution by solid liquid separation followed by conventional calcination to obtain alumina.
  • the subsequent controlled treatment phase conducted within an oven or reactor, is calibrated to optimize reaction conditions. Following low temperature treatment, the samples undergo leaching with distilled water. [0028] Subsequent to leaching, the filtration process, effectively separating the solid residues from the leachate. To ensure the removal of residual sodium aluminate, water washing is performed. [0029] In conjunction with these procedures, X-ray fluorescence spectrometer (XRF) analysis is carried out on both the as-received sample and the leach residues obtained from the experiment. This analytical step or other techniques enables the precise quantification of the elemental composition, providing crucial data for subsequent calculations as illustrated in Figure 2. Primarily, Al(OH) 3 is characterized by three phases: gibbsite, bayerite and nordstrandite.
  • Figure 2 shows Bayerite phase which is one form of aluminium hydroxide, which is produced from dross.
  • Figure 3 illustrates exemplary XRD pattern of sodium aluminate, formed upon NaOH treatment with red mud at different low temperature with 20% water.
  • Figure 3 shows XRD analysis of heat-treated red mud mass with NaOH to red mud mass ratio of 1 and 20% water addition which revealed the formation of sodium aluminate at different temperatures below 150 degrees Celsius.
  • the present invention introduces a novel and simple process that eliminates the need for high temperature or acids as disclosed by the conventional techniques.
  • the method of the present invention represents a significant advancement in alumina production.
  • this innovative technique operates at low temperatures without the need for elevated temperature/pressure conditions.
  • the proposed method By directly treating alumina-containing resources with NaOH, the proposed method generates a water-soluble sodium aluminate phase, a crucial step in the production of alumina. Addition of small amount of water in the raw materials during low temperature process make the alumina recovery efficiency highly significant. This water makes the reaction more effective to form NaAlO 2 .
  • One of the key benefits of the proposed method is its sustainability. By eliminating or significantly reducing the reliance on chemicals like acids or temperature or pressure, the proposed method minimizes the environmental impact associated with alumina production.
  • the proposed method conserves energy, addressing one of the primary challenges of conventional alumina production. Energy-intensive processes often contribute to greenhouse gas emissions and are costly to operate.
  • the present invention offers a promising solution by significantly reducing energy requirements, thus contributing to a more sustainable and cost-effective production process.
  • the present invention represents a significant leap forward in the field of alumina production from different resources. Its ability to produce alumina sustainably, while overcoming the challenges associated with energy-intensive processes, makes it a promising solution for the industry's future.
  • Example 2 This experiment was conducted to assess the influence of treatment & leaching duration on the recovery percentage of alumina from 5 g portions of red mud. Each sample was placed with varying NaOH concentrations, (specifically 0.5 and 1 to NaOH to red mud mass including 10% water). A homogenized mixture was prepared meticulously using a glass rod and spatula to ensure uniform distribution of components.
  • Example 3 The objective of this experiment was to examine the impact of water percentage on the recovery of alumina from 5 g portions of red mud.
  • each sample was placed in nickel crucibles with a NaOH concentration of 100% relative to the weight of red mud, supplemented with no water and 10%, 20%, 30%, 40% water.
  • a homogenized mixture was meticulously prepared.
  • these homogenized mixtures were subjected to low temperature treatment in an oven at varying temperatures, specifically 80, 100, 120, and 140 degrees Celsius, each for a duration of 4 hours.
  • Post-treatment the samples underwent leaching with water in a glass beaker positioned on a hot plate equipped with a magnetic stirrer, maintaining a temperature of 60 degrees Celsius. Following the leaching process, the filtrate was subjected to filtration, accompanied by three rounds of washing with ambient water to eliminate any residual impurities.
  • the resulting residue was dried in an oven, and the subsequent weight was accurately recorded.
  • the recovery percentage of alumina demonstrates an increasing trend with no water to water addition.
  • the disparity in recovery percentages between 10% and 20% water content is minimal, only 1%.
  • the disparity becomes markedly significant when comparing treatment processes with and without water.
  • the alumina recovery percentages at 140°C are 37%, 71.5%, and 72.5% respectively for processes without water, with 10% water, and with 20% water.
  • the recovery decreased further with water addition beyond 20%, yielding 66% and 59.3% recovery for 30% and 40% water addition, respectively.
  • Example 4 5 gm dross was milled in a planetary ball mill with a ball to powder ration of 1:10 for 1 hour to convert the dross to 90 microns. The milled dross was leached with water with 1:2 ratio at 95 °C for 4 hours to dissolve the salt and convert most of the AlN to Al(OH) 3 and ammonia gas. The slurry was filtered, and the solution was evaporated to produce the salt (NaCl+KCl), which is about 0.6 g. After drying, the solid was mixed with NaOH with 1:1 wt ratio in a mortar pestle. Then it was roasted at 80-140 °C for 4 h followed by water leaching at 60 °C for 1 h.
  • Example 5 Each 5 g portion of low-grade iron ore was mixed with varying NaOH concentrations: 0.50, and 1 NaOH to low grade iron ore mass ratio, each comprising 20% water relative to the iron ore weight. A homogenized mixture was prepared Subsequently, these homogenized mixtures underwent low temperature treatment in an oven at different temperature settings (80, 100, and 120 degrees Celsius) for a standardized duration of 4 hours. Following treatment process, the samples were subjected to leaching with water at 80 degrees Celsius. Post-leaching, filtration was carried out followed by three rounds of washing with ambient water to remove any residual sodium aluminate.
  • the resulting residue was then dried in an oven, and the subsequent weight was accurately recorded.
  • the maximum alumina recovery achieved is at both 100 & 120 degrees Celsius, reaching 81% when utilizing 1 NaOH to low grade iron ore mass ratio concentration. Specifically, at 120°C with a 50% NaOH concentration, the alumina recovery stands out at 76%. In contrast, at 100°C, the recovery percentage slightly decreases to 71%. Notably, the recovery percentage appears to increase with a higher concentration of NaOH, particularly evident at 0.5 NaOH to low grade iron ore mass ratio concentration compared to 1 NaOH to low grade iron ore mass ratio. Interestingly, even at a relatively low temperature of 80°C, significant differences in alumina recovery percentages are observed between varying NaOH concentrations.
  • Example 6 Each 5 g portion of low-grade iron ore homogenized with varying NaOH concentrations: 0.5, and 1NaOH to low grade iron ore mass ratio, each comprising 10% water relative to the iron ore weight.
  • these homogenized mixtures underwent treatment in an oven at settings temperature of (140 degrees Celsius) for a standardized duration of 4 hours. Following the treatment process, the samples were subjected to leaching with water at 80 degrees Celsius. Post-leaching, filtration was carried out, followed by three rounds of washing with ambient water to remove any residual sodium aluminate. The resulting residue was then dried in an oven, and the subsequent weight was accurately recorded.
  • the alumina recovery percentage stands at 73%, while at 1 NaOH to low grade iron ore mass ratio concentration, it rises to 79%. Remarkably, these recovery percentages are similar to those observed at 80 degrees Celsius.
  • the present invention applies to all kinds of alumina-containing sources both primary and secondary. This way we can increase alumina production as well as minimize or eliminate the waste generated from mining (overburdens) and metallurgy (tailings, residues, dross). [0046]
  • the present invention is significantly energy efficient since the operating temperature for the process is in the range of 80 – 140°C and no use of pressure is involved.
  • the present invention is free of the use of acids and free of more steps making it easy to control and since the main chemical reagent NaOH is regenerated in this process so making the process more economical and environmentally friendly.
  • the present invention for the production of alumina is indigenous technology which can have significant implications for a society's technological advancement, economic development.
  • the present invention also incurs cost of alumina production that is significantly lower than the conventional route and also no use of expensive vessels or equipment is required.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
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  • Inorganic Chemistry (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)

Abstract

The present invention relates to a low-temperature method of recovery of alumina from various alumina-containing resources. The method comprises the steps of treating an alumina- containing resource with Sodium Hydroxide (NaOH) at a predefined low temperature in presence of water (5-50%), and leaching the treated alumina-containing resource with hot water to dissolve Sodium Aluminate (NaAlO₂) and produce leachate. The method further comprises causing precipitation of Aluminium Hydroxide (Al(OH)3) by reacting the leachate with CO2 so as to convert the Sodium Aluminate (NaAlO₂) to Aluminium Hydroxide (Al(OH)3). The method includes performing filtration for effectively separating the solid residues from the leachate; and performing calcination of the precipitated Aluminium Hydroxide (Al(OH)3) at a pre-defined temperature to obtain alumina. Further, the sodium carbonate solution is treated with lime/slaked lime to regenerate sodium hydroxide.

Description

TITLE: LOW-TEMPERATURE PROCESS FOR RECOVERY OF ALUMINA FROM DIFFERENT SOURCES FIELD OF INVENTION [0001] The present disclosure relates to the method for the production of Alumina. Particularly, but not exclusively, the present disclosure is directed toward method for the synthesis of Alumina at low temperature from different alumina-containing sources. BACKGROUND OF THE INVENTION [0002] Alumina (Al2O3) is a versatile compound with wide-ranging applications mostly derived from bauxite (Primary ore of aluminium) through various extraction techniques. Key uses of Alumina are the main constituent for aluminium production. There are other areas of application of alumina such as ceramics, abrasive, catalyst flame retardant, and high- performance materials in electronics and aerospace. Primary source of alumina is bauxite (30 – 40% alumina) and there are a lot of secondary resources of alumina such as Bauxite residue (Red Mud), low-grade iron ore, aluminium dross, overburden. Bauxite residue contains 15 – 20% alumina, Low-grade iron ore 4 – 8% alumina, aluminium dross 50 – 75% and overburden and iron ore tailings have 5-10% alumina. [0003] Global alumina production reached approximately to 140 million metric tons in 2022. Conventional and current alumina production in world is mostly done by the Bayer process, developed in the late 19th century, which involves refining bauxite through digestion, precipitation, and calcination. Bayers process utilizes a temperature of around 150-270 degrees centigrade depending upon the types of alumina rich phase present in bauxite ore and also a pressure of around 25 atm is used. For digestion, it requires an expensive pressure vessel (autoclave). Corrosion of the pressure vessel and all these parameters and equipment used makes this process expensive. Another limitation of this process is that it is not suitable for all the alumina resources such as aluminum dross and diasporic bauxite and low-grade ore or ore containing high silica due to the formation of sodium alumino silicate phase leading to loss of sodium hydroxide as well as alumina leading to less recovery. [0004] Other conventional process for lean bauxite ore or ore with high silica content are soda sintering or lime soda sintering process which involves refining bauxite through sintering/roasting, leaching, and carbonizing. This process utilized a temperature of around 950-1050 °C which is extremely high so it is an energy-intensive process. Another process which are mostly experimental and not yet commercialized are acid leaching or acid baking process which involves lots of mineral acids including more steps, and the dissolution of other components in the source makes this process time-consuming and more expensive. It is important to note that because of the increasing demand for alumina for various usage, it’s high time to focus on all kinds of alumina-containing sources including primary and secondary (lean ore & wastes) to extract alumina with less energy (low temperature). The process must be a close loop, having reduced steps, utilizes inexpensive equipment, and should not generate harmful effluents. [0005] Further, in a patent literature, IN202021022813 discloses a method to selectively enriching and separating alumina and silica from clay minerals and alumino- siliceous industrial rejects using acid, which generates huge volumes of effluents. The reagents are consumed in this process. [0006] In another patent literature, US730952 discloses a method to recover the caustic and alumina values from Bayer Red mud. However, it’s worth noting that this process utilized a temperature of around 1050° C which is significantly high. And use of both lime stone (calcium carbonate) and NaOH and coke. [0007] However, it's worth noting that these above-mentioned processes require several steps, a significant amount of chemicals, utilized high temperature and generates effluents, and is expensive. Therefore, to avoid such problems, there is a need for a simple and cost- effective process to produce alumina that should overcome some of the problems of the prior art. SUMMARY [0008] One or more shortcomings of the prior art are overcome, and additional advantages are provided through the present disclosure. Additional features and advantages are realized though the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure. [0009] The present invention is directed to a low-temperature (T < 200° C) method of recovery of alumina from various alumina-containing resources. The method comprises the steps of treating an alumina-containing resource with Sodium Hydroxide (NaOH) at a predefined temperature in presence of small amount (5-50%) of water, which helps in better reaction between alumina containing phases and NaOH, and leaching the treated alumina- containing resource with water to dissolve Sodium Aluminate (NaAlO₂) and produce leachate. The method includes performing filtration/clarification for separating the solid residues from the leachate. The method further comprises causing precipitation of Aluminium Hydroxide (Al(OH)3) by reacting the leachate with CO2 so as to convert the Sodium Aluminate (NaAlO₂) to Aluminium Hydroxide (Al(OH)3), and performing calcination of the precipitated Aluminium Hydroxide (Al(OH)3) at a pre-defined temperature to obtain alumina. The sodium carbonate generated after alumina is regenerated by treating the solution with lime/slaked lime (CaO/Ca(OH)2) to convert sodium carbonate to sodium hydroxide. After solid/liquid separation, NaOH solution is evaporated and the solution or crystals containing NaOH.H2O is send back for the reuse in the treatment. [0010] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description. A BRIEF DESCRIPTION OF THE DRAWINGS [0011] The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which: Figure 1 illustrates a flowchart for workflow a low-temperature method of recovery of alumina from various alumina-containing resources, in accordance with an embodiment of the present disclosure; Figure 2 illustrates exemplary XRD pattern of aluminum hydroxide produced from dross, in accordance with an embodiment of the present disclosure; and Figure 3 illustrates exemplary XRD pattern of sodium aluminate, formed upon NaOH treatment with red mud at different low temperature with 20% water, in accordance with an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION [0012] In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. [0013] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and the scope of the disclosure. [0014] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device, or process that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or process. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus. [0015] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense. [0016] Alumina, a versatile compound derived mostly from bauxite, finds wide-ranging applications, including as the main constituent for aluminium production and in ceramics, abrasives, catalysts, flame retardants, and high-performance materials in electronics and aerospace. While bauxite is the primary source of alumina, there are numerous secondary resources available, such as bauxite residue (red mud), low-grade iron ore, aluminium dross, and overburden. These resources contain varying percentages of alumina, providing ample opportunities for secondary resource utilization and waste management, which saves not only primary resources for future generation also saves mining and mineral processing cost to a large extent. [0017] Currently, alumina production relies heavily on complex and expensive technologies, with methods like the Bayer process dominating the industry. However, the Bayer process is limited by its temperature and pressure requirements, as well as its efficiency and suitability for low-grade ore or ore with high silica content. Other conventional methods, such as soda sintering or lime soda sintering, also pose challenges due to their high energy consumption and carbon dioxide emissions. Experimental processes like acid leaching or acid baking are time-consuming, expensive, and generate effluents further highlighting the need for alternative approaches like the present invention. [0018] Embodiments of the present disclosure provide a method for recovery of alumina from various alumina-containing resources as illustrated in Figure 1. The various alumina-containing resources include but not limited to red mud, dross, iron ore slime, overburden, low-grade iron ore any industrial waste or natural source. [0019] However, it is understood by a person skilled in the art that the size and configuration of the required set of machinery for accomplishing the method (100) may be variable in accordance with the requirement of the different types of installation environment. Any such variation/modification shall be construed to be within the scope of the present disclosure. [0020] As illustrated in Figure 1, the method (100) comprises one or more blocks to be performed for recovery of alumina from various alumina containing resources. The order in which the method (100) is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. [0021] At block (102), an alumina-containing resource is treated with Sodium Hydroxide (NaOH). In one embodiment, the alumina-containing resource is treated with Sodium Hydroxide (NaOH) at a predefined temperature in the presence of water preferably below 1:1 ratio of the NaOH to water and most preferably below 1:0.5. In one embodiment, the amount of water can be in a range of 5% to 50% and the critical amount of water can be in a range of 10% – 20%. Critical amount of water 10 – 20% relative to weight of alumina containing sources is beneficial for maximizing the alumina recovery at this low temperature treatment. The alumina-containing resource can also be treated with other alkali hydroxides such as KOH, LiOH etc. The predefined temperature for treating the alumina-containing resource is in a range of 60 – 200°C, most preferably below 150°C. Further, the alumina containing resource and the sodium hydroxide is in a ratio ranging from 1:0.1 to 1:2. The alumina-containing resource is mixed with NaOH and treated at temperatures between 80- 140°C to convert the alumina into sodium aluminate, as depicted in equation 1: Al2O3+NaOH + H2O → 2NaAlO2.H2O (1) [0022] At block (104), the treated alumina-containing resource is leached with water. In one embodiment, the treated alumina-containing resource is leached with water to dissolve Sodium Aluminate (NaAlO₂.xH2O) and produce leachate. Wherein, leaching the treated alumina-containing resource with water is carried out in temperature between room temperature to 100°C i.e., in a range of 25ºC – 100ºC. [0023] At block (106), filtration is carried out to separate NaAlO₂.xH2O from the leached residue. [0024] At block (108), Aluminium Hydroxide (Al(OH)3) is precipitated from the leachate using CO2 gas. In one embodiment, the Aluminium Hydroxide (Al(OH)3) is precipitated by reacting the leachate with CO2 gas so as to convert the Sodium Aluminate (NaAlO₂) to Aluminium Hydroxide (Al(OH)3). Al(OH)₃ is precipitated by introducing CO₂ into the sodium aluminate solution, as shown in equation 2. NaAlO2+CO2+H2O→Na2CO3 + Al(OH)3 (2) [0025] At block (110), filtration is performed. In an embodiment, filtration is performed for effectively separating the Al(OH)3 from Na2CO3 solution produced upon CO2 purging. [0026] At block (112), calcination of the precipitated Aluminium Hydroxide (Al(OH)3) is performed and Sodium Hydroxide is regenerated. In an embodiment, calcination of the precipitated Aluminium Hydroxide (Al(OH)3) is performed at a pre-defined temperature to obtain alumina. Further, Alumina hydroxide is separated from sodium carbonate solution by solid liquid separation followed by conventional calcination to obtain alumina. Thereafter, sodium carbonate solution is treated with lime/slaked lime (CaO/Ca(OH)2) to regenerate NaOH. After solid-liquid separation to remove calcium carbonate, the solution is concentrated to get NaOH solution, crystals containing water below 50% so that it can be reused in block (102). [0027] In an example, the present invention discloses a method for the recovery of valuable components from meticulously dehydrated red mud, emphasizing the nuanced effects of critical variables such as sodium hydroxide (NaOH), water amount, treatment temperature, leaching duration. Red mud is systematically blended with sodium hydroxide (NaOH), generating two distinct sets of samples – one with the inclusion of water and the other without. The subsequent controlled treatment phase, conducted within an oven or reactor, is calibrated to optimize reaction conditions. Following low temperature treatment, the samples undergo leaching with distilled water. [0028] Subsequent to leaching, the filtration process, effectively separating the solid residues from the leachate. To ensure the removal of residual sodium aluminate, water washing is performed. [0029] In conjunction with these procedures, X-ray fluorescence spectrometer (XRF) analysis is carried out on both the as-received sample and the leach residues obtained from the experiment. This analytical step or other techniques enables the precise quantification of the elemental composition, providing crucial data for subsequent calculations as illustrated in Figure 2. Primarily, Al(OH)3 is characterized by three phases: gibbsite, bayerite and nordstrandite. Figure 2 shows Bayerite phase which is one form of aluminium hydroxide, which is produced from dross. [0030] Further, Figure 3 illustrates exemplary XRD pattern of sodium aluminate, formed upon NaOH treatment with red mud at different low temperature with 20% water. Figure 3 shows XRD analysis of heat-treated red mud mass with NaOH to red mud mass ratio of 1 and 20% water addition which revealed the formation of sodium aluminate at different temperatures below 150 degrees Celsius. [0031] The present invention introduces a novel and simple process that eliminates the need for high temperature or acids as disclosed by the conventional techniques. [0032] The method of the present invention represents a significant advancement in alumina production. Unlike traditional approaches that often involve high temperatures or hydrothermal treatment, this innovative technique operates at low temperatures without the need for elevated temperature/pressure conditions. By directly treating alumina-containing resources with NaOH, the proposed method generates a water-soluble sodium aluminate phase, a crucial step in the production of alumina. Addition of small amount of water in the raw materials during low temperature process make the alumina recovery efficiency highly significant. This water makes the reaction more effective to form NaAlO2. [0033] One of the key benefits of the proposed method is its sustainability. By eliminating or significantly reducing the reliance on chemicals like acids or temperature or pressure, the proposed method minimizes the environmental impact associated with alumina production. Such reduction in chemical usage/temperature/pressure not only lessens the environmental footprint but also lowers production costs, making the proposed method more economically viable in the long term. [0034] Moreover, by sidestepping the need for high temperatures, the proposed method conserves energy, addressing one of the primary challenges of conventional alumina production. Energy-intensive processes often contribute to greenhouse gas emissions and are costly to operate. The present invention offers a promising solution by significantly reducing energy requirements, thus contributing to a more sustainable and cost-effective production process. [0035] Overall, the present invention represents a significant leap forward in the field of alumina production from different resources. Its ability to produce alumina sustainably, while overcoming the challenges associated with energy-intensive processes, makes it a promising solution for the industry's future. Experimental Details: [0036] According to the present invention's embodiments, the present process's advantages and benefits would become more apparent from the experimental details below to a person skilled in the art. [0037] Example 1: Each 5 g portion of red mud was meticulously placed with varying NaOH concentrations: NaOH to Red mud mass ratio 0.25, 0.50, 0.75, and 1 (on the basis of red mud mass). A homogenized mixture was prepared ensuring thorough blending of the components. Subsequently, these homogenized mixtures underwent low-temperature treatment at different temperature settings (60, 80, 100, 120, and 140 degrees Celsius). Following the low temperature treatment process, the samples were subjected to leaching with water, maintaining a temperature of 60 degrees Celsius. Post-leaching, filtration was carried out, followed by washing to remove any residual sodium aluminate or soda. The resulting residue was then dried, and the subsequent weight was accurately recorded. The maximum alumina recovery achieved is at 140 degrees Celsius, reaching 72.2% when utilizing NaOH to red mud mass ratio of 1. There is a consistent trend of increasing alumina recovery with higher NaOH concentration and treatment temperature. For instance, at 140 degrees Celsius and 0.75 NaOH to red mud mass ratio, the alumina recovery is 70 %. Similarly, at 120 degrees Celsius with 1 NaOH to red mud mass ratio concentration, the recovery rate remains high at 72%. Even at lower temperatures, such as 80 degrees Celsius, coupled with 1 NaOH to red mud mass ratio concentration, a substantial recovery of 63% is attained. Additionally, at 100 degrees Celsius with 1 NaOH to red mud mass ratio concentration, the recovery percentage stands at 69%. These results underscore the positive correlation between NaOH concentration, treatment temperature, and alumina recovery, indicating the potential for optimizing these parameters to enhance recovery efficiency in alumina processing. [0038] Example 2: This experiment was conducted to assess the influence of treatment & leaching duration on the recovery percentage of alumina from 5 g portions of red mud. Each sample was placed with varying NaOH concentrations, (specifically 0.5 and 1 to NaOH to red mud mass including 10% water). A homogenized mixture was prepared meticulously using a glass rod and spatula to ensure uniform distribution of components. These homogenized mixtures were then subjected to low-temperature treatment in an oven at a set temperature of 100 degrees Celsius for 4 hours. [0039] Following the treatment period, the samples underwent a leaching process with water in a glass beaker positioned on a hot plate equipped with a magnetic stirrer, maintaining a temperature of 60 degrees Celsius. After leaching, the filtrate was subjected to filtration, followed by three rounds of washing with ambient water to eliminate any residual sodium aluminate. The resulting residue was dried in an oven, and the subsequent weight was meticulously recorded. The recovery percentages (for 0.5 NaOH to red mud mass ratio) remain relatively stable at 65% across durations of 1 hour, 2 hours, 3 hours, and 4 hours, with a slight increase to 68% observed at the 4-hour mark. For treatment processes with 1 NaOH to red mud mas ratio concentration, there is no significant variance in alumina recovery percentages with respect to treatment time. Similarly, the leaching duration of 30-120 minutes has a negligible effect on the recovery percentage. [0040] Example 3: The objective of this experiment was to examine the impact of water percentage on the recovery of alumina from 5 g portions of red mud. In this study, each sample was placed in nickel crucibles with a NaOH concentration of 100% relative to the weight of red mud, supplemented with no water and 10%, 20%, 30%, 40% water. A homogenized mixture was meticulously prepared. Subsequently, these homogenized mixtures were subjected to low temperature treatment in an oven at varying temperatures, specifically 80, 100, 120, and 140 degrees Celsius, each for a duration of 4 hours. Post-treatment, the samples underwent leaching with water in a glass beaker positioned on a hot plate equipped with a magnetic stirrer, maintaining a temperature of 60 degrees Celsius. Following the leaching process, the filtrate was subjected to filtration, accompanied by three rounds of washing with ambient water to eliminate any residual impurities. The resulting residue was dried in an oven, and the subsequent weight was accurately recorded. The recovery percentage of alumina demonstrates an increasing trend with no water to water addition. The disparity in recovery percentages between 10% and 20% water content is minimal, only 1%. However, the disparity becomes markedly significant when comparing treatment processes with and without water. For a 1:1 NaOH: red mud concentration, the alumina recovery percentages at 140°C are 37%, 71.5%, and 72.5% respectively for processes without water, with 10% water, and with 20% water. Similarly, the recovery decreased further with water addition beyond 20%, yielding 66% and 59.3% recovery for 30% and 40% water addition, respectively. [0041] Example 4: 5 gm dross was milled in a planetary ball mill with a ball to powder ration of 1:10 for 1 hour to convert the dross to 90 microns. The milled dross was leached with water with 1:2 ratio at 95 °C for 4 hours to dissolve the salt and convert most of the AlN to Al(OH)3 and ammonia gas. The slurry was filtered, and the solution was evaporated to produce the salt (NaCl+KCl), which is about 0.6 g. After drying, the solid was mixed with NaOH with 1:1 wt ratio in a mortar pestle. Then it was roasted at 80-140 °C for 4 h followed by water leaching at 60 °C for 1 h. leaching efficiency is around 70% and does not improve significantly in spite of increase in temperature from 80 – 140 °C. Experimental details are indicated in the Table 1 below. Table 1 Experimental details for the dross sample. [0042] The slurry was subsequently filtered to remove/recover the residue rich with alpha alumina and magnesium aluminate. The filtered solution was then subjected to 2 g lime treatment to remove the silica from the solution. After removal of silica rich precipitate, the solution was treated with CO2 bubbling until the 70-90 % of the aluminium was precipitated. Then the slurry was filtered and washed to separate sodium bicarbonate and Al(OH)3. This Al(OH)3 was subjected to calcination at 700°C - 1200°C to produce high purity alumina. [0043] Example 5: Each 5 g portion of low-grade iron ore was mixed with varying NaOH concentrations: 0.50, and 1 NaOH to low grade iron ore mass ratio, each comprising 20% water relative to the iron ore weight. A homogenized mixture was prepared Subsequently, these homogenized mixtures underwent low temperature treatment in an oven at different temperature settings (80, 100, and 120 degrees Celsius) for a standardized duration of 4 hours. Following treatment process, the samples were subjected to leaching with water at 80 degrees Celsius. Post-leaching, filtration was carried out followed by three rounds of washing with ambient water to remove any residual sodium aluminate. The resulting residue was then dried in an oven, and the subsequent weight was accurately recorded. The maximum alumina recovery achieved is at both 100 & 120 degrees Celsius, reaching 81% when utilizing 1 NaOH to low grade iron ore mass ratio concentration. Specifically, at 120°C with a 50% NaOH concentration, the alumina recovery stands out at 76%. In contrast, at 100°C, the recovery percentage slightly decreases to 71%. Notably, the recovery percentage appears to increase with a higher concentration of NaOH, particularly evident at 0.5 NaOH to low grade iron ore mass ratio concentration compared to 1 NaOH to low grade iron ore mass ratio. Interestingly, even at a relatively low temperature of 80°C, significant differences in alumina recovery percentages are observed between varying NaOH concentrations. Specifically, at a 50% NaOH concentration, the alumina recovery percentage remains at 71%. However, at the same temperature but with 1 NaOH to low grade iron ore mass ratio concentration, the recovery percentage notably increases to 79.3%. This suggests a complex relationship between temperature, NaOH concentration, and alumina recovery. While higher temperatures generally promote higher recovery percentages, the data also highlights the significant impact of NaOH concentration. Specifically, the alumina recovery percentage varies notably with changes in NaOH concentration, indicating a substantial dependency on NaOH concentration irrespective of temperature. [0044] Example 6: Each 5 g portion of low-grade iron ore homogenized with varying NaOH concentrations: 0.5, and 1NaOH to low grade iron ore mass ratio, each comprising 10% water relative to the iron ore weight. Subsequently, these homogenized mixtures underwent treatment in an oven at settings temperature of (140 degrees Celsius) for a standardized duration of 4 hours. Following the treatment process, the samples were subjected to leaching with water at 80 degrees Celsius. Post-leaching, filtration was carried out, followed by three rounds of washing with ambient water to remove any residual sodium aluminate. The resulting residue was then dried in an oven, and the subsequent weight was accurately recorded. At 140 degrees Celsius and a 0.5 NaOH to low grade iron ore mass ratio concentration, the alumina recovery percentage stands at 73%, while at 1 NaOH to low grade iron ore mass ratio concentration, it rises to 79%. Remarkably, these recovery percentages are similar to those observed at 80 degrees Celsius. This similarity could potentially be attributed to the utilization of a lower water concentration (10%) rather than the previously mentioned 20%, thereby showcasing the discernible effect of water concentration on alumina recovery percentages. Advantages of the present disclosure: [0045] The present invention applies to all kinds of alumina-containing sources both primary and secondary. This way we can increase alumina production as well as minimize or eliminate the waste generated from mining (overburdens) and metallurgy (tailings, residues, dross). [0046] The present invention is significantly energy efficient since the operating temperature for the process is in the range of 80 – 140°C and no use of pressure is involved. The present invention is free of the use of acids and free of more steps making it easy to control and since the main chemical reagent NaOH is regenerated in this process so making the process more economical and environmentally friendly. The present invention for the production of alumina is indigenous technology which can have significant implications for a society's technological advancement, economic development. The present invention also incurs cost of alumina production that is significantly lower than the conventional route and also no use of expensive vessels or equipment is required. [0047] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the disclosure of the embodiments of the invention is intended to be illustrative, but not limited, of the scope of the invention, which is set forth in the following claims. [0048] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity. [0049] While various aspects and embodiments have been disclosed herein, other aspects and embodiment will be apparent to those skilled in the art. In the detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The description is, therefore, not to be taken in a limiting sense.

Claims

Claims: 1) A low-temperature method (100) of recovery of alumina with critical amount of water from various alumina-containing resources, the method comprises: treating (102) an alumina-containing resource with Sodium Hydroxide (NaOH) at a predefined low temperature in presence of water in a range of 5% - 50%; leaching (104) the treated calcine with water at temperature in a range of 25°C - 100°C to dissolve Sodium Aluminate (NaAlO₂) and produce leachate; separating (106) of leachate from solid residue; causing (108) precipitation of Aluminium Hydroxide (Al(OH)3) by reacting the leachate with CO2 so as to convert the Sodium Aluminate (NaAlO₂) to Aluminium Hydroxide (Al(OH)3) and sodium carbonate solution; performing (110) filtration for effectively separating the aluminium hydroxide from sodium carbonate solution performing (112) calcination of the precipitated Aluminium Hydroxide (Al(OH)3) at a pre-defined temperature to obtain alumina and regenerating the sodium hydroxide from sodium carbonate solution by adding lime 2) The method (100) as claimed in claim 1, wherein three sequential ambient water washes are performed after the filtration to ensure removal of residual sodium aluminate. 3) The method (100) as claimed in claim 1, wherein the predefined temperature for treating the alumina-containing resource is in a range of 80 – 140°C. 4) The method (100) as claimed in claim 1, wherein the alumina containing resource and the sodium hydroxide is in a ratio ranging from 1:0.1 to 1:1. 5) The method (100) as claimed in claim 1, wherein calcination of the precipitated Aluminium Hydroxide (Al(OH)3) is performed at a temperature of 700°C -1200°C. 6) The method (100) as claimed in claim 1, where in alumina resources include but not limited to red mud, iron ore, low grade iron ore/tailings, bauxite ore, aluminum dross, slags etc.
16
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