1. Concept for an industrial scale HCl-based bauxite residue valorization and idea for using available technology for piloting at batch scale
David Konlechner, Egon Sehner, Ernst Pichler, Mario Stein
07/05/18

2. The idea of producing Alumina via a HCl route is not novel
History
The idea of producing Alumina via a HCl route is not novel
Camille Jenatza
a Belgian race driver
reached 100 km/h
29th April 1899
in an electric car
07/05/18

3. Single treatment steps follow known chemistry
Vision
Single treatment steps follow known chemistry
21st century materials make HCl process possible
Target is a zero waste approach
07/05/18

4. Process Overview Industrial Scale
Assumed Process
~ 77,6 kt BR
9,6 kt
SiO2
TiO2
12 kt
Al2O3
39,2 kt
Fe2O3
Simple PFD
Required process equipment, preliminary summary
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5. Step 1: Bauxite Residual Leaching with HCl
Leaching BR
15,6 wt% Al2O3
6,5 wt% SiO2
50,6 wt% Fe2O3
6,3 wt% TiO2
8,7 wt% CaO
3,5 wt% Na2O
Batch operation
Acidic filtration
31,9 t/h HCl conc.
9,7 t/h BR
Step 1:
Leaching
40,2t/h Solution
1,4 t/h (wet)
SiO2
TiO2
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6. Step 2: ACH Precipitation by using HCl gas
11,3 t/h HCl >95%
40,2 t/h Solution
Step 2:
Precipitation
43,8 t/h Solution
7,7 t/h ACH
07/05/18

7. Step 3: AlCl3.6H2O Calcination and Step 4: Al2O3 Washing
ACH is decomposed
AlCl3.6H2O  Al2O3 +3H2O + 6HCl
recycling high concentrated HCl gas
Al2O3 / NaCl separation by washing
7,7 t/h ACH
Step 3/4:
Calcination & Washing
5,6 t/h HCl/H2O
2,1 t/h Al2O3 & NaCl
1,5 t/h
Al2O3
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8. Step 5: Fe2O3 Precipitation
Only Fe2O3 is precipitated at process conditions
2FeCl3 + 3H2O  Fe2O3 + 6 HCl
Remaining elements are concentrated
37,3 t/h HCl/H2O
43,8 t/h Solution
Step 5:
Fe2O3 Precipitation
44,1 t/h Solution
42,5 t/h Backfl.
4,9 t/h
Fe2O3
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9. Step 6: REE and Trace Element Removal Step 7: HCl Purification
19,3 t/h H2O
44,1 t/h Solution
Step 6:
Trace Element Removal
42,5 t/h Backfl.
37,3 t/h HCl/H2O
Step 7:
HCl Drying
18 t/h HCl > 95%
1,6 t/h
Rest, incl. REE, Ca
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10. Nobody wants to be the guinea pig Industry available process
Concept to Industry
Valley of death
Nobody wants to be the guinea pig
Lab proven process
Industry available process
07/05/18

11. Using a customized CARLA as Pilot
Compact Acid Regeneration Liquid Assembly (CARLA)
Originally designed with the steel industry
Including key equipment suitable for HCl
Ready for process Step 1, 2, 5 and 6
Smart possibility for batch demonstration / piloting
Operating at site
Using original feedstock material
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12. CARLA Concept
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13. CARLA Concept
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14. Summary
HCl based BR treatment a possible solution for sustainable alumina
CARLA an opportunity for straight forward piloting and demonstration activities
Outlook
Process has to be demonstrated
Further upscaling and equipment availability has to be investigated
REE enrichment and behavior has to be studied
07/05/18

15. Thank you for your attention!
David KONLECHNER
Owner
KON Chemical Solutions e.U.
Obermuellnerstrasse 2A/4/2
1020 Vienna, Austria T:
Egon SEHNER
Product Line Manager
CMI Industry
CMI UVK GmbH
Robert-Bosch-Str. 12
56410 Montabaur, Germany T: F: M:
07/05/18