Exploring innovative strategies for precipitation extent enhancement in a downscaled Bayer process tank

Abstract The Bayer process is a cornerstone of alumina production, and its precipitation stage holds the key to both efficiency and product quality. In this study, we embarked on a comprehensive exploration of strategies to enhance the precipitation extent of aluminium hydroxide, a pivotal step in the Bayer process. Utilizing a newly constructed reactor, along with experiments using reactors in series, we rigorously experimented with various factors, including the addition of hydrogen peroxide (H 2 O 2 ) as an enhancer, seed activation methods, the integration of a hydrocyclone within the processing unit, the application of a magnetic field, and the injection of supersaturated liquor midway through the process. These diverse strategies were systematically assessed to decipher their individual and synergistic effects on precipitation extent. Our research aims to uncover the optimal conditions for maximizing alumina precipitation while maintaining product quality and seed particle stability. By offering new insights and practical solutions, this study contributes to the ongoing advancement of alumina production within the Bayer process.