A method for producing flocculants for complex ores based on the Bayer process

Abstract

This invention relates to the field of alumina production technology, and provides a method for producing sedimentation flocculants for complex ores based on the Bayer process, comprising the following steps: Step 1, real-time monitoring of the ore ratio of the Bayer process leaching slurry, wherein the proportion of foreign ore is 30%-70%; Step 2, dynamically matching the type and concentration of flocculant according to the ore ratio, wherein: liquid flocculant is used in the separation section, with a unit consumption meeting the requirement of dry red mud; dry powder flocculant is used in the washing section, with a unit consumption meeting the requirement of dry red mud; Step 3, verifying the adaptability of the flocculant through sedimentation performance tests to ensure that the sedimentation system fluctuation rate is ≤5%; the anion concentration of the flocculant is dynamically adjusted according to the ore composition, and the adjustment formula is: , where is the anion concentration (ppm). By dynamically matching the type and concentration of flocculant and precisely controlling the dosage using the formula, a 36% reduction in unit consumption is achieved; real-time monitoring and self-correction of the compression layer height ensures annual operational stability ≥95%; dynamic formulation reduces the loss of flocculant and red mud alkali.

Description

Technical Field

[0001] This invention relates to the field of alumina production technology, specifically to a method for producing complex ore settling flocculants based on the Bayer process. Background Technology

[0002] In the alumina production field, the Bayer process, with its advantages of simple process and low energy consumption, has become the most widely used production technology worldwide. In the Bayer process, the sedimentation and flocculation stage is a key step to achieve solid-liquid separation and ensure the quality of alumina products and production efficiency. Especially when processing ores with complex composition and large differences in mineral properties, the quality of sedimentation and flocculation technology directly affects the economic benefits and sustainability of production.

[0003] Traditional Bayer processes for treating complex ores rely primarily on fixed-formulation flocculants, lacking a dynamic response mechanism to changes in ore composition. Due to significant variations in impurity content and particle characteristics among different batches of complex ores, achieving optimal matching with a fixed concentration of flocculant is difficult, resulting in high flocculant consumption per unit volume. This not only increases production costs but also wastes resources. Furthermore, current technologies rely heavily on manual, periodic monitoring of the settling process, failing to accurately obtain key parameters such as compression layer height and settling velocity in real time. When settling velocity fluctuates, rapid adjustments are difficult, leading to reduced settling efficiency, frequent equipment failures, poor annual operational stability, and significant red mud alkali loss, resulting in the ineffective recovery of substantial alkali resources. These factors severely limit the economic benefits and environmental friendliness of the Bayer process for treating complex ores. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a method for producing sedimentation flocculants for complex ores based on the Bayer process, which solves the problems of high flocculant consumption, delayed monitoring, and alkali loss in the traditional Bayer process for treating complex ores.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a method for producing complex ore settling flocculants based on the Bayer process, comprising the following steps: Step 1: Monitor the ore composition of the Bayer process leaching slurry in real time, with imported ore accounting for 30%-70%; Step 2: Dynamically match the type and concentration of flocculant according to the ore ratio, wherein: The separation section uses liquid flocculant, and the unit consumption meets the requirements. Dry red mud; The washing section uses dry powder flocculant, and the unit consumption meets the requirements. Dry red mud; Step 3: Verify the suitability of the flocculant through settling performance tests to ensure that the settling system volatility is ≤5%; The anion concentration of the flocculant is dynamically adjusted according to the ore composition, and the adjustment formula is as follows: ,in Anion concentration (ppm) The percentage of foreign ore (%) This represents the deviation value of the silica-alumina ratio in the ore. , For experimental correction coefficients .

[0006] Preferably, when When the concentration is 30%-50%, a medium molecular weight anionic flocculant should be selected; when... When using high molecular weight anionic flocculants, select those with high molecular weight.

[0007] Preferably, the settling performance test includes a compression layer height monitoring module, which provides real-time feedback on the red mud settling velocity and automatically adjusts the flocculant flow rate to control the settling velocity between 0.8 and 1.2 m / h.

[0008] Preferably, the flocculant has a hydrolysis loss rate of ≤8%, which is more than 35% lower than that of conventional production.

[0009] Preferably, it includes: an ore proportion monitoring unit, a dynamic blending unit, and a flocculant addition execution unit.

[0010] Preferably, the dynamic blending unit has a built-in ore-flocculator matching database, which includes the optimal flocculant molecular weight, anion concentration, and unit consumption threshold for different ratios.

[0011] Preferably, the system is equipped with a fluctuation early warning module, which triggers an alarm and initiates parameter self-correction when the settling velocity deviates from the set range of ±15%.

[0012] Preferably, the ore proportioning monitoring unit detects the ore composition in real time using an XRF spectrometer, the dynamic blending unit calculates the flocculant parameters based on the monitoring data, and the flocculant addition execution unit accurately adds flocculant according to the calculation results.

[0013] Preferably, the system has an annual operational stability of ≥95% and a reduction in red mud alkali loss of 0.5%-0.8%.

[0014] Preferably, the medium molecular weight anionic flocculant has a molecular weight of 8 million to 12 million, and the high molecular weight anionic flocculant has a molecular weight > 12 million.

[0015] This invention provides a method for producing flocculants for complex ores based on the Bayer process. It has the following beneficial effects: 1. This invention achieves a flocculant consumption of ≤160g / t dry red mud by dynamically matching the type and concentration of flocculant, which is 36% lower than the traditional method; and it precisely controls the dosage of the agent by combining the anion concentration formula, thereby reducing the agent cost.

[0016] 2. This invention monitors the height of the compression layer in real time based on settlement performance tests and controls the settlement speed within 0.8-1.2 m / h. When the speed deviates by ±15%, the fluctuation warning module triggers self-correction within 30 minutes. The annual operating stability is ≥95%, and the downtime due to failure is reduced by 62.5%.

[0017] 3. The dynamic formulation reduces the flocculant hydrolysis loss rate to ≤8%, and the red mud alkali loss to 0.5%-0.8%, resulting in excellent annual alkali recovery value; it can also quickly recover stability under extreme operating conditions. Attached Figure Description

[0018] Figure 1 This is a flowchart of the present invention; Figure 2 This is a system diagram of the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1: Please see the appendix Figure 1 and attached Figure 2 This invention provides a method for producing a settling flocculant for complex ores based on the Bayer process, comprising the following steps: Step 1: Monitor the ore composition of the Bayer process leaching slurry in real time, with imported ore accounting for 30%-70%; Specifically, imported bauxite accounts for 30%, while domestic ore accounts for 70%. The ore composition and silica-alumina ratio deviation are detected in real-time using an XRF spectrometer. The value is 0.5. The dynamic allocation unit receives the ore ratio data and triggers the matching logic of "medium molecular weight anionic flocculant".

[0021] Step 2: Dynamically match the type and concentration of flocculant according to the ore ratio, wherein: The separation section uses liquid flocculant, and the unit consumption meets the requirements. Dry red mud, liquid flocculant consumption is 160g / t dry red mud, and it is added evenly through a metering pump; The washing section uses dry powder flocculant, and the unit consumption meets the requirements. Dry red mud, with a dry powder flocculant consumption of 160g / t dry red mud, is transported to the settling tank by airflow; Specifically, when the proportion of foreign ore is 30%-50%, medium molecular weight anionic flocculants (molecular weight 8-12 million) are selected. Concentration calculation: Taking experimental correction coefficients k1=0.8 and k2=0.5, then: C=0.8×30+0.5×0.5=24.25ppm.

[0022] Step 3: Verify the adaptability of the flocculant through a settling performance test to ensure that the settling system fluctuation rate is ≤5%. The settling performance test includes a compression layer height monitoring module, which provides real-time feedback on the red mud settling velocity and automatically adjusts the flocculant flow rate to control the settling velocity between 0.8-1.2 m / h. The anion concentration of the flocculant is dynamically adjusted according to the ore composition, and the adjustment formula is as follows: ,in Anion concentration (ppm) The percentage of foreign ore (%) This represents the deviation value of the silica-alumina ratio in the ore. , For experimental correction coefficients ,when When the concentration is 30%-50%, a medium molecular weight anionic flocculant should be selected; when... When using high molecular weight anionic flocculants, the flocculants must meet the requirement that the hydrolysis loss rate is ≤8%, which is more than 35% lower than conventional production. The medium molecular weight anionic flocculants have a molecular weight of 8 million to 12 million, and the high molecular weight anionic flocculants have a molecular weight >12 million. Specifically, the real-time feedback of the compression layer height monitoring module showed a settlement velocity of 0.9 m / h, which is within the range of 0.8-1.2 m / h. The settlement system fluctuation rate was 3% (≤5%), and no fluctuation warning was triggered. The detection result was 7.5% (≤8%), which is more than 35% lower than that of conventional production.

[0023] Please see the appendix Figure 1 and attached Figure 2A system for producing complex ore settling flocculants based on the Bayer process is disclosed, comprising: an ore proportion monitoring unit, a dynamic blending unit, and a flocculant addition execution unit. The dynamic blending unit has a built-in ore-flocculator matching database containing the optimal flocculant molecular weight, anion concentration, and unit consumption threshold for different proportions. The system is equipped with a fluctuation warning module, which triggers an alarm and initiates parameter self-correction when the settling velocity deviates from the set range of ±15%. The ore proportion monitoring unit detects the ore composition in real time using an XRF spectrometer. The dynamic blending unit calculates the flocculant parameters based on the monitoring data. The flocculant addition execution unit accurately adds flocculant according to the calculation results. The system has an annual operating stability of ≥95% and reduces red mud alkali loss by 0.5%-0.8%.

[0024] Specifically, the loss of alkali adhering to red mud was reduced by 0.6%, and the annual operational stability reached 96%, meeting the goal of "stable production and high yield".

[0025] Example 2: Please see the appendix Figure 1 and attached Figure 2 Foreign bauxite accounts for 50%, domestic ore accounts for 50%, and the silica-alumina ratio deviation value is... The XRF spectrometer detected fluctuations in ore composition at a value of 0.8. The dynamic adjustment unit activated its parameter self-correction mechanism, and the flocculant was dynamically adjusted: still within the 30%-50% range. A medium molecular weight anionic flocculant (molecular weight 10 million) was selected. The concentration was calculated as follows: k1=1.0, k2=0.6, then: C=1.0×50+0.6×0.8=50.48ppm. The unit consumption of the separation and washing sections was maintained at 160g / t dry red mud, and the liquid and dry powder flocculants were added simultaneously in proportion. Settling performance experiment: Monitoring indicators: settling velocity 1.1m / h, stable compression layer height, system fluctuation rate 4.2%, dynamic adjustment: due to fluctuations in the silica-alumina ratio of the ore, the fluctuation warning module was not triggered (deviation ≤15%), the system automatically fine-tuned the flocculant flow rate ±5%, the hydrolysis loss rate was 7.8%, and the red mud alkali loss was reduced by 0.5%, verifying the adaptability of the flocculant at a 50% ratio.

[0026] Example 3: Settlement treatment with 70% foreign ore

[0027] Ore blending monitoring: Ore composition: 70% imported bauxite, 30% domestic ore, silica-alumina ratio deviation value. The value is 1.2. Monitoring data: The dynamic allocation unit identified that the proportion of foreign ore was >50%, triggering the matching logic of "high molecular weight anionic flocculant"; Dynamic adjustment of flocculant: Type selection: According to claim 2, a high molecular weight anionic flocculant (molecular weight > 12 million, 15 million in this example) is selected. Concentration calculation: take k1=1.2, k2=0.8, then: C=1.2×70+0.8×1.2=85.92ppm, the liquid flocculant consumption in the separation section is 160g / t dry red mud, the dry powder flocculant consumption in the washing section is 160g / t dry red mud, and the addition accuracy is ±2%. Settling performance test: Monitoring indicators: Settling velocity 1.0 m / h, system fluctuation rate 2.8%, stable data feedback from the compression layer height monitoring module, extreme case response: If the settling velocity deviates to 1.2 m / h (+20%), the fluctuation warning module will trigger an alarm, and the dynamic adjustment unit will automatically increase the flocculant concentration by 5% to bring the velocity back to 0.9 m / h; System performance: hydrolysis loss rate 7.2%, red mud alkali loss reduced by 0.8%, annual operating stability 95.5%, meeting the goal of "stable system operation when foreign ore is mixed in 70%".

[0028] Example 4: System fluctuation early warning and self-correction verification

[0029] Simulated abnormal operating conditions: The ore mix ratio is artificially set to suddenly increase to 80% of foreign ore (exceeding the 30%-70% range), and the silicon-aluminum ratio deviates. =1.5; System Response: Warning Triggered: The settling velocity suddenly increases to 1.4 m / h (deviation from the set range +15%). The fluctuation warning module immediately alarms and initiates parameter self-correction. Dynamic Adjustment: The dynamic allocation unit calls the backup database, temporarily selects ultra-high molecular weight flocculant (molecular weight 18 million), and calculates the concentration according to the formula: C=1.2×80+0.8×1.5=97.2ppm. The flocculant addition execution unit increases the dosage to 170g / t dry red mud (temporary over-adjustment of 10%). Recovery results: Within 30 minutes, the settlement velocity dropped to 1.1 m / h, and the system volatility recovered to 4.5%, verifying the effectiveness of the volatility early warning module.

[0030]

[0031] Example 5: High-efficiency application of low-concentration flocculants

[0032] Operating conditions: Imported ore percentage: 40% (domestic ore: 60%), Si / Al ratio deviation ΔSi / Al = 0.3 (low Si / Al ratio fluctuation); Dynamic blending unit judgment: medium molecular weight flocculant (molecular weight 9 million). Concentration optimization: Correction coefficient adjustment: k1=0.7 (reduced demand at low silicon-aluminum ratio), k2=0.4, anion concentration calculation: C=0.7×40+0.4×0.3=28.12ppm, unit consumption control: liquid flocculant unit consumption in the separation section is reduced to 155g / t dry red mud (normally 160g / t), and dry powder flocculant consumption in the washing section is maintained at 160g / t; Performance verification:

[0033]

[0034] Technical significance: This demonstrates that under low silica-alumina ratio deviation, reducing the k1 coefficient can decrease the amount of flocculant used (by 3%) while maintaining sedimentation stability, highlighting the economic efficiency of the dynamic formula.

[0035] Example 6: System self-learning capability verification: Scenario construction: run continuously for 3 months, accumulate data with different ratios (30%-65% in foreign mines), dynamically adjust the unit to start the machine learning module, and optimize the matching database; Self-optimization process: Initial response time: 10 seconds → After optimization: 5 seconds. New rule: When ΔSi / Al > 1.0 and foreign ore > 60%, automatically activate high molecular weight flocculant + concentration increase of 5%. Emergency working condition test: Simulating a sudden increase in the proportion of foreign mines to 65% ( =1.3), system response: automatically switch to flocculant with a molecular weight of 14 million, concentration calculation: C=1.2×65+0.8×1.3=79.04ppm→float up to 82.99ppm according to the new rules, settling speed: from 1.25m / h (exceeding the standard) back to 1.05m / h (self-correction time <8 minutes).

[0036]

[0037] Example 7:

[0038]

[0039] The cost of the reagents is calculated based on the market price of 11,250 yuan / ton for anionic flocculants and 12,000 yuan / ton for conventional flocculants. The value of alkali recovery is based on the price of sodium hydroxide at 2,500 yuan / ton. The amount of alkali loss is calculated as: dry red mud amount × loss rate × alkali concentration (assuming an alkali concentration of 40%).

[0040] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for producing flocculant for settling complex ores based on the Bayer process, characterized in that, Includes the following steps: Step 1: Monitor the ore composition of the Bayer process leaching slurry in real time, with imported ore accounting for 30%-70%; Step 2: Dynamically match the type and concentration of flocculant according to the ore ratio, wherein: The separation section uses liquid flocculant, and the unit consumption meets the requirements. Dry red mud; The washing section uses dry powder flocculant, and the unit consumption meets the requirements. Dry red mud; Step 3: Verify the suitability of the flocculant through settling performance tests to ensure that the settling system volatility is ≤5%; The anion concentration of the flocculant is dynamically adjusted according to the ore composition, and the adjustment formula is as follows: ,in Anion concentration (ppm) The percentage of foreign ore (%) This represents the deviation value of the silica-alumina ratio in the ore. , For experimental correction coefficients .

2. The method for producing complex ore settling flocculants based on the Bayer process according to claim 1, characterized in that, when When the concentration is 30%-50%, a medium molecular weight anionic flocculant should be selected; when... When using high molecular weight anionic flocculants, select those with high molecular weight.

3. The method for producing complex ore settling flocculants based on the Bayer process according to claim 1, characterized in that, The settling performance test includes a compression layer height monitoring module, which provides real-time feedback on the red mud settling velocity and automatically adjusts the flocculant flow rate to control the settling velocity between 0.8 and 1.2 m / h.

4. The method for producing complex ore settling flocculants based on the Bayer process according to claim 1, characterized in that, The flocculant meets the requirement of a hydrolysis loss rate of ≤8%, which is more than 35% lower than that of conventional production.

5. A system for producing complex ore settling flocculants based on the Bayer process, using the method for producing complex ore settling flocculants based on the Bayer process as described in any one of claims 1-4, characterized in that, include: The unit includes an ore proportioning monitoring unit, a dynamic blending unit, and a flocculant addition execution unit.

6. A system for producing complex ore settling flocculants based on the Bayer process according to claim 5, characterized in that, The dynamic blending unit has a built-in ore-flocculator matching database, which includes the optimal flocculant molecular weight, anion concentration, and unit consumption threshold for different ratios.

7. A system for producing complex ore settling flocculants based on the Bayer process according to claim 5, characterized in that, The system is equipped with a fluctuation early warning module, which triggers an alarm and initiates parameter self-correction when the settling velocity deviates from the set range of ±15%.

8. A system for producing complex ore settling flocculants based on the Bayer process according to claim 5, characterized in that, The ore proportioning monitoring unit detects the ore composition in real time using an XRF spectrometer, the dynamic blending unit calculates the flocculant parameters based on the monitoring data, and the flocculant addition execution unit accurately adds flocculant according to the calculation results.

9. A system for producing complex ore settling flocculants based on the Bayer process according to claim 5, characterized in that, The system has an annual operational stability of ≥95%, and the loss of alkali adsorbed in red mud is reduced by 0.5%-0.8%.

10. A method for producing a settling flocculant for complex ores based on the Bayer process according to claim 2, characterized in that, The medium molecular weight anionic flocculant has a molecular weight of 8 million to 12 million, and the high molecular weight anionic flocculant has a molecular weight > 12 million.

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