Silicon-Containing Polymer Flocculation for Bayer Process

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Solution Overview

Problem

Efficient removal of suspended solids, particularly desilication products (DSP), from Bayer alumina process streams remains a challenge in the Bayer process, affecting the purity and efficiency of alumina production.

Innovation Solution

Contacting Bayer process streams with silicon-containing polymers, either alone or in combination with conventional flocculants, to effectively flocculate and separate suspended solids, including DSP, thereby reducing the need for filtration and improving alumina product purity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional flocculants (polyacrylate, starch, flour) are used to separate suspended solids, then some flocculation effect is achieved, but the separation efficiency is insufficient and filtration is still required

Engineering Contradiction:

Improveseparation efficiencyVSAvoidfiltration requirement

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent changes the chemical parameters of the flocculant by incorporating silicon-containing groups (such as silane or siloxane groups) into the polymer structure. This modification alters the flocculation mechanism to specifically target and effectively aggregate desilication products (DSP) and suspended solids, enabling complete separation without filtration and improving overall productivity.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If silicon-containing polymers are used to flocculate suspended solids, then flocculation effectiveness is significantly improved, but the complexity of the chemical process increases

Engineering Contradiction:

Improveflocculation effectivenessVSAvoidchemical process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs composite polymer structures that combine conventional flocculant components with silicon-containing groups. This creates a hybrid flocculant material that leverages the proven effectiveness of conventional polymers while adding the specific DSP-targeting capability of silicon-containing groups, achieving reliable flocculation without requiring entirely new chemical processes.

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If complete removal of suspended solids is achieved through improved flocculation, then alumina product purity is improved, but the cost of flocculant chemicals increases

Engineering Contradiction:

Improvealumina product purityVSAvoidflocculant chemical cost

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent applies local quality modification by introducing silicon-containing groups at specific positions within the polymer structure. This localized modification provides specific binding affinity for DSP and suspended solids, enabling complete removal of impurities and improvement of alumina product purity while maintaining cost-effectiveness through targeted rather than bulk chemical action.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Significantly enhances the flocculation of suspended solids, leading to improved settling rates and clarity of the alumina process streams, resulting in a cleaner separation of constituents and reduced impurities in the alumina product.

Implementation Method 1

contacting a Bayer process stream with a silicon-containing polymer flocculant to flocculate suspended solids

Methodology Applied

Scientific EffectFlocculation: Flocculation

Implementation Method 2

leading to improved settling rates and clarity of the alumina process streams

Methodology Applied

Scientific EffectSettling: Settling

Data Source

PatentEP2139812B1Use of silicon-containing polymers to improve red mud flocculation in the bayer process

Publication Date: 2019.01.02 CYTEC TECHNOLOGY CORP

AI summary

The suspended solids content of a Bayer process stream is reduced by contacting the stream with silicon-containing polymers