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<p>Recovering aluminum from the high-pressure acid leaching (HPAL) residue of laterite ore offers a sustainable and efficient solution for resource utilization in metallurgical processes. This study optimizes aluminum extraction through an innovative multi-step process involving wet sieving, alkali leaching, CO<sub>2</sub> precipitation, and calcination. The initial wet sieving effectively removed impurities, notably CaSO<sub>4</sub>, reducing calcium and sulfur content and enhancing the efficiency of subsequent alkali leaching. Under optimal conditions, the alkali leaching achieved an aluminum recovery rate of 94.02%. The leachate was then subjected to CO<sub>2</sub> precipitation at 80&#xa0;°C, achieving high recovery rates with a mass ratio of CO<sub>2</sub> to the product of 1.6. X-ray diffraction analysis confirmed the formation of pure bayerite (Al(OH)<sub>3</sub>) after 8&#xa0;h of reaction, with the finest and most uniform particle size obtained at an agitation speed of 400&#xa0;rpm. Calcination of the precipitated product at 400&#xa0;°C yielded pure γ-Al<sub>2</sub>O<sub>3</sub> with an exceptionally high specific surface area of 285.5&#xa0;m<sup>2</sup>/g, a mean particle size of 14.26&#xa0;µm, and an average pore size of 3.06&#xa0;nm, highlighting its suitability as a catalyst carrier. This comprehensive and sustainable approach not only demonstrates an efficient method for aluminum recovery from industrial residues but also provides valuable insights for industrial applications, advancing the circular economy in metal processing.</p> Graphical Abstract <p></p>

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Enhancing Aluminum Recovery from High-Pressure Acid Leaching Residues: A Pathway to High-Purity γ-Al2O3 Catalyst Production

  • 期刊论文

  • 发表日期：

    2025年5月21日

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  • Akhsan Fakhrurozi,
  • Yilin Wang,
  • Wei Liu,
  • Yi Wang

摘要

Recovering aluminum from the high-pressure acid leaching (HPAL) residue of laterite ore offers a sustainable and efficient solution for resource utilization in metallurgical processes. This study optimizes aluminum extraction through an innovative multi-step process involving wet sieving, alkali leaching, CO2 precipitation, and calcination. The initial wet sieving effectively removed impurities, notably CaSO4, reducing calcium and sulfur content and enhancing the efficiency of subsequent alkali leaching. Under optimal conditions, the alkali leaching achieved an aluminum recovery rate of 94.02%. The leachate was then subjected to CO2 precipitation at 80 °C, achieving high recovery rates with a mass ratio of CO2 to the product of 1.6. X-ray diffraction analysis confirmed the formation of pure bayerite (Al(OH)3) after 8 h of reaction, with the finest and most uniform particle size obtained at an agitation speed of 400 rpm. Calcination of the precipitated product at 400 °C yielded pure γ-Al2O3 with an exceptionally high specific surface area of 285.5 m2/g, a mean particle size of 14.26 µm, and an average pore size of 3.06 nm, highlighting its suitability as a catalyst carrier. This comprehensive and sustainable approach not only demonstrates an efficient method for aluminum recovery from industrial residues but also provides valuable insights for industrial applications, advancing the circular economy in metal processing.

Graphical Abstract