There are provided processes for treating red mud. For example, the processes can comprise leaching red mud with HCl so as to obtain a leachate comprising ions of a first metal (for example aluminum) and a solid, and separating said solid from said leachate. Several other metals can be extracted fro
There are provided processes for treating red mud. For example, the processes can comprise leaching red mud with HCl so as to obtain a leachate comprising ions of a first metal (for example aluminum) and a solid, and separating said solid from said leachate. Several other metals can be extracted from the leachate (Fe, Ni, Co, Mg, rare earth elements, rare metals, etc.). Various other components can be extracted from solid such as TiO2, SiO2 etc.
대표청구항▼
1. A process for treating red mud, said process comprising: leaching red mud with HCl at a temperature of about 125 to about 225° C. to obtain a leachate comprising aluminum ions and iron ions and a solid, and separating said solid from said leachate;reacting said leachate with HCl to obtain a liqui
1. A process for treating red mud, said process comprising: leaching red mud with HCl at a temperature of about 125 to about 225° C. to obtain a leachate comprising aluminum ions and iron ions and a solid, and separating said solid from said leachate;reacting said leachate with HCl to obtain a liquid comprising said iron ions and a precipitate comprising said aluminum ions in the form of AlCl3, and separating said precipitate from said liquid; andheating said precipitate under conditions effective for converting AlCl3 into Al2O3 and optionally recovering gaseous HCl so-produced. 2. The process of claim 1, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight %. 3. The process of claim 1, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight % at pressure of about 50 to about 150 psig. 4. The process of claim 1, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight % at a temperature of about 160 to about 190° C. 5. The process of claim 1, wherein said red mud is leached with HCl having a concentration of about 18 to about 45 weight % at a temperature of about 125 to about 225° C. 6. The process of claim 1, wherein said process further comprises recycling gaseous HCl so-produced by contacting it with water to obtain a composition having a concentration of about 25 to about 45 weight % and using said composition for leaching said red mud. 7. The process of claim 1, wherein said process comprises reacting said leachate with gaseous HCl to obtain said liquid and said precipitate comprising said aluminum ions, said precipitate being formed by crystallization of AlCl3.6H2O. 8. The process of process of claim 1, wherein said process comprises converting AlCl3.6H2O into Al2O3 by carrying out a calcination of AlCl3.6H2O, said calcination comprising steam injection. 9. The process of 1, wherein said red mud is leached at a pressure of about 4 to about 10 barg. 10. The process of 5, wherein said red mud is leached at a pressure of about 4 to about 10 barg. 11. The process of claim 1, wherein said process further comprises converting said Al2O3 into aluminum. 12. A process for treating red mud, the process comprising: leaching said red mud comprising a first metal with HCl at a temperature of about 125 to about 225° C. to obtain a leachate comprising ions of said first metal and a solid, and separating the solid from the leachate;reacting the leachate with HCl to obtain a liquid and a precipitate comprising a chloride of the first metal, and separating the precipitate from the liquid; andheating the precipitate under conditions effective for converting the chloride of the first metal into an oxide of the first metal. 13. The process of claim 12, wherein said first metal is chosen from aluminum, iron, zinc, copper, gold, silver, molybdenum, cobalt, magnesium, lithium, manganese, nickel, palladium, platinum, thorium, phosphorus, uranium titanium, at least one rare earth element or at least one rare metal. 14. The process of claim 12, wherein said first metal is aluminum. 15. The process of claim 13, wherein the liquid comprises a second metal. 16. The process of claim 15, wherein the second metal is chosen from aluminum, iron, zinc, copper, gold, silver, molybdenum, cobalt, magnesium, lithium, manganese, nickel, palladium, platinum, thorium, phosphorus, uranium, titanium, at least one rare earth element or at least one rare metal. 17. The process of claim 15, wherein the second metal is iron. 18. A process for treating red mud comprising: leaching red mud with an acid to obtain a leachate and a solid residue, and separating said leachate from said solid residue; at least partially removing iron ions from said leachate by substantially selectively precipitating said iron ions at a pH greater than 10 by reacting said leachate with a base and at least partially removing said precipitated iron ions from said leachate, thereby obtaining an Al-rich composition comprising Al3+ ions;precipitating said Al3+ ions in the form of Al(OH)3 at a pH of about 7 to about 10;optionally purifying said Al(OH)3; andconverting said Al(OH)3 into alumina. 19. A process for preparing titanium chloride, said process comprising: leaching red mud with HCl to obtain a first leachate comprising ions from at least one metal and a solid, and separating said solid from said first leachate;at least substantially isolating said ions of said at least one metal from said leachate; andleaching said solid with HCl in the presence of at least one chloride that is an alkali metal chloride or an alkaline earth metal chloride to obtain a second leachate comprising titanium chloride. 20. A process for treating red mud, said process comprising: leaching red mud with HCl to obtain a leachate comprising aluminum ions and iron ions and a solid that comprises less than 10 weight % of the aluminum atoms contained in said red mud, and separating said solid from said leachate;reacting said leachate with HCl to obtain a liquid comprising said iron ions and a precipitate comprising said aluminum ions in the form of AlCl3, and separating said precipitate from said liquid; andheating said precipitate under conditions effective for converting AlCl3 into Al2O3 and optionally recovering gaseous HCl so-produced. 21. A process for treating red mud, said process comprising: leaching red mud with HCl under conditions effective to obtain a solid and a leachate comprising at least 90 weight % of the aluminum contained in said red mud in the form of aluminum ions and iron ions, and separating said solid from said leachate;reacting said leachate with HCl to obtain a liquid comprising said iron ions and a precipitate comprising said aluminum ions in the form of AlCl3, and separating said precipitate from said liquid; andheating said precipitate under conditions effective for converting AlCl3 into Al2O3 and optionally recovering gaseous HCl so-produced. 22. The process of claim 1, wherein said liquid comprises at least one iron chloride. 23. The process of claim 22, wherein said liquid is concentrated to a concentrated liquid having a concentration of said at least one iron chloride of at least 30% by weight; and then hydrolyzed at a temperature of about 155 to about 350° C. 24. The process of claim 1, wherein said process comprises reacting said leachate with HCl to increase concentration of HCl at conditions effective to substantially selectively precipitate aluminum ions, said precipitate being formed by crystallization of AlCl3.6H2O. 25. The process of claim 7, wherein said process comprises reacting said leachate with HCl to increase concentration of HCl at conditions effective to substantially selectively precipitate aluminum ions, said precipitate being formed by crystallization of AlCl3.6H2O. 26. The process of claim 24, wherein said gaseous HCl has a HCl concentration of at least 85% by weight. 27. The process of claim 24, wherein during said crystallization of AlCl3.6H2O, said liquid is maintained at a concentration of HCl of about 25 to about 35% by weight. 28. The process of claim 24, wherein said crystallization is carried out at a temperature of about 45 to about 65° C. 29. The process of claim 12, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight %. 30. The process of claim 12, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight % at pressure of about 50 to about 150 psig. 31. The process of claim 12, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight % at a temperature of about 160 to about 190° C. 32. The process of claim 12, wherein said red mud is leached with HCl having a concentration of about 18 to about 45 weight % at a temperature of about 125 to about 225° C. 33. The process of 12, wherein said red mud is leached at a pressure of about 4 to about 10 barg. 34. The process of claim 20, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight %. 35. The process of claim 20, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight % at pressure of about 50 to about 150 psig. 36. The process of claim 20, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight % at a temperature of about 160 to about 190° C. 37. The process of claim 20, wherein said red mud is leached with HCl having a concentration of about 18 to about 45 weight % at a temperature of about 125 to about 225° C. 38. The process of 20, wherein said red mud is leached at a pressure of about 4 to about 10 barg. 39. The process of claim 20, wherein said process comprises reacting said leachate with HCl to increase concentration of HCl at conditions effective to substantially selectively precipitate aluminum ions, said precipitate being formed by crystallization of AlCl3.6H2O. 40. The process of claim 39, wherein said gaseous HCl has a HCl concentration of at least 85% by weight. 41. The process of claim 39, wherein during said crystallization of AlCl3.6H2O, said liquid is maintained at a concentration of HCl of about 25 to about 35% by weight. 42. The process of claim 39, wherein said crystallization is carried out at a temperature of about 45 to about 65° C. 43. The process of claim 21, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight %. 44. The process of claim 21, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight % at pressure of about 50 to about 150 psig. 45. The process of claim 21, wherein said red mud is leached with HCl having a concentration of about 25 to about 45 weight % at a temperature of about 160 to about 190° C. 46. The process of claim 21, wherein said red mud is leached with HCl having a concentration of about 18 to about 45 weight % at a temperature of about 125 to about 225° C. 47. The process of 21, wherein said red mud is leached at a pressure of about 4 to about 10 barg. 48. The process of claim 21, wherein said process comprises reacting said leachate with HCl to increase concentration of HCl at conditions effective to substantially selectively precipitate aluminum ions, said precipitate being formed by crystallization of AlCl3.6H2O. 49. The process of claim 48, wherein said gaseous HCl has a HCl concentration of at least 85% by weight. 50. The process of claim 48, wherein during said crystallization of AlCl3.6H2O, said liquid is maintained at a concentration of HCl of about 25 to about 35% by weight. 51. The process of claim 48, wherein said crystallization is carried out at a temperature of about 45 to about 65° C. 52. The process of claim 12, wherein said process further comprises converting said Al2O3 into aluminum. 53. The process of claim 18, wherein said process further comprises converting said alumina into aluminum. 54. The process of claim 20, wherein said process further comprises converting said Al2O3 into aluminum. 55. The process of claim 21, wherein said process further comprises converting said Al2O3 into aluminum.
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