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The Bayer process is the principal industrial means of refining bauxite to produce alumina (aluminium oxide) and was developed by Carl Josef Bayer.Bauxite, the most important ore of aluminium, contains only 30–60% aluminium oxide (Al 2 O 3), the rest being a mixture of silica, various iron oxides, and titanium dioxide. [1]
Bauxite is the main source of the rare metal gallium. [17] During the processing of bauxite to alumina in the Bayer process, gallium accumulates in the sodium hydroxide liquor. From this it can be extracted by a variety of methods. The most recent is the use of ion-exchange resin. [18]
The Hall-Héroult electrolysis process is the major production route for primary aluminium. An electrolytic cell is made of a steel shell with a series of insulating linings of refractory materials. The cell consists of a brick-lined outer steel shell as a container and support. Inside the shell, cathode blocks are cemented together by ramming ...
The liquid aluminium is removed from the cell via a siphon every 1 to 3 days in order to avoid having to use extremely high temperature valves and pumps. Alumina is added to the cells as the aluminum is removed. Collected aluminium from different cells in a factory is finally melted together to ensure uniform product and made into metal sheets.
Bauxite was discovered in 1821 by Pierre Berthier who named it after a village named Les Beaux where he found it. [6] To obtain the alumina from the bauxite ore, a process was developed that used acid to dissolve aluminium but resulted in a product that contained large amounts of iron and titanium dissolved within which were difficult to remove. [6]
Aluminium metal has an appearance ranging from silvery white to dull gray depending on its surface roughness. [d] Aluminium mirrors are the most reflective of all metal mirrors for near ultraviolet and far infrared light. It is also one of the most reflective for light in the visible spectrum, nearly on par with silver in this respect, and the ...
This step could be replaced by the Pedersen process -- either result in alumina. Unlike the smelting processes of iron and coal into steel or copper and tin into bronze, which require thermal energy, alumina must be smelted with electrical energy. This is done through the Hall–Héroult process, producing 99.5–99.8% pure aluminum. [2] [7]
Some non-ferrous materials are also used in the iron and steel industries. For example, bauxite is used as flux for blast furnaces, while others such as wolframite, pyrolusite, and chromite are used in making ferrous alloys. [3] Important non-ferrous metals include aluminium, copper, lead, tin, titanium, and zinc, and alloys such as brass.