Research on the mechanism of sodium separation in bauxite residue synergy preparation of potassium-containing compound fertilizer raw materials by the hydrothermal method

Abstract

Bauxite residue poses an increasingly serious ecological safety problem in the alumina industry. A novel process for removing sodium in bauxite residue synergistic preparation of potassium-containing compound fertilizer raw materials was proposed to relieve pressure on the fertilizer industry. In this paper, synthetic sodalite and katoite were used to simulate the main mineral phases of bauxite residue to determine the suitable conditions for the method, and the transformation mechanism of the process was researched by analyzing the phase structure and microscopic morphology of the samples using X-ray diffraction (XRD), scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FTIR), and specific surface area detection. The results show that the ideal reaction condition is 320 g/L K₂O with solid reactants at 200 °C for 1 h. The separation rate of Na in the sodalite-katoite mixture reached 93.60%, with potassium aluminum silicate and katoite being the primary phases of the product, with a mesoporous structure and easy to be absorbed by crops. The bauxite residue transformation residue consisted of katoite and kaliophilite. With a total effective K₂O, CaO, and SiO₂ content of 38.22%, the Na₂O content was 0.54%, meeting the requirements of compound fertilizer content on the market. The transformation mechanism is a dissolution-precipitation controlled sodium-potassium ion replacement reaction. This study provides theoretical guidance for the preparation of mineral fertilizer from bauxite residue and has practical production potential, opening up a new perspective for bauxite residue resource usage in the agricultural field.

Keywords: Bauxite residue; Fertilizer; Hydrothermal method; KOH solution; Sodalite-katoite.