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Iron removal from kaolin by oxalic acid using a novel pre-agitating and high-pressure washing technique

Published online by Cambridge University Press:  24 May 2023

Bijan Taheri*
Affiliation:
Department of Mining Engineering, University of Kashan, Qotb-e-Ravandi Blvd, Kashan, Iran
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Abstract

This study reports a leaching process along with a novel physical pretreatment technique to remove iron impurities from kaolin using oxalic acid. A detailed examination of the physical properties of the minerals confirmed that almost none of the leaching-resistant iron oxides, specifically hematite, was completely interlocked with the clay minerals. Accordingly, a pre-agitating technique followed by high-pressure washing of the sample on a 600 μm sieve were applied. In this method, by discarding up to 20% of the raw material, >54% of the total iron content of the raw kaolin was removed, and the iron content was reduced from 9.75% in the initial sample to <6.00% in the passing fraction. Application of this pretreatment method rendered the leaching process successful at 97°C using 0.3 M oxalic acid solutions for 1 h under atmospheric pressure. Compared to the leaching of the raw material without pretreatment, which consumed at least 0.5 M oxalic acid over a minimum period of 2 h, the method used was very cost-effective and favourable, reducing the iron content of the product to <1% and producing high-quality kaolin.

Information

Type
Article
Copyright
Copyright © The Author(s), 2023. Published by Cambridge University Press on behalf of The Mineralogical Society of the United Kingdom and Ireland
Figure 0

Figure 1. XRD trace of the raw kaolin sample.

Figure 1

Table 1. Chemical composition of the raw material.

Figure 2

Figure 2. Micrographs of polished cross-sections of the various size fractions. G = goethite; H = hematite.

Figure 3

Table 2. Degree of liberation of iron oxide particles.

Figure 4

Figure 3. Particle-size distribution curves of crushed samples classified under dry, wet and pre-agitated conditions.

Figure 5

Table 3. Iron content (wt.%) in various size fractions after crushing followed by pretreatment.

Figure 6

Figure 4. XRD traces of >2000, 300–600 and <100 μm size fractions.

Figure 7

Figure 5. Images of coarse particles and powders of >2000, 300–600 and <100 μm size fractions.

Figure 8

Figure 6. Particle-size distribution curves of wet-ground pre-agitated samples after various reaction times.

Figure 9

Table 4. Distribution of iron content (wt.%) in various size fractions after grinding.

Figure 10

Figure 7. (a) Iron removal (wt.%) and (b) iron content (wt.%) as a function of leaching temperature under various acid concentration and leaching time conditions.

Figure 11

Figure 8. Iron removal and iron content (wt.%) at 97°C with oxalic acid of various concentrations for a reaction time of 120 min.

Figure 12

Figure 9. Effect of particle size on iron removal and iron content (wt.%; temperature = 97°C, stirring speed = 1200 rpm, leaching time = 120 min, oxalic acid concentration = 0.3 M, L/S ratio = 10).

Figure 13

Figure 10. Effect of liquid-to-solid ratio on iron dissolution from kaolin (temperature = 97°C, stirring speed = 1200 rpm, leaching time = 120 min, oxalic acid concentration = 0.3 M).

Figure 14

Figure 11. Effect of stirring speed on iron dissolution from kaolin at L/S ratios of 2, 4 and 10 (temperature = 97°C, leaching time = 120 min, oxalic acid concentration = 0.3 M).

Figure 15

Figure 12. Effect of leaching time on iron dissolution from kaolin (temperature = 97°C, L/S ratio = 4, oxalic acid concentration = 0.3 M, stirring speed = 800 rpm).

Figure 16

Figure 13. Changes to slurry colour before and after leaching (left to right: before leaching, after leaching and separated solid–liquid, respectively).