To mimic the process of gibbsite nucleation on sodium oxalate crystals and their intergrowth in alumina Bayer process, such a coprecipitation process has been broken down into three distinct stages and studied by in situ AFM and ex situ SEM under static conditions. In the first stage, a solution saturated in aluminate and supersaturated in oxalate has been used for investigating the oxalate growth on its {110} face, which is controlled by a layer-by-layer mechanism. In the second stage, in a solution saturated in oxalate and supersaturated in aluminate, gibbsite secondary nucleation was preferred along macrosteps of sodium oxalate {110} faces and appeared as two-dimensional (2D) islands with pisolitic shapes. There does not appear to be a preferred epitaxial relationship at the heterointerface between gibbsite crystals and sodium oxalate substrates, indicating that the magnitude of the surface free energy for nucleation is greater than that associated with strain energy caused by lattice mismatch. In the third stage following gibbsite secondary nucleation, in a solution saturated in aluminate and supersaturated in oxalate, the inclusion of gibbsite crystallites into the bulk of sodium oxalate crystals through step growth on {110} faces of sodium oxalate was observed.
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