The influence of Na2SO4 at chemical equilibrium in the NaOH-Al2O3-SiO2-Na2SO4-H2O system were studied in synthetic Bayer liquors. Sodium aluminosilicate, otherwise referred to as desilication product (DSP) in the alumina industry, was synthesised hydrothermally from kaolin used in a rotating bomb heater. Experiments spanned several days to reach equilibrium at 90 °C, 150 °C and 250 °C and employed Na2SO4 concentration ranging from 0 to 0.4 M. The SO42− incorporation into DSP was best modelled by the mathematical form of Langmuir-type isotherms, and reached maximum occupancy of 85%, primarily displacing OH−, and Al(OH)4− to a lesser degree. The presence of Na2SO4 enhanced desilication (measured by solution SiO2 concentration) by up to 80% compared to sulphate-free tests, with diminishing relative effect with increasing SO42− concentration. Approximate maximum sulphate cage occupancy and effect on desilication were achieved at a Na2SO4 concentration of 0.1 M. Solid residues contained Bayer (alumina)-type cancrinite, sulphate-type cancrinite (vishnevite), hydroxycancrinite, hydroxysodalite and amorphous material as determined by X-ray diffraction. The presence of sulphate led to different transformation pathways for DSP precipitated from kaolin. Sulphate-bearing DSPs exhibited rod-like morphology and presented enhanced thermal stability over their hydroxy counterparts. Valuable new data on the relationship between sulphate ion uptake, and the composition, structure and solubility of DSP are presented, and the results are suitable for the development of kinetic and thermodynamic models describing zeolite equilibria in alumina processing.
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