In
the Bayer process, reactive silica associated with bauxite dissolves
into alkaline solution and subsequently precipitates as a sodium aluminosilicate
“desilication product” (DSP). Multiple DSP phases can
be formed, which include an amorphous solid as well as crystalline
zeolite A, sodalite, and cancrinite. Even though the ability to control
DSP particle size would be of great practical benefit, there remains
limited fundamental understanding of the precipitation process, especially
during the early stages of the reaction. In this study, DSP was precipitated
from synthetic NaOH–NaAl(OH)4–Na2SiO3–H2O solution at 75 and 90 °C.
Four distinct reaction stages were observed: (1) precipitation of
the amorphous solid, (2) dissolution of the amorphous solid, (3) growth
of crystalline phases, and (4) maturation of the crystalline phases.
In addition to the amorphous phase, the nucleation of both particles
and two-dimensional crystal planes occurs in the early stages of the
reaction. Subsequently, the amorphous phase dissolves, which feeds
the early growth of the crystalline DSP phases. After the amorphous
phase disappears, the crystal phases continue to grow with reactants
from the bulk solution until equilibrium is approached. In the maturation
stage, the solution silicate concentration decreases only slightly;
however, during this time the sizes of individual crystals decrease
slightly while the overall particle size increases via crystal agglomeration,
which is promoted at higher temperature.