The Minerals, Metals & Materials Series Corleen Chesonis Editor Light Metals 2019 123 Editor Corleen Chesonis Metal Quality Solutions, LLC Avonmore, PA, USA ISSN 2367-1181 ISSN 2367-1696 (electronic) The Minerals, Metals & Materials Series ISBN 978-3-030-05863-0 ISBN 978-3-030-05864-7 (eBook) https://doi.org/10.1007/978-3-030-05864-7 Library of Congress Control Number: 2018964235 © The Minerals, Metals & Materials Society 2019, corrected publication 2019 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. 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This Springer imprint is published by the registered company Springer Nature Switzerland AG The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland Preface It is my honor to present the Light Metals 2019 proceedings and to welcome you to the TMS 2019 Annual Meeting and Exhibition in San Antonio. I hope that being the second woman to edit this respected publication is an indication of increasing and ongoing inclusion and diversity in the light metals community. TMS has always been welcoming to me, both as a woman and as a chemical engineer rather than a metallurgist. The aluminum industry has continued to change in the past year with the announcement of Elysis, a joint venture to scale up and commercialize a revolutionary smelting technology that emits oxygen and eliminates greenhouse gases. If successful, this technology could help solve one of the major challenges of our industry and our world. In the meantime, a number of manufacturers have introduced certified low-carbon products and products made with 100% recycled metal. No matter what smelting technology is used in the future, recycling, reduced energy consumption, and lower environmental impact will continue to be important to our industry. These proceedings reflect an incredible effort by all the authors and their organizations in conducting their research and preparing the manuscripts that are published here. I would like to thank all of them for their work; their contributions continue to make Light Metals the pre-eminent annual publication for technical information on aluminum production processes. As in the past, this volume contains research and development papers on aluminum pro- cesses organized into the traditional Light Metals symposia: Alumina and Bauxite; Aluminum Alloys, Processing, and Characterization; Aluminum Reduction Technology; Cast Shop Technology; and Electrode Technology for Aluminum Production. It also includes two special symposia for 2019: Ultrasonic Processing of Liquid and Solidifying Alloys and Scandium Extraction and Use in Aluminum Alloys. We are honored to also have included papers on aluminum processing from two joint symposia: REWAS 2019: Cast Shop Recycling Tech- nologies and the TMS-DGM Symposium on Lightweight Metals: A Joint US-European Symposium on Challenges in Light Weighting the Transportation Industry. This last sym- posium is the result of a Memorandum of Understanding between TMS and the German Materials Society (DGM). I would like to thank the subject chairs and symposium organizers for all of their hard work: Sébastien Fortin, Hiromi Nagaumi, Marc Dupuis, Pierre-Yves Menet, Lorentz Petter Lossius, Nigel Ricketts, John Grandfield, Dmitry Eskin, Mertol Gökelma, Eric Nyberg, Wim Sillekens, Norbert Hort, and Jürgen Hirsch. I also appreciate the guidance of the previous editors, Olivier Martin and Arne Ratvik. Finally, my sincere thanks to all the wonderful staff at TMS who guided us through the production of these proceedings. Corleen Chesonis v Contents Part I Alumina & Bauxite: Bayer Process and Non-conventional Processing Advances in Beneficiation of Low-Grade Bauxite ........................ 3 Lala Behari Sukla, Archana Pattanaik and Debabrata Pradhan Leaching Kinetics of Thermally-Activated, High Silica Bauxite .............. 11 Hong Peng, Steven Peters and James Vaughan Rheological Improvements in Alumina Industry Clarification Circuits ........ 19 Lawrence J. Andermann Jr., Adrian Mullins, Cameron Smyth and Clive Roscoe Improving the Reliability of Fluidized Bed Alumina Calciners by Suitable Refractory Lining Selection ......................................... 27 Mariana A. L. Braulio, José R. Cunha, Austin J. Maxwell, Dean Whiteman and Victor C. Pandolfelli Valorization of Bauxite Residue: A Challenge that Leads to a Mentality Shift and Eventually Innovation ..................................... 33 Yiannis Pontikes Synchronous Desulfurization and Desilication of Low-Grade and High-Sulfur Bauxite by a Flotation Process ....................................... 35 Wencui Chai, Guihong Han, Yanfang Huang, Yijun Cao and Jiongtian Liu Preparing Alumina by an Electrolytic Method from Sulfuric Acid Leachate of Coal Fly Ash .................................................. 39 Yuan Shi, Kai-xi Jiang, Ting-an Zhang and Guo-zhi Lv Part II Alumina & Bauxite: Bauxite Residue: Management and Valorization Use of Two Filtration Stages for Bauxite Residue ........................ 47 Roberto Seno Jr., Rodrigo Aparecido Moreno and Heri Cristine Nakamura Environmental Friendly Transformation of the First and Oldest Alumina Refinery in the World ............................................. 57 Laurent Bonel, Philippe Clerin and Laurent Guillaumont Accelerating Bauxite Residue Remediation with Microbial Biotechnology ...... 69 T. C. Santini, K. Warren, M. Raudsepp, N. Carter, D. Hamley, C. McCosker, S. Couperthwaite, G. Southam, G. W. Tyson and L. A. Warren Simulation and Experiment Study on Carbonization Process of Calcified Slag with Different Ventilation Modes ..................................... 79 Guanting Liu, Liu Yan, Xiaolong Li, Weihua Sun, Zimu Zhang and Ting’an Zhang An Ecological Approach to the Rehabilitation of Bauxite Residue ............ 87 Elisa Di Carlo and Ronan Courtney vii viii Contents Quantitative X-Ray Diffraction Study into Bauxite Residue Mineralogical Phases .............................................. 93 John Vogrin, Harrison Hodge, Talitha Santini, Hong Peng and James Vaughan Technospheric Mining of Rare Earth Elements and Refractory Metals from Bauxite Residue .............................................. 101 John Anawati and Gisele Azimi Migration of Iron, Aluminum and Alkali Metal Within Pre-reduced-Smelting Separation of Bauxite Residue ....................................... 107 Jian Pan, Siwei Li, Deqing Zhu, Jiwei Xu and Jianlei Chou Part III Aluminum Alloys, Processing and Characterization: Aluminum Alloy Development Influence of Amine Additives on the Electrodeposition of Aluminum from AlCl3-Dimethyl Sulfone Electrolytes .............................. 115 S. A. Salman, Sangjae Kim, Kensuke Kuroda and Masazumi Okido Determination of the Intermetallic a-Phase Crystal Structure in Aluminum Alloys Solidified at Rapid Cooling Rates ............................... 121 Joseph Jankowski, Michael Kaufman, Amy Clarke, Krish Krishnamurthy and Paul Wilson Comparison of the Effects of B4C and SiC Reinforcement in Al-Si Matrix Alloys Produced via PM Method ..................................... 129 Yavuz Kaplan, Engin Tan, Hakan Ada and Sinan Aksöz The Effects of Manganese (Mn) Addition and Laser Parameters on the Microstructure and Surface Properties of Laser Deposited Aluminium Based Coatings ......................................... 135 O. S. Fatoba, S. A. Akinlabi and E. T. Akinlabi Understanding the Role of Cu and Clustering on Strain Hardening and Strain Rate Sensitivity of Al-Mg-Si-Cu Alloys........................ 143 M. Langille, B. J. Diak, F. De Geuser, G. Guiglionda, S. Meddeb, H. Zhao, B. Gault, D. Raabe and A. Deschamps Production of the AA2196-TiB2 MMCs via PM Technology ................ 153 Engin Tan, Yavuz Kaplan, Hakan Ada and Sinan Aksöz Retrogression-Reaging Behavior in Aluminum AA6013-T6 Sheet ............ 159 Katherine E. Rader, Jon T. Carter, Louis G. Hector Jr. and Eric M. Taleff Part IV Aluminum Alloys, Processing and Characterization: Microstructures and Mechanical Properties of Aluminum Alloys Advanced Characterization of the Cyclic Deformation and Damage Behavior of Al-Si-Mg Cast Alloys Using Hysteresis Analysis and Alternating Current Potential Drop Method ............................................ 167 Jochen Tenkamp, Kevin Bleicher, Sven Klute, Karin Chrzan, Alexander Koch and Frank Walther 3-D Microstructural Distribution and Mechanical Analysis of HPDC Hypereutectic Al-Si Alloys via X-Ray Tomography ......................