Study on Experimental Parameters of Alkali-Assisted Extraction of Aluminum from Fly Ash

Extracting aluminum from FA is an effective way to improve its utilization rate. Since aluminum oxide is found in high polymerization degree, inert substances such as mullite and sodium aluminosilicate make the reaction process difficult because of their stable chemical properties; within these highly polymerized matrices, the chemical stability of alumina typically persists across a broad temperature range from 1000 °C to over 1600 °C. To address the issue of stable mullite structure that hinders aluminum extraction, a combined acid-base method using sodium carbonate as an activating agent and hydrochloric acid at a temperature of 100 °C as a leaching agent is employed. XRD and SEM were used to analyze the phase characterization and microstructure of fly ash before and after activation and acid leaching, examining the effects of activation parameters and acid leaching parameters on the activation of FA and the aluminum extraction rate. The research results indicate that after calcination activation, mullite is transformed into zeolite, which is easily soluble in acid, and the aluminum within the activated molten material is transferred to the filtrate through acid leaching, achieving the goal of extracting aluminum. Under the activating conditions with sodium carbonate flux, the Al-O bonds in mullite are broken, the crystal structure is transformed, and the aluminum compounds obtained from hydrochloric acid leaching have a stable form of existence, which has a low impact on the error of the experimental results. When the material ratio of fly ash to sodium carbonate is 1:0.7, after reacting at a calcination temperature of 880 °C for 1.5 h, and leaching in 6 mol/L hydrochloric acid at 100 °C with a solid-liquid ratio of 1:6 for 2 h, the extraction rate of aluminum in fly ash is the highest, reaching 97%.