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    In the late 19th Century the search was on to find a mordant, or fixer for textile dyes. In fact what was found was to revolutionize not only the metal industry, but several others too, including surface treatment.

    In Russia Carl Josef Bayer discovered that aluminium hydroxide that precipitated from his alkaline solutions was crystalline in  form and so could be easily filtered and washed, as opposed that which precipitated from an acidic solution which was gelatinous, and so difficult to handle. The year was 1887.

    Bauxite, in its raw form, contains only 30 – 50% aluminium oxide, the rest being in various proportions, titanium dioxide, silica and a variety of iron oxides. The aluminium oxide must therefore be refined/concentrated before it can be processed into either aluminium metal or the alumina powders used in polishing, refractory, ceramic  and other applications.

    Initially the raw bauxite is washed in a solution of Sodium hydroxide at 175 degrees centigrade. The aluminium oxide in the bauxite thus becomes Sodium aluminate.

    As the impurities in the bauxite do not dissolve they can be easily filtered off. The resulting red mud is highly toxic (Reference the Ajka Alumina plant disaster in 2010 when huge quantities of red mud were discharged into the Danube).

    Next the alkaline solution is cooled and aluminium hydroxide precipitates out. This precipitant is then calcined and hydroxide decomposes to oxide giving off water in the process.

    Thereafter there is a divergence as the alumina to be used for aluminium metal production, and that destined to become the alumina powders such as those that we supply begin to take very different routes.