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ABSTRACT: The formation of sodium chromate from mixtures of high silica chromite ore concentrate (48.8%)
and soda ash with the addition of cement by-pass dust (CKD) and limestone was investigated. The results
revealed that roasting of briquettes containing a mixture of Cr2O3: Na2CO3: total CaO (in cement dust) (mole
ratios= 1: 2.5: 3) at 1000 oC for 2 hours and PO2 0.21 atm yielded a maximum of 86% sodium chromate. On the
other hand, roasting a similar mixture of Cr2O3: Na2CO3 and total CaO (in limestone) (mole ratios= 1: 2.5: 0.4)
under the same experimental conditions only gave a 55% yield. Kinetically, both reactions were solid –gas
diffusion processes that were controlled by an initial stage of decomposition of both the cement dust and
limestone. However, the addition of cement dust to the Na2CO3: Cr2O3 mixture significantly decreased the
process energy of activation from 112 kJ/mole to 84 kJ/mole whereas, in the case of limestone addition, the
process Ea was 117 kJ/ mole. In conclusion, the study findings support the use of CKD in the local production
of chromate salts as well as it provides an economic alternative for the recycling of around 600-tons/ month of
CKD generated within the Greater Cairo Urban Region.
Keywords: Sodium Chromate formation, cement by-pass dust, limestone, waste recycling.
Papanastassion and Bitsines [13] stated that the rate chlorides and sulfate content. As well, no single
for a gas-solid mechanism at the initial stage could be technical option applied locally was effective in
either a chemical reaction controlled, gas diffusion absorbing the bulk of the waste generated within (ca
controlled or boundary layer controlled depending 600 tons / month) in order to reduce its
upon the experimental conditions (temperature and environmental impacts.
flow rate of gas). As well, the activation energy
With this in mind, the option to utilize the cement
reflected the energy barrier associated with the rate-
dust in the pilot scale production of sodium
determining step. Ansari et al. [14] indicated that
chromate from local chromite ore concentrate (48.8
obtaining activation energy between 62-65 kJ/mole
% Cr2O3) was explored relative to the use of
was indicative of a chemical reaction controlled
abundant raw materials, namely: limestone. In this
mechanism. A 33-38 kJ/mole activation energy was
work, the kinetics of the reaction of formation of
indicative of a rate that was not limited by chemical
sodium chromate from an optimal mixture of Cr2O3
reaction but also by a gas diffusion step. As well, it
ore concentrate and Na2CO3 (1: 2.5 mole-ratio [15, 2]
was noted that if the energy increased to between
by the addition of cement bypass dust and limestone
121-158 kJ/mole, the reaction mechanism was solid-
(based on CaO content) as a catalyst was
state diffusion controlled.
investigated. The study was conducted in a tube
Tripathy et al [9] indicated that the reaction between furnace at PO2 0.21 atm (open air system) to
Na2CO3 and Cr2O3 was not a solid phase reaction as determine the influence of temperature and change
the activation energy for the system (Cr2O3-Na2CO3) in CaO/ Cr2O3 mole ratio within the reaction
was 72 kJ/mole. Shalabi et al. [8], on the other hand, mixture using bypass dust and limestone.
illustrated that the mechanism of roasting of
chromite ore concentrate with soda ash in air and in 2. EXPERIMENTAL STUDIES
pure oxygen providing a 60 % chromic oxide
recovery was a solid diffusion mechanism having 2.1 Materials
activation energy of 119.1 kJ/mole. Moreover, A representative sample of chromite concentrate
Shalabi et al. [15] indicated that the mechanism of (48.8 %) from El-Baramiya region was provided by
roasting of chromite ore concentrate and soda ash the Beneficiation Unit of the CMRDI. Soda ash
plus lime in air and oxygen at 60% chromic oxide (90% Na2CO3) used in these investigations was
recovery was a solid diffusion mechanism having an provided by Misr Chemical Co. (El- Max,
activation energy of 106 kJ/ mole and 88 kJ/ mole, Alexandria). Cement bypass dust (CKD) used was
respectively. Furthermore, El-Dars et al. [16] obtained from the National Cement Co. in Helwan.
showed that maximum sodium chromate yield was Limestone used was obtained from the Egyptian
attained when a mixture of soda ash chromite ore Iron and Steel Co. in Helwan. The physical and
concentrate (sodium carbonate: chromic oxide = 2.5: chemical properties as well as the size distribution of
1 mole ratio) was roasted at 1000 oC for 2 hrs with these raw materials used are illustrated in Tables 1
no introduction of air. The reaction energy of and 2.
activation was 112 kJ/mole for and a maximum
chromate recovery (expressed chromic oxide) of 63% 2.2 Briquetting / Roasting Procedures
yield was obtained.
The reaction materials were mixed thoroughly
On the other hand, cement production was together then charged to a special mold (3-cm long
introduced in Egypt during the mid 50’s around the and 1-cm inner diameter) and shaped using a manual
area of Helwan, a southern district of the Greater hydraulic pressing machine. The study was
Cairo Urban Region [17]. Initially, the three large conducted in a vertical tube open (open air system)
cement plants constructed around this suburb to allow for the introduction of air into the furnace
(namely: National, Torrah and Helwan cement during roasting (from up downwards) and to
companies) employed the wet process technology maintain the reaction PO2 at 0.21 atm accordingly.
until the mid 1970s. However, with the aim to The roasting reactor used consisted of a heavy-duty
increase productivity and decrease energy temperature controlled tube furnace inside which a
consumption, the plants converted to the dry nickel-chrome wire basket of a diameter 5-cm hung
technology, which does not require pretreatment of vertically on a balance. A thermocouple (Ni-Ni/Cr)
raw materials by soaking. Since that date, cement was set in the middle of the tube furnace and the
dust emissions have plagued the area as hazardous temperature inside the furnace was held constant at
arial characteristic as well as being a problematic 900 – 1000 oC (± 1°C) using a voltage regulator. A
waste [18]. Essentially, this cement kiln (bypass) dust typical roasting procedure conducted was as follows:
(CKD) is not amenable to recycling within the
cement production process due to its high alkali
F. M. S El-Dars, M. E.H. Shalabi, Hanaa A.M. Abuzeid, M. G. Khalifa, A. .B. Farag / The Journal of ORE DRESSING ® 2008 11
i- The system was checked for operation effectively was removed, and briquettes were cooled in a
and corrective measures, if required, were taken desiccator.
accordingly. iv- Chemical analysis of the samples was conducted
ii- The required weight of agglomerated materials after each individual run was performed [16].
was charged into the basket and then into the The percentage of sodium chromate obtained
reactor assembly when the furnace temperature was calculated according to the following
reached the experimental predestined value (900, equation [6]:
925 oC, etc.).
Chromate recovery % (expressed as chromic oxide)
iii- After a predetermined period, roasting was
= (Chromic oxide as sodium chromate / chromic
stopped, the basket with the roasted products
oxide in the sample) *100
Table 1. Chemical analysis of Chromite ore concentrate and Cement By-pass Dust (wt %)
SiO
Raw materials FeO Cr2O3 CaO Al2O3 MgO Na2O+K2O+Cl L.O.I.
2
By-pass cement dust 2.35 as Fe2O3 -- 14 51 (16% as free CaO) 3.5 1.8 3.18+1.98+4.42 9.5
Limestone -- -- 1.05 54.67 -- 0.12 -- 42.81
3. RESULTS AND DISCUSSIONS Consequently, the excess sodium carbonate was free
to react with Cr2O3 to form sodium chromate. On
3.1 The Effect of Varying the Total CaO Added the other hand, the calcium oxide addition was
(CKD / Limestone) on the Chromic Oxide reported to enhance the rate of sodium chromate
Recovery formation [6]. This was in accordance to the
observations with the mixture of chromite ore/ soda
Previous work [16] indicated that the optimum
ash and cement dust (CKD) as a maximum chromic
amount of Cr2O3 recovery for the same ore
oxide recovery (86%) was achieved when the total
concentrate was obtained at Cr2O3: Na2CO3 mole
CaO / Cr2O3 mole ratio= 3.
ratio = 1: 2.5 roasted at ~ 1000 oC and for 40 min
(briquette pressure ~ 75 kg/cm2 and briquette height 90
Chromate recover y, %.
0.4 mole ratio. The latter increase may be attributed increased as well as the rate of adsorption of oxygen
to the reaction of calcium oxide with SiO2, Fe2O3, molecules, which increased the rate of reaction.
MgO, Al2O3 to form calcium silicate, calcium ferrite However, for roasting of an optimal mixture of ore
and calcium magnesium aluminate. Thus, the excess concentrate: soda ash: total CaO (limestone) (mole
sodium carbonate was free to react with Cr2O3 to ratio= 1:2.5:0.4) under the same conditions, the
form sodium chromate. On the other hand, the maximum chromic oxide recovery obtained was 55
increase in limestone mole ratio to 0.5 leads to a % (Figure 4). Comparatively and from Figures 3 and
decrease in the chromic oxide formation to about 4, it was clear that the addition of limestone
9%. This may be due to the fact that the increase of negatively affected the chromic oxide recovery as it
limestone leads to an increase of the free sodium significantly decreased below 68%, a value obtained
carbonate which leads to an increase in melt from roasting an optimal mixture of chromite ore
formation and, subsequently, decreased the porosity and soda ash without CaO (1 :2.5).
of briquette and Cr2O3 recovery. As well, the
limestone contained higher ignition losses than 100
CKD, which when eliminated during roasting, 90
45 50
40 4 0 m ins 40
35
30 30
25 For 900 C.
20 For 925 C.
20 For 950 C.
15 10 For 975 C.
10 For 1000 C.
5 0 Poly (For 925 C )
0 0 10 20 30 40 50 60 70 80 90 10 11 12 13 14
0 0,1 0 ,2 0,3 0,4 0,5 0 0 0 0 0
Time, min.
Total Ca O mole ratio
Fig 3. The effect of varying roasting time (mins.) of
the optimal mixture Chromite ore concentrate: soda
Fig 2. The effect of varying the total CaO mole ratio ash: total CaO (CKD) (mole ratio =1:2.5: 3) within the
(Limestone) on chromic oxide recovery % (as temperature range of 900-1000 C and for 2 hrs on
chromic oxide)- roasting time 40 mins. sodium chromate recovery% (expressed as Cr2O3).
3.2 The Effect of Varying the Roasting 3.3 Kinetics of The Formation of Sodium
Temperature on Chromic Oxide Recovery from Chromate in The Presence of CaO
Both CKD and Limestone Mixtures
To determine the reaction rate controlling
Isotherms for roasting of a briquette composed of a mechanism for both reactions studied, different
mixture of chromite ore concentrate: soda ash: total models were applied [19]. From these applications,
CaO for both CKD and limestone optimal mole the following mathematical model [20] – indicative of
ratios were studied within the temperature range of a solid diffusion mechanism through product layer
900 – 1000 oC (Figures 3 and 4, respectively). control – was found to be the most appropriate and
During these procedures, the sample weight was kept acceptable for data interpretation:
constant at 4.6 g. From Figure 3, it was clear that as
the temperature increased, the recovery of Cr2O3 k t = (1 – (1 – R)1/3)2
increased significantly to above 81% for a mixture of
ore concentrate: soda ash: total CaO (CKD) (mole where:
ratio= 1:2.5:3). This may be attributed to the fact R the decimal fraction of chromic oxide
that this increase in temperature enhanced the rates recovered.
of various chemical and physical processes involved
in the overall reaction. As well, the increase in T the time of reaction, min.
temperature lead to an increase in the number of k the rate constant (min-1)
reaction molecules that have acquired activation
energy and, therefore, an increase in the reaction rate A plot between (1– (1–R)1/3)2 and roasting time
was observed [19]. Subsequently, at elevated (min) is illustrated in Figures 5 and 6 for mixtures
temperatures, the rate of mass transfer of diffusion containing cement dust and limestone, respectively,
which indicated the presence of linear relationship.
F. M. S El-Dars, M. E.H. Shalabi, Hanaa A.M. Abuzeid, M. G. Khalifa, A. .B. Farag / The Journal of ORE DRESSING ® 2008 13
ln k
For 925 C.
0,4
0,35 For 950 C.
(1-(1 - R)1/3) 2
Fig 5. The relationship between [1-(1-R)1/3]2 and time On the other hand, Figure 8 indicated a reaction
(min) for roasting of briquettes with the optimal activation energy for a mixture of ore concentrate:
mixture of Chromite ore concentrate, soda ash and
soda ash: total CaO (limestone) (mole ratio=
total CaO (CKD) (mole ratio=1:2.5:3) at different
temperatures. 1:2.5:0.4) around 117 kJ/mole. From previous
works, these activation energies correspond to a gas-
solid diffusion through product layer control
0,06 mechanism [6, 8, 9, 13, 15, 20].
For 900 C.
-0,6
0,05 For 925 C.
y = -19194x + 15,756
For 950 C.
(1-(1- R )1/3)2
0,04 -0,1
For 975 C.
ln k
0,01
7,60E- 7,80E- 8,00E- 8,20E- 8,40E- 8,60E- 8,80E-
04 04 04 04 04 04 04
0
0 20 40 60 80 100 120 1/T, K
Time, min.
Fig 6. The relationship between [1-(1-R)1/3]2 and Fig 8. Arrhenius plot for ln k versus 1/T for Chromite
time (min) for roasting of briquettes with the optimal ore concentrate, soda ash and limestone (total CaO)
mixture of Chromite ore concentrate, soda ash and (mole ratio=1:2.5:3) at the different temperatures.
total CaO (limestone) (mole ratio=1:2.5:0.4) at
different temperatures. 3.4 Factors Affecting the Extraction of Sodium
Chromate in Distilled Water
Briquettes of the reaction mixture of chromite ore
concentrate, soda ash and CaO (in CKD) (1: 2.5: 2.5)
and CaO (in limestone) (1: 2.5 : 0.4) roasted at 1000
oC for 2 hr were subject to a set of experimental
80 120
Cement dust
110
70
limestone
Chromate recover y, %.
100
60 90
80 cement dust
50
70 limestone
40
60
0 2 4 6 8 10 12 14
50
Stirring time, min. 40
30
Fig 9. The effect of Stirring time on chromic oxide 100 200 300 400
recovery from briquettes of CKD and limestone Liquid / Solid ratio
roasted at 1000 C
Fig 11. The effect of varying the liquid / solid ratio on
The results indicated that for the mixture containing chromate recovery% in solution from mixtures of
CKD as the temperature of the water increased the cement dust and limestone.
chromic oxide recovery % increased (Figure 10),
which may be attributed to the increase in chromate 5. CONCLUSIONS
dissolution [2, 16]. However, for the mixture
containing limestone, the chromic oxide recovery Roasting a reaction mixture of Cr2O3: soda ash and
remained around 50%. total CaO in CKD (mole ratio 1: 2.5: 3.0) yielded a
maximum chromic oxide recovery of 86 %.
However, the addition of limestone to a similar
reaction mixture of Cr2O3: soda ash and total CaO
F. M. S El-Dars, M. E.H. Shalabi, Hanaa A.M. Abuzeid, M. G. Khalifa, A. .B. Farag / The Journal of ORE DRESSING ® 2008 15
(mole ratio 1: 2.5: 0.4) decreased the maximum yield [8] Shalabi, M.E.H., El-Hussiny, N.A., Zaher,
to 55% from 68% without CaO. F.M.S., El-Ebiary, N.N. and El-Afifi, S.Y 1999,
Kinetic of Formation of sodium chromate
The kinetics of the formation of sodium chromate in
from El-Baramiya Chromite Ore Concentrate
the presence of CaO from CKD (mole 3.0) and
with soda ash briquetting,’ Gospadarka
limestone (mole 0.4) from chromite ore concentrate
Surowcami Mineralnymi, 15: 111-131.
and soda ash mixture was a solid diffusion
mechanism, which was controlled at the initial stages [9] Poppf, L.I., 1925, J. Chem. Ind. Russian , (2):
by the decomposition of both CKD and limestone. 465.
The addition of CKD to the mixture of soda ash and [10] Doerner, H. A., 1930, Bur. Mines Rept. of
chromite ore concentrate (Cr2O3/ sodium carbonate: Invest. 2999, 30.
Total CaO: mole ratio 1: 2.5: 3.0) decreased the
[11] Ozer, A., Gulaboglu, S. M., Bayrakeken, S.G.
energy of activation from 112 kJ/mole for a mixture
and Ahmet, K. Kim. Muhendisligi Semp, No. 4,
of chromite ore concentrate with soda ash (mole
1992, pp. 31-36.
ratio 2.5 : 1 ) to 84 kJ / mole. However, the
addition of limestone to the mixture of soda ash and [12] Papanatassion, D. and Bitsines, G., 1973, Met.
chromite ore concentrate (Cr2O3/ sodium carbonate: Trans. , 4: 477-480
Total CaO: mole ratio 1: 2.5: 0.4) increased the
[13] Ansari, O., A. Khier, S. and Singer, J. (1990):
energy of activation from 112 kJ/mole for a mixture
ARE Iron and Steel Making, 11: 237-246.
of chromite ore concentrate with soda ash (mole
ratio 2.5 : 1) to 117 kJ / mole. [14] Tripathy, A. K., Ray, H. S. and Pattanayak, P.
K. (1994)., Kinetics reaction between
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