Effect of mineral acids on the production of alumina nanopowder from raw bauxite

In this study a novel synthetic method for the large-scale production of spherical, high surface area and ultra-fine alumina (Al 2O 3) powder has been described. Synthetic Bayer liquor was extracted by alkali fusion of raw bauxite with sodium hydoxide. Alumina nanopowders were synthesised through a ball mill-aided precipitation method using the synthetic Bayer liquor and mineral acid precipitants. The powders produced were characterised by X-ray diffraction (XRD), particle size distribution (PSD), Fourier transform infrared spectroscopy (FTIR), Brunauer–Emmett–Teller surface area and pore size analysis, energy-dispersive spectroscopy (EDS), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). In this article, the effects of precipitants such as H 2SO 4, HCl and HNO 3 on crystallite and particle size, surface area, pore volume, and pore size and shape are reported. The experimental results prove that precipitation leads to an aggregated particle that is disaggregated by the ball-milling method. The ball milling process strongly influences the formation of uniform-sized spherical particles with a high surface area. It was revealed that nitric acid is an effective precipitant for controlling particle size and textural properties of Al 2O 3 powder. A nanopowder of γ-Al 2O 3 with an average crystallite size of 3 nm and an average particle size of 58 nm with a specific surface area (SSA) of 190 m 2 g − 1 is produced. This article elucidates a new method with a simple reaction scheme for the mass production of Al 2O 3 nanoparticles from raw bauxite for various commercial applications. This study provides some support to the selection of mineral acid precipitants for the production of alumina nanopowder from synthetic Bayer liquor. It is observed that precipitation yields aggregated particles that are disaggregated by the ball-milling process. It is noteworthy that the ball-milling process develops reduced particle size with spherical morphology. [Display omitted] ► The spherical-shaped, cubic γ-Al 2O 3 nanopowder with 95.7% chemical purity was produced from raw bauxite. ► The effect of mineral acid precipitants (H 2SO 4, HCl and HNO 3) on synthesis of alumina nanopowder from the synthetic Bayer liquor was established in terms of crystallite and particle size, surface area, pore volume, pore size and shape. ► The precipitants are the key factors for controlling the textural properties of alumina nanopowder. The obtained results reveal the