Simulación y optimización del procedo de producción de sulfato de aluminio liquido en un reactor Batch Heterogéneo para la mezcla: Bauxita- Agua- Ácido Sulfúrico

Abstract

CONDITION FOR PROJECT PUBLICACTION. The growing water crisis and pollution highlight the need for efficient treatment methods. Coagulation and flocculation are key processes to purify these resources, using substances that modify the properties of solids and cause their precipitation. Liquid aluminum sulfate, obtained from the mixture of bauxite and sulfuric acid at high temperatures, is employed in these processes. The quality of the product depends on the ratio of acid to bauxite, which is decisive for profitability and effectiveness in water treatment. This work presents the simulation of the production process of liquid aluminum sulfate, establishing operating conditions that maximize the efficiency of the reaction and reduce raw material consumption. Aspen Plus was used to simulate the process, evaluating its performance with data from a plant in Quito, Ecuador. The simulation included physicochemical parameters and the kinetic model of bauxite dissolution with sulfuric acid adapted from the literature. Sensitivity and optimization analyses were carried out to determine the appropriate ratio of raw materials and their influence on the final product quality. The results showed a 5.56% reduction in sulfuric acid consumption, equivalent to 200 kg per Batch. This savings leads to an accumulated capital of 696 000 USD over 5 years, representing 7.85% of the total annual cost of the process. In addition, the final production increased by 4.8% due to the optimized dosing. This study demonstrates the potential of simulators to represent reactive processes and compare them with industrial results. Keywords: liquid aluminum sulfate, sensitivity analysis, process simulation, bauxite, sulfuric acid.