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R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                   Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                    Vol. 2, Issue 5, September- October 2012, pp.732-742

      Determination Of The Optimum Dissolution Conditions Of
      Ukpor Clay In Hydrochloric Acid Using Response Surface
                           Methodology
                               R. O. Ajemba and O. D. Onukwuli
   Department of Chemical Engineering, Nnamdi Azikiwe University, P. M. B. 5025, Awka, Anambra State,
                                               Nigeria

ABSTRACT
         Ukpor clay was dissolved in solutions of       mineral type and reaction conditions, such as the
hydrochloric acid to investigate its dissolution        acid/clay ratio, acid concentration, time and
rate. Response surface methodology was                  temperature of the reaction [8 – 10].
employed to determine the optimum conditions            Most of the reports in the literature on dissolution
for the dissolution. The experiments were               of ores in acidic media were conducted using the
performed within the ranges of the process              conventional method of investigation, by varying
variables as mentioned herein: 400 – 8000C for          one factor whilst maintaining all other factors
calcination temperature; 0.5 – 4 mol/L for acid         constant. This conventional method is cumbersome
concentration; 0.02 – 0.10 g/ml for clay to acid        and time consuming and has low efficiency when it
ratio; 60 – 1200C for reaction temperature; and         comes to optimizing the process [11, 12]. Process
90 to 720 rpm for stirring speed. The analysis of       factors do interact with each other, but this
variance indicated that a second order                  interaction cannot be investigated using the
polynomial regression equation was appropriate          conventional      method.       Response     surface
for fitting the experimental data. The                  methodology (RSM) technique helps in
experimental confirmation tests showed a                overcoming the limitations of the conventional
correlation between the predicted and                   method of analysis. The main objective of RSM is
experimental response values (R2 = 0.9400). The         to check the optimum operational conditions for a
optimum conditions for the process variables            given system and determine a region that satisfies
were obtained as: 6680C for calcination                 the operational specifications [13]. It helps in
temperature; 2.93mol/l for acid concentration;          obtaining a second-order polynomial prediction
0.027g/ml for clay to acid ratio; 107 0C for            equation or some other mathematical equations to
reaction temperature; and 368rpm for stirring           describe the experimental data obtained at some
speed. Under these conditions the dissolution           particular combinations of the input variables.
rate was 97.85%.                                        In this work, the determination of the optimum
                                                        extraction of Al3+ ion which is one of the most
Keywords: Optimization; calcination; dissolution;       important metal ores present in clay minerals and
hydrochloric acid; ANOVA; clay                          can be extracted by dissolution is the target. The
                                                        clay mineral from Ukpor will be calcined before
    1. INTRODUCTION                                     dissolution in hydrochloric acid and RSM will be
          Clay dissolution in acid medium is gaining    used to optimize the dissolution parameters,
serious academic attention in the recent time. This     thereby ensuring high dissolution efficiency and
is as a result of the need of a low cost source of      determining the interactive effects of the
metallic ores. Clay is a well known aluminous and       calcination temperature, reaction temperature, acid
siliceous material from which the metallic ions can     concentration, particle size, clay/acid ratio, and
be replaced by the hydrogen ions from inorganic         stirring speed on the dissolution process.
acids. Metallic ions such as Al3+, Fe3+, Mg2+, and
sometimes Mn2+ can be extracted from the clay               2. MATERIALS AND METHODS
mineral by dissolution in acid mediums.                          The clay samples from Ukpor was mined
Dissolution of various metal ores in different acidic   from the region and separated from dirt that
media has been investigated by a great number of        contaminated them. The mined clay was wet and
authors [1 – 7]. Depending on the extent of acid        was sun-dried for three days after which the dried
dissolution, the resulting solid product contains       sample was grinded with mortar and sieved with
unaltered layers and amorphous three-dimensional        75µm sieve size. The sieved samples were then
cross-linked silica, while the ambient acid solution    calcined in a furnace with a temperature range of
contains ions according to the chemical                 1000C to 12000C. The calcination temperature was
composition of the clay and acid used. The extent       chosen in the range of 5000C to 8000C for all the
of the dissolution reaction depends on both clay        samples. The calcination time was also varied
                                                        between 0.3 to 8 hours. The clay was characterized


                                                                                             732 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                   Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                    Vol. 2, Issue 5, September- October 2012, pp.732-742

with X-ray fluorescence to ascertain the chemical              fractional factorial design as established by Design
composition.                                                   Expert software (8.0.1 trial version). The process
                                                               variables were calcination temperature of 500 –
     2.1.     Dissolution experiment                           8000C, reaction temperature of 60 – 1200C, acid
          The calcined samples were then ground                concentration of 0.5 – 4mol/l, solid/liquid ratio of
and sieved into various particle sizes and labeled             0.02 – 0.10g/ml, and stirring speed of 90 – 720rpm.
accordingly. For each experiment, 10 g of the sized            The response variable was chosen as % yield of
fractions was weighed out and reacted with already             alumina. The factor levels were coded as –α, - 1, 0,
determined volume of the acids in a 250 ml                     +1 and +α. The range and levels are shown in
bottomed flask. The flask and its contents were                Table 1.
heated to a fixed temperature of 700C while on a               A total of 31 runs were carried out to optimize the
magnetic stirring plate and stirring was continued             process variables and experiments were performed
throughout the reaction duration. Also the reactor             according to the actual experimental design matrix
was fitted with a condenser to prevent losses by               shown in Table 2. The experiments were performed
evaporation. After the reaction time was completed,            randomly to avoid systemic error. The results were
the suspension was immediately filtered to separate            analyzed using the coefficient of determination,
un-dissolved materials, washed three times with                analysis of variance (ANOVA), and response plots.
distilled water. The resulting solutions were diluted          In RSM, the most widely used second-order
and analyzed for aluminum ion using MS Atomic                  polynomial equation developed to fit the
Absorption Spectrophotometer. The residue was                  experimental data and identify the relevant model
also collected, washed to neutrality with distilled            terms may be written as:
water, air dried and oven dried at 600C and then               Y = β0 + ∑βi xi + ∑βii xii2 + ∑βij xi xj + ε   (1)
reweighed. The difference in weight was noted for
determining the fraction of the alumina ore that               Where Y is the predicted response variable, in this
dissolved.                                                     study the % yield of alumina, β0 is the constant
                                                               coefficient, βi is the ith linear coefficient of the
    2.2.    Design of Experiment                               input variable xi, βii is the ith quadratic coefficient
    The process variables affecting the dissolution            of the input variable xi, βij is the different
of Ukpor clay in sulphuric acid were investigated              interaction coefficients between the input variables
using RSM combined with five-level, five-factor                xi and xj, and ε is the error of the model.

  Table 1: Experimental range of the independent variables, with different levels, to study alumina production
                 during the dissolution of local clays in sulphuric, hydrochloric, and nitric acids
Independent variable             Symbol Range and levels
                                             -α        -1          0            +1                +α
Calcination temp (0C)               X1        350       500        650           800            950
Leaching temp. (0C)                 X2       30         60          90           120            150
Acid Conc. (mol/l)                  X3        -1.25    0.5         2.25          4.0            5.75
S/L Ratio (g/l)                     X4        0.01     0.02         0.03          0.04         0.05
Stirring Rate (rpm)                 X5        -225      90         315            720          1035

                        Table 2: Experimental design/plan for alumina leaching from local clays
Run         Calcin     Temp Leach Temp Acid                Conc. Solid/Liquid         Stirring Speed     % Yield
order       (0C), X1           (0C), X2         (mol/l), X3        Ratio (g/l), X4    (rpm), X5
            Coded      Real Coded Real Coded Real                  Coded Real         Coded Real         Exp.      Pred.
1           -1         500     -1       60      -1        0.5      -1         0.02    +1        720      34.8      36.3
2           +1         800     -1       60      -1        0.5      -1         0.02    -1        90       57.8      54.4
3           -1         500     +1       120     -1        0.5      -1         0.02    -1        90       42.6      41.0
4           +1         800     +1       120     -1        0.5      -1         0.02    +1        720      65.0      63.7
5           -1         500     -1       60      +1        4.0      -1         0.02    -1        90       39.6      40.5
6           +1         800     -1       60      +1        4.0      -1         0.02    +1        720      55.4      56.5
7           -1         500     +1       120     +1        4.0      -1         0.02    +1        720      50.7      53.6
8           +1         800     +1       120     +1        4.0      -1         0.02    -1        90       67.0      65.0
9           -1         500     -1       60      -1        0.5      +1         0.04    -1        90       33.7      31.0
10          +1         800     -1       60      -1        0.5      +1         0.04    +1        720      37.5      35.1
11          -1         500     +1       120     -1        0.5      +1         0.04    +1        720      40.2      39.6
12          +1         800     +1       120     -1        0.5      +1         0.04    -1        90       59.0      53.5
13          -1         500     -1       60      +1        4.0      +1         0.04    +1        720      44.9      46.7



                                                                                                      733 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                   Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                    Vol. 2, Issue 5, September- October 2012, pp.732-742

14          +1     800     -1        60      +1        4.0        +1        0.04     -1        90     47.6     44.5
15          -1     500     +1        120     +1        4.0        +1        0.04     -1        90     45.3     44.0
16          +1     800     +1        120     +1        4.0        +1        0.04     +1        720    66.0     65.0
17          -2     350     0         90      0         2.25       0         0.03     0         405    43.0     40.4
18          +2     950     0         90      0         2.25       0         0.03     0         405    60.0     66.7
19          0      650     -2        30      0         2.25       0         0.03     0         405    46.0     47.0
20          0      650     +2        150     0         2.25       0         0.03     0         405    64.0     67.1
21          0      650     0         90      -2        -1.25      0         0.03     0         405    44.0     49.9
22          0      650     0         90      +2        5.75       0         0.03     0         405    67.0     65.2
23          0      650     0         90      0         2.25       -2        0.01     0         405    57.4     56.2
24          0      650     0         90      0         2.25       +2        0.05     0         405    38.0     43.3
25          0      650     0         90      0         2.25       0         0.03     -2        -225   34.0     41.2
26          0      650     0         90      0         2.25       0         0.03     +2        1035   50.0     46.9
27          0      650     0         90      0         2.25       0         0.03     0         405    71.0     69.4
28          0      650     0         90      0         2.25       0         0.03     0         405    69.0     69.4
29          0      650     0         90      0         2.25       0         0.03     0         405    70.0     69.4
30          0      650     0         90      0         2.25       0         0.03     0         405    70.0     69.4
31          0      650     0         90      0         2.25       0         0.03     0         405    71.0     69.4

     3. RESULTS AND DISCUSSIONS                                design used and shown in Table 4. The ANOVA of
     3.1.    Characterization                                  the quadratic regression model indicates that the
         The results of the X-ray fluorescence                 model is significant. The model F-value of 7.83
analysis are shown in Table 3. The results show                implied the model to be significant. Model F-value
that Ukpor clay is composed of mainly silica,                  was calculated as ratio of Adj. mean square of the
alumina and iron oxides, and other trace oxides like           regression and Adj. mean square of the residual.
calcium oxide, magnesium oxide, titanium oxide,                The model P-value (Prob. > F) is very low which
potassium oxide and others.                                    reiterates the model significant. The P-values were
                                                               used as a tool to check the significance of each of
  Table 3: Chemical composition of Ukpor clay                  the model coefficients. These values are all given
               determined by XRF                               in Table 3. The smaller the P-value the more
Chemical constituent       Composition (%)                     significant is the corresponding coefficient. Values
         Al2O3                      26.9                       of P < 0.05 indicate the model terms to be
          SiO2                      48.6                       significant. In Table 3, the values of P for the
         Fe2O3                     17.13                       coefficients estimated indicate that among the
          CaO                       0.08                       tested variables used in the design, X1, X2, X3, X4,
         MnO                       0.003                       X12, X22, X32, X42 and X52 (where X1 = Calcination
         MgO                       0.329                       temperature, X2 = leaching temperature, X3 = acid
                                                               concentration, X4 = stirring rate, and X5 =
          P2O5                       0.2
                                                               liquid/solid ratio,) are significant model terms. The
          TiO2                      2.06
                                                               model equation with the significant coefficients is
         V2O5                       0.14
                                                               shown in Equation (4).
          CuO                      0.064                       Y = 69.37 + 6.56X1 + 5.02X2 + 3.83X3 – 3.23X4 – 3.95X12 –
          ZnO                      0.008                       3.08X22 – 2.95X32 – 4.90X42 – 6.33X52 (4)
         Rb2O                       1.15                        In terms of the actual factors the model equation is
 Loss on ignition (LOI)             3.05                       as follows:
                                                               % YieldAl2O3 = - 30.96 + 0.09 * Calcination temperature +
     3.2.     Statistical Analysis                             0.60 * leaching temperature + 6.53 * acid concentration +
          The second-order model tested at the 95%             0.05 * Stirring rate – 5.08 * Calcination temperature2 – 3.07
confidence level obtained for extraction of Al 2O3             * Leaching Temperature2 – 1.16 * Acid Concentration2 –
from Ukpor clay is as follows:                                 4.04 * stirring rate2 – 35355.45 * Solid/Liquid ratio2 (5)
YAl2O3 = 69.37 + 6.56X1 + 5.02X2 + 3.83X3 –                    The coefficient of regression (R2), calculated as the
3.23X4 + 1.41X5 + 2.06X1X2 – 0.78X1X3 –                        ratio of the regression sum of squares to the total
1.97X1X4 – 1.05X1X5 – 0.09X2X3 + 0.57X2X4 +                    sum of squares, was found to be 0.9400, this
0.88X2X5 + 1.31X3X4 + 2.07X3X5 + 0.26X4X5 –                    indicates that 94.00% of the variability in the yield
3.95X12 – 3.08X22 – 2.95X32 – 4.90X42 – 6.33X52                data is explained by the regression model, showing
(3)                                                            a very good fit of the model. The S-value of 0.2471
The results were analyzed by using ANOVA i.e.                  and R-Sq (adj.) value of 0.8200 indicates a better
analysis of variance suitable for experimental                 fitting model. S is the square root of the error mean



                                                                                                   734 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                   Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                    Vol. 2, Issue 5, September- October 2012, pp.732-742

square, MSE, and represents the “standard error of            fitting model. R-Sq (adj.) indicates how well the
the model” and a lower value of S indicates a                 model       fits     the       observed     data.


                            Table 4: ANOVA for response surface quadratic model
Source             Coefficient        Sum         of Degree         of F-value                   P-value (Prob.
                   Estimate           Squares         Freedom                                    > F)
Model              69.37              4531.55         20                  7.83                   < 0.000
X1                 6.56               326.30          1                   59.19                  < 0.000
X2                 5.02               225.38          1                   40.89                  < 0.000
X3                 3.83               308.92          1                   56.04                  < 0.006
X4                 -3.23              46.42           1                   8.42                   0.015
X5                 1.41               118.71          1                   21.53                  0.227
X 1X 2             2.06               0.48            1                   0.086                  0.157
X 1X 3             -0.78              4.58            1                   0.83                   0.574
X 1X 4             -1.97              12.63           1                   2.29                   0.174
X 1X 5             -1.06              8.72            1                   1.58                   0.450
X 2X 3             -0.09              13.13           1                   2.38                   0.946
X 2X 4             0.57               0.26            1                   0.048                  0.681
X 2X 5             0.88               0.11            1                   0.020                  0.527
X 3X 4             1.31               0.0028          1                   0.0005                 0.354
X 3X 5             2.07               0.69            1                   0.13                   0.155
X 4X 5             0.26               6.39            1                   1.16                   0.853
X 12               -3.95              211.95          1                   38.45                  < 0.003
X 22               -3.08              392.53          1                   71.21                  < 0.013
X 32               -2.95              644.27          1                   116.88                 < 0.015
X 42               -4.90              825.83          1                   149.81                 < 0.000
X 52               -6.33              641.06          1                   116.29                 < 0.000
Residual                              289.43          10
Lack of fit                           286.63          6                   68.25                  < 0.001
Pure Error                            2.80            4
Cor. Total                            4820.98         30

 Std Dev. = 2.34; Mean = 52.95; C.V.% = 3.57; PRESS = 590.63; R 2 = 0.9400; Adj. R2 = 0.8200; Predicted R2 =
0.8006; Adeq. Precision = 17.001; S = 0.2471.
To determine the adequacy of the models depicting the removal of alumina by the dissolution of Ukpor clay in
hydrochloric acid, two different tests, i.e. the sequential model sum of squares and the model summary statistics,
were conducted. The corresponding results are tabulated in Table 5. The results from the sequential model
indicated that the 2FI model did not provide a good description of the experimental data. From the model
summary statistics, it can be seen that the “Predicted R2” of 0.8006 was in reasonable agreement with the
“Adjusted R2” of 0.8200 for the quadratic model. Furthermore, the quadratic model had maximum “Predicted
R2” and “Adjusted R2” values. The afore-mentioned results indicate that the quadratic model provided an
excellent explanation for the relationship between the independent variables and the corresponding response.

                                    Table 5: Adequacy of the Model Tested
Source           Sum        of      Degree     of Mean squares       F-value               P-value       Remarks
                 squares            freedom
Sequential model sum of squares
Linear           2288.65            5                457.73             15.81              0.000         Significant
2FI              271.85             10               27.19              0.94               0.538         Not significant
Quadratic        1971.05            5                394.21             13.62              < 0.000       Significant
Cubic            119.05             15               7.94               3.20               0.0244        Significant

Source         Standard             R2               Adjusted R2        Predicted R2       PRESS         Remarks
               Deviation
Model summary statistics
Linear         6.54                 0.3436           0.2578             0.2919             2054.01       Inadequate



                                                                                                     735 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                     Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                      Vol. 2, Issue 5, September- October 2012, pp.732-742

                                                                                                                            signal
2FI                         7.39                  0.3802            0.0897              0.1720            2336.00           Inadequate
                                                                                                                            signal
Quadratic                   2.35                  0.9400            0.8200              0.8006            590.63            Adequate
                                                                                                                            signal

Cubic                       1.58                  0.9694            0.9086              0.6205            788.48            Inadequate
                                                                                                                            signal

The data were also analyzed to check the correlation between the experimental and predicted dissolution yield
(Y %), as shown in Fig. 1. The experimental values were the measured response data for the runs designed by
the CCRD model, while the predicted values were obtained by calculation from the quadratic equation. It can be
seen from Figure 1 that the data points on the plot were reasonably distributed near to the straight line (R 2 =
0.9400), indicating a good relationship between the experimental and predicted values of the response, and that
the underlying assumptions of the above analysis were appropriate.

                    80.5
                    0




                    73.0
      Predicted




                    8




                    65.6
                    5




                    58.2
                    2




                    50.8
                    0

                            50.8                  58.2              65.6              73.0             80.5
                            0                     2                 5                 8                0

                                                                   Actua
                                                                   l
                                       Figure 1: Predicted values versus the experimental values.

The main effects of the process variables on the response variable are plotted in Fig. 2. The figure shows that
increasing the calcination temperature, leaching temperature, and acid concentration increases the % yield,
while solid/liquid ratio and stirring speed has no statistical significant effect on the response and should be held
constant at the center values.




                       67
          % Yield




                      59
                      51

                       43
                       35
                                   Calcina               Dissolu           Acid              Solid/l          Stirrin
                                   t                     t                 con               i                g


                                             Figure 2: Main effects plot of the process variables.

    3.3.      Response surface plots
The three-dimensional response surface plots, obtained as a function of two factors maintaining all other factors
constant at the mid-values, are helpful in understanding both the main effects and the interaction effects of these



                                                                                                                        736 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                     Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                      Vol. 2, Issue 5, September- October 2012, pp.732-742

five factors. The corresponding contour plots, represented by the projection of the response surfaces in the x-y
plane, provide a straightforward determination of the effects of the independent variables on the dependent
variable. The three-dimensional response surface plots and related contour plots obtained are depicted in Figs. 3
to 14. Fig. 3 shows the dependency of alumina yield on calcination temperature and leaching temperature.
Alumina yield increased with increase in calcination temperature to about 730 0C and thereafter yield remained
constant with further increase in Calcination temperature, this is in agreement with the findings of Ata et al,
[14]. The same trend was observed in Figs. 4 to 6. Increase in leaching temperature resulted in increase in
alumina yield up to 1070C and thereafter decreased gradually. This is evident from Figs. 4, 7, 8 and 9. Low
levels of solid/liquid ratios resulted in higher % yield as shown in Figs. 6, 9, 11, and 12.




              82



              79
  Y ie ld




               76



               73



                   70




             120.00                                                                                      800.00

                        105.00                                                                 700.00

                                   90.00                                            600.00

                                             75.00                       500.00
            B: Leach Temp                                                                    A: Cal Temp
                                                        60.00   400.00




             Figure 3: 3D plot showing the effect of calcination temp and leaching temp. on % yield.




             82


            78.5
  Y ie ld




              75


             71.5


               68



              4.00                                                                                       800.00
                        3.13                                                                   700.00
                                   2.25                                             600.00
                                             1.38                        500.00
              C: Acid conc                                                                   A: Cal Temp
                                                        0.50    400.00




              Figure 4: 3D plot of the effect of calcination temp and acid concentration on % yield.




                                                                                                    737 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                   Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                    Vol. 2, Issue 5, September- October 2012, pp.732-742




             81


             78
Y ie ld




              75


              72


               69



            720.00                                                                                           800.00
                        562.50                                                                     700.00
                                   405.00                                               600.00
                                              247.50                         500.00
            D: Stirring Rate                                                                  A: Cal Temp
                                                          90.00   400.00



                     Figure 5: 3D plot of the effect of calcination temp and stirring rate on yield.




             82


             79
Y ie ld




              76


              73


               70



              0.04                                                                                           800.00
                           0.03                                                                    700.00
                                     0.03                                               600.00
                                                0.02                         500.00
          E: Solid/Liquid Ratio                                                               A: Cal Temp
                                                           0.02   400.00



                   Figure 6: 3D plot of effect of calcination temp and solid/liquid ratio on % yield.




                                                                                                        738 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                   Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                    Vol. 2, Issue 5, September- October 2012, pp.732-742




            82


          78.75
Y ie ld




           75.5


          72.25


              69



             4.00                                                                                         120.00
                          3.13                                                                   105.00
                                    2.25                                              90.00
                                               1.38                        75.00
             C: Acid conc                                                                B: Leach Temp
                                                          0.50   60.00



                       Figure 7: 3D plot of leaching temp and acid concentration on % yield.




            81


          78.25
Y ie ld




           75.5


          72.75


              70



          720.00                                                                                          120.00
                       562.50                                                                    105.00
                                  405.00                                              90.00
                                             247.50                        75.00
           D: Stirring Rate                                                              B: Leach Temp
                                                         90.00   60.00



                    Figure 8: 3D plot of the effect of leaching temp and stirring rate on % yield.




                                                                                                     739 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                   Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                    Vol. 2, Issue 5, September- October 2012, pp.732-742




             81


             78
Y ie ld




              75


              72


               69



              0.04                                                                                             120.00
                           0.03                                                                    105.00
                                      0.03                                              90.00
                                                 0.02                        75.00
          E: Solid/Liquid Ratio                                                            B: Leach Temp
                                                           0.02   60.00



                   Figure 9: 3D plot of the effect of leaching temp and solid/liquid ratio on % yield.




             81


           77.75
Y ie ld




            74.5


            71.25


               68



            720.00                                                                                             4.00
                         562.50                                                                    3.13
                                   405.00                                               2.25
                                              247.50                         1.38
            D: Stirring Rate                                                                   C: Acid conc
                                                          90.00   0.50



                  Figure 10: 3D plot of the effect of acid concentration and stirring rate on % yield.




                                                                                                          740 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                   Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                    Vol. 2, Issue 5, September- October 2012, pp.732-742




             81


           77.75
Y ie ld




            74.5


            71.25


               68



              0.04                                                                                              4.00
                           0.03                                                                     3.13
                                      0.03                                               2.25
                                                 0.02                         1.38
          E: Solid/Liquid Ratio                                                                 C: Acid conc
                                                            0.02   0.50



             Figure 11: 3D plot of the effect of acid concentration and solid/liquid ratio on % yield.




             81


           78.25
Y ie ld




            75.5


            72.75


               70



              0.04                                                                                              720.00
                           0.03                                                                     562.50
                                      0.03                                               405.00
                                                 0.02                         247.50
          E: Solid/Liquid Ratio                                                             D: Stirring Rate
                                                            0.02   90.00



                   Figure 12: 3D plot of the effect of stirring rate and solid/liquid ratio on % yield.




                                                                                                           741 | P a g e
R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and
                   Applications (IJERA) ISSN: 2248-9622 www.ijera.com
                    Vol. 2, Issue 5, September- October 2012, pp.732-742

    3.4.       Numerical Optimization                           alumina from Lampang clay, E-Journal of
          One of the primary objectives of the                  Chemistry, 9(3), 2012, 1364 – 1372.
present study was to find the optimum process            [6]    Abdulwahab A., Suad A., Alumina
parameters for maximizing the dissolution of                    recovery from Iraqi kaolinitic clay by
Ukpor clay in hydrochloric acid solution. The                   hydrochloric acid route, Iraqi Bulletin of
model capable of predicting the maximum                         Geology & Mining, 2 (1), 2006, 67 – 76.
dissolution capacity showed that the optimum             [7]    Zafar I. Z., Ashraf M., Reaction kinetic
values of the process variables were a calcination              model for dissolution of low grade bauxite
temperature of 668.540C, a leaching temperature of              rock in sulphuric acid, Journal of
107.220C, an acid concentration of 2.93 mol/l, a                Chemical Society of Pakistan, 30 (1),
stirring rate of 368.24 rpm, and a solid/liquid ratio           2008, 49 – 54.
of 0.027g/ml. Under these conditions, the predicted      [8]    Lai-shi L., Yu-sheng W., Ying-ying L.,
dissolution % yield was 97.85, which was in good                Yu-chun Z., Extraction of alumina from
agreement with the experimental value of 97.67%.                coal fly ash with sulphuric acid leaching
                                                                method, The Chinese Journal of Process
    4. CONCLUSION                                               Engineering, 11 (2), 2011, 254 – 258.
          The optimum levels of the process              [9]    Li D., Park K., Wu Z., Guo X., Response
parameters for the dissolution of Ukpor clay in                 surface design for nickel recovery from
hydrochloric acid solution were investigated in this            laterite by sulfation-roasting-leaching
work using response surface methodology. Highly                 process, Transactions of Nonferrous
accurate model developed showed that the                        Metallurgy Society of China, 20, 2010,
percentage yield of alumina from Ukpor clay was                 s92 – s96.
influenced by calcination temperature, leaching          [10]   Narayana S. K., King P., Gopinadh R.,
temperature, acid concentration, stirring speed and             Sreelakshmi V., Response surface
solid/liquid ratio. The optimum leaching conditions             optimization of dye removal by using
of alumina recovery from Ukpor clay are 668.54 0C               waste prawn shells,” International Journal
calcination temperature, 107.22 0C leaching                     of Chemical Sciences & Applications, 2
temperature, 2.93 mol/L acid concentration, 368.24              (3), 2011, 186 – 193.
rpm stirring speed, and 0.027 g/ml solid/liquid ratio    [11]   Yartasi A., Copur M., Ozmetin C.,
and under these conditions about 97.85% of the                  Kocakerim      M.,    Temur     H.,    An
alumina content of the clay sample would have                   optimization study of dissolution of
been removed. The above results show that Ukpor                 oxidized copper ore in NH3 solutions,
clay is a good source for alumina and the method                Energy      Education,     Science    and
employed is efficient for maximum production.                   Technology, 3, 1999, 77.
                                                         [12]   Shyi-Liang S., Hwang L., Process
REFERENCES                                                      optimization of vacuum fried carrot chips
  [1]      Abali Y., Colak S., Yapici S., “The                  using central composite rotatable design,
           optimization of the dissolution of                   Journal of Food & Drug Analysis, 19 (3),
           phosphate rock with Cl2-SO2 gas mixture              2011, 324 – 330.
           in aqueous medium,” Hydrometallurgy,          [13]   Box G. E. P., Hunter W. G., and Hunter J.
           46, 1997, 27 – 35.                                   S., Statistics for experimenters: an
  [2]      Abali Y., Salih B., Kadir A., Ali V.,                introduction to design, data analysis and
           Optimization of dolomite ore leaching in             model building, (Wiley and Sons, New
           hydrochloric         acid        solutions,          York, 1978).
           Physicochemical Problems of Mineral           [14]   Ata O. N., Colak S., Ekinci Z., Copur M.,
           Processing, 46, 2011, 253 – 262.                     Determination of the optimum conditions
  [3]      Veglio F., Ubaldin S., Optimization of               for the dissolution of stibnite in HCl
           pure stibnite leaching conditions by                 solution, Chemical and Biochemical
           response surface methodology, European               Engineering Quarterly, 24, 2001, 409.
           Journal of Mineral Processing &
           Environmental Protection, 1 (2), 2001,
           103 – 112.
  [4]      Uzun D., Gulfen M., Dissolution of iron
           and aluminium from red mud in sulphuric
           acid solution, Indian Journal of Chemical
           Technology, 14, 2007, 263 – 268.
  [5]      Numluk P., Chaisena A., Sulphuric acid
           and ammonium sulphate leaching of




                                                                                           742 | P a g e

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  • 1. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 Determination Of The Optimum Dissolution Conditions Of Ukpor Clay In Hydrochloric Acid Using Response Surface Methodology R. O. Ajemba and O. D. Onukwuli Department of Chemical Engineering, Nnamdi Azikiwe University, P. M. B. 5025, Awka, Anambra State, Nigeria ABSTRACT Ukpor clay was dissolved in solutions of mineral type and reaction conditions, such as the hydrochloric acid to investigate its dissolution acid/clay ratio, acid concentration, time and rate. Response surface methodology was temperature of the reaction [8 – 10]. employed to determine the optimum conditions Most of the reports in the literature on dissolution for the dissolution. The experiments were of ores in acidic media were conducted using the performed within the ranges of the process conventional method of investigation, by varying variables as mentioned herein: 400 – 8000C for one factor whilst maintaining all other factors calcination temperature; 0.5 – 4 mol/L for acid constant. This conventional method is cumbersome concentration; 0.02 – 0.10 g/ml for clay to acid and time consuming and has low efficiency when it ratio; 60 – 1200C for reaction temperature; and comes to optimizing the process [11, 12]. Process 90 to 720 rpm for stirring speed. The analysis of factors do interact with each other, but this variance indicated that a second order interaction cannot be investigated using the polynomial regression equation was appropriate conventional method. Response surface for fitting the experimental data. The methodology (RSM) technique helps in experimental confirmation tests showed a overcoming the limitations of the conventional correlation between the predicted and method of analysis. The main objective of RSM is experimental response values (R2 = 0.9400). The to check the optimum operational conditions for a optimum conditions for the process variables given system and determine a region that satisfies were obtained as: 6680C for calcination the operational specifications [13]. It helps in temperature; 2.93mol/l for acid concentration; obtaining a second-order polynomial prediction 0.027g/ml for clay to acid ratio; 107 0C for equation or some other mathematical equations to reaction temperature; and 368rpm for stirring describe the experimental data obtained at some speed. Under these conditions the dissolution particular combinations of the input variables. rate was 97.85%. In this work, the determination of the optimum extraction of Al3+ ion which is one of the most Keywords: Optimization; calcination; dissolution; important metal ores present in clay minerals and hydrochloric acid; ANOVA; clay can be extracted by dissolution is the target. The clay mineral from Ukpor will be calcined before 1. INTRODUCTION dissolution in hydrochloric acid and RSM will be Clay dissolution in acid medium is gaining used to optimize the dissolution parameters, serious academic attention in the recent time. This thereby ensuring high dissolution efficiency and is as a result of the need of a low cost source of determining the interactive effects of the metallic ores. Clay is a well known aluminous and calcination temperature, reaction temperature, acid siliceous material from which the metallic ions can concentration, particle size, clay/acid ratio, and be replaced by the hydrogen ions from inorganic stirring speed on the dissolution process. acids. Metallic ions such as Al3+, Fe3+, Mg2+, and sometimes Mn2+ can be extracted from the clay 2. MATERIALS AND METHODS mineral by dissolution in acid mediums. The clay samples from Ukpor was mined Dissolution of various metal ores in different acidic from the region and separated from dirt that media has been investigated by a great number of contaminated them. The mined clay was wet and authors [1 – 7]. Depending on the extent of acid was sun-dried for three days after which the dried dissolution, the resulting solid product contains sample was grinded with mortar and sieved with unaltered layers and amorphous three-dimensional 75µm sieve size. The sieved samples were then cross-linked silica, while the ambient acid solution calcined in a furnace with a temperature range of contains ions according to the chemical 1000C to 12000C. The calcination temperature was composition of the clay and acid used. The extent chosen in the range of 5000C to 8000C for all the of the dissolution reaction depends on both clay samples. The calcination time was also varied between 0.3 to 8 hours. The clay was characterized 732 | P a g e
  • 2. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 with X-ray fluorescence to ascertain the chemical fractional factorial design as established by Design composition. Expert software (8.0.1 trial version). The process variables were calcination temperature of 500 – 2.1. Dissolution experiment 8000C, reaction temperature of 60 – 1200C, acid The calcined samples were then ground concentration of 0.5 – 4mol/l, solid/liquid ratio of and sieved into various particle sizes and labeled 0.02 – 0.10g/ml, and stirring speed of 90 – 720rpm. accordingly. For each experiment, 10 g of the sized The response variable was chosen as % yield of fractions was weighed out and reacted with already alumina. The factor levels were coded as –α, - 1, 0, determined volume of the acids in a 250 ml +1 and +α. The range and levels are shown in bottomed flask. The flask and its contents were Table 1. heated to a fixed temperature of 700C while on a A total of 31 runs were carried out to optimize the magnetic stirring plate and stirring was continued process variables and experiments were performed throughout the reaction duration. Also the reactor according to the actual experimental design matrix was fitted with a condenser to prevent losses by shown in Table 2. The experiments were performed evaporation. After the reaction time was completed, randomly to avoid systemic error. The results were the suspension was immediately filtered to separate analyzed using the coefficient of determination, un-dissolved materials, washed three times with analysis of variance (ANOVA), and response plots. distilled water. The resulting solutions were diluted In RSM, the most widely used second-order and analyzed for aluminum ion using MS Atomic polynomial equation developed to fit the Absorption Spectrophotometer. The residue was experimental data and identify the relevant model also collected, washed to neutrality with distilled terms may be written as: water, air dried and oven dried at 600C and then Y = β0 + ∑βi xi + ∑βii xii2 + ∑βij xi xj + ε (1) reweighed. The difference in weight was noted for determining the fraction of the alumina ore that Where Y is the predicted response variable, in this dissolved. study the % yield of alumina, β0 is the constant coefficient, βi is the ith linear coefficient of the 2.2. Design of Experiment input variable xi, βii is the ith quadratic coefficient The process variables affecting the dissolution of the input variable xi, βij is the different of Ukpor clay in sulphuric acid were investigated interaction coefficients between the input variables using RSM combined with five-level, five-factor xi and xj, and ε is the error of the model. Table 1: Experimental range of the independent variables, with different levels, to study alumina production during the dissolution of local clays in sulphuric, hydrochloric, and nitric acids Independent variable Symbol Range and levels -α -1 0 +1 +α Calcination temp (0C) X1 350 500 650 800 950 Leaching temp. (0C) X2 30 60 90 120 150 Acid Conc. (mol/l) X3 -1.25 0.5 2.25 4.0 5.75 S/L Ratio (g/l) X4 0.01 0.02 0.03 0.04 0.05 Stirring Rate (rpm) X5 -225 90 315 720 1035 Table 2: Experimental design/plan for alumina leaching from local clays Run Calcin Temp Leach Temp Acid Conc. Solid/Liquid Stirring Speed % Yield order (0C), X1 (0C), X2 (mol/l), X3 Ratio (g/l), X4 (rpm), X5 Coded Real Coded Real Coded Real Coded Real Coded Real Exp. Pred. 1 -1 500 -1 60 -1 0.5 -1 0.02 +1 720 34.8 36.3 2 +1 800 -1 60 -1 0.5 -1 0.02 -1 90 57.8 54.4 3 -1 500 +1 120 -1 0.5 -1 0.02 -1 90 42.6 41.0 4 +1 800 +1 120 -1 0.5 -1 0.02 +1 720 65.0 63.7 5 -1 500 -1 60 +1 4.0 -1 0.02 -1 90 39.6 40.5 6 +1 800 -1 60 +1 4.0 -1 0.02 +1 720 55.4 56.5 7 -1 500 +1 120 +1 4.0 -1 0.02 +1 720 50.7 53.6 8 +1 800 +1 120 +1 4.0 -1 0.02 -1 90 67.0 65.0 9 -1 500 -1 60 -1 0.5 +1 0.04 -1 90 33.7 31.0 10 +1 800 -1 60 -1 0.5 +1 0.04 +1 720 37.5 35.1 11 -1 500 +1 120 -1 0.5 +1 0.04 +1 720 40.2 39.6 12 +1 800 +1 120 -1 0.5 +1 0.04 -1 90 59.0 53.5 13 -1 500 -1 60 +1 4.0 +1 0.04 +1 720 44.9 46.7 733 | P a g e
  • 3. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 14 +1 800 -1 60 +1 4.0 +1 0.04 -1 90 47.6 44.5 15 -1 500 +1 120 +1 4.0 +1 0.04 -1 90 45.3 44.0 16 +1 800 +1 120 +1 4.0 +1 0.04 +1 720 66.0 65.0 17 -2 350 0 90 0 2.25 0 0.03 0 405 43.0 40.4 18 +2 950 0 90 0 2.25 0 0.03 0 405 60.0 66.7 19 0 650 -2 30 0 2.25 0 0.03 0 405 46.0 47.0 20 0 650 +2 150 0 2.25 0 0.03 0 405 64.0 67.1 21 0 650 0 90 -2 -1.25 0 0.03 0 405 44.0 49.9 22 0 650 0 90 +2 5.75 0 0.03 0 405 67.0 65.2 23 0 650 0 90 0 2.25 -2 0.01 0 405 57.4 56.2 24 0 650 0 90 0 2.25 +2 0.05 0 405 38.0 43.3 25 0 650 0 90 0 2.25 0 0.03 -2 -225 34.0 41.2 26 0 650 0 90 0 2.25 0 0.03 +2 1035 50.0 46.9 27 0 650 0 90 0 2.25 0 0.03 0 405 71.0 69.4 28 0 650 0 90 0 2.25 0 0.03 0 405 69.0 69.4 29 0 650 0 90 0 2.25 0 0.03 0 405 70.0 69.4 30 0 650 0 90 0 2.25 0 0.03 0 405 70.0 69.4 31 0 650 0 90 0 2.25 0 0.03 0 405 71.0 69.4 3. RESULTS AND DISCUSSIONS design used and shown in Table 4. The ANOVA of 3.1. Characterization the quadratic regression model indicates that the The results of the X-ray fluorescence model is significant. The model F-value of 7.83 analysis are shown in Table 3. The results show implied the model to be significant. Model F-value that Ukpor clay is composed of mainly silica, was calculated as ratio of Adj. mean square of the alumina and iron oxides, and other trace oxides like regression and Adj. mean square of the residual. calcium oxide, magnesium oxide, titanium oxide, The model P-value (Prob. > F) is very low which potassium oxide and others. reiterates the model significant. The P-values were used as a tool to check the significance of each of Table 3: Chemical composition of Ukpor clay the model coefficients. These values are all given determined by XRF in Table 3. The smaller the P-value the more Chemical constituent Composition (%) significant is the corresponding coefficient. Values Al2O3 26.9 of P < 0.05 indicate the model terms to be SiO2 48.6 significant. In Table 3, the values of P for the Fe2O3 17.13 coefficients estimated indicate that among the CaO 0.08 tested variables used in the design, X1, X2, X3, X4, MnO 0.003 X12, X22, X32, X42 and X52 (where X1 = Calcination MgO 0.329 temperature, X2 = leaching temperature, X3 = acid concentration, X4 = stirring rate, and X5 = P2O5 0.2 liquid/solid ratio,) are significant model terms. The TiO2 2.06 model equation with the significant coefficients is V2O5 0.14 shown in Equation (4). CuO 0.064 Y = 69.37 + 6.56X1 + 5.02X2 + 3.83X3 – 3.23X4 – 3.95X12 – ZnO 0.008 3.08X22 – 2.95X32 – 4.90X42 – 6.33X52 (4) Rb2O 1.15 In terms of the actual factors the model equation is Loss on ignition (LOI) 3.05 as follows: % YieldAl2O3 = - 30.96 + 0.09 * Calcination temperature + 3.2. Statistical Analysis 0.60 * leaching temperature + 6.53 * acid concentration + The second-order model tested at the 95% 0.05 * Stirring rate – 5.08 * Calcination temperature2 – 3.07 confidence level obtained for extraction of Al 2O3 * Leaching Temperature2 – 1.16 * Acid Concentration2 – from Ukpor clay is as follows: 4.04 * stirring rate2 – 35355.45 * Solid/Liquid ratio2 (5) YAl2O3 = 69.37 + 6.56X1 + 5.02X2 + 3.83X3 – The coefficient of regression (R2), calculated as the 3.23X4 + 1.41X5 + 2.06X1X2 – 0.78X1X3 – ratio of the regression sum of squares to the total 1.97X1X4 – 1.05X1X5 – 0.09X2X3 + 0.57X2X4 + sum of squares, was found to be 0.9400, this 0.88X2X5 + 1.31X3X4 + 2.07X3X5 + 0.26X4X5 – indicates that 94.00% of the variability in the yield 3.95X12 – 3.08X22 – 2.95X32 – 4.90X42 – 6.33X52 data is explained by the regression model, showing (3) a very good fit of the model. The S-value of 0.2471 The results were analyzed by using ANOVA i.e. and R-Sq (adj.) value of 0.8200 indicates a better analysis of variance suitable for experimental fitting model. S is the square root of the error mean 734 | P a g e
  • 4. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 square, MSE, and represents the “standard error of fitting model. R-Sq (adj.) indicates how well the the model” and a lower value of S indicates a model fits the observed data. Table 4: ANOVA for response surface quadratic model Source Coefficient Sum of Degree of F-value P-value (Prob. Estimate Squares Freedom > F) Model 69.37 4531.55 20 7.83 < 0.000 X1 6.56 326.30 1 59.19 < 0.000 X2 5.02 225.38 1 40.89 < 0.000 X3 3.83 308.92 1 56.04 < 0.006 X4 -3.23 46.42 1 8.42 0.015 X5 1.41 118.71 1 21.53 0.227 X 1X 2 2.06 0.48 1 0.086 0.157 X 1X 3 -0.78 4.58 1 0.83 0.574 X 1X 4 -1.97 12.63 1 2.29 0.174 X 1X 5 -1.06 8.72 1 1.58 0.450 X 2X 3 -0.09 13.13 1 2.38 0.946 X 2X 4 0.57 0.26 1 0.048 0.681 X 2X 5 0.88 0.11 1 0.020 0.527 X 3X 4 1.31 0.0028 1 0.0005 0.354 X 3X 5 2.07 0.69 1 0.13 0.155 X 4X 5 0.26 6.39 1 1.16 0.853 X 12 -3.95 211.95 1 38.45 < 0.003 X 22 -3.08 392.53 1 71.21 < 0.013 X 32 -2.95 644.27 1 116.88 < 0.015 X 42 -4.90 825.83 1 149.81 < 0.000 X 52 -6.33 641.06 1 116.29 < 0.000 Residual 289.43 10 Lack of fit 286.63 6 68.25 < 0.001 Pure Error 2.80 4 Cor. Total 4820.98 30 Std Dev. = 2.34; Mean = 52.95; C.V.% = 3.57; PRESS = 590.63; R 2 = 0.9400; Adj. R2 = 0.8200; Predicted R2 = 0.8006; Adeq. Precision = 17.001; S = 0.2471. To determine the adequacy of the models depicting the removal of alumina by the dissolution of Ukpor clay in hydrochloric acid, two different tests, i.e. the sequential model sum of squares and the model summary statistics, were conducted. The corresponding results are tabulated in Table 5. The results from the sequential model indicated that the 2FI model did not provide a good description of the experimental data. From the model summary statistics, it can be seen that the “Predicted R2” of 0.8006 was in reasonable agreement with the “Adjusted R2” of 0.8200 for the quadratic model. Furthermore, the quadratic model had maximum “Predicted R2” and “Adjusted R2” values. The afore-mentioned results indicate that the quadratic model provided an excellent explanation for the relationship between the independent variables and the corresponding response. Table 5: Adequacy of the Model Tested Source Sum of Degree of Mean squares F-value P-value Remarks squares freedom Sequential model sum of squares Linear 2288.65 5 457.73 15.81 0.000 Significant 2FI 271.85 10 27.19 0.94 0.538 Not significant Quadratic 1971.05 5 394.21 13.62 < 0.000 Significant Cubic 119.05 15 7.94 3.20 0.0244 Significant Source Standard R2 Adjusted R2 Predicted R2 PRESS Remarks Deviation Model summary statistics Linear 6.54 0.3436 0.2578 0.2919 2054.01 Inadequate 735 | P a g e
  • 5. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 signal 2FI 7.39 0.3802 0.0897 0.1720 2336.00 Inadequate signal Quadratic 2.35 0.9400 0.8200 0.8006 590.63 Adequate signal Cubic 1.58 0.9694 0.9086 0.6205 788.48 Inadequate signal The data were also analyzed to check the correlation between the experimental and predicted dissolution yield (Y %), as shown in Fig. 1. The experimental values were the measured response data for the runs designed by the CCRD model, while the predicted values were obtained by calculation from the quadratic equation. It can be seen from Figure 1 that the data points on the plot were reasonably distributed near to the straight line (R 2 = 0.9400), indicating a good relationship between the experimental and predicted values of the response, and that the underlying assumptions of the above analysis were appropriate. 80.5 0 73.0 Predicted 8 65.6 5 58.2 2 50.8 0 50.8 58.2 65.6 73.0 80.5 0 2 5 8 0 Actua l Figure 1: Predicted values versus the experimental values. The main effects of the process variables on the response variable are plotted in Fig. 2. The figure shows that increasing the calcination temperature, leaching temperature, and acid concentration increases the % yield, while solid/liquid ratio and stirring speed has no statistical significant effect on the response and should be held constant at the center values. 67 % Yield 59 51 43 35 Calcina Dissolu Acid Solid/l Stirrin t t con i g Figure 2: Main effects plot of the process variables. 3.3. Response surface plots The three-dimensional response surface plots, obtained as a function of two factors maintaining all other factors constant at the mid-values, are helpful in understanding both the main effects and the interaction effects of these 736 | P a g e
  • 6. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 five factors. The corresponding contour plots, represented by the projection of the response surfaces in the x-y plane, provide a straightforward determination of the effects of the independent variables on the dependent variable. The three-dimensional response surface plots and related contour plots obtained are depicted in Figs. 3 to 14. Fig. 3 shows the dependency of alumina yield on calcination temperature and leaching temperature. Alumina yield increased with increase in calcination temperature to about 730 0C and thereafter yield remained constant with further increase in Calcination temperature, this is in agreement with the findings of Ata et al, [14]. The same trend was observed in Figs. 4 to 6. Increase in leaching temperature resulted in increase in alumina yield up to 1070C and thereafter decreased gradually. This is evident from Figs. 4, 7, 8 and 9. Low levels of solid/liquid ratios resulted in higher % yield as shown in Figs. 6, 9, 11, and 12. 82 79 Y ie ld 76 73 70 120.00 800.00 105.00 700.00 90.00 600.00 75.00 500.00 B: Leach Temp A: Cal Temp 60.00 400.00 Figure 3: 3D plot showing the effect of calcination temp and leaching temp. on % yield. 82 78.5 Y ie ld 75 71.5 68 4.00 800.00 3.13 700.00 2.25 600.00 1.38 500.00 C: Acid conc A: Cal Temp 0.50 400.00 Figure 4: 3D plot of the effect of calcination temp and acid concentration on % yield. 737 | P a g e
  • 7. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 81 78 Y ie ld 75 72 69 720.00 800.00 562.50 700.00 405.00 600.00 247.50 500.00 D: Stirring Rate A: Cal Temp 90.00 400.00 Figure 5: 3D plot of the effect of calcination temp and stirring rate on yield. 82 79 Y ie ld 76 73 70 0.04 800.00 0.03 700.00 0.03 600.00 0.02 500.00 E: Solid/Liquid Ratio A: Cal Temp 0.02 400.00 Figure 6: 3D plot of effect of calcination temp and solid/liquid ratio on % yield. 738 | P a g e
  • 8. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 82 78.75 Y ie ld 75.5 72.25 69 4.00 120.00 3.13 105.00 2.25 90.00 1.38 75.00 C: Acid conc B: Leach Temp 0.50 60.00 Figure 7: 3D plot of leaching temp and acid concentration on % yield. 81 78.25 Y ie ld 75.5 72.75 70 720.00 120.00 562.50 105.00 405.00 90.00 247.50 75.00 D: Stirring Rate B: Leach Temp 90.00 60.00 Figure 8: 3D plot of the effect of leaching temp and stirring rate on % yield. 739 | P a g e
  • 9. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 81 78 Y ie ld 75 72 69 0.04 120.00 0.03 105.00 0.03 90.00 0.02 75.00 E: Solid/Liquid Ratio B: Leach Temp 0.02 60.00 Figure 9: 3D plot of the effect of leaching temp and solid/liquid ratio on % yield. 81 77.75 Y ie ld 74.5 71.25 68 720.00 4.00 562.50 3.13 405.00 2.25 247.50 1.38 D: Stirring Rate C: Acid conc 90.00 0.50 Figure 10: 3D plot of the effect of acid concentration and stirring rate on % yield. 740 | P a g e
  • 10. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 81 77.75 Y ie ld 74.5 71.25 68 0.04 4.00 0.03 3.13 0.03 2.25 0.02 1.38 E: Solid/Liquid Ratio C: Acid conc 0.02 0.50 Figure 11: 3D plot of the effect of acid concentration and solid/liquid ratio on % yield. 81 78.25 Y ie ld 75.5 72.75 70 0.04 720.00 0.03 562.50 0.03 405.00 0.02 247.50 E: Solid/Liquid Ratio D: Stirring Rate 0.02 90.00 Figure 12: 3D plot of the effect of stirring rate and solid/liquid ratio on % yield. 741 | P a g e
  • 11. R. O. Ajemba and O. D. Onukwuli / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.732-742 3.4. Numerical Optimization alumina from Lampang clay, E-Journal of One of the primary objectives of the Chemistry, 9(3), 2012, 1364 – 1372. present study was to find the optimum process [6] Abdulwahab A., Suad A., Alumina parameters for maximizing the dissolution of recovery from Iraqi kaolinitic clay by Ukpor clay in hydrochloric acid solution. The hydrochloric acid route, Iraqi Bulletin of model capable of predicting the maximum Geology & Mining, 2 (1), 2006, 67 – 76. dissolution capacity showed that the optimum [7] Zafar I. Z., Ashraf M., Reaction kinetic values of the process variables were a calcination model for dissolution of low grade bauxite temperature of 668.540C, a leaching temperature of rock in sulphuric acid, Journal of 107.220C, an acid concentration of 2.93 mol/l, a Chemical Society of Pakistan, 30 (1), stirring rate of 368.24 rpm, and a solid/liquid ratio 2008, 49 – 54. of 0.027g/ml. Under these conditions, the predicted [8] Lai-shi L., Yu-sheng W., Ying-ying L., dissolution % yield was 97.85, which was in good Yu-chun Z., Extraction of alumina from agreement with the experimental value of 97.67%. coal fly ash with sulphuric acid leaching method, The Chinese Journal of Process 4. CONCLUSION Engineering, 11 (2), 2011, 254 – 258. The optimum levels of the process [9] Li D., Park K., Wu Z., Guo X., Response parameters for the dissolution of Ukpor clay in surface design for nickel recovery from hydrochloric acid solution were investigated in this laterite by sulfation-roasting-leaching work using response surface methodology. Highly process, Transactions of Nonferrous accurate model developed showed that the Metallurgy Society of China, 20, 2010, percentage yield of alumina from Ukpor clay was s92 – s96. influenced by calcination temperature, leaching [10] Narayana S. K., King P., Gopinadh R., temperature, acid concentration, stirring speed and Sreelakshmi V., Response surface solid/liquid ratio. The optimum leaching conditions optimization of dye removal by using of alumina recovery from Ukpor clay are 668.54 0C waste prawn shells,” International Journal calcination temperature, 107.22 0C leaching of Chemical Sciences & Applications, 2 temperature, 2.93 mol/L acid concentration, 368.24 (3), 2011, 186 – 193. rpm stirring speed, and 0.027 g/ml solid/liquid ratio [11] Yartasi A., Copur M., Ozmetin C., and under these conditions about 97.85% of the Kocakerim M., Temur H., An alumina content of the clay sample would have optimization study of dissolution of been removed. The above results show that Ukpor oxidized copper ore in NH3 solutions, clay is a good source for alumina and the method Energy Education, Science and employed is efficient for maximum production. Technology, 3, 1999, 77. [12] Shyi-Liang S., Hwang L., Process REFERENCES optimization of vacuum fried carrot chips [1] Abali Y., Colak S., Yapici S., “The using central composite rotatable design, optimization of the dissolution of Journal of Food & Drug Analysis, 19 (3), phosphate rock with Cl2-SO2 gas mixture 2011, 324 – 330. in aqueous medium,” Hydrometallurgy, [13] Box G. E. P., Hunter W. G., and Hunter J. 46, 1997, 27 – 35. S., Statistics for experimenters: an [2] Abali Y., Salih B., Kadir A., Ali V., introduction to design, data analysis and Optimization of dolomite ore leaching in model building, (Wiley and Sons, New hydrochloric acid solutions, York, 1978). Physicochemical Problems of Mineral [14] Ata O. N., Colak S., Ekinci Z., Copur M., Processing, 46, 2011, 253 – 262. Determination of the optimum conditions [3] Veglio F., Ubaldin S., Optimization of for the dissolution of stibnite in HCl pure stibnite leaching conditions by solution, Chemical and Biochemical response surface methodology, European Engineering Quarterly, 24, 2001, 409. Journal of Mineral Processing & Environmental Protection, 1 (2), 2001, 103 – 112. [4] Uzun D., Gulfen M., Dissolution of iron and aluminium from red mud in sulphuric acid solution, Indian Journal of Chemical Technology, 14, 2007, 263 – 268. [5] Numluk P., Chaisena A., Sulphuric acid and ammonium sulphate leaching of 742 | P a g e