Leaching of Ibute-Nze kaolin iron-oxide impurity with oxalic acid process optimization of dissolution conditions using response surface methodology

The goal of this research was to remove iron oxide from Ibute-Nze kaolin by dissolving the clay mineral in an aqueous oxalic acid solution and optimizing the process. The chemical composition of the raw and modified clay was determined using x-ray fluorescence, and the morphology of the solid sample was determined using a scanning electron microscope. The best conditions for the oxalic acid leaching of iron-oxides impurity from Ibute-Nze kaolin were determined using response surface methodology based on Box-Behnken design. The studies were carried out within the following process parameter ranges: 40–90 leaching temperature; 0.075-0.355mm particle size; 1–6 mol/dm3 acid concentration; 0.02–0.12 g/cm3 kaolin sample to acid ratio and 30-240 min contact time. The characterization revealed that Ibute-Nze clay is kaolinitic in nature and calcination at 750 opens more pores for its leaching. According to the analysis of variance, a second-order polynomial regression equation provided the best fitting for the experimental data. The predicted and experimental response values were shown to be correlated (R2 = 0.9276) in the experimental runs. The following were found to be the best conditions for the leaching process variables: 83.2051 leaching temperature, 0.0827mm particle size, 3.6179mol/dm3 acid concentration; 0.0287g/cm3 kaolin to acid ratio and 217.932min reaction time. The chemical leaching process was 92.6035 per cent under these conditions, which made the clay good for industrial applications.