Overview of our research on ‘structure and reactivity’ of gibbsite and boehmite under varied conditions of mechanical activation, e.g. milling energy and presence of a second phase is presented. Bulk and surface changes induced in the solids by milling are characterized in terms of morphology, particle size distribution, specific surface area and nature of porosity, crystallite size and zeta potential. Results on enhanced amorphisation of gibbsite in presence of a second phase (quartz, hematite etc), changes in zeta potential of gibbsite due to loss of texture during milling and anomalous decrease in surface area of boehmite during milling are reported. Reactivity of the activated solids in sodium hydroxide and variation in thermal transformation temperatures is correlated with physicochemical characteristics of the samples and plausible explanation for the observed correlations presented. Significance of the results with specific reference to bauxite and alumina processing in Bayer process is highlighted
