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Transcript of Alumina Brochure
7/27/2019 Alumina Brochure
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Advanced Alumina Solutions
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Bauxite crushing & grinding
Bauxite
Bauxite ore is the major mineral
source or extraction o alumina and
subsequently aluminium, the most
abundant element ound in the
earth’s crust. The name bauxite
originates rom France where it was
discovered. There are three (3) main
structural types o bauxite:
• Gibbsite – Al(OH)3
• Boehmite – AlO(OH)
• Diaspore – AlO(OH)
Each o these three types o bauxite
has dierent chemical and physical
properties that make them more or
less dicult to mine and subsequently
use or economically rene to
alumina.
O the bauxites currently being mined,
the dominant orm is gibbsite,
ollowed by a mixture o gibbsite and
boehmitic. The main impurities are
compounds o iron, silicon and
titanium.
A large quantity o the world’s bauxite
is mined rom large blanket type
deposits with an overburden rom 0
to 70 m o rock and/or clay, which
may require blasting beore being
loaded by ront end loader or shovel
and transported by truck, rail or
conveyor to the renery.
Processing
At the renery, the bauxite is stored in
a stockpile by a stacker or later
reclaiming and processing into
alumina. Roller screening o the
bauxite to remove coarse waste
material may be the rst unit
operation beore the bauxite is
crushed in one or more stages to a
particle size o about 50 - 75 mm,beore being mixed with a hot caustic
soda solution in the grinding mills.
ABON® sizers
Since most bauxite mines are located
in the tropics with its rainy season,
bauxite processing equipment must,
as a rule o thumb, be able to handle
wet and sticky bauxite as well as dry
and dusty bauxite, which makes the
ABON Mineral Sizer the preerred type
o crusher selected or both primary,
secondary and tertiary crushing o the
bauxite in many cases.
Ball or rod mills, rod-ball mill
or SAG mill
Ater crushing, wet grinding o
bauxite is accomplished in either open
or closed-loop milling circuits using
various types o grinding mill designs,
tailor made to the bauxite.
FLSmidth has operating experience
with all the above equipment and
cover the complete equipment fow
sheet rom Run-o-Mine bauxite up to
and including the de-silication tank
reactor prior to digestion.
World’s largest Rod Mills on Bauxite
at Gove, Australia
4400 t/h Primary ABON Sizer
crushing bauxite
2500 t/h Secondary ABON Sizer
crushing bauxite
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3
Solid liquid calcination (SLC)
The SLC process converts spent plant
liquor and Sodium Oxalate to Sodium
Aluminate and recovers the Caustic
rom Sodium Carbonate using Bauxite
and/or Alumina Dust
as solid eedstock.
Liquor productivity is increased by
decreasing content o organic agents
and sodium carbonate in the liquor,allowing an increase in caustic
concentration.
Quality o hydrate and alumina is
improved by reduction o sodium in
alumina and production o a coarser
hydrate.
Improved plant eciency is achieved
by:
• Recovery o dissolved caustic and
alumina
• Lower viscosity o plant liquor
and pumping power
• Increased settling rates and less
oaming
• Utilization o high organic
bauxite deposits without
decreasing plant eciency
• Environmentally sound processing
o salt cake to sodium aluminate
without additional residue
generation
R&D timeline o SLC process
1st generation 120 TPD Solid Liquid
Calciner with Alcan and Alumina
Espanola.
1992-1993: Equipment Selection
1993–1996: 24 tpd Pilot Testing
1997–1999: Construction o 120
tpd Unit
1999–2000: Commissioning,Demonstration,
Consolidation and
Optimization;
2nd Generation SLC Process
developed with Alcan or Liquor
Purication at Gove, Northern
Territory
2002: Pilot Testing - Gas Suspension
2003: Pilot Testing - Environmental
2004: Basic Engineering
2004: Environmental impact study
2005: Detailed Engineering
2005-2006: PAM Construction
Liquor Purifcation with the Solids Liquid Calcination Process
(SLC)
2 x 300 SLC Units arrives (as PAM) to the Gove Refnery
in Australia
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Settler & washer trains
Deep Cone® paste thickeners
• Maximum underfow slurry solids
and minimum thickener ootprint
• Produce uniorm, non-
segregating paste consistency
underfow slurry
• State o the art approach or dry
stacking o red mud
• Torque capacities available to
13,500,000 Nm• 138 Deep Cone Paste Thickeners
sold to over 45 operating sites
Main eatures
• E-Duc® autodilution and
focculation eed systems
(or washers)
• Mud bed in compression
• Rakes with pickets or increase o
solids concentration
• High torque drives
• Steep foor slope
• Mud discharge cone with
centre scraper
• Designs without bottom bearing
available
Hi-rate thickeners
• Technology or high specic
capacity at reduced ootprint
• In combination with red mud
drum lters or mud disposal at
highest solids concentration and
minimum soda losses
• Advanced mud level and
thickener control systems
available
New generation o drive
heads — A-type
• State-o-the art design or bridge
type thickeners
• Multiple eciency planetary
gears replacing traditional worm
gear arrangements
• Heavy duty, high precision
4-point contact ball bearing
designed to handle tilting orces
• Reverse rotation eature
• Permanent torque measurement
by load cell(s)
• High saety span between design
torque, 100% - alarm and cut-o
at 180% resulting in extended
reaction time or corrections
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Red mud lter
Red mud lters
• 22 mm high fow lter cells or
highest hydraulic and pneumatic
capacities
• Air sweeping device at both ends
o the drum cell to assure quick
ltrate and cake discharge
• Large diameter (1000 mm dia.)
vacuum valve and wear plate
with large sealing area or long
resistance to wear
•
Dedicated discharge roller drivesystem – allowing or optimising
ration o drum vs. discharge
roller speed
• Agitator drive is designed or
easy maintenance access to the
drive, the bearings and the
eccenters; especially the agitator
shat is divided in such a way,
that also inside eccenter-bearings
can be dismantled and replaced
without disassembling the
eccenter and the outside bearing
• Agitator drive is supported on the
lter vat (not on the oundation)
or best t o components in the
workshop and ater site erection
• Robust cake discharge comb in
special red mud design
• Agitator pivot bearings can be
replaced rom the outside
without disassembling the drum.
They are provided with
lubrication points to assure to thebearings a long lie
• Mud pockets with sluicing pipes
and drainage nozzles to
temporarily drain out the
settled sand
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Pressure ltration
Shriver® Filter Press
The FLSmidth Shriver® automated membrane lter presses are
supplied with overhead lter plate suspension and automatic
indexing plate shiting. These rugged construction lter presses
are tted with automatic high-pressure cloth washing mecha-
nisms or lter cloth cleaning at pressures up to 100 bar.
Years o experience and thousands o installations have resulted in
a wide array o designs, eatures and styles o Shriver® lter
presses. A variety o plates, skeletons, opening mechanisms,
shiters, and special designs with patented Shriver options
provides FLSmidth the knowledge and experience to handle the
most complex to the simplest application.
Benets
• High-solids red mud lter cake
• Maximum caustic recovery
• Overhead Plate Suspension
•
Automatic lter cloth washing at 100 bar• Filtration area up to 1,000 square meters
Features
• Over 100 years experience in process and design
• More than 30,000 installed units worldwide
• Flexibility in design to meet special needs
• Qualied and experienced technical sta
• North American technologies combined with local manuac-
turing, local service and spare parts
AFP IV™ automatic lter presses
The FLSmidth AFP IV™ automatic lter press oers considerably
reduced cycle time as compared to conventional lter presses.
The mechanical time between cycles is minimal and, as a
result, more production is achieved.
The selection o AFP IV™ lter presses can greatly reduce the
number o installed lters or a given installation. These lters
not only provide high throughput, ecient solids capture and
low moisture content red mud lter cakes, but they also
operate continuously and automatically in harsh environments,
and can handle abrasive or corrosive slurries.
Benets
• High-solids red mud lter cake
• Maximum caustic recovery
• Positive, ully automatic cake discharge
•
Easier operation and maintenance accessibility• Lower maintenance costs and higher perormance
• Filtration area up to 2,000 square meters in a single lter
Features
• Push closure cylinder mounted at centerline o lter press
• Rolling cross-head or extra long plate-stacks
• Fast opening & closing w/shaker or quick cake discharge
• Heavy-duty design specially adapted or minerals service
• Automatic cloth washing apparatus
• Recessed chamber and membrane plate designs
• Filter Press Control Packages – Automatic ltration, cake
wash, membrane squeeze, & discharge. Local processcontrol and DCS communication.
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7
Mobile conveyors & dry stacking
Mobile conveyors
The mobile stacking conveyor can be
used to handle various materials. It is
a single conveyor supported on a
series o truss rames and crawler
tracks. The trusses are connected by a
specially developed joint that allows
the machine to ollow uneven ground
conditions and relieve stresses that
could damage the structure.
A single conveyor belt fight runs
along the top chord o the trusses the
length o the mobile conveyor. The
belt drive typically is located at the
end o the machine where it is closest
to the electrical power.
The mobile conveyor tripper travels
along the top chords o the mobile
stacking conveyor. The tripper “trips”
ore onto the cross conveyor belt and
discharges the material onto the
stack. The cross conveyor is long
enough so the pile can be built to the
design height while keeping the
crawler track back rom the advancing
toe o the pad.
The mobile conveyor’s control system
combines human interace and
automatic controls or various
unctions. The operator can override
the automatic controls i needed as
well as control the upstream
equipment. Manual controls such as
the tripper speed and cross conveyor
position can be used to build the
smoothest possible leach pad.
Automatic controls generally monitor
rame alignment, leveling, and other
conveyors upstream or the operator.
The controls system is unique to the
equipment and allows the MSC to
handle material while it moves. It is
important to point out that ore
handling does not stop when the
tripper or the entire machine moves.
Waste Stacking System
This is a very ecient and cost-
eective method o stacking waste
ore. The Mobile Stacking System
advance stacks in a radial mode, as
indicated by the arcing sweeps. Once
a lit has been completed, additional
lits can be stacked on top through
the use o elevating conveyors. By
stacking in lits, several years o waste
material can be stacked on a small
ootprint, thereby reducing the
environmental impact.
A stacker, such as a Mobile Bridge
Boom Stacker, can be added to the
Mobile Stacking System to increase
the distance between the edge o the
pile and the stacking system,
depending on geotechnical
requirements o the stacking plan.
The addition o a stacker can also
increase the fexibility o the stacking
system when lling complex valleys.
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Hydrate classication & slurry pumping
Hydrocyclones
Hydrocyclones are used in many
alumina reneries to enhance
classication eciency.
A partial list o applications includes
• Bauxite grinding
• Bauxite renement
• Sands separations rom red muds
• Sand washing,• Hydrate classication
• Product size control
• Seed size control
• Hydrate thickening
• Deliquoring
• Agglomeration
• Preerential separation/reduction
o oxalates
• Spent liquor solids recovery
• Cooling tower water clean-up
• Lime slurry degritting
The most common applications are
sands separation rom red muds and
the various duties in the hydrate
classication and debottlenecking area.
The versatility o hydrocyclones
suggests they may be suitable
problem solvers in many applications
and this must be determined by a
step-by-step evaluation. Solutions are
tailored to meet the individual plant
and operating conditions with
hydrocyclones which are a low cost
investment item. High eciencies and
outstanding fexibility are combined
with simple operation and
maintenance without any special
space or installation requirements.
FLSmidth Krebs is an innovative
hydrocyclone supplier oering
experience and value in proving
benets, thorough testing, optimum
equipment design, suitable controls,
maintenance riendly, and an
appreciation o the limits o
perormance.
KREBS® millMAX™ or the
alumina industry
KREBS® millMAX™ Pumps treat the
cause o pump wear and loss o
eciency. In most established
millMAX™ installations, wear lie o
parts has been even and in the
majority, overall wear lie has
generally improved by 100%. The
increase in wear lie is achieved
together with a reduction in power
consumption typical in the 10-20% or
lower range.
The reduction in power consumption
can be as a cost saving, or additional
pumping capacity with the same
installed motor.
• Patented design eature to
reduce degradation o solids
• High Chrome Iron Construction
• Reduced energy consumption or
same fow/head
• Longer, more uniorm wear lie
• Optional driMAX™ slurry
mechanical seal
• High temperature elastomer seals
• Stainless steel asteners
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9
Seed & product hydrate ltration
Seed hydrate ltration
High capacity, large diameter disc
lters
The large diameter, high capacity disc
lter is the state-o-the art lter or
ltration o seed and product hydrate
in the precipitation circuit.
• HiFlow hydraulic design or
highest ltration capacity and
lowest cake moisture
• Reliable cake discharge by
advanced blow back design
• Large diameter discs with 5.5 or
6.0 m diameter
• High speed lter with up to 6.0
rpm disc speed
• Multiple discs with up to 6 discs
per lter
• Multi-channel design providing 40
channels or 40 sectors per disc
• Optimum slurry agitation by discs
running in multiple low volume
troughs• Special design or quick and
simple disc replacement
• Improved sector and rim xing
system resulting in proven
long-term mechanical and
operating reliability
• Extended cloth lie time due to
modern sector design and
improved cloth cleaning eatures
Product hydrate ltration
High capacity horizontal pan lters
The high capacity horizontal pan lter
is a highly reliable lter specially
designed or the actual needs in the
alumina industry.
• The lter design envelopes a
modern synthesis o latest
process achievements with
reliable and rugged equipment
design or highest customer
satisaction
• Advanced ltration rates are
combined with most ecient
counter current washing
technology
• Enhanced product hydrate
characteristics achieved through
heel cake ltration
• Large diameter pan lters with
up to 10 m diameter in successul
conventional (71m²) operation
•
Advanced sel-control eatures• Lowest cake moisture through
using vacuum steam drying
technology
• Special uniorm slurry distribution
device resulting in even cake
build-up
• Reliable cake discharge by
wear-resistant discharge scroll
• Highest lter productivity due to
extended operation cycles
• Preventative maintenance
riendly design
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0
Gas suspension calcination (GSC)
The gas suspension calciner (GSC) or
alumina was developed by FLSmidth
rom 1976 to 1984. The rst unit at
Hindalco, India, has now been in
operation since 1986.
The GSC units at Queensland
Alumina in Gladstone, Australia,
shown on the cover page were the
rst calciners in the alumina industrywith application o a bag-house or
air pollution control located directly
ater the calcination process.
This calcination acility comprises 3 x
4500 t/day o GSC units, the world’s
largest calciners producing alumina.
Today, FLSmidth has proven GSC
operation with Heavy Fuel Oil, Natural
Gas and Coal Gas rom a gasication
plant.
Typical annual calciner availability
exceeds 98% with particulate dust
emission not exceeding 20 mg/Nm3
(dry) exhaust gas.
Air pollution control
More than 7,500 Air Pollution
Control Installations -
State-of-the-Art Gas Distribution
using CFD Modelling
Electrostatic precipitators
or low dust emission
• Minimum spare parts stock
• 65 years o experience
• Emission < 15 mg/Nm³
• High availability
• > 20 years o lietime
• Low pressure drop
• Back corona eliminated
• Low power consumption
• Multi-level collecting plates
rapping
• Automatic perormance
optimization
• Unbreakable discharge
electrodes
Fabric lters or cement &
minerals Industry
• Tailor-made to alumina & cement
• Low maintenance costs
• On line maintenance
• High availability
• On line supervision
• Own bag abrication
• Constant low emission
•
Low air consumption• Star-shaped cages
• “Smart” pulse control
• Down fow between bags
• Low cleaning pressure
GSCTechnologyFeature
GSC CustomerBenefts
Operation below
ambient pressure
•Sae on linemaintainability
•
Minimumdown time ormaintenance
Calcination inone urnace passonly, without re-circulation o partlycalcined alumina
•Minimummechanical impacton alumina
•Minimizing particlebreakdown
Four (4) direct heatrecovery stages
Minimum thermalenergy consumption,CO
2-Emission and
heat lost to thecooling water
Hot stand-byoperation withoutalumina production
•Minimum thermalshock o reractory
•Maximizes servicelie o reractory
Electrostatic Precipitator
Fabric Filters
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1
Alumina handling & storagein renery and smelter
Handling o primary alumina,
secondary alumina, crushed
bath, fuoride, calciner dust
and petcoke
• Loading and unloading o trucks,
railcars and ships
• Pneumatic and mechanical
transport
• Screening, Dosing and Blending
• Storage in dierent silos• Silo eeding and discharge with
special systems on silo top and
bottom in Anti-Segregation
Design or low separation o
nest particles
• Direct pot eeding systems
Storage
• Mechanical Belt Conveyors or
1,200 t/h rom Ship Unloader to
Transer Towers with Weighing
and Dust Extraction Systems
• Large Capacity Silos up to 85,000
m3 (and more, i required )
• Transer Towers with Airlit
Systems 600 t/h each or 65 m
vertical transport
• Distribution Airslide Conveyors to
various Storage Silos
• Anti-Segregation Silo Feeding
Systems downstream mechanical
conveyors and Airlit
• Anti-Segregation Silo Reclaim
Systems, designed also to limit
dead stock volumes to smallest
possible extent
• Downstream pneumatic transport
equipment such as Airlit, Dust
Pump or Pressure Vessels with
TURBUFLOW® Pipe
• Tanker and Railcar Loading and
Discharge Stations
FLSmidth’s proprietary Möller
technology
• Pneumatic MÖLLER TURBU-
FLOW® pressure vessel systems
• High dense phase conveying
• High conveying capacities over
long distances – up to 250 t/h
and more
• First and only 3,000 m direct
conveying project worldwide(Sumitomo Kashima Steelworks,
Japan)
• Airslide systems or distribution
and storage acilities
• Airlits or vertical conveying
• MÖLLER dust conveying pumps
(screw conveying)
• Small, medium, and large steel
and concrete silos or short and
long-term storage
• Special silo eeding and discharge
equipment to minimize particle
segregation and to achieve
uniorm particle size distribution
or the material passing through
the silos
• Direct pot eeding technology or
alumina smelter plants
TURBUFLOW® eatures
• High dense phase conveying
• High loading ratio (kg bulk/kg air)
• Very low air/bulk velocity at the
beginning and the end o the
conveying pipe
• Low wear due to very low
velocities
• Very low particle segregation
during conveying o alumina
• No plugging
• Start-up with bulk loaded pipe
• Sel-regulating system
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2
Expert control system (ECS) & simulation
More than 39 years o process
knowledge and experience
Gain access to FLSmidth’s unparalleled
knowledge and experience with
process control, entailed in our ECS
range o adaptable solutions.
ECS/control center solution
• More than 39 years o process
knowledge and processexperience is unparalleled in the
industry and is a unique support
in our control centre solutions
• SCADA/PLC system with DCS
unctionality providing highly
fexible solutions that are
independent rom PLC platorm
• More than 700 ECS/
ControlCenter solutions
commissioned since our rst
computer based Plant Control
and Supervision system was
installed in 1972
ECS/process epert solution
• Our ECS/ProcessExpert
applications have a eld proven
track record since 1978 providing
signicantly improved process
stability through continuous,
accurate and consistent process
evaluation and control actions
• The ECS/ProcessExpert solution
entails uniorm control strategy
improving end-product quality
regardless o individual operators’
skills
• Improved process stability and
fow providing
• Lower operation costs
• Increased throughput
• Improved temperature control
=> more consistent quality
• Less blockages => less down
time => less wear
• Typical results in the industry,
with variations in productiontype, product type, maintenance
level, etc.:
• Production increase: .....3-8%
• Fuel savings: .................2-8%
• Quality improvement:up to 30%
• Decreased standard deviation:
10-20%
Remote services
• Remote Process Troubleshooting
• Remote Process Support
• Remote Sotware Maintenance
• Remote Engineering
• Remote Optimization
Simulator
• State o the art in computer-
based training
• Risk ree environment enabling
learning about:
• Processes behaviour
• Control system behaviour
• Provide hands-on experience with
a true-to-live plant
• Enable aster start-up and
productivity in new plants
• Built-in operator evaluation and
certication
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13
Quality control by x-ray(QCX) & RoboLab solutions
First automated quality control
solution in operation in 1971.
FLSmidth has a unique experience in
the quality control market, with a
proven track record o more than 500
automated laboratories commissioned
in the industry.
QCX/RoboLab
• FLSmidth’s Quality Control
Solutions are supported by more
than 36 years o process
knowledge and process
experience
• The unique QCX/RoboLab
solution’s ability to operate 24/7
at constant, high pace and high
accuracy will provide an improved
and precise overview on
production
• Thus achieving signicantly
reduced variation in product
quality
• An automated sampling process
will procure correct representative
sampling at the process and at
the specied locations supported
by ast delivery o samples to the
lab
• Improved health and saety
environment by releasing
operators rom heavy liting and
working in a dusty and noisy
environment
• The QCX/RoboLab solutions
range rom sampling to analysing
in the Bayer Process as well as in
the Renery and Smelter Process
• Our robotic cell structure clearly
denes each cell’s unctionality
providing a high degree o
fexibility in design, layout and
development o the laboratory
• The fexible concept allows or
partial and step-by-step
automation, e.g. step one; ocus
on quality and/or health and
saety issues; expanding to ullyautomated operation at a later
stage
Centralized laboratory or
dedicated in-situ lab
• FLSmidth’s alternative to the
centralized laboratory is an
automated container laboratory
solution, transportable to any
location, close to the process
requiring time critical analysis
• Fully sel-contained solution with
electrical and compressed air
distribution, de-dusting ensures
the optimum environment or
high quality analysis
• The typical conguration includes
the ollowing analysis equipment:
• Sample milling machine
PAL-MIL R
• Sample handling robot
• Optical emission Spectrometer
SPECTROLAB
• QCX metal control system
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Renery capabilities
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Smelter capabilities
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Copyright © 2011 FLSmidth A/S. ALL RIGHTS RESERVED. RTA settler-washer technology presented with authorization of Rio Tinto Alcan. FLSmidth is a (registered)
trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are
for general reference only and may change at any time. www.fsmidth.com
Australia
FLSmidth Pty Ltd
Tel: +61 3 8336 1233Email: [email protected]
Brazil
FLSmidth Ltda.Tel: +55 15 3416 7400
E il f id h@f id h b
Germany
FLSmidth Wiesbaden GmbH
Tel: +49 (0) 6123 / 975 300
Email: [email protected]
India
FLSmidth Private LtdTel: +91 44 4748 1000
E il f i @f idth
USA
FLSmidth Salt Lake City, Inc.
Tel: +1 801 871 7000
Email: [email protected]
USA
FLSmidth Krebs Inc.Tel: +1 520 744 8200
E il k b @f id h
Russia
FLSmidth Russia CIS
Tel: +7 495 641 2778
Email: [email protected]
Denmark
FLSmidth A/STel: +45 36 18 10 00
E il i @f id h