Alumina Brochure

7/27/2019 Alumina Brochure

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Advanced Alumina Solutions



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



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



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



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



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.



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.



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



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



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



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



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



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



4

Renery capabilities



1

Smelter capabilities



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


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


Denmark

FLSmidth A/STel: +45 36 18 10 00

E il i @f id h

Alumina Brochure

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