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i

Aluminium Industries Carbon Area -

Equipment Breakdowns Lessons Learnt


ii

EDUCREATION PUBLISHING

RZ 94, Sector - 6, Dwarka, New Delhi - 110075 Shubham Vihar, Mangla, Bilaspur, Chhattisgarh - 495001

Website: www.educreation.in

________________________________________________________________

© Copyright, 2018, Maheswar Behera

All rights reserved. No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form by any means, electronic, mechanical, magnetic, optical, chemical, manual, photocopying, recording or otherwise, without the prior written consent of its writer.

ISBN: 978-1-5457-2463-7

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Printed in India


iii

Aluminium Industries

Carbon Area

Equipment Breakdowns Lessons Learnt

Maheswar Behera

EDUCREATION PUBLISHING (Since 2011)

www.educreation.in


iv


v

Contents

Sr.No. Title Page

Preface xv

About Author xviii

1 Process - Aluminium Industries 1

2 Mining - Bauxite 3

3 Process - Alumina Refinery 5

4 Alumina Refinery No.1 Industries Ltd 7

4.1 No Water for Commissioning 7

4.2 Vertical Pumps Have Failed 8

4.3 Stacker and Reclaimer Collapsed 9

4.4 Bauxite Crusher Tools Fails 10

4.5 The Rod Mill Body Leakages 10

4.6 Rod Mill Rods Twists 11

4.7 Precipitators Shaft Fails 11

4.8 Pylon Boom Trailer Tilted 12

4.9 Crane Fell into River 12

4.10 Approach Road to Mines Washed Away

Two Times

13

4.11 Bauxite Stock Yard on Stream 13

4.12 No Drinking Water to Remote Bauxite

Mines Top

13

4.13 Bauxite Crusher House De Dusting

Systems

13

5 Alumina Refinery No. 2 Still to Mine Bauxite 15

5.1 Alumina Refinery Still to Mine Bauxite 16

6 Process - Aluminum Smelters 17

7 Process - Carbon 19

8 Process - Green Anode Plant 22

9 Process - Anode Baking Furnaces 24

10 Process - Rod Shop 25

11 Process - Carbon Recycling 27

12 Process - Bath Recycling and Handling Plan 29


vi

13 Aluminium Smelter No. 1 31

13.1 Preheating Screw Breakdown: 31

13.2 Vibrating Compactor Issues 31

13.3 Exhaust Fan Impeller Worn Out 32

13.4 Fta Lt Drive Motor Misaligned. 32

13.5 Vertical Jaw Crusher Leg Cracked 33

13.6 Apron Feeder Butts Belt Joint Is

Repaired.

33

13.7 Secondary Jaw Crusher Hydraulic Jack

Leaked

34

13.8 Primary Jaw Crusher Movable Jaw

Replaced

34

13.9 Kneader Gear Box Cracked 34

13.10 Kneader Cooling Water Tube Fails 35

13.11 Thimble Stripper Hydraulic Cylinder

Seal Fails

35

13.12 Furnace Water Line Cracked 35

13.13 Bath Cleaning Machine Hydraulic

Cylinder Fails

36

13.14 Bath Plant Swept Mill Discharge Screen

Damages

36

13.15 Bag Filter - Screw Replaced 37

13.16 Telescopic Chute Replaced 37

14 Aluminium Smelter No. 2. Company Ltd 38

14.1 Coke Belt Conveyor Coupling Fails 38

14.2 Pitch Impact Breaker Jams 38

14.3 Screw Conveyor Flights Chocks by Pitch 39

14.4 Melter Agitator Shaft Shears 39

14.5 Pitch Pump Wears 39

14.6 No Pitch to Plant 40

14.7 Htm Boiler Leaks 40

14.8 Htm Pump Gland Leaks 41

14.9 Bucket Elevator Bucket Breaks 41

14.10 Vibrating Screen Deck Shifts 42

14.11 Impact Breaker Fluid Coupling 42

14.12 Ball Mill Pinion Damage 43

14.13 Ball Mill Discharge Screen Cracks 43

14.14 Vibrating Compactor Issues 43

14.15 Paste Kneaders Screw and Casing Wears 44


vii

Out

14.16 Pre-Heating Screw Greasing System

Trips

45

14.17 Transfer Hopper Flap Bearings Fails 45

14.18 Cooling Tunnel Trollies Jams 46

14.19 Turn Table Does Not Rotate 46

14.20 Planetary Extractor Does Not Move 47

14.21 Horizontal Butts Jaw Crusher Got Stuck 47

14.22 Power and Free Conveyor Stop Stations

Over Hauling

48

14.23 Hooking and Un-Hooking Station Lift

Table Breaks

48

14.24 Motor Bicycle Chain Slips. 49

15 Aluminium Smelter No. 3, Kingdom of Saudi

Arabia

50

15.1 Transfer Hopper Gate Not Operating 50

16 Aluminium Smelter No. 4 51

16.1 Plant Capacity Increased To 52 Tons Per

Hour

51

16.2 Bucket Elevator Buckets 52

16.3 Vibrating Screen for Butts Oversize 53

16.4 Vibrating Screen Has Larger Openings

on Screen Decks

54

16.5 Centrifugal Fans Has High Vibrations 55

16.6 Preheating Screw Htm Leaks 55

16.7 Preheating Screw Caught Fire 56

16.8 Bag House Caught Fire 57

16.9 Bag Filter Bag House Chocks 57

16.10 Id Fan Base Bolts Shear 58

16.11 Fines Bag Filter Does Not Produce Fines 58

16.12 Mixer Discharge Choked 59

16.13 Mixer Motor Has Sound 60

16.14 Mixer Discharge Gate Mal Function 60

16.15 Mixer Slewing Bearing Failed 60

16.16 Cooler Wall Scrapper Worn Out 61

16.17 Vibro-Compactor Mold Lifting

Hydraulic Cylinder Seal Failed

62

16.18 Vibro-Compactor Bearing Block Oil

Leaked

62


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16.19 Vibro-Compactor Mold Cracked 63

16.20 Vibro-Compactor Top Cover Counter

Weight Bellows Fails

64

16.21 Vacuum Pump Oil Gets High

Temperature

64

16.22 Htm Pump Oil Leaks 65

16.23 Rhodax Crusher Synchronization and

Timing Belt Damaged

66

16.24 Mixer Top Hood and Barrel Sealing

Rubber Replaced

66

16.25 Electric Linear Actuator Failed to Work 67

16.26 Mixer and Cooler Agitator Blades Pre-

Mature Failures

67

16.27 Repair of Eddy Current Separator 68

16.28 Coolant Tank Soap Lyre 68

16.29 Pitch Pumps Worn Out 69

16.30 Bucket Elevator Bucket’s Lip Plates

Replacement

70

16.31 Hpu Heat Exchanger Dirty 71

16.32 Vibrating Slot Plate Damage 71

16.33 Rhodax Rotary Actuator Shaft Broken 72

16.34 Rhodax Feeding Chute Worn Out 73

16.35 Top Cover Rope Changed 74

16.36 Top Cover Drive Hydraulic Motor Gear

Box Changed

74

16.37 Breveni Gear Box Fitted with Local Gear 75

16.38 Pre-Heating Screw Trough Was Twisted 75

16.39 Vertical Jaw Crusher Bearings Started

Sparking

76

16.40 Double Roller Crusher Not Crushing 77

16.41 Gtc Silo Collapsed 77

16.42 Hooking and Unhooking Rollers Worn

Out

78

16.43 Tilting Gear Box Internal Gears Damage

Frequently Along with Lock Nut and

Sleeves

79

16.44 Damage of The Dynamic Classifier 80

16.45 Vibrating Compactor Pivot Cage Rubber

Bush Damage

80


ix

16.46 A Valve Is Solution to Bag Filter Mal-

Functioning

81

16.47 Bath Belt Conveyor Spillages Stopped 81

16.48 Thimble Stripper Hydraulic Cylinder

Replacement with Guide Bush

82

16.49 Rodding Bench Gear and Pinion Wear

Out

83

16.50 Casting Machine Ct And Lt Rollers Are

Damaged

84

16.51 Casting Machine Lead Screw Electric

Cylinder Damaged

84

16.52 P& F Conveyor Drive Chain and Tracks

Wear Out

85

16.53 Hooking and Unhooking Stem Aligner

Base Bolts Sheared

85

16.54 Cleaning Machine Remained Idle 86

16.55 Cleaning Machine Lateral Scrapper

Frame Is Bent

87

16.56 Pre-Cleaning Machine Outside Tools -

Short Tools Are Getting Bent

88

16.57 Bath Plant Tire Is Aligned and Rollers

Are Replaced

88

16.58 Bath Plant Mill Drive Chain Lubricated 89

16.59 Bath Plant Mill Drive Gear Box Replaced 89

16.60 Cpp Crusher House Dust Level High 90

16.61 Ash Not Flowing to Slurry Tanks to

Pump Out

90

16.62 Coal Handling Belt Conveyor Support

Frame Sagging

91

16.63 Chp Conveyors Need More People to

Operate

91

16.64 Anodes Rejected for Vibro Screen

Defective Mesh

92

16.65 Anodes Cracked in Cooling Tunnel 93

17 Aluminium Smelter No. 5 Ltd 95

17.1 Ball Mill Pinion Alignment with Girth

Gear

96

17.2 Ball Mill Gear Box Shaft Broken 96

17.3 Ball Mill Girth Gear Is Oval. 98


x

17.4 C.P. Coke Impact Breaker Motor Shaft

Sheared.

99

17.5 Dilution Chamber Gets Blocked with

Dust and Fume

100

17.6 22 De-Dusting Units Improves Sub Floor

and Ambient Air Quality

100

17.7 Bath Plant Does Not Produce Required

Particle Size

101

17.8 Preheater Screws Shifted 102

17.9 Dust Collector Has Five Rotary Air Lock

Valve

103

17.10 Dust Collector Does Not Work for Two

Floors

104

17.11 Anodes Have Horizontal Cracks 105

17.12 Preheating Screw All Four Screws

Replaced

105

17.13 Kneader Discharge Is Blocked 106

17.14 Vibro Compactor Rail Worn Out 106

17.15 Kneader Gear Box Mating Gears Single

Teeth Damaged

106

17.16 Ball Mill Balls Are Segregated 107

17.17 Ball Mill Balls Shifted the Duct

Foundations

107

17.18 Auto Bath Base Frame Cracked 108

17.19 Horizontal Jaw Crusher New Segment

Mismatched

109

17.20 Bath Plant Secondary Crushe 109

17.21 Bath Plant Perforated Mill Repair 110

17.22 Double Roller Crusher Spring Breaks 111

17.23 Casting Machine Total Cycle Time High

in Summer

111

17.24 Casting Machine Speed Is Low in

Summer

112

17.25 Rod Shop Pin Bending Machine

Malfunction

113

17.26 Bath Plant Hydraulic Power Pack

Location

113

17.27 Bath Plant Air Swept Mill Pinion and

Girth Gear Worn Out

114


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17.28 Vibro Compactor Vibrating Table Cracks 114

17.29 Vacuum Pump Rotor Metal Loss 115

17.30 Slot Plate Rectification 116

17.31 Abf Fta And Asc Rails Are Noisy 117

17.32 Abf Furnace Walls Has No Bricks 117

17.33 Hydraulics Mal-Function After Periodic

Check

118

17.34 Bath Plant Air Swept Mill Id Fan Bearing

Damaged

119

17.35 Bath Swept Mill Girth Gear Guard

Sealing Arrangement

119

17.36 Anode Heights Are Different at Both

Ends

120

17.37 Overhead Water Lines Leak 121

17.38 Tail Drum Shaft Worn Out 122

17.39 Coupling Alignment 122

17.40 Bath Belt Conveyors Pit Has Bath Dust

and Water

124

17.41 Ath Recycle Plant Has Deficiency in

Number Of Issues

124

17.42 Carbon Recycle System - Poor Layout 126

17.43 Double Roller Crusher Gear Box Shaft

Broken

127

17.44 Double Roller Crusher Teethes Built Up 128

17.45 Vibrating Feeder Material Does Not

Flow

128

17.46 Bath Flaring Machine Bearing Damages 128

17.47 Bath Plant Both Stream Stopped 129

17.48 Bath Plant Mill Tire Cracked 129

17.49 High Sodium in Baked Anodes 130

17.50 Shot Blasting Machine Does Not Clean

Bottom of The Butts

133

17.51 Breakdowns Takes More Time to Restore

Operation

134

17.52 Auto Bath Pre-Cleaning Machine Blunt

Cutting Tools on Hard Bath

135

17.53 Bath Plant Throughput Suffers for

Grizzly Opening

135

17.54 Hpu All Three Pumps Down in Same 136


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Shift

17.55 Spent Anode Pallets Twists 137

17.56 Leaky Water Line Caused Different

Stations Breakdown

137

18 Aluminum Smelter No. 6 Ltd 142

18.1 Both Ball Mills Stopped and Close Both

Plants

142

18.2 Anode Inventory at Low Level, Both Gap

Are Under Breakdown

145

18.3 Double Roller Crusher Is Stressed 145

18.4 Bath Plant Is Full of Dust on Floors and

On Equipment

146

18.5 Bath Plant Perforated Mill Tire Welding 146

18.6 Ball Mill Pinion Bearing Plumber Block

Base Bolts Were Tilted

147

18.7 All Floors Are Full of Dust and Spillages 147

18.8 Pitch Vapor Treatment Is Non-Functional

in Gap

148

18.9 Kneader Through Put Is Low 148

18.10 Kneader Gear Box Gland Leaks 149

18.11 Anodes Have Loose Paste in Periphery 150

18.12 Crusher Hydraulic Cylinder Base Bolt

Breaks

150

18.13 State Pollution Authority Asked to Stop

the Mill

151

18.14 Need Tool to Cut the Cast Iron 152

18.15 Shots Are Lost 153

18.16 Both Gap Need Free of Pitch Fumes and

Dust

154

18.17 Roller Crusher Vibrates the Floor 154

19 Process – Chloro -Alkali Industry 155

20 Jay K.S. Chemicals Ltd 156

20.1 Fishermen Slept of Caustic Lye Drain to

Save River Rushikulya

156

20.2 Sodium Hydro- Sulphate Manufacturing

Technology Failed

157

20.3 Concentrate Acid Fell on Face Of The

Shift Engineer

157

20.4 Pumps Breakdowns 158


xiii

21 Process - Synthetic Rutile Plant 160

22 Odisha Rare Earths Ltd 162

22.1 Pre-Concentrator Was Solution 162

22.2 Synthetic Rutile Could Not Be Produced

Forever

163

22.3 Slurry Lines Gets Choked 163

22.4 Bore Well Pumps Not Pumping Water 164

22.5 Water Not Available to Float the Dredge 164

22.6 Vertical Water Pump Trips 165

22.7 Trammel Shaft Breaks 165

22.8 Concentrate Have Gaunge 166

22.9 Slurry Pumps Rubber Linings Worn Out 166

22.10 Slurry Pumps Gland Damaged 167

22.11 Sand Slurry Is Filtered on Pan Filters 167

22.12 Sand Dryers Feeding Has Hole 168

22.13 Bucket Elevators Chains Slips 168

22.14 Screw Conveyors Hanger Bearings Bolts

Shear

168

22.15 Vibrating Conveyors Rockers Break 169

22.16 Rotary Dryers 170

22.17 Flotation Cells 170

23 Process – Packaged Edible Salt Refineries 172

24 Odisha Home Products Ltd 173

24.1 Ffs Machines Lifted and Company Was

Closed

173

24.2 Tripler Truck Went into Hopper 174

24.3 Bucket Elevator Wood Casing Worn Out 175

24.4 Compressor Piston Worn Out 174

24.5 Dg Turbo Fan Damage 175

24.6 Thermal Expansion Tank Fire 175

24.7 Finger Got Cut in The Rotary Feeder 176

24.8 Centrifuge Is Overhauled 177

24.9 Pin Mill Rotor Is Unbalanced 177

24.10 Blenders 177

24.11 Forklift Diesel Engine Overhauling 178

24.12 Pay Loader Hydraulic Pump Repair 178

24.13 Ffs Machine Dusting

178


xiv

25 Kutch Salt Ltd 180

25.1 Centrifuge Base Was Wrong 181

26 Indian Heavy Chemicals Ltd 181

26.1 Salt Dust Closed the Plant 181

26.2 Evaporator, Condenser and Crystallizer

Dyke Wall Breaks

181

26.3 Removal of Sand and Slimes from Raw

Salt

182

26.4 10 Core Salt Refinery Sold At 32 Lakhs 183

26.5 Wet Scrubber for Catching the Fines

Particle

184

27 Process - Seamless Pipes 185

28 Odisha Seamless Ltd 187

28.1 Fourteen Inch Piping Hydro Testing 187

28.2 Straightener Was Overhauled 187

28.3 Scrap Bundler Hydraulic 188

28.4 On Line Crack Detector Does Not Work 189

29 Annexure - 1: Different Process for Green

Anode Plant

190

30 Annexure - 3: Development of Vibro

Compactors Construction

192

31 Annexure - 4: Development of Rod Shop

Technology

197

32 Annexure - 5: Development of Bath Plant 210

33 Annexure - 6: Development of Butt Crushing/

Carbon Recycle System

214


xv

Preface

The equipment are required to run a unit, the group or set of

equipment keeps running any process. The equipment have

undergone many developments and improvements by different

OEM, as per technology and as per the project requirements in

Aluminium Industries. The Aluminium industries Smelters went

through drastic changes from old soderberg process to pre-bake

technology and accordingly the pre-baked technology demanded

new design, new equipment in the process.

The operation and maintenance of the equipment required skilled

manpower, knowledgeable engineers, experienced technical

support staff, and project executives, engineering consultants.

The earlier practices of operation and maintenances remained same

for the present technology as the individual equipment features

remains same. However the hydraulics, electrical, instrumentations

and control systems have undergone major changes for all

industries. Technical as well as supporting staffs of all Aluminium

Industries acquired, and experienced knowledge of the equipment.

The operation by advance electronics and control systems made the

manufacturing easier with less manpower but the requirement for

the basic care for the equipment remains same. The operation and

maintenance of the equipment need dedicated, innovative,

experienced staff for the industry.

Engineers and operation staff in the field may have their own

approach and opinion about the listed breakdowns but these are as

experienced at site. The association at site with such events and

occurrences provides actual picture of the equipment behavior.

This is part of routine operation and maintenance activities of all

smelters, and plants in the world but it is captured here to educate


xvi

the young engineers and managers for technical guidance in their

roles.

Operation shall focus on production, quality rather equipment

breakdown and its lesson learnt. Lesson learnt shall guide the sub

floor to produce more in safe, with healthy conditions. Breakdown

for its equipment sake is for maintenance engineers. Maintenance

engineer’s stress and hard toil for equipment breakdown shall be

advised to end. Sub floor ignorance about basics of equipment

maintenance is considered as negative performance for the

operation and it is item for the extra cost. Operation shall develop

own tools depending on Company structure, policies and processes

to avail the maximum output out of existing assets. Hard work,

skill, and innovative operation staff shall eliminate the breakdowns

by concentrated efforts. The reasons for the breakdowns shall be

nailed down by sub floor in-depth technical discussion over basic

facts, rather everyone talks irrelevant science and engineering

topics which is not applicable to the equipment. Loose ends of the

technical reasons shall be consolidated and shall be made more

field oriented. In any case of the breakdown and its consequences

shall be recorded for future review. The best course of action shall

be planned for breakdown and after the resume of the equipment in

operation, focus on future, operation shall focus on moving ahead

with better solutions. Maintenance engineer’s prime responsibility

shall be to produce more than the designed ratings from an

equipment going beyond traditional maintenance methods and

maintenance management.

Task list, computerized maintenance management systems, SAP,

Information technology support to develop the maintenance

activities. These are good for the sub floor planners but it is not

good for sub floor maintenance engineer if it is not followed. This

is common for small to heavy industries in sub floor with

uneducated and unskilled manpower. Sub floor shall come out with

solutions and work for reduction of the equipment breakdown

rather keeping buried many surprises. Negligence of equipment

maintenance shall not be taken as granted.

The improved equipment and the process developments are

detailed here in short. The improvement of the equipment came

with progress of the pre-baked technology and time. There are


xvii

limited manufacturers and suppliers of the carbon area equipment.

The list is long so here it is discussed few major supplier’s design,

development and delivery to various smelters.

Maheswar Behera.

Consultant – Aluminium Industries.

*****


xviii

About Author

Mr. Maheswar Behera.Born 8th September 1958 Passed

matriculation from Bharati Bidya Peetha, Ganjam, and Odisha,

India.Completed Degree in Mechanical Engineering in 1981 from

VSSUT, Burla, and Sambalpur in Odisha.

Working experience of various industries for last 35 years,

prominent companies as below:

- Jay Shree Chemicals Ltd, Ganjam.

- Indian Rare Earths Ltd. OSCOM, Chatrapur, Odisha.

- National Aluminium Company Ltd. Anugul, Odisha.

- Aluminium Bahrain, Bahrain.

- DCW Home Products Ltd. Mumbai.

- Gujarat Heavy Industries Ltd. Ahmedabad.

- Vedanta Alumina Refinery Ltd., Langigarh, Odisha.

- Maharashtra Seamless Ltd. Nagothane. Maharashtra.

- Bechtel Inc. Gurgaon.

- Bechtel Inc, Centre of Excellency, Montreal, Canada.

- Ma’aden Aluminium Smelter, KSA.

- Kitimat, British Columbia, Canada.

- Utkal Alumina International Ltd., Tikiri, Odisha.

- Aditya Aluminium Ltd., Lapanga, Odisha.

- Vedanta Ltd., Jharsuguda, Odisha.

- Balco Vedanta Ltd., Korba, Chattisgarh.

*****


Aluminium Industries Carbon Area

1

1. Process - Aluminium

Industries

The Aluminium industries is considered as combination of

bauxite mining, Alumina Refinery, Aluminium smelter,

integrated or captive power plants, and infrastructures.

The Bauxite ore is composition of Aluminium Oxide,

which is mining at place of occurrence after the removal

of the top soil on hill tops. The ore is transported by the

on land belt conveyors or by trucks to the Alumina

refinery. The Alumina refinery handles the bauxite ore,

grinds to small particles, then particles under goes the

following process in different units within the refinery. It

rejects out the undesirable as red mud from the ore slurry.

It reduces the ore of red color into white Alumina.

Alumina is white color powder. The refineries can have

captive power plant for process steam requirement as well

as for the electric power. The Alumina is sent to the

Aluminium smelters, where powder Alumina undergoes

the electrolysis process in pots to convert into prime

metal liquid Aluminium and carbon dioxide. The carbon

dioxide along with other gases are absorbed with fresh

Alumina powder, then liberated into atmosphere. The

electrolysis process occurs in presence of the carbon

block anodes and cathodes as both side conductors of the

pot, electrolytes. The power is supplied through the

anodes and cathodes from integrated/ captive power plant

or from the external power grids. The anodes are

manufactured by calcined petroleum coke, recycled coke,

and liquid pitch as binder to the above calcined petroleum

coke. The anodes are baked in furnaces and then these are

inserted with rods so that it can be fixed on top of the pot.

The hot liquid metals are transported to cast house where


Maheswar Behera

2

it is made to marketable shape of prime products with

different quality. These includes saw mold, ingot, bars,

billets, and slabs. The down- stream industries converts

these shapes into numerous products like wires, plates,

various extrusion items. Further the value addition are

done on the secondary products like plates are used to

make Aluminum cans and so on. The metal is considered

as green metal as it can be reused after the recycling.

The infrastructure requirement is intensive for a mega

project. The port facility handles input raw materials like

Alumina, coke and coal, to import finished products for

export. The rail network is used for the transporting

bauxite, Alumina and coke and coal within the land if the

smelter located in the same region. The road transported

also an integrated mode for handling all inputs and output

prime metal as wells as finished products.

The restoration of the surrounding air, water and habitants

in original condition shall be a major role of the industry.

The various climate friendly processes in mining,

refinery, smelters and power plants keeps the surrounding

in habitable conditions. The state authorities and people

around industry shall demand from the industry. The red

mud from refinery, waste solids from smelters, and the

ash from power plants need established technologies to

reprocess for beneficial utilization for the society.

*****


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