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This book provides a comprehensive review of the production of smelter grade alumina from bauxite ores. It emphasizes the best practices applied in the industry today but seen in a historical context with a view to future challenges and developments. The control of alumina quality is discussed in detail including the effects that alumina quality have on the aluminum smelter process with respect to environmental performance, current efficiency, and metal purity. The discussion of alumina quality will be relevant to people on the smelter side, as this is the interface between refinery and smelter. Emphasis is placed on the major steps of the Bayer Process including: digestion, clarification, precipitation, calcination, and management of water, energy, and bauxite residue. This book is a valuable resource for active, seasoned practitioners and for new engineers entering the industry.
This book provides a comprehensive review of the production of smelter grade alumina from bauxite ores. It emphasizes the best practices applied in the industry today but seen in a historical context with a view to future challenges and developments. The control of alumina quality is discussed in detail including the effects that alumina quality have on the aluminum smelter process with respect to environmental performance, current efficiency, and metal purity. The discussion of alumina quality will be relevant to people on the smelter side, as this is the interface between refinery and smelter. Emphasis is placed on the major steps of the Bayer Process including: digestion, clarification, precipitation, calcination, and management of water, energy, and bauxite residue. This book is a valuable resource for active, seasoned practitioners and for new engineers entering the industry.
Über den Autor
The Co-Editors of this book have a slightly different perspective on the recovery of alumina from bauxite. Benny and Fred received their technical training as MS Chemical engineers.
Benny Raahauge was employed by FL Schmidt and thus represented a manufacturer and seller of equipment used in that industry.
Fred Williams was employed by Alcoa and was assigned management responsibilities in alumina processing research, plant process engineering and running plant production.
Both individuals have conceived technical improvements to the alumina recovery process as recognized by patents and technical awards, written and presented numerous papers at international technical meetings and have served as chairmen and organizers of international technical sessions.The authors of the individual chapters in this book are noteworthy experts from around the world in alumina manufacturing and researchtechnology.
Zusammenfassung
Includes a historical summary outlining future challenges and developments
Provides a wealth of example calculations, rules of thumb, useful illustrations, tables, and formulas
Written by industry experts for a broad audience working in plants, engineering offices, refineries, and smelters
Inhaltsverzeichnis
1. Introduction: Primary Aluminium - Alumina - Bauxite (Benny E. Raahauge)
i. Property Driven Applications
ii. Supply-Demand Balance and Forecast
iii. Cost Drivers and Pricing
iv. Environmental Footprints and Challenges
2. Bauxite Mineralogy, Classification and Beneficiation (Hydro/RTA?)
i. Bauxite Resources
ii. Mineralogy and Chemistry
iii. Classification from Bayer Process Perspective
iv. Beneficiation Options
3. Bayer Process Design and Physical Chemistry (Steve Healy)
i. Bayer Process Design Overview
ii. Liquor Properties - Physio Chemical Data
iii. Lime (CaO) Chemistry
4. Bauxite Processing - Crushing/Grinding, De-silication and Digestion (CSIRO?)
i. Crushing & Grinding
ii. Silica Chemistry, Desilication Kinetics and Reactor Design
iii. Digestion Chemistry, Breakpoint and Kinetics
a. Maximum Extractable Alumina (MEA) and Breakpoint
b. Digestion Models
c. Degradation of Organics
iv. Digestion Conditions, Bauxite Mineralogy and Yield
a. Effect of Lime addition
b. Impact of impurities
v. Applied Digestion Technology and Heat Consumption
a. Autoclaves
b. Tube Digester
c. Double Digestion
vi. Digester Mass and Heat Balances
a. Theoretical Heat of Digestion
b. Boiling Point Elevation
c. Steam Requirements
5. De-sanding - Floculation / Sedimentation - Liquor Filtration (Tim Laros)
i. De-Sanding Equipment
ii. Flocculation and Sedimentation Principles
iii. Mud Rheology, Rake Drives and Mud Pumping
iv. Decantation and Clarification Technology
v. Rise Rate and Tank Design
vi. Pregnant/Green Liquor Filtration Options and Trends
6. Bauxite Residue: Washing - Dewatering (Tim Laros) and Disposal (Paul McGlade)
i. Mud Washing - Recovery of Soda and Alumina
ii. Dewatering Options: Filtration and Centrifuging
a. Filtration Theory and Applications
b. Filtration Pressure and Equipment Options
c. Centrifuge Theory and Applications
iii. Mud Cake Disposal Options and Principle
a. Wet Disposal w/wo Neutralization
b. Dry Stacking w/wo Mud Farming
c. Dry Disposal
7. Hydrate Precipitation (Dennis R. Audet) , Classification and Filtration (Manfred Bach)
i. Hydrate Crystallization Fundamentals
a. Nucleation, Agglomeration, Breakage and Growth
b. Crystallization Mechanism and Kinetics
c. Heat of Crystallization
d. Control of Residual Soda
e. Impact of Organics and other impurities on Yield
ii. Precipitation Flow Sheets and Particle Morphology
a. Retention Time and Temperature Profile impact on Yield
b. Modelling of Precipitation Flow sheet
iii. Precipitator Tank Design Options
a. Agitation and Mixing
b. Hydrodynamic Effects on Yield
iv. Classification Options and Mass Balance Control
a. Hydro Clones
b. Fine Seed Thickener
v. Seed and Product Hydrate Filtration Options
a. Seed Preparation
b. Washing Efficiency and Flow sheets
8. Liquor Purification and Impurity Control (Steve Healy)
i. Organics removal
ii. Removal of Inorganic impurities
a. Iron
b. Phosphor
c. Other...
9. Water Balance, Evaporation, Heat Exchange and Co-Generation (Daniel Thomas)
i. Refinery Water Balance
ii. Bayer Process Heat Balance
a. Heat Transfer
b. Inter-department heat exchange
iii. Evaporation
iv. Co-Generation of Steam and Power
10. Alumina Production by Calcination (Benny E. Raahauge)
i. Calcination Chemistry, Phase Changes and Combustion
a. Chemistry, Degree of Calcination and Stoichiometry
b. Crystalline and X-Ray Amorphous Phases
c. Fuels and Combustion Products - Acid dew Point
ii. Drying and Calcination Theory
a. Gas-Solid Heat Transfer and Drying/Calcination
b. Heat Conduction
c. Alpha Phase Formation and Kinetics
iii. Heat of Calcination
a. Standard Heats of Reaction
b. Calcination Heat in Practice
iv. Calcination Furnace/Reactor Design and Operating Conditions
a. Rotary Kiln
b. Fluid Flash (FF) and Gas Suspension Calciner (GSC)
c. Fluidization and the Circulating Fluid Bed (CFB)
d. Gas Suspension Calciner Reaction Model
v. Gas-Solid Separation in Cyclones
vi. Air Pollution Control and Dust Management
a. Gas Emissions and Carbon Foot Print
b. Particulate Dust Emissions and Management Options
c. Electrostatic Precipitator or Bag House
vii. Refractory Selection and Surface Heat Losses
viii. Calcination Flow Sheet Options
a. Heat Recovery Options
b. Hydrate By-Pass and Alumina Quality
c. Heat Balance and Specific Heat Consumption
d. Specific Power Consumption
ix. Particle Breakdown and Strength During Calcination
a. Particle Breakdown Defined and Observed
b. Attrition Index Defined and Observed
c. Impact from Precipitation and Calcination
11. Alumina Quality, HF Removal, Dissolution and Aluminium Purity (Stephen Lindsay)
i. Chemical Composition of Smelter Grade Alumina
a. Loss of Ignition (LOI) and Degree of Calcination
b. Phase Composition and Alpha Alumina Content
c. Chemical Composition and Gibbsite
ii. Physical Properties of Smelter Grade Alumina
a. Particle Size Distribution, Dustiness and Attrition Index
b. Angle of Repose and Flow ability
c. Bulk Density and Heat Conductivity
d. Specific Surface Area and Pore Size Distribution
iii. Efficient HF Removal and Dry-Scrubber Efficiency (Margaret Hyland)
a. Sources of HF from Smelting
b. Pore Size Distribution and accessible Specific Surface Area
¿ Primary Alumina
¿ Secondary Alumina
c. The Role of Sulfur Dioxide?
iv. Alumina Dissolution and Current Efficiency (Pascal Lavoie)
a. Theoretical Analysis of Dissolution Process
b. Dissolution Rate under Laboratory Conditions
¿ Effect of Particle Size Distribution: Sandy vs Floury
¿ Effect of Phase Composition: Gamma vs Alpha
c. Impact of Calcination Technology
d. Impact of Alumina Feeder Design and Operation
v. Impurities impact on Aluminium Production, Purity and Properties
a. Soda and CaO
b. Silica and Iron
c. Phosphor and Beryllium
d. Vanadium and Sulfur
12. Alumina Storage and Handling Options
13. Health, Safety and Plant Management (Carlos Suarez)
14. Process Control, Simulation and Operator Training (NN?)
15. Process Economics and Plant Design (Peter-Hans Ter Weer)
Details
| Erscheinungsjahr: | 2022 |
|---|---|
| Fachbereich: | Fertigungstechnik |
| Genre: | Mathematik, Medizin, Naturwissenschaften, Technik |
| Rubrik: | Naturwissenschaften & Technik |
| Medium: | Buch |
| Reihe: | Springer Series in Materials Science |
| Inhalt: |
xxiii
844 S. 196 s/w Illustr. 323 farbige Illustr. 844 p. 519 illus. 323 illus. in color. |
| ISBN-13: | 9783030885854 |
| ISBN-10: | 3030885852 |
| Sprache: | Englisch |
| Ausstattung / Beilage: | HC runder Rücken kaschiert |
| Einband: | Gebunden |
| Redaktion: |
Williams, Fred S.
Raahauge, Benny E. |
| Herausgeber: | Benny E Raahauge/Fred S Williams |
| Auflage: | 1st ed. 2022 |
| Hersteller: |
Springer International Publishing
Springer International Publishing AG Springer Series in Materials Science |
| Maße: | 241 x 160 x 52 mm |
| Von/Mit: | Fred S. Williams (u. a.) |
| Erscheinungsdatum: | 24.01.2022 |
| Gewicht: | 1,449 kg |
Über den Autor
The Co-Editors of this book have a slightly different perspective on the recovery of alumina from bauxite. Benny and Fred received their technical training as MS Chemical engineers.
Benny Raahauge was employed by FL Schmidt and thus represented a manufacturer and seller of equipment used in that industry.
Fred Williams was employed by Alcoa and was assigned management responsibilities in alumina processing research, plant process engineering and running plant production.
Both individuals have conceived technical improvements to the alumina recovery process as recognized by patents and technical awards, written and presented numerous papers at international technical meetings and have served as chairmen and organizers of international technical sessions.The authors of the individual chapters in this book are noteworthy experts from around the world in alumina manufacturing and researchtechnology.
Zusammenfassung
Includes a historical summary outlining future challenges and developments
Provides a wealth of example calculations, rules of thumb, useful illustrations, tables, and formulas
Written by industry experts for a broad audience working in plants, engineering offices, refineries, and smelters
Inhaltsverzeichnis
1. Introduction: Primary Aluminium - Alumina - Bauxite (Benny E. Raahauge)
i. Property Driven Applications
ii. Supply-Demand Balance and Forecast
iii. Cost Drivers and Pricing
iv. Environmental Footprints and Challenges
2. Bauxite Mineralogy, Classification and Beneficiation (Hydro/RTA?)
i. Bauxite Resources
ii. Mineralogy and Chemistry
iii. Classification from Bayer Process Perspective
iv. Beneficiation Options
3. Bayer Process Design and Physical Chemistry (Steve Healy)
i. Bayer Process Design Overview
ii. Liquor Properties - Physio Chemical Data
iii. Lime (CaO) Chemistry
4. Bauxite Processing - Crushing/Grinding, De-silication and Digestion (CSIRO?)
i. Crushing & Grinding
ii. Silica Chemistry, Desilication Kinetics and Reactor Design
iii. Digestion Chemistry, Breakpoint and Kinetics
a. Maximum Extractable Alumina (MEA) and Breakpoint
b. Digestion Models
c. Degradation of Organics
iv. Digestion Conditions, Bauxite Mineralogy and Yield
a. Effect of Lime addition
b. Impact of impurities
v. Applied Digestion Technology and Heat Consumption
a. Autoclaves
b. Tube Digester
c. Double Digestion
vi. Digester Mass and Heat Balances
a. Theoretical Heat of Digestion
b. Boiling Point Elevation
c. Steam Requirements
5. De-sanding - Floculation / Sedimentation - Liquor Filtration (Tim Laros)
i. De-Sanding Equipment
ii. Flocculation and Sedimentation Principles
iii. Mud Rheology, Rake Drives and Mud Pumping
iv. Decantation and Clarification Technology
v. Rise Rate and Tank Design
vi. Pregnant/Green Liquor Filtration Options and Trends
6. Bauxite Residue: Washing - Dewatering (Tim Laros) and Disposal (Paul McGlade)
i. Mud Washing - Recovery of Soda and Alumina
ii. Dewatering Options: Filtration and Centrifuging
a. Filtration Theory and Applications
b. Filtration Pressure and Equipment Options
c. Centrifuge Theory and Applications
iii. Mud Cake Disposal Options and Principle
a. Wet Disposal w/wo Neutralization
b. Dry Stacking w/wo Mud Farming
c. Dry Disposal
7. Hydrate Precipitation (Dennis R. Audet) , Classification and Filtration (Manfred Bach)
i. Hydrate Crystallization Fundamentals
a. Nucleation, Agglomeration, Breakage and Growth
b. Crystallization Mechanism and Kinetics
c. Heat of Crystallization
d. Control of Residual Soda
e. Impact of Organics and other impurities on Yield
ii. Precipitation Flow Sheets and Particle Morphology
a. Retention Time and Temperature Profile impact on Yield
b. Modelling of Precipitation Flow sheet
iii. Precipitator Tank Design Options
a. Agitation and Mixing
b. Hydrodynamic Effects on Yield
iv. Classification Options and Mass Balance Control
a. Hydro Clones
b. Fine Seed Thickener
v. Seed and Product Hydrate Filtration Options
a. Seed Preparation
b. Washing Efficiency and Flow sheets
8. Liquor Purification and Impurity Control (Steve Healy)
i. Organics removal
ii. Removal of Inorganic impurities
a. Iron
b. Phosphor
c. Other...
9. Water Balance, Evaporation, Heat Exchange and Co-Generation (Daniel Thomas)
i. Refinery Water Balance
ii. Bayer Process Heat Balance
a. Heat Transfer
b. Inter-department heat exchange
iii. Evaporation
iv. Co-Generation of Steam and Power
10. Alumina Production by Calcination (Benny E. Raahauge)
i. Calcination Chemistry, Phase Changes and Combustion
a. Chemistry, Degree of Calcination and Stoichiometry
b. Crystalline and X-Ray Amorphous Phases
c. Fuels and Combustion Products - Acid dew Point
ii. Drying and Calcination Theory
a. Gas-Solid Heat Transfer and Drying/Calcination
b. Heat Conduction
c. Alpha Phase Formation and Kinetics
iii. Heat of Calcination
a. Standard Heats of Reaction
b. Calcination Heat in Practice
iv. Calcination Furnace/Reactor Design and Operating Conditions
a. Rotary Kiln
b. Fluid Flash (FF) and Gas Suspension Calciner (GSC)
c. Fluidization and the Circulating Fluid Bed (CFB)
d. Gas Suspension Calciner Reaction Model
v. Gas-Solid Separation in Cyclones
vi. Air Pollution Control and Dust Management
a. Gas Emissions and Carbon Foot Print
b. Particulate Dust Emissions and Management Options
c. Electrostatic Precipitator or Bag House
vii. Refractory Selection and Surface Heat Losses
viii. Calcination Flow Sheet Options
a. Heat Recovery Options
b. Hydrate By-Pass and Alumina Quality
c. Heat Balance and Specific Heat Consumption
d. Specific Power Consumption
ix. Particle Breakdown and Strength During Calcination
a. Particle Breakdown Defined and Observed
b. Attrition Index Defined and Observed
c. Impact from Precipitation and Calcination
11. Alumina Quality, HF Removal, Dissolution and Aluminium Purity (Stephen Lindsay)
i. Chemical Composition of Smelter Grade Alumina
a. Loss of Ignition (LOI) and Degree of Calcination
b. Phase Composition and Alpha Alumina Content
c. Chemical Composition and Gibbsite
ii. Physical Properties of Smelter Grade Alumina
a. Particle Size Distribution, Dustiness and Attrition Index
b. Angle of Repose and Flow ability
c. Bulk Density and Heat Conductivity
d. Specific Surface Area and Pore Size Distribution
iii. Efficient HF Removal and Dry-Scrubber Efficiency (Margaret Hyland)
a. Sources of HF from Smelting
b. Pore Size Distribution and accessible Specific Surface Area
¿ Primary Alumina
¿ Secondary Alumina
c. The Role of Sulfur Dioxide?
iv. Alumina Dissolution and Current Efficiency (Pascal Lavoie)
a. Theoretical Analysis of Dissolution Process
b. Dissolution Rate under Laboratory Conditions
¿ Effect of Particle Size Distribution: Sandy vs Floury
¿ Effect of Phase Composition: Gamma vs Alpha
c. Impact of Calcination Technology
d. Impact of Alumina Feeder Design and Operation
v. Impurities impact on Aluminium Production, Purity and Properties
a. Soda and CaO
b. Silica and Iron
c. Phosphor and Beryllium
d. Vanadium and Sulfur
12. Alumina Storage and Handling Options
13. Health, Safety and Plant Management (Carlos Suarez)
14. Process Control, Simulation and Operator Training (NN?)
15. Process Economics and Plant Design (Peter-Hans Ter Weer)
Details
| Erscheinungsjahr: | 2022 |
|---|---|
| Fachbereich: | Fertigungstechnik |
| Genre: | Mathematik, Medizin, Naturwissenschaften, Technik |
| Rubrik: | Naturwissenschaften & Technik |
| Medium: | Buch |
| Reihe: | Springer Series in Materials Science |
| Inhalt: |
xxiii
844 S. 196 s/w Illustr. 323 farbige Illustr. 844 p. 519 illus. 323 illus. in color. |
| ISBN-13: | 9783030885854 |
| ISBN-10: | 3030885852 |
| Sprache: | Englisch |
| Ausstattung / Beilage: | HC runder Rücken kaschiert |
| Einband: | Gebunden |
| Redaktion: |
Williams, Fred S.
Raahauge, Benny E. |
| Herausgeber: | Benny E Raahauge/Fred S Williams |
| Auflage: | 1st ed. 2022 |
| Hersteller: |
Springer International Publishing
Springer International Publishing AG Springer Series in Materials Science |
| Maße: | 241 x 160 x 52 mm |
| Von/Mit: | Fred S. Williams (u. a.) |
| Erscheinungsdatum: | 24.01.2022 |
| Gewicht: | 1,449 kg |
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