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Alumina and Aluminium Technologies Alumina and aluminium technologies Outotec's aluminium expertise is a powerful combination of innovative proven technologies. Cooperation and having a team approach enable us to provide you with the best possible service and vast expertise in alumina refining, paste plant and rodding shop as well as casthouse machinery – tailored to meet your specific needs. 002 Alumina and aluminium technologies Proven technologies for the aluminium Alumina refinery Aluminum smelting Steam Grinding Boiler industry Bauxite Tube digestion Clarification Residue washing Evaporation Liquor filtration Red mud storage Coal tar pitch Calcined coke Heat Precipitation Heat exchange exchange Hydrate wash & filtration Alumina Calcination Green anode plant Fume treatment plant Anode baking plant Bath treatment Fume treatment plant Electrolysis/Potline(s) Load/unload I Bath removal Butt crushing plant SPL treatment plant ALUMINIUM Rodding shop Casthouse Rod Billet Slab Ingot Sow Experience in aluminium processing and production One partner for the plant's life cycle A global leader in the development of minerals Early choice of a single technology partner, who can processing and metallurgical technologies, Outotec manage production processes and design throughout has a distinguished history of achievement going back the entire operation, saves time and money. more than a hundred years. Outotec has a long tradition Without bottlenecks, plant operation is smooth, of developing metallurgical processes, which are and profits accrue quickly. Outotec is committed to environmentally sustainable. The company's aluminium continuously developing processes and equipment expertise is based on former Lurgi Metallurgie, KHD for customers' production plants. Outotec helps you and AISCO technologies, now united under the common enhance your production process – and will take care of Outotec brand. the whole delivery. In the global aluminium industry, Outotec provides As your partner, Outotec offers comprehensive total business solutions for processing and engineering and project implementation services as production of alumina and aluminium. Outotec offers well as customer support through its worldwide you proven expertise in alumina refining, paste plant, network of service centers. Outotec's qualified and rodshop, and casthouse machinery. Today, Outotec's experienced field personnel ensures trouble-free circulating fluidized bed (CFB) technology for the commissioning. Every plant is unique and therefore calcination of alumina is the industry standard. processes modified to meet specific requirements. Alumina and aluminium technologies 003 Alumina refinery Aluminum smelting Steam Grinding Boiler Bauxite Tube digestion Clarification Residue washing Evaporation Liquor filtration Red mud storage Coal tar pitch Calcined coke Heat Precipitation Heat exchange exchange Hydrate wash & filtration Alumina Calcination Green anode plant Fume treatment plant Anode baking plant Bath treatment Fume treatment plant Electrolysis/Potline(s) Load/unload I Bath removal Butt crushing plant SPL treatment plant ALUMINIUM Rodding shop Casthouse Rod Billet Slab Ingot Sow Outotec's long-term commitment and extended customer service minimize operating risks throughout Proven technologies for the life cycle of the plant. Cooperation can begin with the aluminium industry a feasibility study leading to a lump-sum turnkey plant Alumina refinery delivery and, ultimately, to a long-term partnership. Aluminium smelter green anode plant Comprehensive aluminium technologies Aluminium smelter rodding shop Casthouse Outotec's solutions for the aluminium industry cover Services and after sales proven technologies. Furthermore, we offer professional engineering and project management services based on extensive R&D resources as well as comprehensive technological and business knowledge of metals production. Our global sales and after-sales network is always close at hand when expertise is needed. 004 Alumina and aluminium technologies Alumina calcination Calcination is the final stage of the Bayer process, in Due to the homogeneous temperature in the CFB reactor, which bauxite is digested with caustic soda to first product qualities regarding specific surface area, loss extract and then precipitate a pure aluminium hydroxide on ignition and alpha content in the alumina can fulfill (hydrate). The hydrate from the Bayer process is then the demands of today's aluminium smelters. We have calcined to alumina in a CFB. This step was earlier installed more than fifty CFB calciner units worldwide. carried out in rotary kilns, but today all new capa-city is This represents approximately one third of the world's installed as fluidized bed calciners. production of smelter grade alumina. CFB calcination process The circulating fluidized bed calciners use a multi-stage venturi preheating system to recover the waste gas Advantages of CFB plants heat by preheating and de-watering the hydrate. Final Low specific energy consumption – low calcination to alumina (Al2O3) is accomplished in the CFB reactor in which the energy is provided by direct temperature profile combustion of fuel (oil or gas). The energy of the hot Low maintenance cost alumina is recovered to the incoming air in a multistage High availability cooling system including cyclones and a fluidized bed Wide range of part load operation alumina cooler. Uniform product quality – no off- Some energy of the hot alumina is also used for direct specification product calcination of incoming hydrate in a so-called ”hydrate Easy and reproducible change of product by-pass”. This efficient heat recovery system leads to quality an overall fuel energy consumption of less than 3 GJ/t Extremely stable and easy operation of of alumina for the calcination process. CFB calciners operate in a range from 900 to 1,000°C depending on the plant without need of sophisticated product quality demands. control equipment Low NOx emission Preheating stage I Electrostatic precipitator Waste gas Preheating stage II Hydrate Cooling stage I Cooling stage II CFB reactor Hydrate Cooling water bypass Alumina Calcining stage Fuel Fluidized bed cooler Secondary air Primary air Cooling water Alumina calcination in the CFB. Alumina and aluminium technologies 005 “Our goal is to produce the highest quality alumina in the world. In order to reach that we needed two things: the best available technology and the most qualified professionals. Outotec provided us with both. Their technology is reliable and easy to work with. The same is true of their people.” Victor César Ribeiro da Cruz, Alunorte, Brazil. Solutions taylored to your needs PAM deliveries – design and construction of largest possible modules off-site Prior to the application of fluidized bed technology, alumina was traditionally calcined in a rotary kiln. Outotec’s preassembled module (PAM) technology While this equipment has the major disadvantage of reduces capital cost. PAM enables plant construction high energy consumption, it has one advantage: it is even in remote areas with undeveloped infrastructure very gentle on the product and thus minimizes fines or lack of skilled workforce. Opting for PAM minimizes generation. on-site construction (structural, mechanical, piping, refractory lining, instrumentation, electrical) and You, our customer, want the advantage of low energy ensures continuation of production at site with minimized consumption that is brought by fluidized bed technology. interruption during the installation process. We also recognise that you want low fines in product. Outotec set itself the challenge to achieve both of these targets in a single plant. By combining the inherent advantages of CFB technology with knowledge gained from our extensive R&D in the field of solids fluidization and heat transfer, Outotec has, in its latest design, achieved a new benchmark in product quality, allowing you to operate your refinery more flexibly and more efficiently. The first PAM delivery of two large calciners took place in 2006 to the Northern Territory in Australia. The calcining units were preassembled in South East Asia and transported by ship to Rio Tinto Alcan Gove. 006 Alumina and aluminium technologies Green anode plant Outotec offers the full scope of technologies and processes for green anode manufacturing, for building new plants or upgrading existing plants. The services cover Basic and detail engineering for complete plant Proprietary and key equipment supply Site supervision, commissioning and start–up services Turnkey plant deliveries, and Plant retrofits and machine upgrades With many years of experience, Outotec is flexible to design green anode plants to the customer’s flow sheet or recommend its own process technology. In any case most up–to–date HES standards will be applied. Alumina and aluminium technologies 007 Liquid pitch facility for bulk storage of liquid pitch Preheating screw used for continuous heating of Special articulated ship unloading arms coarse or fine–grained anode dry aggregate Liquid pitch storage tanks Intermeshing of helical flights of hollow screws Special road tanker loading facilities with fume Adjustable speed of screws by frequency converter return line Gentle product conveyance at low speed, with Totally sealed pitch pumps negligible wear on screws Nitrogen blanketing system for storage tanks Dedicated HTM–systems The vibrocompactor meets the growing demand for Hydraulic anode crusher and butt crushing plants to green anode quality for modern aluminium smelters
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