ote alumina and aluminium technologies eng web
TRANSCRIPT
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 1/12
Alumina and aluminium
technologies
Outotec's aluminium expertise is a powerful combinationof innovative proven technologies. Cooperation and havinga team approach enable us to provide you with the bes tpossible service and vast exper tise in alumina refining,paste plant and rodding shop as well as casthousemachinery – tailored to meet your specific needs.
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 2/12
Hydrate wash & ltration
Bauxite
Steam
Alumina
Ro
Heatexchange
Heatexchange
Grinding
Calcination
Clarication
Tube digestion
Liquor ltration
Fume treatment plant
SPL treatment plant
Red mud storage
Residue washing
Boiler
Evaporation
Precipitation
002 Alumina and aluminium technologies
Experience in aluminium processing and production
A global leader in the development of mineralsprocessing and metallurgical technologies, Outotechas a distinguished history of achievement going backmore than a hundred years. Outotec has a long traditionof developing metallurgical processes, which areenvironmentally sustainable. The company's aluminiumexpertise is based on former Lurgi Metallurgie, KHDand AISCO technologies, now united under the commonOutotec brand.
In the global aluminium industry, Outotec providestotal business solutions for processing andproduction of alumina and aluminium. Outotec offers
you proven exper tise in alumina refining, paste plant,rodshop, and casthouse machinery. Today, Outotec'scirculating fluidized bed (CFB) technology for thecalcination of alumina is the industry standard.
One partner for the plant 's life cycle
Early choice of a single technology partner, who canmanage production processes and design throughoutthe entire operation, saves time and money.Without bottlenecks, plant operation is smooth,and profits accrue quickly. Outotec is committed tocontinuously developing processes and equipmentfor customers' production plants. Outotec helps youenhance your production process – and will take care ofthe whole delivery.
As your partner, Outotec offers comprehensiveengineering and project implementation services aswell as customer support through its worldwide
network of service centers. Outotec's qualified andexperienced field personnel ensures trouble-freecommissioning. Every plant is unique and thereforeprocesses modified to meet specific requirements.
Proven technologies for the aluminiumindustry
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 3/12
Billet Slab Ingot Sow
Bath treatment
Casthouse
Rodding shop
Butt crushing plant
Anode baking plant
Green anode plant
Aluminum smelting
Alumina renery
Electrolysis/Potline(s)
Fume treatment plant
Load/unload I Bath removal
ALUMINIUM
Coal tar pitch Calcined coke
Alumina and aluminium technologies 003
Outotec's long-term commitment and extendedcustomer service minimize operating risks throughoutthe life cycle of the plant. Cooperation can begin witha feasibility study leading to a lump-sum turnkey plantdelivery and, ultimately, to a long-term par tnership.
Comprehensive aluminium technologies
Outotec's solutions for the aluminium industry coverproven technologies. Furthermore, we offer professionalengineering and project management services basedon extensive R&D resources as well as comprehensivetechnological and business knowledge of metals
production. Our global sales and after-sales network isalways close at hand when expertise is needed.
Proven technologies for
the aluminium industry Alumina refinery
Aluminium smelter green anode plant
Aluminium smelter rodding shop
Casthouse
Services and after sales
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 4/12
004 Alumina and aluminium technologies
Alumina calcinationCalcination is the final stage of the Bayer process, in
which bauxite is digested with caustic soda to firstextract and then precipitate a pure aluminium hydroxide(hydrate). The hydrate from the Bayer process is thencalcined to alumina in a CFB. This step was earliercarr ied out in rotary kilns, but today all new capa-city isinstalled as fluidized bed calciners.
CFB calcination process
The circulating fluidized bed calciners use a multi-stageventuri preheating system to recover the waste gas
heat by preheating and de-watering the hydrate. Finalcalcination to alumina (Al 2O3) is accomplished in theCFB reactor in which the energy is provided by directcombustion of fuel (oil or gas). The energy of the hotalumina is recovered to the incoming air in a multistagecooling system including cyclones and a fluidized bedalumina cooler.
Some energy of the hot alumina is also used for directcalcination of incoming hydrate in a so-called ”hydrateby-pass”. This efficient heat recovery system leads toan overall fuel energy consumption of less than 3 GJ/tof alumina for the calcination process. CFB calcinersoperate in a range from 900 to 1,000°C depending onproduct quality demands.
Alumina calcination in the CFB.
Hydrate
Fuel
Secondary air
Primary air
Cooling water
Preheating stage I
Preheating stage II
CFBreactor
Calcining stage
Cooling stage I Cooling stage II
Cooling water
Alumina
Fluidized bed cooler
Hydratebypass
Electrostaticprecipitator
Waste gas
Advantages of CFB plants
Low specific energy consumption – low
temperature profile
Low maintenance cost
High availability
Wide range of part load operation
Uniform product quality – no off-
specification product
Easy and reproducible change of product
quality Extremely stable and easy operation of
the plant without need of sophisticated
control equipment
Low NOx emission
Due to the homogeneous temperature in the CFB reactor,
product qualities regarding specific surface area, losson ignition and alpha content in the alumina can fulfillthe demands of today's aluminium smelters. We haveinstalled more than fifty CFB calciner units worldwide.This represents approximately one third of the world'sproduction of smelter grade alumina.
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 5/12
Alumina and aluminium technologies 005
Solutions taylored to your needs
Prior to the application of fluidized bed technology,alumina was traditionally calcined in a rotary kiln.While this equipment has the major disadvantage ofhigh energy consumption, it has one advantage: it isvery gentle on the product and thus minimizes finesgeneration.
You, our customer, want the advantage of low energyconsumption that is brought by fluidized bed technology.We also recognise that you want low fines in product .
Outotec set itself the challenge to achieve both of thesetargets in a single plant. By combining the inherentadvantages of CFB technology with knowledge gainedfrom our extensive R&D in the field of solids fluidizationand heat transfer, Outotec has, in its latest design,achieved a new benchmark in product quality, allowingyou to operate your refinery more flexibly and moreefficiently.
PAM deliveries – design and construction of largestpossible modules off-site
Outotec’s preassembled module (PAM) technologyreduces capital cost. PAM enables plant constructioneven in remote areas with undeveloped infrastructureor lack of skilled workforce. Opting for PAM minimizeson-site construction (structural, mechanical, piping,refractory lining, instrumentation, electrical) andensures continuation of production at site with minimizedinterruption during the installation process.
The rst PAM delivery of two large calciners took place in 2006 to the
Northern Territory in Australia. The calcining units were preassembledin South East Asia and transported by ship to Rio Tinto Alcan Gove.
“Our goal is to produce the highest quality alumina in the world. In order to reach that weneeded two things: the best available technology and the most qualied professionals. Outotecprovided us with both. Their technology is reliable and easy to work with. The same is true oftheir people.” Victor César Ribeiro da Cruz, Alunorte, Brazil.
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 6/12
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 7/12
Alumina and aluminium technologies 007
Liquid pitch facility for bulk s torage of liquid pitch
Special articulated ship unloading arms Liquid pitch storage tanks
Special road tanker loading facilities with fumereturn line
Totally sealed pitch pumps Nitrogen blanketing system for storage tanks Dedicated HTM–systems
Preheating screw used for continuous heating of
coarse or fine–grained anode dry aggregate Intermeshing of helical ights of hollow screws Adjustable speed of screws by frequency conver ter
Gentle product conveyance at low speed, withnegligible wear on screws
The vibrocompactor meets the growing demand forgreen anode quality for modern aluminium smelters
Sliding table and turntable typeCombination of two or more sliding table vibratingcompactorsVacuum technology
Inatable rubber bellows for vibrating tablesupport and prestressing of cover weight Online density control system Densitrol ® for
consistent anode quality
Hydraulic anode crusher and butt crushing plants tobreak any size of green or baked reject anode b locksor carbon butts
Capacity approximately 80–100 butts/ h Capability to crush full size anodes up to
1700x1200x650 mm
Pressure type crushing avoids huge amount ofne particles Low head room Heavy duty design, easy to operate and maintain
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 8/12
008 Alumina and aluminium technologies
Total roddingshop solutions
As your partner we offer
Basic and detail engineering for complete plant Proprietary and key equipment supply Site supervision, commissioning and start–up services Turnkey plant deliver ies Plant retrots and machine upgrades
Load/unload system for multiplerod styles
Fully automatic – no operatorrequired
Used with pallet transpor teror trailersCentering devices for aligningwith P&F bells
Use with bath conveyor in pit orcompletely above oor level
95° pallet dump completelycleans pallet directly into bathconveyor
Primary bath cleaning for both in-line and spider configurations
Suitable for hot or cold bath Hydraulic prebreak station Secondary cleaning with
hydraulic pushers or ailcleaning
Final air blow-off Fallen carbon conveyor
Butt shotblast machine designedspecifically for the aluminiumindustry tak ing into account theunique challenge of cleaning bathresidue from carbon butts
360° rotation during cleaningcycleBlow off ensures no carry outof shot
Steel cabinet with rubber soundinsulation and manganese wearlining
Use of multiple chambers for upto 90 butts/hr
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 9/12
Alumina and aluminium technologies 009
Semi-automatic pouring systemcustomized to meet existing furnaceand rodshop layout and productivityrequirements
Various ladle congurations Can be relled with ladle in
casting car or removed Operator control room to
oversee complete pouring system Single or double casting car
system for redundancy
Thimble cleaning drum for cleaningof cast iron
Manual and fully automatedsystem
Capacity from 100 kg to7,000 kg/hour
Built in dust take off points Storage silos, hoppers and
feeders also available
Mating station for aligning rodsand carbon anodes
clamps and guides ensureperpendicularity
Rod remains attached to P&Fcarrier
High productivity Simple walking beam or pusher
design depending on productionrates
Butt stripping press for the removal of spent carbon. Up to 425 mt force for removing up to full size double anodes Bottom up or push down styles available Bottom up press will break carbon into several smaller pieces Production up to 80 rods per hour
Single combination press to strip both carbon and thimbles
at same time
Thimble stripping press designedto break the thimbles away fromthe stubs
Strip one thimble at a time orup to four at once
Ideal for both in–line and spider
rod conguration
Rod reconditioning after removalof bath, carbon and thimbles
Rod brushing for removal ofmarks, chalk lines andscratches
Graphite coating and s tub
drying Stub straightening Rod straightening Stub cut off and welding
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 10/12
010 Alumina and aluminium technologies
Casthouse technologiesJumbo sow caster with capacity up to 35 tph
Water or air primary cooling Fully automated, single operator Pouring from single or dual crucibles Robotic skimming, vacuum demoulding Weighing, marking and stacking
Rolling slab and T–bar sawline designed tomeet your specific needs
Fully automatic material handling Variable cut length Weighing, marking and stacking Choice of saw types and brands Chip collection and briquetting
Foundry ingot casting systems Complete supply from furnace tap hole to nal
strapped bundle
Automatic pouring to 95% bundle weight accuracy Weighing, marking and bundle strapping Building and loading of superstacks available
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 11/12
Alumina and aluminium technologies 011
R&D and after sales services
With a growing list of worldwide references, Outotec iscontinuing its dominance in the supply of technology andsolutions of the aluminium industry.
Outotec's extended customer service operates througha global network of service centers that offers not onlyassistance to the customer 's needs but al so commitmentto provide advanced customer support whenever needed.
With offices on every continent, Outotec has an a
unparalleled line-up of professionals who are highlyexperienced and understand exactly what it takes tooptimize customers' plants and processes. They havedeveloped, constructed, commissioned and servicedmany of Outotec's technologies around the globe. Coreexperience is, therefore, built onleading-edge technologies, is"hands-on" and focused onensuring a customer's plantis optimized.
Outotec's extensive after salesservices cover
Site services Equipment and plant diagnostic
and audits Process optimization Upgrades and modernizations Spare parts Training and users' meetings
700 mm Circofer ® demonstration plant, R&D Center, Germany.
Outotec's largest CFB based test facility is the Circofer® demonstrationplant at the R&D Center in Frankfurt. This plant is equipped with a700 mm diameter CFB, recycle cyclone, integrated heat generator, charseparator, magnetic separator, gas cleaning system, and all necessaryancillary equipment.
Innovation through research
To maintain its position at the forefront of innovation,Outotec has two in-house research centers,in Finland and in Germany, with a broad rangeof laboratories, bench-scale and pilot plants.
These R&D centers are engagedin development of existing and new technologies, processresearch and measurement and analyses services. CFBtest facilities are available at the R&D center in Frankfurt,Germany, for technology development and for testing of
customer’s aluminium hydrate.
8/12/2019 OTE Alumina and Aluminium Technologies Eng Web
http://slidepdf.com/reader/full/ote-alumina-and-aluminium-technologies-eng-web 12/12
[email protected] © 2011 Outotec Oyj. All rights reserved.
F i n l a
n d
, J
u n e
2 0 1 1
.
Outotec develops and provides technology solutions for the sustainable use of Earth’s natural
resources. As the global leader in minerals and metals processing technology, Outotec has developed
over decades several breakthrough technologies. The company also offers innovative solutions for
the chemical industry, industrial water treatment and the utilization of alternative energy sources.
Outotec shares are listed on the NASDAQ OMX Helsinki.