Light Metals 2011

1164 Pages·2016·185.69 MB·English

by  Stephen J. Lindsay B.S. in Chemical Engineering, M.A. in Applied Behavioral Science (eds.)

CbD~OUG
TMS2011
14oth Annual Meeting & Exhibition
Proceedings of the technical sessions presented
by the TMS Aluminum Committee
at the TMS 2011 Annual Meeting & Exhibition,
San Diego, California, USA
February 27-March 3, 2011
Edited by
Stephen J. Lindsay
Editor
Stephen J. Lindsay
ISBN 978-3-319-48567-6 ISBN 978-3-319-48160-9 (eBook)
DOI 10.1007/978-3-319-48160-9
Chemistry and Materials Science: Professional
Copyright© 2016 by The Minerals, Metals, & Materials Society
Published by Springer International Publishers, Switzerland, 2016
Reprint of the original edition published by John Wiley & Sons, Inc., 2011,978-1-11802-935-0
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TABLE OF CONTENTS
Light Metals 2011
Preface ........................................................................................................................................................................xxi
About the Editor .......................................................................................................................................................xxiii
Program Organizers...................................................................................................................................................xxv
Aluminum Committee ..............................................................................................................................................xxxi
Alumina and Bauxite
Organizers......................................................................................................................................................................1
Bauxite Resources and Utilisation
Session Chairs ...............................................................................................................................................................3
New Development Model for Bauxite Deposits ............................................................................................................5
P. ter Weer
Study on the Characterization of Marginal Bauxite from Pará/Brazil .........................................................................13
F. Silva, J. Sampaio, M. Medeiros, and F. Garrido
Resource Utilization of High-sulfur Bauxite of Low-median Grade in Chongqing China..........................................19
J. Yin, W. Xia, and M. Han
Development of Bauxite and Alumina Resources in the Kingdom of Saudi Arabia ...................................................23
A. Al-Dubaisi
Digestion Studies on Central Indian Bauxite...............................................................................................................29
P. Raghavan, N. Kshatriya, and Dasgupta
Effects of Roasting Pretreatment in Intense Magnetic Field on Digestion Performance of Diasporic Bauxite...........33
Z. Ting-an, D. Zhihe, L. Guozhi, L. Yan, D. Juan, W. Xiaoxiao, and L. Yan
Bayer Process I
Session Chairs .............................................................................................................................................................39
Application of Operation Integrity Management in the Alumina Industry..................................................................41
C. Suarez, D. Welshons, J. McNerney, and J. Webb
Influence of Solid Concentration, Particle Size Distribution, Ph And Temperature on Yield Stress
of Bauxite Pulp ............................................................................................................................................................47
C. Barbato, M. Nele, and S. França
A New Method for Removal Organics in the Bayer Process.......................................................................................51
B. Yingwen, L. Jungi, S. Mingliang, and Z. Fei
Alunorte Expansion 3 - The New Lines Added to Reach 6.3 Million Tons per Year .................................................57
D. Khoshneviss, L. Corrêa, J. Ribeiro Alves Filho, H. Berntsen, and R. Carvalho
viii
One Green Field Megaton Grade Large Alumina Refinery with Successful Engineering & Operation Experience...63
L. Xianqing, and Y. Xiaoping
Advanced Process Control in the Evaporation Unit ....................................................................................................69
C. Kumar, U. Giri, R. Pradhan, T. Banerjee, R. Saha, and P. Pattnaik
Improvements in Smelter Grade Alumina Quality at Clarendon Alumina Works ......................................................75
R. Shaw, A. Duncan, and M. Crosdale
Red Mud
Session Chairs .............................................................................................................................................................79
Application of Nanofiltration Technology to Improve Sea Water Neutralization of Bayer Process Residue .............81
K. Taylor, M. Mullett, L. Fergusson, H. Adamson, and J. Wehrli
Caustic and Alumina Recovery from Bayer Residue ..................................................................................................89
S. Gu
Investigation on Alumina Discharge into the Red Mud Pond at Nalco’s Alumina Refinery, Damanjodi,
Orissa, India.................................................................................................................................................................93
B. Mohapatra, B. Mishra, and C. Mishra
Production of Ordinary Portland Cement( OPC) from NALCO Red Mud..................................................................97
C. Mishra, D. Yadav, M. Alli, and P. Sharma
Recovery of Metal Values from Red Mud.................................................................................................................103
P. Raghavan, N. Kshatriya, and K. Wawrynink
Red Mud Flocculants used in the Bayer Process .......................................................................................................107
S. Moffatt, F. Ballentine, and M. Lewellyn
Reductive Smelting of Greek Bauxite Residues for Iron Production ........................................................................113
A. Xenidis, C. Zografidis, I. Kotsis, and D. Boufounos
Precipitation, Calcination and Properties
Session Chairs ...........................................................................................................................................................119
Effect of Technological Parameters on PSD of Aluminum Tri-Hydroxide from Seed Precipitation in Seeded Sodium
Aluminate Solutions ..................................................................................................................................................121
Y. Wu, L. Mingchun, and Q. Yanping
Methods to Reduce Operating Costs in Circulating Fluidized Bed Calcination........................................................125
C. Klett, M. Missalla, B. Reeb, and H. Schmidt
Pressure Calcination Revisited ..................................................................................................................................131
F. Williams, and C. Misra
Dynamic Simulation of Gas Suspension Calciner (GSC) for Alumina .....................................................................137
B. Raahauge, S. Wind, M. Wu, and T. Jensen
Physical Simulation and Numerical Simulation of Mixing Performance in the Seed Precipitation Tank with a
Improved Intermig Impeller ......................................................................................................................................145
Z. Ting-an, L. Yan, W. Shuchan, Z. Hongliang, Z. Chao, Z. Qiuyue, D. Zhihe, and L. Guozhi
ix
Two Perspectives on the Evolution and Future of Alumina ......................................................................................151
L. Perander, J. Metson, and C. Klett
Significant Improvement of Energy Efficiency at Alunorte's Calcination Facility ...................................................157
M. Missalla, H. Schmidt, J. Ribeiro, and R. Wischnewski
Attrition of Alumina in Smelter Handling and Scrubbing Systems...........................................................................163
S. Lindsay
Energy and Environment
Session Chairs ...........................................................................................................................................................169
Perspective on Bayer Process Energy........................................................................................................................171
D. Donaldson
Optimization of Heat Recovery from the Precipitation Circuit .................................................................................175
R. Singh, S. Hial, and M. Simpson
Alunorte Global Energy Efficiency ...........................................................................................................................179
A. Monteiro, R. Wischnewski, C. Azevedo, and E. Moraes
Opportunities for Improved Environmental Control in the Alumina Industry ..........................................................185
R. Mimna, J. Kildea, E. Phillips, W. Carlson, B. Keiser, and J. Meier
Alumina Refinery Wastewater Management: When Zero Discharge Just Isn’t Feasible… ......................................191
L. Martin, and S. Howard
High Purity Alumina Powders Extracted from Aluminum Dross by the Calcining-Leaching Process .....................197
L. Qingsheng, Z. Chunming, F. Hui, and X. Jilai
Effect of Calcium/Aluminium Ratio on MgO Containing Calcium Aluminate Slags...............................................201
W. Bo, S. Hui-Lan, G. Dong, and B. Shi-Wen
Study on Extracting Aluminum Hydroxide from Reduction Slag of Magnesium Smelting by Vacuum
Aluminothermic Reduction .......................................................................................................................................205
W. Yaowu, F. Naixiang, Y. Jing, H. Wenxin, P. Jianping, D. Yuezhong, and W. Zhihui
Application of Thermo-gravimetric Analysis for Estimation of Tri-hydrate Alumina in Central Indian Bauxites-An
Alternative for Classical Techniques.........................................................................................................................211
Y. Ramana, and R. Patnaik
Determination of Oxalate Ion in Bayer Liquor Using Electrochemical Method .......................................................215
S. Turhan, B. Usta, Y. Sahin, and O. Uysal
Alternative Alumina Sources - Poster Session
Session Chairs ...........................................................................................................................................................219
The Effect of Ultrasonic Treatment on Alumina Leaching from Calcium Aluminate Slag ......................................221
S. Hui-lan, W. Bo, G. Dong, Z. Xue-zheng, and B. Shi-wen
Theory and Experiment on Cooling Strategy during Seeded Precipitation ...............................................................227
Z. Liu, W. Chen, and W. Li
x
Extraction of Alumina from Red Mud by Divalent Alkaline Earth Metal Soda Ash Sinter Process.........................231
S. Meher, A. Rout, and B. Padhi
Dissolution Kinetics of Silicon from Sintering Red Mud in Pure Water...................................................................237
X. Li, K. Huang, and H. Zhu
The Effect of Cooling Rate on the Leachability of Calcium Aluminate Slags ..........................................................241
W. Bo, S. Hui-lan, Z. Xue-zheng, and B. Shi-wen
Preparing Polymerized Aluminum-ferrum Chloride with Red Mud .........................................................................245
L. Guilin, Y. Haiyan, and B. Shiwen
Adsorption of Polyethylene Glycol at the Interface of Dicalcium Silicate - Sodium Aluminate Solution ................251
Y. Haiyan, X. Pan, Z. Lu, and T. Ding
Production of Hematite Ore from Red Mud ..............................................................................................................255
P. Raghavan, N. Kshatriya, and K. Wawrynink
Aluminum Reduction Technology
Organizers..................................................................................................................................................................259
Enviroment- Emissions/ Anode Effect I
Session Chairs ...........................................................................................................................................................261
HF Measurements Inside an Aluminium Electrolysis Cell........................................................................................263
K. Osen, T. Aarhaug, A. Solheim, E. Skybakmoen, and C. Sommerseth
LasIRTM-R - The New Generation RoHS-Compliant Gas Analyzers Based on Tunable Diode Lasers ..................269
J. Gagne, J. Pisano, A. Chanda, G. Mackay, K. Mackay, and P. Bouchard
Use of Spent Potlining (SPL) in Ferro Silico Manganese Smelting ..........................................................................275
P. vonKrüger
Reduction of PFC Emissions at Pot Line 70 kA of Companhia Brasileira de Alumínio...........................................281
H. Santos, D. Melo, J. Calixto, J. Santos, and J. Miranda
Towards Redefining the Alumina Specifications Sheet - The Case of HF Emissions...............................................285
L. Perander, M. Stam, M. Hyland, and J. Metson
Design of Experiment to Minimize Fluoride and Particulate Emissions at Alumar ..................................................291
E. Batista, P. Miotto, E. Montoro, and L. Souza
Innovative Distributed Multi-Pollutant Pot Gas Treatment System ..........................................................................295
G. Wedde, O. Bjarno, and A. Sorhuus
Fluoride Emissions Management Guide (FEMG) for Aluminium Smelters .............................................................301
N. Tjahyono, Y. Gao, D. Wong, W. Zhang, and M. Taylor
Bayer Process Chemistry and Alumina Quality I
Session Chairs ...........................................................................................................................................................307
xi
Enviroment- Emissions/ Anode Effect II
On Continuous PFC Emission Unrelated to Anode Effects ......................................................................................309
X. Chen, W. Li, J. Marks, Q. Zhao, J. Yang, S. Qiu, and C. Bayliss
Monitoring Air Fluoride Concentration around ALUAR Smelter in Puerto Madryn
(Chubut Province, Argentina)....................................................................................................................................315
J. Zavatti, C. Moreno, J. Lifschitz, and G. Quiroga
Reduction of Anode Effect Duration in 400kA Prebake Cells ..................................................................................319
W. Zhang, D. Wong, M. Gilbert, Y. Gao, M. Dorreen, M. Taylor, A. Tabereaux, M. Soffer, X. Sun,
C. Hu, X. Liang, H. Qin, J. Mao, and X. Lin
Sustainable Anode Effect Based Perfluorocarbon Emission Reduction....................................................................325
N. Dando, L. Sylvain, J. Fleckenstein, C. Kato, V. Van Son, and L. Coleman
The Initiation, Propagation and Termination of Anode Effects in Hall-Héroult Cells ..............................................329
G. Tarcy, and A. Tabereaux
Towards Eliminating Anode Effects..........................................................................................................................333
A. Al Zarouni, B. Welch, M. Mohamed Al-Jallaf, and A. Kumar
Correlation between Moisture and HF Formation in the Aluminium Process...........................................................339
C. Sommerseth, K. Osen, T. Aarhaug, E. Skybakmoen, A. Solheim, C. Rosenkilde, and A. Ratvik
Particulate Emissions from Electrolysis Cells ...........................................................................................................345
H. Gaertner, A. Ratvik, and T. Aarhaug
Investigation of Solutions to Reduce Fluoride Emissions from Anode Butts and Crust Cover Material ..................351
G. Girault, M. Faure, J. Bertolo, S. Massambi, and G. Bertran
PFC Survey in Some Smelters of China....................................................................................................................357
W. Li, X. Chen, Q. Zhao, S. Qiu, and S. Zhang
Considerations Regarding High Draft Ventilation as an Air Emission Reduction Tool............................................361
S. Broek, N. Dando, S. Lindsay, and A. Moras
Bayer Process Chemistry and Alumina Quality I
Session Chairs ...........................................................................................................................................................367
Cells Thermal Balance
Increasing the Power Modulation Window of Aluminium Smelter Pots with Shell Heat Exchanger Technology...369
P. Lavoie, S. Namboothiri, M. Dorreen, J. Chen, D. Zeigler, and M. Taylor
New Approaches to Power Modulation at TRIMET Hamburg .................................................................................375
T. Reek
Some Aspects of Heat Transfer Between Bath and Sideledge in Aluminium Reduction Cells.................................381
A. Solheim
Towards a Design Tool for Self-heated Cells Producing Liquid Metal by Electrolysis ............................................387
S. Poizeau, and D. Sadoway
ix
Heat Recovery from Aluminium Reduction Cells.....................................................................................................393
Y. Ladam, A. Solheim, M. Segatz, and O. Lorentsen
Effects of Composition and Granulometry on Thermal Conductivity of Anode Cover Materials ............................399
H. Wijayaratne, M. Hyland, M. Taylor, A. Grama, and T. Groutso
Restart of 300kA Potlines after 5 Hours Power Failure.............................................................................................405
X. Zhao, B. Gao, H. Han, J. Liu, J. Xiao, J. Qian, J. Yan, and D. Wang
Multiblock Monitoring of Aluminum Reduction Cells Performance ........................................................................407
J. Tessier, C. Duchesne, and G. Tarcy
Bayer Process Chemistry and Alumina Quality I
Session Chairs ...........................................................................................................................................................413
Cells Technology, Development and Sustainability
High Amperage Operation of AP18 pots at Karmøy.................................................................................................415
M. Bugge, H. Haakonsen, O. Kobbeltvedt, and K. Paulsen
Aluminium Smelter Manufacturing Simulation - Can These Bring Real Cost Savings? ..........................................421
M. Meijer
Simultaneous Preheating and Fast Restart of 50 Aluminium Reduction Cells in an Idled Potline - A New Soft Re-
start Technique for a Pot Line ...................................................................................................................................425
A. Mulder, A. Folkers, M. Stam, and M. Taylor
SWOT Perspectives of Midage Prebaked Aluminium Smelter .................................................................................431
P. Choudhury, and A. Sharma
Integrated Approach for Safe and Efficient Plant Layout Development ...................................................................437
R. Pires, R. Baxter, L. Tikasz, and R. McCulloch
New Progress on Application of NEUI400kA Family High Energy Efficiency Aluminum Reduction Pot ("HEEP")
Technology ................................................................................................................................................................443
D. Lu, J. Qin, Z. Ai, and Y. Ban
Improving Current Efficiency of Aged Reduction Lines at Aluminium Bahrain (Alba)...........................................449
A. Ahmed, K. Raghavendra, H. Hassan, and K. Ghuloom
Development of NEUI500kA Family High Energy Efficiency Aluminum Reduction Pot ("HEEP") Technology ..455
D. Lu, Y. Ban, X. Qi, J. Mao, Q. Yang, and H. Dong
Cells Process Control
Current Efficiency for Aluminium Deposition from Molten Cryolite-alumina Electrolytes in a Laboratory Cell....461
G. Haarberg, J. Armoo, H. Gudbrandsen, E. Skybakmoen, A. Solheim, and T. Jentoftsen
x