Major steps to avoid risk and losses in Alumina refinery

Hi Friends,

Alumina refinery is a combination of hydro-metallurgical and pyro-metallurgical processes involving variety of unit operations and unit processes. Process problems in Alumina refinery are unique in nature and isolated solution may have series of consequences in the down stream process areas. Thus each and every tiny process problem noticed during operation should be handled carefully. The remedial action must be based on detailed technical analysis of problem and its probable effect on subsequent process stages.

We have experienced a number of complicated process problems in smooth functioning of various  Alumina refineries in India and abroad. All out efforts are made for steady state operational conditions of plant so as to maximize the efficiency without compromising on throughput rate and quality of product. The diagnosis of complicated process problems in Alumina refinery is really very difficult  which is required to arrive at most appropriate solution without any time lag. Here, I would like to pin point three major steps for efficient, trouble-free and safe operation of Alumina refinery.

1. Regular checking of instruments and controls: As most of our process control decisions are  based on the data recorded through installed instrumentation and control system, hence health of instruments and control system play vital role. Thus, regular preventive maintenance and their calibration of all online and offline instruments is a must for checking and rectifying the accuracy level, otherwise any fowl output data may cause serious process problem affecting the plant operation for longer duration. 
2. Step-wise changes in control parameters: The second key issue to avoid complicated operational and process problems is step by step changes in process control and operating parameters of the plant. Under no circumstance, drastic changes in any process parameter to be done in one go in order to avoid sudden variation in parameters of other process areas. It is prudent to remember that plant efficiency, product quality and human safety are more important than notional increase in production for short duration. The standard deviation of all key parameters should be minimum tending to zero. It is always better to have safe and steady rather than furious steps in plant operation.
3. Periodic checks on emergency power supply system: Alumina production is the  continuous process requiring no interruption in plant operation. Sudden power supply failure without back up power may cause serious impact on process, operation and health of critical process equipment because of sudden settling of solids in vessels and pipelines. Thus, as a back up support to normal power supply system, auto-start DG sets are generally kept as emergency source for power supply to critical equipment to take care of exigencies, if any. Since, the DG set is operated only in emergency during black outs thus it becomes essential to keep this equipment along with associated facilities in tip top condition by its periodic checking and maintenance as forced shutdown and frequent start up of Alumina refinery involve huge risk and losses.

Negligence on these three important issues are counted as very serious matters as they create complex situation in plant operation as well as damage to critical equipment. Thus, these precautions and preventive majors are considered crucial for normal and steady operation of Alumina refineries.


Request to put your views / suggestions / remarks / comments, if any.


If you like this article and find it useful, then please press your rating as  +1  .


Kunwar Rajendra