Severe Damage in Steam Line of High Pressure Digestion Unit

Hi Friends,

In present, we will present a few photographs to assess the severity of damage in bypass line of high pressure steam line in high pressure digestion unit of an operative Alumina refinery adopting  Double digestion technology for processing of gibbsite-boehmite mixed bauxite. It may not be proper to mention the name of technology supplier, detailed engineering consultant, erector and plant owner as fault finding is not our objective. These photos have been presented to take a lesson as precautionary measures to prevent such incidents in future.  This incident occurred in a newly constructed Alumina refinery within a year of commissioning. It was a sudden burst and you can have the feel of severity of damage by observing the following photographs. I am thankful to my friends who have shared these photographs with us, specifically for the benefits of professionals who are involved in planning and execution stage of Alumina refinery in any part of the globe.

The reasons for damage of  bypass line in high pressure steam line are still a matter of investigation. The possible reasons may be one of the following-

• Material defects,
• Design defects,
• Welding defects,
• Stress corrosion,
• Combination of two or more of above.

The exact reason will be known as outcome of investigations in progress. Thanks to almighty God for safeguarding the operating personnel  as no body was present in the vicinity of indicated steam bypass line area at the time of incident. Thus it's a word of caution for all concerned to take all possible measures to avoid such incidents in future.

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Thanks and regards.

Kunwar Rajendra