Hi Friends,
Given below please find the detailed Content Sheet of our recently published book on Alumina Technology. The content of the book has been appreciated by global Bauxite-Alumina-Aluminium fraternity.
In case, you wish to have any clarification / confirmation on any issue, it would be our pleasure to furnish thew same.
Best regards.
Rajendra Kunwar
Principal Consultant-Engineering
CETI Enterprises, India.
www.ceti.co.in
Given below please find the detailed Content Sheet of our recently published book on Alumina Technology. The content of the book has been appreciated by global Bauxite-Alumina-Aluminium fraternity.
In case, you wish to have any clarification / confirmation on any issue, it would be our pleasure to furnish thew same.
Best regards.
Rajendra Kunwar
Principal Consultant-Engineering
CETI Enterprises, India.
www.ceti.co.in
CONTENTS
1.
Introduction
1.1.
Overview
1.2.
Emerging
Challenges
1.2.1.
Efficient
Process Technology
1.2.2.
Rugged
Design of Residue Sorage
1.2.3.
Compact
Design of Equipment
1.2.4.
Optimized
Plant Layout
1.2.5.
Zero
Effluent Discharge
1.2.6.
Planning
for Development of Green Belt
1.2.7.
Optimized
Capex and Opex
1.3.
Key Objectives
1.4.
Acknowledgements
2.
Raw Materials
2.1.
Bauxite
2.1.1.
Specific
Consumption
2.1.2.
Typical
Specifications
2.1.3.
Quality
Control Method
2.1.4.
Bauxite
Reserves in the World
2.1.5.
Bauxite
Reserves in India
2.1.6.
Brief
About Gibbsitic Bauxite and Laterite
2.1.7.
Beneficiation
of Bauxite
2.2.
Caustic
Soda
2.2.1.
Specific
Consumption
2.2.2.
Typical
Specifications
2.2.3.
Quality
Control Method
2.3.
Burnt
Lime
2.3.1.
Specific
Consumption
2.3.2.
Typical
Specifications
2.3.3.
Quality
Control Method
2.4.
Fuel
Oil
2.4.1.
Specific
Consumption
2.4.2.
Typical
Specifications
2.4.3.
Quality
Control Method
2.5.
Coal
2.5.1.
Specific
Consumption
2.5.2.
Typical
Specifications
2.5.3.
Quality
Control Method
2.6.
Flocculent
2.6.1.
Specific
Consumption
2.6.2.
Typical
Specifications
2.6.3.
Quality
Control Method
2.7.
Synthetic
Filter Cloth
2.7.1.
Specific
Consumption
2.7.2.
Typical
Specifications
2.7.3.
Quality
Control Method
3.
Process technology
3.1.
Alumina
technology overview
3.2.
Process
technology considerations
3.3.
Quality
of Alumina
3.3.1.
Specifications
of Metallurgical grade alumina
3.3.2.
Applications
of Smelter grade alumina
3.4.
Technological
options for design of Alumina refinery
3.4.1.
Bauxite
crushing
3.4.2.
Bauxite
grinding
3.4.3.
Desilication,
digestion and slurry flashing
3.4.4.
Residue
thickening, washing and disposal
3.4.5.
Heat
interchange system
3.4.6.
Precipitation
and hydrate classification
3.4.7.
Calcination
System
3.5
Recommended
process route
3.6
Technological & Design features of units
3.6.1
Basic
considerations for design of bauxite crushers
3.6.2
Principles
of Desilication process
3.6.3
Significance
of sodalite factor
3.6.4
Impact
of dissolved silica in pregnant liquor on product quality
3.6.5
Desilication
methods
3.6.6
Design
of efficient digestion system
3.6.7
Techniques
of liquor decantation and residue washing
3.6.8
TCA as
filter aid for polishing filtration
3.6.9
Heat
interchange system
3.6.10
Principles
of hydrate precipitation
3.6.11
Techniques
of hydrate classification
3.6.12
Multiple
effect evaporation system
3.6.13
Hydrate
washing and filtration
3.6.14
Energy
efficient calcination system
3.7
Technology
and Equipment Oriented Unit Areas
3.8
Major
process control parameters
4.
Plant Design Criteria
4.1
Basic design
guidelines for green-field Alumina refinery
4.1.1
Reserves
and quality of Bauxite
4.1.2
Fixation
of plant capacity
4.1.3
Product-mix
and product specifications
4.1.4
Finalisation
of production process route
4.1.5
Sizing
of plant and equipment
4.1.6
Safety
and pollution control measures
4.2
Design
criteria for Residue storage pond
4.2.1
Location
of residue storage pond
4.2.2
Natural
topography
4.2.3
Characteristics
of soil
4.2.4
Volumetric
capacity
4.2.5
Rain
water drainage
4.2.6
Geo-textile
lining
4.2.7
Adequate
free board
4.2.8
Proper
fencing of area
4.3
Plant availability,
design margin and turn down ratio
4.3.1
Overall
availability of plant
4.3.2
Design
margin
4.3.3
Turndown
ratio
4.4
Major
efficiency parameters
4.4.1
Overall
alumina recovery
4.4.2
Total
soda loss
4.4.3
Liquor
productivity
4.4.4
Fuel
for calcination
4.4.5
Total
process steam
4.5
Basic
terminology used in Alumina refinery
4.5.1
Solid
concentration in slurry
4.5.2
Liquor
concentration
4.5.3
Plant
causticity
4.5.4
Alumina
to caustic ratio
4.6
Plant
operating schedule
4.7
Critical
technical data
5.
Design of Equipment
& Facilities
5.1.
Design of critical
equipment
5.1.1
Sizing of liquor
decanters
5.1.2
Sizing of
residue washers
5.1.3
Sizing of
security filters
5.1.4
Design of
rotary vacuum drum filters
5.1.5
Design of
rotary vacuum disc filters
5.1.6
Design of
horizontal rotary vacuum filters
5.1.7
Design of
multiple effect evaporators
5.2.
Design of Tailor-made
Equipment
5.2.1
Design of
Bauxite grinding mills
5.2.2
Design of
Bauxite slurry heat exchangers
5.2.3
Design of
Desilication tanks
5.2.4
Design of
Digestion vessels
5.2.5
Design of
Slurry flash tanks
5.2.6
Design of
Condensate flash tanks
5.2.7
Design of
Vacuum flash tanks
5.2.8
Design of
Liquor storage tanks
5.2.9
Design of
Primary hydrate settlers
5.2.10
Design of
Slurry mixing agitators
5.2.11
Design of
Plate heat exchangers
5.2.12
Motor rating
calculations for Centrifugal pumps
5.2.13
Motor rating
calculations for Air blower
5.2.14
Guidelines
for design of Vacuum pumps for Evaporators
5.2.15
Design
guidelines for belt conveyors
5.3.
Equipment
sparing basis
5.4.
Design
Guidelines for sizing of Pipelines
5.4.1
Design Guidelines
for sizing of pipelines
5.4.2
Material of
construction for pipes
5.4.3
Guidelines
for colour coding of pipelines
5.5.
Design Guidelines
for pipe racks
5.6.
Guidelines
for selection of valves
5.7.
Guidelines
for thermal insultation
5.8.
Methodology for estimation of paint requirement
6.
Design of Utilities and
Services
6.1.
Design guidelines
for Co-generation plant
6.1.1
Design basis
for Co-generation plant
6.1.2
Condensate
returns to Boilers
6.1.3
Electrical
power requirement
6.1.4
Design basis
for Co-generation plant
6.1.5
Guidelines
for Stack height calculations of boilers
6.2.
Design of Raw
Water Supply System
6.2.1.
Quality
Specifications of Industrial Water
6.2.2.
Estimated
Water Requirement
6.2.3.
Quality
specifications of Drinking water
6.2.4.
System Design
Calculations for Water supply system
6.3.
Design
Guidelines for Cooling Towers
6.4.
Design
Guidelines for Firefighting System
6.5.
Design
Guidelines for Power Receiving & Distribution System
6.5.1.
Power Control
Center
6.5.2.
Motor Control
Center
6.5.3.
Diesel
Generating Set
6.5.4.
Guidelines
for Selection of Starters and Motors
6.6.
Design
Guidelines for Instrumentation and Control System
6.6.1.
Bauxite
Crushing, Grinding and Desilication Area
6.6.2.
Digestion,
Heat recovery & Sand Washing Area
6.6.3.
Liquor
Decantation and Residue Washing Area
6.6.4.
Security
Filtration and Precipitation Area
6.6.5.
Evaporation
and Liquor Preparation Area
6.6.6.
Product
Classification, Washing and Calcination Area
6.7.
Central
Control Room and Data Storage System
6.7.1.
Data Storage
System
6.7.2.
Visual
Display System
6.7.3.
Report Generation
System
7.
Specifications
of Equipment and Motor List
7.1.
Specifications of plant and equipment
7.1.1.
Technical specifications of secondary crushers
for bauxite
7.1.2.
Technical specifications of ball mills
7.1.3.
Technical specifications of liquor to ball
mill heat exchangers
7.1.4.
Technical specifications for bauxite slurry
heat exchangers
7.1.5.
Technical specifications agitators for
pre-desilicators
7.1.6.
Technical specifications of 1st stage
regenerative slurry heat exchangers
7.1.7.
Technical specifications for 2nd stage
regenerative slurry heat exchangers
7.1.8.
Technical specifications for 3rd stage
regenerative slurry heat exchangers
7.1.9.
Technical
specifications for live steam slurry heat exchangers
7.1.10.
Technical
specifications of Digesters
7.1.11.
Technical
specifications of sand cyclones
7.1.12.
Technical
specifications of sand classifier
7.1.13.
Technical
specifications for rake mechanism for liquor decanters
7.1.14.
Technical
specifications for rake mechanism for residue washers
7.1.15.
Technical
specifications of rotary vacuum drum filters
7.1.16.
Technical
specifications of Evaporators
7.1.17.
Technical
specifications of hydroclones for hydrated alumina
7.1.18.
Technical
specifications of auto dumping security filters
7.1.19.
Technical
specifications of vacuum disc filters
7.1.20.
Technical
specifications of horizontal rotary vacuum disc filters
7.1.21.
Technical
specifications of Alumina calciners
7.1.22.
Technical
spefcifications of pumps
7.1.23.
Technical
specifications of agitators
7.2.
Drive
motor list of plant and equipment
7.3.
Equipment
requiring emergency power supply
8.
Design Features of
Civil and Structural Work
8.1.
Civil Work in Alumina Refinery
8.1.1.
Geo-technical characteristics of soil
8.1.2.
Design features of civil work
8.2.
Design
features of structural work
8.2.1
Process
equipment and storage tanks
8.2.2
Structural
buildings and storage sheds
9.
Specialty Grade Products
9.1.
Chemical
grade bauxite
9.1.1.
Quality
specifications
9.1.2.
Main
uses
9.2.
Refractory
grade calcined bauxite
9.2.1.
Quality
specifications
9.2.2.
Main
uses
9.2.3.
Market
potential
9.2.4.
Production
process
9.3.
Abrasive
grade calcined bauxite
9.3.1.
Quality
specifications
9.3.2.
Main
uses
9.3.3.
Market
potential
9.4.
Cement
grade bauxite
9.4.1.
Quality
specifications
9.4.2.
Properties
and Uses
9.5.
Chemical
grade hydrate
9.5.1.
Product
specifications
9.5.2.
Production
process
9.5.3.
Industrial
applications
9.5.4.
Packing
and transport
9.6.
High
purity hydrate
9.6.1.
Product
specifications
9.6.2.
Production
process
9.6.3.
Industrial
applications
9.7.
Dry
coarse hydrate
9.7.1.
Product
specifications
9.7.2.
Production
process
9.7.3.
Industrial
applications
9.8.
Superfine
hydrate
9.8.1.
Product
specifications
9.8.2.
Production
process
9.8.3.
Industrial
applications
9.9.
Fire
retardant filler grade hydrate
9.9.1.
Product
specifications
9.9.2.
Production
process
9.9.3.
Industrial
applications
9.10.
Pharmaceutical
grade hydrate
9.10.1.
Product
applications
9.10.2.
Production
process
9.10.3.
Industrial
applications
9.11.
Light
hydrate
9.11.1.
Product
specifications
9.11.2.
Industrial
applications
9.12.
Low
soda high alpha alumina
9.12.1.
Product
specifications
9.12.2.
Production
process
9.12.3.
Industrial
applications
9.13.
High
purity high alpha alumina
9.13.1.
Product
specifications
9.13.2.
Industrial
applications
9.14.
Activated
alumina
9.14.1.
Product
specifications
9.14.2.
Production
process
9.14.3.
Industrial
applications
9.15.
Tabular
alumina
9.15.1.
Product
specifications
9.15.2.
Production
process
9.15.3.
Industrial
applications
9.16.
Refractory
grade alumina
9.16.1.
Product
specifications
9.16.2.
Industrial
applications
9.16.3.
Production
process
10.
By-Products & Alumina Chemicals
10.1.
Vanadium
Sludge
10.1.1.
Quality
specifications
10.1.2.
Main
uses
10.1.3.
Production
process
10.2.
Vanadium
Pentoxide
10.2.1.
Quality
specifications
10.2.2.
Main
uses
10.2.3.
Production
process
10.2.4.
Market
potential
10.3.
Gallium
metal
10.3.1.
Characteristics
of gallium
10.3.2.
Main
applications
10.3.3.
Production
process
10.3.4.
Purification
of Gallium
10.3.5.
Storage
and transportation
10.4.
Bauxite
residue
10.4.1.
Residue
generation rate
10.4.2.
Composition
of bauxite residue
10.4.3.
Main
uses
10.5.
Ferric
alum
10.5.1.
Product
specifications
10.5.2.
Uses
of Ferric alum
10.5.3.
Market
potential
10.5.4.
Production
process
10.6.
Non-Ferric
alum
10.6.1.
Product
specifications
10.6.2.
Main
applications
10.6.3.
Market
potential
10.6.4.
Production
process
10.6.5.
Key
design guidelines for plant
10.7.
Zeolite
10.7.1.
Types
of zeolite and uses
10.7.2.
Specifications
of Zeolite-4A
10.7.3.
Global
market potential
10.7.4.
Production
process
11.
Basic Process Calculations
11.1.
Material flow
balance
11.2.
Alumina
Balance
11.3.
Breakup
of process steam requirement
11.4.
Technological
water balance
11.5.
Caustic
balance
11.6.
Bauxite
consumption factor
11.7.
Residue
factor
11.8.
Alumina
extraction efficiency
11.9.
Liquor
productivity
11.10.
Sodalite
factor
11.11.
Chemical soda
loss
12.
Pre-Investment Studies
12.1.
Project
conceptualization
12.2.
Market
perspective
12.3.
Characterization
and cost of bauxite
12.3.1.
Characterization
of bauxite
12.3.2.
Mining
cost of bauxite
12.4.
Process
technology
12.5.
Land
requirement and site selection
12.5.1.
Land
requirement
12.5.2.
Site
selection
12.6.
Capital
cost estimate
12.6.1.
Enabling
works
12.6.2.
Land and
site development
12.6.3.
Process
Know-how and engineering
12.6.4.
Civil
& structural work
12.6.5.
Plant
& machinery
12.6.6.
Electricals,
instrumentation and controls
12.6.7.
Piping
& valves
12.6.8.
Cogeneration
plant
12.6.9.
Cranes
and hoists
12.6.10.
Erection
work
12.6.11.
Pre-operative
expenses
12.6.12.
Margin
money for working capital
12.6.13.
Provision
for contingencies
12.6.14.
Sample
capital cost estimation
12.7.
Production
cost
12.7.1.
Variable
cost
12.7.2.
Fixed
cost
12.7.3.
Sample
production cost calculations
12.8.
Financial
analysis
12.9.
Financial
results
12.10.
Sensitivity
analysis
12.11.
Implementation
schedule
12.12.
Conclusions
and recommendations
13.
Engineering Approach
13.1.
Basic
engineering
13.2.
Detail
engineering
13.2.1.
Review
of basic engineering
13.2.2.
Preliminary
drawings and documents
13.2.3.
Contracting
and procurement
13.2.4.
Inspection
and expediting
13.2.5.
Construction
and erection drawings
13.2.6.
As-built
drawings.
“As a military family, we are very thankful for Mr Lee professional service. he was attentive, knowledgeable and took his time to walk us through the loan process. We were informed in a timely manner of any pertinent details we needed to take into account. He was very approachable, understanding and trustworthy. We can’t thank him enough for his excellent service. We highly recommend his and feel blessed to have had his loan assistance to enable us have our home purchase. Military and non military families, Mr Lee you would want to work with for your home purchase & any kind of loan asistance!”
ReplyDeleteMr Lee Loan Officer Contact Details:WhatsApp : + 1-989-394-3740E-Mail: lfdsloans@outlook.com
With the vast experience of international market with the reputed Steel, Sugar and Cotton industries we would like to draw your attention to our newly lunched aluminium extrusion company located in Jinja called G Das Industries limited.
ReplyDeleteVisit: The Best aluminium Industry