Saturday, March 28, 2020

CONTENT SHEET OF RECENTLY PUBLISHED BOOK ON ALUMINA TECHNOLOGY

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




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.



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