Major Requirements for Successful Commissioning of New Alumina Refinery

Hi Friends,

In continuation to our earlier post, we would like to discuss the requirement of critical facilities, quantity of input materials and documents in readiness for successful commissioning of new Alumina refinery as described here under.

Readiness of plant and facilities:

It is essential to keep the keep following plant, equipment and facilities before starting the commissioning of Alumina refinery-

• Bauxite receipt, unloading, stacking and reclaiming system.
• Readiness of Bauxite crushing, Grinding, Predesilication, Digestion, Residue settling & washing, Security filtration, Heat interchange unit, Precipitation, Classification, Evaporation, Hydrate storage, Calcination  and alumina handling system.
• Major infrastructure facilities like co-generation plant, raw water supply system, cooling towers, compressed air station, emergency power supply system, railway and road network.
• Readiness of Process water storage and Drinking water distribution network.
• Storage vessels for Caustic lye, Fuel oil and other consumables.
• Availability of filter cloth, lubricants and other consumables.
• Adequate stock of input materials like Bauxite, Caustic soda, Coal, Fuel oil, Diesel, Burnt lime, Acids, Flocculent and Seed hydrate.
• Availability of experienced technical executives and operating workforce.

Materials Requirement:

Adequate quantity of major input raw material must be ensured in the stock for smooth commissioning of Alumina refinery as stoppage of plant after commissioning may cause losses for the company. Major raw materials are Bauxite, Caustic soda, water, lime, seed hydrate, flocculent and furnace oil / LSHS.

Documentation Requirement:

Following documents are required for systematic commissioning of Alumina refinery-

• Detailed commissioning procedures.
• Step by step process commissioning sequence.
• Safety and risk management Plan.
• Broad schedule for commissioning.
• Organization chart of Commissioning team.
• Training of commissioning team.
• Formats for recording various parameters and activities.

The above information will suffice the commissioning requirement of new Alumina refinery. Please put your views / suggestions / remarks / comments, if any, further improvements in planning the required activities.
Regards.


Kunwar Rajendra
www.bauxite2aluminium.blogspot.com