A to Z on Bauxite, Hydrate, Alumina, Alumina Chemicals and Aluminium

Hi Friends,

We are planning to publish a wonderful and unique technical book on "A to Z on Bauxite, Hydrate, Alumina, Alumina Chemicals and Aluminium" covering various technical aspects with emphasis on process, design, engineering, project management, commissioning, process control and successful operation including trouble-shooting of metallurgical and non-metallurgical (Specialty grades) Alumina Plants including byproducts, chemicals and glimpse of major critical issues of aluminium smelters as well. We have already structured a table of content with variety of technical inputs for inclusion in the book. Previously, we had a plan to publish this book by early this year but could not be done due to many major changes in the content of the book on request of our friends and well wishers. Now, our team members are planning to publish this book at the earliest latest by the mid of 2016.

The proposed new book will be unique with regard to following key features:

• Technical data, information & detailed calculations useful for process design engineers,
• Detailed specifications of basic input materials,
• Treatise for process control, process development & product development,
• Production, consumption and forecast data for products across the globe for taking strategic decisions,
• Method to optimize techno-economically viable plant with provision for expansion,
• Basic parameters for selection of suitable project site for new plant,
• List of required statutory clearances for setting up new Alumina plant,
• Specifications of different grades of bauxite, hydrate, calcined alumina & chemicals,
• Applications and production process routes for standard and specialty grades of bauxite, hydrate, calcined alumina and value added chemicals,
• Methodology to develop PFD, P&ID, general layout of plant & shop layout / equipment arrangement drawings of units, 
• Clear understanding about minimum feasible capacity for Alumina refinery,
• Working out volume of work / bill of materials / Material take-off for civil, structural, electrical, co-generation and instrumentation and control units for new Alumina project,
• Methodology for estimation of capital cost, production cost, IRR and pay back period,
• Arriving at consumption factors for all input materials,
• Procedure for working out requirements of fresh water, cooling water, steam and other utilities,
• Sizing calculations for tailor made process equipment and facilities,
• Systematic approach for sizing of pipelines and valves,
• Techniques for selection of critical equipment & appropriate material of construction,
• Finalization of process technology based on characterization of bauxite,
• Basic inputs and methodology for developing Basic engineering documents,
• Methodology with sample drawings, data sheets and documents to be developed during Detailed engineering for execution,
• Reference guide for Entrepreneurs  and strategic planners of respective fields particularly with regard to specific capital investment, profitability and other related aspects,
• Planning & scheduling for execution of new Alumina plant,
• Detailed systematic planning for successful commissioning,
• Wide coverage on safety, occupational health and environmental protection,
• Technical input data for research and development and
• Many more topics of interest which have not been published in any document so far.

This book will be the outcome of life time experience of a group of professionals located in different parts of the globe who have designed, executed, commissioned and successfully operated many such Alumina plants in the World.

We are thankful to all individuals and organizations who helped us directly or indirectly in making this book with rich data, information and calculations. We would also like to put on record our sincere thanks to those individuals who approached us for early publication of this unique technical book. All friends of bauxite-alumina-aluminium fraternity will appreciate the wide coverage of technical information with addition of many topics / contents compared to earlier envisaged. Editing of technical information and calculations are in advance stage and concerted efforts are being made by our team members to expedite the finalization of manuscript with utmost accuracy.

As such all out efforts will be made to cover all technical issues, however if you wish to include detailed coverage on any topic, please let us know by writing your opinion under comment column which will be passed on to the editorial board for inclusion in appropriate place in the proposed book.

We will welcome your comments, remarks and suggestions, if any.

Best regards.

Kunwar Rajendra
www.bauxite2aluminium.blogspot.com

Scope Matrix for Execution of Alumina Refinery Projects on EPC Contract Methodology

Hi Friends,

All of us are aware that each and every Alumina refinery is tailor made because of changes in processes, equipment and facilities because of variation in quality of basic input raw materials. Thus, generally Basic engineering & Process technology supplier, Detailed engineering consultants, equipment suppliers and of course the Project owners are involved in execution of Alumina refinery projects. In the recent past, some changes in execution methodology for Alumina refinery projects have been distinctly observed. 

These days, project owners across the globe are approaching various design, engineering and construction agencies to carry out execution of Alumina refinery projects on EPC basis. This methodology has its own advantages like single point responsibility, less involvement of project owner and remote chances of schedule & cost over run for the project. But capex may be little high because of loading on prices by EPC Contractor for their efforts in execution of project such as procurement of equipment & facilities from different sources and appointment of various agencies for inspection, quality control, safety, security and other associated activities within as well as outside the premises of project site. 

In present post, we are presenting the major responsibility matrix with indicative scope of services of EPC Contractor and The Project Owner for successful execution of green-field Alumina refinery project as tabulated here under-

  RESPONSIBILITY MATRIX FOR EXECUTION OF ALUMINA PROJECT ON EPC BASIS

S.No.	Activity Description	EPC Contractor	Project Owner	Remarks
1	Feasibility Study Report		√	Owner to provide data pertaining to hydrological, meteorological, geological, estimated ore reserves, bauxite quality specifications with range including available infrastructure in the vicinity of proposed site.
2	Technological Testing Report for characterization of Bauxite		√	Owner to provide, hard groove index of bauxite, digestion conditions, residue settling characteristics and other associated figures derived from quality specifications with detailed test results and conclusions.
3	Project Clearances		√	Owner to provide land acquisition status, site details with topography, EIA / EMP reports, consent for establishment, safety assessment and fire rating.
4	Geological Survey Report		√	Preliminary exploration and Detailed exploration reports.
5	Basic Engineering	√		Design basis, process description, PFDs, P&IDs, equipment List, motor list, data Sheets, MSDS, utility requirement, plot plan, SLD, list of packages, details of DCS with control philosophy, design drawings for tailor made equipment and tankages, list of instruments & controls, specifications for critical equipment, pollution control equipment, 3D piping drawing upto pipe size of 50 mm and more including instruments and other details as per scope for Basic Engineering.
6	Detailed Engineering	√		Development of general layout of plant, area-wise equipment arrangement drawings, technical specifications for equipment & facilities including utilities & services, SLD for MRDS & MCCs, construction drawings for civil, architectural & structural buildings, pipe & cable racks, roads, drains, environment & safety equipment, all foundation drawings, cable routing diagrams, firefighting system, 3D piping drawings incorporating utilities & services, equipment for maintenance workshop, water supply & distribution network, erection tenders for civil, architectural, structural, electrical, instrumentation and control work and other LSTK packages plus other work as per scope for detailed engineering.
7	Development of General Layout of Plant.	√		Starting from raw material unloading, handling & storage to storage and loading of products including all processing, utility & services facilities and Land escaping.
8	Construction Drawings	√		Construction drawings for all civil buildings including boundary wall, Main gates, foundations for footings of Pipe racks, footings for PEBs and operating platforms.
9	Site Preparation	√		Marking location of plant units and offices depending on topography of land, geotechnical study reports.
10	Temporary Construction Facilities	√		Temporary office space for Client as well as Contractor officials, communication equipment, arrangement for supply of construction power and construction water, Labour sheds and stores.
11	Fabrication drawings	√		Fabrication drawings of tanks with nozzle orientation and Fabrication drawings for pipe racks.
12	Structural buildings	√		Fabrication and erection drawings for Structural buildings and ware houses.
13	Cogeneration Plant	√	√	Only system design drawings to be provided by Owner and detail drawings to be developed by contractor.
14	Design, Fabrication and erection of non-standard equipment	√
15	Installation of Piping network	√
16	Design for electrical power receiving and distribution system.	√
17	Erection of PCC & MCCs	√
18	Electrical and Control Cables	√
19	Distributed Control System	√
20	Installation of all instruments & controls	√
21	Laboratory Equipment	√
22	Effluent Treatment Plant		√
23	Sewage Treatment Plant		√
24	Construction of Office buildings		√
25	Fire Fighting System		√
26	Plantation and development of greeneries		√
27	Preparation of Operation manuals		√
28	Preparation of Maintenance Manuals		√
29	Supervision during testing & Commissioning		√
30	Stabilization of plant operation		√
31	Supply of Commissioning Spares		√
32	Establishing plant performance guarantee parameters		√
33	Submission of ‘As Built’ drawings		√	‘As built’ drawings for entire plant within the premises to be prepared and submitted by contractor.

The above stated scope matrix is for reference only which is also applicable for brown-field expansion of Alumina refinery and other industrial projects to be executed on EPC basis. These are just the guidelines and the same may be further elaborated on case to case basis.

Trust, our friends of Bauxite-alumina-aluminium fraternity will find this article useful more specifically while freezing & finalizing the scope of EPC contract. We will welcome your remarks and comments for further improvement by incorporating your valued suggestions, if any, at our end. Please feel free to put your remarks under "Comments" provided below each article published on this unique technical blog.

Regards.

Rajendra Kunwar
rajendra@ceti.co.in
www.ceti.co.in