Overview

This book provides a comprehensive review of the production of smelter grade alumina from bauxite ores. It emphasizes the best practices applied in the industry today but seen in a historical context with a view to future challenges and developments. The control of alumina quality is discussed in detail including the effects that alumina quality have  on the aluminum smelter process with respect to environmental performance, current efficiency, and metal purity. The discussion of alumina quality will be relevant to people on the smelter side, as this is the interface between refinery and smelter. Emphasis is placed on the major steps of the Bayer Process including: digestion, clarification, precipitation, calcination, and management of water, energy, and bauxite residue. This book is a valuable resource for active, seasoned practitioners and for new engineers entering the industry.

Full Product Details

Author:   Benny E. Raahauge ,  Fred S. Williams
Publisher:   Springer Nature Switzerland AG
Imprint:   Springer Nature Switzerland AG
Edition:   1st ed. 2022
Volume:   320
Weight:   1.306kg
ISBN:  

9783030885885

ISBN 10:   3030885887
Pages:   844
Publication Date:   25 January 2023
Audience:   Professional and scholarly ,  Professional & Vocational
Format:   Paperback
Publisher's Status:   Active
Availability:   Manufactured on demand  
We will order this item for you from a manufactured on demand supplier.

Table of Contents

1. Introduction: Primary Aluminium - Alumina - Bauxite (Benny E. Raahauge)i. Property Driven Applicationsii. Supply-Demand Balance and Forecastiii. Cost Drivers and Pricingiv. Environmental Footprints and Challenges 2. Bauxite Mineralogy, Classification and Beneficiation (Hydro/RTA?)i. Bauxite Resourcesii. Mineralogy and Chemistryiii. Classification from Bayer Process Perspectiveiv. Beneficiation Options 3. Bayer Process Design and Physical Chemistry (Steve Healy)i. Bayer Process Design Overviewii. Liquor Properties - Physio Chemical Dataiii. Lime (CaO) Chemistry 4. Bauxite Processing - Crushing/Grinding, De-silication and Digestion (CSIRO?)i. Crushing & Grindingii. Silica Chemistry, Desilication Kinetics and Reactor Designiii. Digestion Chemistry, Breakpoint and Kineticsa. Maximum Extractable Alumina (MEA) and Breakpointb. Digestion Modelsc. Degradation of Organicsiv. Digestion Conditions, Bauxite Mineralogy and Yielda. Effect of Lime additionb. Impact of impuritiesv. Applied Digestion Technology and Heat Consumptiona. Autoclavesb. Tube Digesterc. Double Digestionvi. Digester Mass and Heat Balancesa. Theoretical Heat of Digestionb. Boiling Point Elevationc. Steam Requirements 5. De-sanding - Floculation / Sedimentation - Liquor Filtration (Tim Laros)i. De-Sanding Equipmentii. Flocculation and Sedimentation Principlesiii. Mud Rheology, Rake Drives and Mud Pumpingiv. Decantation and Clarification Technologyv. Rise Rate and Tank Designvi. Pregnant/Green Liquor Filtration Options and Trends 6. Bauxite Residue: Washing - Dewatering (Tim Laros) and Disposal (Paul McGlade)i. Mud Washing - Recovery of Soda and Aluminaii. Dewatering Options: Filtration and Centrifuginga. Filtration Theory and Applicationsb. Filtration Pressure and Equipment Optionsc. Centrifuge Theory and Applicationsiii. Mud Cake Disposal Options and Principlea. Wet Disposal w/wo Neutralizationb. Dry Stacking w/wo Mud Farmingc. Dry Disposal 7. Hydrate Precipitation (Dennis R. Audet) , Classification and Filtration (Manfred Bach)i. Hydrate Crystallization Fundamentalsa. Nucleation, Agglomeration, Breakage and Growthb. Crystallization Mechanism and Kineticsc. Heat of Crystallizationd. Control of Residual Sodae. Impact of Organics and other impurities on Yieldii. Precipitation Flow Sheets and Particle Morphologya. Retention Time and Temperature Profile impact on Yieldb. Modelling of Precipitation Flow sheetiii. Precipitator Tank Design Optionsa. Agitation and Mixingb. Hydrodynamic Effects on Yieldiv. Classification Options and Mass Balance Controla. Hydro Clonesb. Fine Seed Thickenerv. Seed and Product Hydrate Filtration Optionsa. Seed Preparationb. Washing Efficiency and Flow sheets 8. Liquor Purification and Impurity Control (Steve Healy)i. Organics removalii. Removal of Inorganic impuritiesa. Ironb. Phosphorc. Other... 9. Water Balance, Evaporation, Heat Exchange and Co-Generation (Daniel Thomas)i. Refinery Water Balanceii. Bayer Process Heat Balancea. Heat Transfer b. Inter-department heat exchangeiii. Evaporationiv. Co-Generation of Steam and Power 10. Alumina Production by Calcination (Benny E. Raahauge)i. Calcination Chemistry, Phase Changes and Combustiona. Chemistry, Degree of Calcination and Stoichiometryb. Crystalline and X-Ray Amorphous Phasesc. Fuels and Combustion Products - Acid dew Pointii. Drying and Calcination Theorya. Gas-Solid Heat Transfer and Drying/Calcinationb. Heat Conductionc. Alpha Phase Formation and Kineticsiii. Heat of Calcinationa. Standard Heats of Reactionb. Calcination Heat in Practiceiv. Calcination Furnace/Reactor Design and Operating Conditionsa. Rotary Kilnb. Fluid Flash (FF) and Gas Suspension Calciner (GSC)c. Fluidization and the Circulating Fluid Bed (CFB)d. Gas Suspension Calciner Reaction Modelv. Gas-Solid Separation in Cyclonesvi. Air Pollution Control and Dust Managementa. Gas Emissions and Carbon Foot Printb. Particulate Dust Emissions and Management Optionsc. Electrostatic Precipitator or Bag House vii. Refractory Selection and Surface Heat Lossesviii. Calcination Flow Sheet Optionsa. Heat Recovery Optionsb. Hydrate By-Pass and Alumina Qualityc. Heat Balance and Specific Heat Consumptiond. Specific Power Consumptionix. Particle Breakdown and Strength During Calcinationa. Particle Breakdown Defined and Observedb. Attrition Index Defined and Observedc. Impact from Precipitation and Calcination 11. Alumina Quality, HF Removal, Dissolution and Aluminium Purity (Stephen Lindsay)i. Chemical Composition of Smelter Grade Aluminaa. Loss of Ignition (LOI) and Degree of Calcinationb. Phase Composition and Alpha Alumina Contentc. Chemical Composition and Gibbsite ii. Physical Properties of Smelter Grade Aluminaa. Particle Size Distribution, Dustiness and Attrition Indexb. Angle of Repose and Flow abilityc. Bulk Density and Heat Conductivity d. Specific Surface Area and Pore Size Distributioniii. Efficient HF Removal and Dry-Scrubber Efficiency (Margaret Hyland)a. Sources of HF from Smeltingb. Pore Size Distribution and accessible Specific Surface Area Primary Alumina Secondary Aluminac. The Role of Sulfur Dioxide?iv. Alumina Dissolution and Current Efficiency (Pascal Lavoie)a. Theoretical Analysis of Dissolution Processb. Dissolution Rate under Laboratory Conditions Effect of Particle Size Distribution: Sandy vs Floury Effect of Phase Composition: Gamma vs Alphac. Impact of Calcination Technologyd. Impact of Alumina Feeder Design and Operation v. Impurities impact on Aluminium Production, Purity and Propertiesa. Soda and CaOb. Silica and Ironc. Phosphor and Berylliumd. Vanadium and Sulfur 12. Alumina Storage and Handling Options 13. Health, Safety and Plant Management (Carlos Suarez) 14. Process Control, Simulation and Operator Training (NN?) 15. Process Economics and Plant Design (Peter-Hans Ter Weer)

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Author Information

The Co-Editors of this book have a slightly different perspective on the recovery of alumina from bauxite.  Benny and Fred received their technical training as MS Chemical engineers. Benny Raahauge was employed by FL Schmidt and thus represented a manufacturer and seller of equipment used in that industry.  Fred Williams was employed by Alcoa and was assigned management responsibilities in alumina processing research, plant process engineering and running plant production.  Both individuals have conceived technical improvements to the alumina recovery process as recognized by patents and technical awards, written and presented numerous papers at international technical meetings and have served as chairmen and organizers of international technical sessions. The authors of the individual chapters in this book are noteworthy experts from around the world in alumina manufacturing and researchtechnology.

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