Alumina Users Meeting 2017 Summary PDF

19TH ALUMINA
USER’S MEETING
6-7 OCTOBER 2017, HAMBURG, GERMANY
Meeting Summary & Presentations

Alumina user’s meeting | Meeting Proceedings
CONFIDENTIALITY STATEMENT
This document contains information that is confidential to
the participating companies and Outotec.
It has been issued to each participant under the relevant

secrecy agreement and is solely intended to be used for
internal purposes only.
The content of this document cannot be reproduced

without the prior written permission of Outotec.
This document is your personal copy of the meeting and is

provided with Outotec compliments.
Your Outotec team
Oberursel, Germany
October 2017
3
FOREWORD
At Outotec we continue to endeavour to provide cutting We would like to thank all participants old and new, and
edge technology to the Bauxite and Alumina industry, we would also like to thank ICSOBA for permitting the
sustaining our current dedication to the value chain. Over conjunctional hosting of these two renowned events within
the past 2 years we have seen the industry go from a our industry. We look forward to your participation at the
period of stagnation to one of promise and growth, with 20th edition of this event.
new mines being opened and the appetite for bauxite
increasing - alumina producers are seeking for ways Finally, we would like to celebrate the contribution to the
to increase productivity or decrease their costs and industry of Dr. Hans-Werner Schmidt, having participated
environmental footprint. on the first installation of a circulating fluid bed calciner
back in 1968 and bringing the technology to where it is
Outotec’s key themes of the meeting around topics such today, his presence will be sadly missed.
as red mud, security filtration upgrades, semi autogenous
mills in bauxite grinding, aspects of HOT digestion
technology, Outotec’s latest service portfolio and of course Dr. Hannes Storch
Outotec’s latest developments in calcination technology.
Not to mention some interesting topics from Alumina SVP, Metals & Chemical Processing
producers such as Chalco’s Bayer process optimization
concepts, AOS maintenance practices for high scaling
tubular digestion, Mykolaev’s developments in grinding Dr. Alessio Scarsella
and calcination and Emirates Global Aluminium’s new
greenfield project in the United Arab Emirates. VP, Alumina
5
CUSTOMER PARTICIPANTS
ALPART Jing Sun EGA Jorg Ruster
ALUM S.A. Sorin Iliev Filter Sales Trevor Sparks
ALUM S.A. Marian Juganariu HINDALCO Rohit Chourasia
ANRAK L.S. Rao HINDALCO P. K. Banerjee
AOG Panagiotis Karampogias HYDRO Robert LaMacchia
AOG Christos Katemliadis HYDRO Wlademir Penna
AOG Marios Skarpidis HYDRO Andre Vidal
AOS Andreas Nollmann HYDRO Pia Magnussen
AOS André Lalla HYDRO Michel Lisboa
AOS Dimitrios Kastritis MAADEN Tariq Al Asmi
AOS Felix Wolters MAADEN Abdullah Mohammed Al-Muhaisen
CBA Roberto Seno Jr. MAADEN Abdulmalik Salih Shaheen
CBA Ricardo Vinhal MAADEN Yousef Talal Al Dossary
CHALCO Zhirong Shi MAADEN Abdullah B. Al Otaibi
CHALCO Gu Songqing MAADEN Abdullatif M. Al-Musabbeh
CHALCO Kaibin Chen RUSAL Aleksandr Suss
CHALCO Zhonglin Yun RUSAL Levchenko Maksim
CHALCO Wanchao Liu RUSAL Vladimir Krasnoyarskiy
EGA Shouqi Hassan Mohammed RUSAL Anna Romanova

Ismail Albastaki
RUSAL Olga Krachun
EGA Ahmed Ebrahim Al Hammadi
RUSAL Sergey Semzenis
EGA Nouf Alobaid
EGA Inam Almarzouqi

OUTOTEC PARTICIPANTS
Christian Binder, Head of Process Dev & Simulation Sonia Noack, Product Engineer
+49 172 688 5999 +49 6171 9693 316
christian.binder@outotec.com sonia.noack@outotec.com
Marcilio Cenisio, Service Product Manager. Linus Perander, Head of Technical Product Mgmt
Account Director Norsk Hydro +49 172 689 6947
+49 172 688 1735 linus.perander@outotec.com
marcilio.cenisio@outotec.com
Ioannis Chatzilamprou, Service Product Manager Michael Ren, Head of Sales

+49 617 969 3473 +1 289 983 0961
ioannis.chatzilamprou@outotec.com michael.ren@outotec.com
Vladimir Hartmann, Sen. Product Manager Refinery Areej Saadeh, Account Manager
+49 617 196 939 076 +971 522 304 461
vladimir.hartmann@outotec.com areej.saadeh@outotec.com
Jarkko Karesvuori, Sales Director Comminution Alessio Scarsella, VP Alumina

+358 020 529 2256 +49 172 688 0333
jarkko.karesvuori@outotec.com alessio.scarsella@outotec.com
Andreas Koschnick, VP Sales & Marketing Trevor Sparks, Head of Filter Sales
+49 172 688 9710 +49 172 688 1733
andreas.koschnick@outotec.com trevor.sparks@outotec.com
Semen Lantcev, Regional Service Sales Head Peter Swash, Senior Bayer Chemist
+79 211 809 188 +49 617 196 931 57
semen.lantcev@outotec.com peter.swash@outotec.com
Chris Mason, Marketing Manager Steven Yu, Service Product Manager

+49 172 688 0348 +49 172 688 0344
chris.mason@outotec.com steven.yu@outotec.com
Michael Missalla, VP New Business Development

+49 172 688 919
michael.missalla@outotec.com
7
ALUMINA USERS’ MEETING HISTORY
1987 New Orleans, LA, USA
1988 1st Phoenix, AR, USA
1989 2nd Las Vegas, NV, USA
1990 3rd Anaheim, CA, USA
1991 4th New Orleans, LA, USA
1992 5th San Diego, CA, USA
1993 6th Sydney, NSW, Australia
1996 7th Darwin, NT, Australia
1998 8th San Antonio, TX, USA
1999 9th Dunsborough, WA, Australia
2000 10th New Orleans, LA, USA
2002 11th Brisbane, QLD, Australia
2004 12th Barcarena/Alunorte, Brazil
2005 13th Perth/Collie Worsley, WA, Australia
2007 14th Orlando, FL, USA
2008 15th Darwin, NT, Australia
2011 16th Outotec Oberursel, Germany
2013 17th Outotec Oberursel, Germany
2015 18th Outotec Perth, WA, Australia
2017 19th Hamburg, Germany

PROGRAM
FIRST DAY
08:30 – 09:00 Registration and Introduction
09.00 - 09.15 Welcome and opening remarks

09:15 – 09:45 SAG Mills x Ball Mills in refinery design operation
09:45 – 10:15 Red Mud Filtration
10:15 – 10:45 Coffee Break and Group Photograph
10:45 – 11:25 Integrated Refinery design New developments

11:25 – 12:05 Calcination Gen 4 to Gen 5 - Risk mitigation in technology development
12:05 – 12:45 Bauxite Enrichment, upgrading low value ores into something processable
12:45 – 14:15 Lunch Time
14:15 – 15:05 Energy Consumption In Bayer Process in China (Chinalco)
15:05 – 15:55 AOS
15:55 – 16:25 Coffee Break
16:25 – 17:15 EGA Al Taweelah Refinery
18.40 – Bus collection from hotel reception

19.00 – Boat tour of the Hamburg harbour area
19.45 – Dinner at Fischereihafen Restaurant
23.00 – Bus collection and back to hotel
SECOND DAY
08:30 Begin
08:30 – 09:25 Alumina Refinery - Service Portfolio

Calciner Shutdown
OT maintenance presentation
Improve plant availability through reliable wear part management with HOT Services
09:25 – 10:00 Digitalization
10:30 – 11:10 Cyclone Optimization and Seal Pot

11:10 – 11:50 HOT digestion technology
11:50 – 12:30 Yarwun security filter retrofit
12:30 – 14:00 Lunch Time
14:00 – 14:50 Grinding: Increase in Mill Availability

(Rusal – Mykolayiv)
14:50 – 15:40 Calcination: Reduction of Specific Energy Consumption (Rusal – Mykolayiv)
16:10 – 17:00 Multipurpose Calcination Plant
17:00 Closing remarks
9
PRESENTATIONS
Opening Remarks..............................................................................................................11
Bauxite Comminution........................................................................................................ 15
Red Mud Management...................................................................................................... 31
Integrated Alumina Refinery Design................................................................................ 54
Risk Mitigation in Technology Development.................................................................... 71
Bauxite Enrichment........................................................................................................... 89
Dr. Gu - Energy Saving for Bayer Process in China ........................................................ 105
AOS - Tube Digestion Cleaning......................................................................................... 113
EGA - Al Taweelah Alumina Refinery............................................................................... 124
Outotec Services Alumina Refinery & Calcination........................................................... 130
Shutdown Service Management ...................................................................................... 137
HOT Services - improve plant reliability through reliable wear part management........ 147
Asset Management & Maintenance................................................................................. 164
Digitalization...................................................................................................................... 175
Cyclone Optimization and Sealpots.................................................................................. 188
Evolution and Improvements in Tube Digestion Technology........................................... 202
Security Filtration Debottlenecking.................................................................................. 210
Rusal - Grinding mills - Availability increase .................................................................. 217
Rusal -Fluidized Bed Units............................................................................................... 225
Multipurpose Alumina Calciner Plant.............................................................................. 231

19th Alumina Users Meeting
6-7 October Hamburg 2017
In Remembrance
Dr.-Ing. Hans-Werner Schmidt
1940 - 2017
• Designed and commissioned the CFB pilot
plant at VAW Luenen 1968
• Design and commissioned the first industrial
calciners at VAW Schwandorf and AOS Stade
1970-1968
• Head of Lurgi/Outotec Alumina technology
from 1975- 2001 and Alumina sales from
2001-2007 and a part of every Outotec
circulating fluid bed calciner installed
throughout the bauxite and alumina industry.
An Industry icon who‘s legacy resonates on every Outotec Bauxite and Alumina Reference
2
© Outotec – All rights reserved
11
New Structure
3
BU Metals, Energy & Water

– BL Metals & Chemical Processing
Metals, Energy &

Water
Kalle Härkki
BL Smelting & BL Metals & Chemical BL Energy &

Hydrometallurgy Processing Environment
Jyrki Makkonen Hannes Storch Johan Grön
F&C
Sales & Finance &
Marketing Control
Kim Fagerlund PL AOR PL Ferrous PL Alumina PL Aluminium Erkko Virrankoski
Stefan Bräuner Michael Müller Alessio Scarsella Ralf Hoppe
HR
Business Human
Delivery Development
Mikko Rantaharju Resources
Paul Merlin Kari Kähäri
MEW
Delivery Legal & CM
Delivery Contract
Global Supply
Andreas Klein Management
Ben Weetman
Mathias Noll
F&C
Products & Business Control

Technologies Lauri Lehtonen
N Anastasijevic
4

Opening Remarks
5
Where is Our Industry Going ?
• Where we were from the year • Where we were from the year
leading to the last user‘s leading to the last user‘s
Meeting: Meeting:
• 115 mMTPA Global • 119 mMTPA Global
• 59 mMTPA China • 68 mMTPA China
6
13
Where is Our Industry Going ?
• New Capacity displacing old capacity

• Ma‘aden
• Well Harvest
• EGA – soon to come
• Increase in Chinese Refining Capacity
• Slow Down in bauxite trading
• Companies expediting plans to increase bauxite mining capacity
- Guinea
- Amrun
• Ban in Indonesia ongoing compound by recent ban in Malaysia
• High cost refineries closing
• Some refineries seeking to products other than SGA
• World Alumina supply is now in deficit
• Idle capacity brought back online – Alpart Alumina Refinery
7

Bauxite Comminution
19° Alumina User’s Meeting
Jarkko Karesvuori
October 2017
15
Outotec Comminution Group
• Outotec – Comminution Group was founded from the combination of three companies,
each with a long history in the grinding mill industry:
• Nordberg : Origin, USA (1946)
• Morgardshammar : Origin, Sweden (Circa 1900)
• Scanmec : Origin, Norway (1976)

Scanmec
Morgardshammar Grinding Group Comminution Group
Morgardshammar Nordberg
Outokumpu Outotec
Nordberg
1900’s 1946 1976 1995 1996 2001 2007 TODAY
2 24 October, 2017 Outotec Alumina Users Meeting – Bauxite Comminution

Expanded Comminution Product Portfolio
ROM • Crushing and materials handling

- alliance with
100mm
• HPGRs
10mm - manufactured by
1mm • Ore Sorting

• Grinding Mills
100µm
• Liner Handlers
10µm • HIGmills
3 24 October, 2017 - fine grinding mills
Outotec Alumina Users Meeting – Bauxite Comminution

References in Bauxite Grinding

Comminution Basics & Definitions
∞ – 1200mm (Blasting, Mining)

80- 90% Comminution 10- 20% Comminution
1200 – 5mm (Crushing)

Energy
300 – 1mm (AG, SAG, Scrubbing)
50mm – 50um (HPGR, Ball, Rod, Pebble)
50um - 5um (Stirred Milling)

Energy

17
Bauxite Comminution – Points to Consider
• Mine is often remote from plant

• Primary crushing usually as site
• Sometimes secondary crushing also
• Bauxite slurries are usually viscous – affects pumping and grate flow (in
grate-discharge mills)
• Bauxite is typically low to medium competency and hardness compared to
hard rock applications
• The use of caustic in the grinding mill is challenging but does not change the
fundamentals of particle breakage.
• All tumbling mills exhibit similar efficiency when operated within their limits.

Ball Mills
• Grinding media is steel balls

• Size virtually unlimited
• Overflow or grate-discharge configuration
• Advantages:
• Very good availability
• Lowest equipment cost
• Disadvantages:
• Grinding action is not optimised for hard, larger feed
particles – not usually a problem for bauxite
• Some over-grinding likely
• Some scatting possible with harder ores
• Requires at least 2-stage crushing


Rod Mills
• Grinding media is steel rods

• Rod media length limit is 6.1m
• L/D >~1.4 to minimise rod tangling risk
→Rod Mills limited to ~1,700 kW power
• Advantages:
• Larger particles preferentially ground
• Good energy efficiency
• Fines production minimised
• Disadvantages:
• Limited maximum size
• Rod charging can be dangerous
• Mill must be stopped for rod charging
• Rod tangle event results in long unplanned downtime

SAG Mills
• Grinding media is steel balls AND rocks

• Size virtually unlimited
• Advantages:
• Very good availability
• Grinding action is very good for medium and large size
particles
• Lower media and liner consumption
• Requires only primary crushing – secondary crushing
and materials handling eliminated
• Lowest overall capital cost
• Disadvantages:
• Some over-grinding likely
• Slightly higher overall energy input (offset by
eliminating crushing and materials handling)
• Slightly higher equipment cost
• Scats must be dealt with
19
Comparison of Common Grinding Tests
Test F100 Screen P80 Comment

(µm) (µm) (µm)
Bond Ball Mill BWi 3,350 150 106 Use screen to match process
Bond Rod Mill RWi 12,700 1,180 1,000 Use in Ball Mill calc for O/S feed
JK / SMC Breakage A*b / DWi ~25,000 + N/A variable SAG specific breakage test

Minimum Comminution Test Work
• ~5 samples from each lithology

• Further testing may be required if significant variability observed
• SG
• UCS
• JK or SMC breakage
• Bond (CWi, RWi, BWi)
• Ai
• Viscosity
• 50 – 70 kg per sample (can be drill core)


Summary – Milling for Bauxite
• As per the Bond-Rowland Ball Mill energy calculation, ideal feed size for a
ball mill is up to 4 mm (F80).
• Also penalises low ratio of reduction, which can come into play with coarse ball milling like in
alumina.
• Morrell model suggests that there is an inflection in energy requirement at
about 750 µm – where impact breakage give way to attrition.
 If we operate a Ball Mill outside that range (ie , we have the possibility of
inefficient operations
• Rod Mills are more suited to the larger feed and product size for Bauxite
Milling but are difficult to operate and have size limit (~1.8MW) – more mills
required for the same duty
• SAG Mills are very good at operating with large feed and product particle
sizes, are much more easily operated than rod mills and are essentially
unlimited in size
Comparison of SAG vs Ball Milling for Bauxite

SAG Milling Conventional Milling (Ball or Rod-Ball)
Single comminution production step 2 stages of crushing, screening, conveyors, additional

stockpile, possibly 2 stage milling
Lower overall capital cost Higher overall capital cost
Very high circuit availability Lower availability in crushing and rod mills
Slightly higher milling energy offset by eliminating Slightly lower milling energy but additional consumption
crushing circuits in crushing circuits
Significantly lower media and wear part consumption Significantly higher media and wear part consumption
(balls, liners) (balls, rods, liners, crusher wear parts, screen panels,
conveyor belts)
Scats (pebbles) can be recycled within the system Scats must be conveyed or manually handled (problem
with caustic)

21
Practical Considerations for
Bauxite SAG Mills

Material Selection
• Caustic can cause grain boundary corrosion cracking in iron and steel
components.
• All steel components in contact with caustic to be suitably stress relieved.
• Cast components must be cast steel rather than cast SG (ductile) iron.
• Where rubber is required, special synthetic material is used.
• Obviously avoid any aluminium alloy components…


Feed Arrangement
• Zero contact
• Minimised leakage
with sand wheel
• Rock box
(autogenous layer
to minimise wear)
• Stress relieved
• 2-axis rail-mounted

Are all Tumbling Mills the same?

Overflow Grate Discharge Open Ended Grate
In-efficient Grinding Efficient Grinding

(Open End = TPL)
Improper Improper
Attrition Attrition
Good Attrition
Slurry
Pool Slurry
Pool
Poor Impact Poor Impact

Good Impact

23
Outotec Turbo Pulp Lifter for Grate Discharge –
Improved Efficiency for SAG mills
18
24 October, 2017 Outotec Alumina Users Meeting – Bauxite Comminution
Discharge Design
• Scoop and return

pipe system added
to trommel to return
scats to mill
• Optional system to
remove steel scats
→ Optimise coarse
grinding
• Metallic screen
panels (instead of
normal rubber or
polyurethane)

Liner Scanning
Optimise Liner Life and Performance

Outotec Relining Machines and Liner

Handlers
Efficient and Safe relining
25
SAG Mill Load Measurement
• Grate discharge arrangement holds charge in mill

• Determination of rock and ball charge requires measurement of both load
and power
• Load cells or hydrostatic bearing pressure (only effective on self aligning,
multi-pad bearings are used)

Advanced Grinding control
Process Optimizer
RockSense
MillSense
LSA process sampler
23 10/24/2017 Grinding Circuit Control Improvements, Introduction


Reference: Ma’aden Ras Al Khair SAG Mills
Ø7.30m x 3.51m EGL, 3,000 kW

Design: Ma’aden Ras Al Khair SAG Mills

27
Design: Ma’aden Ras Al Khair SAG Mills

Installation: Ma’aden Ras Al Khair SAG Mills


Installation: Ma’aden Ras Al Khair SAG Mills

Ready to Operate: Ma’aden Ras Al Khair SAG Mills

29
Comments on Operation of Ma’aden Ras Al Khair
SAG Milling Circuit
• Grinding circuit achieved nameplate throughput within 1 week of ramp up
• Product size requirements met
• High overall availability
• Mills designed to minimise steel media and liner consumption
• Low wear items consumption – 2 years before first reline


TECHNOLOGICAL SOLUTIONS FOR
RED MUD MANAGEMENT
Vladimir Hartmann
Trevor Sparks
Content
TYPICAL COMPOSITION
TAILINGS GENERATED FROM ALUMINA

PRODUCTION
SAFE STORAGE
DISPOSAL SELECTION CRITERIA

RED MUD
OUTOTEC SOLUTIONS
CASE STUDY
SEA WATER NEUTRALIZATION PLANT
FILTRATION PLANT
2
31
Red Mud Typical Composition
Solid Phase Properties
Fe2O3 30 – 60 wt% pH 12 – 14
Al2O3 10 – 20 wt% Density 2.6 – 3.5 t/m³
SiO2 3 – 50 wt% Particle Size (coarse) >100 µm
Na2O 2 – 10 wt% Particle Size (fine) < 10 µm

CaO 2 – 8 wt%
Mineral phases present in the red mud depends on
TiO2 Trace – 25 wt%
bauxite composition and digestion technology
Liquid Phase implemented.
Alumina 3 g/l
Main mineral phase:
Caustic soda 7 g/l hematite, goethite, gibbsite, boehmite, diaspore,
Sodium carbonate 1 g/l calcium aluminate hydrate, quartz, sodalite,
cancrinate, rutile, anastase, sodium & calcium
titanate, etc.
Source: 1, 2
3
Tailings Generated from Alumina Production
~2.2billion metric
tonnes of alumina
has been produced
from 1974 to 2016.
Some 5.0 billion

metric tonnes of
red mud has been
generated, as well.
130 million tonnes

of red mud are
produced each
year
Source: IAI Statistics3
4

Tailings Generated from Alumina Production
~2.2 billion metric tonnes of alumina has

been produced from 1974 to 2016.
Some 5.0 billion metric tonnes of red mud
has been generated, as well.
Source: IAI Statistics3
5
Safe Storage - Red Mud
Red mud spill in 2010, in

Hungary: reservoir wall failed
spilling 1 million m³ of the
bauxite residue with high
alkali, high Na+, metals (Al, As,
Cr, Mo, V) content.
Polluting hectares of
agricultural land and leading to
the Danube river.
Mitigation costing of approx.

125 million Euros.
Source: Chemistry World5
Source: The Times4
6
33
Safe Storage - Tailings
The Bento Rodrigues dam disaster

occurred on 5 November 2015, when
an iron ore tailings dam in Bento
Rodrigues, a subdistrict of Mariana,
Brazil, suffered a catastrophic
failure,[4] causing flooding and at least
17 deaths.[3] At least 16 people have
been injured.[1]
About 60 million cubic meters of iron
waste flowed into the Doce River.
Toxic brown mudflows reached the
Atlantic Ocean 17 days later.[5] The
total impact and environmental
consequences to the river and the
beaches near its mouth, or to the
wildlife are still unclear.[6] This incident
has been described as the worst
Source: By NASA - http://earthobservatory.nasa.gov/IOTD/view.php?id=86990, Public environmental disaster in Brazil's
Domain, https://commons.wikimedia.org/w/index.php?curid=45081179
history.[7][8][9]
Source Wikipedia 7
7

Plant with different disposal methods used during lyfe cycles of the plant.
8

Dry Stacking: Gove Australia
40 – 50 % wt Solids, 2,6 MTPA Alumina
Source: Google Earth, Gove
9
Source: Google Earth, Hydro Alunorte
10
35
Source: Google Earth

11
Disposal Selection Criteria
LOCAL CLIMATIC AND GEOLOGICAL CONDITIONS
COMPOSITION AND AMOUNT OF SOLIDS AND LIQUID PHASE
RED MUD
DISPOSAL
POTENTIAL ENVIROMENTAL CONTAMINATION
(GROUND, SURFACE, DUST)
CAPEX AND OPEX
12

Outotec Solutions for Red Mud
WET DISPOSAL INCLUDING PASTE THICKENING

PUMPING/
THICKENER DISPOSAL
CONVEYING
WET DISPOSAL INCLUDING THICKENING, VACCUM FILTERS + FARMING

PUMPING/
THICKENER FARMING
CONVEYING
RED MUD
REFINERY
DRY DISPOSAL INCLUDING FILTER PRESS
FILTER
CONVEYING DISPOSAL
PRESS
RED MUD NEUTRALIZATION

NEUTR. FILTER
CONVEYING DISPOSAL
PLANT PRESS
13
Neutralization as an option to be studied for

specific cases
14
37
Outotec’s Seawater Neutralization Technology
Seawater Neutralization
• Outotec has proven technology and knowledge in
• Significant amounts of caustic and alumina in liquor
treating large amounts of red mud
phase require removal prior to further handling
• Neutralisation facility in Gladstone, Queensland
• Caustic and alumina solutions are readily treated with
sea water • Can treat 12,500 tonnes of mud per day
• Caustic and alumina reacts with magnesium forming • Proven reduction of caustic concentration in
insoluble precipitates such as hydrotalcite and solution from 7 g/L to 0.2 mg/L
magnesium hydroxide. • Proven reduction of alumina concentration in
solution from 2.8 g/L to 2 mg/L
Facility with relatively small

footprint neutralising all of the
mud from one of the world’s
largest alumina refineries.
15
Neutralisation Plant
16

Vane FeedwellTM
17
Neutralization Facility - Result
• Red mud neutralized and thickened for semi dry-disposal
• Filtrate out of filter press neutralized for disposal
• Consistently clear overflow meeting specific chemistry
• Small single footprint clarifier/thickener
• Cost minimization by use of gravity forwarding systems
• Reliable, robust design, capable of remote control from refinery
• ‘Zero harm’ to environment
18
39
Neutralization Plant - Performance
• Reduces dissolved aluminum to level well below 5 mg/L
• Neutralizes last washer underflow to a pH of < 9

• Delivers a clear, magnesium deficient supernatant with a solids
content of 30 mg/L
• Provides a thickened neutral red mud solid underflow above 340
g/L for semi dry storage
• Treats high flow rates (5800 m3/h) of neutralized slurry containing
up to 520 t/h (dry) red mud solids
19
From - Wet Disposal
Slurry conc.
37 – 55 wt.%
M
To refinery
MUD STORAGE
Effluent pond
Wet disposal can be improved with addition of Drum Filtering - Farming
20

To - Dry Disposal : Filter Press
Optional wash water
Mud slurry from

underflow last washer
FILTER 1 FILTER 2 FILTER 3 FILTER 4
FILTER FILTER
2 3
To red mud disposal Red mud solids conc > 75 wt.%

via trucks or
conveyor system
Filtrate
To washers
21
Red Mud Cake from Outotec Filter Press

Existing Drum Filter Product
Filter Press Product

Pictures courtesy from Alunorte Plant
22
41
Dry Disposal downstream Filter Press
To refinery or
Treatment plant
Dry red mud from
filter- presses
Effluent
pond
Bleed water
23
Evaluation of Disposal Alternatives

• Wet disposal may be applied when evaporation exceeds rainfall, but
environmental risks, high surface area, unfavorable water balance and poor
remediation make it less desirable choice
• Paste disposal after deliquoring by vacuum filtering and optional farming
(other means than filterpress) allows for smaller footprint or longer disposal
lifetime with reduced environmetal risks, better remediation and improved
water balance
• Dry Disposal with filter presses provides for best use of disposal area,
lowest water production, minimized environmental risks, good remediation
and partially compensated for the initially higher CAPEX by caustic
recovering
(remark: caustic recovery potentially limited by reduced impurities bleed !)
• Dry Disposal with filter presses - is the benchmark to beat !
24

Case Study: Red Mud Disposal Alternatives
Criteria Wet Disposal Wet Disposal Paste Disposal Dry Disposal

Paste Thickener + Filter Press
Thickener Vacuum Filter
+ Farming
Storage capacity requirement with 100 72 53 12

100% for Wet Disposal
CAPEX for 30 years with 100% 100 75 58 37
for Wet Disposal
Final Moisture in solids, % >55 40-55 30-40 <25
Water Quantity to be re-pumped

40 35 20 -
to plant %
Storage Stability ---- ++ ++++ ++++
High Re-vegetation possibility ---- + +++ ++++
Low Environmental Risk -- ++ +++ ++++
Low Closure cost -- ++ +++ ++++
25
Case Study: Red Mud Disposal Alternatives
26
43
Substantial problems require substantial
solutions
27
Outline
• Description of the technology

• Challenges in adopting new
technology
• Outotec’s vision
28

Red Mud Disposal Alternatives
Rotary Vacuum Drum Filter cake Filter Press (with pressing membrane)
~36% moisture. ~25% moisture.
Outotec Filtration Plant - 7 filters installed

29
30 45
served
Inside this Outotec Filtration Plant
31
Membrane Filter Plate Technology

• Outotec Larox Membrane Filter Presses
• Based on proprietary Hoesch Membrane
plate technology, invented 1968.
• Replaceable rubber membrane in PP plate
construction
• Updated for large-scale mining

applications:
• Minimising caustic losses.
• Maximising disposal area lifetime.
• Robust construction
• Rubber membrane for abrasion resistance
and process flexibility
• Stay-bosses for additional strength
• Oversized ports to minimise velocity of
abrasive suspensions
32

Membrane Filter Technology
• Filtration
• Chamber depth of 32,5mm or 45mm to suit bauxite
residue and tailings filtration
• Membrane plates
• Variable chamber volume operation
• Flexibility to adjust filter performance
• Shorter filtration times
• Higher pressures possible
• Prevents cake cracking
• Top feed filter plates

• Supporting fast filling and large feed port diameters
• Maximising the available filter area
• Keeping the feed ports out of the cake area
• Replaceable wear resistant filling shoes
33
Outotec Larox FFP Filtration Plant

www.youtube.com/watch?v=D4IUD7VWiIU
34
47
Challenges
• Historically, red-mud is treated

with less advanced equipment
• Large scale installations in this
application are new.
• There will be an adoption period.
• Re-training and continuous focus
on the benefits are therefore
crucial:
- Environmental impact
- Safety
- Cost savings (recovery of liquors)
- Plant longevity
35
Outotec Fast Opening Filter Presses

(FFP Filters) for Red Mud Filtration
• Plate pack technology designed for higher capacity (kg/m2.h)
 Largest plates (2.5m x 3.5m = 13.4m2/chamber), fewer components
 Fastest chamber filling time
 Fast cake squeezing with compressed air
 Fast opening/closing of plate pack
 Filter cake fully discharges in < 20 sec
• Cloth shaking and washing

 Shaking (cloth, not plate) ensures cake discharge
 Washing (15-20s) ensures clean sealing surfaces
 Washing using last washer overflow
• Process control optimisers

 Such as, patented plate pack weighing system
 Consistent cake dryness in unsteady conditions
• Filter cloths not attached to plate 

 Replace 10 cloths in 5 minutes (maximum).
 Safety, no personnel getting between plates
• Very high equipment availability

 Higher productivity with less downtime
36

FFP filter press portfolio for residues
Outotec Larox FFP

2512 Series
37
Unique Filter Plate Design
• Plate bending and breakages

• Differential pressures can occur
during filtration either through
blockages or uneven filling with
different cloth permeabilities
• Outotec design utilises stay bosses

• to confine differential pressure forces
to one chamber
• Outotec’s plate design protects the
membranes by removing them from
the stay boss, creating a more rigid
support
38
49
Plant Safety – Filter Cloth Replacement
 FFP3512 filter plate has all porting outside of the filtration area.
No penetrations or holes in the body of the cloth to align.
 Filter cloths not attached to plate  also increases availability
Replace 10 cloths in 5 minutes (maximum)
Safe working – no personnel getting between plates
Logistics – Cloth storage racks on operating floor level for each filter
39
In-Plant Safety & Uptime
Cloth exchange tool which can lift five cloth pairs (10 cloths) at the same time to speed up cloth
maintenance.
Cloth storage racks for clean cloths. Racks are close to filters so the change can happen easily and
quickly.
Cloth storage racks can also be used for storing of the dirty cloths. Drippings from wet cloths are
collected to a drain vat located under the racks.
40

Cloth Cleaning and Replacement
• Cleaning by means of flushing
• Flushing liquor cleans cloth as well as the feed shoe area
• Flushing from top to bottom into the chambers
• As liquor might block spray nozzles, the Outotec Larox system has easy
interchangeable spray bars with slots instead
41
FFP Control Panel

• Standardised control panel
• Programme architecture and base logic same for all filters in
the Outotec Larox range improving support, minimising start-
up errors
• Each system is customized through recipe selection without

changing the PLC programme
• Dual language standard (English + local language)
• Control philosophy designed to keep the filter

operating at the highest possible level of performance
• Optional advanced control options

• Flow, weight, cloth hole detection, cake wash and drying
control
• Programme and data table structure designed for

easy integration into the local DCS system
• Highly experienced personnel in DCS and SCADA protocols
programming
42
51
Features that support performance
• Large plates,  • Higher capacity per unit

• Fast opening system • Reduced investment costs
• Reduction of wear-and-tear
parts
• Slurry port design  • Reduction of inlet velocities
• Filtrate port design  • Increased hydraulical

capability
• Reduced residual moistures
• Reduction of wear-and-tear
parts
• Integrated cloth cleaning  • Increased process
performance
• Cloth lifting device  • Automated cake discharge
• Fewer operating personal
• Integrated squeezing medium  • No external plate connections

distribution
• Hydraulic closing system  • Standard components
43
This is happening now
44

• Outotec wants to be a part of
the solution to the problem of
red mud.
• Treatment, Filtration and Dry
Disposal:
• Reducing Capex
• Improving water balance
• Improving process yield
• Ultimately helping restore land
for other use post operation.
Source: Wikimedia
45
53
Integrated Alumina Refinery Design
New Developments
Dr. A. Scarsella
Contents
• Outotec‘s approach to integrated refinery design

• What Services Outotec provides for the client
• Previous examples of integrated refinery design by Outotec
• Case Study 200,000 tonne per annum alumina refinery in Iran.

Our Services in Integrated Refinery Design
What is meant by integrated refinery design

• Design of the integrated Alumina refinery to a tailored level
for the specific bauxite and site, utility and requirements
specified by a client.
• Applicable for greenfield projects and brownfield
expansions
• Bringing to together process and planning knowledge for
a specific design criteria.
55
Major project steps, content and failures
Gate Review Gate Review Gate Review Gate Review Commissioning

0 1 2 3
Technology
Pre-Feasibility
Order Of Magnitude Study Feasibility Study
Commercial Concept & (FEL1) (FEL 2) (FEL3) Detail Studies
Start-up &
Evaluation Business Appraisal Select Best Define Project &
Ramp-up
(FEL0) Up to 0,5% TIC Solutions 3 to 5% TIC Construction
Accuracy +/-30% Up to 1,5% TIC Accuracy +/-10%
Marketing Accuracy +/-20%
Cancel
75% of the 50% of the Only 1% of the
projects do not remaining projects projects do not
pass the cut do not pass the cut pass the cut
Decision
Continue
Recycle
Outotec can perform most studies prior to

construction of a Bx/alumina refinery
 Bauxite test work
 Modeling, heat & mass balance
Concept & evaluation FEL0
 Process description
Order of magnitude FEL1
 PFDs
Pre-feasibility FEL2  P&IDs
Feasibility study FEL3  Equipment list
 Drawings
Detail study FEL4
 CAPEX (plant unit and specialty)
 Financial model

Outotec technology and delivery layers
Leading Technology for Equipment and Process Components
Thickener Circulating Preheating FFP- Filter Cyclone Grinding Mill

Fluidized Bed (CFB) Burner
Combination of Process Know How with Equipments and Services:

= Plants with dedicated process and performance guarantees
Tube Digestion CFB Alumina Grinding Plant Security Clarification Red Mud
Plant Calciner Plant Filtration Plant Plant Treatment plant
Examples of Integrated Refinery Design

from Outotec
57
Commalco Alumina Refinery ,Australia 1.4 MTPA
• Client:
Commalco (now RTA)
• Location:
Gladstone, Australia
• Plant capacity:
1.4 MTPA Alumina
Project Phase: FEL 3
• Special features:
• Feasibility study for the production of smelter grade alumina, Weipa boehmitic
bauxite. Scope restricted to digestion only. Executed via the Hatch-Ouotec
(HOT) Joint Venture.
Ma‘aden Alumina Refinery ,Saudi Arabia 1.8 MTPA

• Client:
Ma’aden/Alcoa
• Location:
Ras Al Khair/KSA
• Plant capacity:
1.8 MTPA Alumina
• Special features:
• Feasibility study for the production of smelter grade alumina, local saudi
boehmitic bauxite. Executed via the Hatch-Ouotec (HOT) Joint Venture. Scope
restricted to digestion and evaporation only.

Aneka Tambang (ANTAM) ,Indonesia 1.2 MTPA
• Client:
Antam
• Location:
West Kalimantan, indonesia
• Plant capacity:
1.2 MTPA Alumina
• Special features: Feasibility study for the production of smelter grade alumina,
using a mixture of local gibbsitic bauxite .
Case Study: Sarab Alumina Refinery
59
Some Facts
• Client:
Imidro
• Location:
Iran, East Azerbaijan Prov.
• Plant capacity:
200 kTPA Alumina
2.58 MTPA Bellite Mud
38 kTPA Sodash
148 kTPA Potash
• Project Phase: FEL 3
• Special features: Feasibility study for the production of smelter grade alumina,
cement and salts using Alumino Silicates feedstock and the complex sinter
processing route.
Some Facts
• Refinery at Sarab City 140 km east of Tabriz
• Limestone: Areshtanab Mine south east of
Tabriz
• Alumino Silicate Ore: Razgah mine east of
Tabriz
• Client conducted a pre-feasibility study 25
years ago using an older technology

Scope of Work
• Full Test work

• Complete Basic Engineering
• Technical Feasibility
• Modernisation of the old Technology
• Flow sheeting, PFD‘s, PID‘s
• Civil and structural
• Piping
• Electrical and Instrumentation
• Procurement
• Planning for the implementation phase
• +/- 10 % capital estimate
Aims of the Basic Engineering
Basic
Engineering
61
Definition of basic technical parameters
Conceptual
Design Phase
Conducted Engineering Works
Engineering
Works

Basis Documents for Estimating Costs
Estimate per
Plant
Estimate per
Discipline ESTIMATION
How did Outotec Approach this ?

Challenges ? OT Approach
• Bayer technology has developed
• Energy and Water consumption for this
considerably throughout the last 100 years
process is significantly higher than the • Alumino silicate liquors have very similar
Bayer process behavior to bayer liquors (Alumina, Caustic,
• Ore alumina content is low scale etc…)
• Ore and Limestone silica content is high
• Latest pyro metallurgical technology and
• Old technology used a single kiln with wet Bayer type technology was designed for this
feed, very little or no heat recovery process with an attempt to considerably
processes improve plant availability and performance
• Availability of water ?
• All process units were verified either by pilot
plant tests, test work or reference case
studies.
63
Alumino Silicate Refinery Process
NEPHELINE CRUSHING AND BLENDING AT MINE STOCKPILE RECLAIMING AND SIZE REDUCTION AT REFINERY
NEPHELINE NEPHELINE NEPHELINE NEPHELINE NEPHELINE

NEPHELINE NEPHELINE STOCKPILE AND SECONDARY MILLING
ROM PRIMARY STOCKPILE
TRANSPORTATION TO
REFINERY RECLAIMING CRUSHING
CRUSHING
LIMESTONE CRUSHING AND BLENDING AT MINE STOCKPILE RECLAIMING AND SIZE REDUCTION AT REFINERY
LIMESTONE LIMESTONE LIMESTONE LIMESTONE LIMESTONE

LIMESTONE LIMESTONE STOCKPILE AND SECONDARY MILLING
ROM TRANSPORTATION TO
PRIMARY STOCKPILE RECLAIMING CRUSHING
REFINERY
CRUSHING
LIMESTONE CALCINATION AND SLAKING AT

REFINERY
LIMESTONE LIMESTONE MILK OF LIME TO

CALCINATION SLAKING DESILICATION AND
CAUSTIZATION
FUEL
WATER
SINTERING
TO CARBONATION AND
BLENDING AND SINTERING SINTER DE-DUSTING DECOMPOSITION
PREHEATING COOLING AND GAS
CLEANING
FUEL TO GRINDING AND LEACH
Alumino Silicate Refinery Process

Sinter plant Technology - Critical
• Wet or dry sinter ? Outotec Solution
• Na2CO3 – Al2O3 – SiO2 – CaO system • New Sinter Technology – Semi Dry
understanding fundamental Process:
• Wet process required single 190 M kilns • Granulation of the Na2CO3- Ore-
with limestone/Soda/Alumino Silciate Limestone mixture with water followed by
mixture at >1200 C – Low risk High energy pre-calcination in a CFB at 800 -900 C for
consumption 10 – 20 Minutes followed by rotary kiln.
• Dry process required fine grinding of all • Segregation risk and liquefaction risk of
ingredients with pre-calcination in a flash Na2CO3 eliminated
furnace at 950 C and rotary kiln at ~1300 C
- High Risk, Material segregation within
flash furnace possible and Na2CO3 turns to
liquid at 857 C
Typical granules
Sinter Plant Fluidized Bed (FB) Test Work
50mm fluidized bed test facility De-carbonized granules Fluidization of granules
Issue Results of test work
Suitability of granules • Granules well suited for fluid bed application (good fluidization)
for fluid bed (FB) • No sticking even at higher temperatures (900°C) due to morphology
process in general • No granules breakage even at high de-carbonization rates (granules get
porous, but hard)
Suitability for Outotec‘s • Granules can be calcined at around 825°C with Outotec CFB
circulated fluidized bed technology to a de-carbonization level of minimum 80%. This allows
application (CFB) calcination of limestone below the melting point of Na2CO3
65
Sinter Plant - Pilot Plant Rotary Kiln Test Work
Why sintering and leaching tests?
• The final sintering of limestone and
alumino silicate needs to be done in rotary
kiln at burning temperatures of
approximately 1250-1350°C
• The feasibility of dry/semi-dry/wet sintering
needs to be tested in a pilot plant
Main goals of tests?

• Comparison of dry and semi-dry sintering
process Pilot-scale rotary kiln
• Decision for dry or semi-dry sintering
process
• Determination of leaching efficiency for
process simulation
• Dry and Semi dry Tests were conducted at
pilot plants here in germany
Pilot Plant Sintering Test Work

Feed material Processes
• Alumino silicate • Dry process: Dry powder (d80=50µm) to rotary kiln
• Limestone • Semi-dry process:Granules with 10-20% moisture to rotary kiln
• Soda (Na2CO3)
Test Process Sintering Raw Material Comments on operation

ID Type Temperature Mass Flow
[°C] [kg/h]
D1 Dry 1260 450 No problems during operation

D2 Dry 1290 450 Heavy sinter ring formation, creation of big
lumps, and forced kiln shut down after 3h of
operation
D3 Dry 1320 450 Heavy sinter ring forming, creation of big

lumps, and forced kiln shut down after 1.5h
of operation
SD1 Semi-dry 1270 450 No problems during operation

SD2 Semi-dry 1320 450 No problems during operation

Pilot Plant performance
Sinter
• The semi dry process from OT granulates limestone, rings
Alumino Silicate and soda at moderate moistures lumps
forming stable granules which easily fluidize, this
minimizes segregation in the pre-calcining fluid bed
and dust loads. Furthermore the use of a circulating
fluid bed allows for a residence time of about 10 - 20
minutes which means that the pre-calcining
temperature of the furnace can be lowered to 800 C
thus avoiding liquefaction of soda, furthermore pilot Typical formation of sinter rings and big
lumps during dry trials in pilot kiln
test results showed no visible signs of sinter ring
formation using this technique.
Sintered product of semi-dry process
Sinter Plant Technology
• Beating Heart of the process

• Wet sinter process: kilns up to 190 m long using wet sinter technology plus water spray
drum coolers, additional sinter crushing required
• OT Semi-Dry Process: 67 m long kilns, 85 m high circulating fluid bed pre-calciner, sinter
cooler equipped with inbuilt crushers
67
Plant Design for Sintering
Remaining Challenges: How to further decrease energy

and water consumption
• Desilication post leaching step requires holding process liquor with seed at 200 C.
• OT design: 8 autoclaves 3+1 for two lines, 5 pre-heating stages plus 1 final heat stage per line, no direct steam
injection, complete redundancy of system to deal with scaling of heater banks and autoclaves, flash tanks so as
there is a minimum disruption to operations
• OT design has provision indirect heating plus 5 recuperative heating stages, including a redundant heating train
so that disruptions to operations are minimimsed during a chemical or mechanical de-scale, in addition all
autoclaves and flash tanks are by passable also allowing for minimum disruption to operations during a
mechanical de-scale.
• Carbonate salts stage use banks of forced circulating crystallizers and evaporators with mist
eliminator.
• Both systems designed to deliver Bayer quality condensate, reducing water consumption.

Other Design features which deviate from old design(s)
• Use of air swept ball mills for the prupose of limestone and nephleine milling in a closed
circuit with cyclones
• Use of closed circuit wet ball milling for sinter grinding.
• Introduction of a modern pan filtration than can achieve together with stationary circulating
fluid bed calciner.
• Fast action filter press plant for the dewatering of bellite mud for the purpose of downstream
cement production
• Vertical shaft furnace is required for lime production
Process Design Achievements

Reference Plant Sarab Reduction in Gas, Water and Steam
Old Technology Outotec
Energy GJ/t 39,01 58,2 Consumption
Alumino Silicate t/t 4,061 6,6
Lime t/t 6,31 13,3
Al2O3 % 28,6%1 19,6% Gas savings with OT design = 285,5
Specific Water Consumption,
Million Nm3 per year
m3/t 252 15 Water savings with OT design = 2,1 Million
Specific Steam Consumption,
t/t 2,71 2,3 m3 per year
Typical Alumina calcination Reduction in Steam consumption = 41,5
energy, GJ/t 3,1 2,8 tonnes per hour
Hydrate refining energy, GJ/t* 35,9 55,4
Total Specific Throughput t/t 11,6 19,8
Specific Energy Consumption

based on a Sarab like
throughput, GJ/t 69,6 58,2
% Improvement on energy 16% NA
1 Arlyuk and Pivnev, Light Metals 1992

2 Ataei, The Journal of The South African Institute of Mining and Metallurgy, 2005
69
Closing Thoughts and Conclusions
• Competition with Bayer process ?

• Very special circumstances
• Low operational costs but a higher investment cost is needed.
• Extremely energy intense than what we in the bauxite and alumina industry is use to hence
access to cheap energy a pre-requisite
• Plant needs to be in a location where cement is in demand, otherwise a major byproduct is

not sellable.

Alumina CFB Calcination Generation 4 to 5
Risk Mitigation in Technology Development
Outotec Users’ Meeting – Dr. Linus Perander
October 2017
1. Calciner Roadmap and past drivers

2. Current drivers and impact on calcination development
3. Risk management in technology development
4. Challenges in the Transition from Gen 4 to Gen 5
5. Summary and Conclusions
71
Outotec CFB Calciner Road Map
• The Outotec® Circulating Fluidised Bed Calciner technology was developed in
the late1960’s
• The first industrial scale plant was operational in the early 1970’s, this was the
first industrial application of the CFB technology
• More than 60 alumina calcination plants have since been delivered and over
10 plants upgraded
• Since 2014 the 5th generation is in operation (2x3500 tpd)) with 3 more plants
in construction
Early Late Early
Gen 1 Gen 2 1990s Gen 3 Gen 4 2011 Gen 5
1970s 1970s 2000s
Capacity
T Al2O3 / day
24 - 800 700 - 2000 2700 - 3100 1300 - 3500 500 - 3500
Fuel Energy
GJ / kg Al2O3 (LHV)
> 3.2 < 3.2 < 3.0 < 2.9 < 2.8
Electrical Energy
kWh / T Al2O3
> 24 < 22 < 20 < 18 < 16
Particle Breakage
-45 µm fraction
> 15 < 10 < 6.0 < 3.0 < 3.0
CFB Calciner Generation O’1
Introduced: early 1970’s
• Main features:
• 2 preheating stages
• ESP preseparation
• 1 cooling stage in form of fluid bed cooler
with dedusting cyclone
• References:
• VAW Lünen (Germany)
• AOS Stade 1 & 3 (Germany)

Introduced: late 1970’s
• Main features:
• Integrated ESP
• 1 cooling stage (cyclone)
• 1 fluid bed cooler
• References:
• Nalco A&B (India)
• Bauxilum 1-4 (Venezuela)
• Worsley 1-3 (Australia)
• Guizhou 1 (China)
• Shandong 1 (China)
• Nikolaev 1-4 (Ukraine)
• Alunorte A&B (Brazil)
• Largest unit 3100 tpd

• Main features:
• Integrated ESP
• 1 fluid bed split cooler (some)
• First stage Bypass
• References:
• Nalco C (India)
• Worsley 5 (Australia)
• Shandong 2 (China)
• Guizhou II (China)
• Nikolaev 5 (Ukraine)
• Jisco Alpart 1,2 (Jamaica)
• Hindlaco Muri (India)
• Gove K5 (Australia)
• Alunorte C (Brazil)
73
• First 3500 tpd units
• Main features:
• Integrated ESP
• 1 fluid bed joined cooler
• References:
• Gove K6&7 (Australia)
• Alunorte D,E,F&G (Brazil)
• CBA VII (Brazil)
• Main features:
• ESP Preseparation
• 1 fluid bed joined cooler
• Advanced Bypass
• References:
• Ma’aden 1&2 (Saudi Arabia), 2x3500 tpd
• Undisclosed Client, 1x500 tpd
• Al Taweelah 1&2 (UAE), 2x3500 tpd

Past Drivers for Technology Improvements
• Changes in alumina quality demand

• The change from floury to sandy coarse alumina
• Reducing particle breakage
• Reducing specific fuel energy
consumption
• Reducing construction cost
• Plant arrangement and specific weight
• Increased capacity
• Improved availability, maintainability
and safety
• Automation and control
• Ease of operation and maintenance
• Safety features (BMS/SIS, design etc.)
Reducing Particle Breakage

• Optimization of velocity profile
• Optimization of fluidization technology (SF
Nozzle™ and improved bubble caps)
• Improved position for fuel injection
• Reduction in calcination temperature
• Improved automation for stable operation
New
Fluidization
Method by
SF Nozzle™
References:
Missalla M., R. Bligh, M. Stroeder, C. Klett., “Design Developments For Fast Ramp-Up And Easy Operation Of New
Large Calciners”, TMS Light Metals (Warrendale, Pennsylvania): pp. 79-86. (2007)
Missalla M., J. Jarzembowski, R. Bligh, H-W Schmidt, “Increased Availability And Optimization Of Calciner
Performance Due To Automation” TMS Light Metals (Warrendale, Pennsylvania): pp. 241-246. (2009)
Hiltunen P., R. Bligh, C. Klett, M. Missalla, H-W. Schmidt., “How To Achieve High Availability With Large Calciners And
PATENTED Avoid Unforeseen Downtime” TMS Light Metals (Warrendale, Pennsylvania): pp. 63-68. (2008)
75
Reducing energy consumption
• More cooling stages
• New cooler design(s)
• New blower concept
• Hydrate bypass
• Cyclone optimization
• Advanced controllers (e.g.
feed forward, airflow
optimizer)
Early Late Early

Gen 1 Gen 2 1990s Gen 3 Gen 4 2011 Gen 5
1970s 1970s 2000s
References:
Schmidt H-W, W. Stockhausen, A. Silberberg., “Alumina Calcination With The Advanced Circulating Fluid Bed Technology: A Design With Increased Efficiency Combined With Operating Flexibility”, TMS Light Metals
(Warrendale, Pennsylvania): pp. 81-87. (1996)
Missalla M., R. Bligh, M. Stroeder, C. Klett., “Design Developments For Fast Ramp-Up And Easy Operation Of New Large Calciners”, TMS Light Metals (Warrendale, Pennsylvania): pp. 79-86. (2007)
Perander L., A. Lalla, C. Klett, B. Reeb, B. Petersen, M. Missalla, E. Guhl. „Application of Optimized Energy Efficient Calcination Configuration to AOS Stade CFB Calciners”, Proceedings of the 9th Alumina Quality
Workshop. 2012
Missalla M., J. Jarzembowski, R. Bligh, H-W Schmidt, “Increased Availability And Optimization Of Calciner Performance Due To Automation” TMS Light Metals (Warrendale, Pennsylvania): pp. 241-246. (2009)
Plant Arrangement and Specific Weight Reduction
Gove K6 & K7
Capacity: 2 x 3500 tpd
AOS Stade Height: <45 meters (excl. stack)
Capacity: 3 x 650 tpd (original)
Height: 73 meters (excl. stack)

Plant Arrangement and Specific Weight Reduction
• Change from tower to flat

arrangement halved the
capacity specific weight
• Further decrease in spec.

weight due to optimization of
plant arrangement and
refractory and equipment
design optimization
References:
Schmidt H-W, W. Stockhausen, A. Silberberg., “Alumina Calcination With The Advanced Circulating Fluid Bed Technology: A Design With Increased Efficiency Combined With Operating Flexibility”, TMS
Light Metals (Warrendale, Pennsylvania): pp. 81-87. (1996)
Larger capacity plants

• In the last two decades Outotec
has mainly delivered plants in
the range 1500-2000 tpd and
3000-3500 tpd
• For today‘s “typical” refinery
size of around 2 MTPY, calciner
capacity of 2x3500 tpd is well
suited (from an opex and capex
perspective)
• Particularly with the large load
flexibility offered by CFB
calciners where plant loads in
the range 25-110 % is easily
achievable.
77
Current Trends and Drivers

• Reduced specific investment cost
• Lower specific energy consumption
• Upgrades and retrofits of old calciners
• AOS CircoCal upgrade (< 2.7 GJ/T Al2O3, LHV)
• Life extension of > 30 year old plants
• Special grade aluminas and dried hydrate
• More stringent environmental requirements
• Dust emission (EU 5-30 mg/Nm³, depending on fuel type and thermal rating)
• NOx (EU 100 mg/Nm³)
- the staged combustion in CFB calcination can reduce NOx to < 50 mg/Nm³
• CO (EU 100 mg/Nm³)
- Typically low in CFB calciners due to intense mixing, uniform temperature in furnace and overstoichiometric conditions
• SOx (EU 5-400 mg/Nm³, depending on fuel type and thermal rating)
- Sulphur with the fuel is the main source of SO2 emissions in calciners
• Dioxines, Furans, PAHs, VOCs, Heavy Metals
- Typically low in calciners due to relatively pure fuels and optimised combustion conditions
• CO2
- Can primarily be influenced by reducing specific energy consumption
• Alumina quality beyond the specification sheet


Thermal Efficiency of CFB Calciner and
Options for Energy Recovery
• Thermal efficiency of CFB Calciner is > 95% due to
refractory design and insulation
• Main sources contributing to efficiency losses (typical)
• Heat loss with the waste gas (0.8 GJ/t Al2O3)
• Heat loss with alumina cooling (0.4 GJ/t Al2O3)
• Recovery of energy from waste gas is feasible but
complex (e.g. heat exchanger, scrubber) but can also
be used for water recovery or combined with
carbonation precipitation
• Recovery of heat loss with cooling water can be
achieved by moderate efforts (e.g. hydrate dryer)
• Decreasing hydrate moisture and increasing hydrate
temperature offers further potential (e.g. wash water
preheating, steam hoods)
References:
Michael Missalla, Andreas Koschnick, Linus Perander, H-W Schmidt, Energy efficiency in alumina refineries-- Combining hydrate filtration with alumina calciner, ICSOBA 2015
Liu Yingying, Li Laishi, Liao Xinqin, Bai Ruisheng; Recovering Waste-heat and Water from Alumina Calciner Gas, TMS Light Metal 2015
Energy Recovery
• The potential of the cooling water of approximately 0.4 GJ/t Al2O3 can be recovered by moderate efforts,
such as:
• Incorporation of hydrate dryer
• Preheating of filter wash water
• Production of low pressure steam for example for steam hoods
• Liquor preheating
• The benefits are threefold:
1. Less heat is wasted at the cooling towers
2. Hydrate moisture is reduced  20-25 kJ/kg Alumina / 1.0 wt-% moisture reduced
3. Hydrate temperature is increased  0.9-1.1 kJ/kg Alumina / 1°C temperature increase
• Particularly of interest when calcination is combined with hydrate filtration
79
Energy management for FB cooler
292 °C 268 °C 156 °C 112 °C <70 °C
Air Circulating Water Wash Water Cooling Water
Purpose Limitation Transferred

heat
1 Air Preheating Tair should be high enough to ensure proper fuel 10%
Directly reduces spec. fuel combustion in CFB, T > 150 °C
energy consumption
2 Hydrate drier Energy should be enough to dry part of the hydrate 51%
Directly reduces spec. fuel completely
energy consumption
3 Wash water Tin, Tout and capacity of wash water is set => 20%
No direct impact on spec. fuel energy requirement
energy consumption
4 Cooling Water T of product < 70 °C to be ensured 19 %
For final cooling Tin and max. Tout of cooling water is fix
19
Integration of hydrate dryer and heat Hydrate from Filtration Preheating Stage I Offgas
to ESP
carrier circuit Dryer Offgas

to ESP
• Heat is transferred from FB cooler via

pressurized water system M
Heat Carrier
• The pressurized water is circulated in a Return
M
closed loop. Alternatively, thermal oil or steam Heat Carrier from

Fluid Bed Cooler Dried Hydrate
can be used Fluidizing Air for Dryer
• Extra tube bundle heat exchanger allows for Fluidizing Air for Dryer
Hot Offgas from
Preheating Stage II
cooling of alumina without dryer in operation

• Top buffer vessel always ensures water
pressure above vapor pressure
• Discharge and bed level is controlled via a
sealpot
Reference:
Perander L., A. Lalla, C. Klett, B. Reeb, B. Petersen, M. Missalla, E. Guhl.
„Application of Optimized Energy Efficient Calcination Configuration to AOS
Stade CFB Calciners”, Proceedings of the 9th Alumina Quality Workshop. 2012

General Approach to Risk Management
• Risk management is a broad subject

• Competing and sometimes conflicting standards
• ISO31000 – Risk Management standards provides a good general overview
• Must be treated as a project

• Objective and scope
• Plan and schedule
• Leadership and ownership/responsibility
• Must be transparent
• Clear rules and guidelines
• Common tools can be applied (RCA, C&E, risk matrix etc.)
• Communication with external and internal stakeholders
81
Risk Management – Establishing the Context
Establish context • Define the scope

RISK ASSESSMENT
• Define the objectives
• Identify the stakeholders
Communicate and Consult

Identify risks
Monitor and Review
• Set up the project

• Collect the main information (e.g.
Analyse risks process data, failure reports,
audit/inspection protocols etc.)
Evaluate risks
Treat risks
Risk Management – Identifying the Risks
Establish context • Brainstorming:

• What could happen?
RISK ASSESSMENT • How could it happen?
• Where could it happen?

Identify risks • Why could it happen?
Monitor and Review
• What could the impacts be?

• Checklists can also be used
Analyse risks
Evaluate risks
Treat risks

Risk Management – Analyse the Risks
Establish context • Root Cause Analysis

• Ishikawa/fishbone
RISK ASSESSMENT • 5 why‘s

• Mindmap/tree
Identify risks
Monitor and Review
• Likelihood and Consequence (Risk)

matrix
Analyse risks • Define possible risk treatment
options
• Effect
Evaluate risks • Cost
Treat risks
Risk Management – Evaluate the Risks
Establish context • Evaluate results from analysis

RISK ASSESSMENT
• Decide on next actions
• No requirement to proceed
Identify risks • Accept the risk, but monitor and evaluate

Monitor and Review
• Treat the risk
Analyse risks
Evaluate risks
Treat risks
83
Risk Management – Treat the Risks
Establish context
•Stop the activity to avoid
RISK ASSESSMENT the risk

Identify risks •Eliminate the risk
Monitor and Review
•Remove the risk source

Analyse risks •Change the likelihood
•Change the consequence
Evaluate risks •Share the risk
•Retain the risk
Treat risks
Risk Management – Monitor and Review / Communicate and Consult
Establish context MONITOR AND REVIEW

• Continuous monitoring
RISK ASSESSMENT
• Audits, inspections
Identify risks • Frequency and methods defined

Monitor and Review
COMMUNICATE AND CONSULT

Analyse risks
• With internal and external
stakeholders
• Meetings
Evaluate risks
• Reports
Treat risks

Key Differences
• Multicyclones for preseparation before ESP

(for some Gen 5 plants)
• ESP size reduced and ESP dust transport
system (re-)introduced
• FB-cooler (compact bundles, reduced size,
reduced fluidising velocity and airflow)
• Plant arrangement
MOTIVATION
Meet market pressure for reduced
investment cost (compact plant design)
30 10/25/2017 Presentation name, Author

85
Gen 4 vs Gen 5 - Arrangement
FEED
FEED
PRODUCT PRODUCT
•31
Presentation name, Author
•10/25/2017
Key Similarities
• Feed bin and feed screw

• Venturi stage 1
• Venturi stage 2
• Cyclone stage 2
• CFB (Furance, Recycle cyclone, Sealpot)
• Liftduct 1
• Sec Air Cyclone 1
• Liftduct 2
• Air Cyclone 2
• Sealpot and pendulum flap valves
32

Challenges in the Transition from Gen 4 to Gen 5
• Outotec calcination technology transitioned from Gen 4 to Gen 5 in 2011 with

two 3500 tpd calciners
• Commissioning commenced late 2014
• Revised flow sheet introduced new risks
• New equipment and new suppliers introduced new risks
33
Risk Mitigation in Technology Development

Example: ESP Dust Transport
• Benefit • Challenge
• Preseparation before ESP allows for • The nature of ESP dust is different (smaller
smaller ESP and overall plant footprint particle size, more alpha alumina)
• Fluidisation of fine dust is challenging (limits
(reduced capex)
application of airslides and airlifts)
• Highly abrasive
• Electrical energy consumption is reduced • Sticky when combined with moisture
- for a 3500 tpd plant only ~20T/h of ESP dust • High temperature (particularly during start-up)
compared to ~240T/h for airlift, reduces
required conveying pressure and flow) • Risk Mitigation
- Smaller ESP requires less el. power • Rigurous testwork campaigns (internal and
external)
• ESP dust can be separated from process to • Application of abrasion resistant materials and
control quality (superfines, <20µm) coatings
• Special focus on shaft sealings
• Sizing and duty rating with sufficient margins
87
Summary and Conclusions
• Driven by a demand for: reduced energy consumption, improved product quality,

reduced investment cost and larger capacity plants, the CFB calcination technology
has undergone some significant changes over its 45 year history
• Outotec continues to develop the calcination technology and equipment to meet
todays and tomorrows expectations
• There is a potential for further energy reduction by heat recovery from the fluid bed
cooler or stack off gas (e.g. hydrate bypass, hydrate dryer, wash water preheating,
steam hoods) that can be utilised in old and new plants
• Introducing new technologies, changing suppliers or making other process changes
carries a certain risk that can have significant consequences unless properly
managed
• Applying a risk management approach in project implementation and technology
development is one way to mitigate such risks
36

Bauxite Enrichment:
Upgrading low value ores
into something processable
Outotec Users Meeting 2017
Peter Swash and Tanja Perander
89
Objective of Presentation
• Bauxite upgrading
• Introduce conventional process technologies
• Identify new business opportunities for Outotec
Low Grade Bauxites
Bauxite Type Processing Solution

• High %RSiO2 Washing Option
• Gibbsitic Bauxites > 9% • Remove RSiO2
• Screen off minus 20 micron size fraction)
• Low Grade Diasporic Bxt Flotation Option

• A/S = 4 and below • „Reverse“ – Float-off silicate minerals
• „Conventional“ – Float-off diaspore
• Silica Reduction  NaOH consumption
• Low %TAA Grade Process in Refinery.

• Gibbsitic Bauxites < 30% • Remove sand fraction from BO Slurry prior to thickening

Outotec Bauxite Enrichment Project
Bauxite Flotation
• Reagent Identification/Screening
• Self frothing collector
• pH 10 using NaOH
• Depressor - Starch
• Dispersant – Na hexametaphosphate
• Reverse & Conventional Flotation
• Size Splitting
• EXCEL Modelling & Bayer Impacts
Bauxite Milling
• Objective – Identify Mill Requirements & Sizing of Mill
• Provide a very provisional estimation
• Use of OMC & related spread sheets
• JKSimMet study
Roasting of Diasporic Bauxite

• Sulphide and impurity removal
• Optimum operating and digestion conditions
Washing Testwork
• Instead of a Mokken Scrubber Mill

• Crush 10kg to -3cm
• Agitate in cement mixer
• Screen
• Chemically Analyse Screen fractions
• Down to -38 micron
• Evaluate data
• Grade of RSiO2 + TAA
• Distribution of RSiO2 + TAA
91
Bauxite Washing Plants
Amazonian Bauxites
• MRN + Juruti + Paragominas
• 50% TAA + 5% RSiO2
• Gibbsitic + no Boehmite
• Low impurities + Low Organics
• No settling problems
• High RSiO2  Removes SO4 and CO3
• Precipitation Yield of >100gpL
• 8GJ/T Al2O3
• Perfect for Sweetening
Weipa
• Washing Plant
• High Grade + High Reactive
Bauxite Washing
Ref - Google

Juruti Washing Circuit
The diagram illustrates the use of

Trommel, Crusher, Screens and
Hydrocyclones in the separation of
kaolinite-rich slimes (20-25 mass%)
Paragominas – Washing plant
Ref - 2012. Operating Experience with the Paragominas bauxite wash plant, F.A. Mendes
93
Weipa Washing Plant
Ref - i.Power Solutions

Handout 2005
AMRUN – 23Mtpa – replace Weipa
Ref –
Presentation name, Author www.miningnews.net

Bauxite Flotation
• Chinese Operations
• Diasporic Bauxite A/S
• Diaspore
• Pyrophyllite
• Kaolinite
• Illite
• Chamosite
• „Conventional“ Flotation
• Reagent specific
• Al2O3 Recoveries ~70%
• Difference in %SiO2
• feed vs conc.
10/25/2017 13
95
Spread Sheet Evaluation
Individual Worksheets
• Process Description
• Flow Sheet
• Inputs and Outputs
• Mass Balance
• Tank Sizes
• Major Equipment List
• Refinery Impacts
• Overview
Mass balancing of data
Conceptual Conventional Flotation Circuit

Refinery Impacts Flotation Flotation Base
Waste Product Case
Tonnage Mine 1 Mine 2 Mine 3
Distribution for
expansion Al2O3 Recovery
Grade Increased
Combined Grade Bauxite tonnage
Production
Mine Grade Control
Bauxite – Cheapest way to
improve grade
Residue
Energy
Raw Materials
Summary
Refinery Impacts
97
Economic Evaluation
-ve +ve
• Flotation plant Capital Cost • Reduction in Silica content
• Plate Filtration Capital Cost • Reduced Caustic consumption
• Increased Moisture Content of Bauxite (20%) • Partial Removal of Organics
• Product Thickener required • Removal of Sulphides
• Separate Tailings Dam for flotation wastes • Control variability in feed
• Flotation Reagent costs • Reduced Lime costs
• Increased Water Usage • Reduced Flocculant costs
• Alumina Recovery <80% • Increased equipment capacity
• Increased Mining costs per tonne of Alumina • Lower gpL solids in slurry
• Increased Milling Cost • Improved BOR and liquor productivity
• Adsorbed reagent impacting on precipitation • Improved refinery production
Mine Grade Control

Economic Evaluation – Cheapest way to
improve grade?
Nepheline Use
Bauxite Importation
-ve +ve
• Flotation plant Capital Cost • Reduction in Silica content
• Plate Filtration Capital Cost • Reduced Caustic consumption
• Increased Mositure Content of Bauxite (20%) • Partial Removal of Organics
• Product Thickener required • Removal of Sulphides
• Separate Tailings Dam for flotation wastes • Control variability in feed
• Flotation Reagent costs • Reduced Lime costs
• Increased Water Usage • Reduced Flocculant costs
• Alumina Recovery <80% • Increased equipment capacity
• Increased Milling Cost • Lower gpL solids in slurry
• Increased Mining costs per tonne of Alumina • Improved BOR and liquor productivity
• Adsorbed reagent impacting on precipitation • Improved refinery production

Processing Low Grade Bauxite in a Refinery
Refinery Production = Flow x Yield
Blow-Off Ratio
Optimisation and
Control
Processability - Bauxite Characteristics

Factor Comments
RSiO2% Fixed Soda Consumption = (RSiO2% x 0.888) / TAA%
E.g. 10% RSiO2 + 50% TAA = 0.177t NaOH consumed
E.g. If NaOH - $300 per tonne  NaOH consumption = $53 per tonne of SGA produced
DSP efficiently removes SO4 and CO3 from liquor (lesser amounts of Cl)
Organic Carbon TC = TOC + TIC* (*Total Inorganic Carbon)

TOC = EOC + NEOC* (*Non Extractable Organic Carbon)
EOC = Extractable Organic Carbon entering liquor (= Bauxite Carbon)
EOC* = Oxalate Carbon + Non-Oxalate Organic Carbon (*does not include Na2CO3 Carbon)
% Extracted TOC = Oxalate Carbon + Non-Oxalate Organic Carbon + Na2CO3 Carbon
Impurity x Bxt Build-up of TOC in circuit. Other impurities - (F + V + SO4 + As + P + Ga + Li)

Usage Factor Impurity build-up  when solubility product is reached  precipitation occurs
Boehmite nano sized nuclei – promoting boehmite growth in slurry
99
Economics of Scale
Lower Bxt Grades  Increased
Flotation + Washing
Unit and Reagent Costs
Dirty Pure
Gibbsite
In
Refinery Gibbsite
Out
Milling Flocculant
Lime
Mud
Mill
consumables >Thickener Unit
PDS Digestion
Capacity Maintenance
Processing in Refinery  Increased Sand and Mud

Red Side Modelling
Removal of Sand
• Spiral Classifiers
• Sand Traps
• Sand Rakes
• Hydrocyclones
• Horizontal Screens
Mud Thickening
• High Rate Thickeners

Bauxite Testwork - Where can Outotec help?
• Chemical & Mineralogical Characterisation
• Bauxite Testwork – Flotation & Washing
• Bauxite Upgrading Options
• Bauxite Digestion testwork
• Bauxite Processability
• Mill Requirement Evaluation
• Bauxite Clarification
• Refinery Modelling
• Refinery Audits, Training,
• Production increase / Debottle necking
Evaluation of Bauxite or Redside upgrading
 Bauxite test work

 Modeling, heat & mass balance
 Concept & evaluation FEL0
 Process description
 Order of magnitude FEL1
 PFDs
 Pre-feasibility FEL2  P&IDs
 Feasibility study FEL3  Equipment list
 Drawings
 Detail study FEL4
 CAPEX (plant unit and specialty)
 Financial model
101
Alumina Refinery –
Outotec Technologies and Reference Plants
Caustic
Red mud
neutralisation
& disposal
Processing Low Grade Bauxites

• No interference from Boehmite in the bauxite. Progressive ratio Idealised Extraction
0,8
increase with increased bauxite charge. The use of Manitol in lab 105
experiments helps stabilizes the liquor and prevents boehmite 100

0,7
auto precipitation. 95
Extraction %
0,6
A/TC Ratio
90
• Good extractions are required when treating an expensive
imported bauxite. Impurity inputs, soda usage and the quantity of 85
A/TC 0,5
the residue must also be considered. 80 %Extraction
0,4
75
• A bauxite overcharge situation essentially wastes bauxite. Need
70 0,3
to hit maximum ratio and add no more bauxite. Otherwise 50 100 150 200 250 300
bauxite consumption rises unnecessarily.
Bauxite Charge (gpL)
Experimental Extraction
• A/TC ratio in plant scale operation data would drop progressively
105 0,8
owing to the impact of boehmite in the bauxite. Nucleation of
boehmite seeds from boehmite depleted bauxite also likely: at 1/ 100
0,7
higher temperatures, 2/ higher ratios and for 3/ extended 95
Extraction %
A/TC Ratio
digestion holding times. Impact of gpL solids and goethite content 90 0,6
also likely. 85 0,5

A/TC
80 %Extraction
• The diagram indicates that there is an extraction loss as the 0,4
75
bauxite charge is increased. The A/TC ratio will never be that
indicated by the theoretical solubility of Gibbsite or boehmite. 70
50 100 150 200 250 300
0,3
Bauxite Charge (gpL)

Processing of Lower Grade Bauxites Data at higher
Liquors are stable. Higher ratio more difficult to Kinetics of dissolution Liquors more viscous
temperatures
Gibbsite seed will grow in acheive for lower grade decreases at higher A/TC at higher A/TC
less accurate
saturated liquor. bauxites (>gpL solids) (Free Caustic reduced)
Solubility High amounts of

increases at lime typically
higher used for
Temperatures Diasporic
and higher TC bauxites
Impurities impact Diaspore

on solubility solubility lower
curves than boehmite
C = TC
High TC chosen
= Total Caustic
for diasporic
A/C Ratio Equilibrium A/C Ratios bauxites
C = Variable in Synthetic liquors.
Caustic
Diaspore milled
Concentration
to approx 80% -
Suite of Gibbsite 74 microns to
solubility curves improve
for different TC dissolution
Kinetics of dissolution very Suite of Boehmite solubility curves for
slow at low Temp & A/TC different TC Kotte – 1981, Light Metals
Equilibrium A/C Ratios in

Synthetic liquors. Trajectory for
dissolution of an ultrafine
gibbsitic bauxite.
Kotte – 1981, Light Metals
103
Sweetening
Equilibrium A/C Ratios in

Synthetic liquors. Illustrating a
trajectory for sweetening of an
ultrafine boehmitic bauxite
Kotte – 1981, Light Metals

Energy Saving for
Bayer Process in China
Gu Songqing
s.q.gu@163.com
+86 13503820936
Content
1. Energy Resources for Chinese Refineries
2. Gradient Utilization of Steam Energy
3. Improvement Demand for Bayer Efficiency
105
1. Energy Resources for Alumina Refineries
Tube Digester
Steam Boiler
Coal
Falling Film Evaporator
Gas Generator
Natural Gas
Natural Gas
Alumina Calciner
Electricity
Power Supply
Pumps Reduction Gears Pressure Filters
2. Gradient Utilization of Steam Energy
Coal Steam Power

Boiling Generation
Steam
Evaporation Energy Tube
Return Water Gradient Digestion
Utilization
Liquor Dead Steam

Evaporation from Live Steam
Condensate

Energy Saving in Digestion
Low
Live Steam Flash Pressure
Condensate Steam
Evaporation
Tank
High
Pressure
Predesilication Pump Preheating Digestion Flash Tanks Dilution
Live Steam Flash

Flash Steam
Steam
Last Stage Flash Steam
Single stream digestion process of diasporic bauxite

Energy Saving in Digestion
Third
Key Factor
Live Steam Low

Condensate Flash Tank Pressure Evaporation
Steam
High
Predesilication Pressure Preheating Digestion Flash Tanks Dilution
Pump
Live Steam Flash Steam Flash Steam
Last Stage Flash Steam
Fourth
Pressure Key Factor
Scaling Reduction
Grinding Orifice
Leakage Sizes
First Key Second
Factor Key Factor
Single stream digestion process of diasporic bauxite
107
Energy Saving in Evaporation
 Most of evaporators set up in Chinese refineries are the falling film

evaporators with higher heat exchange efficiency.
 There are two important factors for Chinese evaporation and both
factors influence the energy efficiency of evaporation:
(1) What is the best stage number of evaporation? 6 or 7 stages?
(2) The serious scaling problem: both sodium aluminum silicates and
sodium carbonates (sodium sulfates)
 The energy efficiency in evaporation can be improved by multi-stage
falling film evaporators to reduce the ratio of steam to water
evaporated and addition of scale inhibitor to extend operation period.

Energy Saving in Calcination
 There are two kinds of alumina calciners in China:
Gas Suspension Calciners Outotec Circulating Fluidized Calciners

 The energy consumption for the circulating fluidized calciner can be
reduced to 2.7 GJ/t alumina, while it becomes as high as 3 GJ/t alumina
for the gas suspension calciner due to its higher calcination temperatures
and more air injection.
 The gas suspension calciners are applied by most Chinese refineries.
(1) The gas suspension calciners can keep negative pressure operation,
which is less dust released and easier to control.
(2) The retention time is shorter in the gas suspension calciners and
alumina size distribution can be kept better.
 The most important consideration for circulating fluidized calciners is
how to make calciner operation easier and avoid the alumina particles
breaking during calcination by keeping energy saving.

The Energy in the flue gas in Calciner

can be reused by heat exchangers
Outlet
gas at 90 installed in the flue gas outlet.
℃
Heat
exchanger
The heat exchange is divided into
Hot water direct heat exchange and indirect heat
outlet
exchange. Indirect heat exchange can
Access
hole only be controlled at higher than about
Flue
gas at
Cool
water
130℃, while direct exchange can be
160 ℃
Inlet used for the gas at lower than 100 ℃.
Diagram of Heat Exchanger for Flue Gas About 1 GJ of energy can be
recovered in this process only if the
anti-corrosion equipment is invented
and the hot water application is found.
109
Energy Saving in Precipitation
CGM Caustic &

Temperature addition temperature
Seed sizes & difference
solid content
Classification
Multi-stages Pregnant liquor
Temp. reduction with seeds
Hydrates
Seed
moisture
Reduction No. 1
No. 3 No. 2
No. 5 No. 4
No. 14 No. 13 No. 12
Agitator Power
Seed
Seed filtration
Filtration Consumption
Precipitator Series in China

The major energy exchange happens in multi-stages temperature
reductions during precipitation.
Hotter Vapor
Water
Heat Air Cooling

Exchanger
Tower
Cooled
Water
The slurry temperature is reduced by cool water in the heat exchangers

and about 0.5 GJ of energy will be released into atmosphere by the
vapor from cooling towers due to the great flow rate of the slurry.
The important issue is how to recover the heat from the hotter water
after heat exchangers.

A great amount of electricity is consumed for the agitators in precipitation
process to keep slurry suspension and alumina precipitation.
Propeller
Gear Pulp
Robin Ekato New Design

The agitator type design can be made for power consumption reduction by
20-40% based on computer analog simulation.

Energy Saving in Red Mud Filtration
Plate-frame Pressure Filter Rotary Disc Pressure Filter
The plate-frame pressure filtration is widely used for drying bauxite residues
in China, which is a discontinuous operation and releases lots of vapor.
The rotary disc pressure filtration can be used for the same purpose but it is
a continuous operation with higher efficiency and no vapor released.
111
• Email : s.q.gu@163.com
• Moble: +86 13503820936
• Call: +86 01082298388

Cleaning of Tube Digestion
at AOS
Dr. André Lalla

Production Manager „White Side“
Aluminium Oxid Stade GmbH
AOS-E / 1
113
Type of Incrustation e.g. depending on
– Bauxite
– Impurities
– Temperature
– Caustic Liquor
– Operation Mode of Digestion
– Position within Digester
AOS-E / 2

• Flash Tanks
Diaphragm Piston Pump
• Slurry/Slurry Heat
• Vapour Heat • Salt Heat Exchanger
Exchanger Exchanger
AOS-E / 3

Effect of Incrustation
− Reduction of Retention Time

− Reduction of Digestion Temperature
− Increase of Pressure Loss
− Increase of Heat Energy Consumption
− Increase of Erosion
AOS- / 4
Methods for Cleaning

− Acid Wash by Fluoric Acid
− Acid Wash by Sulfuric Acid
− Hydro Jetting
− Hydro Cleaning
AOS- / 5
115
Hydro Jetting
AOS- / 6

Results by Hydro Jetting
AOS- / 7

Cleaning Techniques – Hydro Cleaning
Cleaning Tool
Water
Scales & Sand Scales & Sand

Pipe of the
Retention time
AOS- / 8

Cleaning Techniques – Hydro Cleaning
AOS- / 9
117
Cleaning techniques - pigging
AOS- / 10

Results by Hydro Cleaning
AOS- / 11

Scaling from Salt Heat Exchangers
AOS- / 12

HTC of Salt-Heat-Exchangers
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
AOS-E / 13
119
Availability of Tube Digestion
100,00
95,00
90,00
%
85,00
80,00
75,00
AOS-E / 14
Throughput of Tube Digestion
AOS-E / 15

Heat Energy Consumption
10,00
9,00
Plant
8,00
7,00
GJ / t Al2O3 (LHV)
6,00
5,00
Digestion
4,00
3,00
2,00
1976
1978
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
2016
AOS-E / 16
Aluminium Oxid Stade GmbH
AOS-E / 17
121
Start Up: September 1973
Annual Design Capacity: ca. 600,000 mt Al2O3
Digestion Temperature: 250 °C
Digester Flow Rate: 280 m³/h
Design Bauxite: 100% Weipa
AOS-E / 18

Typical Scaling within Retention Time
AOS- / 19

Scaling from Salt Heat Exchangers
AOS- / 20
Bauxites Processed Up to Date

• Weipa miscellaneous SiO2-content
• Gove
• Boké high and low mono content
• Haiti
• Jamaika
• Guyana chemical and metal grade
• Sierra-Leone
• Ghana
• Trombetas
• Ashapura / Indian Bauxites
• Kindia
AOS-E / 21
123
Al Taweelah Alumina Refinery
Abu Dhabi
Date 18.09.2017
Emirates Global Aluminium
Presentation
• Strategic rationale
• Al Taweelah alumina refinery project description
• Al Taweelah alumina refinery environment management
Emirates Global Aluminium 2

Through Al Taweelah alumina refinery, the first in the UAE, EGA will further
strengthen its business and the environment for years to come
Safeguard EGA’s business

Develop the Al Taweelah alumina refinery will expand EGA upstream in the value chain allowing it
industrial to secure margins amid shifts in alumina market pricing and due to freight savings
sector
Contribute to the local economy
Catalyze the expansion of the industrial cluster and supplier base; ~60% of capital
cost and ~40% of operating cost to be spent locally achieving a forecast total GDP
contribution of ~$1bn
Implement leading technology and responsibly utilise resources

First refinery
Catalyze the to integrateofinto
expansion theaindustrial
smelter powerplant
cluster and–supplier
saving minimum
base; of 18 mmscfd of
gas
~60% andof reducing carbon
capital cost and dioxide
~40% ofemissions
operatingby 350kt
cost to beper yearlocally
spent (equivalent to ~75,000
cars on the road) as compared to best alternative. Energy conscious design with first
quartile energy consumption rate
Safeguard the environment
First refinery to locate bauxite residue storage area 35km away from refinery site,
with industry leading bauxite residue management including:
>70% solids, dry stacking with multiple ground liners, capping, and land reuse.
Research programs initiated to explore residue reuse opportunities
Create high quality jobs while developing new skillsets
Generate 1000 direct jobs, with Emiratization rate at supervisory level of 25%
Talent factory
STRATEGIC RATIONALE
EGA currently is the only global player with no captive alumina or bauxite
capacity
Aluminium-
Global players Aluminium capacity Alumina capacity Bauxite production equivalent alumina
Millions of tonnes Millions of tonnes Millions of tonnes capacity
4.6 10.3 11.3 117%
4.2 11.4 48.0 139%
3.8 16.5 14.4 228%
2.6 9.1 39.1 180%
2.4 0.0 0.0 0%
2.2 6.3 15.1 150%
1.4 5.2 15.0 199%
Percent of
EBITDA per ton 57% 28% 15%
of Aluminium1
1 % for top quartile producers: historical average EBITDA (2008-2010) during period of relatively high LME prices
4 4
125
ATA Project Description
Al Taweelah Alumina Refinery – a 2 mtpa Alumina Refinery
Project description
Power
 ATA: KP-1B KP
KP-
- Refinery alumina capacity: 2 mtpa KP-1A
1A
EMAL
- Bauxite: Consumption 4.9 mtpa - residue
produced 2.4 mtpa
- Gas required: ~50 mmscfd (+/- 5%) (Q1 2017) KP
KP-1A
KP-
KP
- Other: caustic soda 234 ktpa (50%) 1A
1A
Project Refinery
ATA
 Land1:10 km2
Refinery
- Refinery: ~1.4 km2
- Residue storage area: ~8.3 km2
 Shipping:
- ~5 mtpa Kizad zone A
 Bauxite to be shipped from Kamsar Port, Guinea to
EMAL Berth, UAE, using cape size vessels
 Bauxite residue to be transported from Refinery to
storage area through Trucking (Future Option for Rail)
 Bechtel-Petrofac JV appointed for EPCM with RTA as
process design subcontractor, and HOT providing
digestion technology
Bauxite
Residue
Storage
Area Kizad zone B
6

Al Taweelah alumina refinery – project
description
Alumina refining will occur at the refinery, with filtered residue generated by the refining
process delivered by truck for disposal to the BRSA
• Alumina refinery located in KIZAD A
• bauxite residue storage area in KIZAD B
EGA
Taweelah
Power
Plants
Al Taweelah alumina refinery

environment management
127
Al Taweelah alumina refinery will be the reference refinery
worldwide for its best in class practices in the
management of bauxite residue
Bauxite Residue Management process consists of multiple stages of which Al Taweelah alumina
refinery is implementing industry best in class practices:
 Filtration: Pressure filtration will minimize liquid content (>70% solid), reduce active footprint (only
25 Ha at any point in time) and total land requirement, and ease the handling of residue; No
effluent to be discharged to the marine environment
 Transportation: through covered trucks, with washing stations (at exit of refinery and BRSA)
ensuring no deposit fall of the wheels. Short truck route (~35km) with minimal impact on existing
and forecast traffic
 Deposition: will be via trucks, with a short distance for bulldozing and compacting with vibrating
machinery
 Management: Multiple liners (e.g., HDPE, gravel etc) beneath the residue area eliminate seepage,
while dust to be suppressed through water spray trucks
 Closure & Capping: Cells are closed and capped progressively, with capping design planned to
consist of original area sand cover to blend with surrounding environment
 Reuse Opportunities: Al Taweelah alumina refinery is targeting 100% land re-use post-capping
with several example applications including storage, light buildings, and solar farms
Al Taweelah Alumina Refinery – General Arrangement
Administration
Calcination
Hydratation
Bauxite storage, Digestion
crushing, grinding & Clarification
desilication
Precipitation
Bauxite
residue

Al Taweelah Alumina Refinery Layout
Administration
Calcination
Hydratation
Bauxite storage, Digestion
crushing, grinding & Clarification
desilication
Precipitation
Bauxite
residue
Thank you
129
Outotec Services for
Alumina Refinery and Calcination
Alumina Users Meeting
Hamburg October 2017
Performance services to boost your business results
Collaboration and understanding of your business allows us to apply our in-depth

process, operation and maintenance expertise and world-class technologies to
develop safe, sustainable and reliable solutions to improve your business
performance throughout the entire life cycle of your plant.
Overall You get

equipment
effectiveness Target level • Improved Health & Safety
• Decreased Operating Cost
• Improved Equipment / Process
Current level
Efficiency
• Improved Environmental Efficiency
• Improved Capital Efficiency
Cost
2

Life cycle approach and service portfolio
Outotec’s life cycle services support clients

Advisory Maintenance
during the entire life span of their plant: Services Services
• Project development
• Project planning and evaluation
• Implementation Operations Remote
Services Services
• Operation and maintenance
• Modernizations and upgrades
Spare and Training

Life cycle service solutions and a Wear Parts Services
global network of service centers
are available to Outotec clients.
Upgrades
3
Outotec service areas in alumina refineries

Alumina Refinery
Filtration, Calcination &
Alumina Handling
Power Bauxite
plant stockpile
Grinding
Precipitation
Seed Classification and
Filtration
Digestion
Red Mud
Separation &
Clarification
4
131
Examples of Performance Solution
Modernization of Shutdown
Spares and Process
plant or Solution to Maintenance
Wears Solution Solution to
equipment to minimize Solution to
to ensure optimize
improve production optimize uptime
availability productivity
efficiency losses
5
Advisory Services
Value
• Improved safety, reliability, availability, and productivity.
• Identify risk areas, close performance gaps and improve operations.
Our offering
• Plant & equipment inspections, audits and assessments conducted by
Outotec technology and process experts providing you in-depth
information and improvement proposals
• Comprehensive engineering and study services
• Outotec laboratories and research facilities providing advanced studies
and comprehensive mineralogical tests
Detailed services product categories

• Equipment inspections
• Technical audits
• Process audits
• Plant performance assessment
• Inventory assessment
• Feasibility studies
• Engineering services
• Research and test services
• Process advisory services
• QEHS advisory services
6

Maintenance Services
Value
• Reduced downtime
• Increased safety, availability & reliability
• Efficient use of labor resources
• Focus on your core business
Our offering
• Maintenance strategy development
• Full complement of preventative, predictive and reliability centered
maintenance planning services.
• Condition monitoring
• Site and equipment-specific maintenance programs, from expert support to
total maintenance execution.
• Installation and commissioning support
• Shutdown planning and management services to safely shorten your
shutdown.
• Component and equipment repair, rebuild and reline services.

• Maintenance strategy, planning and scheduling
• Emergency, corrective and preventative Maintenance
• Condition monitoring
• Installation and commissioning
• Refractory demolition and Catalyst services
• Shutdown planning, scheduling and management
• Grinding Mill Reline Service
• VERSA XO2® lancing services
• Component repair and rebuild services
7
Operations Services
Value
• Reliable plant operation
• Optimized processes and production
• Enhanced operational performance
Our offering
• Operations strategy development
• Support with operations planning, scheduling and execution
• Outotec process knowledge and operation specialists
• Services to ensure efficient ramp-up to full production
• Continuous process optimization and improvement
• Digital Process Optimization Service

• Operations strategy and program
• Operations planning and scheduling
• Operations execution
• Ramp-up services
• Digital process optimization service
8
133
Remote Services
Value
• Higher plant availability, reliability and performance
Our offering
• End-to-end operational visibility with remote monitoring, assessment,
troubleshooting and online condition monitoring
• Continuous process optimization and improvement
• Right level of support to suit your needs

• Outotec Operations Support Center
• Online Condition Monitoring
9
Spares and Wears

Value
• Higher safety, reliability and availability for your equipment
• Minimize the risk of missing critical spare parts
• Improved maintenance planning and budgeting
Our offering
• Spare and wear parts in high quality to secure the functionality of your
equipment
• Global distribution network
• Easy identification of spare parts
• Spare parts recommendations
• Outotec eCatalogue online tool providing one-stop access to wide
spare parts offering

• Spare and wear parts to Outotec deliveries
• Inventory assessment
10

Training Services
Value
• Optimized plant operation and maintenance
• Increased know-how and safety
• Independence from third party suppliers
• Getting the most out of your assets
Our offering
• Comprehensive training offering for process and maintenance
• Key know-how development
• Customized trainings
• Virtual Experience training - Fast, safe, cost-efficient training using
advanced process simulation tools and virtual environment

• Maintenance training
• Process training
• Virtual Experience training
11
Upgrades
Value
• Improved equipment efficiency
• Decreased operating costs
• Extended equipment lifetime
• Increased environmental efficiency
• Optimized return on investment
Our offering
• Latest Outotec technology and development
• Improved or new functionality
• Our extensive experience in managing the complete upgrade solution,
thus optimizing time between feed off to feed on

• Upgrades for process equipment
12
135
Alumina calcination service product portfolio
Easy maintenance Plant availability
 Windbox and easy nozzles  Interlock strategies

 Tubular airslide  Cooler Discharge Seal Pot
 Soft Flow NozzlesTM  Discharge Device and Control
 Enhanced Fluid Bed Cooler Design  Preheat and Pilot Burner
 Shut down and operational support  Airslide and Airlift upgrade
 Refractory services
Process support Energy saving
 Training  CircoCal® Process

 Remote Diagnostic Services  Hydrate Dryer and Drying Station
 Testwork  Advanced Hydrate By-pass
 Audits and studies  Feed Logic Control System
 Cyclone Optimization
 Filtercake Drying (waste water preheating, steam
hoods)
13

Integrated Life-cycle Approach to
Shutdown Planning & Management
19th Alumina Users’ Meeting

Dr. Ioannis Chatzilamprou – Randy Donaldson
7 October 2017
Quality-Environment-Health-Safety (QEHS)
Safety First / Zero Harm
QEHS Integrated Management System (IMS)

Since 2007 Outotec operates an IMS covering:
1. Quality Management (QM) – fully certified to ISO 9001

• Outotec is fully conversant with the concept of QM system,
certified according to ISO 9001; tailored to suit Outotec’s
requirements working worldwide
2. Health, Safety and Environment (HSE)
• Outotec is committed with the concepts of safe and healthy
work environment
3. Environment Management – certified acc. to ISO 14001 and continually maintained
4. Occupational Health and Safety (OHS) – certified acc. to BS:OHSAS 18001
2 7/10/2017 External | 19th Alumina Users 2017, Shutdown Planning & Management
137
Content
1. Integrated life-cycle approach

2. Shutdown planning overview
3. Shutdown execution
4. Alumina calciner shutdown tasks – typical
5. Integrated shutdown projects
6. Conclusions
Integrated life-cycle approach

Shutdown management
• OEM support
• Local Outotec engineer 2-way feedback
Integrated • Spare parts support planning

Shutdown • Local workshop support
• Global support planning
• Local competencies
*) Different modules and contract models

Shutdown Planning Overview
Shutdown services value

Experience, resources
• 35 years experience ensures delivery of project on time and budget

• >20 years experience in furnace reconstruction and combined with
process know-how technology
• Largest fleet of remote-controlled machines
• The only provider with 2 kinds of shaft
scalers for rapid de-scaling of
furnace shafts
• Safety – specialized PPE and award
winning safety management >50
Experts
139
Furnace demolition services
Largest fleet of remote-controlled machines
Outotec Versa-Hoe®
Remote-Controlled and Custom Designs
Demolition services
Alumina refinery
• An industrial drone is a solution Outotec is preparing to offer, providing:

• Perfect tool for remote, fast and safe inspection
• Elimination of scaffolding and confined space work for detailed inspection
• Costs reduction
• Increase customer’s profitability
• Areas of application:
Remote-Controlled
Custom Design
• Alumina calcination plant
− Potential to save 12-24 hrs for the first inspection
• Settling thickeners
• Digestion tanks
• Precipitation tanks
• Any confined space; less personnel, lower risk

Shutdown Execution – Management
(Construction Management)
What is Construction Management (CM)?

Typical scope of work
1. CM reports to Client and manages trade contractors

2. Trade contractors have contracts (purchase orders) with Client
141
Why Outotec as construction manager?
Over 30 years of complete furnace projects experience (brownfield):

• Specialization to brownfield furnace construction – many smelters
• Deep knowledge of how trade work is executed: mechanical, refractory…
• Approach from construction contractor’s point of view, when do planning
• Managed shutdown execution projects of up to 1000 persons at site !
Outotec shutdown team executes the project as follows:
 In the field manages coordination/communication,

safety, schedule, quality, scope
 Drives the work schedule to preserve/beat the
planned schedule
Shutdown execution
Typical deliverables
• Daily management meetings

• Deliver QEHS and shutdown objectives
• Complete refractory inspections & reports
• Provide manpower on request to assist customer
• Manage daily work schedules to project critical path
• Ensure sub-contractors are trained, have permits & carry proper PPE
• Deliver KPI Zero Lost Time Injury, Zero environmental incidents
• Manage critical issues & contingencies in a safe & timely manner
• Manage supervision of contractors and coordinate all work groups
• Quality assurance guarantees for refractory demolition / installation
Shutdown execution within 20-30 days; subject to site and project specifics!

Typical Calciner Shutdown Tasks
Why preventive maintenance?
A global team of >30 Refractory Experts organized to deliver complete and tailored Life Cycle Solutions
for calcination plants.
143
Shutdown & refractory services
QA/QC services
Laser scanning analysis (Outotec® VesselMapping) monitors the condition of layer thickness;
benchmarking and follow-up.
Deviation from design
Cyclone wear liners view

Cylindrical wear liners deviation *Source: alumina calcination plant in AUS
Shutdown management
Typical site team – Outotec and trade contractors
Project
manager
Shutdown team
Resource
Construction Trade Contractor

manager
Hired by Customer
OT Product line Quality Construction Schedulers Safety

Contract Project
/ Engineering / superintendent
planner (1d / 1n) manager administrator manager
Supervision (1d / 1n)
Demo/Cleaning Mech/Structural Refractory Day shift Night shift

supervisor E&I supervisors Emergency
supervisor supervisors safety safety
(1d / 1n) Response Team
(1d / 1n) (1 per shift) (1d / 1n) superintendent superintendent
Mech/Structural
Demolition Refractory Contractor Contractor
Repair E&IContractors
Contractor contractor safety officers safety officers
Contractor
Labour Supply
Tailored-made team size, subject to project specifics

12-36 hour look ahead schedule
Integrated shutdown projects

Lifecycle approach
The lifecycle approach offers plant operators a number of benefits:
• Improved plant availability

Inspections at all levels of complexity and digitalization can avoid
unplanned downtime
• Optimal campaign life
Plant condition and process audits can provide insight into optimal Integrated
operating parameters plant
• Regular and reliable process data shutdown
Digital solutions of continuous online data analysis identify plant
design improvement opportunities
• Continuity of expertise and support over equipment or plant lifecycle
Outotec’s support is vertically integrated with expertise at all plant
levels
145
Conclusions and what’s next
Process, plant know-how and engineering excellence: key factor for execution of the
construction during shutdown for success of planned outage or modernization in
 delivering a safe shutdown
 optimizing shutdown schedule, minimizing production loss
 achieving performance targets
 maximizing ROI of the modernization
Shutdown optimum execution can only be

guaranteed with integration of construction
planning into the engineering phase.
Can be achieved by different contract models
Planning does not cost money, it makes money!
Satisfied customers
• BHP • Codelco
- South Africa - Chile
- Australia
- Columbia
• Nyrstar
- Australia
• Glencore
- Canada
• Ma’aden aluminium
- Saudi Arabia
• Vale
- Canada
- Brazil
• Anglo American Planning does not cost money,

- Brazil it makes money!
- South Africa

Improve plant availability through reliable wear part management
HOT Services
Presentation for Users’ Meeting
147
Content
1 Introduction
2 Mathematical modeling
3 Wear mechanism and failure prevention
4 Maintenance Concept
5 Spare and wear parts for digestion plants by HOT
6 Summary and work with Outotec
2 10/25/2017 Alumina Users' Meeting 2017 | HOT Spare Parts | Steven YU

Introduction
• In modern Alumina refinery, energy (heat)

recovery through slurry flashing is a
common practice with both tube digestion
and normal vessel digestors.
• The downside of the flashing practice is the

addition of complexity in managing the
spare and wear parts to meet plant
availability requirements, while minimize the
budget spent on normal spare and wear
parts.


Introduction
For the optimization of spare and wear parts Outotec (together with our partner Hatch) can
provide:
• Process simulation for debugging process weak points, thus to propose modernization
- e.g. relief system design
• Mathematical hydraulic modeling with 2- or 3-phase fluid modeling to guide piping
design, component sizing, and even to predict/prevent excessive wear in the digestion plant
- e.g. especially flash tank related components
• Extensive cross-over know-how sharing from other mining and metals product lines
- e.g. HPAL leaching; slurry rheology and experimentation from mineral processing
• CFD and FEA simulation capability for fluid dynamics and structural simulation.
• Metallurgical and material knowledge on wear and corrosion resistance
- e.g. with welding overlay, thermal spray, high chromium white iron, sinter powder metal and
ceramic product as SiC.

Mathematical modelling

149
Flash Tanks
• The pre-mature failure of flash tank pipework

components in digestion cost millions each year in
spares and plant downtime
• Flash cooling of digestion slurries mean that they
cool from the digestion temperature to atmospheric
boiling conditions along the liquor saturation curve
• The combination thermodynamic and hydraulic
energy losses will mean that flashing of vapour will
occur in the interconnecting pipework
• The flash vessels themselves work purely as devices
of dis-entrainment between slurry and vapour

Two-phase evaporative flow
• Two-phase evaporative flow in many industrial processes (as in case of flashing in Alumina
digestion plant) is characterized by sudden pressure drop induced phase change and
relatively high downstream velocities. Such high velocities cause wear in slurry pipelines
and equipment due to the hydraulic transport of solids.


Two-phase evaporative flow
• Practical and reliable means of quantifying two-phase flow behavior have been developed
by Outotec (Dr. Scarsella) and Hatch (Dr. Tran) based on various models found in the
literature review describing two-phase flow behavior.
• The models developed enables designers and operators to determine the location in the
pipework where two-phase flow commences.
• It allows to limit the velocities in the piping system and its components, to select and size of
piping components subject to flashing conditions.

Mathematical modelling of 2/3-phase flow
The mathematical modelling of 2/3-phase flow of slurry flashing in digestion flash vessel train
is mainly governed by laws in thermodynamics and hydraulics
Thermodynamics Hydraulics
+
The upstream and downstream process con- The progressive conditions from the start and
ditions among flash tanks is strictly governed end points (of the pipework) are governed by
by the thermodynamics of the digestion unit: the hydraulics
- boiling point elevation - Static
- heat transfer - Momentum
coefficients - Frictional
- heat transfer area
- etc

151
Wear mechanism and failure prevention

HOT digestion flash tanks

flash vapour
• Digestion & evaporation flash tank bottom entry for:
• Wear reduction
• Optimization condensate quality
• Special internal castings and hard-faced spools to
survive against erosive effects of a flashing slurry
• Symmetrical conical outlet for good discharge
• Flash vapour → condensate at <100 µSiemens/cm
→ cyclone separators used on export vapour lines
slurry inlet
slurry outlet


Digestion flash tank hydraulics
• Slurry residing in each flash tank under normal operations at saturation or boiling conditions
• The hydraulic resistance from interconnecting
pipe work between flash tanks results in a stable
level of slurry inventory in upstream flash tank
• As the slurry moves through the collection
of pipe work and fittings, hydraulic and static
losses will be encountered
Equivalent
frictional and
accelerational
losses
• Once the line pipe pressure falls below the

saturation pressure of the slurry, phase
Upstream static
head
change (flashing) takes place resulting in

an increase in net volumetric flow.

© Outotec - All rights reserved

• The net change in volume due to flashing resulting in a change in flow regime and velocity
• Flow regimes in both horizontal and vertical two phase flow and their effects on erosion
are well understood
153
• The net change in volume constitutes Recirculation Vorticies
problems in bends, tees and valves.

Area of Wear
• This results in higher localised velocities
where a non-uniform velocity profile is
present
Outlet
Streamlines
Area
of Wear Inlet
Consequences of flash tank pipe work failure
• Capital cost
• Continuous replacement of spares
• Maintenance cost
• Down time of process equipment

• Depending on the design philosophy of the
digestion unit this could be either a single flash
tank outage or an entire digestion unit outage.
• Occupational Health and Safety (OHS)

• Loss of containment
• Pinhole leakages can make the area inaccessible,
rendering flash tank isolation difficult.


Failure prevention techniques
• Process design of pipe work

• Strategic placing of orifice plates and expansions will allow the mean flow mixture to expand without
incurring high velocities
( dP / dz )total = (dP / dz ) static + (dP / dz ) Momentum + (dP / dz ) Frictional
• Simultaneous hydraulic and thermodynamic elemental solution over a length of pipe will allow analysis
for different geometries.
• Qualitative understanding of average velocities in specific fittings
• Mechanical design of pipe work

• Hard-facing
• Erosion resistant linings


155
Critical point of wear
• Last T-piece prior to
A discharge is at risk
3375 mm
A)
2900 mm
2500 mm
500 mm
2750 mm
1690 mm
500 x 600
• Case A) suggests
5500 mm
that the mean
30
velocity at this
B) 25
point is indeed
Average Velocity, m/s

3375 mm
20
reduced
B
2900 mm
2500 mm 15
500 mm 10
• Designers have the

500 x 700
B)
1690 mm
2750 mm 0
option to protect the

5500 mm
suspect fittings with

liners or hard facing
1390 mm
1390 mm
C)
600 x 700
C
2900 mm 2500 mm
500 mm
500 x 600
2750 mm
1690 mm
5500 mm

Conclusions
• Wear and erosion in flash fittings is a result of poor

design and/or lack of understanding of thermo-fluid
dynamic phenomena of slurries operating close to
their saturation pressure
• Wear and erosion, through poor design, can be
responsible for individual equipment and/or whole
digestion unit outages
• Wear and erosion can be mitigated by a combination
of thermo-hydraulic modelling and mechanical design
experience, particularly understanding of how high
average velocities behave through various fittings.


Conclusions
The modelling enables designers and end users to

• Identify the flashing point
• Reduce wear in pipe work
• Predict and avoid choke-flow conditions
• Limit the impact on internal piping components
• Minimise slurry carry-over into the vapour stream
• Determine the tank elevation in the flash train
In plant operation, the modelling can simulate and predict

• Transient flows from a power outage
• Momentum change in relief headers
• Downstream blockage in a flash train
• Action of the safety relief system

Maintenance concept
Orifice as an example

157
Digestion flash vessel spares
1. LCV Mating hard-faced

reducing spool
2. Hard-faced elbow spool
3. Reducing flange (part of #2)
4. Restriction Orifice
5. Standard inlet nozzle liner
6. Hard faced internal riser pipe
7. Diffuser head

Function of restriction orifice
• Critical to perform the function of pressure and temperature decreasing for slurry,
thus to produce flash steams.
• Failure mode of restriction orifices can be:

1. Abrasion by inlet slurries (most common failure mode)
2. Improper sizing (already illustrated in previous slides)
3. Improper material selection
4. Workmanship problems
• Orifice is also the boundary layer of the 2/3-phase slurry fluid which passes through it.
On the boundary layer, if local vortex/turbulence is induced, cavitation erosion can occur,
eventually leading to the failure of the restriction orifices


Function of restriction orifice
• Orifice as sacrificial parts

• Control valve protection

Overview of industrial practices
Practice 1: base material structural steel,

welding overlay to achieve HRC 60
Practice 2: base material structural steel,

insert with high chrome cast iron, to
achieve HRC 60-62 (~ HRA 82)
Practice 3: base material structural steel

(AISI 1045), insert with sinter powder
metal (Tungsten Carbide with Cobalt
matrix), to achieve HRA 89

159
Material selection
There is no absolutely the best solution in material selection. It is determined by slurry

property, system engineering requirement, as well as customer maintenance strategy:
Practice Prons Cons Remarks

Hard-facing Layer Metallurgical bonding Very difficult to perform
instead of insert hard-facing as the space
(orifice) is very confined
Insert – Hi Cr White Iron Higher hardness than

hard-facing
Insert – Sintered Very high in hardness A balance of hardness There are range of
powder metal and brittleness must be sintered powder metal
considered availability
Insert – Ceramic Very high in hardness Material tend to be OT experiences with
brittle SiC material

Maintenance concept
• Mathematical modeling of the flashing line to determine optimized sizing of orifice plates
(Outotec and HOT can assist)
• Condition monitoring of orifice component by observing the process data, to ensure regular
replacement of orifices as sacrificial components, protecting the complete flashing line and
control valves.
(Outotec and HOT can consider remote condition monitoring)
• Selection of proper material and orifice design configuration to suit the actual application
(HOT can supply)


Spare and wear part for digestion plant by HOT

Spare and wear parts for HOT digestion plants
HOT can offer across-the-board spare and wear parts for the complete Alumina Refinery,
especially on digestion plants where HOT holds the leading edge of delivering tube digestion
plant.
More value added to end customers would be process/hydraulic modelling to optimize the
component selection and sizing.

161
Spare and wear parts for HOT digestion plants
PD Pump spares Digestion vessel BOP spares

for digestion feed train spares
BOP = balance of plant.
Main spare parts: i.e. all other spares in the
- Diaphragms Typical spares such as the
flash vessel related special digestion area.
- Check/poppert valves
piping spools.
These can be
It can be divided into following - Consumables
categories: for various equipment
- Pipe work
Leverage from OT filters where 1. slurry inlet liner with leak
detection system (HOT IP) - Normal centrifugal pumps /
large size rubber diaphragms valves repair and overhaul
are extensively used. 2. normal high chrome white
(part of the overall rotable
OT has good in-house know- iron liner lined spools
parts management)
how of hard-facing by welding 3. normal hard-faced (welding
overlay, thermal spray (plasma overlay) spools
coating, HVOF, HVAF etc) as
4. diffuser heads
well as laser cladding.

Digestion flash vessel spares
In terms of mechanical engineering of the

components, Outotec has repertoire of
wear resistance know-how in
• Hard-facing welding overlay
(with own workshop)
• Thermal spray
(partner workshop)
• High Cr white iron
(partner workshop)
• Sintered powder metal
• Ceramic product


Summary – Work with Outotec!

Work with Outotec
Process and Material sciences Industry application Other capabilities

hydraulic simulation know-how
- In house know-how - Wear resistance - CFD simulation in
- Strong tradition as and partners for know-how from smelting and other
process engineering various wear resis- other Outotec plant related industrial
house with in-depth tance techniques: and equipment processes
process application • Hard-facing welding engineering in - FEA analysis
know-how overlay metals and mining
- Worldwide installed
- Slurry flow hydraulic • Thermal spray - Ni or Au autoclave bases with OT know-
modelling developed (plasma, HVOF, processing (POX, how
in-house and HVAF) HPAL – high
- OT service network
together with partner pressure acid
• Laser cladding
Hatch leaching) with slurry
• High Cr white iron flashing
• Ceramic material - Slurry rheology

163
Asset Management & Maintenance
19th Alumina Users’ Meeting

Dr. Ioannis Chatzilamprou – Guy Mewburn
7 October 2017

Asset Management:
“Asset management is one of the key business drivers for mining and remains a source
of considerable competitive advantage, and a major source of value creation.”
CEO of BHP
“Asset management is much more than just maintenance. Successful asset

management requires commitment that spans functional divides and impacts at every
operational level. From buying the right equipment in the first place, through operations
and maintenance, to disposal.”
CEO of Rio Tinto
2 7/10/2017 External | 19th Alumina Users 2017, Asset Management & Maintenance
Assets are not just plants but include…
People: who have to be well Trained, Engaged,

Motivated and Lead
Systems: and procedures to ensure we work in a

systematic, consistent and directed way
Software: to make sure we are automated,

communicate effectively and can make
knowledge based timely decisions
165
Enterprise Asset Management road map
• Asset register • Spare parts optimization
• Asset assessment • Work planning & control
• Asset policy strategy

EAM • Continuous improvement
• Operational readiness • Asset life management
• Maintenance plans
EAM is a long journey…

Asset Life Management
If the right equipment

• is built or bought in the first place  Health, safety and
• is operated within its design parameters environment
• has the right maintenance performed (at right  Availability, reliability
time and in right way) and integrity
And well-informed decisions are made  Throughput and yield
when retiring and/or disposing of equipment   Quality
 Cost
the equipment will continually deliver
the value that is expected in terms of:
All major pieces of plant and equipment with their own plan

Focus on equipment and maintenance
Strategic criteria:
• Work instructions
• Preventive maintenance
• Planning methods
• Improved lubrication
• Up-to-date CMMs
(Computerized
Maintenance
Management)
Why work instructions?

Induced Errors
6% 5%
Operations
33 % Maintenance
56%
Manufacturing Defect
Installation
33% of equipment fails due to incorrect or poor maintenance

(John Moubray – RCM,1991)
167
Why preventive maintenance?
Vibration
Analysis
20%
Look, Listen
40%
Oil Analysis
40%
40% of equipment trending to failure can be found by look & listen

(Dupont)
Rapid Planning Method (RPM)
No task changes; 3% Improved task description; 7%

Change discipline; 2%
Reduce frequency; 3%
Increase frequency; 8%
Task deleted; 30%

New task created; 47%
40 – 50 % of existing site PMs do not achieve much


Why improved lubrication?
fatigue
poor
9%
installation
27%
Other
21%
poor
lubrication
43%
43% of equipment fail from poor lubrication

(John Moubray – RCM,1991)
Uploaded and automated

• Training Conducted
• All plans generated Reviewed then
Uploaded into your CMMs
• Minimum disruption to your staff to let them
get on with their jobs
CMM • Spares, PMs, Work Instructions, Trade,
Planner Groups, Resources & Task Duration
all set
• Start Dates Set
Complete plant and equipment
169
How can Outotec support you to improve your assets?
Asset management and maintenance solutions

Holistic assessment approach for optimum results
Key-driver: Process & plant know-how, engineering excellence
• Assess all areas of Asset Management

• People, process, systems, equipment
• Decide where is the best potential
of Your assets
• Apply Outotec practical assessment tool

• Work instructions
• Improved lubrication
• Rapid planning methods
• Maintenance assessment / support
* PRT: production resources and tools

MOC: management of change

Outotec practical assessment tool
Based on ISO 00055 and best practices on Outotec technologies
Maintenance benchmarking Analysis and comparison on plant equipment with:
• Industry min - Industry max - Best in class*
Core maintenance performance metrics
Bigger numbers are better Smaller numbers are better

100%
Industry Min
75%
Industry Max
50% Plant XX
Best in Class
25%
0%
Amount of A- Percentage of Level of planned Percent Level of Number of Technical
critical inventory work (%) overtime/normal unplanned work emergency training
equipment accuracy (%) time (%) (%) purchases (%) hours/total
having PM's (%) maintenance
hours (%)
Rapid planning methods and work instructions

Outotec rapid methods/work instructions do not drain customer’s resources
What’s new and different:
• Short working time
• Detailed PMs
• Reduced customer
resources on activities
• Upload work on CMM
• Outotec continuous support
• Customer retains ownership

of the existing process
171
Outotec plant perfomance assessment
Operations and maintenance management
Maintenance
management and
practices -
Average
4,0
3,5
3,0
Workshop & 2,5 Reliability
Facilities - 2,0 Management -
average 1,5 Average
1,0
0,5
0,0
Material and
Warehousing - EAM - Average
Average
Planning&sched
uling - Average
Outotec plant performance assessment

QEHS management
QEHS Management -
average
4,0
3,5
3,0 People and competence
Energy - Average 2,5 management - average
2,0
1,5
1,0
0,5
0,0
Asset walk - average Operation - average
3rd party management-

Maintenance - average
average
Site x, Customer World Class Benchmark Data

Case study: improving productivity at Boliden Harjavalta
Copper smelter
Customer: Boliden Harjavalta – Finland Year: early 2016
Challenge: Insource maintenance after 15 years of outsourcing. Need of cooperation between O&M
functions. Lack of benchmarking data and understanding of as-is situation.
Solution:
• Outotec Plant Performance Assessment, including pre-questionnaire, assessment, and full report on
possible improvement actions helped to achieve this goal
• Proposals for improving O&M practices as well as new performance target set
Customer achieved
• Improved understanding of as-is situation
• Clear understanding of overall improvement potential
• Identification of main actions towards productivity improvement
• Improvement in maintenance and reliability
• Intangible benefits in areas of safety & HR
Why invest?
“Best-in-class companies with comprehensive Asset

Management plans averaged a 25% return on assets
versus
a 10% return on assets for laggard companies with
older, less efficient practices”
Source: Aberdeen Group public announcement
173
Asset Management Services
The focus is to
• improve safety
• increase production
• increase profit
• reduce failure costs
• reduce down time
through
improved
Asset Management
Outotec combine process & plant known-how, engineering excellence,

asset management and maintenance solutions

Digitalization
Lifting plant performance to technological reference
Dr. C. Binder
Outline
1. Digitalization – part of the modernization journey
2. Digitalization – how we do it
3. Examples
Optimizer
Digital Advisor
Dynamic Simulator
4. Customer Benefits
5. Summary
2
175
Main cost drivers - Alumina Production
• Main cost drivers in calcination plants are:

• Feed material costs
• Investments costs
• Energy, utilities costs
• Maintenance costs
• Skilled personnel
• How do we offer to support cost savings?

• Plant assessment
• Modernization
• Debottlenecking Improve energy efficiency
• Digital operational support Reduce maintenance costs
Increase plant production
3
What does Digitalization mean?

Closed
Industry 4.0 loop PLM
Data-based
Digitalization Decision
There is no Making
Automation common
Pyramid understanding on Data Mining
what Digitalization
Big means! Internet
Data of Things
Cyber
Predictive
Physical
Maintenance
Systems
4

Digitalization - part of modernization journey
Plant upgrade
Pretium phase and ongoing Lifetime
continuous Pretium use customer
Perficiency
Baseline improvement support
Pretium
Operator
Pretium operation
Starting from the audit, we will understand the
certification
customizing challenges and offer support
Technical plant modifications
Plant life-cycle Perficiency optimization
Plant Audit
Pretium Contract time
operation start
• Perficiency – a rating to evaluate plant performance

• Evaluation of plant availability and efficiency
• Identification of financial losses
• Help for prioritization of improvement measures
• Outotec Pretium Advisor – our contribution to the digitalization

5
Perficiency rating
What can we achieve with digitalization
Production time
100%
Environmental 95% Additional
footprint 90% production losses
85%
80%
Utility efficiency 75% Availability
70%
Target
Raw material
Performance
utilization efficiency Achieved
Energy efficiency Quality

Technological
reference
• Perficiency – compares plant performance with target and reference
• Numerical values for objective plant assessment
• Digitalization helps to reach operational excellence
• Perficiency rating tracks our success
6
177
Digitalization – how we do it
Our understanding of Digitalization

• Unlimited storage
of data
• Processes are well
Data acquisition
instrumented
• World-wide access
to data
The challenge is not

Digitalization collecting the data!
We have the digital
experts & the process
know-how What you do with the
data is relevant!
8

Outotec process know-how in Digitalization
Outotec (plant design) Real plant operation
calcination process know- • Process plant simulators
how • Based on Outotec simulation
models
• Equipment models
• Heat and mass balance
• Product quality models
Virtual plant Real time
simulator process data • Simulator fine tuning to
calculates
Analysis
accessible customer plant
ideal operation ideal and real via DCS • Expected simulation
plant operation
accuracy 95-99%
Outotec Pretium Advisor • Mismatch between

simulation and plant
9Plant oper. support by advice or full automation
analysed in Outotec Pretium
9Closing gap btw. theoretically possible and real Advisor
plant operation
9Plant operation shifts towards ideal operation
9
Structure and set up at customer’s site

• System uses connection to DCS to retrieve real-time plant data
• Processes DCS data to create advice information
• Pretium Advisor highlights deviations of real time plant measurements
from most efficient settings
• Allows predictions of possibilities
• Less operator actions required Æ safer and more efficient plant operation
Outotec Digital Advisor
Lab Data Different
communication Remote access
options Tool Outotec
Plant updating process
Outotec
capability know how
DCS Pretium
Advisor
Classic plant Advisory information via

Operator intuitive graphical display
control via operator
10
179
Advice and control implementation
Outotec Pretium Advisor
Mode 1 Mode 2 Mode 3
Advice and confirmation Operator confirmation Direct DCS connection
Operating mode: Operating mode: Operating mode:

Outotec Outotec Outotec
Digital Digital DCS Digital DCS
Advisor Advisor Advisor
Information Automatic
via graphical
Supervision advisor Fully automatic
display & approval (optional)
Acknowledge
Operator (optional) Operator Operator
• Based on the task, different advice/control options are available

• Outotec Pretium Advisor can later fully take over control tasks (Mode 3)
• Critical operational actions can remain with the operator, example:
• Malfunction warning by Pretium (Mode 1), including safe sequence proposal of
counter-measures Æ action steps taken by operator
11
Integrated concept of fully digitalized process plant

Project Phase 3
Pretium lifetime support and
advanced features including
Project Phase 2 operator certification
Operational support
and ongoing Predictive
Customer Benefit
Project Phase 1 improvement Maintenance

Simulation fine Advanced
tuning to Automation
customer plant
Training System
Plant Monitoring
and Fault Detection
Extended Model
Digital Assistant
Order of implementation can be
Simplified Model adjusted upon customer requirements
Module
1 2 3 4 5 6 7 Stage
12

References Fault detection
Detail equipment
• PORS (Sulphur) Advanced optimization
models e.g.: • Alumina hydrate moisture
• Seal pot • Zn-Roaster
estimation
• Cyclone • Furnace optimization
• Product quality Operator
estimations
training system Predictive
Customer Benefit
• Feed mixture models Maintenance

• Waste-to-Energy
• Pressure loss calculations
Advanced
Technology Automation
models: Training System
• Alumina calcination
Plant Monitoring
• Roasting and Fault Detection Auto-Pilot
• Sulphur plant • Smelter operation
• Iron ore pellet plant Extended Model • Outotec® SmartFeed
Dynamic plant
control
Digital Assistant model:
• Power plant
Simplified Model • Oil shale plant
Operational advice:
• Roaster optimizer
Module
1 2 3 4 5 6 7 Stage
13
Digitalization – examples
181
Optimization experience: process stabilization
Temperature stabilization Improved plant
KPI performance
• Plant A: without automatic control Æ wide variation in
9 MitigatesCustomer
temperature range Safety risks on decision-
• Plant B: without automatic control Æ high temperature taking
and sudden temperature changes
Production 9 Increases throughput,
• Plant C: with automated operation Æ stable
Level e.g. 2-6%
temperature, improved product quality, increased
throughput >6%
9 Reduces operating
Availability costs
Product 9 Improves
Quality recovery rate
15
Digital Advisor
Gap analysis
Overview Gap analysis KPI’s Feed quality
Overview Trends CFB Trends cooling
Value Value Color code

Section Reading Deviation
measured simulated for deviation
CFB Furnace temperature (top) 942 °C 938 °C 0.4% <2%
CFB Specific energy consumption 3241 kJ/kg 3154 kJ/kg 2.7% 2–3%
Cooling section Alumina product temperature 68°C 61°C 10.3 % >3%
… …
• Process variables are read from DCS and compared to expected simulation value
• Deviation is indicated in coloured system (green, yellow, red)
• Hyperlinks enables direct navigation to respective trend including deviation interpretation
• Color-code can be customized, e.g.: 0% < green < 2% < orange < 3% < red
16

Digital Advisor
KPI monitoring
Overview Gap analysis KPI’s Feed quality

Overview Trends CFB Trends cooling section
Last 8h Last 24h Last week Nominal value

Production rate (t/h) 46.1 47.5 46.2 55 t/h
Specific energy 3430 3320 3291 3180 kJ/kg

consumption (kJ/kg)
LOI (%) 0.65% 0.73% 0.72% 0.70 %
• Most important KPIs are read from DCS and compared to target value
• Colored indication shows quality of current operation at first glance
• Color-code can be customized
17
Simulation Accuracy Example

Error peaks can indicate malfunctions
Temperature signal
time
• Real world example of simulation accuracy

• Error ca. 5K at ~500K
• Good prediction of real plant performance based on simulation
• Deviation is used in fault detection algorithms
• Long time error trends used to detect equipment degradation
18
183
Dynamic training simulator
Example: Waste-to-Energy plant
• Interactiveness & Dynamics
resemble the real plant
• In a physical way
• In a controllable way
• Including balances
• Incl. equipment models
Features:
• Simulation speed up
• Malfunction training
• Start-up & shut-down
• Natural feed
fluctuations & quality
changes
19
Customer Benefit

Benefit for customer with digital products:
Improved Safety & Profit, reduced energy consumption and/or emissions
Top management Plant management Operators

(GM & Maintenance Manager)
• KPI • Plant availability Options for enabling

• Status of • Hot spots & fault optimum plant
production in real detection performance:
time • Operational team A) Autopilot process
performance control
B) 24/7 expert
advisory process
control
Insight in plant Understanding of current Easy life at optimum

performance & plant bottlenecks plant performance
potential savings.
21
Commercial potential
Customer benefit
Effect
Productivity- Energy- Plant
Stage Description
increase savings availability
1 Simplified Model 0.5% 0.5% -
2 Digital Assistant 1.0% 2.0% -
3 Extended Model 0.5% 0.5%
Plant Monitoring and Fault
4 - - 1.0%
Detection
5 Training System 2.0% 1.5% 0.5%
6 Advanced Automation 2.0% 2.0% -
7 Predictive Maintenance - - 2.5%
1 to 7 Effect of all stages 6.0% 6.5% 4.0%
• Dependent on plant, full digitalization reveals potential up to 2-10 M€/a per plant
22
185
Digitalization - part of modernization journey
How a long term project is set up
100% Perficiency – involves ideal plant operation due to plant technology upgrade
Perficiency
Ideal Performance – best operation on existing plant Lifetime
customer
Plant upgrade
Pretium phase and ongoing
support
continuous Pretium use
Baseline improvement
Pretium
Operator
Pretium operation
certification
customizing
Technical plant modifications
Plant Audit Customer licenses Pretium
Pretium
Milestone 2 Milestone 3 Contract time
operation start Milestone 1
Perficiency development by Pretium Advisor and technical process plant

modernization
23
Perficiency evaluation results in increased profit
Perficiency rating evaluation
100
80
60
40
20
0
KPI baseline Milesone 1:
Milestone 1: Milestone 2: Plant upgrading Lifetime support -
assessment Pretium in Pretium phase and achieving
operation continuous ongoing Pretium technological
improvement use reference values
• Every Milestone lifts plant performance to a new level
• A combined lifetime journey generates maximum profit via Digitalization
and Modernization together
24

Summary
Summary
• Digitalization at Outotec involves process know-how
• Digitalization is related to process know-how and can be customized
• Several working references exist for various levels of digitalization
• Significant potential of savings and efficiency increase by using Pretium solutions
187
Cyclone optimization and Sealpots
Alumina User Meeting
Dr. Christian Binder
07.10.2017

Contents
1. Cyclone operation improvement
2. Sealpots
3. Testing and Simulation

2
Cyclone operation improvement
189
Cyclones – separation equipment used in many industries
• Inhouse expertise and know-how not only for Calcination plants (Roasting,
Energy, Cement, Direct reduction, etc.)
• Expertise for development of own models, tools
• Each individual cyclone has specific operation conditions and has to be

treated individually (by applying an individual solution)
• Analysis for changed operation conditions can be performed (due to e.g.

capacity increase)
4
Customer challenge example

• Particles entering separation cyclones near the top wall (roof) are leaving
through the top gas outlet, being lost for downstream process
• This is because of two reasons:

• lower pressure in the vortex core attracts part of the particles near the roof which have only
small kinetic energy due to low energy boundary layer.
• the particles which had one turn inside the cyclone hit the incoming particle stream and are
guided towards the vortex finder
• Cyclone shows poor separation efficiency and possibly damage of

vortex finder influencing downstream process:
• severe pressure losses,
• increased temperatures in the following venturi,
• increased dust content at the following ESP.
5

Solution developed for this case
• Installation of ramp system on the inlet duct roof guiding

particles downwards and away from the vortex finder
• According to simulation
Æ separation efficiency increase
Æ pressure losses decrease
6
Results alumina plant baseline recycling cyclone

Side view Top view
Note: Particles are able to hit the vortex

finder due to stream overlapping. Pressure
drop increases together with forces acting
on the vortex finder. Particles leave
through the “wrong” outlet
7
191
Results of alumina plant improved recycling cyclone
by ramp modification
Baseline geometry Improved geometry
8
Results of improved alumina plant recycling

cyclone by ramp modification
Side view Top view slightly below the ramp
Note: Particles are guided around the vortex

finder. Hence less wear as well as
improved separation efficiency
9

Estimated efficiencies and pressure losses
through the recycling cyclone system
Baseline case Improved case
Pressure drop = 30 mbar 20 mbar
Efficiency = 68% 85%
High vortex finder wear Reduced vortex finder wear
10
Case 1: Impact of vortex finder length

(Alumina Plant Recycle Cyclone 113)
Separation Efficiency
Vortex Finder Insertion Length
11
193
Case 2: Impact of vortex finder length with installed ramp
(Alumina Plant Recycle Cyclone 134)
Separation Efficiency
Ramp + 1000mm vortex finder

Baseline / No ramp
Baseline/
No ramp
12
Summary
• In changing operational environment, the efficiency of cyclones might drop
• Simulation is one tool we use for investigating changes and developing

ideas implemented for improving efficiency while keeping/reducing pressure
drop across the cylcone
• Simulations performed for Alumina demonstrated additional potential savings

due to vortex finder length optimization
• Although solutions for individual equipments are individual as well, results

achieved in one industry are applicable to other industries
13

Connection to other equipments - Sealpots
Issues exist for transport of solids
Solids
• need to overcome pressures, lengths and heights
• are abrasive, can cause damage to moving parts
• change densities and shape
• can become sticky
15
195
Solution
• Installation of seal pots for

• Overcoming pressures,
• Overcoming lengths,
• Overcoming heights,
• Allowing for some flexibility,
• Being robust
• Still an issue:
• Stickyness Æ such phases need to be passed by fast
• Materials with strange shape (needles, flakes) cannot be transported
well
16
Seal Pot principle – Siphon – sealing A against B
A • Similarly to hydrostatics because

the solids flow like a fluid when
downer
they are in fluidized state
H
• pressure balance:
Hd
pA + U g H = pB
riser Hr
A B
H
Fluidizing gas
B
17

Seal Pot principle – Siphon – sealing A against B
pA < p B pA = p B pA > p B
A B A B A B
H H=0 H
A A A
B B B
downer downer downer
riser riser riser
18
Sealpots in Alumina Calciners
Functions:
- non-mechanical valve
- seal pressure differences
- transport of solids from one unit to another

- to lower pressure
- against higher pressure
- lifting to desired heights
- level control
Shapes in alumina plants: U-shape, Y-shape

(L-valve not controllable with Geldart A type materials)
19
197
Sealpots in Alumina Calciners: Shapes
U-shape (siphon)
• is the standard used for geometries where:
- distance L between downer and riser is small,
- solids are redirected to CFB (recycled)
• is well described in Literature (see e.g. Basu, 2006*)

• is very stable in broad range of solid fluxes
• needs large amount of gas to fluidize whole bottom area
riser • has a high pressure drop Æ high CAPEX/OPEX
H downer BUT: discharge device influences process pressures as

well
L
Application:
Recycle seal pots in CFB’s
Fluidizing gas
*Combustion and gasification in fluidized beds, 2006
20
Sealpots in Alumina Plants: Shapes
Y-shapes are used for

- transporting and sealing over larger
distances L, while
- minimizing fluidizing gas (in spite of
additional fluidization needed in inclined
parts)
- minimizing CAPEX/OPEX costs
L
- additional lifting possible
BUT: they are restricted to a defined maximum

solids flux and need additional fluidization
Application:
Secondary air, furnace feed, discharge seal pots in
new generations of alumina calcination plants
Fluidizing gas
21

Possible issues with sealpots and how to overcome them
Blockage Loss of seal
A • Too high solids • Not enough solids

throughput A in the system/
• Incorrect fluidization entrainment
• Sticky particles/ • Incorrect
downer moisture downer fluidization
ris • Very fine PSD ris
er er
• Changed
• Changed operational
operational conditions
conditions
Fluidization Fluidization
B B
22
Summary:
It is important:
• To have proper instrumentation (measuring T and p in defined locations)
• To meet operation conditions ranges defined for the equipment
• Possible discharge device influence on process

• Fluidization of sealpots in the designed range (downer, bottom and riser
fluidization might be necessary to achieve desired fluidization states)
• Solids flux restrictions for capacity increase (e.g. blocking might occur at
very high fluxes Æ debottlenecking)
• Particle properties (PSD‘s, consistencies, shapes, etc.)
23
199
Testing and Simulation
for Validation and Variation
Cleaned off-gas
Red parts:
Testing facilities design as individual
modules for later
solids
modification or throttle valves
feed filter
replacement container
• Downer-riser facility Blue parts:
acrylic glass piping for
for visual observation
• identifying bottlenecks solids feed rate
of customers by adjustable range
adjusting operation Black parts:
Made of steel solids
conditions collecting
container
• Troubleshooting, finding L
new solutions
(on demand)
auxiliary air
• Validating simulations
and own models
Pressurized air
primary air
primary + secondary air
25 secondary air

Simulation possibilities
• Process (mass, energy, operation)
• CFD (own developed solvers)
26
Continuous refining of own models and design tools

Industrial Scale data
• Analyze efficiently
Design Models
possible scenarios,
Balances (energy, mass)
troubleshooting
• Development of new
solutions to changing
operation conditions with
application to other areas
(e.g. ramp)
27
201
Evolution and Improvements of the Tube Digestion
Technology
Dr. A. Scarsella

Agenda
1. Introduction 3. Operational Improvements
2. Technical - Improvements 2.1. Automation & Process Control
1. Vessel Train pressure profile stabilization
1.1. Digestion
1. Yarwun Overview of Design or Reference Plant 2. Flash Tank level control
2. Ma’aden Overview of Design 3. DCS operated hydraulic/pneumatic drive valves
3. Al Taweelah Overview of Design
4. Feed system improvements 2.2. Access / Operability
5. JPH insulation & cladding
6. Vessel train design improvements 1. PD Pump house / carnage
7. Digestion availability considerations 2. JPH Cleaning
3. JPH Removal
1.2. Evaporation
1. Ma’aden overview of design 4. JPH Bends Access
2. Improvements to evaporator design 5. Holding Tube Cleaning
6. Flash Tank bypassing
1.3. Advancements in safety (Overpressure
Protection Systems)
1. Code changes since 2008
2. Passive Integrity & SIS
2
1. Introduction
From KLV to HOT

• First tube digestion plants in Germany in the 1960s by Vereinigte Aluminium
Werke (VAW)
• AOS Stade - KLV reference plant - built in 1973
• Kaiser Engineers (now Hatch) built a reference plant in Korea based on a
“Multi-cell“ heater patent
• Kaiser Engineers, Lurgi Metallurgie (now Outotec) and VAW formed KLV JV
in 1995 to market tube digestion technology
• KLV designed the integrated tube digestion and evaporation circuit for the
Yarwun Refinery in 1998-2001
• Yarwun 1 online since 2003 - Yarwun 2 In operation
• Hatch (ex-Kaiser) and Outotec (ex-Lurgi Metallurgie) have now formed HOT
JV
3
203
Technical: 2.1.1 Digestion - Yarwun Overview
Origin:
• In the 1990s, the ‘KLV’ joint venture was formed

between Kaiser Engineers, Lurgi Metallurgie and
VAW to develop tube digestion technology for world
wide application.
• The in-tube single stream heating and digestion
concept from VAW was combined with multi-train
heat exchange and flash tank/piping design know-
how
 Hybrid design as executed at the Yarwun Alumina
Refinery in Gladstone
4
Technical: 2.1.1 Digestion - Yarwun Overview
Key Parameters
• Total refinery annual capacity: ~3.4 million t Al2O3 /a

• 2 off, 0.7mio.tpa digestion units + 2 off, 1.0mio.tpa digestion units each with 10 flash stages
• Each unit has 3/4 parallel slurry heating trains. One heating train at a time is off line for cleaning.
• Final digestion temperature is achieved by indirect heating with high pressure steam
• The slurry digestion holding time is provided in pipes
5

Technical: 2.1.2 Digestion - Ma’aden Overview
Strategic Goals
• Saudi Arabian Mining Company (Ma’aden) established 1977 to

develop mineral resources in Kingdom.
• Refinery part of an integrated Mine to Metal Plan incorporating
bauxite mine (~600 km from refinery), refinery, smelter and
rolling mill.
• Economic diversification & balanced regional development
• Ease strain on existing cities
• Job creation (as of 2007, 50% of the population < 25yrs of age)
in labour intensive mining industries relative to oil and gas.
6
Technical: 2.1.2 Digestion - Ma’aden Overview
Key Parameters
• 1.8 MTpa smelter grade alumina.

• Overall Refinery operating factor 94%
• A high Monohydrate bauxite (~55% of available alumina is Boehmitic)
• High temperature Digestion at 270°C with recuperative target 200°C to mitigate titanate scaling
7
205
Technical: 2.1.3 Digestion – Al Taweelah Overview
Strategic Goals
• Emirates Global Aluminium (Mubadala Development Company of
Abu Dhabi & Investment Corporation of Dubai Partnership).
• Smelting assets are DUBAL and EMAL with 2.4 Mtpa metal –
amongst top 5 aluminium producers.
• Development of Bauxite & Alumina resources via Mining
Company GAC and Al Taweelah
• Balanced regional development & diversification
• Job creation
Key Parameters
• Phase 1 – 2.0 MTpa smelter grade alumina.
• Bauxite imported from Guinea
• Energy integrated with EMAL Power plant for delivery HP steam
• High temperature Tube Digestion at 280°C
• Bottom quartile energy consumer
• Plant layout for Phase 2 & possible Phase 3
8
Technical: 2.1.1.4 – 2.1.1.5 Digestion
1.1.4. Feed System Improvements

• Suction line design to mitigate potential for sliding bed formation
• PD pump discharge manifold valves incorporate design to mitigate pressure transient effects
1.1.5. JPH Insulation & Cladding

• Measures to mitigate CUI incorporated
• Protective coating of heater shell
• Appropriate Materials of Construction for cladding to suit environmental conditions
• Enhanced specification & installation details of insulation & cladding to minimise potential for
moisture ingress & retain thermal insulation targets
• 2.5 yrs operation of Ma’aden and no evidence thus far of CUI.
9

Technical: 2.1.1.6 – 2.1.1.7 Digestion
1.1.6. Vessel Train Design Improvements

• FT design with bottom entry to simplify wear component replacement
• FT level control being successfully used at Ma’aden
• Enhanced materials for control valve trims being incorporated (WC etc) once hydraulic duties
verified
1.1.7. Digestion Availability Considerations

• Sparing of JPH train to “n+1”
• Al Taweelah PD pumps “n+2”
• FT bypassing incorporated to Ma’aden and Al Taweelah, Maaden with dedicated spare stage to
target “n” online stages of continuous operation
• Enhanced materials for control valve trims being incorporated (WC etc) once hydraulic duties
verified
10
Technical: 2.1.2. Evaporation
2.1.2.1. Ma’aden Overview

• 4 off trains at Design capacity 127 Tph each
• Temperature 135°C
• 9 stage multiple effect
• Chemical cleaning at 6 week cycles
• Export energy from Digestion Units
for evaporator “live” steam
• No use of LP boiler house steam for normal duty
2.1.2.2. Evaporator Improvements

• Incorporation of mist eliminators in flash tank design reducing vessel size and cost
11
207
Technical: 2.1.3. Advancements in Safety
(Overpressure Protection System)
2.1.3.1. Code Changes since 2008
• API Std 521 (2008) Effect of Operator Response …Commonly accepted 10‐30min
• API Std 521 (2014) Effect of Operator Response …User to ensure consequences of
operator intervention to be understood.
• Although codes are not retrospective, compliance with this latest standard may require
re‐visitation of passive integrity reliance subject to client risk acceptance criteria.
2.1.3.2. Passive Integrity & SIS

• Ma’aden incorporates SIS as a result of direct steam sparge into Digesters.
• SIS being discussed with EGA presently to supplement passive integrity for vessel
train.
12
Operation 3.2.1. Automation & Process Control
1. Vessel Train Pressure Stabilisation

• Assists with maintaining hydraulic parameters, minimises potential vapour short circuiting, improves vapour
quality from vessels
• Automated controls for pressure profile stabilisation implemented for Ma’aden
• Automated controls for pressure profile stabilisation incorporated into design for Al Taweelah
2. Flash Tank Level Control

• Being used successfully at Ma’aden.
• Implemented for Al Taweelah.
3. DCS operated hydraulic/pneumatic drive isolation valves

• Ma’aden incorporates automated isolation of selected vapour valves as part of integrated control philosophy and
hydraulic operation of all Digester angle isolation valves utilising hydraulic power packs.
• Al Taweelah back pressure pot isolations incorporating full hydraulic operation from control panel.
13

Operation 3.2.2. Access / Operability
1. PD Pump house
• Pump house to largely eliminate environmental conditions from routine Mtce
• Overhead single girder travelling crane 5T for Ma’aden.
- Pump NRV’s
- Pump Diaphragms
• Overhead double girder 20 Tn travelling crane for Al Taweelah.
- Pump NRV’s
- Pump Diaphragms
- Crank / gearbox
2. JPH Cleaning
• Dedicated access platforms provided.
• Based on recuperative temperature limit, chemical cleaning every 9 weeks only for Ma’aden.
• Al Taweelah design based on similar expectations for sodalite scaling and titanate scaling as per Yarwun
• Scale traps on heater trains with Lime Injection upstream of BPCS
14
Operation 3.2.2. Access / Operability
3. JPH Removal
• Maaden and AL Taweelah structural building designed to accommodate JPH removal
• Layout space in plot plan provided for heater extraction
• Condensate system and vapour inlets with flanged spools to assist with breakout and bypassing of heaters
4. JPH Bends Access

• Maaden bend removal via Franna / mobile crane.
• Al Taweelah bend removal via 0.5T travelling single girder gantry and jib cranes.
5. Holding Tube Cleaning

• Pigging of Holding Tubes incorporated
• DN350 tubes for improved line velocities and hydraulic balance with lime injection.
6. Flash Tank Bypassing

• Ma’aden incorporates bypassing of each vessel with last flash tank able to be Blow Off tank.
• Al Taweelah bypassing of all vessels excluding first and Blow Off tank.
• Vessels are bypassed as a stage including condensate system.
15
209
Security Filtration Debottlenecking
Dr. A. Scarsella
Agenda
1. Overview
2. Existing installation
3. Target and Challenges
4. Filter Cartridge Design
5. Operation
6. Future Operational Improvements
2

Overview – Alumina Production
Red mud
neutralisation
& disposal
3
Existing Installation
16 vertical pressure filters (VPF) at Reference

Site
• 8 x VPFs 1st washer overflow
• 8 x VPFs in security filtration
Scope of modifications:
VPFs in security filtration

8 x new filter cartridges 8 x new wash manifolds
4
211
Target and Challenges
Improvement Target:
• Capacity increase ~15% (throughput)
Mechanical Design Requirements:

• Design of new cartridges to fit space and supports in existing pressure vessels
• cartridge weight limited to fabrication weight of existing cartridges
 Larger filtration area and stiffer cartridge design with „0“ % weight increase
• Control and operating philosophy remain unchanged
5
Filter Cartridge Design – Existing Design
Existing pressure vessel Existing filter cartridge / leaf design
6

Filter Cartridge Design – New Design
New cartridge / wash manifold
New filter cartridge design
design
7
Filter Cartridge Design – Leaf Design
• Old design stiffer but heavier and Top view on leaf cross section:
more prone to scale build up inside old new
the sandwich structure of the
cartridge leafs
• New design with less scaling „area“
and more „space“ for cake build up Filter cake
on outside of cloth
 allows for less space between
cartridge leafs ( more leafs per
cartridge = increased filter area)
8
213
Filter Cartridge Design – Benefits of New Design
Existing filter cartridge design New filter cartridge design
• 441m² filter mesh area / Cartridge • 520m² filter nom. area / cartridge
• 21 rectangular leafs • 23 extended & wider leaves
• Leaf design: sandwich structure • Leaf design: double mesh
• Weight: unscaled ~12.5t • Weight: unscaled ~12.5t
Benefits:
• Larger filter area  16% increased filtration capacity

• Double mesh less prone to scaling
• Longer lifetime of cartridge
• „0“ increase in cartridge weight
9
Filter Cartridge Design: FEA bottom plate of

filtrate manifold
• Cartridge analyzed with FEA to select optimal

design
• Key factor highest strength at minimum weight
• Strength of OLD vs. NEW design for 8 different
configurations analyzed
Oval spool
• Bending of single leaf and simultaneous bending
of multiple leafs considered
• As a result bottom plate thickness increased and
oval spool connection design reinforced
10

Filter Cartridge Design: CFD simulation
• Filling and ramp up procedure simulated in CFD

• Excessive flow rates & forces on elements detected during filling
Reduced filling flow rate determined
Forces and pressure differentials incorporated in FEA model
Flow reduction has positive impact on throughput – see cake
formation
• Drainage procedure analytically investigated
• Rapid dumping of filter cake can generate high loads on the tips
of the filter leafs
• Possibility that cake can not drain fast enough and can block the
free area in btw the leafs
 perpendicular forces on the leafs
• Recommendation: change the drainage procedure in order to
drain vessel gradually
11
Operation –Cake Formation & Cloth Life
• Cake formation on entire cloth including support beams

- Slow cake build up at start up important to develop non-compressed cake
- Cake formation on entire leaf area
• Even cake thickness ~4mm
- Cloth type has impact on recovery after washing
- Outotec recommends polypropylene multi-mono heat set fabric type cloth
• Cloth life: Typically 600hs depending on cloth type
• Re-clothing:
- Improved turnaround time for re-clothing (~8h)
- Simple replacement of scaled cartridge with a new re-clothed cartridge
• Filter cleaning:
- Cloth washing procedure after every cycle (~15min)
- Caustic washing every 2-4 cycles depending on pressure drop
12
215
Future Operational Improvements
During the modifications the following areas for operational improvements

have been discussed:
• Venting during filling (including level control during cycle):
Optimal air volume retained in top of vessel, extension of cycle time & slow, uncompacted cake build up
• Drainage sequence – open drain valve gradually:
Avoid rapid cake dropping  uncontrollable forces on leafs leading to structural damage
• Blow down of liquor level at cycle end:
Extension of cycle time & reduction of dumping of valuable product during drainage
• Further areas impacting the filtration performance are:
TCA (addition, quality)
Flocculent dosing
Filter cloth type
13

GRINDING MILLS–
AVAILABILITY INCREASE
July 2017
Grinding Mills – Availability Increase
Target: Increase of mill availability from 88.4% to 91.5%

to assure scheduled AL₂O₃ output of 1.71 mtpa
COMPANY PRESENTATION March, 2017
217
3
Asset (mills) characteristics

Bauxite grinding process utilizes 7 uniform ball mills of the following specifications
specifications:
 L= 6.25 m, D= 3 m; Ball load 60 tonnes; Q.=88 t/h by dry bauxite.
Ball mills КВ
КВ101
101-501
101-
101 501 ((5
5 pcs
pcs),
pcs)),
designed to supply the main autoclave digestion stream with raw slurry
slurry:
 OEM: FIVES CAIL BABCOCK, GIVORS (France).
 Commissioned in 1980-1982
Ball mill КВ701

КВ701 (1
(1 pc
pc),
),
designed to provide raw slurry for HTTD
(agitation digestion
digestion)):
 OEM: MEKHANOBRCHORMET RESEARCH
INSTITUTE FOR ENRICHING AND SINTERING OF
FERROUS ORES, PUBJSC, Ukraine
• Commissioned in 2004
Ball mill КВ801

КВ801 (1
(1 pc),
pc
intended to supply raw slurry to the sweetening
circuit:
circuit
 OEM: MEKHANOBRCHORMET RESEARCH
INSTITUTE FOR ENRICHING AND SINTERING OF
FERROUS ORES, PUBJSC, Ukraine
 Commissioned in 2010
Bauxite grinding process data

Bauxite mix processed in 2016
2016:
 Kindia, Guinea – 75.4%, Guyana – 15.9%, Juruti, Brazil – 2.0%, Jamaica – 2.7%, Trombetas,
Brazil – 1.8%, Sierra Leone -2.2%
Bauxite mix processed in 2017 (Business Plan

Plan):
Plan)
 Kindia, Guinea– 64.7%, Guyana – 18.7%, Juruti, Brazil – 1.2 %, Trombetas, Brazil – 7.6%,
Sierra Leone - 2.3%, Jamaica – 0.4%, Weipa, Australia – 2.7%, Boke – 2.3%.
Bauxite mix to be processed in 2018 (Business Plan

Plan):
Plan)
 Kindia, Guinea– 76.8%, Guyana – 23.2%
Processing parameters
parameters:
 Recycled liquor concentration 220-216 g/l
 +0.315 μm content in raw slurry – 5.3%
 CaO dosage per bauxite:
 Kindia, Guinea– 1.5%
 Jamaica – 4.5%

5
Review of mills unscheduled downtime in 2011 – 2016
Unscheduled and emergency downtime of the mills, hours

including
(of the consumer)

Electrical reasons
No raw materials
energy resources
Availab
contiguous units
Instrumentation
Control system
Mechanical
or fuel and
Total ility
Year
Repair of
reasons
failures
failures
2011 1338 1093 60 2 93 88 2 88,4
2012 709 480 68 6 20 100 35 91,1
2013 367 276 28 11 1 47 4 90,9
2014 765 583 26 4 5 20 128 91,0
2015 299 147 18 11 11 108 5 89,5
2016 58 24 19 0 0 6 9 91,8
2017 (fact for 7
89 52 20 0 0 13 14 90,7
months)
Review of the mill unscheduled downtime in 2011–2016
2011
1200 1093
1000
800
600
400
2011г.
200 60 93 88
2 2
0
219
7
Emergency downtime due to the mill mechanical in

2011 – 2016
600 548
500
400
2011г.
300
2016г.
200
129
87
100
3 0 0,9
0
Нарушение футеровки, Неисправность систем смазки Износ загрузочных течек
разгерметизация Lubrication system problem Charging spout wear
Lining breakdown,
depressurization
Grinding Mills – Availability increase
Emergency downtime due to Mechanical

Mechanical:
 Lining integrity damage, depressurization of the lining fitting holes of the mill
drum - 548 hours;
 Lubrication system problems - 129 hours;
 Wear of charging spouts and hole formation due to high abrasivity of the
processed material - 87 hours.
Actions taken
taken:
1 stage – measures not requiring design solutions
solutions,, expenditures
expenditures:
 Changing the type of the rubber rings with metal fastener pucks on lining
mounting bolts;
 Manufacturing of charging spouts of Hardox - highly abrasion resistant
material
material.
2 stage - measures requiring design solutions
solutions,, significant expenditures and long
implementation times
times:
 Change of the applied lining type to no-wedge type;
 Updating of the mill equipment lubrication systems.

недостаточное перемешивание в ввиду отсутствия водопадного режима.
9
Decrease in unscheduled downtime of the mills

due to depressurization of the lining fitting
holes
Problem analysis:
1. The type of lining (wedges) applied is subject
to gapping between the lining parts, which
contributes to weakening and outage of the
fitting elements.
2. The applied hole seals of the lining fitting do
not seal hermetically.
3. Mathematical modeling of the lining
operation showed its wear due to presence of
shuffling in point А.
10
Decrease in unscheduled downtime of the mills due to

problems with the lining fitting
Measures carried out:
1. Fitting the lining mounting bolts with
rubber rings with metal fastener pucks.
2. Change of the type of the lining
applied to a wedgeless one considering
results of the mathematical modeling.
Results:
Number of the ball mill shutdown for the
bolt tightening in 2016
was 9.
Unscheduled downtime
of the mills equaled
2.86 hours.
221
11
Decrease in unscheduled downtime of the mills for

malfunctions repair of the lubrication systems
Problem analysis:
1. With increased or decreased oil
pressure in the lubrication systems,
emergency shutdown of the mill took
place. The oil flow mechanical sensors
applied did not measure pressure.
2. The ball mill downtime to repair
malfunctions of the lubrication systems
in 2011 made 129 hours.
12
Decrease in unscheduled downtime of the mills for

malfunctions repair of the lubrication systems

1. Equipping the lubrication systems
with a hydraulic sensor reading not only
the oil pass through, but also pressure.
2. Equipping the lubrication systems
with a manometer to define true
pressure in the lubrication system.
3. Installation of indicating lights
allowing for immediate fault-finding in
the lubrication system.
Results:
1. There were no shutdowns or
downtimes of the mills to repair
malfunctions of lubrication systems in
2016.

13

abrasion wear of the charging spouts
Problem analysis:
1. Wear of charging spouts of the mills
and hole occurrence due to high
abrasion of the material processed.
2. The (lining) material used does not
assure failure-free operation during time
between overhauls.
3. Duration of unscheduled downtime of
the ball mills to repair charging spouts in
2011 was 87 hours.
14

abrasion wear of the charging spouts

1. Equipping the charging spouts of the
mills with Hardox mill liners of increased
abrasion resistance.
Results:
Duration of unscheduled downtime of
the mills to repair the charging spouts
made 0.9 hour in 2016.
223
15
Review of the mill unscheduled downtime in 2011–2016
1200 1093
1000
800
600
400
2011г.
2016г.
200 93 88
24 60
19 2 0 0 6 2 9
0
16
Grinding mills – Availability increase
Result: In 2016, mills availability achieved 91.8% (target –

91.5%), which will allow for the refinery capacity as much
as 1.71 mtpa in 2018.

RUSAL
MYKOLAYIV LTD.
Fluidized Bed Units
2017
FB Unit Capacity
Item Design Fact, 2015 Expected fact 2017 BP 2018
1 000 000 1 469 506 1 655 744 1 700 000

Calcined Alumina Output
tonnes tonnes tonnes tonnes
FB Units Availability 91 % 83,7 % 90,9 % 91,3 %
Lurgi Units 753 t/d 885 t/d 900 t/d 900 t/d
Outokumpu Unit 1 500 t/d 1 270 t/d 1 390 t/d 1 500 t/d
225
3
Commercial Product Quality

Description Buyer’s requirement Fact, 2015 Expected fact 2017 BP 2018
SiO2 content 0,03 % 0,023 % 0,028% 0,022 %
Na2O content 0,40 % 0,34 % 0,35 % 0,33%
-45 content 40 % 38,0 % 35,6 % 30,0%
Not more than 0,8

LOI content 0,8 % 0,79 0,78 %
%
α-phase conent 8% 5,0 % 5,8 % 5 -10 %
Specific Fuel Consumption

Description Design Fact, 2015 Expected fact 2017 BP2018
Lurgi units 753 t/d 885 t/d 900 t/d 900 t/d
Heat consumption 3,40 GJ/t 3,05 GJ/t 3,06 GJ/t 3,00 GJ/t
Hydrate moisture from the

11,0 % 8,5 % 8,2 % 8,2 %
drum filters
Outokumpu unit 1 500 t/d 1 270 t/d 1 390 t/d 1 500 t/d
Heat consumption 2,97 GJ/t 3,03 GJ/t 2,96 GJ/t 2,96 GJ/t
Hydrate moisture from the

8,5 % 6,8 % 6,8 % 6,8 %
pan filter

5
Existing Problems in Lurgi Units

Heat loss:
1) Temperature of gases exiting drier II is 390 deg. C.
This indicates that the hydrate has not mixed well with the gases exiting the furnace and recycle
cyclone as this temperature should be about 330 deg. C – 340 deg. C.
Was Now
Existing Problems in Lurgi Units

Heat loss:
Modeling the path of particles with design layout of hydrate feed pipeline to Venturi drier, gave the
result (gas stream, solids flow). A conclusion can be made that the existing pattern of feeding
hydrate to Venturi drier is more effective.
Gas stream Solids flow
The color, from blue to red, indicates rate of flow, 0-20 m/s
227
7
Existing Problem in Lurgi Units

Heat loss:
Recirculation occurs when the cyclones can not collect the material and it keeps flowing with the air
stream towards the ESP.
Lurgi cyclones are very effective, but they cannot collect very fine material often caused by
breakdown.
Was Now

Heat loss:
Reduced CO – Improved Furnace Combustion
For combustion to be completed air and gas must mix. Mixing in all alumina calciner furnaces is
difficult as very good mixing between the gas and air creates very high temperature and not too
much alpha alumina. Poor mixing results in high CO.
Existing design Prospective changes

9

Calciner 3 – Leak of air type collector (burn-through)
10

Calciner 5 – Breakage of discharger tip
229
11
Targets for 2017 - 2020

Modification of FB calciners 1-4:
2017 – Basic Engineering
2018 – Project work, equipment purchase
2019 -2020 – Modification of FB units

MULTIPURPOSE ALUMINA
CALCINATION PLANT
M.S.c Sonia Noack
231
CONTENT
BACKGROUND
ALUMINA MARKET TENDENCY
ALUMINA REFINERY VALUABLE

MULTIPURPOSE PRODUCTS
ALUMINA
CALCINATION PLANT
OUTOTEC SOLUTION
OUTOTEC MULTIPURPOSE CALCINER
SUMMARY
2
BACKGROUND
Aluminium and its alloys derived from conventional

smelter grade alumina has been utilized more and
more for metallurgical applications increasing their
demand over the years
Specialty alumina and hydrate has found more

and more applications for non-metallurgical
purposes increasing their demand in the last years
3

BACKGROUND
Aluminium and its alloys for metallurgical applications
Transportation, building and construction; packaging, electrical and
electronics; appliances, tools and utensils for household and industries
Aluminium Tri-hydroxide for non - metallurgical applications

Construction, cabling wire coating, plastic, rubber, paper, paint and
polymer industry
Alumina for non - metallurgical applications

Abrasives and refractory, electrical, electronics, synthetic rubies and
sapphire; cosmetic, medical, glass and ceramic industry
4
2,300,246 thousand
metric tons of alumina
has been produced
from 1974 to 2017
Source: IAI Statistical
5
233
166,831 of 2,300,246
thousand metric tons has
been utilized in non-
metallurgical applications
Source: IAI Statistical
6
ALUMINA REFINERY VALUABLE

PRODUCTS
Source: http://www.aos-stade.de/
Source: https://rusal.ru/en/
http://www.almatis.com/
7

OUTOTEC SOLUTION
OUTOTEC SOLUTIONS FOR:
Washing
Special Aluminium Tri-hydroxide (low sodium) Filtration
Plant
Dry Aluminium Tri-hydroxide by indirect heating

Hydrate
Dryer
Special alumina (higher alpha, high purity, etc.)
Calcination
Plant
8
OUTOTEC SOLUTION
Test work
Modeling, heat & mass balance

CONCEPT & EVALUATION FEL0
Process description
ORDER OF MAGNITUDE FEL1
PFDs
PRE-FEASIBILITY FEL2 P&IDs
Drawings & 3D Model

FEASIBILITY STUDY FEL3
Equipment list and BoQ
DETAIL STUDY / EXECUTION FEL4
CAPEX (plant unit & specialty)
Financial model
9
235
OUTOTEC SOLUTION
Outotec Calcination Plant is based on Circulating Fluid

Bed (CFB) Technology
Why does Outotec uses CFB for Alumina Calcination ?
10
OUTOTEC SOLUTION
circulation of solids which provides:
 Excellent heat and mass transfer
 Uniform solids retention time
 Even temperature distribution
 Easy and exact control of

temperature and retention time
11

OUTOTEC SOLUTION
 Superior Product Quality

 Uniform product quality
 Stable product quality
 Low particle breakage
 Target BET, LOI and alpha alumina in product
 No Gibbsite (hydrate) present in product
 Low energy consumption

 Low emissions
 Safe and easy to operate and maintain
 Experience and reference plants
12

Main Challenges:
• Wide range of operating temperature
• Higher max. operating temperature
• Small capacity plant
LAYOUT
DESIGN SGA QUALITY
CGA QUALITY
PROCESS PARAMETERS
VESSELS MATERIAL
MECHANICAL
REFRACTORY
CONTROL PHILOSOPHY
OPERATION
HYDRATE BYPASS
13
237
PROCESS LAYOUT
Simple layout including:
Two preheating stages
Seal pot in-between
Improved hydrate bypass
14

PROCESS LAYOUT
CFB furnace
Mixing pot
Improved hydrate bypass

(disable for CGA)
15

PROCESS LAYOUT
Two cooling stages
Flap Valves in-between
FBC
16

PROCESS PARAMETER
Calcination temperature and retention time dictates alumina’s quality:
Loss On Ignition (LOI)
Specific Surface Area

(BET)
Alpha Alumina content
17
239
TESTWORK RESULT
100
1000
90 1050
1100
80 1150
70
Alpha content [%]
60
50
40
30
20
10
0
0 5 10 15 20 25 30 35 40
Retention Time [min]
18

PROCESS PARAMETER
1200
CGA
1000 SGA
800
Temperature [°C]
600
400
200
0
Stack Venturi Cyclone Recycling CFB Mixing pot Secondary Secondary FB Cooler
Preheater Stage 2 Cyclone Cyclone 1 Cyclone 2 Discharge
Stage 1
19

CONCRETE /
REFRACTORY
PM CONCRETE /
CASTING CASTING
BRICK
FIRE CLAY BRICK
Wide range of operating

temperature: DENSE CONCRETE /
CASTING
LW CONCRETE
Upper part of the furnace GUNNING
with brick Standard Solution for

design for SGA/CGA
DENSE CONCRETE / SGA
Lower part with
CASTING
monolithic lining with

ceramic anchors
(undefined shape) FIRE CLAY BRICK
DR CONCRETE/CASTING DR CONCRETE/CASTING
+2% STEEL FIBERS
PM CONCRETE PART
PM CONCRETE PART
20

MECHANICAL
Standard Solution for SGA/CGA
Wide range of operating
temperature:
Vortex finder excluded
Restrictor for avoid

bypassing
Recycling Cyclone
21
241
MECHANICAL
Capacity to operate a
two different
temperature profile
Easy maintainability
due to smaller
air/water coils
Normal cranes to lift-

up the coils
22

OPERATION
Simple programming
Controls for target qualities
Controller set values

PROGRAMMING
EQUIPMENT
Safety features regardless

production targets
Adjusted set values for safety

functions
Enable / disable equipment or

part
Procedures to switch production

targets
23

SUMMARY
Increasing demand for special grade aluminas and hydrate
Outotec has wide range of solutions for special grade aluminas
Custom design multipurpose calciner was developed
Main Challenges:
Wide range of operating temperature
Higher max. operating temperature
Small capacity plant
Key features are:
Mechanical design adapted for multiple products
Material/refractory adapted to temperature requirement
Control philosophy adapted for multiple products

24
243
THANK YOU FOR JOINING US!
We look forward to seeing you next time.

245
Outotec provides leading technologies and services for the sustainable use of Earth’s
natural resources. As the global leader in minerals and metals processing technology,
we have developed many breakthrough technologies over the decades for our customers
in metals and mining industry. We also provide innovative solutions for industrial water
treatment, the utilization of alternative energy sources and the chemical industry.
Outotec shares are listed on NASDAQ OMX Helsinki. www.outotec.com
Outotec® is a registered trademark. Copyright © 2017 Outotec Oyj. All rights reserved.

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19TH ALUMINA

Meeting Summary & Presentations

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Your Outotec team

ALUM S.A. Sorin Iliev Filter Sales Trevor Sparks

ALUM S.A. Marian Juganariu HINDALCO Rohit Chourasia

ANRAK L.S. Rao HINDALCO P. K. Banerjee

AOG Panagiotis Karampogias HYDRO Robert LaMacchia

AOG Christos Katemliadis HYDRO Wlademir Penna

AOG Marios Skarpidis HYDRO Andre Vidal

AOS Andreas Nollmann HYDRO Pia Magnussen

AOS André Lalla HYDRO Michel Lisboa

AOS Dimitrios Kastritis MAADEN Tariq Al Asmi

AOS Felix Wolters MAADEN Abdullah Mohammed Al-Muhaisen

CBA Roberto Seno Jr. MAADEN Abdulmalik Salih Shaheen

CBA Ricardo Vinhal MAADEN Yousef Talal Al Dossary

CHALCO Zhirong Shi MAADEN Abdullah B. Al Otaibi

CHALCO Gu Songqing MAADEN Abdullatif M. Al-Musabbeh

CHALCO Kaibin Chen RUSAL Aleksandr Suss

CHALCO Zhonglin Yun RUSAL Levchenko Maksim

CHALCO Wanchao Liu RUSAL Vladimir Krasnoyarskiy

EGA Shouqi Hassan Mohammed RUSAL Anna Romanova

EGA Inam Almarzouqi

Alumina user’s meeting | Meeting Proceedings

Ioannis Chatzilamprou, Service Product Manager Michael Ren, Head of Sales

Jarkko Karesvuori, Sales Director Comminution Alessio Scarsella, VP Alumina

Chris Mason, Marketing Manager Steven Yu, Service Product Manager

Michael Missalla, VP New Business Development

1988 1st Phoenix, AR, USA

1989 2nd Las Vegas, NV, USA

1990 3rd Anaheim, CA, USA

1991 4th New Orleans, LA, USA

1992 5th San Diego, CA, USA

1993 6th Sydney, NSW, Australia

1996 7th Darwin, NT, Australia

1998 8th San Antonio, TX, USA

1999 9th Dunsborough, WA, Australia

2000 10th New Orleans, LA, USA

2002 11th Brisbane, QLD, Australia

2004 12th Barcarena/Alunorte, Brazil

2005 13th Perth/Collie Worsley, WA, Australia

2007 14th Orlando, FL, USA

2008 15th Darwin, NT, Australia

2011 16th Outotec Oberursel, Germany

2013 17th Outotec Oberursel, Germany

2015 18th Outotec Perth, WA, Australia

2017 19th Hamburg, Germany

Alumina user’s meeting | Meeting Proceedings

09.00 - 09.15 Welcome and opening remarks

10:15 – 10:45 Coffee Break and Group Photograph

10:45 – 11:25 Integrated Refinery design New developments

12:45 – 14:15 Lunch Time

14:15 – 15:05 Energy Consumption In Bayer Process in China (Chinalco)

15:05 – 15:55 AOS

15:55 – 16:25 Coffee Break

16:25 – 17:15 EGA Al Taweelah Refinery

18.40 – Bus collection from hotel reception

08:30 – 09:25 Alumina Refinery - Service Portfolio

10:00 – 10:30 Coffee Break

10:30 – 11:10 Cyclone Optimization and Seal Pot

12:30 – 14:00 Lunch Time