ote alumina and aluminium technologies eng web

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Alumina and aluminium

technologies

Outotec's aluminium expertise is a powerful combinationof innovative proven technologies. Cooperation and havinga team approach enable us to provide you with the bes tpossible service and vast exper tise in alumina refining,paste plant and rodding shop as well as casthousemachinery – tailored to meet your specific needs.



Hydrate wash & ltration

Bauxite

Steam

Alumina

Ro

Heatexchange

Heatexchange

Grinding

Calcination

Clarication

Tube digestion

Liquor ltration

Fume treatment plant

SPL treatment plant

Red mud storage

Residue washing

Boiler

Evaporation

Precipitation

002 Alumina and aluminium technologies

Experience in aluminium processing and production

A global leader in the development of mineralsprocessing and metallurgical technologies, Outotechas a distinguished history of achievement going backmore than a hundred years. Outotec has a long traditionof developing metallurgical processes, which areenvironmentally sustainable. The company's aluminiumexpertise is based on former Lurgi Metallurgie, KHDand AISCO technologies, now united under the commonOutotec brand.

In the global aluminium industry, Outotec providestotal business solutions for processing andproduction of alumina and aluminium. Outotec offers

you proven exper tise in alumina refining, paste plant,rodshop, and casthouse machinery. Today, Outotec'scirculating fluidized bed (CFB) technology for thecalcination of alumina is the industry standard.

One partner for the plant 's life cycle

Early choice of a single technology partner, who canmanage production processes and design throughoutthe entire operation, saves time and money.Without bottlenecks, plant operation is smooth,and profits accrue quickly. Outotec is committed tocontinuously developing processes and equipmentfor customers' production plants. Outotec helps youenhance your production process – and will take care ofthe whole delivery.

As your partner, Outotec offers comprehensiveengineering and project implementation services aswell as customer support through its worldwide

network of service centers. Outotec's qualified andexperienced field personnel ensures trouble-freecommissioning. Every plant is unique and thereforeprocesses modified to meet specific requirements.

Proven technologies for the aluminiumindustry



Billet Slab Ingot Sow

Bath treatment

Casthouse

Rodding shop

Butt crushing plant

Anode baking plant

Green anode plant

Aluminum smelting

Alumina renery

Electrolysis/Potline(s)

Fume treatment plant

Load/unload I Bath removal

ALUMINIUM

Coal tar pitch Calcined coke

Alumina and aluminium technologies 003

Outotec's long-term commitment and extendedcustomer service minimize operating risks throughoutthe life cycle of the plant. Cooperation can begin witha feasibility study leading to a lump-sum turnkey plantdelivery and, ultimately, to a long-term par tnership.

Comprehensive aluminium technologies

Outotec's solutions for the aluminium industry coverproven technologies. Furthermore, we offer professionalengineering and project management services basedon extensive R&D resources as well as comprehensivetechnological and business knowledge of metals

production. Our global sales and after-sales network isalways close at hand when expertise is needed.

Proven technologies for

the aluminium industry Alumina refinery

Aluminium smelter green anode plant

Aluminium smelter rodding shop

Casthouse

Services and after sales




Alumina calcinationCalcination is the final stage of the Bayer process, in

which bauxite is digested with caustic soda to firstextract and then precipitate a pure aluminium hydroxide(hydrate). The hydrate from the Bayer process is thencalcined to alumina in a CFB. This step was earliercarr ied out in rotary kilns, but today all new capa-city isinstalled as fluidized bed calciners.

CFB calcination process

The circulating fluidized bed calciners use a multi-stageventuri preheating system to recover the waste gas

heat by preheating and de-watering the hydrate. Finalcalcination to alumina (Al 2O3) is accomplished in theCFB reactor in which the energy is provided by directcombustion of fuel (oil or gas). The energy of the hotalumina is recovered to the incoming air in a multistagecooling system including cyclones and a fluidized bedalumina cooler.

Some energy of the hot alumina is also used for directcalcination of incoming hydrate in a so-called ”hydrateby-pass”. This efficient heat recovery system leads toan overall fuel energy consumption of less than 3 GJ/tof alumina for the calcination process. CFB calcinersoperate in a range from 900 to 1,000°C depending onproduct quality demands.

Alumina calcination in the CFB.

Hydrate

Fuel

Secondary air

Primary air

Cooling water

Preheating stage I

Preheating stage II

CFBreactor

Calcining stage

Cooling stage I Cooling stage II

Cooling water

Alumina

Fluidized bed cooler

Hydratebypass

Electrostaticprecipitator

Waste gas

Advantages of CFB plants

Low specific energy consumption – low

temperature profile

Low maintenance cost

High availability

Wide range of part load operation

Uniform product quality – no off-

specification product

Easy and reproducible change of product

quality Extremely stable and easy operation of

the plant without need of sophisticated

control equipment

Low NOx emission

Due to the homogeneous temperature in the CFB reactor,

product qualities regarding specific surface area, losson ignition and alpha content in the alumina can fulfillthe demands of today's aluminium smelters. We haveinstalled more than fifty CFB calciner units worldwide.This represents approximately one third of the world'sproduction of smelter grade alumina.




Solutions taylored to your needs

Prior to the application of fluidized bed technology,alumina was traditionally calcined in a rotary kiln.While this equipment has the major disadvantage ofhigh energy consumption, it has one advantage: it isvery gentle on the product and thus minimizes finesgeneration.

You, our customer, want the advantage of low energyconsumption that is brought by fluidized bed technology.We also recognise that you want low fines in product .

Outotec set itself the challenge to achieve both of thesetargets in a single plant. By combining the inherentadvantages of CFB technology with knowledge gainedfrom our extensive R&D in the field of solids fluidizationand heat transfer, Outotec has, in its latest design,achieved a new benchmark in product quality, allowingyou to operate your refinery more flexibly and moreefficiently.

PAM deliveries – design and construction of largestpossible modules off-site

Outotec’s preassembled module (PAM) technologyreduces capital cost. PAM enables plant constructioneven in remote areas with undeveloped infrastructureor lack of skilled workforce. Opting for PAM minimizeson-site construction (structural, mechanical, piping,refractory lining, instrumentation, electrical) andensures continuation of production at site with minimizedinterruption during the installation process.

The rst PAM delivery of two large calciners took place in 2006 to the

Northern Territory in Australia. The calcining units were preassembledin South East Asia and transported by ship to Rio Tinto Alcan Gove.

“Our goal is to produce the highest quality alumina in the world. In order to reach that weneeded two things: the best available technology and the most qualied professionals. Outotecprovided us with both. Their technology is reliable and easy to work with. The same is true oftheir people.” Victor César Ribeiro da Cruz, Alunorte, Brazil.




Liquid pitch facility for bulk s torage of liquid pitch

Special articulated ship unloading arms Liquid pitch storage tanks

Special road tanker loading facilities with fumereturn line

Totally sealed pitch pumps Nitrogen blanketing system for storage tanks Dedicated HTM–systems

Preheating screw used for continuous heating of

coarse or fine–grained anode dry aggregate Intermeshing of helical ights of hollow screws Adjustable speed of screws by frequency conver ter

Gentle product conveyance at low speed, withnegligible wear on screws

The vibrocompactor meets the growing demand forgreen anode quality for modern aluminium smelters

Sliding table and turntable typeCombination of two or more sliding table vibratingcompactorsVacuum technology

Inatable rubber bellows for vibrating tablesupport and prestressing of cover weight Online density control system Densitrol ® for

consistent anode quality

Hydraulic anode crusher and butt crushing plants tobreak any size of green or baked reject anode b locksor carbon butts

Capacity approximately 80–100 butts/ h Capability to crush full size anodes up to

1700x1200x650 mm

Pressure type crushing avoids huge amount ofne particles Low head room Heavy duty design, easy to operate and maintain




Total roddingshop solutions

As your partner we offer

Basic and detail engineering for complete plant Proprietary and key equipment supply Site supervision, commissioning and start–up services Turnkey plant deliver ies Plant retrots and machine upgrades

Load/unload system for multiplerod styles

Fully automatic – no operatorrequired

Used with pallet transpor teror trailersCentering devices for aligningwith P&F bells

Use with bath conveyor in pit orcompletely above oor level

95° pallet dump completelycleans pallet directly into bathconveyor

Primary bath cleaning for both in-line and spider configurations

Suitable for hot or cold bath Hydraulic prebreak station Secondary cleaning with

hydraulic pushers or ailcleaning

Final air blow-off Fallen carbon conveyor

Butt shotblast machine designedspecifically for the aluminiumindustry tak ing into account theunique challenge of cleaning bathresidue from carbon butts

360° rotation during cleaningcycleBlow off ensures no carry outof shot

Steel cabinet with rubber soundinsulation and manganese wearlining

Use of multiple chambers for upto 90 butts/hr




Semi-automatic pouring systemcustomized to meet existing furnaceand rodshop layout and productivityrequirements

Various ladle congurations Can be relled with ladle in

casting car or removed Operator control room to

oversee complete pouring system Single or double casting car

system for redundancy

Thimble cleaning drum for cleaningof cast iron

Manual and fully automatedsystem

Capacity from 100 kg to7,000 kg/hour

Built in dust take off points Storage silos, hoppers and

feeders also available

Mating station for aligning rodsand carbon anodes

clamps and guides ensureperpendicularity

Rod remains attached to P&Fcarrier

High productivity Simple walking beam or pusher

design depending on productionrates

Butt stripping press for the removal of spent carbon. Up to 425 mt force for removing up to full size double anodes Bottom up or push down styles available Bottom up press will break carbon into several smaller pieces Production up to 80 rods per hour

Single combination press to strip both carbon and thimbles

at same time

Thimble stripping press designedto break the thimbles away fromthe stubs

Strip one thimble at a time orup to four at once

Ideal for both in–line and spider

rod conguration

Rod reconditioning after removalof bath, carbon and thimbles

Rod brushing for removal ofmarks, chalk lines andscratches

Graphite coating and s tub

drying Stub straightening Rod straightening Stub cut off and welding




Casthouse technologiesJumbo sow caster with capacity up to 35 tph

Water or air primary cooling Fully automated, single operator Pouring from single or dual crucibles Robotic skimming, vacuum demoulding Weighing, marking and stacking

Rolling slab and T–bar sawline designed tomeet your specific needs

Fully automatic material handling Variable cut length Weighing, marking and stacking Choice of saw types and brands Chip collection and briquetting

Foundry ingot casting systems Complete supply from furnace tap hole to nal

strapped bundle

Automatic pouring to 95% bundle weight accuracy Weighing, marking and bundle strapping Building and loading of superstacks available




R&D and after sales services

With a growing list of worldwide references, Outotec iscontinuing its dominance in the supply of technology andsolutions of the aluminium industry.

Outotec's extended customer service operates througha global network of service centers that offers not onlyassistance to the customer 's needs but al so commitmentto provide advanced customer support whenever needed.

With offices on every continent, Outotec has an a

unparalleled line-up of professionals who are highlyexperienced and understand exactly what it takes tooptimize customers' plants and processes. They havedeveloped, constructed, commissioned and servicedmany of Outotec's technologies around the globe. Coreexperience is, therefore, built onleading-edge technologies, is"hands-on" and focused onensuring a customer's plantis optimized.

Outotec's extensive after salesservices cover

Site services Equipment and plant diagnostic

and audits Process optimization Upgrades and modernizations Spare parts Training and users' meetings

700 mm Circofer ® demonstration plant, R&D Center, Germany.

Outotec's largest CFB based test facility is the Circofer® demonstrationplant at the R&D Center in Frankfurt. This plant is equipped with a700 mm diameter CFB, recycle cyclone, integrated heat generator, charseparator, magnetic separator, gas cleaning system, and all necessaryancillary equipment.

Innovation through research

To maintain its position at the forefront of innovation,Outotec has two in-house research centers,in Finland and in Germany, with a broad rangeof laboratories, bench-scale and pilot plants.

These R&D centers are engagedin development of existing and new technologies, processresearch and measurement and analyses services. CFBtest facilities are available at the R&D center in Frankfurt,Germany, for technology development and for testing of

customer’s aluminium hydrate.



[email protected] © 2011 Outotec Oyj. All rights reserved.

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Outotec develops and provides technology solutions for the sustainable use of Earth’s natural

resources. As the global leader in minerals and metals processing technology, Outotec has developed

over decades several breakthrough technologies. The company also offers innovative solutions for

the chemical industry, industrial water treatment and the utilization of alternative energy sources.

Outotec shares are listed on the NASDAQ OMX Helsinki.

ote alumina and aluminium technologies eng web

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