CbD~OUG TMS2011 14oth Annual Meeting & Exhibition Proceedings of the technical sessions presented by the TMS Aluminum Committee at the TMS 2011 Annual Meeting & Exhibition, San Diego, California, USA February 27-March 3, 2011 Edited by Stephen J. Lindsay Editor Stephen J. Lindsay ISBN 978-3-319-48567-6 ISBN 978-3-319-48160-9 (eBook) DOI 10.1007/978-3-319-48160-9 Chemistry and Materials Science: Professional Copyright© 2016 by The Minerals, Metals, & Materials Society Published by Springer International Publishers, Switzerland, 2016 Reprint of the original edition published by John Wiley & Sons, Inc., 2011,978-1-11802-935-0 This work is subject to copyright. 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Printed on acid-free paper This Springer imprint is published by Springer Nature The registered company is Springer International Publishing AG The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland TABLE OF CONTENTS Light Metals 2011 Preface ........................................................................................................................................................................xxi About the Editor .......................................................................................................................................................xxiii Program Organizers...................................................................................................................................................xxv Aluminum Committee ..............................................................................................................................................xxxi Alumina and Bauxite Organizers......................................................................................................................................................................1 Bauxite Resources and Utilisation Session Chairs ...............................................................................................................................................................3 New Development Model for Bauxite Deposits ............................................................................................................5 P. ter Weer Study on the Characterization of Marginal Bauxite from Pará/Brazil .........................................................................13 F. Silva, J. Sampaio, M. Medeiros, and F. Garrido Resource Utilization of High-sulfur Bauxite of Low-median Grade in Chongqing China..........................................19 J. Yin, W. Xia, and M. Han Development of Bauxite and Alumina Resources in the Kingdom of Saudi Arabia ...................................................23 A. Al-Dubaisi Digestion Studies on Central Indian Bauxite...............................................................................................................29 P. Raghavan, N. Kshatriya, and Dasgupta Effects of Roasting Pretreatment in Intense Magnetic Field on Digestion Performance of Diasporic Bauxite...........33 Z. Ting-an, D. Zhihe, L. Guozhi, L. Yan, D. Juan, W. Xiaoxiao, and L. Yan Bayer Process I Session Chairs .............................................................................................................................................................39 Application of Operation Integrity Management in the Alumina Industry..................................................................41 C. Suarez, D. Welshons, J. McNerney, and J. Webb Influence of Solid Concentration, Particle Size Distribution, Ph And Temperature on Yield Stress of Bauxite Pulp ............................................................................................................................................................47 C. Barbato, M. Nele, and S. França A New Method for Removal Organics in the Bayer Process.......................................................................................51 B. Yingwen, L. Jungi, S. Mingliang, and Z. Fei Alunorte Expansion 3 - The New Lines Added to Reach 6.3 Million Tons per Year .................................................57 D. Khoshneviss, L. Corrêa, J. Ribeiro Alves Filho, H. Berntsen, and R. Carvalho viii One Green Field Megaton Grade Large Alumina Refinery with Successful Engineering & Operation Experience...63 L. Xianqing, and Y. Xiaoping Advanced Process Control in the Evaporation Unit ....................................................................................................69 C. Kumar, U. Giri, R. Pradhan, T. Banerjee, R. Saha, and P. Pattnaik Improvements in Smelter Grade Alumina Quality at Clarendon Alumina Works ......................................................75 R. Shaw, A. Duncan, and M. Crosdale Red Mud Session Chairs .............................................................................................................................................................79 Application of Nanofiltration Technology to Improve Sea Water Neutralization of Bayer Process Residue .............81 K. Taylor, M. Mullett, L. Fergusson, H. Adamson, and J. Wehrli Caustic and Alumina Recovery from Bayer Residue ..................................................................................................89 S. Gu Investigation on Alumina Discharge into the Red Mud Pond at Nalco’s Alumina Refinery, Damanjodi, Orissa, India.................................................................................................................................................................93 B. Mohapatra, B. Mishra, and C. Mishra Production of Ordinary Portland Cement( OPC) from NALCO Red Mud..................................................................97 C. Mishra, D. Yadav, M. Alli, and P. Sharma Recovery of Metal Values from Red Mud.................................................................................................................103 P. Raghavan, N. Kshatriya, and K. Wawrynink Red Mud Flocculants used in the Bayer Process .......................................................................................................107 S. Moffatt, F. Ballentine, and M. Lewellyn Reductive Smelting of Greek Bauxite Residues for Iron Production ........................................................................113 A. Xenidis, C. Zografidis, I. Kotsis, and D. Boufounos Precipitation, Calcination and Properties Session Chairs ...........................................................................................................................................................119 Effect of Technological Parameters on PSD of Aluminum Tri-Hydroxide from Seed Precipitation in Seeded Sodium Aluminate Solutions ..................................................................................................................................................121 Y. Wu, L. Mingchun, and Q. Yanping Methods to Reduce Operating Costs in Circulating Fluidized Bed Calcination........................................................125 C. Klett, M. Missalla, B. Reeb, and H. Schmidt Pressure Calcination Revisited ..................................................................................................................................131 F. Williams, and C. Misra Dynamic Simulation of Gas Suspension Calciner (GSC) for Alumina .....................................................................137 B. Raahauge, S. Wind, M. Wu, and T. Jensen Physical Simulation and Numerical Simulation of Mixing Performance in the Seed Precipitation Tank with a Improved Intermig Impeller ......................................................................................................................................145 Z. Ting-an, L. Yan, W. Shuchan, Z. Hongliang, Z. Chao, Z. Qiuyue, D. Zhihe, and L. Guozhi ix Two Perspectives on the Evolution and Future of Alumina ......................................................................................151 L. Perander, J. Metson, and C. Klett Significant Improvement of Energy Efficiency at Alunorte's Calcination Facility ...................................................157 M. Missalla, H. Schmidt, J. Ribeiro, and R. Wischnewski Attrition of Alumina in Smelter Handling and Scrubbing Systems...........................................................................163 S. Lindsay Energy and Environment Session Chairs ...........................................................................................................................................................169 Perspective on Bayer Process Energy........................................................................................................................171 D. Donaldson Optimization of Heat Recovery from the Precipitation Circuit .................................................................................175 R. Singh, S. Hial, and M. Simpson Alunorte Global Energy Efficiency ...........................................................................................................................179 A. Monteiro, R. Wischnewski, C. Azevedo, and E. Moraes Opportunities for Improved Environmental Control in the Alumina Industry ..........................................................185 R. Mimna, J. Kildea, E. Phillips, W. Carlson, B. Keiser, and J. Meier Alumina Refinery Wastewater Management: When Zero Discharge Just Isn’t Feasible… ......................................191 L. Martin, and S. Howard High Purity Alumina Powders Extracted from Aluminum Dross by the Calcining-Leaching Process .....................197 L. Qingsheng, Z. Chunming, F. Hui, and X. Jilai Effect of Calcium/Aluminium Ratio on MgO Containing Calcium Aluminate Slags...............................................201 W. Bo, S. Hui-Lan, G. Dong, and B. Shi-Wen Study on Extracting Aluminum Hydroxide from Reduction Slag of Magnesium Smelting by Vacuum Aluminothermic Reduction .......................................................................................................................................205 W. Yaowu, F. Naixiang, Y. Jing, H. Wenxin, P. Jianping, D. Yuezhong, and W. Zhihui Application of Thermo-gravimetric Analysis for Estimation of Tri-hydrate Alumina in Central Indian Bauxites-An Alternative for Classical Techniques.........................................................................................................................211 Y. Ramana, and R. Patnaik Determination of Oxalate Ion in Bayer Liquor Using Electrochemical Method .......................................................215 S. Turhan, B. Usta, Y. Sahin, and O. Uysal Alternative Alumina Sources - Poster Session Session Chairs ...........................................................................................................................................................219 The Effect of Ultrasonic Treatment on Alumina Leaching from Calcium Aluminate Slag ......................................221 S. Hui-lan, W. Bo, G. Dong, Z. Xue-zheng, and B. Shi-wen Theory and Experiment on Cooling Strategy during Seeded Precipitation ...............................................................227 Z. Liu, W. Chen, and W. Li x Extraction of Alumina from Red Mud by Divalent Alkaline Earth Metal Soda Ash Sinter Process.........................231 S. Meher, A. Rout, and B. Padhi Dissolution Kinetics of Silicon from Sintering Red Mud in Pure Water...................................................................237 X. Li, K. Huang, and H. Zhu The Effect of Cooling Rate on the Leachability of Calcium Aluminate Slags ..........................................................241 W. Bo, S. Hui-lan, Z. Xue-zheng, and B. Shi-wen Preparing Polymerized Aluminum-ferrum Chloride with Red Mud .........................................................................245 L. Guilin, Y. Haiyan, and B. Shiwen Adsorption of Polyethylene Glycol at the Interface of Dicalcium Silicate - Sodium Aluminate Solution ................251 Y. Haiyan, X. Pan, Z. Lu, and T. Ding Production of Hematite Ore from Red Mud ..............................................................................................................255 P. Raghavan, N. Kshatriya, and K. Wawrynink Aluminum Reduction Technology Organizers..................................................................................................................................................................259 Enviroment- Emissions/ Anode Effect I Session Chairs ...........................................................................................................................................................261 HF Measurements Inside an Aluminium Electrolysis Cell........................................................................................263 K. Osen, T. Aarhaug, A. Solheim, E. Skybakmoen, and C. Sommerseth LasIRTM-R - The New Generation RoHS-Compliant Gas Analyzers Based on Tunable Diode Lasers ..................269 J. Gagne, J. Pisano, A. Chanda, G. Mackay, K. Mackay, and P. Bouchard Use of Spent Potlining (SPL) in Ferro Silico Manganese Smelting ..........................................................................275 P. vonKrüger Reduction of PFC Emissions at Pot Line 70 kA of Companhia Brasileira de Alumínio...........................................281 H. Santos, D. Melo, J. Calixto, J. Santos, and J. Miranda Towards Redefining the Alumina Specifications Sheet - The Case of HF Emissions...............................................285 L. Perander, M. Stam, M. Hyland, and J. Metson Design of Experiment to Minimize Fluoride and Particulate Emissions at Alumar ..................................................291 E. Batista, P. Miotto, E. Montoro, and L. Souza Innovative Distributed Multi-Pollutant Pot Gas Treatment System ..........................................................................295 G. Wedde, O. Bjarno, and A. Sorhuus Fluoride Emissions Management Guide (FEMG) for Aluminium Smelters .............................................................301 N. Tjahyono, Y. Gao, D. Wong, W. Zhang, and M. Taylor Bayer Process Chemistry and Alumina Quality I Session Chairs ...........................................................................................................................................................307 xi Enviroment- Emissions/ Anode Effect II On Continuous PFC Emission Unrelated to Anode Effects ......................................................................................309 X. Chen, W. Li, J. Marks, Q. Zhao, J. Yang, S. Qiu, and C. Bayliss Monitoring Air Fluoride Concentration around ALUAR Smelter in Puerto Madryn (Chubut Province, Argentina)....................................................................................................................................315 J. Zavatti, C. Moreno, J. Lifschitz, and G. Quiroga Reduction of Anode Effect Duration in 400kA Prebake Cells ..................................................................................319 W. Zhang, D. Wong, M. Gilbert, Y. Gao, M. Dorreen, M. Taylor, A. Tabereaux, M. Soffer, X. Sun, C. Hu, X. Liang, H. Qin, J. Mao, and X. Lin Sustainable Anode Effect Based Perfluorocarbon Emission Reduction....................................................................325 N. Dando, L. Sylvain, J. Fleckenstein, C. Kato, V. Van Son, and L. Coleman The Initiation, Propagation and Termination of Anode Effects in Hall-Héroult Cells ..............................................329 G. Tarcy, and A. Tabereaux Towards Eliminating Anode Effects..........................................................................................................................333 A. Al Zarouni, B. Welch, M. Mohamed Al-Jallaf, and A. Kumar Correlation between Moisture and HF Formation in the Aluminium Process...........................................................339 C. Sommerseth, K. Osen, T. Aarhaug, E. Skybakmoen, A. Solheim, C. Rosenkilde, and A. Ratvik Particulate Emissions from Electrolysis Cells ...........................................................................................................345 H. Gaertner, A. Ratvik, and T. Aarhaug Investigation of Solutions to Reduce Fluoride Emissions from Anode Butts and Crust Cover Material ..................351 G. Girault, M. Faure, J. Bertolo, S. Massambi, and G. Bertran PFC Survey in Some Smelters of China....................................................................................................................357 W. Li, X. Chen, Q. Zhao, S. Qiu, and S. Zhang Considerations Regarding High Draft Ventilation as an Air Emission Reduction Tool............................................361 S. Broek, N. Dando, S. Lindsay, and A. Moras Bayer Process Chemistry and Alumina Quality I Session Chairs ...........................................................................................................................................................367 Cells Thermal Balance Increasing the Power Modulation Window of Aluminium Smelter Pots with Shell Heat Exchanger Technology...369 P. Lavoie, S. Namboothiri, M. Dorreen, J. Chen, D. Zeigler, and M. Taylor New Approaches to Power Modulation at TRIMET Hamburg .................................................................................375 T. Reek Some Aspects of Heat Transfer Between Bath and Sideledge in Aluminium Reduction Cells.................................381 A. Solheim Towards a Design Tool for Self-heated Cells Producing Liquid Metal by Electrolysis ............................................387 S. Poizeau, and D. Sadoway ix Heat Recovery from Aluminium Reduction Cells.....................................................................................................393 Y. Ladam, A. Solheim, M. Segatz, and O. Lorentsen Effects of Composition and Granulometry on Thermal Conductivity of Anode Cover Materials ............................399 H. Wijayaratne, M. Hyland, M. Taylor, A. Grama, and T. Groutso Restart of 300kA Potlines after 5 Hours Power Failure.............................................................................................405 X. Zhao, B. Gao, H. Han, J. Liu, J. Xiao, J. Qian, J. Yan, and D. Wang Multiblock Monitoring of Aluminum Reduction Cells Performance ........................................................................407 J. Tessier, C. Duchesne, and G. Tarcy Bayer Process Chemistry and Alumina Quality I Session Chairs ...........................................................................................................................................................413 Cells Technology, Development and Sustainability High Amperage Operation of AP18 pots at Karmøy.................................................................................................415 M. Bugge, H. Haakonsen, O. Kobbeltvedt, and K. Paulsen Aluminium Smelter Manufacturing Simulation - Can These Bring Real Cost Savings? ..........................................421 M. Meijer Simultaneous Preheating and Fast Restart of 50 Aluminium Reduction Cells in an Idled Potline - A New Soft Re- start Technique for a Pot Line ...................................................................................................................................425 A. Mulder, A. Folkers, M. Stam, and M. Taylor SWOT Perspectives of Midage Prebaked Aluminium Smelter .................................................................................431 P. Choudhury, and A. Sharma Integrated Approach for Safe and Efficient Plant Layout Development ...................................................................437 R. Pires, R. Baxter, L. Tikasz, and R. McCulloch New Progress on Application of NEUI400kA Family High Energy Efficiency Aluminum Reduction Pot ("HEEP") Technology ................................................................................................................................................................443 D. Lu, J. Qin, Z. Ai, and Y. Ban Improving Current Efficiency of Aged Reduction Lines at Aluminium Bahrain (Alba)...........................................449 A. Ahmed, K. Raghavendra, H. Hassan, and K. Ghuloom Development of NEUI500kA Family High Energy Efficiency Aluminum Reduction Pot ("HEEP") Technology ..455 D. Lu, Y. Ban, X. Qi, J. Mao, Q. Yang, and H. Dong Cells Process Control Current Efficiency for Aluminium Deposition from Molten Cryolite-alumina Electrolytes in a Laboratory Cell....461 G. Haarberg, J. Armoo, H. Gudbrandsen, E. Skybakmoen, A. Solheim, and T. Jentoftsen x