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Introduction: Primary Aluminum–Alumina–Bauxite Read chapter Read first chapter

2022 | OriginalPaper | Chapter

9. Bayer Process—Water and Energy Balance

Authors : Robert LaMacchia, Raphael Costa

Published in: Smelter Grade Alumina from Bauxite

Publisher: Springer International Publishing

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Abstract

This chapter aims to illustrate and discuss the inputs and outputs for both water and energy in the context of the Bayer process, highlighting throughout the sections their interconnectedness. It breaks down these inputs and outputs in light of the unit operations of the Bayer process and discusses the reasons as to the variations in consumption figures, based on refinery design and other raw material considerations. The section on water shows how different technological developments, in conjunction with the bauxite to be processed, can drive much of the Bayer loop water balance. Explanations are given as to why boehmitic bauxites have the potential to drive somewhat different water balances compared to gibbsitic bauxites, owing to higher digestion temperatures and the removal of water within their precipitation circuits. Going through the history of the Bayer process and the changes brought out by modern equipment, examples show how the alumina refining process has undergone significant change over time. From a design standpoint, examples discussing caustic washing systems for precipitators highlight the significant impact this critical system can have on both equipment availability as well as the plant water balance. Beyond the Bayer loop, the greater water balance of the refinery is considered, showing how much of this balance is a slave to the climatic conditions of the refinery, but also highlighting how residue disposal technology has significantly changed the net balance through adjusting the areas for water catchment versus evaporation. Within energy, a significant focus is placed on the importance of precipitation yield of alumina in the Bayer liquor, in determining a plant energy efficiency, and how this can perhaps help to explain the variability in different plant energy numbers. The quality of the bauxite is also discussed, including the analysis of energy requirements in high temperature digestion refineries, or boehmitic/diasporic bauxite operators. The subsequent section on clarification reinforces the importance of yield further, emphasizing how residue handling solutions in different parts of clarification have both hindered and helped yield and recovery. The sections on heat interchange and precipitation show how modern design improvements such as plate heat exchange between green and spent liquor as well as inter stage cooling have unlocked even more potential in energy efficiency.

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previous chapter Bayer Process Impurities and Their Management
next chapter Production of Smelter Grade Alumina (SGA) by Calcination
Footnotes
1
Thomas [9] suggests ~ 1985 but this is based on an unofficial personal communication.
 
2
Referenced by Cooling [50].
 
3
This comment within the publication by Thomas is from a personal communication that cannot be independently verified.
 
4
As the author’s published after O’Neill and reference his work, use the scale formation rate equation but not the other heat transfer equations.
 
5
The number of moles of water in the DSP structure has not been well defined either, with values varying between 2 and 6.
 
6
Not valid if the A/C target is too close to, or above the thermodynamic solubility.
 
7
This last point is largely dependent on plant layout: some refineries are designed to handle a single heater swap at a time, others change an entire bank at a time, while others may not be able to handle a swap and manage this through running a spare digester unit.
 
8
The pressure head is all that is preventing the slurry from further flashing.
 
9
Possibly identified by removing a heater head, pumping water into the shell and waiting for flow from the holed tube to reveal itself.
 
10
Note that in the context of slurry heaters, while mechanical cleaning is required, the maintenance is finalized with an acid wash after mechanical acid cleaning to ensure a bare metal surface. In the case of slurry heaters which have had lime added to the process slurry, H2SO4 is not as efficient, presumably due to the unwanted formation of solid calcium sulfate. Thus, for these heaters, HCl is used (see for example: [132]).
 
11
The exact ID of the inhibitor was not identified.
 
12
AOS uniquely operates a molten salt heater to achieve their final digestion temperature of 270 °C, which reportedly assists in their excellent energy performance.
 
13
No longer running.
 
14
The refinery must also consider any possible limitations in precipitation associated with the A/TC which may affect product quality.
 
15
Notwithstanding possible impacts on oxalate stability and precipitation kinetics if its precipitation is to be avoided.
 
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Metadata
Title
Bayer Process—Water and Energy Balance
Authors
Robert LaMacchia
Raphael Costa
Copyright Year
2022
Book
Smelter Grade Alumina from Bauxite

Print ISBN: 978-3-030-88585-4

Electronic ISBN: 978-3-030-88586-1

Copyright Year: 2022

DOI
https://doi.org/10.1007/978-3-030-88586-1_9

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