AA-ALATR-1-2001.pdf
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1、Il F November 2001 I N T E R N A T I O N A L Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 04:20:25 MDTNo reproduction or networking permitted without license from IHS -,-,- Alumina Techno
2、logy Roadmap Sponsors Alcan Inc. Alcoa World Alumina Aluminium Pechiney Comalco Aluminium Limited Hindalco Industries Ltd Hydro Aluminium Metal Products Kaiser Aluminum v Needs Ud his roadmap represents a concerted look by the global alumina industry at its technology challenges T over the next 20 y
3、ears. While most of the R the supply of economical gibbsitic ore is not as large as ores requiring more vigorous treatment. Improvements in resource utilization create benefits that ripple through to plant efficiency and environmental performance. By maximizing the alumina extracted per ton of bauxi
4、te, refiners reduce the input of impurities per ton of alumina and also the quantity of residue generated. The energy efficiencyof the Bayer process can be improved directly or indirectly through the use of cogeneration, waste heat utilization, and synergies with nearby industries, as well as throug
5、h equipment advances or process changes. Alumina Technology Roadmap 5 Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 04:20:25 MDTNo reproduction or networking permitted without license from
6、 IHS -,-,- The non-utilization of waste heat within some refineries represents one of the biggest energy inefficiencies in the industry. Opportunities for utilizing the waste heat of nearby power generators should also be considered. Reducing residence time in the Bayer process equipment also reduce
7、s energy consumption, losses, and capital costs while increasing production. Any operating change that increases productivity essentially reduces the unit energy requirements of producing alumina. Improving the thermal efficiency of refinery operations also reduces emissions of greenhouse gases. The
8、 alumina industry is not as advanced as the chemical and some other industries in its use of process management techniques, particularly models and control systems. Refiners often use models that have not been tailored for the specific conditions found in a refinery and therefore do not work particu
9、larly well. Increased use of Bayer-specific models and automation reduces process variation while reducing human exposure to the caustic environment. Knowledge management systems are also critically lacking in the alumina industry, leading to repeated mistakes, particularly at the operations level.
10、Benchmarking is a mechanism by which individual refineries can gauge their performance and practices against each other, and the industry can measure itself against other industries. Benchmarking tends to be most successful in those industries where an information infrastructure already exists. The
11、alumina industry has been investigating options for residue treatment and utilization for years with limited success. The economics of using the residue in most applications are not currently favorable. Inventories of this byproduct represent a liability for the industry that extends well into the f
12、uture, and technology is needed to find economically viable alternative uses. Reducing human exposure to safety risks can be accomplished through many of the topics already discussed, including reducing scale and increasing plant automation. The push for full automation is a common goal throughout t
13、he industry and would promote the awareness of refineries as well-run, modern, and safe. Industry-wide standards and criteria for safety in plant design and operation, as well as standardized training, would help establish a culture of operating safety within the refining industry. The ensuing pages
14、 highlight the twelve pfiofity R capital cost; energy consumption; environment, safety, and health; and product quality * - Following the highest priority needs is a discussion of thirteen Rm Energy Environment, Safety, lower maintenance costs Fewer pfecipitators; lower capital cost per ton of alumi
15、na for brownfield and greenf e I d projects Increased yield is equivalent to lower unit energy , requirements I Fewer energy-related emissions per ton of alumina See comments under “Description“ 8 Alumina Technology Roadmap Copyright The Aluminum Association Inc. Provided by IHS under license with A
16、A Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 04:20:25 MDTNo reproduction or networking permitted without license from IHS -,-,- PRIORITY R improved sustainability and environmental responsibility Alumina Technology Roadmap 9 Copyright The Aluminum Association Inc
17、. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 04:20:25 MDTNo reproduction or networking permitted without license from IHS -,-,- PRIORITY R fewer heaters required Energy savings associated with moving to low- temperature d ges
18、tion Fewer energy-related emissions; reduced odor Improved alumina properties with fewer impurities 10 Alumina Technology Roadmap Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 04:20:25 MDT
19、No reproduction or networking permitted without license from IHS -,-,- PRIORITY R reduced energy requirements; reduced manpower requirements Elimination of Bayer process equipment Substantial reduction in energy requirements of producing aluminium Unknown ? ! ! $ J pt Unknown Alumina Technology Road
20、map 11 Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 04:20:25 MDTNo reproduction or networking permitted without license from IHS -,-,- PRIORITY R automation reduces process upsets requiri
21、ng human intervention in potentially dangerous environments. Automation can also lead to better product quality and consistency. Potential Partners Alumina companies, academia, research organizations, equipment and instrument suppliers Potential Payoff Moderate Technical/Economic Risk Time Frame Cha
22、llenges 2001 Description Impacts , - Negligible impact Small savings from better control of digestion and calcination Reduced human interaction in potentially dangerous I environments Better product quality and consistency through improved I process control and I predictive modeling 12 Alumina Techn
23、ology Roadmap Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 04:20:25 MDTNo reproduction or networking permitted without license from IHS -,-,- PRIORITY R remote sensing technology (e.g., u
24、ltrasonics) that can evaluate material thickness and defects without opening up equipment; and industry-specific control valves that are cheap, low pressure-drop, nonscaling, and reliable for use in liquor and slurry applications. . “ . ._ . . . . _. Bayer-specific sensors for In-situ techniques tha
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