Advanced Solutions for Aluminum Smelters

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1 Advanced Solutions for Aluminum Smelters

2 2 3 Material Handling in Port Areas Petcoke Storage & Handling Harbour Equipment With a proven range of loading and unloading equipment for ships and barges, FLSmidth provides comprehensive solutions for both seaport and inner harbour handling facilities, including state-of-the-art safety and environmental devices. FLSmidth port handling equipment allows faster loading and unloading of ships up to cape size vessels. Custom-designed components such a telescopic loading chutes ensure optimal loading of the cargo holds. FLSmidth loading and unloading facilities: Shiploaders up to 16,000 t/h Ship Unloader Continuous, screw, or bucket chain type Grab Unloader Barge loaders and unloaders Pneumatic Unloader Based on the experience of FLSmidth s Kovako brand, new standard models have been developed that represent common combinations of capacities vs. ships sizes and platforms (e.g. trailer, gantry and skid mounted units). As a result, FLSmidth can now offer standard unloader models from road mobile units with a nominal capacity of 170 tph for DWT ships to gantry mounted unloaders of 450 tph nominal capacity for DWT ships. KOCH Pipe Conveyor FLSmidth Pipe Conveyors, using the KOCH technology, offer forwardlooking conveying solutions for all types of bulk materials, from cement to coal, from phosphate granulates to wood chips. With their special design, they ensure high availability and low investment costs as well as a perfect protection for both material and environment. Furthermore, we deliver advanced expertise in fully enclosed pipe conveyors in both, in-plant and overland applications and are considered the worldwide market leader with hundreds of installations,including one of the world s longest KOCH Pipe Conveyor, spanning 8.2 km in Peru KOCH Pipe Conveyors the smarter way of transporting bulk solids: Dust and spillage free transportation Low noise emissions Inclines up to 30 Horizontal and vertical curves with minimal radii of up to 45 metres Axial spacings of 8 km and more without transfer stations Simultaneous conveying of different materials in both directions Multiple feed and discharge points Low power consumption FLSmidth is your One Source for mechanical transport equipment and systems as well as pneumatic conveying technologies with over 60 years of experience from trusted brand names like Möller, KOCH, MVT TM, RAHCO, and FLSmidth Pneumatic Transport. Our material handling products and systems include traditional troughtype belt conveyors, fixed/ overland conveyors, portable conveyors, at-the-face mining conveyors, stacker/ reclaimer systems, mobile conveyors, radial stackers, bulk material and bag loading and unloading systems for barges and ships, shuttle conveyors, chain feeders, belt feeders, apron feeders, spreading technologies, complete crushing and screening plants, and ancillary equipment such as high capacity tripper cars. Petcoke Storage and Handling FLSmidth offers a complete range from A to Z for storage and handling of petcoke in smelters, which comprise: Unloading facilities for all types of transportation means, whether by barge or ship, railcar, truck Loading of petcoke into silo or open trucks, railcars or ship and barges. Overland transportation using advanced pipe conveyor technology or standard belt conveyor systems. All types of in-plant transportation e.g. by conventional conveying, transportation by drag chain or pneumatic conveying. Various storage systems, such as: Steel silo for smaller volume requirements Concrete silos Enclosed storage hall using standard machines, e.g. Linear stacking with semi-portal reclaimer or side-reclaimer Circular stacker/reclaimer system (with/without blending) Open storage system with types of linear or circular arrangements Using the material handling expertise, FLSmidth can offer complete packages including all secondary and auxiliary systems, such as explosion protection/area classification, fire detection and fire fighting or dust suppression. (top) KOCH Pipe conveying system in Brazil (second) Enclosed storage system (third) Truckloading facility for petcoke (fourth) Petcoke storage silo (bottom) Open petcoke storage system with conventional stacker and portal reclaimer

3 4 5 Primary Alumina Storage & Handling Material Handling in Smelter Areas Feeding of alumina silo by pipe conveyor or airlift Anti-segregation filling and discharge equipment Different discharge systems available to ensure Absolutely uniform withdrawal of alumina Very even lowering of material level inside the silo during discharge Easy arrangement of the silo bottom Low air (blower) requirement Feeding of alumina to different transport systems according to distance of port to smelter (e.g. truck filling station) Minimized Dead Stock Using the Möller technology, FLSmidth offers engineering and installation for all different silo types which the bulk handling market asks for. The range of know-how starts with small pre hoppers and ends with large capacity silos with a capacity of tons and more if necessary. Special distribution systems on top and inside of silos ensure low Truck Filling Station separation of finest particles (antisegregation) during silo feeding processes. For minimizing energy consumption the air slide systems for reclaiming/discharge are designed with different aeration areas which are only fluidised one after the other. Reliable flow control valves at the silo discharge are followed by air slide or other conveying systems. Möller Turbuflow Dense Phase Conveying Wherever feasible, FLSmidth designs pressure vessel conveying systems incorporating the patented Möller Turbuflow pipe which operates at low velocities and high material/air rates, resulting in low energy consumption. This kind of low velocity dense phase conveying system also means significantly lower levels of wear and tear, avoiding frequent disruptive and costly maintenance work. Turbuflow dense phase conveying systems have been on the market for over 20 years. The principle is a conveying pipe with an inner bypass pipe. This ingenious but simple design prevents bulk and air separation during pneumatic conveying. If a plug forms, pressure loss in the conveying line will be greater at that point. This causes more conveying gas to flow into the inner bypass pipe. However, at the next opening in the bypass pipe the gas will re-enter the conveying pipe. Upon release of the conveying gas, the bulk lump or clot becomes fluidised by local turbulences. This immediately reduces flow resistance. The bulk is thus conveyed compactly, slowly and highly efficiently without any danger of pipe blockages. This process is self-regulating and does not require any control equipment. The Turbuflow conveying system can even be restarted when the pipe is full. Due to continuous and intensive mixing, high bulk to air ratios will be achieved at low conveying velocities. FLSmidth Möller also designs pressure vessel systems with standard pipes and the decision as to which type of pipe to use will depend on the transport system.

4 6 7 Möller Direct Pot Feeding System Modularization Benefits Self-regulating and continuous feeding of ore bunkers Absolutely dust-free operation No generation of fine particles No segregation No scaling Lowest possible (over) pressure No pressure-tight sealing of the electrolyte cell Minimized energy consumption Minimized maintenance work Various designs of Möller Super Feeding System (SFS) pipe DN 100 on top of the electrolysis cell Möller Direct Pot Feeding System installed at DUBAL Möller direct pot feeding is an innovative system that ensures constant and reliable feeding of secondary alumina oxide to the electrolyte cells ore bunkers. This smooth working transport system combines the Möller Turbuflow or Möller Fluidflow transport system from a storage silo to intermediate bins at the electrolyte cells and the Möller Fluidflow pipe air slide feeding system directly to each of the electrolyte cells. The Turbuflow dense phase feeding and the Fluidflow pipe air slide are approved systems that preserve particle size distribution and the flowability of the alumina. Low conveying velocities preserve particle size distribution and the flowability of the secondary alumina while minimising scaling effects. Separation of the main conveying air volume in the intermediate bin avoids feeding secondary alumina from intermediate bins via point feeders into the ore bunker of the electrolytic cell. Complete assembled modules housing: Primary alumina day silos for gas treatment centres Secondary alumina silos for feeding of electrolyte cells Covering alumina and crushed bath silos including mixing station Transport systems for primary, secondary and covering alumina Complete assembled modules shipped to site

5 Your Alumina & Bauxite Contacts Rev. 09/2012 al-us/els-de FLSmidth in brief FLSmidth is the leading supplier of equipment and services to the global cement and minerals industries. FLSmidth supplies the whole range of products, from single machinery to complete cement plants and minerals facilities including services before, during and after the construction. FLSmidth is a global company with a local presence in more than 50 countries and project and technology centres in Denmark, Germany, USA and India, with more than 13,000 employees. FLSmidth stands for continuous research and development; our plants are setting state-of-the-art standards and convince by outstanding economic efficiency. FLSmidth is heading an international group of companies supplying the most complete line of equipment for the global bauxite, alumina and aluminium industry. Our brand names include ABON, DORR-OLIVER, EIMCO, KREBS, KOCH, MVT TM, RAHCO, FULLER-TRAYLOR TM and MÖLLER getting together under the FLSmidth umbrella. Australia FLSmidth Pty Ltd Tel: info.australia@flsmidth.com Germany FLSmidth Wiesbaden GmbH Tel: +49 (0) 6123 / doe.de@flsmidth.com FLSmidth Hamburg GmbH Tel: hamburg@flsmidth.com India FLSmidth Private Ltd Tel: flsm-in@flsmidth.com Brazil FLSmidth Ltda. Tel: flsmidth@flsmidth.com.br FLSmidth Wadgassen GmbH Tel: wadgassen@flsmidth.com USA FLSmidth Salt Lake City, Inc. Tel: info.slc@flsmidth.com Denmark FLSmidth A/S Tel: info@flsmidth.com Copyright 2012 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.