Howard Epstein, RVA, FRANCE. Developments in Sustainable Sources of Minerals: Alumina from Aluminium Salt Slag

Transcription

1 Howard Epstein, RVA, FRANCE Developments in Sustainable Sources of Minerals: Alumina from Aluminium Salt Slag March 2011

2 Agenda Origins of secondary aluminas Analytical information Current and potential applications Commercial benefits Environmental benefits Where we go from here

3 Interdependent d t Systems Source: European Environment Agency

4 Minerals Supply ASt Strategic t Imperative The prospect of insufficient and critical raw materials (metals and minerals) will hamper further economic development. Source: Critical Raw Materials for the EU (European Commission)

5 Tug of war?

6 Tug of war? Price & supply stability

7 Tug of war? Sustainable development Price & supply stability

8 Tug of war? Sustainable development Price & supply stability

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10 Life Cycle Origins i of VALOXY Scrap Al Sltl Salt slag Al users Secondary Al Algranules & regenerated salt

11 Life Cycle Origins i of VALOXY Scrap Al Sltl Salt slag Al users Secondary Al Algranules & regenerated salt VALOXY

12 Growth in Slag Arisings: i A Function of 2 Y Aluminium i Production on Tonnes Milli Secondary Aluminium Salt Slag

13 Growth in Slag Arisings: i A Function of 2 Y Aluminium i Production on Tonnes Milli Secondary Aluminium Salt Slag

14 Slag Arisings 6.6 million tonnes (2010) Rest of the World 15% USA 28% China 37% Europe 20%

15 Typical Slag Composition NaCl/KCl 40% Oxides 55% Aluminium metal 5%

16 Secondary Aluminas Production Global l Potential ti 1 tonne 550 kg 300 kg Secondary Aluminium 12 million Tpa Salt Slag Secondary 6.6 million Tpa Aluminas 3.6 million Tpa

17 Di Drivers for Development of fsecondary Aluminas Regulatory Salt slag: Waste prohibition of processing landfill into useful products Economic Secondary aluminas: potential savings in operating cost C ti l l i Conventional aluminas: comparatively higher production cost

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19 RVA Sustainably Developed

20 Mill Plant

21 Filtration ti Plant

22 Material Storage

23 RVA Process Salt Slags Heat recovery Regenerated Salt Mill Screen Magnet Salt residues Dissolution Reaction Filtration Brine Crystallization Water recirculation Al granules VALOXY

24 An Environmental Services Business Landfilling of salt slag avoided Value-added materials returned to the productive cycle Closed loop recycling system with no waste

25 Sustainable Outputs t Aluminium granules Salt VALOXY Returned to secondary aluminium production cycle Returned to refiners for melting process Mineral applications as potential alternative to bauxite/alumina

26 VALOXY Chemical Composition Typical composition dry weight (%) Al 2 O MgO 11.0 SiO CaO 2.2 Na 2 O + K 2 O 2.3 F 0.4 Cl 0.5

27 VALOXY - Typical Mineralogy Typical composition - dry weight (%) Corundum Al 2 O Boehmite γ-alo(oh) 25 Gibbsiteit γ-al(oh) 3 10 Spinel MgAl 2 O 4 33 Silica SiO Fluorite CaF

28 VALOXY Particle Size Distribution ib ti 80% 70% 60% 50% 40% 30% 20% 10% 0% Clay (<2.5 μm) Silt ( μm) Fine sand (62.5 Medium sand ( μm) 500 μm)

29 Applications, Current & Potential ti Cement Fired products Mineral wool Slag conditioning i Structural composites

30 Secondary Aluminas Reported Technical Advantages Application Benefit Source of Benefit Cement Improved sintering Al 2 O 3 Early setting CaF 2 Mineral Superior fluxing CaF 2 Wool properties Fine particle size Reduced communition energy Fired Extended firing range Mineralogy Products Stable micro-structure

31 Application Focus: VALOXY in Cement Production

32 Application Focus: VALOXY in Cement Production VALOXY

33 VALOXY in Clinker Formation Feature Benefit Cost Savings Chemically around Corundum, Spinel, Gibbsite and w/w savings in alumina 70% high alumina minerals Boehmite available for clinker formation material cost Minor fluorspar Fluxing agent - stimulates Reduces residence time content formation of clinker minerals Reduced operating temperature fuel savings Fine tune Lime Saturation ti Factor and Silica Modulus PSD similar to raw cement meal Produces softer clinker savings in mill cost Improved burnability of the clinker Fuel savings in the kiln Improved sintering process Early setting strength development Available in bulk Reduced milling and transportation costs

34 Application Focus: VALOXY in Fired Products %Volume Firing Shrinkage at 1250 C % 10% 20% 30% 40% fireclay Valoxy substitution

35 Application Focus: VALOXY in Fired Products %Water Absorption at 1250 C % 20% 30% 40% 50% fireclay Valoxy substitution

36 VALOXY - Commercial Benefits Supply stability Long-term fixed price structures Inexpensive compared to bauxite/alumina Potential savings in operating costs

37 VALOXY Environmental Benefits Sustainable product derived from existing industrial process Eliminates need for extraction of non-renewable raw materials

38 VALOXY - Conclusion Commercial Environmental + Benefits Benefits = A Cost Effective, e, Sustainable Alumina Source

39 Scope for Collaboration - VALOXY Direct sale Product development Applications research Market development

40 Sustainable Development Secondary aluminas playing their part

41 Sustainable Development Price & Supply Stability

42 Sustainable Development Price & Supply Stability

43 For more information: