Howard Epstein, RVA, FRANCE. Valoxy: A Sustainable Alternative Source of Alumina
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- Sharlene Jefferson
- 5 years ago
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1 Howard Epstein, RVA, FRANCE Valoxy: A Sustainable Alternative Source of Alumina
2 Agenda Origins of secondary aluminas Analytical information Current and potential applications Commercial benefits Environmental benefits Where we go from here
3 Inter-Dependent Systems
4 Minerals Supply A Strategic 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 of VALOXY Scrap Al Salt slag Al users Secondary Al Al granules & regenerated salt
11 Life Cycle Origins of VALOXY Scrap Al Salt slag Al users Secondary Al Al granules & regenerated salt VALOXY
12 Million Tonnes Growth in Slag Arisings: A Function of 2 Y Aluminium Production Secondary Aluminium Salt Slag
13 Million Tonnes Growth in Slag Arisings: A Function of 2 Y Aluminium Production Secondary Aluminium Salt Slag
14 Slag Arisings 6.6 million tonnes 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 Potential 1 tonne 550 kg 300 kg Secondary Aluminium 12 million Tpa Salt Slag 6.6 million Tpa Secondary Aluminas 3.6 million Tpa
17 Drivers for Development of Secondary Aluminas Regulatory Economic Salt slag: prohibition of landfill Waste processing into useful products Secondary aluminas: potential savings in operating cost Conventional aluminas: comparatively higher production cost
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19 RVA Sustainably Developed
20 Mill Plant
21 Filtration 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 Aluminium granules Returned to secondary aluminium production cycle Salt Returned to refiners for melting process VALOXY 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 3 15 Boehmite γ-alo(oh) 25 Gibbsite γ-al(oh) 3 10 Spinel MgAl 2 O 4 33 Silica SiO Fluorite CaF 2 1.4
28 VALOXY Particle Size Distribution 80% 70% 60% 50% 40% 30% 20% 10% 0% Clay (<2.5 μm) Silt ( μm) Fine sand ( μm) Medium sand ( μm)
29 Applications, Current & Potential Cement Fired products Stainless steel slag stabilization Mineral wool Structural composites
30 Secondary Aluminas Reported Technical Advantages Application Benefit Source of Benefit Cement Stainless Steel Slag Mineral Wool Improved sintering Early setting Phase transformation inhibited Increased micro-hardness Cr (III) containment reduced leaching Superior fluxing properties Reduced milling energy Al 2 O 3 CaF 2 Al 2 O 3 CaF 2 Fine particle size Fired Products Extended firing range Stable micro-structure Mineralogy
31 Application Focus: VALOXY in Cement Production February 2012
32 Application Focus: VALOXY in Cement Production VALOXY February 2012
33 VALOXY in Clinker Formation Feature Benefit Cost Savings Chemically around 70% high alumina minerals Minor fluorspar content Corundum, Spinel, Gibbsite and Boehmite available for clinker formation Fluxing agent - stimulates formation of clinker minerals w/w savings in alumina material cost Reduces residence time Reduced operating temperature fuel savings Produces softer clinker savings in mill cost
34 VALOXY in Clinker Formation (contd.) Feature Benefit Cost Savings Fine tune: Lime Saturation Factor Silica Modulus PSD similar to raw cement meal Improved burnability of the clinker Improved sintering process Early setting strength development Available in bulk Fuel savings in the kiln Reduced milling and transportation costs
35 Application Focus: VALOXY in Fired Products % Volume Firing Shrinkage at 1250 C % fireclay 10% 20% 30% 40% Valoxy substitution
36 Application Focus: VALOXY in Fired Products % Water Absorption at 1250 C % fireclay 20% 30% 40% 50% Valoxy substitution
37 VALOXY - Commercial Benefits Supply stability Long-term fixed price structures Inexpensive compared to bauxite/alumina Potential savings in operating costs
38 VALOXY Environmental Benefits Sustainable product derived from existing industrial process Eliminates need for extraction of nonrenewable raw materials
39 VALOXY - Conclusion Commercial Benefits Environmental + Benefits = A Cost-Effective, Sustainable Alumina Source
40 Scope for Collaboration in Asia-Pacific Region Strategic partnerships Direct sale Product development Applications research Market development
41 Sustainable Development VALOXY - a secondary alumina playing its part
42 Valoxy: turning a tug of war... Sustainable Development Price & Supply Stability
43 ...into a handshake Sustainable Development Price & Supply Stability
44 For more information: