Startup and tuning of material distribution system at aluminium smelter in qatar
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Startup and Tuning of Material Distribution System at Aluminium Smelter in Qatar. Mr. Julian Sowah – Qatalum Mr. Vivek Shroff – Qatalum Mr. Santosh Kumar – Qatalum Mr. Arne Hilck - Claudius Peters Mr . Jan Paepcke - Claudius Peters. Content of Today. Introduction of Claudius Peters

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Startup and Tuning of Material Distribution System at Aluminium Smelter in Qatar

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Startup and tuning of material distribution system at aluminium smelter in qatar

Startup and Tuning of Material Distribution System at Aluminium Smelter in Qatar

Mr. Julian Sowah – Qatalum

Mr. Vivek Shroff – Qatalum

Mr. Santosh Kumar – Qatalum

Mr. Arne Hilck - Claudius Peters

Mr. Jan Paepcke - Claudius Peters


Content of today

Content of Today

  • Introduction of Claudius Peters

  • Aerated Distribution System for Potroom Feeding (ADS) – Basics

  • Claudius Peters - Outlook for 2015

  • Introduction of Qatalum

  • Startup and Tuning - Results

  • Summary and Outlook 2015


Outlook tms 2013 for 2014

Outlook TMS 2013 for 2014

  • FLUIDCON: Attrition factortesting

  • ADS: ResultsofQatalumSmelter

  • AS – System: CommissioningofBoguchanyandResults


Introduction claudius peters

Introduction – Claudius Peters

Claudius Peters

  • Worldwide actingEngineering Company (born 1906)

  • Main Business Areas: Aluminium, Cement, Steel, Gypsum, Power

  • More than 550 employeesworldwide

  • Delivererfor AIRBUS Industries

  • Turnover150 Mio €

  • Offices in Germany, USA, France, China, BrazilUK, Spain, Italy, Romania, Singapore, India


The ads principle

The ADS Principle


The ads principle1

The ADS Principle


The ads principle2

The ADS Principle


Introduction who are we

Introduction - Who are we?

Qatalum


Startup and tuning of material distribution system at aluminium smelter in qatar

Introduction Qatalum: Our Milestones

2004

2011

December

Heads of agreement

2009

March

Project completion

​September 21

Qatalum achieved full production of 585,000 tonnes

2010

2007

April

Power from grid

October

First raw material ship

November

Commissioning of cast house

December 18

First Metal from potline

First Export of PFA

January

First EI Export

Fuel gas for power plant gas turbines

Initial power available from power plant

January

Site preparation start-up

July

Final approval

November

Construction commences

2006

March

Joint venture agreement and approval of feasibility

October

Investment decision


Startup and tuning of material distribution system at aluminium smelter in qatar

39 Nationalities at Qatalum

Qatalum: About Us

34

6

5

3

16

1

1

1

1

3

2

1

15

1

3

3

1

11

357

239

172

30

9

47

3

1

21

3

2

1

7

50

98

1


Startup and tuning of material distribution system at aluminium smelter in qatar

Reduction (Potlines) - Qatalum

Designed for low specific energy consumption, high labour productivity, low emissions, no SPL landfill

314 kA

  • Delete text box and insert Picture/Photo/Figure here

x 704 pots

1.2 km


Startup and tuning of material distribution system at aluminium smelter in qatar

Qatalum

  • Delete text box and insert Picture/Photo/Figure here


Aerated distribution system in operation since 2009

Aerated Distribution Systemin operation since 2009


Qatalum pot line design parameters

Qatalum Pot Line Design Parameters


Startup and tuning of material distribution system at aluminium smelter in qatar

Qatalum ADS Design Parameters


Challenges

CHALLENGES

  • Constant Flow into System with varying Material Properties

    • Silo fluidisation

    • Silo aeration timing

    • Material overflow from Silo to Coarse Particle Separator (CPS)

  • Coarse Particle Separator (CPS) Accessibility & Performance

  • Air supply nozzles (blockages)

  • De-aeration of transport system

  • Fine tuning of operational settings


Modifications carried out

Modifications carried out

  • Modification CPS for accessibility

  • Repositioning of Level switches

  • Conversion of level switches to adjustable types.

  • Installation of additional manual valves on 750t secondary alumina silo

  • Filling time optimization

  • Provision of continous venting (2015)


Coarse particle separator

Coarse Particle Separator

Improvements

  • Baffle plates for flow control

  • Vibrator design

  • Silo fluidisation adjustment

  • Aeration nozzle size repositioning

  • Easier access for daily inspections


Coarse particle separator improvement results

Coarse Particle Separator- Improvement Results


Other modifications carried out

Other Modifications Carried Out

Modification of CPS for accessibility

Repositioning of Level switches on airslides

Installation of adjustable level switches

Additional manual valves on alumina silo

20


Verification of improvements

Verification of Improvements

How the improvements were measured

Alumina spills on CPS

Maintenance cost

- No significant wear can be seen on the airslide fabric

- Spare / Wear parts consumption is extremely low

Timing of aeration system

(Small increaments of 10s resulted in more consistent filling)


Ads results advantages

ADS – Results & Advantages

  • NO RISK for Potline – Easy catch up after stoppage.

  • Easy maintenance. Low manpower.

  • 2013 Maintenance cost = 0.126 USD/ton of alumina

  • Operational activities: Cleaning of CPS and visual inspections!

  • System availibility is more than 98%;

  • The buffer silosensures constant material supply to pots.

  • Dust free system (environmentally friendly)

  • No accumulation of coarse particles in the system, as material is screened out in the beginning.

  • Little variations in alumina grain size distribution during conveying


Startup and tuning of material distribution system at aluminium smelter in qatar

Variations in alumina grain size distribution during conveying

Longest Conveying distance = 280m


Particle size distribution check

Particle Size Distribution/ Check

Ø 8,1% < 45µm

Ø 8,21% < 45µm

Ø 8,3% < 45µm

Ø 7,9% < 45µm


No effect on psd and anode effect distribution

No Effect on PSD and Anode effect distribution

Material

Number of AE


Ads maintenance

ADS Maintenance

  • No significant wear has been seen on the airslide fabric since the plant startup

  • Spare / Wear parts consumption is extremely low


No scaling

No Scaling

No build-up of scales inside Airslides

No Coarse particle accumulation.


Lessons learned

Lessons Learned

Material Flow from silo

  • Control of alumina flow out of silo / inlet box by optimization of aeration air.

  • Coarse particle seperator upgrade

    Quality of aeration air/Aeration nozzles

  • Flushing of the air system before start-up is helpful

  • Selection of air filtration system for compressed air

    Stability of deaeration pressure is crucial for the system operation


Thank you for your attention

Thank you for your attention


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