1 / 29

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. Introduction of Claudius Peters

uma-hodges
Télécharger la présentation

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

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. 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

  2. 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

  3. Outlook TMS 2013 for 2014 • FLUIDCON: Attrition factortesting • ADS: ResultsofQatalumSmelter • AS – System: CommissioningofBoguchanyandResults

  4. 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

  5. The ADS Principle

  6. The ADS Principle

  7. The ADS Principle

  8. Introduction - Who are we? Qatalum

  9. 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

  10. 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

  11. 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

  12. Qatalum • Delete text box and insert Picture/Photo/Figure here

  13. Aerated Distribution Systemin operation since 2009

  14. Qatalum Pot Line Design Parameters

  15. Qatalum ADS Design Parameters

  16. 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

  17. 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)

  18. Coarse Particle Separator Improvements • Baffle plates for flow control • Vibrator design • Silo fluidisation adjustment • Aeration nozzle size repositioning • Easier access for daily inspections

  19. Coarse Particle Separator- Improvement Results

  20. 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

  21. 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)

  22. 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

  23. Variations in alumina grain size distribution during conveying Longest Conveying distance = 280m

  24. Particle Size Distribution/ Check Ø 8,1% < 45µm Ø 8,21% < 45µm Ø 8,3% < 45µm Ø 7,9% < 45µm

  25. No Effect on PSD and Anode effect distribution Material Number of AE

  26. ADS Maintenance • No significant wear has been seen on the airslide fabric since the plant startup • Spare / Wear parts consumption is extremely low

  27. No Scaling No build-up of scales inside Airslides No Coarse particle accumulation.

  28. 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

  29. Thank you for your attention

More Related