Transcript TMS2014 - Presentation

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
• 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
• FLUIDCON: Attrition factor testing
• ADS: Results of Qatalum Smelter
• AS – System: Commissioning of Boguchany and Results
Introduction – Claudius Peters
Claudius Peters
• Worldwide acting Engineering Company (born 1906)
• Main Business Areas:
Aluminium, Cement, Steel, Gypsum, Power
• More than 550 employees worldwide
• Deliverer for AIRBUS Industries
• Turnover 150 Mio €
• Offices in Germany, USA, France, China, Brazil
UK, Spain, Italy, Romania, Singapore, India
•4
The ADS Principle
•5
The ADS Principle
•6
The ADS Principle
•7
Introduction - Who are we?
Qatalum
•8
Introduction Qatalum: Our Milestones
2004
December
Heads of
agreement
2006
March
Joint venture
agreement and
approval of
feasibility
October
Investment
decision
2011
2009
2007
January
Site preparation
start-up
July
Final approval
November
Construction
commences
April
Power from grid
October
First raw material
ship
November
Commissioning of
cast house
December 18
First Metal from
potline
First Export of PFA
2010
January
First EI Export
Fuel gas for power
plant gas turbines
Initial power
available from
power plant
March
Project
completion
​September 21
Qatalum
achieved full
production of
585,000 tonnes
Qatalum: About Us
39 Nationalities at Qatalum
34
6
1
1
2
5
3
16
1
1
1
3
15
3
3
1
1
11
357
239
9
3
21
2
172
30
47
1
3
1
7
50
98
1
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
1.2 km
Qatalum
• Delete text box and insert
Picture/Photo/Figure here
Aerated Distribution System
in operation since 2009
Qatalum Pot Line Design Parameters
Design Parameter (704 pots)
Design
Present Day
Name Template
Capacity
Amperage
Number of
Pots
585,000 t/y
300 kA
704
+ 605,000 t/y
314 kA
704
Qatalum ADS Design Parameters
ADS desgin parameters
Distribution
Air slide
Inclination
Cell Airslide
Inclination
Design
50 t/h
1°
10 [t/h]
0.5 °
Present Day
100 t/h
1°
10 t/h
0.5 °
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
•16
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
Improvements
• Baffle plates for flow control
• Vibrator design
• Silo fluidisation adjustment
• Aeration nozzle size
repositioning
• Easier access for daily
inspections
•18
Coarse Particle Separator- Improvement Results
NO of CPS Spills
Weekly Count of Coarse Particle Separator (CPS) Failures Causing Material Spills
15
10
5
0
•
Month
No. of CPS
overflows
Jul-12
26
Aug-12
32
Sep-12
34
Oct-12
28
Nov-12
29
Dec-12
30
Jan-13
11
Feb-13
5
Mar-13
2
Apr-13
5
May-13
4
Jun-13
0
Jul-13
5
Aug-13
2
Sep-13
5
Oct-13
13
Nov-13
3
Dec-13
3
0
Week
•19
Other Modifications Carried Out
Modification of CPS for accessibility
Installation of adjustable level switches
Repositioning of Level switches on airslides
Additional manual valves on alumina silo
20
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)
•21
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
Variations in alumina grain size distribution during conveying
Longest Conveying
distance = 280m
Alumina Grain Size Distribution During Conveying (Lab analysis)
100%
80%
60%
40%
20%
0%
-45
+150
-0.020
-0.045 +0.020
-0.075 +0.045
-0.106- +0.075
-0.150 +0.106
-0.200 +0.150
-0.300 +0.200
+0.300
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
Material
Number of AE
ADS Maintenance
• No significant wear has been seen on the airslide
fabric since the plant startup
• Spare / Wear parts consumption is extremely low
ADS Annual Maintenance & Operational Cost/ton of Alumina
0.223
0.25
USD / ton
0.2
0.142
0.15
0.126
0.1
0.05
0
Dec-09
2010
2011
2012
2013
No Scaling
• No build-up of scales inside
Airslides
• No Coarse particle accumulation.
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