Solution Provided | Determined the potential impacts of future bauxite ore variations on refinery operations and provided recommendations for further investigation.
Disciplines | Process, Mechanical, Electrical, and Structural Engineering
Carnac performed a Concept Study to understand the impact of future bauxite ore variations at an alumina refinery. Carnac assessed the impact on both current and future operations (following planned plant upgrades).
Carnac carried out the following:
Investigated historical impacts of bauxite ore variations;
Assessed the potential impacts of future bauxite ores on process chemistry;
Used SysCAD to model the bauxite ore variations to determine the suitability of the current and future operations;
Provided hydraulic calculations to support SysCAD modelling findings;
Developed the Process Design Criteria for future ore;
Developed several recommendations for changes in current and future plant operations to handle bauxite ore variations;
Provided plant layout drawings and Process Flow Diagrams (PFDs) including mass and energy balances for the recommendations provided;
Developed a Capital Expenditure Estimate (CAPEX) and implementation barrier versus reward analysis; and
Developed indicative schedules for the recommended items.
Carnac determined that the current operation was not suitable for processing certain bauxite ore types and that the future plant will be suitable with minor design modifications. Carnac provided the following recommendations to the client based on its findings from the Study:
Continue developing existing capital works projects with investigation into minor design/operational modifications;
Develop test work programs to test the bauxite ore variations for further de-risking;
Conduct further studies to identify suitable mineral contaminant removal technologies; and
Expedite the optimisation of process design based on future ore samples to enable early adoption in future studies.
