JNARDDC Technology for Spent Pot Lining Utilisation New Delhi 22 nd - - PowerPoint PPT Presentation

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JNARDDC Technology for Spent Pot Lining Utilisation New Delhi 22 nd September, 2015 Earth Crust Metal of Future Abundant element- 3 rd Most abundant metal - 8% Aluminium Age Total metals available- 32% Growth Strategic Metal Largest growing

SLIDE 1

JNARDDC Technology for Spent Pot Lining Utilisation

New Delhi 22nd September, 2015

SLIDE 2

Aluminium Age

Earth Crust

Abundant element- 3rd Most abundant metal - 8% Total metals available- 32%

Growth

Largest growing metal (9.45X) since 1960 followed by Cu, steel (4.56X), Pb, Sn etc.

Volume

Metal used - 2nd largest Non ferrous industry – 1st

Metal of Future Strategic Metal Green Metal

Al Indust Al Industry y is is the onl the only y indust industry y in t in the he Wor

rld t

ld to

claim

laim to to become g become green house een house gas (GHG) neutr gas (GHG) neutral, al, by t by the y he year ear 2030 2030

SLIDE 3

New capacities : Asia to dominate

SLIDE 4

Bauxite Reserves

SLIDE 5

Coal Reserves

India
Reserves 250 bn tons
Production 605 million tons

Bauxite and Coal are found in roughly the same geographies

Source:www.coalindia.nic.in

SLIDE 6

Manpower Reserves

India has a formidable pool of manpower – both skilled

and unskilled

India and China have cheaper manpower as compared

to developed countries

0.7 0.7 0.9 7.1 9.1 9 14.4 15.7 15.9 0.9 0.9 1.1 8.5 11.6 10.1 15.9 18.7 18.9 1.2 1.3 1.3 10.2 14.8 11.2 17.5 20.5 23

India China S E Asia Taiwan Korea ANZ Japan Germany USA

2004 2009 2014

Comparison of Labour Rates ( USD/hr)

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Demand

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Advantage India…

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SLIDE 10

Waste Generation in Al Industry

5-6t 8-10t 3-4t 1 t 30-40kg 15-20kg 2.0 – 3.0 ton Bauxite Waste RM Aluminium Dross SPL CO2-D 14-15 ton CO2-ID

SLIDE 11

Section View of H-H Pot

SLIDE 12

Section View of Cathode

SPL-- Cathode lining- 1st cut (Carbon Portion) SPL--Refractory lining- 2nd cut (Refractory portion)

SLIDE 13

Spent Pot Lining

Life of pot is 2500-3000 days
SPL generation is 3-5% of

Aluminium Production

0.6-0.8 lakhs tons of SPL

generation annually in India

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Cement – SPL Issues

Hard material, crushing of SPL is a problem
Bond index of lime stone is 13-15 and of SPL is

around 40-45 (lime crusher not feasible)

Plants are not coming forward because of its

transportation cost and initial capital investment

Continue availability of raw material is also an

issue

GCV value of SPL is around 6000 & hazardous

substance in SPL is CN and Fluoride

SLIDE 15

Major components (%) First Cut SPL SiO2 1-8 Al2O3 8 - 20 Na2O 10 - 15 CaO 1-3 C 54-66 F 6 - 12 Total Cyanide 100 - 1000 ppm Leachable Cyanide 100 - 600 ppm An increasing number of countries are banning the traditional method of landfill disposal of SPL due to presence of significant quantities of fluorides and cyanides. SPL is listed as a hazardous waste (K088) by Environmental Protection Agency (EPA) TOTAL CYANIDE : > 590 ppm LEACHABLE CYANIDE : > 30 ppm

Typical Composition of SPL – 1st Cut

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Work Carried out at JNARDDC

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SPL from Plant Crushing to -2+1mm Heat Treatment Process

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Destruction of Leachable Cyanide >97%

20 40 60 80 100 120 100 200 300 400 500

% Leachable cyanide destruction Temperature (°C)

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Gas Liberation during Heat Treatment of SPL

Heat treatment temperature ~ 425 °C

1. NaOH solution-

colorless

Solution

titrate with AgNO3, no Cyanide found

Solution analysed on ion

analyser, no Fluoride found

2. Distilled water with 2-3

drops of phenolphthalein indicator—colourless

Colour change to pink

(liberation of NH3 gas)

Tests Carried Out

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SPL Treatment with Recovery of Soda & Fluoride

Flow Sheet -

SLIDE 21

Bench Scale Unit

SLIDE 22

Carbon Residue free of Soda & Fluorides

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JNARDDC along with NALCO has commercialised SPL treatment technology

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JNARDDC SPL Technology

SPL into an environmentally stable product
Technology tolerant of a fluorine

environment

Safe treatment of problematic orphan SPL
Compact plant that can be readily installed
Recover fluorine and energy for the

aluminium production process

SLIDE 25

JNARDDC Major R&D Projects

SLIDE 26

Waste Utilisation

Pilot plant setup

– “Swachh Bharat Abhiyaan” – “Vision 2022” – BMTPC/NALCO/Ministry

f Mines

– SPL utilisation & fluroides recovery- NALCO / Green Energy resources / Vedanta – Dross to Alum & Refractory - Vedanta

SLIDE 27

Downstream

Super Thermal Aluminium Alloy

– MoM/NFTDC

Extrusion facilities like die

design, die fabrication, prototype product etc. For MSME – MoM / Local Extrusion Industry

Setting up of pilot plant facilities

for casting, rolling & forging – MoM / MSME

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Bauxite / Alumina / Aluminium

Upgradation of low grade

E/W coast bauxite - MoM

Proppant from PLK &

flyash - NALCO

Refractory from saprolite –

MoM

Low soda Hydrate – MoM
Liquidus and alumina %

measurement instrument – MoM / Vedanta

SLIDE 29

Thank You

Anupam Agnihotri Director