ITP Aluminum: Alumina Technology Roadmap

Alumina Technology Roadmap

SponsorsAlcan Inc.

Alcoa World Alumina

Aluminium Pechiney

Comalco Aluminium Limited

Hindalco Industries Ltd

Hydro Aluminium Metal Products

Kaiser Aluminum & Chemical Corporation

Queensland Alumina Limited

Worsley Alumina Pty Ltd

U.S. Department of Energy

Office of Industrial Technologies

Australian Department of Industry, Science and Resources

Energy Efficiency Best Practice Program

in association with

The Aluminum Association

The Australian Aluminium Council Limited

coordinated by

Amira International

facilitated and prepared by

Energetics Incorporated


Table of Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i

Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Chapter 2 Alumina Industry Research and Technology Needs . . . . . . . . . . . . . . . . . . . . . .5

Chapter 3 Moving Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Appendix A Roadmap Contributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Appendix B List of Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39


The origins of this roadmap began with an agreementbetween The Aluminum Association, acting on behalfof the U.S. aluminium industry, and the U.S.

Department of Energy, Office of Industrial Technologies(DOE/OIT), signed in October 1996. Under this agreement,both industry and the DOE/OIT agreed to collaborate onindustry-led, government-suppor ted, pre-competitiveresearch and development to increase energy efficiencyand reduce wastes in the production of aluminium.

This “Industry of the Future” agreement called for industryto develop a vision for its future and a technology roadmapto achieve that vision. The government then agreed toprovide cost-shared financial resources to help the industryattain that vision. The program has been sufficientlysuccessful that, following the development of the vision —Partnerships for the Future — not one but a series oftechnology roadmaps has been developed. In addition to ageneric roadmap, the industry has developed roadmapsrelated to inert anodes and advanced smelter technology,the use of aluminium in automotive markets, the handlingand treatment of bauxite residue, and the use of advancedceramics to improve aluminium production and processing.These roadmaps have been distributed globally and havehelped spawn similar strategic planning activities aroundthe world. The present alumina roadmap represents thelast significant portion of the production chain to beaddressed.

Over the past five years, the aluminium industrypar tnership with the DOE/OIT has been extremelysuccessful. In this time, over 35 cost-shared projects havebeen initiated with a total of more than 80 technologypartners. Assuming all these projects run to completion, atotal of some US$100M will have been expended in thedevelopment of technology for the aluminium industry.Further, the technology roadmaps have communicated theneeds of the industry, focused the efforts of diversegroups such as national laboratories, supplier companiesand the universities on critical issues, and aligned theinterests of all stakeholders.

Independently in the early 1990s, Australian aluminaproducers collaborated with joint research projects plannedunder the auspices of the Australian Mineral IndustriesResearch Association (now AMIRA International). Theassociation coordinated production of the AluminaTechnology Roadmap which was a joint collaborationbetween the DOE/OIT, the Australian Department ofIndustry, Science and Resources and nine aluminacompanies and was facilitated by Energetics, Incorporated,USA.

Alumina Technology Roadmap i

Preface

Alumina Technology Roadmapii

This Alumina Technology Roadmap represents aunique global partnership, a partnership that maywell signal the future of the aluminium industry. This

roadmap partnership has involved the collaborative effortsof industry groups from the major international companiesoperating on four continents, government representativesfrom both the United States and Australia, andrepresentatives from the academic community andindustry associations (The Aluminum Association and theAustralian Aluminium Council). All were drawn togetherunder the auspices of AMIRA International, the mineralindustry research association, to consider and developtechnology plans for the alumina industry through the year2020. Given the globalization of the aluminium industry,and the fact that Australia is by far the largest producerand exporter of alumina, it is most appropriate that theinput for this Alumina Technology Roadmap was developedat a workshop in Fremantle, Western Australia in May2001.

The alumina industry is facing similar issues as most otherglobal commodity producers: social and environmentalreporting, the challenge of sustainable operations, theimage of a ‘green’ industry, and competition fromsubstitute materials. Individually each producer isaddressing these challenges. However, it is now evidentthat some challenges are best dealt with by an industrysector above and beyond the direct competitiveenvironment. One key outcome of a technology roadmap isidentifying these collaborative areas and the steps thatmust be taken to achieve the industry-wide goals.

A steering committee of international technology expertsguided the development of the roadmap. An essential firststep was the development of critical technology goals towhich the industry should aspire. These ambitious goalsestablish the longterm vision and encompass thechallenges for alumina as a commodity — energyefficiency, safety, environmental per formance,sustainability issues, and customer expectations — as wellas the product challenges of quality, consistency, andper formance. The goals reflect the industry’sacknowledgment of the growing impact of environmentaland social issues on business practices. Improving overallperformance on environment, health, and safety, forexample, will push the industry beyond current bestpractice and enhance its long-term competitiveness. Thespecific industry strategic goals for the year 2020 areshown in Exhibit 1.

The resulting roadmap outlines a comprehensive long-termresearch and development plan that defines the industry’scollective future and establishes a clear pathway forward.It emphasizes twelve high-priority R&D areas deemed mostsignificant in addressing the strategic goals. Bothcontinuous improvement through incremental changes aswell as significant advances through innovative stepchanges will be essential if the industry is going to respondeffectively to the challenges in the years to come.

The expected benefits of using the technology roadmapinclude increasing governments’ capacity to build strategicresearch alliances and enabling industry to capitalize onemerging economic opportunities through early and

Alumina Technology Roadmap 1

1 Introduction

improved access to leading-edge technology. It isanticipated that the development of this AluminaTechnology Roadmap will serve to complement otherongoing efforts to enhance the understanding of theindustry by government and other stakeholders such as thenational laboratories and universities. The Australianindustry and Government are currently putting in place along-term vision for the industry in Australia, under the titleof the Light Metals Action Agenda. The technology roadmapapproach has been embraced as a key component of thisstrategy. The development of the Alumina TechnologyRoadmap has also been a major action item under theGovernment’s Energy Efficiency Best Practice program. Theparticipating government agencies of both the UnitedStates and Australia are encouraged by the willingness ofalumina producers from around the world to collaborate ona strategic plan to guide the industry’s growth and enhanceits competitiveness in the world economy over the nextseveral decades.

Alumina Technology Roadmap2

Exhibit 1. Alumina Technology Roadmap Strategic Goals

The Commodity Challenge

Through the application of technology

◆ Reduce operating costs of existing plants by 3% per annum◆ Achieve substantial energy efficiency gains against a benchmark of reducing total energy consumption to 25%

below current bauxite specific best practice◆ Target capital costs of new plants at <US$500/annual tonne and falling, with major expansion at half this cost,

achieved within a framework of return on investment before tax of greater than 18%◆ Contribute to improvement of overall performance on environment, health and safety to world’s best practice and

consistent with global sustainable development principles◆ Produce a product that meets all of our customers’ current and future needs

This indicates a need to improve over a 5 to 20 year period, with 3 year intermediate goals, through

◆ Increasing yield by 20% above current bauxite specific best practice◆ Reducing DSP caustic consumption to 30 kg/tonne Al2O3 and reducing other losses (excluding to product) to best

practice◆ Achieving a simple capable process by significantly reducing process variability (3 sigma of <5%) through

elimination of the effects of scaling and blockages, by more reliable equipment, better materials, processautomation, and advanced control

◆ Reducing total energy consumption through improved methods of calcination, cogeneration and processimprovements

◆ Developing and applying combustion and power generation technology from which waste heat sources can be usedfor production of alumina, capable of operating at a power generation to alumina ratio that is not significantly lessthan that for the benchmark of best present technology operated on natural gas, unaffected by bauxite digestiontemperature or energy source, other than its net calorific value

◆ Developing capable processes to achieve a significant reduction and recycling of all other inputs and outputsincluding water, odours, VOCs, mercury, oxalates, etc.

◆ Focussing on opportunities with synergistic industries such as caustic soda and power generation◆ Developing methods to achieve a 1,000-year ecologically sustainable storage of red mud and other solid wastes

in existing storages, and make substantial progress in storage for later reuse as well as achieve substantialprogress in the reuse of the red mud

The Product Challenge

◆ Improving consistency of alumina with 3 sigma limits of less than half of the present levels, with emphasis ondust, particle toughness after dry scrubbing, and impurities including sodium and silica

◆ Developing, in conjunction with the aluminium industry, sufficiently good delivery systems such that adequatedispersion is obtained at the cell, thus allowing the alumina to readily dissolve in conventional and modifiedreduction cells in the temperature range 840-900C and potentially as low as 750C


4 Alumina Technology Roadmap

This roadmap represents a concerted look by theglobal alumina industry at its technology challengesover the next 20 years. While most of the R&D needs

themselves are not new, the industry has reached aconsensus on the highestpriority issues, creating a visionfor the industry as a whole to move forward.

Six major themes encompass the highest-priority researchand development needs identified by the industry, asshown in Exhibit 2. These themes are

• Bayer process chemistry and alternatives,• resource utilization,• energy efficiency,• process and knowledge management,• residue treatment and reuse, and• safety/human exposure.

Changes in Bayer process chemistry can improve refineryproductivity and yield, which in turn impact cost and energyefficiency. Major topics include acceleration of precipitationrates, desilication product (DSP) chemistry, scaleformation, and the removal and recovery of impurities fromthe Bayer circuit (either from the liquor or the bauxiteitself). Understanding and reducing the variations inalumina quality and consistency is also a key element ofimproved process chemistry. The development ofalternatives to the Bayer process (i.e., direct reduction of

alumina or a non-caustic route) must be considered aspotential long-term solutions to eliminating problemsassociated with the Bayer process. Step changeapproaches are also indicated in changing the processchemistry to eliminate scale.

Resource utilization issues center on bauxite modificationor beneficiation and caustic soda consumption. Theindustry must take further steps to develop technologiesand strategies to effectively manage its resources for thefuture. The capability to use lower quality input materials –including lower grades of bauxite, caustic, and lime – is akey part of this strategy. The challenge of substantiallyreducing caustic soda consumption is not new but mayrequire a significant process change. Maximizing the use ofbauxite reserves is particularly important to the future ofthe industry; the supply of economical gibbsitic ore is notas large as ores requiring more vigorous treatment.Improvements in resource utilization create benefits thatripple through to plant efficiency and environmentalperformance. By maximizing the alumina extracted per tonof bauxite, refiners reduce the input of impurities per ton ofalumina and also the quantity of residue generated.

The energy efficiency of the Bayer process can be improveddirectly or indirectly through the use of cogeneration, wasteheat utilization, and synergies with nearby industries, aswell as through equipment advances or process changes.


2 Alumina IndustryResearch and

Technology Needs

The non-utilization of waste heat within some refineriesrepresents one of the biggest energy inefficiencies in theindustry. Opportunities for utilizing the waste heat ofnearby power generators should also be considered.Reducing residence time in the Bayer process equipmentalso reduces energy consumption, losses, and capitalcosts while increasing production. Any operating changethat increases productivity essentially reduces the unitenergy requirements of producing alumina. Improving thethermal efficiency of refinery operations also reducesemissions of greenhouse gases.

The alumina industry is not as advanced as the chemicaland some other industries in its use of processmanagement techniques, particularly models and controlsystems. Refiners often use models that have not beentailored for the specific conditions found in a refinery andtherefore do not work particularly well. Increased use ofBayer-specific models and automation reduces processvariation while reducing human exposure to the causticenvironment. Knowledge management systems are alsocritically lacking in the alumina industry, leading torepeated mistakes, particularly at the operations level.Benchmarking is a mechanism by which individualrefineries can gauge their performance and practicesagainst each other, and the industry can measure itselfagainst other industries. Benchmarking tends to be mostsuccessful in those industries where an informationinfrastructure already exists.

The alumina industry has been investigating options forresidue treatment and utilization for years with limitedsuccess. The economics of using the residue in mostapplications are not currently favorable. Inventories of thisbyproduct represent a liability for the industry that extendswell into the future, and technology is needed to findeconomically viable alternative uses.

Reducing human exposure to safety risks can beaccomplished through many of the topics alreadydiscussed, including reducing scale and increasing plantautomation. The push for full automation is a common goalthroughout the industry and would promote the awarenessof refineries as well-run, modern, and safe. Industry-widestandards and criteria for safety in plant design andoperation, as well as standardized training, would helpestablish a culture of operating safety within the refiningindustry.

The ensuing pages highlight the twelve priority R&D needsfor the alumina refining industry. The details showninclude:

• the likely partners to be involved in each researcheffort

• the technical and economic risk of developing thetechnology and the potential payoff if successful

• the time frame for usable results to be developed,given that research could begin almost immediatelywith no funding constraints

• the key challenges that the R&D activity would address• a list of some of the technical elements that should be

considered during project scoping• the potential impacts of the successful technology on

the five main industry goals – operating cost; capitalcost; energy consumption; environment, safety, andhealth; and product quality

Following the highest priority needs is a discussion ofthirteen R&D areas that encompass all of the additionalresearch needs identified by the industry. Some of theitems are related to those in the priority R&D list but aresufficiently unique to warrant separate mention. As withthe priority R&D needs, the key challenges for each R&Darea are noted. The individual research needs areorganized by the time frame in which results couldreasonably be anticipated: near term (1 to 3 years), midterm (3 to 7 years), and long term (>7 years).


Operating Cost

Capital Cost

Energy

Environment, Safety,& Health

Product Quality

Strategic Goal Legend

7Alumina Technology Roadmap

Bayer ProcessChemistry andAlternatives

ResourceUtilization

EnergyEfficiency

Process andKnowledge

Management

ResidueTreatment and

ReuseSafety/Human

Exposure

Alternative Methodsto AcceleratePrecipitation Rates

Bauxite Residue:Cost-EffectiveInerting andAlternative Uses

Conversion ofMonohydrateBauxite to a MoreBeneficial State

Direct Reduction ofBauxite or OtherAluminium Materials

Full Automation/Improved ControlStrategies

Impurity Removal:Bauxite and BauxiteBeneficiation

Impurity Removal:Bayer Liquor

KnowledgeManagement andBest PracticesBenchmarking

Major Reduction inCausticConsumption

Scale Management

Technical Solutionsfor RefineryReleases

Waste HeatRecovery

Exhibit 2. Relationship Between Priority R&D Needs and Major Roadmap Themes

Priority R&D NeedMajor Themes

✔ ✔

✔ ✔

✔ ✔ ✔

✔ ✔ ✔

✔ ✔

✔ ✔ ✔

✔

✔

✔ ✔ ✔ ✔

✔

✔ ✔

✔ ✔ ✔

Description


PRIORITY R&D NEEDS

Alternative Methods to Accelerate Precipitation Rates

Dissolved alumina is recovered from liquor in precipitation tanks seeded with alumina trihydrate crystals. The rate ofprecipitation depends on the temperature of the process, the concentration of the alumina hydrate and the caustic soda,the seeding process, impurities in the liquor, and other factors. Precipitation is typically very slow, necessitating the use ofmany large tanks.

Potential Partners Alumina companies, academia, research organizations

Potential Payoff High

Technical/Economic Risk

Time Frame

2001 2005 2010 2020

Investigate alternative methods (both chemicaland physical) to accelerateprecipitation rates whilemaintaining product quality.Develop a fullunderstanding of theprecipitation mechanism.Develop cost-effectivecatalysts.

Key Technical Elements•Examine process

kinetics/activationenergy

•Examinesupersaturation/solubility

•Study alternative (non-sodium) solvents

Comments•Significant previous

work; focus should beon new methods

•May be a challenge tomaintain product quality

• Increase precipitation rate

• Improve seed management

•Understand fundamental precipitation chemistry

Lower energy costs;lower maintenancecosts

Fewer precipitators;lower capital costper ton of aluminafor brownfield andgreenfield projects

Increased yield isequivalent to lowerunit energyrequirements

Fewer energy-relatedemissions per ton ofalumina

See commentsunder “Description”

Challenges Description Impacts

Bauxite Residue: Cost-Effective Inerting and Alternative Uses

The sheer volume of bauxite residue generated at refineries, combined with its alkalinity and the cost of treatment andhandling, are major constraints in finding economical applications for this byproduct. Rendering the residue inert wouldmake it easier and cheaper to store in a sustainable form and would facilitate its use in many applications.

Potential Partners Alumina companies (corporate level), government, industry associations, academia, research organizations, potential customers

Potential Payoff Moderately high


Time Frame


PRIORITY R&D NEEDS

Conduct expert brainstormingsession or workshop to scopeout potential solutions.Investigate inerting options.Coordinate with other sectorsand industries on potential usesof the residue.

Key Technical ElementsInerting

• Inorganic polymers or othernew chemistries

•Use of sea water

Alternative Uses•Metal recovery

•Absorbent for CO2

•Road base/leveeconstruction

•Soil amendment

•Treatment for acid-generatingmaterials/acid minedrainage

• Cement kiln additive

• Effluent treatment

• Bricks/building products

Comments•Additional information found

in Bauxite ResidueTechnology Roadmap (TheAluminum Association,February 2000)

• Improve bauxite residue management

• Increase focus on corporate social responsibility

Small reduction inrefinery operatingcosts

Reduced residuestoragerequirements

No impact

Large reduction inresidue stockpiles;improvedsustainability andenvironmentalresponsibility

No impact


2001 2005 2010 2020

Conversion of Monohydrate Bauxite to a More Beneficial State

A significant fraction of the bauxite being refined in the world today is monohydrate bauxite (boehmite or diaspore) thatrequires high-temperature digestion. Bauxite in the form of some intermediate state between monohydrate and trihydrate(gibbsite) could be digested at lower temperatures and would require less caustic and energy.

Potential Partners Alumina companies, academia, research organizations

Potential Payoff Moderate


Time Frame


PRIORITY R&D NEEDS

Estimate direct and spin-offbenefits of convertingmonohydrate to trihydrate orsome intermediate state.Identify intermediaries andinvestigate thermallyefficient process options forconversion.Key Technical Elements

•Perform cost/benefitstudy

•Study mineralogy• Investigate thermal

processing options

Comments•New conversion

process(es) willconsume energy; overallnet effect must bepositive

•Elimination of oxalateand other impuritiesfrom the process couldindirectly lead toaccelerated precipitationrates

•Not appropriate for allrefineries

•Reduce causticconsumption

•Reduce impuritycontent ofliquor

•Modify bauxiteproperties

•Eliminate unitoperations

•Increasecogeneration

Large reduction inenergy requirements

Eliminates need forcausticization,oxalate destruction,sweetening, andseed wash; fewerheaters required

Energy savingsassociated withmoving to low-temperaturedigestion

Fewer energy-relatedemissions; reducedodor

Improved aluminaproperties withfewer impurities


2001 2005 2010 2020

Direct Reduction of Bauxite or Other Aluminium Materials

The development of a direct reduction process for producing aluminium from bauxite or other aluminium-bearing mineralscould eliminate many of the problems associated with alumina production. Direct reduction could be combined with analuminium refining process to produce aluminium with the desired quality. This new process would be a radical change fromthe current alumina/aluminium production route with major impacts on costs and energy consumption.

Potential Partners Alumina companies, government, academia, research organizations


Technical/Economic Risk High

Time Frame


PRIORITY R&D NEEDS

Examine the limits of theprocess and establish abaseline of fundamentaldata. Identify and evaluatereduction process options.Determine the materialrequirements of thereaction vessel.Key Technical Elements

•Explore pyrometallurgyoptions

• Investigate chlorinationprocess

• Investigate hydratereduction

•Develop aluminiummetal refining process

•Develop materialstechnology for reactionvessel

Comments•Additional details on

technical options to bedeveloped incooperation with thealuminium industry

•Developalternatives tothe Bayerprocess


•Encouragemanagement toadopt long-termview

Elimination ofcaustic; reduced energyrequirements;reduced manpowerrequirements

Elimination of Bayerprocess equipment

Substantialreduction in energyrequirements ofproducing aluminium

Unknown

Unknown


2001 2005 2010 2020

Full Automation/Improved Control Strategies

The motivating factors for increased automation in the refinery are improved efficiency and productivity as wellas reduced manpower requirements. Safety considerations also represent a key driver; automation reducesprocess upsets requiring human intervention in potentially dangerous environments. Automation can also leadto better product quality and consistency.

Potential Partners Alumina companies, academia, research organizations, equipment and instrument suppliers



Time Frame


PRIORITY R&D NEEDS

2001 2005 2010 2020

Benchmark status of thealumina refining industryversus other industries.Develop more reliablesensors andinstrumentation capable ofsurviving in causticenvironments.Develop predictive modelsfor the Bayer process.Key Technical Elements

•Develop new sensorsand control software(e.g., for precipitation)

•Conduct dynamicmodeling

• Investigate low-cost,online precision control(e.g., liquor analyzer)

•Develop expert systemsand neural networks

Comments•Some sensing methods

don’t work well in therefinery environment

•Continuous advanceswill be needed toachieve the long-termgoal of full automation

• Improve processautomation andcontrol

•Use morecapableprocesses andelegant design

• Improve seedmanagement

•Minimizehumanexposure

Incrementalimprovements inproductivity andenergy efficiency;reduced laborrequirements

Negligible impact

Small savings frombetter control ofdigestion andcalcination

Reduced humaninteraction inpotentially dangerousenvironments

Better product qualityand consistencythrough improvedprocess control andpredictive modeling


Impurity Removal: Bauxite and Bauxite Beneficiation

Efficient use of the world’s bauxite resources requires maximizing both the quantity and quality of the alumina that isextracted. A major cause of Bayer process inefficiency is the introduction of impurities contained in the bauxite. The industrylacks technically and economically viable methods for controlling and removing these impurities. The trend toward lowergrades of bauxite available in the future will only exacerbate this problem.

Potential Partners Alumina companies, research organizations, government, suppliers


Technical/Economic Risk Moderate

Time Frame


PRIORITY R&D NEEDS

2001 2005 2010 2020

Develop a better understanding ofbauxite and estimate futurerequirements. Develop methods tomodify bauxite in order to increasethe percentage of extractablealumina. Explore chemical andbiological means for removingimpurities from bauxite.

Key Technical Elements•Develop technologies to

extract organics from bauxite• Investigate thermal treatment

to remove carbon and changethe mineralogy and chemistryof the bauxite

•Develop cheaper, cleanerliquor burning technologies

•Explore in-situ heap leachingof bauxite to remove certainorganic and inorganicimpurities

•Explore bauxite beneficiationoptions, including biologicalmethods

•Develop selective miningtechniques

Comments•Alternative is to remove

organics from the Bayer liquor(see “Impurity Removal:Liquor”)

•Conducteconomicbauxitebeneficiation

•Addressdeclininggrades ofbauxitereserves

•Reduceimpurity contentof the liquor

•Reduce scale

Increased liquorproductivity (lowercausticconsumption)

Increased refineryoutput and a lowercapital cost per tonof alumina

Better energyefficiency fromincreased causticconcentration

Maximized use ofbauxite reserves

Less degradation ofalumina quality


Impurity Removal: Bayer Liquor

Almost all organic compounds enter the Bayer circuit with the bauxite. Inorganic impurities also are introducedvia bauxite as well as caustic and makeup water. The presence of significant concentrations of impurities inthe liquor has a detrimental effect on almost every aspect of the Bayer process, including digestion andprecipitation capability, liquor productivity, and product quality.

Potential Partners Alumina companies, academia, research organizations, government



Time Frame


PRIORITY R&D NEEDS

2001 2005 2010 2020

Develop a betterunderstanding of variousorganics and determine theirrelative impact. Examinevarious options for removingimpurities, includingtechniques to specificallyattack the worst offenders.

Key Technical Elements•Explore alternative

chemistries• Investigate organic

destruction technologies•Develop improved wet

oxidation techniques•Explore specific

surfactants to targetimpurities

•Consider double-layer,hydroxide, ion exchange,electrolysis, molecularsieve technology, andphysical techniques

• Investigate biologicalimpurity reducers

Comments•Alternative is to remove

organics from the bauxitebefore it enters the Bayerprocess (see “ImpurityRemoval: Bauxite“)

•Reduceimpurity contentof the liquor

• Improveunderstandingof how organicsaffect aluminaquality andyield

•Reduce scale

Increased liquorproductivity (lowercausticconsumption)

Increased refineryoutput and a lowercapital cost per tonof alumina

Better energyefficiency fromincreased causticconcentration

Fewer residues,increased use oflower-grade bauxites

Less degradation ofalumina quality


Knowledge Management and Best Practices Benchmarking

The alumina industry lags behind the chemical and some other industries in terms of its use of process modelingto optimize operations, the sophistication of its control systems, its handling and treatment of raw materials andbyproducts, and its safety culture. Poor knowledge management, particularly at the operations level, inhibitsthe industry’s ability to improve its performance. Benchmarking may help the refining industry identify potentialsolutions to some of its key problems by learning from other industries.

Potential Partners Alumina companies, government, suppliers


Technical/Economic Risk Low

Time Frame


PRIORITY R&D NEEDS

2001 2005 2010 2020

Benchmark operatingpractices in the aluminaindustry versus otherindustries (e.g., chemicalsand petrochemicals, power).Develop informationmanagement tools andknowledge managementtechniques. Establishindustry-wide cooperativestandards and criteria forengineering design.Key Technical ElementsBenchmark the following:

•Scale control•High-solids material

handling•Particulate chemistry•Beneficiation processes•Process control•Reliability•Maintenance practices•Safety

Comments• Implementation of

existing technologiesfrom other industries inthe alumina industrymay be risky

• Improveprocess design

• Improveprocessautomation andcontrol

•Reduce scale


Potential for lowermaintenance costs,reduced manpowerrequirements

Potential for moreelegant processes,fewer unitoperations

Potential for moreefficient operation

Potential to reducehuman exposure fordescaling

Potential to improveproduct throughbetter processcontrol andpredictive modeling


Major Reduction in Caustic Consumption

The caustic soda used in Bayer liquor represents one of the largest operating costs in an alumina refinery. Major factorsinfluencing caustic requirements are the composition of the bauxite being processed and the chemistry of the desilicationproduct (DSP) formed during digestion. Much of the caustic soda content of DSP is currently unrecovered.

Potential Partners Industry, academia, research organizations, government



Time Frame


PRIORITY R&D NEEDS

2001 2005 2010 2020

Benchmark current causticconsumption in terms oflocations and quantity.Develop methods to alter thechemistry of bauxite so thatless caustic is required.Develop a betterunderstanding of DSP andinvestigate ways to alter itschemistry so that lesscaustic is lost.Key Technical Elements

•Further develop theSumitomo process

•Develop improved bauxitecharacterization andseparation technologies

•Examine silica dissolution• Investigate alternative

DSP structures•Develop methods to

recover soda and valuableby products from DSP

•Develop high temperatureseparation technologies

• Improve mud washingtechniques

•Promote causticselfsustainability

•Conducteconomicbauxitebeneficiation

•Addressdeclining gradesof bauxitereserves

•Alter thechemistry ofDSP

Large cost savingsfrom reducedcausticrequirements

No impact

No impact

Reduced handling of a dangeroussubstance, lesslikelihood of spills

No impact


Scale Management

The precipitation of sodium aluminosilicate crystals from spent Bayer liquor leads to scaling of heat exchanger vessels andpiping. Other types of scale can occur elsewhere in the plant (e.g., calcium titanate-containing scale and alumina trihydratescale). Maintenance personnel are required to remove scale manually, presenting a serious risk for injury because of thecorrosive environment and enclosed space. Scale leads to a significant reduction in heat transfer efficiency and liquorthroughput, resulting in increased energy and caustic soda consumption and loss of productivity.

Potential Partners Alumina companies, academia, research organizations, suppliers, government


Technical/Economic Risk Moderately high

Time Frame


PRIORITY R&D NEEDS

2001 2005 2010 2020

Perform scoping study of thescale issues, including industrybenchmark comparison.Conduct fundamental researchto eliminate scale and preventscale initiation and formation.Investigate chemical, biological,mechanical, and materialsolutions as well as newprocess designs.

Key Technical Elements•Study surface chemistry

fundamentals•Optimize hydrodynamics

and use CFD modeling toeliminate dead spots

• Investigate scale-resistantconstruction materials andsurface coatings

•Develop chemical solutionssuch as additives or smartreagents

•Develop robotic cleaningtechnology

• Investigate technologies toremove silica and otherimpurities that cause scale

Comments•Future regulations may

restrict manual removal ofscale

•Reduce scale


•Use morecapableprocesses andelegant design

Large reduction inmaintenancerequirements,improvedproductivity; lowerenergy requirements

Fewer heatersrequired

Savings from higherheat transferefficiency in theheat exchangers

Reduced humaninteraction indescaling (enclosedspace, causticenvironment)

Small benefitthrough bettercontrol of silica


Technical Solutions for Refinery Releases

The issue of refinery releases (including air emissions, effluents, and solid wastes) is becoming more prominentand must be viewed from a broader perspective than in the past. Cost-effective solutions are needed to dealwith caustic, organics, trace metals, particulates, and other releases. Insufficient attention has been given togroundwater contamination in particular.

Potential Partners Research organizations, government, refineries,industry trade associations


Technical/Economic Risk High

Time Frame


PRIORITY R&D NEEDS

2001 2005 2010 2020

Conduct scoping study todetermine possible nextsteps. Investigate technicaloptions. Share industry bestpractices.

Key Technical Elements•Determine environmental

impact at the boundary ofthe refinery

•Develop non-end-of-piperemoval of trace metals(e.g., selective mining)

•Conduct mixing zoneestimation (e.g., toxicologystudies, generic models)

•Develop betterinstrumentation andstandardize design andpractices to minimizespills

•Develop caustic spillmanagement techniquesother than concretetechnology

•Model full mass balanceto track all constituents

Comments•Solutions are a mix of best

practices and researchactivities

• May be needed for futureoperation/expansion

•Reducegroundwaterpollution

•Minimize waterusage


• Increase focuson corporatesocialresponsibility

Small reduction incaustic consumption

No impact

Small opportunity to recover low-gradewaste heat from flue gas

Reduction in airpollutant emissions,spills, andgroundwatercontamination

Provide “green”alumina tocustomers


Waste Heat Recovery

The alumina industry is a large sink for low-grade heat and presents significant opportunity for cogeneration.The industry is currently not taking advantage of available waste heat, mainly because of economic and regulatory reasons.The initial focus should be on recovering waste heat generated in the refinery.

Potential Partners Alumina companies, adjacent industries, government


Technical/Economic Risk Low

Time Frame


PRIORITY R&D NEEDS

2001 2005 2010 2020

Recover and use the wasteheat in the Bayer circuit.Utilize waste heat fromnearby power plants orother primary energy users.Key Technical Elements

•Examine existingtechnologies in energystorage or conversionthat are applicable torefineries

• Investigate if any Bayerprocess reactions canbe done using wasteheat (e.g., calcinationalternatives)

•Study waste heat fromother sources

Comments•Linkages with other

primary energy users issite-specific

•Will the use of wasteheat have anassociated greenhousegas credit?


• Increasecogeneration

• Integrate withnearbyindustries

Moderately lowerenergy costs

Recovery of refinerywaste heat–no netimpact (fewer boilersbut more heatrecovery equipment)Recovery of outsidewaste heat–largesavings from fewerboilers

Moderate to highsavings (higher ifcogeneration isused)

Fewer combustion-related emissions

No impact


Digestion

During the digestion process, the alumina contained in the bauxite is dissolved in the Bayer liquor in the form of sodiumaluminate. R&D needs in digestion focus on reducing the energy requirements (e.g., by carrying out the process at lowertemperature or using biotechnology), facilitating the use of different grades of bauxite such as those with more reactivesilica and reducing caustic requirements. A specific activity would be research into altered desilication technologies thatreduce sodium consumption, which would have a substantial payoff for refiners processing high-silica bauxite. The successof this effort would also significantly increase usable bauxite reserves. A true countercurrent digestion process forextracting monohydrate grades of bauxite at low temperatures (using a vertical upflow vessel where the monohydrate isintroduced at the top and the spent liquor at the bottom) would be a valuable progression of the “best practice”countercurrent technology currently used. The use of “free” evaporation (where entropy is used as a substitute for additionallive steam) should also be investigated.


R&D AREAS

Achieve higher alumina extraction efficiency

Alter the chemistry of DSP

Sustain higher supersaturation in the digester

Reduce embrittlement in the digester

Lower temperatures in Bayer operations

Reduce caustic consumption

Increase use of biotechnology

Address declining grades of bauxite reserves

Challenges

R&D Activities

Near Term

◆ Flexible digestion technologyto accept variable grades ofbauxite

◆ Free evaporation using entropy◆ Design of a real

countercurrent digestionprocess to extractmonohydrates at lowtemperatures

Mid Term

◆ Non-milling digestiontechnology

◆ Altered desilication technologywith lower soda consumption

◆ Technology for high aluminaextraction at low temperature

◆ Selective bauxite biodigestion◆ New digestion system for high-

silica bauxite◆ Methods to eliminate coarse

particles from the digestioncircuit

Long Term

◆ Continuation of near- and mid-term activities

Clarification

Bauxite residue is separated from the liquor containing the dissolved sodium aluminate in a settling process, after whichthe residue is washed to recover caustic soda and any remaining aluminate liquor. Potential improvements to this processcould include the elimination of security filtration, which would improve safety while decreasing capital and operating costs.Combining digestion and clarification into a single unit operation would improve the stability of these processes. If thecombination process is continuous, it would represent a step change in current operations. An alternative to pressuredecanter technology for the combined process would be a liquid/solid separation process utilizing membrane technology.


R&D AREAS

Achieve better separation of components in the process

Combine unit operations to reduce capital intensity

Use more capable processes and elegant designs

Reduce wash water requirements

Reduce energy consumption

Challenges

R&D Activities

Near Term

◆ Pressure decanter to carry outboth digestion and clarificationat elevated temperature

Mid Term

◆ Low-wash soda recovery

Long Term

◆ Alternative liquid-solidseparation process for residuefrom liquor

◆ Alumina stabilizer that can beeasily removed from pregnantliquor

◆ Elimination of security filtration

Precipitation

Alumina hydrate crystals are precipitated from Bayer liquor in a series of tanks seeded with gibbsite. The development ofcatalysts for reducing the activation energy for precipitation (as well as other Bayer process steps) could significantlyimprove productivity. Computer modeling techniques should be developed to improve the efficiency of designing thesecatalysts as well as other additives. An alternative to current precipitation operations would be to focus on the yield of theprecipitation process and adjust the quality of the product afterwards.


R&D AREAS

Increase precipitation rates

Use more capable processes

Improve seed management

Reduce equipment residence time

Increase use of lower-grade reagents

Understand fundamental precipitation chemistry and physics

Challenges

R&D Activities

Near Term

◆ Continue ongoing projectsaimed at incrementalimprovements

Mid Term

◆ Better seed management◆ Molecular simulation of new

reagents to promote rapidcrystallization

◆ Highly energy-efficientagitators

Long Term

◆ Identification of a gibbsiteprecipitation catalyst

◆ Accelerated precipitationtechnology

◆ Computer modeling to designadditives

◆ Countercurrent precipitation◆ Methods to make quality after

precipitation

Calcination

Calcination represents one of the costliest and most energy-intensive operations in alumina refining. In calcination, theprecipitated alumina hydrate crystals are sent to calciners or kilns where the water is removed. Several properties of thealumina product are very dependent on the conditions of the calcination process. The main focus of R&D is investigatingpotential means for improving the thermal energy efficiency of calcination. These efficiency gains must be sufficient tooffset the high cost of retrofitting the calciner. Refiners and smelters need to collaboratively examine whether the trendtoward decreasing smelting temperatures would affect calcination requirements. The quality of reprocessed calciner dustand technologies that activate it for use in the Bayer process also merit more research.


R&D AREAS

Improve energy efficiency of calcination

Lower the overall temperature in Bayer operations

Increase use of waste products

Challenges

R&D Activities

Near Term

◆ Determination of effect oflower Al smeltingtemperatures on calcination

Mid Term

◆ Study of oxygen-enrichmentbenefits of calcination

◆ Methods to reduce thetemperature of calcination

◆ Technology that activatescalciner dust for use

Long Term


New Process Chemistries and Alternative Raw Materials

The development of new process chemistries could eliminate many of the problems associated with alumina production(e.g., scale, impurities). Some options (the use of trona, for example) have been considered in the past but wereunsuccessful. Other options include an aluminium chloride route to alumina production and the physical separation ofmonohydrates and trihydrates. New physical or chemical methods to reduce the amount of reactive silica that is dissolvedor to remove kaolin from Bayer liquor before dissolution is complete are needed. The alumina industry also needs toestablish a strategy for managing its use of resources in the future. The trend toward lower grades of bauxite and higherraw material costs will require the industry to maximize the use of its bauxite reserves, possibly through the use ofalternative raw materials.


R&D AREAS

Develop alternatives to the Bayer process

Understand other process chemistries that may supplant Bayer

Use more capable processes and elegant design

Reduce scale

Find cheaper sources of raw materials

Address declining grades of bauxite reserves

Encourage management to adopt long-term view

Challenges

R&D Activities

Near and Mid Term

◆ Study of simpler systems and analogy to theBayer process

Long Term

◆ Dry particle separation for bauxite◆ Physical separation of mono- and tri-hydrate◆ Use of low-alumina laterites◆ Economic use of trona◆ Mechanical and chemical fine grinding technology and

kaolin immobilization◆ Kaolin complexation technology process agent◆ Process for converting kaolin to absorbents◆ Viable alternative caustic source◆ Use of other caustic salts as solvents◆ Solvent extraction technology for Bayer liquors◆ Investigation of a chloride route (production of aluminium

trichloride)◆ Alternate means of inducing reactions (e.g., microwave)

Product Characteristics and Quality

Alumina refiners and aluminium smelters need to work cooperatively on a number of issues related to alumina quality andproperties. A solid fundamental understanding of alumina’s chemical and physical properties and their variations willprovide the framework for achieving consistent product quality. This will also enable refiners to tailor product characteristicsto better meet their customers’ needs. Better data on product characteristics may also indicate the potential use ofbeneficial process changes (e.g., calcining at lower temperatures) while still producing an acceptable alumina. New orrevised product classification technologies are also needed, as are new measures for product quality itself. The refiningindustry could also work with smelters to redesign pot feeders capable of handling variable density alumina and to redesigndry scrubbing systems.


R&D AREAS

Better rationalize product strength

Develop better measures of product physical quality

Improve fundamental understanding of product quality

Develop better understanding of alumina’s properties

Increase cooperation with experts from other industries

Improve coordination between suppliers and customers

Challenges

R&D Activities

Near Term

◆ Improved method for attritionindex/alumina dustiness

◆ Scrubbing technology thatuses weak alumina

◆ Studies of alumina dissolutionat low temperature

◆ Study of product variability

Mid Term

◆ Cooperative effort withcustomers to redesign potfeeders to handle variable bulkdensities of alumina and fines

Long Term


Controls and Instrumentation

Advances in process controls, instrumentation, and measurement techniques are key to the long-term goal of full refineryautomation. Achieving a high level of process control without significant human labor requires instrumentation that isprecise, reliable, and robust. Reliable instruments that are specific to alumina refining are needed to measure commonparameters such as temperature, pressure, density, and flow. New on-line measurement techniques and robust sensors arealso needed for parameters specific to the Bayer process such as A/C and caustic analysis. The use of “at-line”instrumentation — a variation of on-line instrumentation that is not in continuous use (and therefore not constantlysubjected to the corrosive stream) — could add operational flexibility by providing the feedback needed to make correctionswithout the delay associated with lab results. Other research needs include the development of new in-situ techniques thatwill survive in sodium chemistry; remote sensing technology (e.g., ultrasonics) that can evaluate material thickness anddefects without opening up equipment; and industry-specific control valves that are cheap, low pressure-drop, nonscaling,and reliable for use in liquor and slurry applications.


R&D AREAS

Improve process control and develop more on-line instrumentation andmeasurement techniques

Increase process automation

Reduce manual labor requirements

Develop more process optimization tools and techniques

Improve knowledge management at the operations level

Develop efficient isolation valves


Challenges

R&D Activities

Near Term

◆ Better plant samplingmethodologies and techniques

◆ Use of new developments inchemometrics

◆ Bayer-specific sensors forparticle size, caustic, A/C

◆ In-situ techniques that willsurvive in sodium chemistry

◆ Remote sensing (e.g.,ultrasonics) to examinematerial or scale thickness

Mid Term

◆ Industry-specific controlvalves, isolation valves, andpumps for liquor and slurry

◆ At-line instrumentation(simple, robust, real-time,operator-controlled)

Long Term

◆ Specifications for sensing ofcommon parameters (i.e.,temperature, pressure,density, flow) reliably andaccurately

Models and Tools/ Process Management

Accurate, validated models can allow more effective management of the refinery from both a process and aneconomic point of view. Better understanding of what is happening in each process step will help refinersoptimize operations and increase throughput. The industry needs to create tailored tools that will allow aluminacompanies to achieve “best practice” status. Models that incorporate economic factors are also needed; capitalefficiency is an area where the refinery industry suffers in comparison to other industries. A refinery tool forcapital process optimization could offer the potential for large savings by sharing knowledge betweencompanies. In addition, the industry could develop an alumina/aluminium process model to determine whethercertain process steps could be shifted from refineries to smelter operations in order to reduce overall costs,energy use, or waste generation.


R&D AREAS

Develop more process optimization tools and techniques

Increase process automation

Improve knowledge management at the operations level

Optimize the efficiency of the overall process

Improve accounting of full product life cycle


Challenges

R&D Activities

Near Term

◆ Industrial process model(continuously updated;contains equipment reliabilitydata)

◆ Capital process optimizationtool

◆ Use of lean manufacturingtechnology

◆ Methodology to convertprocess parameters to keyperformance indicators

◆ Methodology to maximizeequipment up-time

Mid Term

◆ Life-cycle modeling (includingenvironmental factors andcost)

◆ Process model (includingenergy and waste data) todefine optimal break points

◆ Modularization andoptimization of plant layout

Long Term

◆ Techno-economic model of theBayer process (validatedcomputational modeling ofprocess steps)

Knowledge Management

Gathering and managing information on developments within the alumina industry as well as those in related industries iscritically important to improving competitiveness. The alumina industry tends to be quite insular and does not typically lookfor solutions from other industries, even those facing the same issues as refiners. The development of an informationinfrastructure for the industry will allow companies to avoid duplication of efforts and take advantage of shared knowledge.Suggested actions include developing a Bayer-sector data base with common units and finding ways to utilize the wealth ofBayer plant knowledge (particularly on instrumentation) in the Eastern Block. A potentially major event would be anexamination of the Bayer process by world-class organic chemists and separations technologists, who would be asked torecommend improvements or even entirely new ways of producing alumina. Finally, the industry needs a guide on how toapproach local communities when moving into new countries to find bauxite reserves.


R&D AREAS

Improve knowledge management at all levels, particularly operations

Work with all levels of plant personnel to develop solutions to problems

Develop new processes and technologies for producing alumina

Keep alumina industry ahead of the curve on dealing with new issues (e.g., environmental)

Increase focus on corporate social responsibility

Challenges

R&D Activities

Near Term

◆ Cooperative efforts with otherindustries to look for ideas andsynergies

◆ Invitation to world-classscientists to evaluate Bayerprocess

◆ Industry-wide process model tomanage knowledge

◆ Expert systems that captureexisting knowledge

◆ Techniques to utilize knowledgein the Eastern Block

◆ Guide on how to approachcommunities on explorationand mining

Mid Term

◆ Study of the theoretical andtechnical limits of existingprocesses

◆ Bayer-sector common database

Long Term


Energy and Fuels

Energy use and process efficiency are key drivers for many process-related issues in the refinery. Reducing thetime spent on unit operations such as digestion and precipitation, increasing product yield, and adopting on-lineinstrumentation all make the overall refining process more efficient. The lack of plant-wide energy balance models makesit difficult to optimize plant thermal efficiency and use of waste heat. The development of process-specific models forcondensate and steam balance would reduce water consumption in addition to energy requirements. In terms of powergeneration, on-site cogeneration is more efficient and has fewer associated greenhouse gas emissions than purchasingpower. One of the most efficient and environmentally friendly options would be the use of a coal-gasification combined-cyclesystem to cogenerate electricity and process steam.


R&D AREAS

Consider thermal efficiency on a system basis

Optimize the efficiency of the overall process

Achieve 16 MW/petajoule of cogeneration industry-wide

Reduce greenhouse gas emissions from energy use

Overcome the difficulties and cost associated with demonstrating new technology

Challenges

R&D Activities

Near Term

◆ Improved condensate andsteam balance

◆ Full model of plant-wide energybalance

Mid Term

◆ Use of geothermal and solarpower to supplement energyrequirements

◆ Methods to improve theefficiency of power houses

◆ Methods to build powerinterruptability into the plant(e.g., different levels of gasturbine output)

◆ Methods to apply combinedcycle system and still use coalefficiently

Long Term

◆ Utilization of organics inbauxite for energy

◆ Coal combustion technologiesthat give cogenerationcapabilities (e.g., low-capitalcoal gasification)

Bauxite Residue

Bauxite residue, or red mud, is the largest environmental concern of alumina refineries mainly because of the size of thiswaste stream and its causticity. Much effort has already been put into developing improved dewatering techniques, disposaltechnologies, and alternative uses. The alumina industry recognizes that it has a cradle-to-grave responsibility for theresidue and that more work is needed to develop reuse opportunities and sustainable storage options. One option may beto neutralize the residue in-situ rather than build up large inventories. Improved methods of separating the components ofthe residue may ease neutralization and reduce the need for future remediation. This may include development of processesto extract valuable materials such as titanium or even organics from the residue. (Note: more detailed information can befound in the Technology Roadmap for Bauxite Reside Treatment and Utilization.)


R&D AREAS

Improve bauxite residue management

Develop economic applications for bauxite residue


Challenges

R&D Activities

Near and Mid Term Long Term

◆ Viable technology to neutralize residue◆ Single-stage washing of residue◆ Separation of residue into components to

facilitate neutralization

◆ Methods to produce a residue with highsolids content and the required rheologicalproperties

◆ More efficient fine particle classification◆ Further development of high-temperature

separation technology◆ Process for extracting useful components

from residue◆ Examination of land reclamation alternatives

Releases

Refinery odours are an issue for on-site personnel as well as refinery neighbors. Most odours are a consequence of theemission of low-grade heat in the form of vapor, which also represents a direct energy loss. An industrywide databasedefining the origins of organic vapors should be created for the worst compounds contributing to plant odours. Thetoxicological effects of emissions of mercury and other compounds are not often clearly understood, creating the need fora health assessment of all refinery emissions. Refineries consume large amounts of water; new effluent treatmenttechnologies and techniques to reduce groundwater pollution can help the industry minimize its water use. Bettertechnologies for reducing flue gas emissions are critical for those refineries burning oil or coal.


R&D AREAS

Reduce or eliminate groundwater pollution

Minimize water usage

Better understand and control toxic emissions

Reduce mercury emissions

Eliminate refinery odours

Increase use of waste products

Challenges

R&D Activities

Near and Mid Term

◆ Health assessment of all emissions◆ Inexpensive way to completely detect organic

vapors◆ Identification of specific compounds with high

levels of odour◆ Flue gas emission reduction technology◆ Bioremediation to address groundwater

problems◆ In-situ barrier technology to control groundwater◆ Downstream uses for oxalate

Long Term

◆ Low-cost effluent treatment technologies

Minimization of Human Exposure and Improved Safety: Technology and Training

Improved materials of construction and processes that are designed with a focus on eliminating human exposureare particularly important in improving the safety of alumina refineries. Techniques to reduce workforcerequirements for maintenance will also reduce human exposure to potentially harmful conditions. Training andeducation programs on safety and the development of systems for housekeeping and health will help establisha safety culture within the alumina refining industry. The acceptance and adoption of behavioral-based safetyby plant personnel will be key. Based on the petrochemical industry model, for example, refiners can establishindustry-wide cooperative standards for ES&H in engineering design.


R&D AREAS

Reduce human exposure

Create better safety systems and supporting culture

Reduce manual labor

Establish standards for hazardous operations


Challenges

Technology R&D Activities

Near Term

◆ New materials for conveyorbelts to reduce noise

Mid Term

◆ Designs to eliminate humanexposure

◆ Improved materials for pipingand tanks to reduce exposure

◆ Scale removal techniques

Long Term

◆ Safer heat transfer mediumthan steam

Training R&D Activities

Near Term

◆ Virtual reality for safety andhazard training

◆ Education programs on safetyprocedures

Mid Term

◆ Behavior-based safety(education and standards)

◆ Uniform industry cooperativestandards for ES&H

◆ Standardization of pressurevessel design and releasesystem criteria

Long Term

◆ Continuation of the near andmid-term activities

The Alumina Technology Roadmap is intended to be adynamic document. The industry will face significantand varied challenges over the next 20 years. During

this period some challenges may diminish in importancewhile others — particularly social and environmentalissues — may become more prominent. By aggressivelypursuing innovative solutions to its long-term problems, thealumina industry can favorably position itself to meet thesechallenges as they arise.

A major objective of this roadmap is to help aluminacompanies align their pre-competitive research programswith the needs of the global alumina industry. The researchagenda described in the roadmap can be pursued by bothindividual companies and collaborative partnerships withinthe industry, as well as help guide governmentparticipation. Individual companies can develop a betterunderstanding of how their own strategic plans mesh withthe priorities of the industry as a whole. The roadmap canalso serve as a mechanism to better educate suppliers tothe alumina industry about its needs and integrate theminto collaborative R&D activities in areas such as processsensors and materials of construction.

Solutions to some of the needs identified in the roadmapalready exist but are limited in their application or are notcommercially viable. Additional research or demonstrationsmay be indicated in these instances. Many of the needshave been the subjects of earlier unsuccessfulinvestigations and may require a fresh approach in order tofind a solution.

A large portion of the needed R&D is precompetitiveand would benefit all refiners. Some activities — bauxite

modification or beneficiation, in particular — would belimited to the point at which they become site-specific.Likewise, the grade of bauxite used at a plant may alsodictate the extent of the benefits of some activities, suchas thermal preprocessing of bauxite to remove impurities.

Scoping projects may provide a low-risk mechanism fordefining potential solutions and outlining possible researchpathways for moving ahead on many problems. Stepchanges in existing processes would likely berecommended for many of the high-risk, potentially high-payoff technical needs. A step change innovation typicallyrequires significant fundamental R&D involving the entireresearch community. These activities are most appropriatefor collaboration between multiple companies becauseindividual ones do not have the resources to perform theresearch themselves.

The alumina industry can greatly improve the efficiency ofits research efforts by sharing the costs of mechanismsalready in place. Individual companies can benefit bysharing research results, thereby increasing the industry’scollective knowledge and avoiding duplication of efforts.

Similarly, the sharing of best practices among refiners canbenefit all areas of plant operation as well as environment,health, and safety aspects. In many cases technologiesexisting in other industries may offer solutions to aluminaindustry problems. Examining other industries’ responsesto scale management, ore beneficiation, and waste heatrecovery, for example, could help refiners develop their ownsolutions to these problems.

Sharing of best practices within the industry or application


3 Moving Forward

of best practices from other industries may represent thebest pathway for industry needs that are considered lowrisk yet have potentially high payoff. It should be noted,however, that even though a technology may besuccessfully applied in another industry does not ensureits success in the alumina industry.

As part of its strategy for implementing the roadmap, theindustry has formed the Alumina Technology Committeeconsisting of representatives from major refiningcompanies. The committee will

• advance initiatives from the roadmap• identify appropriate subgroups to sponsor research

projects and other initiatives and monitor their progress • establish and maintain an ongoing review of the long-

term goals of technology development for the aluminaindustry and benchmark technical progress towardsthese goals

• monitor and enhance the alumina researchinfrastructure to facilitate delivery of leadingedge, pre-competitive research and suitably trained personnel forthe industry

• inform key decisionmakers within companies andgovernments to ensure adequate understanding of thepriorities in alumina technology development andcommitment to necessary research funding

• engender a long-term perspective for research needsand delivered outcomes

• leverage industry research funds with successfulapplications to relevant government funding programs

• provide a concerted technical focus for dealings withsuppliers (chemical, equipment, engineering) to theindustry

• act in a referral role in dealings with the industryassociations on technical issues

• provide an appropriate framework for discussion of thefuture technology goals of the alumina industry andwide dissemination of information.

Implementing the research activities in this roadmap willrequire a substantial effort on the part of the aluminaindustry to increase corporate spending on R&D, handlecomplex intellectual property issues, and overcome otherdif ficulties and costs involved in developing anddemonstrating new technology. Historically, companieshave been reluctant to embrace the outcome of R&Dbecause of the perceived risk and the push for a quickpayback on investments.

Implementation of this inherently collaborative technologyroadmap may be complicated by the competitive natureand historic secretiveness of the refining industry. Whileresearchers at one company may develop information thatwould benefit other companies, sharing this knowledgemay eliminate the competitive advantage gained by thecompany spending the money on the research in the firstplace. Strategies to reconcile the competitive versuscollaborative nature of alumina companies will be neededearly in the roadmap implementation phase.

The alumina industry should make every effort to moveforward with the research priorities in the roadmap so thatit can begin to reap the benefits. New technologies thatcan lower costs, decrease energy consumption, reduceenvironmental impact, and improve worker health andsafety will help ensure the industry’s continued health andprosperity well into the 21st century.


Partnerships for the Future, The Aluminum Association, Inc., March, 1996.Aluminum Industry Technology Roadmap, The Aluminum Association, Inc., May 1997.Inert Anode Roadmap, The Aluminum Association, Inc., February 1998.Aluminum Industry Roadmap for the Automotive Market: Enabling Technologies and Challenges for BodyStructures and Closures, The Aluminum Association, Inc., May 1999.Technology Roadmap for Bauxite Residue Treatment and Utilization, The Aluminum Association, Inc., February 2000.Applications for Advanced Ceramics in Aluminum Production: Needs and Opportunities, sponsored by the United StatesAdvanced Ceramics Association, The Aluminum Association, and the U.S. Department of Energy, February 2001.

For further information contact:

AMIRA International Tony BagshawPO Box 1368West Perth W.A. 6872AUSTRALIATel: +61 8 9324 1090Fax: + 61 8 9324 1190E-mail: [email protected]/documents/Alumina/index.htm

The Aluminum Association, Inc. Mike Skillingberg900 19th Street NWWashington, DC 20005-2168USATel: +1 202 862 5121Fax: +1 202 862 5164E-mail: [email protected]

The Australian Aluminium Council David CouttsLevel 1, Dickson Square, PO Box 63Dickson ACT 2602AUSTRALIATel: +61 2 6262 9155Fax: +61 2 6262 9144E-mail: [email protected]


Bibliography


Appendix ARoadmap Contributors

This roadmap was prepared by Energetics, Inc. of Columbia, Maryland with input from the following:


E. AdamekAlcoa World Alumina

I. Anich*Alcoa World Alumina (since left)

A. N. Bagshaw*AMIRA International

J. BarnesNabalco Pty Ltd

L. BursztynWestern Australian Department ofResources Development

C.S.R. ChandrashakarComalco Aluminium Limited

H. ChristensenConsultant

D. Coutts*The Australian Aluminium Council Limited

R.A.H. Davies*AMIRA International

J. FarrowThe AJ Parker Cooperative Research Centrefor Hydrometallurgy

J. Green*The Aluminum Association, Inc.

R. GreenhalghQueensland Alumina Limited

S. HealyNabalco Pty Ltd

N. HegnaHydro Aluminium Metal Products

R. HillCSIRO Minerals

M. HitchensConsultant

M. Hollitt*Comalco Aluminium Limited

D. Howard*Australian Department of Industry,Science and Resources

A.R. Kjar*Gibson Crest Pty Ltd

J. A. LarsenHydro Aluminium Metal Products

P. McIntoshKaiser Aluminum

J. MordiniAluminium Pechiney

C. NewtonAlcan International

D. OlsenHydro Aluminium Metal Products

G. ParkinsonThe AJ Parker Cooperative Research Centrefor Hydrometallurgy

P. Potter*Worsley Alumina Pty Ltd

A. RijkeboerBilliton International Metals BV

G. RoachAlcoa World Alumina

S. RosenbergWorsley Alumina Pty Ltd

*steering committee member


V. RosinoEurallumina S.p.A.

M. RudmanCSIRO Building, Construction and Engineering

R. P. ShahHindalco Industries Limited

R. W. ShawRio Tinto

M. Skillingberg*The Aluminum Association, Inc.

D.J. StribleyAMIRA International

D. Sutherland*Nabalco Pty Ltd

D. ThomasQueensland Alumina Ltd

Note: The following are also members of the steering committee:R. Bitsch (Queensland Alumina Ltd)N. Davey (Queensland Alumina Ltd)S. Dillich (U.S. Department of Energy)R. Roberts (Northwest Aluminum Company)

Appendix BList of Acronyms

A/C Ratio of alumina to caustic

CFD Computational fluid dynamics

DISR Australian Department of Industry, Science and Resources

DOE/OIT U.S. Department of Energy, Office of Industrial Technologies

DSP Desilication product

ES&H Environment, safety and health

MW Megawatt

R&D Research and development

U.S. United States

VOCs Volatile organic compounds


Documents

ITP Aluminum: Alumina Technology Roadmap