The film is a teaching aid for training alumina production operators.
Panorama of the alumina plant.
Bauxite storage area.
Chemical formulas for obtaining aluminum oxide from bauxite.
Finished technical alumina.
Nepheline is another raw material for obtaining alumina.
Soda, potash and cement are also obtained from it.
Nepheline is processed by sintering.
At high temperatures, aluminum oxide interacts with sodium oxide to form sodium aluminate, which decomposes into alkali and aluminum hydroxide in an aqueous medium.
After calcination, the hydroxide turns into alumina.
Process formulas.
Alunite is an ore containing aluminum alum.
Alunite is used to obtain alumina, sulfuric acid, and mineral fertilizers.
Process formulas.
There are combined bauxite processing schemes that combine hydrochemical and thermal methods.
Process formula.
Collage of photographs of the hydrochemical method of bauxite processing.
Bauxite ore arriving at the plant.
It can have different chemical compositions and lump sizes.
At the plant warehouse, the bauxites are averaged and piled in horizontal layers.
A rotary excavator extracts bauxites vertically, mixing the layers.
Transportation of the charge for rock crushing.
Crushing in hammer crushers.
A cartoon explains the operation of crushers.
A cone crusher.
A cartoon explains the operation of cone crushers.
A ball mill.
The mill drum is filled with steel balls that grind the bauxite in an alkaline solution.
Hydrocyclones that select large particles and return them for grinding.
The hydrocyclone drain, the raw pulp, is sent to the mixers.
In the mixers, at a temperature of 95 degrees, the pulp is maintained.
In this case, chemical reactions occur, during which some impurities pass into insoluble compounds.
Process formula.
The leaching process, the main useful product sodium aluminate is extracted.
Process formula.
The autoclave battery consists of heaters, autoclaves and self-evaporators.
Cartoon explaining the structure of autoclaves.
The pulp is squeezed out of the autoclave through a vertical pipe and goes to the next autoclave.
Then the autoclave pulp is sent to the system of self-evaporators.
Cartoon explaining the operation of the self-evaporators.
Tanks for holding pulp for desiliconization.
Thickeners in which the separation of the aluminate solution from the red mud takes place.
Cartoon explaining the processes taking place in thickeners.
The clarified aluminate solution flows freely into a bypass trough and then to control filtration.
Some sodium aluminate remains in the red mud, so it is washed in a series of washing devices.
Cartoon explaining the operation of the devices.
Sludge field.
Bauxites, Sodium aluminate, Alumina
Perm
Classes are held for vocational school students at the sludge field.
Here, the sludge settles and is separated from the wash water, which is returned to production.
Process controller.
The sludge can be used in metallurgy and the building materials industry.
The aluminate solution undergoes control filtration in sand filters.
Process operator.
After filtration, the aluminate solution is sent for decomposition or decomposition.
The aluminate solution, after preliminary cooling in plate heat exchangers, is decomposed in a battery of decomposers.
Cartoon explaining the processes taking place in decomposers.
Chemical formula for the decomposition of sodium aluminate into aluminum hydroxide and an alkaline solution.
The hydroxide pulp from the last decomposer is fed to disk vacuum filters for filtration.
Synthetic fabric is stretched over the disks.
Pulp particles stick to the fabric in the filter trough.
In the vacuum zone, the hydroxide settles and dries, and in the air zone it is blown off the disks, poured into a bin and fed to a conveyor.
Aluminum hydroxide is divided into two streams.
One is sent to decomposition for seeding, the second to final cleaning and calcination.
The hydroxide of the second stream is washed from alkali residues on drum vacuum filters and dried.
The liquid part of the decomposition pulp - the mother liquor is sent for water evaporation.
Installation of evaporation apparatuses on which evaporation is carried out.
Heat exchangers and condenser.
Cartoon explaining the processes taking place in evaporation apparatuses.
The mother liquor becomes concentrated and is sent to the beginning of production.
Automated control panel for the evaporation process.
Calcination.
Calcination unit.
It consists of heat exchangers designed for preliminary drying of hydroxide.
Calcination furnaces.
Refrigerator.
Electrostatic precipitator.
Fluidized bed furnace.
In it, the hydroxide is converted into oxide with the release of steam.
Cartoon explaining the process.
Rotary kilns.
After calcination, alumina is cooled and pumped to the finished product warehouse.
From the silo towers, alumina is loaded into cement trucks and sent to aluminum production.
Raw materials and semi-finished products are examined in the enterprise laboratory.
Panoramic shot of the enterprise.
Aluminate solution, Aluminum hydroxide, Alumina
Perm