Sidelights on Secondary Development of Bayer Process for Mineral Processing in Zhongzhou Zhongzhou Branch

In the category of innovation, technological innovation is given a pivotal position. This is because technological innovation has three major functions: First, technological innovation will create new and better products; Second, technological innovation will reduce product costs, thereby reducing prices; Third, technological innovation will improve product quality. In today's increasingly fierce market competition, the success or failure is no longer a company's innovation, but the company's ability to continue to innovate. Chinalco Zhongzhou Branch Co., Ltd., in the face of the “new technology for producing alumina by beneficiation Bayer process”, firmly grasped the “nine nose” of technological innovation, continuously improved and continuously innovated, and successfully realized the “concentration Bayer process to produce alumina. The secondary development and utilization of new technologies has enabled this new technology with independent intellectual property rights to continue to create value. At the same time, the technical theories and routes are improving, laying a solid foundation for more extensive use in the future. Basic and practical experience. Relying on technological transformation to gradually eliminate bottlenecks in the process, is a spirit that must be met in the face of new things. Mineral processing Bayer process is a high-tech alumina production with independent intellectual property rights and international initiative. The emergence of this new product has not only triggered a new revolution in the alumina production process, but has also found a way for the future development of the Zhongzhou branch. A feasible way. “The feasibility may not be feasible and the general rule is long.” In order to achieve this goal smoothly, on January 15, 2004, the Zhongzhou Branch Company built the alumina in the world on the basis of the Bayer process with the first 300,000 tons of ore by 14 months. The high-tech industrialization demonstration project production line is also the date when the Zhongzhou branch's secondary development of the technology starts. The double-flow method of high-pressure dissolution of caustic soaks and frequent leakage of preheated casing is a major difficulty encountered by Zhongzhou Branch. When it was put into production, it was necessary to stop and inspect and replace the casing every three or five days. Production was often stopped and stopped. This difficult situation became an insurmountable hurdle to the engineers and technicians of the Zhongzhou branch company. child. Inspired by the spirit of unsuccessful decision-making at the decision-making level of the Zhongzhou branch, the branch's engineers and technicians quickly established a technical research group and a pressure plugging group. The team is down for 24 hours and is ready to handle at any time. After 3 months of tracking and exploration, the main law of casing leakage was finally found. They replaced the small elbow with a large elbow and eliminated unnecessary three-way, valve, and other ancillary components, successfully solving the problem. At the same time, a series of effective technological transformations such as the transformation of flotation processes, the improvement of pickling methods, and the attempt of overflow operations are also proceeding in an orderly manner. A difficult road was successfully conquered, and the advantages of beneficiation Bayer's high-tech technology began to be clearly displayed in front of people. In May 2004, the Bayer process of beneficiation was able to reach its designed capacity by the production line of the previous production line, and remained stable at a monthly output of more than 25,000 tons, ie an annual output of over 300,000 tons. At this time, the construction of the second production line has opened. Based on the experience of successful technological transformation based on the previous production line, the construction speed and quality of the second production line have been continuously improved. On November 22, 2004, the second production line was completed and put into operation. The joy of just savoring success, with the parallel operation of the two production lines, new problems and conflicts reappear. The Zhongzhou Aluminium people who dared to struggle with difficulties were not intimidated by difficulties. At the beginning of 2005, the Central Branch of the company focused on “improving ceramic filter capacity”, “optimizing dissolution indicators” and “improving product granularity” for the beneficiary Bayer process production system. 40 issues were fully rolled out. Technical staff, chief staff, and post-graduate students have all participated in the research and technological transformation. In addition, the roughing of the mine supply plant, the flotation system of the flotation plant, the addition of flotation machines, the use of highly efficient sedimentation tanks for the fine tailings, the use of steam in the dissolution workshop, the defoaming of the sedimentation system, and the reformation of evaporators and seed systems in the decomposition workshop , tailings, dam backwater system reform, high-efficiency tank flocculant water reform, overflow water into the ash slag well process transformation ... ... a series of technical transformation to lay a solid foundation for the stability of the production process, the dissolution unit single group operating rate Achieve 100% better results in a shorter period of time. Through technological transformation, the equipment performance and operating mode have been improved, the entire system has been operating stably, and the advantages of beneficiation Bayer process have become increasingly apparent. In the first eight months of this year, a total of 487,000 tons of alumina was actually produced. Taking scientific and technological breakthroughs as a means to continuously optimize economic and technical indicators With the arrival of the era of knowledge economy, the status of technological innovation is particularly important in the development of enterprises. The Zhongzhou branch puts technological innovation in a very important position on the basis of striving for a stable process. Since 2005, the weekly technical meeting system and the project responsibility system have been adhered to. This has not only promoted the optimization of production technical indicators, but also played a role in boosting the technical level of technical personnel. In the past year, 23 subjects have reached the target value, and most of the topics have achieved very good results. On March 17th this year, “Concentration—Improved Bayer Process for Production of Alumina, Key Technology and Equipment Development and Industrialization Application”, “Bauxite Mine Selective Grinding, Industrialization of New Process for Agglomeration Flotation”, and “Concentrate for Concentrate” The "Two-Flow Method" Dissolution New Process Industrialization Technology Research and Application", "Bauxite Flotation Separation, Research and Application of New Tailings Dewatering Technology" and "Bayer Process Red Mud Separation and Washing New Process Research and Application" Passed the expert appraisal. Experts agreed that in the world, the Zhongzhou Branch Company has for the first time fully realized the large-scale industrial production of alumina from the "Chinese Alcoal Method" that is a medium or low-grade diaspore as raw material, and the improved Bayer process. Annual production capacity of 600,000 tons of alumina. The core selective grinding, agglomeration flotation and high-temperature enhanced dissolution of the two-flow method are two innovations that are innovative and integrated. The overall process technology is at the international leading level. Among them, “Selective grinding of bauxite—industrialization of agglomeration new flotation process”, “Selective Concentrate” dual-flow method “dissolution of new process industrialization technology research and application” and “concentration—modified Bayer process for production of alumina key” The three achievements of technology and equipment development and industrial application are all internationally pioneered. The research and application of new technologies for bauxite flotation, tailings dewatering, and new research and application of Bayer process red mud separation and washing technology are international Advanced level has extensive promotion significance. At the same time, significant progress has been made in the "industrial trials to improve the effect of the dissolution of ore concentrates." A series of factors that affect dissolution, such as dissolution time, temperature, alkali concentration, lime addition amount, stirring intensity, and lime addition method, were tested one by one, and it was finally determined that “lime activity” was the key factor affecting the dissolution index. As of May this year, this work has achieved major results in phases. There is no end to innovation, innovation creates the future. In the continuous innovation of the Zhongzhou branch, the Bayer process system for beneficiation has become increasingly sophisticated and the technology has matured. Relative to the treatment of bauxite with the sample location, the cost of beneficiation Bayer process is reduced by more than 80 yuan per ton compared to the cost of alumina, and the process energy consumption is reduced by more than 300 kg of standard coal. The ore A/S also decreased from above 10 to below 6. This has opened up an effective way for the economical and full use of low-grade diaspore-type bauxite resources in China. It is estimated that through the application of beneficiation Bayer process, the service life of existing bauxite resources in Henan can be increased by more than three times.