The Situation

Our client’s alumina refinery was experiencing large, cyclic variations in product particle size and was producing material with a high attrition index. This was causing some downstream problems in the smelting process and was a significant obstacle to their plans to replace their rotary kilns with more energy-efficient calciners.

Scope

To develop an improved precipitation-size control strategy and procedure, to reduce the variability of product size, to reduce the attrition index.

Our Solution

Advisian provided the alumina refinery with off-site technical support in relation to product particle size control. Within 3 months, the product fines content had reduced by 44%, the variability of fines content had reduced by 52%, the product attrition index had reduced by 26% and the precipitation yield had increased by 3% (despite plant flow increase of 4%). This was achieved with no capital expenditure.