Advanced Solutions for
Aluminum Smelters
2
Material Handling in Port Areas
Harbour Equipment
With a proven range of loading and
unloading equipment for ships and
barges, FLSmidth® provides
comprehensive solutions for both
seaport and inner harbour handling
facilities, including state-of-the-art
safety and environmental devices.
FLSmidth port handling equipment
allows faster loading and unloading
of ships up to cape size vessels.
Custom-designed components such a
telescopic loading chutes ensure
optimal loading of the cargo holds.
FLSmidth loading and
unloading facilities:
• Shiploaders up to 16,000 t/h
• Ship Unloader
• Continuous, screw, or
bucket chain type
• Grab Unloader
• Barge loaders and unloaders
Pneumatic Unloader
Based on the experience of FLSmidth’s
Kovako® brand, new standard models
have been developed that represent
common combinations of capacities
vs. ships sizes and platforms (e.g.
trailer, gantry and skid mounted
units). As a result, FLSmidth can now
offer standard unloader models from
road mobile units with a nominal
capacity of 170 tph for 5.000 DWT
ships to gantry mounted unloaders of
450 tph nominal capacity for 40.000
DWT ships.
KOCH Pipe Conveyor®
FLSmidth Pipe Conveyors, using the
KOCH® technology, offer forwardlooking conveying solutions for all
types of bulk materials, from cement
to coal, from phosphate granulates to
wood chips. With their special design,
they ensure high availability and low
investment costs as well as a perfect
protection for both material and
environment.
Furthermore, we deliver advanced
expertise in fully enclosed pipe
conveyors in both, in-plant and
overland applications and are
considered the worldwide market
leader with hundreds of
installations,including one of the
world’s longest KOCH Pipe Conveyor,
spanning 8.2 km in Peru
KOCH Pipe Conveyors – the
smarter way of transporting
bulk solids:
• Dust and spillage free
transportation
• Low noise emissions
• Inclines up to 30°
• Horizontal and vertical curves
with minimal radii of up to 45
metres
• Axial spacings of 8 km and more
without transfer stations
• Simultaneous conveying of
different materials in both
directions
• Multiple feed and discharge
points
• Low power consumption
3
Petcoke Storage & Handling
FLSmidth is your One Source for
mechanical transport equipment and
systems as well as pneumatic
conveying technologies with over 60
years of experience from trusted
brand names like Möller®, KOCH®,
MVTTM, RAHCO®, and FLSmidth
Pneumatic Transport.
Our material handling products and
systems include traditional troughtype belt conveyors, fixed/ overland
conveyors, portable conveyors,
at-the-face mining conveyors, stacker/
reclaimer systems, mobile conveyors,
radial stackers, bulk material and bag
loading and unloading systems for
barges and ships, shuttle conveyors,
chain feeders, belt feeders, apron
feeders, spreading technologies,
complete crushing and screening
plants, and ancillary equipment such
as high capacity tripper cars.
Petcoke Storage and
Handling
FLSmidth offers a complete range
from A to Z for storage and handling
of petcoke in smelters, which
comprise:
Unloading facilities for all types of
transportation means, whether by
barge or ship, railcar, truck Loading of
petcoke into silo or open trucks,
railcars or ship and barges. Overland
transportation using advanced pipe
conveyor technology or standard belt
conveyor systems. All types of in-plant
transportation e.g. by conventional
conveying, transportation by drag
chain or pneumatic conveying.
Various storage systems, such as:
• Steel silo for smaller volume
requirements
• Concrete silos
• Enclosed storage hall using
standard machines, e.g.
• Linear stacking with semi-portal
reclaimer or side-reclaimer
• Circular stacker/reclaimer
system (with/without blending)
• Open storage system with types
of linear or circular arrangements
Using the material handling expertise,
FLSmidth can offer complete
packages including all secondary and
auxiliary systems, such as explosion
protection/area classification, fire
detection and fire fighting or dust
suppression.
(top) KOCH Pipe conveying system in Brazil
(second) Enclosed storage system
(third) Truckloading facility for petcoke
(fourth) Petcoke storage silo
(bottom) Open petcoke storage system with
conventional stacker and portal reclaimer
4
Primary Alumina Storage & Handling
• Feeding of alumina silo by
pipe conveyor or airlift
• Anti-segregation filling and
discharge equipment
• Different discharge systems
available to ensure
• Absolutely uniform
withdrawal of alumina
• Very even lowering of
material level inside the silo
during discharge
• Easy arrangement of the silo
bottom
• Low air (blower) requirement
• Feeding of alumina to
different transport systems
according to distance of port
to smelter (e.g. truck filling
station)
Minimized Dead Stock
Truck Filling Station
Using the Möller® technology,
FLSmidth offers engineering and
installation for all different silo types
which the bulk handling market asks
for. The range of know-how starts
with small pre hoppers and ends with
large capacity silos with a capacity of
85.000 tons and more if necessary.
Special distribution systems on top
and inside of silos ensure low
separation of finest particles (antisegregation) during silo feeding
processes. For minimizing energy
consumption the air slide systems for
reclaiming/discharge are designed
with different aeration areas which
are only fluidised one after the other.
Reliable flow control valves at the silo
discharge are followed by air slide or
other conveying systems.
5
Material Handling in Smelter Areas
Möller Turbuflow® Dense
Phase Conveying
Wherever feasible, FLSmidth designs
pressure vessel conveying systems
incorporating the patented Möller
Turbuflow® pipe which operates at
low velocities and high material/air
rates, resulting in low energy consumption. This kind of low velocity
dense phase conveying system also
means significantly lower levels of
wear and tear, avoiding frequent
disruptive and costly maintenance
work.
Turbuflow dense phase conveying
systems have been on the market for
over 20 years. The principle is a
conveying pipe with an inner bypass
pipe. This ingenious but simple design
prevents bulk and air separation
during pneumatic conveying.
If a plug forms, pressure loss in the
conveying line will be greater at that
point. This causes more conveying gas
to flow into the inner bypass pipe.
However, at the next opening in the
bypass pipe the gas will re-enter the
conveying pipe. Upon release of the
conveying gas, the bulk lump or clot
becomes fluidised by local turbulences. This immediately reduces flow
resistance. The bulk is thus conveyed
compactly, slowly and highly efficiently without any danger of pipe
blockages. This process is self-regulating and does not require any control
equipment. The Turbuflow conveying
system can even be restarted when
the pipe is full. Due to continuous and
intensive mixing, high bulk to air
ratios will be achieved at low conveying velocities.
FLSmidth Möller also designs pressure
vessel systems with standard pipes
and the decision as to which type of
pipe to use will depend on the
transport system.
6
Möller Direct Pot Feeding System
Benefits
• S
elf-regulating and continuous
feeding of ore bunkers
• Absolutely dust-free operation
• No generation of fine particles
• No segregation
• No scaling
• L
owest possible (over)
pressure
• N
o pressure-tight sealing of
the electrolyte cell
• M
inimized energy
consumption
• Minimized maintenance work
Various designs of Möller Super Feeding
System (SFS) pipe DN 100 on top of the
electrolysis cell
Möller Direct Pot Feeding System installed at DUBAL
Möller direct pot feeding is an
innovative system that ensures
constant and reliable feeding of
secondary alumina oxide to the
electrolyte cells’ ore bunkers. This
smooth working transport system
combines the Möller Turbuflow or
Möller Fluidflow® transport system
from a storage silo to intermediate
bins at the electrolyte cells and the
Möller Fluidflow pipe air slide feeding
system directly to each of the
electrolyte cells. The Turbuflow dense
phase feeding and the Fluidflow pipe
air slide are approved systems that
preserve particle size distribution and
the flowability of the alumina. Low
conveying velocities preserve particle
size distribution and the flowability of
the secondary alumina while
minimising scaling effects. Separation
of the main conveying air volume in
the intermediate bin avoids feeding
secondary alumina from intermediate
bins via point feeders into the ore
bunker of the electrolytic cell.
7
Modularization
Complete assembled
modules housing:
• Primary alumina day silos for
gas treatment centres
• Secondary alumina silos for
feeding of electrolyte cells
• Covering alumina and crushed
bath silos including mixing
station
• Transport systems for primary,
secondary and covering
alumina
Complete assembled modules shipped to site
www.flsmidth.com
FLSmidth in brief
FLSmidth® is the leading supplier of
equipment and services to the global
cement and minerals industries.
FLSmidth supplies the whole range of
products, from single machinery to
complete cement plants and minerals
facilities including services before,
during and after the construction.
FLSmidth is a global company with a
local presence in more than 50
countries and project and technology
centres in Denmark, Germany, USA
and India, with more than 13,000
employees.
FLSmidth stands for continuous
research and development; our plants
are setting state-of-the-art standards
and convince by outstanding economic
efficiency.
FLSmidth is heading an international
group of companies supplying the
most complete line of equipment for
the global bauxite, alumina and
aluminium industry. Our brand names
include ABON®, DORR-OLIVER®,
EIMCO®, KREBS®, KOCH®, MVTTM,
RAHCO®, FULLER-TRAYLORTM and
MÖLLER® getting together under the
FLSmidth umbrella.
Australia
FLSmidth Pty Ltd
Tel: +61 3 8336 1233
Email: [email protected]
Germany
FLSmidth Wiesbaden GmbH
Tel: +49 (0) 6123 / 975 300
Email: [email protected]
USA
FLSmidth Salt Lake City, Inc.
Tel: +1 801 871 7000
Email: [email protected]
Russia
FLSmidth Russia CIS
Tel: +7 495 641 2778
Email: [email protected]
Brazil
FLSmidth Ltda.
Tel: +55 15 3416 7400
Email: [email protected]
India
FLSmidth Private Ltd
Tel: +91 44 4748 1000
Email: [email protected]
USA
FLSmidth Krebs Inc.
Tel: +1 520 744 8200
Email: [email protected]
Denmark
FLSmidth A/S
Tel: +45 36 18 10 00
Email: [email protected]
Copyright © 2012 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or
warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.
Rev. 09/2012 al-us/els-de
Your Alumina
& Bauxite Contacts