Aluminium Oxide Production by Bayer Process

This report provides an extensive cost evaluation of aluminium oxide production by Bayer Process. Bayer Process is a complex multi-staged process that involves various sequential methods to be followed in order to produce aluminium oxide or alumina for commercial applications. Bauxite ore is the primary source of extracted alumina. The mineral ores are mined and ground to obtain its powders. The ground bauxite is then washed, dried, and dissolved in a solution of caustic soda and lime to form a slurry. The mixture is heated at around 145 °C and placed at a pressure of 50 lbs.

The slurry is then pumped through multiple flash tanks to reduce the pressure and heat on the material and cools the same at atmospheric pressure while flashing off steam. Impurities present in the mixture settle down in the tank, and the liquor at the top is moved through a set of filters and is washed to obtain alumina. After filtering, sodium aluminate is pumped into a set of precipitators with an addition of alumina in it. After processing, the precipitates are obtained, and the mixture is filtered again to produce alumina hydrate. The resultant is then heated to remove the water content and obtain alumina or aluminium oxide.

The project economic analysis provided in the report discusses a Germany-based plant:

• Manufacturing Process
  • Process Flow
  • Material Flow
  • Material Balance
• Raw Material and Product's Specifications
  • Raw Material Consumption
  • Product and Co-Product Generation
  • Capital Investment
• Land and Site Cost
  • Offsites/Civil Works
  • Equipment Cost
  • Auxiliary Equipment Cost
  • Contingency
  • Engineering and Consulting Charges
  • Working Capital
• Variable Cost
  • Raw Material
  • Utilities
• Fixed Cost
  • Labor Requirement & Wages
  • Overhead Expenses
  • Maintenance Charges
• Financing Costs
  • Interest on Working Capital
  • Interest on Loans
• Depreciation Charges
• General Sales and Admin Costs
• Production Cost Summary