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Modeling and Simulation of a DiasporeTubular Digestion Process
Mälardalen University, School of Business, Society and Engineering, Future Energy Center.
Mälardalen University, School of Business, Society and Engineering, Future Energy Center.
Mälardalen University, School of Business, Society and Engineering, Future Energy Center.ORCID iD: 0000-0002-7233-6916
2013 (English)In: International Journal of Simulation and Process Modelling, ISSN 1740-2123, E-ISSN 1740-2131, Vol. 33, no 2, p. 126-133Article in journal (Refereed) Published
Abstract [en]

A simulation model is developed to predict the performance of a tubular digestion process of a low alumina/silica ratio diaspore bauxite type. The electrolyte - NRTL property method is used to calculate the equilibrium and thermodynamic properties of the slurry. The Aspen Plus simulator has been employed to solve the reaction and thermodynamic submodels. The model was validated with several sets of the industrial experimental data in terms of the flash tanks temperatures and close agreement was found. The simulation model has been utilized by the R&D department to predict the digestion process behaviour at various operation conditions. One practical output of this work is suggestion for a new design to increase the vapour and thermal energy recovery in the digestion process unit. As a result, the exhaust vapour from the last flash tank was directed to a new pre-heater section. The industrial output has been confirmed by the energy department that has decreased 8% in the furnace fuel consumption and leads to an increase of water recovery in the digestion unit.

Place, publisher, year, edition, pages
2013. Vol. 33, no 2, p. 126-133
National Category
Engineering and Technology
Identifiers
URN: urn:nbn:se:mdh:diva-19076DOI: 10.2316/Journal.205.2013.2.205-5798Scopus ID: 2-s2.0-84880843143OAI: oai:DiVA.org:mdh-19076DiVA, id: diva2:624453
Available from: 2013-05-31 Created: 2013-05-31 Last updated: 2017-12-06Bibliographically approved
In thesis
1. Thermodynamic process modeling and simulation of a diaspore bauxite digestion process
Open this publication in new window or tab >>Thermodynamic process modeling and simulation of a diaspore bauxite digestion process
2013 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Bauxite ores which originated from separate mines have different characteristics, i.e. each bauxite ore has its own individual specifications. Jajarm bauxite is of the diaspore-chamosite type and its alumina to silica mass ratio is lower than other diaspore ores. Diaspore bauxite digestion in comparison with other bauxite types has more complicated operational conditions and requires higher temperature, pressure and caustic concentration.

 The present study was thus performed on the above mentioned digestion process and include two parts. First, the behavior of some key parameters of the process was experimentally investigated. Second, a simulation model was developed to predict the performance of the process, particularly thermal energy consumption.  The model was validated with several sets of the industrial data and close agreement was found.

 The effects of various trends in pressure drops of the flash tanks on the slurry preheating were analyzed. The results showed that the proposed pressure profile can lead to an increase in the furnace inlet slurry temperature. Alternatively, it can lead to an appreciable decrease in the furnace fuel consumption, which is required for having the existing operating temperature.

 The generated vapor in different stages of the process was determined. A considerable amount of the generated water vapor and thermal energy were lost. The model was further developed to study the effect of using a part of these vapors on heat recovery. The simulation results showed that in the new design, the pre-heater sections can gain 5.71GJ/h additional heat and the fresh slurry temperature increases by 11°C. Therefore, the furnace required energy is reduced by 11.9%.  The new design was implemented in the refinery and according to the energy department report, it has reduced the furnace fuel consumption by 8%, which is around 200kg of natural gas /h less than the earlier condition for every digestion line.

Place, publisher, year, edition, pages
Västerås: Mälardalen University, 2013
Series
Mälardalen University Press Licentiate Theses, ISSN 1651-9256 ; 170
National Category
Engineering and Technology Materials Engineering
Identifiers
urn:nbn:se:mdh:diva-19001 (URN)978-91-7485-113-7 (ISBN)
Presentation
2013-06-12, Lambda, Västerås, 13:00 (English)
Opponent
Supervisors
Available from: 2013-05-16 Created: 2013-05-14 Last updated: 2013-05-31Bibliographically approved

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