Brit Ex Geo Ppt
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A simple presentation about the extraction and refining of aluminium and cement. This was made some time ago, so the info from a few slides may no longer be relevant.
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Brit Ex Geo Ppt
- 5. Introduction • Aluminium is a key component of so many aspects of our life, from the buildings, cars, cans and flights. • Aluminium is the third most abundant element in the earth's crust. • Aluminium Industry is one of the leading segments of the Indian Economy. • India is endowed with large deposits of high quality bauxite ore. • Aluminium has a potentially large and growing market.
- 6. Why Aluminium ??? • Strength • Durability • Flexibility • Impermeability • Lightweight • Resistance to Corrosion • Recyclable • Other
- 7. • Aluminium was first used by Ancient Greeks and Romans. • Sir Humphrey Davey coined the name ‘Aluminium’ for this metal in 1808. • The production of Aluminium started in India In the year 1938. • It took almost 46 years to make its production commercially viable. • India stands at the eighth position in the list of leading primary Aluminium producers in the world.
- 18. Recycling Aluminium cans are more widely recycled than any other consumer container. Some people take them to recycling centres that pay cash, while others donate them to nonprofit groups that sell cans to raise funds.
- 19. • The key consumer industries in India are power, transportation, consumer durables, packaging and construction. • Of this, power is the biggest consumer (about 44% of total) followed by infrastructure (17%) and transportation (about 10% to 12%).
- 20. The Indian aluminium industry is dominated by four or five companies that constitute the majority of India's aluminium production. Following are the major players in the Indian aluminium industry: • Hindustan Aluminium Company (HINDALCO) • National Aluminium Company (NALCO) • Bharat Aluminium Company (BALCO) • MALCO • INDAL
- 21. • Packaging • Transport • Electrical Conductors • High Pressure Gas Cylinders • Machined Components • Ladders and Access Equipment • Sporting Goods • Road Barriers and Signs • Domestic and Office Furniture
- 22. The People’s Republic of China The Russian Federation Canada
- 23. TOP 5 ALUMINIUM PRODUCING COMPANIES OF THE WORLD THE RUSSIAN FEDERATION CANADA THE UNITED STATES OF AMERICA PEOPLE’S REPUBLIC OF CHINA THE KINGDOM OF NORWAY
- 27. • Cement is a fine, soft, powdery-type substance. • It is made from a mixture of elements that are found in natural materials such as limestone, clay, sand and/or shale. • When cement is mixed with water, it can bind sand and gravel into a hard, solid mass called concrete.
- 28. Raw materials used for manufacture of cement • The four essential raw materials are: 1. Limestone - mined from an underground mine 2. Silicon – obtained from sand 3. Aluminium – obtained from bauxite deposits 4. Gypsum – obtained from large and dense beds under the earth
- 29. PROCESSING • Mining [limestone] • Crushing • Grinding • Blending and Storage • Cement Grinding [with gypsum] • Cement Storage • Packaging & Marketing
- 35. USES OF CEMENT Building (floors, beams, columns, roofing, piles, bricks, mortar, panels, plaster) Transport (roads, pathways, crossings, bridges, sleepers, viaducts, tunnels, stabilization, runways, parking) Water (pipes, culverts, kerbing, drains, canals, weirs, dams, tanks, pools) Civil (piers, docks, retaining walls, silos, warehousing, poles, pylons, fencing) Agriculture (buildings, processing, housing, feedlots, irrigation)
- 36. Cement Industry in India • The cement industry comprises of 125 large cement plants. • The Cement Corporation of India, which is a Central Public Sector Undertaking, has 10 units. • There are 10 large cement plants owned by various State Governments.
- 37. Cement Industry in India • The total installed capacity in the country as a whole is 159.38 million tonnes. • Major players in cement production are Ambuja Cement, Aditya Cement, J K Cement and L & T cement.
- 38. 38 The People’s Republic of China The Republic of India The United States of America
- 39. 39 REPUBLIC OF INDIA UNITED ARAB EMIRATES REPUBLIC OF INDIA PEOPLE’S REPUBLIC OF CHINA LIBIYA
Editor's Notes
- Modern life is full of advantages brought about by the use of aluminium. Some of the major benefits of this unique metal are: Strength Pure aluminium is soft enough to carve but mixed with small amounts of other metal to form alloys, it can provide the strength of steel, with only one-third of the weight. Durability Aluminium sprayed on a polymer forms a thin insulating sheet. Flexibility Its combination of properties ensure aluminium and its alloys can be easily shaped by any of the main industrial metalworking processes - rolling, extrusion, forging and casting. Impermeability Aluminium has excellent barrier function which makes it ideal for food and drink packaging and containers. It keeps out air, light and microorganisms while preserving the contents inside. Lightweight Aluminium used in transport reducing the weight of the vehicles, hence in providing fuel efficiency, reducing energy consumption and greenhouse gas emissions. Corrosion-resistantThe metal's natural coating of aluminium oxide provides a highly effective barrier to the ravages of air, temperature, moisture and chemical attack, making aluminium a useful construction material. Recyclable Once made, aluminium can be recycled again and again, using only a very small fraction of the energy required to make "new" metal. Recycling saves about 95% of the energy required for primary production. Other Aluminium is a superb conductor of electricity which has seen it replace copper in many electrical applications. It is also non-magnetic and non-combustible, properties invaluable in advanced industries such as electronics or in offshore structures
- The country has seen significant growth in Aluminium production in the past five years. Indian Aluminium Industry Government started regulating and controlling during the 1970's
- The most important aluminium ore, an iron-containing rock consisting of about 52 percent aluminium oxide, was discovered in 1821 near Les Baux in southern France. The material was later named bauxite. Bauxite is best defined as an aluminium ore of varying degrees of purity in which aluminium in the form of aluminium hydroxide or aluminium oxide is the largest single constituent. The impurities are largely iron oxide, silica, and titania. Mining By far the greatest quantity of commercially exploited bauxite lies at or near the Earth’s surface. Consequently, it is mined in open pits requiring only a minimal removal of overburden. Bauxite beds are blasted loose and dug up with power shovel or dragline, and the ore is transported by truck, rail, or conveyor belt to a processing plant, where it is crushed for easier handling. Refining plants are located near mine sites, if possible, since transportation is a major item in bauxite costs. Approximately 90 percent of all bauxite mined is refined into alumina, which is ultimately smelted into aluminium. The remaining 10 percent is used in other applications, such as abrasives, refractories, and proppants in the recovery of crude oil. Approximately four tons of high-grade bauxite yield two tons of alumina, from which one ton of aluminium is produced. Extraction and refining The production of aluminium from bauxite is a two-step process: refining bauxite to obtain alumina and smelting alumina to produce aluminium. Bauxite contains a number of impurities, including iron oxide, silica, and titania. If these impurities are not removed during refining, they will alloy with and contaminate the metal during the smelting process. The ore, therefore, must be treated to eliminate these impurities. Purified alumina usually contains 0.5 to 1 percent water, 0.3 to 0.5 percent soda, and less than 0.1 percent other oxides. The Bayer process, with various modifications, is the most widely used method for the production of alumina, and all aluminium is produced from alumina using the Hall-Héroult electrolytic process. Refining the ore There are a number of alkaline, acid, and thermal methods of refining bauxite, clay, or other ores to obtain alumina. Acid and electro thermal processes generally are either too expensive or do not produce alumina of sufficient purity for commercial use. A process that involves treatment of ore with lime and soda is used in China and Russia. The Bayer process involves four steps: digestion, clarification, precipitation, and calcination. Refining four tons of bauxite yields about two tons of alumina. A typical alumina plant, using the Bayer process, can produce 4,000 tons of alumina per day. The cost of alumina can vary widely, depending on the plant size and efficiency, on labour costs and overhead, and on the cost of bauxite. Smelting In a modern smelter, alumina is dissolved in reduction pots—deep, rectangular steel shells lined with carbon—that are filled with a molten electrolyte consisting mostly of a compound of sodium, aluminium, and fluorine called cryolite. The smelting process is continuous. Additional alumina is added to the bath periodically to replace that consumed by reduction. Heat generated by the electric current maintains the bath in a molten condition so that fresh alumina dissolves. Periodically, molten aluminium is siphoned off. Recycling Because the remelting of aluminium scrap consumes only 5 percent of the energy required to make primary aluminium from bauxite, “in-process” scrap metal from fabricating sheet, forgings, and extrusions has found its way back to the melting furnace ever since production began. In addition, shortly before World War I, “new” scrap produced during the fabrication of commercial and domestic products from aluminium was collected by entrepreneurs who began what is known as the secondary aluminium industry. The chemical composition of new scrap is usually well defined; consequently, it is often sold back to the primary aluminium producers to be remade into the same alloy. “New” scrap is now greatly supplemented by “old” scrap, which is generated by the recycling of discarded consumer products such as automobiles or lawn chairs. Because old scrap is often dirty and a mixture of many alloys, it usually ends up in casting alloys, which have higher levels of alloying elements. Used aluminium beverage containers constitute a unique type of old scrap. Although the bodies and lids of these cans are made from different aluminium alloys, both contain magnesium and manganese. Consequently, recycled beverage containers can be used to remake stock for either product. The energy required to produce a beverage can from scrap is about 30 percent of the energy needed to produce the can from primary metal. For this reason, the recycling of used beverage containers represents an increasing source of metal for primary metal producers
- About 6.2 kWH (kilowatt hours) of electricity is required to produce one pound of aluminum from alumina.
- However, internationally; the pattern of consumption is in favour of transportation, primarily due to large-scale aluminium consumption by the aviation space.
- HINDALCO: Hindalco is the biggest player in the aluminium industry in India with around 39% of market share. An Aditya Birla Group flagship company, Hindalco has its aluminium plant at Renukoot in Uttar Pradesh. It has various aluminium products with a market share of 42% in primary aluminium, 20% in extrusions 63% in rolled products, 31% in wheels and 44% in foils. Sterlite Industries: The aluminium business of Sterlite Industries Limited comprises of two Indian aluminium giants – BALCO and MALCO. While BALCO is a partially integrated, MALCO is a fully integrated producer of aluminium. Sterlite has got a market share of around 32%. NALCO: It is also one of the leading aluminium producers in India. Government of India has a stake of 87.15% in this company. Its aluminium refinery is located at Damanjodi. It also has a smelter located at Angul, Orissa. Currently, NALCO is concentrating on a capex programme to increase its production from 345,000 tonnes to 460,000 tonnes.
- SPEAKING- {Cement is usually gray. White cement can also be found but it is usually more expensive than gray cement. Cement mixed with water, sand and gravel, forms concrete. Cement mixed with water and sand, forms cement plaster. Cement mixed with water, lime and sand, forms mortar. Cement powder is very, very fine. One kilo contains over 300 billion grains, although we haven't actually counted them to see if that is completely accurate! The powder is so fine it will pass through a sieve capable of holding water. }
- :{Some typical materials used for calcium carbonate in cement manufacturing are limestone, chalks, marbles, marls, and oyster shell. Some typical materials used for alumina in the cement manufacturing are shale, clay, slags, fly ash, bauxite, alumina process waste, and granite. Some typical materials used for silica in cement manufacturing are sand, clay, claystone, shale, slag, and fly ash. Some typical materials used for iron in cement manufacturing are iron ores, blast furnace flue dusts, pyrite clinker, mill scale, and fly ash. The general mining methods are surface mining, while some silicates, such as sand, are commonly mined using dredges, from lakes, rivers and waterways. There are a few underground limestone mines, but most are pits on the surface. }