Object-oriented simulation of hydrometallurgical processes: Part II. Application to the bayer process

Kiranoudis, Chris T.; Voros, N.G.; Kritikos, Theodoros; Maroulis, Z.B.; Marinos-Kouris, D.; Papassiopi, Nymphodora; Dimitropoulou, O.; Paspaliaris, Ioannis; Kontopoulos, A.

doi:10.1007/s11663-997-0005-7

Cited by 5 publications

(2 citation statements)

References 2 publications

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“…The performance of a flashing system and the impact of the process parameters on its production efficiency can be studied and analyzed using the above software. Kirandoudis et al [25] built a modular object-oriented steady-state simulation software named PRISMA and used it to perform a simulation of the Bayer process, including leaching, flashing, washing, and settling processes. In general, the applicability of process simulation software is limited due to the simplicity of the mathematical model, the restricted range of physical parameters, and the inappropriate description of local physical phenomena in the process.…”

Section: Research Of Flashing In Pressure Hydrometallurgymentioning

confidence: 99%

An Overview of Flashing Phenomena in Pressure Hydrometallurgy

Liu

Zhou

et al. 2023

Processes

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Pressure hydrometallurgy has attracted much attention for its characteristics, such as the high adaptability of raw materials and environmental friendliness. Flashing (flash boiling or flash evaporation) refers to the phase change phenomenon from liquid to gas triggered by depressurization, which is an important connection between high-pressure processes and atmospheric ones in pressure hydrometallurgy. This paper takes the flashing process in zinc leaching and alumina Bayer processes as examples, describes the flashing process in pressure hydrometallurgy in detail for the first time, and shows the importance of the flashing process in energy recovery, solution concentration, and liquid balance, as well as increasing equipment life. According to solid holdup (the volume percentage of solid), this paper proposes to divide the flashing process into solution flashing (low solid holdup) and slurry flashing (high solid holdup). A further focus is put on reviewing the state of the art of related studies. The results reveal that the research on the flashing process in pressure hydrometallurgy is scarce and often oversimplified, e.g., ignoring the BPE (boiling point elevation) and NEA (non-equilibrium allowance) in solution flashing and the effect of solid particles in slurry flashing. Computational fluid dynamic (CFD) simulation is a promising tool for investigating the flashing process. Based on the progress made in other fields, e.g., seawater desalination, nuclear safety analysis, and engine fuel atomization, we suggest that solution flashing can be studied using the CFD–PBM (population balance model) coupled two-fluid model, since a wide size range of bubbles will be generated. For slurry flashing, the effect of solid holdup on the bubble nucleation rate and mechanism as well as other bubble dynamics processes should be accounted for additionally, for which a quantitative description is still lacking. Meanwhile, data for validating the numerical method are scarce because of the harsh experimental conditions, and further research is needed. In summary, this work presents an overview of the flashing processes in pressure hydrometallurgy and some guidelines for future numerical studies.

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Section: Research Of Flashing In Pressure Hydrometallurgymentioning

confidence: 99%

An Overview of Flashing Phenomena in Pressure Hydrometallurgy

Liu

Zhou

et al. 2023

Processes

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“…It incorporates the effects of growth, nucleation, agglomeration, and seeding, taking into account plant-specific parameters. Kiranoudis et al 27 reported an object-oriented simulation of the precipitation plant which focused on studying the overall effects of certain design parameters on the entire plant efficiency. They reported that the precipitation of alumina in crystallizers is greatly affected by the corresponding soda concentration of the washing unit product stream.…”

Section: Clarification and Washingmentioning

confidence: 99%

Dynamic Simulation and Control of the Bayer Process. A Review

Sidrak

2001

Ind. Eng. Chem. Res.

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In the Bayer process, used for the production of alumina from the bauxite ores, there are frequent disturbances and a large number of interacting processes which incorporate considerable dead time. The challenge to any alumina refinery is to maximize the production of alumina (plant flow and yield) and minimize the energy costs per ton of alumina subject to constraints on liquor sodium oxalate concentration, levels of silica in liquor, digester ratio, mud washer dilution, and particle size distribution in precipitation. In addition, liquor inventories and the surge volume must be maintained within high and low limits. As a result, steady-state operation is difficult to attain, and the refinery, in general, does not run at its optimal operating conditions. There are, however, major economic incentives, typically in excess of several million dollars per year, to stabilize the operation of the plant, and cost competitiveness is one crucially important strategic factor in the alumina industry. Bayer process simulation and process control are two important tools available for use by management and process engineers to evaluate and improve performance in their plants. This paper reviews the current simulation and control technologies in alumina refineries and the basis for the application of advanced control to various processes within a refinery.

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Design and Simulation of a Green Chromate Compound Production Process

Song¹,

Qu²,

Liu³

et al. 2014

Chem Eng & Technol

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A green process for the production of chromate compounds from chromite ore was simulated using process simulation software. Firstly, the phase equilibria of the KOH‐K2CrO4‐H2O system were investigated to determine the feasible operating conditions for the separation of K2CrO4 from the KOH alkaline solution. The green process model of chromate production was developed and three cases with different concentrations of alkali solution were simulated based on several assumptions. The mass and energy balances in the three cases were simulated, showing that the energy consumption of the evaporation unit is the largest in the whole process. The simulation results provide important information for the implementation of this green chromate production process.

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Object-oriented simulation of hydrometallurgical processes: Part II. Application to the bayer process

Cited by 5 publications

References 2 publications

An Overview of Flashing Phenomena in Pressure Hydrometallurgy

An Overview of Flashing Phenomena in Pressure Hydrometallurgy

Dynamic Simulation and Control of the Bayer Process. A Review

Design and Simulation of a Green Chromate Compound Production Process

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