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How to use real-time guidance in alumina production for raw material blending and ore allocation

How to use real-time guidance in alumina production for raw material blending and ore allocation

In alumina production via the Bayer process, the objective of “raw material blending” is not to achieve the highest grade but rather to operate the digestion, precipitation, and calcination systems steadily within their optimal operating windows at the lowest overall cost.

Online measurement of bauxite grade has been achieved.

Online measurement of bauxite grade has been achieved.

Online measurement of bauxite grade (including Al₂O₃, SiO₂, Fe₂O₃, etc.) is highly valuable in both mining operations and the alumina (Bayer process) production chain; however, it is also widely recognized as one of the most challenging analytical tasks to achieve accurate, long-term stability.

In the alumina industry, flow measurement challenges caused by scaling.

In the alumina industry, flow measurement challenges caused by scaling.

In the alumina Bayer process, scaling—also known as fouling or scale deposition—poses a highly typical challenge to flow measurement. Measurement deviations directly undermine the precision of process control, rendering production automation unattainable. Despite attempts to employ various flow‑measurement technologies, none have succeeded in resolving this issue.

How is the flow rate of magnetic slurry measured?

How is the flow rate of magnetic slurry measured?

Because commonly used electromagnetic flowmeters or Doppler ultrasonic flowmeters cannot overcome the challenges of measuring flows containing magnetic slurries, the magnetic particles in magnetite cause significant and irregular deviations in the measurements of magnetic flowmeters due to fluctuations in magnetic field strength, making compensation impossible. Doppler ultrasonic flowmeters struggle to maintain high accuracy and stability over long periods. When the slurry contains large particles, wear can lead to electrode failure and pipeline leaks, compromising measurement performance. Such malfunctions necessitate unscheduled repairs and replacements, thereby increasing production costs.

The challenge of cyclone feed flow rate?

The challenge of cyclone feed flow rate?

Wear in the cyclone feed pipeline and variations in ore composition can cause signal instability, ultimately leading to failure of the electromagnetic flowmeter. Coarse particulate matter, under high flow velocities, accelerates wear on the electrodes and flow tube of the electromagnetic flowmeter. This results in distorted flow measurements, hindering optimization of cyclone performance and throughput. Ultimately, measurement failure and/or leakage may occur, necessitating frequent and costly replacement of the flowmeter.

Breakthrough in Slurry Density and Solids Content Measurement Technology

Breakthrough in Slurry Density and Solids Content Measurement Technology

Pulp density is of paramount importance in the mineral processing industry, as it influences grinding pulp consistency, cyclone classification efficiency, flotation stability, and thickener control; however, accurate online measurement has long been a significant challenge.

The sonar flowmeter has been installed at the Qidashan Concentrator of Ansteel!

The sonar flowmeter has been installed at the Qidashan Concentrator of Ansteel!

The mineral‑processing technology upgrade project at the Qixuan Plant of Anshan Iron and Steel Group Co., Ltd. is currently underway in full swing. The Plasen team is honored to be involved in this modernization effort. For this project, 19 Plasen sonar‑based flow and gas‑content measurement systems have been designed and installed—specifically at the cyclone inlets, at the outlets of various pumps, and along long‑distance pipeline sections.

Tianyuan Chemical has once again chosen sonar flow meters.

Tianyuan Chemical has once again chosen sonar flow meters.

Tianyuan Chemical was established in 2005 and is located in Xiaoyi City, Lüliang, Shanxi Province. The company primarily manufactures chemical raw materials such as alumina and aluminum hydroxide.

Alumina industry

Alumina industry

Nanjing Pulaisen Instrument Co., Ltd.’s NK caustic soda online analyzer and RP online analyzer are two products custom‑designed for alumina production processes. They measure critical process parameters—caustic soda concentration and the RP/αK ratio. To meet the demanding conditions of alumina plants—high temperature, high alkalinity, high pressure, and corrosive, scaling‑prone environments—the company’s instruments feature a unique design that ensures reliable operation under harsh conditions, while delivering real‑time, accurate measurement data to customers.

External‑clamp‑type combination—sonar flow meters and non‑nuclear density gauges support the full‑process commissioning and operation of the Macheng Iron Mine’s beneficiation system.

External‑clamp‑type combination—sonar flow meters and non‑nuclear density gauges support the full‑process commissioning and operation of the Macheng Iron Mine’s beneficiation system.

The Macheng Iron Mine is located in Macheng Town, Luannan County, Tangshan City, Hebei Province, situated on the resource-rich eastern Hebei Plain. The mining area covers 10.08 square kilometers, with proven reserves of 995 million tons, making it one of the largest deep‑shaft iron mines in China.

Magnetite slurry flow measurement

Magnetite slurry flow measurement

The sonar volumetric flowmeter overcomes the technical limitations of other flowmeters—such as electromagnetic and ultrasonic flowmeters—through its sonar‑based measurement method, while offering excellent cost‑effectiveness.

Jiulong Wanbo New Materials has placed another order for a batch of Prasen online monitoring instruments.

Jiulong Wanbo New Materials has placed another order for a batch of Prasen online monitoring instruments.

Two years after the successful commissioning of the 3.6-million-ton alumina production facility at Jiulong Wanbo New Materials, in response to production upgrades and modernization needs, another batch of online instruments from Pulsar Instruments has been procured, including ultrasonic flowmeters, online NK analyzers, and fully automated sodium aluminate solution analyzers.

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Nanjing Pulasen Instrument Co., Ltd. 普来森仪器

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