Beruflich Dokumente
Kultur Dokumente
Operating Factor
Availability 90 % AK C
Operating Schedule
Days per week 7 d/wk TR 1.7 A
Shifts per day 3 shift/d LG C
Hours per shift 8 h/shift LG C
Total operating hours 7884 hours calc C
Hourly Product Rate (FeV) 634 kg/h calc C
Climate Conditions
Average maximum 30 °C TR 1.7 A
Average minimum 23 °C TR 1.7 A
Mean (annual) TBD °C
Design minimum TBD °C
Design maximum TBD °C
Rainfall TR 1.6 A
average 35 years (before 1987) 437 mm per year
minimum (1961) 160.7 mm
maximum (1964) 843.2 mm
dry season from May to October
rainy season from February to March
Total 100
Soda Ash
Chemical Na2CO3 TW 1.2 C
Format powder AK C
Purity 99 % SI A
Particle size <1 mm AK C
Specific gravity 2.53 EH A
Bulk density 600-700 kg/m³ EH C
Storage capacity 3 wks AK C
Sulphuric Acid
Chemical formula H2SO4
Format liquid SI A
Purity (min.) 93 % SI A
Freezing point -29.5 °C SI A
Specific gravity 1.84 EH A
Delivery in trucks ECM 1.2 C
Storage capacity 2 weeks + 1 truck load AK C
Aluminum Sulphate
Chemical formula Al2(SO4)3.14H2O SI A
Format powder SI A
Purity (as Al2O3) 16 % SI A
Specific gravity 2.71 EH A
Solution strength 20 wt% AK A
Solution s.g. 1.1 calc
Delivery 40 kg bags ECM 1.2 C
Storage capacity 2 wks AK C
Ammonium Sulphate
Chemical formula (NH4)2SO4
Format white/grey crystals SI A
Composition
(NH4)2SO4 (dry) 99 % SI C
free acid 0.2 % SI C
moisture content 0.3 % SI C
Specific gravity 1.77 EH A
Bulk density 1000 kg/m³ SI A
Solubility at 20°C 760 g/L EH A
Delivery TBD
Storage capacity 3 wks AK C
NaOH
Chemical formula NaOH
Format liquid SI C
Purity (min.) 50 % SI C
Freezing point 12 °C SI C
Specific gravity 1.5 SI C
Delivery drums C
Storage capacity 2 weeks AK C
Flocculant
Flocculant type MagnaFloc 455 TW 1.3 C
Form powder
Packaging 25 kg bag As A
Mixing strength 0.5 wt% SI A
Solution S.G. 1.0 As A
Filter Aid
Filter Aid Type TBD TW B
Form powder
Packaging TBD kg bag As B
Mixing strength TBD wt% SI B
Solution S.G. 1.0 As B
Fresh Water
Average temperature 20 °C As A
Minimum temperature TBD
Maximum temperature TBD
Pressure 400 kPa (g) SI A
Water analysis
pH TBD
Solidity TBD mg-equiv/L
Ca2+ TBD mg/L
Mg2+ TBD mg/L
CO32- TBD mg/L
HCO3- TBD mg/L
Active Cl TBD mg/L
Cl 70 mg/L AD C
SO42- TBD mg/L
Cu ions TBD mg/L
Fe ions TBD mg/L
Small mixture TBD mg/L
Alcality TBD mg/L
Cooling Water
Maximum supply temperature 20 °C AK C
Maximum Return temperature 30 °C AK C
Steam
Temperature 180 °C AK C
Supply pressure 1013 kPa(abs) EH C
Fuel
Fuel type 1A ECM 1.3 C
Low heat value 9650 kcal/kg ECM 1.3 C
High heat value 10238 kcal/kg ECM 1.3 C
Density 1.017 ECM 1.3 C
Sulphur content 1.9 % V C
Viscosity EH C
65 °C 178 SSF
82 °C 73 SSF
100 °C 30 SSF
135 °C 15 SSF
Storage method vertical tanks, type API, with internal heating SI C
Supply method supplying system to the plant by tanker trucks with burner SI C
Process Plant
Concentrate Tank
Capacity 2 hrs AK C
No. of tank 1 AK C
Concentrate Filtration
Equipment vacuum belt filter AK C
2
Filtration rate 2 t/m /h TW 1.1 C
Cake moisture content 10 % As C
Roasting
Roasting
Equipment oil fired rotary kiln
Roasting temperature 1250 °C TW 1.2 C
Hot air temperature TBD °C C
Retention time (reaction zone) 60 minutes TW/ES 1.2 / C
Off-gas temperature 293 °C V C
Sodium salts addition (Na2CO3 & Na2SO4) 2.0 wt% total Na Calc C
4.5 wt% Na2CO3 TW 1.2 C
Reaction and extent
Na2CO3 (s) = Na2O (s) + CO2 (g) 100 % ES C
Na2SO4 (s) = Na2O (s) + SO3 (g) 100 % ES C
V2O5 (s) + Na2O (s) = 2 NaVO3 (s) combined with leach stage C
4 Fe3O4 (s) + O2 (g) = 6 Fe2O3 (s) 98 % ES C
Off-gas Treatment
Equipment electrostatic precipitator & wet scrubber ES/AK C
ESP discharge destination rotary kiln feeder
Scrubbing agent NaOH solution AK C
Scrubber discharge destination TBD
Scrubber off-gas stack to atmosphere AK C
Leaching
Concentrate Regrinding
Equipment ball mill SI C
Type of circuit open ES/AK C
Feed size (F80) 30 mm ES C
Product size (80% passing) 100 µm ES C
Bond work index (BWI) 14.2 kwh/t As C
Slurry %solids in mill 30 % ES/AK C
Grinding retention time 3 minutes ES C
Slurry solution regrind thickener overflow ES/AK C
Slurry discharge destination regrind cyclone ES/AK C
Regrind Cyclone
Cyclone underflow solids 95 % of feed ES C
Cyclone underflow % solids 70 % ES C
Off-gas Treatment
Equipment venturi scrubber AK C
Scrubber discharge destination regrind ball mill AK C
Scrubbing agent regrind thickener overflow AK C
Scrubber off-gas stack to atmosphere AK C
Regrind Thickener
Thickener type conventional As C
No. of stages 1
3 2
Settling rate N/A m /m /h
Slurry dilution TBD %
Underflow solids 60 % ES C
Leach Tanks
No. of tanks (minimum) 2 AK A
Mode of operation Continuous
Total retention time 60 min TW 1.2 C
Operating temperature 60 °C, minimum TW 1.2 C
Operating pH 9 to 11 TR/TW 1.8 B
Reactions and extent *
NaVO3 (s) + H2O = NaVO3 (aq) + H-2O 84.8 % TW 1.2 C
Na2Si2O5 (s) + H2O = Na2Si2O5 (aq) + H-2O 100 % ES C
Filtration
Equipment vacuum belt filter AK C
Wash water process water AK C
No. of wash stages 4 ES C
Wash water displacement 4 ES C
Filtration rate 0.77 t/m²/h TW 1.2 C
Efficiency per displacement 70 % As A
Filter cake moisture 15 % TW 1.2 C
Filtrate destination AK C
primary filtrate to desilication ES/AK C
secondary filtrate to regrind thickener ES C
Filter cake destination to leach residue stockpile AK C
Filtrate V2O5 concentrate 44 g/L ME C
Desilication
Desilication Tanks
No. of tanks (minimum) 2 AK A
Mode of operation Continuous AK
Total retention time 60 min TW 1.2 C
Operating temperature 60 °C TW 1.2 C
Operating pH 8.3 ES C
Al2(SO4)3 addition stoichiometric ES C
Reation and extent TW 1.2 C
3 Na2Si2O5 (aq) + Al2(SO4)3 + NaOH = 2NaAlSi3O8 + 3Na2SO4 + H2O controlled to give 20 mg/L Si in solution
Filtration
Equipment recessed-plate pressure filter ES C
Wash water process water AK C
No. of wash stages 1 ES C
Wash water displacement 3 As C
Filtration rate 0.4 t/m²/h estimated As C
Efficiency per displacement 90 % As C
Filter cake moisture 15 % ES C
Filtrate destination to regrind thickener ES C
Filter cake destination to tails AK C
Filtrate V2O5 concentrate 44 g/L ME C
PLS Cooling
Equipment plate and frame cooler
Discharge temperature 25 °C AK C
Cooling medium cooling water AK C
Precipitation Tanks
No. of tank 3 AK C
Mode of operation Continuous
Total retention time 9 hr AK C
Operating temperature 25 °C max. TW C
(NH4)2SO4 addition to the first tank AK C
(NH4)2SO4 dosage 2.5 x stochiometric V2O5 ES C
Target pH 7.3 to 7.8 TW 1.2 C
(NH4)2SO4 in discharge solution 90 g/L ES C
Reation and extent 97 % TW/ES 1.2 C
2 NaVO3 a + (NH4)2SO4 = 2 NH4VO3 s+ Na2SO4 controlled to give 0.2 gpl V in solution TW 1.2 C
AMV Cyclone
Cyclone underflow solids 80 % of feed ES C
Cyclone underflow % solids 60 % ES C
AMV Thickener
Thickener type high rate, covered As C
No. of stages 1
Settling rate 0.024 t/m²/h TR 1.7 C
Slurry dilution TBD %
Underflow solids 50 % ES C
Flocculant type TBD
Flocculant stock strength 0.5 % SI A
Flocculant addition strength 0.01 % SI C
Flocculant dosage 50 g/t solids As A
Overflow suspended solids 10 ppm As C
AMV Filtration
Drying
Equipment flash dryer
Drying temperature 400 to 475 °C V C
Heating medium electricity V C
Product discharge temperature < 100 °C V C
Product moisture < 0.5 % V C
Off-gas Treatment
Equipment bag filter V C
Recovered product destination dried AMV bin V C
Off-gas destination stack to atmosphere V C
Deammoniation
Equipment reduction kiln V C
No. of kilns 2 V C
Deammoniation temperature 800 °C V C
Operating atmosphere reducing V C
Retention time (reaction zone) 30 minutes V C
Heating medium electricity V C
Off-gas temperature 600 °C V C
Reaction and extent
2 NH4VO3 = V2O3 + N2 + 3 H2O + H2 95.7 % ES C
Note: Extent includes conversion to FeV
Cooling
Equipment screw coolers V C
No. of coolers 2 working in parallel V C
Discharge temperature < 110 °C V C
Cooling medium cooling water V C
Barren Treatment
Barren Evaporation
Equipment MVR V/AK C
Operating temperature 110 °C V C
Operating pressure atmospheric V
Heating medium steam V C
Condensate destination process water tank AK C
Crystal destination hydrocyclone V C
Hydrocyclone
Feed From MVR V C
Overflow destination centrate tank V C
Underflow destination centrifuge V C
Centrifuge
Equipment pusher type centrifuge V C
Product moisture content 5% V C
Solids Destination to sodium sulfate dryer V C
Liquid Destination to centrate tank V C
Na 2 SO 4 Drying
Equipment flash dryer V C
Operating temperature 150 °C As C
Operating pressure ambient As C
Final product purity 98.7 % V C
Heating medium hot air As B
Product destination cyclone V C
Liquid/Solid Separation
Equipment cyclone V C
Solids Destination to sodium sulphate silo V C
Off-gas Destination vent scrubber V C
Off-gas Treatment
Equipment vent scrubber V C
Scrubbing solution wash water V C
Scrubber discharge destination to centrate tank V C
Baghouse off-gas vent to atmosphere AK C
FeV Plant
V 2 O 3 Storage Silo
Capacity 8 days AK C
No. of Silo 1 V C
Al Storage Silo
Capacity 1.5 weeks AK C
No. of Silo 1 V C
Al Weigh Bin
Capacity 1 batch V C
No. of bins 1 V C
Fe Storage Silo
Capacity 8.5 weeks AK C
No. of Silo 1 V C
Fe Weigh Bin
Capacity 1 batch V C
No. of Silo 1 V C
FeV Smelting
Operation batch V C
Equipment DC arc furnace V C
Reaction time 260 minutes V C
Typical discharge temperature Metal 1900 °C V C
Slag 2000 °C
Final metal composition V 80 % V C
Fe 17 %
Final slag composition CaO 15.4 % V C
Al2O3 76.0 %
MgO 5.6 %
V 2 O5 3.0 %
SiO2, FeO, Fe2O3, TiO2, MnO <1 %
Metal destination to FeV crushing facility V C
Slag destination to tails V C
Off-gas Treatment
Equipment baghouse V C
Recovered product from baghouse to furnace feed bin V C
Baghouse off-gas stack to atmosphere V C
Crushing
Equipment hydraulic hammer V C
No. of hydraulic hammer 1 V C
Equipment jaw crushers V C
No. of crushers 2 V C
Screening
Equipment double/triple deck vibrating screens V C
No. of screens 4 V C
Final screened product size & destination 25 to 50 mm to product packing V C
10 to 25 mm to product packing V C
6 to 10 mm to product packing V C
3 to 6 mm to product packing V C
1 to 3 mm to product packing V C