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Aluminium Refinery


185 TPH capacity Aluminate Liquor Concentration Plant for Alumina Refinery Phase-II Expansion, Nalco, Damanjodi

 

In association with GEA Messo AG of Switzerland, MBE builds Evaporation Systems for concentration of aluminate liquor in the alumina refineries. GEA has built large number of evaporation plants world-wide and MBE with its experience of building over 250 plants on LSTK basis has the unparalleled track record of completing projects within the shortest possible time-frame.

The unique “Falling film Technology” of GEA Messo is the latest advanced technology and has certain distinct advantages as compared to other systems available for this application. It has low steam consumption, utilization of full heat transfer area, minimal scaling, low power requirement, consistently good condensate quality and accurate control of product temperature.

Hence GEA with MBE is the best possible combination to build the Evaporation Plants of international standards in optimum time adopting the most advanced technology.

 

Red Mud Thickening & Disposal System

The system is installed in an Alumina refinery. The waste of the refinery is dumped in a suitable location. The technology used for decanting the mass is called red mud transportation. MBE is capable of executing such projects on EPC basis or as a part of a turnkey project.

 

Aluminium Smelter : Carbon area

Pre-baked Green anode plant (GAP)

MBE has built the largest number of Anode Paste and Pre-baked Green Anode Plants in India.

  • Paste Plant for INDAL at Belgaon
  • Paste Plant for BALCO at Korba
  • Green Anode Plant for NALCO at Angul
  • Green Anode Plant for BALCO at Korba
  • Green Anode Plant for VEDANTA at Orissa - Phase : I
  • Green Anode Plant for VEDANTA at Orissa - Phase:II (under construction)
  • Green Anode Plant for BALCO at Korba - Phase:II (under construction)

The 35 TPH capacity Green Anode Plant at Korba has been built by MBE in 19 months, which is a world record for early completion.The quality of anodes produced is comparable with the best globally, resulting in higher electrical conductivity in pots, amounting to huge savings in electricity cost.

Green anode Plant 3 & 4, Vedanta Alumina

 

Carbon Recycling (butt handling)

2 Modules of Green Anode Plant (35 TPH each) for Aluminium Smelter Plant at Jharsuguda, Orissa

 

MBE builds Carbon Recycling Plants deploying state-of-the-art technology. The equipment involved - crushers and feeders - are manufactured by MBE according to global standards. The carbon recycling plant of NALCO at Angul has been built by MBE.

The 72 m long, partly inclined apron conveyor in this plant is the world’s largest apron conveyor in the aluminium sector and it has been designed & manufactured by MBE in its works.

 

Bath processing with autogenous mill

For economic operation, recycling of bath scraps in smelters is a must. MBE builds Bath Recycling plants deploying single stage grinding of bath in fully air-swept autogenous mills. The bath recycling plant of NALCO at Angul has been built by MBE and the unique autogenous mill in this plant has been manufactured by MBE in its works.

 

Anode Storage

For economic operation, recycling of bath scraps in smelters is a must. MBE builds Bath Recycling plants deploying single stage grinding of bath in fully air-swept autogenous mills. The bath recycling plant of NALCO at Angul has been built by MBE and the unique autogenous mill in this plant has been manufactured by MBE in its works.

 

Baking Furnace

MBE is capable of building Anode Baking furnace on turn key basis. Anode baking furnace comprises furnaces with fuel firing system, Anode conveying system, Grouping / ungrouping, Baked anode cleaning and furnace tendering assembly. Green anodes brought from anode storage to anode grouping systems are taken to furnaces by furnace tendering assembly. After baking through a pre-set cycle time, baked anodes are taken out to anode ungrouping by FTA. Baked anodes are then fed to anode cleaning m/c and after cleaning, the baked anodes are sent back to the storage area and ultimately to the Rodding shop for rodding.

 

Fume treatment plant for baking furnace

MBE is capable of building Baking Furnace Fume Treatment plants using most advanced state-of-the-art technology. It has unique features like controlled fume flow balance, optimized fume distribution at the inlet of cooling towers and under filters and elimination of dust buildup.

 

Rodding Shop

MBE is capable of building Anode Rodding shop on turnkey basis. Rodding shop generally comprises overhead P& F conveyor, Bath cleaning m/c, shot blasting m/c, butt press m/c, thimble stripping & cleaning m/c, belt conveyors, roller conveyors, rod brushing & graphite coating m/c, induction furnace, ladle & crane etc. In rodding shop, baked anodes are fitted with thimble & rod and kept ready for use in electrolysis at pot room. At the same time the spent anodes are brought back from pot room and all consumables such as carbon butt, bath, thimble and rods are separated and stored for future use.

Aluminium Smelter : Pot area

Pot Manufacture and Installation

Pot assembly work consists of cradles, pot shells, pot super structure, aluminium busbar, air supply systems, insulation material. MBE has in-house capability towards manufacturing of cradles, pot shells and pot super structure at its workshop. For fabrication of aluminium busbar, air supply system and insulation material , MBE has tied up with reputed agencies.

 

Gas treatment center for potline

MBE is capable of building Pot Gas Treatment plants using the best technology globally available. The emission level is below 1 mg per Nm³ resulting in cost savings due to increased fluorine recovery. It is of modular concept with even gas distribution to each module. The accurate fresh alumina distribution arrangement to each reactor and gas flow rate control system at each module ensures consistent emission level at stack.

 

Hyper dense phase system for pot feeding

In association with Rio Tinto Alcan of France, MBE builds Hyper dense phase systems for pot feeding at Aluminium smelter plants. HDPS is an automated continuous feeding process which maximizes the performance of pots and ensures that all pot hoppers shall remain full permanently. Its power consumption and maintenance requirements are also very less. The HDPS at Nalco Smelter at Angul, Orissa was made by MBE.