Performance study

Reducing OPEX and emissions with the latest gas suspension calciner for alumina refining

The installation of a latest-generation gas suspension calciner (GSC) at an Indian alumina refinery resulted in significant operational benefits, while also reducing the refinery’s environmental footprint.

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Key benefits

  • 10%

    Reduction in power consumption

  • 4%

    Reduction in fuel consumption

  • 4%

    Reduction in COe

  • 5%

    Reduction in OPEX

Details of the performance study

CommodityAlumina
TechnologyGas Suspension Calciner (GSC)
ApplicationAlumina Calcination
Study typeCustomer story
CountryIndia

The state-of-the-art design incorporates a range of features that help to maximize throughput, cost efficiency, and alumina quality – key concerns of alumina refinery customers.

It includes improvements to many key components, including the dust transport system, cyclone, and holding vessel. The calcination process can also be optimised by utilising advanced process control via ECS/ProcessExpert®.

In comparison to the previous-generation GSC at the plant, the new design delivers a:

  • >10% reduction in power consumption.
  • 4% reduction in specific heat consumption (kcal/kg).
  • 4% reduction in CO2e emissions.

As a result, OPEX for the new system is 5% lower than for the old design, demonstrating that profitability and sustainability are not mutually exclusive but can often be found overlapping in the latest technological advances.

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