ALUMINUM INDUSTRY

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP81-01043R001700220004-1
• Release Decision: RIPPUB
• Original Classification: C
• Document Page Count: 76
• Document Creation Date: December 23, 2016
• Document Release Date: February 11, 2013
• Sequence Number: 4
• Publication Date: February 4, 1958
• Content Type: REPORT

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INFORMATION REPORT INFORMATION REPORT
INFORMATION REPORT INFORMAT'ION RE'PORT
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The Hungarian Bauxite Mining looks back on a past of over 30
years and the rich occurences of this material in our country
ensure a first class position even on a world scale for the
Hungarian Bauxite, Alumina and Aluminium Industries
parallel to the development of the prospecting for Bauxite
and of mining methods have been developing the Alumina Indus-
try and Piletallurgy as well as the manufacture of Aluminium
salts, of semi-finished and finished products. From the view-
point of production per head /3,5 kgs per head/ the position
hold by the Hungarian Industry is even on a world scale a
considerable one.
The methods of Bauxite prospecting have been developing in
an up-to-date manner and as a consequence, at present we
dispose of modern processes riot only as regards the adoption
of geological and geophysical methods but also concerning
the mineralogical and technological testing of Bauxite.
Our Bauxite mining methods /open mining and deep level mi-
ning/ are modern, the mechanization of mining has been deve-
loping to a considerable extent. Owing to the development of
the Bayer and modified Bayer processes, our Alumina Industry
disposes of an up-to-date technology. Our new methods aiming
at the extraction of other components of Bauxite /Titanium,
Vanadium etc./ as well as of Aluminium salt are of a similar
importance.
Hungarian Aluminium Metallurgy applied as one of the first
the Soederberg process and nowadays we dispose of 60 KA
electrolysis cells with vertically arranged anode studs as
well as of modified, heavy duty electrolysis cells with ho-
rizontally arranged anode studs.
The development of modern technics calls in many fields of
industry and commerce for employing high purity /99,99 ~/
5 80/g/N.
a.
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aluminium. Some types of high intensity /27 KA/ refining fur-
naces were developed first in Hungary, similarly to a method
allowing to use the furnaces in aluminium electrolysis systems
working on similar intensity.
As a consequence, also the development of the manufacture of
semi'products and finished products has become necessary.
we dispose of a large scale of experience as regards .the
manufacture of sheets, stripes different section bars, tubes,
foils etc. made of Aluminium or Aluminium Alloys The last
Leipzig Pair too has borne testimony to the high level of
the manufacture of finished products e.g. cables /with Alu-
minium conductors, high purity aluminium protecting coats/,
aluminium bus-bars, electrical fittings, transmission lines,
food industry, scaffoldings, transport vehicles /tramway cars,
busses, waggons, ships etc./. As reference see "Light Metals"
/London, March 1956/.
Please find below the description of a hypothetical Alumina
Plant with Aluminium Electrolysis Plant. Our data, however,
are but informatory, more detailed offers can only be elabo-
rated in the knowledge of the mineralogical, physical and
chemical properties of the Bauxite available, after having
thoroughly studied the local conditions. We dispose of a
modern Light Metal Research Institute as well as of an Ala''
minium Planning Institute both qualified to solve your prob-
lems and to elaborate up-to-date plans in this line, on the
basis of many years' experience.
'580/g/N
a
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The raw material used is bauxite, of the supposed following
average
composition:
A12 03
S102
Fe203
Ti02
P205
V205
Others
Combined water
The data are applied to a material dried at 105? Co Our plans
are based on a material of 20 % water content. In case of bau-
xites of other composition - of course - we undertake the exe-
cution of an other plan, by making the necessary changes in
the present scheme.
I. SHORT TECHNOLOGICAL DESCRIPTION
The technology of the alumina plant to be erected is based
upon the "Bayer" process modified due to the up-to-date de-
velopment of the same. We are in the position, however? to
elaborate technological processes for different bauxite qua"
Cities, having an excellent Research Institute, laboratories9
pilot plants and Projecting Institute with great experiences
at our disposal.
The phases of the modified "Bayer" process are the following:
1. Dressing of the raw material
2. Digesting of bauxite and settling
of red mud
3. Precipitation of aluminium hydrate
4. Calcination of aluminium hydrate
5. Concentration of diluted caustic
lye and removing of the impurities:
580/g/N
bo
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?.DRESSING yF iRAw MATRIA.LS
arriving in railway cars 'vich axe emptied ;
a waggon t,i' perms T.he bauxite. ets:, nto the "arop A
crashing equipment by means ,of a _,plate conveSre'~ and
a. b~~cket elevator e Th 1auxite : rushed t.o 40; mE 1siz.e ;will be
forwarded by a c -rveyCr belt to the bauxite ?,s,to,rage hal.~,q;
wherefrom it will be lifted rv mee.ns of `grabs. 'and transported
further tJ a onveycr belt and an intilined, el=evator 'to 1;.he_
drying and, roasting kilnsa The bauxite= pa'ssin.g, throu.gl. the
ascutfired multiple-stage c ry n :ki,Ip, wi1,I, be; freed,
from its water content and from a certain part o its comb-
The dried bauxite will fie crushed in ball mills to the re-
quired grain-size arid conveyed by means of a suction fan in-
to the storage bunkers Afterwards adequate quantity of bau-
xite powder will be mixed with the circulating recovered
caue'V5.c lye of soda in the mixing tank and the mixture will
be pumped 'to the digesters /autoclaves,,/,
2. DIGESTING OF BAUI ITE A1~7~ SETTII OF RED MUD
In the autoclaves the mixture of ?auetic lye of soda and
bauxite will be heated or ,indireotly by 82O atma pressure
superheated steam, The digeatio l is performed under 4-J.~ atmo
pressure at a temperature o l1.O1?5o C anc require, abt 26
hours, During this processs the alumina is dissolved by the
caustic lye of soda from the hauiite while the insoluble re-
sidues of the latterp will form the red muds
After boiling, the slurry leaving the autoclaves, will be di-
luted with washing water r'nning back from the > ettlers and
pumped in the settling tan: system, where the red mud sepa-
rates from the clear solution of aluminate, The sodium=ai.u-,
minate solution is pumped to the precipitators, while the
mixture of red mud and alum i nate liquor coming from the
bottom of the settling tank passes through a washing tank
or filter system consisting of several units,
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The red mud leaving the washing system and thrown into the
wastepit, contains practically no alkali at all. The washing
water serving for the dilution of the digested slurry leaving
the autoclaves, is fed into the last settling apparatus, and
is led through the whole system. It is customary to submit
the sodium aluminate liquor before being pumped into the pre-
cipitators, to a so-called control-filtering, removing thus
the red mud particles in suspension.
3. PRECIPITATION OF ALUMINIUM HYD,RATB
First of all, the clear sodium-aluminate liquor has to be
cooled to a temperature of 60 - 65? C, then it is pumped in-
to the pneumatically agitated precipitators. During this pro-
cess, in consequence of agitating and feeding with aluminium
hydrate seeds, the sodium aluminate liquor decomposes and
about half of its alumina content will be precipitated in
form of aluminium hydrate. The separated aluminium-hydroxide
will be settled and filtered. One part of the aluminium-hyd-
rate will be utilised for starting the decomposition of the
sodium-aluminate liquor, the other part is fed into the rota-
ry calcining kilns.
4. CALCINATION OF ALUMINIUM-HYDRATE
The aluminium-hydrate washed twice and coming from the f il-
ters, will be fed into the rotary calcining kilns. The kilns
could be fired by producer gas or by oil. In the kilns the
aluminium-hydroxide looses its combined water at a tempera-
ture--of abt.12OO? C and is transformed into alumina. To prevent
the loss of a great quantity of alumina powder through the
flue gas exhausting system, the exhauster is provided with
mechanical gas cleaning and electrical dust precipitator
equipment. The recuperated alumina dust which contains water,
will 1e fed again into the calcining kilns. The calcinated
alumina falls from the openings arranged at the end of the
kilns and passes the recuperator pipes where it is cooled by
means of suct.Lun air. The produced alumina is forwarded by
means of pneumatic conveyors - operated by suction or pres-
sure - into the alumina silos.
5 80/g/N.
b.
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The caustic soda liquor circulating in the plant having been
diluted by different washing watersD has to be adequately
concentrated before re- usingo The concentrated lye after an
addition of fresh caustic soda v in order to recover the los-
ses - will be pumped back into the dressing plant ansd mixed
with bauxite again.
CONCENTRATION OF THE DILUTED CAUSTIC LYE AND RE~OVSDtG
OF THE IMPURITIES
During the process, the caustic soda liquor accumulates the
impurities more and more, so that it has to be concentrated
to a higher degree of concentration after which the impuri-
ties and salts may be separated from it partly by cooling
and partly without,
The separation and utilization of the by-products increases
the overall economics of the process and, on the other hand,
cleans the recirculating liquor.
5 80/g/N
b4
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11 0 M A C H L L __R Y E Q U I_ F_ ME W T S
Denomination
Punetion and technical data
1.
Waggon tipping device 1
2.
Coarse crushers 2
3,
pine cru.shere 2
4T
Grabs 2
5.
Bauxite bunkers 3
b.
Roasting kilns 3
8. Bauxite silo 1
9. Grinding mills
10e Bunkers for bauxite
Unloading the raw bauxite
froze the w&ggone
Cylindrical crushers dia
1150 mi x 800 m for pre-
crushing
Dia 1000 m~q x 1000 m for
crushing to 20-30 mm grain
size
To feed the raw bauxite in-
to the bauxite hall and in-
to the bunkers
Each with a capacity of 33
m3 for the intermediate sto-
rage of crushed wet bauxite
Rotary or stage kiln with
producer gas or maaout-fi-
rings for dryLng and roas-
ting the wet bauxite
Electrostatic duet separa-
ting equipment for the re-
cuperation of bauxite par-
ticles from the flue gas
With a capacity of 2610 m3
for the storage of crushed
dry bauxite
Dia 2200 mm x 3700 mm, pneu-
matic ball mill producing
bauxite of adequate grain-
size
Each with a capacity of 150
m39 for the intermediate
storage of ground bauxite
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ti
Item
Dertominat ion
Pcs
11,
Mixing tanks
12.
Weighing machines
3
13.
Lye storage tanks
3
14.
Autoclaves /digesters/ 20
15.
Set"?. ~?g tanks
/t?,: = k~.ners/
7
16o
Yaelly filters
5
17.
Cooling apparatusses
3
18.
Precipitators
24
19a
Drum _filters
8
5 8 0/g/ N
c
I
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Function and technical data
For mixing the bauxite pow-
der and caustic lye of soda
Tank for weighing the baw-
x.ite pow~zer
or the storage of caustic
lye cif soda required for
bauxite digesting
Each with a t~apac tty of
32 m. for steam-heating at
25 atm. pressure with hea-
ting coils.
Dia. 14 m9 height 1Q mfl with
5 chambers e for the spara~
ti on of red mead and washing
of red mud respextlvely
Pressuar_ e operated filtrating
apparatussess each with a
filtering surfa' e of 109 m2
for the filtering oi` the so~
dium aluminate liquor
Double stage vau.urn r:oolers
for the cooling of sodium
aiu.minate liquor
Dia, 7 mA height 28 mA pneu-a
maticaily agitated tanks for
decomposing the al.uminate
liquor
Vanuum operated drum filters,
.4 filters havt._ng a fii t ering
s urf a e of 24 !a? and $ ia~-
ving a filtering surface o-f.
12i m2 for filtering and.
w~.shi ng the aluriii.v" uv hydra-
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Denomination
Pee Function and technical data
~. with 6 travelling dump cars,
each with a capacity of 750
kgs9 for the conveying of
aluminium hydrate to the ro~
tart' calcining kilne
2l Hydraulic separator 1-2 For classifying the alumiA
nium hydrate particles
22. Settling tanks 2 Dia 6 ma height 12 m,, with
6 chambers for settling the
aluminiamvhydrate from the
sodium aluminate liquor
23, Rotary calcining kilns 4 Dia 298 m, length 50 in, pro-
vided with recuperators,for
the calcination of alumini~
um hydrate
24, Gas cleaning equipments 4 Centrifugal and electrosta
tic gas cleaning equipment
for the recuperation of alu~
mina dust from the flue ga-
ses
25. Pneumatic alumina con-
veyors 2 Pneumatic exhauster equip
went for conveying the pro
duced alumina into the alu~
mina silos pneumatically
26. Oil or producer gas 4 With fuel tanks, with air
firing equipments steam- or pressure spray-
burners for the firing of
rotary calcining kilns
580/g/N
b.
Quickstream condensers ope-
rating with quadru~ c? ef-
fects each with a heating
surface of 1000 m2 for the
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Denomination
28. Salt separator
P unction and technical data
concentration of dilated
sodium alami.nate liquor
1 Cooling device with conden-
sers and filters, to remove
the impurities from the ao-
dium aluminate ligv.or
29. Bagging machine or 1 To fill the alumina in
special tanks or bagso
special wagg^rs if
needed
SPECIFIC (CONSUMPTIONS RELATING TO THE PROUCTION
OF 1 TON OF ALUMINA
The specific consumption ioe, the quantities of raw materi-
als, power etc. required for the production of one ton of
alumina, depend first of all on the quality of the bauxite,
In this regard the A1203 and 8102 content and mineralogical
properties are of a decisive importance. With the decline of
the quality of the bauxite i.e. with the reduction of the
A1203 content and the rise of the S102 content, the auxili-
ary raw material requirements and the power consumption in-
crease, while the capacity of the equipments decrease and
finally all the cost determining factors, independent of the
produced quantity, rise /wages, ~wverhead expenses, amortisa-
tion,/.
Supposing the above mentioned average bauxite composition,
the specific requirements for the production of 1 ton of alu-
mina are the followingz
Raw bauxite
Dry bauxite
Caustic soda /96/
Steam 21 atm.
Steam 4,5 atm.
P uei
/10.000 cal/kg/
Electric current
5 80/g/N
b.
2,6-3,2 tans/1
2,0-2,3
0,110-0,150
2,3-3,2
4,0-6,0
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plant has not been ~onsiderad.
the own consumption of the power plant supplying the alumina
The above data refer exclusively to the production of alumina
IV. INPGrii4MTORY MATERIAL BALANCE REFER1~ED TO ONE HOUR
PRO DUO T I ON
In case of a capacity of 60,000 tons per year, the plant has
tc produce 7 t/hour of alumina. is a consequence, the underm
mentioned quantities have been considered for some of the
most important phases of the technological process8
1/ Raw materials
5/ Quantity of slurry to
be digested
6/ Slurry to be settled
7/ Quantity of sodium
aluminate liquor
8/ Quantity of the red
mud produced
9/ ;rater for red mud
washing
10/ Quantity of the alu~
minium hydrate pro-
duced
11/ Calcinated alumina
produced
12/ Separated salt /im-
purities/
tauxite 21 tons/h
caustic soda i ton/h
bauxite 21 tons
dry bauxite 15 tons
bauxite powder 15 tons/h
concentrated caustic lye of
soda containing 270 g/litre
Na20,.. 55 m3/h
60 m3/h
165 n
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The A1203 content of the produced alumina is not less than
987-92 %
'd DESCRIPTION AND ROUGH ESTIMATE OP THE POWER SUPPLY OP
THE ALUMINA P ACTORY WITH A CAPACITY OP 60.000 TONS/YEAR
St artin data
a/ Steam requirements digesting 21 ata /absolute 20 tone/h
atm./
others 4,5 "
own consumption of the
power plant
"
50
10 "
Total: 80 tone/h
b,/ Electric powers for the alumina production
350 kWh/ton 2600 kW
own consumption of the
power
plant
500 "
other
plant
consumption
100 "
water
plant
300 "
Total loads
3500 kW
cj' Compressed sire Por the pneumatic agit-
ation and for pneumatic
material handling 900 m3/ton
d/ '.Pater requirement: for the lye concentrating
apparatusses and other
industrial water requi-
rements 150 m3/ton
VIA iECHNICKAL DESCRIPTION
of Power plant
To supply the steam- power required for the alumina production
a back-pressure steam power plant with a working pressure of
25 ata has been designed, connected continuously to the pubs
lac network on the electric side.
In view of a high safety factory we designed 4 masoutfired
steam boilers with a max? capacity of 50 tons/h and a working
pressure of 25 ataa eachfl supplying 400? C superheated steam,
with the required feed-water equipment, masout s? r. age and
auxili a.ry equipment s 0
b?
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There are 2 steam turbines, with directly coupled generators.
The steam turbine is designed for an inlet pressure of 22 ata,
and a back-pressure of 4,5 ata. The generator has a capacity
of abt 5000 kW, supplying 10500 V, 50 cycles, 3-phase current
1 steam pressure reducer and cooling equipment is provided for
a pressure of 25/4,: ata.
1 e*itch plant and control room equipment with all the instru-
ments and accessories required.
12 various transformers with a rate of transformation of
10,5/0,4/0,23 kV mounted on the most important consumption
places, and the required switchboards.
The electric .quipments of the alumina factory, motors, swi-
tches and cables.
b J plant
A central compressor plant Is required for the supply of comp-
reseed air. For this purpose piston- or other type compressors
of a strong design is projected with gearing, directly coupled
with the electric motor.
The plant consists of 3 units with an /inlet/ air capacity of
3000 m3 and 7 atm each, out of which two units are running and
one is a spare one. The air tanks and the air cooling equip-
ment are arranged outdoor. An electrically driven crane had
been designed to facilitate the erection and the maintenance.
For water supply the water of a river can be used by means
of a water station. The pump house consists of the following
parts*
4 pumps with a capacity of 480 m3/h each and a manometric head
of 68 m, directly coupled with an electric motor, with all the
accessories, piping and hand-operated erection crane.
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- 12 -
The water piping is made of suitably dimensioned steel pipes
coated with double bitumenous jute layer, Provision is made
for adequate valves and fittings.
J Electric power and steam generation
Steam requirement per year for the alumina plant
is 600.000 tone
Own consumption of the power plant
85.000
Total yearly requirement
Electric power generation, on the generator
685,000 tone
terminals per year
35,000.000 kWh
Own consumption of the plant
4,000.000 "
Total ueeful generation per year
31.000.000 kWh
Consumption of the alumina plant
per year
26,000.000 kWh
Available for sale
5,000.000 kWh
The power economy of the alumina plant is in equilibrium. The
electric power generated relative to the steam conaumptdan is
sufficient to cover the requirements and only a small surplus
arises.
YILBUILDINGS OF THE ALUMINA PLANT
The buildings required for the plant equipments are made of
iron frame work. The filling walls are made of bricks. The
foundations of the mechanical equipments, tanks, etc, are
made of concrete and reinforced concrete respectively. The
required cubature of the shops is the following*
Bauxite store
60.000.m3
Dressing plant
30,000
Digesting plant
55.000
Precipitation
80.000
Calcination
35.000
Lye-concentrat ion
300000
Total
290.000 m3
5 80/g/N
b.
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The entire alumina plant is built in a pavilion-system, the
buildings accomodating the various departments being at a
determineld distance from each other. The shops are connected
by means of bridges, through wich the material handling from
one shop into the other is carried out. The piping too will
be aceomodated here.
Not included in the above statement are the various auxiliary
shops /machine tool shop, laboratory etc./ as well as the ma-
nagement building. The alumina plant and the aluminium elec-
trolysis plant /aluminium plant/ must be considered as one
unit, so that their requirements must be considered commonly.
In view of the climatic conditions and considering the fact
that the alumina plant is a hotworking plant, some of the
departments may be aceomodated on the open area. The rotary
calcining kilns and the precipitator tanks can be located for
instance in the open area. Of the calcining equipment only
those parts would be aceomodated in a closed building, where
the handling and operation of the machine is accomplished,
In this way abt 80.000 m3 building volume can be economised.
According to the above, the total built-in volume /cubature/
of the technological plant /alumina plant/ amounts to abt.
210.000 m3.
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The plant is designed to be built according to the General
Disposition Scheme at a scale of 1 : 1000 as enclosed. The
Power Station should be situated within a 200 metres distance
from the plant boundary for the sake of securing a low lose
aid low cost of power supply, The area required by the plant
has a length of 750 m and a width of 250 m.
Prom the viewpoint of location it is preferable that the lon-
gitudinal axis should form a 20-30 degree angle with the wind
direction prevailing in the plant area.
The plant is bordered by a railroad designed for the plant,
running parallel to one of the longer aides. Parallel to the
railway are situated all the buildings dealing with the mate-
rial handling or else, whose operation requires contact with
the railway.
The porduotive plant unit proper, the Electrolysis Plant is
situated alongside the longitudinal axis and is designed to
aecomodate abt. 160 electrolyser cells needed to attain the
capacity set as a target.
On the side near the Power Station the Electrolysis Plant
joins the Rectifier Plant, whose job is to rectify the A.C4
supplied by the power station into D.O. as required for the
operation of the Electrolysis Plant.
The office building to house the central management of the
plant is designed to be situated on the other side of the
Electrolysis Plant, opposite the railroad. On the same side
is to be located the Laboratory, whose task is to control and
record the conditions of production as regards the quality of
the product.
5 80/g/N
a.
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 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
The number of the atxiliary buildings required for the full
operation of the plant is 19Q adding up a total of ba11t-in
area of
The total area of the plant is 250 z 750 187.500 sq.mo
TECHNOLOGY AND PLANT ORGANISATION
2.1 The main product
The technology of the aluminium plant follows basically the
principle of electrolysis at melting temperature, ae is usu-
ally employed in this industrym All the requirements of up-
to-date production have been considered in the designing of
the aluminium plant. Special attention has been given to at-
tain a maximum saving of material and energy, furthermore to
secure a continuous plant operation and to organize the most
rational material handling. Steps have been taken to make it
possible that the usable portion of the slag could again be
used. For particulars see paragraph 2.2.
The production itself takes place in the electrolysing cells,
whose design has followed the most modern technological prin-
ciples. The cells have a capacity of 54.000 amperes, are fit-
ted with vertical power entries and are equipped with the Soe-
derberg-type continuous work anodes.
Abt. 160 such cells are required to reach the capacity set as
a target. The cells are connected in series and are situated
in four rows in accordance with the dimension of the Electro-
lysis Plant. The theoretical output of one cell is as follows
18,063 kg Al/hour.
Average power efficiency can be put at 84 %, one unit having
consequently an hourly output of roughly 15,2 kg aluminium,
adding up to 365 kg aluminium a days Bearing in mind that the
580/g/N
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 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
Elektrolysis Plant is working continuously, and taking 365
days into account, the yearly output of one cell is
133,2 to aluminium/year.
Now taking the 160 cells, as have been planned, into conside-
ration, it appears that 151 are required to attain produc-
tion of 20.000 tons/year, while the 9 cells left serve as a
reserve, respectively will be at disposal for the periodic
renovation service.
A cell consists of two major parts: the cathode part is a
sheet iron tank structure, lined with an insulating layer and
with a layer of conducting carbon bricks in which the liquid
electrolyte of melting temperature /930 to
9500/
takes place.
Into this hangs the other main part of the
cell,
the anode,
consisting of suspended iron structure jacket, enclosing the
anode carbon block serving as current conductor. The carbon
block is heated by the heat of the current and of the electro-
lyte. By this heating process the anode mass is being burnt on
the spot. Horizontally fitted steel bars built into the cathode
and steel studs fixed up vertically in the anode serve as a
connection with the power oarrying network.
The steel bars and steel studs join the power carrying sys-
tem made of rolled aluminium bus-bars, leading through the
Electrolysis Plant, connecting the cells in series. Leaving
the plant and conducted through the building situated bet-
ween the Electrolysis Plant and the Rectifier Plant they
serve as collecting bus- bars for the D.C. of the rectifier
system.
The liquid electrolyte of melting temperature is a melting
product containing fluorine salts and alumina /A1203/. The
latter, being the basic material for the manufacture of alu-
minium, dissociates as an effect of treatment by eleetriq~
current. Molten aluminium, obtained this way, being heavier
than the electrolyte, will settle on the bottom of the cathode
tank, whereas the oxygen will combine with the anode carbon
5 80/g/N
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 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
hanging into the bath, and will form partly 00, partly O02
gases. These gases will be collected by the cast iron jacket
fitted around the anode and v,ill than be led to the burner
mounted on the shorter side of the cell. Hare the gases still
combustible will be burned with addition of fresh air. Com-
bustion products will be led away by a pipe system to the
exhaust ventilators arranged in the shop. The latter pump
the gases into iron chimneys high enough to make sure, that
the gas leaving the chimney can do no harm to the environ-
ment.
In the case water supplies available are sufficient, a gas
cleaning equipment can be added to the exhaust equipment.
The fluorine contained in the gas can be absorbed and made
thus safe against its effect detrimental to health.
Though theoretically the alumina alone takes part in the
process of electrolysis, certain losses in cryolite
/Na3A1F6/ and aluminium fluoride /A1F3/ appear to be unavoi-
dable and have to be made up for o
The aluminium as collected in the cathode tank of the cells
will have to be tapped every 3-4 days. This process takes
place with the help of suction pipes under vacuum.
The electrolyser cells have a 491 to 4,6 V operation voltage.
Occasionally, however, when the ratio of alumina contents in
the electrolyte drops below a critical limit, the cells sud-
denly adjust themselves to a higher voltage. This is the so
called anodic effect and while it lasts, the cell voltage may
rise for a short period to 30-40 volts.
The anodic effect can be stopped by breaking up the hard
crust that has formed on the electrolyte surface and by sup
plying additional alumina to the bathe
5 80/g/N0
a.
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 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
The raw liquid aluminium as ?;ained in the cells will be trans-
ported to the foundry in electric trucks, where it will be fed
into electrically heated fan aces. The different qualities of
aluminium produced by the cells, if necessary, can be equa-
lized in the furnaces. The aluminium thus equalized and res-
ted gets rid of its gas contentsg and the electrolyte contents
of the metal will swim up to the surface in form of cinder
/slag/.
The metal having been sufficiently rested and desiagg?d, will
be founded from the mechanically tilted furnaces into casting
machines consisting of a chain of ingot moulds with continu-
ous motion, in which the molten aluminium solidifies in the
form of ingots weighing about 15 kg /pigs/.
On part of the production will be turned in slabs designed
for the rolling mills. Automatic, semi-continuous casting
equipments are provided for the manufacture of the slabs.
Ingots and slabs for rolling or pressing will be finished
in the foundry as well.
Smooth operation of the electrolyser cells requires that the
cinder accumulating in the electrolyte should be periodical-
ly removed. The cinder is made up of moldered carbon of the
anode and also of electrolyte sticking to the grains. The
process of flotation is employed to regain the cryolite and
alumina contents of this cinder, and to use again both mate-
rials. Following proper handling the cryolite regained by
flotation can again fed into the cells.
Two ventilator systems provide for fresh air supplies for
the furnace hall. Fresh air is being blown into the air of
the furnace hall through channels laid underground between
the cell-rows. Airing lanterns fitted parallelly tc the lon-
gitudinal axis of the furnace hall are provided to enhance
the venti1at5?n.
Power required for the operation of the plant is supplied by
the rectifying station, which, as is chown on the enclosed
sketch, consists of eight groups, six thereof have to secure
5 aoi'g/N
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 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
the normal operation of the plant, one serves as a warm spare
unit to be at disposal shoulci any of the working groups break
down, hale the eighth group is designed for the carrying out
of repair and periodic maintenance works.
The rectifier system consists of the mercury vapour rectifi-
ers. The rectifier units employed are of a six-phase type in
order to improve the sinusoid. response and to diminish the
distortion by superharmonicsR Every unit consists of six
anodes. Every anode is in a separate vacuum housing to res-
trict the overall vacuum space. A common pump system is pro-
vided for securing the vacuum of the six anodes.
Back-current switches mounted in the D.C.circuit have t pro-
vide for the selective safeguard of the rectifying groups.
Furthermore there have been provided safeguards for each of
the phases inasmuch as separate switches serve for the se-
lective switching off of the individual anodes between the
transformers, and rectifiers.
Electric power is, as designed, to be provided directly by
the Power Plant by way of bus -bar systems spanned on poles.
This bar system feeds the double collecting bar system si-
tuated in the other part of the rectifier shop. The latter
bar system is in connection with the regulating and the main
transformers, supplying the rectifying groups and with the
transformers designed for the power supply for any other
plant purposes.
The eight regulating transformers belonging to the eight main
transformers have to provide the D.C. voltage required by the
number of cells in operation. The main transformers transform
the three-phase current arriving from the Power Plant into
the six-phase A.C. to feed the rectifiers.
The transformer repair shop situated near to the Rectifier
shop is to provide for the periodic supervision and the rou-
tine repair work of all the transformers, This building is
connected ?by a standard gauge railway with the main railway
53C/g/N
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 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
7
-J
and the transformer building so that the transport of trans-
formers should take the miniu um time and trouble.
Two oblong buildings are situated parallel with the railroad.
The one nearer to the head building houses the general repair
shops, while the other one is designed to serve as store for
materials needed for the operation of the plant, /e.g. cryo-
lite, aluminium fluoride, anode carboxi, cathode carbon etc./.
The Foundry building joins the farther end of the Electroly-
sis Plant. The building partly serves as a store for finished
products, for packing and shipping as well. The alumina silos
are situated about in the center line of the Electrolysis
Plant building. Alumina supplies arriving by rail are con-
veyed pneumatically from the railway cars into the storing
silos. The laboratory will be on the side of the Electrolysis
Plant opposite to the Foundry. This laboratory is designed
to carry out quickly analysis work with a view to control
constantly the output of the individual cells as well as to
supervising the plant operation. The laboratory supplies data
for the equalizing work to be carried out in the Foundry and
also determinate the chemical analyses of the finished pro-"
ducts.
2.2 By-product
The cinder to be removed from time to time during the opera
tion of the cells, contains considerable quantities of cryo?
lite and alumina. The cinder overwhelmingly consists of grains
separated from the anode carbon, that happen to fall into the
electrolyte and being lighter than the same are floating on
its surface. For the sake of smooth plant running the cinder
with the electrolyte particles sticking to them, have to be
removed.
This cinder is transported from the Electrolysis Plant to the
Regenerating Plant where it will be treated by the flotation
prooeaao
5 80/g/N
a.
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 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
Reagents to en-
The cinder will be orushed ar.d classified.
hance foalring will be added before the mixture is fed into
the flotation cells. The earton and the foam will leave while
after proper drying the remaining f lotated alumina and cryo-
lite can be again well aaedo
The flotation equipment has a capacity of handling 2000 tons
of cinder yearly.
3. MATERIALS NEEDED FOR H PLANT
alt Raw materials
In order to utilize the full capacity of the plant the follo-
wing raw materials are required yearly and monthly respecti-
vely*
alumina
cryolite
anode mass
aluminium fluoride
cathode carbon
ramming mass
3,340 tons
110 a
943 "
3.2 Basic stores
It is advisable to maintain considerable quantities as basic
stores of the above mentioned raw materials in the interest
of undisturbed and smooth plant operation, since the mate-
rials are being shipped from great distances to the plant.
It is recommended to store permanently these materials for
a three-months' period of plant operation, taking into con-
sideration eventual delays as to the shipping of materials.
Suggested basic stores should therfore be as follows:
alumina
5000
- 10.000 tons
cryolite
200
- 300 "
anode mass
2000
-- 3000 "
aluminium fluoride
100 "
Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
ear ne Amon h
 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
cathode carbon
150-200 tons
sodium fluoride
12 "
ramming mass
160 "
Dimensions of the store-houses are determined by the quanti-
ties to be stored.
f POWER AND WATER REQUIREPdENTS
4s1 Electric power
The aluminium plant
running
day and night represents a prac-
It follows, that energy peaks are
and that the power requirement of
as constant.
tically peakless operation.
practically out of question
the plant can be considered
To figure out the power requirements of the plant one has to
start from the 20.000 tons set as the capacity target and a
constant 54.000 ampere D.C. intensity needed for this task.
Now taking into account that each cell requires an average
of 4,5 V voltage, the total 151 working cells will add this
up to 675 V D.C. voltage requirement. This gives an output of
36,7 MW and considering that the efficiency of the rectifier
equipment is 94 ~, the total power needed amounts to
39,2 MW.
Power is also required for the auxiliary shops, that may be
estimated roughly at
2,8 MW
so that the overall plant need of power appears to be
42 MW.
Taking into account the relatively good efficiency of the
aluminium plant, the A.C. requirement can be set at
46,5 MVA.
Considering this output value, the power consumption
a work year of 8.760 work-hours amounts to
344.000 MW hours,
while the total consumption of the plant amounts to
368.000 MW hours.
580/g/N.
a.
O
during
I
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 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
To run the rectifier equipment securely, it is indispensable
to employ cooling water to transfer the heat due to the ca-
thode loss of the rectifier vans. The water to perform this
cooling effect represents the major part of the water needed
by the plant.
The ingot casting system of the Foundry requires equally con-
siderable water supplies, since the latent heat produced by
the solidification of the molten metal has as well to be dis-
posed off by cooling water.
Considering all these factors, the total water consumption of
the plant appears as follows:
cooling water for the rectifiers
water required for gas cleaning
2.500 m3/day
/provided the scheme will be
carried out/
400
cooling water for the Foundry
1.200 "
compressors, shops etc.
400 "
drinking water
100
Totally 4.500 m3f day
The temperature of industrial water as given above for cooling
is understood to be 15? C. Should the water available fail to
meet this temperature, the same may be raised up to 25? C.
The quantities stated above should in this case be adequately
corrected upwardso
In areas poor in water it is advisable to build a coo14ag
tower or to choose an other appropriate system.
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 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
I.i:Z$S 6::ti ULt:T
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0
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Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-(
Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01
043R001 700220004-1
 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
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I eaoamam
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GENERAL LAY- c'Li T.
~r+ r -,
r ti Y i i 1J(,~ ``ll (C\~
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LAIN n:' ' -1 S~b~E
 Declassified in Part - Sanitized Copy Approved for Release 2013/02/11: CIA-RDP81-01043R001700220004-1
LEGEND:
I
1 BAUXITE - ,YARD
2 CRUSHER WCT GRIHDER?~IIxING
3 NATRON SOLVER
4 DIGESTORS
5 5ETTUHG TANKS (DORR APPARATUS)
E KELLY FILTERS
7 COMPRE55oRS
KCRTINC COOLeR5
=? HIDRATE SETTLING TANKS
PRECIPITATION
H HYDRAE FILTi RING
12 C.~LCINATICN
LYE EVA?ORATICH
''. POWER ITLANT
(: A!
-YA2p
:. TPaauru CLNT