A Study on Design and Fabrication of Red Mud Filtration Machine

I. INTRODUCTION

The Indian Aluminum Industry is one of India's leading industries. The aluminium sector in India is a highly concentrated industry with several of the country's five largest firms. As Indian aluminium demand rises, the Indian aluminium industry also grows at an enviable pace. Indeed, aluminium development in India is now beyond demand. India's most energy, consumer durables, shipping, building and packaging industries involve the aluminium industry. The aluminium industry will expand in India by diversifying and exploring new horizons for the industry. Hindalco and Nalco are now one of the most cost-effective in the world's aluminium processing. Bayer generally produces red bauxite aluminium sludge or waste as a by-product, known as red mud. Around 90 million tonnes of red mud are generated annually globally. But nowadays most of the aluminium industry is focusing on environmental sustainability how products produced by these factories, especially bauxite residues and red mud, can be reduced and reused in a different way since they have a serious environmental effect. New technology is specifically developed for use in all areas of industrial applications, such as the production of bricks, ground filling or use of cement.

laterite soil, severely sprinkled in a tropical or sub-tropical rainy weather with silica and other soluble materials. In 1821, Bauxite was named to Les Baux village in Provence in the Southern France by the French geologist Pierre Berthier where he found and became the first to acknowledge that it had aluminium. Bauxite is a composite of hydrous oxides from aluminium, aluminium and insoluble elements such as quartz, hematite, magnetite, siderites and goethite. The composition is composed of bauxite. Usually, bauxite is a soft structure of special gravity 2.6 to 3.5 (h: 1 to 3). light content. The ordinary bauxite colour is rose but when it is low in iron, it is likely to become white in colour and reddish brown in epistolic design as seen in Figure 2 with increasing iron colour.[1]

The bauxite deposits in Indian sense are divided into five broad catagories, according to geological and geographical areas: Eastern Ghats, Central India, Western Coast, Gujarat, Jammi & Kashmir. Indian bauxite can be separated into fout groups, based on mineralogy and order of preference:[1] 1) Gibbsitic Bauxite 2) Mixed Gibbsitic- Boehmitic Bauxite 3) Boehmitic Bauxites 4) Diasporic Bauxites

The Bayer Process is the cheapest way of producing bauxite alumina. The bauxite from the mine is compressed and ground at the start of the operation and then blended into big claves with a solution of caustic soda. At 1-6 atm pressure and at temperature 110-270°C, the aluminium in the ore is dissolved into sodium aluminium. The bauxite silica normally behaves as a sodium aluminium silicate, which precipitates the solution. Iron, titanium oxide and other contaminants are not and are solid and chemically damaged. It is isolated from the sodium aluminium solution from this waste liquid, Identified as red mud and gradually dumped for regeneration of caustic soda into the disposal fields. The solution of hydroxide is dissolved and cooled to about 1000 C. The aluminium hydroxide Al(OH)3 (hydrargillite) is dissolved as a white fluffy solider by agitating and cooling to about 60°C. The aluminium hydroxide decomposes into alumina whether it is heated by rotor heaters or fluidized beds, at 1100°C to 1300°C (calcinated), thereby giving water vapour in which the hydroxide is converted to a dry, white powder. This powder consists with alumina of technical purity, comprising as many as 0.01–0.02% SiO2, 0.01–0.03% Fe2O3, and 0.3-0.6% NaO2 as impurities. Like this, a significant amount of the alumina created in this way is then smelted to manufacture aluminium in the Hall Heroult method. [1]

During the aluminium production phase, It's made "Red Mud." A tonne of alumina manufactured depending on the raw material treated is given for 1-2,5 tonne of red mud. In India, approx. 5.71 million

Table 3: Typical Composition of Red Mud

Red Mud is a vital problem for alumina refineries or Bauxite Residue management. The quantity of residue varies depending on the quality of the bauxite and the site of the alumina refinery. Most of the red mud has been deposited in mud-lakes and/or impoundment areas in recent years; this has been standard procedure at worldwide alumina refineries. Many refineries want to manufacture a red mud cake that is strong, cold and transportable by camion or transport.

The RDFV (Figure 9) has historically been applied in the event of red mud filtration for more than fifty years now and washed after the end washer. The filtration is carried out using vacuum to shape a semi-dry filter cake during the final stage of the CCD-settler-washer circuit. Additional cake washing on the RDVF is performed using a spray header with the use of wash liquor. The filters generate a filter cake of 50 to 65% refineries are looking at ways for lower cakes filtering the moisture content in red mud disposal sites to minimise waste volumes. Pressure filters may make cakes that are very dry. Effective cake washing for caustic recovery are provided by filter presses. RDFVs play an important role in the resolution of the vast volume of red mud created by the machine to increase the recycling potential of caustic soda which is used in the process itself. In most cases RDFVs play a crucial role. [15]

Logical and rigorous research is established. The topic analysis is based on scientific and precise methodology and analyses consumer statistics. This study needs accurate details such that information gathered from consumers and certain information gathered from internet sources. I visited Hindalco (Aditya Birla Group), Hirakud, Sambalpur, Odisha to research the different processes and technologies and to recognise the different aspects of aluminium industry and management of red mud disposal. For industrial purposes, the bulky Red Mud behaviour and low caustic content are important problems for custom superior filtration technologies. The first phase of the study is on red mud filtration and dieting processes, which make mud paste for industrial purpose in general, and which efficiently use the filtration phénomene. Thus, system design and filtration along with many components was carried out with the help of CAD and CAM software. The following section focuses on experimental procedures to increase the performance of the filtration system by calculating the design. As a consequence, the moisture content of red mud slurries is observed to be somewhat smaller.

S. K. Tamotia (2000)' said that the industrial usage of red crazy and red mud was both experimental. For instance, red mud tiles, blades, bricks, windows of doors, etc.' [1]E. Balomenos, and others, (2011) have described economically the ability to dramatically enhance the diversity and profit margin of the aluminium manufacturing industry as well as resolving the red mud disposal crisis, a single phase of co-production of two highly precious byproducts (pig-iron and mineral wool). [2]These advances and improvements achieved that will be quite helpful in the light of environmental considerations for the disposal and usage of red mud have been analysed by the SuchitaRai et al. (2012). And as a consequence the restoration operation of the red mud ponds was performed." [3] The following: [3] The details of the different flow sheets and the effective mud disposal equipment are described in Avery and Wilson, (2013). Q. The test results reflect changes by form of machinery, geography and water and caustic recuperation, storage and rehabilitation costs in waste areas." [4] Subbrat K. Rout et al.,(2013) discussed using red mud as the basis on laboratory research and finite element analysis in development of tailing dams. The geotechnical characteristics are provided such as plasticity, compaction, permeability, shear strength and red mud dispersion. The stable analysis and the filtration of tailing dams is seen in line with the finite element analysis by using the above geotechnical parameters." [5] HAREETNATH Harjeet Harjeet "The RM, PSA, XRD, FESEM, EDX, BET and FT-IR techniques are analysed in conceptual form and stage compositions with this paper," says Abanti Sahoo " (2014). "The status and potential trends of red mud characterization, disposal, different neutralisation methodologies, and use both in the world and in the Indian sense were examined by Sucharita Patel and B.K. Pal, 2015,.".. [6]. "After several years of debate theoretically, industrial reuse of bauxite residues in the most advanced alumina refinery is now to be achieved," said ReinhardBott and Thomas Langloh, (2015). A bulky behaviour of the Red Mud and a low caustic content is the primary requirement for industrial application, which threatens a superior filtration technology, which is primarily used for easy separation, if the Red Mud is removed like a post." [8] "Red mud is agricultural waste in large volumes, and its handling is a particular task. PetrosKounalakis et al.,(2016). The study reveals that investments in an industrial plant that treats red mud and turns commercial materials into hazardous industrial waste are healthy and sustainable." [9] Li Wang et al., (2019) "The context, characteristics and applications of RM as an adsorbent are summed up as discussed. A thorough review and comparison of proper methods to removing metal and non-metallic materials from wastewater. The surface alteration of RM is emphasised to ensure strong adsorption. Finally, there is a thorough debate on the potential for future study in this area." [10] The report is in progress.

With the Rotating Vacuum Drum Filter, the bottom feed category is the best component of the solid liquid separation operation, so rotor vacuum drum filters are surely used. Figure 6 displays the scheme views and the specifications with rotary vacuum drum filters. Figure 6 shows. A highly efficient liquid/solide isolation system is the herotary drum vacuum filter.

When a certain cake purity is desired, cakes are washed. It also improves the removal from the filter cake of liquid components or dissolved compounds. The reliability and efficacy of cake washing on the rotating vacuum filter machine can be measured using laboratory pilot research.[2] The drum is protected on the valve end that is bearing on the end of the drive by a wide trunnion diameter. Any single drum face forms one independent vacuum cell, separated into circumferential segments. Internal tubing linked to each industry passes via the trunnion and finishes of a wear plate with ports that match the amount of industries. [6] Filter valve: A bridge valve manages the cycle sequence such that any sector is vacuum, blast and dead region. A valve with a bridge setting. When a sector reaches into an underwater setting, vacuum starts and begins to wash. Adjustable blocks enable optimization of the filtration period form-dry ratio as well as the "efficient submergence" of the drum if the amount of Red Mud in the tank is as high as possible. [6] Vacuum Pump: A vacuum pump is an instrument that draws gas molecules from the enclosed volume such that a partial vacuum is left behind. The role of a vacuum pump involves the generation of a relative vacuum. Vacuum Receiver: Air receiver tanks are designed for air storage or full vacuum receive service. It is made of steel structure. Filter Pump: This pump mainly has the purpose of supplying red mud slurry for continuous filtering of vat. A pump-associated filter is used by drawing and going through different filter modes to clean the red mud from the red mud slurry tank and then put the red mud into a red mud tank. Knife Blade: The blade of the knife has the purpose of constantly collecting the red crazy dry cake from the vacuum filter drum and places its conveyed location to quickly remove excess dry red mud cake.

One Compartment: There is one room inside the vacuum filter for gigantic water in the process of drying red mud cake. The Cloth of the pump: The filter holds the red mud cake and attaches unique cords to the drum face in the grooved stripes. The filter cloths are currently made of synthetic materials with advanced layers to increase the drying quality. [18]

Where, t=time for red mud cake formation, if ‗tc‘ is the time for one full rotation of the drum. Where, f is the fraction of the cycle available for red mud cake formation. f= fractional submergence of drum in the red mud slurry V= Filtrate volume obtained in one drum rotation and (V/tc) represents the filtration intensity. For Compressible Red Mud Cake,

The "apparent submergence" usually amounts to 33-35% while the overflow is set at most, hence the slurry ranges are 04.00 to 8.00 hours. If a sector joins the submerging void, it begins to shape a cake before it comes from the slurry. The cycle part required for forming is "successful dip" and its length is determined by the number of sectors, the volume of slurry in the tank and the bridge positioning that monitors the shape to dry ratio. [6] Continuous Removal of the Deposited Red Mud Cake: The thickness of the cake is not permitted to rise to high values, so a constant rate of pressure differential is needed for the filtration operation. The complete batch loop corresponds to a single drum rotation. The equation designed for batch filtration should also be used for continuous filtration, bearing in mind that the equation represents one complete batch rotation. and lasts until about 01.30 hours in non-wash applications with the vacuum cut. When cake washing is necessary, the washing would take place at about 10.30 to 11.30. The remainder is for the final drying of the coke at 1:30 hrs[5]. Once the whole field has its vacuum, the air cut off starts at about 02.00 hours to allow the discharge of the coke. The blow is cut out at about 03.00 hours, based on the location of the tip of the scraper blade. Drum filters are usually run at a low pressure blast, although a snap blow is added for certain applications, and it is preferred that the fabric is not snapped out of the tapers or ropes.

1) Horizontal drum which rotates in a red slurry trough at 0.1-2 r/min. 2) Medium of the filter exposes a partly submerged drum face 3) Vacuum & air are used as the drum rotates alternately 4) The washing liquid pulled through the pump is drawn while the panel exits slurry areas, so the red mud cake is sucked with the air and then the cake is scrapered down. 5) The filter field may be submerged from 30% to 70%

Following the formation of the CAD and CAM models, the MATLAB programme validated and interpreted this model for the control of various operating parameters of the vacuum drum filter. For example, the following findings were obtained when vacuum drum filter with a surface of 1.0 m2 worked on a constant pressure of 1.8 bar.

The "Red Mude samples slurry" had around 10% strong residue, such as silica and caustic, and the Red mud cake was practically incompressible, by weight of specific gravity. The time necessary for washing the red bowl created at the end of a 70-minute filtering by using the same pressure at 3.0m3 was calculated with the aid of MATLAB software programming special relation to the simulation at the start.

The original calcium hypochlorite slurry humidity is determined using experimental methods. The first step is to determine the weight of the dry and wet cake and use these findings to calculate the original humidity value. Table 6 and Table 7 tabled the readings.

Filtration Rate = (Dry solids/1000) x (1/form time) x (1/leaf area) For First Test (31.5/1000) x 3600 x (1/5) x (1/0.1) = 230.8 Kg/h/ft2

Filter Rate = Form filtration factor x Submergence xScale up factor = 226.8 x 0.8 x 0.33 = 59.8 Kg/h/ft Leaf area is found out by measuring the outer surfacearea of the filtering medium.

At vacuum pressure sustained at 500 mm Hg. Finally, during the experiment, vacuum pressures are said to be less than 450 mm Hg. Filter Area =(Slurry flow x % dry of solids) / Filtration Rate= 35.6 ft2 So, now we can calculate the rotary vacuum drum filter Area = Kr2 = 3.14 x 4 x 4 = 50.24 ft2 This 4ft x 4 ft. revolving drum will then be appropriate for the given slurry. This is fine for the operation. In this experiment the weight of the dry and moist cake is initially calculated and these measurement effects are used to determine the initial moisture value. Table 8 showed the readings. The diagram is now drawn with the values entered between Form filtration rate Vs Time. The vacuum is kept at a pressure of 500 mm Hg. Finally, during the experiment the vacuum pressure is recorded to be lowered to 450 mm Hg. Filter Area = (Slurry flow x % dry of solids) /Filtration Rate= 41.66 ft2 So, now we can calculate the rotary vacuum drum filter Area = Kr2 = 3.14 x 4 x 4= 50.24 ft2 This revolving 4ft x 4 ft drum will then be the right drum for this particular litter. This is fine for the operation. The moisture content of red mud slurries is quickly decreased by 10 to 20 percent as a result. Thus the experiment makes the creation of red mud cake smoother than other filters. The efficiency of the red mud filter system in terms of its moisture content is then improved.

For alumina refineries, handling of red or bauxite residues is a key concern. The amount of 2,5 tons of red mud residue must be manufactured for each tonne of Al2O3 processed at the alumina refinery. The quantity of residue varies depending on the quality of the bauxite and the site of the alumina refinery. Most of the red mud has been deposited in

friction to render a red mud cake into a high-solid, fryable and conveyor belt. For industrial purposes, the bulky Red Mud behaviour and low caustic content are important problems for custom superior filtration technologies. The first part of the study text deals with a Red Mud Filtration and dieting process for the production of mud cake in general for industrial use and the efficient utilization of the filtering phase. The design and filtration of the system together with various components is done with CAD and CAM software (CATIA). The following section focuses on experimental procedures to increase the performance of the filtration system by calculating the design. The humidity content of red mud slurries was therefore observed to decrease significantly from 10 to 20 percent. Thus it is simpler to shape the red dung cake than other filters. It is well known. The efficiency of the red mud filter system in terms of its moisture content is then improved.

[1] S. K. Tamotia (2000). ―Management of Red Mud‖, Processing of Fines (2), ISBN: 18-87053-53.3, pp. 430-434, NML Jamshedpur, India. [2] E. Balomenos et. al. (2011). ―A Novel Red Mud Treatment Process: Process design and preliminary results‖, TRAVAUX Vol. 36, No. 40, pp-255-266. [3] Suchita Rai et. al. (2012). ―Neutralization and utilization of red mud for its better waste management‖, ARCH. ENVIRON. SCI., 6, pp. 13-33. [4] Q. Avery and K. Wilson (2013). ―Red mud pressure filtration for the alumina refinery‘s bauxite residue tailings disposal‖, Australian Centre for Geomechanics, Perth, ISBN 978-0-9870937-6-9,doi:10.36487/ACG_rep/1363_17_Avery, 2013. [5] Subrat K. Rout et. al. (2013). ―Design of tailing dam using red mud‖, Central European Journal of Engineering, 3(2), pp. 316-328, DOI: 10.2478/s13531-012-0056-7. [6] Harjeet Nathand Abanti Sahoo (2013). ―A Study on the Characterization of Red Mud‖,International Journal on Applied Bioengineering, Vol. 8, No. 1 January 2014. [7] Bauxite Residue Management, World Aluminium, Europian Aluminium, Association, Aug, 2014.

ISSN 2278 – 2540.

[9] Petros Kounalakis et. al. (2016). ―Feasibility study for an innovative industrial red mud utilisation method‖, Waste Management & Research, Vol. 34(2) 171–175, sagepub.co.uk/journals Permissions.nav, DOI: 10.1177/0734242X15615423. [10] Li Wang et. al. (2019). ―Application of Red Mud in Wastewater Treatment‖ Mineral Reviews, 7 May 2019. [11] Addressing the Challenge of Bauxite Residue - Light Metal Age Magazine, March 11, 2019. [12] Alumina refinery residue storage: from lagooning to dry stacking – Metso Outotec, Aug 6, 2019. [13] Indian Minerals Yearbook 2018. [14] Day, Martin (September–October 2003). "Gehry, Dassault and IBM Too". AEC Magazine. Archived from the original on 2005-12-01. Retrieved 2007-03-07. [15] "Digital Project". Gehry Technologies. Archived from the original on 2007-02-05. Retrieved 2007-03-07.

Department of Mechanical Engineering, GIET University, India