{
  "authors": [],
  "basis": {
    "capacity": "3000 t/d smelter-grade alumina (ASSUMED normalisation basis)",
    "location": "generic (not chosen)",
    "operating_hours_per_year": 8400
  },
  "benchmarks": [],
  "chemistry": {
    "inputs": [
      {
        "chemical": "bauxite",
        "grade": null,
        "note": "feed:BX: gibbsitic bauxite, crushed, 2.19 kg/kg alumina",
        "role": "feedstock"
      },
      {
        "chemical": "calcium-oxide",
        "grade": null,
        "note": "feed:LIME: quicklime, 0.052 kg/kg",
        "role": "feedstock"
      },
      {
        "chemical": "sodium-hydroxide",
        "grade": null,
        "note": "feed:NAOH: caustic soda make-up, 50 wt% solution, counted by mass of the solution",
        "role": "feedstock"
      },
      {
        "chemical": "methane",
        "grade": null,
        "note": "feed:NG: calciner natural gas, taken as methane (D-008)",
        "role": "feedstock"
      },
      {
        "chemical": "water",
        "grade": null,
        "inventory_key": "feed:PW",
        "note": "Fresh water make-up to the hot water tank",
        "role": "feedstock"
      },
      {
        "chemical": "air",
        "grade": null,
        "inventory_key": "feed:AIR",
        "note": "Calciner combustion air",
        "role": "feedstock"
      }
    ],
    "outputs": [
      {
        "chemical": "aluminium-oxide",
        "grade": null,
        "inventory_key": "product:ALU",
        "note": "Smelter-grade alumina to storage",
        "role": "main-product"
      },
      {
        "chemical": "carbon-dioxide",
        "grade": null,
        "inventory_key": "emission:CO2",
        "note": "Calciner natural gas CO2, ~0.154 kg/kg alumina",
        "role": "emission"
      }
    ],
    "utilities": [
      {
        "chemical": "electricity",
        "grade": null,
        "inventory_key": "feed:POWER",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "feed:MPS",
        "note": "MP steam 1000 kPa(a), digestion heaters, counted as heat delivered",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "feed:LPS",
        "note": "LP steam 450 kPa(a), liquor heater trim and evaporators, counted as heat delivered",
        "role": "utility"
      },
      {
        "chemical": "cooling-water",
        "grade": null,
        "inventory_key": "product:CW",
        "note": "25/35 C (ASSUMED)",
        "role": "utility"
      }
    ]
  },
  "description": "Bauxite (Debele/Balaya plateau type, 54.7 wt% Al2O3, 0.76 wt% SiO2, sourced assay) is ground\nin spent liquor with milk of lime, pre-desilicated at 373 K and digested at 418 K, where the\ngibbsite dissolves as sodium aluminate. The blow-off is flashed (the flash vapour preheats the\nslurry), the residue settles, is washed counter-currently and leaves as filter cake for dry\nstacking. The pregnant liquor is cooled and seeded; gibbsite precipitates, is classified\n(seed recycle), filtered, washed and calcined with natural gas to alumina. The spent liquor\nis evaporated, made up with caustic soda and returned to the mill: the defining recycle.\n\nAll flows are concept estimates from an independent sequential balance on assumed liquor\nratios (A/C 0.70 blow-off, 0.38 spent; caustic 250 g/L as Na2CO3), washing and cake\nparameters: no caustic aluminate speciation or gibbsite solubility is calculated.\nLime dose and electricity are IAI 2019 global averages; calciner energy is a sourced\nspecific energy (cheme process furnace refuses gibbsite). See DESIGN.md.\n",
  "design_basis": {
    "assumptions": [
      "ASSUMED low-temperature digestion at 418 K (gibbsitic bauxite; 413-423 K per ICSOBA 2024 paper AA05), 98 % of the gibbsite dissolved, diaspore/boehmite and quartz not attacked (D-004).",
      "ASSUMED liquor: spent caustic 250 g/L as Na2CO3, A/C 0.38 spent and 0.70 at blow-off, density 1.30 kg/L for every liquor (D-004, D-006).",
      "ASSUMED kaolinite fully converted to DSP carried as hydroxysodalite Na8Al6Si6O24(OH)2; all lime leaves as TCA (D-004).",
      "ASSUMED settler underflow 2.0, washer underflow 1.0 and residue cake 0.43 kg liquor/kg solids; 6 ideal CCD stages at wash ratio 1.6 (D-005).",
      "ASSUMED seed charge 250 g/L, slurries 1 kg liquor/kg hydrate, hydrate cake 8 wt% free water, hydrate wash 0.25 kg/kg; occluded soda sets the product's 0.40 % Na2O (D-006).",
      "ASSUMED heat model: liquor cp 3.35 and solids cp 1.0 kJ/kg K, 3 flash/regenerative stages with 5 K approach, 70 % of the pregnant liquor cooler duty recovered, evaporator economy 3.0 (D-007).",
      "ASSUMED calciner specific energy 2.8 GJ/t alumina LHV (ICSOBA 2017 paper AA22: about 2.72 GJ/t for gas suspension calciners), air excess 1.15 (D-008).",
      "No electrolyte thermodynamics: liquors are carried as neutral NaOH + NaAlO2 + H2O; no property package covers the streams; carbonate, oxalate, organics and other impurities are not carried (D-006)."
    ],
    "source": "process/design-basis.yaml"
  },
  "engineering": {
    "description": "Bayer alumina refinery, 3000 t/d smelter-grade alumina from gibbsitic bauxite (concept, issue ChemE-as-Code/process-library#178)",
    "name": "Alumina (Bayer process)",
    "requires": "cheme-as-code>=0.8",
    "stage": "concept",
    "stages": [
      {
        "id": "concept",
        "title": "Concept and feasibility"
      },
      {
        "id": "basic",
        "title": "Basic engineering"
      },
      {
        "id": "detail",
        "title": "Detail engineering"
      }
    ],
    "tool": "plantcode"
  },
  "facets": {
    "feedstock_basis": [
      "mineral"
    ],
    "product_classes": [
      "materials"
    ],
    "region": "generic",
    "unit_operations": [
      "reaction",
      "crystallization",
      "sedimentation",
      "filtration",
      "evaporation",
      "calcination"
    ]
  },
  "families": [
    "aluminium"
  ],
  "gap_count": 3,
  "gates": null,
  "id": "alumina-1",
  "issues": {
    "closed_count": 0,
    "list_url": "https://github.com/ChemE-as-Code/process-library/issues?q=is%3Aissue%20label%3A%22process%3Aalumina-1%22",
    "new": {
      "action": "https://github.com/ChemE-as-Code/process-library/issues/new?template=1-action-item.yml&labels=process%3Aalumina-1&process=alumina-1",
      "change": "https://github.com/ChemE-as-Code/process-library/issues/new?template=4-design-change.yml&labels=process%3Aalumina-1&process=alumina-1",
      "hold": "https://github.com/ChemE-as-Code/process-library/issues/new?template=2-engineering-hold.yml&labels=process%3Aalumina-1&process=alumina-1",
      "process": "https://github.com/ChemE-as-Code/process-library/issues/new?template=6-process-development.yml&labels=process%3Aalumina-1&process=alumina-1",
      "tq": "https://github.com/ChemE-as-Code/process-library/issues/new?template=3-technical-query.yml&labels=process%3Aalumina-1&process=alumina-1",
      "tracker": "https://github.com/ChemE-as-Code/process-library/issues/new?template=7-process-tracker.yml&labels=process%3Aalumina-1&process=alumina-1"
    },
    "open": [],
    "open_by_gate": {},
    "open_count": 0,
    "private": false,
    "repository": "ChemE-as-Code/process-library"
  },
  "keywords": [
    "alumina",
    "aluminium oxide",
    "Bayer process",
    "bauxite",
    "gibbsite",
    "digestion",
    "red mud",
    "bauxite residue",
    "precipitation",
    "calcination",
    "caustic soda",
    "sodium aluminate"
  ],
  "lca": {
    "allocation": "none",
    "backend": "factors",
    "boundary": "cradle-to-gate",
    "categories": [
      {
        "id": "climate-change",
        "method": "GWP100",
        "title": "Climate change",
        "unit": "kg CO2-eq"
      }
    ],
    "data_sources": [],
    "factors_status": "published",
    "functional_unit": {
      "amount": 1,
      "chemical": "aluminium-oxide",
      "grade": null,
      "label": "1 kg aluminium oxide",
      "product": "ALU",
      "product_name": "Aluminium oxide",
      "product_title": "Smelter-grade alumina to storage",
      "unit": "kg"
    },
    "goal": "Preliminary foreground (gate-to-gate) life cycle inventory of smelter-grade alumina by the Bayer process at the concept stage: which raw materials, utilities, emissions and wastes the balanced flowsheet implies per kg of product, ready to be linked to background datasets later. Flows are concept estimates on assumed design parameters (DESIGN.md D-003..D-008).",
    "inventory": [
      {
        "direction": "input",
        "key": "feed:BX",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 2.19335,
        "title": "Bauxite, gibbsitic (Guinea, Debele type), crushed",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:LIME",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.052,
        "title": "Quicklime",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:NAOH",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.03096,
        "title": "Caustic soda make-up, 50 wt% solution",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:PW",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.134234,
        "title": "Fresh water make-up",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:NG",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.056,
        "title": "Natural gas (calciner fuel)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:AIR",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.11017,
        "title": "Calciner combustion air",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:MPS",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.462023,
        "title": "MP steam 1000 kPa(a) to the digestion heaters (condensate returned)",
        "unit": "kWh"
      },
      {
        "direction": "input",
        "key": "feed:LPS",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.209646,
        "title": "LP steam 450 kPa(a) to the liquor heater and the evaporators (condensate returned)",
        "unit": "kWh"
      },
      {
        "direction": "input",
        "key": "feed:POWER",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.152,
        "title": "Electric power",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "product:ALU",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.0,
        "title": "Smelter-grade alumina to storage",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:RES",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.758462,
        "title": "Bauxite residue filter cake to the residue storage area (dry stacking)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:STACK",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.81826,
        "title": "Calciner flue gas to atmosphere",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:CW",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.567011,
        "title": "Cooling water return",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "emission:CO2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.153619,
        "title": "CO2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:H2O",
        "kind": "emission",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.777851,
        "title": "H2O to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:N2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.853277,
        "title": "N2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:O2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0335079,
        "title": "O2 to the environment",
        "unit": "kg"
      }
    ],
    "not_computed": [],
    "publishable": false,
    "result": {
      "classification": "partial",
      "gaps": 10,
      "label": "partial screening carbon footprint",
      "publication": "public"
    },
    "sources": [
      "lca/README.md",
      "lca/dataset.yaml",
      "lca/factors.yaml",
      "lca/gaps.csv",
      "lca/inventory.csv",
      "lca/lca.yaml",
      "lca/mappings.yaml",
      "lca/results.csv",
      "lca/results.md",
      "lca/uncertainty.csv"
    ],
    "values_withheld": "stale-run-manifest",
    "withheld_reason": "stale-run-manifest"
  },
  "lci_gaps": [
    {
      "dataset": "alumina-by-the-bayer-process-3000-t-d-smelter-grade-alumina",
      "key": "feed:BX",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "alumina-by-the-bayer-process-3000-t-d-smelter-grade-alumina",
      "key": "feed:LIME",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "alumina-by-the-bayer-process-3000-t-d-smelter-grade-alumina",
      "key": "product:RES",
      "link": "technosphere",
      "type": "output"
    }
  ],
  "maintainers": [
    {
      "name": "Artur Schweidtmann"
    }
  ],
  "maturity": "concept",
  "preliminary": true,
  "provenance": {
    "library_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "previews": {
      "sheets": [
        "BFD",
        "PFD"
      ],
      "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
      "tool": "cheme 1.6.0 (pyDEXPI 2.1.0)"
    },
    "previews_stale": false,
    "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0"
  },
  "publication": {
    "license": "CC-BY-4.0",
    "status": "public"
  },
  "references": [
    {
      "doi": "10.1016/j.heliyon.2023.e19070",
      "title": "Zainudeen, N. M. et al. (2023) A comparative review of the mineralogical and chemical composition of African major bauxite deposits. Heliyon 9, e19070 (CC BY 4.0), Tables 5 and 6 (bauxite assay and minerals)"
    },
    {
      "title": "International Aluminium Institute (2022) Life Cycle Inventory (LCI) Data and Environmental Metrics for the Primary Aluminium Industry, 2019 data: s. 3.4 (bauxite and residue per t alumina), s. 3.11.2.2 Table 4 (alumina energy mix), s. 3.11.2.3 (lime)",
      "url": "https://international-aluminium.org/resource/2019-life-cycle-inventory-lci-data-and-environmental-metrics/"
    },
    {
      "title": "ICSOBA 2017, paper AA22: Thermal Energy Consumption in Gas Suspension Calciners (abstract-level: ~2.72 GJ/t alumina NHV)",
      "url": "https://icsoba.org/assets/files/publications/2017/AA22 - Thermal Energy Consumption in Gas Suspension Calciners.pdf"
    },
    {
      "title": "ICSOBA 2024, paper AA05: Enabling Improved Waste Heat Recovery in Digestion for Energy and Carbon Footprint Reduction (abstract-level: low-temperature digestion 145-150 C; refinery energy split)",
      "url": "https://icsoba.org/assets/files/publications/2024/Papers/AA05 - Enabling Improved Waste Heat Recovery in Digestion for Energy and Carbon Footprint Reduction.pdf"
    },
    {
      "title": "International Aluminium Institute: Bayer refining process overview (operation sequence)",
      "url": "https://alustory.international-aluminium.org/mining-refining/process-refining/"
    },
    {
      "doi": "10.1002/14356007.a01_557",
      "title": "Ullmann's Encyclopedia of Industrial Chemistry: Aluminum Oxide (route reference lead; production sections not audited in this run)"
    },
    {
      "title": "Wagman, D. D. et al. (1982) The NBS tables of chemical thermodynamic properties. J. Phys. Chem. Ref. Data 11, Suppl. 2; Robie, R. A. and Hemingway, B. S. (1995) USGS Bulletin 2131 (formation enthalpies; values to be checked)"
    }
  ],
  "repository": {
    "access": "public",
    "path": "processes/alumina-1",
    "url": "https://github.com/ChemE-as-Code/process-library"
  },
  "representations": [
    {
      "bytes": 44979,
      "id": "BFD",
      "kind": "bfd",
      "preview": "artifacts/alumina-1/BFD.svg",
      "source": "process/BFD.xml",
      "status": "preview",
      "title": "Block flow diagram"
    },
    {
      "bytes": 227496,
      "id": "PFD",
      "kind": "pfd",
      "preview": "artifacts/alumina-1/PFD.svg",
      "source": "process/PFD.xml",
      "status": "preview",
      "title": "Process flow diagram"
    },
    {
      "id": "process-model",
      "kind": "process-model",
      "source": "process/flowsheet.yaml",
      "status": "viewer",
      "title": "Flowsheet and stream table"
    },
    {
      "id": "simulation",
      "kind": "simulation",
      "source": "process/simulation.yaml",
      "status": "viewer",
      "title": "Process simulation"
    },
    {
      "id": "equipment-list",
      "kind": "equipment-list",
      "source": "equipment/equipment-list.yaml",
      "status": "viewer",
      "title": "Equipment list"
    },
    {
      "id": "lca",
      "kind": "lca",
      "source": "lca/lca.yaml",
      "status": "viewer",
      "title": "Life cycle assessment"
    }
  ],
  "summary": "Smelter-grade alumina from Guinean gibbsitic bauxite by the Bayer process: low-temperature caustic digestion, red mud settling, washing and filtration, seeded gibbsite precipitation, spent liquor evaporation and gas suspension calcination; caustic and lime make-up, bauxite residue and calciner CO2 explicit. Concept stage, assumed liquor basis.",
  "title": "Alumina by the Bayer process (3000 t/d smelter-grade alumina, concept)",
  "validation": {
    "notes": "Concept BFD/PFD with closed mass, component and element balances (cheme validate, cheme process streams: 6 blocks, 19 steps, reactive balances by extents for 8 reactions). All flows and compositions are specified values of an independent balance (scripts/bayer_balance.py) on assumed design parameters; no electrolyte speciation or gibbsite solubility is calculated, and no property package covers the liquors and solids, so energy closure is not evaluable in core: the duties are a lumped script estimate. The calciner uses a sourced specific energy (gibbsite calcination is refused by cheme process furnace, core's furnace energy covers limestone only). The gate-to-gate LCI is preliminary, with every background unmapped. Not reviewed.",
    "status": "unreviewed"
  },
  "viewer": {
    "commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "dirty": false,
    "sheets": [
      "process/BFD.xml",
      "process/PFD.xml"
    ],
    "skipped": [],
    "snapshot": "snapshots/alumina-1/",
    "stale": false,
    "tool": "cheme-as-code 1.6.0",
    "views": [
      "checks",
      "streams"
    ]
  }
}