氧化鋁生產(chǎn)工藝的全廠物料衡算計(jì)算過程案例目錄TOC\o"1-3"\h\u29712氧化鋁生產(chǎn)工藝的全廠物料衡算計(jì)算過程案例 1174771.1氧化鋁總回收率 1298831.2原礦漿的配制 2232361.3高壓溶出 7292711.4礦漿稀釋，赤泥分離及洗滌 8324521.5精液分解和種分母液蒸發(fā) 1639671.6氫氧化鋁焙燒 19278981.7主要技術(shù)經(jīng)濟(jì)指標(biāo) 20計(jì)算的基本數(shù)據(jù)是按以鋁廠生產(chǎn)出來1t氧化鋁計(jì)1.1氧化鋁總回收率ηηA總100%—Al2A式中A水—鋁酸鈉水解失去的Al2A機(jī)—濕法系統(tǒng)中Al2O3A焙—Al2OA化—Al2OAA礦和AASA則：Aη1.2原礦漿的配制溶出過程如圖2-1：原料礦石原料礦石苛化堿液循環(huán)母液苛化堿液循環(huán)母液補(bǔ)充堿液補(bǔ)充堿液溶出液溶出溶出液溶出赤泥赤泥圖2-1溶出過程進(jìn)出物料及其含堿示意圖（1）鋁土礦質(zhì)量：QA成—純Al2OQ各組成量：Al2O3：QSiO2：QFe2O3：QTiO2：CaO：灼減CO2：QH2O：Q（2）石灰量：Q各組成含量：Al2O3：209.956×3%=6.299SiO2：209.956×2.8%=5.879Fe2O3：209.956×0.6%=1.260CaO：209.956×87%=182.662CO2：209.956×5%=10.498（3）循環(huán)母液量：設(shè)循環(huán)母液量為V循n=0.608各組分：NNNNN式中nK循—循環(huán)母液Na2MR溶—溶出液Na2Ok與Al2OMR循—循環(huán)母液Na2Ok與Al2OnK循V循—循環(huán)母液中的NanK循nK循N耗N化—反應(yīng)過程N(yùn)aN化N機(jī)—Na2O機(jī)械損失量，kg，N成—帶走的NaNA礦和A石、A化和N化—礦石和石灰中的Al2O3量、赤泥中Al20.608MR溶A礦+N轉(zhuǎn)—苛性堿被CO2反應(yīng)生成碳酸堿（Na2OC礦—礦石中COC石—石灰中CON轉(zhuǎn)N苛—返回的苛化堿中Na2ON吸—種分過程N(yùn)a2OK反應(yīng)生成Na2OmC—種分過程吸收CONC損—苛化過程中Na2OC損失量，得：N綜上得：V==7.340各組成量：Na2OK：NNa2OC：NCO2：44Al2O3：1.645×H2O：循環(huán)母液總質(zhì)量?溶質(zhì)質(zhì)量=7.340×1300?=6498.356kg補(bǔ)充堿液和苛化堿液：補(bǔ)充堿液：按NK補(bǔ)堿=體積：VNa2OK：167.304kgH2O：V苛化堿液：體積：VηNNa2OC濃度nC苛：CO2量：3.1418×CO2濃度nCO2H2O量：V=285.871kg（5）原礦漿中的溶液量：總體積：V原Na2OK量：N=1761.6+167.304+28.276?29.585=1927.595Na2OC量：N=220.2+3.142+29.585=252.927kg（6）原礦漿物料平衡表見表2-1表2-1原礦漿物料平衡(kg)項(xiàng)目AlSiOFeTiOCaONaNaCOH其他合計(jì)進(jìn)入鋁土礦1341.616251.947128.07367.1861.10010.498281.34116.7962099.557石灰6.2995.8791.260181.66210.4983.359209.957循環(huán)母液905.5731761.600220.200156.2716498.3569541.000補(bǔ)充堿液167.304376.525543.829苛化堿液28.2763.1427.887285.871325.176N-29.585→N+29.585總計(jì)2253.488257.826129.33367.186184.7621927.595251.927185.1547441.09320.15512720.519支出原礦漿2253.488257.826129.33367.186184.7621927.595251.927185.1547441.09320.15512720.5191.3高壓溶出赤泥量：Q赤泥=（S礦+F礦QS礦F礦η赤泥取灼堿全為結(jié)晶水，ηQ赤泥鋁酸鈉溶液水解損失的AlA水解產(chǎn)物Al(OH)3中的結(jié)晶水量：16.175×Q溶出液和棄赤泥的各組成量溶出液的成份量=原礦漿的成份量?赤泥的成份量棄赤泥的成分量=赤泥的成分量+水解生成的Al(OH)高壓溶出的物料平衡見表2-2

表2-2高壓溶出的物料平衡（kg）項(xiàng)目AlSiOFeTiOCuONaNaCOH其他合計(jì)進(jìn)入原礦漿2253.488257.826129.33367.186184.7621927.595251.927185.1547441.09320.15512720.519出去赤泥309.391257.826129.33367.186184.762141.804123.38020.1551233.837溶出液1944.0971785.791251.927179.4975430.5559591.867溶出礦漿自然蒸發(fā)水1993.9781993.9781.4礦漿稀釋，赤泥分離及洗滌赤泥沉降分離底流的溶液量：赤泥量：Q取赤泥沉降分離底流LSQ其中各成分量：Al2O式中ρ稀，nA稀分別為稀釋液的密度（ρ稀=1270kg/m3Na2NNa2即N所以NCO2：H2O=4404.837×520.261+474.478+62.258+44.183棄赤泥的附液量：棄赤泥的成份量=赤泥的成份量+水解生成的Al(OH)3成分量，苛化渣量的估算：進(jìn)入苛化工序的NCNa2CO含Na2CO3：63.682×106石灰乳量：Na2CO3+Ca(OH)按Ca(OH)2量為105%計(jì)算，加入Ca(OH)54.438×η所以實(shí)際參加苛化反應(yīng)的Ca(OH)39.904多余的Ca(OH)239.904?34.203=5.701又因工業(yè)石灰純度（CaO含量）為89%，所以，應(yīng)加入的Ca(OH)2石灰?guī)氲碾s質(zhì)量：22.923×石灰渣量：34.203×綜上：Q=棄赤泥量：Q棄赤泥附液量：QNT棄附損—NK棄赤附量COAl2OH2O=棄赤泥附液各組成質(zhì)量列于表2-3

表2-SEQ表格\*ARABIC3棄赤泥附液的各成分質(zhì)量成分AlNaNaCOH合計(jì)質(zhì)量/kg10.1929.2941.2200.8662606.8042628.376赤泥洗液量：為底流附液成分量減去棄赤泥附液成份量A赤洗=520.261?10.192=510.069kgH赤洗=H=696.889+赤泥洗水（kg）Al(OH)3過濾洗滌過程如圖2-2所示Al(OH)Al(OH)3Al(OH)3Al(OH)3洗液新水Al(OH)3新水新水氫氧化鋁過濾洗滌稀釋稀釋稀釋稀釋Al(OH)3Al(OH)3圖2-2氫氧化鋁過濾洗滌過程進(jìn)出物料示意圖Al(OH)3洗液為后面的分解工序返回的物料，可用試算法求其數(shù)量。下面我們用代數(shù)法計(jì)算Al(OH)3洗液量。過濾分離的Al(OH)3設(shè)Al(OH)3分離濾餅附液量為x，取Al(OH)3濾餅附液含水率為79．44%xX=1530—生產(chǎn)1tAl2O各組成量：NKAH分餅附xnK種母NCAH分餅附xρ式中nC種母—種分母液的NaAlCOH2O=171.333?=135.508Al(OH)3洗液含水率：Al(OH)3洗滌用水量QAH洗水=1000kgQAl(OH)3Q洗滌Al(OH)3濾餅的附液量設(shè)洗滌Al(OH)3濾餅的附液量為y，已定洗滌Al(OH)3濾餅的含水率為96.94%y所以y=各組分量：NK:所以NNC：Al2OCO2：H2O洗滌平衡見表2-4。表2-4氫氧化鋁洗滌的物料平衡(kg)項(xiàng)目AlNaNaCOH合計(jì)進(jìn)入Al(OH)310.46720.3621.9221.074135.508171.333項(xiàng)目10001000合計(jì)10.46720.3621.9221.0741135.5081171.333出去Al(OH)31.2281.3920.3430.243133.415137.621Al(OH)39.23917.9701.5791.8311001.0931033.712合計(jì)10.46720.3621.9221.0741135.5081171.333AlAlOHAlOHAH赤泥洗液A赤泥洗液AH溶出液AH水解生成AlOH3A水解生成AlAH稀釋液AH稀釋圖2-3礦漿稀釋過程中的進(jìn)出溶液及其Al2赤泥洗液的含水量：稀釋液中各組成量：ANNCO稀釋液量：QnA稀——Al2Oρ稀——密度，1260g/L稀釋液中的水量=Q==15462.517由平衡關(guān)系得：H洗液含水量：H=15462.517+8.563?5430.553?1002.093=9038.434(kg)分離過程的粗液量：Q粗液體積：VρAl2ONa2ONa2OCO2：H216315.008?(1926.969+1794.467+254.286+180.462)=12158.824礦漿稀釋平衡見表2-5。表2-5溶出礦漿稀釋的物料平衡（kg）項(xiàng)目AlNaNaCOH合計(jì)進(jìn)入溶出液1944.0971785.791251.927179.4975430.5539591.865赤泥洗液510.069465.18461.03843.3179038.43410118.042Al(OH)9.23917.9701.5791.8311001.0931033.712合計(jì)2463.4052268.945316.544224.64515471.08020744.619出去Al16.1758.56324.738稀釋液2447.2302268.945316.544224.64515461.51720719.881合計(jì)2463.4052268.945316.544224.64515471.08020744.619（6）赤泥洗水量：赤泥分離底液附液H赤泥分離底液附液H赤泥洗水H赤泥洗水H溶出礦漿自蒸發(fā)水H棄赤泥附液H棄赤附棄赤泥附液H赤泥洗液H赤泥洗滌圖2-4赤泥洗滌過程中的進(jìn)出液體物料及其含水量示意圖由平衡關(guān)系得：HH=2606.804+9038.434?3303.693?1993.978=6347.567（7）赤泥分離平衡見表2-6。表2-6赤泥分離的物料平衡（kg）項(xiàng)目AlNaNaCOH合計(jì)進(jìn)入稀釋液2447.2302268.945316.544224.64515461.51720719.881出去赤泥分離底流附液520.261474.47861.25844.1833303.6934404.873精液1926.9691794.467254.286180.46212158.82416315.008合計(jì)2447.2302268.945316.544224.64515461.51720719.881（8）赤泥洗滌平衡見表2-7。表2-7赤泥洗滌的物料平衡（kg）項(xiàng)目AlNaNaCOH合計(jì)進(jìn)入赤泥分離底流附液520.261474.47861.25844.1833303.6934404.873赤泥洗水6347.5676347.567溶出礦漿自蒸發(fā)水1993.9781993.978總計(jì)520.261474.47861.25844.18311645.23812746.418出去棄赤泥附液10.1929.2941.2200.8662606.8042628.376赤泥洗液510.069465.18461.03843.3179038.43410118.042總計(jì)520.261474.47861.25844.18311645.23812746.4181.5精液分解和種分母液蒸發(fā)Al2O3根據(jù)氧化鋁生產(chǎn)工藝全過程的Al2OA所以=1341.616+6.299?309.391?16.175?10.192?(11341.616+6.299)×1.2%?986.000=9.982其中A機(jī)損——生產(chǎn)1t氧化鋁在濕法工藝系統(tǒng)因物料跑冒滴漏而損失的A焙——生產(chǎn)1t氧化鋁在焙燒過程損失的A成——每1t成品氧化鋁中具有的而N=20?(9.294+1.220)=9.486NNN=1.177+1.220+0.343=2.740(kg)已知NC總損=3kg，少0.260kg。相差0.260/3=8.67%>1%，為使NNNAH分解析出的精液種分析出的Al(OH)3中AlA析出的Al(OH)3H所以析出的Al(OH)3Q已知種分過程吸收CO2為1.5kg，由此使精液中的N種分過程溶液的自蒸發(fā)水量：H種分母液中的水量：H=12158.824?(547.147+530.780+135.508+62.985)=10882.404種分母液蒸發(fā)水量：由平衡關(guān)系計(jì)算蒸發(fā)水量應(yīng)為：H=4374.804(kg)HNC結(jié)晶—析出精液分解的物料平衡見表2-8。

表2-8精液分解的物料平衡（kg）項(xiàng)目AlNaNaCOH合計(jì)進(jìn)入精液1926.9691794.467254.286180.46212158.82416315.008出去機(jī)械損失9.9828.0491.4371.02061.98583.473種分自蒸發(fā)、吸收CO-1.619+1.619+1.200547.147548.347析出Al(OH)1001.584530.7801553.887Al(OH)310.46720.3621.9221.074135.508171.333赤泥洗液903.9361766.056249.927177.36810881.40413959.168總計(jì)1926.9691794.467254.286180.46212158.82416315.008種分母液蒸發(fā)的物料平衡見表2-9。表2-9種分母液蒸發(fā)的物料平衡（kg）項(xiàng)目AlNaNaCOH合計(jì)進(jìn)入種分母液890.5491766.056249.927177.36810881.40413959.168出去蒸發(fā)水4367.7004367.700析出Na31.84021.5969.24463.680循環(huán)母液890.5491766.056218.087154.7726498.3569527.788總計(jì)890.5491766.056249.927177.36810881.40413959.1681.6氫氧化鋁焙燒（1）已知（2）得到的氧化鋁成品分為：1000=其他雜質(zhì)量：QANNQ取QAl(OH)3表2-10Al(項(xiàng)目AlNaNaCOH其他合計(jì)進(jìn)入Al(OH)1001.584530.7809.6261541.990Al(OH)31.2301.3920.3430.243133.413137.621總計(jì)1003.8141.3920.3430.243664.1939.6261680.611出去焙燒損失16.1750.243664.193680.661成品Al987.6391.3920.3439.6261000.000總計(jì)1003.8141.3920.3430.243664.1939.6261680.611N1.7主要技術(shù)經(jīng)濟(jì)指標(biāo)總回收率：73.15%堿耗：折算成NaOH212.308kg蒸發(fā)水：4