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FELT FILTER SYSTEM /DRY SCRUBBING SYSTEM (D.S.S.)/FUME TREATEMENT SYSTEM(F.T.P.) Need for D.S.S./F.T.P.

During the electrolysis process for producing aluminium, the alumina(Al2O3) liberates oxygen and the metal (Al)is produced. The electrolysis process takes place in an electrolytic bath consisiting of Aluminum fluoride and some other chemicals. During this process hazardous gases are emitted (mainly consisting of Hydrogen fluoride and other fluorides). To prevent these gases to escape into the atmosphere, it is mandatory to install F.T.P. Since fumes are treated by adsorption of fluorides gases onto dry alumina, hence the system is called Dry Scrubbing System. The F.T.P. treats exhaust gas from Aluminum reduction cells by dry scrubbing process, followed by bag filter(felt filter) collection of fluoride enriched alumina. F.T.P. reduces the emission of the HF gas and the dust particulate into the atmosphere. PROCESS DESCRIPTION The process of the F.T.P. is divided into following main sections : Gas ducting, fan and Stack System Reactor and Bag Filter System(felt filter system) Alumina Handling System All this is backed up by Instrumentation and Electrical system Gas Ducting, Fan and Stack System : The gases from pots are sucked into the ducts fabricated of steel by fans (3 No. fans are installed, two remain in operation and one stand by).The ductwork leads gases from each pot into the reactor and bag filter/felt filter compartments. The cleaned gas leaves the felt filter through the outlet plenum leading to the outlet duct, exhaust fan and stack. Reactor and Bag Filter System(felt filter system) The bag filter system /felt filter system consists of reactor, bag filters and outlet plenum. The gas enters the bag filter unit at the bottom of the reactor where primary/fresh alumina is injected. The velocity in the reactor is designed to obtain adsorption of HF on the alumina particulate. The bags are suspended from a horizontal tube sheet , which divide the filter compartment into the raw gas side (housing, reactor, hopper) and the clean gas side ( filter top). Primary alumina injected into the reactors rises and accumulates on bags. This necessitates bag cleaning. The cleaning of the bags is accomplished by a pulse jet technique whereby a medium pressure pulse of air is introduced into the open top of each filter bag through nozzle. Alumina and dust having accumulated on the outside of the bags is dislodged and collected in the hopper below. ALUMINA HANDLING SYSTEM The primary alumina is fed to each FTP from the existing belt conveyors through a diverter valve leading the alumina into air slides (2 air slides / one standby) for filling of the primary alumina silo. An emergency air lift is also provided for filling the primary silo when alumina supply from conveyor belts is stopped due to breakdown or shutdown. Stoppage of alumina supply can lead to F.T.P. stoppage. F.T.P. in potlines II,VI and VIII was also modified to take care of required

alumina storage capacity . This modification facilitates continous operation of F.T.P.(during alumina supply interruptions) and Potrooms. Primary alumina handling : The primary alumina silo is equipped with two manually operated discharge valve , one ( bypass) leading directly to the distribution box , the other feeding air slide to a feed box with loss- of weight control system. From the feed box, the primary alumina is fed into the reactors through airslide. Alumina Injection and Recirculation : Adsorption of fluorides takes place after the primary alumina has been injected into the raw gas in the reactor. The fluorinated alumina (called secondary alumina) dust is then collected by filter bags and settles in the filter hoppers. Screw conveyors for Recirculation of secondary alumina are installed at the lowest point of each hopper and rate of recirculation is controlled by varying the speed of the screw conveyor. Recirculation helps in increasing adsorption to the capacity. Secondary Alumina Handling: After alumina is pulsed from bag surface by pulse jet, it falls into the hopper. This alumna is recirculated back by Screw Conveyors and overflow alumina is transported by airslides to the airlifts. Airlifts transfer the enriched alumina through vibrating screen into the enriched alumina storage silo. From this silo alumina is supplied to the pot rooms as per their requirement.