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Wednesday, May 20, 2020

Aluminium Smeltering

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Most people take many things around them for granted. They get up in the morning, turn on the light, open their can of peaches then eat the peaches with a spoon. The light goes on magically, the peaches are still fresh in their can to no surprise and it takes little to no effort to lift the light spoon to the mouth. All these things happen or are there thanks to Aluminium. Amazingly enough, aluminium does not magically appear and to be produced lots of raw materials, chemical reactions, money and time are needed.


The process in which aluminium is made involves three complex steps; the mining of bauxite, the refining of aluminia and the smeltering of aluminium.


The first step, mining Bauxite, is planned five years in advance so the areas that are to be mined can be developed. Once mined the Bauxite has to be processed before being shipped to the refineries. In a beneficication plant, fine particles are removed from the Bauxite by screening and washing it. It is then placed on stockpiles before being shipped away.


In the second step aluminium oxide, which is Alumina, is removed from the Bauxite using the Bayer Refining Process. Firstly the bauxite is ground up into fine particles and is mixed with hot, caustic soda (NaOH) solution to dissolve the alumina and some forms of silica. Not dissolved in this process are other elements such as silica, iron and titanium. These are then filtered off.


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The alumina and caustic soda solution is then put into rows of thickener tanks. In the tanks a fine red mud sinks to the bottom as well as the silica, iron and titanium. Remaining alumina trihydrate is then filtered to clean it even more. The solution is then cooled, concentrated and stirred in open top tanks until pure alumina tyhydrate crystals form. To speed up the process pure alumina is added to the mixture to act as a growth site for the crystals. This process can take several days. The alumina trihydrate crystals are then washed and filtered before being heated to 1100 C in kilns, to remove the water molecules. A fine dry powder, alumina is formed, which is then cooled down and stored.


The third step in the process of manufacturing aluminium is smeltering, which is the part of the process, which is done at Tiwai Point in New Zealand at the Comalco Smelter.


To produce aluminium the Aluminium and Oxygen in the Alumina need to be separated. For this reaction to take place the alumina is put into a large, steel furnace, lined with carbon (cathode). These furnaces are known as reduction cells. In the cells the alumina is dissolved in molten cryolite, (NaAl ), which also conducts electricity at approximately 70 C. Electricity is then put into the cells through anodes which are carbon blocks made by smelters. An electric current of about 170 000 amperes is passed through all the cells and the temperature stays at nearly 1000 C. The current flows from the anode, through the alumina/cryolite mixture, the cathode lining and to the anodes in the next cell. The current causes the carbon anode to react with the alumina, forming aluminium and carbon dioxide. The aluminium sinks to the bottom of the cell and sticks to the carbon cathode. It is then siphoned out in a process called tapping and then put in holding furnaces to be cast into products such as pure aluminium or into aluminium alloys.


CROSS SECTION OF POT OF ELECTRIC FURNACE


The diagram below shows a cross section of one of the reduction cells.


It is evident that this process requires many raw materials, which are obtained from many different places from all over the world.


The raw materials required to produce the alumina are Bauxite, Caustic soda, lime, water and electricity. Bauxite, which is ore formed from weathered sedimentary rocks, which contain a large percentage of minerals containing aluminium. The Bauxite is mined in Weipa, on the Cape York Peninsula, Northern Queensland. Here the Bauxite is small, red pebbles or piscolites, approximately 5mm in diameter.


The caustic soda, which is used in the Bayer Process is obtained from the United States, the Middle East and Asia and the electricity, coal, lime and water are found locally. In the refining of the alumina and smeltering of aluminium the raw materials needed are Alumina, Alaska crude oil, coke, pitch cryolite and electricity. The pure Alumina is obtained from Queensland. The crude oil from America and Coal from China and Korea are used to make the coke and pitch required to make the anodes. The Cryolite used to dissolve the alumina is synthetically produces and electricity used for the reduction of alumina to Al is sourced from Lake Manapouri in Fiordland.


During the process a number of chemical reactions take place to transform the raw materials into other things such as Alumina then aluminium.


The key chemical reactions that take place are the dissolving of crushed bauxite in caustic soda, the filtering of Al(OH) then the decomposition . Also the two parallel reactions in which Aluminium is formed.


The filtering of the iron oxide, titania and silica are filtered off using the equations


·Al O + 6NaOH + H O - Na Al(OH)and


·SiO + 4NaOH - Na SiO4 + H O


The insoluble Fe O is insoluble and is filtered out.


Na Al(OH) decomposes into Al(OH) over time which is insoluble and is filtered out.


·Na Al(OH) + H O - NaOH + Al(OH) H O


Decomposed under extreme temperatures to produce alumina.


·Al(OH) HO - Al O + H O


Aluminium is produced using these two parallel reactions.


·Al O + C - Al + CO


·Al O + C - 4Al +CO


The process in which aluminium is made is the same in smelters around the world, although the scrubbing system, which is used at the New Zealand smelter, is currently the best one in the world.


Various waste materials are also produced during the process and they are dealt with in different ways.


In the second step of the process of manufacturing aluminium, during clarification, a red mud is formed which is a waste product. It is washed with water then put into ponds called tailings dams. Also in the process of smeltering the aluminium, carbon anodes, which are used, are recycled by being reformed and used again. Offgasses from the reduction step are cleaned to remove contaminants and are then released into the atmosphere. Primary aluminium, itself, is also recycled by being melted down and forming new products.


Aluminium is a very light and durable metal, which is a very good conductor of heat and electricity. It is easily shaped through moulding and extruding. Its main advantages are that compared with other metals it has a low density and it forms an oxide layer, which prevents it from reacting with oxygen in the air so a surface protection coating is not necessary. Therefore because of its many beneficial characteristics, aluminium is used for many things including uses in the transport, construction, packaging and electrical industries. Aluminium is used in the transport industry because of its lightness, which enables more metal to be used. In the packaging industry it is used for cans and tops, foil, drink cartons and as packaging for pharmaceuticals. It is used for electrical conductors, heat exchangers and cooking utensils as well as roofing and wall cladding. . Aluminium is also made into alloys, which improve its properties. Many alloys are lighter and corrosion resistant.


The aluminium, which is produced at the smelter, is a very economical and environmentally friendly product. It is easily recycled, by being melted and casted into new products, without loosing any of its properties, which means it is very economical. The recycled or secondary aluminium only uses five per cent of the energy used to produce the primary aluminium from Bauxite. Alumimium cans are one of the most important products made by secondary aluminium. Also because of aluminiums light, strong and pliable characteristics it is easily transported and requires less energy to manufacture it into products. This means significant energy cost savings for the industry. When costs of production decrease, supply increases (a little economic theory) and therefore more aluminium products are produced. Another environmental benefit is that lighter cars can be produced from aluminium, which consume less fuel and put out less pollution into the atmosphere.


To produce aluminium a lot people, time, money, raw materials and equipment are needed. In 17 the Tiwai smelter produced approximately 08,000 tonnes of aluminium. The smelter gets shipped over 750,000 tonnes of raw materials to a special wharf opposite Bluff Harbour. More than 700 megawatts of electricity is used at the smelter, which is 5% of New Zealands total generating capacity. There are 00 employees working at the smelter. 660 reduction cells are continuously operating with some 48 cells using technology. The technology is the most efficient in the world.


From all the information above it is clear that aluminium is made in a very complex process involving many peoples’ time and the efficiency of machinery.


Next time you get up in the morning, turn on your light and eat your can of peaches, remember that the electricity for your light is passing through aluminium wires, your peaches are sitting in one of the most important aluminium products and your spoon is probably light thanks to an alloy of aluminium.


REFERENCES


·VIII-Metals-D-Aluminium Production


·www.comalco.com.au


·Beginning Chemistry- Anne wignall & Terry Wales


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Tuesday, May 19, 2020

Managers Qualities

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Link http//www.todolatino.com/development/article11.htm


I recently attended the Society of Hispanic Professional Engineers national conference in Washington DC. I had a great time seeing all of my friends, who like me, seem to be getting older. At the conference I remember talking to a younger person and I noticed that I kept repeating the same thing to him over and over again. The reason I was repeating myself was that he wasnt getting what I was trying to tell him. In exasperation I finally said to him Listen, I hate to sound like a broken record but... he looked at me with a puzzled look and said, Whats a broken record?


Im skilled at communication. I watch body language; I look for hidden meaning in the message and all of the stuff that communication experts suggest you do. Why then wasnt I effectively communicating? After several minutes of just looking at him, I realized that this person grew up listening to CDs and had no idea what a broken record sounded like or why I used that phase to make a point. This person was probably a college freshman who, by my calculations, was born somewhere around 181.


Todays college freshmen share a perspective of the world thats much different from the perspective many of us more mature (older) individuals have. The same is true for todays graduating seniors many who are entering the workforce for the first time. They have a different point of view than most of the managers and supervisors charged with overseeing their work. How different is that point of view or perspective? And how does it complicate communications in the workplace?Cheap custom writing service can write essays on Managers Qualities


According to a list making the rounds on the Internet, people who started college last fall feel the same way about Kennedys assassination as Lincolns. Youve probably have seen it. The list originated at Beloit College in Wisconsin by a group of college professors who compared notes on the incoming freshman class. Says Ron Nief, director of public affairs, Id refer to Walter Cronkite, and the kids looked at me like they didnt know who I was talking about. This prompted Nief and his colleagues to put together a list that puts things into perspective. Heres a short sampling of this years list


The People who started college last fall across the nation were born in 181.


•They have no meaningful recollection of the Reagan era and probably did not know he had ever been shot.


•There has only been one Pope (and the Pope has always been Polish!)


•They were 11 when the Soviet Union broke apart and dont even remember the Cold War.


•They have never feared nuclear war.


•They are too young to remember the space shuttle blowing up.


•Tianamen Square means nothing to them.


•Their lifetime has always included Aids.


•Bottle caps have always been screw off and plastic.


•They have never owned a record player.


•They have always had an answering machine.


•They cannot fathom not having a remote control.


•They have always had cable.


•Jay Leno Has always been on the Tonight Show.


•The Vietnam War is an ancient history to them as WWI, WWII and the Civil War.


•They dont have a clue how to use a typewriter.


All though the list was compiled for fun I believe it can be used as tool to help us better understand the significance of ones Frame of Reference. Our experience with the world provides us with a unique perspective causing us to see certain things in given situations. People who work in organizations can probably site the frequent occurrence of misunderstandings in the workplace. Different parties interpret the same facts quite differently such that each comes to a different conclusion.


You cant live your life without adding meaning or drawing conclusions. It would be an inefficient tedious way to live but, you can improve your communications by


1.Becoming more aware of how your frame of reference influences your thinking and reasoning.


.Making your thinking and reasoning more visible to others.


.Inquiring into others thinking and reasoning with an open mind.


Hey, I have an idea. Someone should compile a list for us older folks. Ill start. Do you know what LSMFT stands for? If you answered yes, do you feel OLD YET?


Further Reading


Masterful Coaching Extraordinary Results by Impacting People and the Way They Think and Work Together


The Platinum Rule Discover the Four Basic Business Personalities - And How They Can Lead You to Success


The Art of Speedreading People How to Size People Up and Speak Their Language


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Monday, May 18, 2020

Leaders

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Leadership


One of the behavioral skills of an effective leader is being able to work effectively with other. I have good communication skills, good listening skills, and good motivational skills. It is essential for a leader to be able to interview, plan, and coordinate. Leaders with good communication skills can communicate orally, through writing, and electronic means. Some technical skills may be required to be an effective leader. The leader must have the ability to perform any particular task. It also helps a leader if they have the ability to think abstractly.


A leader must have confidence in themselves before they decide to lead a group of others. It also helps if they have self-awareness. It is important to know about yourself in order to be an effective leader. Enthusiasm helps leaders get their group motivated. Initiative will help a leader work towards their goals. It is important for a leader to be assertive and decisive in order to decide on and reach a goal.


It is important to treat people in your group with fairness and respect. A positive leader attempts to explain why a job is to be done other than just push a person to do the job. Help with essay on leaders


Active Listening is another effective part of communication. Listening to what others are saying will help in getting a better understanding of the situation and the person. Acknowledging and respecting the other persons point of view is important in positive communication. Not everyone in the family communicates in the same manner. Family members must take into consideration the ages and maturity of the person. Proper interpretation of nonverbal behavior can assist in avoiding misunderstandings. Effective communication is primarily positive


Comments


"And communication is the primary way we satisfy our social needs. In fact, some social scientists have argued that communication is the principal way by which relationships are created." (Looking Out Looking In, Page 6). This statement supports Kathleens views towards family communication. Effective communication will form positive lasting relationships. Communication helps us grow and satisfy our needs.


"More Americans believe that communication problems very frequently cause


a marriage or a relationship to end than attribute relationship problems to money, relatives or in-laws, sex previous relationships ( percent, or children (7 percent)" ( Looking Out Looking In, Page 7). The main problem that relationships are severed is because of poor communication. We must keep our communication positive in relationships. Better communication and positive relationships will raise you self-esteem. Positive relationships will allow you to live a longer happier life.


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