Alumina in the southwest of Western Australia is processed from bauxite, which is found in abundance in the region. Alumina is usually exported to aluminium smelters but it can be used as a raw material as a filler for cosmetics and toothpaste. Carnac possesses extensive technical capabilities in engineering services catered to the alumina processing industry from concept to operations support. Our team is well-versed in Bayer process design and modelling, having gained their expertise in alumina refinery works nationally and globally.
Relevant Projects
Carnac identified a high-value Greenhouse Gas (GHG) reduction opportunity for an alumina refinery. Carnac were subsequently engaged to complete a Pre-Concept Study for technical validation of the opportunity.
Carnac were engaged to assess the operating limits of an alumina refinery in relation to its environmental licence restrictions.
Carnac’s assessment was successful in providing the client with a go-forward strategy to improve the operation’s return on investment whilst ensuring environmental limits are adhered to.
Carnac identified several cost reduction opportunities for an alumina refinery via the completion of a Maximum Technical Capability Assessment (debottlenecking study). Carnac further developed the opportunities at a concept level and selected which opportunity to take forward for a prefeasibility study.
Carnac undertook a debottlenecking study and provided plant improvement recommendations for an existing Tailings Liquor Treatment Plant at an Alumina Refinery.
Carnac undertook an options assessment for the logistics, supply, and handling of a tailings liquor treatment reagent for an Alumina Refinery.
Carnac performed a Concept Study to understand the impact of future bauxite ore variations at an alumina refinery. Carnac assessed the impact on both current and future operations (following planned plant upgrades).
Carnac identified several high-value opportunities for an alumina refinery that would help the client gain a competitive advantage in the alumina market. One opportunity identified involved recovering reagent from a spent liquor stream. The opportunity was developed by Carnac from a concept to feasibility study level.
Carnac Project Delivery Services (Carnac) was engaged by the client to conduct an assessment of the current High Pressure Purge (HPP) condensate systems and provide recommendations for future improvements.
Carnac were engaged by the client to identify, plan and resolve issues with the client's Calciners and to ensure future production is met and achieved sustainably.
Due to an inability to meet duty flow rates for an alumina hydrate conveyor system in an alumina refinery, Carnac was engaged to investigate the drum filters, transfer chutes, conveyors, and conveyor head chutes and develop options for resolving the capacity issues.
Carnac provided engineering services to investigate the live steam condensate system and whether a business case exists to re-commission the recovery systems.
Carnac provided engineering services to investigate opportunities to reduce Green House Gas emission.
Carnac provided engineering services to investigate the use and capacity requirements of Biomass as a fuel source in a Multi-Fuel-Cogeneration (MFC) power station.
Carnac – Project Delivery Services Pty (Carnac) were engaged to perform a pipe stress analysis on a pump discharge pipe network at a client’s mineral processing plant.
Carnac Project Delivery Services (Carnac) was engaged by the client to carry out a PFS on the security of the water sources at the client's site.
Carnac provided engineering services to investigate observed vibrations across evaporation and crystallisation systems.
Carnac provided engineering services to assess the take-up tensions for hydrate conveyors that had been experiencing tripping on under speed.
Carnac provided engineering services to investigate the failures of the motor and couplings of a hydrate conveyor.
Carnac provided engineering services to design a maintenance platform to simplify the maintenance process.
Carnac provided engineering services to develop a solution to prevent water ingress in the drying circuit of an Alumina Refinery.
Carnac provided engineering services to review the management of the critical risk of a calciner gas explosion.
Carnac provided engineering services to aid an Alumina Refinery had with CUI issues, specifically in new pipe lines.
Carnac provided engineering services to develop a chute to collect leaking material.
Carnac provided engineering services to assess design options to remove the process flow constraint of the digestion facility relief system.
Carnac provided engineering services to investigate a dedicated operational scenario within the MS Hydraulic Model.
Carnac provided services to identify the root cause of bauxite liquefaction, outline material, administrative and other controls to mitigate, avoid and remove risk of product liquefaction and assess capacity one existing chutes.
Carnac provided engineering services to an Alumina Refinery for the redesign of the Flash Vessel PSV blowdown line.
Carnac provided engineering services to our client who were experiencing and increase in the amplitudes of vibrations in the bearing of a fan motor.
Carnac provided engineering services to complete a review of the operability of a pan filter vacuum pump.
Carnac conducted a concept level validation of 5 opportunities to reduce GHG emissions in an Alumina Refinery by making energy improvements. Of the opportunities reviewed, three were identified for a Pre-Feasibility Study.