Solution Provided | Identified refinery operating limits and produced a capability roadmap for the future in relation to environmental constraints.
Disciplines | Process and Mechanical
Carnac were engaged to assess the operating limits of an alumina refinery in relation to its environmental licence restrictions. The study comprised of three (3) stages as follows:
Phase 1 – Maximum Technical Capability:
Assessed all systems of the operation to determine current operating limits and the maximum potential operating limits within the environmental licence restrictions; and
Assessed criteria including product throughput, product yield, energy efficiency, various types of emissions, water consumption, tailings production, and input bauxite ore.
Phase 2 – Constraint and Opportunity Analysis:
Identified systems that are near, or close to being constrained;
Identified systems with surplus capacity; and
Created a SysCAD model to assess the impacts of future process improvement projects on the operating envelope.
Phase 3 – Operations Capability Roadmap:
Scoped out recommended future studies; and
Engaged with key stakeholders to create a roadmap for the short- and medium-term future in relation to optimising operational output.
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’s assessment delivered the following outcomes:
Highlighted environmental factors nearing constraint;
Confirmed that the execution of planned projects will allow the operation to continue to meet its environmental licence limits;
Determined that the plant production rate can be increased whilst decreasing emissions; and
Identified which systems pose the greatest threat to meeting production and environmental targets and provided recommendations to resolve the issues.
