Zhongzhou Enterprise Silicon Slag Sinter Alumina Recovery Project Successful

According to the Zhongzhou Branch of China Aluminum Corporation, a recent final acceptance inspection was conducted by the expert group from the Ministry of Science and Technology of the corporation on the industrial pilot project for recycling alumina slag and alkali. This project focused on the sintering process of silicon slag at the branch. The expert panel confirmed that the industrial trial of silicon slag sintering at Zhongzhou reached the designed capacity of 30m³/h. The dissolution rate of alumina standard ranged between 75% and 85%, while the dissolution rate of sodium oxide was between 83% and 93%. Once production meets these standards, the process can be scaled up for full industrial application. This project represents the largest R&D investment since the establishment of China Aluminum Corporation and marks a major success in the development of the silicon slag sintering technology for recovering alumina and alkali. It is considered an innovative advancement following the company’s improvements in sintering methods, Bayer process, and post-enrichment techniques. Earlier, the China Nonferrous Metals Industry Association recognized this technology as world-leading, with its successful industrialization expected to significantly reduce the ore grade required for sintering and expand its application range. Over 90% of the alumina in silicon slag can now be recycled, maximizing resource utilization and improving thermal efficiency and production capacity of the kiln. Traditionally, silicon slag was reintroduced into the production process for batching and sintering, but the high silicon content made it difficult to control production indices. The new circular economy approach not only enhances resource use but also reduces energy consumption. Through continuous innovation, the Zhongzhou team developed an independent sintering technology that separates silicon slag after sintering, producing high-quality alumina and recycling sodium oxide efficiently. To implement this groundbreaking process, the Zhongzhou Branch conducted extensive preparations, including detailed test runs, multiple plan discussions, and comprehensive documentation. A dedicated team of engineers worked through several iterations to finalize the "Slag Sintering Test Project." Regular meetings were held to address challenges and ensure smooth execution. Technicians were deployed throughout the process, providing real-time support and resolving issues promptly. By July 2007, the plant had completed three shutdowns and over 40 improvements, such as optimizing the calciner cone, hot air pipes, fluidized bed, burner nozzles, and soot blowers. Nozzle life was extended fourfold through on-site modifications. By late October 2007, the furnace unloading volume reached the design capacity of 30m³/h. In February 2008, the operation rate of the silicon slag furnace reached 96%, with stable discharge at 31.43m³/h. The highest average throughput reached 34m³/h, exceeding the design capacity by 10%. Dissolution rates of alumina and sodium oxide exceeded design targets, reaching 87.74% and 91.74%, respectively. As output and operational efficiency increased, the advantages of the atomization and drying cycle sintering technology became more evident. Despite a decline in the A/S ratio of incoming ore, the system remained highly efficient and stable. The aluminum-to-silicon ratio dropped from around 7.2 to 6.0, saving 14,000 tons of high-aluminum ore annually and reducing monthly ore costs by over 700,000 yuan. Thermal equilibrium measurements showed the furnace's thermal efficiency reached 80.95%, 20% higher than traditional kilns. By separately firing and dissolving sintered silicon slag, the process maximizes recovery of alumina and alkali, increasing annual alumina output by 70,000 tons and returning about 60,000 tons of alkali to the production cycle.

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