ActionLaser’s Solution for Alcoa’s Alumina Refineries

Improving productivity and safety, while reducing operating cost, injuries and downtime

Mineral processing is an extensive multi-activity process of separating commercially valuable minerals from their orebodies. ActionLaser has been reviewed and selected for use by companies such as BHP, Rio Tinto and Alcoa and other miners for processing of minerals such as Nickel, Uranium, Iron Ore and Bauxite.

Alcoa, a global leader in integrated bauxite mining, alumina refining, and aluminium smelting, operates across various sectors within the metals industry. Among its assets, the Pinjarra and Wagerup refineries in Western Australia stand out for their efficiency and technological advancement.

The Problem: Alcoa faced a recurring challenge with its large-volume continuous pan filters, crucial in the alumina refining process. These filters traditionally utilised cloth filtration screens, requiring frequent replacement due to short lifespans of a few weeks. This not only incurred high maintenance and downtime costs, but also posed safety risks, particularly back and hand injuries, during replacement procedures.

The Brief: In 1998, Alcoa sought ActionLaser’s expertise to develop a durable alternative to the traditional cloth filtration materials. The aim was to enhance efficiency, reduce maintenance costs, and mitigate safety hazards associated with frequent cloth replacements.

The Process: Collaboration between Alcoa and ActionLaser spanned four years from initial contact to successful implementation. ActionLaser devised laser drilled shim panels to replace cloth filtration screens. These panels featured a robust “sandwich” construction to endure the high-pressure blowback stage of the pan filter rotation sequence. Furthermore, they were designed to accommodate various pan filter sizes, ensuring versatility across Alcoa’s refineries.

The Solution: Since the initial installation of the laser-drilled stainless-steel panels in 2002, Alcoa has converted 15 pan filters across their Pinjarra and Wagerup refineries, with ongoing conversions. The success of this solution lies in the co-operation between Alcoa’s industry expertise and ActionLaser’s innovative approach. By leveraging laser technology and durable materials, the conversion program not only addressed the issue of short filter material lifespan but also enhanced productivity and safety within the refineries.

Outcome and Benefits: The transition from cloth filters to ActionLaser’s stainless steel panels resulted in a significant improvement in maintenance efficiency and safety. The lifespan of the new panels extended to an estimated 5 to 6 years, compared to the 6-8 weeks of cloth filters. This dramatic increase in durability translated into substantial cost savings for Alcoa, stemming from reduced maintenance, downtime, and injury-related expenses. Moreover, the implementation of the laser-drilled stainless-steel screens facilitated longer run times between routine caustic washes required for filter descaling, further boosting productivity.

Conclusion: The collaboration between Alcoa and ActionLaser exemplifies the power of innovation and strategic partnership in addressing industry challenges. By combining their expertise, the two companies solved a longstanding issue in alumina refining and set a benchmark for sustainable and efficient solutions in the metals industry. The success of this project underscores the value of continuous improvement and collaboration in achieving operational excellence – 25 years on ActionLaser remains a supplier to Alcoa.

For further information, or to discuss your business needs contact:
W: www.actionlaser.com
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