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August 10, 2007
Joint work between Alcoa and UFSCar receives a prize at the recent ABAL congress
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An increase in the availability of calcinating ovens, used in the production of alumina, is guaranteed by a new joint development between Alcoa and UFSCar (Federal University of São Carlos)
The work entitled, “The characterization of sprayable refractory concrete for facing alumina calcinators” won a prize from the Brazilian Aluminum Association (ABAL) at its recent congress. The increase in operational availability of the calcinating ovens in Alcoa’s unit in Poços de Caldas (MG) was guaranteed by applying refractory materials using a new spray technique called “ShotCreting”, a suspension application, where the component ingredients of the refractories are sprayed directly onto the internal walls of the vessel, with the help of compressed air equipment.
The development consisted in establishing a custom-built technical specification to suit Alcoa’s requirements and following a strict supplier qualification process, in association with UFSCar (Federal University of São Carlos).
“In addition to meeting the requirements of this particular Alcoa application, the material developed also allowed for an increase in the operational availability because of the seven day reduction in necessary maintenance time”, explains Jorge Gallo, Alcoa’s Superintendent of the Special Products’ Applications, Development and Sales Department and coordinator of the Alcoa-UFSCar agreement.
“The key to the success of this work was its technical and scientific basis, which was provided by the partnership that Alcoa has had for 17 years with GEMM, UFSCar’s Materials’ Engineering and Microstructure Group and the good relationships that existed in the multidisciplinary team that was involved with the work (see below)”, the Superintendent considers.
“The “ShotCreting” application needed a lot of prior logistics, assembly and equipment adjustment work that was compensated for by the excellent results we achieved. Another advantage that this technique offers is a very small loss of rebound material (around 4%) when compared to other spray techniques that exist in the market. We have concluded that this system will bring us more benefits in the future”, concludes Claudia Brandt, Maintenance Engineer at Alcoa’s Refinery in Poços de Caldas.
“Applying refractory materials by spraying in the calcinators at Poços brought about a paradigm shift. For years it was thought that this was impossible because of the internal reduced dimensions of the plant equipment”, concludes Daniel Lopes, Superintendent of the Calcination Area at the Poços Refinery.
Members of the winning team
Fernando Valenzuela (studying for a Masters degree in the Materials’ Engineering and Microstructure Group at the Federal University of São Carlos (UFSCar);
Cláudia Brandt (Maintenance Engineer at the Poços Refinery and studying for a Masters degree, from the Alcoa-UFSCar Agreement);
Paschoal Bonadia (engineer from the Special Products’ Applications, Development and Sales Area of Alcoa’s Primary Products Commercial Division);
Daniel Lopes (Superintendent in the Calcination and Precipitation Area at Alcoa’s Refinery in Poços);
Professor Victor Pandolfelli (scientific tutor and coordinator of UFSCar’s Materials’ Engineering and Microstructure Group);
Jorge Gallo (Superintendent of the Special Products’ Applications, Development and Sales Area of the Primary Products Commercial Division and Alcoa’s coordinator of the Alcoa-UFSCAR Agreement).
About Alcoa
Alcoa Alumínio S.A. is a subsidiary of Alcoa Inc., the world’s leading company in the production and transformation of aluminum, which operates in the aerospace, automotive, packaging, construction, transport and industrial markets, and has been in Brazil for 42 years. The Company has 123,000 employees in 44 countries and in 2007, during the World Economic Forum in Davos, Switzerland, was named for the third year running as one of the most sustainable companies in the world. The Company is also part of the Dow Jones Sustainability Index for the fifth time and is one of the founders of the United States Climate Action Partnership (USCAP), an association of 10 major North American companies and environmental NGOs, dedicated to working to significantly reduce the emission of greenhouse gases.
In Latin America Alcoa has more than 6000 employees and operations in six Brazilian states (Pernambuco, Minas Gerais, Maranhão, Pará, São Paulo and Santa Catarina), including a new bauxite mine that is being set up in Juruti (PA).
It also has operations in Argentina, Chile, Colombia, Peru and Venezuela. In addition to the Barra Grande and Machadinho power stations, Alcoa has shareholdings in the hydroelectric power station consortiums of Estreito, on the border between Tocantins and Maranhão states, and Serra do Facão, between Goiás and Minas Gerais. The company was recognized by the Corporate Good Citizenship Guide, 2006, published by ‘Exame’ magazine, in the areas of Values and Transparency and Government and Society.
Further information about Alcoa can be found on its website www.alcoa.com.br
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