Bauxite crushing & grinding plant:

Bauxite is mined and crushed at bauxite deposit. Crushed bauxite ore is then transported by overland conveyor to the refinery. Mining starts with flora and fauna surveys. Topsoil and overburden is removed and kept for use in rehabilitation.

The bauxite is excavated and taken by truck to primary and secondary crushing stations at the mine site. The primary crusher can take rocks as large as 1.5m in diameter. By the time the ore comes through the other end the biggest rocks are less than 180mm. A secondary crushing plant further reduces the size to less than 30mm. The crushed ore is fed into a stockpile, ready to be carried by conveyor to the refinery.

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Bauxite, the primary aluminum ore, uses the Bayer Process to extract alumina from the ore. The processing begins with crushing to 1-2 inch particles and wet screening, to remove some silica fines, which are generally present with bauxite.

Bauxite exists in free-flowing form, which makes it relatively easy to dig out of the ground. Front end loaders load the bauxite into 150 tonne bottom-dump trucks, which take the ore to a dump station for transportation to the processing plant (called a beneficiation plant) by rail and belt conveyor.

Treatment of the run-of-mine bauxite consists mainly of crushing and drying before shipment. Ore wagons are tipped individually, the material being crushed to –100mm before stockpiling. After reclaim using bucket-wheel stacker-reclaimers, the ore is dried from an average 12.5% moisture to 6.7% for shipping.

Dried ore is held in a 150,000t-capacity covered stockpile, and is then reclaimed for transport along the plant's 1.6km jetty to the shiploaders.

At the beneficiation plant, the bauxite is screened and washed to remove fine particles. It is then placed on stockpiles, which are loaded onto ships. Most of beneficiated bauxite is refined into alumina. After crushing process, the crushed bauxite ore will be carried to the refinery.

From here, the ore is digested in a heated, pressurized vessel at temperatures up to 450 defrees F and pressures of 500 psi. Generally, there are differing types of alumina ores in the bauxite deposit, and these require different temperatures to digest. The low temperature digestor typically operates at 275 to 290 degrees F. Sodium Hydroxide (NaOH) is used to dissolve the alumina in the digestor. The Pregnant liquor is separated from the red mud tailings using a series of thickeners set up in counter current decantation arrangement, to continuously wash the alumina bearing liquor from the tailings, until only barren tailings remain. Various contaminates (iron, organic matter) can play havoc with the process and may require sub routines to remove them.

Bauxite is the mineral form of aluminium, occurring naturally in the earth's crust, and containing about 50 per cent alumina. It is formed by the weathering of sedimentary rocks which contain a high proportion of aluminium-bearing minerals. Bauxite is normally found in a layer averaging three to five metres deep, located about half a metre beneath the topsoil. Mined bauxite resembles small red pebbles, called pisolites, averaging about five millimetres in diameter.