Laboratory Introduction

Introduction to Central Laboratory of Iran Alumina Company

The Central Laboratory unit of Iran Alumina Company, with an approximate area of 2000 square meters in two floors, has been established. The laboratory personnel include 23 experts and higher and 19 technicians. This unit possesses high scientific and technical capabilities and plays a significant role in achieving the company’s goals (high production of quality products).
The specialized fields of the laboratory staff include chemistry, physics, geology, chemical industries, and metallurgy, each engaged in their specific laboratories.
With the specialized personnel and available equipment, the laboratory can analyze many mineral samples.

Laboratory Duties in Iran Alumina Company are summarized as follows:

1

Routine tests to control chemical processes of various production and auxiliary units.

2

Analysis of samples sent from bauxite and lime mines.

3

Laboratory tests and bench-scale research activities for solving process issues.

4

Producing innovative knowledge to develop company products and optimize processes.

5

Analyzing produced products, input materials, and output from the plant.

6

Developing, implementing, and compiling new methods for special or routine analyses.

7

Providing an appropriate platform for research activities and their execution to improve production conditions.

8

Review and control of analyses.

9

Analysis of samples sent from customers outside the company.

To achieve the above goals, this unit consists of the following laboratories:

1

Water and operations laboratory (wet chemistry)

2

X-ray fluorescence (XRF) laboratory

3

X-ray diffraction (XRD) laboratory

4

Neutron laboratory (FNAA)

5

Physics laboratory

6

Atomic absorption laboratory (AAS)

7

Aluminum ingot laboratory (OES)

8

Processing and product section

The Central Laboratory performs daily about 750 analyses to fully monitor the production flow, track key operational parameters of production units, and analyze input, interprocess, and product samples. These analyses cover lime and bauxite samples entering the process, raw materials, intermediate products, produced alumina, and aluminum ingots. It also serves bauxite and lime mines by analyzing exploration and extraction samples.
Analysis results are entered into a computer network and simultaneously shared with the operations control center, local control rooms, and operational units.
Currently, the laboratory is a capable member of the Strategic Technologies Laboratory Network.

Water and Operations (Wet Chemistry) Laboratory

Laboratory Operations (Wet Chemistry)

This laboratory performs full analyses of limestone samples, burnt lime, slaked lime, sodium aluminate liquor, aluminum hydroxide, red mud, caustic soda, ammonia, and acids entering the plant. Titration is a core method in wet chemical analyses.

Key equipment includes:

  • UV spectrophotometer with double beam system
  • Laboratory furnaces programmable up to 1500°C for temperature ramp and holding time control
  • Mill and shaker
  • Analytical and laboratory balances with precisions from 0.1 to 0.0001 grams
  • pH meter and conductivity meter
  • Laboratory centrifuge
  • Magnetic and simple heaters
  • Automatic burettes
  • Programmable dryers
  • Water bath and ultrasonic cleaner (for cleaning laboratory sieves)

Water Laboratory

Water and steam are vital elements in every plant. To prevent scaling and corrosion caused by unfavorable chemicals, this laboratory performs tests and services related to water, wastewater, steam, and effluent quality, employing specialized staff and proper equipment.

It performs internationally recognized standard tests including:

  • Turbidity
  • Alkalinity
  • Acidity
  • Suspended solids
  • Ammonia
  • Phosphate
  • Nitrate
  • Hydrazine
  • Silica
  • Calcium
  • Manganese
  • Iron
  • Electrical conductivity
  • pH
  • Magnesium
  • Sodium
  • Potassium
  • Chloride
  • Chlorine
  • Sulfate
  • TDS
  • COD
  • BOD5
  • Dissolved oxygen (DO)

Important equipment includes:

  • UV spectrophotometer
  • Analytical and laboratory balances
  • Dryers and furnaces
  • Vacuum and diaphragm pumps
  • Water bath and shaker
  • Incubator for BOD5 tests
  • Autoclave for microbiological tests

X-ray Fluorescence (XRF) Laboratory

The XRF laboratory can identify and perform elemental analysis of all elements in the periodic table from fluorine to uranium in all natural (natural and artificial) materials using high-speed, accurate, and reliable X-ray radiation.
The current capabilities of the laboratory’s equipment are tailored to meet the needs of Iranian Alumina Company, providing auxiliary devices necessary for routine analyses and research work, capable of qualitative and quantitative analysis of all mineral substances including silicate and carbonate rocks, some light metals, and their alloys.
The analyzer devices in this lab include types WDXRF and EDXRF. Also available are:

  • Laboratory furnace and dryer
  • Semi-automatic and manual press
  • Analytical and laboratory balances
  • Electric mortar (Grinder)

X-ray Diffraction (XRD) Laboratory

In the mineralogy laboratory, X-ray diffraction (XRD) is used for qualitative identification of the mineral or organic crystalline phases (minerals) of an unknown sample. Crystal structure, unit cell size, and phase type can be determined with this equipment.
Capabilities include quantitative mineralogy analysis of mineral samples and quantitative analysis of slag from reduction furnaces in the aluminum ingot unit of Iranian Alumina Company.
This lab also features a polarizing photomicroscope equipped with reflective and transmitted light for studying and photographing thin sections of rocks and minerals.

Fast Neutron Activation Analysis (FNAA)Laboratory

The neutron analyzer (FNAA) operates based on isotope formation and decay of elements in mineral materials according to their half-lives. It is highly useful for rapid analysis of aluminosilicate materials, capable of analyzing 100 mesh powder samples to measure SiO2 and Al2O3 percentages in 15 to 30 minutes.
This equipment aids in fast exploration, discovery, and extraction processes for such materials.

Physics Laboratory

The mission of the Physics Laboratory is to control the quality of intermediate and final products. The equipment of this laboratory can serve various industries with a wide range of services. The most important of these equipments are:

Surface Area Determination Device

This device measures the specific surface area of ​​materials based on the BET method (S. Brunauer, P.H. Emmett and E. Teller). In this laboratory, this equipment is used to measure the specific surface area of ​​alumina.

Laser Particle Sizer

This equipment can determine the particle size distribution (in liquid or powder form) for a wide range of materials and plot it using the relevant software.

Attrition Index Determination Device

This equipment actually measures the strength of the hydrate crystal or bauxite based on the attrition index.

Angle of Repose Device

This device determines the angle of the hill surface resulting from the accumulation of particles relative to the horizon. This angle is important in order to optimize the carrying capacity of powder materials by train cars.

Atomic Absorption Spectroscopy (AAS)Laboratory

The equipment available in this laboratory includes:

Atomic absorption spectrometer (AAS)

Atomic absorption spectrometer is widely used in the mining sector. This device is capable of measuring elements in a sample from a few ppm to a few percent (depending on the type of element).
Considering the available lamps, 28 elements can be measured in mineral samples. In this device, except for the elements “Zr, Ti ‌‌, Si‌‌, Ga, Ca ‌‌, Ba, Al” which are measured by acetylene-nitrous oxide flame, other elements can be measured directly by acetylene-air flame.
The lamps available in this laboratory are:
Al, Ag, As, Ba, Bi, Ca, Cd, Co, Cr, Cu, Fe, Ga, Hg, K, Li, Mg, Mn, Na, Ni, Pb, Sb, Si, Sn, Sr, Ti, V, Zn, Zr

Flame Photometer

Measuring alkali and alkaline earth metals by flame photometer is one of the most important common methods of chemical analysis. In this method, using a low-temperature flame, the amount of these metals in the sample can be easily measured. In fact, the compounds of these two groups decompose in the flame and eventually turn into atoms. Some of these atoms are excited to a higher energy level and when they return to their ground state, they emit light. The light emitted by the atoms of these two groups is in the visible region of the electromagnetic spectrum. The intensity of the light emitted at any given moment is proportional to the number of particles in the flame and thus the concentration of the element is determined. The elements “Ba, Ca, Na, Li, K” can be measured by this device.

Aluminum Ingot (OES)Laboratory

Analysis of aluminum produced and cast iron consumed in the ingot production unit of Iran Alumina Company, as well as slag from reduction boilers, is carried out in this laboratory.
The following are the equipment available in this laboratory:

  • ARL-3460 Optical Emission Spectrometer and Unix Quantum Meter for analyzing aluminum and cast iron samples
  • Sample preparation equipment including turning, chip removal, and polishing machines for aluminum and cast iron samples
  • Planetary ball mill

Due to the expert manpower and available equipment, this laboratory has the ability to analyze various types of aluminum and cast iron-based metal samples.

Processing and ProductSection

Innovation in technology drives economic growth and industrial development. This section aims to improve existing technologies and foster innovations at Iranian Alumina Company. The mission includes planning and coordination of research activities to provide scientific solutions for improving production operations using wet chemical methods and equipment.
With expert personnel, scientific knowledge, and modern equipment, this section can improve and offer solutions to production units.

Key activities include:

  • Participating in new scientific-research projects and providing solutions
  • Reviewing and monitoring raw materials for quality procurement to produce quality products
  • Developing new knowledge for product development and process optimization

Major equipment includes:

  • UV spectrophotometer with Double Beam system
  • Analytical and laboratory balances
  • Dryer and furnace
  • Vacuum and diaphragm pumps
  • Water bath
  • Autoclave