HEAT TRANSFER IN THE BAYER PROCESS

Heat transfer equipment represents a significant portion of Bayer process plant capital and operating costs. Heater operation and maintenance activities can also create potential hazard exposure. Very early flowsheets tended to rely on direct heat transfer, i.e. steam injection heating and flash cooling, and this still persists to some extent today. There has however been an ever increasing utilization of indirect heat exchange over the past 100 years. This has been driven by higher energy efficiency targets and enabled by improvements in heat transfer equipment. In more recent decades there has been a partial shift towards slurry heating and cooling instead of liquor heating and cooling. This paper presents an historical perspective, explores some heater selection scenarios, and looks at future challenges and opportunities.