Alumina Processing Fundamentals



Outstanding Features

Want to learn more about how to reduce production loss opportunities, reduce material consumption and make timelier decisions in an alumina refinery environment?

This course is aimed at new technical and production personnel who are involved in running and optimizing the processing functions in an alumina refinery.

Course Overview

The course aims to provide participants with an understanding of materials used in the Bayer process; including Bayer process chemistry, typical Bayer process unit operations and their impacts, appreciation of key product quality parameters and their impact on downstream smelting operations. 

Target Audience

The course is aimed at refinery personnel who are unfamiliar with the Bayer process. It is recommended for junior process engineers and supervisors, with little or no alumina refinery experience.

You Will Learn How to

  • Develop an understanding of Bayer Process fundamental chemistry and its creation
  • Develop an understanding of common unit operations in Bayer plants
  • Develop an understanding of how operating practices impact on Bayer plant performance
  • Develop an appreciation of how product alumina quality variations impact on downstream smelter performance


  • Birth of the Bayer Process (history)
  • Bauxite to Alumina Processing Overview:
  • Bauxite Minerals and their Impacts
  • Plant Liquor Chemistry Basics
  • Digestion – Alumina Extraction
  • Clarification – Residue Separation
  • Precipitation
  • Classification and Filtration
  • Calcination Impurity Management
  • Water Management
  • Product Quality
  • Cleaning Practices
  • Additives

    Course Details

    Day 1

    • What is Alumina?
    • Bayer Process Fundamentals
    • Key Cost Drivers

    Day 2

    • Bauxite Processing Functions
    • Bauxite Key Parameter
    • Impacts Residue Processing

    Day 3

    • Hydrate Production
    • Calcination Energy Processes

    Day 4

    • Water Balance Additives

    Day 5

    • Troubleshooting Common Process Calculations

    Course Length

    5 Days

    Course Director

    Jock Armstrong


    Upon completion, you will receive a Worley Academy Certificate of Completion. 

    More Information

    • Please enter your email and we will contact you with more information about this course.