ICI Pakistan Ltd

Soda Ash Business

Technical Department Monthly Report

February – 2010

 HEALTH, SAFETY & ENVIRONMENT

SAFETY STATISTICS

 No LTI, RW, MT, and FAC were recorded for the month of February 2010 in Technical Department.

HSE ACTIVITIES

 Safety talk on the topic “Housekeeping” was carried out with Technical Department staff.

HSE CHALLENGE 2010

 Summary of Progress on HSE Challenge 2010 actions is given in the table below.

Target 2010
Sr. Base Line Achieved February
Parameters @ 5% 2010 Actual
No. 2005 2009 2010
Reduction
Energy (T/T)
1 0.01414 0.01343 0.01325 0.01396* 0.01400
Energy related CO2
2 0.7241 0.6879 0.7169 0.8855** 0.9078
(T/T)
Reusable waste non-
hazardous (reportable)
3 (T/T) 0.0240 0.0228 0.0313 0.0339*** 0.01919

Fresh water usage

4 (T/T) 12.8289 12.187 8.786 9.172 9.778

Acid Gases (T/T)

5 0.00936 0.00889 0.00158 0.00599 0.00609

Greenhouse gases
6 (T/T) 1.03485 0.98311 1.0687 1.2579**** 1.286

* Energy figure is high due to high fuel consumption

** Energy related CO2 figure is high due to high furnace oil consumption
*** Waste figure is higher than target due to high coke fines
**** Green house gases are high due to high consumption of furnace oil, limestone and coke

HSE IMPROVEMENT PLAN 2010

 HSE improvement plan 2010 finalization is in progress

 PRODUCTION HIGHLIGHTS

 Production for the month at 19,108 tons was 4,881 tons lower than the budget

 DA production for the month at 2,835 tons was 2,765 tons lower than the budget because of low market demand

 RSB production for the month at 1,515 tons was 585 tons lower than the budget because of low market demand

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February 2010
 ICI Pakistan Ltd

Soda Ash Business

Following table shows the production figures for February 2010

February 1st QTR 2nd QTR 3rd QTR 4th QTR YTD

Budget Tes 23,989 36,706

Actual Production Tes 19,108 37,028

Difference (4,881) 322

Maximum Rate Achieved 800 837

Tes / day
Average Rate Tes / day 682 628

 DAILY SODA ASH PRODUCTION

1200

Daily Target 1010 tpd

1000
Descon Boiler outage to carry out
Target 800 tpd inspection and tuning on natural gas
Low market
800 demand
Target 650 tpd

600

400

200

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Major Losses with respect to Budget

 Jan 10: The production remained higher than the budget

 Feb 10: Low market demand, Descon 10 outage to carry out its inspection & tuning on natural gas and partial plant
shutdown

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February 2010
 ICI Pakistan Ltd

Soda Ash Business

 PRODUCTION LOSS DETAILS

Monthly Soda Ash Production
Actual Vs Budget
Act Budget
(Tes)

30,377
29,254
25,957
24,459 23,857
25,119 25,643
23,989 25,215 24,158
12,716

14,847

17920 19108

Jan Feb Mar Apr M ay Jun J uly Au g Sept Oct No v Dec

Production loss (Tons) Section Wise

- Feb 2010 85 Instt 149 Mech
54 Elec
455 PS

0 Civil 130 Process

67 Others

178 SD

0 CW

7746
Commercial

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February 2010
 ICI Pakistan Ltd

Soda Ash Business

Production loss (Tons) Section Wise

- YTD
158 Elec 145 Instt
281 Mech
0 Civil
2455 PS

301 Process
9840
Commercial

8506 Others

0 CW

227 SD

Production loss (Tons) Equipment Wise 102 Kiln & MOL

35 Tower 29 SD Basin /
- Feb 2010
52 Abs / Dist Brine
82 Calciners
123 Others
0 SNGPL 493 Boilers

161 Turbines

41 Compressors

7746
Commercial

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February 2010
 ICI Pakistan Ltd

Soda Ash Business

Production loss (Tons) Equipment Wise 29 SD Basin /

- YTD 52 Tower Brine
183 Kiln & MOL
92 Abs / Dist
211 Calciners
253 Others
2610 Boilers

220 Turbines

8371 SNGPL 52 Compressors

9840
Commercial

 MANUFACTURING EXCELLENCE PARAMETERS

100.00%

90.00%

80.00%

70.00%

60.00%

50.00%
Jan Feb Mar April May June July Aug Sep Oct Nov Dec

OEE Availability Product Rate Quality Rate

 PROJECTS

65 KTPA

 All the pending DCS issues have been resolved and acceptance document signed off
 GT2 chiller process water tie in is in progress whereas the electrical tie ins would be carried out during any
opportunity in coming months

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February 2010
 ICI Pakistan Ltd

Soda Ash Business

 DEVELOPMENT WORK

Reverse Osmosis

 Meetings were held with WEMS and Progressive Consultants to finalize the control logic & ELD for the RO
project
 Hazard Study team for the RO project has been announced
 Final draft of the RO contract has been received from ICI’s Legal Counsel, final amendments are in progress
 Initial draft of the RO newsletter has been prepared

Others

 To ensure the TA > 99 % as per international standard, a trial run was carried out at plant with extensive
testing. Since 1st March 2010 all export product is being supplied with Certificate of Analysis having TA > 99
%. However, it will have an impact of 1 dm3 PTA on energy
 Proposal for developing an e – Modification Form database is being prepared
 Technical and Commercial proposal received for installing a Float Valve on Jhelum water reservoir
 Technical and Commercial proposal of liquid online mass flow meter has been received

 ENERGY
Following graph shows the energy trend for year 2008, 2009 and YTD 2010.

MONTH WISE ENERGY BUDGET & ACTUAL

45
42.5
40
Energy (DM3 PTA)

Budget 10
37.5
Actual 10
35
Actual 09
32.5
30
Actual 08
27.5
25
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Months

Following graph shows the MMBTU PTA consumption trend for 2008, 2009 and YTD 2010

MONTH WISE MMBTU PTA CONSUMPTION TREND

15.00
MMBTU PTA

12.50

10.00

7.50

5.00
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Months

MMBTU PTA 10 MMBTU PTA 09 MMBTU PTA 08

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February 2010
 ICI Pakistan Ltd

Soda Ash Business

 COKE EFFICIENCY
0.105

Coke (Tons PTA)

0.1

0.095 Coke 2008

Coke 2009
0.09 Coke 2010
0.085

0.08

Aug
Apr
May
Jan

Jun

Jul

Oct
Mar

Nov
Dec
Feb

Sep
Months
 PLANT EFFICIENCIES

Coke Consum ption

0.10
0.10
0.097 0.097 0.097
0.10 Budget
0.10 0.095
Tes PTA

0.095
0.10
0.09 0.093
0.09
0.09
0.09
0.09
Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct No v Dec Bud10 YTD10 Act09 Act 08

1.54 1.54 Salt Consum ption 1.54 1.54 1.54 1.536

1.54
Budget
1.54
Tes PTA

1.53

1.53

1.52

1.52

1.51
Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act 09 Act 08

Am m onia Consum ption

9.00

8.00 Budget
7.00
KG PTA

6.00 5.499 5.4

5.4 4.968 5.261
5.001
5.00

4.00

3.00

2.00
Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act 09 Act08

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February 2010
 ICI Pakistan Ltd

Soda Ash Business

1. 50 Limestone Consumption
1. 45 Budget
1. 40
Tes PTA

1. 35
1. 30 1. 250 1.238
1.250 1.262 1.241
1.250
1. 25
1. 20
1. 15
1. 10
Jan Feb Mar Apr May J un Jul Aug Sep Oct Nov Dec Bud10 YT D10 Act09 Act08

Total Fuel Consum ption

41.00

39.00 Budget 37.724

37.549 37.084 37.559 36.67
37.309
37.00
DM3 PTA

35.00

33.00
31.00

29.00
27.00

25.00
Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct No v Dec Bud10 YTD10 Act 09 Act 08

 OTHER EFFICIENCIES

Purchased Power Consumption DGs Power Consumption

30 6

25 22.0 5
20.8
19.5 4
KWH PTA

20
KWH PT A

15.4 3.0
15 3
11.1
8.2 2 1.8 1.5 1.4
10
1.0 0.9
5 1

0 0
Jan

Jun
May
Mar

Bud 10

Actual 08
Oct
Feb

Aug

Sep

YTD 10
Jul

Nov

D ec
Apr

Actual 09
Jan

F eb

Jun

Aug

Sep

Bud 10

YTD 10

Actual 09

Actual 08
Jul

Dec
Mar

Apr

Oct
May

Nov

Diesel Consumption on GTs Nacl Brine free

0.25
0.21
0.20 0.20
0.4 0.20 0.20
0.2 0.17
0.4
Eq D M3 PT A

0.3
0.3 0.15
0.2
0.2 0.1
0.1
0.1
0.0 0.05
Aug

Dec
Jul
Mar

Apr
Jan

Feb

Jun

Sep

Bud 10

YTD 10

Actual 08
O ct
May

Nov

Ac tual 09

0
Actual 09

Actual 08
Jan

Jun
Feb

Aug
Sep

Bud 10
Jul
Mar

Apr

May

Nov
Oct

Dec

YTD 10

 PRODUCT QUALITY & ISO 9000

 ISO 9001

 Findings of URS surveillance audit were circulated to all concerned and action completion dates are
being awaited.

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February 2010
 ICI Pakistan Ltd

Soda Ash Business

 New accreditation certificates of new ISO 9001:2008 version received from URS.

 COMPETITOR’S SAMPLE ANALYSIS

Competitor ICI Olympia China Turkey Russia Magadi Romania Ansac Ukraine Iran
Light Soda Ash
Date Feb-10 28/2/10 5/1/06 19/8/03 19/8/03 15/5/05 23/11/06 22/2/05 17/11/09
TA % 99.01 95.60 98.80 97.80 98.20 97.80 97.80 - 98.60 99.20
Cl % 0.41 0.41 0.20 0.10 0.39 0.33 0.24 - 0.36 0.42
Fe2O3 % 0.0019 0.0030 0.0018 0.0010 0.0016 0.0060 0.0060 - 0.0016 0.0025
H2O % 0.21 2.93 0.15 1.29 0.67 1.16 0.66 - 0.54 0.11
NaHCO3 % 0.25 1.93 0.67 0.34 0.34 0.67 2.60 - 0.17 0.25
Density gm/lit 560 587 590 535 562 496 484 - 551 588
Sieve
Analysis
On 16 mesh 1.40 2.36 0.46 0.55 0.69 1.69 1.91 - 0.95 3.34
On 36 mesh 1.20 3.30 0.26 0.47 0.57 0.59 4.82 - 0.78 1.71
On 85 mesh 14.60 7.70 16.25 9.73 9.53 13.13 18.10 - 6.91 14.94
On 120 mesh 38.30 55.47 37.03 29.50 45.33 33.35 35.70 - 38.18 36.62
On 200 mesh 29.90 22.76 27.52
On 240 mesh 5.90 2.13 36.59 45.84 34.11 40.06 28.69 - 44.08 4.54
Thru 240
8.40 6.32 9.27 14.44 9.76 10.82 10.56 - 8.99 11.08
mesh
Dense Soda Ash
Date Feb-10 31/03/08 10/11/06 23/11/02 21/09/06 20/10/04
TA % 98.99 98.80 98.60 91.00 - 96.20 - 98.80 - -
Cl % 0.53 0.38 0.20 0.13 - 0.31 - 0.03 - -
Fe2O3 % 0.0025 0.005 0.0040 0.0010 - 0.0380 - 0.0010 - -
H2O % 0.14 0.25 0.45 - - 1.14 - 0.80 - -
NaHCO3 % 0.17 0.34 0.420 - - 3.530 - 0.230 - -
Density gm/lit 994 1078 1078 - - 805 - 1000 - -
Sieve
Analysis
On 16 mesh 2.16 7.40 0.02 2.98 - 1.26 - 0.20 - -
On 36 mesh 23.32 48.60 8.57 54.11 - 48.66 - 9.20 - -
On 85 mesh 54.71 37.50 68.61 39.93 - 35.59 - 76.50 - -
On 120 mesh 12.90 4.40 14.86 1.93 - 9.00 - 9.70 - -
On 240 mesh 4.48 1.50 5.74 0.47 - 4.44 - 4.10 - -
Thr. 240
2.04 0.50 1.99 0.33 - 1.12 - 0.40 - -
mesh

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February 2010
 ICI Pakistan Ltd

Soda Ash Business

 CUSTOMER COMPLAINTS

No customer complaint was received during the month of February 2010

 PLANT CRITICAL PARAMETERS

Unit Target February Q1 Q2 Q3 Q4 YTD

CB Cl mls N / 20 105. 2 105. 3 105. 5

PB Cl mls N / 20 104. 4 104. 1 104. 4

o
CW Temp. C 24. 8 25. 0

CVL test mls N / 20 104 101. 9 102. 7

TE % 40 – 41 40. 0 39. 9

Mix gas old side % 70 – 71 67. 5 66. 6

Mix gas new side % 70 – 71 66. 0 64. 5

Gases PTA M3 PTA 800 – 820 808 792

Conversion 1 % 72 – 74 72. 3 72. 0

Conversion 2 % 72 – 74 72. 1 71. 9

Conversion 3 % 72 – 74 71. 9 71. 6

 PARTICLE SIZE DISTRIBUTION

Cal-1, 2, 3 & 4 Particle size distribution Feb 2010

45
40
35
30
particles

25
20
15
10
5
0
.+16 .+36 .+85 .+120 .+200 .+240 ,-240
mesh size
Cal- 1 Ash Cal- 2 Ash Cal- 3 Ash Cal- 4 Ash

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February 2010