11-024 DE FINAL Rev01 2014-03-14 PDF

Final Engineering Design of a KCl Industrial Plant in Bolivia
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EXECUTIVE SUMMARY
The economic activity of the Salar de Uyuni does not focus only on tour- Introduction
ism but also on salt production realized by neighboring cities.
The Salar de Uyuni is considered the world's largest salt lake with an
extension of 10,582 km2 located 3,650 meters above the sea.
In the province of Daniel Campos department of Potosí in the southwest
of Bolivia, is one of the largest reserves of lithium, potassium, boron and
magnesium of the world.
Thus, after preliminary studies recently conducted, the Mining Corpora-
tion of Bolivia (GNRE-COMIBOL), responsible for the exploitation of min-
eral resources in the country, has decided to carry out the design and
planning of an industrial plant in the Salar de Uyuni for obtaining high
purity potassium chloride with a product quality of 95 %.
After processing, the brine collected will be used mainly as fertilizer.
Due to the large reserves of the Salar, the Mining Corporation of Bolivia
(GNRE-COMIBOL) raises a consistent industrial scale production by
700,000 t/y.
The natural brine from the Salar will be processed in different process
sections as explained in the following chapters of this document.
For the production of 700,000 t/y, the plant will work over 7,500 hours per
year with two independent lines producing 350,000 t/y each, working 24
hours per day in three shifts.
The remaining time of the year will be used for maintenance of equip-
ment in the plant.
For the design of the Industrial KCl Plant in Bolivia, the Mining Corpora- Project History
tion of Bolivia (GNRE-COMIBOL) published the bidding procedure called:
"FINAL DESIGN ENGINEERING INDUSTRIAL PLANT IN BOLIVIA KCl"
in the year 2011.
ERCOSPLAN has extensive experience backed by over 60 years of con-
tinuous work and good references in the potash and mineral salt indus-
try, has been awarded to make the carry out this project.
The contract between GNRE-COMIBOL and ERCOSPLAN was signed on
July 31, 2012 and on February 18, 2013 the ‘Document Verifying Readi-
ness for Activities’ was approved.
From this time, ERCOSPLAN had a period of 15 days to deliver the Pro-
ject Procedures Manual, which was accepted by the Authority.
The objective of this manual was to define the procedures and relation-
ships of the parts to be applied during the development of the contract.
ERCOSPLAN defined two phases for the project. The first phase called
Basic Engineering and the second phase called Detail Engineering.
The development of the Basic Engineering started with signature of the
‘Document Verifying Readiness for Activities’, in February 2013 and was
completed in July 2013.
During this period, project team members of ERCOSPLAN travelled on
several occasions to La Paz in Bolivia to present the state of the work.
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ERCOSPLAN Ingenieurbüro Anlagentechnik GmbH
Arnstaedter Strasse 28, 99096 Erfurt, Germany
Phone: + 49 361 3810 370 Fax: +49 361 3810 403 e-mail: processing@ercosplan.com web: http://www.ercosplan.com
P:\2011\024_GNRE_KCl_Industrial_Plant_Bolivia\Allgemein\Liefer\Auslieferung\14-03-14_Detail\Report\11-024_DE_FINAL_rev01_2014-03-14.docx
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From May 13 to 17, 2013 ERCOSPLAN and GNRE-COMIBOL visited the

pilot plant located in the Salar de Uyuni.
The Basic Engineering documentation developed for the sections pro-
cess, mechanical, electrical and civil engineering was finalized and deliv-
ered to GNRE-COMIBOL on July 17, 2013.
From July 22 – 24, 2013, another meeting in La Paz was held where the
ERCOSPLAN project team introduced and explained the Basic Engineer-
ing to GNRE-COMIBOL. Upon GNRE-COMIBOL’s approval of the docu-
ments, the basic engineering phase was completed.
Immediately after ERCOSPLAN started with the second phase, the De-
tailed Engineering, which lasts about 5 months.
During this Detailed Engineering phase, ERCOSPLAN travelled twice to
La Paz, Bolivia to present the development documents. The last trip was
in September 2013.
The final project was delivered by ERCOSPLAN in the time stipulated in
the contract (300 days from the signature of the readiness for activities)
on December 14, 2013.
At the same time ERCOSPLAN’s project team travelled again to La Paz to
present the final project which includes following documents:
• Detail Engineering Report
• Enclosures
• Appendices
• Drawings
Process Engineering
Mechanical Engineering
Electrical Engineering
Civil and Construction Engineering
Piping Isometric
Finally, it should be noted that the project manager of ERCOSPLAN pre-
pared and delivered a monthly report which shows the progress of the
project at all time.
Due to a contract modification, ERCOSPLAN furthermore provides the
detail engineering for drying section, product storage and truck loading.
The revised detail engineering documents including the contract modifi-
cation will be delivered to GNRE-COMIBOL 90 days after finalizing the
main contract on March 14, 2014 and presented in La Paz subsequently.
This executive summary describes the main important features of the
project.
For the project, ERCOSPLAN has always worked with internationally rec- Nomenclature
ognized standards for rationalization and technical quality assurance
ERCOSPLAN dedicates the chapter 3 of the Detail Engineering report to
the explanation of the nomenclature.
In the preparation of drawings and other project documents it has been
followed the model of the Normative German DIN (German Institute for
Standardization).
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It is very important to note that in this project there are codes indicating
the name of each equipment necessary for the operation of the plant
based on the DIN EN ISO 10628.
Similarly there is another code indicating the name to each control points
in the process. It is governed by the German standard DIN 19227-2 and
this is being extended for both valves as pipes.
All belonging documents are listed in chapter 4 of the Detail Engineering Belonging Documents
report. The Design Base Document prepared at the beginning of the
project by ERCOSPLAN and later confirmed by GNRE-COMIBOL is at-
tached as Appendix A1.
For the mechanical engineering part, Quotations (Appendix Q1 – Q66) of
suppliers for plant equipment are attached as well as cost estimations for
Equipment (Appendix G1 and G1.1), Piping (Appendix G2 and G2.1) and
Valves (Appendix G3 and G3.1) which are necessary for plant operation.
In the Block Flow Diagram, which is indicated as Drawing A01, the single
processing stages from the evaporation ponds to the final product (KCl
with 95 % purity) are schematically shown.
Also included is the Equipment List (Appendix A2 and A2.1), Equipment
Data Sheets (Appendix A3 and A3.1), List of Drawings (Appendix A4), List
of Instruments (Appendix A5 and A5.1), Specification for Mechanical
Equipment (Appendix A6 and A6.1) as well as Pipe List (Appendix A8 and
A8.1), Valve List (Appendix A9 and A9.1) and Pipe Classification (Appen-
dix A10).
The Inquiry Specification (Appendix A7) was provided to potential equip-
ment suppliers within the request for proposal defining the essential fea-
tures for the proper design of the equipment.
ERCOSPLAN prepared a list with all valves used in the project as well as
a piping list and a list in which the leading suppliers of equipment are
reflected.
Finally, drawings of piping and instrumentation (PID), arrangement draw-
ings and isometric drawings for pipes exceeding 100 mm diameter are
attached to this Detailed Engineering.
Chapters 4.4 and 4.5 cover all belonging documents for the sections
Electrical Engineering and Civil/Building Engineering and the respective
documents are attached to this Detailed Engineering report as well.
Chapter 5 of the Detail Engineering report is referring to the meteorologi- Property Description
cal conditions, earthquake risk and soil conditions of the Salar de Uyuni.
The Salar de Uyuni is located at an altitude of 3,653 m above sea level.
The exact location of the plant has been defined by mapping and was
provided by the Mining Corporation of Bolivia (GNRE-COMIBOL) to ER-
COSPLAN along with the coordinates of the current evaporation ponds.
As for the weather, there is a stable average temperature with ranges
from 21 °C to 13 °C depending on the time of year. The nights are cold
with temperatures between -9 °C to 5 °C.
The relative humidity is quite low and precipitations are usually not great-
er than 13 mm per month between the months of April and November,
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but may be higher in January.

Concerning the seismic risk, according to the seismic map of Bolivia, a
maximum magnitude up to 4.9 exists. However, ERCOSPLAN has con-
sidered the maximum magnitude of 5.9 existing in Germany. This is the
reference for calculation of buildings and civil structures of the project.
Finally, it should be noted that the foundation of the plant will be founded
on the salt lake. The Mining Corporation of Bolivia (GNRE-COMIBOL) has
conducted surveys showing that the ground consists of a bed of salt
including other materials such as sand, clay and tuff mix.
Chapter 6 of the Detail Engineering report describes the raw material Process Design for
used for production, its condition in the evaporation ponds and its com- Production MOP
position.
According to these data, ERCOSPLAN has selected the flotation process
for processing the raw material to final product.
The block flow diagram presents each of the processing stages where
the material is treated. Furthermore, tables defining the mass flow and
the composition at any process stage to become MOP product are in-
cluded in the report.
In Chapter 7 of the Detail Engineering report, all facilities inside and out- Production Facilities
side the production plant are described.
Thus ERCOSPLAN defines the following facilities in general:
• Bottom dump truck load out and further transportation to wet salt
storage.
• Wet salt storage with afterwards iron/non-iron metal detecting,
lump crushing and further transportation to process building.
• Processing plant for producing the final product (MOP).
• Tank farm for reclaim brine and process water with pumps and
thickeners.
Remark: For producing saleable MOP product it was mandatory to add
following facilities:
• Product drying section (as extension of processing plant)
• Product storage
• Product truck loading
Due to modification of the existing contract signed by GNRE-COMIBOL at
the Gate 3 Meeting, these facilities are considered in this revised docu-
mentation.
The processing plant is designed as two production line operation. The Production Plant
production lines are called "Line A" and "Line B". Regarding the capacity Description /
and type of equipment, the production lines are similar. Advantage of a Process Building
two line production is that there is a 50 % production guarantee even if
one line is disturbed.
The processing plant consists of following technological process sec-
tions:
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• Wet screening and milling

• Rougher flotation
• Cleaner flotation
• Leaching and cold product dewatering
• Scavenger flotation
• Tails process
• Compressor plant
• Reagent dosing plant
• Rising water system
• Sealing water system
• Product drying
• Process water storage
• Reclaim brine storage
• Drying section
• Product storage
• Truck loading.
Generally ERCOSPLAN recommends a design safety factor of 20 %.
The buffer times in tanks and vessels are calculated with 10 minutes min-
imum. The pumps are generally executed redundant, which means in
case of malfunction the second pump can take over the task.
The huge and insensible equipment will be placed outside of the process
building to save building construction cost. Process building’s dimen-
sions will be approx. 84 x 109 meters. The building consists of following
estimated main floors/platforms:
• 0.00 meters
• 6.00 meters
• 12.00 meters
• 18.00 meters.
The building height will be in average approx. 30 meters. The highest
part of the building will be approx. 36 meters. The building consists of
two areas, one for production line A and a second for production line B.
These both areas are connected by a free passage for repair and
maintenance reasons. Five overhead cranes are installed above selected
areas of process building to ensure hoisting of huge equipment in case
of repairs and maintenance. One additional overhead crane is installed
above both rod mills.
Although the main processing facilities are located in the main buildings Outside Facilities
on the plant site, e.g. wet salt storage, process building, product storage
and truck loading, there are several and necessary facilities located out-
side of the main buildings:
• Trucks unloading
• Conveyors belts
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• Distribution towers for belts conveyors

• Tanks farm for circulating reclaim brine
• Tanks for process suspensions
• Tank for muriatic acid
• Tank for LPG (media for product drying and building heating),
osbl
• Tanks for spare
• Thickeners for generation of reclaim brine
• Roads
• Retention basin.
The KCl plant has to be designed to produce 700,000 t/y of MOP (KCl Design Criteria
95).
Design safety factor applied to the production rate will be 15 % in mini-
mum. ERCOSPLAN considered a design safety factor of 20 %.
The operation time of KCl production plant will be 7,500 hours per year.
Remaining time is envisaged for maintenance and repairs. The KCl plant
will be operated 24 hours per day.
There is a power line and water supply network coming from the west. Existing Services
Water supply:
For the processing plant approx. 300 m³/h of process water is required.
Process water is delivered in sufficient quantity to the plant site via pipe
line. Also for the staff potable water is required. Due to the total number
of persons at the plant site, the daily amount of potable water is estimat-
ed under consideration of the working shift factor with approx. 30 m³.
Power supply:
Energy is transported to the industrial complex via 230kV overhead line
which is not sufficient and the electrical energy distribution in the area of
the industrial complex Salar de Uyuni starts from a distribution station
that still has to be realized via local network with a voltage level of 24.9kV.
Finally a reliable interim solution for the energy supply will have to be
realized for the transitional period.
Roads:
There are also roads to the plant site that can be used by heavy trucks
(20 tons).
Consumables supply:
To keep the plant operational, supplies have to be brought to the plant
and stored accordingly. Lubricants and others consumables are packed
correctly and delivered to the production plant via truck.
In order to minimize unscheduled shutdown, critical equipment will be Design Capacity

equipped with 100 % installed spare, e.g. one operating and one stand-
by.
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This applies to critical process equipment identified as such on the PFD’s

and P&ID’s. The critical process devices will be equipped with by-pass
facilities.
The specific capacity for each section and equipment is mentioned in the
process calculation and in the single equipment data sheets and equip-
ment specifications.
Also general requirements are required for compliance and standardized
operation of the equipment mentioned.
Due to extensive technology and continuous issues of the client, chapter Technical Description
7.4.2 “Technical Description of Selected Main Equipment” has been in- of Selected Main
cluded to the Detail Engineering report. Equipment
In this chapter, not only the operating mode is described, but also the
most important dimensional characteristics for each equipment.
The main process equipment are such as portal scraper, centrifuges,
screening machinery, rod mill, flotation cells, vacuum band filter, dry-
er/cooler belonging to each of the processes.
After the performance of laboratory tests and calculation processes, ER- Equipment Test Work
COSPLAN researched and selected the main equipment based on the
specific demand.
Once selected, ERCOSPLAN requested quotations from different suppli-
ers. It should be noted, that some of the supplier have requested test
runs on site since the will work under special conditions due to the high
altitude of the Salar.
Note that some of the suppliers have requested test work for their
equipment because of the special conditions due to the high altitude of
the Salar.
ERCOSPLAN recommends that GNRE-COMIBOL takes these outstand-
ing test works into consideration during the purchase of equipment, so
that the delivered equipment by the supplier can meet 100 % of GNRE-
COMIBOL’s expectations.
ERCOSPLAN made a description of the overall process in technological Technical Description

process sections. of Process Sections
Each of these sections describes the process in detail, together with a list
of the equipment in each section and a list of all appendices which in-
clude all information and details.
The process sections are:
• Wet salt storage including truck loadout
• Cold leaching and product dewatering
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• Tails process
• Rinsing water system
• Drying section product storage
• Truck loading.
The control circuits are defined with the help of a table (Appendix E8) for
all single sections of the process.
ERCOSPLAN can only give a general description on operation manuals, Operation Manuals
since GNRE-COMIBOL was not in the position to specify any suppliers
and type of equipment during compilation of the Final Engineering report.
Anyway, ERCOSPLAN defines the preconditions for start-up process or
notice of start of operation.
For the production of 700,000 t/y an energy demand of 11.2MVA is re- Utilities
quired.
This energy will be produced by power generator. The generator station
will be installed in a 40 foot container attached to the process building.
Another material required for process operation is water which must have
a temperature in the range from 12 °C to 18 °C.
The treatment of wastewater is not included in ERCOSPLAN’s scope of
work.
A network of rainwater systems will collect and lead rainwater to retention
basins for evaporation.
Finally the management of waste or tailings generated in the process will
be stockpiled in a dump 500 meters to the east of plant site.
The civil and building engineering of the KCl plant is defined and de- Structural/ Architectural
scribed in detail in chapter 7.8. Systems
The civil engineering comprises the implementation of roads or streets
that provide vehicular and pedestrian circulation.
In the building engineering, buildings are described where some of the
equipment is accommodated as well as other buildings such as wet salt
storage, small workshops, generator station and transformer station.
Administration and other social buildings are not within ERCOSPLAN’s
scope of work.
Each of these main and secondary buildings is described in detail as well
as the materials used for construction. More details are referenced in the
construction drawings.
As for the civil works is included the belt conveyors, support pipelines
structures, network of water and paved streets.
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Finally a description of the discharge area for trucks and the tailings pile
is provided.
This chapter provides the description of an execution procedure pro- Project Execution
posal, applicable for the execution structure of this project.
However, execution procedure is outside battery limits of ERCOSPLAN’s
scope and is in full responsibility of GNRE-COMIBOL:
The main objectives of the proposed project execution plan are to com-
plete the project:
• Within (or below) the budget
• On (or ahead of) schedule
• While meeting the quality requirements and constructing the
plant in the most efficient manner
• While ensuring that health, safety, environmental and social obli-
gations are adhered to.
The project execution philosophy adopted also complies with the follow-
ing criteria:
• Maximization of the sourcing of the equipment and materials from
Bolivian or South American Sources.
• Execution by a general contractor team owned by GNRE with the
capacity to manage and execute the full scope of work to be per-
formed.
• Training of local residents so that they can be productively em-
ployed during the construction phase.
• Establishment of a construction-driven schedule.
ERCOSPLAN establishes a protocol between GNRE-COMIBOL and the Project Management

contractor.
It is important to have representatives on both sides with sufficient experi-
ence in such projects and to define the responsibilities of both parties.
Also note that the project procedures manual will be prepared by the
project implementation team of GNRE where the most important aspects
including project will be defined:
• Communication and organization between members of the GNRE
project execution team and others
• Work methods
• Project schedule and budget
• Review and approval of technical documents
• Project coding for documents, drawings and cost control
• Project meetings and reviews
• Coordination with stakeholders
• Project monthly report format/ progress reporting
• Applicable languages
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• Change order procedure

• Procurement procedure
• Visits to the project site and vendor’s workshops.
In this project, a detailed schedule of the overall development of the pro- Project Schedule
ject including activities is attached as Appendix G6
• Basic Engineering
• Detailed Engineering
• Acquisition
• Construction
• Mounting
• Commissioning.
At the same time a timely supply of equipment, materials and accessories
is considered in order to minimize the time until the start of production.
The full scope of engineering is defined in terms of activities. Project Services

Work plan will be defined with relevant activities by monitoring the pro- Controls
gress and advancement of the work.
It is also important to approve by the superiority the man-hour cost that
will be fixed.
So, the real cost have to be monitored and possible deviations from the
original budget have to be analyzed.
The management is very important during the construction phase to co- Construction
ordinate, direct and supervise the work of contractors on site. Management
During this stage it is very important to locate aspects like temporary facil-
ities, machinery park which will assist in the execution of the work, mate-
rial stockpile areas.
On the other hand it is also important to exercise oversight of the con-
struction process and take steps to ensure the safety and health of work-
ers.
Performance tests and studying the technical specifications of the materi-
als put in work is also important, always under the control of activities at
the time reflected in the work plan.
Also for maintenance of the environment, it is necessary to manage
wastes generated on site, implanting during the construction phase and
marking guidelines for actions to be followed.
Before commissioning of the plant, test runs and several checks have to
be performed to control that all equipment and facilities work properly.
The necessary staff has been classified into different groups with different Personnel Require-
salary levels based on their qualifications. Shifts will be three a day, each ments
shift lasting eight hours.
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Therefore ERCOSPLAN proposes the following levels working together

each with the number of positions.
For management level, 8 positions are required. 84 technical positions
are calculated for processing personnel and 43 positions for maintenance
personnel.
Along with these, 112 other new jobs will be provided for administration,
laboratory, services etc.
Taking into account the stage of construction and commissioning and
operation, a total of 247 new jobs will be created, which will activate the
economy in the area.
ERCOSPLAN developed a table with the three most important equipment Technical Evaluation
suppliers. Quotations
The table provides for each company contact person, date of request of
proposal, quotation number, the date of quotation and the number of
appendix where the quotation can be found.
Finally ERCOSPLAN show the quotations that have been considered in
the detail engineering. Attached to this final report are only quotations
that have been considered in the Detailed Engineering.
It defines the average consumption required for production of KCl at plant Media Consumption
site with respect to:
• Raw material is in the evaporation pools.
• Water consumption
• Power consumption
• Consumption of liquefied gas
• consumption of chemicals
• Fuel for trucks, cars, machinery
• Oils and lubricants.
In general, ERCOSPLAN propose ensuring the safety and health of work- Risk Analysis
ers as well as measures to ensure environmental protection.
Prior to the commencement of activities, a safety and health plan will be
presented showing risks and preventive measures based on the activities
as well as the made jobs.
Also risks for accidents caused by natural phenomena or fire are men-
tioned.
The basic structure of a plan of emergency must be defined and ap-
proved by the superiority during implementation and commissioning of
the plant site.
Environmentally it is referred to the various risks arising by water, atmos-
phere and soil. Therefore it is important to have a plan of environmental
protection where preventive measures as well as the regeneration or envi-
ronmental restoration of the area are indicated.
It should be noted that ensuring the safety and health of workers at the
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plant at different stages and environmental protection should be gov-

erned by the Bolivian legislation.
All machinery, materials and equipment that are within ERCOSPLAN’s Capital Cost Estimate
scope have been chosen according to the widespread experience of the
authors in potash processing operations worldwide.
Remarks: All equipment, buildings, devices that are outside battery limits
(especially water sewage, furniture, laboratory equipment, equipment for
office, administration building, laboratory, canteen, warehouse, work-
shop, fire station, hospital and vehicles such as fire ambulances, trucks,
cranes, buses, loaders, vehicles) have not been considered in this calcu-
lation.
The direct CAPEX include: Cost Direct CAPEX

• Costs for site preparation, infrastructure, buildings and areas
Costs related to the preparation of the plant area, construction of
facilities and infrastructure, tailing areas.
• Costs for production facilities (scope of ERCOSPLAN)
Machines, material, systems and works necessary for processing
of the raw ore to the final product, including electrical equipment.
The total project costs are: Total Project Cost
Total project direct cost 184,513,199.22 USD
Total project indirect cost 36,902,639.84 USD
Total project contingency 11,070,791.95 USD
Total project capital expenditures 232,486,631.01 USD
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LIST OF CONTENTS
EXECUTIVE SUMMARY 2
LIST OF CONTENTS 14
LIST OF FIGURES 21
LIST OF TABLES 22
LIST OF ENCLOSURES 23
LIST OF APPENDICES 24
LIST OF DRAWINGS 28
LIST OF ABBREVIATIONS 50
1 Introduction 51
2 Project History, Database and Battery Limits 53
2.1 Project History 53
2.2 Database 54
2.2.1 Design Base 54
2.3 Battery Limits 55
2.3.1 Interface Delivery of Wet Crystallizate from Evaporation Ponds 55
2.3.2 Interface Product Truck Loading 55
2.3.3 Interface Debrined Tailings to Tailings Pile 55
2.3.4 Interface Brine Disposal 55
2.3.5 Interface Delivery of Process Media 55
3 Nomenclature 57
3.1 Indication Code for Devices and Equipment 57
3.2 Indication Code for Measuring and Control Points 58
3.3 Indication Code for Pipelines / Chutes 61
3.4 Indication Code for Valves 61
3.5 Overview of Media Codes (Can Be amended Anytime) 62
4 Belonging Documents 63
4.1 General Documents 63
4.1.1 Design Base Document 63
4.1.2 Equipment Quotations 63
4.1.3 Cost Estimation Equipment 63
4.1.4 Cost Estimation Pipes 64
4.1.5 Cost Estimation Valves 64
4.1.6 Cost Estimation Electrical Equipment 64
4.1.7 Cost Estimation Civil Works (Infrastructure, Buildings) 64
4.1.8 Project Schedule 64
4.2 Documents Processing Engineering 65
4.2.1 Block Flow Diagram 65
4.3 Documents Mechanical Engineering 65
4.3.1 Equipment List 65
4.3.2 Equipment Data Sheets 65
4.3.3 Drawing List 65
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4.3.4 List of Instruments 66

4.3.5 Equipment Specifications 66
4.3.6 General Inquiry Specification 66
4.3.7 Pipes List 66
4.3.8 Valve List 66
4.3.9 Pipe Classification 67
4.3.10 Equipment Supplier List 67
4.3.11 Piping and Instrumentation Diagrams (PID) 67
4.3.12 Arrangement Drawings 67
4.3.13 Piping Isometric Drawings 68
4.4 Documents Electrical Engineering 68
4.4.1 Appendices 68
4.4.1.1 Appendix E1 / Energy Consumer 68
4.4.1.2 Appendix E2 / Electrical Energy Demand 68
4.4.1.3 Appendix E3 / Utilized Capacity Power Supply System 68
4.4.1.4 Appendix E4 / Cable List Power Supply System 68
4.4.1.5 Appendix E5 / Cable List 0.69KV cable 69
4.4.1.6 Appendix E6 / Cable List Control Cable 69
4.4.1.7 Appendix E7 / Cable List Lighting, Socket System 69
4.4.1.8 Appendix E8 / Control Circuits 69
4.4.1.9 Appendix E9 / Interlocking System 69
4.4.1.10 Appendix E10 / I/0-List 70
4.4.1.11 Appendix E11 / Short Circuit Calculation 70
4.4.1.12 Appendix E12 / Voltage Drop Calculation 70
4.4.1.13 Appendix E13 / Lighting Calculation 70
4.4.1.14 Appendix E14 / Cable List Information System 70
4.4.1.15 Appendix E15 / Requirements Rooms Power Station 71
4.4.1.16 Appendix E16 / Cable List Automation System 71
4.4.1.17 Appendix E17 and E17.1 / Specification 71
4.4.2 Drawings 71
4.4.2.1 Power Supply System (E2000 – E2005) 71
4.4.2.2 0.69kV-Switch Gears MCC (E2011 – E2040) 71
4.4.2.3 0.4kV-Switch Gears (E2071 – E2091) 72
4.4.2.4 Equipment (E2101 – E2111) 72
4.4.2.5 Main Cable Trays (E2121 – E2131) 72
4.4.2.6 Lighting and Socket System (E2201 – E2222) 72
4.4.2.7 Control Cabinets (E2300 – E2351, 2393 – 2400) 72
4.4.2.8 Typical Wiring Diagrams (E2353 – E2391) 72
4.4.2.9 Automation Equipment (E2401 – E2409) 72
4.4.2.10 Room Planning (E2501 – E2504) 73
4.4.2.11 Lightning Protection (E2550 – E2576) 73
4.4.2.12 Communication / Safety Equipment (E2601 – E2671) 73
4.5 Documents Building and Structural Engineering 73
5 Property Description 74
5.1 Location 74
5.2 Meteorological Conditions, Earthquake Risk, Soil Conditions 74
5.2.1 Meteorological Conditions 74
5.2.2 Earthquake Risk 77
5.2.3 Soil Conditions 77
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6 Process Design for MOP Production 78

6.1 General 78
6.2 Design Qualities and Quantities 79
6.3 Process Scheme and Processing Description 81
6.3.1 Crystallisate Debrining 83
6.3.2 Crystallisate Treatment 83
6.3.3 Rougher Flotation 83
6.3.4 Cleaner Flotation and Leaching 84
6.3.5 Scavenger Flotation 84
6.3.6 Reclaim Brine and Solid Tailings Handling 84
6.3.7 KCl-Product Debrining and Drying 85
6.3.8 Mass Flow Table and Mass Flow Balance 85
6.4 Process Reagents 110
7 Production Facilities 112
7.1 Production Plant Description 112
7.1.1 Process Building 112
7.1.2 Outside Facilities 113
7.2 Design Criteria and Memories of Calculation of Major Equipment 114
7.2.1 Design Criteria 114
7.2.2 Memories of Calculation of Major Equipment 114
7.3 Infrastructural Battery Limits 115
7.3.1 Road 115
7.3.2 Water Supply 115
7.3.3 Consumables Supply 115
7.3.4 Power Supply 116
7.4 Processing Facility and Process Sections 116
7.4.1 Processing Facility 116
7.4.1.1 Design Capacity 116
7.4.1.2 General Requirements 116
7.4.1.3 Corrosion – Abrasion 118
7.4.1.4 Welding 118
7.4.1.5 Gears and Gear Type Speed Reducers 118
7.4.1.6 Chain Drives 118
7.4.1.7 V-Belt Drives 118
7.4.1.8 Couplings 119
7.4.1.9 Bearings 119
7.4.1.10 Seals 119
7.4.1.11 Lubrication 120
7.4.1.12 Safety Guards 120
7.4.1.13 Base Plates 121
7.4.1.14 Screw Conveyors 121
7.4.1.15 Drag Chain Conveyors 121
7.4.1.16 Chutework 122
7.4.1.17 Slurry Pumps 122
7.4.1.18 Tanks 124
7.4.1.19 Pipes and Pipe Classification 124
7.4.1.20 Secondary Steelworks 126
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7.4.1.21 Assembly, Mounting and Erection of Equipment at Plant Site 127

7.4.2 Technical Description of Selected Main Equipment 127
7.4.2.1 Portal Scraper 127
7.4.2.2 Centrifuges 134
7.4.2.3 Wet Screen 146
7.4.2.4 Rod Mill 147
7.4.2.5 Flotation 153
7.4.2.6 Vacuum Belt Filter 154
7.4.2.7 Fluid Bed Dryer / Cooler 159
7.4.3 Equipment Test Work 159
7.4.4 Technical Description of Process Sections 160
7.4.4.1 Wet Salt Storage Including Truck Loadout 160
7.4.4.2 Wet Milling and Screening 162
7.4.4.3 Rougher Flotation 164
7.4.4.4 Reagent Dosing Plant 165
7.4.4.5 Cleaner Flotation 170
7.4.4.6 Cold Leaching and Product Dewatering 171
7.4.4.7 Scavenger Flotation 173
7.4.4.8 Tails Process 174
7.4.4.9 Compressor Plant 175
7.4.4.10 Process Water Storage 176
7.4.4.11 Reclaim Brine Storage 178
7.4.4.12 Rinsing Water System 180
7.4.4.13 Sealing Water System 180
7.4.4.14 Drying Section 182
7.4.4.15 Product Storage 189
7.4.4.16 Truck Loading 190
7.4.5 Description of Control Loops (Control Circuits) 192
7.5 Operation Manuals 193
7.5.1 Preconditions for start-up Process respectively Notice of Start of Operation 193
7.6 Utilities 196
7.6.1 Electrical Power Supply 196
7.6.1.1 Energy Demand 196
7.6.1.2 Power Generator Station 196
7.6.1.3 Power Supply via Local Grid 197
7.6.2 Process Water Treatment 197
7.6.3 Waste Water Treatment 197
7.6.4 Rain Water Drainage 198
7.7 Processing Facility Infrastructure 198
7.7.1 Energy Supply and Electrical Distribution 198
7.7.1.1 Energy Source Generator Power Station 198
7.7.1.2 Energy Source Local Grid 198
7.7.1.3 Power Distribution 199
7.7.1.4 Grounding / Equipotential System / Lightning Protection 202
7.7.2 Automation System 203
7.7.2.1 Control Philosophy 203
7.7.2.2 Control System 204
7.7.2.3 Instruments 208
7.7.3 Communication and Safety Equipment 208
7.7.3.1 Communication 208
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7.7.3.2 Safety Equipment 209

7.7.3.3 Video Camera Monitoring 211
7.7.4 Water Supply (Process, Fire Fighting Water) 211
7.7.5 Waste Management 211
7.8 Structural / Architectural Systems 212
7.8.1 General 212
7.8.1.1 Soil Preparation 212
7.8.1.2 Buildings 212
7.8.1.3 Facilities 213
7.8.1.4 Infrastructure 213
7.8.2 Process Buildings 213
7.8.2.1 Process Building 213
7.8.2.2 Wet Salt Storage 215
7.8.2.3 Product Storage 216
7.8.2.4 Truck Loading 216
7.8.2.5 Distribution Tower 1 216
7.8.2.6 Distribution Tower 2 217
7.8.3 Secondary Buildings 217
7.8.3.1 Power Station 217
7.8.4 Infrastructure 218
7.8.4.1 In-plant Roads 218
7.8.4.2 Belt Conveyors 218
7.8.4.3 Sewage Pipe System 219
7.8.4.4 Sewage Plant 219
7.8.5 Facilities 219
7.8.5.1 Truck Unloading 219
7.8.5.2 Outside Process Area 219
7.8.5.3 Reclaim Brine Storage 220
7.8.5.4 Generation Storage 220
7.8.5.5 Rainwater Retention Basins 220
7.8.5.6 Tailing Pile (outside battery limits) 222
8 Project Execution 223
8.1 Objectives 223
8.2 Criteria 223
8.3 Project Management 223
8.3.1 Mobilization and Project Kick-Off 223
8.3.2 Project Procedures 224
8.3.3 Project Meetings 224
8.3.4 Communications 225
8.3.5 Reporting 225
8.3.6 Project Organization 226
8.4 Project Schedule 226
8.5 Project Services and Controls 228
8.5.1 Overall Plan and Procedures for Project Controls 228
8.5.2 Scope Definition and Control 228
8.5.3 Schedule Control 228
8.5.4 Man-Hour Control 229
8.5.5 Cost Control 229
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8.5.6 Project Change Control 230

8.6 Construction Management 230
8.6.1 Construction Camp 231
8.6.2 Safety 231
8.6.3 Execution Supervision 231
8.6.4 Quality Control 232
8.6.5 Scheduling and Productivity Control 232
8.6.6 Labor Relations 232
8.6.7 Security 232
8.6.8 Materials Control 232
8.6.9 Construction Waste Disposal 233
8.6.10 Pre-Commissioning 233
8.6.11 Commissioning and Start-up 234
8.7 Overall Operations 235
8.7.1 General 235
8.7.2 Personnel Requirements 236
8.8 Technical Evaluation of Quotations 245
8.9 Capital Cost Estimate 250
8.9.1 Direct CAPEX 250
8.9.1.1 Main Equipment Estimation 250
8.9.1.2 Pipes and Valves Estimation 250
8.9.1.3 Electrical Equipment / Instrumentation / Communication / Automation 251
8.9.1.4 Infrastructure, Building 251
8.9.2 Capital Expenditures 251
8.9.3 Media Consumption 253
8.9.4 Crystallizate 253
8.9.5 Process Water 253
8.9.6 Electrical Energy 253
8.9.7 Liquefied Petroleum Gas 253
8.9.8 Process Chemicals 254
8.9.9 Fuel for Combustion Engines 254
8.9.10 Oil and Lubricants 254
8.10 Risk Analysis 254
8.10.1 Prevention in Work Risk 254
8.10.2 Risks 255
8.10.2.1 Accident Risks 255
8.10.2.2 Risk by Natural Phenomenon 256
8.10.2.3 Risk of Fire 256
8.10.2.4 Risks in the Transport; Handling and Storage of Hazardous Waste 257
8.10.3 Emergency Plan 258
8.10.3.1 Performance Standards in Traffic Accidents 259
8.10.3.2 Performance Standards of Accidents caused by Natural Phenomenon 259
8.10.3.3 Performance Standards in the Case of Accidents Caused by Fire and / or Explosion 260
8.10.3.4 Performance Standards Substance Spill and / or Hazardous Waste 260
8.10.4 Environmental Risk Conditions 260
8.10.4.1 On the Water (Potable Water Outside of Salar) 261
8.10.4.2 About the Atmosphere 262
8.10.4.3 Acoustic and Vibration Levels 262
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8.10.4.4 About the Floor 262

8.10.5 Regeneration of Spaces 263
8.10.6 Forecast of Implementation of Environmental Monitoring 263
8.10.7 Bolivian Legislation in Safety and Environment 265
9 Impact on Environment by Processing and Environmental Protection Measures 266
9.1 Impacts by Handling 269
9.2 Impacts by Processing 269
9.3 Waste Generation 270
9.4 Water Consumption 270
9.5 Water Contamination 270
9.6 Soil Contamination 271
9.7 Air Contamination 271
9.8 Noise and Vibration 271
9.9 Resource Maximization 271
9.10 Protection Measures by Waste Management 272
9.10.1 Waste Disposal Methods 272
9.10.2 Tailings 272
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LIST OF FIGURES
Figure 1 Block Flow Diagram (see also Drawing A01) Crystallisate Debrining 82
Figure 2 Cross Section of a Screen Worm Centrifuge CX 135
Figure 3 Overview of modules 137
Figure 4 Hydraulic diagram 7-138
Figure 5 Centrifuge characteristics and circumferential speed 7-139
Figure 6 RF-∆t-diagram 145
Figure 7 Working scheme wet screen 146
Figure 8 Vacuum belt filter 154
Figure 9 Capacities of Truck Loading 191
Figure 10 Organization Chart General Superintendent Process 240
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LIST OF TABLES
Table 1 PCE (Process Control Engineering) Categories and Processing

Functions (According to DIN EN 62424; VDE 0810-24:2010-01) 60
Table 2 Media Codes 62
Table 3 Meteorological Conditions 75
Table 4 Overview of the Precipitation in mm from 2010 to 2012 (Data
provided by GNRE-COMIBOL) 76
Table 5 Mass Flow Table 86
Table 6 Storage Quantities of Process Reagents for 6 Weeks Production 111
Table 7 Selection of Pipe Material 125
Table 8 Water and Anticaking Reagent Consumption for 3 Hours Operating
Time 187
Table 9 Water and Anticaking Reagent Consumption for Continuous Dosing 188
Table 10 Operator Stations 204
Table 11 Control Servers 205
Table 12 Location and Function of Automation Stations AS1 to AS4 205
Table 13 Location and Function of Automation Stations ET 207
Table 14 Rain Data 220
Table 15 Project Meetings 225
Table 16 Project Implementation Schedule 227
Table 17 Complete Management 237
Table 18 Estimate of Required Processing Personnel 237
Table 19 Maintenance Personnel 238
Table 20 Administration Personnel 238
Table 21 QC & Lab Personnel 239
Table 22 Utilities Personnel 239
Table 23 Services Personnel 239
Table 24 Technical Evaluation of Quotations 246
Table 25 Cost Overview of Direct and Indirect Capital Expenditures of
Processing Plant 252
Table 26 Forecast of Implementation of Environmental Monitoring 263
Table 27 Major Potential Environmental Effects that may occur during Potash
Production 267
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LIST OF ENCLOSURES
ENCLOSURE 1 Supplier List Mechanical Engineering (Rev.01)

ENCLOSURE 2 Process Building Heating and Power Station Air-Conditioning
ENCLOSURE 3 Soil Report
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LIST OF APPENDICES
Mechanical Engineering
Appendix A1 Design Base Document
Appendix A2 Equipment List incl. Electrical Energy Consumption (Rev.01)
Appendix A3 Equipment Data Sheets (Rev.02)
Appendix A4 Drawing List (Rev.01)
Appendix A5 List of Instruments (Rev.01)
Appendix A6 Specification Mechanical Equipment (Rev.03)
Appendix A7 Inquiry Specification
Appendix A8 Pipe List (Rev.01)
Appendix A9 Valve List (Rev.01)
Appendix A10 Pipe Classification
Appendix A2.1 Equipment List incl. Electrical Energy Consumption
Appendix A3.1 Equipment Data Sheets (Rev.02)
Appendix A5.1 List of Instruments
Appendix A6.1 Specification Mechanical Equipment (Rev.02)
Appendix A8.1 Pipe List
Appendix A9.1 Valve List
Electrical Engineering
Appendix E1 Energy Consumer (Rev.01)
Appendix E2 Electrical Energy Demand (Rev.01)
Appendix E3 Utilized Capacity Power Supply System (Rev.01)
Appendix E4 Cable List / Power Supply Cable (Rev.01)
Appendix E5 Cable List / 0.69kV Cable (Rev.01)
Appendix E6 Cable List / Control Cable (Rev.01)
Appendix E7 Cable List / Lighting, Socket System (Rev.01)
Appendix E8 Control Circuits
Appendix E9 Interlocking System
Appendix E10 I/O-List (Rev.01)
Appendix E11 Short Circuit Calculation
Appendix E12 Voltage Drop Calculation
Appendix E13 Lighting Calculation
Appendix E14 Cable List / Information System (Rev.01)
Appendix E15 Requirements Rooms Power Station
Appendix E16 Cable List / Automation System
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Appendix E17 Specification

Appendix E17.1 Specification
General Appendices
Appendix G1 Cost Estimation Mechanical Equipment (Rev.01)
Appendix G2 Cost Estimation Pipes (Rev.01)
Appendix G3 Cost Estimation Valves (Rev.01)
Appendix G4 Cost Estimation Electrical Equipment
Appendix G5 Cost Estimation Civil Works (Infrastructure, Buildings) (Rev.01)
Appendix G6 Project Schedule
Appendix G1.1 Cost Estimation Mechanical Equipment
Appendix G2.1 Cost Estimation Pipes
Appendix G3.1 Cost Estimation Valves
Quotations
Appendix Q1 Overbelt Magnetic Separator / Eriez (Rev. 02)
Appendix Q2 Overbelt Magnetic Separator / Steinert (Rev. 01)
Appendix Q3 Flotation / FLSmidth
Appendix Q4 Quotation canceled
Appendix Q5 Pumps / KSB (Rev. 02)
Appendix Q6 Pumps / Allweiler
Appendix Q8 Belt Conveyor / SBM
Appendix Q9 Belt Conveyor / FAM
Appendix Q10 Belt Conveyor / Doubrava
Appendix Q12 Trough Chain Conveyor / Emde
Appendix Q13 Portal Scraper / FAM
Appendix Q14 Portal Scraper / Schade
Appendix Q18 Screen / Siebtechnik TEMA-BV (Rev. 01)
Appendix Q19 Screen / Rhewum (Rev. 01)
Appendix Q20 Rod Mill / FAM (Rev. 01)
Appendix Q21 Mill / FLSmidth
Appendix Q22 Centrifuges / Andritz (Rev. 01)
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Appendix Q23 Centrifuges / Siebtechnik (Rev. 01)

Appendix Q24 Thickener / Andritz (Rev. 01)
Appendix Q25 Thickener / FLSmidth
Appendix Q26 Agitator / Ekato (Rev. 01)
Appendix Q27 Agitator / MUT-Tschamber (Rev. 01)
Appendix Q28 Two-way Distributor / Schaeffer
Appendix Q29 Two-way Distributor / Emde (Rev. 01)
Appendix Q30 Box Feeder / Staudacher
Appendix Q31 Box Feeder / Aumund
Appendix Q32 Box Feeder / SMT Scharf Saar
Appendix Q33 Reagent Dosing Plant / Prominent
Appendix Q34 Reagent Dosing Plant / Lewa
Appendix Q35 Vacuum Belt Filter / Andritz (Rev. 01)
Appendix Q36 Vacuum Belt Filter / FLSmidth
Appendix Q37 Hydrocyclone / FLSmidth
Appendix Q39 Hydrocyclone / AKW
Appendix Q40 Compressor Plant / Nillius
Appendix Q41 Overhead Cranes / Suhler Hebezeugtechnik
Appendix Q42 Valves / IWZ Ingenieurbüro Wolfgang Zierz (Rev.01)
Appendix Q43 Measurement Instruments / Endress + Hauser (Rev.02)
Quotations Drying Section

Appendix Q50 Dryer/Cooler Package / Andritz
Appendix Q51 Dryer/Cooler Package / Binder
Appendix Q52 Dryer/Cooler Package / Imtech Ventilex
Appendix Q53 Dryer/Cooler Package / TEMA (Rev. 01)
Appendix Q54 Pump / KSB
Appendix Q57 Belt Conveyor / SBM (Rev. 03)
Appendix Q59 Bucket Elevator / Two-Way-Distributor / Emde
Appendix Q60 Mixer / Emde
Appendix Q62 Mixer / Lodige
Appendix Q63 Anticaking Dosing Package / LEWA HOV (Rev. 01)
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Appendix Q64 Agitator Vessel / IWZ Ingenieurbüro Wolfgang Zierz

Appendix Q65 Valves / IWZ Ingenieurbüro Wolfgang Zierz
Appendix Q66 Instruments / SWR engineering Messtechnik
Structural Engineering
Appendix S1 Structural Analysis Wet Salt Storage
Appendix S2 Structural Analysis Process Building. Building Stabilization Part 1
Appendix S3 Structural Analysis Process Building. Building Stabilization Part 2
Appendix S4 Structural Analysis Process Building. Platforms
Appendix S5 Structural Analysis Truck Unloading
Appendix S6 Structural Analysis Distribution Tower 1
Appendix S7 Structural Analysis Power Station
Appendix S8 Calculation of Rainwater Retention
Appendix S9 Rough Steel Lists, Technical Specifications for Construction
Appendix S10 Structural Analysis Truck Loading
Appendix S11 Structural Analysis Distribution Tower 2
Appendix S12 Structural Analysis Foundations (Process Building, Wet Salt Storage,
Truck Unloading, Distribution Tower 1, Outside Facilities)
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LIST OF DRAWINGS
A 0001-0999 Drawings Processing Engineering
A01/2 Block Flow Diagram
A 1000-1999 Drawings Mechanical Engineering
A 1000-1199 Basic Engineering
A 1000-1049 Process Flow Diagrams (PFD)
A 1050-1099 Piping and Instrumentation Diagrams (PID)
A 1100-1199 Arrangement Drawings
A 1350-1999 Detail Engineering
A 1350-1400 Piping and Instrumentation Diagrams (PID)

A1350/1 PID Wet Salt Storage
A1351/1 PID Wet Screening and Milling Line A
A1352/1 PID Wet Screening and Milling Line B
A1353/1 PID Rougher Flotation Line A
A1354/1 PID Rougher Flotation Line B
A1355/1 PID Cleaner / Scavenger Flotation Line A
A1356/1 PID Cleaner / Scavenger Flotation Line B
A1357/1 PID Cold Leaching and Product Dewatering Line A
A1358/1 PID Cold Leaching and Product Dewatering Line B
A1360/1 PID Reagent Dosing Plant
A1361/1 PID Tails Process Line A
A1362/1 PID Tails Process Line B
A1363/1 PID Compressor Plant
A1364/1 PID Process Water Storage
A1365/1 PID Reclaim Brine Storage
A1366/1 PID Rinsing Water System Line A
A1367/1 PID Rinsing Water System Line B
A1368/1 PID Sealing Water System Line A
A1369/1 PID Sealing Water System Line B
A1370 PID Drying Line A
A1371 PID Drying Line B
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A1372/1 PID Product Storage

A1373/1 PID Truck Loading
A1374 PID Anticaking Agent Dosing System
A 1400-1508 Arrangement Drawings

A1401 Arrangement Drawing Process Building Platform +18.00m Part 1
A1405/1 Arrangement Drawing Process Building Platform +6.00m Part 1
A1406/1 Arrangement Drawing Process Building Platform +6.00m Part 2
A1407 Arrangement Drawing Process Building Ground Floor +/- 0.00m-Part 1
A1408 Arrangement Drawing Process Building Ground Floor +/- 0.00m-Part 2
A1409/1 Arrangement Drawing Process Building Outside Facilities Overview
A1410 Arrangement Drawing Process Building Drying Section Ground Floor +/- 0.00m
A1411 Arrangement Drawing Process Building Drying Section Platform +4.00m/
+6.00m
A1412 Arrangement Drawing Process Building Drying Section Platform +9.00m
A1420 Arrangement Drawing Process Building Longitudinal Section A'-A'
A1421 Arrangement Drawing Process Building Longitudinal Section A''-A''
A1422 Arrangement Drawing Process Building Longitudinal Section A-A
A1423 Arrangement Drawing Process Building Longitudinal Section B-B
A1424 Arrangement Drawing Process Building Longitudinal Section C-C
A1425 Arrangement Drawing Process Building Longitudinal Section D-D
A1426 Arrangement Drawing Process Building Longitudinal Section E-E
A1427 Arrangement Drawing Process Building Longitudinal Section F-F
A1428 Arrangement Drawing Process Building Longitudinal Section G-G
A1429 Arrangement Drawing Process Building Longitudinal Section H-H
A1430/1 Arrangement Drawing Process Building Longitudinal Section I-I
A1431/1 Arrangement Drawing Process Building Longitudinal Section J-J
A1432/1 Arrangement Drawing Process Building Longitudinal Section K-K
A1433/1 Arrangement Drawing Process Building Longitudinal Section L-L
A1434 Arrangement Drawing Process Building Longitudinal Section M-M
A1435 Arrangement Drawing Process Building Longitudinal Section N-N
A1436 Arrangement Drawing Process Building Longitudinal Section O-O
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A1437 Arrangement Drawing Process Building Longitudinal Section O'-O'

A1438 Arrangement Drawing Process Building Outside Facilities
Longitudinal Section P-P
A1440 Arrangement Drawing Process Building Drying Section
Longitudinal Section A-A; C-C
Longitudinal Section D-D; E-E
Longitudinal Section F-F; G-G
Longitudinal Section H-H; I-I
Longitudinal Section J-J; K-K
A1450 Arrangement Drawing Process Building Cross Section 1'-1'
A1451 Arrangement Drawing Process Building Cross Section 1-1
A1463/1 Arrangement Drawing Process Building Cross Section 14-14
A1464 Arrangement drawing Process Building Cross Section 15-15
A1469 Arrangement Drawing Process Building Outside Facilities Cross Section 1''-1''
A1470 Arrangement Drawing Process Building Main Pipeline Routes
A1480 Arrangement Drawing Process Building Drying Section Cross Section 16-16
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A1501 Parameter for Civil Engineering Process Building Platform +18.00m Part 1
A1505/1 Parameter for Civil Engineering Process Building Platform +6.00m Part 1
A1506/1 Parameter for Civil Engineering Process Building Platform +6.00m Part 2
A1507/1 Parameter for Civil Engineering Process Building Ground Floor +/- 0.00m Part 1
A1508/1 Parameter for Civil Engineering Process Building Ground Floor +/- 0.00m Part 2
A1510 Parameter for Civil Engineering Process Building Drying Section
Ground Floor +/- 0.00m
Platform +4.00/+6.00m
Platform +9.00m
Platform +15.50m
Platform +18.00m
E 2000-2999 Drawings Electrical Engineering
E2000/1 Power supply / Overview diagram

E2001 24.9kV-Switch gear / Overview diagram
E2002/1 6kV-Main switch gear SM / Overview diagram
E2003 6kV-Generator switch gear SG / Overview diagram
E2004 24.9kV-Switch gear / Assembly plans
E2005 6kV-Main switch gear SM / Assembly plans
E2011 0.69kV-Switch gear MCC1 / Overview diagram
E2013/1 0.69kV-Switch gear MCC3 / Overview diagram
E2031 0.69kV-Switch gear MCC1 / Assembly plan
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E2032 0.69kV-Switch gear MCC 2 / Assembly plan

E2033/1 0.69kV-Switch gear MCC 3 / Assembly plan
E2071/1 0.4kV-Main switch gear / Overview diagram

E2072/1 0.4kV-Main switch gear / Assembly plan
E2073 0.4kV-Subdistribution UV 1 / Overview diagram
E2075 0.4kV-Subdistribution HV / Overview diagram
E2101/1 Equipment / Process building Ground floor / Layout

E2102 Equipment / Process building +6.00m / Layout
E2105/1 Equipment outside / Layout
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E2106/1 Equipment tank farm / Layout

E2107 Equipment / Drying section Ground floor / Layout
E2108 Equipment / Drying section +4,0/+6,0m / Layout
E2109 Equipment / Drying section +9,0m / Layout
E2110 Equipment / Drying section +15,5m / Layout
E2111 Equipment / Drying section 18,0 m / Layout
E2121/1 Main cable trays / Process building Ground floor / Layout

E2122/1 Main cable trays / Process building +6.00m / Layout
E2123/1 Main cable trays / Process building +12.00m / Layout
E2124 Main cable trays/ Process building +18.00m / Layout
E2125/1 Main cable trays / Power station +6.00m / Layout
E2126/1 Main cable trays outside/ Layout
E2127 Main cable trays / Drying section Ground floor / Layout
E2128 Main cable trays / Drying section +4,0/+6,0m / Layout
E2129 Main cable trays / Drying section 6,0m / Layout
E2201/1 Lighting - Socket system / Power station Ground floor / Layout

E2202/1 Lighting - Socket system / Power station +6.00m / Layout
E2205/1 Lighting - Socket system /Process building Ground floor / Layout
E2206/1 Lighting - Socket system /Process building +6.00m / Layout
E2209/1 Lighting system / Streets / Layout
E2210 Lighting - Socket system /Wet salt storage / Layout
E2211 Lighting – Socket system and Automation equipment / Product storage Page 1-2
/ Layout
E2212 Lighting system and Automation equipment / Truck loading Ground floor,
+3,07m / +7,93m / Layout
E2213 Lighting system / Truck loading Platform, +12,61m / +24,80m / Layout
E2216 Lighting system and Automation equipment / Distribution Tower 2 Ground floor,
+3,51m / Layout
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E2217 Lighting system and Automation equipment / Distribution Tower 2 +9,27m, Roof
/ Layout
E2218 Lighting – Socket system / Drying section Ground floor / Layout
E2219 Lighting – Socket system / Drying section +4,0/+6,0m / Layout
E2220 Lighting – Socket system / Drying section +9,0m /Layout
E2221 Lighting – Socket system / Drying section +15,5m / Layout
E2222 Lighting – Socket system / Drying section +18,0m / Layout
E2300/1 Automation system / Overview diagram

E2301 Control cabinet AS 01 / Overview diagram
E2305 Control cabinet ET 01 / Overview diagram

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E2350 Control cabinet DCS1 / Overview diagram
E2351 Control cabinet DCS2 / Overview diagram
E2353 Typical wiring diagram WD1.1 / Pump < 10kW

E2354 Typical wiring diagram WD1.2 / Pump > 10kW
E2355 Typical wiring diagram WD1.3 / Pump with frequency converter
E2356 Typical wiring diagram WD2.1 / Belt conveyor < 10kW
E2357 Typical wiring diagram WD2.2 / Belt conveyor > 10kW
E2358 Typical wiring diagram WD2.3 / Belt conveyor with frequency converter
E2359 Typical wiring diagram WD3.1 / Trough chain conveyor < 10k
E2360 Typical wiring diagram WD3.2 / Trough chain conveyor > 10kW
E2361 Typical wiring diagram WD3.3 / Trough chain conveyor with frequency converter
E2364 Typical wiring diagram WD4.1 / Blower < 10kW
E2365 Typical wiring diagram WD4.2 / Blower > 10kW
E2366 Typical wiring diagram WD5.1 / Belt filter
E2367 Typical wiring diagram WD5.2 / Belt filter with frequency converter
E2368 Typical wiring diagram WD6.1 / Agitator < 10kW
E2369 Typical wiring diagram WD6.2 / Agitator > 10kW
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E2370 Typical wiring diagram WD6.3 / Agitator with frequency converter
E2374 Typical wiring diagram WD7.1 / Centrifuge

E2375 Typical wiring diagram WD7.2 / Centrifuge –Oil pump
E2376 Typical wiring diagram WD8.1 / Flotation cell – Agitator
E2377 Typical wiring diagram WD8.2 / Flotation cell – Skimmer
E2378 Typical wiring diagram WD17.1 / Rotary feeder
E2380 Typical wiring diagram WD9.1 / Two-way-distributor (on/off)

E2381 Typical wiring diagram WD9.2 / Two-way-distributor (with intermediate position)
E2382 Typical wiring diagram WD10.1 / Movable and reversible conveyor - chassis
E2383 Typical wiring diagram WD10.2 / Movable and reversible conveyor –
belt conveyor
E2384 Typical wiring diagram WD11.1 / Crusher
E2385 Typical wiring diagram WD12.1 / Wet screen
E2386 Typical wiring diagram WD13.1 / Overbelt magnetic separator
E2387 Typical wiring diagram WD16.1 / Screw conveyor <10kW
E2389 Typical wiring diagram WD16.3 / Screw conveyor with Frequency converter
E2391 Typical wiring diagram WD15.2 / Bucket elevator >10kW

E2401/1 Automation equipment / Process building Ground floor / Layout

E2402 Automation equipment / Process building +6.00m / Layout
E2403 Automation equipment / Process building +12.00m / Layout
E2404 Automation equipment Process building +18.00m / Layout
E2405 Automation equipment / Drying section Ground floor / Layout
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E2406 Automation equipment / Drying section +4,0m / +6,0m / Layout

E2407 Automation equipment / Drying section +9,0m / Layout
E2501/1 Power station / Room planning 0.00m, +6.00m

E2502/1 Power station / Room planning +8.55m, +12.60m
E2504 Generator power station / Room planning
E2550/1 Meshing earthing / Equipotential system outside / Layout

E2551 Lightning protection / Process building and Power station / Floor plan
E2552 Lightning protection / Process building and Power station / Roof plan
E2561 Lightning protection / Wet salt storage / Page 1-8
E2562 Lightning protection / Product storage / Page 1-8
E2571 Lightning protection / Generator station / Page 1-4
E2573 Lightning protection / Truck loading Ground floor

E2574 Lightning protection / Truck loading Roof plan
E2575 Lightning protection / Distribution Tower 2 Ground floor
E2576 Lightning protection / Distribution Tower 2 Roof plan
E2601 Communication system / Overview diagram
E2651/1 Automatic fire protection / Overview diagram

E2652/1 Video control system / Overview diagram
E2653 Automatic fire protection / Video control system /Process building Ground floor
E2654 Automatic fire protection / Video control system /Process building +6.00m
E2657/1 Automatic fire protection / Video control system / Outside
E2658 Automatic fire protection / / Video control system / Wet salt storage / Page 1-2
E2659/1 Automatic fire protection / Power station / Ground floor
E2660/1 Automatic fire protection / Power station / +6.00m
E2663 Automatic fire protection / Generator station
Page 37 of 273
EAT 11-024
E2664 Automation fire protection Video control system / Product storage / Page 1-2
E2665 Automation fire protection Video control system / Truck loading
E2666 Automation fire protection Video control system / Drying section Ground floor /
Layout
E2667 Automation fire protection Video control system / Drying section +4,0m / +6,0m
/ Layout
E2668 Automation fire protection Video control system / Drying section +9,0m / Layout
E2669 Automation fire protection Video control system / Drying section +15,5m /
Layout
E2670 Automation fire protection Video control system / Drying section +18,0m /
Layout
E2671 Access control system / Overview diagram
3000-3999 Drawings Building/Structural and Civil Engineering
3001/1 Site Layout Plan
3002-3011 Basic Engineering
Page 38 of 273
EAT 11-024
3100-3999 Detail Engineering
Wet Salt Storage

3100/1 Ground Plan Grid 1 – 13
3101/1 Ground Plan Grid 13 - 26
3102/1 Cross Section
3103/1 Longitudinal Bracings
3104 Conveyor Platform +22.80 m, Grid Line 1-15
3106 Roof Construction, Purlins Arrangement, Grid Line 1-13
3108/1 Front Wall Construction, Grid Line 1
3109/1 Front Wall Construction, Grid Line 26
3110/1 Stairs Tower
3111/1 Anchoring Plan, Anchor Detail, Grid Line 1-13
3112/1 Anchoring Plan, Anchor Detail, Grid Line 13-26
3115 Views
3121 Gate / Door Details
Process Building
3200 Ground Plan, Grid Line 1-9 / A-H
3201 Ground Plan, Grid Line 1-9 / H-O
3202/1 Ground Plan, Grid Line 10-20 / A-H
3203/1 Ground Plan, Grid Line 10-20 / H-O
3204 Platform +6.00 m, Grid Line 1-9 / A-H
3205 Platform +6.00 m, Grid Line 1-9 / H-O
3206/1 Platform +6.00 m, Grid Line 10-20 / A-H
3207/1 Platform +6.00 m, Grid Line 10-20 / H-O
3208/1 Service Platforms on Platform +6.00 m
3209/1 Platform +9.00 m
3210/1 Platform +4.00 m
3215/1 Service Platforms on Platform +12.00 m
3216 Platform +15.00 m
Page 39 of 273
EAT 11-024

3221 Service Platforms on Platform +18.00 m
3222 Overhead Maintenance Crane Runways
3224 Roof Structure, Grid Line 1-9 / A-H
3225 Roof Structure, Grid Line 1-9 / H-O
3226 Roof Structure, Grid Line 10-20 / A-H
3227 Roof Structure, Grid Line 10-20 / H-O
3228/1 Elevation on Grid A
3229/1 Elevation on Grid O
3230 Elevation on Grid 1
3231/1 Elevation on Grid 20
3240 Foundation Loads
3241 Anchor Details
3250 Roof Details
3260 Exterior Wall Details
Product Storage
3300 Ground Plan Grid 1 – 13
3301 Ground Plan Grid 13 - 26
3302 Cross Section
3303 Longitudinal Bracings
3308 Front Wall Construction, Grid Line 1
3309 Front Wall Construction, Grid Line 26
3310 Stairs Tower
3311 Anchoring Plan, Anchor Detail, Grid Line 1-13
3312 Anchoring Plan, Anchor Detail, Grid Line 13-26
3315 Views
3320 Gate / Door Details
Page 40 of 273
EAT 11-024
Truck Unloading
3400 Top View, Cross Sections
3401 Ground Plans
3402 Sections
3403 Bin Structure
3404 Abutments. Formwork Plan
Truck Loading
3500 Ground Plan -0.50 m, Platform +3.07 m, +4.87 m, +7.93 m
3501 Platform +12.61m, +14.95/17.11 m, +19.27 and Roof View
3502 Elevation on Grid Line 1, 2, and 3
3503 Elevation on Grid Line 4, 5 and 6
3504 Elevation on Grid Line A
3505 Elevation on Grid Line B
3507 Anchoring Plan, Anchor Detail
3510 Views
Power Station
3600/1 Ground Floor
3601/1 Level +6.00 m
3602/1 Level +8.55 m
3603/1 Level +12.60 m
3604/1 Level +16.00 m
3605/1 Cross Section A-A
3606/1 Longitudinal Section B-B
3607 Elevations
3608 Roof Steel Structure
In-plant Roads, Cable Lines, Belt Conveyor Foundations, Evaporation

Ponds, Rainwater Retention Basins
3700 Evaporation Pond, Dike Section
3705 Building Ground Preparation
3710/1 Belt Conveyor Foundations / Cable Channels. Section Wet Salt Storage
3711 Belt Conveyor Foundations / Cable Channels. Section Product Storage
3720 In-plant Roads. Section Truck Loading
Page 41 of 273
EAT 11-024
3721 In-plant Roads. Section Process Building

3722 In-plant Roads. Section Product Storage
3723 In-plant Roads. Section Truck Unloading
3724 In-plant Roads. Section Wet Salt Storage
3725 In-plant Roads. Principle Cross Sections
3726 In-plant Roads. Longitudinal Profiles
Distribution Tower 1
3800/1 Ground Plan -0.50 m, Platform +4.05 m, +7.65 m
3801/1 Platform +13.59 m, 19.17 m, and Roof
3802/1 Elevation on Grid 1, 2, and 3
3803/1 Elevation on Grid 4 and 5
3804/1 Elevation on Grid A
3805/1 Elevation on Grid B
3806/1 Elevation on Grid C
3807/1 Anchoring Plan, Anchor Detail
3810/1 Views
Distribution Tower 2
3850 Ground Plan -0.50 m, Platform +3.51 m
3851 Platform +9.27 m and Roof View
3852 Elevation on Grid Line 1 and 2
3853 Elevation on Grid Line 3 and 4
3854 Elevation on Grid Line A
3855 Elevation on Grid Line B
3856 Elevation on Grid Line C
3857 Anchoring Plan, Anchor Detail
3860 Views
Outside Facilities
3900/1 Outside Process Area. Ground Plan
3901/1 Reclaim Brine Storage / Generator Station. Ground Plan
A 4000-4999 Piping Isometric Drawings
A4002/1 A02-RL-002-SP-125-GFK/PP
A4003/1 A02-RL-003-SP-300-GFK/PP
Page 42 of 273
EAT 11-024
A4005/1 A02-RL-005-SP-300-GFK/PP
A4006/1 A02-RL-006-SP-250-GFK/PP
A4007/1 A02-RL-007-SP-250-GFK/PP
A4008/1 A02-RL-010-SP-350-GFK/PP
A4009/1 A02-RL-015-SP-200-GFK/PP
A4002/1 A02-RL-002-SP-125-GFK/PP
A4003/1 A02-RL-003-SP-300-GFK/PP
A4005/1 A02-RL-005-SP-300-GFK/PP
A4006/1 A02-RL-006-SP-250-GFK/PP
A4007/1 A02-RL-007-SP-250-GFK/PP
A4008/1 A02-RL-010-SP-350-GFK/PP
A4009/1 A02-RL-015-SP-200-GFK/PP
A4010/1 A02-RL-016-FI-250-GFK/PP
A4011/1 A02-RL-019-SP-300-GFK/PP
A4012/1 A02-RL-020-SP-250-GFK/PP
A4013/1 A02-RL-023-SP-150-GFK/PP
A4014/1 A02-RL-024-SP-150-GFK/PP
A4015/1 A02-RL-025-SP-250-GFK/PP
A4016/1 A02-RL-026-SP-250-GFK/PP
A4017/1 A02-RL-027-SP-250-GFK/PP
A4021/1 A02-RL-045-SP-350-GFK/PP
A4022/1 A02-RL-046-SP-350-GFK/PP
A4024/1 A02-RL-050-SP-300-GFK/PP
A4025/1 A02-RL-055-SP-250-GFK/PP
A4026/1 A02-RL-057-SP-450-GFK/PP
A4027/1 A02-RL-058-SP-300-GFK/PP
A4028/1 A02-RL-059-SP-300-GFK/PP
A4029/1 A02-RL-060-SP-300-GFK/PP
A4030/1 A02-RL-066-SP-250-GFK/PP
A4031/1 A02-RL-069-SP-300-GFK/PP
A4032/1 A02-RL-070-SP-250-GFK/PP
A4034/1 A02-RL-080-SP-250-GFK/PP
A4036/1 A02-RL-092-SP-250-GFK/PP
A4037/1 A02-RL-095-SP-250-GFK/PP
A4038/1 A02-RL-110-SP-125-GFK/PP
A4040/1 A02-RL-112-SP-150-GFK/PP
A4041/1 A02-RL-115-SP-500-GFK/PP
Page 43 of 273
EAT 11-024
A4042/1 A02-RL-116-SP-450-GFK/PP
A4043/1 A02-RL-119-SP-450-GFK/PP
A4044/1 A02-RL-120-SP-500-GFK/PP
A4045/1 A02-RL-121-SP-150-GFK/PP
A4050/1 A02-RL-135-SP-400-GFK/PP
A4051/1 A02-RL-136-SP-400-GFK/PP
A4056/1 A02-RL-155-RW-150-GFK/PP
A4058/1 B02-RL-002-SP-125-GFK/PP
A4059/1 B02-RL-003-SP-300-GFK/PP
A4061/1 B02-RL-005-SP-300-GFK/PP
A4062/1 B02-RL-006-SP-250-GFK/PP
A4063/1 B02-RL-007-SP-250-GFK/PP
A4064/1 B02-RL-010-SP-350-GFK/PP
A4065/1 B02-RL-015-SP-200-GFK/PP
A4066/1 B02-RL-016-FI-250-GFK/PP
A4067/1 B02-RL-019-SP-300-GFK/PP
A4068/1 B02-RL-020-SP-250-GFK/PP
A4069/1 B02-RL-023-SP-150-GFK/PP
A4070/1 B02-RL-024-SP-150-GFK/PP
A4071/1 B02-RL-025-SP-250-GFK/PP
A4072/1 B02-RL-026-SP-250-GFK/PP
A4073/1 B02-RL-027-SP-250-GFK/PP
A4077/1 B02-RL-045-SP-350-GFK/PP
A4078/1 B02-RL-046-SP-350-GFK/PP
A4080/1 B02-RL-050-SP-300-GFK/PP
A4081/1 B02-RL-055-SP-250-GFK/PP
A4082/1 B02-RL-057-SP-450-GFK/PP
A4083/1 B02-RL-058-SP-300-GFK/PP
A4084/1 B02-RL-059-SP-300-GFK/PP
A4085/1 B02-RL-060-SP-300-GFK/PP
A4086/1 B02-RL-066-SP-250-GFK/PP
A4087/1 B02-RL-069-SP-300-GFK/PP
A4088/1 B02-RL-070-SP-250-GFK/PP
A4090/1 B02-RL-080-SP-250-GFK/PP
A4092/1 B02-RL-092-SP-250-GFK/PP
A4093/1 B02-RL-095-SP-250-GFK/PP
A4094/1 B02-RL-110-SP-125-GFK/PP
Page 44 of 273
EAT 11-024
A4096/1 B02-RL-112-SP-150-GFK/PP
A4097/1 B02-RL-115-SP-500-GFK/PP
A4098/1 B02-RL-116-SP-450-GFK/PP
A4099/1 B02-RL-119-SP-450-GFK/PP
A4100/1 B02-RL-120-SP-500-GFK/PP
A4101/1 B02-RL-121-SP-150-GFK/PP
A4106/1 B02-RL-135-SP-400-GFK/PP
A4107/1 B02-RL-136-SP-400-GFK/PP
A4112/1 B02-RL-155-RW-150-GFK/PP
A4114/1 A03-RL-003-SP-450-GFK/PP
A4115/1 A03-RL-004-SP-450-GFK/PP
A4116/1 A03-RL-005-SP-450-GFK/PP
A4117/1 A03-RL-010-LG-400-GFK/PP
A4118/1 A03-RL-011-LG-400-GFK/PP
A4119/1 A03-RL-012-LG-350-GFK/PP
A4121/1 A03-RL-016-LG-300-GFK/PP
A4122/1 A03-RL-020-SP-150-GFK/PP
A4123/1 A03-RL-021-SP-150-GFK/PP
A4124/1 A03-RL-024-SP-125-GFK/PP
A4125/1 A03-RL-025-SP-125-GFK/PP
A4126/1 A03-RL-026-SP-125-GFK/PP
A4127/1 A03-RL-030-SP-400-GFK/PP
A4128/1 A03-RL-033-SP-350-GFK/PP
A4130/1 B03-RL-003-SP-450-GFK/PP
A4131/1 B03-RL-004-SP-450-GFK/PP
A4132/1 B03-RL-005-SP-450-GFK/PP
A4133/1 B03-RL-010-LG-400-GFK/PP
A4134/1 B03-RL-011-LG-400-GFK/PP
A4135/1 B03-RL-012-LG-350-GFK/PP
A4137/1 B03-RL-016-LG-300-GFK/PP
A4138/1 B03-RL-020-SP-150-GFK/PP
A4139/1 B03-RL-021-SP-150-GFK/PP
A4140/1 B03-RL-024-SP-125-GFK/PP
A4141/1 B03-RL-025-SP-125-GFK/PP
A4142/1 B03-RL-026-SP-125-GFK/PP
A4143/1 B03-RL-030-SP-400-GFK/PP
A4144/1 B03-RL-033-SP-350-GFK/PP
Page 45 of 273
EAT 11-024
A4146/1 03-RL-150-EL-250-PE
A4147/1 A04-RL-001-SP-500-GFK/PP
A4149/1 A04-RL-003-SP-300-GFK/PP
A4151/1 B04-RL-001-SP-500-GFK/PP
A4153/1 B04-RL-003-SP-300-GFK/PP
A4155/1 A05-RL-001-SP-250-GFK/PP
A4156/1 A05-RL-004-SP-200-GFK/PP
A4157/1 A05-RL-006-SP-200-GFK/PP
A4158/1 A05-RL-007-SP-300-GFK/PP
A4159/1 A05-RL-012-VK-500-GFK/PP
A4160/1 A05-RL-013-SP-350-GFK/PP
A4161/1 A05-RL-014-VK-500-GFK/PP
A4162/1 A05-RL-015-SP-200-GFK/PP
A4163/1 A05-RL-018-SP-150-GFK/PP
A4164/1 A05-RL-019-SP-300-GFK/PP
A4165/1 A05-RL-020-SP-300-GFK/PP
A4166/1 A05-RL-021-SP-300-GFK/PP
A4167/1 A05-RL-022-SP-250-GFK/PP
A4168/1 A05-RL-026-SP-200-GFK/PP
A4170/1 A05-RL-035-SP-250-GFK/PP
A4171/1 A05-RL-040-SP-200-GFK/PP
A4172/1 A05-RL-047-SP-200-GFK/PP
A4173/1 A05-RL-050-SP-150-GFK/PP
A4174/1 A05-RL-051-SP-125-GFK/PP
A4175/1 A05-RL-055-LG-300-GFK/PP
A4176/1 A05-RL-057-SP-150-GFK/PP
A4177/1 A05-RL-059-LG-300-GFK/PP
A4178/1 A05-RL-060-LG-250-GFK/PP
A4179/1 A05-RL-063-LG-200-GFK/PP
A4180/1 B05-RL-001-SP-250-GFK/PP
A4181/1 B05-RL-004-SP-200-GFK/PP
A4182/1 B05-RL-006-SP-200-GFK/PP
A4183/1 B05-RL-007-SP-300-GFK/PP
A4184/1 B05-RL-012-VK-500-GFK/PP
A4185/1 B05-RL-013-SP-350-GFK/PP
A4186/1 B05-RL-014-VK-500-GFK/PP
A4187/1 B05-RL-015-SP-200-GFK/PP
Page 46 of 273
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A4188/1 B05-RL-018-SP-150-GFK/PP
A4189/1 B05-RL-019-SP-300-GFK/PP
A4190/1 B05-RL-020-SP-300-GFK/PP
A4191/1 B05-RL-021-SP-300-GFK/PP
A4192/1 B05-RL-022-SP-250-GFK/PP
A4193/1 B05-RL-026-SP-200-GFK/PP
A4195/1 B05-RL-035-SP-250-GFK/PP
A4196/1 B05-RL-040-SP-200-GFK/PP
A4197/1 B05-RL-047-SP-200-GFK/PP
A4198/1 B05-RL-050-SP-150-GFK/PP
A4199/1 B05-RL-051-SP-125-GFK/PP
A4200/1 B05-RL-055-LG-300-GFK/PP
A4201/1 B05-RL-057-SP-150-GFK/PP
A4202/1 B05-RL-059-LG-300-GFK/PP
A4203/1 B05-RL-060-LG-250-GFK/PP
A4204/1 B05-RL-063-LG-200-GFK/PP
A4206/1 A07-RL-004-SP-350-GFK/PP
A4207/1 A07-RL-005-SP-300-GFK/PP
A4209/1 B07-RL-004-SP-350-GFK/PP
A4210/1 B07-RL-005-SP-300-GFK/PP
A4212/1 A08-RL-003-SP-400-GFK/PP
A4213/1 A08-RL-006-SP-350-GFK/PP
A4215/1 A08-RL-008-SP-400-GFK/PP
A4216/1 A08-RL-015-SP-450-GFK/PP
A4217/1 A08-RL-016-SP-150-GFK/PP
A4219/1 A08-RL-030-SP-350-GFK/PP
A4220/1 A08-RL-031-SP-350-GFK/PP
A4221/1 A08-RL-034-SP-300-GFK/PP
A4223/1 A08-RL-039-SP-125-GFK/PP
A4224/1 A08-RL-040-SP-350-GFK/PP
A4225/1 A08-RL-041-SP-125-GFK/PP
A4226/1 A08-RL-042-VK-500-GFK/PP
A4227/1 A08-RL-043-FI-300-GFK/PP
A4228/1 A08-RL-044-FI-300-GFK/PP
A4230/1 A08-RL-046-FI-300-GFK/PP
A4232/1 A08-RL-050-FI-250-GFK/PP
A4234/1 A08-RL-052-FI-300-GFK/PP
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A4236/1 B08-RL-003-SP-400-GFK/PP
A4237/1 B08-RL-006-SP-350-GFK/PP
A4239/1 B08-RL-008-SP-400-GFK/PP
A4240/1 B08-RL-015-SP-450-GFK/PP
A4241/1 B08-RL-016-SP-150-GFK/PP
A4243/1 B08-RL-030-SP-350-GFK/PP
A4244/1 B08-RL-031-SP-350-GFK/PP
A4245/1 B08-RL-034-SP-300-GFK/PP
A4247/1 B08-RL-039-SP-125-GFK/PP
A4248/1 B08-RL-040-SP-350-GFK/PP
A4249/1 B08-RL-041-SP-125-GFK/PP
A4250/1 B08-RL-042-VK-500-GFK/PP
A4251/1 B08-RL-043-FI-300-GFK/PP
A4252/1 B08-RL-044-FI-300-GFK/PP
A4254/1 B08-RL-046-FI-300-GFK/PP
A4256/1 B08-RL-050-FI-250-GFK/PP
A4258/1 B08-RL-052-FI-300-GFK/PP
A4259/1 B08-RL-055-SP-125-GFK/PP
A4263/1 A10-RL-68-LG-300-GFK/PP
A4264/1 A10-RL-98-LG-300-GFK/PP
A4265/1 A10-RL-125-LG-600-GFK/PP
A4266/1 A10-RL-128-LG-500-GFK/PP
A4267/1 A10-RL-156-LG-250-GFK/PP
A4268/1 10-RL-170-LG-250-GFK/PP
A4269/1 A10-RL-173-LG-125-GFK/PP
A4270/1 A10-RL-185-RW-200-GFK/PP
A4271/1 A10-RL-188-RW-125-GFK/PP
A4272/1 B10-RL-78-LG-300-GFK/PP
A4273/1 B10-RL-108-LG-300-GFK/PP
A4274/1 B10-RL-135-LG-600-GFK/PP
A4275/1 B10-RL-138-LG-500-GFK/PP
A4276/1 B10-RL-157-LG-250-GFK/PP
A4277/1 B10-RL-190-RW-200-GFK/PP
A4278/1 B10-RL-193-LG-125-GFK/PP
A4284/1 10-RL-008-LG-250-GFK/PP
A4285/1 10-RL-016-RW-500-GFK/PP
A4286/1 10-RL-017-RW-200-GFK/PP
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A4288/1 10-RL-021-RW-150-GFK/PP
A4289/1 10-RL-022-RW-700-GFK/PP
A4290/1 10-RL-023-RW-450-GFK/PP
A4291/1 10-RL-024-RW-500-GFK/PP
A4292/1 10-RL-032-RW-450-GFK/PP
A4279/1 10-RL-040-LG-700-GFK/PP
A4295/1 10-RL-043-LG-250-GFK/PP
A4296/1 10-RL-044-LG-250-GFK/PP
A4298/1 10-RL-046-LG-700-GFK/PP
A4299/1 10-RL-047-LG-700-GFK/PP
A4294/1 10-RL-050-LG-700-GFK/PP
A4302/1 10-RL-055-LG-250-GFK/PP
A4303/1 10-RL-058-LG-150-GFK/PP
A4304/1 10-RL-085-LG-250-GFK/PP
A4305/1 10-RL-088-LG-150-GFK/PP
A4306/1 10-RL-115-LG-250-GFK/PP
A4307/1 10-RL-118-LG-200-GFK/PP
A4309/1 10-RL-165-LG-200-GFK/PP
A4310/1 10-RL-168-LG-150-GFK/PP
A4315/1 A15-RL-020-PW-150-PE
A4316/1 A15-RL-050-PW-250-PE
A4317/1 A15-RL-053-PW-200-PE
A4318/1 B15-RL-002-PW-150-PE
A4319/1 B15-RL-030-PW-250-PE
A4320/1 B15-RL-033-PW-200-PE
A4321/1 15-RL-005-PW-300-PE
Page 49 of 273
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LIST OF ABBREVIATIONS
Abbreviations of physical units/constants used throughout this study are as follows:

bld. below limit of detection
g gram
g/cm³ gram per cubic centimeter
g/l gram per liter
H2O water
ha hectare
isbl inside battery limits (scope of ERCOSPLAN)
K2O potassium oxide
KCl potassium chloride
kg kilogram
km kilometer
km² square kilometer
m meter
m² square meter
m³ cubic meter
m³/a cubic meters per annum
m³/d cubic meters per day
m³/h cubic meters per hour
m% percentage by mass
Mg magnesium
MgCl2 magnesium chloride
MOP KCl 95
mm millimeter
mtpy million tons per year
NaCl sodium chloride
osbl outside battery limits
t ton
t/y ton per year
t/d ton per day
t/h ton per hour
t/m³ ton per cubic meter
vol. % percentage by volume
% percent
Page 50 of 273
EAT 11-024
1 Introduction
The Salar de Uyuni is located about 3,650 m.s.n.m. in southwest Bolivia, in the Province of
Daniel Campos, Department of Potosi, in the Andean high plateau. It is the largest continuous
salt desert in the world with an area of 10,582 km².
The salt is formed in one of the largest reserves of lithium in the world and has significant
amounts of potassium, boron and magnesium.
The economic activity of the Salar does not focus only on tourism but also salt production real-
izes by neighboring cities as Colchani City.
The employed extraction method is traditional in which the salt is collected in small piles, facili-
tating the evaporation of the water and its optimizing transport.
Today it is possible to know the structure of the salt with the help of researches and the realiza-
tion of test drillings, knowing it that consists of approximately 11 overlapping layers of salt and
mud lake, with thicknesses ranging from less than 1 meter to 20 meters, and its depth of 120
meters and that its origin corresponds to the drought of an ancient salt lake.
Therefore, and according to official data of the Mining Corporation of Bolivia (GNRE-COMIBOL)
estimates that the Salar contains 10 billion tons of salt, of which only 25,000 tons are extracted
annually.
In view of the large reserve of material, the Mining Corporation of Bolivia expects to exploit on
an industrial scale and plans to build a production plant of 700,000 t/y of potassium chloride of
high purity (KCl 95) in the Salar de Uyuni.
Thus GNRE-COMIBOL currently starts a pilot plant that produces about 1,000 tons of potassi-
um chloride monthly supply the local market and to set basic parameters, for the design of the
plant.
In Bolivia, this industrial production of potassium chloride and other derivatives is operated
100 % by state administration using technologies always compatible with the preservation of
the environment.
It is the German company ERCOSPLAN Ingenieurbüro Anlagentechnik GmbH as specialist in
the sector and with extensive experience in the design of the mining of salt guarantee for its
professional path over the years, which has carried out the development of the engineering
project.
One of the main premises on which it´s based ERCOSPLAN for industrial production is the
application of flotation process, which helps in the recovery of potassium chloride presents in
the brine (sylvite) and whose final destination is the production of fertilizer potash.
The processing plant designed by ERCOSPLAN will work continuously 24 hours a day, in three
shifts, seven days a week, with a total production of 7,500 hours per year. The remaining time
will be used a year in performing preventive maintenance.
Prior to processing the brine, it will be pumped from the salt and is led to a battery of ponds,
whose main function is water evaporation and crystallization of sodium chloride and potassium
chloride.
It then proceeds to supply the process plant through loaded brine in trucks with 20 tons of ca-
pacity that will work for 16 h/day and transport the material to a lump crushing that reduces its
initial grain size.
Then and, with the help of the belts conveyor, the material is divided into two production lines A
and B are exactly the same and that produce 350,000 tons/year respectively.
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Each of the two lines has the following stages:

• Debrining of crystallized NaCl / KCl
• Treatment of crystallizate - screening and grinding
• Cleaner flotation and leaching
• Handling of tails and recovered brine
• KCl product debrining
• KCl product drying
• Truck loading of dry KCl product.
Each of these stages will be developed and explained in the different sections that make up
this project.
It is noted that all installations that make both lines (A and B) are accommodated in the pro-
cess building which have been designed in this project while all those needed installations but
larger are located in the proximity of the building.
The aim of this processing plant becomes the initial product or brine contents approximately
70 % of NaCl in a product with a purity of 95 % KCl, together with a recovery of over 80 % of
their tails.
Finally note that the implementation and processing of the brine in the Salar de Uyuni will con-
tribute to socio-economic development of the region, generating jobs, to will enable better liv-
ing conditions of its inhabitants of the area as well as positioning of the Bolivian country as one
of the leading producers of KCl worldwide.
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2 Project History, Database and Battery Limits
2.1 Project History
On January 17, 2012, the Mining Corporation of Bolivia awarded to the German company ER-
COSPLAN INGENIERURBURO ANLAGENTECHNIK GmbH, Contract No. CTTO: COMIBOL-
GNRE/AL-022/2012 consisting of the design and implementation of the project:
"ENGINEERING DESIGN INDUSTRIAL PLANT 700,000 Tn / Time OF KCl BASED PROCESS
SYLVINITE FLOATING IN UYUNI"
with a duration of 10 months from the date of signing of the minutes of the start of work.
The contract signing was on July 31, 2012 and the meeting minutes of the start of work are
dated February 18, 2013.
In the first ten days after the start date of the act, ERCOSPLAN achieved an initial document to
schedule the phases of project and work plan.
In February 28, 2013 ERCOSPLAN began with the basic engineering project.
In March, ERCOSPLAN sent a questionnaire to GNRE-COMIBOL to ensure the further possible
progress in the design of the project.
This questionnaire asked for a sample of brine from existing pools in the Salar de Uyuni, for
analysis by the company, as well as defining certain general criteria as general criteria for the
implementation of engineering project.
In this month, ERCOSPLAN made two more deliveries. The first one was a coordination proce-
dure establishing roles and routines that should be followed by both companies ERCOSPLAN
and GNRE-COMIBOL.
In the second delivery, ERCOSPLAN sent a report of the progress made so far, with the results
obtained in the flotation of the previously requested brine sample.
At the beginning of the following month, GNRE-COMIBOL answered to the questionnaire sent
by ERCOSPLAN days earlier.
Also during the month of April 2013, ERCOSPLAN sent the manual for the use of a data server
through which documents are delivered digitally, as well as a file with the functional require-
ments to prepare the subsoil, the specifications required for the basic and detailed engineering
and so far there was no geotechnical report endorsed by an expert.
From May 13 - 17, 2013 the first meeting (Gate 1) took place in La Paz and in these days, ER-
COSPLAN and GNRE-COMIBOL made a visit to the pilot plant located in the Salar de Uyuni.
Already in June, ERCOSPLAN, delivered the "Milestone 2" documents, a precursor to the final
Basic Engineering which was delivered on July 17, 2013. On July 5, 2013 ERCOSPLAN sent
addendum documents for the “Milestone 2” report
Between June 22 and July 24, 2013 there was a second meeting "Gate 2" in La Paz where ER-
COSPLAN, explained the basic engineering developed in the different sections that make up
the project: process, mechanical, electrical ,civil and finally the building engineering, getting
the confirmation from the GNRE-COMIBOL, assuming completion of the phase consisting of
basic engineering.
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Since then, ERCOSPLAN has begun with the development of the detailed engineering, deliver-
ing on August 1, 2013 a Basic Addendum and on August 30, 2013 "Milestone 3" documents
which have been presented to GNRE-COMIBOL on September 23 – 25, 2013 during the "Gate
3" meeting in La Paz.
On October 1, 2013 GNRE-COMIBOL contracted ERCOSPLAN for a modification of the already
existing contract. The contract modification includes the Basic and Detail Engineering for prod-
uct drying, product storage and product truck loading at plant site. The final detail engineering
has to be delivered to GNRE-COMIBOL in March 2014.
Furthermore ERCOSPLAN delivered the final equipment data sheets, final equipment specifica-
tions and updated civil and electrical drawings at Milestone 4 on November 08, 2013 as agreed
on Gate 3 Meeting.
From November 13 – 15, 2013 an additional meeting in Erfurt took place. ERCOSPLAN held
presentations about the progress of works of all the involved departments.
ERCOSPLAN presented the final detail engineering (Milestone 5) at Gate 4 meeting in La Paz
on December 16. – 18, 2013.
Due to a contract modification, ERCOSPLAN furthermore provides the detail engineering for
drying section, product storage and truck loading. The revised detail engineering documents
including the contract modification will be delivered to GNRE-COMIBOL 90 days after finalizing
the main contract on March 14, 2014 and presented in La Paz subsequently.
Finally, it should be noted that the project manager belonging to ERCOSPLAN makes and de-
livers a monthly report which shows the progress of the project in all moment.
2.2 Database
ERCOSPLAN prepared a design base document for the project where all conditions by the
client and assumptions by ERCOSPLAN are listed. Assumptions were confirmed at
Gate 1 meeting. Conditions by the client are same as written in the contract. Furthermore
GNRE-COMIBOL submitted weather data and technical drawings regarding the location of the
plant site. Specific questions by ERCOSPLAN were answered almost promptly by GNRE-
COMIBOL via email. All information is considered in the following documents.
2.2.1 Design Base
The Design Base Document is attached as App.A01_EAT-11-024-GNRE-EAT-06-05-13-008-

PNO_Design Base.docx
The Design Base Document is reliable and was accepted by GNRE-COMIBOL.
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2.3 Battery Limits
2.3.1 Interface Delivery of Wet Crystallizate from Evaporation Ponds
Interface according to the contract between GNRE-COMIBOL and ERCOSPLAN:

Citation GNRE-COMIBOL: “From the delivery and stacking of sylvinite with existing loaders.”
ERCOSPLAN’s design starts with the crystallizate unloading facility of trucks (truck unloading)
coming from the evaporation ponds. The evaporation ponds, the production of sufficient quality
and quantity of crystallizate and the transportation of crystallizate to the truck unloading facility
are out of ERCOSPLAN’s scope of works.
2.3.2 Interface Product Truck Loading
ERCOSPLAN’s scope of works ends after dry standard product truck loading. Transportation of
dry standard product after truck loading is out of ERCOSPLAN’s scope of works.
2.3.3 Interface Debrined Tailings to Tailings Pile
During production of KCl 95, also NaCl is produced. This NaCl is envisaged to be stored on a
tailings pile. The tailings pile probably will be erected by GNRE-COMIBOL 500 meters to the
east of plant site. ERCOSPLAN’s scope of works ends with the conveyor belt for debrined tail-
ings at the border of plant site. The concept of erecting the tailings pile, the operation of the
tailings pile and necessary equipment for tailings pile is out of ERCOSPLAN’s scope of works.
2.3.4 Interface Brine Disposal
During production of KCl 95, furthermore disposal brine is produced. It is envisaged to dispose
these brines into the salt lake. ERCOSPLAN’s scope of works ends with the pipes for disposal
brines at the border of plant site. The concept of disposing these brines, the operation of brine
disposal and necessary equipment for brine disposal is out of ERCOSPLAN’s scope of works.
2.3.5 Interface Delivery of Process Media
Process water is required for operation of process plant. GNRE-COMIBOL delivered the chemi-
cal composition and ph-value of delivered process water at Gate 3 Meeting on 25th September
2013. GNRE delivers process water in sufficient quality and quantity into the process water
storage tank at plant site. ERCOSPLAN’s scope of work starts with the process water tank.
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Heating media for building heating, drying plant and any other heating processes will be LPG
(liquefied petroleum gas). LPG will be delivered in sufficient quality and quantity by GNRE-
COMIBOL to plant site. ERCOSPLAN’s scope of work starts at the emptying flange of the LPG
tank.
Consumables for processing are chemicals for flotation, after treatment and flocculation. Fur-
thermore general consumables like working material, lubricants, etc. are delivered by truck to
plant site and stored in envisaged places. The delivery to plant site and storing of consumables
at plant site is out of ERCOSPLAN’s scope of work.
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3 Nomenclature
3.1 Indication Code for Devices and Equipment
B 03 01 A/B . 1
Code number for redundant devices or equipment,

one-digit (e.g. 1, 2, …)
Divider for indication of redundant devices or equipment
Letter for production line (A, B or without letters if there is only one
plant line)
Sequence number, two-digit (from 01 to 99)
Code number of process section, two-digit
Code letter according to German standard DIN EN ISO 10628,

one-digit (e. g. B for bins, P for pumps etc.)
Code letter according to German standard DIN EN ISO 10628
A Apparatus, machinery
As far as not classified in one of the following groups
B Vessel, tank, bunker, silo
C Chemical reactor
D Steam generator, gas generator, oven
F Filter apparatus, fluid filter, gas filter, screening apparatus,
screening machine, separator
G Gearbox
H Lifting device, conveying device, transporting device
K Column
M Electrical motor
P Pump
R Agitator, agitated tank, mixer
S Centrifuge
T Dryer
V Compressor, vacuum pump, ventilator
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W Heat exchanger
X Distributing device, splitting device, other devices
Y Drive device except electrical motor
Z Crushing machine, milling machine
Code numbers of process sections

01 Wet salt storage
02 Wet screening and milling
03 Rougher flotation
04 Cleaner flotation
05 Cold leaching and product dewatering
06 Product storage
07 Scavenger flotation
08 Tails process
09 Compressor plant
10 Reclaim brine storage
11 Rinsing water system
12 Sealing water system
13 Drying
14 Truck loading
15 Process water storage
3.2 Indication Code for Measuring and Control Points
The regulations of German standard DIN 19227-2 generally apply for the indication of measur-
ing and control points.
Regarding the subsequent letters I and R, the following is applied:
Subsequent letter I indicates the local indication of an analog measured value, subsequent
letter R indicates the transfer of an analog measured value to a control system (in normal case -
the PLS, for package units - the SPS). Therefore the letter sequence IR only appears it an addi-
tional local indication of measured data is required for transmitters.
The function of actuated OPEN/SHUT control valves (valves, ball valves, butterfly valves etc.) is
indicated with YV. Final position switches for tap position indication are indicated with GO fol-
lowed by the letters H for OPEN end position and L for SHUT end position.
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In case their separate presentation is required, control valves that are assigned to control cir-
cuits receive a function indication that consists of the code letter of the control variable and the
letter V for the actuator function. The measurement and control code is identical to the control
circuit code (for example: control valve PVB0902B-01 belongs to pressure control PRC-0001).
Remote-controlled control valves that are not assigned to a control circuit are indicated with
YC.
The measurement and control code numbers consist of:
LSA
B02-025
Sequence number, three-digit (from 001 to 999)
Code number of plant unit (plant section), two-digit
Letter for plant line (A, B or without letters if there is only one
plant line)
Code according German standard DIN 19227-2
Double numbers with different first letters (not subsequent letters) are allowed.
Switching and alarm limit values of analog measured data have to be recorded in separate
lists. According to German standard, the code for measuring and control points has to be add-
ed by the subsequent letters A or S resp., limit values have not to be indicated.
Switching and alarm limit values of binary signaling devices have to be indicated clearly. The
measuring and control symbol – but not the measuring and control position indication - for eve-
ry limit indicators that generates an electrical signal has to be added by the relevant sign.
A manometer that is equipped with a lower and two upper switching or alarm limit indicators
receives the code PISA followed by the number; the letters L, H and HH have to be specified
next to the symbol in a smaller font type.
Following convention applies to the indication of single-signals from measuring and con-
trol points:
The signal names of analog input signals are formed by the functional letter of the measuring
and control point and the measuring and control number omitting the subsequent letters (with
the exception of C).
In case of speed or frequency of drives, analog feedback signals of frequency converters get
the functional letter S, otherwise the first letter E from measuring and control code (EU) is used.
Analog output signals are called like the corresponding input signals whereat an additional
secondary letter is inserted (for control valves: V, for set-point for frequency converter: W).
After the functional letter (L, P, F, …), the signals of the digital limit switch get the letter S as
code (but according to function also A or O) and, as far as required for distinction, the code for
switching status H, L, HH or LL. The position indicators at ball valves get the signal names
GOH plus a measuring and control number for the OPEN position and GOL plus measuring
and control number for the SHUT position. The operation signal of drives (main contactor ON
position) gets code NB plus measuring and control number and the common electrical fault
indication (over-current release, control fuse) the signal code NA plus measuring and control
number. Fault indications generated by other switch gears (e. g. frequency converters) get the
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code XA plus measuring and control number. An input signal that shows if a drive is switched
off on site or from PLS gets the code NU plus measuring and control number. Switch signals of
ball valves and drives are called Y plus measuring and control number. If ball valves have two
control pulses these are distinguished by secondary letters A (as code for input signal OPEN)
or Z (as code for input signal SHUT). That applies correspondingly for drives (YE for ON switch
signal; YA for OFF switch signal). Release and interlock signals respectively are named YF plus
measuring and control number.
If several signals of one measuring and control point have the same letter combinations ac-
cording to above described rules, they can be distinguished by a sequence number added to
the letters. In such a case, the sequence number is separated by an underline from the meas-
uring and control number (e. g. XA1_-01 and XA2_-01).
Table 1 PCE (Process Control Engineering) Categories and Processing Functions

(According to DIN EN 62424; VDE 0810-24:2010-01)
Identification PCE category PCE processing function

letter First letter Subsequent letter
A Analysis Alarm, signal
B Burner (flame) monitoring Limitation, containment
C User’s choice Control
D Density Difference
E Voltage N. A.1
F Flow rate Ratio
G Distance, length, position N. A.
H Hand (manual input, manual override) High - upper limit, on, open
I Electric current Indication
J Electric power N. A.
K Time (time based functions) N. A.
L Level (fill level) Low - lower limit, off, closed
M Moisture N. A.
N Motor N. A.
O User’s choice Local or PCS status indication of binary
signals
P Pressure N. A.
Q Quantity Integral or sum
R Radiation measurement Registered value
S Speed, rotation speed, frequency Switch - binary control or switching
function (not security-relevant)
T Temperature N. A.
U N. A. N. A.
V Vibration N. A.
W Weight, mass, force N. A.
X (for not listed terms that are used only once or in limited amount)
Y Control valve Arithmetic function
Z User’s choice Binary control or switching function
(security-relevant)
1
N.A. = Not Applicable
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3.3 Indication Code for Pipelines / Chutes
A02-RL-025-SP-DN100-GFK/PP
Material of pipeline / chute

St = steel
PE = polyethylene
VA = stainless steel
GFK/PP = glass fibre reinforced plastic with polypropylene liner
Nominal diameter of pipeline / dimensions of chute
Abbreviation of media (see section 3.5: Overview of media codes)
RL for pipeline
SL for flexible line
SH for chute
Letter for plant line (A, B or without letter if there is only one plant line)
3.4 Indication Code for Valves
A02-S-025-SP-DN100
Nominal diameter of valve
Abbreviation of media (see section 3.5: Overview of media codes)
Type of valve according to German standard

DIN EN ISO 10628 (max. two-digits)
A= divertor
F= filter
G= inspection glass
S= slider
K= butterfly valve
R= check valve
H= ball valve
V= valve
X= others
U= plug valve
Y= valve with safety function
VR= valve with control mode
Letter for plant line (A, B or without letter if there is only one plant line)
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3.5 Overview of Media Codes (Can Be Amended Anytime)
Table 2 Media Codes
Media code Media

AL Exhaust air
AM Anticaking agent
BW Operating water
DL Compressed air
DU Dust
EL Ventilation
FI Fugate / filtrate
FM Flocculation agents
FR Flotation reagent
KO Condensate
KW Cooling water
LG Brine, reclaim brine
LP Liquefied petroleum gas
PD Product
PW Process water
RW Rinsing water
SP Suspension
SW Sealing water
UL Ambient air
VK Vacuum
WS Wet salt
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4 Belonging Documents
Beside the report several documents are belonging to this detail engineering. The following
chapter gives an overview and explanation of all belonging documents.
Appendices which are associated with the contract modification, such as drying section, prod-
uct storage and truck loading, differentiate by “.1” after the appendix name.
Example: Appendix A2.1 for equipment list of contract modification (drying section, product
storage and truck loading)
4.1 General Documents
4.1.1 Design Base Document
The “Design Base Document” is the base of ERCOSPLAN’s work. It includes substantial re-
quirements to the processing plant, battery limits, boundary conditions, appropriated normative
as well as ERCOSPLAN’s assumptions.
The “Design Base Document” was created at the beginning of ERCOSPLAN’s work, presented
at the “Gate Meetings” and was confirmed by GNRE-COMIBOL.
The “Design Base Document” is attached as Appendix A1.
4.1.2 Equipment Quotations
After calculating the process route and the designing of equipment, ERCOSPLAN made a pre-
selection of main equipment. Afterwards ERCOSPLAN sent inquiries for the main equipment to
suppliers which are familiar with the potash industry.
As response ERCOSPLAN received quotations for the specific equipment from the equipment
suppliers. The quotations are attached as Appendices Q. These individual quotations have to
be checked for up-to-dateness during equipment purchase phase by GNRE-COMIBOL and
appropriate equipment supplier.
4.1.3 Cost Estimation Equipment
The cost estimation for equipment was created under consideration of equipment quotations
sent by the suppliers and ERCOSPLAN’s data base. In this list the price for every main equip-
ment sorted into the belonging process section is easy to find.
The cost estimation for equipment is attached as Appendix G1 and G1.1.
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4.1.4 Cost Estimation Pipes
The cost estimation for pipes was created under consideration of price list (price per meter) of
pipe suppliers and ERCOSPLAN’s data base. In this list the price of pipes, sorted into the be-
longing process section and summed up to total piping length, is easy to find.
The cost estimation for pipes is attached as Appendix G2 and G2.1.
4.1.5 Cost Estimation Valves
The cost estimation for valves was created under consideration of valves quotations sent by the
suppliers and ERCOSPLAN’s data base. In this list the prices of valves, sorted by process sec-
tion and the type of valve, are easy to find.
The cost estimation for valves is attached as Appendix G3 and G3.1.
4.1.6 Cost Estimation Electrical Equipment
The cost estimation for electrical equipment is attached as Appendix G4.
4.1.7 Cost Estimation Civil Works (Infrastructure, Buildings)
The cost estimation for civil works is attached as Appendix G5.
4.1.8 Project Schedule
The project schedule shows following process steps and its durations from the beginning until
the end of the project:
• Engineering phase
• Procurement / acquisition phase
• Delivery phase
• Building construction
• Civil construction
• Erection / assembly phase
• Commissioning / start-up phase.
The project schedule is attached as Appendix G6.
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4.2 Documents Processing Engineering
4.2.1 Block Flow Diagram
The “Block Flow Diagram” shows the complete process route as considered by ERCOSPLAN.
Each processing step is shown as block. Blocks are connected with arrows to define inputs,
outputs and the direction of flow.
The “Block Flow Diagram” is attached as drawing A01.
4.3 Documents Mechanical Engineering
4.3.1 Equipment List
The “Equipment List” shows all main equipment necessary for production at plant site. In this
list the item number, item name, basic description of the item and electrical energy consump-
tion of the item of every main equipment, sorted into the belonging process section, is easy to
find.
The “Equipment List” is attached as Appendix A2 and A2.1.
4.3.2 Equipment Data Sheets
ERCOSPLAN has prepared “Equipment Data Sheets” for each main equipment. The “Equip-
ment Data Sheets” include more detailed information in comparison to the overall “Equipment
List”.
“Equipment Data Sheets” are attached as Appendix A3 and A3.1.
4.3.3 Drawing List
The “Drawing List” gives an overview about all technical drawings belonging to this Detail En-
gineering report.
The “Drawing List” is attached as Appendix A4.
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4.3.4 List of Instruments
The “List of Instruments” shows all measuring equipment in the process necessary for produc-
tion at plant site and its specific parameters. This list sorted into the belonging process section.
The “List of Instruments” is attached as Appendix A5 and A5.1.
4.3.5 Equipment Specifications
ERCOSPLAN has prepared “Equipment Specifications” for each main equipment. The “Equip-
ment Specifications” include detailed information about main equipment necessary for produc-
tion at plant site. With these documents in addition to the “Equipment Data Sheets” GNRE-
COMIBOL is in the position to make specific inquiries to equipment suppliers respectively pre-
pare the public bidding phase.
The “Equipment Specifications” are attached as Appendix A6 and A6.1.
4.3.6 General Inquiry Specification
The “General Inquiry Specification” is the central and general document necessary for making
inquiries to equipment suppliers.
The “General Inquiry Specification” gives an overview about boundary condition around the
equipment, necessary to know for designing the equipment.
The “General Inquiry Specification” is attached as Appendix A7.
4.3.7 Pipes List
The “Pipes List” shows all main pipes installed in the processing plant. Pipes are listed belong-
ing to the process sections.
The “Pipes List” is attached as Appendix A8 and A8.1.
4.3.8 Valve List
The “Valve List” shows all valves installed in the processing plant. Valves are listed belonging
to the process sections.
The “Valves List” is attached as Appendix A9 and A9.1.
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4.3.9 Pipe Classification
Applied pipes at plant site are separated into different pipe classifications according to purpose
and application of pipes.
The “Pipe Classification” is attached as Appendix A10.
4.3.10 Equipment Supplier List
The “Equipment Supplier List” shows a selection of recommended equipment suppliers sorted
by the type of main equipment. Recommended suppliers possess long term experience and
various references in the potash industry.
The “Equipment Supplier List” is attached as Enclosure E1.
4.3.11 Piping and Instrumentation Diagrams (PID)
“Piping and Instrumentation Diagrams” (PIDs) created by ERCOSPLAN show detailed infor-
mation about the piping of the process flow together with the installed equipment and instru-
mentation.
The entire process is classified into two production lines (Line A&B) and several process sec-
tions. Hence, the single production lines and process sections are shown separately on PIDs.
Furthermore ERCOSPLAN added a table of all volume and mass streams shown on the PID.
PIDs are attached as drawings A 1350 – A 1374.
4.3.12 Arrangement Drawings
“Arrangement Drawings” are generated for orientation in process building. “Arrangement

Drawings” show details about building platforms, location of equipment inside the building,
arrangement of stairways and elevators, mounting areas and erection openings.
“Arrangement Drawings” are executed as:

• Platform drawings of process building
• Cross sections of process building
• Longitudinal sections of process building
• Platform drawing of process building with main pipeline routes
• Platform drawings of process building with parameters for civil engineering.
“Arrangement Drawings” are attached as drawings A 1400 - A 1514.
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4.3.13 Piping Isometric Drawings
“Piping Isometric Drawings” are generated for all main pipes necessary for processing. Main
pipes are pipes with a diameter > DN 100.
“Piping Isometric Drawings” show the details necessary for manufacturing and installing the
pipe.
“Piping Isometric Drawings” are attached as drawings A 4000 - A 4321.
4.4 Documents Electrical Engineering
4.4.1 Appendices
4.4.1.1 Appendix E1 / Energy Consumer
Appendix E1 includes all electrical details for the electrical energy consumer of the project.
4.4.1.2 Appendix E2 / Electrical Energy Demand
Appendix E2 includes the electrical energy demand calculation, calculation of the power and
number of the necessary transformer.
4.4.1.3 Appendix E3 / Utilized Capacity Power Supply System
Appendix E3 includes the calculation of the utilized capacity power of the transformer.
4.4.1.4 Appendix E4 / Cable List Power Supply System
Appendix E4 includes following cables:

• 24.9kV cables
• 6kV cables
• 0.69kV cables between transformer and MCC
• Necessary control cables.
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4.4.1.5 Appendix E5 / Cable List 0.69KV cable
Appendix E5 includes all 0.69kV cables between MCC and consumer.
4.4.1.6 Appendix E6 / Cable List Control Cable
Appendix E6 includes following control cables:

• Automation system to instruments
• Automation system to local control equipment.
4.4.1.7 Appendix E7 / Cable List Lighting, Socket System
Appendix E7 includes following cables:

• Connection cables between 0.4kV switch gears
• Cables from 0.4kV switch gears to lamps and sockets.
4.4.1.8 Appendix E8 / Control Circuits
Appendix E8 is basis for the programming of the automation system. The document includes:
• List of all control circuits at the KCl plant
• Equipment measurement value logging
• Control device
• Description of the control process.
4.4.1.9 Appendix E9 / Interlocking System
Appendix E9 is also basis for the programming of the automation system and includes:
• List of all interlocking requirements at the KCl plant
• Description of safety interlocking requirements
• Description of technologically-related requirements.
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4.4.1.10 Appendix E10 / I/0-List
Appendix E10 is basis for the programming of the automation system as well and comprises
• Input contacts to the automation system
• Output contacts from the automation system to other control equipment.
4.4.1.11 Appendix E11 / Short Circuit Calculation
Appendix E11 includes all results of the short circuit calculation which are represented in a sin-
gle line diagram of the power supply system.
4.4.1.12 Appendix E12 / Voltage Drop Calculation
Appendix E12 includes all results of the voltage drop calculation which are represented in a
single line diagram of the power supply system.
4.4.1.13 Appendix E13 / Lighting Calculation
Appendix E13 comprises all results of the lighting calculation for:

• All levels of the KCl plant
• Wet salt storage
• Distribution towers
• Product storage
• Truck loading
• All power station rooms
• Roads/Streets.
4.4.1.14 Appendix E14 / Cable List Information System
Appendix E14 includes all connection cables for following parts of the electrical system:
• Fire protection system
• Video control system
• Access control system
• Communication system.
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4.4.1.15 Appendix E15 / Requirements Rooms Power Station
Appendix E15 includes all technical requirements for the rooms of the power station:
• Floor load
• Liability of electrical power loss
• Necessary illumination level
• Minimal and maximal temperature inside the rooms.
4.4.1.16 Appendix E16 / Cable List Automation System
Appendix E16 includes all cables for the connection of central control equipment for the auto-
mation system.
4.4.1.17 Appendix E17 and E17.1 / Specification
Appendix E17 includes all quantities and qualities for:

• Electrical plant equipment to be delivered
• Installation works to be realized
• Programming and miscellaneous services for operation of the KCl plant.
4.4.2 Drawings
4.4.2.1 Power Supply System (E2000 – E2005)
Drawings E2000 – E2005 present the overview diagrams and assembly plans of the middle
voltage level (24.9kV, 6kV).
4.4.2.2 0.69kV-Switch Gears MCC (E2011 – E2040)
Drawings E2011 – E2038 present the overview diagrams and assembly plans of the 0.69kV
MCC (Motor control center).
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4.4.2.3 0.4kV-Switch Gears (E2071 – E2091)
Drawings E2071 – E2088 present the overview diagrams of 0.4kV main switch gear and the
0.4kV sub-distribution panel.
4.4.2.4 Equipment (E2101 – E2111)
Drawings E20101 –E2106 presents all installation points of the electrical energy consumer.
4.4.2.5 Main Cable Trays (E2121 – E2131)
Drawings E2121 – E2126 present the main cable trays on each platform of the production plant
and inside the power station.
4.4.2.6 Lighting and Socket System (E2201 – E2222)
Drawings E2201 – E2210 present the installation points of lightings and sockets on each plat-
form of the production plant, inside the power station and the outside facilities.
4.4.2.7 Control Cabinets (E2300 – E2351, 2393 – 2400)
Drawings E2301 – E2351 present the wiring diagrams, terminal connection tables and assem-
bly plans of all control cabinets.
4.4.2.8 Typical Wiring Diagrams (E2353 – E2391)
Drawings E2353 – E2386 present detailed wiring diagrams for all gear types within the techno-
logical process.
4.4.2.9 Automation Equipment (E2401 – E2409)
Drawings E2401 – E2404 present the installation points for the automation equipment on each
platform of the production plant.
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4.4.2.10 Room Planning (E2501 – E2504)
Drawings E2501 – E2504 comprise the arrangement drawings for the power and generator sta-
tion.
4.4.2.11 Lightning Protection (E2550 – E2576)
Drawings E2501 – E2571 comprise all technical details for the lightning protection.
4.4.2.12 Communication / Safety Equipment (E2601 – E2671)
Drawings E2601 – 2671 comprise block diagrams and installation drawings for plant sections
communication, fire protection system, video control system and access control system.
4.5 Documents Building and Structural Engineering
The documents building and structural engineering are:

• General description of all building objects
• Design drawings of buildings and structures including drawings of steel structures in
scales 1:200, 1:100, 1:75, and 1:50
• Memories of calculation for the main structure of wet salt storage, process building,
truck unloading
• Technical specifications for truck unloading, wet salt storage, distribution tower 1 and
process building with material needed in cubic meters, square meters, meters
• Civil work’s costs.
Since the soil report will not be available in time for this final report, all foundation’s design and
calculations will be delivered in the first quarter of 2014 within the scope of work of the contract
modification.
Furthermore, the construction of distribution tower 2, product storage and of truck loading in-
cluding the belonging exterior facilities are included in the contract modification’s scope of
work.
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5 Property Description
The Salt Lake is found at an altitude of 3,653 meters above sea level and has an area of 10,000
km². It is the largest salt lake in the world en one of the most important reserves of various
chemical components.
The Uyuni Salt Lake basin forms part of the Southern Altiplano, bordering on the north with the
Intercalar mountain range, on the south by the San Cristóbal mountain range, on the east by
the Cordillera Oriental, and on the west by the Cordillera Occidental. In the eastern section are
found the peaks Jatum Mundi (5,348 m), Choque Huarani (5,388 m), Cuzco (5,386 m), Cosuño
(5,243 m). The Cordillera Occidental consists of a volcanic chain with a predominant north-
south direction and a maximum altitude of 5,600 m. The Salt Lake is 545 km from La Paz, 315
km from Oruro and 230 km from Potosí, which represents a justification for the investments
planned in transport infrastructure.
5.1 Location
ERCOSPLAN received maps from GNRE-COMIBOL (12.02.2013 / 08.04.2013 via mail and
05.06.2013 via email). Furthermore GNRE-COMIBOL handed over maps at the meeting in La
Paz 22.01.-24.01.2013. These maps are showing location of plant site and evaporation ponds
with coordinates. The area for erecting the production plant and storages will be approx. 500 x
500 meters. An extension of 500 x 500 meter area is possible, e.g. due to the huge buildings
and limited incline angle of conveying equipment. Evaporation ponds are located in the north
of plant site area.
5.2 Meteorological Conditions, Earthquake Risk, Soil Conditions
5.2.1 Meteorological Conditions
The area has a relatively stable average temperature with a peak of 21 °C (70 °F) from Novem-
ber to January and a low of 13 °C (55 °F) in June. The nights are cold all through the year, with
temperatures between -9 and 5 °C (16 and 41 °F). The relative humidity is rather low and con-
stant throughout the year at 30 to 45 %. The rainfall is also low with1 to 3 mm (0.039 to 0.12)
per month between April and November, but it may increase up to 70 mm (2.8) in January.
However, except for January, even in the rainy season the number of rainy days is fewer than 5
per month.
GNRE-COMIBOL provided ERCOSPLAN with following climatic data in digital form (on CD-R):
• Relative humidity
• Precipitation
• Temperature
• Wind speed.
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These data represent measurements in the time from February 08, 2010 to December 16, 2012
at different locations (Coipasa, Piscinas de Evaporacion, Planta Piloto, UOP).
The extreme values are shown in Table 3.
Table 3 Meteorological Conditions
Coipasa Piscinas de Evap. Planta Piloto UOP

Relative Humidity [%]: 0 … 98.5 0 … 97.35 0 … 97.3 0 … 96.75
Precipitation [mm]
per measurement: 0.25 … 30.0 0.1 … 962.8 0.1 … 11.6 0.1 … 15.7
per year 2010 65.8 42.4 48.9 33.4
2011 1,036.4 301.7 258.5 266.9
2012 624.6 1135.3 227.8 217.4
Temperature [°C]: -13.0 …25.7 -13.9 … 24.5 -17.0 … 25.0 -10.7 … 24.4
Wind Speed [m/s]: 0 … 20.2 0 … 24.7 0 … 18.3 0 … 23.4
Table 4 gives an overview of the precipitation measured from 2010 to 2012.

The maximum yearly rain was in 2012 with 1,135.3 mm (Piscinas de Evaporacion). The monthly
maximum was in December with 967.7 mm. Also in Coipasa an extreme value of 1,036.4 mm
was measured. There was the monthly maximum in February with 535.9 mm.
In case of heavy precipitation there is a risk of flooding. To prevent the flooding of buildings,
the ground floor of all buildings will be elevated minimum 0.5 m over natural ground surface.
Because of the high geographical level of the plant site, an increased UV radiation has to be
considered.
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Table 4 Overview of the Precipitation in mm from 2010 to 2012 (Data provided by GNRE-COMIBOL)
Piscinas de Evaporacion
Year Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Sum/Year
2010 20.2 1.7 0.8 12.9 6.8 42.4
2011 54.3 142.1 27.4 6.1 3.6 11.6 3.3 53.3 301.7
2012 43.6 89.2 29.6 5.2 967.7 1135.3
Coipasa
2010 65.8 65.8
2011 192.3 535.9 96.3 11.2 21.1 39.1 4.1 136.4 1036.4
2012 188 242.6 173.7 20.3 624.6
Planta Piloto
2010 65.8 65.8
2011 192.3 535.9 96.3 11.2 21.1 39.1 4.1 136.4 1036.4
2012 188 242.6 173.7 20.3 624.6
UOP
2010 26.7 3.6 1.8 0.1 1.2 33.4
2011 48.3 108.7 32.1 4.5 4.4 68.9 266.9
2012 63.8 106 37.2 5.4 5 217.4
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5.2.2 Earthquake Risk
Regarding the earthquake hazard, GNRE-COMIBOL delivered to ERCOSPLAN a Seismic Map

of Bolivia. This document displays that an earthquake hazard with a maximum magnitude up to
4.9 (5.9) exists for the location of the plant.
For the Structural Analysis earthquake loads will be determined by UBC 1997.
5.2.3 Soil Conditions
For the plant site area a geological report including expert opinions is available. The following
soil layers were detected:
1. Salt crust thickness = 0.25 m
2. Peat clay thickness = 0.55 m
3. Rock salt I thickness = 4.30 m
4. Clay thickness = 18.35 m
The permanent brine level is close to the bottom edge of the salt crust layer.
For foundation of buildings and facilities layer 1 and 2 are not suitable. These layers have to be
cut and replaced by a good bearing material. The next layers are suitable for founding of all
buildings and facilities and the infrastructure.
For more information see the soil report (ENCLOSURE 3).
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6 Process Design for MOP Production
6.1 General
The exploitation of the Salar de Uyuni will be carried out by salar brine processing. Hence, at
first there is saline (KCl containing) brine available for processing to a KCl product (MOP) with
95 % purity (equates a K60 product). The salar brine is led through a multistep solar evapora-
tion system. In the first evaporation pond water is evaporated until KCl saturation of the brine is
reached. Contemporaneously sodium chloride crystallizes. At the time when the brine is satu-
rated with KCl, the brine is pumped to a second evaporation pond where also water is evapo-
rated and a material crystallizes that mainly consists of NaCl and KCl. Regarding improvement
of total plant recovery rate the surplus reclaim brine from processing plant should also subject-
ed to a solar evaporation pond in order to recover the contained KCl as a KCl/NaCl bearing
crystallisate. These crystallisates are transported to the processing area. ERCOSPLAN is as-
signed to plan and design the processing of this material via flotation to a MOP product. The
dried MOP product will have a purity of at least 95 %. Following the flotation process is de-
scribed.
The process can be grouped in following sections:
• Crystallisate debrining
• Crystallisate treatment
• Cleaner flotation and leaching
• Reclaim brine handling and tails handling
• KCl product debrining and drying.
The production capacity is envisaged with 700,000 t/y of MOP. It is assumed that the produc-
tion plant is run continuously 24 hours a day, seven days a week in total 7,500 hours per year.
The remaining time of one year is for scheduled maintenance.
By the reason that no data from the pilot plant at the Salar de Uyuni are available for ERCO-
SPLAN, the following process design (process description, block flow diagram and mass flow
balance) is only based on "test-size scale" test work (batchwise, 4 l volume flotation cell) with a
crystallizate from the evaporation of natural salar brine in evaporation ponds at the envisaged
plant area. When the existing pilot plant at the Salar de Uyuni run continuously, the gathered
data from its operation have to be compared with the test work results and the process design
should be refined if necessary.
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6.2 Design Qualities and Quantities
The analysis of the potash containing wet crystallisate from the second salar brine evaporation
pond that shall be processed to a MOP product shows following average composition:
KCl 27.04 %
K2SO4 0.30 %
NaCl 69.98 %
MgCl2 0.18 %
MgSO4 0.25 %
CaSO4 0.34 %
Insolubles 0.08 %
H2O 1.85 %
Lithium 31.27 mg/kg
Boron 62.49 mg/kg.
The analysis of the adhered brine at the crystallisate shows following brine composition:
KCl 39.20 g/l
NaCl 31.20 g/l
LiCl 23.76 g/l
MgCl2 237.00 g/l
MgSO4 67.40 g/l
CaSO4 bld.
H2O 899.7 g/l.
The expected crystallisate composition from surplus reclaim brine evaporation pond is as fol-
lows:
KCl 27.17 %
K2SO4 0.00 %
NaCl 69.02 %
MgCl2 0.00 %
MgSO4 0.00 %
CaSO4 0.51 %
Insolubles 3.30 %
H2O 0.00 %.
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The expected composition of the adhered brine at the crystallisate from surplus reclaim brine
evaporation pond is as follows:
KCl 89.46 g/l
K2SO4 6.91 g/l
NaCl 179.35 g/l
LiCl 7.27 g/l
MgCl2 72.53 g/l
MgSO4 23.19 g/l
CaSO4 2.00 g/l
H2O 876.75 g/l.
For the average production amount of 700,000 t/y MOP a representative process calculation
was accomplished considering the above mentioned crystallisate and adhered brine composi-
tion. Following amounts refer to this representative calculation. For the production amount of
700,000 t/y MOP, an amount of 3.4 mtpy wet crystallisate from second evaporation step and
0.7 mtpy wet crystals from surplus reclaim brine evaporation pond are required for the pro-
cessing plant. This corresponds to a production capacity of 93.3 t/h saleable product MOP and
for that 452.7 t/h wet crystallisate from second salar brine evaporation pond and 89.7 t/h wet
crystallisate from surplus reclaim brine evaporation pond are required. The KCl recovery rate of
the designed process route has been calculated to be 82.35 %.
The expected composition of dried product is as follows:
KCl 95.44 %
NaCl 3.79 %
MgCl2 0.01 %
CaSO4 0.00 %
Insolubles 0.56 %
H2O 0.2 %.
The flotation process requires certain amounts of water and produces certain amounts of saline
water (saturated with KCl and NaCl). In this case the surplus saline water (surplus reclaim
brine) is led to a surplus reclaim brine evaporation pond and a part of the contained KCl and
NaCl can be recrystallized and led to the flotation plant feed again. Here the advantage is that
most of the contained KCl in the surplus reclaim brine is recovered.
Besides the KCl product, also residue materials accumulate during processing the raw ore.
This residue materials are discharged from the process as wet salt (wet tailings). The residue
material consists mainly of NaCl.
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The composition of the residue material (wet tailings) is as follows:

KCl 1.83 %
NaCl 87.82 %
MgCl2 0.15 %
MgSO4 0.05 %
LiCl2 0,02 %
CaSO4 0.37 %
Insolubles 0.74 %
H2O 9.0 %.
For production of 700,000 t/y MOP approx. 2.13 mtpy of wet tailings arise from the process.
This corresponds to an amount of approx. 283.51 t/h of wet tailings.
Beside crystallisate from second salar brine evaporation pond and crystallisate from surplus
reclaim brine evaporation pond, a main feed component to the processing plant is water. The
net feed charge of water direct into the process is approx. 270 m3/h for the production of
700,000 t/y MOP. This corresponds to an amount of 2.05 million m3 water per year. A large
amount of process water, 177.8 m3/h, is used for cold leaching in order to reach the product
quality of MOP.
6.3 Process Scheme and Processing Description
The processing concept is illustrated in the block flow diagram in Figure 1. Explanations are
provided in the following subsections.
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Figure 1 Block Flow Diagram (see also Drawing A01)

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6.3.1 Crystallisate Debrining
It is supposed that the crystallisates from the second salar brine evaporation pond and the sur-
plus reclaim brine evaporation pond have 15 % adhered brine. Due to the fact that this brine
has a magnesium chloride content of approx. 237 g/l which will negatively influence the flota-
tion processes, the crystallisates have to be debrined. The combined crystallisates will be de-
brined with centrifuges. Therefor the crystallisate is mixed with filtrate from the centrifuges in a
repulping tank to adjust the correct solid content for the centrifuge inflow. The centrifuges de-
water the crystallisate to residual moisture of 3.8 %. The dewatered crystallisate is led to the
second process step, the crystallisate treatment. The filtrate is clarified in a thickener. Under-
flow of the thickener is led to rougher flotation. The main part of the overflow is led back to the
repulping tank to adjust the correct solid content. The leftover of the overflow has to be dis-
posed of to reduce the magnesium chloride amount in the flotation process.
6.3.2 Crystallisate Treatment
The second step of plant processing is the screening of the crystallized material. For flotation it
is essential to mill the feed material to a certain grain size for an optimal flotation result. By
screening the loading of the mill is reduced and the generation of much additional fines by mill-
ing of the fine raw material can be avoided.
Milling of the solid material is necessary in order to ensure an optimal flotation process. The
KCl crystals which shall be floated are mostly intergrown with other crystals mainly with NaCl,
the main component of the crude salt. To assure good contact of collector molecules with KCl
crystals during flotation the liberation of KCl crystals by crushing has to be ensured. The milled
material is mashed with reclaim brine.
From the repulping tank the suspension is conducted to wet screening. There, the solids are
divided in two fractions: overflow and underflow. The coarse overflow is subjected to wet mill-
ing and subsequently led back to wet screening. The solids in the fine underflow fraction have
the appropriate grain size below 0.8 mm and are conducted to the rougher flotation.
6.3.3 Rougher Flotation
The rougher flotation is the first flotation step and occurs as sylvite flotation. Herein mass flows
are processed which contain approximately 20 – 30 % KCl in the solid. The KCl content of the
crystallisate from solar evaporation is approx. 27 %. Aim of the rougher flotation is to enrich the
KCl in one mass flow and to separate most of the non-KCl solids. The concentrate will have a
KCl content of around 55 % in the solid.
The rougher flotation concentrate is given to the cleaner flotation. Tailings of the rougher flota-
tion are given to the scavenger flotation.
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6.3.4 Cleaner Flotation and Leaching
The cleaner flotation occurs as sylvite flotation. Mass flows which possess a relatively high KCl
percentage in the solids are given to the cleaner flotation for further enrichment of KCl in the
solid phase. The KCl content of the solids in the flotation concentrate will amount to 70 %. The
rougher flotation concentrate and scavenger flotation concentrate are led into the cleaner flota-
tion cells combined with an aqueous solution of flotation reagents and reclaim brine for ad-
justment of solid content in the feed suspension. Tailings of the cleaner flotation exhibit KCl
content in the solids of almost 30 %. This makes it appropriate for re-usage in the rougher flota-
tion. The cleaner flotation concentrate is subsequently leached with leaching water. KCl-dust
from drying is dissolved in the leaching water before it is used for leaching. Cleaner concen-
trate leaching is performed in two steps with that amount of leaching water which is necessary
for dissolution of most of the solid sodium chloride to reach the envisaged quality of the dried
product. In the first step of cold leaching the solids will be treated with low concentrated brine
from the second cold leaching step. Thereby a moderate increase of KCl content is achieved.
In the second cold leaching step the wet solid will be treated with leaching water. Thereby the
KCl content increases to approx. 96.3 % in the centrifuged solids, which finally results in the
envisaged product quality of at least 95 % KCl after de-brining and drying. The suspension
from leaching is then conducted to the product centrifuge for debrining.
6.3.5 Scavenger Flotation
The scavenger flotation is fed with the rougher flotation tails. Indeed the KCl content in the sol-
ids is relatively low but the amount is absolutely worthwhile to be recovered. The scavenger
flotation is also a sylvite flotation. The scavenger flotation concentrate is conducted to the
cleaner flotation process. The scavenger flotation tailings are subjected to the tails leach tank
where it is leached with process water to dissolve a certain amount of the remaining KCl.
6.3.6 Reclaim Brine and Solid Tailings Handling
Suspension from tails leach tank is thickened with hydrocyclones and thickeners. The thicken-
er overflow is re-used as reclaim brine, a NaCl and KCl saturated solution for mashing, trans-
portation and solid content adjustment in flotation processes. There are three main sources for
the reclaim brine, the overflow of the thickener prior rougher flotation, the overflow of the thick-
ener after first product cold leaching step and the overflow of the tails thickener. These over-
flows are led to an additional reclaim brine thickener to ensure that there are as less as possi-
ble solids in the reclaim brine. The underflow of this thickener is led to tails leach tank. Clarified
reclaim brine is permanently distributed to many different process parts. But there is more re-
claim brine generated than needed for the process. The surplus is discharged to the surplus
reclaim brine evaporation pond where the contained KCl and NaCl can crystallize again and is
then given back to the flotation process.
The tails thickener underflow is given on a belt filter for further debrining. The filtrate is led back
to the tails thickener. The filter cake is washed with process water to replace the adhered po-
tassium chloride rich brine. The remaining wet solid consists mainly of NaCl. With this mass
flow the main amount of NaCl and high amounts of insolubles are discharged from the pro-
cess. The solid tailings have to be stockpiled.
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6.3.7 KCl-Product Debrining and Drying
The KCl product suspension from leaching is conducted to hydrocyclones to adjust the right
solid content for feed into the product centrifuges. In the product centrifuges the product is
further debrined up to a remaining water content of max. 6 % in the wet solid. The filtrate is giv-
en into first step of cold leaching. The de-brined solid is then led to a dryer and dried to mois-
ture of 0.2 %. Dust from the drying is dissolved in cold leaching water and so reused in the
process. Dry solids are led to product storage. The dried product is led to the product treat-
ment (anticaking mixing vessel), where it is treated with an aqueous solution of Potassium Fer-
rocyanide and Sodium Chloride to avoid product caking.
6.3.8 Mass Flow Table and Mass Flow Balance
The following Table 5 presents the calculated mass flows of the process which are shown in
the process flow scheme in Figure 1. The following mass flow numbers are not used in the
process calculation: 15, 19, 20, 23, 24, 25, 26, 52. During progression of process development
these mass flows were omitted.
The numbers in the shown mass balance are calculated values. Due to the fact that this is an
iteration process by several thousands of calculation steps, it is normal that there will be slight
changes in the single numbers within every iteration step. So it is not worrying if there are mar-
ginal differences, in the range of ± 0.2 %, between the numbers shown in the mass flow table
and the numbers shown e.g. in the datasheets and PIDs. For the same reason it is not worry-
ing, that there are marginal differences in the whole mass balance between the respective de-
sign work milestones.
The mass flow table refers to 7,500 operating hours per year. The MOP production amounts
700,000 t/y. This means approx. 93.34 t/h of saleable product.
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Table 5 Mass Flow Table
Mass Flow Composition Quantities Properties

Component
No. Appellation Solution Solids Solution Solids Object Solution Solids
KCl 39.2 g/l 27.58 % 2,049 kg/h 106,018 kg/h ρ [g/l] 1,297.65
NaCl 31.2 g/l 71.57 % 1,631 kg/h 275,149 kg/h V [m3/h] 52.28 181.25
KCl / NaCl LiCl 23.8 g/l 0.00 % 1,242 kg/h 0 kg/h m [t/h] 67.84 384.44
MgCl2 237.0 g/l 0.00 % 12,391 kg/h 0 kg/h V susp [m3/h] 233.53
Mixture from
1 MgSO4 67.4 g/l 0.11 % 3,524 kg/h 439 kg/h fsusp [kg/m3] 1,646.20
Solar Evap. CaSO 4 0.0 g/l 0.35 % 0 kg/h 1,338 kg/h T [°C] 15.00
Pond Insolubles 0.0 g/l 0.08 % 0 kg/h 315 kg/h
K2SO4 0.0 g/l 0.31 % 0 kg/h 1,181 kg/h
H2O 899.1 g/l 0.00 % 47,005 kg/h 0 kg/h
KCl 89.5 g/l 27.17 % 1,372 kg/h 19,111 kg/h ρ [g/l] 1,257.46
KCl / NaCl LiCl 7.3 g/l 0.00 % 111 kg/h 0 kg/h m [t/h] 19.28 70.34
MgCl2 72.5 g/l 0.00 % 1,112 kg/h 0 kg/h V susp [m3/h] 48.43
Mixture from
2 MgSO4 23.2 g/l 0.00 % 356 kg/h 0 kg/h fsusp [kg/m3] 1,452.27
Surplus Brine CaSO 4 2.0 g/l 0.51 % 31 kg/h 357 kg/h T [°C] 10.00
Evap. Pond Insolubles 0.0 g/l 3.30 % 0 kg/h 2,324 kg/h
K2SO4 6.9 g/l 0.00 % 106 kg/h 0 kg/h
H2O 876.8 g/l 0.00 % 13,442 kg/h 0 kg/h
KCl 50.6 g/l 27.51 % 3,421 kg/h 125,129 kg/h ρ [g/l] 1,288.00
LiCl 20.0 g/l 0.00 % 1,354 kg/h 0 kg/h m [t/h] 87.12 454.78
Raw Material MgCl2 199.6 g/l 0.00 % 13,502 kg/h 0 kg/h V susp [m3/h] 281.99
3 to MgSO4 57.4 g/l 0.10 % 3,879 kg/h 439 kg/h fsusp [kg/m3] 1,612.72
CaSO 4 0.5 g/l 0.37 % 31 kg/h 1,695 kg/h T [°C] 15.00
Repulping
Insolubles 0.0 g/l 0.58 % 0 kg/h 2,639 kg/h
K2SO4 1.6 g/l 0.26 % 106 kg/h 1,181 kg/h
H2O 893.6 g/l 0.00 % 60,448 kg/h 0 kg/h
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Component
KCl 97.7 g/l 26.64 % 71,905 kg/h 393 kg/h ρ [g/l] 1,240.07
Reclaim Brine LiCl 2.5 g/l 0.00 % 1,860 kg/h 0 kg/h m [t/h] 912.62 1.47
MgCl2 25.2 g/l 0.00 % 18,553 kg/h 0 kg/h Vsusp [m3/h] 736.64
to
4 MgSO4 8.1 g/l 0.00 % 5,934 kg/h 0 kg/h fsusp [kg/m3] 2.00
Raw Material CaSO4 1.9 g/l 0.30 % 1,430 kg/h 4 kg/h T [°C] 6.35
Repulping Insolubles 0.0 g/l 0.63 % 0 kg/h 9 kg/h
K2SO4 2.4 g/l 0.00 % 1,768 kg/h 0 kg/h
H2O 870.8 g/l 0.00 % 640,852 kg/h 0 kg/h
KCl 96.8 g/l 27.68 % 72,577 kg/h 118,569 kg/h ρ [g/l] 1,242.40
Raw Material MgCl2 28.1 g/l 0.00 % 21,038 kg/h 0 kg/h Vsusp [m3/h] 952.05
5 to MgSO4 9.0 g/l 0.00 % 6,728 kg/h 0 kg/h fsusp [kg/m3] 450.00
CaSO4 2.0 g/l 0.34 % 1,499 kg/h 1,469 kg/h T [°C] 7.31
Wet Screening
K2SO4 2.7 g/l 0.00 % 2,005 kg/h 0 kg/h
H2O 869.9 g/l 0.00 % 651,991 kg/h 0 kg/h
KCl 96.4 g/l 28.20 % 5,609 kg/h 61,286 kg/h ρ [g/l] 1,242.13
LiCl 2.7 g/l 0.00 % 158 kg/h 0 kg/h m [t/h] 72.29 217.35
Backflow MgCl2 27.2 g/l 0.00 % 1,580 kg/h 0 kg/h Vsusp [m3/h] 161.00
6 from MgSO4 8.7 g/l 0.00 % 505 kg/h 0 kg/h fsusp [kg/m3] 1,350.00
CaSO4 2.0 g/l 0.31 % 116 kg/h 676 kg/h T [°C] 6.92
Wet Mill
K2SO4 2.6 g/l 0.00 % 151 kg/h 0 kg/h
H2O 870.0 g/l 0.00 % 50,628 kg/h 0 kg/h
Page 87 of 273
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Component
KCl 97.7 g/l 26.64 % 46,855 kg/h 256 kg/h ρ [g/l] 1,240.07
NaCl 231.4 g/l 72.43 % 110,980 kg/h 695 kg/h V [m3/h] 479.55 0.45
Reclaim Brine LiCl 2.5 g/l 0.00 % 1,212 kg/h 0 kg/h m [t/h] 594.68 0.96
to
Wet Sizing CaSO4 1.9 g/l 0.30 % 932 kg/h 3 kg/h T [°C] 6.35
Screens Insolubles 0.0 g/l 0.63 % 0 kg/h 6 kg/h
K2SO4 2.4 g/l 0.00 % 1,152 kg/h 0 kg/h
H2O 870.8 g/l 0.00 % 417,590 kg/h 0 kg/h
KCl 96.4 g/l 28.20 % 160,843 kg/h 143,002 kg/h ρ [g/l] 1,242.13
NaCl 232.6 g/l 70.94 % 388,166 kg/h 359,781 kg/h V [m3/h] 1,668.67 239.86
Wet Sizing LiCl 2.7 g/l 0.00 % 4,543 kg/h 0 kg/h m [t/h] 2,072.71 507.13
Screens MgCl2 27.2 g/l 0.00 % 45,319 kg/h 0 kg/h Vsusp [m3/h] 1,908.53
8 Underflow MgSO4 8.7 g/l 0.00 % 14,494 kg/h 0 kg/h fsusp [kg/m3] 265.72
CaSO4 2.0 g/l 0.31 % 3,337 kg/h 1,577 kg/h T [°C] 6.92
to
Rougher Cyclone K2SO4 2.6 g/l 0.00 % 4,318 kg/h 0 kg/h
H2O 870.0 g/l 0.00 % 1,451,687 kg/h 0 kg/h
KCl 96.0 g/l 29.63 % 42,158 kg/h 23,430 kg/h ρ [g/l] 1,242.29
Cleaner Flotation LiCl 2.8 g/l 0.00 % 1,222 kg/h 0 kg/h m [t/h] 545.49 79.08
Tailings MgCl2 27.8 g/l 0.00 % 12,192 kg/h 0 kg/h Vsusp [m3/h] 476.58
CaSO4 2.0 g/l 0.17 % 878 kg/h 133 kg/h T [°C] 6.79
Wet Sizing
Insolubles 0.0 g/l 0.32 % 0 kg/h 250 kg/h
Screens K2SO4 2.6 g/l 0.00 % 1,162 kg/h 0 kg/h
H2O 870.2 g/l 0.00 % 382,116 kg/h 0 kg/h
Page 88 of 273
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Component
KCl 96.4 g/l 28.20 % 68,562 kg/h 114,667 kg/h ρ [g/l] 1,242.13
Underflow LiCl 2.7 g/l 0.00 % 1,937 kg/h 0 kg/h m [t/h] 883.53 406.64
Rougher Cyclone
to CaSO4 2.0 g/l 0.31 % 1,423 kg/h 1,264 kg/h T [°C] 6.92
Rougher Flotation Insolubles 0.0 g/l 0.55 % 0 kg/h 2,223 kg/h
K2SO4 2.6 g/l 0.00 % 1,841 kg/h 0 kg/h
H2O 870.0 g/l 0.00 % 618,807 kg/h 0 kg/h
KCl 96.4 g/l 28.20 % 92,281 kg/h 28,333 kg/h ρ [g/l] 1,242.13
Overflow LiCl 2.7 g/l 0.00 % 2,607 kg/h 0 kg/h m [t/h] 1,189.18 100.49
MgCl2 27.2 g/l 0.00 % 26,000 kg/h 0 kg/h Vsusp [m3/h] 1,004.90
Rougher Cyclone
to CaSO4 2.0 g/l 0.31 % 1,915 kg/h 312 kg/h T [°C] 6.92
Rougher Thickener Insolubles 0.0 g/l 0.55 % 0 kg/h 549 kg/h
K2SO4 2.6 g/l 0.00 % 2,477 kg/h 0 kg/h
H2O 870.0 g/l 0.00 % 832,878 kg/h 0 kg/h
KCl 96.4 g/l 28.15 % 14,171 kg/h 27,088 kg/h ρ [g/l] 1,242.12
Underflow LiCl 2.7 g/l 0.00 % 400 kg/h 0 kg/h m [t/h] 182.50 96.22
Rougher Thickener
to CaSO4 2.0 g/l 0.31 % 294 kg/h 299 kg/h T [°C] 6.95
Rougher Flotation Insolubles 0.0 g/l 0.55 % 0 kg/h 527 kg/h
K2SO4 2.6 g/l 0.00 % 380 kg/h 0 kg/h
H2O 869.9 g/l 0.00 % 127,816 kg/h 0 kg/h
Page 89 of 273
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Component
KCl 96.4 g/l 28.15 % 78,212 kg/h 1,144 kg/h ρ [g/l] 1,242.13
Rougher Thickener MgCl2 27.1 g/l 0.00 % 22,011 kg/h 0 kg/h Vsusp [m3/h] 812.82
CaSO4 2.0 g/l 0.31 % 1,622 kg/h 13 kg/h T [°C] 6.95
Reclaim Brine
Storage K2SO4 2.6 g/l 0.00 % 2,097 kg/h 0 kg/h
H2O 869.9 g/l 0.00 % 705,436 kg/h 0 kg/h
KCl 95.0 g/l 57.17 % 17,291 kg/h 122,738 kg/h ρ [g/l] 1,243.67
Rougher LiCl 3.3 g/l 0.00 % 596 kg/h 0 kg/h m [t/h] 226.45 214.69
Concentrate
Cleaner Flotation Insolubles 0.0 g/l 0.32 % 0 kg/h 685 kg/h
K2SO4 3.1 g/l 0.00 % 566 kg/h 0 kg/h
H2O 871.3 g/l 0.00 % 158,644 kg/h 0 kg/h
KCl 95.0 g/l 8.07 % 68,966 kg/h 25,082 kg/h ρ [g/l] 1,243.67
Rougher Tailings LiCl 3.3 g/l 0.00 % 2,375 kg/h 0 kg/h m [t/h] 903.24 310.73
to
Scavenger CaSO4 2.0 g/l 0.40 % 1,453 kg/h 1,245 kg/h T [°C] 6.91
Flotation Insolubles 0.0 g/l 0.71 % 0 kg/h 2,196 kg/h
K2SO4 3.1 g/l 0.00 % 2,258 kg/h 0 kg/h
H2O 871.3 g/l 0.00 % 632,783 kg/h 0 kg/h
Page 90 of 273
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Component
KCl 95.2 g/l 48.54 % 2,729 kg/h 14,689 kg/h ρ [g/l] 1,243.61
Scavenger LiCl 3.2 g/l 0.00 % 93 kg/h 0 kg/h m [t/h] 35.63 30.26
MgCl2 32.4 g/l 0.00 % 928 kg/h 0 kg/h Vsusp [m3/h] 43.23
Concentrate
21 MgSO4 10.4 g/l 0.00 % 297 kg/h 0 kg/h fsusp [kg/m3] 700.00
Cleaner Flotation Insolubles 0.0 g/l 0.31 % 0 kg/h 93 kg/h
K2SO4 3.1 g/l 0.00 % 88 kg/h 0 kg/h
H2O 871.1 g/l 0.00 % 24,958 kg/h 0 kg/h
KCl 95.2 g/l 3.56 % 67,596 kg/h 9,948 kg/h ρ [g/l] 1,243.61
Scavenger LiCl 3.2 g/l 0.00 % 2,306 kg/h 0 kg/h m [t/h] 882.60 279.34
Tailings
Tails Leach Tank Insolubles 0.0 g/l 0.75 % 0 kg/h 2,105 kg/h
K2SO4 3.1 g/l 0.00 % 2,192 kg/h 0 kg/h
H2O 871.1 g/l 0.00 % 618,240 kg/h 0 kg/h
KCl 0.0 g/l 0 kg/h ρ [g/l] 999.01
NaCl 0.0 g/l 0 kg/h V [m3/h] 55.77
LiCl 0.0 g/l 0 kg/h m [t/h] 55.71
Process Water MgCl2 0.0 g/l 0 kg/h Vsusp [m3/h]
27 to MgSO4 0.0 g/l 0 kg/h fsusp [kg/m3]
CaSO4 0.0 g/l 0 kg/h T [°C] 15.00
Tails Leach Tank
Insolubles 0.0 g/l 0 kg/h
K2SO4 0.0 g/l 0 kg/h
H2O 999.0 g/l 55,713 kg/h
Page 91 of 273
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Component
KCl 95.5 g/l 1.50 % 118,033 kg/h 4,035 kg/h ρ [g/l] 1,242.66
Suspension LiCl 2.9 g/l 0.00 % 3,608 kg/h 0 kg/h m [t/h] 1,536.08 269.01
Tails Leaching
Tails Cyclone Insolubles 0.0 g/l 0.83 % 0 kg/h 2,243 kg/h
K2SO4 2.8 g/l 0.00 % 3,429 kg/h 0 kg/h
H2O 870.6 g/l 0.00 % 1,076,219 kg/h 0 kg/h
KCl 93.0 g/l 0.00 % 41,812 kg/h 0 kg/h ρ [g/l] 1,240.93
Filtrate LiCl 2.8 g/l 0.00 % 1,272 kg/h 0 kg/h m [t/h] 558.11 8.80
Tails Belt Filter
back to CaSO4 2.1 g/l 0.00 % 924 kg/h 0 kg/h T [°C] 6.95
Tails Thickener Insolubles 0.0 g/l 1.21 % 0 kg/h 107 kg/h
K2SO4 2.7 g/l 0.00 % 1,209 kg/h 0 kg/h
H2O 871.5 g/l 0.00 % 391,948 kg/h 0 kg/h
KCl 95.5 g/l 1.45 % 5,037 kg/h 565 kg/h ρ [g/l] 1,242.66
Tails Thickener
Tails Belt Filter Insolubles 0.0 g/l 0.84 % 0 kg/h 325 kg/h
K2SO4 2.8 g/l 0.00 % 146 kg/h 0 kg/h
H2O 870.6 g/l 0.00 % 45,921 kg/h 0 kg/h
Page 92 of 273
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Component
KCl 95.5 g/l 1.45 % 75,010 kg/h 57 kg/h ρ [g/l] 1,242.66
Overflow LiCl 2.9 g/l 0.00 % 2,292 kg/h 0 kg/h m [t/h] 976.12 3.94
Tails Thickener MgCl2 29.1 g/l 0.00 % 22,863 kg/h 0 kg/h Vsusp [m3/h] 787.33
CaSO4 2.0 g/l 0.41 % 1,571 kg/h 16 kg/h T [°C] 6.69
Reclaim Brine
H2O 870.6 g/l 0.00 % 683,889 kg/h 0 kg/h
KCl 97.7 g/l 26.64 % 156,764 kg/h 856 kg/h ρ [g/l] 1,240.07
LiCl 2.5 g/l 0.00 % 4,055 kg/h 0 kg/h m [t/h] 1,989.65 3.21
Reclaim Brine MgCl2 25.2 g/l 0.00 % 40,449 kg/h 0 kg/h Vsusp [m3/h] 1,605.98
CaSO4 1.9 g/l 0.30 % 3,117 kg/h 9 kg/h T [°C] 6.35
Process
K2SO4 2.4 g/l 0.00 % 3,854 kg/h 0 kg/h
H2O 870.8 g/l 0.00 % 1,397,158 kg/h 0 kg/h
KCl 97.7 g/l 26.65 % 30,906 kg/h 169 kg/h ρ [g/l] 1,240.07
Surplus LiCl 2.5 g/l 0.00 % 800 kg/h 0 kg/h m [t/h] 392.26 0.63
Reclaim Brine MgCl2 25.2 g/l 0.00 % 7,974 kg/h 0 kg/h Vsusp [m3/h] 316.61
CaSO4 1.9 g/l 0.30 % 614 kg/h 2 kg/h T [°C] 6.35
Solar Evaporation
Pond K2SO4 2.4 g/l 0.00 % 760 kg/h 0 kg/h
H2O 870.8 g/l 0.00 % 275,447 kg/h 0 kg/h
Page 93 of 273
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Component
KCl 0.0 g/l 0 kg/h ρ [g/l] 999.01
NaCl 0.0 g/l 0 kg/h V [m3/h] 24.97
LiCl 0.0 g/l 0 kg/h m [t/h] 24.94
Process Water MgCl2 0.0 g/l 0 kg/h Vsusp [m3/h]
35 to MgSO4 0.0 g/l 0 kg/h fsusp [kg/m3]
CaSO4 0.0 g/l 0 kg/h T [°C] 15.00
Tails Belt Filter
Insolubles 0.0 g/l 0 kg/h
H2O 999.0 g/l 24,940 kg/h
KCl 52.3 g/l 1.49 % 1,428 kg/h 3,766 kg/h ρ [g/l] 1,136.71
De-brined
Tailings CaSO4 1.1 g/l 0.41 % 30 kg/h 1,026 kg/h T [°C] 10.42
K2SO4 1.5 g/l 0.00 % 41 kg/h 0 kg/h
H2O 933.1 g/l 0.00 % 25,492 kg/h 0 kg/h
KCl 97.7 g/l 26.64 % 35,556 kg/h 194 kg/h ρ [g/l] 1,240.07
Reclaim Brine MgCl2 25.2 g/l 0.00 % 9,174 kg/h 0 kg/h Vsusp [m3/h] 364.25
CaSO4 1.9 g/l 0.30 % 707 kg/h 2 kg/h T [°C] 6.35
Cleaner Flotation
K2SO4 2.4 g/l 0.00 % 874 kg/h 0 kg/h
H2O 870.8 g/l 0.00 % 316,891 kg/h 0 kg/h
Page 94 of 273
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Component
KCl 96.0 g/l 69.48 % 13,314 kg/h 114,293 kg/h ρ [g/l] 1,242.29
Cleaner LiCl 2.8 g/l 0.00 % 386 kg/h 0 kg/h m [t/h] 172.27 164.49
Concentrate MgCl2 27.8 g/l 0.00 % 3,850 kg/h 0 kg/h Vsusp [m3/h] 219.32
CaSO4 2.0 g/l 0.17 % 277 kg/h 285 kg/h T [°C] 6.79
Cold Leaching
1st Stage K2SO4 2.6 g/l 0.00 % 367 kg/h 0 kg/h
H2O 870.2 g/l 0.00 % 120,675 kg/h 0 kg/h
KCl 147.3 g/l 96.33 % 12,565 kg/h 8,651 kg/h ρ [g/l] 1,183.23
Filtrate LiCl 0.1 g/l 0.00 % 9 kg/h 0 kg/h m [t/h] 100.93 8.98
Product Centrifuge MgCl2 1.0 g/l 0.00 % 87 kg/h 0 kg/h Vsusp [m3/h] 89.80
40 to MgSO4 0.3 g/l 0.00 % 28 kg/h 0 kg/h fsusp [kg/m3] 100.00
CaSO4 0.1 g/l 0.00 % 13 kg/h 0 kg/h T [°C] 2.43
Cold Leaching
H2O 894.3 g/l 0.00 % 76,289 kg/h 0 kg/h
KCl 105.9 g/l 81.75 % 37,641 kg/h 135,308 kg/h ρ [g/l] 1,229.00
Suspension LiCl 1.1 g/l 0.00 % 408 kg/h 0 kg/h m [t/h] 436.91 165.52
Cold Leaching MgCl2 11.4 g/l 0.00 % 4,066 kg/h 0 kg/h Vsusp [m3/h] 437.52
41 1st Stage MgSO4 3.7 g/l 0.00 % 1,300 kg/h 0 kg/h fsusp [kg/m3] 378.30
CaSO4 1.7 g/l 0.00 % 594 kg/h 0 kg/h T [°C] 4.18
to
Product Filtration K2SO4 1.1 g/l 0.00 % 387 kg/h 0 kg/h
H2O 873.2 g/l 0.00 % 310,423 kg/h 0 kg/h
Page 95 of 273
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Component
KCl 105.9 g/l 81.84 % 1,647 kg/h 7,370 kg/h ρ [g/l] 1,228.99
Product Thickener
Product Filtration Insolubles 0.0 g/l 0.38 % 0 kg/h 34 kg/h
K2SO4 1.1 g/l 0.00 % 17 kg/h 0 kg/h
H2O 873.2 g/l 0.00 % 13,580 kg/h 0 kg/h
KCl 105.9 g/l 81.75 % 2,047 kg/h 133,921 kg/h ρ [g/l] 1,228.99
De-brined Solids LiCl 1.1 g/l 0.00 % 22 kg/h 0 kg/h m [t/h] 23.76 163.81
Product Filtration MgCl2 11.4 g/l 0.00 % 221 kg/h 0 kg/h Vsusp [m3/h] 100.50
43 to MgSO4 3.7 g/l 0.00 % 71 kg/h 0 kg/h fsusp [kg/m3] 1,629.87
CaSO4 1.7 g/l 0.00 % 32 kg/h 0 kg/h T [°C] 4.18
Cold Leaching
2nd Stage K2SO4 1.1 g/l 0.00 % 21 kg/h 0 kg/h
H2O 873.2 g/l 0.00 % 16,881 kg/h 0 kg/h
KCl 105.9 g/l 81.75 % 37,239 kg/h 8,757 kg/h ρ [g/l] 1,228.99
Filtrate LiCl 1.1 g/l 0.00 % 403 kg/h 0 kg/h m [t/h] 432.26 10.71
Product Filtration
Product Thickener Insolubles 0.0 g/l 0.37 % 0 kg/h 40 kg/h
K2SO4 1.1 g/l 0.00 % 383 kg/h 0 kg/h
H2O 873.2 g/l 0.00 % 307,126 kg/h 0 kg/h
Page 96 of 273
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Component
KCl 105.9 g/l 81.83 % 35,599 kg/h 1,379 kg/h ρ [g/l] 1,229.00
Overflow LiCl 1.1 g/l 0.00 % 386 kg/h 0 kg/h m [t/h] 413.21 1.69
Product Thickener MgCl2 11.4 g/l 0.00 % 3,845 kg/h 0 kg/h Vsusp [m3/h] 337.06
CaSO4 1.7 g/l 0.00 % 562 kg/h 0 kg/h T [°C] 4.19
Reclaim Brine
Storage K2SO4 1.1 g/l 0.00 % 366 kg/h 0 kg/h
H2O 873.2 g/l 0.00 % 293,588 kg/h 0 kg/h
KCl 0.0 g/l 0 kg/h ρ [g/l] 999.01
NaCl 0.0 g/l 0 kg/h V [m3/h] 137.18
Process Water LiCl 0.0 g/l 0 kg/h m [t/h] 137.04
MgCl2 0.0 g/l 0 kg/h Vsusp [m3/h]
to
47 MgSO4 0.0 g/l 0 kg/h fsusp [kg/m3]
Cold Leaching CaSO4 0.0 g/l 0 kg/h T [°C] 15.00
2nd Stage Insolubles 0.0 g/l 0 kg/h
H2O 999.0 g/l 137,041 kg/h
KCl 147.3 g/l 96.33 % 32,035 kg/h 108,700 kg/h ρ [g/l] 1,183.23
Suspension LiCl 0.1 g/l 0.00 % 22 kg/h 0 kg/h m [t/h] 257.31 112.84
Cold Leaching MgCl2 1.0 g/l 0.00 % 221 kg/h 0 kg/h Vsusp [m3/h] 274.04
48 2nd Stage MgSO4 0.3 g/l 0.00 % 71 kg/h 0 kg/h fsusp [kg/m3] 411.77
CaSO4 0.1 g/l 0.00 % 32 kg/h 0 kg/h T [°C] 2.43
to
Product Cyclone K2SO4 0.1 g/l 0.00 % 21 kg/h 0 kg/h
H2O 894.3 g/l 0.00 % 194,487 kg/h 0 kg/h
Page 97 of 273
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Component
KCl 147.3 g/l 96.33 % 780 kg/h 94,615 kg/h ρ [g/l] 1,183.23
Wet Product NaCl 139.9 g/l 3.10 % 741 kg/h 3,047 kg/h V [m3/h] 5.30 49.25
from LiCl 0.1 g/l 0.00 % 1 kg/h 0 kg/h m [t/h] 6.27 98.22
Product Centrifuge
Wet Product Insolubles 0.0 g/l 0.57 % 0 kg/h 559 kg/h
Storage K2SO4 0.1 g/l 0.00 % 1 kg/h 0 kg/h
H2O 894.3 g/l 0.00 % 4,739 kg/h 0 kg/h
KCl 62.8 g/l 27.53 % 17,171 kg/h 378 kg/h ρ [g/l] 1,323.81
Overflow LiCl 19.8 g/l 0.00 % 5,410 kg/h 0 kg/h m [t/h] 362.24 1.37
De-brining MgCl2 197.2 g/l 0.00 % 53,963 kg/h 0 kg/h Vsusp [m3/h] 274.28
51 Thickener MgSO4 63.1 g/l 0.00 % 17,258 kg/h 0 kg/h fsusp [kg/m3] 5.00
CaSO4 2.0 g/l 0.35 % 547 kg/h 5 kg/h T [°C] 14.00
to
Repulping Tank K2SO4 18.8 g/l 0.00 % 5,142 kg/h 0 kg/h
H2O 884.3 g/l 0.00 % 241,987 kg/h 0 kg/h
KCl 62.7 g/l 27.53 % 21,469 kg/h 124,630 kg/h ρ [g/l] 1,322.41
Raw Material LiCl 19.8 g/l 0.00 % 6,764 kg/h 0 kg/h m [t/h] 452.76 452.75
Suspension MgCl2 197.1 g/l 0.00 % 67,465 kg/h 0 kg/h Vsusp [m3/h] 556.36
CaSO4 2.0 g/l 0.35 % 685 kg/h 1,593 kg/h T [°C] 14.03
De-Brining
Centrifuge K2SO4 18.8 g/l 0.00 % 6,428 kg/h 0 kg/h
H2O 883.3 g/l 0.00 % 302,435 kg/h 0 kg/h
Page 98 of 273
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Component
KCl 62.7 g/l 27.53 % 791 kg/h 118,058 kg/h ρ [g/l] 1,322.41
NaCl 75.8 g/l 71.54 % 955 kg/h 306,805 kg/h V [m3/h] 12.61 202.70
De-Brined LiCl 19.8 g/l 0.00 % 249 kg/h 0 kg/h m [t/h] 16.68 428.88
Solid
to CaSO4 2.0 g/l 0.35 % 25 kg/h 1,509 kg/h T [°C] 14.03
Repulping Tank Insolubles 0.0 g/l 0.58 % 0 kg/h 2,507 kg/h
K2SO4 18.8 g/l 0.00 % 237 kg/h 0 kg/h
H2O 883.3 g/l 0.00 % 11,139 kg/h 0 kg/h
KCl 62.7 g/l 27.53 % 20,678 kg/h 6,572 kg/h ρ [g/l] 1,322.41
Fugate LiCl 19.8 g/l 0.00 % 6,515 kg/h 0 kg/h m [t/h] 436.09 23.87
De-Brining MgCl2 197.1 g/l 0.00 % 64,982 kg/h 0 kg/h Vsusp [m3/h] 341.05
55 Centrifuge MgSO4 63.0 g/l 0.00 % 20,783 kg/h 0 kg/h fsusp [kg/m3] 70.00
CaSO4 2.0 g/l 0.35 % 660 kg/h 84 kg/h T [°C] 14.03
to
Thickener K2SO4 18.8 g/l 0.00 % 6,192 kg/h 0 kg/h
H2O 883.3 g/l 0.00 % 291,296 kg/h 0 kg/h
KCl 147.3 g/l 96.33 % 18,687 kg/h 5,435 kg/h ρ [g/l] 1,183.23
Product Cyclone MgCl2 1.0 g/l 0.00 % 129 kg/h 0 kg/h Vsusp [m3/h] 129.69
56 to MgSO4 0.3 g/l 0.00 % 41 kg/h 0 kg/h fsusp [kg/m3] 43.50
CaSO4 0.1 g/l 0.00 % 19 kg/h 0 kg/h T [°C] 2.43
Cold Leaching
H2O 894.3 g/l 0.00 % 113,457 kg/h 0 kg/h
Page 99 of 273
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Component
KCl 147.3 g/l 96.33 % 13,346 kg/h 103,265 kg/h ρ [g/l] 1,183.23
Product Cyclone
Product Centrifuge Insolubles 0.0 g/l 0.57 % 0 kg/h 610 kg/h
K2SO4 0.1 g/l 0.00 % 9 kg/h 0 kg/h
H2O 894.3 g/l 0.00 % 81,028 kg/h 0 kg/h
KCl 95.5 g/l 1.50 % 80,026 kg/h 643 kg/h ρ [g/l] 1,242.66
Tails Cyclone
Tails Thickener Insolubles 0.0 g/l 0.83 % 0 kg/h 358 kg/h
K2SO4 2.8 g/l 0.00 % 2,325 kg/h 0 kg/h
H2O 870.6 g/l 0.00 % 729,638 kg/h 0 kg/h
KCl 95.5 g/l 1.50 % 38,012 kg/h 3,392 kg/h ρ [g/l] 1,242.66
Underflow LiCl 2.9 g/l 0.00 % 1,162 kg/h 0 kg/h m [t/h] 494.67 226.11
Tails Cyclone
Tails Filtration Insolubles 0.0 g/l 0.83 % 0 kg/h 1,886 kg/h
K2SO4 2.8 g/l 0.00 % 1,104 kg/h 0 kg/h
H2O 870.6 g/l 0.00 % 346,578 kg/h 0 kg/h
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Component
KCl 62.7 g/l 27.56 % 1,887 kg/h 6,159 kg/h ρ [g/l] 1,323.81
CaSO4 2.0 g/l 0.35 % 60 kg/h 79 kg/h T [°C] 14.00
to
Rougher Flotation K2SO4 18.8 g/l 0.00 % 565 kg/h 0 kg/h
H2O 884.3 g/l 0.00 % 26,595 kg/h 0 kg/h
KCl 62.7 g/l 27.53 % 18,788 kg/h 413 kg/h ρ [g/l] 1,323.81
Overflow MgCl2 197.2 g/l 0.00 % 59,051 kg/h 0 kg/h Vsusp [m3/h] 300.14
61 De-brining MgSO4 63.1 g/l 0.00 % 18,886 kg/h 0 kg/h fsusp [kg/m3] 5.00
CaSO4 2.0 g/l 0.35 % 599 kg/h 5 kg/h T [°C] 14.00
Thickener
K2SO4 18.8 g/l 0.00 % 5,627 kg/h 0 kg/h
H2O 884.3 g/l 0.00 % 264,798 kg/h 0 kg/h
KCl 62.7 g/l 27.53 % 1,618 kg/h 36 kg/h ρ [g/l] 1,323.81
CaSO4 2.0 g/l 0.35 % 52 kg/h 0 kg/h T [°C] 14.00
to
Disposal K2SO4 18.8 g/l 0.00 % 485 kg/h 0 kg/h
H2O 884.3 g/l 0.00 % 22,811 kg/h 0 kg/h
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Component
KCl 97.7 g/l 26.64 % 1,157 kg/h 1,556 kg/h ρ [g/l] 1,240.07
Reclaim Brine MgCl2 25.2 g/l 0.00 % 299 kg/h 0 kg/h Vsusp [m3/h] 14.60
63 Thickener MgSO4 8.1 g/l 0.00 % 95 kg/h 0 kg/h fsusp [kg/m3] 400.00
CaSO4 1.9 g/l 0.30 % 23 kg/h 17 kg/h T [°C] 6.35
to
Tails Leaching K2SO4 2.4 g/l 0.00 % 28 kg/h 0 kg/h
H2O 870.8 g/l 0.00 % 10,314 kg/h 0 kg/h
KCl 97.7 g/l 26.64 % 187,670 kg/h 1,024 kg/h ρ [g/l] 1,240.07
Overflow NaCl 231.4 g/l 72.43 % 444,517 kg/h 2,785 kg/h V [m3/h] 1,920.78 1.82
Reclaim Brine LiCl 2.5 g/l 0.00 % 4,854 kg/h 0 kg/h m [t/h] 2,381.90 3.84
Thickener
Reclaim Brine Insolubles 0.0 g/l 0.63 % 0 kg/h 24 kg/h
H2O 870.8 g/l 0.00 % 1,672,605 kg/h 0 kg/h
KCl 95.44 % 4,770 kg/h ρ [g/l]
NaCl 3.79 % 189 kg/h V [m3/h]
Dust LiCl 0.00 % 0 kg/h m [t/h] 5.00
MgCl2 0.01 % 0 kg/h Vsusp [m3/h]
from
65 MgSO4 0.00 % 0 kg/h fsusp [kg/m3]
Product CaSO4 0.00 % 0 kg/h T [°C]
Drying Insolubles 0.56 % 28 kg/h
K2SO4 0.00 % 0 kg/h
H2O 0.20 % 10 kg/h
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Component
KCl 0.0 g/l 0 kg/h ρ [g/l] 999.01
NaCl 0.0 g/l 0 kg/h V [m3/h] 40.59
Water LiCl 0.0 g/l 0 kg/h m [t/h] 40.55
for
Dust CaSO4 0.0 g/l 0 kg/h T [°C] 15.00
Dissolution Insolubles 0.0 g/l 0 kg/h
H2O 999.0 g/l 40,553 kg/h
KCl 112.4 g/l 0.00 % 4,770 kg/h 0 kg/h ρ [g/l] 1,073.08
NaCl 4.5 g/l 0.00 % 189 kg/h 0 kg/h V [m3/h] 42.42 0.01
Pre-concentrated LiCl 0.0 g/l 0.00 % 0 kg/h 0 kg/h m [t/h] 45.52 0.03
Brine MgCl2 0.0 g/l 0.00 % 0 kg/h 0 kg/h Vsusp [m3/h] 42.43
67 for MgSO4 0.0 g/l 0.00 % 0 kg/h 0 kg/h fsusp [kg/m3] 0.66
CaSO4 0.0 g/l 0.00 % 0 kg/h 0 kg/h T [°C] 8.58
Product Leaching
2nd Step K2SO4 0.0 g/l 0.00 % 0 kg/h 0 kg/h
H2O 956.2 g/l 0.00 % 40,563 kg/h 0 kg/h
KCl 95.44 % 95,395 kg/h ρ [g/l]
NaCl 3.79 % 3,789 kg/h V [m3/h]
LiCl 0.00 % 1 kg/h m [t/h] 99.95
Product MgCl2 0.01 % 5 kg/h Vsusp [m3/h]
68 from MgSO4 0.00 % 2 kg/h fsusp [kg/m3]
CaSO4 0.00 % 1 kg/h T [°C]
Drying
Insolubles 0.56 % 559 kg/h
K2SO4 0.00 % 1 kg/h
H2O 0.20 % 200 kg/h
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Component
KCl 95.44 % 90,625 kg/h ρ [g/l]
NaCl 3.79 % 3,599 kg/h V [m3/h]
Dried Product LiCl 0.00 % 1 kg/h m [t/h] 94.95
to MgCl2 0.01 % 5 kg/h Vsusp [m3/h]
69 Anti Caking MgSO4 0.00 % 2 kg/h fsusp [kg/m3]
CaSO4 0.00 % 1 kg/h T [°C]
Reagent
Application K2SO4 0.00 % 0 kg/h
H2O 0.20 % 190 kg/h
KCl 95.35 % 88,994 kg/h ρ [g/l]
NaCl 3.79 % 3,534 kg/h V [m3/h]
LiCl 0.00 % 1 kg/h m [t/h] 93.34
MgCl2 0.01 % 5 kg/h Vsusp [m3/h]
Saleable
70 MgSO4 0.00 % 2 kg/h fsusp [kg/m3]
Product CaSO4 0.00 % 1 kg/h T [°C]
K2SO4 0.00 % 0 kg/h
H2O 0.30 % 280 kg/h
KCl 0.0 g/l 0 kg/h ρ [g/l] 999.01
NaCl 0.0 g/l 0 kg/h V [m3/h] 0.095
Water LiCl 0.0 g/l 0 kg/h m [t/h] 0.095
to
Anti Caking CaSO4 0.0 g/l 0 kg/h T [°C] 15.00
Reagent Mixer Insolubles 0.0 g/l 0 kg/h
H2O 999.0 g/l 95 kg/h
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Component
KCl 95.35 % 90,625 kg/h ρ [g/l]
NaCl 3.79 % 3,599 kg/h V [m3/h]
Anti Caking LiCl 0.00 % 1 kg/h m [t/h] 95.05
Reagent Treated MgCl2 0.01 % 5 kg/h Vsusp [m3/h]
90 Product MgSO4 0.00 % 2 kg/h fsusp [kg/m3]
CaSO4 0.00 % 1 kg/h T [°C]
to
Storage / Loading K2SO4 0.00 % 0 kg/h
H2O 0.30 % 285 kg/h
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Component
a) Flocculant Reagent 0.401 kg/h

Flocculant
12 to
b) Water for Flocculant 401 kg/h 0.402 m³/h
Rougher Thickener

Flocculant
30 to
Tails Thickener

Flocculant
45 to
Product Thickener
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Component
Flocculant a) Flocculant Reagent 0.095 kg/h
to
71
Repulping b) Water for Flocculant 95 kg/h 0.096 m³/h
Thickener
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Component
a) Collector 31 kg/h
Reagents b) Water for Collector 1,505 kg/h 1.540 m³/h
c) Hydrochloric Acid (37%) 12 kg/h 9.89 l/h
to
18
Scavenger d) Frother 12 kg/h
Flotation e) Water for Frother 813 kg/h 0.814 m³/h
f) Reclaim Brine for Frother 11,528 kg/h 19 kg/h 9.296 m³/h
b) Water for Collector 1,658 kg/h 1.696 m³/h
Reagents c) Hydrochloric Acid (37%) 13 kg/h 10.89 l/h
37 to
d) Frother 10 kg/h
Cleaner Flotation
e) Water for Frother 640 kg/h 0.640 m³/h
f) Reclaim Brine for Frother 0 kg/h 0 kg/h 0.000 m³/h
b) Water for Collector 3,065 kg/h 3.136 m³/h
Reagents c) Hydrochloric Acid (37%) 24 kg/h 20.13 l/h
50 to
d) Frother 21 kg/h
Rougher Flotation
e) Water for Frother 1,380 kg/h 1.381 m³/h
f) Reclaim Brine for Frother 19,564 kg/h 32 kg/h 15.777 m³/h
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Mass Flow Quantities

Component Volume
No. Appellation Solution Solids
Potassium
Hexacyano
Ferrat(II)
81 K4[Fe(CN)6] 11 kg/h
to
Anti Caking
Reagent Mixer
Sodium
Carbonate
82 to Na2CO3 5 kg/h
Anti Caking
Reagent Mixer
a) Water 95 kg/h 95.05 l/h

Anti Caking
Reagent
83 Solution b) K4[Fe(CN)6] 11 kg/h
to
Application c) Na2CO3 5 kg/h
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6.4 Process Reagents
In flotation processes always certain reagents are used for separation of substances and
therefore, for Sylvite flotation process several reagents are required, too. The most essential
reagent is the collector. The collector molecules adhere to the KCl crystals and effect the
accumulation of the KCl in the concentrate. Additionally, also frothers and stabilizer oils are
used for flotation. These reagents are responsible for formation of a stable froth on the liquid
surface in the flotation cell. Moreover, further reagents are used such as flocculants for op-
timal settlement of solids during thickening.
Requisite for Sylvite flotation is a collector which will be in every case an organic amine. Typ-
ical products are for example Armeen® from AKZONOBEL or Genamin® from CLARIANT. In
this case we used for the testwork Genamin SH 100 from CLARIANT. It can be expected that
approx. 280 g of collector are needed per ton processed raw ore. It is recommended to
have approx. 130 t of the collector reagent in stock. The wet tailings can contain 20 – 25 g/t
collector.
Hydrochloric Acid is always added to a Sylvite flotation because it is necessary for formation
of alkylammonium ions from the collector amine which is the particle interacting with the
Sylvite crystals. It can be expected that approx. 90 ml conc. Hydrochloric Acid are needed
per ton of processed raw ore. It is adequate to keep approx. 41 m³ of the Hydrochloric Acid
in stock. The Hydrochloric Acid will be discharged as Chloride salt with the Alkylamine col-
lector (as alkylammonium chloride salt).
For optimal flotation process a frother agent is needed. This will be an organic alcohol, e. g.
a polypropylene glycol. There are several stabilizer oils which are used for Sylvite flotation.
In this case we used for the testwork MIBC from AKZO NOBEL. It can be expected that ap-
prox. 95 g of frother reagent are needed per ton of processed raw ore. It is adequate to
store the frother reagent with an amount of approx. 43 t. The frother is mainly contained in
the adhering brines after flotation and thus in the process brines. It is discharged from the
process with the wet tailings. It can be assumed that the frother is contained with 20 – 25 g/t
in the wet tailings.
Which reagents will be used for Sylvite flotation has to be decided finally in large scale test
works (pilot plant operation). There is a wide variety of collector and frother reagents and
which combination of reagents is in this case most appropriated for the raw ore will be a
result of these test works.
In order to ensure a fast and effective settlement of fine particles flocculating agents are
used, which often is polyacrylamide. It can be expected that approx. 1.5 g flocculant are
needed per ton processed raw ore. It is recommended to have approx. 1 t of the flocculant
in stock. Nearly all of this flocculant will be discharged with the wet salt tailings, hence 5 –
10 g per ton of wet tailings are expected to be disposed.
In order to avoid product caking, Potassium Ferrocyanide and Sodium Chloride are used for
final product treatment. It can be expected that approx. 120 g Potassium Ferrocyanide and
50 g Sodium Chloride are needed per ton product. It is recommended to have approx. 10 t
of Potassium Ferrocyanide and 5 t of Sodium Chloride in stock. Nearly all of this anticaking
reagents will be discharged with the wet product.
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Table 6 Storage Quantities of Process Reagents for 6 Weeks Production
Reagent Form Storage Quantity

Collector Solid 130 t
Hydrochloric Acid (conc.) Liquid 41 m³
Frother Liquid 43 t
Flocculant Solid 1t
Potassium Ferrocyanide Solid 10 t
Sodium Carbonate Solid 5t
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7 Production Facilities
Production facilities at plant site are in general:
• Bottom dump truck loadout and further transportation to wet salt storage
• Wet salt storage with afterwards iron / non-iron metal detecting, lump crushing and
further transportation to process building
• Processing plant for producing MOP
• Tank farm for reclaim brine and process water with pumps and thickeners.
Remark: For producing saleable MOP it was mandatory to add following facilities:
• Product drying section (as extension of processing plant)
• Product storage
• Product truck loading.
Due to a modification of the existing contract signed by GNRE-COMIBOL at Gate 3 Meeting,

product drying section, product storage and product truck loading are considered in detail
in this revised documentation.
7.1 Production Plant Description
7.1.1 Process Building
Processing plant is designed as two production line operation. Production lines are called
“Line A” and “Line B”. Regarding the capacity and type of equipment production lines are
similar. Advantage of a two line production is the guarantee of 50 % production even if there
is on line disturbed.
Processing plant consists of following technological process sections:
• Tails process
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• Product drying
• Drying Section
• Product Storage
• Truck Loading.
Generally ERCOSPLAN recommends a design safety factor of 20 %. Mechanical equipment

as shown in Appendix A02 is designed to handle an over capacity of 20 %. So, volume
stream peaks in the production can be balanced.
Buffer times in tanks and vessels to handle peaks and lowest values in operation are gener-
ally calculated with 10 minutes in minimum.
Pumps are generally executed redundant, which means when there is malfunction the sec-
ond pump can take over the task. A possibility to save equipment cost would be to sum sim-
ilar pumps into groups and store them in warehouse.
Huge and insensible equipment will be placed outside of process building to save building
construction cost. Process building’s footprint will be approx. 84 x 109 meters. The building
consists of following estimated main floors / platforms:
• 0.00 meters
• 6.00 meters
• 12.00 meters
• 18.00 meters.
The building height will be in average approx. 30 meters. The highest part of the building will
be approx. 36 meters. The building consists of two areas, one for production line A and a
second for production line B. These both areas are connected by a free passage for repair
and maintenance reasons.
Five overhead cranes are installed above selected areas of process building to ensure hoist-
ing of huge equipment in case of repairs and maintenance. One additional overhead crane
is installed above both rod mills.
7.1.2 Outside Facilities
For details see drawing “Layout Plan”, drawing No. 3001.

ERCOSPLAN’s scope of works includes all facilities directly necessary for production of KCl
95 at plant site. Main processing facilities are located in the main buildings at plant site, e.g.
wet salt storage, process building, product storage and truck loading.
Furthermore several necessary facilities are located outside of main buildings. These facili-
ties are called “Outside Facilities”.
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Outside Facilities consist of:

• Truck unloading
• Conveyor belts
• Distribution towers for belt conveyors
• Tank farm for circulating reclaim brine
• Tanks for process suspensions
• Tank for HCl
• Tank for LPG, osbl (heating media)
• Tanks for spare
• Thickeners for generation of reclaim brine
• Roads
• Retention basins
7.2 Design Criteria and Memories of Calculation of Major Equip-

ment
7.2.1 Design Criteria
KCl plant has to be designed to produce 700,000 t/y of MOP (KCl 95).
Design safety factor applied to the production rate will be 15 % in minimum. ERCOSPLAN
considered a design safety factor of 20 %.
Operation time of KCl production plant will be 7,500 hours per year. Remaining time is en-
visaged for maintenance and repairs. KCl plant will operate 24 hours a day.
7.2.2 Memories of Calculation of Major Equipment
As first step of the engineering ERCOSPLAN designs the process and customizes a process
calculation. Due to this process calculation ERCOSPLAN knows about mass, volume
streams and all other relevant parameters all over the process.
Under consideration of all the parameters ERCOSPLAN’s experts estimate the main equip-
ment by use of long lasting experience in potash processing and also ERCOSPLAN’s data
base.
Parallel to this, ERCOSPLAN’s estimation is confirmed by the knowhow of contacted suppli-
ers of potash equipment.
Necessary parameter for designing of all major equipment can be found in the equipment
data sheets (Appendix A03) and in the equipment specifications (Appendix A06).
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7.3 Infrastructural Battery Limits
Pipeline for process water (average temperature 12 … 18 °C) and power line for electrical
energy comes from West direction into plant site area in sufficient quality and quantity. Bat-
tery limit for process water used in the process is the filling flange of process water tank.
Solid and liquid disposal from processing will be transferred by belt conveyor and pipeline
into East direction (distance approx. 500 m) out of plant site area.
Battery limit for LPG as heating media for building heating and drying section is the empty-
ing flange of LPG tank. On the layout plan a delivery area with LPG tank is envisaged.
7.3.1 Road
Plant site is accessible on public roads by huge vehicles (e.g. 20 tons trucks). A map show-
ing road connections to plant site from Oruro City was delivered by client.
7.3.2 Water Supply
For processing at plant site approx. 300 m³/h of process water are required. Process water
is delivered in sufficient quantity to plant site by pipe line.
Process water is mainly required to keep the amount of flotation brine constant as part of
this brine has to be disposed of to keep the MgCl2 content low.
Process water temperature is in a range from 12 to 18 °C.
For staff potable water is required. The estimated amount of potable water per person is
calculated with 120…160 liters per day. Due to the total number of persons at plant site, the
daily amount of potable water is estimated under consideration of the working shift factor
with approx. 30 m³.
Potable water is delivered in sufficient quality and quantity to plant site by GNRE-COMIBOL.
7.3.3 Consumables Supply
To keep the plant operational supplies have to be brought to the plant and stored accord-
ingly. Lubricants and other operational consumables are packed in adequate packages and
delivered to the production site via truck. All these are stored in provided storages on the
production site.
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7.3.4 Power Supply
The complete industrial complex on Salar de Uyuni is supplied with electric energy from the
communal network.
Energy is transported to the industrial complex via 115kV overhead line. The electric energy
distribution in the area of the industrial complex Salar de Uyuni starts from a distribution
station (that still has to be realized) via local network with a voltage level of 24.9kV.
Two 24.9kV feedings are planned for the energy supply of the potash plant.
Since the 230kV overhead line and the local 24.9kV network will be only finished after erec-
tion of the potash plant, a reliable interim solution for the energy supply has to be realized
for the transitional period.
For that purpose, a generator power station has to be installed in the area of the KCl plant at
the same time as the erection of the flotation plant.
7.4 Processing Facility and Process Sections
7.4.1 Processing Facility
7.4.1.1 Design Capacity
The plant capacity will be designed for average 700,000 t/y production.
In order to minimize unscheduled shutdown, critical equipment will be equipped with 100 %
installed spare, e.g. 1 operating and 1 stand-by.
This applies to critical process equipment identified as such on the PFD’s and P&ID’s. Criti-
cal process devices will be equipped with by-pass facilities.
The specific capacity for each section and equipment is mentioned in the process calcula-
tion and in the single equipment data sheets and equipment specifications.
7.4.1.2 General Requirements
The product storage and all conveyor belts are protected by automatic dry chemical sys-
tems discharging at the head end of the conveyor belt.
Adequate clearances shall be made around mechanical equipment to ensure no interfer-
ence during detail design phase, in the event that final selected equipment varies dimen-
sionally compared to that used prior to equipment purchase.
All plant equipment and materials shall be new and of best quality. No welding, fitting or
plugging of defective parts are permitted without prior written approval by the engineer.
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All equipment and materials shall be suitable for the specified general site conditions and for
any specific conditions of exposure to dust, temperature variations, moisture and humidity
as specified in the individual technical specifications and drawings. The equipment shall
function reliably and achieve the specified performance throughout the specified range of
the above conditions.
Design service factors for all equipment shall equal or exceed such factors as are specified
in the appropriate technical specifications. These factors shall take into account duration
(i.e. intermittent, 12 hours, 24 hours, duty, etc.) and the nature of the loading (i.e. steady,
surge, reversing, shock, etc.).
Equipment selections shall be based on the maximum design loading conditions taking into
account the appropriate service factor.
The make and model of all components shall be such that replacement components are
readily available and shall include all wearing and small mechanical parts, valves, piping,
fittings, instruments, etc.
Selection of component parts shall be standardized to optimize the requirement for stocking
spare parts. This principle shall be applied to large components and assemblies of compo-
nents to the best possible advantage.
All equipment, equipment parts, piping with a temperature of more than 45 °C are provided
with a protection against direct contact by the personnel.
Provision shall be made for the reduction of vibration transmitted to the covers and cladding
of any equipment or any structure that is liable to radiate noise due to the vibration.
All items of equipment weighing more than 40 kg shall be provided with a convenient ar-
rangement for slinging or handling during maintenance.
King lugs shall be provided and located so that the equipment can be lifted in balance with-
out the use of wrap around slings.
Instruction plates, name plates and labels shall be fitted to all equipment requiring identifica-
tion and instructions for operation. Where possible, they shall be fitted to equipment before
packing for transit. Where this is not practical they shall be supplied loose for fitting during
erection, but great care shall be taken in identification and packing to minimize the chance
of misplacement or loss.
The construction, location, size and engraving of all nameplates and labels shall be such
that they are easily readable from equipment operation levels. Materials used for nameplates
and labels that remain as part of the permanent work shall be corrosion resistant.
Electric motors and electrical equipment shall be located above the maximum flooded level
of the dyked area.
Ladders shall not be used where frequent access is required.
Stairs shall be designed with a minimum width inside stringers of 750 mm. The optimum
riser to tread ratio shall be 7.5:10.
All ladders, stairs, handrails and platforms shall be designed in accordance with the OSHA
and applicable codes.
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7.4.1.3 Corrosion – Abrasion
In high corrosion area, such as in potash processing, the material of construction of equip-
ment shall be selected to be compatible with the process solution, Titanium, Monel, thermo-
set material (FRP), thermoplastic material (PVC, CPVC, PP, HDPE, Kynar, Teflon, etc.) will
be considered.
7.4.1.4 Welding
All welding shall be in accordance with DIN, EN, CSA W59 or ASME IX or equivalent.
All welders shall be qualified for the type of welding they are engaged.
7.4.1.5 Gears and Gear Type Speed Reducers
Gears and gear type speed reducers shall be of standard manufacture, designed, rated and
fabricated in accordance with the latest standards published by the DIN or American Gear
Manufacturer's Association (AGMA) or equivalent.
Speed reducers shall be supplied complete with inspection covers, multi-labyrinth seals or
double lip seals, filtered air breathers, oil drain plugs, and oil dip sticks.
7.4.1.6 Chain Drives
Chain drives shall be designed and supplied in accordance with EN or ANS1 Standard for
Transmission Roller Chain and Sprocket Teeth.
Adequate adjustments shall be available to install and take up chain slack. Where take up
allowance is not possible, due to fixed sprocket centers, an adjustable chain wheel idler
shall be fitted.
The minimum chain drive service factor shall be 1.5.
All sprockets shall be attached to the shafts using "QD" type hubs with standard keyway.
7.4.1.7 V-Belt Drives
V-belt drives shall be designed and supplied in accordance with RMA standards or equiva-
lent. Belts shall be provided in matched sets.
The arc of contact on the smaller sheaves shall be at least 120". Belt sheaves shall be accu-
rately balanced.
Drive motors and intermediate speed reducers shall be mounted on pivoted bases or slide
rails, allowing sufficient adjustment for correct belt tensioning. Bases shall incorporate jack-
ing screws with lock nuts.
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7.4.1.8 Couplings
Couplings shall be of the horizontal split cover flexible type unless otherwise approved.
The minimum service factor shall be 1.5 based on the motor nameplate rating.
The tolerance limits and fits of shafts and coupling bores shall be in accordance with the
coupling manufacturer's recommendations. Light interference fits without set screws over
the keyways are preferred.
Fluid couplings shall be fitted to the motor shaft of conveyor drives and other mechanical
equipment only where designated by the Engineer.
Fluid couplings shall be of the delayed fill type to provide soft starting capabilities. All fluid
couplings shall be provided with thermal trip plugs and limit switches to prevent oil losses.
Do not use lubricated coupling for low speed shaft (less than 1,500 rpm).
7.4.1.9 Bearings
For arduous duties and continuous service, self-aligning double row spherical roller type
bearings with seals on both sides are preferred.
Ball bearings may, subject to the approval of the engineer, be acceptable for lighter duties.
Shafts supported by two or more bearings shall have bearing housings capable of accom-
modating expansion and contraction with only one bearing being fixed.
Where brinelling of rolling element bearings could occur (e.g. equipment subjected to vibra-
tion while stationary), plain bearings with non-ferrous bushes or linings (e.g. gun metal,
phosphor bronze, white metal, etc.) should be provided. However, the supplier may submit
alternative types of bearings to the engineer for approval.
Provision shall be made for removing the bearing by split pillow blocks, removable end co-
vers on housings, etc.
Pillow blocks shall be mounted to avoid direct static tension loads on the holding down
bolts and cap bolts. However, the pillow block units shall be designed to withstand any form
of loading imposed upon them during normal operation of the plant.
Pairs of pillow blocks shall be fully self-aligning with one "fixed" and one "free" type for each
shaft.
When pillow blocks are mounted at shaft ends, covers shall be supplied.
Plain bearings are not preferred, but if used, they must be designed to have adequate oil
film lubrication and the bearing length should be at least one and a half times the diameter.
On vertical shafts, thrust and guide bearings shall be provided.
7.4.1.10 Seals
Seals for shafting shall be of the heavy duty "rubbing" type (i.e. felt or spring steel washers
and lip seals), or the "non-rubbing" type (labyrinths) suitable for dusty and wet environ-
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ments. Seals shall be selected for each application so as to preclude the ingress of dust,
moisture and other contaminants and to retain lubricants (grease or oil) used within the
housing.
Felt seals shall not be used when dusty and abrasive materials are to be handled. Their use
shall be restricted to shafts with peripheral speeds less than 3.65 m/s and temperatures be-
low 100 °C.
Lip seals, either in rubber or plastic, shall be used for peripheral speeds in excess of
3.65 m/s. The double lip type is preferred.
For high temperature applications, suitable special materials (e.g. Teflon, carbon, etc.) shall
be used for the seal surfaces.
Where corrosive gases or liquids are being handled, seal materials shall be corrosion re-
sistant.
Where wet and extremely dirty conditions prevail, a thrower shall be provided additionally to
seals.
A thrower shall also be provided above the upper bearing seal on all vertical shafts.
7.4.1.11 Lubrication
Provision shall be made for suitable lubrication wherever necessary to ensure smooth oper-
ation and freedom from undue wear.
Gearboxes and oil baths shall be provided with filling and drain plug or valves, both of ade-
quate size and shall be provided with an approved means of oil level indication, e.g. dip-
sticks or constant level oilers.
Lubrication of ball/roller bearing pillow blocks may be by:
• Grease packing for life
• Periodic grease lubrication by nipple
• Oil lubrication
• Periodic automatic lubrication.
The seals must be adequate to retain the lubricant.

All pressurized oil lubricating systems shall be fitted with electrical contacts to provide for
indication of oil pressure failure.
A separate, standard button head fitting such as Alemite No. A-1184 or equivalent shall be
provided to serve each lubrication point and all grease nipples or oil cups and dip sticks
shall be readily accessible.
7.4.1.12 Safety Guards
All hazardous revolving or reciprocating parts not guarded by the frame of the machine or
by remote location shall be guarded in conformance with the part 1910219, sub-part "O”,
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"Machinery and Machine Guarding" of the Occupational Safety and Health Standards of the
OSHA or equivalent.
7.4.1.13 Base Plates
Base plates shall be robustly and rigidly constructed generally of fabricated steel or cast
steel.
Mounting pads and base plate feet shall be machined true and parallel.
Shims shall be provided for final adjustment of alignment. All packing pieces and shims
shall have an effective loading area approximately equal to that of the foot.
7.4.1.14 Screw Conveyors
Screw conveyors shall be designed and supplied in accordance with CEMA Standard 350 or
equivalent.
Screw conveyors shall be of heavy duty construction with minimum 4 mm trough plate
thickness fitted with angle flange and with trough supports independent from the end flang-
es.
The clearance between the flight and the trough shall be 12 mm.
Flights shall be made of abrasion resistant carbon steel, or hard surfaced if required, sec-
tionalized, minimum 5 mm plate.
Screw conveyor sizing shall be based on 30 % trough loading for granular non-abrasive
material and 15 % for fluidizing materials using the flow sheet tonnage per hour.
Trough end packing shall be externally mounted and easily replaceable.
7.4.1.15 Drag Chain Conveyors
The drag conveyor shall be of heavy duty type equipped with one or multiple inlets and mul-
tiple outlets.
The drag conveyor will be of horizontal or inclined, bottom flight conveying type.
Flights should be of rectangular type, driven by double strand chain for slug services.
The casing shall be rectangular with removable covers. The casing shall be dust tight and
weatherproof for outdoors installation and to prevent cross contamination.
The drag conveyor shall be sized to operate at less than 60 % of recommended maximum
speed.
The chain speed shall be limited to 0.15 m/s.
The chain shall be protected from the material flow as much as possible with deflector for
double strand chain in slug services
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7.4.1.16 Chutework
All chutework and hoppers shall be structurally designed for full plugged operating condi-
tions of the material they are conveying.
Chutes and hoppers shall be fabricated from 6 mm minimum thickness steel plate suitably
stiffened and supported to deal with the loads and forces imposed on them.
All chutework and hoppers shall be structurally supported independently of equipment un-
less noted otherwise.
Unless otherwise specified or approved in writing by Engineer, all chutework and hoppers
shall maintain a minimum slope of 60° or better from horizontal.
7.4.1.17 Slurry Pumps
7.4.1.17.1 General
Pumps shall be capable of starting or stopping under open discharge condition.

For a pump nominated as variable speed, the pump shall be selected such that the normal
duty speed is not greater than 75 % of maximum recommended speed.
At maximum recommended speed the motor will draw no more than 95 % of the nameplate
rating.
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7.4.1.17.2 Pump Type
• Pumps shall be of the following type unless otherwise approved:

– Centrifugal
– Horizontal shaft or vertical spindle
– Closed or open impeller
– End suction.
• Bearings
Pump bearings shall be heavy duty, and selected for an L10 life of 40,000 - 50,000
hours.
• Materials of construction
Materials of construction of pump casing and impellers shall be as nominated for each
pump.
All components shall be new and manufactured from sound material, completely free
from all visible imperfections such as cracks, flaw or blowholes.
• Disassembly
Pump design shall allow removal of wearing elements with the minimum of disassembly,
e.g. for horizontal, end suction, the long coupled type.
• Reversed flow
Pump shall accept, without damage, counter rotation with flow reversed such as could
occur during shutdown of drive or power failure.
• Casings
Each casing shall be designed to withstand a hydrostatic test pressure of at least 1.5
times the maximum shut-off head.
• Base plates
The pump supplier shall supply a common steel base plate for pump and motor, or
pump base plate with steel motor support for those pumps with an overhead drive ar-
rangement.
Closed base plates and motor mounts shall have at least two holes of 75 mm diameter in
the base to allow for pouring of grout and venting when grouting base plates.
• Mounting and alignment
Pump/motor sets shall be supplied fully assembled, mounted and pre-aligned.
The pump supplier shall supply all components and hardware necessary for future dis-
assembly, assembly, mounting and alignment adjustment of pump, drive and motor, in-
cluding motor slide rails and all bolts, nuts and washers for the alignment adjustment of
components and for the mounting of components to the base plate.
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• Shaft sealing
Shaft sealing in each application shall be as nominated on the relevant "Pump Data
Sheet", either:
– Packing with full flow gland, with PTFE lantern ring
– Packing with restricted flow gland, with metal lantern ring.
Replaceable shaft sleeves of hardened and ground, abrasion resistant alloy steel shall
be provided at the gland area where the duty demands it.
Mechanical seals shall be of single or double, used only for clean liquid services com-
plete with appropriate seal flushing as required. Single external mechanical seal may be
used for crystallizing fluid, only with written approval from the engineer.
7.4.1.18 Tanks
a) Mixing Tanks
The project requires a number of process tanks with mechanical agitation.

For such tanks, height to diameter ratios, number and size of baffles and bottom shapes
(such as cone and fillet type) must be selected to promote solid suspension or dispersion,
blending and heat transfer.
Agitator supplier shall be consulted with regard to the optimum tank dimensions for applica-
tion.
They shall be round, constructed of stainless steel or carbon steel and shall feature flat bot-
toms. For abrasive material services, tanks may be lined with rubber or equivalent, suitable
for the intent service.
Tanks having agitators will be equipped with baffles according to agitator manufacturer's
recommendations.
Large closed tanks will be provided with 2 manholes one on the roof (where roofs are pro-
vided) and one on the side wall near the bottom level.
b) Storage Tanks
Large storage tanks will be provided with one manhole on the side wall near the bottom lev-
el. One additional manhole will be provided on the roof of the tank for closed tanks.
Tanks larger than 15 m in diameter may require additional manholes in the side wall and/or
roof.
7.4.1.19 Pipes and Pipe Classification
For classification of pipes applied in the potash plant please see Appendix A10.
The pipelines are described in the pipe classification (Appendix A10) that provides an over-
view on all pipelines required for the project and in the isometric drawings (A4002 ff.).
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The planning of pipelines and pipeline routes is based on the basic engineering. The iso-
metric drawings indicate the course of pipelines for the fitting and installation companies but
do not substitute the installation planning. At any rate the executing companies have to
check the course of pipelines given in the isometric drawings for practicability and have to
arrange for the necessary pipeline elements. The material for supporting structures for pipe-
line elements is given as all-inclusive rate.
The pipelines of the plant serve for the transport of different media. According to their sub-
stances of content and the material requirements for pipelines and fittings, these media were
divided into different groups that have been provided with medium codes.
Table 7 Selection of Pipe Material
Medium Pipe material

Suspension GFK/PP, PN 10
Filtrate Bow-pieces, T-fittings, and other abrasion-endangered elements,
Fugate flanged
Reclaim brine
Vacuum
Rinsing water
Process water PE, PN 10
Cooling water Connection butt welding / electric socket welding and flange connection
Sealing water
Condensate
Flocculation agents
Flotation reagent
Compressed air Steel / (outside coated approx. 200 µm)
VA
All pipelines have been uniformly planned with nominal pressure 10, even if the operating
pressures in part are clearly under that value.
All pipelines containing salt solutions or suspensions have to be laid with continuous slope
to the deepest point. At the highest points the pipeline has to be provided with ventilation
devices.
The suspension of pipelines is arranged at the pillars or platform structures of the particular
platforms. For that the pipeline installation companies possibly have to install additional
supporting structures to keep the maximum possible distances between supports and to
exclude line sway.
As part of the technological steel construction, relocation constructions for fittings have to
be provided by the pipeline construction companies. During installation, it is important to
pay attention to good accessibility of fittings and measurement instruments for operation
and maintenance. Attention should also be paid to the required build-in conditions of the
manufacturers for this equipment.
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For measurement instruments, it is intended to attach a flange connector DN 50 for pipelines

< DN100 and a flange connector DN 100, PN 10/16 with stainless steel blind flange for pipe-
lines ≥ DN 100 respectively. It has to be checked by the operating company if alternative
designs for measurements in suspensions are more reasonable (danger of sedimentation in
measurement connection). The mounting position of the measurement connections has to
be agreed with the operating company.
The pipeline routes are provided in the pipeline plans.
All pumps, vessels and equipment are planned with discharge and flush connections. The
discharge and overflow lines are led to the low point.
Attention should be paid to the mounting instructions of the manufacturers of measurement
equipment. The given lengths for the mounting connections for the required measurement
devices have to be checked when the contract of delivery for measuring equipment is
placed and the binding documents of the manufacturers are on hand.
7.4.1.20 Secondary Steelworks
Secondary steelworks are necessary for erection and installing of technical equipment in the
process building and also for equipment belonging to the outside facilities.
After handing over of the final Detail Engineering report, GNRE-COMIBOL will start the pur-
chase phase of technical equipment. Due to the Bolivian regulations, GNRE-COMIBOL
needs to start the purchase phase with a public bidding. Due to the necessity of the public
bidding, GNRE-COMIBOL was not in the position to fix suppliers and type of the technical
equipment during ERCOSPLAN’s engineering phase, so that ERCOSPLAN had to make
assumptions. Hence, the chapter of “Secondary Steelworks” can only have a general char-
acter.
Secondary steelworks should include:

• Delivery and mounting of supporting constructions for technical equipment including
connecting material to main steel works
• Delivery and mounting of erection beams including run-over safety devices for hoist-
ing devices and connection material to steel works
• Delivery and mounting of handrails, balustrades (fixed mounted and pluggable)
• Delivery and mounting of auxiliary constructions for technical equipment
• Adaptions to covers
• Delivery and mounting of steel sections necessary for removal of technical equip-
ment including fixing material.
Remark:
Secondary steelworks for piping and piping construction is in the scope of work of the com-
pany which installs the pipes at plant site.
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7.4.1.21 Assembly, Mounting and Erection of Equipment at Plant Site
GNRE-COMIBOL needs to define an erection company for built up buildings and equipment
at plant site. Activities at plant site should follow the erection schedule of the erection com-
pany.
Maintenance shop
For erection and assembling it is necessary to build up a maintenance resp. work shop at
plant site at first. Work shop should be equipped according to the requirements of the erec-
tion company. Special tools for equipment (e.g. tools for centrifuges) should be included
with the equipment delivery.
Equipment storage / warehouse
During erection phase, delivered equipment should be stored dry in warehouse. Afterwards
the equipment should be installed step by step according to the installation schedule of the
erection company. A central place for storing empty packaging material has to be defined.
Assembling of huge equipment at plant site
Huge equipment is transported in segments to plant site. The maximum dimensions of sin-
gle segments must be according to Bolivian regulations for transportation of goods.
For assembling of huge equipment, which cannot transported in one piece to plant site, e.g.
thickeners, mounting areas resp. erection places have to be prepared at plant site. At
mounting areas huge equipment is then assembled.
For erection of huge equipment at mounting areas mobile cranes are necessary.
Assembling and installation of special equipment
General equipment should be installed by the overall erection company. For the assembling
and installation of special equipment (e.g. centrifuges), representatives of the supplier com-
panies are managing at plant site as supervisor.
7.4.2 Technical Description of Selected Main Equipment
Due to the extensive technology and continuous issues of the client at the Gate Meeting, the
project manager has decided to add a chapter regarding selected main equipment to the
Detail Engineering report.
7.4.2.1 Portal Scraper
Operation method
To reclaim the stored bulk material the reclaimer travels along a pre-selected working dis-
tance on rails arranged parallel to the stockpile with a constant boom inclination preset be-
fore starting the operation. At each end position the travelling direction is reversed after low-
ering the boom by one cutting depth. The material will be pulled down the face of the pile
and into the discharge chute and the impact roller table. The material is deposited onto the
reclaim conveyor.
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The relocation of the reclaimer into a different working position is effected by manual opera-
tion with the booms retracted.
Maintenance and repair

All maintenance points of the reclaimer are accessible via stairs, catwalks and ladders, ex-
cept for the boom. To maintain the boom the reclaimer has to be located in the maintenance
area to have access from the floor. All electric drives can be separately started and operated
for maintenance.
Modes of operation
The reclaimer can be operated in three different modes:
A) Non–interlocked manual mode

In this mode all electric drives can be individually and separately controlled from the control
panel. It is mainly used for maintenance and repair.
B) Interlocked manual mode

• The scraper chains are in operation only, if the receiving conveyor is in operation.
• The reclaimer can travel at working speed only, if the scraper chains are in operation.
• The reclaimer can travel at re-location speed only, if the reclaimer boom is complete-
ly retracted.
• The reclaimer can travel only, if all controls are active.
C) Automatic mode
In this mode the reclaimer is electrically interlocked with all receiving conveyors. All operat-
ing conditions are visually indicated. The reclaimer operates automatically until the stock-
piled material is completely reclaimed or until the operator stops the automatic operation.
Reclaiming in automatic operation mode requires the following pre-conditions:
• Pile is dressed by the operator (plan surface)
• Working range is set by the operator to limit the reclaimer travel.
Malfunctions
Malfunctions at any drive will be indicated as follows:
• Acoustical signal by means of alarm horn
• Signal lamp on the panel.
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Component description
The reclaimer consists of the carriage made of sectional steel and sheet metal in welded,
torsion resistant and rigid design, with pedestals for the boom, rope pulleys and lifting winch
with connecting flanges for the bogies as well as pedestals for catwalk and stairway.
The travel mechanism, consisting of bogies, idler wheels, driven wheels, drive units, buffers,
etc., is fitted on the carriage. The reclaimer will traverse the pile on two runway rails, which
are arranged outside of the pile section. The booms are arranged laterally to the supporting
structure. The boom is supported by cables from the overhead suspension structure, and is
lifted and lowered by means of an electric hoist. The scraper booms are equipped with
chain drives, chain guides, scraper blades and hoist etc. Walkways and work platforms will
be provided for access to rope sheaves and hoists at top the suspension structure.
The reclaimer consists of the following components:

• Main boom and auxiliary boom
• Boom hoisting system for main boom and auxiliary boom
• Carriage including platforms, catwalks, stairs and ladders
• Travelling gear
• Material transfer through and feeding table
• Central lubrication system
• Operator’s cabin
• Electrical equipment.
Main boom and auxiliary boom

The main boom and the auxiliary boom are in principle designed in the same manner.
Each boom is hinged at the tail end and supported on the carriage by means of joint bear-
ing and suspended at the head by means of a rope system from the suspension structure.
The rope support system will be arranged so that the inclination of the scraper conveyor can
be adjusted to follow the pile slope. The supporting boom structure is designed as a com-
pletely closed tubular construction with brackets to support the chain guiding unit. The en-
closed construction is most suitable to minimize material build-up. The reclaimer chain as-
sembly consists of chain drive units, chain take-up unit, chain with chain guiding device and
scraper blades.
Chain drive unit:

• Driving shaft with antifriction bearings and labyrinth seals
• Divided drive sprockets with hardened teeth
• Mounted drive assembly supported by a flexible torque arm
• Motor
• Starter and overload protection coupling
• Motor bracket, as intermediate flange between gearbox and drive motor
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• Bevel gearbox with shrink disk, hollow-shaft connection and protective cover.
Chain take-up unit:

• Chain tension will be applied by hydraulic take-up
• Chain tension will be automatically adjusted.
Chain and chain guiding device:

• Reclaimer chain consists of two single strand chains carried on roller supports
• Chain drive sprockets will be equipped with teeth segments bolted on for and allow
replacement
• Without disassembly of chain and sprockets
• Chain is vertically and horizontally guided in stationary wear-resistant guiding rails to
absorb the forces.
Scraper Blades:
• Scraper blades are bolted to the chain
• Blades will be equipped with hard faced cutting edges scraping teeth
• Blades will be bolted to the blade holders / chain for easy replacement and be
equipped with locknuts
• Blades will be designed for best flow characteristics.
Boom hoisting system for main boom and auxiliary boom

A complete hoist assembly will be provided for each scraper boom.
The hoist will be composed of a rope drum coupled to a drive unit. Access to the rope
sheaves and hoists assemblies located atop the portal structures will be provided by stair-
way, ladder
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The hoisting assembly consists of:

• Special motor
• Brake
• Gearbox with splash lubrication
• Rope drum
• Wire rope with slack rope device for safety
• Special rope
• Rope sheaves with antifriction roller bearings
• Limit switches to set the upper and lower limits of scraper boom inclination.
Portal
The portal will be of the enclosed box-girder design. The portal includes all required beams
and brackets to fix and operate the boom, the operator's cabin as well as staircases, lad-
ders, catwalks and platforms to provide access for maintenance.
Travelling gear
The truck assemblies will be rigid structural steel frames of welded and bolted construction.
The assembly shall be connected to each leg of the carriage.
Fixed side:
• Head (cross) beam of sectional welded steel
• Double flanged wheels of cast steel with wheel shafts supported in antifriction bear-
ings
• Guide roller units supported in antifriction bearings to transfer the horizontal forces
into the rail on the fixed side only
• VFD controlled travel drives to regulate travel speeds and maintain synchronized (an-
ti-skew) positioning.
Floating side:
The travelling gear at the floating side consists of the same design as described for the fixed
side.
The only difference is the floating bearing between carriage and head (cross) beam to com-
pensate the rail tolerances and the deformation in the structure due to loads and tempera-
ture.
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Material feeding table

• Discharge chute made of steel plates and lined with material as stainless steel
• Material guide plate with clamped rubber edges
• Feeding table of sectional steel design, with the necessary impact idlers.
• Lump breaker with one grizzly frame, a rotating shaft with cutting knifes to shred big-
ger material parts.
Central lubricating system

Consisting of:
• Grease pump with grease reservoir
• Distributing system with pipelines, manifolds, connecting hoses, safety valves, fit-
tings.
The grease pump is mounted on the carriage and supplies grease automatically to the lu-
bricating points. The bearings of chain sprocket wheels will be automatically lubricated.
Electrical and controls

The electrical power and control systems will be designed to provide a safe and reliable op-
eration of material handling equipment. The electrical equipment is designed and rated for
the ambient operating temperatures specified.
Design and supply of all electrical equipment and accessories as specified in the following
will be for the best operation of the handling system.
All equipment is properly grounded to the green-yellow jacketed ground wire, which at the
switchgear is tied to the ground wire of the feeder cable.
All motors are totally enclosed fan cooled with the enclosure rated IP55. All field sensors will
be water tight and dust tight with protection degree IP 65.
Electrical codes and standards

The electrical equipment is designed in accordance with DIN VDE / IEC standards and gen-
erally accepted European practices.
The design of the reclaimer is considered as non-hazardous areas.
Operator's cabin
The operator's cabin with E-house is mounted on the operating platform of the portal and
accommodates the switching cabinets and the control panel.
The cabin will have wide safety glass windows giving the operator an unobstructed view of
the working area. The cabin will have adequate space for an operator and all required
equipment.
The cabin will be of sheet steel construction, complete with wall and ceiling insulation. The
operator’s seat shall have an adjustable backrest. The cabin will be complete with air condi-
tioning, heating and lighting.
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The cabin consists of:

• Insulated side walls, roof and the rubber-lined cabin bottom plate
• Cabin door
• Windows (safety glass)
• Air conditioning
• Intermediate-bottom plate for cables.
Control system
The machine is controlled and monitored by a SIEMENS S7-300 programmable logic con-
troller (PLC). The PLC is located in the respective control cabin.
Limit switches, actuators, sensors

The following actuators limit switches etc. are provided among other things to interlock ma-
chine operation:
• Emergency-stop push-button
• Chain Speed monitoring
• Warning devices to indicate equipment starting
• Ultra-sonic sensors for pile detection / interlock
• Safety limit switches for travel, hoisting etc.
• Operation limit switches for travel, hoisting etc.
• Absolute value encoder for travel distance, angle boom etc.
• Local control boxes for main drive like chain etc.
Lighting
Illumination to ensure safe working conditions will be provided at the portal and walkways.
Sufficient floodlights are mounted at top of the cabin or boom. All stairs and ladders are pro-
vided with sufficient illumination by means of fluorescent lighting.
The cabin, electrical equipment room and machinery platform will be illuminated by means
of fluorescent lighting fixtures.
Portable emergency hand lamps with battery chargers are supplied for operator cabin in
order to leave the machine in case of power loss.
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Cables
Flexible cables will mainly be provided. Distinctive numbering or colors will identify multi-
conductor cables. A separate earth conductor will protect all electrical life parts.
7.4.2.2 Centrifuges
Machine Description
The construction and functional principles of the versatile screen worm centrifuge
KONTURBEX are shown in the sectional drawing. The drive and bearings, the rotating parts
in the fluid area and the solid matter discharge are arranged synoptically and maintenance
friendly.
The centrifuge is driven by V-belts. The rotational speed of the rotating parts is matched to
the process engineering requirements. The solid matter retained by the screen coating is
conveyed by the drum inclination and by a worm with slightly different rotational speed from
small to large diameter and there thrown off into the product housing. Thus with respective
drum inclination matched to the input feed material, various products of different origin and
consistency can be separated most successfully from the suspension fluid and, if neces-
sary, cleaned by washing.
A centrifuge gearbox ensures the required differential rotational speed between the drum
and the worm even in the case of high friction of the material on the screen coating. An over-
load fuse protects the gearbox to prevent damage. The gearbox and the bearings are
equipped with oil circulation lubrication, except for the H 200 which is equipped with a gear-
box with oil filling.
The machine and drive motor are connected as a unit to the substructure via rubber buffers.
Thus even large centrifuges do not require any special foundations or steadying masses.
The relative movement of the worm prevents unbalance due to uneven distribution of the
material in the drum. No product residues leading to unbalance remain in the machine after
switch off.
The screen drum is equipped - depending on the wear stress - with perforated sheets or
with wedge wire screens.
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Figure 2 Cross Section of a Screen Worm Centrifuge CX
Construction
The name "screen worm centrifuge" specifies the chief features of this kind of centrifuge:
• Screening element for retaining the solid matter in the centrifuge drum,
• Feed worm for continuous feed of the solid matter.
The drum and the worm rotate in the same direction with high centrifugal force, but with a
slight mutual rotational speed difference resulting from the conveying effect of the worm.
The rotating parts, carried by the cantilevered shafts of the drive, project onto the product
area. This arrangement has the advantage of clear separation between the oil-lubricated
drive and the process space, so that only a fast running component has to be sealed
against the product housing.
An over dimensioned gearbox guarantees a constant speed difference between worm and
screen drum and thus constant results.
The centrifuge is driven by an electric motor with V-belts. Depending on the process re-
quirements, it is also possible to use frequency converters to achieve a variable control of
the main speed and/or differential speed. For purposes of vibration absorption, the machine
stands on rubber buffers.
The centrifuge features a wedge wire basket with special profile. Depending on the applica-
tion, a special screening plate can be used alternatively. In every case the screening ele-
ments can be replaced very easily.
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If required, the centrifuge casing can be equipped with rinsing fittings that allow cleaning the
parts coming in contact with the product.
The largest fluid portion is separated on the small drum diameter in the area of low circum-
ferential speed and small centrifugal acceleration.
Towards the large diameter the small amount of residual fluid is flung off with increasing
centrifugal acceleration.
The rotating parts usually have conical shape. Inclination angles of the drum basket jacket
with respect to the rotation axis in the range from 10° to 20° have proved to be successful
because the friction coefficients of nearly all products correspond to the tangential values of
these angles.
With ideal choice of drum angle the solid matter slides without significant intervention of the
feed worm from the input area on the small diameter of the drum along a mantle line to the
large diameter and thus to the exit. The worm must perform a regulating function during the
residence time of the solid matter. In the initial phase it prevents too rapid slide down of the
wet solid matter and later, when the friction coefficient has become greater due to the cen-
trifugal drying, it pushes the solid matter towards the removal discharge.
Materials
The parts in contact with the product are made of special steel 1.4571 / 81 for normal appli-
cations. If necessary, a highly abrasion proof coating can be applied to the worm volutions.
Alternatively, higher material grades up to Hastelloy or Titanium can be used depending on
the process.
Specific auxiliary and special equipment

For example:
• Filtrate cyclone
• Rinsing ring pipe and washing devices
• Wear protection for the rotating parts inside the product space
• Discharge gutter with scraper knife to avoid incrustation or adhesion of the
product
• PT 100 to monitor the bearing temperature
• Explosion-protected version according to the directive 94/9 EC (ATEX 100a)
• Version compatible with foodstuffs
• Further special versions on inquiry
• Gastight process space sealing.
Due to the tendency of any centrifuge to convey air, a pressure difference of approx. 1 mbar
(=10 mm water column) will build up between filtrate and solid matter space, i.e. a very
small overpressure of approx. 1 mbar will occur in the filtrate space!
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If it should be impossible to lead the air flow generated in the filtrate space outside, an air
recirculation is required in the solid matter space of the product housing.
This ensures pressure compensation between the filtrate space and the solid matter space
and prevents penetration of moisture fog into the solid matter space.
If the centrifuge is a gastight model (version K), a special sealing may cause internal pres-
sures of up to 0.2 bar. In this case, the gases and vapors can directly be exhausted sepa-
rately which prevents the dehumidified solid matter from getting moistened.
1 Bearing housing 9 Worm

2 Product housing 10 Gearbox
3 Suspension feed 11 Overload protection
4 Inlet pipe 12 Oil inlet
5 Screen drum 13 Solids discharge
6 Drum hub 14 Discharge gutter
7 Inspection flap 16 Rubber buffer
8 Screen drum
Figure 3 Overview of Modules
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1 Lubricating oil pump 12 Oil thermometer

2 Oil pump motor 13 Oil inspection glass
3 Pressure adjusting valve 14 Feed opening / ventilation
4 Oil filter 15 Oil drain
5 Pressure monitor 16 Oil cooler*
6 Oil pressure gauge 17 Flow indicator*
7 Machine (gearbox / bearing) 18 Distribution to the individual
8 Oil inlet lubrication points (bearings,
9 Oil return flow gears)*
10 Flexible oil hose * Optional / depending on type of
11 Oil tank machinery and equipment
Figure 4 Hydraulic Diagram
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Centrifuge characteristics and circumferential speed

The centrifugal acceleration is conventionally not expressed as absolute value in m/s² but as
multiple of the gravitational acceleration (1 g), the so-called centrifugal or spinning factor (z).
The most commonly used centrifugal factors, referred to the large drum diameter, are be-
tween 500 and 1500 g and depend on product and machine dimensions.
v = Circumferential speed [m/s]

D = Diameter [m]
n = Rotational speed [rpm]
z = Centrifugal factor (multiple of gravitational acceleration)
Figure 5 Centrifuge Characteristics and Circumferential Speed
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Residence time of the solid matter

The worm volutions can be designed with very low pitch, e.g. with two volutions around the
worm body, or with very high pitch, e.g. with only 1/3 volution. If theory is simplified by the as-
sumption that the solid matter moves axially across the screen, which is admissible in almost
every case, the ∆t residence time of the solid matter in the centrifuge drum can be derived from
the number of volutions (w) and the differential speed as follows ∆n :
w
∆t = 60
∆n
∆t = residence time [s]

w = number of volutions
∆n = differential speed in RPM [min-1]
The residence times used in practice, range from 1 to 5 seconds.

The residence time remains constant and is independent of the amount of solid matter fed in.
Washing the solid matter

If a solid matter is not only to be dried but also to be cleaned of any original liquor or foreign
substances sticking to it, washing spaces close to the screen drum allow to spray washing fluid
onto the solid matter layer.
The employed screening elements are special perforated plates with aperture diameters be-
tween 0.08 and 1 mm and a thickness between 0.3 and 1.5 mm, or wedge wire baskets with
different profiles and slot widths between 0.1 and 0.4 mm.
There are two requirements for these screening elements that are contradictory:
• To prevent that penetrated fine particles jam and clog the apertures but are ejected in-
stead, the apertures should widen soon towards the outside. In this respect, the ideal
aperture design would have razor-sharp edges and the widest possible opening angle.
• On the other hand, the apertures must not widen excessively if the screen surface
wears out because otherwise, the separating result would change, i.e. too much solid
matter would be contained in the filtrate. In this respect, parallel aperture wall faces
would be ideal.
The compromise that needs to be found between these extreme demands depends on many
factors, like grain size range, abrasion attack, adhesive properties of the solid matter, liquid
portion or feed concentration, and requirements for the separating yield.
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The compromise to be found in a specific case must ensure that the screening element will
keep clear during continuous operation because screen worm centrifuges work continuously.
• The production cannot be interrupted due to regular reverse flow rinsing processes or
the replacement of filter layers that are required on machines which work discontinu-
ously.
• The discharge area of the screen depends on spacing and dimensions of the apertures
and ranges between 4 % and 10 %.
Since the filtration resistance in the solid matter is in most cases higher than the residual flow
resistance the liquid must overcome on its way to the one or other screen aperture, the size of
the discharge area is of minor importance to the residual moisture. In combination with aper-
ture shape and aperture size, the discharge area of the screen is however decisive for the
amount of fine particles entering the filtrate and which quantities of liquid can be separated in
the feed zone, i.e. it determines the swallow volume of the machine.
Worm gap towards the drum

If spacers are inserted between worm hub and hub, the worm can be shifted axially which var-
ies the gap between the conveying volutes and the conical drum section.
For safe operation of the screen worm centrifuge, the gap is adjusted to 1.0 to 1.5 mm.
Smaller gaps are admissible only after consultation with the supplier.
A narrow gap offers advantages in terms of conveyance for fine-grained products.
In addition, the conveying edges of the volutes should be sharp, relief-ground and not worn out
or round.
Layer thickness
The dehumification process commences at the instant when the cake of solid matter has
formed. Dehumification of grainy solid matters is performed by filtration. Sufficiently large parti-
cle diameters and appropriate centrifugal forces permit a dehumidification by spontaneous
drainage of the liquid from the cake capillary system and, as far as possible, by the filtering
away of the cuneal and film liquid adhering to and enveloping the particles of solid matter.
The grain size and consistency of the solid matter substantially determine the extent to which
the layer thickness affects the residual moisture.
Very coarse incompressible solid matters facilitate filtration so that the residual moisture de-
creases only slightly when the layer thickness increases. In contrast to this, very fine-grained
incompressible solids have such a high filtration resistance that any increase in the layer thick-
ness will cause a considerable decrease in the residual moisture due to the longer filtration
distance if this is not compensated by a longer residence time.
Fine grained incompressible particles of solid matter have a high degree of filtration resistance.
Large layer thickness significantly impairs the residual moisture because of the longer filtration
path.
Through the machine geometry (drum inclination, slot width of the screening element), choice
of rotational speed, residence time, grain geometry, input feed concentration and input feed
quantity
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Drive and gearbox

Centrifuges are driven by A.C. motors via a V-belt. The centrifuge speed can be modified if the
motor belt pulley is exchanged. Reduction gears generate the low differential speed ∆n and
the high conveying torque of the worm.
The excenter shaft of the gearbox can be locked or be driven, too.
The worm's rotational speed, nSchn, results from the following three factors:
• Transmission gear ratio, i
• Excenter shaft speed, nExz
• Drum speed, nTr
n Tr − n Exz
n Schn = n Tr + = n Tr + ∆ n
i
If the drum speed is higher than the excenter shaft speed, the value of the differential speed
turns positive; this means the worm rotates slightly faster than the drum. In this case, the worm
is said to be advancing.
In contrast to this, the value of the differential speed is negative if the drum speed is lower than
that of the excenter shaft; this means the worm rotates slightly slower than the drum. In this
case, the worm is said to be lagging. However, lagging operation is not practicable with the
Conthick due to the short decanter section.
The differential speed with the excenter shaft at standstill results directly from the transmission
gear ratio and the drum speed; the transmission gear ratio and accordingly, the differential
speed can be varied by exchanging some gearbox parts.
To ensure a precise tuning of the centrifuge at high speeds, the excenter shaft is driven in this
case. If the gearbox type is the same, the excenter shaft is driven by the main motor via a sec-
ond motor belt pulley.
Accordingly, the differential speed in case of double transmission is calculated as follows:
n Tr − n Exz
∆n =
i
Overload protection
The centrifuge will hardly suffer overload during the processes that usually run continuously at
constant product flow. Notwithstanding that, the admissible maximum suspension flow must
not be exceeded.
Malfunctions may however occur during restarting after production stops if the machine is
jammed due to insufficient rinsing, or due to a feed flow surge.
In order to protect the gearbox from such overload, the torque is limited by different mecha-
nisms on the excenter shaft that prevent inadmissible gearbox overload by disengaging the
shaft. Furthermore, they generate an electric signal to close the suspension feed and discon-
nect the main motor.
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Sealing
The protruding design requires only one part rotating at high speed, the neck piece of the
drum hub, to be sealed against the rear wall of the product housing.
The absolute rotational speed of the worm hub may be even higher. But thanks to the low dif-
ferential speed between worm hub and drum hub, this sealing point can be mastered easily
with standard shaft seal rings.
The neck of the drum hub requires the use of non-contact labyrinths because the circumferen-
tial speed is high and there is the risk of impairment by the product.
If the production system is self-contained, then contacting seals like chamber packings or axial
face seals need to be used.
Solids discharge
Crystals that could be smashed by the impact onto the housing wall, or solids that tend to ad-
here, are caught in a gutter that envelops the drum discharge and are discharged tangentially
downwards through a gutter aperture. Metal wings fixed to the drum that rotate at high speed
in the internal space support the flow of solid matter by their ventilating effect.
But the gutter would clog despite the high speed and the flat angle of impact if a product is
sticky.
Therefore, the machine must be operated without discharge gutter in such cases and the solid
matter space needs to be lined with PTFE or similar suitable material to avoid incrustations and
machine jamming.
Ventilation
The tendency of centrifuges to convey gas may cause an overpressure in the filtrate space and
a filtrate fog may be pressed through all existing apertures. In this way, the filtrate fog may
moisten the dried solid matter another time.
To achieve effective deairing of the filtrate space, at least one large-dimensioned deairing con-
nection must be installed on top of the filtrate discharge, or even better a filtrate cyclone that is
open on top, to separate fine droplets.
Self-enclosed production systems require an air extraction of a pressure equalizing pipe be-
tween filtrate space or cyclone and solid matter space.
Discharge of the solid matter

On the screen part of the centrifuge, the liquid will drag along a certain fraction of the very fine
particles which may be desired in some production processes involving crystallisation because
the fine particles act as seed on recirculation and because the dried product is coarser and
better pourable.
In other cases, the solid content is returned into the suspension feed.
However, targeted sizing is not possible in the centrifuge.
If solid particles of different sizes are compared where the smaller particles have half the di-
ameter of the big ones, the surface of the smaller particles will be twice as large as that of the
big particles although the volume is the same.
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Thousand crystals with a diameter of 0.1 mm have even ten times the surface of one crystal
with a diameter of 1 mm.
Due to their large surface, very fine particles will bind particularly much liquid and deteriorate
the residual moisture that can be achieved.
If a solid matter is provided in two fractions with significantly differing grain sizes, it may be
economical to discharge the very fine particles along with the filtrate and process them in an-
other way so that the coarser solid particles will contain so little residual moisture that they can
be stored and possibly even packed as a finished product without need for further dehumidifi-
cation.
The centrifuge is to discharge the supplied solid matter despite fine-grained constituents with-
out significant screening loss at the lowest possible residual moisture.
To this end, the following conditions should be given if possible:
• Highest possible feed concentration
• Low revs, tuned to the required residual moisture
• Thick layer on the screening element
• Small screen apertures
• Optimized discharge area of the screen.
The higher the feed concentration is, the better will the process efficiency of the screen worm
centrifuge normally be because small suspension volumes with high solid content require a
minimum of acceleration energy and a maximum discharge rate of solid matter can be
achieved.
Residual moisture
The residual moisture depends on the following influence factors:
• Grain size, grain size distribution, grain fracture
• Grain shape and surface structure of the solid matter
• Permeability of the solid matter layer on the conical drum section
• Viscosity
• Adhesion characteristics between solid matter and liquid
• Feed concentration
• Inclination of the cone
• Residence time
• Centrifugal factor
• Layer thickness of the solid matter on the conical drum section.
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As the retention time ∆t increases, the residual moisture RF initially decreases fast but then
only slowly so that very long retention times do not result in any economic advantage but on
the contrary limit the throughput without necessity.
If the centrifuginal factor z increases, the graph largely maintains its shape but is shifted to-
wards lower residual moisture and shorter residence time. The zone of transition between
steep decrease and flat branch indicates which residence time should be selected.
Figure 6 RF-∆t-diagram
At the same time, the parameters wear, grain fracture and loss of fine particles must be consid-
ered, too.
Very coarse incompressible solids facilitate filtration so that the residual moisture increases
only slightly when the layer thickness increases.
In contrast to this, very fine-grained solid matter has such a high filtration resistance that any
increase in the layer thickness will cause a considerable rise in the residual moisture due to the
longer filtration distance if this is not compensated by a longer residence time.
Machine lubrication
According to standard all Centrifuges should be equipped with an integrated recirculating oil
lubrication system.
At the base frame an oil reservoir is attached, in which the oil pump aggregate is integrated.
From here the oil is fed to the lubrication system.
From this pressure line the supplies the gearbox and all antifriction bearings are supplied via
individual throttling ports with oil. Thus the temperature development is affected at high num-
bers of revolutions as well as a contamination of the antifriction bearings is prevented to the
best advantage.
The recirculating oil is supplied to the oil reservoir and will be filtered. Control devices belong to
the scope of supply. This perfect lubrication system guarantees high life span for gear and
bearings with smallest maintenance costs.
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From this pressure channel, the gear unit and all roller bearing are supplied specifically with oil
via single throttling bores.
This has a positive influence on the development of temperature even at high rotation speed
and contamination of the roller bearing is prevented as well.
7.4.2.3 Wet Screen
Wet screens as considered in the project have various fields of applications such as:
coal, raw and washed iron and copper ores, minerals, granular material, pellets, potash and
halite, aggregates, limestone, sand and gravel, building materials.
Operational characteristics
“Banana“ screens are high speed screening machines. Due to the steep screen inclination,
high transport speeds are achieved. A very fine layer is formed and a large proportion of the
fines pass through the elongated apertures. The inclination is less in the middle and discharge
sections, which reduces the transport speed. In these sections a good separation, even of
marginal particles, is achieved.
"Banana" screens achieve a very accurate separation, even with extremely high feed rates and
difficult material. Originally “Banana“ screens were developed for two separations and have
proved themselves in that field. However they have also been used successfully many times on
multiple separation applications.
Machine details
Considered "Banana" screens are double counterweight screening machines. These screens
are manufactured as single or double deck machines, of two to five sections with gradually
flattening inclination. E.g. In the steep part it might be 25° - 40°, in the middle sections 15° - 25°
and 0° - 15° towards the discharge. The effective screening areas can be up to 50 m². The
quantity of inclination sections and their degree of slope can be designed according to specific
requirements (e.g. restrictions in height of the steel structure of the processing plant).
Figure 7 Working Scheme Wet Screen
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7.4.2.4 Rod Mill
The Rod Mill should been manufactured to the latest state of the art and under consideration of
the FEM Codes and Standard (Fédération Européenne de la Manutention), ISO und DIN
standards and the acknowledged rules of safety engineering. Nevertheless, use of this equip-
ment might involve risks to life of operators or third parties or damage to equipment, its com-
ponents or other property.
Therefore, the operator of the Rod Mill shall prepare job-specific instructions on the basis of the
intra-company occupational safety and accident prevention codes and declare them obligatory
so that accident-free operation, repair and maintenance of this equipment can be ensured.
The Rod Mill should be used only in technically perfect condition and in full accordance with
the intended purpose, with safety awareness and under strict adherence to the operation and
maintenance instructions so that accidents can be excluded. Troubles that might impair opera-
tional safety must be immediately eliminated.
The Rod Mill shall be used only for the application parameters. Use of equipment for other pur-
poses and/or different application parameters is considered as not in accordance with the in-
tended purpose.
The crystallizate grinding system described herein is designed to mill in continuous wet grind-
ing process for the use in further process.
The plant is equipped with instruments to provide the necessary signals and contacts. The im-
plementations of controls will be accomplished in the DCS system.
Mill Components
Mills are O' flow type and have central drive consisting of a squirrel cage motor, mechanical
starter coupling with entrainment charge of oil and steel rods, a speed reducer and toothed
coupling connected to the rod mill’s central drive trunnion. An inching drive is installed on each
mill at the high-speed shaft of the speed reducer side opposite to the mill main E-motor.
The mill trunnion bearings are of bush type with lead bronce inserts with large oil bags. Self-
aligning swivelling rollers support the bush body. Mill trunnion bearings are provided with au-
tomated low pressure oil lubrication sets each comprising motor gear-pump set and gap filter
at suction side, oil flow switch and thermocouples transmitting the oil gap temperature signal 4-
20mA to the DCS system permissions, feedback and alarms.
Trunnion bearing housing contains also its own oil tank in bottom section. To ensure dust &
water tightness of bearing housings, each housing is sealed off by a grease lubricated double
lip seals clamped to the bearing housings and fed with grease by a timer controlled grease
pump one for each mill.
To ensure proper grinding kinetics of the grinding rod charge - mill liners of lifter bar type made
of solid rubber are installed inside the mill body.
The grinding rod charges are composed of steel rods.
The mill slurry is gravity discharged through the discharge trunnion carrying a return spiral of
solid PU lining, in order to prevent grinding parts from being flushed out into the mill tank with
the mill discharge slurry. Return spiral is followed by a discharge liner with outlet slots - both
items installed on inside diameter of discharge trunnion.
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Mill Body
The mill body is composed of a shell and two heads screwed to the shell.
Both mill heads consist of a conical casted head part.
The shell carries in that case peripheral outlet slots at its discharge end - without a discharge
chamber.
The three main parts are made of heavy gauge steel plate or forged parts and are annealed
before machining.
The body is supported by two bearings.
Trunnion Bearings
Self-aligning bush bearing lined with high-grade babbit, under dust-tight housing, with auto-
matic lubrication set.
Floating bearing drawing and fixed bearing version.
Roller-Bearing Block
Heavy-duty, self-aligning roller bearing carried in sealed mounting with grease lube-plug and
grease discharge valve.
Feed Arrangement
Rod mill has a conical feed cone.
A feed box with spout feeder and wear part, the entire arrangement removable, ensures a save
flow into the grinding chamber for the mill new feed.
The feed box further carries:
• One flanged rectangular opening for mill new feed.
• Flanged connections for grinding water.
• One inspection flap on top.
Discharge Arrangement
Central Discharge
• Overflow
Mill Liners
The following mill liner system is used:
• Rubber liners of the lifter bars type, for wet fine grinding as in the subject case.
The liners are fastened by special fine-threaded bolts with leak proof washer, nut and lock-nut.
This operation is carried out at the site or in the shop after mill assembly or installation respec-
tively.
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Mill and Drive Base Frame

The Mill should be shipped completely assembled and test run on machined frames i.e. con-
siderably reducing the erection and installation time. The motor can be installed on the drive
base frame. Both frames are installed over a massive concrete foundation.
Grinding Media Charge

The initial charge is composed of rods.
Process Flow Description

To ensure proper grinding kinetics of the grinding rod charge - mill liners of lifter bar type made
of solid rubber are installed inside the mill body.
The grinding rod charges are composed of steel rods. The mill slurry is gravity discharged
through the discharge trunnion. A return spiral is installed inside the discharge trunnion in or-
der to prevent grinding parts from being flushed out.
Product slurries are gravity discharged into the afterwards tanks.
Plant Start-Up Procedures

• Completing mechanical and electrical erection and installation
• Completing cold test and test runs with single equipment
• Logic sub function groups and function groups appliance testing and control functions
with the DCS specialists
• Testing of interlocks with DCS specialists.
Information to Optimize Mill Performance
Recall of the Usual Terminology About Grinding Process in Rod Mills

THE WORK-INDEX (or BOND index) is generally expressed in kWh per short ton or ton of
product ground to the required fineness and is often used to define the grindability of a certain
mineral.
The Wi in KWh per short ton indicates the energy required to reduce a material of theoretically
average infinite dimension to a product of 80 % minus 100 microns fineness.
The short-ton is equal to 0.907 tons.
The energy expressed by the work-index corresponds to the energy required in wet process, in
closed circuit with a circulating load of 250 % using a mill of 2.45 m (8') diameter.
Correction factors permit to correct this Wi in case of operation in dry-process, in open circuit,
bigger or smaller mill diameters, oversize feed and so on.
The Wi of a product is found by a test on a representative sample of at least 10 kg of the prod-
uct to be ground.
This test can be carried out in the research laboratory of the supplier or in an independent insti-
tute.
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It is also possible to derive the Wi from known industrial plant results.

The specific power required for one ton of mineral to be milled this can be calculated.
Bond's 3rd theory basic law:
Wb=Wi.10.(P80-1/2 - F80-1/2).1,1 (1)
For certain materials it is usual to apply the HARDGROVE index to define the grindability.
If a product is harder its HARDGROVE index is lower- what is inversely proportional to the Wi
figure.
The supplier should be in the position to carry out the HARDGROVE tests.
Particle size distribution of product ground
In order to define a product before and after grinding, the granular curves of this product are
plotted, based on the screen analysis.
A representative screen analysis is carried out under defined conditions on a range of standard
screens.
It is most popular to express a certain fraction in mesh, or microns, which is a concrete term
avoiding confusion.
Number for the grain size
The results of the screen analysis expressed per passing or per retained cumulated at 100 %
one wt. % and mesh permit to plot the granular curve.
Specific surface of a particle size distribution
The result of a grinding operation can be checked by measuring the specific surface of the
product.
The specific surface is expressed by cm²/g. It is the surface of one gram of product with all
grain sizes contained.
Amongst the usual methods & instruments we like to mention the permeability meter acc. to
Blaine.
Critical speed of a mill
It is usual to express the rotating speed of a mill as percentage of its critical speed. The critical
speed is the speed at which the outermost layer of mill rods starts centrifuging.
It is calculated by: Nc=42.3/√Dil (2)
whereas Dil (m) is the mill diameter, inside liners.
The rotating speed of the mill in % of the critical speed is chosen as function of the dimensions
of the mill and its application.
L/D - ratio of mills
It is the ratio of the length to the useful diameter of the mill. It is defined primarily at an optimum
value according to the kind of operation, open or closed circuits, reduction ratio, etc.
Charge of the mill
This is the percentage of the useful volume of the mill filled with grinding rods and material to
be ground.
It is generally equal or less than 30 % according to the applications.
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Factors Influencing the Efficiency of Rod Mills

General
Rod mills are utilized in wet process with open circuit or with closed circuit.
Discharge can be of over-flow, average or low type diagram or combined discharge.
Influence of the Rod Charge

The volume and the composition of the rod charge have considerable influence on the efficien-
cy of the grinding.
The initial rod size distribution is determined with the basic data that have justified the dimen-
sions of the machine particularly:
• The Wi of the product
• The mesh size through which 80 % of the feed material are passing.
• The characteristic factor of the kind of mill operation (wet or dry process).
The equilibrium charge of a mill is the charge composed from the maximum diameter previous-
ly calculated.
Different Definitions and Terms of Mass Flow Concentration

Several definitions of the concentration of slurries are in current use:
v = ratio volume of solid / volume of pulp.
s = ratio weight of solid / weight of pulp.
x = ratio weight of solid / volume of pulp (in g/l)
whereas: dm = specific gravity of solid
d = specific gravity of pulp
l = specific gravity of the liquid
d-l d-1
v = dm-l
(5); and v= d (5a)
m-1
When we consider the most usual case where the liquid is cold water and where l = 1, then we
obtain (5a).
The solids concentration by weight / wt % is then:
dm൫d-1൯ d
S= d൫d = v ˙ dm (6) S=s˙100 (6a)
m-1൯
Of which is derived the specific gravity of the pulp:

1-v
D= 1-s (7)
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The concentration in g/I is given by:

dm(d-1)
x = 1000.s˙d = 1000˙ = 1000.v˙dm (8)
(dm-1)
Our diagrams and flow sheets of wet-process installations contain the following terms to de-
scribe the different mass flows:
Total mass flow (M) (kg/h)
Solids flow (Sm) (kg/h)
Water flow (W) (m³/h)
Density (d) (kg/m³)
Volume flow (Q) (m³/h)
Solids wt% (S) (wt.%)
Grinding Circuits
Open Circuit
Rod mills operate with open or with closed circuit.
With open circuit grinding, it is intended to obtain by only one passage through the mill a cer-
tain granulometry that is characterized by a maximum percentage of remainder admissible at a
certain mesh size.
If the remainder has to be strictly limited, the working in open circuit will result in excessive
power consummation because of the surface increase involved.
This increase of power consumption can reach 1.3 to 2 times to energy theoretically required.
Closed Circuit
In ore processing, mostly try to liberate the mineralogical components without going beyond
this mesh called liberation size.
This can be reached by working in closed circuit, either in dry grinding on air-separators or in
humid process on hydro cyclones, curved sieves, screen panels and mechanical classifiers.
This classification allows to work on comparatively short mills with circulating loads varying
from 100 to 500 % and more.
The efficiency of the work can be considerably improved and optimum adjustments for the
product particle size distribution are possible.
Power Required by Grinding Mills

This power is:
• Proportional to the rotating speed of the mill,
• Proportional to the apparent density of the mill charge,
• Up to a certain extent independent of the feed rate function of the mill slurry density,
• Function of the shape or the wear of the liners,
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• Proportional to the filling rate of the mill as indicated by the curves here-after (c-factor
for the calculation of the mill power).
7.4.2.5 Flotation
In the designed process for producing KCl 95, several steps of flotation for concentrating the
ore are necessary. These flotation steps are rougher flotation, cleaner flotation and scavenger
flotation. The consultant decided to consider agitated flotation machines within the detail engi-
neering. The consideration of pneumatic flotation machines was evaluated. During this evalua-
tion the focus was set on operational requirements of the flotation machine in the overall pro-
cess, operational safety, references in the potash industry, capital costs and operational costs.
The consultant came to the conclusion to prefer agitated flotation machines under considera-
tion of the requirements of this special project.
Agitated flotation machines feature a unique design that is demonstrably superior to other flota-
tion systems. In direct comparisons by major mining companies, the considered flotation ma-
chines in this detail engineering, have repeatedly delivered higher recovery and grade with
easier start-up, simpler operation, lower reagent consumption, longer mechanism life and less
required maintenance. The considered flotation machine is the world leader in large cell tech-
nology with the greatest installed capacity of any other flotation machine.
At the heart of each cell is a rotor-disperser that delivers intense, mixing and aeration. Ambient
air is drawn into the cell and uniformly distributed throughout the pulp, providing optimum
air/particle contact. In larger cells a false bottom and draft tube channel flow, ensuring high
recirculation and eliminating sanding. The combination of efficient aeration and optimum solids
suspension gives these machines the highest specie recovery and concentrate grade perfor-
mance available, and reduces reagent consumption.
Air flow into the pulp is induced by the turning rotor. No forced air supply is required, eliminat-
ing the capital and operating costs of blowers and distribution piping. Air flow compensation
for varying feed densities is automatic, minimizing the operator attention required. An additional
benefit is that one mechanism can be removed for service without interrupting production, un-
like forced air systems which require shut down of an entire cell bank for service access to a
single mechanism.
To reduce wear on rotor and disperser surfaces, the aeration mechanism is positioned above
the tank bottom, eliminating contact with abrasive, oversize tramp material. After a shutdown,
the elevated rotor allows cells to be restarted instantly, unlike conventional designs with rotor
and floor-mounted stator located in the zone of heaviest solids accumulation.
Aerator mechanism erosion is further reduced by large design clearances between rotor and
disperser. Normal wear life of the considered mechanism is 2-4 times that of closely spaced
conventional rotor/stator designs. Because the mechanism stay with design tolerances longer,
peak metallurgical performance is maintained over a longer period, further enhancing profitabil-
ity.
For reasons of productivity the superior air dispersion and high slurry recirculation ensures
adequate residence time for optimum recovery and concentrate grade. In regard to economy
the simple induced aeration reduces both capital and operating cost. Furthermore the efficient
air dispersion reduces frother consumption and the reduced mechanism erosion slashes
maintenance costs.
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7.4.2.6 Vacuum Belt Filter
Description of Operation
The horizontal belt filter dewaters thickener underflow slurry by applying a vacuum to the un-
derside of a filter cloth moving across the filter bed. The filter cloth is transported by a rubber
transporter belt, which is also grooved and holed to allow liquid runoff under the cloth. Filtrate
and air are mixed in the vacuum box, which is spaded internally to separate the flow streams.
Slurry is fed onto the filter at ambient temperatures. The filter can be equipped with one (or
more) wash stages. The dewatered slurry cake is discharged from the end of the horizontal belt
filter into a cake discharge system
The filtrate and wash water from the stages are drawn off into filtrate receivers each filtrate re-
ceiver and moisture trap can be equipped with NPSH pumps, which pumps away the accumu-
lated filtrate. Each vessel is connected through a common vacuum system to a moisture trap
and then to a vacuum pump.
Figure 8 Vacuum Belt Filter
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Process Description
FEED
Slurry is fed onto the horizontal belt filter via an agitated/flocculated tank and onto a fishtail
feeder. The feeder ensures even product distribution over the cloth width. This is important for
uniform washing and drainage.
FORM ZONE
The form zone is the area of the belt visible from the feed dam roller to the point where no sur-
face liquid is visible. The feed rate must be such that a uniform layer of material covers the en-
tire width of the belt.
WASH ZONE
The wash zone is the area of the belt after the form zone where wash liquid on the filter forms a
dam covering the filter cake. The wash liquid will be drawn through the filter cake displacing
residual filtrate and washing the filter cake.
DRYING ZONE
The drying zone is the area of the belt where the filter cake is further dewatered. In the drying
zone, no surface moisture will be visible and during the last stages of drying, air will be drawn
through the filter cake.
DISCHARGE ZONE
At the discharge zone, the filter cloth is separated from the carrier belt by passing over a sepa-
rate roller. This has the added function of breaking the cake prior to discharge. The filter cloth
then wraps around cake slide roller or discharge slide through an angle of 90°. At this point that
the wet filter cake and the filter cloth are separated by gravity.
CLOTH WASHING ZONE

The filter cloth is then returned towards the head of the filter and passes through a high-
pressure curtain of wash water to remove any entrained solids from the cloth. The sprays pro-
long the life of the cloth by minimizing blinding. The spray bars are fed with spray water from
two sides. The two halves of the spray bars can be removed separately for ease of mainte-
nance and cleaning.
VACUUM SYSTEM
Vacuum is applied to the horizontal belt filter via a vacuum system connected to filtrate receiv-
ers where the filtrate is separated from the airblow. The vacuum pump vents into atmosphere
and the mine water is passed once through the vacuum pump as seal water.
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Operating Strategies
There are two variable in the control of the horizontal belt filter, with the aim being the dis-
charge of a uniform filter cake having a minimum liquid content.
Feed Rate: The feed rate should be controlled such that the filter cake thickness on the belt at
the drying zone is uniformly thick with no openings or wet patches.
Cycle time: The cycle time is the time taken for a known point of the belt to pass over the vacu-
um boxes along the length of the belt and is directly related to belt speed.
Operating Instructions
FILTER DESCRIPTION
The horizontal belt filter comprises the following:
Filter Frame
This is a painted mild steel structure for pre-leach filters and stainless steel for acid. The frames
are manufactured from angle and channel sections with welded and/or bolted construction.
The unit is designed for delivery to site in small pieces.
Head Pulley
This is an oversized mild steel pulley with corrosion resistant shafting and rubber lined with a
grooved diamond pattern. It is located at the filter cake discharge end, and is also known as
the drive pulley.
Tail Pulley
This is similar to the head pulley but is fitted at the feed end of the filter, i.e., the idler pulley.
The pulley is fitted with take-up bearings to facilitate belt tracking and tensioning.
Drive Unit
The filter drive comprises an AC motor, fixed ratio gearbox and pulleys driven by a variable
speed drive.
Transporter Belt
The main transporter belt is manufactured from neoprene rubber reinforced with a polyester
fabric carcass. The belt has regularly spaced sloped grooves cut at right angles to the direction
of travel and has drainage holes punched in the center for filtrate extraction into the vacuum
box. The belt is delivered unspliced and must be spliced, tracked, drilled and have curbing
added on site.
Belt Support
The transport belt is supported by a system if airboxes supplied with low-pressure air from a
single fan. The rubber transport belt slides on an aircushion over perforated stainless steel
plates. Guide rollers are fitted along the length of the filter to assist with guiding the transport
belt along the top deck of the filter.
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Vacuum Boxes
The stainless steel vacuum box is made up from a set of flanged fabricated high-grade stain-
less steel box construction. Wear belts slide in machined plastic sliding strips mounted on top
of the vacuum box, and are lubricated by injecting seal water. The vacuum box is connected by
large bore hoses to the vacuum manifold and then by rigid piping to the filtrate receivers.
Filter Cloth
An endless length Needlefelt cloth is carried along the main transporter belt. After the filter cake
discharge, the cloth and the transport belt separate and both return to the tail pulley via a sys-
tem of return rollers. The cloth has a pneumatically controlled tracking system. Tensioning is
achieved by a weighted gravity tensioned roller. A bowed roller is fitted to the head of the filter
and acts to prevent the cloth from creasing.
Cloth Wash Sprays

After the filter cake has been discharged, the filter cloth returns through a series of cloth wash
sprays located at the discharge end of the filter. The spray bars are split in two halves for easy
removal. The nozzles are easily replaceable for cleaning purposes.
Bearings
The head and tail pulleys have sealed plumber blocks on the shaft ends. The DE bearing is
static while the NDE bearing is floating. All bearings are lubricated with the aid of a dual line
lubrication system. The tail pulley is equipped with take-up bearings. All other rolls are fitted
with high quality double spherical roller bearings.
Slurry Feeder
The feeder consists of a dual fishtail feed distributor to regulate and evenly distribute the slurry
onto the filter cloth. All slurry feeders are rubber lined.
Wash Distributors
The wash distributors are designed to ensure that wash water is evenly distributed over the
entire cake.
FILTER PLANT
The filter plant can be viewed as three sections:
• Filter feed
• Horizontal belt filter
• Washed cake disposal.
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FILTER FEED
An ultrasonic level sensor mounted over the form zone measures feed dam level. The PID con-
trol loop either stands alone or in the client PLC controls the modulating flow control valve in
the feed line to ensure a constant cake thickness.
BELT FILTER
Slurry is distributed over the width of the belt in the formation zone by the fishtail feeder. The
length of the formation zone is the distance from the feed dam roller to the point where no sur-
face liquid is visible. The filter cake bed thickness is dependent on the following:
• Feed flow rate
• Feed density
• Belt speed.
Strong filtrate extracted from the form zone and wash filtrate extracted from the wash is
pumped away by the filtrate pumps and not recycled on the belt filter. An overflowing cake
wash distributor distributes wash water over the wash area. A second ultrasonic level detector
is mounted above the wash zone on the acid filters, to alarm high and low dam levels for preset
levels. Level switching is carried out in client PLC. The belt filter transport speed is controlled
by a frequency inverter coupled to the filter drive. The belt speed is visually monitored and is
set manually during commissioning and adjusted during filter operation as required.
Cake Disposal
The cake produced by the filter plant is discharged off the end of the belt into cake discharge
system and disposal to a plant supplied by others.
INTERLOCKS/BELT FILTER PROTECTION – GENERIC

The filter plant control must permit feed to the horizontal belt filters unless process conditions
dictate.
• Vacuum box seal protection. The filter drive motor is stopped on low seal water flow.
• Transporter belt and filter cloth protection. The filter drive motor is stopped should the
transporter belt or cloth track too far on either side of the filter via limit switches. All four
switches on the filter are connected in series.
• Safety switches. The filter drive motor is stopped should either of the hand switches be
activated. Both switches are connected in series.
• Wash water supply low. The feed is cut back in stages should the wash water supply
stop.
• Vacuum pump trip. The filter reverts to the cleaning cycle should the vacuum pump trip.
• Filter drive motor stop. Filter drive motor stop initiates shutdown of the horizontal belt fil-
ter as follows:
o Stop feed to the horizontal belt filter
o Close wash water.
• Shut all auxiliary equipment except agitators and pumps.
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7.4.2.7 Fluid Bed Dryer / Cooler
A shaking fluid bed dryer is used for continuous drying of powders, crystals and granulated
materials. Drying is achieved by the transfer of heat from a fluidizing air stream as it comes into
contact with the material.
Working Principle
Centrifuge wet material is continuously fed in to the dryer. In the shaking fluid bed is a perforat-
ed stainless steel plate (air distributor) through which the drying air flows. The air is of sufficient
volume that it lifts or fluidizes the bed of material allowing intimate contact between drying air
and each particle. The shaking action of the fluid bed assists in the transportation of the mate-
rial over the length of the dryer and improves the fluidization of the wet material. Moisture is
carried away with the air and fine particles into a dust recovery system, an exhaust air fan
transport the cleaned air to ambient. The flow of air is controlled along the length of the dryer to
maximize fluidization enabling wet and sticky materials to be handled. As the material passes
along the length of the dryer it gradually loses moisture until the target dryness is achieved at
which point it passes into a cooling zone. In the cooling section the product is fluidized with
cool ambient air which reduces the product temperature to the requested value. Cooling of
product is required to allow further product handling on bucket elevators, belt conveyors etc.
The exhaust air from the cooling section is also de-dusted in a filter installation and recycled to
the drying section.
Air Heating
Air is pumped by a fan into a burner housing which is fuelled by liquefied petroleum gas. The
flue gasses from the burner and process air are mixed in the burner chamber to an even tem-
perature. The heated air is then blown into a chamber under the perforated bed from which air
passes into the material bed. De-dusted exhaust air from the cooling section is recycled to the
burner for fuel efficiency. The burner capacity is adjusted to control the final product moisture
content depending on the measured exhaust air temperature and product temperature; this is
a fully automated system that requires no adjustments from the process operators.
De-dusting System
The entrained fine particles in the exhaust air from the dryer and the cooler are separated from
the air stream in separate filter sections. The filter is equipped with a filter material (polyester
needle felt) supported by stainless steel cages. The dust is collected on the filter material and
the air permeates though the filter cloth. In regular intervals compressed air is used to remove
the dust from the filter cloth. The dust is collected in a screw conveyor and removed from the
filter through a rotary airlock valve.
7.4.3 Equipment Test Work
After laboratory test work, process calculation, pre-selection of equipment ERCOSPLAN made
inquiries for main equipment. Afterwards equipment suppliers sent quotations for main equip-
ment. Along with the quotations, some suppliers asked for equipment test work due to the
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specific high altitude of installation of equipment. Equipment test work is necessary e.g. for
vacuum belt filters and settling tests for thickeners.
ERCOSPLAN recommends that GNRE-COMIBOL takes these outstanding test works into con-
sideration during the purchase phase of equipment, so that the delivered equipment by the
supplier can meet 100 % of GNRE-COMIBOL’s satisfaction.
7.4.4 Technical Description of Process Sections
The overall process is divided into following technological process sections. For details see
Piping & Instrumentation Diagrams (PID).
• Wet salt storage including truck loadout
• Tails process
• Drying section
• Product storage
• Truck loading.
7.4.4.1 Wet Salt Storage Including Truck Loadout
For details see PID A 1350

The wet crystallizate is harvested by front end loaders at pond site. Front end loaders charge
bottom dump trucks (capacity 20 tons) at pond site. Bottom dump trucks transport wet crystal-
lizate to truck loadout at plant site. Truck transportation will be 16 h/d. At night (8h/d) in general
there is no truck transportation of wet salt to processing plant. Within the truck transportation
time (16h/d) enough wet crystallizate has be transported to plant site to guarantee 24 h/d pro-
duction of processing plant. The truck transportation rate to processing plant will be approx.
1000 t/h or 16,000 t/d.
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The truck loadout is constructed as a ramp from compacted salt. The ramp has two parallel
lanes upwards the ramp, two parallel openings for discharging the crystallizate from trucks and
two parallel lanes downwards the ramp. So a parallel loadout of two trucks is possible. Due to
this construction, backwards driving and shunting of trucks is not necessary and a quick
loadout cycle is ensured. Once the truck has reached the top of the ramp, the truck has to stop
and to open the bottom valve. When the crystallizate is discharged, the truck drives down the
ramp back to the crystallizate pond. In the center of the ramp the crystallizate bunker is in-
stalled. The level indication of the bunker prevents overfilling. In case of a high level inside the
bunker, a traffic light signals the truck driver to wait until the bunker level has been sunk. Inside
the bunker a rotating beater crushes possible crystallizate lumps coming from the ponds. Un-
derneath the bunker a discharge conveyor, equipped with speed control, is installed. A belt
conveyor transports the crystallizate from truck loadout ramp to a two-way distributor.
Due to a liquid content up to 15 % in the crystallizate, the adhered brine from crystallizate is
collected in a low point next to the bunker. The collected brine in the low point is then pumped
to disposal. The low point is equipped with a level indicator which lets the pumps start when
the upper level is reached.
The crystallizate arriving the two-way distributor has the possibility to be transported to the wet
salt storage, to bypass the wet salt storage by going directly to processing plant, or to be dis-
tributed between wet salt storage and processing plant.
Wet crystallizate to be stored in the wet salt storage is done by an increasing belt conveyor.
Afterwards a moveable and reversible conveyor belt generates the longish storage. Wet salt
storage’s capacity is designed with 30,000 tons of wet salt. Discharging of wet salt into pro-
cessing plant will be done by automatic scraping technology. The scraper feeds a conveyor
belt leading out of the wet salt storage. Discharge capacity will be approx. 650 t/h.
Wet crystallizate stored in the wet salt storage has an adhered brine content of approx. 15 %.
During storage time these moisture will flow out of the bulk and will settle on the ground floor of
the storage. On ground floor there is a drainage system (channels) which lead the adhered
brine to a central low point where brine is collected. From there adhered brine is pumped to
disposal. The low point is equipped with a level indicator which lets the pumps start when the
upper level is reached.
Lump crushing and iron / non-iron metal detecting is necessary for trouble-free operation. Af-
terwards lump crushing a two-way distributor distributes crystallizate to conveyor belt including
belt weigher leading to production line A and B. At these conveyor belts it is envisaged to take
samples for controlling crystallizate quality. Furthermore a K2O measurement device and mois-
ture measurement device is installed at these conveyor belts.
Chutes afterwards belt conveyor drops are generally equipped with overfilling detectors (LSA).
Wet salt storage will be a closed building, so that there is no bad influence due to precipitation
and contamination.
Main equipment in wet salt storage will be:
• Crystallizate bunker
• Discharge conveyor
• Belt conveyors
• Scraper
• Iron / Non-iron detector
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• Lump crusher
• Belt weigher
• Low point pumps.
Details regarding the wet salt storage are set in:

• PID Wet salt storage (Drawing No. A1350)
• Equipment list (Appendix A02)
• Equipment data sheets (Appendix A03)
• Equipment specifications (Appendix A06).
7.4.4.2 Wet Milling and Screening
For details see PID A 1351 / 1352

Wet screening and milling section contains generally following processing steps:
• Suspending of wet crystallizate with reclaim brine
• Dewatering of suspended crystallizate in centrifuges to separate adhered high content
magnesium brine
• Thickening, collecting and pumping of fugates from centrifuges to rougher flotation
• Suspending of wet crystallizate (which is free of adhered high content magnesium
brine) for wet screening
• Wet screening of suspended crystallizate to guarantee liberation of KCl / NaCl particles
• Wet milling of crystallizate (wet screen overflow) to guarantee liberation of KCl / NaCl
particles
• Collecting of wet screen underflow and pumping to rougher flotation.
The wet screening and milling process section is executed in two parallel production lines (line
A & B). In case of disturbance due to the delivered crystallizate, a connection between both
lines is envisaged after the first suspending step of crystallizate. So there is a possibility to
switch between both production lines. A second connection between both lines is before the
wet screens.
Wet crystallizate coming from wet salt storage is suspended with reclaim brine in an agitated
vessel. The amount of brine to be used for suspending is monitored with flowmeters. From
there suspension is pumped to a distributor tank and from there it flows to 3 parallel installed
centrifuges to separate adhered magnesium brine. The volume flow of suspension to distribu-
tion tank is monitored by flowmeter. Furthermore the correct distribution between the 3 centri-
fuges is monitored by flowmeters and valves. The centrifuges are equipped with an oil cooling
circuit. The cooling media is process water (average 15 °C).
The adhered brine has to be separated because of the high content of magnesium chloride.
Magnesium chloride makes the recovery in flotation go down.
Liquid fraction of centrifuges flows into a central vessel. From there it is pumped to a thickener
to separate the fine remaining particles. The thickener overflow is collected in a tank and then
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pumped to the suspending vessel in the beginning of the process section. Here it is used for
suspending the crystallizate coming from wet salt storage. In case of a surplus of suspending
brine, the brine can be disposed to disposal. The thickener underflow is pumped directly to
rougher flotation because of the particles containing KCl.
Solid fraction from centrifuges is collected on centrifuge discharge conveyor and is conveyed
to agitated vessel. Solid fraction is there suspended with reclaim brine. Afterwards suspension
is pumped to 3 parallel installed vibrating wet screens together with cleaner flotation tailings.
The correct distribution between the screens is monitored by flow meters and valves. Split cut
will be at 0.8 mm because of the results of laboratory flotation tests. In the flotation tests was
manifested that the liberation grade, the grade where almost all KCl and NaCl particles are
separated from each other, is at a maximum grain size of 0.9 mm. Each screen is charged by
its own pump, so that an independent operation is ensured.
Screen overflow bigger than 0.8 mm is milled in a rod mill, collected in agitated vessel and then
pumped back to screen. By pumping back the milled fraction to screens, the operator has the
guarantee that all the particles are smaller than 0.8 mm.
Screen underflow is collected in an agitated vessel and is then pumped to rougher flotation.
The volume stream is monitored by flowmeter.
An overhead crane is installed above wet milling and screening process section to ensure
hoisting of huge equipment in case of repairs and maintenance.
The rod mill including its grinding media (rods) is one of the heaviest equipment in the process
building. So, above the rod mills an extra overhead crane is installed.
Generally all tanks in this process section are equipped with a level indication. The level inside
the tank is regulated by the afterwards installed pumps with speed control. Furthermore tanks
are equipped with an overflow pipe leading to central drainage system on platform 0.00 m.
The underflow of thickeners is monitored by checking the density. Chutes afterwards the centri-
fuges leading to centrifuge discharge conveyor are generally equipped with overfilling detec-
tors (LSA). Afterwards all pumps a pressure indicator is installed to ensured correct working of
pumps.
Centrifugal pumps in this process section are supplied with sealing water from sealing water
system.
Main equipment in wet screening and milling section will be:
• Centrifuges
• Centrifuge discharge conveyor
• Thickener
• Vibrating screens
• Rod mills
• Agitated tanks
• Pumps
• Overhead cranes.
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Details regarding the wet screening and milling section are set in:
• PID Wet screening and milling (Drawing No. 1351 and 1352)
• Arrangement drawings
7.4.4.3 Rougher Flotation
For details see PFD A 1353 / 1354
Rougher flotation section contains generally of following processing steps:

• Dewatering of rougher flotation feed to generate necessary solid content
• Conditioning of collector reagent with rougher flotation feed
• Rougher flotation for separation of KCl content
• Generation of solid free reclaim brine in thickener.
The rougher flotation process section is executed in two parallel production lines (line A & B).
Wet screened crystallizate from wet screening and milling process section is fed to hydro cy-
clones battery for generating flotation solid content. Hydro cyclone underflow is then collected
in an agitated vessel and flows from there via agitated conditioning vessel to rougher flotation.
The density of hydro cyclone underflow is monitored by density measurement. Conditioning
tank additionally receives reclaim brine in dependence of density of flotation feed. Correct den-
sity respectively solid content of flotation feed is important for flotation results.
Collector reagent from central reagent dosing plant is added by dosing pumps to agitated
conditioning vessel in front of flotation, so that 1 minute reagent resident time is guaranteed.
When dosing the collector agent reagent directly to rougher flotation (without conditioning)
floating of KCl will not work well in the first rougher flotation cells. After conditioning density and
volume flow of rougher flotation feed is monitored. Rougher flotation is designed as 8 cell agi-
tated flotation machine with a single cell volume of approx. 8 m³. Flotation machines are
equipped with its own level regulation. Flotation machines are self-aerating, due to the generat-
ing of under pressure by the agitators. Surrounding air flows into the cell through a hollow
shaft. So, no external supply of compressed air for flotation is needed. Flotation time will be
according to flotation test work in laboratory 6 minutes. Rougher flotation is furthermore fed by
frother agent from central flotation reagent plant. Frother reagent is mixed with flotation feed in
static mixer directly before flowing into flotation cell. Rougher flotation concentrate flows to
cleaner flotation. Rougher flotation tailings flow to scavenger flotation.
Hydro cyclone overflow flows freely to thickener. The thickener feed is monitored by flowmeter.
The thickener separates fine particles from hydro cyclone overflow. Generated solid free thick-
ener overflow is pumped to reclaim brine storage. Thickener underflow is pumped to condition-
ing vessel in front of rougher flotation. The thickener receives optional flocculant reagent, which
supports settling of fine particles in the thickener.
An overhead crane is installed above rougher flotation process section to ensure hoisting of
huge equipment in case of repairs and maintenance.
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The underflow of thickeners is monitored by checking the density. Afterwards all pumps a
pressure indicator is installed to ensured correct working of pumps.
system.
Main equipment in rougher flotation section will be:

• Hydro cyclone battery
• Rougher flotation machines
• Thickener
• Agitated / Non agitated tanks
• Conditioning vessel
• Pumps.
Details regarding the rougher flotation section are set in:

• PID Rougher flotation (Drawing No. 1353 and 1354)
7.4.4.4 Reagent Dosing Plant

In the process of flotation of KCl collectors, foamers and muriatic acid are needed. Furthermore
thickeners may need flocculation agents, so that these chemicals are envisaged optionally.
These chemical reagents are concentrated and delivered to plant site by truck transportation.
At plant site, especially in the process building a central reagent dosing plant for flotation and
thickeners is located on the ground floor. From there reagents are pumped to flotation cells
and thickeners.
Flotation reagent dosing plant works automatically and consists in general of agitated vessels
(muriatic acid, collector, mixing vessels, final reagent mixture vessel) and dosing pumps. For
producing flotation additive at first process water is mixed with muriatic acid. Afterwards collec-
tor, e.g. ARMEEN, is added and agitated. The final mixture is stored in vessel. From there dos-
ing pumps send the flotation additive to flotation process. Foaming agent is produced separate
in vessel and then pumped separate to collector mixture to flotation. Reagent dosing plant runs
automatically. Just vessels for ingredients (muriatic acid, collector, foamer) need to be refilled
from time to time.
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7.4.4.4.1 General
Chemical reagents are required for potash flotation processing. These reagents help to enable
separation processes respectively to increase recovery. Chemical reagents are delivered highly
concentrated and are transported in industrial common packages. For processing needs, rea-
gents have to be conditioned and almost diluted with process water. Conditioning can be a
melting of solid reagents in heated vessels to realize the subsequent dilution with process wa-
ter. The dilution takes place in agitated vessels. The finished reagent solution is then stored in a
next vessel, ready to be added into the process. Adding to the process is done with special
dosing pumps to guarantee exact dosing. Processing inside the reagent dosing plant runs au-
tomatically, feed vessel for delivered reagents however has to be filled from time to time.
7.4.4.4.2 Dosing of Liquids
In general, dosing means adding of highly effective substances (e. g. polymers, additives etc.)
to a given media (e. g. water). Control processes in dosing technology base on short-term add-
ing of high or small amounts of these substances according to requirements.
Purposes of dosing are for example:
• Exact keeping of mixing proportions (e. g. polymers and water as flocculants) under in-
fluence of disruptions
• Adding of active media into fixed quantities (e. g. water stabilizing substances) in peri-
odic times
• Adding of active media into fixed quantities, triggered by special events (e. g. filling of
tanks or vessels).
7.4.4.4.3 Time-controlled Dosing
Many dosing processes base on adding of fixed quantities of a substance after occurrence of
specific incidences. For example, such an incidence can be the new-filling of a tank or vessel,
when a fixed quantity shall be charged at a time. As on the one hand the fixed quantity shall be
adjustable (selectable) and on the other hand it cannot understandably be added all at once at
the time of the incidence, adjustable time relays are used for such tasks. For instance: if 450 ml
of a product shall be dosed after occurrence of an incidence, the time relay of a pump with a
flow rate of 150 ml/min is set at 3 minutes. That means the dosing quantity results from the
product of flow rate and elapsed time. Based on that setting procedure, the term "time-
controlled dosing" has become common in dosing technology.
7.4.4.4.4 Quantity-based Dosing
In some dosing processes (e.g. for flotation), a mixing ratio as exact as possible of two media
(main medium, dosing medium) shall be set up. That is called proportional dosing. One me-
dia often is water (e. g. process water) to which a chemical shall be proportionally added in an
exact ratio. If the flowing-in water flow is constant, the mixing ratio can be adjusted during
active filling-in via dosing device with adjustable flow rate (e. g. magnetic valve). In that case
the dosing device is switched on or off by the magnetic valve.
With unsteady water flow the flowing-in has to be measured, mostly by contact water flow
meter installed in the flowing-in flow. Contact water flow meters emit a fixed number of impuls-
es per liter so that the run-through volume can be measured exactly. Dependent on the num-
ber of impulses (of the actual water in-flow) a conveying device (e. g. pump) can be switched in
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such a way by special equipment for contact water flow meters that an exact proportion of dos-
ing substance and flowing-in water is reached.
7.4.4.4.5 Dosing by Controlled Process Variable
Numerous tasks require a continuously controlled dosing to keep a fixed concentration or mix-
ing ratio of dosing substance and base product (e. g. hydrochloric acid / process water). If a
physical or technical variable is a function of the concentration, that variable can be used to
control the concentration and disturbances can be "compensated". The most important con-
trolled process variables in dosing technology are:
• Electrical conductivity
• Flow rate (see also section 7.4.4.4.4)
• Redox potential
• pH value.
For process water and hydrochloric acid there is a functional correlation between electrical
conductivity and process water mixed with hydrochloric acid. If a certain concentration is
reached, this concentration represents the nominal value of the application. That amount of
concentration corresponds to a certain electrical conductance on which the control device is
adjusted (mostly at a trimm potentiometer or by keyboard and display). If hydrochloric acid is
spent during the process, the electrical conductivity decreases. In accordance with the differ-
ence, hydrochloric acid is gradually added by a conductivity control unit till the nominal value
of electrical conductivity is reached again.
Reagent dosing plant contains generally following processing steps:

• Optional flocculation reagent dosing plant
o Manual dosage preparation
o Automatic dosage addition
o Mixing in agitated vessel
o Ripening in agitated vessel
o Consumption of final flocculant solution from agitated vessel
o Dosing pumps transport the final flocculant solution to consumers
• Flotation reagent dosing plant

o Heating of process water and mixing with muriatic acid in mixing tank
o Heating of amines and pumping to mixing tank
o Final collector agent pumping to flotation from consumption tank via dosing
pumps
o Mixing of frother and process water in agitated vessel
o Transportation of final frother solution from consumption tank to flotation via
dosing pumps.
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Remark:
As written in the MOM of Gate 2 Meeting, GNRE-COMIBOL made no decision about package
sizes of delivered chemicals used in reagent dosing plant. ERCOSPLAN designed the reagent
dosing plant under making assumptions regarding the package sizes.
In reagent dosing plant a fork lifter for handling collector barrels, big bags and IBC is neces-
sary.
The reagent dosing plant is executed as central dosing plant for production line A & B. The
reagent dosing plant consists of a dosing plant for flocculation reagent for thickeners and a
reagent dosing plant for dosing frother solution and collector solution to flotation.
Flocculation Reagent Dosing Plant

The reagent dosing plant for flocculation agent is optional. With rising insoluble content in the
wet crystallizate from the evaporation ponds the settling behavior of fine solids (e.g. insolubles)
deteriorates. An addition of flocculation reagent to the thickeners supports the settling of these
fine particles.
The flocculation reagent used in the flocculation reagent dosing plant can be Polyacrylamide
(PAA) or starch, as a natural product. ERCOSPLAN made the assumption, that flocculation
reagent is delivered in big bags (capacity approx. 1 m³) to plant site. The final flocculation solu-
tion is prepared in a batch process. The dosing of flocculation reagent is done by an automatic
rotating dosing machine. The working principle of this machine is similar to the loading of a
revolver’s drum. This dosing machine has to be filled once in every working shift of 8 hours by
GNRE-COMIBOL staff. The flocculation reagent is dosed into the first chamber of a 3-chamber
(3 x 800 l) agitated vessel. This first chamber is filled with process water. The content of the first
chamber is then mixed by agitator. The filling with water, dosing of flocculation reagent and the
mixing has a duration of approx. 30 min. Followed by this the mixed solution of process water
and flocculation reagent flows into the second chamber. Here the suspension is agitated for
further 30 minutes for ripening purposes. Then the ripened suspension flows into the third
chamber. The third chamber is used for storing the suspension. The capacity of this third
chamber is approx. 1 hour. The final flocculant reagent solution is pumped with dosing pumps
to the thickeners inflow boxes.
The flocculation reagent dosing plant is equipped with level indicators in tanks and flowmeters
afterwards the pumps to monitor the flocculation reagent preparation and dosing.
Flotation Reagent Dosing Plant - Frother

The second reagent dosing plant is used for flotation purposes. Flotation needs three different
kinds of reagents – frother reagent, collector reagent and muriatic acid.
In the laboratory test work MIBC as frother reagent and Genamin SH 100 as collector reagent
showed good flotation results. Genamin is produced on the base of amines. MIBC is produced
on the base of alcohol. The handling of these both chemicals has to be under consideration of
available material safety data sheets. According to these data sheets, Genamin can be hazard-
ous. Muriatic acid is hazardous, too. MIBC is flammable and might cause explosions. Hence, in
the design of the reagent dosing plant the special chemicals are considered, e.g special pump
for MIBC, exhaust ventilation at collector mixing area. So, the “safety at work” regulations are
considered.
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MIBC, used for flotation frother preparation, is delivered in IBC (Intermediate Bulk Container).
The capacity of an IBC is 1 m³. The agitated vessel is filled with process water. The capacity of
the agitated vessel is approx. 1 m³.
The frother is pumped by barrel pump (explosion preventing equipment) to the agitated vessel
and mixed with the process water. Afterwards the mixed solution flows into a storage vessel.
The capacity of the storage vessel is approx. 3 m³. The storage tank can feed the process for 1
hour, within this time a new batch for frother preparation has to be produced. From the storage
vessel the frother mixture is pumped by dosing pumps to flotation.
The frother reagent dosing plant is equipped with level indicators in tanks and flowmeters af-
terwards the pumps to monitor the frother reagent preparation and dosing.
Flotation Reagent Dosing Plant – Collector

For collector solution process water, muriatic acid and collector amine is necessary. Muriatic
acid is delivered by tank truck to plant site. At plant site the tank truck pumps the acid into a
storage vessel in front of the process building. Collector amine is delivered in 200 l steel bar-
rels.
At first step heated process water flows into an insulated agitated vessel. Before the process
water is heated up to 80 °C in a water heater. The heating media is LPG (liquefied petroleum
gas). The agitated vessel is equipped with an electrical heating to hold the temperature. Then
the heated process water is mixed with muriatic acid coming from the HCl storage vessel.
When water and muriatic acid are mixed, collector amine is added and mixed too. The agitated
vessel has a capacity of 2000 l.
Before mixing collector amine with process water and muriatic acid, the collector amine has to
be heated in the barrel heating station to make it flow able. Tree barrel heating stations for two
barrels each are envisaged to guarantee continuous operation. Barrel heating stations have to
be filled with new barrels by fork lifter when barrels are empty. Barrel pumps transport the
melted collector amine to mixing.
The final collector solution flows after complete mixing from agitated vessel to storage tank.
The storage tank is agitated too and has a capacity of approx. 10 m³. The storage tank can
feed the process for 1 hour, within this time a new batch for collector solution has to be pro-
duced. From the storage vessel the collector solution is pumped by dosing pumps to flotation.
The collector solution preparation is equipped with level indicators and temperature measure-
ment in tanks and flow meters afterwards the pumps to monitor the collector solution prepara-
tion and dosing.
The area of mixing and storing muriatic acid with process water and collector amine is
equipped with exhaust ventilation.
Main equipment in reagent dosing plant will be:
• Agitated vessels
• Non agitated vessels
• Dosing pumps
• Process water heater and LPG burner
• Barrel pumps
• Electrical barrel heaters
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• Insulated agitated vessels.
Details regarding the rougher flotation section are set in:

• PID Reagent dosing plant (Drawing No. 1360)
Remark:
The reagent dosing plant as offered in quotation App. Q34 includes listed goods. These goods
are listed “dual-use-goods” according to EG-VO 428/2009, 2B350i. The supplier’s export con-
trol manager may support GNRE-COMIBOL at generating a request of an export license at the
BAFA (Federal Office of Economics and Export Control). Before shipping the goods, GNRE-
COMIBOL needs to show a positive BAFA approval.
7.4.4.5 Cleaner Flotation
Cleaner flotation section contains generally following processing step:

• Cleaner flotation for concentration of KCl solids.
The cleaner flotation process section is executed in two parallel production lines (line A & B).
Rougher flotation concentrate, scavenger flotation concentrate, reclaim brine and flotation rea-
gents flow into cleaner flotation. The cleaner flotation consists of five flotation cells installed in
line. From there a stepwise concentration of concentrates is realized due to the interconnection
of cleaner flotation cells. Final concentrate flows into leach tank. Final cleaner flotation tailings
are pumped back to rougher flotation.
Cleaner flotation is designed as 5 cell agitated flotation machine with a single cell volume of
approx. 8 m³. Flotation machines are equipped with its own level regulation. Flotation machines
are self-aerating, due to the generating of under pressure by the agitators. Surrounding air
flows into the cell through a hollow shaft. So, no external supply of compressed air for flotation
is needed. Flotation time will be according to flotation test work in laboratory 6 minutes. Clean-
er flotation is furthermore fed by frother reagent and collector reagent from central flotation re-
agent plant. Frother reagent and collector reagent are fed into the hollow shaft of the first flota-
tion cell.
An overhead crane is installed above cleaner flotation process section to ensure hoisting of
system. Afterwards all pumps a pressure indicator is installed to ensured correct working of
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pumps. Flow rates are monitored with flow meters. Flotation tailings are monitored by K2O
measurement.
Main equipment in cleaner flotation section will be:

• Agitated flotation machines
• Pumps.
Details regarding the cleaner flotation section are set in:

• PID Cleaner flotation (Drawing No. 1355 and 1356)
7.4.4.6 Cold Leaching and Product Dewatering
Cold leaching and product dewatering section contains generally following processing steps:
• Two step cold leaching to generate product quality
• Dewatering of suspension by vacuum belt filter
• Generation of solid free reclaim brine in thickener
• Dewatering of KCl product in centrifuges
• Conveying of wet KCl product via belt conveyors to drying section.
The cold leaching and product dewatering process section is executed in two parallel produc-
tion lines (line A & B).
First of all it has to be explained that the usage of term “dewatering” is a common household
name in potash processing. Of course, the usage of the term “debrining” would be more appli-
cable when handling with brines.
Cleaner flotation concentrate’s K2O value will be checked by K2O measurement. Cleaner flota-
tion concentrate is cold leached (cold leaching first step) together with thickener underflow and
hydro cyclone overflow as well as fugate from product centrifuges in agitated vessel. The tem-
perature measurement in agitated vessel (cold leaching tank 1) was included in the Detail En-
gineering documents according to MOM of Gate Meeting 13.-15.11.2013. Cold leached sus-
pension is then pumped to vacuum belt filter for dewatering purposes. The flow rate is checked
by flow meter. Belt filter’s filtrate is collected in vessel and pumped to thickener for generation
of solid free reclaim brine. The flow rate is monitored by flow meter, too. Filter cake from belt
filter is cold leached a second time (cold leaching second step) in agitated vessel and pumped
for pre-dewatering to hydro cyclone. The flow rate is monitored by flow meter. Hydro cyclone
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underflow flows to product centrifuges. Liquid fraction’s flow rate of product centrifuges is mon-
itored by flow meter and is collected in vessel and pumped to cold leaching first step. De-
watered solids from product centrifuges (moisture 6 % or less) are conveyed to drying section.
Conveyor belts leading to drying section are equipped with K2O measurement and belt weigh-
er.
Furthermore there is envisaged that there is a possibility to bypass first cold leaching step. In
this case cleaner flotation concentrate is sent directly to second cold leaching.
The underflow of thickeners is monitored by checking the density.
The thickener receives optional flocculant reagent, which supports settling of fine particles in
the thickener.
An overhead crane is installed above cold leaching and product dewatering process section to
ensure hoisting of huge equipment in case of repairs and maintenance.
pumps. Flow rates are monitored with flow meters.
Furthermore a K2O measurement device and moisture measurement device is installed at vac-
uum belt filters.
Main equipment in cold leaching and product dewatering section will be:
• Vacuum belt filters
• Thickeners
• Centrifuges
• Agitated tanks
• Pumps
• Belt conveyors
• Hydro cyclones.
Details regarding the cold leaching and product dewatering section are set in:
• PID Cold leaching and product dewatering (Drawing No. 1357 and 1358)
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7.4.4.7 Scavenger Flotation
Scavenger flotation section contains generally following processing step:

• Scavenger flotation for concentrating KCl in flotation concentrate
The scavenger flotation process section is executed in two parallel production lines (line A and
B).
Scavenger flotation is charged with rougher flotation tailings, flotation reagents from central
flotation reagent dosing plant (into first scavenger flotation cell) and reclaim brine for genera-
tion of necessary solid content. Scavenger flotation concentrates flow directly to cleaner flota-
tion. Scavenger flotation tailings are pumped to tails leach tank.
The scavenger flotation consists of nine flotation cells installed in line. From there a stepwise
concentration of concentrates is realized due to the interconnection of scavenger flotation cells.
Scavenger flotation is designed as 9 cell agitated flotation machine with a single cell volume of
approx. 8 m³. Flotation machines are equipped with its own level regulation. Flotation machines
are self-aerating, due to the generating of under pressure by the agitators. Surrounding air
flows into the cell through a hollow shaft. So, no external supply of compressed air for flotation
is needed. Flotation time will be according to flotation test work in laboratory 6 minutes. Scav-
enger flotation is furthermore fed by frother reagent and collector reagent from central flotation
reagent plant. Frother reagent and collector reagent are fed into the hollow shaft of the first
flotation cell.
An overhead crane is installed above scavenger flotation process section to ensure hoisting of
pumps. Flow rates are monitored with flow meters. Scavenger flotation feed and flotation tail-
ings are monitored by K2O measurement.
Main equipment in scavenger flotation section will be:

• Flotation machines
• Pumps.
Details regarding the scavenger flotation section are set in:

• PID Scavenger flotation (Drawing No. 1355 and 1356)
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7.4.4.8 Tails Process
Tails process section contains generally following processing steps:

• Leaching of KCl in agitated tank
• Separation of solids and generation of reclaim brine in thickener
• Dewatering of thickener underflow by vacuum belt filter
• Conveying of dewatered tailings to tailings pile.
The tails process section is executed in two parallel production lines (line A & B).
Scavenger flotation tailings are collected in agitated vessel and mixed with process water to
leach remaining KCl out of the solid fraction. From there the suspension is pumped to hydro
cyclone for pre-dewatering reasons. Hydro cyclone underflow is collected and then free flowing
to vacuum belt filter for dewatering. Hydro cyclone overflow flows to thickener to separate re-
maining solids. Thickener overflow is used for reclaim brine generation and is pumped to re-
claim brine storage. Thickener underflow is dewatered together with hydro cyclone underflow
on vacuum belt filter.
Thickener underflow and hydro cyclone underflow is collected in vacuum belt filter feeding
tank. Filtrate from belt filter is collected and pumped back to thickener. Filter cake from belt
filter is washed with process water to leach remaining KCl solids and is then conveyed on belt
conveyors out of process building to tailings pile.
Conveying equipment to generate tailings pile and to distribute solid tailings on the tailings pile
is not considered.
The thickener receives optional flocculant reagent, which supports settling of fine particles in
the thickener
An overhead crane is installed above tails process section to ensure hoisting of huge equip-
ment in case of repairs and maintenance.
pumps. Flow rates are monitored with flowmeters.
Furthermore a K2O measurement device and moisture measurement device is installed at vac-
uum belt filters.
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Main equipment in tails process section will be:

• Thickeners
• Agitated / non agitated tanks
• Vacuum belt filters
• Pumps
• Belt conveyors
• Hydro cyclones.
Details regarding the tails process section are set in:

• PID Tails process (Drawing No. 1361 and 1362)
7.4.4.9 Compressor Plant
Compressor plant contains generally following processing step:

• Generation of compressed air for dedusting equipment and pneumatic valves
The compressor plant is a central unit which serves production line A and B.
The compressor plant is required to supply dedusting filters in the drying section and pneumat-
ic valves in the entire plant with compressed air.
Compressed air needs to meet the requirements of DIN ISO 8573-1 – class 3.
Following technological units require compressed air:

• Dryer dedusting Line A
• Dryer dedusting Line B
• Dryer dedusting aftertreatment
• Cooler dedusting
• Pneumatic valves.
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The compressor plant consists of three main components:

• 1 air compressor for continuous operation
• 1 air compressor for reserve
• 1 compressed air vessels
• 2 filters / coolers.
Main equipment in compressor plant will be:

• Air compressors
• Compressed air vessels
• Filters
• Coolers.
Details regarding the compressor station section are set in:

• PID compressor station (Drawing No. 1363)
7.4.4.10 Process Water Storage
Process water storage section contains generally following processing steps:

• Storing of process water
• Distribution of process water.
Process water distribution is necessary for supply of:

• Cold leaching and product dewatering section lines A and B
• Tails process section
• Drying section.
Continuous process water supply to process plant is essential for stable production of KCl.
Hourly demand of process water will be approx. 270 m³/h (without design safety factor of
20 %). The process water storage tank is designed with a capacity of 2,000 m³. This amount of
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process water is able to feed the processing plant for approx. one working shift. Process water
storage will be located outside of process building to save building construction cost.
Process water storage generally consists of an insulated tank and two redundant process wa-
ter pumps. These pumps supply the process with process water for sealing water system, cold
leaching, tails leaching and dilution of flotation reagents. Later on process water is needed for
drying section (not considered at the moment).
The distribution of process water to process is realized by two circular pipelines. Each circular
pipeline will be fed by a redundant process water pump.
Circular pipeline 1 feeds following consumers:

• Cold leaching and product dewatering line A
• Tails process line A
• Drying section line A (not considered at the moment).
Circular pipeline 1 feeds following consumers:

• Cold leaching and product dewatering line B
• Tails process line B
• Drying section line B (not considered at the moment).
Remark:
Process water storage tank is equipped with a level indication. Feeding pumps have to switch
off when maximum level of tank is reached (out of ERCOSPLAN’s scope of works).
Storage tank is equipped with an overflow pipe leading to central drainage system.
Afterwards all pumps a pressure indicator is installed to ensured correct working of pumps.
Flow rates are monitored with flow meters.
Optionally a water softening system for sealing water purposes is considered.
Main equipment in process water storage section will be:

• Process water storage tank
• Pumps
• Chemical water softening system (optional).
Details regarding the process water storage section are set in:
• PID Process water storage (Drawing No. 1364)
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7.4.4.11 Reclaim Brine Storage
Reclaim brine storage section contains generally following processing steps:

• Storing of reclaim brine
• Distribution of reclaim brine to process
• Disposing of reclaim brine surplus
• Pumping of reclaim brine back to evaporation ponds
• 2nd thickening of all thickener overflows from process for certainty purposes
• Thickening of collected rinsing water from process building drainage system
• Thickening of process suspensions in case of shutdown of process sections.
Reclaim brine distribution is generally necessary for supply of:

• Wet screening and milling process section lines A & B
• Tails process section lines A & B
• Rougher flotation process section lines A & B
• Cleaner flotation process section lines A & B
• Scavenger flotation process section lines A & B.
Reclaim brine storage consists of reclaim brine storage tanks, thickeners and centrifugal
pumps.
Thickener overflows from process are sent to an additional thickener, belonging to the reclaim
storage, because of certainty reasons. The generated thickener underflow is pumped back to
tails process section. The generated thickener overflow flows into two parallel reclaim brine
storage tanks. The reclaim brine storage tanks are operated intermitted, due to the fact that the
solid content inside the tank rises long term, even if there are only a few grams of solid in the
overflow of the process thickeners. Hence, the tanks are operated intermitted, so that from time
to time solid sediments on tank bottom can be emptied. From the storage tanks the process is
supplied with reclaim brine.
The supply of the overall process with reclaim brine is envisaged with an optimized system of
pumps feeding single consumers and pumps feeding several consumers to decrease the
number of pumps necessary for supply of process.
In general it is envisaged that the supply of:

• Partial wet screening and milling process section line A resp. line B
• As well as the supply of all flotation process section line A resp. line B
will be executed by one redundant pump.
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The supply of:

• Partial wet screening and milling process section line A resp. line B
• Tails process section line A resp. line B
• Rinsing water system line A resp. line B
• Disposal
will be executed by single redundant pumps.
A second thickener is envisaged for the case of shutdown of operation of process sections,
e.g. in the situation of repairs or frequent maintenance. Process sections will be emptied by
leading thickener’s volume flows to this “shutdown” thickener. This thickener’s underflow is
then sent to wet milling and screening process section or to disposal. Thickener overflow is
pumped back to process or to evaporation pond.
As a third thickener in the reclaim brine storage a thickener for rinsing water purposes is envis-
aged. Due to the necessity of rinsing and cleaning the process plant and its equipment, con-
taminated rinsing water is generated. Collected rinsing water from drainage system will be sent
to this thickener. Underflow will be disposed. The generated overflow feeds the rinsing water
system line A & B. Hence the rinsing water has a recycling philosophy.
Furthermore there is a surplus of brine generated in the process, so that reclaim brine partially
has to be sent to evaporation pond. So leached KCl in the brine is recycled and will be fed
again to the process in form of crystallizate.
The storage tanks are located outside to save building construction cost. The storage tanks
don’t need to be insulated due to the salt concentration. Generally all tanks in this process sec-
tion are equipped with a level indication. The level inside the tank is regulated by the afterwards
installed pumps with speed control (partial). Furthermore tanks are equipped with an overflow
pipe leading to central drainage system.
Thickeners are supplied with flocculation agent to improve settling of fine particles (option).
pumps. Flow rates are monitored with flow meters.
Main equipment in reclaim brine storage section will be:

• Reclaim brine storage tanks
• Thickeners
• Centrifugal Pumps.
Details regarding the reclaim brine storage section are set in:
• PID Reclaim brine storage (Drawing No. 1365)
• Equipment specifications (Appendix A06)
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7.4.4.12 Rinsing Water System
The rinsing water system is a central unit which serves production line A & B.
During maintenance and repair cycles it is necessary to clean pipes and equipment by rinsing.
Furthermore the production plant needs to be cleaned from time to time. Hence, a rinsing wa-
ter system should be installed inside the process building.
The rinsing water system consists of a fix installed piping system. In relevant areas of produc-
tion line A and B, flanges to install flexible pipes are envisaged. In the necessity of cleaning,
flexible pipes can be installed at these flanges to clean desired areas respectively desired
equipment and pipes.
The rinsing water system includes butterfly valves from where the supply of rinsing water can
be realized. Furthermore the rinsing water system includes pressure measurement to monitor
sufficient pressure for all places of consumption. Used rinsing water is collected at ground floor
in low points. From there the used rinsing water is pumped to a thickener for rinsing water pur-
poses.
7.4.4.13 Sealing Water System
The sealing water system is a central unit which serves production line A & B.
By sealing water, the control leakage shaft seals of the pump shaft bearings are sealed against
the aggressive agent inside the pump.
Remark:
The adding of chemicals is optional, due to the fact that there is no specific information about
the leached oxygen in the process water available.
The central sealing water system works as dynamic pressurize system with pumps.
The sealing water central unit consists of following equipment:
• Mixing vessel B1201 with storage volume of 25 m³
• Dissolution vessel B1202 with a content of 1200 l for the dilution of 25 % so-
lution zinc complex of oxyethylidene-diphosphonic acid (Zn-OEDF)
• Dosing pump P1201 – arranged as completely piped unit next to the mixing
vessel
• Centrifugal pump P1202A for central sealing water supply of line A.
Centrifugal pump P1202B for central sealing water supply of line B.
• Standby centrifugal pump P1202 – applied in case of damage of the pumps
for line A or B.
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The 25 % solution of Zn-OEDF and water (supplied in 40 l-canisters) is watered down to 1 %

solution in dissolution vessel B1202. By discharge measurement, the 1 % solution is mixed at a
ratio of one part of 1 % solution with two thousand parts of process water. That takes place in
mixing vessel B1201 by adding process water with dosing pump P1201 depending on the
amount of process water flown into mixing vessel B1201. The distribution pipelines for sealing
water are designed as branch pipes, each with spare distribution pipeline to maintain the pro-
duction in case of damages. In case of pumping plants with standby pumps, the standby
pumps are connected via ball valves to the spare pipelines. In case of single pump plants,
each pump is connected via ball valves to the distribution lines and the spare distribution lines.
These measures are required to maintain the production in case of damages at the distribution
lines.
The sealing water is filtered with reversible flow filters that consist of two filter chambers. One
chamber can be rinsed and the other one ensures the further operation of the sealing water
system without interruptions. In normal operation, both chambers are used for filtering of seal-
ing water.
Control Circuits
Within the framework of planning for KCl production plant Salar de Uyuni, six control circuits
have been integrated into the sealing water system.
Control circuits 1 and 3 control the maintenance of constant pressure in sealing water lines A
and B.
Control circuit 2 controls the process water supply from the network to mixing vessel B1201
with engine valve for compensation of sealing water losses.
In control circuit 4, 1 % solution zinc complex of oxyethylidene-diphosphonic acid is conveyed
with dosing pump P1201 – depending on the discharge measurement of the process water –
from dissolution vessel B1202 into mixing vessel B1201 in a ratio of one part of 1 % solution to
two thousand parts of process water.
Control circuits 5, 6 and 7 are differential pressure control circuits used to discover the filters’
degree of soiling and to perform the automatic backflush during operation, guaranteed by a
two-chamber reversible flow filter.
Main equipment in sealing water system will be:

• Tanks
• Pumps
Details regarding the sealing water system are set in:

• PID Sealing water system (Drawing No. 1368)
• Arrangement drawing
• Equipment specifications (Appendix A06)
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7.4.4.14 Drying Section
For details see PID A 1370 / 1371/ 1374
7.4.4.14.1 Drying and Cooling
The purpose of the drying section is to dry wet KCl from flotation process with residual mois-
ture of 6 % but with H2O content of approx. 4.5 % and convert it into a saleable product of in-
ternational standard with a requested quality of at least 95 % KCl and minimized amount of
0.3 % H2O or less.
Drying and subsequent cooling of KCl is envisaged in a vibrating fluid bed dryer/cooler unit.
Advantages in comparison to a separate arrangement of dryer and cooler are opposed at the
end of this chapter. In the following paragraphs, there is a description of the principle of fluid
bed dryer/cooler.
Inside vibrating fluid bed dryer/cooler the product is treated by causing it to vibrate on a perfo-
rated surface where air is blown in. Continuous air flow and vibration are separating and fluidiz-
ing individual particles and maximizing the surface area of material. In accordance, the rate is
increased at which heating and drying but cooling as well will occur. The vibration of the pro-
cessor also serves for uniform and continuous transportation of the material along a defined
pathway according a "first in/first out" method.
This equipment has two processing zones. In the first zone of the dryer/cooler moisture is re-
moved from KCl by blowing in hot air which is heating the product. Hot air has a high potential
for dehumidifying the product down to 0.2 % H2O. Hot air is generated by gas burners. There-
for cleaned but still hot exhaust air from cooling is reused and blown with recirculation fan
through gas burner where it is indirectly heated up to 450 °C. As heating media for burners
liquefied petroleum gas (LPG) and additional ambient air is applied. LPG is stored outside pro-
cess building in a tank. A pipeline is connecting the tank with the burners. The LPG tank is not
in the scope of work of ERCOSPLAN.
During the drying process KCl is heated up to approx. 120 °C and so it needs to be cooled to
get the optimal temperature for conditioning with anticaking agent and to reduce risk of injury.
For that reason in the second zone of the dryer/cooler heated fluidized product is cooled down
to 60 – 70 °C by blowing ambient air from the bottom into the equipment.
In order to prevent the uppermost layers of fluid bed particles from being pulled into the ex-
haust stream, the fluid bed exhaust ducts have large diameters to reduce air velocity. However,
fine particles are entrained in the exhaust air from drying and cooling. Therefor fluid bed appli-
cations are requiring a de-dusting system.
According to the flotation process the drying section is arranged in two lines each with a ca-
pacity of 47.5 t/h of KCl and designed for parallel but independent and continuous operation
(regular operation mode). But design capacity per drying line is approx. 80 t/h of KCl. So in
case of disruption in one drying line it is considered to dry the entire product from flotation in
the other line of drying section (emergency operation mode). Under this exceptional circum-
stance the production in the flotation department is reduced to 80 %. The anticaking agent dos-
ing system, as part of the drying section, is executed as central facility which serves both dry-
ing lines. The drying section contains generally following processing steps:
• Distribution of wet KCl in drying line A and B

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• Drying and cooling of KCl product

• Separation of agglomerates and lumps
• Conditioning of dry KCl product with anticaking agent
• Preparation and dosing of anticaking agent
• Dedusting of exhaust gases from drying section.
Since the arrangement of both drying lines is almost identical in the following the layout of one
line is described. Differences in the layout of line A and B are mentioned in connection with
particular cases.
In the first step of drying process dewatered KCl from the belt conveyor beneath product centri-
fuge is continuously transported via inclined belt conveyor to vibrating feeder placed in front of
the dryer/cooler unit. Vibrating feeder has the same conveying direction as the dryer/cooler to
ensure an optimal distribution of wet product inside the dryer/cooler.
In the next step after wet product has entered the dryer/cooler it is dried with hot air and after-
wards cooled with ambient air by using the principle of fluidized bed. With regard to the drying
and cooling of mineral materials such as KCl this technique is very reliable and well approved.
Under certain conditions it is advantageous to combine it with a water cooling system to make
this equipment more effective in achieving the required temperature but due to the low ambient
pressure water cooling is not necessary.
Dried KCl product is leaving the dryer/cooler via chute to bucket elevator. Inside the chute an
iron grid is installed to separate lumps and agglomerates. Such particles may temporary occur
during start up und shut down of dryer/cooler unit but from the “Cold leaching and product
dewatering process section” as well. Agglomerates have no influence on the drying process.
Lumps will be collected in a small container on ground floor. With regard to the composition
and quality of this by-product it has same properties like the produced standard KCl but higher
grain size. Therefor it can be sold as B-Product.
After the KCl has been dried and cooled it is transported vertically via bucket elevator. Due to
the characteristics of dry KCl product, a sticking of KCl product at the buckets is not given. Af-
terwards the bucket elevator the dry KCl product flows freely via chute into a double-trough
screw mixer with horizontal mixing shaft. There KCl is treated with 1 l/t of liquid anticaking
agent based on process water. This solution containing the dissolved reagent is sprayed into
the product inlet of the mixing device to gain a better distribution. Inside the mixer the surface
of KCl crystals is coated with reagent. Coating of the KCl causes a much better flowability and
improves handling of the product during transportation and storing. Conditioning of the prod-
uct with this water based anticaking agent humidifies the product but residual moisture should
not exceed 0.3 %. From the mixer of line A the finished product is leaving drying section
through a two-way distributor onto one of two inclined belt conveyors. The other inclined belt is
fed with product from mixer of line B. Both conveyors are independently transporting the KCl
product from every drying line to storage. Due to the distance between mixer of line B and the
inclined conveyors to storage one additional horizontal belt conveyor is needed for drying
line B. From this belt product is passing through a two-way distributor. The two-way distributors
of line A and B allow switching between conveyors to storage in a case of emergency respec-
tively the operation of only one drying line.
The anticaking agent is prepared in the “Anticaking agent dosing station” where fine-grained
powder of potassium ferrocyanide and sodium carbonate is dissolved in process water (for
explanation see abstract “Post Treatment”). The prepared solution is then pumped to the mix-
ers of drying section.
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During the process of drying and cooling exhaust gas is generated that contains a certain
amount on fine KCl dust. The dust needs to be separated from exhaust air by filters comply
with environmental regulations and standards and to minimize product losses. Therefor per line
are installed two bag filters for the dryer/cooler and one for conveying equipment of dried KCl.
Exhaust air is sucked inside the filter with a fan what causes negative pressure inside the bag
house filter. The bag filter housing is generally designed for a low-pressure of 50 mbar whereas
low-pressure of maximum 30 mbar is available during normal operation. All the air taken in is
forced to stream through the filter tubes toward the upper exit. These bags are holding the dust
back and therefor need to be cleaned regularly. The cleaning is carried out via compressed air
(6 bar). Here electrically controlled compressed air pulses are provided section-wise (e.g. filter
tubes 1-3-5-x and in the next step 2-4-6-x) in a predefined timing.
Pulse duration is about 60 ms and is gauged such that the filter area is cleaned sufficiently.
Nevertheless, cycle and break times are variable and can be adapted to operating conditions.
It should be added that cleaning can be carried out via vibration as well. However, this method
is not recommendable especially in the potash field due to various disadvantages.
In case compressed air is used, it is differentiated between time-controlled, differential pressure
controlled and pre-pressure controlled operation mode. All three modes are considered to be
continuous processes.
Cycle times and compressed air are defined for time-controlled cleaning.
During pure differential pressure control the cleaning is carried out with fixed compressed air
depending on differential pressures measured in the filter sections.
For the pre-pressure controlled cleaning the compressed air demand is regulated via continu-
ous adaption of the cleaning pressure depending on the operating conditions.
Thereby the compressed air demand is minimized, amount of dust is more even, capacity of
dust discharge can be better utilized and finally mechanical stress including abrasion of bag
filters is minimized.
An exhaust fan is transporting filtered air from drying zone of dryer/cooler to environment
though filtered air from cooling zone of dryer/cooler is sent back to drying with recirculation fan
to save thermal energy. KCl dust is discharged from bag filters into a vessel where it is dis-
solved and pumped back to cold leaching step. Hence, product will be saved.
the tank is regulated by afterwards installed pumps with speed control. Afterwards all pumps
pressure indicators are installed to ensure correct working of pumps. Centrifugal pumps in this
process section are supplied with sealing water from sealing water system.
An overhead crane with a lifting force of 200 kN is installed above drying section to ensure
hoisting of huge equipment in case of repairs and maintenance.
7.4.4.14.2 Post Treatment
Potassium chloride is a hygroscopic material. Especially after drying and cooling KCl has high
affinity to absorb water. Therefor application of anticaking agent is necessary to avoid agglom-
eration and clumping of product.
After the product has left the cooler it is fed to a mixer. Anticaking agent solution is also
sprayed into the inlet of the mixer to optimize pre-distribution in product stream. During mixing
process the anticaking solution is coating KCl crystals on the surface and prevents a water ad-
sorption from ambient.
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The anticaking agent dosing system is executed as a central facility for drying line A & B.
The required reagents are delivered to plant site by truck. The anticaking agent dosing system
consists of:
• Big-bag discharge system consisting of two big-bag discharge stations
• Anticaking solution dosing station
Anticaking agent dosing system is located in the process building in the drying section on plat-
forms +9m and +18m.
The anticaking agent dosing system is operating automatically and consists in general of two
big-bag discharge stations, two agitated vessels and three dosing pumps.
Two anticaking reagents are required for the conditioning of KCl. They are delivered and stored
in big-bags. For application of these two reagents two discharge stations are necessary.
The big-bags are lifted by crane in the discharge station. These big-bags are automatically cut
by knives and emptied into buffer container.
The anticaking reagents are added by screw conveyors into the repulping tank and dissolved
with water. After the dissolving process the anticaking solution flows into the agitated vessel
from which the solution is continuously delivered to the mixers in both drying lines by dosing
pumps.
Selection of Anticaking Agents

In the process industry different chemicals are applicable to prevent products from caking.
In the food and salt branch following reagents are common:
- Fat alkylamine
- Potassium ferrocyanide (K4[Fe(CN)6]) combined with sodium carbonate (Na2CO3)
- Sodium ferrocyanide (Na4[Fe(CN)6]) combined with sodium carbonate (Na2CO3)
Potassium ferrocyanide (K4[Fe(CN)6]) and sodium ferrocyanide (Na4[Fe(CN)6]) are very similar
molecules with similar mode of action. Application of both chemicals is possible.
In order to avoid an additionally contamination of the product with Na+ ions, we decided to use
potassium ferrocyanide.
For the selection between K4[Fe(CN)6] and fat alkylamine, it is important to compare the differ-
ent solvents.
Potassium ferrocyanide (K4[Fe(CN)6]) and sodium carbonate (Na2CO3) solve optimally in water
at 40 °C. It forms a homogeneous liquid mixture. It is necessary to temper the solution at 40 °C.
The optimum KCl temperature (after cooling) for coating process is circa 60 °C.
Fat alkylamine can be added in different ways to the product:

Var. 1. Solid as granulate at 80 °C to 100 °C KCl temperature. An exact dosing and proper
mixing of the solid is required.
Var. 2. Homogeneous solution with gas-oil at 60 °C minimum.
Var. 3. (Heterogeneous) water/ gas-oil/ fat alkylamine-emulsion. The solution must be
stirred and tempered continuously to avoid separation of the phase.
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Variant 1 was dismissed because exact dosing of the solid and an optimal mixing process are
difficult to realize. Furthermore, the pre-mixing with the product before the mixer is not good.
Variants 2 and 3 require delivery of gas-oil to the production plant and appropriate storage as
well. Gas-oil consumption is approximately 265 l/h.
Additionally, there are safety concerns for handling with gas-oil at temperatures of 50 °C –
60 °C. Therefore, increased safety standards are necessary.
Furthermore, variant no.3 requires constant stirring for emulsification.
Fat alkylamine is generally sensitive to high temperatures and tends to stick during transporta-
tion and storing.
After these considerations, the combination of potassium ferrocyanide and sodium carbonate
was preferred as anticaking agent. Water with a temperature of 40 °C is used as solvent.
Safety note
The handling of Potassium ferrocyanide (K4[Fe(CN)6]) and sodium carbonate (Na2CO3) has to
be under consideration of available material safety data sheets. According to these data
sheets, the both chemicals can be hazardous.
Anticaking Big-Bag Discharge System

The first part of anticaking agent dosing system is the big-bag discharge system. This facility
consists of two big-bag discharge stations which are erected on the platform +18m in the dry-
ing section.
The big-bags with anticaking chemicals are lifted by hoisting equipment and stored on platform
+18m. The size of anticaking big-bag is assumed:
• 0.8m x 0.8m x 0.8m for potassium ferrocyanide (K4[Fe(CN)6]) with approx. 500 kg
• 0.8m x 0.8m x 0.5m for sodium carbonate (Na2CO3) with approx. 300 kg
The stock amount is designed for an operating time of approx. one week. There are three big-
bags of each chemical, which must be lifted weekly on the platform +18m.
Each of two discharge stations has its own crane for hoisting the big-bag into the discharge
equipment. In the discharge station the big-bag is automatically cut by knives and emptied into
buffer container. Pneumatic actuated fittings loose up hardened material of big-bag.
From the buffer container the reagent are added by screw conveyor to repulping tank for dis-
solving. The repulping tank is a part of anticaking solution dosing station.
Big-bag discharge system is equipped with an aspiration system for dustless operation.
Anticaking Solution Dosing Station

In the second part of anticaking agent dosing system both chemicals are dissolved in water to
prepare the anticaking agent solution. Further the solution is pumped to the mixers, where the
dried KCl is conditioned. Location of anticaking solution dosing station is platform +9m.
The preparation of anticaking agent solution proceeds in following steps:
• Heating of water and filling of the repulping tank
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• Dosing of potassium ferrocyanide and sodium carbonate by dosing stations

• Dissolving of solids in water by stirring
• Emptying by gravity into agitated vessel
• From the agitated vessel the solution is discontinuously pumped to the mixer
The water for the preparation of anticaking agent solution is heated by flow-type heater up to
40 °C. After the water the solid anticaking agents can be dosed by screw conveyors into the
repulping tank. The required amount of chemicals and water are shown in Table 8.
The operation mode of the repulping vessel is discontinuous. It is considered to prepare 285 l
of anticaking agent solution for one batch. This amount is calculated for 3 hours of operation.
After approx. 20 min stirring time the solid agents are completely dissolved and the repulping
tank can be emptied into the agitated vessel. Repulping tank is emptied by gravity because it is
placed on the frame above the agitated vessel. Because of this arrangement, no pump is re-
quired for emptying.
After emptying of the repulping tank new batch with anticaking agent solution can be prepared.
From the agitated vessel the solution is continuously pumped by dosing pumps to the mixers.
Each drying line is fed by own dosing pump. The third pump serves as redundance in case of
malfunction of one pump.
The agitated vessel is level-controlled. When the level of anticaking agent solution has reached
the defined minimum, the valve under the repulping tank gets a signal to open the valve and
agitated vessel is refilled with prepared solution.
According to the remaining drying section anticaking dosing pumps are designed for two op-
eration modes:
• Regular operation mode
• Emergency operation mode
The ratio of solution to product is 1 l/t. This ratio is controlled by sensor for measurement of
bulk solids after dryer/cooler and flow meter on discharge side of dosing pump. Thus, the solu-
tion flow rate is adjusted in proportion to the dry product mass flow.
The repulping and agitated vessels are designed for pressureless operation. Ventilation open-
ing of vessel is equipped with a filter for dustless operation.
The temperature in the agitated vessel, repulping vessel and pipes to the mixer is self-
controlled by flexible heating tapes. It is necessary to keep the temperature at 40 °C to ensure
quick dissolving of chemicals and to optimize storing and transportation. Therefore, the vessels
and pipes for anticaking solution are insulated.
Media Consumption
Table 8 Water and Anticaking Reagent Consumption for 3 Hours Operating Time
Batch (discontinuous) for 3 h

K4[Fe(CN)]6 Na2CO3 Water Solution
[kg/h] [kg/h] [l/h] [l/h]
33.14 14.28 285 285
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Table 9 Water and Anticaking Reagent Consumption for Continuous Dosing
Conditioning of 95 t/h product

Amounts for continuous dosing
K4[Fe(CN)]6 Na2CO3 Water Solution
[kg/h] [kg/h] [l/h] [l/h]
11.05 4.76 95 95
Remark:
The supplier of anticaking agent dosing system, considered in the detail engineering docu-
ments, cannot have any knowledge about the finally applied chemicals by GNRE-COMIBOL.
Finally applied chemicals by GNRE-COMIBOL still need to be surveyed and tested on chemi-
cal's product quality and pourability by GNRE-COMIBOL together with the supplier of anticak-
ing agent dosing system after the detail engineering phase to guarantee optimum design and
proper functioning of this facility.
7.4.4.14.3 Evaluation of Dryer and Cooler Systems (According to Existing Quotations)
Based on supplier’s quotation installation of fluid bed dryer and cooler as separate equipment
and as combined equipment including peripheral equipment have been evaluated.
In respect to the two-line process design of the flotation and due to the product volume two
drying lines with one combined dryer/cooler aggregate per line is installed. Combined dry-
er/cooler aggregate occupies less space inside the process building than separate devices
and transportation is more easy. Instead of static equipment we recommend equipment with
vibration drive to make sure product will pass the dryer/cooler in any case, even when agglom-
erates occur.
Sending back filtered but still hot exhaust air from the cooler section to the burner saves fuel
and reduces demand on thermal energy by approx. 20 %. A positive side effect is the demand
on electrical energy can be further reduced because of the recirculation fan at the same time is
feeding the drying section and one big electrical consumer per line can be saved.
For feeding of product to the dryer installation of vibration feeder is recommended. Compared
to a trough chain conveyor a vibrating conveyor assures optimal distribution of wet KCl inside
the dryer/cooler and needs less energy.
For the filter system we recommend to use separate bag house filters for drying and cooling
section instead of arrangement of cyclone-scrubber-droplet separator plus bag house filter. In
general combination of cyclones and bag house filters is proven technology but has several
disadvantages compared to application of only bag house filters. While influence to investment
costs is insignificant operating costs for bag house filters are lower and further peripheral
equipment such as pumps and tanks is not required, just as there is no demand on additional
water. Last but not least content of dust in the exhaust air from bag house filter can be reduced
to one fifteenth compared to a cyclone. In the end content of dust in the exhaust air will be less
than 10 mg/m³.
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Main equipment in drying section will be:

• Belt conveyors
• Two-way distributors
• Dryer / cooler including vibration feeder, LPG-burner, fans, dedusting filters
• Bucket elevators
• Mixers
• Agitated vessels
• Dosing pumps
• Centrifugal pumps
Regarding the equipment of drying section including anticaking details are set in:
• PID Drying / Anticaking (Drawing No. A 1370 / 1371 / 1374)
• Equipment list (Appendix A02.1)
• Equipment data sheets (Appendix A03.1)
• Equipment specifications (Appendix A06.1)
• Quotations App.Q53
• Quotations App.Q63
7.4.4.15 Product Storage
The product storage is a central unit which serves production line A and B.
Product comes from drying line A & B, each on its own conveyor belt. If there is a malfunction
of one of these conveyor belts, product can be transported on a redundant conveyor. Hence,
no shutdown of drying because of conveyor belts is necessary. Conveyor belts are equipped
with belt weigher, so that the product leaving the drying section can be registered.
The dried product arriving from the drying section has the possibility to be transported to the
product storage, to bypass the product storage by going directly to truck loading, or to be dis-
tributed between product storage and truck loading.
Product to be stored in the product storage is done by an increasing belt conveyor. Afterwards
a moveable and reversible conveyor belt generates the longish storage. Product storage’s ca-
pacity is designed with 30,000 tons of wet salt. In case of empty product storage, approx. 322
hours of production can be charged into the storage until the full capacity is reached. Hence,
the storage capacity is approx. 14 days respectively 2 weeks.
Discharging of product to truck loading will be done by automatic scraping technology. The
scraper feeds a conveyor belt leading out of the product storage. Discharge capacity will be
approx. 320 t/h.
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Afterwards product storage discharge the product is transported to truck loading on conveyor
belt. The conveyor belt is equipped with K2O measurement, moisture measurement and belt
weigher to register the final product leaving the product storage.
Product storage will be a closed building, so that there is no bad influence due to precipitation
and contamination.
Main equipment in product storage will be:

• Belt conveyors
• Two-way distributors
• Scraper
• Belt weigher.
Details regarding the product storage are set in:

• PID Product storage (Drawing No. A 1372)
• Equipment specifications (Appendix A06.1).
7.4.4.16 Truck Loading
The truck loading is a central unit which serves production line A and B.
Design Criteria
The truck loading section is designed for loading 12 h/d and 5 d/w. It consists in general of
4 silos (2 silos charging – 2 silos discharging and reverse). The truck loading section is de-
signed with a necessary minimum loading capacity of approx. 320 t/h. Hence, at two silos eve-
ry 7.5 minutes a truck needs to be loaded to transport all the product which is produced in the
potash plant (16 loading cycles per hour are necessary).
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Figure 9 Capacities of Truck Loading
Dry product from product storage is conveyed to truck loading section. Truck loading will take
place in an additional building. Dry product is split by two-way distributor to two conveyor
belts. Chutes afterwards belt conveyor drops are generally equipped with overfilling detectors
(LSA). At conveyor belt drops fine dust is generated. Dust will be separated by dedusting de-
vices, executed as bag filters including air ventilators. Separated dust is led back to conveyor
belt. Bag filters are equipped with pressure measurement to indicate filter charge.
Each of these two conveyor belts feeds alternating two silos:

• Conveyor belt H1401 feeds alternating Silo B1401 and B1403
• Conveyor belt H1402 feeds alternating Silo B1402 and B1404.
Alternated feeding principle of silos is done because of charging one silo by conveyor belt and
discharging of second silo into truck at the same time. The truck loading capacity is designed
with 20 tons, hence the capacity of each silo is > 20 tons due to possible plugging of product
inside of the silos.
Silos are equipped with dedusting device on top of the silo. Bag filters are equipped with pres-
sure measurement to indicate filter charge.
Furthermore silos are equipped with weighing cells, so that exact loading of trucks is guaran-
teed. Each silo discharge flange is equipped with five pneumatic sliders which are opening in
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case of loading one after another. Hence the truck doesn’t need to change its position during
loading. Before and after truck loading it is recommended to install a truck scale.
Sequence of Loading Cycle
• Empty truck is passing the gate to plant site

• Convertible top of empty truck has to be opened at truck waiting zone
• Empty truck has to be weighed at truck scale (for incoming trucks)
• Empty truck has to stop below free silo (silo 1, 2, 3 or 4)
• When truck loading is done truck has to drive to parking area
• Convertible top of truck has to be closed at parking area
• Loaded truck has to be weighed at truck scale (for leaving trucks)
• Loaded truck is passing the gate out of plant site.
Main equipment in truck loading will be:

• Truck scales
• Two-way distributor
• Belt conveyors
• Dedusting (bag filters including air ventilators)
• Silos
• Weighing cells.
Details regarding the truck loading are set in:

• PID Truck loading (Drawing No. A 1373)
• Equipment specifications (Appendix A06.1).
7.4.5 Description of Control Loops (Control Circuits)
For detailed logical description of control loops (control circuits) please see Appendix E8 –
Control Circuits.
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7.5 Operation Manuals
After handing over of the final Detail Engineering report, GNRE-COMIBOL will start the pur-
chase phase of technical equipment. Due to the Bolivian regulations, GNRE-COMIBOL needs
to start the purchase phase with a public bidding. Due to the necessity of the public bidding,
GNRE-COMIBOL was not in the position to fix suppliers and type of the technical equipment
during ERCOSPLAN’s engineering phase, so that ERCOSPLAN had to make assumptions.
Hence, the chapter of “Operation Manual” can only have a general character.
7.5.1 Preconditions for start-up Process respectively Notice of Start of Op-

eration
The start of the test-run and in particular start-up process is a critical interface during the com-
missioning phase. Safety risks but also risks regarding costs, schedule and quality increase
considerably once more. For all parties involved, the „moment of truth“ starts during the hot
phase of commissioning. Before the plant is started “on the push of a button”, all preconditions
should be checked minutely again and be analyzed and confirmed by the commissioning
team. This chapter provides a checklist for the pre-commissioning inspection and especially
pre-start-up inspection.
For the intended normal operation of the production plants, independent single plants will be
installed by suppliers to realize several performance steps.
Start-up of the single plants is carried out under the responsibility of the respective suppli-
er/installation company and in cooperation with GNRE-COMIBOL employees.
The supplier is also responsible for the provision of the operating material and input/raw mate-
rial.
Focal points for commissioning preparation:
1) Assembly/Maintenance
• Units installed; mechanics/technicians and operators briefed
• Spare parts and consumables available in the store-room
• Special tools and operating instructions available
• Inspection and maintenance instructions for equipment announced
• Input/raw material available
• Requirements of equipment manufacturers/suppliers catalogued (documentation)
• Inspection protocol is available.
2) Installation Check, Inspection

• Equipment, tanks and pipelines
• Tank installation – all fastening points are checked
• Pipelines in compliance with the R&I flow schemes
• Equipment, tanks, pipelines and other components identified
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• Start position of distribution chutes checked

• Installation/array of equipment regarding accessibility and handling is checked
• Cleanliness of the plant is provided, critical pipelines (hydraulic system) examined
• Sampling device checked, laboratory prepared
• Equipment
o Selection and installation in compliance with planning/drawing
o Equipment installation regarding accessibility, operation, maintenance, repair
and cleaning, compliance of emergency exits/ escape routes
Other: determination of special measures
o Appropriate mounting/fixing
o Identification
o Protection and safety devices complete
o Chute connections appropriate and leakproof
o Equipotential bonding by-passes complete (if required), position emergency
stop switch defined and checked
o Adequate closure / securing of platform openings
o Electrical grounding
o Sampling device
o Connection communication
o Connection dedusting
o Documentation
o Inspection protocols available.
3) Hydraulic Pressure Test, Cleaning and Drying (Hydraulic System)

• Pressure tests of equipment and pipelines
• Flushing and cleaning of equipment and pipelines
• Blowing-out of pipelines
• Continuous pressure tests with air
• Drying-out of process equipment.
4) Operating Materials
• Electricity
• Inspection of constant availability
• Overload setting for redistributions
• Insulation and safety regulations
• Samples from transformer oil analyzed
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• Compressed air
• Compressed-air pipeline cleaned by blowing-out
• Water from equipments removed
• Drying plant filled with adsorption agent and compressed-air pipeline dried-out.
5) Laboratory
• Laboratory furnished, laboratory staff trained
• Sampling schedule published
• Specifications for all products and input/raw materials available
• Analysis of samples in the laboratory defined.
6) Equipment – Auxiliary and Monitoring Facilities

• All plants
• Measuring devices and control systems checked
• Electrical drive motors
• Direction of rotation checked
• Drying-out finished
• Successful performance of idle test runs
• Auxiliary systems for lubrication and cooling checked
• Instrumentation and rotation speed control checked.
7) Preparation for Operation

• Operating log sheets available
• Auxiliary equipment, flexible tubes and ladders available
• Other supply auxiliary equipment such as lubricants and additives available, order or
material requisition sheets available.
8) Safety
• Protective clothing, helmets, work gloves, lamps
• Safety regulations for power blackout, fire etc. available
• First-aid and medical care/treatment guaranteed
• First-aid-kits, blankets, portable stretchers, medicine, reanimation devices ready for use.
9) Fire Protection
• Portable fire extinguishers ready for use
• Fire extinguishing procedure planned
• Fire brigade informed/organized.
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7.6 Utilities
7.6.1 Electrical Power Supply
7.6.1.1 Energy Demand
The amount of electrical energy demand is required for the production of 700,000 t/y KCl,
based on a flotation process.
The calculation is based on following basic information/assumptions:
• Calculated installed electrical power for flotation process, wet salt storage, product
storage and truck loading
• Factor for coincidence, working load and power factor (experienced data from analog
plants)
• Energy demand for drying equipment (experienced date from analog plants)
• Energy demand for necessary plant parts outside of ERCOSPLAN battery limits (experi-
enced data from analog plants).
The calculation of the electrical energy demand is attached to this report in Appendix E2. For
the KCl plant a total electrical energy demand of
Ptotal = 11 MVA
is required.
The power supply of the KCl plant will be realized in two phases:
- Phase 1: Without connection to the local grid via generator power station
- Phase 2: Electrical power supply via local grid (final variant).
7.6.1.2 Power Generator Station
The generator power station has to be erected in modules with units of 8 pcs. en-
gines/generator. Each unit is provided with a power of 1.9 MVA, they are each installed in a
separate 40-feet-container and delivered in bloc to the building site.
Following plant units are arranged in the individual containers:
• Diesel engine
• Generator 1.9MVA / 6kV
• Day fuel tank for diesel
• Control system for complete unit
• Engine cooler (will be installed on the container roof).
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7 pcs. engine/generator units are required for the running operation of the production plant.
One additional unit is permanently maintained rotational.
The energy of generators is fed into a 6kV generator switch gear which is installed in a sepa-
rate container.
According to the planning, diesel is stored in two supply tanks. Both tanks are also installed in
separate 40-feet-containers and are delivered to the building site en bloc.
Electrical energy is fed via cable to the 6kV switch gear SM which is installed inside the power
station.
The generator power station should be set up as turnkey system. It is only used up to the
commissioning of the electrical power supply via local grid.
Arrangement of the power generator station is presented in drawing E2504.
7.6.1.3 Power Supply via Local Grid
The final electrical energy supply of the KCl plant is made from the Bolivian energy supply net-
work. Energy supply of the industrial plants within the Salar de Uyuni shall be made via 230kV
overhead line.
An electrical power transformer substation 230kV/24.9kV is built in the Salar de Uyuni area as
central supply station from where energy is fed via two cable systems into the 24.9kV switch
gear within the power station of the KCl plant.
Power supply terminals of the 24.9kV switch gear of the power station KCl plant are defined as
power limit.
Delivery, installation and connection of both 24.9kV cable systems between central electrical
power transformer substation 230kV/24.9kV and power station KCl plant is not scope of the
present Detail Engineering.
7.6.2 Process Water Treatment
Delivered process water temperature is between 12 and 18 °C. Process water must have suffi-
cient quality for processing needs.
7.6.3 Waste Water Treatment
Waste water treatment is osbl (outside battery limits). A waste water treatment plant should be
installed by GNRE-COMIBOL.
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7.6.4 Rain Water Drainage
The rain water from the roofs of the production building and from the wet salt storage will be
collected in separate retention basins, where the rain water will evaporate. The relative low pre-
cipitation allows such simple solution.
For the roofs of the production building two basins of approx. 400 m³ will be enough; for the
wet salt storage two basins of approx. 200 m³ will be enough. For the drainage of in-plant
roads several basins will be arranged.
7.7 Processing Facility Infrastructure
7.7.1 Energy Supply and Electrical Distribution
7.7.1.1 Energy Source Generator Power Station
8 generator systems, each with a power of 1,900kVA, are installed in the power station for the
energy supply of the KCl plant.
Considering that one generator system is permanently switched-off for maintenance purposes,
a maximum continuous power of 13,300kVA is available. Only for a short time, e.g. for activa-
tion operations, generator can be overloaded up to 10 %.
Connection and disconnection of the diesel/generator units is manually depending on the re-
quired power of the entire plant. The associated control system is included within the scope of
delivery of the generator power station.
Electrical energy is fed into the 6kV switch gear SG which is installed inside the container of the
generator power station. This switch gear is also included in the turnkey scope of supply of the
generator power station.
Energy transport from 6kV switch gear SG to 6kV main switch gear SM in the power station at
the process building is made via two separate cable systems. Each of the cable systems has to
be designed for transfer of the entire generator power.
7.7.1.2 Energy Source Local Grid
This type of energy supply is the final version and will be put into operation as soon as follow-
ing upstream plant units are ready-to-operate:
• 230kV overhead line
• 230kV/24.9kV power transformation substation
• 24.9kV cable connection between substation and power station KCl plant.
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Energy is fed via two separate cable systems into the 24.9kV switch gear of the power station
KCl plant.
This switch gear consists of 6 cabinets (see drawing E2001 and E2004):
• Cabinet 1: Feed 1 from 230kV/24.9kV substation
• Cabinet 2: Feed 2 from 230kV/24.9kV substation
• Cabinet 3: Coupling
• Cabinet 4: Measuring cabinet
• Cabinet 5: Outgoing 1 to transformer 1.01 (12.5MVA 24.9kV/6kV)
• Cabinet 6: Outgoing 2 to transformer 1.02 (12.5MVA 24.9kV/6kV).
Energy supply of the 6kV main switch gear SM is made via transformer 1.01 and 1.02.
Considering a power demand of 11MVA for the entire plant, energy supply of the KCl plant
shall be realized via 2 transformers each with a total power of 12.5MVA.
Thus, following requirements are guaranteed:
• During normal operation with two transformers, these work in a low-loss operating
range.
• In case of failure of one transformer, the operation of the entire plant is possible via the
second transformer.
• When operating the plant with two transformers, enough power reserves for a possible
increase of the production capacity are available.
7.7.1.3 Power Distribution
7.7.1.3.1 General
Main system for power distribution in the KCl plant is the 6kV main switch gear. All electrical
energy consumers of the KCl plant are directly/indirectly supplied via this switch gear.
• Supply 6kV level: In the KCl plant, altogether 7 motors with a power of 350kW respec-
tively 500kW are installed. The motors are directly connected to the 6 kV main switch
gear SM.
• Supply 0.69kV level: Supply of the 0.69kV consumer is made from 6kV main switch
gear SM via transformers 1.6MVA...6kV/0.69kV. These transformers supply the 0.69kV
motor control center MCC.
• Supply 0.4kV level: Supply of the 0.4kV consumer is made from 6kV main switch gear
SM via transformer 1.6MVA 6kV/0.4kV. These transformer supply 0.4kV main switch
gear.
(Power supply system see drawing E2000)
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7.7.1.3.2 6kV Main Switch SM
(see drawing E2002 and E2005)

This switch gear has following characteristic features:
• Nominal voltage: 7.2kV
• Operating voltage: 6kV
• Nominal current: 2000A
• Type: switch gear with gas-insulated switches
• Number of cabinets: 28
This switch gear is divided into two sections that are connected via cable-coupling:
Section 1
• Feed of transformer 1.01 (24.9kV / 6kV)
• Feed1 of 6kV Generator switch gear SG
• Outgoings transformers 6kV/0.69kV
• Outgoings motors
Section 2
• Feed of transformer 1.02 (24.9kV / 6kV)
• Feed 2 of 6kV Generator switch gear SG
• Outgoings transformers 6kV/0.69kV
• Outgoings transformer 6kV/0.4kV
• Outgoings motors
The switch gears are placed at the ground level in the power station.
7.7.1.3.3 0.69kV Main Switch Gear
(see drawing E2011 – E2020 and E2031 – E2040)

The switch gears have to be designed as motor control center (MCC) and to be delivered as
draw-out unit system.
For the supply of the 0.69kV consumer in the KCl plant, 10 pcs MCC (excluding drying) are
envisaged.
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Basically, MCCs are structured as follows:

• Feed from transformer 1.6MVA 6kV/0.69kV
• Coupling
• Motor control cabinets
• Cabinets with outgoing switches to substations
• Cabinet for automation unit
• Automatic reactive power compensation.
During planning phase of which gear has to be connected with which MCC, affiliation of gears
to both technological production lines A and B has been considered. For increasing the supply
guarantee it is possible to connect the MCC for example via coupling switches and mounted
busbars in case of failure of one transformer.
With this type of operation, two transformer maximum are allowed to feed into the MCC for rea-
sons of short circuit protection. This has to be ensured via interlocking system between feeding
switches and coupling switches.
The switch gears are placed on the +12.60m platform in the power station.
7.7.1.3.4 0.4kV Main Switch Gear
(see drawing E2071 – E2086)

The switch gears have to be designed as draw-out unit system, too.
The 0.4kV main switch gear is provided for the supply of the lighting and socket system inside
and outside the KCl plant.
The switch gear is structured as follows:
• Feed from transformer 1.6MVA 6kV/0.4kV
• Cabinets with outgoing switches to substations.
0.4kV sub-distribution panels that are installed within the plant section are connected to this
switch gear. Energy supply of lightings and sockets is made via sub-distribution panels.
The 0.4kV-switch gears are placed on the +12.60m platform in the power station.
7.7.1.3.5 Transformer
According to GNRE-COMIBOL’s request, basically oil insulated transformers shall be used.

Transformer 1.01 and 1.02
• Primary nominal voltage: 24,9kV +/- 2 x 2.5 %
• Secondary nominal voltage: 6kV
• Max. power loss: 78kW
• Short circuit voltage: 6 %
• Vector group: YynO.
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Transformer 2.01 to 2.08

• Primary nominal voltage: 6kV +/- 2 x 2.5 %
• Secondary nominal voltage: 0.69kV
• Max. power loss: 18.5kW
• Vector group: Dyn5.
Transformer 3.01
• Primary nominal voltage: 6kV +/- 2 x 2.5 %
• Secondary nominal voltage: 0.4kV
• Max. power loss: 18.5kW
• Vector group: Dyn5.
The transformers are located at the ground level in the power station.
7.7.1.4 Grounding / Equipotential System / Lightning Protection
7.7.1.4.1 Grounding System
All buildings have to be equipped with a separate grounding system which consists of follow-
ing subsystems:
• Foundation earth electrode
• Band iron loops from stainless steel, which are installed under the foundations of the
buildings.
• The ends of these foundation earth electrodes are led un-insulated out of the foundation
and are connected with the steel construction of the building and the remaining ground-
ing system.
• Depth earth electrode
• Components of the grounding system of the single buildings have to be interconnected
(intermeshing).
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7.7.1.4.2 Equipotential System
In order to avoid unduly high touch voltages for the operating staff, all continuous metallic parts
of the production plant have to be connected among each other and in addition with the
grounding system. That regards following parts of the plant:
• Building construction
• Pipelines
• Frames of plant equipment
• Cable trays
• Control cabinets
• Substructures (e. g. belt conveyor systems, pipelines).
7.7.1.4.3 Lightning Protection System
The buildings and plant facilities have to be equipped with a lightning protection system that
consists of following components:
• Outside lightning protection system
For that system, lightning arresters have to be installed on the roofs of the buildings and
conveyor bridges as well as on the chimneys. These arresters have to be connected
with the metallic roof constructions and, via down conductor lines, with the grounding
system.
• Overvoltage protection
All over-voltages induced into the cable by a lightning strike are directly diverted to the
grounding system via lightning arresters.
7.7.2 Automation System
7.7.2.1 Control Philosophy
For the entire production process, three different control options have to be realized for all
gears, which can be optionally activated.
• Interlocked central control (selected from operator station central control room)
All processes run fully automated. Abnormalities from standard operation conditions are
visually and acoustically displayed at the operator station of the central control room. In
case critical conditions occur, endangered plant components are switched-off automat-
ically.
This type of control is the preferred option.
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• Un-interlocked central control (selected from operator station central control room)
This type of control shall only be used in exceptional cases and only for limited opera-
tional areas. All system conditions are displayed in the central control room. Necessary
switching operations are carried out manually by the operator.
• Local control (selected from local control box)
This type of control is only for test purposes after repairing works. Corresponding gears
are activated via local control boxes. The control is carried out without interlocking sys-
tem.
During development of software for plant control, Appendices E8 and E9 (control circuits and
interlocking system) have to be considered.
7.7.2.2 Control System
7.7.2.2.1 Architecture
The control system is divided into three system units:

• Operation level
• Control level
• Field level.
Data transfer between these units is made via Ethernet respectively profibus systems.
The process control system PCS 7 from SIEMENS serves as basis for the present Detail Engi-
neering planning. However, it is also possible to use analog systems of the same quality.
7.7.2.2.2 Operation Level
Information about the process flows and process status in the potash plant as well as their
manual influence is carried out by operator stations assigned to the individual production sec-
tions according to the requirements.
Table 10 Operator Stations
Operator Station Location Function

OS1 Central control room Processing of process software in continuous pro-
power station duction process
OS 2 - 4 Central control room Main operator station

power station Visualization and interference of all process flows
in the KCl plant
OS 5 Administration building Information management
OS 6 Central control room Organization of preventive maintenance of the en-
power station tire plant equipment
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The exchange of data with the automation stations AS well as the manual access to the opera-
tion stations is organized by redundant route control servers.
Table 11 Control Servers
Server Location Function

1 Central control room Routing data between AS1 (PLC1) /AS2(PLC2)
power station
2 Central control room Routing data between AS3 (PLC3) /AS4(PLC4)
power station
3 Central control room Batch-/ Archive-server
power station
ES Central control room Engineering-Station
power station
The structure of the operation level is shown in drawing E2300.
7.7.2.2.3 Control Level
Actual control of the process is made via automation stations AS1 (PLC1) to AS4 (PLC4).
Via the programmable CPU’s installed in these automation stations, processing of data and
realization of control tasks is performed according to the control philosophy. The inputs and
outputs of the signal units are logically linked.
Data transfer from the peripheral control units ET from the field level is made via Profibus DP
cables.
Table 12 Location and Function of Automation Stations AS1 to AS4
Automation station Location Function

AS1/PLC1 Central control room Master station for slave stations :
power station ET01,ET03,ET05,ET07,ET011,ET71,ET73,ET75,ET77,
Frequency converter MCC1,3,5,7, 9
Thickener Line A
Pneumatic valve cluster 1 - 10
power station ET02,ET04,ET06,ET08,ET72,ET74,ET76,
Frequency converter MCC2,4,6,8, 10
Thickener Line B
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ET53,ET55,ET61,ET63
Belt weigher, Portal scraper, Dosing plant
ET54,ET56,ET62,ET64
Belt weigher, Portal scraper
All technical details for the four automation stations are presented in drawings E2301 – E2304.
7.7.2.2.4 Field Level
In the field level, data and test results of following plant components are recorded:
• Local control boxes
• Measurement equipment
• Limit switches
• Sensors
• Operating conditions of the technological equipment.
Following plant equipment are activated via control equipment in the field level:
• Contactors MCC
• Magnetic valves
• Frequency converter
• Separate control cabinets for technological units (thickener, portal scraper).
Information transfer towards this plant equipment is made via multi-core copper cables or Pro-
fibus DP cables.
Local control tasks are realized via peripheral control units ET (remote input/output RIO). In-
formation transfer towards this plant equipment is made via multi-core copper cables or Profi-
bus DP cables.
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Table 13 Location and Function of Automation Stations ET

ET 01 0.69kV-MCC1 DI/DO MCC control system
ET02 0.69kV-MCC2 DI/DO MCC control system
ET11 6kV-Switch gear room DI/DO 24.9kV/6kV-Switch gear
ET12 Product storage DI/AI Instruments/Equipment
ET21 – ET30 Process building level 0m DI/AI Instruments/Equipment
ET71 – ET74 Process building outside DI/AI Instruments/Equipment
ET75 Wet salt storage DI/AI Instruments/Equipment
ET76 Distribution tower DI/AI Instruments/Equipment
ET77 Wet salt discharging DI/AI Instruments/Equipment
ET81 Process building / Drying level 0m DI/AI Instruments/Equipment
ET86 Process building / Drying level DI/AI Instruments/Equipment
15.5m
ET88 Truck loading DI/AI Instruments/Equipment
All technical details for automation stations ET are presented in the drawings E2305 – E2349
and E2393 – E2400.
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7.7.2.3 Instruments
The continuous production process of the potash plant requires the installation of extensive
measurement equipment in all areas of the plant. That measurement equipment is basis for the
realization of following tasks:
• Manual monitoring of processes
• Realization of control circuits
• Realization of interlocking systems
• Safety measures
• Evaluation/archiving of production data.
According to the P&ID drawings of mechanical and mining engineering, the following continu-
ous measurement devices are intended in the production process:
• Temperature measuring device
• Pressure measuring device
• Density measuring device
• Flow rate measuring device
• Level measuring device
• Conductivity measuring device
• K2O measuring device
• Bulk measuring device (belt weigher).
These measurement devices are implicated in the process control by digital signals, 4-20mA-
analog signals or Profibus DP (belt weighers).
The complete list with all required instruments is attached as Appendix A5 and A5.1.
7.7.3 Communication and Safety Equipment
7.7.3.1 Communication
a) Communication Network Configuration
For the communication in the area of the potash plant a uniform Ethernet-network has to be
realized. This network consists of intermediate distribution frames (including active and passive
components) and their connection via fiber optic cable. The communication system consists of
following main components:
• Communication server
• Main intermediate distribution frame (MIDF)
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• Building intermediate distribution frame (BIDF)

• Digital switch center (DSC)
• Digital mobile radio basic station.
b) Communication System
According to the present planning, the communication center consists of following main func-
tion blocks:
• Redundant server system
• Monitor workstations that can control all communication devices
• VoIP-system telephones
• IC-telephone-stations for the operation of EA/IC systems
• VoIP-telephone gateway for the transition from the internal network to the local tele-
phone provider
• EA/IC basis station (EA/IC electro-acoustic/intercom) for the connection of EA/IC sub-
stations on the site
• Internet service purchased from an Internet service provider (ISP).
c) Telephone System
The telephone system has to be designed as VoIP-system (Voice over Internet Protocol).
For the selection of telephone types, the local operating conditions have to be considered.
The telephones are connected to the intermediate distribution boxes via copper-data-cable.
d) Radio-Communication
It is planned to use a DMR-system (digital mobile radio) as radio system. According to present
planning, the radio system operates in the 4 m-band.
For a comprehensive site supply (exclusive of guaranteed indoor supply) on the surface it is
assumed that four DMR basis stations are sufficient.
The cross-linking of stationary radio stations is carried out by Ethernet-network.
Following function can be realized by DMR-system:
• Direct communication of handheld and
• Car radio transceivers among each other (exclusive of stationary radio station).
7.7.3.2 Safety Equipment
a) Automatic Fire Detection System

For fire detection, an automatic fire detection system will be installed in following plant areas:
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• Process building
• Power station
• Generator station
• Product storage
• Truck loading.
The system is expandable for further buildings or plants.
The central fire alarm system is accommodated in the power station. Here the central alarm is
given if the system is triggered.
On the site, there are planned substations that are connected to the central fire alarm system.
Automatic detectors, manual alarms and signaling devices are installed in areas with extended
endangerment as well as in relevant rooms.
In order to increase the functional reliability, detectors and signal transmitters are connected
via ring-bus-system to the respective substation.
Via corresponding fire service indicator panel and fire service operator panel in the substations,
the action force can catch up on the position of the triggered detector and purposively investi-
gate the reason of triggering, and if necessary initiate the firefighting.
A flash light at the outside front of the respective building, already visible over a long distance,
informs about the triggering place.
b) Video Control System

It is planned to establish a video control system on the basis of IP monitoring cameras and by
that the video signal transmission can be carried out via Ethernet.
In principle, the video control system meets one requirement:
• Monitoring of the production process by video observation of important places.
The display of the video screens is carried out in the central control room.
By choice of the IP network cameras, a flexible assignment of the video screens to the respec-
tive displays is possible. Via configuration software the assignment of camera to display can be
determined.
c) Access Control System

At the entrances, the fingerprint readers of the access control system are installed on the basis
of optical fingerprint sensor.
The fingerprints of the staff are stored together with specifications about the person and a pho-
to.
On entering and leaving the site, the employee holds his finger to the reader. With that, the
personal data are read and the entering or leaving time is recorded and stored on the server.
Authorized persons will be granted access to the factory premises, for unauthorized persons
the access is denied and an alarm will be triggered. Legitimated members of staff can access
and adequately evaluate these data.
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7.7.3.3 Video Camera Monitoring
Relevant areas at plant site are monitored by video cameras. Therefore IP-Cameras (internet
protocol cameras) with ingress protection rating 66 (IP 66) are used. The data transfer is real-
ized by Ethernet. Displaying of video camera data is available at all working station computers.
Video cameras are installed:

• At truck unloading
• In distribution tower for wet salt
• In wet salt storage
• In relevant areas of the process building (26 video cameras)
• In Distribution tower 2
• In product storage
• At truck loading station 1
For detail please see drawing E2652.
7.7.4 Water Supply (Process, Fire Fighting Water)
Process water must have sufficient quality and quantity and is delivered to plant site from West
direction. For processing needs an insulated process water storage tank is envisaged. The
process water tank is located in front of the process building to save building cost.
Firefighting is outside battery limits.
7.7.5 Waste Management
At plant site processing and sanitary waste is produced. Processing waste consists of solid,
liquid and other waste. Solid processing waste is conveyed to tailings pile approx. 500 meters
away from process building. Liquid processing waste is pumped back to evaporation pond
respectively is pumped to disposal.
Sanitary waste and other waste management is outside battery limits.
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7.8 Structural / Architectural Systems
7.8.1 General
7.8.1.1 Soil Preparation
(For arrangement see constructional drawing 3705)

According to the soil report a soil preparation nearly of the whole plant site area has to be ar-
ranged.
For this purpose both upper layers, that means both the salt crust and the peat clay, have to be
cut. The cut layers have to be replaced by another good bearing material to a level of 50 cm
above the natural ground surface. According to the proposal of the soil report this replacement
layer can consist of rough stones with grain size up to 0.5 m. For building of constructions on
the replacement layer it can be leveled with gravel sand of grain size up to 20 cm and covered
by non-reinforced concrete of 15 cm thickness. This construction was tested by the author of
the soil report during his site investigation.
The soil report proposes the use of material which can be broken off close to the salt lake.
There the required material should be available in sufficient quantity.
7.8.1.2 Buildings
Following process buildings are included in the scope of this report:

• Process building (including drying)
• Power station
• Distribution tower 1
• Distribution tower 2
• Product storage
• Truck loading
Buildings for maintenance, storages for spare parts, workshops, administration, social func-
tions, security, etc. are not included in the scope of work of ERCOSPLAN.
For arrangement of buildings, facilities and infrastructure on plant site see drawing 3001_Site
Layout Plan.
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7.8.1.3 Facilities
The following facilities will be built:

• Truck unloading
• Outside process area
• Generator station
• Tailing pile (outside battery limits)
7.8.1.4 Infrastructure
The infrastructure belonging to the production buildings and facilities includes:

• In-plant roads
• Belt conveyors
• Rain water retention
• Sewage pipe system
The sewage plant is not included in the scope of work of ERCOSPLAN. Sanitary facilities,
where sanitary wastewater will be accumulated, are only placed in the power station. Since
there a no permanent working places foreseen in the production building, there will be no sani-
tary facilities available. The size of the sewage plant will determine the sanitary facilities of
change and wash rooms of the employees and workers, which are not in the scope of ERCO-
SPLAN.
It is proposed that the sewage plant will be designed as modular wastewater treatment plant as
rotating immersion disk system.
Such modular wastewater treatment plant will be dimensioned for the actual demand. If re-
quired, a later extension is possible. The modules are supplied as pre-assembled units. The
complete plant is assembled of several modules which are arranged in parallel.
Because of the parallel arrangement of the units, it is possible to take one unit out of service
and therefore the maintenance of the plant is simple.
The units will be located on a paved surface and in case of removal it will be very simple to take
off the modules. All modules can be further used at another site.
7.8.2 Process Buildings
7.8.2.1 Process Building
(For arrangement see constructional drawings from 3200 to 3260)
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The process building has a length of approx. 115 m (including drying) and a width of approx.
85 m. The process equipment is supported on the ground floor and on three technological
main platforms. There are additional technological platforms arranged. The height of the build-
ing is up to approx. 31 m on average, in an elevated part approx. 36 m.
For access to the technological platforms, seven stairways are installed, which will also be
used for evacuation in case of fire. The walls of the stairways are constructed as masonry walls
for fire protection. The way to reach a stairway from any point inside the building may not be
longer than maximum 70 m. Because of the minimal number of persons inside the building,
minor fire load density, big height between main technological platforms and big platform
openings, the size of the fire battle block and the length of the evacuation way of 70 m are suf-
ficient.
For maintenance the whole area of the process building is provided with indoor-cranes.
The process building is a conventional braced-steel structure of standard rolled sections and
welded wide flanges supported on a foundation slab. High-strength structural bolts are used
for all connections of beams, columns and bracings.
Due to the big size of the structure an expansion joint in the steel structure between the grid
lines 9 and 10 will be arranged.
The platform covering is made of wooden floorboards of 50 mm thickness, or steel plates, or in
exceptional cases of concrete slabs. Elevated concrete slabs will be constructed in process
areas only if essential. In wet areas, the covering of steel plates and concrete slabs is equipped
with formed soffits.
Horizontal bracing of floors and roofs is provided by open structural sections. Generally, dia-
phragm capability of floors and roofs is not utilized as primary bracing in process areas. Dia-
phragm contributions from concrete decks and floors are utilized as primary load-carrying
components in office areas and roofs over electrical rooms, pump houses and similar installa-
tions. Concrete floors, roofs and checkered-plate floors are utilized for stiffness if essential.
Vertical bracing is located in exterior walls where possible.
In general, hollow structural sections are not used in areas of severe and extreme corrosion.
The roofing system consists of trapezoidal cross sections with thermal insulation and roof seal-
ing. Generally, the roof is sloped and provided with gutters and downspouts.
The process building will get siding of trapezoidal cross sections or bi-stretched PVC sheets in
the high resistance range (RENOLIT ONDEX HR) with thermal insulation. All flashing and fas-
teners are stainless with sealing washers. Inside, the wall will get a siding with wooden panels.
Windows with wooden frames will be used for lighting and natural air ventilation.
The steel structure and dado walls will be based on a foundation slab of approx. 1.0 m thick-
ness. All steel columns will be based on single pedestals of 0.3 m height.
A small channel on the surface of the foundation slab will be arranged around the building to
prevent decomposition of the salt ground by drainage of rain water from the siding of building.
The structure will be founded on a reinforced concrete foundation slab, which will be built on
the soil preparation of the plant site. The foundation slab will be made of reinforced concrete
and accommodate anchor bolts and embedded parts.
The concrete is made of sulphate-resisting cement. Because of high and severe corrosion,
foundation slab is made with a high strength of concrete, for example 45 N/mm², and an ele-
vated concrete cover.
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The production plant will be provided with heating to guarantee an inside temperature of more
than 5 °C.
7.8.2.2 Wet Salt Storage
(For arrangement see: constructional drawings from 3100 to 3121)

The wet salt storage building has following dimensions: 40 m width, 150 m length and approx.
26 m height. The storage capacity is 30,000 tons of wet salt.
Due to local climatic conditions, in winter up to -17 °C, the storage will be provided with hous-
ing.
The storage will be filled by moveable reversible belt conveyor. The charging on the shuttle
conveyor takes place approximately in the middle of the storage by an above sited belt con-
veyor from the truck unloading.
For take-out of storage a portal scraper, which will be moved over the storage area, will be
used.
For the support of the moveable reversible belt conveyor, a conveyor platform is hung up in the
roof ridge of the building. The above sited belt conveyor will be placed on top of the roof.
The dimensions of the real storage area are 133 m x 27 m. This area is bordered at the long
sides by reinforced concrete walls, which are loaded by the product filled in. The front sides will
be open for dewatering of the fill mass. There will be placed drainage channels which transport
the brine to pumping shafts.
The access to the conveyor platform will be realized via staircase tower located in front of the
storage building.
On one front side a maintenance area will be arranged for the portal scraper maintenance.
The storage area needs no ground floor. The maintenance area will be a concrete.
The roof structure will be a structure of glued-laminated timber (glulam) or a braced-steel struc-
ture of standard rolled sections. The primary roof trusses will be solid-web or lattice girders.
The roofing will be a trapezoidal cross section or bi-stretched PVC sheets in the high resistance
range (RENOLIT ONDEX HR) without thermal insulation. The siding of the gable walls will also
be trapezoidal cross sections or PVC sheets.
The primary roof trusses, the supporting of reclaimer rails and the walls of storage area will be
placed on two foundation slabs on each long side. The roof trusses will be based on single
pedestals of 0.5 m height.
The rain water from the roof will be carried by a rainwater gutter on each long side of the stor-
age. In order to retain rainwater in the case of heavy rainfall a retention basin on each side of
the storage will be arranged.
the soil preparation of the plant site. The foundation slab will be made of reinforced concrete
and accommodate anchor bolts and embedded parts.
The concrete of the foundation slabs and storage walls is made by using sulfate-resisting ce-
ment. Because of high and severe corrosion, the concrete construction is made with high
strength concrete as well as an elevated concrete cover.
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7.8.2.3 Product Storage

The dimensions and the structure of the product storage are the same as that of the wet salt
storage (see section 7.8.2.2).
Unlike the wet salt storage, the product storage area is bordered at all sides by reinforced con-
crete walls including an opening for access into the storage area. The drainage channels at the
front sides are not applied. Also other than the wet salt storage the product storage obtains a
paved ground floor of non-reinforced concrete with a sealing under it to protect the product
against rising damp.
7.8.2.4 Truck Loading

The truck loading for the loading of four trucks at the same time is a conventional braced-steel
structure of beams and columns of standard rolled sections. On the ground plan, the grid of
the structure is 5x 6.0 m x 1x 6.0 m. The length of the building is approx. 30.5 m and the width
approx. 6.5 m. The height is approx. 24.8 m.
There are platforms at the levels +4.87 m, +7.93 m, +12.61 m, and +19.27 m. The loading
bins are supported on platform +7.93 m.
For platform access, stairs will be arranged. The platforms will be covered with wooden floor-
boards of 50 mm thickness. At the stairs grid, two rooms for electric equipment are arranged
on top of each other. Erection beams and openings are placed to lift equipment to the plat-
forms.
The roof and siding will be executed with trapezoidal cross sections or bi-stretched PVC sheets
in high resistance range (RENOLIT ONDEX HR) without thermal insulation. The loading area is
covered by canopies on both sides for protection against rain.
the soil preparation of the plant site.
At the loading area the columns are protected by concrete construction against vehicle impact.
7.8.2.5 Distribution Tower 1

The distribution tower 1 is a conventional braced-steel structure of beams and columns of
standard rolled sections. The grid of structure is 7.5 m x 4.5 m (9.0 m) in the ground. There are
platforms at level +4.05 m, +7.65 m, +13.59 m, and +19.17 m. For platform access, stairs will
be arranged. The platforms will be covered with wooden floorboards of 50 mm thickness. The
roof and siding will be executed with trapezoidal cross sections or bi-stretched PVC sheets in
the high resistance range (RENOLIT ONDEX HR) without thermal insulation.
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7.8.2.6 Distribution Tower 2

Distribution tower 2 is a conventional braced-steel structure of beams and columns of standard
rolled sections. On the ground view, the grid of the structure is 3x 7.5 m x 2x 4.5 m. The length
of the building is approx. 23.0 m, the width approx. 9.5 m and the height approx. 16.0 m.
There are platforms at level +3.51 m and +9.27 m. For platform access, stairs will be arranged.
The platforms will be covered with wooden floorboards of 50 mm thickness.
Erection beams and openings are placed to lift equipment to the platforms.
The roof and the siding of the upper floors will be executed with trapezoidal cross sections or
bi-stretched PVC sheets in the high resistance range (RENOLIT ONDEX HR) without thermal
insulation. The ground floor is not sided.
7.8.3 Secondary Buildings
7.8.3.1 Power Station

The power station is designed as annex building of the process building. The power station is a
conventional masonry building with elevated concrete slabs. It has a length of approx. 40 m, a
width of approx. 14 m and a height of approx. 18 m. On the ground floor, the transformers and
the middle voltage switch gears will be placed, above those the cable tray room. The second
floor takes the low voltage switch gears and control equipment.
The transformers are oil transformers. In order to protect the underground in case of a break-
down, a collecting tray without any discharge will be placed under each transformer.
The foundation will also be a foundation slab of reinforced concrete.
The control room will be air-conditioned. A lavatory will be located near the control room.
For protection against lightning a steel construction will be arranged in front of the facades,
which connected with the steel roof structure and the steel structure of process building. All the
connections have to execute electrically conducting, so that a Faraday cage will become.
The siding will be realized with the same covering like the process building.
The power station will be founded on a reinforced concrete foundation slab, which will be built
on the soil preparation of the plant site.
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7.8.4 Infrastructure
7.8.4.1 In-plant Roads
(For arrangement see: constructional drawings 3720 and 3726)

The in-plant roads allow access to all process and miscellaneous buildings and facilities. The
normal main roads –two-lane traffic roads – will be 7 m wide. The service roads to the truck
unloading and to the wet salt storage will get a width of 4 m.
The road structure will be built on the building ground preparation (see chapter 5.2.3) with the
following layer structure:
Normal main roads and service roads:

4 cm asphalt overlay
4 cm binder course
14 cm asphalt base course
28 cm gravel as frost protection
50 cm
Heavy traffic roads (roads to truck unloading and truck loading):

4 cm asphalt overlay
8 cm binder course
22 cm asphalt base course
21 cm gravel as frost protection
55 cm
For drainage, the road is sloped to one side. The drainage will be done into the site preparation
structure across the road.
7.8.4.2 Belt Conveyors
(For arrangement see: constructional drawing 3710)

All belt conveyors are self-supporting structures with walkways on both sides. The supports
and foundations will be built on site.
In the case of an arrangement even with the ground, belt conveyors will be set directly on a
similar sub base like buildings.
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7.8.4.3 Sewage Pipe System
A sewage pipe system will be built from points where waste water accumulates to the sewage
plant. In case of impossibility of underground pipelines, a gravity drainage system cannot be
used. The waste water has to be pumped to the sewage plant. All pipelines will be provided
with heating and insulation.
7.8.4.4 Sewage Plant
See section 7.8.1.4.
7.8.5 Facilities
7.8.5.1 Truck Unloading
(For arrangement see constructional drawing from 3400 to 3403)

A truck unloading station, where the loaded bottom dump trucks coming from the evaporation
ponds will be unloaded, will be built at the plant site. For unloading, it will be erected a bridge
construction of approx. 8.5 m height. To reach the top there will be built a ramp construction
with a slope of 10 %. On it, there will be arranged two traffic lanes for the unloading of two
trucks at the same time. The total width of the access will be 10 m. The total length will be
232 m. The driveway structure will be the same like in-plant roads.
The ramp will be built with the same material like the site preparation.
The unloading point will be sited on the bridge. Under it, a bin with a discharging conveyor will
be arranged. From there the salt will be transported by belt conveyor to the wet salt storage or
to the process building.
The bin area will be bordered by the abutments of ramps. The abutments are reinforced con-
crete structures with a height of approx. 9.5 m with reinforced concrete wing walls of approx.
17 m length.
All the walls will be fixed in the foundation slab of the whole structure.
7.8.5.2 Outside Process Area

Outside in the west, north and east of the process building some technological equipment like
tanks, thickeners, and pumps have to be arranged. All these equipment will be placed on
foundation slabs of reinforced concrete. The surface will be sloped for drainage rainwater or
brine, whose will be collected in a pump pit or in the rainwater retention basins.
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7.8.5.3 Reclaim Brine Storage

Like the outside process area the reclaim brine storage is an outside area with technological
equipment and it will be founded on a separate foundation slab of reinforced concrete. The
surface will be executed sloped for rainwater and brine drainage. The rainwater and brine will
be collected in two pump pits.
7.8.5.4 Generation Storage

The generator station is a concrete paved area for assembly of electrical trailers. The drainage
will be done in a channel around the area.
7.8.5.5 Rainwater Retention Basins
(For arrangement see: constructional drawings 3721 and 3900)

To protect the building constructions in the case of heavy rainfall the rainwater from roofs and
other sealed surfaces has to be retained in separate retention basins. For calculation of reten-
tion capacity the knowledge of heavy precipitation amounts depending on duration and annu-
ality determined on extreme statistics is necessary.
Due to the missing heavy precipitation amounts depending on duration and annuality deter-
mined on extreme statistics, modificated rain data of Germany (Site Unterbreizbach) will be
assumed.
The medium yearly height of precipitation on site Unterbreizbach is approx. 600 mm. The relat-
ed rain data in l/sec*ha are following (provided by Deutscher Wetterdienst):
Table 14 Rain Data
Duration 1 year 5 years 100 years

5 min 163.3 312.6 590.5
10 min 131.7 232.7 420.7
15 min 108.9 189.3 338.9
30 min 72.2 126.6 227.8
60 min 43.3 80.1 148.6
2h 25.2 42.6 75.0
3h 18.4 29.6 50.5
4h 14.7 22.9 38.2
6h 10.7 16.0 25.9
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9h 7.8 11.2 17.6
12 h 6.3 8.8 13.4
18 h 4.4 6.1 9.3
24 h 3.5 4.8 7.2

2.1 3.0 4.7
48 h
1.6 2.3 3.5
72 h
On the plant site in Bolivia, the measured maximum between 2010 and 2012 is 1,135.3 mm,
that is approx. the double capacity as in Unterbreizbach.
For calculation of rainwater retention, the German values will be doubled. For an industrial site
usually an annuality of 5 years is used. Since statistical extreme values are missing in this case,
the values of an annuality of 100 years are used.
Calculation of retention capacity (see Appendix S8)

North-western retention basin of process building:
Connected Areas
A1 (Roof) = 85 m x 49 m/2 = 2,082.5 m²
A2 (Outside process area) = 89 m x 15 m/2 = 667.5 m²
2,750 m²
Required retention capacity: without pump --> 533 m³
North-eastern retention basin of process building:

Connected Areas
A1 (Roof) = 85 m x 49 m/2 = 2,082.5 m²
A2 (Outside process area) = 89 m x 15 m/2 = 667.5 m²
A3 (Outside process area) = 88 m x 19 m/2 = 836 m²
3,586 m²
with pump 100 m³/h --> 285 m³
South-western retention basin of process building:

Connected Areas
A1 (Roof) = 85 m x 60 m/2 = 2,250 m²
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South-eastern retention basin of process building:

Connected Areas
A1 (Roof) = 85 m x 60 m/2 = 2,250 m²
2
A3 (Outside process area) = 88 m x 19 m/ = 836 m²
A4 (Roof Power Station) = 40 m x 15 m = 600 m²
3,986 m²
with pump 60 m³/h --> 382 m³
Retention basin of storages:

Connected Areas
A (Roof) = 151 m x 40 m/2 = 3,020 m²
Retention basin of truck unloading sloped road:

Connected Areas
A (Road) = 108 m x 9 m/2 = 486 m²
Due to the limited place closed to the process building the north-eastern and the south-eastern
retention basin will be equipped with pumps.
The dikes of retention basins will be built with the same material like building ground prepara-
tion of the plant site. The sealing will be done with a PVC-membrane. For drainage of rainwater
to the basins prefabricated concrete channels will be arranged.
7.8.5.6 Tailing Pile (outside battery limits)
The tailing pile will be located approx. 500 m in the east of the plant site. The ground of the
tailing pile will have the preparation as the plant site. The disposal will be filled up there to a
height of approx. 30 m. For drainage of the brine, the leak from the filled-up mass, a dike of
compacted salt with a height of approx. 2 m, will be arranged around the filled-up mass. The
distance between dike and the base point of filled-up mass should be approx. 20 m. The brine
will be collected in that interspace and evaporate there.
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8 Project Execution
Below mentioned is a description of an execution procedure proposal, applicable for the exe-
cution structure of this project. However the execution procedure is outside battery limits of
ERCOSPLAN´s scope and is in full responsibility of GNRE-COMIBOL.
8.1 Objectives
The main objectives of the proposed project execution plan are to complete the project:
• Within (or below) the budget
• On (or ahead of) schedule
• While meeting the quality requirements and constructing the plant in the most efficient
manner
• While ensuring that health, safety, environmental and social obligations are adhered to.
8.2 Criteria
The project execution philosophy adopted also complies with the following criteria:
• Maximization of the sourcing of the equipment and materials from Bolivian or South
American Sources
• Execution by an general contractor team owned by GNRE-COMIBOL with the capacity
to manage and execute the full scope of work to be performed
• Training of residents local to the project site such that they can be productively em-
ployed during the construction phase
• Establishment of a construction-driven schedule.
8.3 Project Management
8.3.1 Mobilization and Project Kick-Off
The GNRE-COMIBOL project manager will be responsible for mobilizing a dedicated team of
senior engineers and technicians with the relevant experience to execute the project. He or she
will be responsible for implementing the necessary tools and systems to perform the work in
accordance with the methodology defined in this section of the report.
Soon after the initial mobilization, a project kick-off meeting will be held to introduce the team
members, confirm the project scope and present the project quality, cost and schedule objec-
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tives. The respective responsibilities of the GNRE-COMIBOL project execution team will be
presented as well as the communication interface methods. The purpose of the kick-off meet-
ing is also for the participants to be made aware of their roles in the overall organization and of
the expectations placed on them.
8.3.2 Project Procedures
A project procedures manual will be prepared by GNRE-COMIBOL’s project execution team to

define the important aspects of the project, including:
• Communication and organization between members of the GNRE-COMIBOL project
execution team and others
• Work methods
• Project schedule and budget
• Review and approval of technical documents
• Project coding for documents, drawings and cost control
• Project meetings and reviews
• Coordination with stakeholders
• Project monthly report format/ progress reporting
• Applicable languages
• Change order procedure
• Procurement procedure
• Visits to the project site and vendor’s workshops.
The project procedure manual is prepared at the beginning of the detailed engineering and is
maintained and updated regularly, simultaneously with the project quality plan.
8.3.3 Project Meetings
Project meetings will be held by the GNRE-COMIBOL project execution team on a regular ba-
sis to review the status of the project and to make decisions related to corrective actions. The
meetings scheduled on a regular basis shall be as shown in Table 15.
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Table 15 Project Meetings
Meeting Chaired by
Monthly overall project review with owner Project manager
Weekly engineering and procurement progress Project manager
Monthly cost review Controls manager
Weekly construction progress review Construction manager
Weekly punch list reviews Engineering department manager
8.3.4 Communications
Successful project execution involves close and open communications among all parties and
all team members.
• The project management personnel must communicate the scope, technical require-
ments, schedule, estimate, project objectives and contractual terms to the team
• An integral part of project communications is defined precisely in the project procedure
manual
• Project web-sites are used to facilitate communications, electronic transfer of data and
e-mail
• To further facilitate communications, the project team will be located in a task-force ar-
ea. This creates an environment conducive to easy communications.
GNRE-COMIBOL’s project execution team’s ability to execute its mandate from the GNRE-
COMIBOL board in an efficient, timely and cost-effective method is dependent on the availabil-
ity and accuracy of information provided by its team and others. It is therefore proposed that
the management of all information flow, normally represented in documents, should be its re-
sponsibility and should be coordinated through a computer-assisted project management sys-
tem.
8.3.5 Reporting
GNRE-COMIBOL’s project execution team must work closely with GNRE-COMIBOL project
management and therefore will provide regular reports, updates and forecasts on the project
progress. Typical reports will include:
• Man-hour expenditure against budget
• Progress against plan
• Change order control
• Areas of concern.
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Engineering data sheets, documents, drawings and other ongoing work will be submitted to
GNRE-COMIBOL project management or review and, where required, for approval. Items of
concern and plans of action will be discussed on a regular basis.
8.3.6 Project Organization
The key elements of success of a project team organization are:

• An executive steering committee
• A specific integrated organization
• The support of local branches or site organization.
The dedicated project team will be located in GNRE-COMIBOL’s project execution team’s of-
fice.
The team of engineers and/or designers should be available on site to address questions from
contractors during the construction phase of the project. They shall represent each of the major
engineering disciplines and shall report to the resident construction manager.
8.4 Project Schedule
The realization of the project follows the project implementation schedule shown in Appendix
G6.
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Table 16 Project Implementation Schedule
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8.5 Project Services and Controls
8.5.1 Overall Plan and Procedures for Project Controls
The complete engineering scope will be defined in terms of deliverables and activities. Pro-
gress templates will be set up to standardize progress measurement. Once the man-hour
budget is approved, it will be frozen and any subsequent change will be through properly ap-
proved change notices. Progress reporting will be based on an earned value method.
A control budget will be prepared for the costs associated with the scope of work. Actual and
forecast-to-complete cost will be recorded to allow status reporting and cost trending. The pro-
ject budget forecast will be revised monthly to reflect proposed and approved changes.
8.5.2 Scope Definition and Control
The complete list of deliverables and activities that constitute the scope of engineering work will
be defined, with a budget assigned to each deliverable and activity. These deliverables and
activities will be grouped into manageable segments called internal work packages (IWPs) that
can be accomplished by a discipline responsible for the work on a definite schedule. The IWPs
will relate to the lower levels of the project WBS, thus allowing proper integration of the scope,
schedule and estimate.
Internal change notices (ICNs) will be recorded and the man-hours distributed over the deliver-
ables involved in the change. The ICN man-hours will become part of the revised budget only
when approved by the project manager.
Standard earned value reports and curves will be provided for engineering progress.
8.5.3 Schedule Control
A GNRE-COMIBOL project planner will develop the implementation schedule showing detailed
activities and important project milestones. Based on the approved schedule, the planner will
provide engineering with the target dates for the issue of each IWP. Engineering will prepare
the detailed schedule for each deliverable and staffing assignment, which will be integrated by
the planner into the project schedule. A permanent baseline schedule will be maintained.
Input to purchase packages and construction contracts will be defined and target dates will be
established for issue of the technical documents required to compete packages so that the
responsible parties may issue the information to vendors and suppliers. Engineering delivera-
bles that are necessary for completing a package will be linked to such packages to ensure
timely completion.
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The GNRE-COMIBOL project planner will hold regular meetings with engineering and pro-
curement groups to review the schedule. The project monthly progress report will show the
current versus planned status for all phases of work and will highlight the critical areas.
8.5.4 Man-Hour Control
Progress measurement templates will be assigned to each deliverable so that progress can be
measured in a standardized manner and with minimum subjectivity.
As work progresses, earned man-hours will be calculated according to the template stage
reached during the reporting period. The planner will validate the physical progress information
to ensure correct progress reporting.
At the end of each reporting period, the GNRE-COMIBOL package engineer will enter forecast-
to-complete man-hours for each deliverable and activity. Spent man-hours will be collected
from the timesheet system and entered at the IWP or discipline level to calculate productivity.
Any productivity issues will be analyzed and corrective action taken.
The forecast-to-complete man-hours from the engineer will be incorporated into the planning
update cycle. Based on the forecast-to-complete man-hours, manpower forecasting and level-
ing will be done on a regular basis to ensure the most efficient use of resources. Any revisions
to manpower profiles and forecast dates will be reviewed and confirmed with engineering.
Engineering will be responsible for early identification of scope changes and their man-hours
and schedule impact. Potential scope changes will be recorded in the system with the estimat-
ed man-hours. All potential changes will be analyzed and either approved or rejected. This in-
formation will be integrated into the forecast-for-man-hours, staffing profiles and project sched-
ule.
8.5.5 Cost Control
Tight cost control will be required throughout the life of the project, quickly identifying devia-
tions so that corrective action can be taken.
Control Budget
The control budget for the project will be established and set as a baseline. Subsequently, all
cost monitoring will be carried out based on this baseline cost.
Cost Monitoring
Cost monitoring will be a continuous process in which cost trends will be recorded and moni-
tored. A monthly project cost control report will be issued showing original budget, scope
changes and transfers, forecast-to-complete, incurred, and period and overall variances.
The cost controller will interface with planning and engineering for monitoring and trending to
ensure that potential cost impacts are identified and mitigated well in advance.
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8.5.6 Project Change Control
Controlling the changes is critical to maintaining the project under its predicted cost and
schedule. Engineering changes will require approval from the GNRE project management,
where applicable, before they are initiated. Departure from approved standards or design crite-
ria will also require approval. Both these elements are important factors in controlling the
growth of the budgeted amounts.
GNRE’s project execution team will be required to submit change notices for the GNRE’s pro-
ject management whenever the project scope or schedule affects the performance of the ser-
vices. Change notices will be reviewed and discussed at regular intervals during the project life.
The project budget forecast will be revised monthly to reflect proposed and approved changes.
8.6 Construction Management
The construction management function co-ordinates, directs and supervises the work of on-site
contractors. The construction manager will also ensure that constructability and access as-
pects are taken into account in the layouts and designs and that adequate temporary facilities
and lay down areas are designed. Part of these activities has been accomplished in coordina-
tion with the selection of the different main construction contractor.
Key points in the coordination of construction activities will include:
• Provision of a well-drained and prepared site
• Clearly defined channels of communication between construction and design personnel
• Comprehensive planning of the sequencing of construction
• Control of the flow of materials
• Co-ordination of shop fabrication activities and site activities
• Comprehensive planning of all temporary construction facilities including accommoda-
tion.
During the design phase of the project, regular reviews of the engineering will be done to en-
sure that appropriate construction input is achieved. Typical features that will be examined dur-
ing the reviews are:
• Construction path and sequence
• Prefabrication and pre-assembly opportunities
• Rigging studies for heavy lifts
• Access for heavy equipment
• Safety considerations
• Scope and preparation of construction contract packages
• Practicality of design with respect to construction.
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The strategy document, which is the base for the authority approval procedure, addresses is-
sues including:
• Approach to the work
• Resource loading
• Health, Safety & environmental plan
• Waste management
• Medical evacuation
• Heavy lift transport.
Certain elements in the strategy report will be revised during the process of preparing imple-
mentation.
8.6.1 Construction Camp
Temporary living accommodation will be provided for workers and supervisory and manage-
ment personnel involved in the project construction and commissioning.
The camp size is based on preliminary estimations of expatriate construction manpower, and
will be adjusted with the different main construction contractor’s recommendations to adapt to
the construction schedule and workforce. Local manpower will find accommodation in local
community villages.
Temporary office buildings will be provided at the construction site for the different main con-
struction contractor’s personnel.
8.6.2 Safety
All construction work on the site will be carried out in accordance with a health and safety pro-
gram established by the GNRE’s project execution team. This program will also meet the re-
quirements of Belarusian regulations and applicable international industry standards.
The safety program will aim at providing the highest levels of safety for the construction work-
ers, all site personnel and visitors. The program and activities will monitor closely the actions of
the contractors and provide supplementary services in order to achieve an exemplary safe site.
The commitment will extend to close liaison and co-operation with the GNRE’s operating plant
personnel during the commissioning phase.
8.6.3 Execution Supervision
The GNRE´s construction manager will have overall responsibility for the execution of work on
site. Site engineers and inspectors will ensure technical compliance to design and standards,
and any deviations will be brought to the construction manager's attention for remedial action.
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8.6.4 Quality Control
The construction manager will be responsible for monitoring all activities affecting the quality of
the physical construction work within the project, whether the work is performed by construc-
tion contractors or vendors. The field quality assurance program will be directed towards mini-
mizing potential quality problems rather than reporting after the fact.
The site quality program will be audited in accordance with the project quality assurance plan
developed by GNRE’s project execution team’s quality assurance manager.
8.6.5 Scheduling and Productivity Control
The contractors will submit their construction schedule to meet the master schedule. GNRE’s
project execution team’s planners will review and recommend approval of the contractors’
schedules.
Weekly reviews and measurements of contractors’ progress will be performed. Problem areas
will be identified and corrective measures will be proposed to maintain the productivity and
meet the required schedules.
8.6.6 Labor Relations
The activities of the construction contractors will be monitored through weekly meetings to en-
sure strict observance of the laws and regulations governing the construction industry in the
Republic of Belarus and of the site labor relation policy, as defined for all contracts.
The responsibility for labor relations will rest with the different main contractor and other site
contractors.
8.6.7 Security
GNRE, in conjunction with the different main contractor, will establish a complete security pro-
gram to ensure protection of the physical assets during the construction phase. It will include
elements such as the site security policy, emergency telephone numbers, emergency re-
sponse plan, site patrols, communications, visitor’s procedures, and the main gates access
control system.
8.6.8 Materials Control
GNRE’s project execution team’s site materials controller will have overall responsibility for
construction materials management. The electronic project management system will be used
to plan and manage the construction materials receipts, distribution and inventory control.
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The proposed approach to material control includes:

• Indoor storage: It is strongly recommended that all electrical equipment instrumenta-
tion, pipe fittings below 2” (50 mm) and instrument cabling be stored indoors, in desig-
nated areas. Larger cable drums shall be stored outside with proper protection before
being issued for construction.
• Color coding: A system of color coding will be established pertaining to all materials for
verification against specification.
• Lay-down area: It must be taken into account that access for cranes is not only for of-
floading, but also for the removal of equipment to the site for installation.
• Any stainless steel vessels that arrive on site that cannot be installed in situ will be
stored on a layer of suitable material prior to installation.
8.6.9 Construction Waste Disposal
A waste management plan will be established in each construction contract. The plans will ad-
dress, as a minimum:
• Construction waste such as scrap metal and non-hazardous liquid waste
• Non-putrescent waste from the construction camp such as cans and bottles
• Putrescent waste from the temporary camp and temporary office facilities such as waste
foodstuffs
• Sanitary waste.
All construction contractors will be required to comply with the waste management plan.
Unless the waste is of a hazardous material, the nominated contractors will be responsible for
removal of any waste to an area allocated by the GNRE.
Any material, waste or otherwise, must have proper authorization before removal from site.
Particular procedures will be adopted relating to the handling of hazardous waste.
8.6.10 Pre-Commissioning
The pre-commissioning manager will co-ordinate, direct and supervise the work of a group of
engineers, technicians and inspectors engaged in the inspection, testing and commissioning
of equipment and systems and in the supervision of contractors’ personnel assigned to com-
missioning and performance testing activities.
The pre-commissioning manager will ensure liaison with operations personnel for the prepara-
tion of checklists showing responsibilities of GNRE, the technology supply contractors, GNRE’s
project execution team, vendors and construction contractors for pre-operational testing, cold
commissioning, hot commissioning and performance testing, and he or she will schedule these
activities.
Preparatory work will consist of detailed pre-commissioning plans and schedules, assembling
of pre-commissioning manuals and vendors' manuals. Close coordination with GNRE’s com-
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missioning team and GNRE’s project execution team’s construction management team will be
maintained throughout the preparatory and execution phases.
Pre-commissioning supervisors and their groups will have direct responsibility for carrying out
pre-commissioning work in their respective sectors. Sector engineers from the design office will
be assigned to these groups to reinforce the knowledge of process and equipment.
Pre-commissioning includes all pre-operational verifications and testing required to make the
plant ready for start-up and commissioning. The work includes the initial run-in of all permanent
equipment and services, including fire detection and prevention systems, testing of controls,
instrumentation and system run-in performances, the verification of alignment, first lubrications
and the installation of temporary facilities required as well as correction of minor omissions and
defects.
8.6.11 Commissioning and Start-up
The commissioning and start-up of an equipment facility and/or system will be the responsibil-
ity of the GNRE’s commissioning manager. During that period, the activities of GNRE’s project
execution team may cover:
• Technical assistance
• Contract administration
• Planning and scheduling
• Project controls
• Procurement and expediting services
• Vendor and/or contractor interface
• Correction of deficiencies.
The plan for the commissioning of this project calls for a two-phase commissioning program.
The commissioning of each area follows mechanical completion and hand-over from the con-
tractor to GNRE’s team. The surface facilities commissioning is normally split in two main seg-
ments, termed cold and hot commissioning. The following are the main activities in each of
these tasks:
Cold commissioning
• Loop checks
• Verification with vendor representatives
• Wet commissioning (filling up with water and transfer for process equipment only).
Hot commissioning
• Bring up to operating condition
• Hot water batch (fill up with hot water and transfer for process equipment only)
• Brine transfer, for process equipment only.
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All of the process utilities, i.e. LPG, electrical power, cooling and process water must be con-
firmed to be available prior to any commissioning activity initiation.
It is to be noted that all of the equipment supplied will have gone through the shop pre-testing
before being shipped to the site for installation. This should minimize the potential extensions
to the duration of commissioning.
The commissioning and testing programs will require that certain analysis of intermediate and
final product will be required. The construction of the laboratory and its equipment, located in
the administration building, will therefore be required to have been completed and the equip-
ment tested and calibrated prior to the start of any commissioning programs.
8.7 Overall Operations
This section covers the requirements needed to run the operations at the processing plant
along with all associated operations. The following figures based on the experiences of ERCO-
SPLAN in their over 60th years of experience in potash plant operations and are only recom-
mendations for the operation procedure of GNRE.
8.7.1 General
Processing Plant Operations

The activities associated with the processing plant operations are as follows:
a. Operating the process and associated equipment;
b. Operating residue management equipment;
c. Monitoring unloading of the raw material from the ponds to the wet salt storage;
d. Electrical and mechanical maintenance of the equipment, conveyer belts, tools, field
equipment, pumps and pipelines to ensure continuous and steady operating capability;
e. Provide engineering services for planning, scheduling, special projects (e.g. optimiza-
tion), equipment evaluations and selection, troubleshooting.
Associated Plant Operations

These operations consist of
a. Operating the water supply and treatment systems;
b. Operating the truck load out facilities;
c. Monitoring and handling of consumables and supplies, fuel supply and handling will be
in the hands of an external contractor;
d. Electrical and mechanical maintenance of the equipment, pumps and pipelines to en-
sure continuous and steady operating capability;
e. Provide engineering services for planning, scheduling, special projects (e.g. optimiza-
tion), equipment evaluations and selection, troubleshooting.
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Laboratory and QA/QC Operations

The major activities associated with the laboratory and quality control are as follows:
a. Potash circuit intermediate process streams sample analysis;
b. KCl finished product quality control samples analysis;
c. Process water, potable water, wastewater analysis.
Services at the Plant Site

Services at the site include
a. Health, social and environment operations;
b. Firefighting;
c. Emergency medical facilities;
d. Security operations;
e. Administration;
f. Training;
g. Workers camp operation.
Based on this analysis the personnel requirements have been estimated in the following ac-
cording to following system:
• Management level personnel;
• Processing personnel for plant operations;
• Maintenance personnel for all operations;
• Administration personnel;
• Laboratory and QA/QC personnel;
• Load and unload personnel;
• Utilities personnel;
• Waste management personnel;
• Service personnel.
8.7.2 Personnel Requirements
The personnel or staffing requirements for the different parts of the operation is discussed in
the following sections. The personnel have been classified in different groups with different
salary levels based on required skill sets, management requirements, and expatriate/non ex-
patriate categories. It is expected that the expatriates will manage and train local personnel.
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(1) Management
The management level includes the upper management for different sections of the operation,
who are responsible for supervising their respective sections. The management level is not
assigned to shift systems; therefore all jobs are calculated as number of jobs.
Table 17 Complete Management
Field of application Level Number of jobs Number of shifts Total demand
General Manager Highest 1 1 1

Assistant Manager Upper 2 1 2
General Superintendent Process Highest 1 1 1
Administration Superintendent Highest 1 1 1
HSCS Manager Upper 1 1 1
LCR Superintendent Highest 1 1 1
General Superintendent Ponds Highest 1 1 1
Σ8
(2) Processing Personnel
Processing personnel includes the staff requirements for the processing plant, as well as for
loading and unloading facilities at the plant. The estimate presented here is based on experi-
ence from operations on similar projects. The fundamental assumption with this estimate is
that. The processing personnel as listed in Table 18 are mostly assigned within a 3 shift-
system.
During start-up and acceleration of the plant, increased personnel may be required. At that
time, start-up staff from different suppliers and installation companies will be engaged.
Table 18 Estimate of Required Processing Personnel
Number Number
Field of application Level Total demand
of jobs of shifts
Chief Project Engineer Production Upper 1 3 4
Project Engineer Deloading Middle 1 3 4
Project Engineer Raw Salt Storage Middle 1 3 4
Project Engineer Potash Circuit Middle 2 3 9
Plant Op - Potash Circuit 1 Lower 2 3 9
Plant Op- Residue Management Lower 3 3 13
Helper Lower 5 3 22
Σ 84
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(3) Maintenance Personnel
The maintenance personnel are assigned within a 3-shift-system; the estimated personnel
numbers are given in Table 19.
Table 19 Maintenance Personnel

Maintenance Manager Middle expat. 1 1 1
Mechanics Middle 3 3 14
Electrician / Instrument Tech. Middle 3 3 14
Laborers Lower 3 3 14
Σ 43
(4) Administration Personnel
The administration personnel are not assigned within shift systems; therefore all jobs are only
calculated for single shifts. The staffing tiers conform to middle and lower level as shown in
Table 20.
Table 20 Administration Personnel

Logistics Coordinator Middle 2 1 2
Plans and Business Middle 2 1 2
Plans and Business Lower 2 1 2
Clerk / Reception Lower 2 1 2
HR / Data Clerk Lower 3 1 3
Driver / Assistant Lower 3 1 3
Σ 14
(5) QC & Lab Personnel
The QC & Lab personnel are assigned within a 3-shift-system as continuous control of brines
and crystal crops are required during operation. The staffing tiers conform to the upper and
middle levels as shown in 0.
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Table 21 QC & Lab Personnel

Lab Technician Upper 1 3 4
Lab Assistant Middle 1 3 4
Σ8
(6) Utilities Personnel
The utilities personnel are assigned with a 3-shift-system. The staff for utilities will conform to
the middle and lower level and are detailed in Table 22.
Table 22 Utilities Personnel
Utilities Manager Middle 3 3 13

Assistant Lower 3 3 13
Σ 26
(7) Services Personnel
The Services personnel are partly assigned within a 3-shift-system and are responsible for
health, safety and security, running the workers camp, and providing cleaning services at the
plant administration building. These staff conforms to the middle and lower level as detailed in
Table 23.
Table 23 Services Personnel
Health Care Officer Middle 1 3 4

Fire brigade (full time) Lower 2 3 9
Security Manager Middle 2 1 2
Security / Watchman Lower 3 3 13
Kitchen Personnel Lower 4 3 18
Cleaning Personnel Lower 4 3 18
Σ 64
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(8) Key Personnel
The key personnel required to run the operations are as follows:

General Manager
This individual has the overall responsibility and accountability for mining and plant production
and operations, HR (human resources), Administration and HSEC (health, safety, environment
and community) management. Operating department leaders called department superinten-
dents would report to this manager.
General Superintendent Process
The general superintendent process is responsible for daily, weekly, monthly and annual pro-
duction of finished product according to customer specifications, grade, hardness/durability
and dust control measures.
This person is responsible for the day-to-day operations of grinding, clarification, centrifuging,
drying, cooling product, application of de-dusting oils, anti-compacting materials, truck load-
ing, product storage, effluent/spent brine disposal, departmental mechanical and electrical
maintenance, steam production, back-up power generation, instrumentation services, water
supply/purification, sewage treatment/handling, departmental engineering services, quality
control, HVAC services (heating, ventilation and air conditioning) and all departmental training.
Shift Production Group of Shift

Assistant Group of Technician
Section Foremann Engineers
Manager
Plant Service Group of Shift Group of

Chief Production Foremann Engineers Technician
Chief Chemist Laboratory Crew
Group of
Plant Maintenance Group of
Maintenance
General Foremann Technicians
Engineers
Superintendent
Process Plant Trainer Group of Trainer
Group of
Chief Loading Technicians
Assistant Manager
Chief Engineering
Group of Engineers
Figure 10 Organization Chart General Superintendent Process
LCR Superintendent
The LCR superintendent fulfils the role of resourcing the operations with both expatriate staff
and local personnel, as required. This person is responsible for all hiring, benefits administra-
tion, labor relations, community relations, company social activities, receptions and parties,
events, donations to eligible recipients, site medical care, site security, site publications (news-
letter) and off-site training courses. Furthermore, managing community relations is his respon-
sibility.
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Administration Superintendent
The administration superintendent plays a key role particularly in assuring that the operation
runs smoothly. Salaries and bills are paid, as well as accounts receivables are handled on a
timely basis. Parts and materials are on hand as needed.
Product handling and shipping is coordinated with quality control and off-shore
sales/marketing, responsible for financial reporting, banking, accounting, payroll, accounts
payable, accounts receivable, lands management, insurance coverage, auditing, building care
and cleaning, road maintenance, purchasing, warehousing, records storage, IT site services,
phone services, lease vehicles administration, infrastructure administration, dealing with cus-
tomer complaints, trash management and tenant relations.
HSEC Manager
The HSEC manager is responsible for safety, health, and environment relations for GNRE at all
sites and locations where GNRE operates, under the direction of the general manager. Emer-
gency response and fire-fighting services come under this person’s area of responsibility
Safety training is coordinated across the entire project site by this person. Recognition of indi-
vidual safety performance by employees is given at annual safety achievement banquets. Safe-
ty and environmental audits are conducted and evaluated in conjunction with third party audi-
tors. The HSE coordinator attends all senior management meetings involving department
heads and meets with community leaders. They also will undertake part of all public relations
activities.
(9) Maintenance
The production site is designed so that equipment maintenance is mainly performed within the
plant in order to be self-sufficient due to the remote nature of the site and reliability of local con-
tractors and suppliers.
For this reason, the plant’s central maintenance workshops shall be equipped with:
• Vehicle maintenance shops
• Machine shop
• Plate work shop
• Welding shop
• Paint shop
• Carpenter shop
• Hydraulic and pneumatic workshop
• Electrical workshop
• Instrumentation and control workshop.
For field maintenance work on mechanical, piping, electrical and instrumentation equipment
and systems, sufficient manpower and organization structure is provided. Allowances are also
made for planned plant shut down maintenance work, and overhauls of major pieces of
equipment that would require the participation of the equipment manufacturers either on site,
or at their own repair shop facilities.
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(10) Machine Shop
The machine shop is equipped with following machine tools:

• Universal milling machine
• Parallel lathe
• Boring machine
• Keyway cutting machine
• Vertical band saw
• Vertical floor drill
• Bench grinder
• Bench press
• Material storage area
• Tool room.
With the above equipment, most of the machining work for equipment repairs such as shaft
turning, keyway cutting, surfacing, etc. can be performed at the plant.
(11) Plate Work Shop
The plate workshop has the following equipment:

• Press brake
• Plate roller
• Plate shear
• Alternating sawing machine
• 30 t hydraulic press
• Material storage area, equipped with cantilever tube rack and plate rack.
(12) Welding Shop
The welding shop is equipped with the following equipment:

• Oxy-acetylene and plasma torches cutting table
• Welding machines (SMAW, TIG, MIG, automatic and semi-automatic)
• Welding curtains
• Weld-fume high efficiency dust collectors.
A common overhead travelling crane serves the machine shop, plate workshop and welding
shop for transfer of parts between the shops.
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(13) Paint Shop
The paint shop is equipped for regular painting of miscellaneous equipment as well as small
vehicles. The booth consists of:
• Paint booth
• Ventilation and filtration system
• Paint storage and preparation area.
No sand-blast facilities are provided. The surface preparation is performed using portable tools
such as hand grinders, rotating brushes, sanders, etc.
This workshop is equipped with a test bench for testing and verification of hydraulic equipment
such as cylinders, hydraulic pumps, valves, distributors, etc.
A similar test bench is supplied for the testing and verification of pneumatic equipment.
This workshop is also equipped with hose clamp machine for fabricating hose fitting re-
placements.
(14) Instrumentation and Electrical Workshop
This workshop has all tools and equipment required for maintenance and testing of electrical
equipment, instrumentation systems, control valves calibration and repair as well as testing of
DCS/PLC hardware.
Maintenance and testing instruments shall include megohmeters, electronic multimeters with
clamp-on attachments, recorders, memory oscilloscopes, vibration meters, digital tachometers
and thermometers as well as:
• Tool box sets
• Electric hoist for lifting control and safety valves, and other heavy instruments such as
mass flow meters
• Calibration rig for control valve
• Calibration rig for safety relief valve
• Pneumatic calibrator
• Water and mercury columns
• Dead weight tester; resistance temperature detector (RTD) calibrator; oil bath complete
with electric heater and test gauges
• Calibrator for moisture transmitters
• Hand held calibrators for smart hart instruments
• DCS/PLC equipment test lab (consisting of lamps and push-buttons panel, control sys-
tem test rack, operator interface station, signal generators and receivers, etc.)
• Clamp meters and digital multi-meters
• Fibre optic cables test kit.
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(15) Field Maintenance
Maintenance crews are will carry out routine maintenance of all mechanical, piping, electrical
and instrumentation equipment and installations. A dedicated team will cover day shifts, while
night shifts are covered by a skeleton multidiscipline crew.
(16) Periodic Plant Shut Down Maintenance and Major Overhauls
Planning and manpower provisions are to be made for handling the increased maintenance
workload during the planned general plant shut downs and major equipment overhauls. A por-
tion of the shut-down work is performed by outside contractors for major equipment such as
the power generators, fluid bed dryers and selected items. The planned major overhauls would
require participation of the equipment manufacturers’ personnel on site. For selected cases the
components would be sent to the manufacturers’ shop for the required repairs and recondition-
ing.
(17) Personnel Training
Overall scope of operator training shall be based around tasks within the plant, to keep the
operation at a steady rate of production; the scope of the training for each individual depends
on the respective job assignment in the plant and is selected from the following:
• Outline of plant
• Orientation and look-at training for plant management
• Orientation for production department
• Orientation for the production control department (laboratory)
• Orientation for the maintenance department (mechanical, instrumentation and comput-
er specialist)
• Orientation on product application tests.
Therefore, two training stages are applied:
A. Theoretical training in courses

The training courses for the employees have a duration of 1 – 2 months and consist of the the-
oretical background for the operations. Several training blocks for plant operation will be nec-
essary, but all will have a comparable structure consisting of:
1. General Introduction
2. Task Overview and Operation Requirement
3. Methodology and Introduction into Practical Exercises
4. Practical Exercises
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B. Training on the job

An experienced crew of expatriates shall train the personnel for operation and maintenance
with specific regard to the operation of the process equipment. Staff shall be trained on the job,
which means at site during supervision of the final erection and commissioning. Therefore,
GNRE will make available trainees who have the necessary qualification and experience. It is
taken for granted that each person of the staff is qualified in his field. During the training, the
staff is specifically trained regarding the process technology, interrelation and function as well
as operational aspects of potash mining.
8.8 Technical Evaluation of Quotations
After pre-designing of equipment, ERCOSPLAN sent inquiries for necessary equipment for pot-
ash processing to possible suppliers. Thereon equipment suppliers sent quotations to ERCO-
SPLAN.
ERCOSPLAN had to decide independently for one supplier for each equipment, to be consid-
ered in the detail engineering documents due to that GNRE-COMIBOL was not in the position
to make a decision because of Bolivian regulations.
ERCOSPLAN’s reasons for consideration of equipment suppliers in the detail engineering
were:
• Technical and technological
• References in potash industry
• Economical
• Quality of delivered quotation documents.
Table 24 below shows all mechanical equipment quotations. Considered mechanical equip-
ment in ERCOSPLAN’s detail engineering documents is marked with a cross in column “Con-
sider in Detail Engineering”.
Remark:
Delivered quotations by various equipment suppliers often had been similar resp. were evalu-
ated as comparable. Hence, the date of delivery of quotation influenced the consideration in
the detail engineering documents.
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Table 24 Technical Evaluation of Quotations
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8.9 Capital Cost Estimate
All machinery, material and equipment which are isbl of the scope of ERCOSPLAN have been
chosen according to the widespread experience of the authors in potash processing opera-
tions worldwide. Prices have been selected from blue chip companies with high experience
supplying equipment, section and bulk material for the potash industry.
Remark: All equipment, buildings, devices which are osbl (especially water sewage, furniture,
laboratory equipment, equipment for offices, administration building, laboratory, canteen,
warehouse, workshop, fire station, hospital and vehicles e.g. fire truck ambulance, trucks,
cranes, buses, loaders, cars) are not considered in the calculation.
8.9.1 Direct CAPEX
The direct CAPEX include:

• Costs for site preparation, infrastructure, buildings and areas
Costs related with the preparation of the plant area, the construction of the facilities and
infrastructure, the tailing areas.
• Costs for production facilities (scope of ERCOSPLAN – without drying, product storage,
product loading)
Machines, material, systems and works necessary for processing of the raw ore to the
final product, including electrical equipment.
8.9.1.1 Main Equipment Estimation
CAPEX of the equipment were estimated on the base of the equipment specified in the equip-
ment list for the whole processing plant isbl of ERCOSPLAN scope (details see Appendix G1).
8.9.1.2 Pipes and Valves Estimation
CAPEX for pipes and valves at plant site were estimated with an accuracy possible at the pre-
sent state of the project and includes all pipes and valves which are planned according to the
scope of ERCOSPLAN (details see Appendix G2 and Appendix G3).
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8.9.1.3 Electrical Equipment / Instrumentation / Communication / Automation
All materials, devices and equipment for the power supply, instrumentation, automation and
communication systems were estimated on the specifications and bills of quantity of the ER-
COSPLAN scope (details see Appendix G4).
8.9.1.4 Infrastructure, Building
CAPEX for infrastructure and buildings at plant site were estimated with an accuracy possible
at the present state of the project and includes all infrastructure and buildings planned accord-
ing to the scope of ERCOSPLAN (details see Appendix G5).
8.9.2 Capital Expenditures
For calculations of the indirect CAPEX costs ERCOSPLAN used the following percentages
• EPCM
It has been established as a 15 % of Direct Capital Expenditures.
• Owner costs
They are estimated as a 1 % of direct capital costs.
• Provisory facilities
• Start up and commissioning
• Insurance
Estimated as 1 % of direct capital costs.
• Contingencies:
Reserve to contingencies is estimated as a 5 % of direct and indirect capital costs.
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Table 25 Cost Overview of Direct and Indirect Capital Expenditures of Processing Plant
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8.9.3 Media Consumption
For production of KCl at plant site, several media are necessary:

• Crystallizate from evaporation ponds
• Process water
• Electrical energy
• Liquefied petroleum gas
• Process chemicals
• Fuel for combustion engines (trucks, cars, front end loaders, etc.)
• Oil and lubricants.
8.9.4 Crystallizate
According to the process calculation the hourly demand for crystallizate from evaporation
ponds is approx. 540 t/h respectively approx. 280 m³/h (without design safety factor of 20 %).
8.9.5 Process Water
According to the process calculation the hourly demand for process water is approx. 270 m³/h
(without design safety factor of 20 %).
8.9.6 Electrical Energy
The total electrical energy demand is estimated with 11,000kVA.
8.9.7 Liquefied Petroleum Gas
Liquefied petroleum gas is majorly necessary for process building heating. Heating itself is
necessary to keep process building frost-free. The liquefied petroleum gas consumption for
heating purposes is estimated with approx. 75,000 Nm³/a.
Furthermore liquefied petroleum gas is used for heating up process water in reagent dosing
plant. The amount, necessary for heating up the process water to approx. 80 °C is estimated
with approx. 20 Nm³/h.
Drying section consumes liquefied petroleum gas, too. Especially heating media is needed for
generating hot air for drying. The liquefied petroleum gas consumption for drying purposes is
estimated with approx. 400 – 500 kg/h during usual operation.
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8.9.8 Process Chemicals
For consumption of process chemicals for flotation and thickeners please see chapter 6.4.
Furthermore chemicals for anticaking treatment of product after drying / cooling are necessary.
The consumption of chemicals for anticaking is as follows:
Potassium ferrocyanide K4[Fe(CN)6] 11.05 kg/h resp. 83 t/y
Sodium carbonate Na2CO3 4.76 kg/h resp. 36 t/y
8.9.9 Fuel for Combustion Engines
Fuel for combustion engines like trucks, cars and front end loaders is not considered in ER-
COSPLAN’s scope of works.
8.9.10 Oil and Lubricants
Oil and lubricants are not considered in ERCOSPLAN’s scope of works.
8.10 Risk Analysis
8.10.1 Prevention in Work Risk
The processes of construction and operation of the Project involve a number of risks inherent
to the activities both for the environment and for human life and health.
This chapter describes the risks associated with such activities and the preventive measures
that are necessary to perform that plan will be part of risk prevention at work and environmental
risks.
At all times, making reference to the Laws and Regulations in Force in the Plurinational State of
Bolivia regarding Health and Safety at Work and Environmental Laws type. These laws are
listed at the end of the chapter.
Before the start of the work, there will be a Health and Safety Study by the contractor to be ap-
proved by the Labor Authority and the Work Center Opening, Book of Outsourcing and Inci-
dent Book.
In this study the following should be considered:
• Appointment of safety and health during the performance of work, commissioning and
operation of the plant as well as the appointment of a preventive action by workgroup or
turn.
• Employee participation system in safety and health.
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• Informing workers on each of the activities they are undertaking and acquired risk in-
formation in their job.
• Training in occupational safety and first aid courses.
• List of equipment of individual and collective protection to use as a play activity and
profession
• Risks associated with each of the activities to be performed during commissioning con-
struction and operation of the plant.
• Risks associated with each of the professions required in the construction, commission-
ing and operation of the plant.
• Preventive measures according to the activities to be developed.
• Preventive measures by occupation.
• List of necessary auxiliary equipment in all phases of the project, and associated risks,
preventive measures.
• And finally, along with the Health and Safety Plan must be accompanied by an Emer-
gency Plan indicating emergency exits, evacuation in case of accident, contact num-
bers in case of accident, maps with evacuation routes to hospitals and centers closest
Health and performance standards based on type of accident. In section 5.2. Emergen-
cy Plan shows the basic guidelines of the content.
8.10.2 Risks
8.10.2.1 Accident Risks
It is essential and necessary to continually evaluate the effectiveness of preventive measures

against the possible risk at all times applying continuous improvement to ensure safety in op-
erations from three major perspectives: laboral, technical and environmental .
Therefore we can consider the following general measures in preventing accidents.
• Health and Safety Plan submitted and approved in advance by the labor corresponding
authorities.
• Experts in risk prevention during the implementation phase, commissioning and opera-
tion of the plant.
• Environmental experts engaged in the implementation and control of work to prevent
damage in the environment.
• Collective protective equipment has to be used when it´s necessary, while personal
protective equipment will be used at all times.
• During installation and operation of big equipment, you must check and verify that the
work areas are cleared and that the operation of the audible and visual alarms is en-
sured.
• Appropriate equipment will be needed to fight fires in areas of work and training staff in
its use.
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• All workers on the project will have mandatory training on health and safety and envi-
ronment.
• It is necessary to evaluate all activities known reviews, and continuous monitoring of the
same.
• It must visually inspect the equipment and tools used at the beginning and end of each
work shift, reporting to superior any type of anomaly detected.
• When performing maintenance work, ensure that interlocking system is working.
• To prevent the risk of road accidents within the project area or area of work, draw up a
plan that includes transit zones of both vehicles and pedestrians, considering speed re-
strictions, demarcations and traffic signals.
• Workers who drive during the execution of the work and during operation of the plant
should be in possession of a valid driver's license appropriate to each vehicle.
• The weight of the trucks loaded with equipment or materials shall not exceed the maxi-
mum allowed according to routes/bridges they are using.
8.10.2.2 Risk by Natural Phenomenon
The unexpected natural phenomenon of high magnitude earthquakes can always involve risks
to those working in the Project.
Although the characteristics of the project (design engineering) and its site are not associated
with particular vulnerabilities to such events, it is considered that upon the occurrence of a cat-
astrophic natural phenomenon must operate the emergency and evacuation systems.
In the event that strong movements produce structural damages and power cut, will take into
account the following preventive measures:
• It will cut the power supply.
• It will establish and maintain demarcated the security area and free of any unnecessary
element.
• It will provide energy support in those critical systems to operational continuity.
• It will be a good signage of emergency exits.
8.10.2.3 Risk of Fire
The fire protection systems proposed for this project are based on good engineering practice
and the use of Bolivian standards.
As general measures Fire Prevention Plan must be:
• All employees shall be subject to the measures and obligations by the same.
• Facilities will be provided with information required to fight any attempts of fire or fire, as
established by current legislation in this area. In the case of treated inside sensitive are-
as of the building will be installed sprinklers and extinguishers, while outdoor facilities
provided hydrants will have complete coverage of all work area. These systems will be
monitored with main fire alarms and detection systems.
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• In surrounding areas, fuel storage shall be prohibited to light fires and/or items cause
sparks as well as to smoke.
• Training will be provided to workers of the project on all activities that may present a risk
of fire.
• It shall provide, maintain and regularly inspect the fire suppression systems.
• It will have defenses, guards or enclosures in areas where works of flame cutting, weld-
ing, sawing, cutting and roughing down, mechanical maintenance and other are done.
• It will achieve the regular maintenance of electrical facilities.
• It will connect to ground all the equipment that can generate sparks and store static
electricity.
With regard to the risks of fire or explosions by handling flammables and/or combustibles, con-
sider the following measures:
• The handling of the fuel elements will be made according to the procedures established
for this purpose.
• All trucks go into the site or in the plant with fuel, must be certified respective sealing
and hermeticism.
• The transport and storage of fuel shall be in compliance with the safety measures stipu-
lated by Normative and Law.
• At the point of discharge will display a sign "Danger fuel unloading, No Smoking," with
the existence of ABC type fire extinguishers, neutralizers and absorbent elements, such
as sand, pellets.
8.10.2.4 Risks in the Transport; Handling and Storage of Hazardous Waste
Hazardous solid industrial waste will be stored, handled and transported in compliance at all
times the current Bolivian law.
The main objectives are:
• Minimizing the amount of waste generated.
• Optimizing the use of resources through reuse or recycling.
• Authorized final disposal sites that ensure minimal environmental impact.
• The transportation of this waste will be performed by an authorized company for this
purpose, which must have its plan of risk prevention and accident control for transport
and management of the waste and it will be compatible with current legislation.
• Drivers of vehicles must be trained in the use and handling of transported substances
as well as first aid procedures and spill control.
• Transport vehicles will have systems of communication, first aid equipment, emergency
equipment (shovels, absorbers, fire extinguishers, personal protective equipment such
as gloves, goggles, helmet, etc..), as applicable. Besides trucks valves are designed to
be watertight and prevent any kind of leakage.
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• Recognition and analysis of the route in which the trucks will move, as well as the alter-
native route in case of interruption or cuts on the normal route.
• During the handling waste will be taken the precautions to prevent inflammation and/or
reaction.
• It is necessary to train all staff who handle and store these hazardous substances.
• Updated maintenance of the list of all controlled products and their review at their re-
ception of packages containing such products (container, label, etc.).
• There will be a special area for the storage of hazardous substances, which will be
properly marked and equipped as required by the authorities.
• Drums of fuel and oil are arranged on wood pallets or other devices in order to facilitate
transport and to prevent moisture or corrosion themselves of by direct contact between
the drum and the soil.
• Tanks for the preparation and storage of reagents possess with containment.
• The fuel loading machinery and used equipment will be in a defined area.
• All facilities receiving, storage and use of these residues will have a fire protection sys-
tem.
8.10.3 Emergency Plan
For control of accidents and/or medical emergencies, the affected area will immediately notify
the hospital or nearest health center, through established communication systems.
An example is shown below.
SERVICES TELEPHONE
Health emergency ----------------
Fire -----------------
Ambulances -----------------
Police -----------------
Civil Protection -----------------
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It is also important to consider emergency brigades on site with appropriate equipment, vehi-
cles and trained personnel.
If the conditions of the victim or victims are not grave, the emergency brigade shall provide
appropriate first aid.
Once patient or patients are stable, it is necessary to transfer them to the nearest hospital to
complete the first aid.
8.10.3.1 Performance Standards in Traffic Accidents
The security brigade will be responsible for maintaining everyday signage, replacing if it is nec-
essary.
Traffic accidents can occur to both the work's own staff, and third parties who are affected by
them. The treatment of these accidents will be the same as for labor accidents.
In the case of an accident traffic performances are:
• Care for the injured.
• Communication with ambulances and first aid.
• Police will be notified of the number of accidents immediately, affected cars, location
and direction.
• Responsible Communication for prevention.
8.10.3.2 Performance Standards of Accidents caused by Natural Phenomenon
In case of high magnitude earthquakes personnel needs to be evacuated to areas previously

defined and known to the workers.
During the evacuation, special care should be taken of falling walls, bricks, electrical artifacts,
shelves and other furniture that can collapse.
People should stay away from windows, mirrors, etc. They should also stay away from tall
structures, walls, poles power lines and other objects that may fall.
• In the event of an earthquake will take place the following: Perform a visual inspection of
all structures for cracks in the walls decreases and deformation of the walls, evidence of
soil liquefaction, etc.
• Revise the instrumental record: inclinometers, etc. Perform specialized technical inspec-
tions, and then issue a report to the control actions and/or repair of facilities
During storms (extreme rain, wind or heavy lightning) following measures have to be taken:
• Outside workers must be directed to covered places until adverse weather conditions
will be better.
• The staff has to be ordered to stay away from doors, windows, pillars or metal struc-
tures.
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8.10.3.3 Performance Standards in the Case of Accidents Caused by Fire and / or Explo-
sion
In the event of fire and/or explosion, an accident management plan will be brought into action
which considers the following actions:
If there are larger fires, set up a perimeter of insulation and communicate the event to the
Emergency Coordinator.
The staff should be transferred to the previously defined security zone.
The areas of greatest risk of fire will be safeguarded, especially the fuel storage and hazardous
substances storage.
To fight fire with existing equipment, it is necessary to know in advance the location of the ele-
ments of fire attack. Usually the first attack should be carried out with extinguishers. If during
firefighting the fire escapes the control of the staff, this must be removed immediately from the
site, give the respective alarm and notify trained teams about the situation.
8.10.3.4 Performance Standards Substance Spill and / or Hazardous Waste
In the event that the spill will occur during transport:

As a control measure, each truck must carry extinguishing powder based dry chemical, with
their corresponding security seal and label revision date, and shall be in suitable condition for
use, fully loaded and located such that they can be used quickly and expeditiously.
A review of their status must be made at least every six months.
The driver is responsible to isolate the accident area with danger tape and warning cones to
alert the risk and prevent the entry of outsiders.
All contaminated material (plastic, paper, wood, metal, soil, vegetation, liquids and personal
protective equipment) must be collected and properly packaged.
These will be treated as hazardous waste and will be properly labeled and subsequently trans-
ported to a waste treatment center.
8.10.4 Environmental Risk Conditions
During implementation, commissioning and operation of the project, executing and managing
companies must have the implementation of an Environmental Management System, such as
Rules and Governing Law on Environmental Safety.
The Environmental Management System states the control and management of waste generat-
ed on site, environmental monitoring measures applied by a waste management plan, envi-
ronmental instructions, environmental monitoring programs and other procedures established
in quality manual company, drafted in accordance with the requirement of the standard.
• Promoter: COMIBOL
• Contractor: The contractor will be responsible for implementing protective and correc-
tive measures provided for in this plan, submitting periodic reports to the promoter. It
will therefore be necessary to appoint a Responsible Environmental Monitoring in
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charge of developing the actions set out in this document and any other document of
good environmental practices reported by the Promoter and their own environmental
measures described in the Environmental Management System of the Promoter.
To do this, the various mechanisms that will be implemented to ensure the execution of the
works will respect the environment:
• Identification and quantification of environmental aspects and impacts
• Reduced pollution and the impact: On the water, atmospheric, acoustics and vibration
and soil.
• Regeneration of spaces
• Environmental Monitoring Program.
In the following sections, the impacts and preventive measures will be studied.
8.10.4.1 On the Water (Potable Water Outside of Salar)
Impacts can cause: increased water turbidity, as in the case of spills and arid lands, which ad-
versely affects the water.
Oils and fuel spills as well as wastewater discharges can cause outbreaks of infection, so they
should also pay special attention.
To avoid direct conditions in the waters, the following preventive measures apply during the
execution of work:
• Each of the containers and waste storage containers located on site will be periodically
emptied as often as necessary.
• The handling of materials will be done to avoid any spill, if it occurs, will proceed to col-
lect and deposit in the appropriate container.
• The stock of machinery and material storage areas will be located away from including
streams, ponds and wetlands in general. In such areas, place a layer of absorbent ma-
terial to control spills of fats, oils, fuels, etc. Also, it will build a perimeter ditch machin-
ery park to collect runoff and manage them properly.
• At the beginning of the execution of the works, the head inform all workers of a total ban
of uncontrolled dump of all work products.
• At the beginning of each working day each of the operators responsible for managing
the various machinery and equipment will review the equipment to do not leak oil or any
other fluid.
• Preferably to be used existing access for the passage of machinery and equipment
avoiding move outside the tracks.
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8.10.4.2 About the Atmosphere
Construction activity causes the emission of large amounts of dust, particles and combustion
gases, due to the operation of the engines of the various equipment, and displacements.
These gases are formed by soot, carbon monoxide, oxides of sulfur and nitrogen oxides.
All these substances are harmful pollutants to the health, hence their control necessary.
As general measures in the execution of the work, it will strictly use the necessary machinery,
making sure that this produces the less possible pollution, both atmospheric as acoustic, re-
gardless of the implementation of other measures, which are detailed below:
• It will monitor the maintenance of the machinery involved in the work is carried out in
suitable workshops and controlled technical inspections passed by machinery and ve-
hicles.
• That machinery that does not pass technical inspections will be checked by periodic
maintenance to ensure low air emissions, for which the Department of Administration
will request documentation of technical inspections performed, or otherwise performed
preventive maintenance on machinery that does not belong to the company.
8.10.4.3 Acoustic and Vibration Levels
The execution of construction work generates high noise levels, especially during phases of
earthmoving.
The impact of such noise depends on the nature of the emissions, distance and receptor sensi-
tivity, for this we can take the following general measures:
• Install mufflers on mobile equipment.
• Minimize the movement of machinery for the works, and so the vibrations will optimize
the location of park construction machinery and storage areas.
• Control noise emissions resulting from the activity, both in levels and timetables estab-
lished by the regulations, performing noisier operations in the central hours of the day.
8.10.4.4 About the Floor
The soil contamination will occur for potential spills agents contaminants: such as liquids and
oils. In order to overcome these spills shall proceed as is provided for in the Emergency Plan
Environmental.
To reduce the impact on the ground, the following measures will be implemented:
• Oil changes will be made machinery in the workshops.
• Cleaning of concrete casks outside the work place.
• As far as possible the existing routes to the machinery works have to be used, neces-
sary auxiliary roads have to be minimized.
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8.10.5 Regeneration of Spaces
After use, all areas affected during the construction phase should be restored to their original
condition.
8.10.6 Forecast of Implementation of Environmental Monitoring
Table 26 shows the required inspections including responsible persons and frequency of in-
spection for all environmental control points.
Table 26 Forecast of Implementation of Environmental Monitoring
ENVIRONMENTAL CONTROL POINT 01: ATMOSPHERE
INSPECTION RESPONSIBLE FREQUENCY

Check with the Department of Administration that
WORKS
the machinery for the maintenance works are com- DAILY
MANAGER
plete and ready for use
ENVIRONMENTAL CONTROL POINT 02: NOISE AND VIBRATION

Not having the machinery revolutionized light or WORKS
DAILY
unless necessary. MANAGER
Particularly noisy operations shall be carried out in WORKS
DAILY
the middle of the day MANAGER
WORKS
Check that the heavy machinery is in possession of
MANAGER AND DAILY
Conformity Commissioning SITE MANAGER
ENVIRONMENTAL CONTROL POINT 03: WATER
The concrete gutter cleanings are performed on WORKS

DAILY
suitable areas for it to prevent spillage. MANAGER
ENVIRONMENTAL CONTROL POINT 04: SOIL AND LAND
INSPECTION RESPONSIBLE FREQUECY

Do not remove / take up more floor stipulated in the WORKS
DAILY
Project MANAGER
WORKS
The lands are reclaimed to their original MANAGER AND WEEKLY
SITE MANAGER
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ENVIRONMENTAL CONTROL POINT 05: CONSUMPTION
Make visual inspections of facilities to collect and WORKS

distribute water to detect leaks DAILY
MANAGER
It must ensure that the machine has passed the WORKS

appropriate maintenance to ensure that there are MANAGER AND DAILY
no excesses in consumption. SITE MANAGER
WORKS
Check that in the works hazardous substances MANAGER AND DAILY
that are being used have been identified SITE MANAGER
ENVIRONMENTAL CONTROL POINT 06: WASTE

The hazardous waste (HW) must be:
Segregated from other waste and segregated from
each other
Protected from adverse conditions
In the storage area must not be viewed or dis- WORKS
charges leachate. DAILY
MANAGER
They should have a label indicating producer in-

formation, residue name, code, pictograms risk,
manager name, number stored and storage date.
Verify that the urban waste is deposited in appro- WORKS

DAILY
priate containers. MANAGER
ENVIRONMENTAL CONTROL POINT 07: PROTECTION OF NATURE

In the site there is a copy of the Environmental
Emergency Plan and reported localized content WORKS
DAILY
and location of operators at the time of entry to MANAGER
work.
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8.10.7 Bolivian Legislation in Safety and Environment
• Labour Law: Decree Law 16998 of 1979 "Occupational Safety, Health and Welfare".
• Environmental Law promulgated on April 27, 1992. Regulation of Law No. 1333 of the
Environment.
– General Rules of Environmental Management.
– Regulation in the Field of Water Pollution.
– Regulations for activities involving hazardous substances.
– Regulation of Solid Waste Management.
– Regulation on Prevention and Environmental Control.
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9 Impact on Environment by Processing and Environmental

Protection Measures
The activities for installing a potash operation plants in Salar de Uyuni result in a wide variety of
adverse environmental effects. Typically, these effects are quite localized, and in most cases,
confined to the mine site. At a specific site, the type and extent of environmental effects may
depend on factors such as
• Characteristics of the raw salt,
• Surface land profile,
• Local climate,
• Surrounding eco system.
However, of greater importance may be the

• Mining methods and equipment;
• Beneficiation and concentration processes;
• Waste disposal methods;
• Scale of the operation;
• Sites location to existing population centers and infrastructure.
Table 27 presents an overview of single steps of a potash production development, their spe-
cific activities and potential environmental impacts.
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Table 27 Major Potential Environmental Effects that may occur during Potash Production
Operation Activities Environmental Impact

Pond Development Exploration, Land surface disturbance
assessment, Air emissions
planning and Water contamination
construction Noise and vibration
Extraction Overburden removal Land surface disturbance
or Ore extraction Water contamination
Water table lowering
Air emissions
Topsoil degradation
Vegetation and wildlife
disruption
Noise and vibration
Handling Transport Air emissions
Storage and reclamation Water contamination
Noise
Beneficiation Separation, Waste generation
concentration and Water consumption
contaminant removal Water contamination
Air emissions
Drying, etc... Noise and vibration
Resource maximization
Subsequent Processing Product transported Waste generation
to further processing, Water consumption
distribution and use Water contamination
Air emissions
Noise and vibration
Waste disposal Wastes to surface Land surface disturbance
storage impoundments Water contamination
and piles, underground Air emissions
backfilling of disposal brine, Stability
Closure Removal of equipment Long term stability
and plant, shaft sealing, Safety
stabilisation, monitoring Future land use
Air emissions
Hazardous waste disposal
Return of site to pool
of available land
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Environmental aspects that can be affected by production activities were grouped under ‘air,
‘water’, ’land’ and ‘social values’.
Air quality can be affected by emissions of
• Dust
• Exhaust particulates and exhaust gases such as carbon dioxide (CO2), carbon monox-
ide (CO), nitrogen oxides (NOX), and sulphur oxides (SOX)
• Volatile organic compounds (VOC's) from fuelling and workshop activities
• Greenhouse gases such as CO2 and methane are believed to contribute to global
warming.
Due to the use of high quality dedusting systems with an exhaust gas content of lower than
20 mg/m3 dust contamination cannot occur.
The used modern burning and incineration systems avoid a high content of carbon dioxide
(CO2), carbon monoxide (CO), nitrogen oxides (NOX), and sulphur oxides (SOX)
The production of volatile organic compounds (VOC's) from fuelling and workshop activities is
minimized
Large volumes of water are typically required by production and beneficiation activities. This
water consumption may lead to a fall in the level of the local water table, affecting the surround-
ing ecosystem and potentially resulting in competition with other users.
All of the requested water will be supplied by wells.
The land surface and sub-surface can be disturbed by activities such as
• Extraction of brine;
• Deposition of overburden;
• Disposal of beneficiation wastes.
These activities could result in wide range of potential impacts on the land, geological structure
and topsoil. Additionally, the production can affect the hydrological cycle, wildlife habitat and
biodiversity of the area. In some instances, sites of archaeological, cultural or other significance
may be affected.
All deposits of waste are safe due to special design of the storages.
Social goods and intangible values such as community lifestyles, land values and the quality of
the ecosystem in the vicinity of the plant site could be affected by factors such as
• Modification of the landscape;
• Noise and vibration from activities such as the operation of equipment;
• Changes in wildlife habitat.
The major potentially adverse environmental effects could occur during the different activities of
the production life cycle. Generally the activities of most significance are construction, extrac-
tion, beneficiation and waste disposal. Associated activities may have an impact but these tend
to be relatively less important. Rehabilitation and closure can have some impact, but these ac-
tivities are carried out with the objective of repairing any adverse effects that may have oc-
curred during production, to leave a safe and stable site. Rehabilitation is more effective when
conducted progressively throughout the life of the operation. Adopting a holistic approach to
planning and environmental management, that encompasses the entire life cycle, helps to pre-
vent or mitigate environment effects from the outset, while fostering stewardship of the ore re-
source and the layers under which it lies.
Page 268 of 273
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9.1 Impacts by Handling
Handling encompasses the transportation and stockpiling operations that occur between the
extraction of the potash crystallizate and their beneficiation to produce concentrated products.
Surface transportation methods may include road trucks and off-road haul trucks, conveyors
and slurry pipelines.
Dust may be generated from traffic on unsealed roadways. During loading and unloading op-
erations and at conveyor transport of salt, dust emissions are negligible as the material has to
be protected against moisture and precipitation. During the stacking of stockpiles and reclama-
tion operations dust emissions can occur.
Equipment emissions are reduced by the use of exhaust filters on critical area, regular equip-
ment maintenance programs.
Heavy vehicles and equipment use can generate significant noise, sometimes around the
clock, affecting the well-being of neighboring communities. The impact is reduced by the care-
ful location of roads, use of noise barriers or buffer zones, sequencing of transporting opera-
tions and restricting the operating hours of the equipment.
9.2 Impacts by Processing
Beneficiation and concentration activities applied in the potash industry may comprise size
reduction separation, concentration using flotation processes and drying.
Beneficiation and concentration processes may adversely affect the environment by the
• Generation of wastes such as salt tailings and brines;
• Consumption and contamination of large volumes of fresh water during processing with
brines;
• Emission of dust from processing operations such as drying;
• Emission of exhaust particulates and gases during the generation of electrical power
and the drying of product.
Other potential impacts include noise and vibration produced by the equipment.
The following measures to minimize the environmental effects given
• Generation of wastes such as salt tailings and brines;
• Tailings and brines are stored during operation in safe and closed areas.
• Consumption and contamination of large volumes of fresh water during processing with
brines;
• Emission of dust from processing operations such as drying
• Each of the critical points were dust can come to the environment where equipped with
bag filters, which cleans the dusty air to a content of 20 mg/m3.
• Emission of exhaust particulates and gases during the generation of electrical power
and the drying of product.
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• All emission data for exhaust gases of burning processes like generation of power
and exhaust air from drying are lower as requested by the Bolivian standards for
emission.
9.3 Waste Generation
The large volumes of waste generated during beneficiation of potash may potentially cause
adverse environmental effects. Volumes and type of waste depend on the ore characteristics
(ore grade, constituent minerals, and contaminants), in addition to the specific beneficiation
process employed.
The beneficiation of potash produces wastes such as
• Tailings consisting largely of impure salt (NaCl) with smaller amounts of other minerals
such as anhydrite;
• Slimes consisting of insoluble fines such as clay and dolomite;
• Brines containing NaCl or MgCl2;
The beneficiation plant implements measures to contain and recover process spillages, in or-
der to minimize environmental effects and product loss.
All wastes like tailings and brines are stored during operation in safe and closed areas.
9.4 Water Consumption
The beneficiation operation consumes large quantities of fresh water for processes such as
washing and flotation. The water will be sourced from nearby water well. Water management is
an important aspect of the operation and is usually integrated with waste disposal. Recircula-
tion or recovery of the waste process water/brine is effected.
Process waters/brines are used to transport waste as a slurry/solution to the disposal areas.
They should be recovered for reuse, minimizing the need for additional fresh water input.
Where fresh water sources are not available for beneficiation, salt water can be used for parts
of the processing process.
Water management is an important aspect of the operation and is usually integrated with waste
disposal. If possible, recirculation or recovery of the waste process water/brine is effected.
9.5 Water Contamination
Contamination of surface may occur from the spillage of process water, brines, ore concen-
trates, wastes or chemical reagents during processing. A variety of methods to contain spills
will be used, such as drains, bunds around storage and processing tanks and dams for major
process spills. These allow spills to be recovered and returned to the process or be disposed
of safely.
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During processing significant amounts of brine can be accumulated only due to malfunction or
incorrect operation.
9.6 Soil Contamination
During beneficiation, concentration and subsequent processing several environmental impacts

can affect the topsoil layer. Contamination by hydrocarbons, chlorinated hydrocarbons (sol-
vents and detergents) and other organic compounds can occur through infiltration of oil and
fuel through leakage and handling losses and at sites of oil and fuel storehouses, workshops
and fuelling stations. In all hazardous areas are collecting points and safe discharge methods
foreseen.
9.7 Air Contamination
Dry processing operations may generate significant quantities of dust during operations. This
can be controlled to some extent through the use of emission control equipment such as bag
houses and wet scrubbers.
Exhaust emissions from vehicle engines, electrical power generation and product dryers may
contain greenhouse gases such as CO2 and other gases such as NOX or SOX.
The use of improved fuel or energy consumption techniques and technologies reduces the
emission of greenhouse gases and other exhaust particulates and gases. Exhaust gases from
the power plant will be filtered with special filters for NOX, SOX and so on.
9.8 Noise and Vibration
Beneficiation processes generate high levels of noise and vibration produced by pumps, centri-
fuges and stirring devices. A high share of these noises will be eliminated by the process build-
ing cover. Residual noise pollution can be reduced in many cases by enclosing the plant and
retaining suitable buffer zones around the plant site. Some of these measures also assist in
reducing the visual impact of the site. Noise from plant components will not exceed 75 dB at
boundary lines of plant.
9.9 Resource Maximization
The efficiency of resource recovery influences the environmental impact of other activities such
as extraction or waste disposal.
Product loss during beneficiation through the loss of crystallizate to waste streams, dust emis-
sions and process spillages results in both an economic loss as well as the need to extract and
process additional ore to meet demand. Spillage of concentrated product brine may occur dur-
ing beneficiation, prevention or recovery of these can assist maximizing the resource. Potash
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minerals are found in association with a variety of other minerals that may have an economic
value if recovered and separated.
9.10 Protection Measures by Waste Management
The beneficiation of potash typically produces large volumes of waste that may cause a variety
of adverse environmental effects if not managed and disposed of in a safe, stable and envi-
ronmentally sound manner.
Major environmental concerns are typically related to
• Land surface disturbance from the construction and operation of large waste disposal
impoundments such as dams, ponds and stacks;
• Safety and stability of the storage facility. Failure can result in extensive and widespread
off-site effects.
• Other impacts may include: wind-generated dust from tailings; adverse effects on wild-
life; and the visual disturbance resulting from large elevated dams or tailings stacks.
9.10.1 Waste Disposal Methods
A wide variety of waste disposal methods can be employed, including

• Stacking wastes such as salt tailings in piles;
• Retention of brines in dams or ponds for storage, settling and clarification;
9.10.2 Tailings
Engineered surface containment methods such as stacks (or piles), dams and ponds can be
used to contain liquid and solid wastes. This involves an integrated system comprising engi-
neered impoundments, walls, containment dykes, liners, drains, ditches and capture wells.
These confine any adverse environmental effects of the waste to a limited area, while providing
a high degree of management control. Stacking may reduce the area of land disturbed.
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Final Engineering Design of a KCl Industrial Plant in Bolivia

From May 13 to 17, 2013 ERCOSPLAN and GNRE-COMIBOL visited the

but may be higher in January.

• Wet screening and milling

• Distribution towers for belts conveyors

In order to minimize unscheduled shutdown, critical equipment will be Design Capacity

This applies to critical process equipment identified as such on the PFD’s

ERCOSPLAN made a description of the overall process in technological Technical Description

ERCOSPLAN establishes a protocol between GNRE-COMIBOL and the Project Management

• Change order procedure

The full scope of engineering is defined in terms of activities. Project Services

Therefore ERCOSPLAN proposes the following levels working together

plant at different stages and environmental protection should be gov-

The direct CAPEX include: Cost Direct CAPEX

The total project costs are: Total Project Cost

Total project direct cost 184,513,199.22 USD

Total project indirect cost 36,902,639.84 USD

Total project contingency 11,070,791.95 USD

Total project capital expenditures 232,486,631.01 USD

4.3.4 List of Instruments 66

6 Process Design for MOP Production 78

7.4.1.21 Assembly, Mounting and Erection of Equipment at Plant Site 127

7.7.3.2 Safety Equipment 209

8.5.6 Project Change Control 230

8.10.4.4 About the Floor 262

Table 1 PCE (Process Control Engineering) Categories and Processing

ENCLOSURE 1 Supplier List Mechanical Engineering (Rev.01)

Appendix E17 Specification

Appendix Q23 Centrifuges / Siebtechnik (Rev. 01)

Quotations Drying Section

Appendix Q64 Agitator Vessel / IWZ Ingenieurbüro Wolfgang Zierz

A 0001-0999 Drawings Processing Engineering

A01/2 Block Flow Diagram

A 1000-1999 Drawings Mechanical Engineering

A 1000-1199 Basic Engineering

A 1000-1049 Process Flow Diagrams (PFD)

A 1050-1099 Piping and Instrumentation Diagrams (PID)

A 1100-1199 Arrangement Drawings

A 1350-1999 Detail Engineering

A 1350-1400 Piping and Instrumentation Diagrams (PID)

A1372/1 PID Product Storage

A 1400-1508 Arrangement Drawings

A1437 Arrangement Drawing Process Building Longitudinal Section O'-O'

E 2000-2999 Drawings Electrical Engineering

E2000/1 Power supply / Overview diagram

E2032 0.69kV-Switch gear MCC 2 / Assembly plan

E2071/1 0.4kV-Main switch gear / Overview diagram

E2101/1 Equipment / Process building Ground floor / Layout

E2106/1 Equipment tank farm / Layout

E2121/1 Main cable trays / Process building Ground floor / Layout

E2201/1 Lighting - Socket system / Power station Ground floor / Layout

E2300/1 Automation system / Overview diagram

E2305 Control cabinet ET 01 / Overview diagram

E2331 Control cabinet ET 45 / Overview diagram

E2353 Typical wiring diagram WD1.1 / Pump < 10kW

E2370 Typical wiring diagram WD6.3 / Agitator with frequency converter

E2374 Typical wiring diagram WD7.1 / Centrifuge

E2380 Typical wiring diagram WD9.1 / Two-way-distributor (on/off)

E2391 Typical wiring diagram WD15.2 / Bucket elevator >10kW

E2393 Control cabinet ET 81 / Overview diagram

E2401/1 Automation equipment / Process building Ground floor / Layout

E2406 Automation equipment / Drying section +4,0m / +6,0m / Layout

E2501/1 Power station / Room planning 0.00m, +6.00m