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Click to edit Master subtitle style Centrifuge

Centrifuge
Current Scenario:
q

Bicarb Cake has residual moisture of 17 18.5%

Approximately 40 - 45% of the generated HP steam is consumed at the Calciners


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Crude Bicarb 17-18.5% Moisture Magma Rotary Filter

Return Ash Calciner Soda Ash

Mixer

Filter Liqour

Existing Schematic

ICI Pakistan Limited is now part of

Centrifuge
Proposal: Installation of a centrifuge downstream of the rotary filters Purpose: Reduce the steam consumption at the Calciners by reducing the moisture content of the Bicarb Feed

Crude Bicarb 12 - 13.5% Moisture Magma Rotary Filter Centrifuge


Mixer

Return Ash Calciner Soda Ash

Filter Liqour

Centrifuged Liqour

Proposed Schematic

ICI Pakistan Limited is now part of

Centrifuge
Vendor: Ferrum, Switzerland
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Centrifuges at RSB from Ferrum

Ferrum Proposes Pusher Centrifuge q Moisture reduction 17% to 12 % on Calciner 3 & 4 & 18.5% to 13% on Calciner 1 & 2 Benefits: q Steam consumption on the basis of designer specifications reduces 0.05 T PTA q Moisture content in Bicarb will increase the operating life cycle of the Calciner

ICI Pakistan Limited is now part of

Centrifuge
Phase wise Installation

Phase 1: Installation of Centrifuge on the upstream of Calciner 3 by 2012 Phase 2: Installation of Centrifuge on the upstream of Calciner 4 by 2013 Phase 3: Installation of Centrifuge on the upstream of Calciner 1 & 2

ICI Pakistan Limited is now part of

Centrifuge
Cost Saving for Phase I:

Furnace Oil Annual Reduction in Energy Cost Total Cost of Utilities / Year Actual EBITDA for the Business Total Estimated Project Cost Project Payback After Considering Utilities 142.2 13.2 129.0 127.9 1.0

Gas 43.1 13.2 29.9 127.9 4.3

Units Million Rs Million Rs Million Rs Million Rs Years

ICI Pakistan Limited is now part of

Cost Saving Calculations (with Gas)


Financial Benefit of Installing 1 Centrifuge Upstream of Calciner 3 Steam Reduction for 1 % Moisture 0.05 tons PTA Reduction Present Moisture in Bicarb 17.0 % Moisture in Bicarb Post Centrifuge 12.0 % Reduction in Moisture 5.0 % Steam Reduction 0.25 tons PTA Daily Capacity of Calciner 3 350.0 TPD Daily Steam Reduction 87.5 TPD Boiler Efficiency @ 917 Btu /ft3 9.0 dm3 PTS Rs / Cost of Natural Gas in 2012 483.7 MMBtu Cost of Natural Gas @ 917 Btu /ft3 in 156.5 Rs / dm3 2012 Daily Reduction in Natural Gas 787.5 dm3 / day Daily Reduction in Energy Cost 123,241.5 Rs / day Days / Annual Days 350.0 year

Utilities Power Power Requirments Annual Power Requirements Cost of WAPDA Power in 2012 Annual Power Cost Cooling Water Cooling Water Requirments Annual Cooling Water Requirements Cost of Cooling Water in 2012 Annual Cost of Cooling Water

145.0 KWH 1,218,000 KW .0 10.6 Rs / kw Million 12.9 Rs 2.4 20,160.0 15.0 0.3 m3 / hr m3 Rs / m3 Million Rs

Annual Reduction in Energy Cost Total Estimated Project Cost Simple Payback

43.1 127.9 3.0

Million Rs Million Rs Years

Total Cost of Utilities / Year

13.2

Million Rs

Actual EBITDA for the Business

29.9

Million Rs

Project Payback After Considering Utilities

4.3

Years

ICI Pakistan Limited is now part of

Cost Saving Calculations (with FO)


Financial Benefit of Installing 1 Centrifuge Upstream of Calciner 3 Steam Reduction for 1 % Moisture 0.05 tons PTA Reduction Present Moisture in Bicarb 17.0 % Moisture in Bicarb Post Centrifuge 12.0 % Reduction in Moisture 5.0 % Steam Reduction 0.25 tons PTA Daily Capacity of Calciner 3 350.0 TPD Daily Steam Reduction 87.5 TPD Furnace Oil Consumption 0.077 Tons PTS Cost of Furnace Oil in 2012 60,316.0 Rs / Ton Daily Reduction in Furnace Oil 6.7 Tons 406,379. Daily Reduction in Energy Cost Rs / day 1 Days / Annual Days 350.0 year Utilities Power Power Requirments Annual Power Requirements Cost of WAPDA Power in 2012 Annual Power Cost Cooling Water Cooling Water Requirments Annual Cooling Water Requirements Cost of Cooling Water in 2012 Annual Cost of Cooling Water

145.0 KWH 1,218,000 KW .0 10.6 Rs / kw Million 12.9 Rs 2.4 20,160.0 16.0 0.3 m3 / hr m3 Rs / m3 Million Rs

Annual Reduction in Energy Cost Total Estimated Project Cost Simple Payback

142.2 127.9 0.9

Million Rs Million Rs Years

Total Cost of Utilities / Year

13.2

Million Rs

Actual EBITDA for the Business

129.0

Million Rs

Project Payback After Considering Utilities

1.0

Years

ICI Pakistan Limited is now part of

Centrifuge

Sensitivity Analysis FO
%increase 5% 10% 20% 30% 40% 50% Cost of FO oil (current) Cost of FO (Rs) EBITDA (Mil Rs) 58,800 61,600 67,200 72,800 78,400 84,000 125 131 142 154 166 177 56000 Payback (yrs) 1.0 1.0 0.9 0.8 0.8 0.7

ICI Pakistan Limited is now part of

Project Cost Calculations


Price of Centrifuge Ferrum Mechanical Equipment Mechanical Equipment Electrical Equipment Electrical Equipment Packing and Transportation 18,100.0 633,400.0 Swiss Franc Swiss Franc 6,500.0 Swiss Franc 128.0 160.0 10.0 8.0 80.0 23,040.0 Swiss Franc / hr Swiss Franc / hr days hrs hrs Swiss Franc 19,500.0 700,540.0 15.0 50.0 1,389,696 .2 92.0 127.9 Swiss Franc Swiss Franc % % of Equipment Cost Swiss Franc PKR Million Rs

Centrifuge Project Phase 1 - Centrifuge For Calciner 3 Only 25,105 Kg / hr .0 Ferrum Centrifuge Capacity 25.1 t / hr 15.8 t / hr Production of Na2CO3 380.2 TPD 16.0 t / hr Production of Soda Ash @ 99 % Purity 384.0 TPD So, the throughput capacity of One Ferrum Centrifuge is sufficient for 1 Chinese Calciner at 370 TPD Soda Ash

Packing and Transportation Installation Supervision Mechanic (Travel and Working Time) Process Engineer (Travel and Working Time) No of Days (Assuming) No of Hours / day Total Working Hours Per Person Cost of Installation Supervision Optional Equipment Optional Equipment Total Mechanical & Electrical Equipment + Transportation + Supervision Cost + Optional Equipment Cost Inflation Other Expenditures (Civil, Electrical, Structure etc) Total Estimated Project Cost 1 Swiss Franc is Equal to Total Estimated Project Cost

ICI Pakistan Limited is now part of

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Centrifuge
Current Activities:
q Sample sent to Ferrum for detailed testing q Finalization of the location of the Centrifuge in progress q Ferrum Query Form being prepared

Future Activities:
q

Revised Quotation to be sort from Ferrum

ICI Pakistan Limited is now part of

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