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Centrifuge
Current Scenario:
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Mixer
Filter Liqour
Existing Schematic
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
Filter Liqour
Centrifuged Liqour
Proposed Schematic
Centrifuge
Vendor: Ferrum, Switzerland
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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
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
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
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
13.2
Million Rs
29.9
Million Rs
4.3
Years
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
13.2
Million Rs
129.0
Million Rs
1.0
Years
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
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
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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:
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