CLIENT

Parber Industry
Colombia

PROJECT
30,000 tpy Fine and Ultra Fine Coated PCC production plant

SCOPE OF DOCUMENT

General Process Description and

Investment overview

Cimprogetti file reference no. 1214 -P

Dated 30 /11/2009

Via Pasubio, 5 24044 Dalmine (BG) - Italy

Tel. +39-035-4550.111 Fax +39-035-4550.335
e-mail: dicom@cimprogetti.com
web: www.cimprogetti.com

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Page 1 of 21

INDEX
1.

Foreword ................................................................................................ 3

2.

Plant capacity ........................................................................................ 4

3.

Limestone specifications (typical) ....................................................... 5

4.

Utilities Specification ............................................................................ 6

5.

Battery limits .......................................................................................... 7

6.

Process and equipment general description ...................................... 8

7.

General exclusions and items not included in the quotation .......... 12

8.

Budgetary quotation............................................................................ 13

9.

Engineering documentation ............................................................... 14

10.

Site Services ........................................................................................ 15

11.

Terms of Delivery................................................................................. 16

12.

Technical & costing notes on limestone laboratory analysis

and production of PCC sample .......................................................... 17

13.

LONG TERM ASSISTANCE ................................................................. 19

14.

Budgetary quotation clause ............................................................... 20

15.

Contacts ............................................................................................... 21

16.

Annexes................................................................................................ 21

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1.

Foreword

As initial guidelines to evaluate the technical and commercial aspects for a PCC plant,
CIMPROGETTI is pleased to submit this budgetary evaluation for the following:
One Fine uncoated and Ultra Fine Coated Precipitated Calcium Carbonate (PCC) plant
30,000 tpy (dry basis) capacity complete with 30,000 tpy capacity drying section
Included one kiln 150 t/d with natural gas fuel

However, we wish to point that at a later stage a final proposal including guaranteed plant
performances should be prepared on the basis of:
-

the required tests in our laboratory on the actual raw material. In fact, most of the
design variables may be finalized only after performing these laboratory scale tests on
the raw materials available at plant site.
a site visit to review the Client responses and better understand the Clients
requirements.

The costs involved for the next step will be quantified and discussed at a later stage.

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2.

Plant capacity

Dried Fine uncoated and Ultra Fine Coated PCC

Final PCC product

residual moisture less then 0,5 %

Nominal plant capacity

30,000 tpy (dry basis), calculated over

330 operating days (plant availability: 90%
approx.) equal to an average daily capacity of
90 t

Crystal morphology

scalenohedral uncoated PCC CIMFIL DRY

and rombohedral NANOCIM coated PCC

PCC product grade specification (Typical values)

See attached data sheets

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3.

Limestone specifications (typical)

Basically the suitable quality of the raw material (limestone) is linked to the required quality of
the finished product (PCC).
A typical limestone specification for initial screening may be as follows:
CaCO3:
MgCO3
Fe2O3:
Al2O3:
MnO:
SiO2:
Acid Insoluble:

> 97%
0,5%
< 0,1%
< 0,5%
< 100 ppm
< 0,5%
< 0,5%

The limestone (and the lime during the calcination) should have a good mechanical
resistance, thus having a lot tendency to decrepitate (to produce fines).
The limestone surface must be free from clayish material

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4.

Utilities Specification

4.1

Fuel

Natural gas
Pressure at battery limits: 3-5 Bar G

4.2

Process water

Temperature
Pressure at battery limits
Allowable pressure variation
Composition

4.3.

30 C (max)
2 bar
0.3 bar
filtered industrial water without color

Electric power

Main voltage
Frequency
Short circuit current
AC Motors
Power equipment feeders
Auxiliary control for panels
Computers system supply
Automation system (PLC) supply
I/O PLC
Process instrumentation supply
Process instrumentation signals
Solenoid valves

400V 10% 3 phases + PE TN-S system

60Hz 1%
35kA
400VAC 3 phases + PE
400VAC 3 phases + PE
240VAC
240VAC
240VAC
24VDC
230VAC
4 20mA
240VAC

Important note:
The consistent availability of electric power is essential for the control of crystal growth of
produced PCC.

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5.

Battery limits

Limestone
Fuel
Compressed air
Drains
Solid waste
Process water
Exhaust gas
Electrical motors feeding
Electric power for control system Feeding

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from plant feeding hopper discharge

from a flange at the kiln basement
PCC building wall (single point)
drain pits (excluded)
screw conveyors (excluded)
PCC building wall (single point)
vent stacks
MCC terminals
control panel terminals / computer console
terminals

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6.

Process and equipment general description

6.3.

Process chemistry

The chemistry of the CIMPROGETTI process follows the milk of lime carbonation route to
PCC.
The first step of the process is milk of lime preparation. Quicklime slakes in contact with
excess water and the following exothermic reaction takes place:
CaO + H 2 O Ca(OH)2
The result of such reaction is calcium hydroxide slurry (milk of lime). The aim of
CIMPROGETTI design is to obtain high and constant quality milk of lime. In fact, exact and
constant calcium hydroxide particles specifications are the key to drive the following
carbonation stage towards the desired PCC particle shape and size.
The carbonation stage is actually a process of absorption with reversible exothermic chemical
reaction:
Ca(OH)2 + CO 2 CaCO 3 + H2 O
The carbonation reaction must be carefully tracked in order to control the PCC quality. Particle
shape and size control is attained by operating conditions control and reactor cleanliness.

CIM-Aquamatic
H2O

CO2 Scrubbing
& Delivery

Slake Tank

CIM-Carbonator
PCC Tank

CIM-Digidoser

CIM-Slaky
Lime (CaO)

Temp. Control

Lime Kiln & CO2 Delivery

6.4.

Lime Slaking & Storage

CO2

Carbonation & PCC Storage

The PCC laboratory

Although to let carbon dioxide bubble in milk of lime is
relatively easy, every different kind of quicklime and
flue gas composition require their own operating
parameters to match the exact PCC particle and shape
requirements.
Every bad batch run is definitely an appreciable waste
of money.
CIMPROGETTI asks to its customers to supply a limestone
sample for full analysis. Then CIMPROGETTI actually runs in its
PCC laboratory a complex test procedure in order to identify the
Best operating parameters and to fine tune the CIMPROGETTI
PCC Process Design. Consequently, the CIMPROGETTI Final

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Proposal is the best compromise between Fixed Capital Investment, Manufacturing Costs and
Profitability.

6.5.

Milk of lime preparation.

A high accuracy feeding and dosing system feeds the quicklime from the silo to the slaker
CIM-SLAKY, where it is mixed with water to produce milk of lime.
Water is carefully dosed to match the required operating parameters.
The slaker CIM-SLAKY itself is divided in three stages, two of which are violently stirred,
while the third acts as a decanter with built-in automatic grits remover. The slaker CIMSLAKY is operated at optimum conditions for best specific surface area. The improved
water distribution system gives dust and vapor free operation.
Milk of lime is then screened in a self-cleaning vibrating screen or hydrocyclone system,
specially designed for milk of lime. Then it is stored in the Slaking tank, which is both an aging
tank and a buffer for the rest of the plant, which operates on a batch basis.
Milk of lime is fed through high efficiency, easy to clean, plate heat exchangers to the lime
tank (also stirred). Then the slurry is transferred to the carbonator CIM-CARB.
Both the lime tank and the heat exchangers incorporate washing facilities.

6.6.

Carbonation and gas treatment

The gas treatment and compression section continuously supplies clean flue gas to the
operating carbonator CIM-CARB at the suitable pressure. Gas compression is obtained by
Liquid Ring Compression system, for optimum steady state operation.
In the carbonators CIM-CARB in operation the incoming flue gases are finely dispersed in
the milk of lime slurry by means of violent agitation. The agitators themselves are double
turbines, computational fluid dynamics designed units, special design for gas in slurry
dispersion.
The agitator and the gas compression keep running for a pre-set time after 100% conversion
of milk of lime is reached, then the precipitated calcium carbonate slurry is transferred to the
PCC tank.
The carbonators CIM-CARB are washed after each batch cycle with a high efficiency
cleaning system.
The PCC slurry is continuously transferred from the PCC tank to a self cleaning vibrating
screen, special design for PCC, and then is sent to coating reactor.

6.7.

Coating preparation

A dedicated tank is used for the coating preparation.

6.8.

PCC coating reactor

After the screening, the PCC is added with the coating preparation.
After the end of reaction, the coated PCC is transferred into a reserve tank

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6.9.

Filtration

A suitable filter is used to filter the Ultrafine coated PCC suspension until a concentration of
about 55 %
A suitable filter is used to filter the Fine PCC suspension until a concentration of about 35 %

6.10.

Drying

Suitable dryers are used to dry the cake coming from the filtration.

6.11.

Milling

A dedicated mill ground the Fine PCC

A dedicated mill ground Ultrafine coated PCC.

6.12.

Packaging

The packaging consist in filling bags of 25 kg or Big Bags.

6.13.

Water and utilities network

The aim of the water network is to reduce at the lowest possible value the plant power
consumption and the utilities waste.
The main components are:
Decanters / storage tanks for the utilities water
One forced draft cooling tower
Pump and valves for service water distribution
Chiller package, air cooled
The system shall be designed to meet the local climatic conditions.

CIM-ISSY-32- Plant Automation and Computerised Supervision System

6.13.1. General philosophy
The general philosophy behind CIMPROGETTI's controls is easy:
Make intrinsically stable, reliable and flexible equipment by mixing experience, technology
and research.

Control it with easy and sound software, so that even an inexperienced operator can get
the best out of the plant.

6.13.2. Functional system architecture

The CIM-ISSY-32 (Integrated Supervision System) is the control system for the lime
production process, specially designed by CIMPROGETTI, software of last generation working
at 32 bit.
The CIM-ISSY-32 system consists of two main parts:
1. CIM-MMI for plant control and regulation on PC, (personal computer)

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2.

CIM-MATIC for automation of the plant with a PLC.

The CIM-ISSY-32 consists of the following modules:

MIMICS (only for the CIM-MMI)
ALARMS
TRENDING & MONITORING
OPERATIONAL & MAINTENANCE SUPPORT
SETTINGS
TECHNOLOGICAL DATA MANAGEMENT
OPERATIONAL DATA REPORTING

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(SYN)
(ALA)
(T&M)
(OMS)
(SET)
(TDM)
(ODR)

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7.

General exclusions and items not included in the

quotation

The following are not included in Cimprogettis quotation:

all equipment outside battery limits
packaging section, if any
civil works design and construction
ventilation and/or air conditioning system
safety equipment
drainage system
waste (solids and liquids) treatment system
lighting system and lightning rod, as applicable
the obtainment of permits, authorizations and licenses of whatsoever nature in connection
with this project,
taxes, duties and fees of any nature to be paid outside Italy in connection with this project.

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8.

Budgetary quotation

The expected evaluation of the Cimprogetti portion of supply is in the range between
10 and 12 M including a typical Technical Assistance package.
The expected evaluation of the Cimprogetti portion of supply may be in the range between
50% and 60 %.

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9.

Engineering documentation

CIMPROGETTI will supply the license, know-how and one complete set of engineering
documents relevant to plant construction, erection, commissioning and start-up, operation of
the PCC plant.
General & Process engineering
Process flow diagram (PFD)
Process and Instrumentation diagram of the plant (P&ID)
Plant lay-out drawings (with elevations)
One-line drawing of utilities take over points
Civil works engineering
One-line drawing of the civil works over ground
To enable the Buyer the detailed engineering of the reinforced concrete foundations: the
schematic drawing of loads and their point of application (center of gravity) for earthquake
impact evaluation, schematic drawing of the surfaces exposed to the wind force (if
applicable)
Equipment engineering
Technical specifications / data sheets / general specifications, if applicable
Supplied equipment outlines drawings
Piping/ducting engineering
Line list
Valve list
Piping/ducting arrangement drawings
Isometric drawings (if applicable)
Insulation drawings
Support arrangement drawings
Electrical & Instrumentation engineering
Motors list
Instrument and sensors list
Cable list (tag, origin and destination points, section and type of cable)
Basic cable way routing plan (schematic)
Interconnecting diagrams
Devices lay-out (location plan)
Typical details of installation
Electrical and automation block diagram
Functional description of the plant
Manuals Package
Erection manual
Operational manual
Use and maintenance manual of the supplied machines and equipment

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10.

Site Services

A package of Cimprogetti technical assistance services for erection and start-up will be
included in the Seller scope of supply.
The Buyer shall make available a qualified representative English speaking, for the duration of
Cimprogetti personnels presence on site.
Training of the Buyer personnel is included in the start-up of the facility. It is important that the
Buyer personnel be available at least one month prior to the mechanical completion of the
plant. Classroom and laboratory training will occur at this time.
Technical assistance at the plant site is calculated based on a typical project schedule lasting
maximum 3 months commissioning. The proposed package includes 340 man days. It may
require adjustments in case of construction difficulties or Buyers product needs changing. All
days away from Cimprogettis office is considered a man-day. Excess man-days, trips and
expenses shall be invoiced additionally, as the case may be.

Erection supervision and assistance service

1 Mechanical engineer
1 Electrical engineer

Supervision and assistance services to Commissioning and Start-up

1 Process engineer
1 Mechanical engineer
1 Electrical engineer
1 Software engineer

Certification of laboratory and measuring procedures and load tests

1 Process engineer
1 Software engineer
1 Laboratory technician

Supervision and assistance to plant product fine tuning

1 Application engineer
1 Process engineer
1 Software engineer

Supervision and assistance to plant taking over test

1 Process engineer
1 Software engineer
1 Laboratory technician

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11.

Terms of Delivery

The delivery of Cimprogetti portion shall take place as follows:

Engineering Package
Within 10 months from EDC (manuals 12 months)
Equipment
Within 14 months from EDC (software 16 months)
Plant Commissioning
Within 18 months

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12.

Technical & costing notes on limestone laboratory

analysis and production of PCC sample

12.1.

Foreword

These notes refer to the following:

STEP A: determination of the suitability of a special limestone quality (sample) for

PCC production

STEP B: generation of PCC samples in slurry or dry form for the various grades, as
per project's requirements, for examination by the Plant Buyer and/or by the PCC
grades End User.

12.1.1. STEP A1
Raw material requirement: 5 kg in size 50-100 mm approx.
Chemical analysis
The qualitative and quantitative content of the following elements/components shall be
determined:
Fe, Mn, V, Cn, Ni, Pb, Cd, As, Cl, SO4 and piritic S, Mg, Na, K, Hg, Cr, Ba, Si, Sr (Strontium),
Insoluble Residue
Costs
As precise chemical analysis must be carried out by certified Laboratories, Cimprogetti would
request the partial contribution of Euro 1.500,- for each sample, to obtain the relevant Test
Report.

12.1.2. STEP A2
In case the PCC plant project features a new lime kiln, additional tests have to be carried out
in Cimprogetti laboratory in order to establish the burning suitability of the raw material.
Such tests will cover the following:

Mechanical resistance test (Cimprogetti proprietary method) both of raw material and
lime
Burning test
Slaking test, according to the agreed method (standard DIN, ASTM, etc.)

Cost
st
nd
1 and 2 sample shall be tested at no cost to the Buyer

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rd

From the 3 sample received onwards and for each sample Cimprogetti would request the
additional partial contribution of Euro 500,- for each sample, to carry out the above Laboratory
tests.
Contemporary testing of multiple samples benefits of 50% cost reduction for each.

12.1.3. STEP B
Raw material requirement: 20 kg in size 50-100 mm approx.
Lab production in batch of various PCC grade samples Max. two sample of PCC grade (s) in
the forms stated here below shall be produced to assess the effective Project Plant
performance on laboratory scale; these samples shall be despatched to the buyer, for due
evaluation by him self and/or the End User. Order for samples shall be for similar
characteristics, i.e. for all slurry or all dry samples.
Sample forms
Slurry form (approx. 20% w/w): 10 litres each
Dry form: 1 kg each of normal Scalenohedral Grade (e.g. for paper/cigarette paper
making), not ultra Fine Coated (UFC) Grade.
Whiteness determination (for paper making end uses).
"Whiteness" degree shall be determined, using one sample in slurry form.
Costs:
Cimprogetti would request the additional partial contribution of Euro 5.000,- for each sample,
to carry out the above Laboratory activities and to obtain the required Test Reports by
Certified Laboratories.
Notes:
Said contribution shall be paid up-front.
These expenses shall subsequently be reimbursed to the Buyer in case of a PCC
Plant Contract awarded to Cimprogetti, by deduction from the contract negotiated
amount.

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13.

LONG TERM ASSISTANCE

The following additional services will be available upon specific request from the Buyer.
Conditions shall be offered at a later stage.

PLANT MANAGEMENT AND OPERATIONS OPTIMISATION SERVICES

Plant management
An experienced PCC Plant Manager will assure the optimal mix between costs and
performances.

Plant supervision
An experienced PCC plant supervisor will boost the PCC quality and coach the PCC
plant team.

Personnel training
Cimprogetti can provide to the PCC team an extended specific training.

Plant operations audit

A team of experienced PCC specialists may come to the plant site, even on a
periodical basis, to asses PCC plant operations, to tune-up the plant procedures and
to check the working conditions of the equipment.

Remote plant supervision

If required, the PCC plant control system may be connected to Cimprogettis
headquarters for a remote check of the plant working parameters.

APPLICATION AND TECHNOLOGY SERVICES

PCC laboratory services
The PCC team and advanced instrumentation available at Cimprogetti technological
laboratory are at the Customers disposal for raw material and finished product detailed
analysis, product assessment and PCC pilot test.

PCC change grade

Process and Application Specialists will be available to modify and tune the PCC plant
in accordance to new product/s specifications.

Technology update
Cimprogetti will keep his Customers updated on the development of his PCC
technology improvements.

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14.

Budgetary quotation clause

This quotation is the property of Cimprogetti. It is confidential and/or privileged. The use of any
information included in the present budgetary quotation that may be detrimental for
Cimprogetti is not allowed. Cimprogetti will take legal action with respect to it if that case will
take evidence.

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15.

Contacts

For any inquiry and/or clarification on the present document please contact:
CIMPROGETTI S.p.A.
Via Pasubio, 5
24044 Dalmine Italy

Phone:
Fax:
e-mail

+39 035 4550 111 (operator)

+39 035 4550 335
dicom@cimprogetti.com

Mr. Bruno Facchinetti

Assistant General Manager
Marketing & Sales Manager

Phone:

+39 035 4550 334 (direct line)

+39 335 6965 149 (mobile phone)

Mr. Claudio Lama

Proposal Manager

Phone:

+39 035 4550 310 (direct line)

Mr. Roberto Rosa

Head of Process Unit

Phone:

+30 035 4550 361 (direct line)

Best regards

B. Facchinetti
Assistant General Manager
Marketing & Sales Manager

16.

Annexes

Nanocim SC and Cimfil Dry technical Data Sheets

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