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Founded 1991

– Confidential –
SCOPE OF
ACTIVITIES:
GENERAL COOPERATION PROPOSAL
CHEMISTRY on Soda Ash Project preparation & implementation
INORGANIC
TECHNOLOGY
Contents
PRE-DESIGN STUDIES 1. SODACONSULT IN BRIEF
• Location study
• Feasibility study 2. FIELDS OF COOPERATION
• Environmental study
2.1 Soda Ash & by-Products production processes
2.1.1 Soda Ash production process
PROCESS DESIGNS 2.1.2 Technology of Soda Ash & by-Products
2.1.3 Scope of Soda Ash Project in B.L. – example
EQUIPMENT BIDDING
2.2 Unit processes & operations
BASIC ENGINEERING 2.2.1 LSA production
PACKAGES 2.2.2 DSA production (monohydrated)
2.2.3 DSA production (compacted)
DETAIL ENGINEERING
DESIGNS
2.2.4 BIC production
• Plant Design & Piping 2.2.5 Environmental protection aspects
• Instrumentation
& Control
2.3 Unit operations
2.3.1 Material conveying systems
• Checking local
engineering 2.3.2 Dedusting systems
• Assistance at 2.3.3 Drying systems
equipment 2.3.4 Crushing & screening
procurement
2.3.5 Storing & packaging
FABRICATED EQUIPMENT 2.3.6 Silos and shipment
MECHANICAL DRAWINGS
2.4 Mechanical designs of fabricated equipment
STAFF TRAINING
2.4.1 Key column apparatuses
PROGRAMS 2.4.2 Big rotary equipment
2.4.3 Bins & storage silos for bulk materials
INSTRUCTIONS 2.4.4 Tanks for process solutions
& MANUALS
• Start-up 2.4.5 Pressure vessels
• Operation 3. OFFERED DESIGN ENGINEERING & SERVICES
• Maintenance 3.1 Stages of documentation preparation
3.2 Equipment bidding & contracting procedure
SUPERVISION SERVICES
• Erection 3.3 Used software tools
• Putting into operation 3.4 Scope of documentation & services
• Conducting
3.4.1 PRE-DESIGN STUDIES (P-DS)
guarantee tests 3.4.2 BASIC ENGINEERING PACKAGE (BEP)
3.4.3 DETAIL ENGINEERING & DESIGN (DED)
ASSISTANCE AT 3.4.4 SUPERVISION SERVICES
INDUSTRIAL RUN
3.4.5 OPERATIONAL ASSISTANCE
PROCESS CONSULTING

TECHNICAL AUDITS

BIURO: ul. F. Konecznego 8/8u, 31 - 216 Kraków, Polska, tel.(+48 12) 416 55 05, fax:420 62 61; NIP 677-004-75-55
e-mail: biuro@soda.krakow.pl ; http: www.sodaconsult.com 1/25
Consulting & Engineering Office

4. COOPERATION WITH LOCAL ENGINEERING COMPANIES


4.1 General assumptions
4.1.1 Introduction
4.1.2 Pre-design Studies
4.1.3 Basic Engineering Package
4.1.4 Detail Engineering
4.1.5 Exemplary list of the Project Units / Sections
4.2 Idea of optional cooperation at detail engineering
4.3 OPTION I
4.4 OPTION II
4.5 OPTION III
5. COOPERATION WITH OWNERS OF INNOVATIVE DESIGNS
5.1 Specific process solutions
5.2 Specific design of critical equipment
5.3 Control systems, visualization and others
6. ADDITIONAL CONSULTANCY SERVICES
6.1 PRE-DESIGN STUDIES (P-DS)
6.2 BASIC ENGINEERING PACKAGE (BEP)
6.3 DETAILED ENGINEERING & DESIGN (DED)
7. ENCLOSURES
7.1 SODACONSULT MAIN REFERENCES
7.2 Historical Folder 1991 – Soda Industry In Poland
7.3 Historical Folder 1996 – Your Partner In Project Development

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1. SODACONSULT IN BRIEF
1.1 Origins & roots
SODACONSULT has its roots in BIPROKWAS KRAKÓW, managed by A. Bukowski, where the basic
staff of the present SODACONSULT office was employed.
In 1991, to face new challenges of transforming Polish economy, two project managers – Andrzej
Auriga (Janikosoda) and Stanisław Smyk (Soda Mątwy) – founded SODACONSULT – a private
company for Consulting & Engineering Services.
In 1994 the owners of SODACONSULT and POLIMEX-CEKOP Ltd. founded a new company
POLIMEX-SODACONSULT Ltd. – dedicated mainly to execution of the contract for Lime Burning
Plant at M.C.I. Alexandria in Egypt.

1.2 Owners & basic staff


Now, the owners of the Office are: Andrzej AURIGA, Stanisław SMYK & Bartosz SMYK
Bartosz Smyk after graduation as civil engineer, has been starting his design coordination activities
and engineering management at SODACONSULT.
Chief Engineer of the Office is Mariusz Zastawny. As chemical engineer has been starting his design
carrier at SODACONSULT.
Within the range of technological & mechanical aspects the independent advisers are Leszek
TARCZYŃSKI (long-term Technical Manager of the Polish Soda Plants and co-author of “Soda
Technology”) and Zdzisław TRZECIAK (Experienced Chief Design Engineer of the Soda Installations
and mechanical designer of critical apparatuses and machinery).
SODACONSULT staff consists of:
– experienced engineers, highly qualified, previously working at BIPROKWAS and CHEMADEX Kraków
– young engineers and economists graduated from the AGH University of Science and Technology,
the Cracow University of Technology and the Cracow University of Economics,
all located in Kraków.
The above group represents the following specializations:
• process technology
• utilities
• mechanical & piping
• instrumental & control
• electrical
• civil & structural
• cost estimation
provided for SODA PROCESS KNOW-HOW and MULTIDISCIPLINED ENGINEERING
covering offered fields of cooperation.

1.3 Special teams


A dynamic team for special tasks can be immediately assembled from the cooperating specialists
living in Kraków. For larger projects, SODACONSULT can organize and manage special teams in
cooperation with well-known Engineering Companies from Kraków and Warszawa.

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1.4 General offer scope – from concept to implementation

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2. FIELDS OF COOPERATION
2.1 Soda Ash & by-Products production processes
2.1.1 Soda Ash production process

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2.1.2 Technology of Soda Ash & by-Products

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2.1.3 Scope of Soda Ash Project in B.L. – example

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2.2 Unit process & operations


2.2.1 LSA production
a) Lime and CO2 production
b) CO2 compression
c) Brine purification
d) Absorption & distillation
e) Carbonation & filtration
f) Calcination

2.2.2 DSA production (monohydrated)


a) Crystallization
b) Drying
c) Crushing & screening

2.2.3 DSA production (compacted)

2.2.4 BIC production (compacted)


a) Soda solution preparation
b) Solution filtration
c) Solution carbonation
d) Drying
e) Crushing & screening
f) Storing & shipment

2.2.5 Environmental protection aspects


a) Washing of slurry
b) Decantation & clarification
c) Filtration
d) Fertilizer chalk production

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2.3 Unit operation


2.3.1 Material conveying systems
a) dusts
b) liquids
c) pulps
d) solids

2.3.2 Dedusting systems


2.3.3 Drying systems
2.3.4 Crushing & screening
2.3.5 Storing & packing
2.3.6 Silos and shipment

2.4 Mechanical designs of fabricated equipment


2.4.1 Column type apparatuses
a) Carbonating towers
b) Distillation towers
c) Washers

2.4.2 Big rotary equipment


a) Lime slakers
b) Calciners

2.4.3 Bins & storage silos for bulk materials

2.4.4 Tanks and mixers for process solutions

2.4.5 Pressure vessels

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3. OFFERED DESIGN ENGINEERING & SERVICES


3.1 Stages of documentation preparation

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3.2 Equipment bidding & contracting procedure

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3.3. Used software tools


For execution of offered design engineering we are using below updated software systems.

No Documentation Designing Software Notes


1 2 3 4

1. Plant Design 1. Bentley AutoPLANT V8i Model 3D


& Piping 2. ISOGEN Pipelines isometric dwgs
3. Autodesk INVENTOR 2013 3D models of equipment
4. AutoCAD 2013 etc.
2. Instrumentation 1. CADprofi Electrical
& Control 2. Schneider Electric Library AutoCAD
3. AutoCAD 2013
3. Electrical 1. CADprofi Electrical
Installation 2. Schneider Electric Library AutoCAD
3. AutoCAD 2013
4. Civil & 1. Autodesk ROBOT Structural System Calculation + model 3D
Structural 2012
2. ZwCAD+ 2014
5. Architecture 1. Autodesk Revid Structure
2. Autodesk INVENTOR 2013
3. AutoCAD 2013
6 Others 1. Microprotol V32.8.8.2 – EuReserch UDT (TÜV) calculation
(www.microprotol.com)
2. MathCAD 14.0 Technological calculation
3. MS Excel 2013
4. MS Word 2013
5. MS Project 2003

NOTE:
1. Application of above designing tools depends on stage of design engineering to be worked out.
2. Technical documentation will be e-mailed and in papers copies.

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3.4 Scope of documentation & services


3.4.1 PRE-DESIGN STUDIES (P-DS)
 Conceptual design studies
 Site selections/evaluations
 Technology evaluation
 Technical and economic feasibility studies
 Optimization studies
 Environmental impact assessments

3.4.2 BASIC ENGINEERING PACKAGE (BEP)


 Process design
- general
- material and heat balances
- process and utilities flow diagrams
- control & visualization philosophy
- main equipment selection
- executive summary

 Basic engineering
- basic design data
- P + ID’s for process and utilities (preliminary)
- equipment arrangements
- general plot plan
- instrumentation philosophy, data sheets and schemes
- electrical general specifications, single line diagrams and load/power user summary
- civil and structural general specification, architectural concept and general arrangement drawings
- data/guide lines for local engineering and activities

 Manuals and instructions


For the whole Plant/Unit
- start-up instruction
- operating and maintenance manual
- chemist’s manual
- safety manual
For mechanical, electrical equipment and instrumentation
- vendor’s manuals

 BEP executive summary

3.4.3 DETAIL ENGINEERING & DESIGN (DED)


 Civil and structural
- concrete/foundation drawings
- structural detail drawings
- steelwork pipe supports
- building drawings
- road lay-outs
- paving and drainage drawings
- U/G coordinated drawings
- material requisitions

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 Plant design & piping


- overall site plans
- unit plot plans
- P + ID’s for process and utilities (final)
- design area matchlines
- piping arrangement drawings
- isometrics
- material requisitions

 Instrumentation/Control & visualization systems


- instrument installation schedules
- instrument lay-out drawings
- logic diagrams
- instrumentation/material requisitions

 Electrical
- tray/racking lay-outs
- cable routing drawings
- communications
- lighting lay-outs
- U/G cable trench drawings
- cable schedules
- interconnecting diagrams
- substation lay-outs
- material requisitions

 Detail mechanical drawings


For fabricated critical equipment
- technical specifications
- assembly drawings
- drawings of subassemblies
- drawings of main details
- operating and maintenance manuals

3.4.4 SUPERVISION SERVICES


 Local detailed engineering
- assistance / supervision and checking the multidiscipline detailed engineering
- assistance/supervision and checking detailed mechanical drawings of fabricated eq-nt
- assistance in obtaining approvals from local authorities

 Technical procurement
- imported critical equipment and machinery
- local equipment and materials
- spare parts for proprietary equipment and others

 Inspection of equipment fabrication


- supervising during fabrication
- inspection before shipment
- assistance at packing and storing

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 Civil works & structural


- supervising in compliance with Plant Design & Piping requirements

 Equipment assembly/erection
- supervision of field – assembled big equipment, locally fabricated or imported
- erection supervising of the equipment and installation
- supervision of mechanical completion operations
- supervision of pre-commissioning operations

 Commissioning & start-up


- supervision of start-up activities
- management of performance tests and commissioning

3.4.5 OPERATIONAL ASSISTANCE


 Technical management
- assistance at plant operation

 Training & technology transfer


- training program
- theoretical and practical training conducting

 Revamp & debottlenecking services


- yield improvement studies
- expertizes on bottlenecks and trouble shooting

 “As-built” documentation
- machinery and equipment lay-outs
- P+ID’s and piping isometrics
- instrument details and lay-outs
- electrical lay-out and cable details
- complete list of plants and equipment

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4. COOPERATION WITH LOCAL ENGINEERING COMPANIES


4.1 General assumptions
4.1.1 Introduction
 SODA WORKS to be designed by SDC including optional participation of INV
 OFF-SITE INSTALLATIONS to be designed by INV including coordination,
guidelines, consultations & checking of SDC

4.1.2 Pre-design Studies


 BASIC REPORT / Feasibility Study to be elaborated by SDC
 PRELIMINARY BUSINESS PLAN to be elaborated by INV including participation of SDC

4.1.3 Basic Engineering Package


 SODA WORK as a whole to be elaborated by SDC
 OFF-SITE INSTALLATIONS – all necessary guidelines & consultation to be rendered by SDC

4.1.4 Detail Engineering


 See Optional Cooperation Proposal it. 4.3, 4.4, & 4.5

4.1.5 Exemplary list of the Project Units / Sections


 100 – DENSE SODA ASH PLANT (DSA)
 200 to 400 – SODA BY-PRODUCTS (Reserved for future)
 500 – UTILITY FACILITIES
 600 – MATERIALS & UTILITIES STORAGES
 700 – GENERAL & MAINTENANCE SERVICES
 800 – WASTE SLURRY TREATMENT
 900 – TRANSPORT INFRASTRUCTURE
 1000 – OFF – SITE INSTALLATIONS

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4.2 Idea of optional cooperation at detail engineering

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4.3 OPTION I

 SODACONSULT / Polish Engineering:


OPTION I o Complete Documentation for the
whole SODA PROJECT covering the following
SODA PROJECT UNITS Units: 100, 200, 500, 600, 700, 800, 900
(Column 3 as below)
 100 – DENSE SODA ASH PLANT (DSA)
 200 to 400 – SODA BY-PRODUCTS  INVESTOR / Local engineering:
(Reserved for the future)
o Adaptation to the local standards selected
 500 – UTILITY FACILITIES parts /disciplines (Column 6) of INVESTOR
 600 – MATERIALS & UTILITIES STORAGES documentation, as below:
 electricals
 700 – GENERAL & MAINTENANCE SERVICES  civil & structural
 800 – WASTE SLURRY TREATMENT  interconnections
 900 –TRANSPORT INFRASTRUCTURE  roads & railways
 general lay-out
 1000 – OFF- SITE INSTALLATIONS
to be agreed later on

Polish En-ng Local En-ng


Guidelines Adaptation
No Multidiscipline Detail Engineering
EXECUTION consulting EXECUTION to local
checking standards
1 2 3 4 5 6
1. PLANT DESIGN & PIPING X – – –
2. INSTRUMENTATION & CONTROL X – – –
3. ELECTRICAL INSTALLATIONS X – – X
4. CIVIL & STRUCTURAL X – – X
5. INTERCONNECTIONS X – – X
6. ROADS & RAILWAYS X – – X
7. GENERAL LAY-OUT X – – X

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4.4 OPTION II

 SODACONSULT / Polish Engineering:


OPTION II o Documentation for the whole SODA PROJECT
covering the following Units: 100, 200, 500,
SODA PROJECT UNITS 600, 700, 800 & 900 (Column 3) excluding the
below parts/ disciplines (Column 5):
 100 – DENSE SODA ASH PLANT (DSA)  electricals
 200 to 400 – SODA BY-PRODUCTS  civil & structural
(Reserved for the future)  interconnections
 500 – UTILITY FACILITIES  roads & railways
 general lay-out
 600 – MATERIALS & UTILITIES STORAGES
o Guidelines, consulting & checking of INVESTOR
 700 – GENERAL & MAINTENANCE SERVICES below documentation
 800 – WASTE SLURRY TREATMENT
 900 –TRANSPORT INFRASTRUCTURE  INVESTOR / Local Engineering:
o Documentation for the whole SODA
 1000 – OFF- SITE INSTALLATIONS PROJECT as above, covering selected
to be agreed later on
parts/ disciplines as below (Column 5):
 electricals
 civil & structural
 interconnections
 roads & railways
 general lay-out

Polish En-ng Local En-ng


Guidelines Adaptation
No Multidiscipline Detail Engineering
EXECUTION consulting EXECUTION to local
checking standards
1 2 3 4 5 6
1. PLANT DESIGN & PIPING X – – –
2. INSTRUMENTATION X – – –
& CONTROL
3. ELECTRICAL INSTALLATIONS – X X –
4. CIVIL & STRUCTURAL – X X –
5. INTERCONNECTIONS – X X –
6. ROADS & RAILWAYS – X X –
7. GENERAL LAY-OUT – X X –

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4.5 OPTION III

 SODACONSULT / Local Engineering:


OPTION III o Complete Documentation for production
& storing of the SODA PROJECT covering the
SODA PROJECT UNITS following Units: 100, 200, 600 & 800 (Column 3)
o Guidelines, consulting & checking of INVESTOR
 100 – DENSE SODA ASH PLANT (DSA)
below documentation (Column 4)
 200 to 400 – SODA BY-PRODUCTS
(Reserved for the future)
 INVESTOR / Local Engineering:
 500 – UTILITY FACILITIES o Complete Documentation for utilities, general
 600 – MATERIALS & UTILITIES STORAGES & maintenance services, roads & railways
covering the following Units: 500, 700 & 900
 700 – GENERAL & MAINTENANCE SERVICES
(Column 5)
 800 – WASTE SLURRY TREATMENT o Adaptation of SODACONSULT documentation
 900 –TRANSPORT INFRASTRUCTURE to the local standards (Column 6)

 1000 – OFF – SITE INSTALLATIONS


to be agreed later on

Polish En-ng Local En-ng


Guidelines Adaptation
EXECUTION consulting EXECUTION to local
No Multidiscipline Detail Engineering checking standards
100+200+ 500+700+
600 +800 500+700+ 900 100+200+
900 600+800
1 2 3 4 5 6
1. PLANT DESIGN & PIPING X X X –
2. INSTRUMENTATION & CONTROL X – X –
3. ELECTRICAL INSTALLATIONS X – X X
4. CIVIL & STRUCTURAL X – X X
5. INTERCONNECTIONS X X X X
6. ROADS & RAILWAYS X X X X
7. GENERAL LAY-OUT X X X X

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5. COOPERATION WITH OWNERS OF INNOVATIVE DESIGNS


5.1 Specific process solutions

5.2 Specific design in critical equipment

5.3 Control systems, visualization and others

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6. ADDITIONAL CONSULTANCY SERVICES AT DESIGN DEVELOPMENT


6.1 PRE-DESIGN STUDIES (P-DS)

ENGINEERING STAGES INVESTOR SODACONSULT


LOCAL SUPPLIER ORDERING CONSULTING SERVICES

 Conceptual design studies


 Site selections/evaluations
< Draft of Invitation to bid (ITB)
 Technology evaluation
P-DS BIDDING &
< Offers/quotations collecting & comparison
 Technical and economic SUPPLIER SELECTION
feasibility studies < Recommendations for contracting

 Optimization studies
 Environmental impact
assessments
 Equipment bidding

< Participation in negotiation (option)


P-DS CONTRACTING
< Advising at contract signing

< Checking Telecon Records


< Checking Design Reports
MONITORING P-DS < Participation in key design meetings
PROGRESS &
DESIGN MEETINGS < Documents transmission way proposal
< E-mail communication system proposal
< Elaboration Design Progress Reports

< Checking recommendations fulfilment by the


Supplier
P-DS APPROVAL < Draft of Final Approval Report
< Participation in the Final Approval meeting
(option)

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6.2 BASIC ENGINEERING PACKAGE (BEP)


ENGINEERING STAGES INVESTOR SODACONSULT
LOCAL SUPPLIER ORDERING CONSULTING SERVICES

 Process design < Draft of Invitation to bid (ITB)


- general BEP BIDDING
< Offers/quotations collecting & comparison
- material and heat balances & SUPPLIER
SELECTION < Recommendations for contracting
- process and utilities flow diagrams
of BEP Supplier
- control & visualization philosophy
- main equipment selection BEP SUPPLIER < Participation in negotiation (option)
- executive summary CONTRACTING < Advising at contract signing (option)
 Basic engineering
< Comment to Supplier execution time schedule
- basic design data
DETAILED TIME < Comment to detailed list of documentation
- P + ID’s for process and utilities
SCHEDULE OF THE (contents)
- equipment arrangements BEP DEVELOPMENT
< Participation in discussion & agreements
- general plot plan
- instrumentation philosophy, data
sheets and schemes < Draft of visiting program
SITE VISITING
- electrical general specifications, < Participation in the site visit (option)
APPROVAL
single line diagrams and
< Draft of visiting Report
load/power user summary
- civil and structural general < Checking Supplier enquiries &
specification, architectural recommendations
concept and general arrangement
drawings KEY EQUIPMENT < Copies of offers/quotation collecting & comparison
BIDDING & DESIGN
- data/guide lines for local DATA < Recommendation for selection of 3. potential
engineering and activities deliverers
TRANSMISSION
 Manuals and instructions < Checking design data to be transmitted
For the whole Plant/Unit to BEP Supplier
- start-up instruction
- operating and maintenance < Checking Telecon Records
manual
< Checking Design Reports
- chemist’s manual
MONITORING < Participation in key design meetings (option)
- safety manual BEP PROGRESS
& DESIGN MEETINGS < Documents transmission way proposal
For mechanical, electrical equipment
and instrumentation < E-mail communication system proposal
- vendor’s manuals
< Elaboration Design Progress Reports
 BEP executive summary
< Checking key items of BEP & recommendations
BEP PRELIMINARY
APPROVAL – < Draft of Preliminary Approval Report
working version
< Participation in the Approval meeting (option)

< Recommendations fulfilment by the Supplier


BEP FINAL
< Draft of Final Approval Report
APPROVAL – final
version < Participation in the Final Approval meeting
(option)

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6.3 DETAIL ENGINEERING & DESIGN (DED)

ENGINEERING STAGES INVESTOR SODACONSULT


LOCAL SUPPLIER ORDERING CONSULTING SERVICES

 Civil and structural < Draft of Invitation to bid (ITB)


- concrete/foundation drawings DED BIDDING &
SUPPLIER SELECTION < Offers/quotations collecting & comparison
- structural detail drawings
- steelwork pipe supports (Option) < Recommendations for contracting
- building drawings
- road lay-outs < Comment to the draft of DED Supplier contract
- paving and drainage drawings DED SUPPLIER
CONTRACTING < Participation in negotiation
- U/G coordinated drawings
- material requisitions (Option) < Advising at contract signing
 Plant design & piping
- overall site plans
< Comment to Supplier schedule
- unit plot plans
of documentation execution
- design area match-lines DETAILED TIME
SCHEDULE & < Comment to detailed list of documentation
- piping arrangement drawings
- isometrics LIST OF < Comment to schedule of telecons & design
DOCUMENTATION meetings
- material requisitions

 Instrumentation/Control < Participation in discussion & agreements


& visualization systems
- instrument installation schedules < Draft of visiting program
- instrument lay-out drawings SITE VISITING
< Participation in the site visit (options)
- logic diagrams APPROVAL
- instrumentation/material < Draft of visiting Report
requisitions
< Checking Supplier contractual specifications
 Electrical KEY EQUIPMENT & recommendations
- tray/racking lay-outs CONTRACTING
- cable routing drawings & CONTRACTUAL < Participation in the contract negotiation
- communications DATA < Advising at guarantee test procedure
- lighting lay-outs TRANSMISSION
TO DED SUPPLIER < Checking the time schedule of contractual
- U/G cable trench drawings
data transmission
- cable schedules
- interconnecting diagrams < Checking Telecon Records
- substation lay-outs < Checking Design Reports
- material requisitions
MONITORING DED < Participation in key design meetings
 Detail mechanical drawings PROGRESS &
For fabricated critical equipment DESIGN MEETINGS < Documents transmission way proposal
- technical specifications < E-mail communication system proposal
- assembly drawings < Elaboration Design Progress Reports
- drawings of subassemblies
- drawings of main details DED PRELIMINARY < Checking key items of DED & recommendations
- operating and maintenance APPROVAL < Draft of Preliminary Approval Report
manuals – working version < Participation in the Approval meeting

< Recommendations fulfilment by the Supplier


DED FINAL < Draft of Final Approval Report
APPROVAL
< Participation in the Final Approval meeting
– final version
(option)

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7. ENCLOSURES
7.1 SODACONSULT MAIN REFERENCES
7.2 Historical Folder 1991 – Soda Industry in Poland
7.3 Historical Folder 1996 – Your Partner in Project Development

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