PRODUCTION OF HANKEL PRODUCT

Product T-1 Product T-2

Requirement 1322 MT/Y Vessel Use Collied vessel Requirement 633 MT/Y
Batch Size 2.0 MT Capacity 3.5 MT Batch Size 2.0 MT
Numbers of Batches 661 Days 221 Numbers of Batches
Basis 3 batches per day After mixing it will be shifted in other Tank Basis 3 batches per day

Charging Time 1.5 Hrs Charging Time

7 Hrs
Mixing Time 3 Hrs Three Batches Mixing Time
Shifting to filling vessel 2 Hrs Shifting to filling vessel
Filling ( depend upon Packing ) 4 Hrs Approximate Filling ( depend upon Packing )
Total 11 Hrs Total

Workers Required Per batch Workers Required

Operator SABCI 1 Operator SABCI
Helpers Contractor 4 Helpers Contractor

Utilities use for above batch Utilities use for above batch
Agitator motor 5.5 KW X 7Hrs = 38.5 Kw/h x 0.14 SR 5.39 Agitator motor 5.5 KW X 7Hrs = 38.5
( Collied vessel 3 Hrs + Filling vessel 4 Hrs ) ( Collied vessel 3 Hrs + Filling vessel 4 Hrs )
Filling Pump 4.0 Kw X 4 Hrs =16 Kw/h x 0.14 SR 2.24 Filling Pump 4.0 Kw X 4 Hrs =16
Cooling of product during Mixing 66 Cooling of product during Mixing
Nitrogen 7 Nitrogen
Bucket filter and other consumable items Per batch 300 Bucket filter and other consumable items Per batch
Packaging material (Depends upon packing ) Packaging material (Depends upon packing )

Total days require to produced T-1 & T-221 + 106 =327 days / Year 27.25 days/Mont
 Vessel Use Collied vessel
Capacity 3.5 MT
317 Days 106
After mixing it will be shifted in other Tank

2 Hrs
7 Hrs

3 Hrs Three Batches

2 Hrs
4 Hrs Approximate
11 Hrs

Per batch
1
4

Kw/h x 0.14 SR 5.39

Kw/h x 0.14 SR 2.24

66
7
ems Per batch 300

27.25 days/MontPlant running 24 hr 7days /week

 PRODUCTION OF HANKEL PRODUCT

Product P-1
Requirement 1913 MT/Y Vessel Use REACTOR ER # 2
Batch Size 3.5 MT Capacity 5.0 MT
Numbers of Batches 547 Days 274
Basis 2 batches per day

Charging Time 1.5 Hrs

12 Hrs
Mixing Time 6 Hrs Two Batches
Filling ( depend upon Packing ) 4 Hrs

Workers Required Per batch

Operator SABCI 1
Helpers Contractor 4

Utilities use for above batch

Agitator motor 7.5 KW X 7Hrs = 53.9 Kw/h x 0.14 SR 7.546
Cooling of product during Mixing 97
Nitrogen 12
Filling Pump 4.0 Kw X 4 Hrs =16 Kw/h x 0.14 SR 2.24
 PRODUCTTION CAPICITY OF PLANT

REACTOR CAPACITY OF REACTOR PRODUCED (Kg) PRODUCT

AR -1 10,000 12000 x (1.25 Batch / Day ) POLYERTER
AR -2 15,000 20250 x (1.25 Batch / day) POLYERTER
AR -3 5,000 7,438 Alkyed (MEDIUM= long OIL)
AR -4 3,000 4,000 Alkyd(SHORT OIL)
ER -1 8,000 8000 x (1.25 Batch /day) ACRYLIC EMULSION
ER -2 5,000 3.5 x (2 Batch / Day Product P-1
ER -2 CV 3,500 2 x (3 Batch / Day ) Product T-1 & T-2

PRODUCTION IN METRIC TONS

AR -1 AR -2 AR -3 AR -4 ER -1
DAYS 22 Days 330 556 164 88 220
264 Per year 3,960 6,672 1,056 1,056 2,640
24 Days 360 607 178.5 96 240
288 Per year 4,320 7,284 2,142 1,152 2,880
27 Days 405 683 200.8 108 270
324 Per year 4,860 8,196 2,410 1,296 3,240
327
* The UPR production depends upon the requirement of Scott Barder
The average 1.25 batch per day .

POLYESTER ALKYD EMULSION (P+ T) TOTAL

ON 22 DAYS 10,632 2,112 2,640 3,432 18,816

ON 24 DAYS 11,604 3,294 2,880 3,744 21,522

ON 27 DAYS 13,056 3,706 3,240 4,212 24,214

Requirement to Produce Henkel Products

Operators 4 Nos To run the plant on continuous basis only to produce Henkel Products.
Labor 4 x3 =12 Nos /day
Equipment and Modification Require

1) Explosion Proof Motor with Gear Pump For filling

One for Reactor ,One for Collied vessel And one Spare
2) SS Filter Bucket 2 Numbers for both filling points
3) Filling System (tube filling machine/weighing
Scale with roller )
4) Inverter for Agitator ( Collied vessel )
5) Control Panel Room For Reactor ,collied and filling tank
control and monitoring
6) Polish of Reactor & collied vessel
7) Liquid Raw material feeding system Pump With Piping
8) Extension of collied vessel floor for Raw material feeding
9) Exhaust on Reactor/Collied vessel to condensate vapors in tank to avoid any ignition & pollution
10) Piping Installation of filling equipments and wiring
11) If needed any Certification
12) Filling vessel for the products or T-1 / T-2
13) Any change in agitation blades will increased the CAPEX.

Total amount in Saudi Rayal

Approximate
 PRODUCT 6650 long oil
8225 Medium oil
7438 Average Production
kyed (MEDIUM= long OIL) Product P-1 ,T-1& T-3
kyd(SHORT OIL) are Henkel Products
RYLIC EMULSION

oduct T-1 & T-2

ONS

ER -2 Collied Vessel TOTAL

154 132 1,644
1,848 1,584 18,816 NOTE The requirement of Product P-1 is 1913 MT/Y
168 144 1,794 Which Can be Produce in 274 Days.
2,016 1,728 21,522
189 162 2,018 NOTE The total requirement of Product T-1 + T-2 are
2,268 1,944 24,214 1955 MT /Y , Which require 326 days Production .
1,955
After fulfill the requirement of P-1 in ER # 2 and shut dow
Than Total Producton on
288 day /Year 21419 MT/Y
327 days /year 23870 MT/Y

25 working days

27 working days

30 working days

basis only to produce Henkel Products.

 3 X40,000 120,000

2 x 12,000 24,000
2X Check With Henkel

15,000
20,000

40,000
55,000
35,000
avoid any ignition & pollution 60,000
70,000
Check With Henkel
225,000

664,000
1 is 1913 MT/Y

ct T-1 + T-2 are

6 days Production .

P-1 in ER # 2 and shut down the reactor ER # 2

 Saleh & AbdulAziz
Chemical Company
At full Capacity

AR -1 AR -2 AR -3 AR -4
Product Category UPR UPR AlKYD AlKYD
Available days / Year 320 320 320 320
Available Hours 24 7,680 7,680 7,680 7,680
Production Hours 7,680 7,680 7,680 7,680
Batch Time - Hrs 19 19 21 20
Output Per Batch 12.564 21.709 6.46 4.079
# of Batches / Year 404.21 404.21 365.71 384.00
Annual Production 5,079 8,775 2,363 1,566

Per Batch Calculation

Batch Time - Hrs 19 19 21 20
Capacity - MT 9.0 15.5 4.8### 2.8
Theoritical Yield - % 91.20% 91.20% 96.00% 95%
Standard Draw - MT 8.208 14.136 4.598 2.660
Dilution Qty - MT 12.627 21.818 6557 4.141
Dilution Yield % 99.50% 99.50% 98.50% 98.5

Total output 12.5 21.5 6.458 40.78

Variable Charges:
Electricity -Kwh. 2,105 2,812 474 463
Nitrogen 45 69 17 17
Diesel- liters 43 43 43 43

Semi: Variable Charges:

Electricity -Kwhrs. 15 41.25 13 8
Diesel - Litres 2 3 2 1
Others, if any 1.69 1.99 1.42 1.29

Fixed Charges: 1554 Kw/day

Note Production of AR # 3 based on 70 % G And AR # 4 on 3560
 ER -1 ER -2 Collied
EMULSION EMULSION EMULSION
320 320 320
7,680 7,680 7,680
7,680 6,576 7,848 in 327 days
18 12 7
8.037 3.5 2
426.67 547.00 978.00 In274 Days
3,429 1,913 1,955 25,079

18 12 2
8.2 3.60 2.06 Material Charge
98.50%
8.077 3.500 2.040
8.077
99.50%

8.036 3.5 2 3 % Evaporation and handling looses

1,910 70 55 Kwh/ batch

- 6 4 ( gal)
28 - -

40 692 475
2 0 0
2.69 water Litre

1000
 REACTOR ER # 2 SS 321 (EMULSION ) 1800 Dx 3000 L x 5 TH
MOTOR OF REACTOR HEYNAU-KOPP VARIABLE K-25
VERTICAL COLUMN SS 321 273 D X1695 L
CONDENSER SS 304 43 D x 2495 L X 74 TUBES
SEPERATOR SS 304 450 D X 750 L
COLLIED VESEL LAMPID COIL SS 304 1760 D X 2620 L X 5 TH
MOTOR OF VESSEL GEARED MOTOR BAUER G 83-20/D5A4-429
MONOMER VESSEL SS0 304 1800 D x 2850 L X 4 TH
MOTOR OF MONOMER GEARED MOTOR BAUER
HOLDING VESSEL # 2 JACKET TYPE 2200 D X 3400 L
MOTOR OF HOLDING VESSEL G-82-20 /D5A4-429
CATALYST TANKS SS 304 500 DX 650 L X 2 TH
FILTER BUCKET SS 304
7.63 CU M 5 MT HAGEMANN 1986
9 -17.5 KW

20 SQ M
100 LITRE
3800 LITRES.
5.5 KW 40 RPM
6600 LITRE
5.5 KW 340 RPM
10 CU M
11 KW 34.5/ 1760 RPM 2000153
100 LITRES
1 Nos
 Production for Abahsain Scott Bader JV
Listing of Additional Capex requirement

Equipment and Modification Require

1) Explosion Proof Motor with Gear Pump For filling 3 X40,000 120,000 NOT USE BECOME SPARE
One for Reactor ,One for Collied vessel And one Spare
2) SS Filter Bucket 2 Numbers for both filling points 2 x 12,000 24,000 NOT USE
3) Filling System (tube filling machine/weighing 2X Check With Henkel NOT USE
Scale with roller )
4) Inverter for Agitator ( Collied vessel ) 15,000 NOT USE
5) Control Panel Room For Reactor ,collied and filling tank 20,000
control and monitoring
6) Polish of Reactor & collied vessel 40,000
7) Liquid Raw material feeding system Pump With Piping 55,000 NOT USE
8) Extension of collied vessel floor for Raw material feeding 35,000 NOT REQUIRE FOR OUR SETUP
9) Exhaust on Reactor/Collied vessel to condensate vapors in tank to avoid any ignition & polluti 60,000 NOT USE
10) Piping Installation of filling equipments and wiring 70,000 NOT USE
11) If needed any Certification Check With Henkel
12) Filling vessel for the products or T-1 / T-2 225,000 NOT USE
13) Any change in agitation blades will increased the CAPEX. NOT USE

Total amount in Saudi Rayal 664,000

Approximate