HCL - Acid Regeneration Plant: Tyasa I E V

Technical Specification
Project No.: D002E.00470
HCl - Acid Regeneration Plant

Fluidized Bed Process
CMI UVK Project No. : D002E.00470
TYASA
IXTACZOQUITLÁN ESTADO DE VERACRUZ
Prepared by Jörg Bollmann • Revision 2 dated 30.10.2020
CMI UVK GmbH Robert-Bosch-Strasse 12 Phone: +49 (0) 151 551 449 82
56410 Montabaur joerg.bollmann@johncockerill.com
GERMANY
Customer : TYASA Ixtaczoquitlán Estado de Veracruz
Customer Inquiry No. :
CMI UVK Project No. : D002E.00470 (Acid Regeneration Plant - Fluidized Bed Process)
TABLE OF CONTENT
Chapter 1 …………………………………………… Basic Design Data
Chapter 2 ………………………………………… Process Description
Chapter 3 ……………………………….…… Mechanical Equipment
Chapter 4 ………………………………………… Electrical Equipment
Chapter 5 ……………………………………………… Plant Dimension
Chapter 6 ……………………………………………………… 3D Model
Chapter 7 ………………………………… Description of Engineering
Chapter 8 ………………………………….………… Technical Service
Chapter 9 …………………………………………..………… Spare Parts
Chapter 10 ……………………………………………… Scope of Supply
Chapter 11 ………………………………………………… Time Schedule
Chapter 12 ……………………………….…… Performance Guarantee
Appendix
- Control and feeder diagram
- Burner control diagram
Rev.: 2
TABLE OF CONTENT Page 2
Date: 30.10.2020
© CMI UVK GmbH 2020, All rights reserved, including all rights relating to the use of this document or its contents
Chapter 1
BASIC DESIGN DATA
Rev.: 2
BASIC DESIGN DATA Page 1
Date: 30.10.2020
1 BASIC DESIGN DATA
1.1 Production Capacity of the Pickling Plant

Material …….……………………............................................... low carbon steel grades
Yearly material throughput ……….……..........………………… - t/y
Yearly operating hours …………..……….……………………… - h/y
Pickling loss (as Fe) …………...……………………………….. - %.
1.2 Liquid Effluent from the Pickling Plant

1.2.1 Waste Acid
The composition of the Waste Acid (WA) is basis for the calculation of the total capacity of
the Acid Regeneration Plant (ARP).
Volume ……….……….……………………………………………..….. 2,700 l/h
Fe2+ content ……….……….……………………………………………..….. 120 g/l
Free HCl content …..………....………………………………………….… approx. 43 g/l
Total HCl content …..…………..…………………………………………… approx. 200 g/l
Specific gravity …..…………………………………………………….…… 1.25 kg/dm³
Fe3+ content ……….………………..….…………………………………….. max. 4 g/l
Fluorides ………………………………………………….………..………... max. 5 ppm
The Waste Acid must be free of unsuspended solids and free of impurities. If there are
impurities in the waste acid, they must be specified by the customer.
1.2.2 Rinse water

The water will be used for the process.
Volume ……….……….……………………………………………..….. 1,550 l/h
Total HCl content ……………….……………………………………………. max. 17.0 g/l
Fe content ……………………………….………………….….……………. max. 5.0 g/l
Fluorides ………………………………………………….………..…... max. 5 ppm
*If not enough rinse water is available, additional industrial / demineralised water must be used.
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1.3 Plant Capacity

The ARP will be designed for a total WPL flow of …………...……………. 2,700 l/h
The capacity range of the ARP is -10% to +5% of the designed flow rate.
1.4 Products
1.4.1 Regenerated Acid
Production rate …………..………..….………………………………………. 2,980 l/h
Acid regenerating rate ………………...………..……………………………. > 99.5%
Total HCl- concentration …………..………………………………………… approx. 190 g/l
Fe content ……………………...….………………..………………………… max. 5 g/l
Note 1: Fe content in regenerated acid does not consider metal-input from rinse water
and fresh water.
1.4.2 Iron Oxide

The Oxide is a grainy granulate, dust free and free flowing.
Production rate …..………………………………………………………. approx. 463 kg/h

Fe2O3 content ……………………………….………….…………………. > 99.3 weight%
Cl- …………………………………………………..………………….…….  0.05 weight%
Particle size ……………..……………………………………… approx. 1.0 mm or smaller
Bulk density ……..……………………..………………………. approx. 3,500 kg/m³
Note: The chloride content in the oxide which is indicated above excludes other metallic
chlorides then iron chloride which may be contained in waste pickle liquor and
may not be decomposed in ARP.
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Date: 30.10.2020
1.5 Utilities
1.5.1 Consumptions
Fuel gas …..……………………….…………………………..……………….. 290 Nm³/h
Rinse water ….…….…………………………..……………..……………….. 1,550 l/h
Process Water (Demineralised water or Industrial Water) …....………….. 2,400 l/h
Cooling water …..…………………………………...…………………………. 5,100 l/h
Compressed air (Instrument air) ………..……….…….……………………. 45 Nm³/h
Electrical power …….…………………….………………………..… 230 kW
Fresh acid (32 %) …………....……………………… approx. 1.0 – 1.5 kg/t pickled material
(for information only as it depends on the pickling line)
If not enough rinse water is available, additional industrial / demineralised water must be
used. Rinse Water, which cannot be used in the ARP must be treated in a Waste Water
Treatment Plant.
1.5.2 Connected Load at the Take Over Point

The Take over point is defined near to the ARP building or Tank Farm, 1m above ground
level. The connecting will be designed with flanges and hand valves for each line.
Fuel gas ……………...………………………………………..……………….. 470 Nm³/h

(0.08 – 0.1 MPa)
Industrial water ……………………………………..…………..…………….. 5,000 l/h
(min. 0.5 MPa, max. 35 °C)
Process Water (Demineralised or Industrial water) ……...…..…………….. 5,000 l/h

(0.4 MPa, max. 35 °C)
Cooling water (closed loop) ….....………………….…………………………. 8,000 l/h

(0.4 MPa)
Compressed air (instrument air) ....…………………………………………. 70 Nm³/h

(0.5 MPa, 35 °C)
Electrical power …………….……………………………………………… 430 kW
(except Power for Auxiliaries related to Building, like power sockets, light, etc.) (./.)
Emergency power …….…………………………………………………… 40 kW

(./.)
Potable water (not continuously, only for safety shower) …..……...…….. 2,500 l/h
(0.4 MPa, max. 35 °C)
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Date: 30.10.2020
1.5.3 Conditions of the Utilities

1.5.3.1 Fuel Gas
Composition ………….………………………………….…………….……… Natural Gas
Min. calorific value ( 2%) …………………………….…………….………. 8,500 kcal
Temperature ………………………………………....………….…………. approx. 20 °C
1.5.3.2 Industrial Water

pH ………………………………...………..……………………….………….. 6.9 – 7.9
Total alkalinity (as CaCO3) ……………………………………………………. 400 ppm
Total hardness (as CaCO3) …………….…………………………………….. 420 mg/l
Dissolved solids ……………….……………………………………………. 436 mg/l
Cl- -Ion ........…………….………….………………….………………………. 80 mg/l
1.5.3.3 Demineralised Water

pH ………………………………...………..……………………….………….. 6.9 – 7.2
Conductivity ……………………………………………………………….  0.1 micro S/cm
1.5.3.4 Cooling Water

Inlet temperature ………….………………….…..………………………… 25 °C
Outlet temperature …………….……………..…..……..…………….……… 35 °C
1.5.3.5 Potable Water

Only for safety shower and eye wash needed!
Quality …...………..……..………………………….. according to the local provisions
1.5.3.6 Instrument Air

Quality ………………………………………………………..…… DIN ISO 8573-1, Class 2
Dust particles …………………….……………..………….………….….… max. 1 μm
Dew point ……………………………..………...……………….……..…... max. - 40 °C
Water content ………………………………………………………………….. 120mg/m³
Oil concentration ……………….…………….………………….....……… max. 0,1 mg/m³
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Date: 30.10.2020
1.5.3.7 Power Supply

Voltage .........………………………...…….……………………. 3 x 460 V / 115 V  10%
Frequency ……………………………………………………………………… 60 Hz  2%
Control voltage ……………………………………………………………….. 24 V, DC
Emergency power …..…….. must be available within one (1) minute after power failure!
1.5.3.8 Fresh Hydrochloric Acid

Concentration ……………………………………………..………..…... 30 - 32 weight%
Cl2 …………………………………………………………..………..…... max. 150 ppm
Fe2+ …………………………………………………………………..…... max. 10 ppm
Fluorides ………………………………………………….………..…... max. 5 ppm
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Date: 30.10.2020
1.6 Environmental
1.6.1 Exhaust Gas from the Stack

Volume …..………..……............................……….................................... 7,700 Nm³/h
N2, CO2, O2, others ….………….……………………………………………. 43 vol%
Water content ………………….…………….……………………………….. 57 vol%
Temperature ........................................................................................... approx. 85 °C
Particles ………………………….…..……….………………………….  20 mg/Nm³
(as insoluble Fe2O3 dust)
HCl ...................................................................................................  20 mg/Nm³

Cl2 ...................................................................................................  5 mg/Nm3
1.6.2 Liquid Effluent to Waste Water Treatment

Flow rate ……..………………..………………………………… none in normal operation
Note : Under normal operation the ARP does not generate any waste water. During start-
up and shut-down some waste liquid could be generated, which will be collected in
the Rinse water tank and will be reused in the process.
During periodic maintenance, plant equipment has to be cleaned with water. This
water may can be reused within the ARP process, but it could also be necessary
to send this volume to the Waste water treatment plant.
1.6.3 Noise level

Allowable site noise ……………..…….……….…………………………….. max. 85 dBA
At working area ……………..…..…………………………………..…….……. max. 85 dBA
(at 1 m distance from the equipment, Equipment with noise emission above 85 dBA shall be housed in.)
Operator room …………………………………………………….……………. max. 65 dBA
1.6.4 Pollution in working area

Particles ………………………….…..……….………………………….  5 mg/Nm³
(as insoluble Fe2O3 dust)
HCl ...................................................................................................  5 mg/Nm³
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1.7 Ambient Conditions at Site
TBD at KOM
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Chapter 2
PROCESS DESCRIPTION
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PROCESS DESCRIPTION Page 1
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2 PROCESS DESCRIPTION
2.1 Flow sheet
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2.2 Fluidised Bed Process Description

2.2.1 Reactor and Venturi Circulation System
The waste acid (WA) is fed from the tank farm to the Separator (CGS1-SP01); from where
it is recirculated through the Venturi Scrubber (HGS1-VN01). It is concentrated in the venturi
using the heat of the reactor off gas. This causes the partial evaporation of the WPL by direct
cooling of the reactor off gas from 850°C to the approximately 100°C, which in turn results
in an increase of the iron chloride concentration, which is monitored by measuring the
density of the concentrated pickle liquor (CPL). The venturi recirculation system also partially
removes dust entrained in the reactor off gas.
If the iron concentration in the WA exceeds approximately 90 g/l, additional water is required
to stabilize the overall heat balance in the venturi scrubber. This can be rinse water from the
pickling line, which has the advantage that it allows recovery of the chlorides in the rinse
water. Depending on the iron content of the WA and the management of the pickling line
parameters, a 99,5% HCl recovery rate can be achieved. The density concentration in the
Venturi circuit is regulated by an automated control system, giving steady operating
conditions.
A side stream from the circulating WA is sent by the reactor feed pump (CGS1-PU03)
through a lance into the fluidised bed in the lower part of the reactor (HGS1-RE01) where
the decomposition of ferrous chloride into hydrogen chloride gas and ferric oxide takes place
at temperature between 800°C and 850°C. The iron chloride solution injected onto the
fluidised bed forms Iron oxide, which sinters down on the seed granules in the bed to form
pellets with an onion like structure. These pellets grow up to approximately 1 mm diameter
before being discharged from the reactor.
The air used for the combustion of the fuel and the fluidisation of the oxide pellet bed is
forced into the wind box in the base of the reactor by a Roots blower (HGS1-BL01). The
height of the fluidised bed during operation influences the wind box pressure and this is used
to control the oxide discharge. The temperature profile in the reactor will be kept uniform by
adding fine Oxide into the reactor. The oxide will be grained before by an oxide mill to an
fixed particle size. The resulting flat temperature gradient results in a very long refractory
life.
Fine iron oxide particles entrained in the reactor off gas stream are separated by the Cyclone
(HGS1-CY01) and returned to the reactor through the oxide return pipe, which is fitted with
check valves to prevent gas backflow.
The gas leaving the cyclone passes through the venturi scrubber, where it is cooled and
washed by the circulating venturi liquid as described previously. The Separator (CGS1-
SP01) separates the WA from the gas stream, which leaves the separator approximately
100 °C and passed then into to the Absorber (CGS1-AB01).
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2.2.2 Absorber System

The HCl Absorber (CGS1-AB01 / AB02) is downstream of the separator. The Absorber is a
two stage adiabatic column using a combination of fresh water and rinse water to produce
Regenerated Acid (RA). The first stage (CGS1-AB01) produces the regenerated acid (RA)
which will be sent to the Storage tanks at the Tank farm. The second stage (CGS1-AB02)
reduces the concentration of HCl aerosols in the gas stream.
The Exhaust Fan (EXS1-FA01), situated downstream of the Absorber, keeps the upstream
sections of the plant under negative pressure, ensuring that no HCl fumes escape into the
atmosphere. Water will be sprayed onto the Impeller. By the intensive mixing with the gas
stream, water droplets will catch remaining HCl droplets and Oxide dust out of the exhaust
stream.
The water droplets, containing HCl and Dust particles, will be removed from the gas stream
by the following Venturi (EXS1-VN01) and the Final Scrubber (EXS1-SC01). In the final
scrubber, fresh water will be circulated over a random packing to ensure, that the emission
will be adhered.
The drains contain traces of HCl will be collected on the Bottom of the Scrubber (EXS1-
SC01). From there it will be send to the absorption column or back to the rinse water tank.
The exhaust gas from the Scrubber (EXS1-SC01) is passed over to the Drop Separator and
then let out to atmosphere through the stack.
OPTIONAL:
The Final Scrubber together with the Venturi (EXS1-VN01) can be operated as caustic soda
scrubber to reduce further the HCl concentration in the exhaust gas. In this case the waste
water will be produced which can not be reused in the ARP process and has to be send to
the Waste water treatment plant.
THIS OPTION IS NOT CONSIDERED FOR THIS PROJECT!
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2.2.3 Oxide System

The oxide pellets formed in the fluidised bed are discharged from the Reactor by means of
the bed level controlled by the wind box pressure.
The dust free oxide pellets are fed by gravity into the Rotary Valve Screw Conveyor (OXS1-
SW01) which carries it into the Bucket Conveyor (OXS1-BC01) which in turn lifts it into the
Storage Bin (OXS1-ST03) or will be filled into the Start-up/Fine Oxide Bin (OXS1-ST01)
located in the top area of the reactor. which in turn filled it into container.
The Oxide bin (OXS1-ST01 is divided into two parts. The oxide in the Start-up Bin is used
for initial start-up and during normal operation fine (grained) oxide from the second
compartment will be feed to the fluidised bed to improve of the operational conditions. The
oxide bin will be filled manually by the transport bin
2.2.4 Tank Farm

The WPL and the rinse water produced by the pickling plant are collected in storage tanks
in the ARP tank farm. The size of the storage tanks allows the pickling line and the ARP to
be operated independently of each other. The buffer volume is usually sized for a three day
hold-up time, which is sufficient to shut down and restart the ARP, for example over a
weekend. The acid recovered in the ARP is collected in storage tanks for transfer to the
pickling line. The capacity of the recovered acid tanks is usually the same as that of the WPL
tanks; the tank farm is usually piped in such a way to allow the RA / WPL tanks to be used
interchangeably.
The storage tanks for rinse water and for fresh HCl are also adapted to the capacity of the
pickling line. The tank farm is equipped with the WPL feed pumps, RA transfer pumps, rinse
water feed pumps and fresh acid pumps. The tanks are all vented and connected to a
scrubber.
A sump serves to collect all liquids in both the Tank farm and ARP which leave the process
vessels and storage tanks as overflows, drains, leaks, pump seal flushes and wash downs.
A sump pump returns these to the rinse water storage tanks or to the Waste water treatment
plant.
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Chapter 3
MECHANICAL EQUIPMENT
Rev.: 2
MECHANICAL EQUIPMENT Page 1
Date: 30.09.2020
3 MECHANICAL EQUIPMENT
All technical data’s (like dimensions, material, specifications) which are given in this
chapter are preliminary and could be changed during the Detail design.
3.1 Reactor and Venturi Circulation System
3.1.1 Reactor
Designation : HGS1-RE01 (lower part of the reactor)
HGS1-RE02 / RE03 (upper part of the reactor)
Quantity : 1 set
Size : Inner Diameter = 1.80 m (HGS1-RE01)
= 0.76 m (HGS1-RE02 / 03)
Total height = 11.00 m
Material : Welded carbon steel jacket
Inside: Refractory (insulating layer and heat resistant bricks,
partially castable material, abrasion resistant
refractory)
Outside: Heat insulation (‘Rockwool’ type and cladded with
metal sheets)
3.1.2 Fuel gas flow control unit

Designation : NGS1-NG01
Quantity : 1 set
Material : carbon steel
Accessories : all necessary piping material, control valves, instruments
according to the DIN EN 12186, skid mounted, pre-fabricated
and shop tested before shipment
3.1.3 Ignition burner system

Designation : NGS1-IBS1
Quantity : 1 set
Material : carbon steel
Accessories : all necessary piping material, control valves, instruments
according to the DIN EN 12186, skid mounted, pre-fabricated
and shop tested before shipment
Rev.: 2
Date: 30.09.2020
3.1.4 Combustion air blower

Designation : HGS1-BL01
Quantity : 1 set
Capacity : Flow rate = 3,830 Nm³/h
Pressure = 400 mbar
Type : Roots blower
Material : Cast steel
Accessories : Motor (frequency controlled), base frame shock-absorber, air
filter, silencer
3.1.5 Cyclone
Designation : HGS1-CY01
Quantity : 1 set
Size : Diameter = 1.8 m
Total Height = 8.5 m
refractory)
metal sheets)
Accessories : Dust return piping with expansion bellows and pendulum flaps
(motor driven)
3.1.6 Gas pipes

Designation : HGS1-GP01 / GP02 / GP03
Quantity : 1 set
refractory)
metal sheets)
Accessories : Man way, Inspection opening
Rev.: 2
Date: 30.09.2020
3.1.7 Venturi
Designation : HGS1-VN01
Quantity : 1 set
Height = 0.8 m
Material : Titanium with partially heat resistant refractory
Accessories : Emergency water connection
3.1.8 Diffusor
Designation : CGS1-PL01
Quantity : 1 set
Material : FRP
Accessories : Expansion joint
3.1.9 Separator
Designation : CGS1-SP01
Quantity : 1 set
Height = 3.8 m
Material : FRP
Accessories : Level control, man way
3.1.10 Venturi circulation pump

Designation : CGS1- PU01 / PU02
Quantity : 2 pieces (1 as stand-by)
Capacity : Flow rate = 45 m³/h
Head = 22 m
Type : Centrifugal pump
Material : all parts in contact with medium are made of acid resistant
material (PVDF/PP)
Accessories : Motor, base frame, coupling with coupling protection
Rev.: 2
Date: 30.09.2020
3.1.11 Acid feed pump

Designation : CGS1- PU01 / PU02
Quantity : 2 pieces (1 as “offline” stand-by, not installed)
Head = 25 m
material (PVDF/PP)
Accessories : Motor (frequency driven), base frame, coupling with coupling
protection
3.1.12 Emergency water tank

Designation : UTS1-TA01
Quantity : 1 set
Volume : 5 m³
Material : Welded carbon steel construction with protective epoxy
painting
Accessories : Level control, Float valve for automatic (mechanical) filling
Rev.: 2
Date: 30.09.2020
3.2 Absorber System
3.2.1 Waste gas pipe

Quantity : 1 set
Material : FRP
Accessories : Expansion joints
3.2.2 Absorber
Designation : CGS1-AB01
Quantity : 1 set
Total Height = 10 m
Material : FRP
Accessories : Structured Packing, Internal supports, liquid distribution
system, man way
3.2.3 Absorber II
Designation : CGS1-AB02
Quantity : 1 set
Material : FRP
Accessories : Structured Packing, Internal supports, liquid distribution
system, man way
3.2.4 Regenerated acid transfer pump

Designation : CGS1-PU05 / PU06
Head = 25 m
material (PP)
Rev.: 2
Date: 30.09.2020

Quantity : 1 set
Material : FRP
Accessories : Expansion joints, throttle valve
3.2.6 Exhaust fan

Designation : EXS1-FA01
Quantity : 1 set
Capacity : Flow rate = 14200 m3/h
Pressure = 225 mbar
Type : Radial fan
Material : Welded steel construction, Impeller made of titanium,
housing made of rubber lined steel
Accessories : Motor (frequency controlled), base frame, coupling with
coupling guard, shock absorbers, vibration control

Designation : EXS1-PL01
Quantity : 1 set
Material : FRP
3.2.8 Separator
Designation : EXS1-SP01
Quantity : 1 set
Material : FRP
Accessories : Level control, man way
Rev.: 2
Date: 30.09.2020
3.2.9 Absorber II circulation pump

Designation : EXS1-PU01 / PU02
Head = 30 m
material (PP)
Accessories : Motor, base frame, coupling with coupling protection.

Quantity : 1 set
Material : FRP
3.2.11 Venturi II
Designation : EXS1-VN01
Quantity : 1 set
Height = 3.3 m
Material : FRP
Accessories : n.a.

Quantity : 1 set
Material : FRP
Rev.: 2
Date: 30.09.2020
3.2.13 Final Scrubber

Designation : EXS1-SC01
Quantity : 1 set
Height = 9.0 m
Material : FRP
Accessories : Random Packing, internal supports, liquid distribution system,
man way, Demister
3.2.14 Final Scrubber circulation pump

Designation : EXS1-PU03 / PU04
Head = 30 m
material (PP)
3.2.15 Waste gas stack

Designation : EXS1-ES01
Quantity : 1 set
Total Height = 3.00 m above building roof
Material : FRP
Accessories : Nozzles for emission tests
Rev.: 2
Date: 30.09.2020
3.3 Oxide Handling System
3.3.1 Screw conveyor

Designation : OXS1-SW01
Quantity : 1 set
Capacity : 0.30 m³/h
Size : Length = approx. 4.50 m
Material : Cast iron, welded steel construction
Accessories : Gear motor (frequency controlled), fan for motor cooling
3.3.1 Rotary Valve

Designation : OXS1-RV01
Quantity : 1 set
Capacity : 0.30 m³/h
Material : Cast iron, welded steel construction
Accessories : Gear motor (frequency controlled)
3.3.2 Bucket conveyor

Designation : OXS1-BC01
Quantity : 1 set
Size : approx. 16 m lifting height
Material : Welded steel construction
Accessories : Gear motor
3.3.3 Oxide storage bin

Designation : OXS1-ST03
Quantity : 1 set
Capacity : 10 m³
Material : Welded carbon steel construction with an protective outside
painting
Accessories : Truck loading facilities
Rev.: 2
Date: 30.09.2020
3.3.4 Start-up / fine oxide bin

Quantity : 1 set
Capacity : 6 m³
(divided into two (2) compartments for Start-up oxide and fine
oxide for process control)
painting
3.3.5 Oxide mill

Designation : OXS1-OM01
Quantity : 1 set
Capacity : 50 kg/h
Type : Roller mill
Material : Welded carbon steel construction with
an protective outside painting
Accessories : Motor, base frame, vibration isolator, funnel, conveying trough
Rotary Valve
3.3.6 Oxide transport bin

Quantity : 2 set
Capacity : 0.5 m³
painting
Accessories : Lifting lugs for overhaul crane
3.3.7 Intermediate Oxide bin

(manual filling into the Oxide storage bin or the Start-up/fine Oxide bin)
Quantity : 1 set
Capacity : 1 m³
Rev.: 2
Date: 30.09.2020
3.4 Tank Farm

Basis considerations:
The buffer volume of the acid storage tanks are designed for an independent operation of
the pickling line for at least 72 hours:
The tanks for the waste pickle liquor / regenerated acid are linked to each other in a way
that always tanks can be used either for waste pickle liquor or regenerated acid.
3.4.1 Storage tanks for Waste acid and Regenerated acid

Designation : TAF1-ST30 / -ST31 / -ST32 / -ST33
Quantity : 1 x 100 m³ - for waste acid
1 x 100 m³ - for regenerated acid
2 x 100 m³ - for waste acid / regenerated acid
The number of Storage Tanks can be increased based on the
concept of the customer
Design : Vertical installation
Material : FRP
Accessories : Level control, Man way, Ventilation
3.4.2 Pump for Waste Acid

Designation : TAF1-PU30 / PU31
Head = 25 m
material (PP)
Accessories : Motor (frequency controlled), base frame, coupling with
coupling protection
3.4.3 Pump for regenerated acid

Head = 25 m
material (PP)
Rev.: 2
Date: 30.09.2020
3.4.4 Storage tank for rinse water

Designation : TAF1-ST10
Quantity : 1 set
Volume : 100 m³
Material : FRP or Steel-Rubber lined
3.4.5 Pump for rinse water

Capacity : Flow rate = 5.7 m³/h
Head = 35 m
material (PP)
3.4.6 Storage tank for fresh acid

Designation : TAF1-ST20
Quantity : 1 set
Volume : 100 m³
Material : FRP or Steel-Rubber lined
Rev.: 2
Date: 30.09.2020
3.4.7 Pump for fresh acid

Head = 25 m
material (PP)
3.4.8 Collecting pit

Designation : TAF1-CP01
Quantity : 1 set
Size : Length = 2.50 m
Width = 2.50 m
Depth = 2.50 m
Material : Concrete work with an acid proofed lining inside
3.4.9 Pump for collecting pit

Quantity : 2 pieces (1 as Stand-by)
Head = 20 m
Type : Cantilever pump
material (PP)
Accessories : Motor
3.4.10 Tank farm scrubber

Designation : TAF1-SC01
Quantity : 1 piece
Size : Inner diameter= 0.20 m
Total height = 3.30 m
Material : PP
Accessories : Random Packing, internal supports, liquid distribution system
Rev.: 2
Date: 30.09.2020
3.4.11 Tank farm scrubber circulation pump

Quantity : 2 pieces (1 as Stand-by)
Capacity : Flow rate = 0.6 m³/h
Head = 10 m
material
Accessories : Motor, base frame
3.4.12 Acid filling station for fresh acid

Designation :
The Acid filling station consists of a hose connection to the transfer pump (for truck
unloading of WA or FA), connection for truck loading (RA) and a water connection for
rinsing (drain to the collecting pit). Furthermore are included warning lights, acid proof
safety equipment for the man on site and level indication from the relevant storage tanks.
3.4.13 Acid filling transfer Pump (to Storage Tanks)

Designation :
Head = 25 m
material (PP)
Rev.: 2
Date: 30.09.2020
3.5 Piping
The rating of temperature and pressure is given by the process.
Venturi circulation piping .……………………………….………………………………. FRP
WPL / RA / FA / RW & scrubber circulation piping ..……….……………………..…... PP
Process water piping (Demineralised or Industrial water) ..….……………………. PP
Potable water and Cooling water ....…….……………….… suitable grade of Carbon steel
Compressed air ...….…………………………………………. suitable grade of Carbon steel
Oxide transport piping ………………….….. high-temperature: heat resistant alloyed steel
low-temperature: carbon steel epoxy painted
Combustion air ducts ..………………………………………………..………….. Carbon steel
Fuel Gas piping ………………….…………………….………………………...... Carbon steel
Note:
 All connecting points will be provided with flange connections.
 PP and steel piping will be supplied to job site in standard lengths.
3.5.1 Definition of the take over points (T.O.P.)

Typical take over point:
1. shut – off valve by Buyer
2. flange connection by Seller
3. flange connection by Seller
Rev.: 2
Date: 30.09.2020
3.6 Painting
The top layer of the coating will be done according to the client’s colour code.
 Carbon steel piping
All Carbon steel pipes (except hot gas piping) will be painted with epoxy resin based
coating material.
 Steel structure
Corrosion prevention with epoxy resin based coating materials.
(Steps: Blast cleaning, ground coating, top coating).
 Equipment
All equipment made of carbon steel (except Roaster and Cyclone) will be painted with
epoxy resin based coating material.
3.7 Insulation material

‘Rockwool’ type will be used with a cladding made of Carbon steel sheets.
The outside temperature of the insulation will be approx. 60°C – 65°C. The thickness of
the insulation depends on the kind of insulation.
List of equipment to be insulated:
 Reactor lower & reactor upper part
 Hot Gas ducts
 Cyclone
Rev.: 2
Date: 30.09.2020
3.8 Civil works

3.8.1 Foundation
Foundation will be made of concrete with piling below.
Concrete works include all imbedded parts.
3.8.2 Steel structure

These include the steel structure to support the equipment and allow access to the
equipment and maintenance areas.
The access platforms will be foreseen for easy and safe access to equipment which
requires maintenance and frequent visual inspection.
All elevated walkways will be provided with handrails.
3.8.3 Anchor bolts and shimming material

For aligning and fixing of individual equipment, foundation bolts will be used.
Shimming of equipment for aligning and levelling might be used to a maximum of 50 mm.
Fastening bolts to fasten the equipment to the steel structure.
3.8.4 Wall and roof of building

The building will be constructed as steel structure and the walls will be constructed as
sheets with trapezoidal corrugations.
The Building will include:
 roof draining
 luminous bands / windows
 blinds for hall aeration / ventilation, doors
 lighting
3.8.5 Acid protection material

Different type of acid proof material can be used for areas, which are exposed to spillage
of acid during maintenance or operation (for example sample points).
The lining basically consists of:
 Acid proof tiling for channels, sump pits, pump rooms and acid storage area
 Acid proof painting on all concrete floors
 Acid proof lining is partially provided on the walls
Rev.: 2
Date: 30.09.2020
3.8.6 Channel and Pit covers

Channels and pit covers will be made out of PP.
3.8.7 Cranes
Maintenance hoists for equipment
The pump area will be equipped with an overhead lifting beam (Hoist) suitable for a
movable manual operated hoist of 0,5 – 1,0 t capacity for lifting of the pump or motors for
maintenance.
One Overhead lifting beam will be installed for the Exhaust Gas Fan.
One Overhead lifting beam will be installed for the Combustion Air Blower.
Major overhaul crane

The main building will be equipped with a lifting beam (maintenance hoist) suitable for a
movable electrical operated hoist of 10 t with the capability to lift goods from ground floor
to the top working level and is arranged under the roof to service all equipment.
Travelling drive must be motorized.
Rev.: 2
Date: 30.09.2020
3.9 Laboratory Equipment List

The laboratory room shall be equipped with (but not limited to):
 Acid proof floor
 Lightning (for analysis during the night)
 Windows (for daylight and ventilation)
 Sink unit
 two water connection points
 Analyze / Working table
 Exhaust- ventilation system
 Lockable cabinet (for the chemicals and for the equipment)
The following laboratory equipment must be available:
Item Size Quantity
Burette 50 ml 4 pieces
Glass burette bottles 2,500 ml 4 pieces
Magnetic stirrers with heating 1 sets
system
Magnetic rod coated with PTFE for 30 mm 5 pieces
the magnetic stirrer
pH-meter with electrode 1 piece
pH-electrode (as spare part) 1 piece
Glass beakers 100; 300 and 500 ml 5 pieces each
Plastic beaker material PE 1,000 ml with handle 2 pieces
Glas or plastic graduated cylinders 50; 100; 250 and 500 ml 2 pieces each
Plastic graduated cylinders 1,000 ml 2 pieces each
Graduated glass pipette 5; 10; 25; 50 and 100 ml 3 pieces each
Graduated glass pipette 1 and 2 ml 10 pieces each
Pileusballs for the pipette ./. 3 pieces
Glass funnels 50, 70, 100, 150 ml 3 pieces each
Erlemeyer volumetric flasks 300 ml (wide necked) 10 pieces
PE - Bottles 250 and 500 ml 10 pieces each
Glass bottles for oxide 150 ml 25 pieces
Hydrometer 1.0 – 1.1; 1.1 – 1.2; 2 sets each
1.2 – 1.3
1.3 – 1.4; 1.4 – 1.5 g/cm3
Spoons for oxide analyze, PE 5 pieces
Rev.: 2
Date: 30.09.2020
Item Size Quantity
PE – wash bottle 1,000 ml 3 pieces

Sieve’s for oxide 1.0 – 0.8 – 0.63 – 0.4 – 0.3 1 set
– 0.2 and < 0.1 mm
Weight scale with a set of weights 0 to 1,000 g 1 set
Chemicals for Analyze
Item Concentration Quantity
approx. 25 l
NaOH
1N (in 1 l bottles
(Sodium hydroxide)
or ampoules)
approx. 25 l
K2Cr2O7
0.1 N (in 1 l bottles
(Potassium di- chromate)
or ampoules)
approx. 10 l
Na2S2O3
0.1 N (in 1 l bottles
(Sodium thiosulfate)
or ampoules)
KJ
powder 500 g
(Potassium iodide)
H3PO4
concentrated 5l
(Phosphoric acid)
H2SO4
concentrated 5l
(Sulphuric acid)
Fe2+ indicator 0.1 g per 100 ml purified
5g
(Diphenylamine sulfonic acid) water
Methyl orange (Indicator) 0.1 % 1,000 ml
FeNH4(SO4)2 (Indicator)
per analysis 1,000 ml
(Ferrous ammonium sulphate)
Condensate Water 10,000 ml
pH - paper 5 rolls
Rev.: 2
Date: 30.09.2020
Safety Equipment (as recommendation)
Item Size Quantity
Safety clothes (Acid resistant) 4 pieces

Safety helmet 4 pieces
Safety glasses 4 pieces
Full safety glasses 4 pieces
Gas mask with HCl - filters 4 pairs
Safety shoes 4 pair
Face protecting shield 4 pieces
Rev.: 2
Date: 30.09.2020
3.11 Sub vendor list (Mechanical equipment)

The herewith mentioned list of suppliers presents only a limited range of companies, whose equipment can be used in CMI
UVK plants.
No Equipment Europe China India
1 Steel Equipment Somin Chamy Plant

(Reactor, Cyclone, gas ducts, Oxide
bins)
2 FRP Equipment PlasticGlass JF Fiber

(Separator, Absorber, Scrubber,
Waste Gas pipe, Storage Tanks) Christen & Laudon Plastochem
Nessler Chemical process

equipment
3 PP Parts PlasticGlass JF Fiber
Hackbarth Plastochem
Chemical process
equipment
4 Refractory Pacific Refractory
Windsor
5 Exhaust Fan EVG Lufttechnik
Rev.: 2
Date: 30.09.2020
FIMA Airtechnic
FIMA Germany
6 Combustion Air Blower Aerzener SWAM India
RKG
Rubuschi
7 Pumps Munsch Fluroline
ITT Rheinhütte Antico India
8 Bucket and Screw Conveyor Wuxi Shanning

Machinery Co., Ltd
Shandong huagui heavy

industry Co., Ltd
Heze Shuanglong
Metallurgical Machinery
Co., Ltd
9 Fuel gas control unit Elster Kromschröder Kromschröder India
Mapeko Pyronics
Rev.: 2
Date: 30.09.2020
Spie SAG
10 Venturi (made of titanium) Chamy Plant
11 Plastic valves (Automatic & Control) FRANK (ASAHII &

Exner)
ASV Stübbe
GEMÜ
12 Steel valves (Automatic & Control) XOMOX
ARI
Plastic valves (manual) FRANK (ASAHII & UNP Polyvalves

Exner)
ASV Stübbe SIGMA INDUSTRIES
GEMÜ
13 Steel valves (manual) ARI SIGMA INDUSTRIES
14 Nozzles Lechler
Bete
VFF
Rev.: 2
Date: 30.09.2020
Chapter 4
ELECTRICAL EQUIPMENT
Rev.: 2
ELECTRICAL EQUIPMENT Page 1
Date: 30.10.2020
4 ELECTRICAL EQUIPMENT
4.1 General
Nominal voltage : 3 x 460 V / PEN  10 %
Frequency : 60 Hz 2%
Control voltage contactors, transmitters : 24 V, DC
Solenoid valves : 24 V, DC
Control voltage PLC- I/O, couple relays : 24 V, DC
Signals : 4 – 20 mA
Protection system : grounding
Ambient temperature
 Plant building : + 5 to + 45 °C
 MCC room : + 5 to + 30 °C
 Controller / Processor room : + 18 to + 28 °C
 Relative humidity MCC : max. 70 %
 Processor room: : non condensing
Total installed power all motors : see motor list

Operating power all motors : see chapter 1.5.1
Emergency power : see chapter 1.7

(Must be available within one (1) minute after power failure!)
Standards and Codes : IEC, DIN, EMC
Rev.: 2
Date: 30.10.2020
4.2 Power Cabinets

4.2.1 Frequency controlled Motors
Internally plate mounted, touch protection for all construction parts, fully wired and in
function.
Quantity : 1 set Power Cabinet
Nominal working voltage : 460 V  5 %
Nominal frequency : 60 Hz  3 %
Control voltage : 230 V, 60 Hz
Enclosure : IP 21, RAL 2004
Protection : protective earthing
Dimension : TBD W x 2100 H x 600 D mm
Ground fault protection for all construction parts with the following equipment:
 Feeder fields for operation power with
 Main switch
 Electronic multi-measuring unit
 Control transformer 230 V, 60 Hz
 Lighting, Cable connecting bars
 Various fields for motor starter with

 Frequency inverter with filter
 Motor circuit breaker
 Motor contactor
 Coupling relay
 Terminals
 Lighting, Cable connecting bars
 Interface for frequency Inverter to PLC via PROFINET
 Number and capacity of motors: see motor list
Rev.: 2
Date: 30.10.2020
4.2.2 Fixed Speed Motors (MCC)

Internally plate mounted touch protection for all construction parts, fully wired and in
function.
Quantity : 1 set Power Cabinet
Normal working voltage : 460 V  5 %
Nominal frequency : 60 Hz  3 %
Control voltage : 230 V, 60 Hz
Dimension : TBD W x 2100 H x 600 D mm
Ground fault protection for all construction parts with the following equipment:
 Feeder fields for operation and emergency power with:
 Main switch
 Electronic multi-measuring unit
 Control transformer (230 V, 60 Hz)
 Cable connecting bars
 Various motor starter with:

 Motor circuit breaker
 Motor contactor
 Coupling relay
 Terminals
 ON / OFF button on each front door
 Signals for “running and fault” to PLC
 The interface between MCC and PLC will be executed via remote I/O
 Automatic switchover from normal power to emergency power.
 Number and capacity of motors: see motor list.
Rev.: 2
Date: 30.10.2020
4.3 Control System

4.3.1 Control Cabinet
Quantity : 1 pc Control Cabinet
Feed voltage : 460 V  5 %, 60 Hz  3 %
Dimension : 2400 W x 2100 H x 600 D mm
 Fully wire and in function with the following equipment:

 Lighting, Cable connection bars
 DC - power pack 460V AC / 24V DC
 Control transformer 460/230V, 60Hz
 Automatic breakers, auxiliary relays
 Terminals, Transmitter etc.
 Interface for Ethernet bus and PROFINET
 PLC: SIEMENS S7-1500

 1 pc. Power supply
 1 pc. CPU
 1 set Digital input modules 32 DI
 1 set Digital output modules 32 DO
 1 set Analogue input modules 8 AO
 1 set Analogue output modules 4 AO
 The CPU will have 20% spare memory
 Including 10% spare I/O’s
4.3.2 UPS
Quantity : 1 pc for ARP and TAF
Capacity : 230 V, 3 kVA
Time duration : 30 minutes
Rev.: 2
Date: 30.10.2020
4.3.3 Operator station – Remote I/O boxes

For the collection of the signals from the field instruments and with the necessary I/O
modules.
Quantity : 1 set metal or plastic closed IP54, RAL 7035
The connection of the distribution boxes to the control cabinet will be done via
PROFINET.
4.3.4 Single switch button stations

For individual pumps and loading devices with the required control switches and status
indication LED.
Quantity : 1 set metal or plastic closed IP54, RAL 7035
Language on name plates : English
Rev.: 2
Date: 30.10.2020
4.3.5 Operation System

The HMI will have two operator stations (for ARP#1 and Tank Farm) for the operation and
monitoring of the entire plant, comprising:
 Industrial Personal Computer with related Hardware:
 Keyboard & Mouse
 CD- R/W
 Colour monitor 22” TFT (Wide Screen)
 Interface for Ethernet bus
 A4 black & white printer for fault print-out
 Software :
 WINDOWS 10
 WIN CC / Siemens
 1 Runtime and 1 Development license
 Operator language: English
 Table for PC’s and HMI
All hardware and software specifications will be updated to the newest generation for the
time of delivery.
Overview of a typical fluidized bed regeneration.
Rev.: 2
Date: 30.10.2020
Only for example:

Overview
Reactor:
Rev.: 2
Date: 30.10.2020
Oxid:
Absorber:
Rev.: 2
Date: 30.10.2020
4.3.6 General Functions

The ARP is controlled by an Automation system, which provides all automatic control
functions, and operator interfaces required to operate the plant.
The status indication and operation will be done on the HMI’s.
The functions included in the system are:

 Process instrumentation
 Pump control and sequencing
 Temperature and Flow control loops
 density control loop
 pressure control loops
 Data exchange with pickling line to indicate storage tank values
The operation of the pumps and fans will be done at the HMI and on site with buttons and
a pre-selection Local/Remote.
The process data can be sent to the level 2 computer.
Rev.: 2
Date: 30.10.2020
4.3.7 Interface between ARP and PL (typical)

 Interface Signal from ARP to PL (in case of hard wired signals)
 Acid Regeneration Plant “Normal” (digital, dry contact)
 Regenerated acid transfer pump “Running / Stop” (digital dry contact)
 Regenerated Acid Storage tank “Level Indication” (analog signal : 4-20mA)
 Waste Acid Storage tank “Level Indication” (analog signal : 4-20mA)
 Rinse water Storage tank “Level Indication” (analog Signal: 4-20mA)
 Interface Signal from PL to ARP (in case of hard wired signals)

 Pickling section “Running/Stop” (digital dry contact)
 Waste acid level control valve (LCV110 analog signal: 4-20mA)
 Interface Signal between PL to ARP (in case of TCP/IP connection)

In the case that the TCP/IP is used for the interface and communication between
ARP and the Instrument PLC for PL section, the take over point (for design and
material supply) between the Buyer and Seller shall be PL-router.
The design for the software to interface with ARP in the Instrument PLC will be
supplied by the Seller. The software for interface and communication in the ARP
side shall be supplied by the Seller.
Rev.: 2
Date: 30.10.2020
4.3.8 Control functions

 Automatic
After selection of this mode, the control system manages control loops (set points
from the mathematical model), sequences start/ stop and logical tests without any
operation of the operator.
 Semi-Automatic
The operator acts on the process, by starting sequences from the control pulpit and
without bypassing any safety conditions.
 Manual
In this mode the operator order acts directly on the function without taking account of
the safety conditions except important interlocks. This mode is available for all
functions where an AUTO mode has failed.
This mode must be strictly reserved to well trained maintenance people who will act
on site according to the site conditions.
 Local Control
This mode is foreseen for commissioning and maintenance and start up. All
operations are done through a local cubicle or box close to the equipment. The control
system will activate the actuator without taking care of safety conditions except
important interlocks.
This mode must be strictly reserved to well trained maintenance people who will act
on site according to the site conditions. In each instance the operator is responsible
to select the desired operation mode.
This mode is only available for pumps, fans and rotating equipment.
Rev.: 2
Date: 30.10.2020
4.3.9 System description

The ARP-Process is controlled through a control system performing all the functions
necessary for the control of the process and its peripheral equipment.
The functions performed by the control system are respectively:
 A continuous closed-loop adjustment of the various actuators based on
information transmitted by the various sensors in order to maintain operating
parameters as close as possible to the pre-determined set points
 Control logic for the fans, pumps, agitators and other miscellaneous functions
 The storage of data for the trend system and display of the operating
parameters and consumption values
 The operator interface through a practical set of interactive displays
 The alarms through a practical interactive display
 The setting of operational parameters
 The set point generator, the operator set point guide and the dynamic control
 The interface for communication and information exchange with other control
systems
 The interface to the site instruments for exchange of analogue and digital
signals
 Alarms
The process alarms are generated by the control system and displayed on designated
displays with the time of coming and going. Alarm comments are designed to be easily
comprehensible to the operator.
Alarms will be indicated with flash light and after acknowledgement will be changed
to steady light.
The alarms are sent to the following devices:
 Alarm table
 Specific alarm display
 Alarm printer
Rev.: 2
Date: 30.10.2020
 Trends
Process data are stored by a trending system. This system provides for data sampling
at various periods.
The trending system incorporates the following functions:
 History function: real time or past data display (time limited according to the
sampling time).
 Time / range zoom: The trending system is able to store data at a sampling
period of 1 sec, this function is designed to analyze a problem in a section of
the installation. It is available for a limited number of signals and a limited time.
 All process analogue control loops are stored in the trending system.
 Operator guidance
The operational display includes the possibility to display the conditions necessary to
start a sequence and an indication of the sub-equipment currently out of commission.
Display of controller parameters and switch point tables.
Control system controller can be displayed to enable adjustment of their parameters.
 Human-machine Interface
The HMI allows the visualization and operating of the process as well as data
archiving.
The HMI (Human-Machine interface) is based on the following principles:
 All instruments related to a function are incorporated in a display assigned
specifically to that function
 An overview display shows a summary of the main parameters and provides
for
the selection of individual groups.
 All analogue values are available on trend displays
 Operator help displays like interlock tables to permit easy detection of
equipment which is out of commission
 Location: Operator room
 Function: - Operation of pumps, fans, etc.
- Adjustment of controller parameter
- Adjustment of set points
- Monitoring of the equipment status
- Trend and alarm display
Rev.: 2
Date: 30.10.2020
 Main Control Loops

 HGS1-BL01-PIC2002 (Pressure measurement)
(Oxide bed level control by the motor speed of the oxide screw conveyor )
 HGS1-RE01 - Temperature control of reactor

(Temperature control with the gas control valve)
 HGS1-RE01 - Flame monitoring in reactor
 HGS1-BL01 - Combustion air flow control
 HGS1-CY01 - Negative pressure control

(Pressure control by the motor speed of exhaust fan)
 CGS1-PU03 - Acid feed with speed controlled pump

(via temperature HGS1-RE01 - TIC 3001 / 3002)
 CGS1-SP01 - CPL Density control

(Density control by adding rinse water via rinse water control valve)
 CGS1-AB02 - Level control for regenerated acid discharge

(Level control via control valve)
 EXS1-FA01 - Conductivity measuring

(in the exhaust fan condensate return line)
 PSA pressure observation for the pumps with MIN switch point
The following control loop diagrams are given as examples and are subject to change during
the detail engineering :
Rev.: 2
Date: 30.10.2020
 Negative pressure control in the ARP system

The negative pressure is a function of the exhaust fan speed.
In AUTO mode the speed is controlled by the pressure measured in the gas duct
upstream of the cyclone.
In MAN mode the speed is adjusted on the HMI.
The operation and adjustment of the controller parameters are modified through the
HMI.
FIELD PLC HMI
DIC_PID_CONTROLLER
4-20_MA ETHERNET
Control
P mbar
Unit
#
Pressure PI
CYC01-PIC 2001
HC
PAH
M 4-20_MA
3~ #
PAL
EXF01-F01 %
SI
Customer Control loop under pressure (speed control exhaust fan)

Contr.-No.: Prepared: JS Process: Job: Modified:
Einlxref.DWG
Date: Checked: Drawing No.: EXF01 Sheet: 01 Rev.:
 Reactor acid feeding control

The acid feed rate to the reactor is controlled by modulating the speed of the scid feed
pump.
In AUTO mode the speed is controlled via the temperature measured in the reactor.
In MAN mode the speed can be adjusted on the HMI.
HMI.
FIELD PLC HMI
DIC_PID_CONTROLLER
4-20_MA ETHERNET
Control
T °C
Unit
#
temperature TI
RLP01-TI 3001/3002
HC
TAH
M 4-20_MA
3~ #
TAL
VPL02-P01 %
SI
Customer Control loop temperature reactor (speed acid feed pump)

Einlxref.DWG
Date: Checked: Drawing No.: VPL02 Sheet: 01 Rev.:
Rev.: 2
Date: 30.10.2020
 Concentrated pickle liquor density control

The density of the CPL in the venturi circuit is controlled by adding rinse water through
a control valve
In AUTO mode the control valve is operated via the density measurement.
In MAN mode the control valve can be opened and closed via the HMI.
HMI.
FIELD PLC HMI
DIC_PID_CONTROLLER
4-20_MA ETHERNET
Control
kg/dm³
Unit
# #
DI
Q_Density
VPL01-DIC 3501
HC
DAH
4-20_MA
M POSITION #
1~ DAL
%
OPEN/CLOSE
position
#
M0V
RWP01-5501
Customer Control loop density with rinse water to venturi separator

Einlxref.DWG
Date: Checked: Drawing No.: DC_D002 Sheet: 01 Rev.:
 Control of the gas quantity for the reactor heating

The temperature into the reactor is controlled by modulating the fuel gas control valve.
In AUTO mode the control valve is operated via the reactor temperature
measurement.
In MAN mode the control valve can be adjusted on the HMI.
HMI.
FIELD PLC HMI
DIC_PID_CONTROLLER
4-20_MA ETHERNET
Control
P m³/h
Unit
#
gas flow FI
NGL01-FIC 1001
HC
%
SI
4-20_MA
M POSITION #
1~
OPEN/CLOSE
gas
#
NGL01-5501
Customer Control loop gas quantity

Einlxref.DWG
Date: Checked: Drawing No.: FC_gas Sheet: 01 Rev.:
Rev.: 2
Date: 30.10.2020
4.4 Control Diagram

The picture show a possible configuration considering 1 ARP and 1 Tank Farm
HMI HMI
Level 2/3
Ethermet -Bus
Power cabinet Control cabinet
PLC
ET200 PROFINET
~
PROFINET
~
Emergency power 380V, 50Hz
Working power 380V, 50hz
M M
3~ 3~
T Q L P F G
Tank Farm
Rev.: 2
Date: 30.10.2020
4.5 Instruments list for ARP and Tank Farm

Wherever possible HART devices will be used.
Control valves will generally be pneumatic type with positioner.
See the flow sheets for information regarding the installed instruments.
Typical instruments as preliminary see separate instrument list.
Rev.: 2
Date: 30.10.2020
4.6 Motors
General characteristics for the motors as follows:
 Fixed speed motors

 Three phase AC induction motor ( squirrel cage )
 class F insulation
 temperature rise 80°C
 construction IM1001 or others
 degree of protection IP55
 special paint for aggressive atmospheres
 forced cooling by self ventilation IC411
 cable termination suitable for copper
 Variable speed motors

 Three phase AC induction motor ( squirrel cage )
 class F insulation
 temperature rise 80°C
 construction IM1001
 degree of protection IP55
 special paint for aggressive atmospheres
 forced cooling by self ventilation IC411
 cable termination suitable for copper
 embedded PTC temperature sensors
Rev.: 2
Date: 30.10.2020
4.7 Miscellaneous
The engineering and equipment for the following will be supplied according to the scope of
supply split.
Belongings to the building

 ITV System
 Intercommunication system
 Lighting
 Ventilation and air condition for the electric rooms
 Fire alarm & fire fighting system
 Earthing system
Rev.: 2
Date: 30.10.2020
4.8 Cables and Installation Materials

This includes the supply of all necessary auxiliaries and small material which is not part of
the electrical equipment, however, is necessary for completion of the electrical installation.
The split up is defined in the Scope of supply list
 Normal Cables
Basically copper cables will be provided with stranded conductors and round outer
sheaths:
 Power cable for fixed speed motors
 Power cable shielded for frequency controlled motors
 Control cable
 Control cable shielded
 Bus cables like PROFINET, Ethernet cable, Fibre optic cable
 Special Cables
As special cables are defined:
 Cables between computer and monitors, keyboards, mouse, printer
 Cables between conductivity sensor and conductivity transmitter
 Erection Material
 Cable trays (galvanized steel)
 Conduits (plastic)
 Supporting material (stainless steel)
 Junction boxes
 Others
Rev.: 2
Date: 30.10.2020
4.9 Subvendor List (Electrical equipment)

The herewith mentioned list of suppliers presents only a limited range of companies,
whose equipment can be used in CMI UVK plants.
Possible customer preferences or requirements can be discussed .
AC-motors ………………………….………….……….………………… Siemens/ABB

Germany
Frequency inverter ……………………………………….…………….. Siemens

Germany
PLC ……………………………………………………..……..………… Siemens

Germany
Level sensors …………………………………………………..……… Endress & Hauser

Germany
Flow meter ……….………………………………………………………. Endress & Hauser

Germany
Temperature measurement …………………….……………..………. Endress & Hauser

Germany
Pressure gauges …………….…………………………………..……… Armaturenbau

Germany
Density measurement …………………………………………..……… Endress & Hauser

Germany
Conductivity measurement …………………..………………..……… Endress & Hauser

Germany
Proximity switches ……………………………………………………… IFM, P&F

Germany
Relays, contactors ……………………………………………….……… Siemens

Germany
Buttons, lights …………………………………………..………..……… Siemens

Germany
Rev.: 2
Date: 30.10.2020
Firma: TYASA Ixtaczoquitlán Estado de Veracruz
Motoren und Komponentenliste Company:
Motors and Components List Anlage: Acid Regeneration Plant and
Plant: Tank Farm
Proj./Auftrags-Nr.: Index: Index Datum: Name/Abt.: Datum:
D002E.00470 2 J.Bollmann 30.10.2020
Proj./Order-No.: Revision: Revision Date: Name/Dept: Date:
Position Antriebs- und Motordaten Speisung Hauptstromkreis Steuerg. Regelg. Zubehör, Anbauten Bemerkungen Index
Item Drive and motor data Supply Power circuit Control Accessoires, attach. Remarks Rev.
Anzahl/ Nennbe- Bauform Art Art Ort der Anzahl/
Art Leistg. kW Drehzahl min-1 Fabrikat, Typ Anzahl Art Art Mech.
Mechanische Ausrüstung Liefer- triebsart Type of con- Spannung V Spannung V Betäti- Liefer-
schlüssel Design Power kW Speed rpm Duty type struction IM. Make, type Frequenz Hz Quantity Design gung schlüssel Design
Mechanical equipment . . .
Quantity/ Schalt- Schutzart Degree of prot. Design Design Location of Quantity/ El.
Elektrische Ausrüstung Supply n1 spiele/Std. IP Voltage V Voltage V control Supply
code Frequency Hz code
Electrical equipment (n2) Duty cycles/h Kühlung Cooling IC . .
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
3.1.4 Combustion air blower
S1 IM1001 N-DS
HGS1-BL01 1 MKL/T 90 1500 IP 55 415 V 1 GF S-EL R, L 1 FT
60 Hz R-FQ 1 FI BUS
3.1.5 Pendulum Flaps
S1 IM1001 N-DS
HGS1-CY01 1 MKL/T 0,37 8 IP 55 415 V 1 GF S-EL R, L 1 FT
60 Hz R-FQ 1 FI BUS
3.1.10 Venturi circulation pump
S1 IM1001 N-DS Emergency power
CGS1-PU01/PU02 2 MKL 11 1500 IP 55 415 V 2 KA S-EL R, L 1 1 stand-by
60 Hz 1 FI
3.1.11 Acid feed pump
S1 IM1001 N-DS
CGS1-PU03 1 MKL/T 4 1500 IP 55 415 V 1 GF S-EL R, L 1 FT
60 Hz R-FQ FI BUS
3.2.3 Regenerated acid transfer pump
S1 IM1001 N-DS
CGS1-PU05/PU06 2 MKL/T 1,5 1500 IP 55 415 V 2 KA S-EL R, L 1 1 stand-by
60 Hz
3.2.8 Exhaust fan
S1 IM1001 N-DS 1 BA
EXS1-FA01 1 MKL/T 160 3000 IP 55 415 V 1 GF S-EL R, L 1 FT
60 Hz R-FQ 1 FI BUS
3.2.10 Absorber II circulation pump
S1 IM1001 N-DS
EXS1-PU01/PU02 2 MKL 7,5 1500 IP 55 415 V 2 KA S-EL R, L 1 stand-by
60 Hz
3.2.15 Final scrubber circulation pump
S1 IM1001 N-DS
EXS1-PU03/PU04 2 MKL/T 11 1500 IP 55 415 V 2 KA S-EL R, L 1 1 stand-by
60 Hz
3.3.1 Screw conveyor
S1 IM1001 N-DS
OXS1-SW01 1 MKL/T/G 0,37 1500 IP 55 415 V 1 GF S-EL R, L 1 FT
60 Hz R-FQ 1 FI BUS
3.3.1 Rotary Valve
S1 IM1001 N-DS
OXS1-RV01 1 MKL/T/G 0,37 1500 IP 55 415 V 1 GF S-EL R, L 1 FT
60 Hz R-FQ 1 FI BUS
Page 1 of 3
Plant: Tank Farm
D002E.00470 2 J.Bollmann 30.10.2020
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
3.3.1 Cooling fan for Screw conveyor
S1 N-GS
OXS1-FA02 1 MKL 0,25 2700 220 V 1 KA S-EL R
50 Hz
3.3.2 Bucket conveyor
S1 IM1001 N-DS
OXS1-BC01 1 MKL/G/Y 1,1 1500 IP 55 415 V 1 KA S-EL R, L
60 Hz
3.3.5 Oxide mill
S1 N-DS
OXS1-OM01 1 MKL 5 415 V 1 QI
60 Hz
3.3.5 Rotary Valve
S1 IM1001 N-DS
OXS1-RV01 1 MKL/T/G 0,37 1500 IP 55 415 V 1 GF S-EL R, L 1 FT
60 Hz R-FQ 1 FI BUS
3.4.2 WPL Pump
S1 IM1001 N-DS
TAF1-PU30/PU31 2 MKL/T 2,2 1500 IP 55 N-DS 2 KA S-EL R, L 3 FT 1 stand-by
415 V GF R-FQ 1 FI BUS
3.4.3 RA pump
S1 IM1001 N-DS
TAF1-PU40/PU41 2 MKL/T 2,2 1500 IP 55 N-DS 2 KA S-EL R, L 1 1 stand-by
415 V
3.4.5 Rinse water pump
S1 IM1001 N-DS
TAF1-PU10 1 MKL/T 4 1500 IP 55 N-DS 1 KA S-EL R, L 1
415 V
3.4.7 Fresh acid pump
S1 IM1001 N-DS
TAF1-PU20 1 MKL/T 7,5 1500 IP 55 N-DS 1 KA S-EL R, L 1
415 V
3.4.9 Sump pump
S1 IM1001 N-DS
415 V
Page 2 of 3
Plant: Tank Farm
D002E.00470 2 J.Bollmann 30.10.2020
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
3.4.11 Scrubber circulation pump
S1 IM1001 N-DS
TAF1-PU03 1 MKL/T 1,1 1500 IP 55 N-DS 1 KA S-EL R, L 1
415 V
3.4.13 Transfer pump
S1 IM1001 N-DS
415 V
Control voltage feeder
N-DS
Control Cabinet 1 Feeder 10 N-DS 1 QI
415 V
Page 3 of 3
Customer TYASA Ixtaczoquitlán Estado de Veracruz Rev2 - 30.10.2020
Customer Inquiry No.
CMI UVK Project No. D002E.00470 (Acid Regeneration Plant - Fluidized Bed Process)
TAG
Function Description Comments Revision

Plant
Area Number
Part
2 3 4 5 6 7 8 9 35
cooling water
A OXS1 100.002 FIT FIRAL Flow measuring to screw conveyor SW01(to
shaft)
cooling water
A OXS1 100.001 FIT FIRAL Flow measuring to screw conveyor SW01(to
shaft)
emergency water to venturi

A HGS1 100.001 FIT FIRQAHL Flow measuring
VN01
flow measuring
Flow measuring whirl air
A HGS1 100.002 FIT FIRCSAHL
(incl. 5 f.-manifold) (safety diff.-pressure switch
must be connected in parallel)
flow monitoring
A CGS1 100.001 FIT FIRCSAHL Flow measuring
for density measuring
waste pickle liquor

A CGS1 100.002 FIT FIRQAHL Flow measuring inlet to
acid regeneration plant
regenerated acid
A CGS1 100.003 FIT FIRQAHL Flow measuring outlet to
tank farm
rinse water to
A CGS1 100.004 FIT FIRQSAHL Flow measuring
absorber AB02
A EXS1 100.002 FIT FIQRAHL Flow measuring compressed air to PL02

industrial water to
A EXS1 100.001 FIT FIQRAHL Flow measuring
PL02
A NGS1 100.001 FIT FIRCSAHL Flow measuring gas control and safety system
sealing water for TAF1-

T TAF1 100.001 FISL FSL Flow measuring
PU01/02
flow monitoring
A UTS1 100.003 FIT FIQRAHL Flow measuring IWA or RWL water to
fan EXS1-FA01
flow monitoring
A UTS1 100.002 FIT FIQRAHL Flow measuring ind. water to
pump CGS1-PU01/ PU02
A UTS1 100.001 FIT FIQRAHL Flow measuring water to SC01
A HGS1 100.003 FI Flow indication purge air to inspection glass

pressure pipe
T TAF1 200.002 PISL PSAL pressure gauge with min contact rinse water pump
TAF1-PU07/PU08
wind box pressure reactor
A OXS1 200.001 PIT PIRCSAHL pressure transmitter
lower part
pressure between venturi
A HGS1 200.004 PIT PIRAHL pressure transmitter pumps and acid lance 3-way
valve
A HGS1 200.006 PI pressure gauge
A HGS1 200.008 PIZL PAL safety pressure gauge min flow monitoring for rinsing
A HGS1 200.002 PIT PIRSAHL pressure transmitter pressure reactor
pressure between acid lance 3-

A HGS1 200.005 PIT PIRAHL pressure transmitter
way valve and acid lance
A HGS1 200.001 PIT PIRSAHL pressure transmitter pressure reactor
pressure measuring
A HGS1 200.010 PDZL PDAL safety pressure gauge
combustion air
A HGS1 200.007 PI pressure gauge
Page 1 / 5
TAG

Plant
Area Number
Part
2 3 4 5 6 7 8 9 35
A HGS1 200.003 PIT PIRAHL pressure transmitter pressure CY01 outlet
pressure between VN01and

A CGS1 200.003 PIT PIRAHL pressure transmitter
SP01
A CGS1 200.004 PIT PIRAHL pressure transmitter pressure behind SP01
Hydrostatic density
A CGS1 200.002 PIT PIRC Density measuring venturi circuit line
measurement
A CGS1 200.001 PIT PIRAHL pressure transmitter pump pressure PU01/02
A CGS1 200.009 PI pressure gauge rinse water to CGS1-AB02

pressure pipe
A CGS1 200.005 PISL PSAHL pressure gauge with min contact regenerated acid pump
CGS1-PU05/06
A CGS1 200.008 PIT PIRAHL pressure transmitter pressure behind in top of AB02
rinse water to EXS1-SC01

A EXS1 200.008 PI pressure gauge
pressure pipe
A EXS1 200.007 PIT PIRAHL pressure gauge with min contact rinse water pump
EXS1-PU31/04
flue gas to
A EXS1 200.003 PI pressure gauge
waste gas stack
pressure between FA01 and
A EXS1 200.001 PIT PIRAH pressure transmitter
SP01
pressure pipe
A EXS1 200.006 PISL PSAL pressure gauge with min contact rinse water pump
EXS1-PU01/02
pressure between VN01 and
A EXS1 200.004 PIT PIRAH pressure transmitter
SC01
A UTS1 200.002 PIT PIRAHL pressure transmitter TOP INA-monitoring
A UTS1 200.003 PIT PIRAHL pressure transmitter TOP COA-monitoring
A UTS1 200.005 PI
pressure gauge with Bourdon tube
A NGS1 200.017 PI gas control and safety system
RFM
A NGS1 200.005 PZH PSAL Pressure switch gas control and safety system
pressure gauge with Bourdon tube instrument air to ignition burner
A NGS1 200.013 PI
RFM system NGS1-IB01
RFM
RFM
RFM
A NGS1 200.006 PZ PSAH Pressure switch gas control and safety system
RFM
RFM
ELECTRI
CAL natural gas to ignition burner
A 200.010 PI pressure gauge with capsule element
EQUIPME system NGS1-IB01
NT
18.06.2 pressure gauge with Bourdon tube instrument air to ignition burner
NGS1 200.014 PI
018 RFM system NGS1-IB01
pressure gauge with Bourdon tube natural gas to ignition burner
A NGS1 200.009 PI
RFM system NGS1-IB01
A NGS1 200.004 PZL PSAH Pressure switch gas control and safety system
Page 2 / 5
TAG

Plant
Area Number
Part
2 3 4 5 6 7 8 9 35
pressure pipe
T TAF1 200.006 PISL PSAL pressure gauge with min contact regenerated acid pump
TAF1-PU03/PU04
pressure pipe
T TAF1 200.001 PISL PSAL pressure gauge with min contact circulation pump
TAF1-PU10
T TAF1 200.005 PIT PIRSAHL pressure transmitter pressure WPL feeding pipe
A EXS1 200.002 PI
A EXS1 200.005 PI
A EXS1 200.010 PI
A EXS1 200.009 PI
pressure pipe
TAF1-PU05/PU06
pressure pipe
TAF1-PU05/PU06
A CGS1 200.011 PDZL PDAL safety pressure gauge pressure reactor
A UTS1 200.001 PIT PIRAHL pressure transmitter TOP IWA-monitoring
level CGS4-SP01
A CGS1 200.007 PIDT PIRAHL pressure transmitter
(PD to 200003)
A UTS1 200.004 PISL PAL
natural gas to ignition burner
A NGS1 200.011 PZL PSAL Pressure switch
system NGS1-IB01
natural gas to ignition burner
A NGS1 200.012 PZH PSAH Pressure switch
system NGS1-IB01
instrument air to ignition burner
A NGS1 200.015 PZL PSAL Pressure switch
system NGS1-IB01
instrument air to ignition burner
A NGS1 200.016 PZH PSAH Pressure switch
system NGS1-IB01
A CGS1 200.012 PI
regenerated acid to CGS1-
A CGS1 200.006 PI pressure gauge
AB01
pressure pipe
A UTS1 200.006 PIT PIRAHL pressure gauge with min contact rinse water pump
TAF1-PU05/PU06
temperature monitoring
A OXS1 300.002 TISH TAH thermometer with max-contact
SW01 cooling water outlet
temperature measuring (STW)

A HGS1 300.004 TZL TAL thermocouple reactor lower part
(safety temp. low)
thermocouple
temperature measuring
A HGS1 300.003 TE/TT TIRAHL
reactor lower part RE01
head temp.-transmitter
thermocouple
temperature measuring dust
A HGS1 300.007 TE TIRSAL TT
return line
field temp.-transmitter
Page 3 / 5
TAG

Plant
Area Number
Part
2 3 4 5 6 7 8 9 35
thermocouple
reactor lower part
A HGS1 300.002 TE TIRSAHL TT
mounted around reactor oxid
feeding
resistance thermometer
PT100
A HGS1 300.008 TE/TT TIRC combustion air (temp.
+ protection tube and
correction f. F100002)
temp.-transmitter
thermocouple
reactor lower part
A HGS1 300.001 TE TIRSAHL TT
mounted around reactor oxid
feeding
temperature measuring (STB)

A HGS1 300.005 TE/TE TIRSAH TTIZH thermocouple
reactor lower part
resistance thermometer
PT100
A CGS1 300.001 TE/TT TIRSAH
+ protection tube difusor
+ head transmitter
A CGS1 300.002 TI tele-thermometer Diffusor
(with protection sleeve)
resistant thermometer
PT100
separator
+ protection tube
+ head transmitter
A CGS1 300.005 TI thermometer waste gas pipe
resistant thermometer
PT100
separator
+ protection tube
+ head transmitter
temperature temperature monitoring
A CGS1 300.006 TI monitoring absorber
with protection sleeve (with protection sleeve)
A EXS1 300.004 TI thermometer waste gas pipe
A EXS1 300.003 TI thermometer waste gas pipe
resistant
temperature
thermometer
monitoring
A EXS1 300.002 TE/TT TISAH PT100
bearing 2
with
exhaust fan
transmitter (mounted in field box)
resistant
temperature
thermometer
monitoring
A EXS1 300.001 TE/TT TISAH PT100
bearing 1
with
exhaust fan
transmitter (mounted in field box)
Page 4 / 5
TAG

Plant
Area Number
Part
2 3 4 5 6 7 8 9 35
A NGS1 300.001 TE/TT TIRC Temperature measuring gas control and safety system
drain exhaust pipe EXS1-PL01

Quality measuring
A EXS1 350.001 QIT QIRSAHL µS/cm to EXS1-AT01 or to EXS1-
conductivity
SB01
Level measuring Waste Pickle Liquor /

T TAF1 400.010 LE/LIT LIRSAHL
radar type Regenerated Acid Tank ST07
Level measuring collecting pit

T TAF1 400.110 LE/LT LIRSAHL
radar type CP01
Level transmitter
A OXS1 400.001 LIT LIRSAHL Oxyde bin / mill control ST01
guided radar
delta pressure instrument for level

A CGS1 400.002 LIT LIRSAHL level AB02
indication (capilar lenght 2,5 m)
A EXS1 400.002 LIT LIRSAHL level SC01
A EXS1 400.001 LIT LIRSAHL level SP01






Level transmitter
A UTS1 400.001 LIT LIRAHL Emergency water tank TA01
guided radar
A NGS1 891.001 ZSL
A OXS1 450.002 SSL SSAL Speed measuring (sensor by supplier AMF)
A OXS1 450.001 SSL SSAL Speed measuring (sensor by supplier AMF)
UV flame detector
A HGS1 450.001 BZ Burner flame detection
heat protector glass
A HGS1 TBD TBD Gas detectors Gas detectors
A EXS1 450.001 VET VIRSAHL Vibration measuring (supply by Fan Manufacturer)
Page 5 / 5
Chapter 5
PLANT DIMENSIONS
Rev.: 2
PLANT DIMENSION Page 1
Date: 30.10.2020
5 PLANT DIMENSIONS
The weights and space requirements mentioned below are preliminary estimations. Any
deviations will not influence the quality, performance or the design of the plant.
5.1 Weight of the Plant

ARP (except steel structure) …………………………………………….… approx. 140 tons
Steel structure, building ………………………………………..…............. approx. 250 tons
Tank Farm ……………………………………....................…..…............ TBD
5.2 Space Requirement

a.) Buildings for the Acid Regeneration Plant:
(including Oxide Station, Operator Room, Electrical, Laboratory, etc.)
Length ……………….…….………….……………………………….. approx. 22.5 m
Width …………………..…………………….…………………..…… approx. 15.5 m
Height ………………….…….………………….…………………….. approx. 28.0 m
b.) Tank Farm

Length ………………..……….……………………………………….. approx. TBD
Width ………….…..…..………………………………………..……. approx. TBD
Height ………….….………..………………………………………… approx. TBD
Rev.: 2
PLANT DIMENSION Page 2
Date: 30.10.2020
Chapter 6
3D MODEL
Rev.: 2
3D MODEL Page 1
Date: 30.10.2020
6 3D MODEL
The here shown Pictures are from a 3D Model of a similar plant and only for reference!
Rev.: 2
3D MODEL Page 2
Date: 30.10.2020
Rev.: 2
3D MODEL Page 3
Date: 30.10.2020
Chapter 7
DESCRIPTION OF ENGINEERING
Rev.: 2
DESCRIPTION OF ENGINEERING Page 1
Date: 30.10.2020
7 ENGINEERING
7.1 Description of the Engineering of UVK

The Engineering includes the project management, project supervision and project
execution from placement of order up to the final performance test.
This ensures the interaction of all time, cost and technology relevant phases and subjects
of the project.
The start-up of the project starts with the system analysis, which is worked out together with
the client and which will finally be available for the project members as a client-approved
document.
The execution of the overall engineering includes specifically:
 Project management: This service covers the control and supervision of all activities with
regard to time and quality of the project. Any deviation from the predicted schedule will
result in corrective action.
 Technical clarification including workout of Instructions for the existing performance lists
 Support for the preparation of necessary documents for approval by the local authorities
 Preparation and approval of static calculations
 Review and issue of basic documents after start-up
 As Built Documentation
Within the scope of Engineering, UVK
 agrees to a close collaboration with the customer acc. to the classification in the supply
and performance list.
 shall be completely responsible for all technology starting from the design (which is in
his scope of supply).
 is responsible to provide drawings and data for those components to be manufactured
locally.
 is obliged to check and approve the relevant drawings furnished by the Buyer.
 will undertake overall responsibility for process design and for the ARP layout.
7.2 Engineering Standards

As far as applicable:
ISO : International Organization for Standardization
IEC : International Electronical Commission
DIN : Deutsche Industrie Norm
DIN EN : European Norm
7.3 Delivery of Technical Documents and Drawings

To be supplied by seller to the buyer and their delivery schedule.
Rev.: 2
Date: 30.10.2020
Documentation Delivery time [weeks]

(Supplementary explanation) Basic Detail
Engineering Engineering
Project Master Schedule 6
(in chart form)
Process Flow Diagram (PFD)
 with the main volume streams 6 12
Media specification 12
 Specification of the medias
General layout drawing
 arrangement of plant equipment 6 12
P & I diagram
 with basic information of operation data 6 12
Foundation drawings
 Basic information with total load data of main 8 12
equipment plant parts
Static load information
 Total load table of main equipment with set-up points 12
Building construction
 General instructions and engineering for earth quake 12
requirements for the main equipment
 Location and details of supports for the equipment 12
and machines
Design of main-apparatuses and equipment
 Scheme drawings with socket table, main dimensions 12
and material specification
 List of apparatuses with material specification, 12
dimensions and total weight
 Equipment list for Apparatuses, machines, piping and 12
instrumentation
 Detail drawings of equipment and apparatuses 28
Design of the refractory lining
 With specification for the hot apparatuses 12
 Drawings of the hot apparatuses with material legend 28
and material specification
Design of the outside insulation
 Specification of the apparatuses 12
 Material specification 12
Drawing list
 of the basic design period 8
 overall list 36
Information of the take-over points (TOP)
 for every kind of interconnecting piping & Utility 8
consumption
Spare part list
Rev.: 2
Date: 30.10.2020
Documentation Delivery time [weeks]

(Supplementary explanation) Basic Detail
Engineering Engineering
 for commissioning and 1 or 2 year operation 24
Schedules
 Shipping schedule 20
 Shop test schedule 16
Manuals
 Erection manual mechanic 40
 Erection manual electric 40
 Operating & maintenance manual 40
Motors and components list 6 16
Single line diagram 16
Circuit– and Terminal diagram
 with cable list, electrical device list and cabinet 28
arrangement design
Functional description
 of the automation control system 18
Instrument list and layout drawing 28
Layout
 electrical rooms & equipment 12
 cable routing, cable tray arrangement 28
 Cabinet arrangement design 28
Erection
 Material list 28
Automation configuration sheet 16
Software
 for PLC and HMI 40
 Applications 40
Rev.: 2
Date: 30.10.2020
7.4 Documents Supplied by the Buyer

Within two weeks after the Contract order coming into force the Seller shall send its
Technical representatives to the site for kick off meeting, site survey and verification of
existing documents in order to provide reliable data to basic design and detailed design.
The Seller shall notify the Buyer in advance of the required existing documents and the
Buyer will prepare them before the Seller visit on site and will assist the Seller to facilitate
the all investigation.
The Buyer’s documents must be in English language.
The documentation to be supplied by the Buyer to the Seller shall be as follows:
Documentation Delivery time

(Supplementary explanation) [weeks]
Building Drawing 4
Drawing relating to building
Utility piping 4
Utility main piping necessary for the mechanical Equipment to be
supplied by seller according to his planned design, including:
 Main pipe route diagram
 Drawing showing the top between main and intermediate
piping
Foundation drawings 24
Final foundation drawing for mechanical equipment to be supplied by
Buyer or Seller according to seller’s planned design
Crane data 8
Data relating to travelling crane providing to building, including:
 Travelling range
 Hook approach to the building column row
 Hook lift
Buyer’s steel standard
 Standards for the steel plates (including SUS), shapes and 4
pipes
 Standard except for item (1) above mentioned 4
Information of Meteorology with contract
Utility with contract
Rev.: 2
Date: 30.10.2020
7.5 The Documentation and Drawing Submit Requirement

The quantity of technical documentation and drawings to be supplied by the Seller to the
Buyer is as follows:
Type Basic Detail Design Erection Operation &
Design Maintenance
Manual
as electronic as electronic 3 sets 5 sets
Drawing
files files
List
files files
Specification
files files
as electronic
Catalogues
files
as electronic as electronic
Software description
files files
CD-Rom 1 set 1 set 1 set
Notice:
 Two copies of the necessary training documents will be forward to the Buyer for
translation and one copy of each of them will be handed to each trainee at the time of
training
 Printed documents such as catalogues will be in English.
 The documents will be prepared in English.
 The CD-Rom will be submitted files in *.DWG or *.PDF format.
7.6 Liaison between Buyer and Seller

In order to ensure the coordination of the design and erection three meetings shall be held:
 Kick off meeting
Will be held approx. 15 days after the contract coming into force. The location will be
at buyers’ location.
 Basic Design Meeting
The Buyer shall delegate competent personnel to the seller for a basic design meeting
2 month after effectiveness of the contract.
The layout, the data relevant for layout, foundation and steel-structure should be
agreed within the first week of this meeting.
 Detailed Design Meeting
The Seller shall delegate competent personnel to the Buyer for coordination of time
schedule, electrical and mechanical equipment for local and foreign components
approx. 5 month after effectiveness of the contract. The Buyer shall provide an
interpreter.
Rev.: 2
Date: 30.10.2020
Chapter 8
TECHNICAL SERVICE
Rev.: 2
TECHNICAL SERVICE Page 1
Date: 30.09.2020
8 TECHNICAL SERVICE
8.1 Definitions
Supervision of Manufacturing
The Seller will dispatch personnel for the purposes of providing technical advice during co-
manufacturing of equipment in Buyer’s country as stipulated in the Contract.
Inspection
The Seller will dispatch personnel for the purposes of inspecting co-manufactured
equipment in Buyer’s country as stipulated in the Contract.
Supervision of Erection and Commissioning
The Seller will dispatch personnel for the purposes of providing supervisory services
during erection, commissioning and start up as stipulated in the Contract.
Training
The Seller personnel on site will during supervisory services for erection, commissioning
will conduct theoretical and practical training at site as stipulated in the Contract.
Man month
A man-month is defined as 24 man-working days.
Working time
The normal working time is defined as 48 hours per week, 8 hours per day, 6 days per
week (excluding Sundays) between 08:00 a.m. to 08:00 p.m.
8.2 Supervision of Manufacturing

The Seller shall dispatch to the Buyer's co-manufactures experienced, healthy, skilled and
competent technical personnel to supervise the co-manufactured equipment in stipulations
of the contract. The Seller's technical personnel will speak English.
Based on the Time Schedule in a separate Chapter to the Contract, the Seller will send a
detailed dispatching schedule to Buyer.
8.3 Personnel to be dispatched by the Seller to the Buyer for Supervision of Erection
and Commissioning and Training
Personnel Time Schedule, the time includes theoretical and practical training of maximum
6 operators on site as stipulated in the Contract.
No. of persons Man-month .

Supervisor for mechanical 1 5
Supervisor for electrical and software 1 3
Process Engineer 1 4
Rev.: 2
Date: 30.09.2020
8.4 Dispatching of the Seller’s Technical Personnel

The Seller will dispatch to the Buyer's site experienced, healthy, skilled and competent
technical personnel to give technical services and technical instructions relating to the
erection, no load test run, load test run, production operation and acceptance test of the
contract plant according to the relevant stipulations of the contract. The Seller's technical
personnel will speak English.
Within 6 (six) months after the effectiveness of the contract, the Seller shall send a detailed
dispatching schedule to Buyer. If necessary, such schedule can be adjusted through
negotiations between General Site Representatives of both parties, and should be confirmed
in writing by them on condition that the total specified number of man x month should remain
unchanged. The exact data of the Seller's technical personnel arrival at and departure from
the contract plant shall be decided by mutual agreement between the General Site
Representatives of both parties according to the construction schedule of the contract plant.
8.5 Training on site

A training for the operators will be held at the facilities of the customer during start-up and
commissioning of the plant.
The training included includes theoretical and practical training of maximum 6 operators on
site.
The theoretical training will take as class room training for 5 working days. The practical
training will take place in the plant during the cold & hot tests of the plant.
The training course implements (but is not limited to):

Introduction: - Pickling and regeneration of HCl
- Process description
Plant description: - Components
- Mechanical equipment
- Liquors
Health and safety regulations: - Dangers
- Acid handling
- Safety during maintenance
Plant operation: - Preparations
- Plant start-up
- Production
- Standby mode
- Shut down the ARP
- In case of emergency
Maintenance: - Treatment of Components
- Intervals
Electrical description: - HMI
- Electrical equipment
Rev.: 2
Date: 30.09.2020
Chapter 9
SPARE PARTS
Rev.: 2
SPARE PARTS Page 1
Date: 30.10.2020
9 SPARE PARTS
The herewith given Spare part list is preliminary and for information purposes. The final list will be prepared during detail design and in
coordination with the customer.
C = Required for commissioning of the Plant; O1 = Required for 1 / 2 year operation, B = Buyer; S = Seller supply
Spec. Asset group Asset Description Req. Quantity Supply Material Weight Price
No. group no. for by Single Single Total
Installed Spare [kg] [€] [€]
3.1.1 Reactor HGS1- Air and gas-nozzles with gasket O1 1 set 1 set 1.4571, 1.4301
RE01 Acid lance C 1 1 Titan / 0,2% Pd
Sight glass C 1 1 Quartz
Gas - stainless steel flexible tube O1 1 set 1 set 1.4571
R3/4, 500 mm length
HGS1- Compensator for RE02 to CY01 O1 1 1
RE02
3.1.4 Combustion air HGS1- V-belts C 1 set 1 set
blower BL01
Air filter insert O1 1 2
Blower pressure pipe compensator O1 1 1
Blower pressure pipe compensator O1 1 1
3.1.5 Cyclone HGS1- Central pipe with flange O1 1 1 1.4828
Dust return CY01
Pendulum flap O1 2 2 1.4828
pipeline
Pendulum flaps Gaskets for pendulum flaps C/O1 1 set 2 set Isotherm
Gaskets for dust return pipeline C/O1 1 set 2 set Isotherm
Compensator O1 1 1 1.4828
3.1.6 Gas pipes HGS1- Compensator for GP01 – GP02 O1 1 1
CS02
Rev.: 2
SPARE PARTS Page 2
Date: 30.10.2020
3.1.7 Venturi HGS1- Gasket for Venturi C/O1 10 m 20 m PTFE

VN01
3.1.8 Diffusor CGS1- Compensator O1 1 1 TEXLAM-
CS01 2000 / PTFE
Protection pipe O1 1 1 PP
3.1.10 Venturi circulation CGS1- Impeller O1 2 1 PVDF
pump PU01 /
PU02 Gaskets O1 2 set 2 set RF 46 Viton, SiC
Sliding seal O1 2 set 2 set Viton, SiC
ST, PVDF-C
Coupling puffer C/O1 2 set 2 set
3.1.11 Acid feed pump CGS1- Impeller O1 1 1 PVDF
PU03
Gaskets O1 1 set 2 set Viton, Bukau
ST, PVDF-C
3.2.2 Waste gas pipe CGS1- Compensator O1 2 1 TEXLAM-
PL02 2000 / PTFE
3.2.3 Regenerated acid CGS1- Impeller O1 1 1 PP
circulation pump PU05 /
PU06 Gaskets O1 1 set 1 set Viton, RF 46
Rev.: 2
SPARE PARTS Page 3
Date: 30.10.2020
3.2.6 Waste gas pipe CGS1- Compensator O1 2 1 TEXLAM-

PL03 2000 / PTFE
3.2.7 Exhaust fan EXS1- Bearings complete O1 1 set 1 set
FA01
Coupling package O1 1 set 1 set
Sealing / gaskets (O-ring, flat gaskets, etc.) O1 1 set 1 set
Rubber vibration damper O1 1 set 1 set
3.2.10 Absorber II CGS1- Impeller O1 1 1 PP
circulation pump PU07 /
Gaskets O1 1 set 1 set Viton, Bukau
PU08
3.2.11 Waste gas pipe EXS1- Compensator O1 3 1 PP / Wellflex
PL01 /
Protection pipe O1 3 1
PL02
3.2.15 Final Scrubber EXS1 - Impeller O1 1 1 PP

circulation pump PU03/
PU04 Gaskets O1 1 set 1 set Viton, Bukau
Rev.: 2
SPARE PARTS Page 4
Date: 30.10.2020
3.3.1 Screw conveyor OXS1- Chain wheel O1 2 2

SW01
Chain O1 1 1
Driving bearing O1 1 1
End bearing O1 1 1
Stuffing box packing C/O1 2 2
Sealing head terminal end C/O1 1 1
Flexible tube connection, for cooling water O1 4 4
3.3.2 Bucket conveyor OXS1- Driving bearing O1 2 set 2 set

BC01
Deflection bearing O1 2 set 2 set
Stuffing box packing C/O1 2 2
Shaft packing C/O1 2 1
3.4.2 Pump for waste TAF1 – Impeller O1 1 1 PP
pickle liquor PU30 /
3.4.3 Pump for TAF1 – Impeller O1 1 1 PP
regenerated acid PU40 /
Rev.: 2
SPARE PARTS Page 5
Date: 30.10.2020
3.4.5 Pump for rinse TAF1- Impeller O1 1 1 PP

water PU10 /
3.4.7 Pump for fresh TAF1- Impeller O1 1 1 PP
acid PU20 /
3.4.9 Pump for TAF1- Impeller O1 1 1 PP
collecting pit PU01 /
3.5 Piping Diaphragm valve O1 1 set PVDF / PP –G /
PTFE + cc
Diaphragm valve O1 1 set PVDF / PP –G /
PTFE
Diaphragm valve O1 1 set PP / PP / PTFE
Butterfly valve O1 1 set PVDF / PVDF /
FPM - F
Butterfly valve (each size) O1 1 set PP / PVDF /
FPM - F
Compensator O1 1 set PTFE
Mechanical pressure gauge (0 – 4 bar) O1 6 1 St. / PTFE
Rev.: 2
SPARE PARTS Page 6
Date: 30.10.2020
Capillar telethermometer O1 6 1
Thermometer protection sleeve O1 6 2 PP
Flow meter O1 1 1.4571 / PTFE
Venturi circulation two way plug valve with solenoid valve O1 1 1 1.0727 / FEP
piping
Three way plug valve with solenoid valve O1 1 1 1.0727 / FEP
Acid – flexible tube for acid to reactor O1 1 1 St. / PTFE
4.7 Electric and DRL1 Thermocouple, temperature measuring O1 1 1 1.4841
TIRAL 3001
control system (tube length 330 mm)
Instruments HGS1-RE03 Thermocouple, temperature measuring O1 5 2 1.4841
TIRAHL 3001
(tube length 650 mm)
HGS1-RE01-
3001/02/03/04
HGS1-RE01 UV flame detector O1 1 1

BE XZAL-
4501
CGS1-AB03 Level switch, min – max level Absorber O1 1 1 PP

LSAL 4001
PLC - analog input card O1 3 1

PLC - analog output card O1 2 1
PLC - digital input card O1 4 1
PLC - digital output card O1 2 1
EXS1- Conductivity sensor O1 1 1 Graphite/ti
FA01 – PP-PTFE
3501
Rev.: 2
SPARE PARTS Page 7
Date: 30.10.2020
EXS1- Motor control valve for rinse water O1 1 1 PP / PTFE

PU01 /
PU02 -
5501
CGS1- Thermometer PT 100 for diffuser C/O1 2 1 316L PTFE
SP01 -
3001/3002
Protection sleeve for PT 100 C/O1 2 1 Tantalum
CGS1- Thermometer PT100 for diffuser C/O1 1 1 316L PTFE
PL01 -
3002
Protection sleeve for PT100 C/O1 1 1 Tantalum
Level transmitter O1 1 PTFE
Rev.: 2
SPARE PARTS Page 8
Date: 30.10.2020
EQUIPMENT DESIGN SUPPLY DIVISION
Firma:
TYASA
EQUIPMENT DESIGN & Company:
SUPPLY DIVISION Acid Regeneration Plant
Anlage:
Plant: and Tank Farm
Proj./Auftrags-Nr.: Index: Index Datum: Name/Abt.: Datum: 30.10.2020
D002E.00470 2 Bollmann
Equipment Supply
Item No. Designation Quantity Equipment weight Engineering Division Technical Assistance Erection Remark
Division
(for 1 ARP)
[S]upplier
Seller Buyer Basic Basic Detail Commis-
or Erection
equipment equipment Information Design Design sioning
[B]uyer
3.1 Reactor and Venturi circulation system
Reactor-steel shell incl. heat resistant parts 1 set S S S S S S B

Refractory 1 set S S S S S S B
3.1.1 Insulation 1 set S S S S S S B
Burner nozzles 1 set S S S S S S B
Acid lance 1 pc. S S S S S S B
3.1.2 Fuel gas control system incl. connecting piping 1 set S S S S S S B
3.1.3 Ignition burner system 1 set S S S S S S B
Combustion air blower 1 pc. S S S S S S B
3.1.4
Motor 1 pc. S S S S S S B
Cyclone–steel shell incl. heat restistant parts 1 set S S S S S S B
Insulation 1 set S S S S S S B
3.1.5
Expension joint 1 pc. S S S S S S B
Dust return pipe with expension bellow and pendulum flap 1 pc. S S S S S S B
Pendulum flap 1 set S S S S S S B
Hot Gas pipe-steel shell incl. heat resistant parts 1 set S S S S S S B
3.1.6
Insulation 1 set S S S S S S B
Compensator 1 pc. S S S S S S B
3.1.7 Venturi 1 pc. S S S S S S B
Diffusor 1 set S S S S S S B
3.1.8
3.1.9 Separator 1 set S S S S S S B
Venturi circulation pump 2 pc. S S S S S S B 1 as Stand-by
3.1.10
Acid feed pump 1 pc. S S S S S S B
3.1.11
3.1.12 Emergency water tank 1 pc. S S S S S S B
Note: In case some items are not defined in the scope of supply list, then service and/or supply of the items shall be provided by relevant party according to the principle of the scope of supply. Page 1 of 5
Equipment Supply
Division
(for 1 ARP)
[S]upplier
or Erection
[B]uyer
3.2 Reactor and

Absorber Venturi circulation system
system
Waste gas pipe 1 set S S S S S S B

3.2.1
Absorber I -shell 1 set S S S S S S B
Internal supports & piping 1 set S S S S S S B
3.2.2
Packing 1 set S S S S S S B
Spray nozzle 1 pc. S S S S S S B
Absorber II -shell 1 set S S S S S S B
3.2.3
Regenerated acid transfer pump 2 pc. S S S S S S B 1 as Stand-by
3.2.4
3.2.5
Exhaust fan 1 pc. S S S S S S B
3.2.6
3.2.7
3.2.8 Separator 1 set S S S S S S B
Absorber II circulation pump 2 pc. S S S S S S B 1 as Stand-by
3.2.9
Waste gas pipe (FRP) 1 set S S S S S S B
3.2.10
3.2.11 Venturi II 1 set S S S S S S B
Waste gas pipe (FRP) 1 set S S S S S S B
3.2.12
Final scrubber shell 1 set S S S S S S B
3.2.13
Final scrubber circulation pump 2 pc. S S S S S S B 1 as Stand-by
3.2.14
Waste gas stack (FRP) 1 set S S S S S S B
3.2.15
3.3 Oxide handling system
3.3.1 Rotary Valve 1 pc. S S S S S S B

3.3.4 Start up / fine oxide bin 1 set S S S S S S B
3.3.5 Oxide mill 1 set S S S S S S B
3.3.6 Oxide transport bin 2 pc. S S S S S S B
Oxide for first filling 1 set S B S S B
Equipment Supply
Division
(for 1 ARP)
[S]upplier
or Erection
[B]uyer
3.4 Reactor
Tank and Venturi circulation system
Farm
3.4.1 WPL / RA tanks 4 set S S B B S S B

Pump for waste acid 2 pc. S S S S S S B 1 as Stand-by
3.4.2
Pump vor regenerated acid 2 pc. S S S S S S B 1 as Stand-by
3.4.3
3.4.4 Rinse water tank 1 set S S B B S S B
Pump for rinse water 2 pc. S S S S S S B 1 as Stand-by
3.4.5
3.4.6 Fresh acid tank 1 set S S B B S S B
Pump for fresh acid 2 pc. S S S S S S B 1 as Stand-by
3.4.7
3.4.8 Sump (Concrete work) 1 set S S B B B B B
Sump pump 2 pc. S S S S S S B 1 as Stand-by
3.4.9
Tank farm scrubber 1 set S S S S S S B
3.4.10
Tank farm scrubber circulation pump 2 pc. S S S S S S B 1 as Stand-by
3.4.11
3.4.12 Acid filling station for fresh acid 1 set S S S S S S B
Acid filling transfer pump 2 pc. S S S S S S B 1 as Stand-by
3.4.13
3.5 Piping
Interconnecting piping between TAF and ARP (PP) 1 set S S S S S S B 10m distance max.
Piping for TAF (PP) 1 set S S S S S S B
Venturi circulation piping (FRP) 1 set S S S S S S B
WPL, RA, FA, RW & Scrubber circulation piping (PP) 1 set S S S S S S B
Industrial water piping (PP or Steel) 1 set S S S S S S B
Cooling water piping & potable water piping (Steel) 1 set S S S S S S B
Emergency shower & Eye wash 6 set S S S S S S B
Compressed air piping 1 set S S S S S S B
Oxide transport piping 1 set S S S S S S B
Combustion air ducts 1 set S S S S S S B
Fuel gas piping from TOP to gas train 1 set S S S S S S B
Hand valves (made of plastic) 1 set S S S S S S B
Hand valves (made of steel) 1 set S S S S S S B
Automatic ON/OFF valves 1 set S S S S S S B
Control valves 1 set S S S S S S B
Compensators 1 set S S S S S S B
Bolts & Nuts, Gaskets 1 set S S S B S S B
Pipe supports 1 set S S S B S S B
Equipment Supply
Division
(for 1 ARP)
[S]upplier
or Erection
[B]uyer
3.6 Reactor and Venturi circulation system

Painting
Carbon steel piping 1 set S S B B S S B

Steel structure - for Building, etc. 1 set S S B B S S B
Steel structure - Equipment support 1 set S S B B S S B
Equipment 1 set S S S S S S B
3.7 Insulation
See above Item 3.1.1, 3.1.5 and 3.1.6 -- -- -- -- -- -- -- -- --
3.8 Civil work and building
3.8.1 Foundations 1 set S B B B B - B

Steel structure - Building, incl. floors, stairways, handrails 1 set S S B B B - B
3.8.2 Steel structure - for Equipment Support 1 set S S B B B - B
Anchor bolts for Steel structure 1 set S S B B B - B
3.8.3 Anchor bolts and shimming material for equipment 1 set S S B B B - B
3.8.4 Wall and roof of Building 1 set S B B B B - B
3.8.5 Acid protection material 1 set S B B B B - B
3.8.6 Channel and Pit covers 1 set S B B B B - B
Mainenance hoists for Equipment 1 set S B B B B B B
3.8.7
Mayor overhaul crane 1 set S B B B B B B
-- Auxilliary Building, Rooms 1 set S B B B B - B
3.9 Laboratory equipment

Laboratory furniture 1 set S B B B B B B
Laboratory equipment 1 set S B B B - - -
Chemicals for analysis 1 set S B B B - - -
Cabinets for anti protection clothing 1 set S B B B - - -
Safety equipment 1 set S B B B - - -
4 Electrical and control system
Power transformer 1 set S B B S B B B Installed at PL

4.1 Power distribution panel 1 set S B B S B B B Installed at PL
Emergency Power 1 set S B B S B B B Diesel generator
Power cabinet for fixed speed motor (MCC) 1 set S S S S S S B
4.2
Power cabinet for variable speed motors (Inverter) 1 set S S S S S S B
Control cabinet incl. PLC 1 set S S S S S S B
Remote I/O cabinets 1 set S S S S S S B
Local control boxes 1 set S S S S S S B
4.3
PLC system software 1 set S S S S S S B
PLC application software 1 set S S S S S S B
UPS for PLC and HMI 1 set S S B S S S B
Operating and Monitoring system 1 set S S S S S S B
Printer 1 set S S S S S S B
4.4 System software 1 set S S S S S S B
Application software 1 set S S S S S S B
Table and chair for HMI's 1 set S B B B S S B
Equipment Supply
Division
(for 1 ARP)
[S]upplier
or Erection
[B]uyer
4.6 Field Instruments

Reactor and Venturi circulation system 1 set S S S S S S B
Intercommunication system 1 set S B B B B B B
ITV Industrial Television 1 set S B B S B B B Not appicable
Fire alarm system (Smoke detectors) 1 set S B B B B B B
Building Lighting, Emergency light 1 set S B B B B B B
4.9 Maintenance power sockets 1 set S B B B B B B
Ventilation and air conditioning system 1 set S B B B B B B
Gas leakage alarm system 1 set S B B S B B B
Earthing 1 set S B B B B B B
Maintenance power sockets 1 set S B B B B B B
Normal cables 1 set S S S S B B B
4.10 Special cables 1 set S S S S B B B
Erection materials 1 set S S B B B B B
Spare parts
Commissioning 1 set S S S B B B B
9
2 year Operation 1 set S S S B B B B
Chapter 11
TIME SCHEDULE
Rev.: 2
TIME SCHEDULE Page 1
Date: 30.10.2020
11 TIME SCHEDULE
No. Item Period 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

weeks
1 Contract date
2 General Basic Engineering 4
2.1 P & I diagram (preliminary) 4
2.2 General Layout (preliminary) 4
3 Detail Engineering 12
3.1 P & I diagram 4
3.2 Layouts & Foundation 6
3.3 Description of construction 4
3.4 Equipment design 8
3.5 Document & Manuals 22
4 Manufacturing 32
5 Shipment 17
6 Erection 20
7 Commissioning 8
7.1 Cold test 4
7.2 Load test 4
7.3 Acceptance test
7.4 Final acceptance certificate
8 Plant hand over
9 Building 22
Architectural, foundations, steel construction, walls and roofing,
concrete platforms, acid protection, civil work, etc.
Rev.: 2
TIME SCHEDULE Page 2
Date: 30.10.2020
Chapter 12
PERFORMANCE GUARANTEE
AND TEST PROCEDURE
Rev.: 2
PERFORMANCE GUARANTEE AND TEST PROCEDURE Page 1
Date: 30.10.2020
12 PERFORMANCE GUARANTEE AND TEST PROCEDURE
12.1 Performance Guarantee

Under consideration of Chapter 1 (Basic Design Data) as basis for the calculation the
following performance will be guaranteed.
Waste Pickle Liquor

Capacity of the ARP ……………………………...………….………………. 2,700 l/h
Regenerated Acid
Total HCl ……………………………………………………..….……………. ≥ 190 g/l
Fe content (except the Fe coming from the rinse water) ..….…………….  5 g/l
Stack Emissions
HCl content ………………………………………………………….………….  20 mg/Nm³
Cl2 content ……………………………………..……………………………….  5 mg/Nm³
Particles (as insoluble Fe2O3) ……….............……………………………….  20 mg/Nm³
The emissions will be measured according the DIN EN 13284-1 and the DIN EN 1911.
Rev.: 2
Date: 30.10.2020
12.2 Test Procedure

No Load Test (NLT)
After completion of the erection, the No-Loads Tests will be carried out to confirm the
performance of each unit without acid on the line.
Before start of the NLT, all utility systems shall be in operation.
During NLT, the functional parameters of the equipment as described in the specification of
the Contract should be tested at site.
These tests will include, but not be limited to:
 Drying procedure for the refractory (detailed procedure description will be given with
the documentation)
 Sensors and interlocks will be set for proper function to protect the equipment from
damage where possible
 Automated functions will be demonstrated to the maximum possible degree
 The instrumentation shall be tested and calibrated sufficiently so that line may be
operated in normal way
 Blower and Fan will be checked for proper working
 The chemical circulation systems and treatment tanks will be filled up with water in
order to check the functionality and to check for leakages in the system
No load tests for main equipment are:
 Start, normal stop, quick stop and emergency stop
 Trial run on temperature and level control on the process
 HMI adjusting
Load Test
Once the No Load Test is successfully completed, the equipment will be made available for
the Load Test.
The LT will confirm the operation of the Acid Regeneration Plant with waste acid as fluid.
The proper function of all systems should be tested and confirmed. All instruments, control,
equipment and devices should perform as designed, specified and described. The emission
level will be check.
The LT comprises preparations, checks, adjustments and function tests of the following
items:
 Automatic operation
 Final adjustment of Instruments
 Test of process computer functions
Rev.: 2
Date: 30.10.2020
12.3 Final Acceptance Test

The Final Acceptance Tests shall be conducted in order to verify that the equipment can
achieve the performance indicated in the proposal. This test will be performing after the
successful Load Test. The FAT is a 48-hour period of operation on acid feed.
Performance tests shall be carried out simultaneously for production and quality in an
integrated performance test during the final acceptance period. It shall be demonstrated that
the ARP process is suitable to reach the given performance figures as mentioned in Chapter
12.1.
The FAT consists of:
 A series of Round-Tests
 Performance tests which shall be carried out and recorded during the FAT
 Availability test
 Environmental test
As the FAT is a test that involve different capabilities of the equipment, in case that the
performance figure for one of the performance items will not be met during any of the
individual Test, the Test for the failed performance figure will be repeated separately.
Preconditions
Before starting the FAT, the following preconditions shall be met:
 Sufficient quantity of Waste Pickle Liquor (WPL) shall be accumulated in the tank farm.
A minimum quantity for an operation of min. 96h is required for the FAT. The pickling
line shall be running continuously and replenishing WPL to support continuous ARP
operation.
 The WPL concentration shall be as listed in the design basis of the contract. Variation in
the above values by more than  5% will affect the plant performance. In such cases,
variation in plant performance will be explained by design calculation based on actual
feed WPL quality and will be accepted by the Customer.
 The ARP shall be staffed with qualified and trained operations and laboratory personnel
over the entire FAT period.
 Laboratory analysis turn-around time shall be less than 20 minutes.
 Sufficient quantities of consumables shall be provided by the Customer and made
available during the FAT period. These include ARP operational as well as laboratory
consumables and spare parts.
 The ARP plant shall be in good working condition, with proper maintenance, prior to the
start of the FAT. All stand-by equipment shall be ready for operation. Instruments shall
be properly calibrated.
Rev.: 2
Date: 30.10.2020
Responsibility
UVK personnel shall supervise and be responsible for the FAT demonstration of
performance standards, with the close assistance of the Customer’s operations and
laboratory personnel. The Customer’s operators shall operate the ARP under the guidance
and in accordance to UVK supervision and instructions.
The test for demonstration of the stack emissions performance standards is in the
responsibility of the Customer and shall be arranged by the Customer. UVK personnel shall
supervise the ARP operations during the stack test period and witness the stack test. The
on-site laboratory analysis required for the demonstration of the performance standards is
in the Customer’s responsibility.
Allowable Interruptions
An interruption is defined as stoppage of acid feed into the reactor.
The allowable interruptions during the forty-eight (48) hour FAT period are as follows:
 Interruptions attributable to UVK supplied equipment, controls, or direct supervision
instructions during the FAT period shall be limited to a maximum of four (4) incidences
of interruptions accumulating up to (120) cumulative minutes.
 Any interruptions longer than 30 min. during the FAT test period that are not attributable
to UVK, the FAT should be aborted and not considered as a FAT attempt.
Rev.: 2
Date: 30.10.2020
Explanation: Automatic ON/OFF valves T Temperature measuring / switch Ethernet and Profinet Cable
Control Diagram – Acid Regeneration Plant
Control and Feeder Diagram Q Quality measuring / switch Profibus
Power cable (Normal power supply)
CMI UVK Document-No.: E00470-G-903010-001_0 Control valves L Level measuring / switch Power cable (Emergency power supply)
P Pressure measuring / switch Power cable (Power supply 230V)
Name: Patrik Schräder Control and measuring cable (hardwired)
Local control boxes
F Flow measuring / switch
Status: Preliminary
Z1 Limit switch at Automatic ON/OFF valves
Date: 27.10.2020 Z2 Limit switch at Hand valves
Buyer Supply Required signals for ATS:

ATS -> Control
Transformer Room Control Room Monitore 1920 x 1200 - operating network is active
- emergency network is active
- operating network is OK/available
400V - emergency network is OK/available
Required power +HMI1 +HMI2
Generator
see M+K List Win-CC Lizenzen, V7.4 HMI-Station 1 HMI-Station 2 Control -> ATS
10kV/0,4kV (Note 6-8 times the - switch back to operating network
starting current of RT8192 WIN CC Engineering WIN CC Runtime
the motors) Function:
The change over from main power
PC’s, supply to emergency power supply will
be done by hardware function (ATS) in
Operating system Win-10 case of power failure.
The switching time from main power to
Main Power emergency power has to happen within
Supply maximum one minute.
If the main power supply is indicated as

“OK/available”, the change over from
emergency power supply to main power
supply take place if the command is
given via “Switch back to main power”
Switch button at HMI.
Cisco
230V AC UPS
Electrical Room Signal Exchange to Picking Line
+CC11 +PC11 Ethernet

Control Power
Cabinet Cabinet
ARP1/TAF1 ARP1/TAF1
MCC and VFD
PLC
Siemens S7 Emergency
Power UPS
CPU1500 Main Siemens
VFD
+CS01 Siemens Power +BC11
ET200MP
Remote IO ET200MP VFD Remote
BCU
Cabinet Switch Cabinet
ATS FCU
Tank Farm Scalance Ignition Burner
Em. Power Supply by
Siemens
Main Power Burner supplyer
Power Supply Infeed Power Supply UPS Supply from BUYER

400V AC/50Hz Main Power 400V AC/50Hz
Main UPS
E-Power
230V AC UPS
230V AC UPS
Rated power = 5 kVA

Operating time after power failure = 30 min
Ethernet
LAN 11.2
hardwired hardwired
M M M M +IB11
T Q L P F Z1 Z2 3~ 3~
T Q L P F Z1 Z2 Oxide 3~ 3~
Mill Ignition
Burner
Fix Cabinet
Speed VFD VFD Fix
Drives Drives Drives Speed
Drives
Tank Farm Acid Regeneration Plant 1

Reactor lower part
STW 750°C 24V, DC
+BC11 / +BC21 + - + - =HGS1+T300.004 Release

Main Burner
Safety chain
release
-22K1
from PLC
230V, AC
Honeywell Kromschröder pilot burner
24V, DC
230V, AC
0V, DC
0V, AC
24V, DC
Q100.4
0V, AC
Pilot burner
0V, DC
230V, AC 24V, DC operation
Profinet to PLC
Profinet to PLC
0V, DC
Ionisation pilot burner
BCU OK
first step Flame signal
-9K1 -25K1
burner on (Main -20K1 -19K1 Ignition pilot burner
safety interlock gaslockvalve 1 Safety
Burner) Air valve
-25K2 Chain
24V, DC
-9K2 gaslockvalve 2
0V, DC Safety Chain
safety interlock -27K1 0V, AC
0V, AC pilot gas valve 1
-22K3
㻝㻞
-9K1
㻠㻝㻠㻞
Main burner operation -19K1
-22K3 㻢㻞㻢㻝㻡㻢㻣㻤㻝㻝㻝㻞 -27K2 -22K2
pilot gas valve 2 Pilot burner operation
-22K1
㻟
230V, AC 㻟㻘㻝㻡㻭㼀 -9K2 Burner Fault
Safety Interlocks
㻝㻢㻝㻣㻝㻤㻡㻣
-19A1 Pilot burner
㻠㻢㻠㻣㻠㻤㻠㻥㻡㻜
E-Stop High temp. operation on
㻞㻠㼂
㻰㻯 Purge
Nossel in
Enable high Temp -18K1
furnace
Ignition 0V, AC
from PLC Q100.2
-9K3 -25K1 Air max
230V, AC Outlet / Vent valve Gas lock valve 1 & 2 -17K1
㻠㻢㻣
㻤㻤
fault
㻝㻟㻝㻠㻝㻡
-22K1 -25K2
Feedback ÄReady Bypass gas valve Gas lock valve 1 & 2
for operation³ -27K1
Bypass gas valve Release for Gas Step 1-8
Air min
㻠㻠
-27K2 -16K1
Release for Gas Step 1-8 fault
Purge or ignition -5K1
㻡㻞
speed reached from
VFD Dynamic
㻡㻟㻡㻠㻡㻡㻡㻢
-9K1 Gas max
㻭㼁㼀㻻
㻠㻡
from PLC Q100.1 monitoring! -15K1
fault
䡱㻯㻸㻻
㻡㻝㻢㻡㻢㻢㻢㻤
e
Digital Feedback 㻴㻵 Gas min
STB -9K2 -14K1
㻯㻻㻹 fault
-9K1 -9K2
㻡㻤
Feedback 㻲㻯㼁㻌㻡㻜㻜
㻲㻯㼁㻌㻡㻜㻜㻚㻚
㻡㻜㻜㻚㻚㻲
㻚㻚㻲㻞㻡㻭㼀
c
Contactor
-9K1 / -9K2
en
To PLC
4-20mA
actual value
AI 512
JUMO STB
230V, AC
Safety Chain Safety Chain
Ignition Burner Safety Chain
er
Windbox
- - + +
=HGS1+T300.005
Reactor upper part
STB 950°C
IB01
+IB11
ef
PI PI
NGS1-200.009 NGS1-200.010 -28T1
Speed from Exhaust
SPS via ProfiBus min
510.097
510.098
NGS1
NGS1
PI PZL PZL PZL PZH
PDL
HGS1- HGS1- HGS1- CGS1- NGS1-200.011 NGS1-200.012
rr
HGS1
200.007 200.008 200.011
200.010 NGS1 450.001
M Fuel Gas 510.096
HGS1 HGS1 QN = 3,34N³/h
797.001 797.002 P = 0,16 bar
NGS1 NGS1 NGS1 NGS1
CGS1 908.001 797.002 797.003 909.002
797.003
fo
Combustion Combustion Behind
HGS1-BL01 air min air flow min Venturi
Siemens Safety Chain
G150
PI PI NGS1
NGS1-200.013 NGS1-200.014 891.001
510.100
904.004
ly
NGS1
NGS1
PI PZL PZH
NGS1
909.006 NGS1-200.015 NGS1-200.016
NGS1
Instrument Air
797.013
Qn = 120N³/h
P = 4-7bar
on
NGS1 NGS1
510.099 909.003
PI
NGS1- Step 9
Valve Train NGS1
200.008
VT01 B
540.002
PI
Step 1
NGS1-
Step 2
NGS1-
Step 3
NGS1-
Step 4
NGS1-
Step 5
NGS1-
Step 6
NGS1-
Step 7
NGS1-
Step 8
NGS1-
NGS1- 797.004 797.005 797.006 797.007 797.008 797.009 797.010 797.011
IB01
790.003
NGS1-
200.007
To
NGS1
to PLC +BCx1 540.003
A AI 516 and AI 518

actual value
NGS1
510.041
NGS1
540.001
797.015
NGS1-
PI PIT FIT TE/TT PI PZL HPZL PLC +BCx1

NGS1 NGS1- NGS1- NGS1- NGS1- NGS1- NGS1- Q100.5/ -30K1 open
200.001 200.002 100.001 300.001 200.003 200.004 200.005
Q101.6/ -30K2 close -40K1 -35K1 -41K1 -42K1 -43K1 -44K1 -45K1 -46K1 -47K1
NGS1 NGS1 AI 514 actual value
510.103 510.001 From PLC From PLC From PLC From PLC From PLC From PLC From PLC From PLC From PLC
NGS1 NGS1 Q101.0 Q100.7 Q101.1 Q101.2 Q101.3 Q101.4 Q101.5 Q101.6 Q101.7
NGS1 NGS1
904.001 904.003 797.012 PZ 797.014
NGS1 NGS1 NGS1-
NGS1 B
200.006
Fuel Gas 510.001 908.002 907.001 I nde x D at um / D at e Gez. Drawn Art der Änderung / Modification
Qn=2,24 N³/h
-27K2
Pu=0,16bar CMI UVK
NGS1 Release
952.001 NGS1 NGS1 Shandong, ARP1 & ARP2
NGS1 230V, AC -25K1 -25K2 640.002 DIN A1 D002E.00280
640.001 600.001 1:1
510.002 Gas Lock Valve 1&2 Gas Lock Valve 1&2 -27K1 Acid Regeneration Plant
Release D at um / D at e N am e Zeichnungsnummer Zeichnungsinhalt
Gez. Drawn 08.02.2018 SSC

E00280-G-903011 Burner Control Diagram
Gepr. Approved 08.02.2018 PSC

HCL - Acid Regeneration Plant: Tyasa I E V

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HCL - Acid Regeneration Plant: Tyasa I E V

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Technical Specification

Project No.: D002E.00470

HCl - Acid Regeneration Plant

CMI UVK Project No. : D002E.00470

Chapter 1 …………………………………………… Basic Design Data

Chapter 2 ………………………………………… Process Description

Chapter 3 ……………………………….…… Mechanical Equipment

Chapter 4 ………………………………………… Electrical Equipment

Chapter 5 ……………………………………………… Plant Dimension

Chapter 6 ……………………………………………………… 3D Model

Chapter 7 ………………………………… Description of Engineering

Chapter 8 ………………………………….………… Technical Service

Chapter 9 …………………………………………..………… Spare Parts

Chapter 10 ……………………………………………… Scope of Supply

Chapter 11 ………………………………………………… Time Schedule

Chapter 12 ……………………………….…… Performance Guarantee

- Control and feeder diagram

- Burner control diagram

BASIC DESIGN DATA

1 BASIC DESIGN DATA

1.1 Production Capacity of the Pickling Plant

1.2 Liquid Effluent from the Pickling Plant

1.2.2 Rinse water

1.3 Plant Capacity

1.4.2 Iron Oxide

Production rate …..………………………………………………………. approx. 463 kg/h

1.5.2 Connected Load at the Take Over Point

Fuel gas ……………...………………………………………..……………….. 470 Nm³/h

Process Water (Demineralised or Industrial water) ……...…..…………….. 5,000 l/h

Cooling water (closed loop) ….....………………….…………………………. 8,000 l/h

Compressed air (instrument air) ....…………………………………………. 70 Nm³/h

Emergency power …….…………………………………………………… 40 kW

1.5.3 Conditions of the Utilities

1.5.3.2 Industrial Water

1.5.3.3 Demineralised Water

1.5.3.4 Cooling Water

1.5.3.5 Potable Water

1.5.3.6 Instrument Air

1.5.3.7 Power Supply

1.5.3.8 Fresh Hydrochloric Acid

1.6.1 Exhaust Gas from the Stack

HCl ...................................................................................................  20 mg/Nm³

1.6.2 Liquid Effluent to Waste Water Treatment

1.6.3 Noise level

Operator room …………………………………………………….……………. max. 65 dBA

1.6.4 Pollution in working area

HCl ...................................................................................................  5 mg/Nm³

1.7 Ambient Conditions at Site

2.1 Flow sheet

2.2 Fluidised Bed Process Description

2.2.2 Absorber System

2.2.3 Oxide System

2.2.4 Tank Farm

3.1 Reactor and Venturi Circulation System

3.1.2 Fuel gas flow control unit

3.1.3 Ignition burner system

3.1.4 Combustion air blower

3.1.6 Gas pipes

3.1.10 Venturi circulation pump

3.1.11 Acid feed pump

3.1.12 Emergency water tank

3.2 Absorber System

3.2.1 Waste gas pipe