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ICI Pakistan Ltd
Soda Ash Business
Page 1 of 10February 2010
Technical Department Monthly Report
February 2010
HEALTH, SAFETY & ENVIRONMENT
SAFETY STATISTICS
No LTI, RW, MT, and FAC were recorded for the month of February 2010 in Technical Department.
HSE ACTIVITIES
Safety talk on the topic Housekeeping was carried out with Technical Department staff.
HSE CHALLENGE 2010
Summary of Progress on HSE Challenge 2010 actions is given in the table below.
* Energy figure is high due to high fuel consumption** Energy related CO2 figure is high due to high furnace oil consumption*** Waste figure is higher than target due to high coke fines
**** Green house gases are high due to high consumption of furnace oil, limestone and coke
HSE IMPROVEMENT PLAN 2010
HSE improvement plan 2010 finalization is in progress
PRODUCTION HIGHLIGHTS
Production for the month at 19,108 tons was 4,881 tons lower than the budget
DA production for the month at 2,835 tons was 2,765 tons lower than the budget because of low market demand
RSB production for the month at 1,515 tons was 585 tons lower than the budget because of low market demand
Sr.
No.
ParametersBase Line
2005
Target 2010
@ 5%
Reduction
Achieved
2009
February
2010
2010 Actual
1Energy (T/T)
0.01414 0.01343 0.01325 0.01396* 0.01400
2Energy related CO2(T/T)
0.7241 0.6879 0.7169 0.8855** 0.9078
3
Reusable waste non-
hazardous (reportable)
(T/T) 0.0240 0.0228 0.0313 0.0339*** 0.01919
4
Fresh water usage
(T/T) 12.8289 12.187 8.786 9.172 9.778
5Acid Gases (T/T)
0.00936 0.00889 0.00158 0.00599 0.00609
6Greenhouse gases(T/T) 1.03485 0.98311 1.0687 1.2579**** 1.286
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ICI Pakistan Ltd
Soda Ash Business
Page 2 of 10February 2010
Following table shows the production figures for February 2010
February 1st QTR 2nd QTR 3rd QTR 4th QTR YTD
Budget Tes 23,989 36,706
Actual Production Tes 19,108 37,028
Difference (4,881) 322
Maximum Rate AchievedTes / day
800 837
Average Rate Tes / day 682 628
DAILY SODA ASH PRODUCTION
0
200
400
600
800
1000
1200
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Daily Target 1010 tpd
Descon Boiler outage to carry out
inspection and tuning on natural gasLow market
demand
Target 650 tpd
Target 800 tpd
Major Losses with respect to Budget
Jan 10: The production remained higher than the budget
Feb 10: Low market demand, Descon 10 outage to carry out its inspection & tuning on natural gas and partial plantshutdown
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ICI Pakistan Ltd
Soda Ash Business
Page 3 of 10February 2010
PRODUCTION LOSS DETAILS
Monthly Soda Ash Production
Actual Vs Budget
(Tes)
1910817920
14,847
29,254
25,643
23,857
25,957
25,119
24,459
24,15825,21523,989
12,716
30,377
Jan Feb Mar Apr May Jun July Aug Sept Oct No v Dec
Act Budget
Production loss (Tons) Section Wise
- Feb 2010
7746
Commercial
54 Elec
0 CW
178 SD
85 Instt 149 Mech
455 PS
130 Process
67 Others
0 Civil
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ICI Pakistan Ltd
Soda Ash Business
Page 4 of 10February 2010
Production loss (Tons) Section Wise
- YTD
9840
Commercial
158 Elec
0 CW
227 SD
145 Instt
281 Mech
2455 PS
301 Process
8506 Others
0 Civil
Production loss (Tons) Equipment Wise
- Feb 2010
123 Others
0 SNGPL
35 Tower
7746
Commercial
41 Compressors
102 Kiln & MOL29 SD Basin /
Brine
82 Calciners
493 Boilers
161 Turbines
52 Abs / Dist
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ICI Pakistan Ltd
Soda Ash Business
Page 5 of 10February 2010
MANUFACTURING EXCELLENCE PARAMETERS
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
Jan Feb Mar April May June July Aug Sep Oct Nov Dec
OEE Availability Product Rate Quality Rate
PROJECTS
65 KTPA
All the pending DCS issues have been resolved and acceptance document signed off
GT2 chiller process water tie in is in progress whereas the electrical tie ins would be carried out during any
opportunity in coming months
Production loss (Tons) Equipment Wise
- YTD
253 Others
8371 SNGPL
52 Tower
9840
Commercial
52 Compressors
183 Kiln & MOL
29 SD Basin /
Brine
211 Calciners
2610 Boilers
220 Turbines
92 Abs / Dist
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Soda Ash Business
Page 6 of 10February 2010
DEVELOPMENT WORK
Reverse Osmosis
Meetings were held with WEMS and Progressive Consultants to finalize the control logic & ELD for the RO
project
Hazard Study team for the RO project has been announced Final draft of the RO contract has been received from ICIs Legal Counsel, final amendments are in progress
Initial draft of the RO newsletter has been prepared
Others
To ensure the TA > 99 % as per international standard, a trial run was carried out at plant with extensive
testing. Since 1st
March 2010 all export product is being supplied with Certificate of Analysis having TA > 99
%. However, it will have an impact of 1 dm3
PTA on energy
Proposal for developing an e Modification Form database is being prepared
Technical and Commercial proposal received for installing a Float Valve on Jhelum water reservoir
Technical and Commercial proposal of liquid online mass flow meter has been received
ENERGY
Following graph shows the energy trend for year 2008, 2009 and YTD 2010.
MONTH WISE ENERGY BUDGET & ACTUAL
Following graph shows the MMBTU PTA consumption trend for 2008, 2009 and YTD 2010
MONTH WISE MMBTU PTA CONSUMPTION TREND
5.00
7.50
10.00
12.50
15.00
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Months
MMBTU
PTA
MMBTU PTA 10 MMBTU PTA 09 MMBTU PTA 08
25
27.5
30
32.5
35
37.5
40
42.5
45
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Months
Energy(DM3PTA)
Budget 10
Actual 10
Actual 09
Actual 08
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ICI Pakistan Ltd
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Page 7 of 10February 2010
COKE EFFICIENCY
PLANT EFFICIENCIES
Coke Consumption
0.097
0.095
0.093
0.097
0.095
0.097
0.09
0.09
0.09
0.09
0.09
0.10
0.10
0.10
0.10
0.10
Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act09 Act 08
TesPTA
Budget
0.08
0.085
0.09
0.095
0.1
0.105
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Months
Coke(Tons
PTA)
Coke 2008
Coke 2009
Coke 2010
Salt Consumption1.54 1.54 1.5361.541.541.54
1.51
1.52
1.52
1.53
1.53
1.54
1.54
Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act 09 Act 08
TesPTA
Budget
Ammonia Consumption
5.4995.261
5.001
5.44.9685.4
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act 09 Act08
KGP
TA
Budget
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ICI Pakistan Ltd
Soda Ash Business
Page 8 of 10February 2010
OTHER EFFICIENCIES
PRODUCT QUALITY & ISO 9000
ISO 9001
Findings of URS surveillance audit were circulated to all concerned and action completion dates are
being awaited.
Purchased Power Consumption
22.0
8.2
20.8
11.1
15.4
19.5
0
5
10
15
20
25
30
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Bud10
YTD10
Actual09
Actual08
KWHPTA
Diesel Consumption on GTs
0.00.10.10.20.20.30.30.40.4
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Bud10
YTD10
Actual09
Actual08
EqDM3PTA
DGs Power Consumption
1.01.5 1.4
0.9
3.0
1.8
0
1
2
3
4
5
6
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Bud10
YTD
10
Actual09
Actual08
KW
HPTA
Nacl Brine free
0.17
0.200.21
0.200.20 0.20
0
0.05
0.1
0. 15
0.2
0.25
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Bud10
YTD10
Actual09
Actual08
Limestone Consumption
1.250 1.2411.250 1.262 1.2501.238
1.101.15
1.20
1.25
1.30
1.35
1.40
1.45
1.50
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act09 Act08
TesPTA
Bud et
Total Fuel Consum ption
37.08437.549 37.559 37.309 36.6737.724
25.00
27.00
29.00
31.00
33.00
35.00
37.00
39.00
41.00
Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act 09 Act 08
DM3PTA
Budget
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ICI Pakistan Ltd
Soda Ash Business
Page 9 of 10February 2010
New accreditation certificates of new ISO 9001:2008 version received from URS.
COMPETITORS SAMPLE ANALYSIS
Competitor ICI Olympia China Turkey Russia Magadi Romania Ansac Ukraine
Light Soda Ash
Date Feb-10 28/2/10 5/1/06 19/8/03 19/8/03 15/5/05 23/11/06 22/2/05 17
TA % 99.01 95.60 98.80 97.80 98.20 97.80 97.80 - 98.60 9
Cl % 0.41 0.41 0.20 0.10 0.39 0.33 0.24 - 0.36 0
Fe2O3 % 0.0019 0.0030 0.0018 0.0010 0.0016 0.0060 0.0060 - 0.0016 0.
H2O % 0.21 2.93 0.15 1.29 0.67 1.16 0.66 - 0.54 0
NaHCO3 % 0.25 1.93 0.67 0.34 0.34 0.67 2.60 - 0.17 0
Density gm/lit 560 587 590 535 562 496 484 - 551 5
SieveAnalysis
On 16 mesh 1.40 2.36 0.46 0.55 0.69 1.69 1.91 - 0.95 3
On 36 mesh 1.20 3.30 0.26 0.47 0.57 0.59 4.82 - 0.78 1
On 85 mesh 14.60 7.70 16.25 9.73 9.53 13.13 18.10 - 6.91 1
On 120 mesh 38.30 55.47 37.03 29.50 45.33 33.35 35.70 - 38.18 3
On 200 mesh 29.90 22.76 2
On 240 mesh 5.90 2.13 36.59 45.84 34.11 40.06 28.69 - 44.08 4
Thru 240mesh
8.40 6.32 9.27 14.44 9.76 10.82 10.56 - 8.99 1
Dense Soda Ash
Date Feb-10 31/03/08 10/11/06 23/11/02 21/09/06 20/10/04
TA % 98.99 98.80 98.60 91.00 - 96.20 - 98.80 -Cl % 0.53 0.38 0.20 0.13 - 0.31 - 0.03 -
Fe2O3 % 0.0025 0.005 0.0040 0.0010 - 0.0380 - 0.0010 -
H2O % 0.14 0.25 0.45 - - 1.14 - 0.80 -
NaHCO3 % 0.17 0.34 0.420 - - 3.530 - 0.230 -
Density gm/lit 994 1078 1078 - - 805 - 1000 -
SieveAnalysis
On 16 mesh 2.16 7.40 0.02 2.98 - 1.26 - 0.20 -
On 36 mesh 23.32 48.60 8.57 54.11 - 48.66 - 9.20 -
On 85 mesh 54.71 37.50 68.61 39.93 - 35.59 - 76.50 -
On 120 mesh 12.90 4.40 14.86 1.93 - 9.00 - 9.70 -
On 240 mesh 4.48 1.50 5.74 0.47 - 4.44 - 4.10 -
Thr. 240mesh
2.04 0.50 1.99 0.33 - 1.12 - 0.40 -
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ICI Pakistan Ltd
Soda Ash Business
Page 10 of 10F b 2010
CUSTOMER COMPLAINTS
No customer complaint was received during the month of February 2010
PLANT CRITICAL PARAMETERS
Unit Target February Q1 Q2 Q3 Q4 YTD
CB Cl mls N / 20 105. 2 105. 3 105. 5
PB Cl mls N / 20 104. 4 104. 1 104. 4
CW Temp. oC 24. 8 25. 0
CVL test mls N / 20 104 101. 9 102. 7
TE % 40 41 40. 0 39. 9
Mix gas old side % 70 71 67. 5 66. 6
Mix gas new side % 70 71 66. 0 64. 5
Gases PTA M3 PTA 800 820 808 792
Conversion 1 % 72 74 72. 3 72. 0
Conversion 2 % 72 74 72. 1 71. 9
Conversion 3 % 72 74 71. 9 71. 6
PARTICLE SIZE DISTRIBUTION
Cal-1, 2, 3 & 4 Particle size distribution Feb 2010
0
510
15
20
25
30
35
40
45
.+16 .+36 .+85 .+120 .+200 .+240 ,-240
mesh size
particles
Cal- 1 Ash Cal- 2 Ash Cal- 3 Ash Cal- 4 Ash