2430/nd- 1016 680 - P66

PE507

September 28, 1995

Qatar General Petroleum

Corporation

Pre-Feasibility Study

for an Aluminium Smelter

in Qatar

Technical Proposal

Table of Contents

1. SOFRESID'S UNDERSTANDING OF THE QGPC INQUIRY3

1.1. OBJECTIVES OF THE PRE-FEASIBILITY STUDY3

1.2. KEY INFORMATION TO BE PROVIDED4

1.3. TECHNICAL DESCRIPTION AND MPLEMENTATION SCHEDULE5

2. BRIEF DESCRIPTION OF THE PROPOSED PLANT6

2.1. POWER PLANT6

2.2. ALUMINIUM SMELTER AND PORT FACILITIES10

2.3. BATTERY LIMITS16

3. TECHNICAL PROPOSAL FOR THE PRE-FEASIBILITY STUDY17

3.1. SCOPE OF SERVICES17

3.2. PLAN OF EXECUTION FOR THE CAPITAL COST ESTIMATE25

3.3. SOFRESID’S STRENGTH27

3.4. ORGANIZATION CHART28

3.5. SCHEDULE OF ACTIVITIES28

4. INFORMATION AND DATA TO BE SUPPLIED BY QGPC AND AP31

4.1. DATA TO BE PROVIDED BY QGPC31

4.2. DATA TO BE PROVIDED BY AP31

5. OUTLINE FOR THE IMPLEMENTATION OF THE PROJECT33

5.1. SCOPE OF SERVICES33

5.2. ORGANIZATION CHARTS39

6. CURRICULUM VITAE OF KEY PERSONNEL43

6.1. SOFRESID44

6.2. GEC ALSTHOM45

1.SOFRESID'S UNDERSTANDING OF THE QGPC INQUIRY

The pre-feasibility study requested by QGPC concerns a smelter producing 25 kg aluminium ingots with an annual production capacity of 240,000-250,000 metric tonnes. The smelter will be based on ALUMINIUM PECHINEY AP 30 technology. It will be associated, on the same site, with a gas-fired power station capable of meeting the electric power requirements of the various units of the plant and of the related ancillary general services and utilities.

The smelter is to be built in UMN SAID, in the port area near other industrial units.

The pre-feasibility study is to be made in co-operation with QGPC. QGPC's approval shall be obtained by SOFRESID for all major assumptions adopted in the course of the study.

1.1.OBJECTIVES OF THE PRE-FEASIBILITY STUDY

  • Provide QGPC with full information to assess the technical cost of the project i.e.

the capital cost of power station and aluminium smelter,

the production costs of electric power and aluminium ingots.

  • After obtaining supplementary marketing and financial inputs, provide a reputed banking institution with appropriate information to enable project financing.

1.2.KEY INFORMATION TO BE PROVIDED

1.2.1.Capital cost estimate ( 15% accuracy)

Summary of 500/600 items for the smelter and 200/250 items for the power plant.

1.2.2.Breakdown of capital cost by currency

(*) Calculated on the basis of exchange rates prevailing in the 1st quarter of1996, to be agreed with QGPC.

1.2.3.Capital cost expenditure schedule

Breakdown of expenditure month by month and by currency.

1.2.4.Production costs ( 15% accuracy)

Power plant :in mills US $/kWh

Smelter :in US $/t aluminium metal

1.3.TECHNICAL DESCRIPTION AND MPLementation SCHEDULE

The key information described above will be supported by a technical description in addition to the process description provided by AP for the aluminium smelter.

As regards the electric power station, EGT (European Gas Turbines) subsidiary of GECAlsthom, acting as subcontractor to SOFRESID, will provide a detailed technical description and a technical memorandum justifying the configuration adopted (number of turbines, unit power, etc...), to satisfy the various operating possibilities.

A project implementation schedule will complete the study.

2.BRIEF DESCRIPTION OF THE PROPOSED PLANT

2.1.POWER PLANT

2.1.1.General

EGT, subsidiary of GECAlsthom will prepare the power plant pre-feasibility study.

EGT provides to the world the most comprehensive range of high efficiency industrial, aeroderivative and heavy duty gas turbines, from 1.6MW to 226MW. Used for simple and combined cycle power generation, cogeneration and mechanical drive applications, every EGT product is specifically designed to meet power and environmental requirements world-wide. With more than 3850 gas turbines operating in 104 countries, they represent a total generating capacity of over 50000MW.

A number of important design philosophies have enabled to develop superior products. A major element is the evolutionary approach of designs. It has resulted from improved components and materials which have been applied prudently and carefully, to increase power and thermal efficiency.

A second, highly successful principle has been the geometric scaling of both compressors and turbines, allowing maximum utilisation of available experience.

A third element of the design philosophy is thorough development involving design analysis, quality manufacturing, testing and feedback from field experience.

2.1.2.Description

The pre-feasibility will cover complete design, manufacture, delivery, and construction. It will include all associated civil works and commissioning on turnkey basis, together with all necessary plant and equipment, to complete a gas turbine generating station of approximately 420MW total capacity at 50°C ambient in Qatar.

The study will take into account the following:

  • N turbines installed of which N1 in service (1 turbine in standby or maintenance),
  • derated operations with N2 turbines (breakdown of 1 turbine with another one in maintenance),
  • connection to the electric grid of Qatar to enable sales of surplus power produced,
  • possibilities of extension are provided in the design,
  • optimisation of operation with local conditions (price of gas, selling price of energy on the national grid, climatic conditions i.e. temperature, marine environment, presence of sand, etc...).

The study will cover Ngasturbines at site conditions operating in open cycle mode and housed in the turbine hall. The study will encompass all necessary auxiliaries for their safe, efficient and reliable operation, associated civil works, 132kV generator transformers, and connection to the GIS substation, fire protection, control buildings, roads, earthing and low and medium voltage electrical systems as well as all services and facilities for the power station.

The proposed site layout shall take into account future conversion to a combined cycle operation and a further development of additional gas turbines and combined cycle plant at a later date; such items as an extension to the control building and cables trenches, etc... shall be designed to accommodate this.

As far as practical, the Gas Turbine Generators shall be independent of each other and shall be arranged in blocks of two units, each block being housed in a separate turbine hall.

The PowerStation shall be designed with primary consideration for reliability and ease of operation and with future extensions in mind.

The main equipment concerned are:

  • N Gas Turbine Generators together with all necessary plant and equipment for their safe, efficient and reliable operation. The exhaust ducting of each Gas Turbine Generator shall incorporate a blast stack.
  • All necessary interconnecting pipework and valves for gas, fuel oil, lubricating oil, control oil, raw water, demineralized water, water cooling, control air, service air, etc...
  • Three phases enclosed generators arranged for air/water cooler duty.
  • Exhaust gas ducting including expansion joints, access doors, safety devices, silencers, lagging and cladding. No internal insulation shall be used throughout the exhaust system.
  • Sets of coolers and heat exchangers complete with all the necessary pumps, piping, valves and fittings.
  • Turbine control cubicles and control equipment including sequence starting equipment, comprehensive alarms, indication and controls.
  • Turbine generator control cubicles and equipment which shall be located in the Central Control Room.
  • Sets of generator neutral earthing equipment including transformer, neutral earthing resistor and connections.
  • Complete station earthing grid systems.
  • Complete pipework, valves, tanks, foundation bolts and plates, anchors, structural steelwork, stairways, walkways, ladders, hand rails and sundries.

  • Outdoor core type oil immersed, three phase, 3 winding air cooled (ONAN/ONAF) generator transformers each continuously rated to match the peak output of the associated generators at all site ambient conditions and transform the generator voltage to 132 kV with on load tap changers.
  • Outdoor core type oil immersed, three phase, air cooled (ONAN) unit and unit/station transformers to transform the generator voltage.
  • Sets of phase isolated connections in continuous bus-ducting between the generator, the generator transformer and unit transformers complete with all necessary auxiliary equipment and supports.
  • A generator circuit breaker, isolation and earthing switches located in the run of the main phase isolated connections between the generator and generator transformer.
  • Unit electrical systems including auxiliary transformers, switchgear, batteries, secure a/c. supply systems, electrical protection earthing.
  • Fire protection and detection systems including buried hydrant system, double hydrant outlets, transformers deluge water spray system, hose reel and equipment cabinets and alarm panel.
  • 132 kV interconnecting bus duct/cables for connection to the 132 kV substation.
  • Necessary fuel gas pipeline including hot tap connection, between the Gas Pressure Reducing Stations and the natural gas main adjacent to the site.
  • All required Control and Instrumentation for the safe, reliable and efficient operation of the Plant.

2.2.ALUMINIUM Smelter AND PORT FACILITIES

The planned aluminium smelter will include the following: (numbers refer to AP/SOFRESID’s coding system).

2.2.1.Site preparation (004)

It includes (without limitation) the following activities :

  • grading, levelling, general earthmoving,
  • drainage, sewerage,
  • fencing,
  • roads and parking lot,
  • landscaping,
  • solid and liquid effluents treatment and disposal,
  • connection of utilities to the site.

2.2.2.Substation (310)

The substation will meet AP requirements with respect to feeding the potline and all the auxiliaries of the entire plant.

  • Power supply: the substation will be energised directly from the dedicated power plant installed on site,
  • It will include :

a high/medium voltage section,

a section for main auxiliaries distribution,

a conversion section,

monitoring and control sections.

2.2.3.Reduction (320)

The reduction area comprises two potrooms equipped with a total of 288 pots, Pechiney AP30 technology.

Each building accommodates 144 pots arranged side by side in one row.

Potroom ventilation uses natural ventilation.

The pots are prebaked type with a continuous point feeding system and a computerized process control system.

Aluminium busbars provide the necessary DC current to all pots.

Each pot is equipped with 20 anode assemblies.

Alumina is fed to the pot by a Hyperdense Phase System (HDPS).

Multipurpose overhead travelling cranes called Pot Tending Assemblies (PTA) perform all necessary operations on the pots :

  • replacement of spent anodes,
  • metal and bath tapping,
  • anode beam raising,
  • miscellaneous operations.

A Cathode Transport Crane (CTC) is used for transferring used cathodes to the relining shop and bring-in newly lined cathodes.

The potline is also equipped with operating equipment such as anode transport vehicles, metal and bath ladles and metal transport vehicles.

A control room will accommodate the central computer system for both the potline and the pot gas treatment centre.

2.2.4.Raw material facilities in reduction area (324 to 328)

Raw material facilities covers the following sections :

  • fluorinated alumina facilities : the fluorinated alumina coming from the gas treatment centre is used for feeding the potline,
  • crushed bath facilities : the recycled bath is used for anode covering in the pots,
  • fresh alumina facilities : fresh alumina coming from the main site silos is stored in the potline in day silos in order to ensure the proper feeding of the Gas Treatment Centre (GTC).

2.2.5.Pot gas collection and treatment (330)

Gas evolved from the pots and collected by the hooding system are treated for cleaning by dry processing in two Gas Treatment Centres.

2.2.6.Potline services (340)

Potline services accommodate the following facilities :

  • cathode sealing shop,
  • lining-delining shop,
  • lining paste heating shop,
  • ladle and tapping tube cleaning shop,
  • PTA maintenance shop,
  • potline maintenance shop.

2.2.7.Casthouse (350)

The casthouse will include the following sections :

  • metal preparation with weighing of the liquid metal, skimming and stirring of liquid metal and holding furnaces,
  • metal casting including ingot casting machines for 25 kg aluminium ingots and ingot stacking,
  • dross treatment,
  • industrial water network for metal cooling,
  • outside storage and truck loading facilities.

2.2.8.Green anode production (360)

The green anode production section includes the following shops :

  • anode paste plant where petroleum coke grains and recycled anode butts are ground and agglomerated by means of coal-tar pitch. It includes proportioning, preheating, mixing, forming cooling phases and fume and dust collection,
  • anode handling and storage shop.

2.2.9.Anode baking (370)

Before being used in the pots, green anodes must be baked to calcine the binding pitch.

It is achieved in an "open" type anode baking furnace.

The baking furnace is fired with gas.

The baking is controlled by a fully automated system.

Handling of anodes is carried out by means of Furnace Tending Assemblies (FTA).

Fumes collected by the exhaust manifolds are sent to a Fume Treatment Centre (FTC) using a dry process system similar to the GTC.

2.2.10.Anode assembly recycling (380)

The recycling of anode assemblies is performed in dedicated shops as follows:

  • anode assemblies cooling and storage shop,
  • anode rodding shop where stems are separated from anode butts then recycled so that new anodes can be attached to it by means of cast iron. Bath crusts and carbon butts are conveyed to dedicated shops for recycling,
  • Stems and brackets repair shop,
  • Bath recycling shop,
  • Carbon recycling shop.

2.2.11.General services (600)

It includes (with no limitation) the following facilities for the project :

  • maintenance shops : central workshop and area workshop,
  • main warehouse,
  • laboratory,
  • management and main offices,
  • cloakroom, washroom, cafeteria, mosque,
  • gasoline station.

2.2.12.Utilities (700)

It includes (with no limitation) the following facilities for the project :

  • electrical power loop. A medium voltage network supplies power to the various shops in the plant. Distribution stations are located close to the consumers,
  • fire fighting network,
  • drinking water network,
  • industrial water network,
  • gas network,
  • compressed air production and distribution,
  • plant information system including :

industrial computers covering the real time supervision shop and sector technical management of each process facility,

business and management computers with office automation systems covering procurement, maintenance, human resources and corporate,

plant wide computer network.

2.2.13.Raw material facilities on site (800)

This chapter concerns the storage and handling of raw materials, namely :

  • alumina,
  • coke,
  • fluorinated products,
  • pitch.

Capacities of sufficient volume are installed on site as to cope with raw material deliveries (capacity of ships and different origins).

Handling is insured by means of belt conveyors.

2.2.14.Port and transport facilities (900)

A dedicated berth is used for raw materials unloading.

It is assumed that an existing berth with sufficient draught can be used.

Port and transport facilities will mainly concern :

  • Materials unloading systems using vacuum process it to be installed on the jetty,
  • loading facilities for aluminium products,
  • transport equipment between plant and port.

2.3.BATTERY LIMITS

The present pre-feasibility study takes into account the following aspects:

  • the power plant and smelter are located on the same site,
  • the port is located at about 2km from the site,
  • natural gas is available at the battery limits of the site,
  • roads and communication facilities are available at the battery limits of the site,
  • no desalination of sea water is considered.

3.TECHNICAL PROPOSAL for the PRE-FEASIBILITY STUDY

3.1.Scope of services

3.1.1.General

To undertake the pre-feasibility study, SOFRESID will involve a team of engineers specialised in the following fields:

  • project management,
  • cost estimations,
  • scheduling,
  • general techniques.

and specialists of GECAlsthom for the electric power plant.

As for general techniques, there will be different specialists in:

  • civil works and structurals,
  • vessels,
  • buildings,
  • fluids,
  • mechanical,
  • lifting, handling and transport,
  • electrical, instrumentation and automation.

The main purpose of involving specialists of general techniques will be to find, on the basis of AP’s process data and considering site conditions, the best technical and cost solutions for building the project. In particular:

  • Civil works

SOFRESID will investigate the type of foundations which are the most appropriate to the characteristics of the soil, as a function of the type of building and forces applied.

In the absence of precise data on the site selected, SOFRESID can achieve a good approach of the problem by using information on a nearby site (QAPCO). Indeed, this site is well known to SOFRESID because it participated to studies for extensions.

Moreover, SOFRESID is well aware of the particular problems of design of concrete structures related to local conditions (temperatures, maritime environment, etc...), and of the possibilities of local supplies in the region (capacity, characteristics, rebars, with or without linings, etc...).

  • Metallic structures and vessels

During the prefeasibility stage, SOFRESID will consider the design of structures taking into account:

the regulatory constraints,

process constraints,

consistency with the various other disciplines (e.g. civil, roofing, cladding, lighting, etc...) and the choice of materials,

local climatic conditions (insulation, protection, ventilation, etc...),

consistency with the construction modes and the problems of supply and erection.

This work is conducted in close co-operation with the specialists of civil works, in order to achieve optimal technical and economic definition of the set foundationsstructures.

  • Mechanical, lifting, handling, transport

SOFRESID will take climatic conditions into account, for the design of all installations in order to avoid the problems related with the presence of sand and with maritime environment.

Particular attention will be given to the protection of mechanisms, to the selection of transport modes and to the definition of storage areas particularly in view of the relative long distance of the port to the site.

  • Electrical and automation

SOFRESID will take climatic conditions into consideration, for selecting the technology of equipment, in order to avoid problems related with:

high ambient temperature,