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Transcript of Design Plant
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Maaden Sulphuric Acid Plant Project
5 June 2009Dr. Peter Weber
President, Metals Processing Division
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Outotec Oyj CMD 20092
1.Basics
2.Project Overview
3.Project Development
4.Project Execution
5. Services
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Outotec Oyj CMD 20093
1.Basics
2.Project Overview
3.Project Development
4.Project Execution
5.Services
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Outotec Oyj CMD 20094
Basics Sources and Use of Sulphuric Acid
Total 200 million t H2SO4
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Outotec Oyj CMD 20095
DryingTower
SulphurFurnace
+WasteHeat
Boilers
ConverterBed 1-3
+Heat-
exchang.
Interm.Absorber
Converter
Bed 4
FinalAbsorberAmbient Air
Dry Air
SO2 SO3+ SO2
SO2SO3
Tail Gas
Diluted Acid
Product Acid
Sulphur Steam
Steam
H2O
BFW
Sulphur Burning Plant Sulphur Burning Plant Block Flow SheetBlock Flow Sheet
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Outotec Oyj CMD 20096
Total 200 million t H2SO4
World Sulphuric Acid Production and Consumption World Sulphuric Acid Production and Consumption -- 20072007
Production Consumption
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Outotec Oyj CMD 20097
1.Basics
2.Project Overview
3.Project Development
4.Project Execution
5. Services
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Outotec Oyj CMD 20098
Project Overview Key Figures
USD 5,52 billions*Total Maaden Investment for Fertilizer Complex
USD 495 M**Total Cost Sulphuric Acid Plants
EUR 270**Outotec Import Contract
* Source Maaden Press Release: June 2008; ** Contracts June 2007
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Outotec Oyj CMD 20099
Project Overview - Geographical Location
Riyadh
Dammam
Ras Az Zawr
Az ZabirahBurayda
Hail
AlJalamid
MaadenPhosphate
Project
R E D S E A
Gulf
4.5Mt/y
3.5Mt/y
Jawf
Jeddah
Qurayyat
Eshidiya Project Location
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Outotec Oyj CMD 200910
Project Overview Fertilizer ComplexAmmonia (1)
0.657 Mt/a NH3
Sulfuric Acid (3)
High Pressure Steam~ 4.5 Mt/a H2SO4
Cogeneration Plant
Phosphoric Acid (3)1.370 Mt/a P2O5Phosphogypsum
DAP (3)2.922 Mt/a
Port
Dry Stack
Electric Distribution System
Panamax Vessels
Natural Gas
Molten Sulphur
Phosphate Concentrate4.50Mt/a
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Outotec Oyj CMD 200911
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Outotec Oyj CMD 200912
Converter A progress
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Outotec Oyj CMD 200913
View from Plant A to Plant B/C
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Outotec Oyj CMD 200914
1.Basics
2.Project Overview
3.Project Development
4.Project Execution
5.Services
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Outotec Oyj CMD 200915
Project Development Convertible EPC approach
Lump SumLump Sum
DESIGN BASISDESIGN BASIS
BIDDINGBIDDING
ANALYSE/ANALYSE/NEGOTIATE/NEGOTIATE/
AWARDAWARD
MAADENMAADEN
EPC EPC CONTRACTORCONTRACTOR
Contractor BidContractor Bid
MANAGE AND CONTROLMANAGE AND CONTROL
ENGINEERINGENGINEERING
PROCUREMENTPROCUREMENT
CONSTRUCTIONCONSTRUCTION
ENGINEERINGENGINEERING
PROCUREMENTPROCUREMENT
OPEN BOOK OPEN BOOK ESTIMATEESTIMATE
CONVERT CONVERT TO LUMP TO LUMP
SUMSUM
ANALYSE/ANALYSE/NEGOTIATE/NEGOTIATE/
COMMITCOMMIT
ReimbursableReimbursable
- Engineering services reimbursable rates
- Agreed profit margin- Agreement on LDs
and major commercial terms
Fix price
May 2006 June 2007
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Outotec Oyj CMD 200916
1.Basics
2.Project Overview
3.Project Development
4.Project Execution
5.Services
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Outotec Oyj CMD 200917
Scope of Services and Supplies Outotecs scope:
Design, engineering, delivery and Commissioningon a Lump-Sum-Turnkey basis
GAMA Arabias scope:Local supplies and Construction
Some key data:Project implementation schedule: 31 month to MCTotal tons of structural steel: 3.800 metric tonnesTotal tons of equipment: 25.000 metric tonnesTotal cubic meters concrete 23.000m3Total electrical drives installed: 200Total cables installed: 350 kmTotal construction hours: 3.750.000
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Outotec Oyj CMD 200918
Project Task Force
Project execution having all project team members in the same location (separate task force office)
Short and efficient communication ways, fast decisions
Interacting of engineering team ensured
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Outotec Oyj CMD 200919
Global SourcingSupplies from and Fabrication in Europe Asia (South Korea, Taiwan, China) North America (Canada) South America (Argentina, Brazil)
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Outotec Oyj CMD 200920
Managing Complex Logistics Approx. 120 shipments Approx. 140.000 freight tons
(100.000 frt break bulk40.000 frt container shipment)
Heavy items up to 290 tons Shipments from Europe,
Asia and America
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Outotec Oyj CMD 200921
Engineering Home Office Oberursel up to 40 Worldwide Expediting (Outotec) up to 5
Construction Site Raz Az Zawr / KSA (GAMA) Technical Management Team up to 35 Suppliers supervision up to 20 Construction Indirects up to 140 Construction Direct Manpower up to 1,200
Commissioning up to 10
Total up to 1,450
Manpower
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Outotec Oyj CMD 200922
Organization Chart Overall Project
Outotec Project Management
ConstructionCompany
Clients engineerEPCM
Employer MPC
Construction CompanyTechnical Mgmt.
Process Engineering
Plant Engineering
Civil/Structural Engineering
Electrical/Instrumentation Engineering
Home Office Construction Mgmt.
QA/QC Management
Procurement/Shipping
Local ConstructionSubcontractors
HSE Management
Vendors/Suppliers
Expediting/Inspection
Outotecsresponsibility area
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Outotec Oyj CMD 200923
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
45,0
50,0
55,0
60,0
65,0
70,0
75,0
80,0
85,0
90,0
95,0
100,0
%
Early / Month 0 10, 2,3 4,1 1,3 3,7 2,4 2,4 2,4 3,3 3,2 3,1 3,3 4,3 3,5 2,9 4,5 4,8 2,9 2,5 3,5 3,4 4,6 4,3 3,6 2,6 2,1 1,8 1,3 1,1 1,0 0,8 0,4 0,3 0,4 0,3 0,3 0,3 0,3 0,1 0,1 0,0
Target / Month 0 6,7 4,2 3,5 1,8 3,2 2,4 2,3 2,5 2,7 2,8 3,0 3,1 3,7 3,3 2,5 3,7 4,3 3,6 3,4 3,5 4,5 5,0 4,3 3,4 3,1 3,4 2,2 1,6 1,3 1,3 1,0 0,3 0,3 0,4 0,4 0,3 0,3 0,3 0,1 0,1 0,0
Actual / Month 0 0,0 8,0 3,9 2,5 2,3 2,9 2,0 2,0 7,3 2,4 1,8 5,7 1,7 1,6 2,3 2,7 4,7 3,7 3,4 5,0 4,3 6,0 4,6
Late / Month 0 2,9 6,0 2,9 2,2 2,6 2,3 2,2 2,6 2,2 2,5 2,9 3,0 3,0 3,1 2,2 2,8 3,7 4,3 4,4 3,5 5,5 5,3 4,4 3,1 3,5 4,8 2,6 2,0 1,5 1,5 1,3 0,3 0,3 0,4 0,4 0,4 0,3 0,3 0,1 0,1 0,1
Early cum. 0 10, 12, 17, 18, 22, 24, 26, 29, 32, 35, 38, 41, 46, 49, 52, 57, 61, 64, 67, 70, 74, 78, 83, 86, 89, 91, 93, 94, 95, 96, 97, 97, 98, 98, 98, 99, 99, 99, 99, 10 10
Target cum. 0 6,7 10, 14, 16, 19, 21, 24, 26, 29, 32, 35, 38, 41, 45, 47, 51, 55, 59, 62, 66, 70, 75, 80, 83, 86, 89, 92, 93, 94, 96, 97, 97, 97, 98, 98, 98, 99, 99, 99, 99, 10
Actual cum. 0 0,0 8,0 11, 14, 16, 19, 21, 23, 31, 33, 35, 40, 42, 44, 46, 49, 53, 57, 61, 66, 70, 76, 81,
Late cum. 0 2,9 8,9 11, 14, 16, 19, 21, 23, 26, 28, 31, 34, 37, 40, 42, 45, 49, 53, 58, 61, 67, 72, 76, 79, 83, 88, 90, 92, 94, 95, 97, 97, 97, 98, 98, 98, 99, 99, 99, 99, 10
0 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 29 30 31 32 33 34 35 36 37 38 39 40 41
early
target
late
Progress Curve - Total Project
Effective Date MC
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Outotec Oyj CMD 200924
Risks and Risk Mitigation Quality
Completion Schedule
Procurement/material cost
Currency exchange rate
Country specific risks
Technological risks
Supplier qualification procedure/ Intensive expediting/permanent fabrication supervision in suppliers workshops for critical items
Intensive suppliers expediting and reporting, permanent analysis of actual vs. target progress by engineering discipline and for construction
Global sourcing and strict bid comparison/analysis
Precise cash planning and forward hedging contracts
Political risk insurance
Largest plant ever built, but manageable upscale factor
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Outotec Oyj CMD 200925
1.Basics
2.Project Overview
3.Project Development
4.Project Execution
5. Services
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Outotec Oyj CMD 200926
Services Important critical Spare Part Package sold
Intelligent computerized training simulator sold for operator training before and after first commissioning
Opportunities for long-term Service frame agreement related to:
Spare Part Supplies Operation assistance Assistance in Maintenance and shut down planning Training frame agreement
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Outotec Oyj CMD 200927
Overall View Construction Site
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Outotec Oyj CMD 200928
Q&AMore out of ore!
www.outotec.com
Grinding mill at Kittil gold mine in Finland