BOM MPAP June 2005 PDF

Basic Operating Manual
Engineering
CONFIDENTIAL
doc. no.
2.187.735 -
page
0.1
doc. type
80
date
2005-06-30
dept
E-PX
author
F. Winkel/fwi
proj. no.
405.014
subject
Basic Operating Manual Magadi Soda Ash Plant
abbr.
BOM
Distribution
book no.
address
Mr. Cleary
Magadi Soda Company, Kenya
Mr. Balasundaran
Larsen & Toubro, Chennai, India
Mr. Schouwenaars
Akzo Nobel Base Chemicals, Amersfoort, The Netherlands
Mr. Geuzebroek
Akzo Nobel Engineering (E-PX), Arnhem, The Netherlands
Mr. van Lotringen
Akzo Nobel Engineering (E-PX), Arnhem, The Netherlands
File
Akzo Nobel Engineering, (E-SI), Arnhem, The Netherlands
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This document and the copyright is owned by Akzo Nobel Engineering bv Arnhem The Netherlands. It may neither be copied
nor submitted to third parties for copying, without permission of the company.
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
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date
2005-06-30
Revisions
rev.
description
Page
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initials
Engineering
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CONTENTS
1
INTRODUCTION ..................................................................................................... 1.1
PLANT OPERATION ............................................................................................... 2.1
2.1
General description of the process .......................................................................... 2.1
2.2
Location, layout and process sections ..................................................................... 2.4
2.2.1
Location ................................................................................................................... 2.4
2.2.2
Plant structure .......................................................................................................... 2.4
2.3
Plant operation and control system.......................................................................... 2.5
2.4
Operating philosophy ............................................................................................... 2.7
SPECIFICATION OF RAW MATERIALS, AUXILIARY MATERIALS AND UTILITIES

................................................................................................................................. 3.1
3.1
Specification of raw material .................................................................................... 3.1
3.1.1
Lake Magadi Trona .................................................................................................. 3.1
3.1.2
Fines Bank Material ................................................................................................. 3.2
3.2
Specification of auxiliary materials ........................................................................... 3.3
3.2.1
Lake brine ................................................................................................................ 3.3
3.2.2
Flocculant................................................................................................................. 3.3
3.2.3
Butane...................................................................................................................... 3.3
3.2.4
Trisodium phosphate ............................................................................................... 3.3
3.2.5
Morpholine/Ammonia ............................................................................................... 3.3
3.2.6
Biocide ..................................................................................................................... 3.3
3.2.7
Flocon 100 ............................................................................................................... 3.4
3.2.8
Emulsified silicone (antifoam) .................................................................................. 3.4
3.2.9
Diatomaceous earth ................................................................................................. 3.4
3.3
Specification of utilities............................................................................................. 3.5
3.3.1
Heavy fuel oil ........................................................................................................... 3.5
3.3.2
Industrial diesel oil (not used) .................................................................................. 3.5
3.3.3
Steam 15 bar ........................................................................................................... 3.6
3.3.4
Steam 3 bar ............................................................................................................. 3.6
3.3.5
Instrument and plant air ........................................................................................... 3.6
3.3.6
Electric power .......................................................................................................... 3.6
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3.3.7
Process water .......................................................................................................... 3.7
3.3.8
Hot process water .................................................................................................... 3.7
3.3.9
Purge water.............................................................................................................. 3.7
3.3.10
Potable water ........................................................................................................... 3.7
3.3.11
Raw water ................................................................................................................ 3.9
3.3.12
Cooling tower water ............................................................................................... 3.10
SAFETY, ENVIRONMENTAL AND HEALTH ASPECTS......................................... 4.1
4.1
Safety....................................................................................................................... 4.1
4.2
Environment............................................................................................................. 4.2
4.3
Health....................................................................................................................... 4.2
4.4
Material Safety Data Sheets .................................................................................... 4.3
200 SECTION .......................................................................................................... 5.1
5.1
Process description.................................................................................................. 5.1
5.1.1
Introduction .............................................................................................................. 5.1
5.1.2
Dredging (PFD 100-01, OSBL) ................................................................................ 5.1
5.1.3
Dredge product receiving and reclaim (PFD 200-01)............................................... 5.1
5.1.4
Classification and centrifugation (PFD 200-02)........................................................ 5.2
5.2
Normal operation ..................................................................................................... 5.4
5.2.1
Dredge product receiving (PID 200-02) ................................................................... 5.4
5.2.2
Washery feed cyclones (PID 200-03) ...................................................................... 5.4
5.2.3
Classification (PID 200-04) ...................................................................................... 5.5
5.2.4
CRS wash tank (PID 200-05)................................................................................... 5.5
5.2.5
Classifier overflow (PID 200-06) .............................................................................. 5.6
5.2.6
CRS hydrocyclones and centrifuges (PID 200-07) .................................................. 5.6
5.2.7
CRS centrate (PID 200-08) ...................................................................................... 5.6
5.2.8
CRS stockpile reclaim (PID 200-09) ........................................................................ 5.7
5.2.9
Tailings settler (PID 200-10) .................................................................................... 5.8
5.2.10
Setting list ................................................................................................................ 5.9
5.3
Logic functions ....................................................................................................... 5.11
5.4
Start up .................................................................................................................. 5.16
5.4.1
Initial start up (with empty tanks)............................................................................ 5.16
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5.4.2
Normal start up, washery section (filled tanks) ...................................................... 5.20
5.4.3
Restart from standby.............................................................................................. 5.21
5.5
Shut down .............................................................................................................. 5.23
5.5.1
Going to standby.................................................................................................... 5.23
5.5.2
Normal shut down of washery................................................................................ 5.23
5.5.3
Maintenance shutdown of washery........................................................................ 5.26
5.6
Operator actions, periodic checks.......................................................................... 5.27
5.6.1
Line flushing to prevent settling in lines ................................................................. 5.27
5.6.2
Tank cleaning to remove scale formation .............................................................. 5.27
5.6.3
Checks ................................................................................................................... 5.27
5.6.4
Critical process parameters ................................................................................... 5.28
5.6.5
Sampling and analyses .......................................................................................... 5.28
5.7
Deviating operating conditions ............................................................................... 5.29
5.7.1
Turn down capacity ................................................................................................ 5.29
5.7.2
Dry reclaim ............................................................................................................. 5.29
5.7.3
CRS reclaim ........................................................................................................... 5.31
5.7.4
Centrifuge flushing ................................................................................................. 5.31
5.7.5
Shut down in case of failure of liquor supply from the dredges.............................. 5.32
5.7.6
Failure of dredge product tank 200-TK-005 or related equipment (bypass of

200-TK-005)........................................................................................................... 5.32
5.7.7
Classifier not available ........................................................................................... 5.33
5.7.8
CRS cyclone or centrifuge not available ................................................................ 5.33
5.7.9
Diverting classified slurry to classifier discharge bunker 200-ZC-030.................... 5.34
5.7.10
Lifting of classifying screw ..................................................................................... 5.35
5.7.11
Plugging of washery sieve bend screen 200-SN-020; use of by-pass................... 5.35
5.7.12
Centrifugal pump start/stop and changeover ......................................................... 5.35
5.7.13
Start/stop and changeover of 200-PP-050/051...................................................... 5.37
5.7.14
General procedure for belt conveyor...................................................................... 5.39
5.7.15
Trouble shooting table controls of 200-TK-030 ...................................................... 5.40
5.7.16
Operation of sump 200-SU-090 ............................................................................. 5.41
MILLING AND CALCINING ..................................................................................... 6.1
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6.1
6.2
6.2.1
Calcination waste (P&ID 400-15) ............................................................................. 6.3
6.2.2
Setting list ................................................................................................................ 6.3
6.3
Logic functions ......................................................................................................... 6.4
6.4
Start-up and shutdown of Dust transport ................................................................. 6.5
6.4.1
Normal start-up ........................................................................................................ 6.5
6.4.2
Normal shut-down .................................................................................................... 6.5
6.5
Start-up and shut-down of dump tank ...................................................................... 6.6
6.5.1
Initial start-up ........................................................................................................... 6.6
6.5.2
Normal start-up ........................................................................................................ 6.6
6.5.3
Procedure for emptying tank after dumping ............................................................. 6.6
6.5.4
Normal shutdown ..................................................................................................... 6.6
6.6
Operator actions, periodic checks............................................................................ 6.7
6.7
Deviating operating conditions ................................................................................. 6.8
6.7.1
Dump tank 400-TK-060............................................................................................ 6.8
6.7.2
Too low liquor feed flow to 200-TK-010 ................................................................... 6.8
6.7.3
Pump failure of 200-PP-011/012.............................................................................. 6.8
6.7.4
High temperature of liquor return from 400-CV-040................................................. 6.9
6.8
Basic operating manual roller mill and calciner section ......................................... 6.10
6.9
Washout procedures roller mill and calciner section.............................................. 6.11
CRYSTALLIZATION ................................................................................................ 7.1
7.1
7.1.1
Introduction .............................................................................................................. 7.1
7.1.2
First stage crystallization (PFD 500-01) ................................................................... 7.1
7.1.3
Second stage crystallization (PFD 500-02).............................................................. 7.4
7.1.4
Second stage monohydrate centrifuges (PFD 500-03)............................................ 7.5
7.1.5
Liquor polishing (PFD 500-04) ................................................................................. 7.5
7.2
7.2.1
First stage crystallizer (PID 510-01)......................................................................... 7.7
7.2.2
First stage elutriator (PID 510-02)............................................................................ 7.8
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7.2.3
First stage centrifuges (PID 510-03) ........................................................................ 7.9
7.2.4
First stage settler (PID 510-04) ................................................................................ 7.9
7.2.5
First stage settler overflow (PID 510-05)................................................................ 7.10
7.2.6
Guar make-up, transfer and distribution (PID 510-07) ........................................... 7.10
7.2.7
Second stage crystallization feed (PID 520-06) ..................................................... 7.10
7.2.8
Second stage anhydrous reactor (PID520-01)....................................................... 7.11
7.2.9
Second stage crystallizer (PID 520-02).................................................................. 7.12
7.2.10
Second stage elutriator (PID520-03)...................................................................... 7.12
7.2.11
Second stage centrifuges (PID 520-04) ................................................................. 7.13
7.2.12
Second stage thermo compressor (PID 520-05).................................................... 7.13
7.2.13
Second stage centrate tank (PID 520-07).............................................................. 7.13
7.2.14
Second stage settler (PID 520-08)......................................................................... 7.13
7.2.15
Polishing filter feed (PID 520-09) ........................................................................... 7.14
7.2.16
Liquor polishing (PID 520-10) ................................................................................ 7.15
7.2.17
Polishing filtrate and backflush (PID 520-11) ......................................................... 7.15
7.2.18
Condensate (PID 520-12) ...................................................................................... 7.16
7.2.19
Precoat and filter aid (PID 520-13) ........................................................................ 7.16
7.2.20
Hot process water (PID 520-14) ............................................................................ 7.16
7.2.21
Setting list .............................................................................................................. 7.17
7.3
Logic functions ....................................................................................................... 7.24
7.4
Start-up and shutdown of the crystallization unit ................................................... 7.29
7.4.1
Fill system and start rotating equipment ................................................................ 7.29
7.4.2
Start first stage production ..................................................................................... 7.37
7.4.3
Start second stage production ............................................................................... 7.39
7.4.4
Shut-down .............................................................................................................. 7.42
7.5
Going standby and restart...................................................................................... 7.45
7.5.1
Going standby of first stage crystallization circuit .................................................. 7.45
7.5.2
Going on standby of second stage crystallization circuit........................................ 7.45
7.5.3
Restart from stand-by of first stage crystallization unit........................................... 7.47
7.5.4
Restart from standby of second stage crystallization circuit .................................. 7.47
7.6
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7.6.1
Water balance ........................................................................................................ 7.49
7.6.2
Critical process parameters ................................................................................... 7.50
7.6.3
7.7
7.7.1
Buffering of slurry in case of capacity variation of first and second stage.............. 7.53
7.7.2
Guar preparation procedure................................................................................... 7.53
7.7.3
Guar flow rate measuring procedure...................................................................... 7.54
7.7.4
Heating process liquor with start-up heater............................................................ 7.54
7.7.5
Pump failure of filter feed pump 520-PP-060/061 .................................................. 7.55
7.7.6
Centrifugal pump start/stop and changeover ......................................................... 7.56
7.7.7
Start/stop and changeover of 510-PP-050/051 and 520-PP-050/051.................... 7.57
7.7.8
Start-up and shutdown of condensate tank 520-TK-045........................................ 7.59
7.7.9
Start-up and shut down of hot water tank 520-TK-091 .......................................... 7.60
7.7.10
Performance monitoring of anhydrous reactor heater............................................ 7.61
7.7.11
Filter regeneration .................................................................................................. 7.62
7.7.12
Precoat preparation ............................................................................................... 7.64
7.7.13
Filter aid system ..................................................................................................... 7.65
7.7.14
Flushing of centrifuge............................................................................................. 7.66
7.7.15
7.7.16
7.7.17
Washout procedure crystallization section............................................................. 7.68
FLUID BED DRYING (PFD600-01).......................................................................... 8.1
8.1
8.2
8.2.1
Feed to static fluidbed dryer for pure soda ash plant (PID 600-01) ......................... 8.3
8.2.2
Static fluidbed dryer for pure soda ash plant (PID 600-02) ...................................... 8.3
8.2.3
Air supply and air heating for static fluidbed dryer for pure soda ash plant (PID 60003)............................................................................................................................ 8.4
8.2.4
Monohydrate dryer dust and condensate discharge (PID 600-04) .......................... 8.5
8.2.5
Setting list ................................................................................................................ 8.6
8.3
Logic functions ......................................................................................................... 8.9
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8.4
Start-up and shutdown of fluid bed dryer ............................................................... 8.11
8.4.1
Normal start-up (from empty bed) .......................................................................... 8.11
8.4.2
Restart from standby.............................................................................................. 8.13
8.4.3
Shut down (empty fluid bed) .................................................................................. 8.13
8.4.4
Going to standby.................................................................................................... 8.14
8.5
Start-up and shutdown Dust transport ................................................................... 8.14
8.5.1
Normal start-up ...................................................................................................... 8.14
8.5.2
Normal shut-down .................................................................................................. 8.14
8.6
Start-up Condensate collection and discharge ...................................................... 8.15
8.6.1
Normal start-up ...................................................................................................... 8.15
8.6.2
Normal shut down .................................................................................................. 8.15
8.7
8.7.1
Periodic checks ...................................................................................................... 8.15
8.7.2
Critical process conditions ..................................................................................... 8.16
8.7.3
8.8
8.8.1
Cleaning of dryer.................................................................................................... 8.17
8.8.2
Too low liquor feed to 520-TK-040......................................................................... 8.17
8.8.3
Pump failure of 520-PP-040/041............................................................................ 8.18
8.8.4
Dust transport ........................................................................................................ 8.18
8.8.5
Washout procedure of fluid bed dryer .................................................................... 8.19
EMERGENCY SITUATIONS ................................................................................... 9.1
9.1
Power Failure ........................................................................................................... 9.1
9.1.1
Consequences for the washery section 200 ............................................................ 9.1
9.1.2
Consequences for calciner unit 400......................................................................... 9.2
9.1.3
Consequences for dumptank 400 ............................................................................ 9.3
9.1.4
Consequences for Dust transport 400 ..................................................................... 9.3
9.1.5
Consequences for Crystallization section ................................................................ 9.4
9.1.6
Dust transport 600 ................................................................................................... 9.4
9.1.7
Steam boiler............................................................................................................. 9.4
9.2
Process water Failure .............................................................................................. 9.4
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9.2.1
Consequences for the washery section 200 ............................................................ 9.4
9.2.2
Consequences for calciner section .......................................................................... 9.5
9.2.3
Consequences for Dumptank 400 ........................................................................... 9.5
9.2.4
Consequences for first crystallization section .......................................................... 9.5
9.2.5
Consequences for second crystallization section .................................................... 9.5
9.2.6
Consequences for cooling water system ................................................................. 9.5
9.3
Purge water failure ................................................................................................... 9.6
9.4
Cooling water failure ................................................................................................ 9.6
9.5
Steam failure ............................................................................................................ 9.6
9.6
Dredge feed failure .................................................................................................. 9.7
9.7
Instrument air and plant air failure ........................................................................... 9.7
9.8
Guar solution failure ................................................................................................. 9.8
9.9
Anti foam solution failure in washery section ........................................................... 9.8
10
COMMISSIONING AND INTIAL START-UP ......................................................... 10.1
10.1
Washery................................................................................................................. 10.1
10.2
Dryer dust transport 400 ........................................................................................ 10.1
10.3
Crystallization......................................................................................................... 10.1
10.4
Dryer ...................................................................................................................... 10.1
10.5
Dryer dust transport 600 ........................................................................................ 10.2
10.6
Condensate tank 600-TK-010 ................................................................................ 10.2
11
MAINTENANCE ..................................................................................................... 11.1
11.1
Maintenance inspection ......................................................................................... 11.1
11.2
Fluid bed dryer inspection ...................................................................................... 11.1
11.3
Pump and agitator seals ........................................................................................ 11.2
11.4
Inspection of tanks ................................................................................................. 11.2
APPENDIX 1:
TROUBLE SHOOTING TABLE FOR 200-PP-050/051, 510-PP-050/051, 520-PP050/051
APPENDIX 2:
TROUBLE SHOOTING TABLE WARMAN PUMPS
APPENDIX 3:
LIST OF ACRONYMS
APPENDIX 4:
UNIT SYSTEM
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INTRODUCTION
This manual describes the basic principles of the start-up and operation of the Pure Soda
ash plant at Magadi Kenya.
The design of this plant is based on process development by Brunner Mond in
cooperation with package unit vendors and on the experience with other comparable units
(e.g. crystallization, drying).
These basic operating procedures have been compiled by Akzo Nobel Engineering and
are based on operating experience at Akzo Nobel and the basic design for Magadi pure
soda ash plant as reported in the Basic Engineering Package.
Furthermore, information from package unit vendors FFEM, HPD, L&T Niro (LTN) and
HDO and from some equipment vendors is also included.
In this manual, input from package unit vendors of mill&calciner, crystallization and drying
are included. This manual, together with the instructions of the different equipment
suppliers, will serve as a guideline for:
training of operating personnel
preparing detailed operating instruction
commissioning and first start-up of the plant
The manual is divided into 11 chapters:
Chapter 1: Introduction
Chapter 2 4: General information on plant operations, specifications of chemicals and
utilities appearing in the process, and safety provisions
Chapter 5 8: Process description, process characteristics and detailed information on
normal operation, start-up situations and deviation from normal operating conditions
Chapter 9: Emergency situations of the plant
Chapter 10: Information on first start-up and commissioning of the plant
Chapter 11: Basic information on maintenance of the plant; for detailed information
refer to information from vendors.
Operating manuals for section 100 (Dredging), Section 700 (Screening), Section 800
(Storage and load-out), Section 900 (Utilities) and Electrical Power Generation are
provided separately from this manual.
Other manuals relevant to this plant include:
Analytical Manual
Magadi Soda Company Safety Manual
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PLANT OPERATION
2.1
General description of the process

The pure soda ash plant is divided into the following sections:
100
Dredging
200
Washing
400
Milling and flash calcining
500
Crystallizing
600
Monohydrate drying
700
Product screening
800
Product storage and load out
900
Utilities
Trona slurry is dredged (see Dredge and mining system basic operating procedures) from
lake Magadi and is pumped to the washery (section 200).
The prime objective of the washery is to remove as much as possible of the soluble
impurities (e.g. NaCl), and insoluble impurities (e.g. organic material) and to produce a
relatively dry CRS (Crushed Refined Soda) as feedstock for the Mill & calciner unit.
In the washery, insoluble impurities are separated by applying cyclones, a classifier and
centrifuge.
Also the washery provides liquor for ESP dust recycle, crystallization second stage vent
condenser and the boiler scrubber.
During occasions when the dredge is incapable of supplying trona, the liquor flow
continues and trona can be supplied from a raw trona stockpile via the dry reclaim route.
Via this route fines bank material can also be supplied as feed stock.
In the calciner section, CRS is ground in the roller mill. Grinding is essential because of
the particle size purification process as applied in the crystallization section. The ground
material is reacted at elevated temperatures (up to 425C) to convert the NaHCO3 part of
trona into Na2CO3. Dust is separated in an electrostatic precipitator (ESP) and recycled to
the process. In order to avoid dust accumulation, it may be necessary to discharge part of
this dust to the washery section using lake liquor as the transportation medium.
Na2CO3 from the calciner unit is supplied to the first crystallization section to form
Na2CO3.H2O. Fixed insolubles (mainly NaF) are then separated in an elutriation leg.
Subsequently the product is de-liquored and washed on a centrifuge. A second
crystallization step is required to reach the low NaF specification of the final product. In
the second stage monohydrate is crystallized to anhydrous Na2CO3 and back to
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Na2CO3.H2O. Fixed insolubles are again separated in an elutriation leg, and subsequently
the product is deliquored and washed on a centrifuge.
A liquor purge is provided in the first stage crystallization section. This purge serves to
keep sodiumsulfate concentration below 3 wt% to prevent contamination of the final
product. Sodiumsulfate is formed in small quantities in the calciner section.
In the fluid bed dryer the monohydrate is dried and subsequently dehydrated to anhydrous
Na2CO3 (dense soda ash), oversize is then removed in the screening section and the
product is then transferred to the storage section and rail load-out section.
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2.2
Location, layout and process sections
2.2.1
Location
The plant is located on the Eastern shore line of Lake Magadi, next to an existing plant of
Magadi Soda Company.
.
Elevation
m
596
Ambient pressure
kPa
94.9
Temperature max. (shade) C
41
min. (shade) C
16
Design dry bulb
C
36
Design wet bulb
C
22
Precipitation
mm/y
455
Days rainfall
d/y
73
Evaporation
mm/y
4105
Average design wind
km/h
3.6
Maximum wind
km/h
161
Seismic zone
2A
2.2.2
Plant structure
In principle all process equipment is located outside in steel structures.
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2.3
Plant operation and control system

For process control, a Distributed Control System (DCS) is installed in the central control
room. In each section field operators are present. The DCS shows process data and
equipment status. For all sections, except the section 400, mill and calciner section, the
desk operator has very limited possibility to remotely start and stop equipment. In general
the field operator will be available to start and stop equipment if needed. For the mill and
calciner section, the desk operator starts and stops the equipment via the DCS.
A boiler control room is provided near the boiler area where the boiler is independently
controlled from. The power generation equipment and the dredge are also controlled and
operated locally from their own control rooms, although certain critical information is
relayed back to the main plant control room for information purposes only.
Control logics are described in the functional description and the FLDs (functional logical
diagrams). The DCS shows remote instrument readings of all relevant process
parameters.
An operator workstation (OWS) is located in the washery section. This OWS provides full
access to the washery section. The washery section can be operated by the field operator
via the OWS and by the desk operator via a DCS station in the control room.
Process interlocks are incorporated within in the DCS and motorstatuss are also
displayed. Alarm is provided for when motors are stopped.
All drives are provided with a thermal overload protection, so they need a reset to be
started when there is a thermal overload situation. In addition all drives can be turned off
by a local switch. Thermal overload and emergency switches are hardwired to the motor
control centre (MCC).
The DCS is provided with an un-interrupted power supply (UPS), which enables the
operator to shutdown the plant safely in case of total loss of electrical power.
For the supply of electrical power a connection with the external grid (KP&LC) is available
and a total of 5 on-site fuel oil fired power generators (see separate operating
procedures). In a normal situation power is supplied by KP&LC and 2 power generators. If
one of the power generators fails, depending on the actual remaining capacity, the pure
ash plant availability is maximized by shedding load in a prioritized order. The Power
management system PMS automatically trips circuit breakers to shed load to allow the
system to stay within voltage and frequency limits in the event of utility power failure, or
failure of Diesel cycle engine drive Generator (DG).
The order of priority (highest first) shall be:
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Critical drives: items of equipment that need to be maintained in a safe mode of

operation and to ensure ease of start up after failure of the electrical power supply.
Essential drives: All other items of the pure ash plant that are needed for continuous
operation, excluding the majority of the washery area.
Non essential drives: Majority of the new washery area
A detailed description of the way the PMS acts on the electrical equipment and
procedures for restart is supplied under separate cover. When sufficient power becomes
available, the equipment can be restarted by operator (no automatic restart of equipment).
Materials management
A system for materials management of auxiliary materials is provided under separate
cover. In this system the following aspects have been covered:
Materials have to be supplied in suitable packaging, with clear identification and
product specification forms (purchasing)
Procedure for sampling and analyzing of materials
Materials have to be stored on dedicated locations in the storage area
Operators that use the auxiliary materials have to be instructed well on the location of
the materials and the applications.
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2.4
Operating philosophy
The dredge supplies trona slurry to the washery. In case the dredge does not supply trona
(unexpected failure or scheduled maintenance), the dredge pump will continue to supply
liquor. In this case trona will be supplied to the dredge product tank from the raw trona
stockpile, via the dry reclaim route.
There is a small buffer between washery (200 section) and the roller mill & calciner
(section 400) in the roller mill feed bin 200-BN-085. In case the washery is out of
operation, CRS can be supplied from the CRS stockpile by front end loader to this bin.
When the above route is used to feed the roller mill, the liquor feed to the washery has to
be maintained, because liquor is required for ESP dust recycle and for cooling of second
stage vent condenser.
Product from the calciner section is directly introduced to the first stage crystallizer. This
means that failure of either of these sections, results in a production stoppage of both
sections.
The product from the first stage crystallizer is collected in the second stage crystallizer
feed tank 520-TK-005. This tank provides the possibility to run the second stage for a
limited time without running the first stage crystallizer. When the first stage is running
without the second stage, then the solids concentration in the feed tank will increase. This
can only carried out be for a short duration in order give the operating team sufficient time
to put the first stage in stand-by mode. Also dilution with filtrate from the 1st stage
centrifuge is not desirable, which would lead to product quality issues.
Turndown of washery
The washery can be turned down to 50% of normal operating capacity in case one of the
centrifuges is not in operation. If required, additional feed to the mill can be supplied with
CRS from CRS stockpile.
As the product from the classifier can be partly diverted to intermediate stockpile 200-ZC030, the dredge feed can continue at 100% rate, but the operator has to remove product
from stockpile 200-ZC-030 whilst operating in this mode. As mentioned previously liquor
supply rate has to be maintained in order to supply liquor at the required flow rates to the
ESP dust recycle and second stage vent condenser.
Turndown of mill and calciner unit
The equipment within the Mill and calciner unit all run at the same capacity. In case the
first stage crystallizer operates with one centrifuge, then the unit will run at 50% capacity.
However, running the calciner unit below 70% can be problematic (decreased
conversion). If this situation occurs in practice, optimum condition will have to be found in
order to maximize rate in an effort to maintain product quality (increase feed over the one
running centrifuge as much as possible to keep the calciner running at as high possible
capacity).
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Turndown of crystallizer
First stage crystallizer can be turned down to 50% of normal rate in case one centrifuge is
not running. The calciner has to reduce capacity as well (see above). Feed tank 200-TK005 provides time to decrease the second stage capacity to 50% also (stop one
centrifuge). If the second stage is running at 50%, the first stage will have to be reduced to
50% as well and in this case the tank provides time for the operators to respond. At
turndown the removal of impurities will be less efficient which lowers product quality.
Turndown of fluid bed dryer
The dryer has no real buffer capacity and it will be turned down to 50% if crystallizer is
turned down.
Buffering time of main buffer tanks of the process:
Tag number
200-TK-005
200-TK-030
Equipment name
Dredge product tank
CRS wash tank
Operating
Normal Operating
volume
capacity
1)
93 m
11 minutes
130 m
95 m
22 minutes
120 m
Buffering time
200-ZC-040
CRS stockpile
5000 ton
5000 ton
47 hours
200-BN-085
Roller Mill feed bin
100 m3
50 m3
60 minutes
520-TK-005
Second stage cryst. Feed tank
269 m
800-BN-020
Product Silo
5000 ton in
A/B/C
190 m
total
1)
Normal operating capacity is defined as follows: from normal operating level to low level
2)
Buffering time is defined as follows:
For stockpiles and bunkers: from empty to full
For tanks from normal liquid level to low liquid level
word 10.0
2 hours
4 days
2)
Engineering
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3.1
date
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SPECIFICATION OF RAW MATERIALS, AUXILIARY MATERIALS AND UTILITIES

Unless specified otherwise the specified pressures are absolute at ground level.
3.1
Specification of raw material
3.1.1
Lake Magadi Trona

Composition (dry basis):
typical
max.
min.
Na2CO3.NaHCO3.2H2O
wt%
> 91.95
Na2SO4
wt%
nil
NaCl (occluded)
wt%
< 0.05
Insolubles
total
wt%
< 6.0
10
1.0
free
wt%
< 5.65
fixed
wt%
< 0.35
NaF
wt%
< 2.0
3.0
0.5
The typical composition is given on a 24 hour time weighed average basis. The maximum
composition is for a maximum of 1 hour on a maximum of 1 occasion per 24 hour period.
Specific gravity
2.15
Bond work index (metric)
5.2
Hardness
moh
2.5 to 3
Screen analysis cumulative (weighed average):
9.5 mm
wt%
0.58
8.0 mm
wt%
0.58
6.7 mm
wt%
6.16
5.7 mm
wt%
10.33
4.0 mm
wt%
16.45
3.4 mm
wt%
20.50
1.0 mm
wt%
54.19
0.595 mm
wt%
68.11
0.420 mm
wt%
76.73
0.125 mm
wt%
92.71
0.050 mm
wt%
95.41
< 0.050 mm
wt%
< 5.0
Supply as 80 wt% solids by front-end loader or as about 20 wt% slurry by pipeline.
Composition of liquor: see lake brine.
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date
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3.1.2
Fines Bank Material

Composition (dry basis):
Na2CO3.NaHCO3.2H2O
Insolubles total
NaF
Moisture
Screen analysis <100 m
Percent of feedstock
Supply by front-end loader.
wt%
wt%
wt%
wt%
wt%
wt%
> 85
< 15
< 0.5
<5
25
< 10
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3.2
Specification of auxiliary materials
3.2.1
Lake brine
Composition:
Na2CO3
NaHCO3
Na2SO4
NaCl
NaF
Specific gravity
pH
Temperature
Viscosity
3.2.2
wt%
wt%
wt%
wt%
wt%
C
mPas
wet
14.0
0.5
0.1
9.0
0.3
1.20
11
35
6
dry season
18.0
0.1
0.1
12.0
0.3
1.30
11
35
6
Flocculant
Solution of 0.5 wt% guar gum.
Viscosity
mPas
400
Supply of guar gum by 50 kg bags (HOLD).
3.2.3
Butane
Quality: LPG with 60 % butane and 40 % propane.
Used as oil burner ignition fuel.
Supplied in 22.5 kg gas bottles.
3.2.4
Trisodium phosphate
Used as antiscalant.
Supply by 50 kg bags
3.2.5
Morpholine/Ammonia
Added to boiler make-up water and condensate.
Supply by 20 liter bottles.
3.2.6
Biocide
Added to cooling tower water.
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date
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3.2.7
Flocon 100
Added to boiler make-up water.
3.2.8
Emulsified silicone (antifoam)

Type: Dow Corning Silicone (B).
Concentration
wt%
Supply by 200 liter carboy.
3.2.9
100
Diatomaceous earth
Type: Celite Hyflo Supercel
Density
< 100 m
Median cake pore size
pH
Supply by 20 kg bags.
kg/m3
wt%
m
-
160
95
7
10
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3.3
Specification of utilities
3.3.1
Heavy fuel oil

Higher heating value
Nitrogen content for design
Sulphur content (max.)
Viscosity at 50 C (max.)
Flash point PMCC (min.)
Pour point (max.)
Density @ 20 C
Water content
Solids content
Metal analysis:
K
Ca
Fe
Ni
Cu
Pb
V
Supply by pipeline.
3.3.2
MJ/kg
wt%
wt%
cSt
C
C
kg/m3
vol%
wt%
43
0.25
3.7
180
65
24
985
0.75
0.15
ppm wt
ppm wt
ppm wt
ppm wt
ppm wt
ppm wt
ppm wt
2.9
34
28
9
8
2
12
Industrial diesel oil (not used)

Higher heating value (min.)
Sulphur content (max.)
Viscosity at 40 C (max.)
Flash point PMCC (min.)
Pour point (max.)
Density @ 20 C (max.)
Water content (max.)
Sediment content
Ash (max.)
Carbon residue (max.)
Strong acids No.
Total acid No. (max.)
Asphaltenes (max.)
Supply by barrel for start-up.
MJ/kg
wt%
cSt
C
C
kg/m3
vol%
wt%
wt%
wt%
mg KOH/g
mg KOH/g
wt%
44.8
1.8
10 (IP test method)
66
12
915
0.25
0.02
0.02
0.45
0.5
2.9
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3.3.3
Steam 15 bar
Generated ISBL.
Process design temperature
Process design pressure
Mechanical
design temperature
design pressure
Supply by pipeline.
3.3.4
210
15.5
C
bar
236
18.5
C
bar
150
3
C
bar
210
6
Steam 3 bar
Generated ISBL.
Process design temperature
Mechanical
design temperature
design pressure
Supply by pipeline.
3.3.5
C
bar
Instrument and plant air

Generated ISBL.
Dust and oil free.
Dewpoint
Minimum pressure
C
bar
bar
Mechanical
design temperature C
design pressure
bar
3.3.6
- 20
7
5.5
50
8
Electric power
24 V dc for instrument power
110 V 1 ph. 50 Hz
240 V 1 ph. 50 Hz
415 V 3 ph. 50 Hz
5.5 kV 3 ph. 50 Hz for > 150 kW.
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3.7
date
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3.3.7
Process water
Quality: Fish-springs water
Composition:
wt%
Na2CO3
NaHCO3
wt%
Na2SO4
wt%
NaCl
wt%
NaF
wt%
SiO2
ppm
Suspended solids
ppm
pH
Temperature
C
Specific gravity
Supply by pipeline via pipeline.
3.3.8
0.83
0.66
0.011
0.63
0.014
200
270
9.4
30
1.012
Hot process water

Generated ISBL.
Quality and composition: see process water
Temperature
C
90
Pressure
bar
7
Supply by pipeline.
3.3.9
Purge water
Generated ISBL.
Quality: Filtered process water.
Pressure
bar
Supply by pipeline.
3.3.10
10
Potable water
Quality: treated raw water.
Composition (analysis 2001-06-25 and 2001-07-25):
HCO3mg/l
49
SO42mg/l
11.54
CO2
mg/l
nil
CO32mg/l
< 6.00
Clmg/l
10.79
Fmg/l
0.34
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PO43+
-P
Na
NH4+
NO3Mn
Cd
Cr
Pb
Cu
Zn
Fe
Mg
Ca
K
Total Si
Hg
Se
As
Ba
Total dissolved solids
Fixed suspended solids
Total alkalinity
pH
Conductivity
Total Coliforms
E. Coli
Pressure
Temperature
Supply by pipeline.
mg/l
0.62
mg/l
3.4
mg/l
0.28
mg/l
2.48
ppm
0.027
ppm
0.020
ppm
nil
ppm
nil
ppm
nil
ppm
0.336
ppm
0.193
ppm
2.783
ppm
4.759
ppm
2.798
ppm
15.0
ppm
< 0.001
ppm
<0.01
ppm
<0.05
ppm
<0.001
wt%
0.02
wt%
< 0.001
mg/l
0.049
7.24
S
200
MPN/100 ml
nil
MPN/100 ml
nil
bar
C
30
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date
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rev
3.3.11
Raw water
Composition:
Composition (design conditions):
ppm
61
HCO32SO4
ppm
8.08
CO2
ppm
10
CO32ppm
< 6.0
Cl
ppm
600
Fppm
15
3PO4 -P
ppm
1.87
Na+
ppm
100
NH4+ as N
ppm
0.6
NO3- as N
ppm
0.6
Mn
ppm
0.1
Cd
ppm
0.015
Cr
ppm
nil
Pb
ppm
nil
Cu
ppm
nil
Zn
ppm
0.024
Fe
ppm
1.4
Mg
ppm
2.76
Ca
ppm
2.74
K
ppm
12
Total Si
ppm
15.0
Hg
ppm
< 0.001
Se
ppm
<0.01
As
ppm
<0.05
Ba
ppm
<0.001
Total dissolved solids
ppm
1500
Total suspended solids
ppm
56
Total hardness (as CaCO3) ppm
90
Total alkalinity
ppm
50
pH
7.35
Conductivity
S
230
Total Coliforms
MPN/100 ml 200
E. Coli
MPN/100 ml 60
Pressure
Temperature
Supply by pipeline.
bar
C
8
30
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3.3.12
Cooling tower water

Generated ISBL from raw water.
Pressure supply
bar
Max. pressure drop
bar
Temperature supply
C
Max. return temperature
C
Mechanical
design temperature C
design pressure
bar
Supply and return by pipeline.
5.5
1
30
45
50
10
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SAFETY, ENVIRONMENTAL AND HEALTH ASPECTS
4.1
Safety
Storage of raw materials and finished products
There are no special requirements for the materials used in the plant. The storage of
fuel oil for the calciner is existing. However, new intermediate storage between the
existing storage and the plant will be provided.
Auxiliary materials (like filter aid or guar) in bags or other types of packaging have to be
stored in an ordered fashion. All materials have to be labeled clearly to prevent using in
the wrong application.
Lay out
The degree of hazards according the DOWs F&EI is in the range of light. For the
layout of the plant no special arrangements are foreseen in terms of safety distances.
Fire safety
No flammable/combustable materials, except for small amounts of fuel oil and LPG, are
present in the plant. There will be fire extinguishing provisions (hydrants).
Area classifications
Storage area of LPG will is a classified area. LPG is used in burner of steam boiler and
calciner burner. In the vicinity of the burner, area classification for instrumentation and
other equipment is not applicable.
No other flammable liquids or gases are used in the process area, therefore no area
classification is executed based on flammable vapors. The way of processing guar gum
and the limited amounts indicates that an area classification to prevent dust explosions
is not needed.
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4.2
Environment
The Plant is designed is in accordance with the requirements of the World Banks
Pollution Prevention & Abatement Handbook, 1998 Edition, the U.S Occupational Safety
and Health Administration and the American Conference of Governmental Industrial
Hygienists.
Emission limits for new sources are:
Particulates
mg/Nm3
SO2
mg/Nm3
NOx
mg/Nm3
50
2000
460
1 Nm3 is 1 m3 (dry) at 1 atm. and 0 C.

The the stack of the calciner section and of the fluid bed dryer will be equipped with
opacity monitoring equipment.
Upper noise threshold limits dictate the level of ear protection required. These have been
ascertained and for the near field as a guidance the following actions are required, based
on the daily personal exposure (LEP,d):
LEP,d < 85 dB(A):There is a general duty to reduce risk of hearing damage to the lowest
level reasonably practical, but it is not necessary to provide warning signs or ear
protectors.
85 dB(A) < LEP,d < 95 dB(A): Provide adequate information, instruction and training on
the risks associated with noise and how personnel can obtain ear protectors if they are
exposed to this noise range and provide appropriate ear protectors to employees.
LEP,d > 95 dB(A): Demarcate the area by providing warning signs and ear protectors for
personnel protection, implement reasonably practical noise attenuation that can be
applied to the works.
4.3
Health
Safety showers and eye-washers are placed at appropriate locations and a map is
included within the safety regulations identifying them.
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4.3
date
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4.4
Material Safety Data Sheets

Following Material Safety Data Sheets are included:
1. Sodium Carbonate Anhydrous
2. Sodium Carbonate Monohydrate
3. Celite Hyflo Supercel
4. Guar Gum
5. Antifoam
6. Nalco 19S Pulv Oxygen Scavanger
7. Nalco Transport-Plus 2801
8. Morpholine
9. Sodium Fluoride
10. Sodium Phosphate
word 10.0
safety data sheet
SODIUM CARBONATE
1. IDENTIFICATION OF THE SUBSTANCE AND COMPANY
Product Name
Chemical Name
Alternative Name
Chemical Formula
:
:
:
:
SODIUM CARBONATE
Sodium Carbonate
Soda Ash Light, Dense, Heavy, Granular
Na2CO3
Manufacturing Sites
Company Address
:
:
Northwich East & West, Delfzijl

Brunner Mond
PO Box 4
Mond House
Northwich
Cheshire
CW8 4DT
Emergency Telephone Number
+44 (0) 1606 781000
2. COMPOSITION/INFORMATION ON INGREDIENTS
Sodium Carbonate
CAS Number
EC Number
ID Number (Annex 1)
:
:
:
497 19 8
207 838 8
011 005 00 - 2
3. HAZARDS IDENTIFICATION
Irritating to eyes, respiratory tract and skin.
4. FIRST AID MEASURES
General
In all cases of doubt, or when symptoms persist, seek medical attention.
Inhalation
Remove to fresh air, keep warm and at rest.
Skin Contact
Remove contaminated clothing

Wash skin with plenty of water
Launder clothes before re-use
Eye Contact
Irrigate eye thoroughly with eye wash solution or clean water for at least 10 minutes.
Eyelids should be held away from the eyeball to ensure thorough rinsing.
Obtain medical attention if necessary.
Ingestion
DO NOT induce vomiting

Wash out mouth with water and give plenty of water to drink (at least 300 ml.)
Obtain medical advice if necessary.
Brunner Mond PO Box 4 Winnington Northwich Cheshire CW8 4DT Tel +44(0)1606 724000 Fax +44 (0)1606 781353 www.brunnermond.com
safety data sheet

IDENTIFICATION/PRODUCT NAME : SODIUM CARBONATE (p.2)
_______________________________________________________________________________________________
5. FIRE-FIGHTING MEASURES
Flash Point
Not applicable
Extinguishing Media
All extinguishing products are allowed
Special Hazards
Non-combustible
Hazardous Decomposition Products (under fire conditions)
Not applicable
6. ACCIDENTAL RELEASE MEASURES

Personal Precautions
See personal protection measures given in Section 8
Environmental Precautions
Prevent discharges into the environment (rivers, water courses, sewers etc.)
See Section 13 for disposal details
Methods for clean up
Clear up spillages by suitable means avoiding dust formation

Collect as much as possible in a suitable clean container, preferably for re-use, otherwise for disposal.
Wash the spillage area with large quantities of water.
7. HANDLING AND STORAGE

Handling
Avoid dust formation

Operate in a well ventilated area, atmospheric levels should be controlled in compliance with the
occupational exposure standard
Do not breathe dust
Avoid contact with skin and eyes
Storage
Store in a cool dry place ( in humid conditions the product will absorb moisture from the atmosphere and this
will eventually cause caking and loss of free flowing properties)
Do not store together with acids
Fire and Explosion Prevention
Non-combustible
8. EXPOSURE CONTROLS/PERSONAL PROTECTION

Engineering Controls
Provide adequate ventilation

Avoid inhalation of dusts
safety data sheet

Occupational Exposure Limits
Not listed by H&SE (Guidance Note EH40) or ACGIH (Ref.UK EH40 Limits for Nuisance Dust)
Recommended Limits: OES 10mg/m3 (total dust) (8hr TWA)
5mg/m3 (respirable dust) (8hr TWA)
Respiratory Protection
In the case of high dust levels wear suitable respiratory protective equipment, ie. dust mask or respirator
Hand Protection
Wear suitable chemical resistant protective gloves for frequent or prolonged operations
Eye Protection
Suitable eye/face protection
Skin and Body Protection
Protective clothing is required, overalls as a minimum
9. PHYSICAL AND CHEMICAL PROPERTIES
Appearance
Colour
Odour
Melting Point
Powder, granules
White
Odourless
851 c
OxidisingProperties
Vapour Pressure
Specific Gravity
Bulk Density
Flash Point
Not applicable
Solubility in water
Flammability
Auto ignition temp.
Explosive properties
Non flammable
Not applicable
None known
Explosion Limits
Not applicable
Solubility in other Solvents

pH value
Partition Coefficient
(n-octanol/water)
Relative vapour density (air = 1)
Viscosity
None known
Not applicable
2.53
Light ash approx.
550kg/m3
Dense ash approx.
1000kg/m3
71 g/l @ 0 c
471 g/l @ 32 c
Not available
11.4 (1% w/w soln @20c
Not applicable
Not applicable
Not applicable
10. STABILITY AND REACTIVITY

Stability
Stable under recommended storage and handling conditions ( see Section 7)
Conditions to avoid
Contact with acids unless under controlled conditions

Contact with lime and moisture produces caustic soda
Humidity and moisture can cause caking of product
Materials to avoid
Aluminium and zinc

Fluorine
Sulphuric and other acids
Lithium
Phosphorus pentoxide
safety data sheet

Hazardous decomposition products
Negligible, carbon dioxide gas can be emitted

Carbon dioxide is liberated on reaction with acids
11. TOXICOLIGICAL INFORMATION

Acute Toxicity
Oral LD 50, rat
: 4090 mg/kg.
: Sodium carbonate is a permitted food additive, however in large doses
corrosion of the mucous membranes of the gastrointestinal tract may occur.
Inhalation LC 50, rat
: 2300 mg/m3/2hr.
: High concentrations of dust may irritate the nasal membranes and respiratory
tract.
Eye Irritation
: Irritating to eyes
: May cause corneal damage, permanent damage is unlikely.
Skin Irritation
: May cause irritation

: Repeated and / or prolonged contact will remove natural grease resulting in
dryness and cracking
Long Term Exposure
Prolonged or repeated inhalation of high dust concentrations may cause ulceration of the nasal septum,
which may in time progress to perforation or complete destruction of the nasal cartilage.
Other Toxicolgical Information
Not teratogenic
12. ECOLOGICAL INFORMATION

Acute Ecotoxicity
Fish, Lepomis macrochirus

Daphnia magna
Algae, Nitszcheria linearis
: 96hr - LC50 : 300mg/l

: 48hr - EC50 : 265mg/l
: 5 day - EC50 : 242mg/l
Bio-degradeability
Aerobic/Anaerobic degradation
Not applicable ( inorganic compound )
13. DISPOSAL CONSIDERATIONS

Product
Must be disposed in accordance with local, state or national regulations

Do not dispose of with acids
Packaging
Must be disposed in accordance with local, state or national regulations

Contact the manufacturer about recycling
14.TRANSPORT INFORMATION
Not classified as hazardous for transport.
safety data sheet

Land Transport
Sea Transport
Air Transport
ADR Class
RID Class
TREM-card
Hazard identification number
Proper shipping name
IMO/IMDG
Packing group
EMS
Marine pollutant
ICAO-TI/IATA-DGR Class
Not restricted
Not restricted
Not relevant
None
None
ADR item number

RID item number
UN Number
Substance identification number
Not relevant
Not relevant
None
None
Not restricted
None
Not relevant
No
Not relevant
Class
UN number
MFAG
Not relevant
None
Not relevant
Not restricted
None
UN number
Packing number
None
None
15. REGULATORY INFORMATION
Sodium Carbonate is classified as irritant for supply and packages
EC Labelling
Chemical description
Requirements according to Annex-1 of EC Directive 67/548/EEC
Meets the requirements of CHIP

EC Number
Symbols
(R)isk phrase(s)
(S)afety phrase(s)
: Anhydrous Sodium Carbonate
207 838 8
Xi Irritant
R36 : Irritating to eyes
S22 : Do not breathe dust
S26 : In case of contact with eyes, rinse immediately
With plenty of water and seek medical advice
National Legislation/Regulations
Water Hazard Class

TSCA Inventory
: WGK 1,
: Listed
VwVwS (Germany) of 17.05.1999, Annex 2
16.OTHER INFORMATION
The information only concerns the above mentioned product and is not necessarily valid if used with other
product(s) or in any process. It does not constitute a hazard assessment and should not be used in place of the
users own assessment of workplace risks as required by other health and safety legislation. The information is to
our best present knowledge correct and complete and is given in good faith but without warranty.
The following sections contain revisions or new statements: 1,2,3,4,5,6,7,8,9,10,11,12,13,14,15
Date of Issue : 21/10/2002
Revision: 03
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi

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page
5.1
date
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rev
200 SECTION
5.1
Process description
5.1.1
Introduction
The washery serves to remove a large portion of impurities from the dredged trona,
resulting in crushed refined soda (CRS).
In this chapter the process of the washery is described. In order to have a complete
picture also the OSBL dredging is described in this chapter.
5.1.2
Dredging (PFD 100-01, OSBL)

Refer to separate dredging operating manual for detailed operating instructions.
No.3 Dredger supplies ~50 tph solids to the existing soda ash plant
No.4 Dredger is shut down and provides a standby spare
No.5 Dredger provides ~200 tph solids which is enough to meet the new pure ash plant
requirements and the shortfall between the requirements of the old soda ash plant and the
output of No.3 Dredger.
5.1.3
Dredge product receiving and reclaim (PFD 200-01)

The dredged trona is transported to the upgrading facility (washery) in lake liquor slurry.
The typical analysis of the solids is: 92% trona, 2% sodium fluoride, and 6% water
insolubles. The insoluble impurities can be substantially rejected by size-based separation
techniques. Sodium fluoride is not amenable to size-based separation.
In the new washery, the dredged slurry will be fed to the agitated dredge product tank
200-TK-005 with a capacity of 120 m3. The slurry will be pumped by washery feed cyclone
pump 200-PP-005/6 from the dredge product tank to the washery feed cyclone
200-CY-005, where a large portion of the fine muds (80%) and fine trona (10%) is
removed. The underflow from the washery feed cyclone, containing 107 t/h of solids, will
flow to the washery sieve bend screen 200-SN-020 which removes the >8 mm material.
The cyclone overflow is collected in the washery feed cyclone overflow tank 200-TK-010
and pumped by the washery feed cyclone overflow pump 200-PP-010/011 to the tailings
tank 900-TK-250. Part of this overflow is used as cooling brine for the second stage vent
condenser 520-HX-020 (section 500). The overflow liquor is also used to collect ESP dust.
For this purpose washery feed cyclone overflow pump 200-PP-012/011 pumps the
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overflow liquor to ESP dust conveyor 400-CV-040 where it picks up the ESP dust. From
here the resulting slurry is returned to 200-TK-010.
In the event that the dredge is unable to meet the solid feed requirements, a dry handling
system will receive material from a front-end loader to allow feeding from a stockpile. The
dredge product tank can also receive fines bank material. Trona and fines bank material
will be reclaimed from the stockpiles by front-end loader with a maximum capacity of 115
t/h solids. The front-end loader discharges onto raw trona reclaim conveyor 200-CV-010
via the raw trona reclaim hopper 200-BN-010. Raw trona reclaim screen 200-SN-010
removes lumps >32 mm from the raw trona. The raw trona is further transported by raw
trona undersize conveyor 200-CV-015 and slurried in the dredge product tank. Metal
contamination is removed by magnet 200-MA-015, which is located on top of the
undersize conveyor. Lumps are transported via raw trona oversize chute 200-CH-010 to
the raw trona oversize bunker 200-ZC-015.
5.1.4
Classification and centrifugation (PFD 200-02)

Crushed Refined Soda (CRS) centrifuge centrate and CRS hydrocyclone overflow liquors
are used as required to assist the transport of the solids across the washery sieve bend
screen 200-SN-020. The screen oversize (> 8 mm) will be open-circuit crushed in feed
delumper 200-CR-025 and then re-combined with the screen undersize, and fed by
launder to the spiral classifier 200-CI-030.
The spiral classifier further separates impurities by gravity settling. The incoming solids
will contain an estimated 1.1 wt% insolubles. This will be reduced to about 0.4 wt% by the
classifier. Operating at a separation size of 150-175 microns, the classifier will produce a
75 wt% solids product and overflow slurry containing about 1.3 wt% solids. The spiral
classifier product will be delivered to the CRS wash tank 200-TK-030 or diverted via the
classifier bypass conveyor 200-CV-030 to a stockpile if problems occur in the downstream
equipment. The classifier is expected to reject 67% of the remaining insolubles, while
recovering about 95% of the trona. No separation of sodium fluoride is allowed for in the
classifier.
A portion of the classifier overflow (255 m3/h) will be pumped to the tailings settler
200-TK-050 and flocculated. The tailings settler will produce about 250 m3/h of clear brine
primarily for CRS wash tank density control. The coagulant, guar gum, is used to create
flocks and promote settling in the tailings settler. Guar gum will be added as a 0.3 wt%
solution at a dosage of 100 g/t of solids. The settler overflow pumps 200-PP-060/1
distribute the brine to the CRS wash tank, the washery sieve bend, the classifier
discharge chute, the spiral classifier and the boiler scrubber. The settler underflow,
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containing 0.7 t/h of solids at 20 wt% solids density, will be pumped by tailings settler
underflow pumps 200-PP-050/1 to the tailings tank 900-TK-250.
The tailings settler overflow brine will dilute the spiral classifier product from 75% to 30%
solids in the CRS wash tank. The tank, with a volume of 125 m3, will receive 110 t/h of
solids and will provide about 30 minutes of surge capacity to smooth fluctuations in solids
flow from the dredge. The CRS wash tank slurry will be pumped by CRS hydrocyclone
feed pumps 200-PP-030/1/2 to CRS hydro-cyclones 200-CY-065/6. The hydro-cyclones
provide further insolubles rejection, whilst pre-thickening the slurry to 60 wt% solids. The
overflow from the hydro-cyclones is fed together with the CRS centrifuge centrate to the
classifier by CRS centrate pump 200-PP-070/1.
The underflow from the CRS hydro-cyclones is directed to the CRS centrifuges
200-CF-070/1. The centrifuges are designed to provide a 93 wt% solids cake. The cake
will be washed with 2-4 displacements of process water to reduce the sodium chloride and
insolubles. Centrate liquor will be pumped via the CRS centrate tank 200-TK-070 to the
spiral classifier. The product CRS cake product will contain 5 to 6 wt% moisture with the
following solids analysis: 97.5% trona, 2% sodium fluoride, up to 0.45% insolubles, and
about 0.05% sodium chloride.
The washery is sized to produce 104.3 ton/h dry base CRS. This will generate more CRS
than the downstream equipment can process. It will therefore be necessary to
continuously divert a portion of the CRS by CRS stockpile conveyor 200-CV-090 to
Intermediate CRS stockpile 200-ZC-090. From this stockpile CRS is transported to CRS
stockpile 200-ZC-040 by front end loader. CRS will be reclaimed from the stockpile as
required.
From conveyor 200-CV-090 running in opposite direction, CRS is transported via CRS
conveyor 200-CV-075 to CRS conveyor 200-CV-080. CRS conveyor belt 200-CV-080 will
transfer the CRS to the roller mill feed bin 200-BN-085. From this bin the CRS is fed to the
roller mill (section 400) via roller mill belt weigh feeder 200-FD-085.
Any metal contamination is removed by magnet 200-MA-080, which is located at the top
of CRS conveyor 200-CV-080.
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project name
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date
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5.2
Normal operation
5.2.1
Dredge product receiving (PID 200-02)

Dredge product tank 200-TK-005 normally receives trona slurry from dredge No. 5. This
tank handles most of the product from this dredge. The excess is supplied to the existing
plant.
When the dredge is supplying only liquor then raw trona is fed via the dry reclaim system.
In this case, the capacity is turned down to ~93 % of the design capacity because the dry
reclaim capacity is 115 ton/h compared to 123.8 ton/h from the dredge.
200-TK-005 is provided with agitator 200-AG-005, which runs at fixed speed.
The level in 200-TK-005 is measured by 200-LICSA-0101. The level is controlled by
adjusting the slurry excess to existing plant, based on the signal from this indicator.
Variations in flow will be small due to the way in which slurry is provided to 200-TK-005 by
fixed speed pump from pumping tank located ~150 m away.
The washery feed cyclone pump 200-PP-005/006 transports the trona slurry from 200-TK005 to the washery feed cyclone 200-CY-005.
200-PP-005/006 are frequency controlled. The speed of the pumps is set by operator with
200-HIC-0001/0002. The speed of these pumps determines the capacity of the washery
section.
Because the density in this tank can vary considerably, an additional high level sensor
200-LSA-0102 and density measurement 200-DIA-0101 are installed.
5.2.2
Washery feed cyclones (PID 200-03)

Washery feed cyclone 200-CY-005 receives trona slurry from the washery feed cyclone
pump. The underflow of this cyclone goes to washery sieve bend screen 200-SN-020 via
washery sieve bend feed chute 200-CH-020. The cyclone has to be able to process a
variable solids concentration feed. The solids concentration varies as a consequence of
the dredge process. Also the cyclone has to be able to handle only liquor in case the
dredge does not supply trona. This is done by an adjustable apex, adjusting the underflow
via 200-HIC-0201.
When properly installed the setpoint 0f 200-HIC-0201 does not need to be adjusted when
there is a variation in solids concentration. This can be realized by providing a pressure
controller on the air supply to the apex, which keeps the pressure at a set value. In this
way the apex will automatically reduce the opening in case the solids concentration in the
feed decreases and vice versa.
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The overflow goes to washery feed cyclone overflow tank 200-TK-010.

The level in this tank is measured by 200-LICSA-0201. From this tank the thin slurry is
pumped to vent condenser 520-HX-020 and tailings tank 900-TK-250. The flow to 520HX-020 is controlled by the outlet temperature of 520-HX-020 and the flow to 900-TK-250
is controlled by the level of 200-TK-010.
In addition the thin slurry is pumped to collect ESP dust. This flow returns to 200-TK-010
and is not controlled. This flow causes the tank content temperature to increase a few
degrees Celsius and also increase in solids content. To prevent overheating and plugging,
the ESP dust recycle has to be shut down when there is no feed of liquor from the
cyclone.
5.2.3
Classification (PID 200-04)

Trona slurry is supplied to washery sieve bend screen 200-SN-020.
Oversize particles (> 8 mm) are crushed in feed delumper 200-CR-025. The absorbed
power of the delumper EI-I-0306 is displayed on the DCS.
Classifier overflow liquor can be supplied to facilitate transport of solids through the
screen and the crusher. Also settler overflow can be recycled to the washery sieve bend
chute 200-CH-020.
Slurry from the washery sieve bend screen and from the feed delumper is discharged into
the primary classifier 200-CI-030. This classifier has a classifying screw. The following
parameters can be adjusted by the operator to control the underflow concentration,
separation efficiency of insolubles and cut size:
speed of the screw
height of the overflow weir
liquor flow rate.
A higher overflow weir provides more time to settle and particles that flow over the weir
are smaller. So this reduces the cut size.
A higher liquor flow rate creates a higher overflow, less settling time, so increased cut size
(more product loss).
A higher screw speed increases turbulence and suspension of solids so better impurities
separation but also more product in the liquor overflow and increased cut size.
5.2.4
CRS wash tank (PID 200-05)

Classified slurry is diluted in CRS wash tank 200-TK-030 with tailings settler overflow
liquor from 200-PP-060/061. The flow of tailings settler overflow liquor is controlled by the
slurry density within 200-TK-030 (200-DICSA-0401). This flow is switched off
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automatically (by closing 200-DCV-0401) when the level in 200-TK-030 200-LISA-0401

becomes high. This flow is restored automatically when the level reduces.
At high high density or high level the supply of feed from the classifier is switched off
automatically (classifier outlet is diverted to 200-ZC-030) and at low density or at low level
the supply of classifier feed is restored automatically; see section 5.2.3.
Classified slurry in 200-TK-030 is suspended by CRS wash tank agitator 200-AG-030,
which is driven by 200-EM-0401. This drive is started and stopped locally by hand.
The absorbed motor power is displayed on the DCS via EIA-I-0401, and an alarm is
generated on the DCS if a high condition is reached.
The CRS hydrocyclone feed pumps 200-PP-030/1/2 transport the CRS slurry from 200TK-030 to the CRS hydrocyclones 200-CY-065/6. Each hydrocyclone is fed by a
dedicated pump. 200-PP-031 acts as common spare pump.
200-PP-030/1/2 are frequency controlled. The speed of the pumps is adjusted by hand on
DCS.
5.2.5
Classifier overflow (PID 200-06)

Overflow from the classifier is discharged into classifier overflow tank 200-TK-040. From
this tank the brine is transported to deaerator 200-DE-050, dredge product tank 200-TK005, washery sieve bend screen 200-SN-020 and the feed delumper 200-CR-025. The
level in the overflow tank is kept between limits by controlling the flow to 200-TK-005. The
flow to the deaerator is controlled by the level in tailings settler overflow tank. Liquor can
be supplied to 200-SN-020 and 200-CR-025 by operation of a manual valve.
5.2.6
CRS hydrocyclones and centrifuges (PID 200-07)

CRS slurry is transported to CRS centrifuges 200-CF-070/1 via CRS hydrocyclones 200CY-065/6. Process water is supplied to the centrifuge continuously to wash the cake.
Centrifuges are offline flushed at a certain frequency. Centrifuge washing is described in
section on deviating operating conditions.
The centrifuges produce a de-liquored cake and centrate liquor.
5.2.7
CRS centrate (PID 200-08)

Centrate from centrifuges 200-CF-070/1 is collected in CRS centrate tank 200-TK-070. To
reduce foam formation in the system emulsified silicone is dosed to the centrate tank by
gravity flow. The flow rate of this is measured with 200-FI-0704 and the normal setpoint is
provided on the setting list.
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project name
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Centrate is pumped from 200-TK-070 to the washery sieve bend feed chute 200-CH-020
by CRS centrate pump 200-PP-070/1. The flow is controlled by the level of the CRS
centrate tank 200-LICSA-0701. At low low level the CRS centrate pumps are
automatically tripped.
In case the feed to both centrifuges is diverted back to the CRS wash tank 200-TK-030,
pump 200-PP-070/071 has to be stopped, to prevent pumping against a closed head.
Stopping the feed to both centrifuges has therefore to be avoided.
5.2.8
CRS stockpile reclaim (PID 200-09)

CRS coming from CRS centrifuges 200-CF-070/1 is collected on CRS centrifuge cake
collection conveyor 200-CV-070 and transported to the roller mill or to an intermediate
CRS stockpile via CRS stockpile conveyor 200-CV-090 (two-way conveyor).
The moisture content of the CRS is monitored with a moisture analyzer 200-MIA-0801. In
case of high moisture samples of each centrifuge cake are taken to determine which
centrifuge is causing high moisture.
CRS stockpile conveyor 200-CV-090 has two directions. At high level in the roller mill feed
bin 200-BN-085 (200-LISA-0801), the direction is switched towards the intermediate CRS
stockpile 200-ZC-090. The feed automatically switches back when the level is low.
CRS conveyors 200-CV-075 and 200-CV-080 transport the CRS centrifuge cake to roller
mill feed bin 200-BN-085. 200-CV-080 can also be fed by front end loader with CRS from
the CRS stockpile 200-ZC-040 to CRS chute 200-BN-080 (see deviating process
conditions).
In case the level in 200-BN-085 is high (200-LISA-0801), the centrifuge cake will be
diverted automatically to the intermediate CRS stockpile as described above.
The capacity of the intermediate stockpile is approx. 20 tons, which gives approx. 10
minutes for full operating capacity of washery, starting with an empty stockpile.
Roller mill feed bin 200-BN-085 has a total capacity for 60 minutes and is provided with
level indication and low and high level switch 200-LISA-0801. A separate level switch 200LA-0802 is installed above the high high level of 200-LISA-0801 (in case of failure of 200LISA-0801). 200-LA-0802 generates an alarm and the operator has to take further action.
From 200-BN-085 the CRS is transported to the roller mill by roller mill belt weigh feeder
200-FD-085. The transport of CRS is weighed and controlled by 200-FICA-0801, which
adjusts the speed of 200-EM-0806.
200-FD-085 is started and stopped by the roller mill control system.
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5.2.9
Tailings settler (PID 200-10)

Classifier overflow liquor is mixed with guar coagulant in the tailings settler deaerator
200-DE-050, which transfers the mixed feed to tailings settler tank 200-TK-050. The flow
of classifier overflow liquor is controlled by the level of the tailings settler overflow tank
200-LICSA-0902.
The flow of guar supply is controlled with the speed of pump 510-MP-070/071 (see
section 510). Process water supply to the deaerator has to be closed during normal
operation.
Tailings settler tank 200-TK-050 is equipped with tailings settler rake mechanism
200-TM-050.
The settler rake motor (200-EM-0901) is provided with torque measurement EISA-I-0901.
At high high torque a lifting mechanism is activated, which is hydraulically driven by the
main drive.
(See vendors operating procedures for further details on operating of lifting mechanism,
e.g. lifting the rake manually for restarting after shut-down).
The underflow from the tailings settler is pumped by 200-PP-050/051 to tailings tank
900-TK-250. Part of the underflow is recycled to the deaerator.
The speed of these pumps is manually controlled by 200-HIC-0901/2. The operator
adjusts the speed is based on the sludge level of the settler, given by 200-LI-0901.
Setpoint for 200-LI-0901 is provided on the setting list.
High level in the settler can mean a lot of sludge inside the settler, or poor separation
(high turbidity). When turbidity is high, several vague discs are seen. When the level is
high, the operator has to check the turbidity by sample and analysis and take the
appropriate action.
The overflow from the tailings settler is collected in the tailings settler overflow tank
200-TK-060. The level of this tank 200-LICSA-0902 controls the feed of classifier overflow
to the settler. Tailings settler overflow pumps 200-PP060/1 pump the overflow liquor to
washery sieve bend chute 200-CH-020, CRS wash tank 200-TK-030, to primary classifier
200-CI-030 and to boiler scrubber 900-DC-035. The flow to the CRS wash tank is
controlled by the density within this tank. The flows to the sieve bend and to the classifier
are controlled manually. The flow to the boiler scrubber is controlled in the boiler system.
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project name
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5.2.10
Setting list
Instrument
Unit
200-DIA-0101
kg/m
200-DICSA-0401
kg/m
Normal
Alarm
1380
L 1330
1440
L 1390
Trip/Switch
H 1430
H 1490
HH 1550
200-EIA-I-0101
kW
65
H 75
200-EISA-I-0301
kW
TBD
HH TBD
200-EI-I-0306
kW
TBD
200-EIA-I-0401
kW
73
H 85
200-EISA-I-0601/02
kW
50
H 63
200-EISA-I-0901
kW
check
HH 1550
HHTBD
HH 70
H TBD
HH TBD
200-FICA-0401/0402
m3/h
130
145 (check)
200-FICA-0601/02
m3/h
5.4
L 2.5
200-FI-0704
l/h
0.5
200-FICA-0801
kg/h
106700
200-HIC-0201
TBD
200-HIC-0301/02
RPM
TBD
200-HIC-0901/02
RPM
TBD
200-KIS-0601/0606
TBD
TBD
200-LICSA-0101
90
HH TBD
101000
LL 15
LL 15
L 35
H 95
200-LSA-0102
200-LICSA-0201
90
HH 100
HH 100
LL 15
LL 15
L 25
H 95
200-LISA-0401
85
LL 15
LL 15
L 60 (check)
H 95
HH 100
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Instrument
Unit
Normal
Alarm
200-LICA0501
90
L 15
Trip/Switch
H 95
200-LSA-0603/0604
TBD
TBD
200-LICSA-0701
90
L TBD
LL 15
LL 15
L 25
H 95
200-LISA-0801
mm 1)
LLL -1000
LLL -1000
LL -500
LL -500
L 1000
H 3100
HH 4000 (check)
200-LSA-0802
mm
200-LICSA-0902
2)
HH 1600-3200
90
LL 15
2)
LL 15
L 25
H 95
200-LI-0901
mm
3)
2000 (4 discs
visible)
200-SSA-0001
L TBD
L TBD
200-SSA-0002
L TBD
L TBD
200-SSA-0301
L TBD
L TBD
200-SSA-0303
L TBD
L TBD
200-SSA-0801
L TBD
L TBD
200-SSA-0802
L TBD
L TBD
200-SSA-0803
L TBD
L TBD
200-SSA-0807
L TBD
L TBD
200-TISA-0601/0602
55
H 60
HH 65
200-XISA-0601/0602
mm/s
H 9
HH 14
Guar 0.5% dosing
g/ton solids
100
Purgerators on instrument
l/h
20
l/h
50
connections
Purgerators on pump seals
1) as measured from bottom weld line of cylindrical section

2) Instrument can be mounted on different nozzles, ranging from 1600 to 3200 as measured from bottom weld
line of cylindrical section
3) as measured from bottom weld line of cylindrical section
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
5.11
date
2005-06-30
rev
5.3
Logic functions
In this section the logic functions that act on equipment and the automatic actions of
valves are described.
Logical functions that act on equipment are for example:
Start conditions and running conditions
Process switches
Safety switches (dry run protection on pumps, speed alarm on conveyors)
Also the way equipment can be started and stopped is provided in this table. This is apart
from a thermal overload which is provided on all motors. The thermal overload shuts off
the motor directly (hardwired from MCC).
Logic functions acting on equipment:
Equipment/Action
Start
Stop
Signal description
Type
Start/
Switch/
Running
Interlock
condition
200-CV-010
Locally by
Locally by
hand
hand and
automatic
200-SN-010 in operation
time delayed 200-SSA-0001
X
Stop
activated
emergency stop 200-HZA-
Stop
0001 activated
200-SN-010
Locally by
Locally by
hand
hand and
Misalignment 200-GA-0001
200-CV-015 running
Alarm
X
automatic
200-CV-015
HH current on 200-EISA-I-
Locally by
Locally by
hand
hand and
0101 of 200-AG-005
automatic
activated
Stop
Stop
activated
Stop
0002 activated
200-AG-005
Alarm
Alarm
Locally by
Locally by
HH current 200-EIA-I-0101
hand
hand
activated
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi
doc. no.
2.187.735 -
page
5.12
date
2005-06-30
rev
Equipment/Action
Start
Stop
Signal description
Type
Start/
Switch/
Running
Interlock
condition
200-PP-005/006
Locally by
Locally by
LL level of 200-LICSA-0101
hand
hand and
activated
Stop
automatic
Dregde feed to
HH level of 200-LSA-0102
Divert to
200-TK-005
activated
wash-out
paddock
200-PP-
Locally by
Locally by
010/011/012
hand
hand and
activated
Stop
automatic
200-CR-025
200-CI-030
Locally by
Locally by
hand
hand
Locally by
Locally by
hand
hand and
directed to 200-TK-030 and
automatic
density 200-DICSA-0401 is
Not valid: 200-GA-030 is
high high

directed to 200-TK-030 and
agitator 200-AG-030 is out
of operation (time delayed)
directed to 200-ZC-030 and

200-CV-030 is out of
operation
200-GA-030
By hand
By hand on
Drive to direction
on DCS
DCS and
of 200-TK-030
and
automatic
automatic
not high high
level 200-LISA-0401 is not
high
agitator 200-AG-030 is in
operation
Start
low
level 200-LISA-0401 is low

limit switch 200-GBS-0301A
activated
word 10.0
Start
Stop
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
5.13
date
2005-06-30
rev
Equipment/Action
Start
Stop
Signal description
Type
Start/
Switch/
Running
Interlock
condition
200-GA-030
By hand
By hand on
Drive to direction
on DCS
DCS and
of 200-ZC-030
and
automatic
200-CV-030 in operation
automatic
Start
high high
level 200-LISA-0401 is high

agitator 200-AG-030 is out
Start
Start
of operation
limit switch 200-GBS-0301B
Stop
activated
200-CV-030
Locally by
Locally by
hand
hand and
automatic
Stop
activated
Stop
0301 activated
200-PP-
Locally by
Locally by
030/031/032
hand
hand and
LL level of 200-LISA-0401
Alarm
Stop
activated
automatic
200-PP-040/041
Locally by
Locally by
hand
hand
200-CF-070./071
Locally by
Locally by
hand
hand and
automatic
200-PP-070/071
Locally by
Locally by
hand
hand and
200-CV-090 running
HH current on 200-EISA-I-
Switch feed
0601/0604
to bypass
LL level of 200-LISA-0701
Stop
activated
automatic
200-CV-070
Locally by
Locally by
hand
hand and
automatic
X
Stop
activated
Stop
0801 activated
word 10.0
Alarm
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
5.14
date
2005-06-30
rev
Equipment/Action
Start
Stop
Signal description
Type
Start/
Switch/
Running
Interlock
condition
200-CV-090
By hand
By hand on
Drive to direction
on DCS
DCS and
of 200-CV-075
and
automatic
automatic
low level on 200-LISA-0801
Start
high level on 200-LISA-0801
Stop
Stop
activated
Stop
0807 activated
200-CV-090
By hand
By hand on
Drive to direction
on DCS
DCS and
of 200-ZC-090
and
automatic
Alarm
high level on 200-LISA-0801
Start
low level on 200-LISA-0801
Stop
Stop
activated
automatic
Stop
0807 activated
200-CV-075
Locally by
Locally by
hand
hand and
automatic
Alarm
Stop
activated
Stop
0803 activated
200-CV-080
Locally by
Locally by
hand
hand and
automatic
Alarm
Stop
activated
Stop
0802 activated
200-FD-085
Locally by
Locally by
hand
hand and
automatic
400-AL-010 in operation
feed release signal from
Alarm
X
X
roller mill package
Stop
activated
Stop
0806 activated
200-PP-050/051
200-TM-050
Locally by
Locally by
hand
hand
Locally by
Locally by
hand
hand
HH torque on 200-EISA-I0901
word 10.0
Lift rake
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
5.15
date
2005-06-30
rev
Equipment/Action
Start
Stop
Signal description
Type
Start/
Switch/
Running
Interlock
condition
200-PP-060/061
Locally by
Locally by
hand
hand and
activated
automatic
Automatic actions of valves:

Valve
Action
Cause
200-LCV-0501
Close
200-XSV0601
Close
On
On
200-LISA-0801 high switch is activated
200-XSV-0602
200-XSV-0604
200-XSV-0605
Green light at 200-
Open
Close
Open
HH level of 200-LSA-0102
200-CF-070 out of operation
flushing of 200-CF-070
200-CV-070 out of operation
200-LISA-0801 high switch is not activated
BN-080
Red light at 200BN-080
word 10.0
Stop
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
5.16
date
2005-06-30
rev
5.4
Start up
5.4.1
Initial start up (with empty tanks)

For this procedure, the following assumptions are made:
As a start condition all manholes/inspection holes are closed.
All tanks in the washery section are empty.
Utilities and auxiliaries are available and ready for use. The following utilities and
auxiliaries are required for this process section:
Process water
Purge water
Guar solution
Anti foam emulsion
Instrument air
Electrical power
No.5 dredge is available, first providing a flow of brine containing few or no solids, for
filling up the system and then providing slurry.
Connections to tailings tank 900-TK-250 and the tailings tank itself have to be available
for use
If the settler is empty, a temporary connection to 200-DE-050 can be made from top
outlet of 200-CY-005 or 200-PP-010/011/012. This is not included in the procedures
described below.
In the procedure, first the tanks are filled with lake brine, containing few or no solids, from
the dredge. When the system is filled up with brine liquor circulation is started and
subsequently solids are introduced in the washery section.
In detail, the procedure involves the following steps:
1
Check free rotation of all pumps. Check that all pump suction lines are closed.
Check that the discharge line of each pump is open, in order to keep purging with
purge water and to prevent pressurizing the system and line damage. Pumps should
be lined up as follows:
200-PP-005/06: flow to 200-CY-005
200-PP-010/11/12: flow to 200-TK-250 (check that bypass of 200-LCV-0201 is
closed), lines to 520-HX-010 and 400-CV-040 remain closed
200-PP-030/31: flow to 200-TK-030 (via CRS slurry return)
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
5.17
date
2005-06-30
rev
200-PP-040/41: flow to 200-TK-005 (check that bypass of 200-LCV-0501 is

closed)and 200-DE-050 (check that bypass of 200-LCV-0902 is closed), lines to
200-SN-020 and 200-CR-025 remain closed
200-PP-050/51: flow to 900-TK-250 and bypass back to 200-DE-050.
200-PP-060/61: flow to 200-TK-030 (check that bypass of 200-DCV-0401 is closed)
and 200 GA-030, lines to 200-CH-020, 200-CI-030 and 900-DC-035 remain closed
200-PP-070/71: flow to 200-CH-020 (check that bypass of 200-LCV-0701 is closed)
2
Open all the purge water connections to instruments and pumps. Open also the
process connections of these instruments at the same time and check if purges
have the correct flow. Specifically for installed spare pumps: check that purge water
can be discharged to a process connection.
3
Make sure all flushing connections are closed.
4
Check underflow of washery feed cyclone 200-CY-005 to be directed through
screen 200-SN-020 (by-pass is closed)
5
Start supply of lake brine (without solids) from the dredge to the dredge product
tank, 200-TK-005.
6
Start agitator 200-AG-005 when level is above 10% in 200-TK-005.
7
Check that cyclone bottom outlet (200-HCV-0201) is fully open and that diverter
200-GA-030 is directed towards 200-TK-030. (200-GBS-0301A active)
8
If level in 200-TK-005 is above 50 %, start feed pump 200-PP-005. Set pump speed
at RPM. Enable level controller (200-LICSA-0101) of 200-TK-005.
9
Check that there is liquid flow to both 200-CH-020 and to 200-TK-010
10 When the level is above 50 % in 200-TK -010, start pump 200-PP-010. Enable level
controller (200-LICSA 0201) and adjust manually, so that a constant level is
maintained in 200-TK-010. Switch to automatic level control when the tank is at
normal level.
11 As soon as classifier starts to overflow, and sufficient liquid level is present in 200TK-040 start 200-PP-040/041 with destination at deaerator 200-DE-050. Activate
level control and adjust manually (LICSA-0501; check that bypass is closed), so that
a constant level is maintained in 200-TK-040. Keep flow through 200-LCV-0501 as
low as possible and preferably lead flow to 200-DE-050, while filling 200-TK-050.
12 Start guar metering pump 510-MP-070/071 and check guar dosing rate (refer to
setting list).
13 Fill settler 200-TK-050.
14 When level in 200-TK-060 is above 25 %, start pump 200-PP-060/061. Open valves
to 200-GA-030 and to 200-TK-030 (200-DCV-0401), adjust 200-DCV-0401
manually. Activate level controller and adjust manually (200-LICSA 0902) in order to
maintain constant level in 200-TK-060; maintain manual control until solids are
added.
15 Start agitator 200-AG-030, when level is above 15 % in 200-TK-030.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
5.18
date
2005-06-30
rev
16
17
18
19
20
21
22
Check slurry discharge from 200-PP-030/031/032 is directed via cyclone bypass

(200-XSV-0601 and 0604 closed and 200-XSV-0602 and 0605 open). Start two
pumps of 200-PP-030/031/032. Check that flow is present at 200-FI-0401/02 and
outlet of CRS recycle. Adjust flow by hand with 200-HIC-0402/03/04 in such a way
that a constant level can be maintained in 200-TK-030.
Start 200-CV-090 in the direction of intermediate stockpile 200-ZC-090
Start-up centrifuge (oil system etc., start centrifuge; info from vendor)
Direct slurry to cyclone inlet (open 200-XSV-0601 and 200-XSV-0604 and close
200-XSV-0602 and 200-XSV-0605)
Check that 200-TK-070 is being filled from the cyclone overflow outlet and CRS
centrate outlet. As soon as sufficient level is present in 200-TK-070, start pump 200PP-070/071. Activate level controller (200-LICSA-0701) so that a constant level in
200-TK-070 is maintained.
Switch level control 200-LICSA-0501 to automatic.
Provide liquor to boiler scrubber 900-DC-035 from 200-PP-060/061.
At this moment the washery section is filled with liquid completely and liquor circulation is
running. The next procedure can now be followed in order to deliver trona slurry from the
dredge.
23
24
25
26
27
28
29
30
Control liquor flow to sieve bend 200-SN-020 and crusher 200-CR-025 with manual
regulator valves. Start crusher 200-CR-025.
Open up feed to 200-CH-020 and 200-CI-030 from 200-PP-060/061
Start classifier screw. See supplier information for exact procedure. Check that 200GA-030 is directed towards 200-ZC-030 (GBS-0301B active).
Start 200-CV-075, direct 200-CV-090 to 200-ZC-090, start 200-CV-070
Provide washing water to centrifuges 200-CF-070/071. By adjusting the set point of
200-FICA-0601/02.
Start 200-PP-050.
Start taking in slurry from the dredge.
When classifier operates stable, divert 200-GA-030 towards 200-TK-030
(200-GBS-0301A active)
Now slurry is flowing to the centrifuges, and the centrifuge cake is being diverted to
intermediate stockpile 200-ZC-090.
31
32
Make sure roller mill feed bin 200-BN-085 is ready for use.
If CRS from centrifuge is of good quality, start 200-CV-080 and 200-CV-075. Set
direction of 200-CV-090 towards 200-CV-075
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
5.19
date
2005-06-30
rev
33
Weigh feeder 200-FD-085 to the roller mill section can be activated, when there is
sufficient CRS in bin 200-BN-085 (200-LISA-0801 > L) and when there is a feed
release signal from the roller mill section. When high level switch 200-LISA-0801 is
activated, 200-CV-090 is set back into the direction of 200-ZC-090 again.
When washery is operating, following items should now be checked:

34
35
36
37
38
39
Activate automatic density control in 200-TK-030 and stop controlling DICSA-0401

manually.
Check that all automated level controls in tanks are on automatic.
Adjust flow of pumps 200-PP-030/31/32, if necessary.
Adjust slurry flow from 200-CY-005 (200-HCV-0201), if necessary. (depends on
particle size distribution)
Check sludge level in settler 200-TK-050 (200-LI-0901) and adjust settler underflow
pump 200-PP-050/051 if required.
Check position of manual gate on 200-BN-080 during CRS feed from stockpile (time
of emptying should keep pace with 200-BN-085)
Before the mill and calciner section comes into operation, the following start-up sequence
for the dust conveyor system applies.
40 Place setpoint of 200-LICSA-0201 to a high value. Check suction valve of spare
pump is closed 200-PP-010/011/012. Open suction valve and close discharge valve,
start up 200-PP-011/012 and open discharge valve. Open flow to 400-CV-040 as
fast as possible considering the level in 200-TK-010. ESP dust conveyor 400-CV040 requires pressure, otherwise backflow can occur in ESP Dust Hopper 400-BN040. (Note: The line volume is significant compared to the tank volume of 200-TK010).
41 As soon as circulation line is filled, (return flow to 200 TK-010), put level control on
normal setpoint and let system transport air for some time before adding dust.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
5.20
date
2005-06-30
rev
5.4.2
Normal start up, washery section (filled tanks)

This procedure differs from the case in section 5.4.1 in that all tanks in the washery are
filled up already.
All tanks in the washery section are filled with liquid.
Process water
Purge water
Guar solution
Anti foam solution
Instrument air
Electrical power
No.5 Dredger is available, first providing a flow of brine containing few or no solids, for
system start-up and thgen slurry for operation.
Connections to tailings tank 900-TK-250 and the tailings tank itself should be available
for use during the start-up procedures.
In the procedure, first liquid circulation is started up in the washery section. When the
system is circulating, dredger slurry is introduced.
In detail, the procedure involves the following steps:
1
Check free rotation of all pumps. Check that all pump suction lines are closed.
2
Check that the discharge line of each pump is open, in order to keep purging with
purge water and to prevent pressurizing the system and line damage. Pumps should
be lined up as follows:
200-PP-005/06: flow to 200-CY-005
200-PP-010/11/12: flow to 900-TK-250 (check that bypass valve of 200-LCV-0201 is
closed), lines to 520-HX-010 and 400-CV-040 remain closed
200-PP-030/31/32: flow to 200-TK-030 (via CRS slurry return)
200-PP-040/41: flow to 200-DE-050 (check that bypass of 200-LCV-0902 is closed)
and to 200-TK-005 (check that bypass of 200-LCV-0501 is closed), lines to
200-SN-020, to 200-TK-005 and 200-CR-025 remain closed
200-PP-050/51: flow to 900-TK-250 and bypass back to 200-DE-050.
200-PP-060/61: flow to 200-TK-030 (check that bypass of 200-DCV-0401 is closed)
and 200 GA-030, lines to 200-CH-020, 200-CI-030 and 900-DC-035 remain closed
200-PP-070/71: flow to 200-CH-020 (check that bypass of 200-LCV-0701 is closed)
3
Check that all purge water connections to instruments and pumps are open and
have the correct flow. Check also that the process connections of these instruments
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
5.21
date
2005-06-30
rev
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
are open at the same time. Specifically for installed spare pumps: check that purge
water can be drained to a process connection.
Make sure all flushing connections are closed
Start 200-PP-060/61. Adjust flow to 200-CH-020 manually.
Start pump of 200-PP-040/041. Adjust flow to 200-DE-050 manually (200-LICSA0902).
Start guar dosing (510-MP-070/71) and check guar dosing rate (refer to setting list).
Start 200-AG-005 and 200-AG-030 if stopped
Check slurry discharge from 200-PP-030/031/032 is directed via cyclone bypass
(200-XSV-0601 and 0604 closed and 200-XSV-0602 and 0605 open). Start 2 pumps
of 200-PP-030/031/032. Check that flow is present at 200-FI-0401/02 and outlet of
CRS recycle. Adjust flow with 200-HIC-0402/03/04 in such a way that a constant
level can be maintained in 200-TK-030
Start 200-PP-070/71. Adjust level in 200-TK-070 by hand (200-LICSA -0701).
Start 200-CV-090 in the direction of intermediate stockpile 200-ZC-090
Start-up centrifuge (oil system, main drive etc.; info from vendor)
Direct slurry to cyclone inlet (open 200-XSV-0601 and 200-XSV-0604 and close
200-XSV-0602 and 200-XSV-0605)
Open 200-DCV-0401 and adjust flow. Close supply from 200-PP-060/61 to 200-CH020.
Start pump 200-PP-010/11. Adjust level (200-LICSA 0201), so that a constant level
is maintained in 200-TK-010. Check that cyclone bottom outlet (200-HCV-0201) is
fully open.
Start 200-PP-005/006.
Start lake liquor brine intake from No5. dredger.
Check bypass valve of 200-LCV-0501 is closed. Adjust flow from 200-PP-040/41 to
200-TK-005 (200-LICA-0501).
Now No5. dredger can start delivering trona slurry as described in procedure for initial
start-up (see step 23 in section 5.4.1).
5.4.3
Restart from standby

The washery is on standby according to procedure 5.5.1 whilst the rest of the plant is in
operation. Liquor is being supplied from the No5. dredger.
1
2
Start supplying trona from the dredge

After 10 minutes trona slurry arrives in 200-TK-005 (time will increase as No.5
dredger moves further from 200-TK-005). This can be monitored with the density
meter 200-DIA-0101. Increase underflow opening 200-HIC-0201 of 200-CY-005.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
5.22
date
2005-06-30
rev
3
4
5
6
7
8
In case classifier is directed to 200-ZC-030, continue to do so until a stable

operation of the classifier is reached.
Increase settler underflow pump 200-PP-050/051 speed to normal speed.
Divert classifier slurry to 200-TK-030.
Open washwater to centrifuges (200-FICA-0601/0602)
Reduce position of 200-DCV-0401 (still on manual). When the density inside
200-TK-030 is approaching its set point, switch 200-DCV-0401 to automatic.
Check CRS is being discharged from the centrifuges and that the moisture content
is OK. When sufficient CRS is being produced, front end loaders can stop CRS
supply to the roller mill feed bin 200-BN-085.
word 10.0
Engineering
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project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
5.23
date
2005-06-30
rev
5.5
Shut down
5.5.1
Going to standby
Solids supply from No5. dredger is stopped and liquor supply continues in order to keep
the rest of the plant in operation.
1
2
3
4
5
5.5.2
Stop solids supply from the dredge.

After 10 min. the solids concentration of the dredge product decreases
(200-DIA-0101. Opening of 200-HCV-0201 decreases automatically as the solids
concentration of the cyclone feed decreases.
For the pumps 200-PP-005/006 and 200-PP-010/011/012 there is no change in
operation.
When the classifier is empty of solids, reduce speed of 200-PP-050/051 to minimum
The liquor for the boiler scrubber continues. Liquor supply from cyclone 200-CY-005
and wash water from centrifuges supply this amount. Adjust position of 200-HIC0201 to allow sufficient liquor passing through the underflow outlet.
When cake supply from centrifuges decreases, start CRS supply to 200-BN-080
from CRS stockpile in order to keep the rest of the plant working (see procedure
CRS reclaim, section 5.7.3)
Solids concentration inside 200-TK-030 decreases. Take 200-DICSA-0401 on
manual and control the level with the supply of liquor and the speed of 200-PP030/031/032.
Slurry from CRS wash tank is gradually washed out towards the centrifuge.
Eventually, when there are no more solids in the classifier and 200-TK-030, process
water supply to the centrifuges can be stopped. Liquor circulation continues
Normal shut down of washery

In case the rest of the plant remains in operation, the solids supply from the dredge is
stopped and liquor supply is maintained. Dredge product tank 200-TK-005 and washery
feed cyclone overflow tank 200-TK-010 with corresponding pumps and cyclone are kept
running.
With liquor supply to 200-TK-010 started via bypass line, also 200-TK-005 with
corresponding pump can be stopped.
CRS is reclaimed from CRS stockpile 200-ZC-040 and supplied to the weigh feeder
system. In this way the ESP fines conveying system and crystallization section can
continue running. However, when the washery circulation system is shut down, liquor
supply to the boiler scrubber has to be shut down when 200-TK-060 is empty (approx. 1
hour buffer). This has to be checked with operating procedures of the boiler scrubber.
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
5.24
date
2005-06-30
rev
At the end of this procedure, the shut down of dredge product tank and overflow tank is
described.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Stop solids supply from the dredge and or dry reclaim and maintain liquor supply.
After approx. 10 minutes only liquor is fed to 200-TK-005 (time will change with
position of dredge). Reduce position of 200-HIC-0201.
Switch 200-DCV-0401 to manual control and keep level in 200-TK-030 constant
When classifier 200-CI-030 is empty of trona, stop screw drive.
Start feeding CRS from stockpile to 200-BN-080 (see CRS reclaim, section 5.7.3)
When 200-TK-030 is empty of trona, stop centrifuges 200-CF-070/71 (procedure
from vendor) and stop process water supply (200-FICA-0601/02)
Underflow valve 200-HIC-0201 of 200-CY-005 closes automatically when no more
solids are supplied to the cyclone.
Stop 200-PP-050/51.
Stop 200-PP-030/31/32 and 200-AG-030 if required.
Stop 200-PP-070/071.
Stop 200-CR-025.
Stop 200-PP-060/061 when low level in 200-TK-060 (this will stop liquor supply to
boiler scrubber).
Stop Guar supply (510-MP-070/71).
Stop 200-PP-040/041.
Stop 200-CV-070, 200-CV-090, 200-CV-075.
Start flushing lines (particularly slurry lines) as soon as possible after stopping a
pump.
If settler remains full, keep rake mechanism 200-TM-050 running.
When done, keep all purgewater to instrument connections open and running.
If the rest of the plant (section 400 to 800) remains in operation and 200-TK-005, 200-AG005, 200-PP-005/006 or 200-CY-005 has to be taken out of operation, than the liquor
bypass to 200-TK-010 can be used:
19 Open bypass line to 200-TK-010
20 Close liquor feed to 200-TK-005
When the rest of the plant is shut down, liquor flow from dredge can be stopped and the
intake part of the washery can be stopped:
21 Calciner section and other down stream units are stopped. Stop 200-CV-080 and
roller mill belt weigh feeder 200-FD-085
22 Stop dust supply to 400-BN-040 (400 section) and stop 200-PP-011/012
23 Stop liquor supply from dredge to 200-TK-005
24 Stop 200-PP-005/006 (and 200-AG-005 if required)
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project name
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date
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25
Stop 200-PP-010/11
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BOM Magadi

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page
5.26
date
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5.5.3
Maintenance shutdown of washery

When the washery needs to be shut-down and drained, first the solids supply from the
dredge is stopped. Liquor is supplied continuously until all trona is washed out of the
slurry tanks 200-TK-005/030 and the classifier.
Then the tank levels of the largest tanks (200-TK-005, 200-TK-030 and 200-TK-060) can
be reduced if needed in case of draining.
At the end of this procedure liquor supply from the dredge is also stopped, which can only
be done if calciner section and crystallization section are shut down as well.
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
Stop solids supply from the dredge and or dry reclaim system and maintain liquor
supply.
After approx. 10 minutes only liquor is fed to 200-TK-005. Reduce position of 200HIC-0201
Switch 200-DCV-0401 to manual control and keep level in 200-TK-030 constant
Divert 200-GA-030 to 200-ZC-030
When classifier 200-CI-030 is empty of trona, stop screw drives.
When 200-TK-030 is empty of trona, stop centrifuges 200-CF-070/71(procedure
from vendor) and stop process water supply (200-FICA-0601/02)
Reduce level in 200-TK-005 (set point 200-LICSA-0101)
The opening of 200-HIC-0201 reduces automatically, which reduces the level in the
washery.
Stop roller mill belt weigh feeder 200-FD-085
Stop dust supply to 400-BN-040 (400 section)
Stop 200-PP-060/061 (stop liquor supply to boiler scrubber)
Stop liquor supply from dredge.
Stop 200-PP-005/006 and 200-AG-005
Stop 200-PP-010/11/12
Stop 200-PP-050/51
Stop 200-PP-030/31/32 and 200-AG-030
Stop 200-PP-070/071
Stop 200-CR-025
Stop Guar supply (510-MP-070/71)
Stop 200-PP-040/041
Stop 200-CV-070 , 200-CV-090, 200-CV-075, 200-CV-080
Start flushing lines as soon as possible after stopping a pump
Settler remains full. Keep rake mechanism 200-TM-050 running.
Tanks can be drained as required. Drained liquor is collected in the sump
200-SU-090. Pump capacity of 200-PP-090 is 35 m3/h.
Keep purgewater to instrument connections open and running as far as possible.
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project name
BOM Magadi

doc. no.
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page
5.27
date
2005-06-30
rev
5.6
Operator actions, periodic checks
5.6.1
Line flushing to prevent settling in lines

Especially for vertical slurry lines with high concentration (200-PP-005/6, 200-PP-030/031)
the line has to be flushed as soon as possible after the pump has been stopped.
Flush the line in top-down direction. Connect wash water via a hose to a flushing
connection on the line and open valve fully. Open a drain valve to a safe location.
The amount of flush water to be used is approx. 3 times the line volume. After flushing,
close the flushing line valve and disconnect the hose.
For pumps, close suction valve, and leave discharge valve open, in order to provide a
way-out for purge water on the pump seals.
5.6.2
Tank cleaning to remove scale formation

The open tanks need to be checked periodically to detect growth of crusts of scale on tank
wall, agitator shafts etc. which will have to be washed away.
This is especially expected on Dredge product tank (200-TK-005), Washery feed cyclone
overflow tank (200-TK-010) and CRS wash tank (200-TK-030).
5.6.3
Checks
Check purge flow rates instruments are set according to the required setting (see
setting list).
Check centrifuge cake visually on 200-CV-070 for high moisture
Check pump seals:
Purge flow rate is set according to setting list
Check that water is dripping from the seal. If no dripping is visible or if a continuous
flow is visible, maintenance attention by a qualified person is required.
Check liquor flow to sieve bend 200-SN-020 and crusher 200-CR-025 are right
Check sump 200-SU-090 (e.g. automatic level switch 200-LSA-0402)
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BOM Magadi
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date
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rev
5.6.4
Critical process parameters

Location
Parameter
Tag or analysis
Target / setpoint
200-PP-005/006
Pump speed
200-HIC-0001/0002
TBD
200-TK-005
Density
200-DIA-0101
1350-1400 kg/m (15-
20 wt%)
200-CY-005
Cyclone underflow solids
Sample (SC207)
60 wt%
concentration
200-CY-005
200-CI-030
Cyclone overflow solids
Sample (SC206)
concentration and particle
3 4 wt%
size
max. size 120 m
Classifier feed solids
Sample (SC208)
25 wt%
concentration
200-CI-030
200-CI-030
Classifier underflow solids
Sample (SC209)
concentration and free
75 wt%
insolubles (organics)
0 wt%
Classifier overflow solids
Sample (SC211)
concentration and particle
2 wt%
D90 cut size 175 m
size
200-TK-030
Density
200-DICSA-0401
1440 kg/m (30 wt%)
200-PP-030/031/032
Pump speed
200-HIC-0402/0403/0404
TBD
200-TK-050
Settler sludge level
200-LI-0901
4 discs visible
510-MP-070/071
Settler guar supply
Calibration tube
100 g/ton solids
200-TK-050
Settler overflow solids
Sample (SC216)
< 0.1 wt%
200-TK-050
Settler underflow solids
Sample (SC217)
20 wt%
concentration
clean
concentration
200-CF-070/071
Cake moisture
200-MI-0801 and Sample
< 6 wt%
200-CF-070/071
Centrifuge wash water flow
200-FICA-0601/0602
5 m3/h
rate
5.6.5
Sampling and analyses

See Analytical Manual.
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project name
BOM Magadi

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page
5.29
date
2005-06-30
rev
5.7
Deviating operating conditions
5.7.1
Turn down capacity

The plant design incorporates a turn down capacity of 50 %. This is an exceptional
situation and should only occur when one centrifuge is out of operation for a prolonged
period of time. During this scenario, the dredge has to supply a normal amount of liquor,
but reduced amount of solids. Alternatively, the dredge supplies a normal amount of solids
and the excess solid is diverted to the classifier discharge bunker 200-ZC-030.
The automated controls are designed for operating at turn down capacity.
The procedure below describes the capacity reduction from normal capacity to 50% of the
capacity.
1
2
3
4
Adjust slurry flow through washery feed cyclone underflow control 200-HCV-0201
Keep one centrifuge operating. Stop one feed pump (200-PP-030 or 031 or 032)
Stop one centrifuge and flush the centrifuge. After flushing: stop process water flow
to the centrifuge. Flush the discharge line to the cyclone that has been stopped.
Adjust flow of antifoam and guar (depending on the expected duration of the turn
down situation)
Adjust the speed of settler underflow pump 200-PP-050/51 in such a way that the
sludge level stays correct.
5.7.2
Dry reclaim
5.7.2.1
Process description (PID 200-01)

The dry reclaim route can be used when No.5 dredger does not supply trona to 200-TK005. The washery is designed for 115 ton/h from dry reclaim route.
A front end loader supplies 1.7 or 3.7 m3 raw trona at a time, so number of front end
loadings is approx. 68 or 33 per hour.
Material from the fines bank can be supplied to the washery via dry reclaim route.
Fines are allowed at 10% maximum of the total feed, which is 12.4 ton/h (approx. a front
loader every 8 minutes). Depending on the actual performance of the washery, the dredge
solids feed has to be reduced by approx 9 ton/h (a front end loader each 11 minutes) in
order to operate within the design conditions. In this way a relatively constant feed of
solids is supplied to dredge product tank 200-TK-005.
Oversize fraction screening section is also collected on the raw trona stockpile.
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Above raw trona undersize conveyor 200-CV-015 a magnet 200-MA-015 is installed. This
magnet has to be inspected periodically and cleaned.
If the magnet has to be removed for cleaning, then raw trona / fines bank supply MUST be
stopped until the magnet is back in place. Make sure the magnet is positioned correctly,
otherwise it will not effectively catch metal parts in the raw / trona fines bank feed.
Raw trona reclaim conveyor 200-CV-010 transports the dry feed, which is delivered by
front-end loader to raw trona reclaim hopper 200-BN-010, to raw trona reclaim screen
200-SN-010.
Raw trona reclaim screen 200-SN-010 rejects lumps larger than 32 mm to raw trona
oversize chute 200-CH-010. Smaller particles are allowed to pass the screen to raw trona
undersize conveyor 200-CV-015.
Raw trona undersize conveyor 200-CV-015 transports the smaller particles to dredge
product tank 200-TK-005.
5.7.2.2
Operating procedure
In the dry reclaim case, the liquor inlet from the dredge into dredge product tank
200-TK-005 remains open. There is no solids supply from the dredge, therefore trona
supply will be started from stockpile 200-ZC-010.
For starting solids supply via the dry reclaim route the following steps are required:
1
Raw trona undersize conveyor 200-CV-015 is started.
2
Raw trona reclaim screen 200-SN-010 is started.
3
Raw trona reclaim conveyor 200-CV-010 is started.
4
Raw trona from stockpile 200-ZC-010 is supplied by front loader to reclaim hopper
200-BN-010. The rate at which solids are added is to be controlled by the front end
loaders.
The speed of the conveyors is fixed and is designed for 115 ton/h. The manual gate of the
raw trona reclaim hopper has to be opened sufficiently to have the bin emptied in between
front end loader loadings.
The output flow of the washery is measured on 200-FICA-0801. The density in the dredge
product tank 200-TK-005 as read on 200-DIA-0101 has to be checked to ensure the
correct amounts of liquor and solid are being added, see setting list.
When returning to the normal operating situation, execute by stopping the equipment in
step 1 to 4 in reverse order.
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If high level switch 200-LSA-0102 HH in 200-TK-005 is activated, then stop dry reclaim
route.
5.7.3
CRS reclaim
CRS conveyor 200-CV-080 transports the CRS centrifuge cake to roller mill feed bin
200-BN-085. 200-CV-080 can also be fed by front end loader with CRS from the CRS
stockpile 200-ZC-040 to CRS chute 200-BN-080.
For a feed of 107 ton/h of CRS, front end loadings are required once per minute for the
1.7 m3 front end loader, and once per two minutes for the 3.5 m3 front end loader.
Check position of manual gate in order to empty BN-080 sufficiently fast.
Two colored lights at 200-BN-080 inform the operator when to load CRS into 200-BN-080:
Green light: 200-LISA-0801 H(S) is not activated: start supplying CRS
Red light: 200-LISA-0801 H(S) is activated: stop supplying CRS
5.7.4
Centrifuge flushing
During normal operation, the flushing of the centrifuges with process water is necessary at
a certain frequency. Centrifuge flushing is activated via a timer switch (200-KIS-0601 and
0606), which activates flush water supply (open 200-KSV-0603 or 200-KSV-0606).
Flushing is stopped again by the same switch. Only one centrifuge can be flushed at a
time.
When flushing centrifuge 200-CF-070 the slurry flow to hydrocyclone 200-CY-065 is
redirected to the CRS wash tank by opening 200-XSV-0602 and closing 200-XSV-0601
(pump remains in operation). When the slurry is redirected the flush valve 200-KSV-0603
is opened. When flushing is complete 200-KSV-0603 is closed, 200-XSV-0601 is opened
and 200-XSV-0602 is closed.
In the same way when flushing centrifuge 200-CF-071 the slurry flow to hydrocyclone
200-CY-066 is redirected to the CRS wash tank by opening 200-XSV-0605 and closing
200-XSV-0604 (pump remains in operation). When the slurry is redirected the flush valve
200-KSV-0606 is opened. When flushing is complete 200-KSV-0606 is closed,
200-XSV-0604 is opened and 200-XSV-0605 is closed.
If the density in 200-TK-030 becomes too high, the classified slurry is diverted to
200-CV-030 automatically. If the slurry is diluted sufficiently again, 200-GA-030 is set in
the direction of 200-TK-030 automatically (see section 2.3.3).
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project name
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date
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If the level in 200-TK-030 becomes too high, 200-DCV-0401 is closed. Control valve
200-DCV-0401 is automatically opened when the level has reduced (see section 2.3.4).
5.7.5
Shut down in case of failure of liquor supply from the dredges

Failure of liquor supply from the dredge results in shut down of liquor supply to the ESP
fines conveying system and the crystallizer vent condenser. This means a total plant shut
down. If the liquor supply to the ESP fines conveying system is running without supply of
liquor from the cyclone, the temperature will increase and the solids will accumulate.
For the washery, the procedure is described in this section.
If liquor from the dredge fails, dredge product tank 200-TK-005 and washery feed cyclone
overflow tank 200-TK-010 with corresponding pumps and cyclone are shut down. The
remaining washery section can remain in circulation for short duration outages. For
prolonged shut-down, the circulation can be stopped.
1
2
3
4
5
6
Put calciner on standby (unit 400) and stop weigh feeder 200-FD-085.
Other units further down stream go to standby
Stop ESP fines supply to 400-BN-040 (unit 400)
When level in 200-TK-005 is low, stop 200-PP-005/006 and 200-PP-010/11/12
Put washery on standby (see section 5.5.1)
When level in 200-TK-060 is low, provide additional process water to the system to
keep feeding the boiler scrubber, or stop 200-PP-060/061
This is the stage where the washery runs in stand-by mode: i.e. full circulation, no feed
and no CRS delivery. Slurry from CRS wash tank is gradually washed out towards the
centrifuge. The liquid loss has been minimized.
In case of a longer failure, the washery can be shut down (see section 5.5.2).
5.7.6
Failure of dredge product tank 200-TK-005 or related equipment (bypass of

200-TK-005)
A failure of one of the elements of the dredge product tank system results in interruption of
slurry supply to washery and liquor supply to the calcination and crystallization. In order to
be able to continue operation of the calcination and crystallization sections a bypass line
from the dredge feed line to 200-TK-010 is provided. The procedure below applies to a
sudden severe failure that requires immediate interruption of slurry supply from the
dredge. If the dredge product system shutdown is scheduled, then skip first steps and
proceed with step 5.
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project name
BOM Magadi

doc. no.
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page
5.33
date
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rev
1
2
3
4
5
6
7
8
9
10
11
Open valve to wash-out

Close inlet valve to 200-TK-005
Take second stage crystallization to standby (500 unit)
Stop ESP dust supply to 400-BN-040 (400 unit)
Make sure only liquor is being supplied from the dredge product line
Open bypass valve to 200-TK-010
Dump sufficient surplus of liquor at the dredge product tank washout valve ensuring
that the supply of liquor to 200-TK-010 is in balance with the capacity of 200-PP010/011/012. The amount dumped will vary depending upon where the liquor is
being provided from. The separate lake liquor pump provides ~420 m3/h whilst the
dredge pump provides ~750 m3/h.
Re-start second stage crystallization (500 section)
Re-start ESP fines to 400-BN-040 (400 section)
Put washery in standby mode (see section 5.5.1)
When level in 200-TK-060 is low, provide additional process water to the system to
keep feeding the boiler scrubber, or stop 200-PP-060/061
This is the stage where the washery operates in stand-by mode: i.e. full circulation, no
feed and no CRS delivery. Slurry from CRS wash tank is gradually washed out towards
the centrifuge. The liquid loss has been minimized.
In case of a longer failure, the washery can be shut down (see section 5.5.2).
5.7.7
Classifier not available

In case classifier 200-CI-030 is not available, there are two ways to proceed:
Interrupt slurry supply from dredge to 200-TK-005
Allow continuation of slurry feeding to the classifier
In the first scenario, second stage crystallization has to go on standby and ESP fines
supply to washery have to be interrupted until the dredge supplies only liquor to
200-TK-005.
In the second scenario there is no disturbance of the down stream process, but more
cleaning of classifier area is required.
5.7.8
CRS cyclone or centrifuge not available

In case the route from CRS wash tank 200-TK-030 to conveyor belt 200-CV-090 can not
be used for some reason the following procedure applies:
1
Put washery in standby mode (section 5.5.1)
2
Start feeding CRS to 200-BN-080 (see procedure CRS reclaim 5.7.3)
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date
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3
4
5
6
7
8
9
10
5.7.9
Divert classifier slurry to bunker 200-ZC-030

Stop 200-PP-030/030/031
Stop wash water supply on centrifuges
Stop centrifuges (see procedure from vendor)
Flush lines
Open liquor line from 200-PP-060/061 to 200-CH-020
Stop 200-PP-070/071
Balance liquor feed from cyclone 200-CY-005 underflow with liquor supply to boiler
scrubber 900-DC-035.
Diverting classified slurry to classifier discharge bunker 200-ZC-030

The classified slurry is directed normally to CRS wash tank 200-TK-030. The slurry is
diverted to bunker 200-ZC-030 in the following cases:
High level or density in tank 200-ZC-030
tank 200-TK-030 or subsequent equipment is out of operation
CRS from centrifuge is out of specification and is not suitable as feed to calciner or
CRS stockpile.
Diverted classified slurry is transported by classifier bypass conveyor 200-CV-030 to the
classifier discharge bunker 200-ZC-030. Apart from disturbances as described above, the
classifier discharge bunker can be used to collect washed trona in the following cases:
1
One centrifuge in operation (for example extensive centrifuge cleaning)
2
In case both centrifuges are temporarily not running, during start-up or shut down
operation
The capacity of the stockpile is 100 ton. The feed rate at 50% capacity is approx. 75 ton/h,
and at 100% capacity 150 ton/h. So the buffer time when starting with an empty bunker is
1.5 hours at 50% capacity and 45 minutes at 100% capacity.
The content of the stockpile has to be transported to the raw trona reclaim hopper
200-BN-010, or to the raw trona stockpile 200-ZC-010 if the dry reclaim route is not in
operation.
During normal operation conveyor 200-ZC-030 is not needed and is therefore not running.
When the slurry needs to be diverted to stockpile 200-ZC-030, the conveyor belt is
started, and subsequently the diverter 200-GA-030 can be activated.
As the diversion of slurry to the stockpile is expected to be for a limited time, the dredge
supply and washery remain in operation.
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project name
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doc. no.
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page
5.35
date
2005-06-30
rev
5.7.10
Lifting of classifying screw

Next to the main drive the classifying screw has a separately driven lifting device. In this
way the classifier spiral can be easily raised for start-up, shut-downs and periodic
inspections or maintenance. The drive 200-EM-0304 can be started and stopped locally
by hand. At high power consumption 200-EISA-I-0301 the screw is lifted automatically.
5.7.11
Plugging of washery sieve bend screen 200-SN-020; use of by-pass

In case the screen is plugged, the slurry feed can be diverted via a by-pass route allowing
the screen to be cleaned. A consequence of using the by-pass is that the slurry is no
longer screened and particles larger than 8 mm are forwarded to the classifier and
centrifuge. The centrifuge is designed for particles up to 8 mm and larger particles can
cause plugging. Therefore, if the by-pass is used, then the slurry from the classifier has to
be diverted to the stockpile to prevent plugging of the centrifuge.
Furthermore, severe plugging of the screen can cause the screen to overflow and more
liquor will proceed to the crusher 200-CR-025, and power consumption will increase. An
alarm is generated when this happens alerting the operator to this issue.
5.7.12
Centrifugal pump start/stop and changeover
5.7.12.1 Centrifugal pump start/stop

The general procedure for a normal start and stop is described here. For switching over
from running to spare pump, see procedure below section 5.7.12.2.
This is applicable for centrifugal pumps. For positive displacement pumps refer to
procedure in section 5.7.13.
Start of pump
3
Open purge water supply shut-off valve and check flow rate (drain valve or
discharge or suction valve MUST be open to have flow of purge water)
4
Check the valves in the discharge line of the pump is set up for the right destination
5
Check suction and/or discharge valve of spare pump is closed.
6
Close drain valve and open suction valve (if pump is empty allow to fill up by venting
on discharge side of the pump).
7
Check discharge valve is closed, start pump and open discharge valve.
Stop pump
8
Close discharge valve and stop pump.
9
Close suction valve.
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date
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rev
10
11
12
13
14
Open flush valve on discharge line upstream of discharge valve, open discharge
valve and flush through discharge valve.
Close discharge valve and open suction valve and flush through suction valve.
Close suction valve, open drain valve and close flush water valve.
Drain pump and leave drain valve open.
Close purge water shut-off valve.
5.7.12.2 Use of installed spare pump

For most application an installed spare pump is provided. This can be used in case of
failure or maintenance of the running pump or for routine pump changeovers. Separate
procedures are provided for each of the above.
The procedure applies to centrifugal pumps. See procedure in section 5.7.13.2 for positive
displacement pumps.
Procedure in case running pump has failed:
15 Close discharge valve of the pump that failed and put local switch in off position.
16 Open purge water supply shut-off valve and check flow rate (drain valve or
17 Close drain valve and open suction valve of spare pump (if pump is empty allow to ill
up by venting on discharge side of the pump).
18 Check discharge valve is closed, start spare pump and open discharge valve
19 For maintenance, flush and drain pump that failed as described in section 5.7.12.1.
Procedure to changeover with running pumps:
20 Open purge water supply shut-off valve and check flow rate (discharge or suction
valve MUST be open to have flow of purge water)
21 Check discharge valve of spare pump is closed, close drain valve and open suction
valve (if pump is empty allow to fill up by venting on discharge side of the pump)
22 Start spare pump and open discharge valve.
23 Close discharge valve of the original running pump and stop the pump.
24 Flush and drain pump as described in section 5.7.12.1.
Note 1:
As soon as the running pump is stopped, backflow can occur (there are no check valves
installed). Therefore, first close discharge valve of the running pump and then stop this
pump.
Note 2:
Close the purge water supply before the pump is isolated, to prevent high pressure in
pump and piping.
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date
2005-06-30
rev
5.7.13
Start/stop and changeover of 200-PP-050/051
5.7.13.1 Start/stop of 200-PP-050/051

from running to spare pump, see procedure below section 5.7.13.2.
This is applicable for 200-PP-050/051. For centrifugal pumps refer to procedure in section
5.7.12.
The pump has to be filled to provide lubrication of the stator (not for priming purpose).
When the pump is stopped sufficient liquid is normally trapped between the pumping
elements to provide the necessary lubrication for restarting. However, if the pump has
been left standing for a long time or has been dismantled, it must be refilled and given a
few turns before starting, to get sufficient lubrication between the rotor and the stator.
Start of pump if line and pump are empty:
1
Fill up suction line (open bottom valve of settler and drain valve at pump suction)
2
Fill up pump with water hose via plug on top of the pump and give it a few turns with
provided tool
If line and pump are full, proceed with:
1
Check purge water supply is open and check flow rate (discharge or suction valve
has to be open to have flow of purge water)
2
Check the valves in the discharge line of the pump are set up for the right
destination
3
Check discharge valve of spare pump is closed.
4
Open suction and discharge
5
Start pump
Stop pump
1
Keep pump running during flushing. Connect process water hose on suction flushing
connection and open flush valve.
2
Close valve in suction line and flush through pump and discharge valve.
3
Stop pump and close discharge valve.
4
Open suction valve and flush through suction valve.
5
Close flush valve and keep suction valve open to allow purge water to flow through
the seal.
Note 1: Never run the pump dry, not even for a few revolutions.
Note 2: Never run pump with a closed suction or discharge valve.
Note 3: Do not vary the flow rate by throttling suction or discharge valve
word 10.0
Engineering
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project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
5.38
date
2005-06-30
rev
5.7.13.2 Use of installed spare 200-PP-050/051

An installed spare pump is provided. This can be used in case of failure or maintenance of
the running pump or for routine pump changeovers.
Separate procedures are provided for each of the above.
The procedure applies to 200-PP-050/051. See procedure in section 5.7.12 for centrifugal
pumps.
1
Close discharge valve of the pump that failed and put local switch in off position.
2
Open suction and discharge valve of spare pump
3
Start spare pump
4
For maintenance, close purge water supply and flush the pump and the enclosed
suction and discharge line sections.
Procedure to changeover with running pumps.
1
Open suction valve and discharge valve of spare pump and start spare pump
2
3
4
5
6
the seal.
Note 1:
Note 2:
Backflow does not occur when the running pump is stopped for positive
displacement pumps
Close the purge water supply before the pump is isolated to prevent high
pressure in pump and piping.
word 10.0
Engineering
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project name
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doc. no.
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page
5.39
date
2005-06-30
rev
5.7.14
General procedure for belt conveyor

Start-up
Before starting the belt conveyor check for foreign objects, no personnel are near the belt,
alignment, and that no safety interlocks activated.
Start the belt with the local on/off switch
Shut down:
If possible the conveyor should be completely discharged before shutting down.
word 10.0
Engineering
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project no.
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project name
BOM Magadi
doc. no.
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page
5.40
date
2005-06-30
rev
5.7.15
Trouble shooting table controls of 200-TK-030

Because various control loops play role in this section, a trouble shooting table is
included. This table refers to section 5.2.3 and 5.2.4.
Event
Automated action
Cause
Recovery action
200-LISA-0401 H(S)
Close 200-DCV-0401 and
Pump 200-PP-030 runs
Increase pump speed
divert classifier feed to 200-
too slow
ZC-030
Pump failure
Start the spare pump
One cyclone/centrifuge
Reduce classifier feed (feed from
out of operation
dredge, or divert to 200-ZC-030)
Leakage via reverse
Check valve positions
flow of standby pump

Line blockage
Isolate line section and flush the line
Valve 200-DCV-0401
Close valve 200-DCV-0401 locally and
fails open
control flow rate with manual bypass

valve
200-LISA-0401 L(S)
High flow from classifier
Check dredge supply capacity
Pumps run too fast.
Restart pump and reduce speed.
Low feed from classifier
Check upstream equipment.
Open 200-DCV-0401 and

restore classifer feed to
200-TK-030
200-LISA-
Pump stop
0401LLL(S)
200-DICSA-0401
Divert classifier feed to
Not sufficient liquor
Check liquor supply from 200-PP-060
HH (SA)
200-ZC-030
supply from 200-PP-060
(pumps, valve positions).
(200-DCV-0401 fully
Monitor level of 200-ZC-030.
open)
When density decreases, activate

classifier discharge diverter 200-GA030 to 200-TK-030
Too high solids flow
Check dredge supply capacity.
from classifier (200-
Monitor level of 200-ZC-030.
DCV-0401 fully open)
When density decreases, activate

classifier discharge diverter 200-GA030 to 200-TK-030
200-DICSA-0401 L
Restore classifer feed to
(S)
200-TK-030
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project name
BOM Magadi

doc. no.
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page
5.41
date
2005-06-30
rev
5.7.16
Operation of sump 200-SU-090

Sump pump 200-PP-090 is started automatically by level switch 200-LS-0402.
For start-up:
1
Make sure deaerator 200-DE-050 and settler 200-TK-050 are ready for receiving
liquor or slurry from the sump.
2
Open discharge valve of 200-PP-090
3
Set pump operating switch in automatic (check)
For shut down:
1
2
Set pump switch on off (check)

Close discharge valve of 200-PP-090
Note: Flushing of line is required after pumping slurries.
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doc. no.
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page
6.1
date
2005-06-30
rev
MILLING AND CALCINING
6.1
Process description
To produce soda ash the CRS cake must be dried and calcined. The complete chemical
reaction is shown below.
2 Na2CO3. NaHCO3.2H2O(Trona) 3 Na2CO3(Calcine) + 5 H2O (g) + CO2(g)
A two stage calcination system is included in the process. The CRS cake is
simultaneously ground and dried in roller mill 400-ML-010. A roller mill is the preferred
grinding device because of energy efficiency, close control of particle size (reduced
generation of super fines), and reduced iron contamination of the product. Grinding is
essential to the process because the subsequent recrystallization process physically
separates impurities based upon their particle size.
The roller mill is the first stage of calcination. The wet CRS is heated to about 100C, fully
drying and partially calcining it. The hot air used for conveying and drying is supplied from
the flash calciner cyclone. The roller mill grinds the product between hydraulically
activated vertical rollers and a horizontal rotating table. The ground material falls off the
table and into a louvered section, in which it contacts the mill air. The solids are
pneumatically conveyed to variable speed impact classifier 400-CI-015 that rejects
oversized material back to the center of the table for regrinding. The fine material (less
than 105 micron) is carried to roller mill cyclone 400-CY-020 that collects about 85 - 90%
of the solids in the underflow. The roller mill cyclone gases are blown by roller mill fan
400-FN-020 to ESP cyclone 400-CY-025 to be combined with the mill bypass gas and the
roller mill dust cyclone underflow. The mill gas flow is controlled by roller mill fan damper
400-DA-010. Damper 400-DA-020 is positioned in the mill bypass gas line to provide
additional flow balancing capability. The gas leaving the ESP cyclone will be at a
temperature of about 130C. It is estimated that the solids leaving the ESP cyclone will be
> 30% calcined.
The ESP cyclone and roller mill fan appear to add complication to the system, but provide
significant cost and operational benefits. The roller mill size is significantly impacted by
airflow. To match the mill size with the grinding requirements, it is necessary to bypass
about 45% of the hot gas around the mill. The higher temperature of the combined gas
stream supports additional calcination in the ESP cyclone. In addition, the ESP cyclone
provides dust recovery that reduces the load on the electrostatic precipitator (ESP). The
roller mill fan provides two important functions. The fan balances the pressure between
the mill discharge and the bypassed gas. In addition, the fan reduces the vacuum on the
ESP, reducing cost and air in-leakage.
word 10.0
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doc. no.
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page
6.2
date
2005-06-30
rev
The ESP cyclone underflow is discharged into flash calciner 400-FD-050 just above the
air-cooled grid plate 400-CK-050. There the hot combustion gases from the flash calciner
burner 400-BU-050, mixed with the colder gas (recycled from the ESP exit) to produce a
mixed gas at 700 to 730C, are introduced. This gas and the solids react almost
instantaneously, quenching the temperature to 400 to 450C. The flash calciner conveying
velocity is near 15 m/s, and the retention is about 2 seconds. This contact time is sufficient
to fully calcine the solids and to heat them to 400C. The high temperature ensures > 99%
calcination, while eliminating organics that can be detrimental in the crystallization
process. Calcined product is separated from the hot gases in flash calciner cyclone 400CY-060 and transported by gravity via crystallizer feed airlocks 400-AL-060 and 400-AL065 to calcined feed chamber 510-CH-010. During washouts and off-spec conditions the
product stream can be diverted to dump tank 400-TK-060, where it is mixed with water for
discharge to the lake.
ESP 400-EP-030 consists of four high voltage electrical fields. Static charge is induced on
the surface of the particles allowing their collection on charged plates. The accumulated
dust is periodically removed from the plates by a rapping system. The ESP will reduce the
exhaust gas dust loading to below 50 mg/Nm3. Dust losses will be less than 10 kg/h.
Sulfur dioxide generated during the combustion of the heavy fuel oil reacts with the roller
mill product in the calciner to produce sodium sulfate. More than 98% of the sulfur dioxide
will be removed during calcination. The chemical reaction is shown below.
SO2 (g) + O2 (g) + Na2CO3(s) Na2SO4(s) + CO2 (g)
3 SO2 (g)+3/2 O2 (g)+2 Na2CO3.NaHCO3.2H2O(s) 3Na2SO4(s)+3 CO2(g) + 5 H2O (g)
The sodium sulfate generated will dissolve in the crystallization process and will ultimately
be purged to the lake.
Cleaned air with a temperature of about 125 C is transported by ESP ID fan 400-FN-030
to stack 400-ST-030, where the air is checked for particulates. Part of the air is
recirculated by dilution air fan 400-FN-035 to be mixed with the calciner burner gases.
When the ESP has a misoperation, the air can contain too much particulate material to be
used for dilution and the dilution air fan suction will change to outside air
Dust collected in the ESP is transported by ESP collection screw conveyor to roller mill
ESP airlock 400-AL-040 and ESP dust bleed airlock 400-AL-030. Via the roller mill ESP
airlock the dust is discharged into a pneumatic transport system, which brings the dust
back to the flash calciner. The pneumatic transport system consists of ESP dust
pneumatic conveyor blower 400-GB-040, ESP dust pneumatic conveyor 400-PN-040,
ESP dust bin 400-BN-010, ESP dust collector 400-DC-010 and ESP dust collector airlock
400-AL-045. Remaining dust, which is not discharged into the pneumatic conveying
word 10.0
Engineering
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doc. no.
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page
6.3
date
2005-06-30
rev
system, is discharged via the ESP bleed dust airlock 400-AL-030 into ESP dust hopper
400-BN-040, where it is mixed with air and sucked into ESP dust conveyor 400-CV-040.
The ESP dust conveyor is driven by washery feed cyclone overflow liquor and transports
the dust to the washery feed cyclone overflow tank, from which it is ultimately discharged
to the lake.
All cyclones are equipped with 2 air cannons (400-AC-020/1, 400-AC-025/6 and
400-AC-060/1). In addition vibrators are mounted on the cyclones and the cyclone
discharge lines (400-VB-020/1/2/3/4, 400-VB-025/6/7/8/9 and 400-VB-060/1/2).
6.2
Normal operation
6.2.1
Calcination waste (P&ID 400-15)

Dust transport
Dust from 400-AL-030 falls into the ESP dust hopper (400-BN-040).
Liquor is supplied by 200-PP-011/012. Solids and entrained gas are sucked into the jet
conveyor 400-CV-040 and transported to the washery feed cyclone overflow tank. ESP
bleed shut-off gate 400-GA-041 is closed when 400-LSA-1401 detects high level and
when 200-PP-011 and 200-PP-012 are out of operation (so when flow to 400-CV-040
stops). 200-PP-011 is spare for both 200-PP-010 and 200-PP-012.
Supplying hot ESP dust to the liquor causes the liquor temperature to increase due to the
sensible heat increase by introduction of hot ESP dust and the heat of dissolution.
Calciner exhaust stack
Off-gasses from the calciner unit are vented through calciner exhaust stack 400-ST-030.
The dust content is monitored with 400-QIA-1401. If an alarm is generated, the ESP
system has to be checked.
6.2.2
Setting list
Instrument
Unit
Normal
Alarm
Trip/Switch
400-FISA-1401
m3/h
100
L 90
L 90
400-QIA-1401
mg/m3
<18
1)
mg/Nm3
<50
2)
H 18
H 50
1) At 127C and 0.95 bara

2) at 0C and 1.013 bara
word 10.0
Engineering
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project no.
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project name
BOM Magadi
doc. no.
2.187.735 -
page
6.4
date
2005-06-30
rev
6.3
Logic functions
In this section the logic functions describing automatic actions of valves are described.
Process switches
Thermal overload is provided on all electric motors. The thermal overload shuts off the
motor directly (hardwired from MCC).
Table: automatic actions of valves
Valve
Action
Cause
400-GA-041
Close
400-XSV-1401
Open
400-XSV-1402
Open
400-LSA-1401 H activated
200-PP-011 or 200-PP-012 out of operation
200-PP-011 or 200-PP-012 out of operation
Signal from 400 section, prior to divert soda ash to
the dump tank
word 10.0
Engineering
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405.014
project name
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doc. no.
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page
6.5
date
2005-06-30
rev
6.4
Start-up and shutdown of Dust transport
6.4.1
Normal start-up
1
2
3
4
5
6
7
8
6.4.2
The Calciner is not yet running, or is not supplying ESP dust to 400-BN-040.
Check 400-GA-041 is closed
Check manual drain valve upstream of 400-CV-040 is closed. The automated drain
valve 400-XSV-1401 has to be closed by the operator (reset on DCS).
Check 200-TK-010 has sufficient level and that No.5 dredger supplies sufficient
liquor.
Check automated drain 400-XSV-1401 valve is closed (reset on DCS)
Start selected pump (200-PP-011 or 200-PP-012)
If pump is running well, then 400-GA-041 can be opened.
Now ESP dust can be supplied to 400-BN-040 by starting 400-AL-030
Normal shut-down
1
2
3
4
Stop the ESP dust stream from the ESP

Close 400-GA-041 (to prevent moisture entering the dust system)
Stop running pump 200-PP-011 or 012. 400-XSV-1401 will be opened automatically
when the pump stops.
400-XSV-1401 can stay open. The valve has to be closed by the operator (reset on
DCS).
word 10.0
Engineering
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project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
6.6
date
2005-06-30
rev
6.5
Start-up and shut-down of dump tank
6.5.1
Initial start-up
1
2
6.5.2
Normal start-up
1
6.5.3
Open 400-XSV-1402 and read flow rate on FISA 1401. Check the recorded amount
with the setting list.
Verify the sprayers provide an even water curtain.
Check that 400-TK-060 does not contain solids from previous dumpings. Liquid level
(rain water) should be at nozzle N2 (1 m level). If water level is below nozzle N2,
add water via manual valve.
Check that manual valve in process water supply line upstream of 400-FISA-1401 is
open and manual valve in bypass line of 400-XSV-1402 is closed.
Procedure for emptying tank after dumping

Before dumping product into the dumptank, the sprayers are activated (400-XSV-1402 is
opened). The valves stays open after dumping and are required to be closed by the
operator.
1
When dumping is complete, close 400-XSV-1402 and check there is no dust
emission.
2
Liquid is flowing out of nozzle N2
3
If needed additional water is added via manual valve, in order to dissolve remaining
solids. Agitation with air lance can be applied.
4
When all solids are dissolved, the tank can be emptied via nozzle N1.
6.5.4
Normal shutdown
No real actions for shutdown. Manual valve upstream of 400-FISA-1401 can be closed.
Tank can be emptied via nozzle N1 or drain nozzle.
word 10.0
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project name
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doc. no.
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page
6.7
date
2005-06-30
rev
6.6

1
2
3
Dump tank level: when not in use, the dump tank level should be at nozzle N2. If too
low, then supply water to fill to this level. If too high, then line 100-SLS1-102,
connected nozzle N2, is plugged, or sump or ditch is flooded.
ESP Dust Hopper: check air inlet opening is free
Sampling and analyses: see Analytical Manual.
word 10.0
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project name
BOM Magadi

doc. no.
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page
6.8
date
2005-06-30
rev
6.7
6.7.1
Dump tank 400-TK-060

Product from the calciner section is passed to the dump tank in case of emergency shut
down. A spraying system is installed on the dump tank to reduce dust emissions from the
dusty calciner product. The tank contains a certain level of water to dissolve and cool
down the dumped solids. Before crystallizer feed diverter 400-GA-060 is allowed to switch
over, water supply to the dump tank via 400-XSV-1402 has to be opened to give a
sufficient flow rate (400-FISA-1401).
The water flow rate continues as long as required. There is no level indication on the
dump tank. When starting with an empty tank, the capacity of the dump tank will give
approx. 1 hour of use.
When 400-GA-060 is closed, the water flow can be stopped. Operator to close 400XSV1402.
Liquid will flow out via nozzle N2 when the level reaches 1 m level in the tank and the
liquid is collected in sump 200-SU-090. Any remaining solids will have to be dissolved with
process water, that can be added via manual valve. Agitation with air lance can be applied
if needed. The tank can be emptied by opening valve on nozzle N1.
6.7.2
Too low liquor feed flow to 200-TK-010

If there is no feed flow or too small a flow from the washery feed cyclone to 200-TK-010,
the temperature will increase beyond what is acceptable. The liquor streams to the vent
condenser 520-HX-010 and to the tailing tank 900-TK-250 will also rise in temperature,
resulting in poor operation of the vent condenser.
The return temperature to 200-TK-010 is monitored with 400-TIA-1401. When the
temperature is too high (see setting list), an alarm is generated, and the cause of the high
temperature has to be investigated or otherwise dust bleed has to be shut off.
If there is no feed flow from the washery feed cyclone the level in 200-TK-010 will go
down and 200-LCV-0201 closes. After a few minutes 200-LICSA-0201 reaches LL level
and the pumps 200-PP-011/012 are switched off automatically.
6.7.3
Pump failure of 200-PP-011/012

When 200-PP-012 goes out of operation, following automated responses are activated:
400-GA-041 is closed, 400-AL-030 is stopped and 400-SC-040 is stopped.
400-XSV-1401 is opened.
In this way liquor cannot enter the calciner system, and will drain out of bin 400-BN-040.
When 200-PP-012 is out of operation and 200-PP-011 goes out of operation the same
actions will follow. Before restart, it has to be verified that the bin 400-BN-040 is empty of
liquid and dry.
word 10.0
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project name
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doc. no.
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page
6.9
date
2005-06-30
rev
Valve 400-XSV-1401 has to be closed by the operator (reset action on the DCS).
6.7.4
High temperature of liquor return from 400-CV-040

The return temperature to 200-TK-010 is monitored with 400-TIA-1401. When the
temperature is too high (see setting list) an alarm is generated, and the cause of the high
temperature has to be found or otherwise dust bleed has to be shut off.
word 10.0
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doc. no.
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6.10
date
2005-06-30
rev
6.8
Basic operating manual roller mill and calciner section
word 10.0
Functional Specification for a Roller Mill and Flash

Calciner System
Prepared for:
Larsen & Toubro Limited

FFE Contract No. (03-51573-727)
DOC Ref: 2076-FF-400-PR-MS-001
Prepared by:
FFE Minerals USA Inc.

3235 Schoenersville Road
Bethlehem, PA 18017
USA
Tel. (610) 264-6900
Revision 2
FFE Minerals USA
Functional Specification for a Roller Mill and Flash Calciner System

Document No. 8.500933
Revision 2
Document Information
Document Number
Title
Contract Number
Originating Author
8.500933
03-51573-727
Michael Prokesch, FFE Minerals USA
Document Revision History

Rev.
Date
Designed
30Nov04
MEP
05May05
MEP
Checked:
Approved
Description
General Revisions as per Oct04 Hazop
Revisions as per P&IDs Rev 10, FLS Mill Control
Review, Airtek ESP Review, and Vendor
Documents Received to Date
Reference Documents
FFE Doc./ Dwg. #
Document / Drawing Description
8.500742 Sheet 4
PID Rev 10 - Roller Mill
8.500742 Sheet 5
PID Rev 10 - Flash Calciner, Dust Return Circuit
8.500742 Sheet 6
PID Rev 10 - Roller Mill Cyclone, ESP Cyclone
8.500742 Sheet 7
PID Rev 10 - ESP, Stack, Dilution Air Circuit, Dust Conveying
8.500742 Sheet 8
PID Rev 10 - Air Heater, Fuel Skids
8.500742 Sheet 9
PID Rev 10 - Mill Drive Lubrication Circuit
8.500742 Sheet 10
PID Rev 10 Mill Roller #1 Lubrication Circuit
8.500742 Sheet 11
8.500742 Sheet 12
8.500742 Sheet 13
PID Rev 10 Upper Mill Body Water Spray Supply
8.500742 Sheet 14
PID Rev 10 - ESP
8.500742 Sheet 15
PID Rev 10 Mill Hydraulic Circuit
ii
Lake Magadi Functional Specification Rev 2
FFE Minerals USA

Revision 2
Document Format
This document begins with a description of the overall process. The entire process is then divided into groups
and each is described in a separate section. The following table provides an overview of the document
structure. Each group section includes a functional description of operation, equipment/instrument
summary, control loop descriptions, alarm table and interlock table.
Group Name
Description
Process Overview
Includes a description of the overall roller mill and calciner process.
Calciner Group
The equipment that performs the high temperature calcination work and delivers product to the
crystallizer circuit. The main components in the group include the fuel skid, valve stand, air
heater, flash calciner and calciner collection cyclone.
Burner
Management
System
The stand-alone PLC-based system that controls the safety interlocks for the air heater burner
system.
Roller Mill Group
The equipment that receives the wet CRS feed and produces a fine, dry, pre-calcined feed for the
Calciner Group.
Process Air Group
All fans and dampers utilized for combustion and process air flow control.
ESP Group
The equipment that removes particulate from the calciner system off gas stream.
Cleaning Group
This group includes equipment utilized to promote stable material flow through cyclones and
material transfer ducts (air cannons, rappers and vibrators).
Dust Handling
Group
Transports ESP dust to the calciner group for calcination.
Water Spray
Group
Provides water to the roller mill for the purpose of bed stabilization and temperature control.
Roller Mill
Hydraulics Group
Controls roller mill grinding pressure and roll position.
Lubrication Group
Provides lubrication to the mill drive, rollers and classifier.
FFE Minerals USA

Revision 2
Table of Contents
DOCUMENT INFORMATION ..................................................................................ii
Document Revision History ............................................................................................................................................. ii
Reference Documents........................................................................................................................................................ ii
Document Format ............................................................................................................................................................. iii
1 PROCESS OVERVIEW .......................................................................................... 1

1.1 Normal Cold Start Sequence ...................................................................................................................................... 3
1.2 Normal Stop Sequence ................................................................................................................................................ 5
1.3 Emergency Shutdown Sequence................................................................................................................................ 6
2 CALCINER GROUP .............................................................................................. 7

2.1 Functional Description................................................................................................................................................ 7
2.1.1 Burner Start Sequence....................................................................................................................................... 8
2.1.2 Burner Preheat Sequence................................................................................................................................ 10
2.1.3 System Idle Sequence ...................................................................................................................................... 11
2.1.4 CRS Feed Start ................................................................................................................................................. 12
2.1.5 CRS Capacity Increases................................................................................................................................... 13
2.1.6 Emergency Cooling Air .................................................................................................................................. 13
2.1.6.1 Combustion Air Fan Failure............................................................................................................................... 13
2.1.6.2 Dilution Air Fan Failure...................................................................................................................................... 13
2.1.6.3 ESP ID Fan Failure ............................................................................................................................................. 14
2.1.6.4 Dual Fan Failure................................................................................................................................................... 14
2.1.6.5 Complete System Power Loss............................................................................................................................ 14
2.1.7 Calciner Cyclone Discharge Tipping Valve ................................................................................................. 14
2.1.8 Tipping Valve Full Open Position Option.................................................................................................. 15
2.1.9 Calciner Cyclone Discharge Diverter Valve ................................................................................................ 16
2.1.10 Calciner Cyclone Discharge Rotary Valve ................................................................................................. 16
2.2 Equipment/Instrument Summary ........................................................................................................................... 16
2.3 Control Loops............................................................................................................................................................. 20
2.3.1 Calciner Exit Temperature Control .............................................................................................................. 20
2.4 Alarms .......................................................................................................................................................................... 21
2.5 Interlocks ..................................................................................................................................................................... 23
3 BURNER MANAGEMENT SYSTEM ..................................................................... 25

3.1 Functional Description.............................................................................................................................................. 25
3.1.1 BMS Function Summary ................................................................................................................................ 25
3.2 Definitions................................................................................................................................................................... 37
3.3 Definitions of Limits.................................................................................................................................................. 37
3.4 Timer Settings ............................................................................................................................................................. 39
4 ROLLER MILL GROUP ...................................................................................... 40

4.1.1 Roller Mill Preheat ........................................................................................................................................... 40
4.1.2 CRS Feed Start ................................................................................................................................................. 41
iv
FFE Minerals USA

Revision 2
4.1.3 CRS Capacity Increases................................................................................................................................... 43

4.1.4 Classifier Speed ................................................................................................................................................ 43
4.1.5 Mill Feed Rotary Valve ................................................................................................................................... 43
4.1.6 Normal Roller Mill Shutdown ....................................................................................................................... 44
4.1.7 Emergency Roller Mill Shutdown ................................................................................................................. 44
4.3 Control Loops............................................................................................................................................................. 47
4.3.1 Roller Mill Gas Flow Control ........................................................................................................................ 47
4.3.2 Mill Outlet Gas Temperature Control.......................................................................................................... 47
4.3.3 Mill Table Speed Control................................................................................................................................ 47
4.4 Alarms .......................................................................................................................................................................... 49
4.5 Interlocks ..................................................................................................................................................................... 50
5 PROCESS AIR GROUP.........................................................................................51

5.1.1 Fan Group Start ............................................................................................................................................... 51
5.1.2 Individual Fan Start ......................................................................................................................................... 52
5.1.3 System Shutdown............................................................................................................................................. 52
5.3 Control Loops............................................................................................................................................................. 55
5.3.1 Calciner Exit Pressure Control ...................................................................................................................... 55
5.3.2 Roller Mill Gas Flow Control ........................................................................................................................ 55
5.4 Alarms .......................................................................................................................................................................... 56
5.5 Interlocks ..................................................................................................................................................................... 57
6 ESP GROUP ..................................................................................................... 58

6.1.1 ESP Start ........................................................................................................................................................... 58
6.1.2 ESP Normal Shutdown .................................................................................................................................. 59
6.1.3 ESP Emergency Shutdown ............................................................................................................................ 59
6.1.4 ESP Dust Screw ............................................................................................................................................... 59
6.1.5 ESP Dust Purge Valve .................................................................................................................................... 60
6.1.6 ESP Hopper Rappers...................................................................................................................................... 61
6.1.7 ESP Outlet/Stack Gas Opacity ..................................................................................................................... 61
6.1.8 ESP Field Loss ................................................................................................................................................. 61
6.3 Control Loops............................................................................................................................................................. 62
6.4 Alarms .......................................................................................................................................................................... 62
6.5 Interlocks ..................................................................................................................................................................... 62
7 CLEANING GROUP ........................................................................................... 63

7.1.1 Air Cannons...................................................................................................................................................... 63
7.1.1.1 Individual Cannon Operation - Manual ........................................................................................................... 64
7.1.1.2 Group Cannon Operation - Manual ................................................................................................................. 64
7.1.1.3 Group Cannon Operation - Timed................................................................................................................... 65
7.1.2 Rappers.............................................................................................................................................................. 65
7.1.2.1 Individual Rapper Operation ............................................................................................................................. 65
7.1.2.2 Group Rapper Operation ................................................................................................................................... 66
7.2 Equipment Description............................................................................................................................................. 66
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7.3 Control Loops............................................................................................................................................................. 67

7.4 Alarms .......................................................................................................................................................................... 67
7.5 Interlocks ..................................................................................................................................................................... 67
8 DUST HANDLING GROUP................................................................................. 67

8.1.1 Dust Feed Start Sequence............................................................................................................................... 68
8.1.2 Dust Feed Stop ................................................................................................................................................ 68
8.1.3 Dust Feed Emergency Stop ........................................................................................................................... 68
8.1.4 Dust Bin Filter Cleaning Circuit.................................................................................................................... 69
8.3 Control Loops............................................................................................................................................................. 70
8.4 Alarms .......................................................................................................................................................................... 70
8.5 Interlocks ..................................................................................................................................................................... 70
9 WATER SPRAY GROUP .......................................................................................71

9.1.1 Mill Table Water Spray.................................................................................................................................... 71
9.1.2 Mill Body Water Spray Circuit ....................................................................................................................... 71
9.3 Control Loops............................................................................................................................................................. 72
9.4 Alarms .......................................................................................................................................................................... 72
9.5 Interlocks ..................................................................................................................................................................... 72
10 ROLLER MILL HYDRAULIC GROUP ................................................................ 73

10.1 Functional Description............................................................................................................................................ 73
10.1.1 Normal Start ................................................................................................................................................... 73
10.1.2 Raise Rollers ................................................................................................................................................... 73
10.1.3 Lower Rollers ................................................................................................................................................. 74
10.1.4 Grinding Pressure Control........................................................................................................................... 74
10.2 Equipment Description........................................................................................................................................... 75
10.3 Control Loops........................................................................................................................................................... 76
10.4 Alarms ........................................................................................................................................................................ 76
10.5 Interlocks ................................................................................................................................................................... 76
11 LUBRICATION GROUP ..................................................................................... 77

11.1 Functional Description............................................................................................................................................ 77
11.1.1 Roller Mill Main Drive Lubrication System .............................................................................................. 77
11.1.2 Roller Mill Roller Lubrication System ........................................................................................................ 78
11.1.3 Roller Mill Grease System ............................................................................................................................ 78
11.1.4 Classifier Drive Lubrication System ........................................................................................................... 78
11.1.5 Classifier Grease System............................................................................................................................... 78
11.2 Control Loops........................................................................................................................................................... 78
11.3 Equipment Description........................................................................................................................................... 78
11.4 Alarms ........................................................................................................................................................................ 81
11.5 Interlocks ................................................................................................................................................................... 83
12 EXTERNAL SYSTEM INTERLOCKS ................................................................... 83

12.1 CRS Weigh Feed Belt (200-FD-085)..................................................................................................................... 84
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1 PROCESS OVERVIEW
The roller mill and flash calciner circuit serves to convert Crushed Refined Soda (CRS) supplied from the
washery to a calcined soda ash product in a form suitable for further processing in the crystallizer circuit. The
CRS is composed primarily of sesquicarbonate (97.4%) with minor amounts of sodium fluoride, sodium
chloride and other inerts. The calciner process supports drying to remove 6% free water, grinding to reduce
the particle top size to approximately 105 microns, and calcining the CRS at a maximum temperature of
400C to convert the sesquicarbonate to an intermediate decimite phase followed by final conversion to
sodium carbonate (soda ash). In addition to the chemical decomposition supported by the flash calciner, the
temperature supports a partial decomposition of organic carbon present in the feed material. Minimizing the
product residual bicarbonate level is important to maximizing the efficiency of the crystallizer circuit, and the
organic carbon reduction is required to improve the color of the final pure ash product.
The CRS is supplied by a transport system from the washery to a weigh feed system. This feed system (200FD-085) meters the wet CRS to the roller mill system (400-ML-010) through a rotary airlock (400-AL-010).
The feed chute between the rotary airlock and the mill body is heated utilizing mill inlet gas passed through a
heating jacket in order to minimize the potential for material flow problems. The CRS drops onto the mill
table where it is crushed between the rotating table and the three vertical rolls. A hydraulic system exerts a
force onto the roll support arms to generate the pressure between the vertical rolls and horizontal table
required to support the communition process. The centrifugal force exerted on the particles by the rotating
table forces the particles to the periphery of the mill housing where they are entrained by the hot process gas
from the calciner (400-FD-050) entering the mill housing through the louver section. The louvers serve to
develop a gas velocity sufficient to limit CRS particles from falling below the table level and into the mill
plenum. Particles that do enter the plenum are discharged from the bottom of the mill through manual gate
valves. Coarse particles disengage from the gas stream and fall back onto the mill table while finer particles
are carried to dynamic classifier 400-CI-015 located in the top section of the mill. The speed of the classifier
is adjusted via a variable-frequency drive to permit the minus 105 micron particles to pass through the
classifier rotor and exit the mill while deflecting the >105 micron particles back onto the mill table.
Energy from the process gas stream supports the vaporization of all free water in the CRS and supports
about 25% calcination of the sesquicarbonate in the roller mill. Additional water may be added onto the mill
table delivered from 900-PP-060 to improve the dynamics of the material load on the table in order to limit
instabilities that create mill vibration. Water may also be delivered to the mill freeboard section in a finely
atomized form via water spray system 400-PP-010. The purpose of this spray is for the control of the mill off
gas temperature, particularly during operation at reduced system capacities due to the need to maintain a level
of process gas flow at the mill exit equivalent to 90% of the normal operating level. Maintaining this flow
level at a reduced system capacity results in an excess of energy in the mill that will damage the classifier if the
gas temperature is not limited to 110C.
Off gas from the roller mill system enters the mill cyclone (400-CY-020). The bulk of the particulate is
disengaged from the process gas stream and discharged from the bottom cyclone cone through a rotary
airlock (400-AL-020). Calciner off gas is pulled through the roller mill and mill cyclone by the roller mill fan
(400-FN-020). Fan inlet damper 400-DA-010 is adjusted to maintain a target pressure drop across the mill
cyclone to ensure sufficient gas flow through the mill.
Vibrators (400-VB-020/021/022) and air cannons (400-AC-020/021) are positioned on the cyclone cone to
prevent material from bridging across the cone and provide a smooth, continuous flow of solids to the next
stage of the process. Additional vibrators (400-VB-023/024) are mounted on the underflow duct to
minimize the potential for solids flow problems.
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Off gas from the roller mill fan is combined with the calciner off gas bypassed around the mill, and then the
roller mill cyclone underflow stream is introduced to this combined gas stream. This reintroduction of the
milled solids into the off gas stream makes effective use of the energy in the mill bypass stream by supporting
about 50% calcination of the sesquicarbonate still present and about 25% calcination of the decimite. This
stream is directed to the ESP cyclone (400-CY-025) for particulate separation. The particulate underflow
passes through the ESP cyclone rotary airlock (400-AL-025) and then enters flash calciner 400-FD-050 via a
splash plate to promote good solids distribution into the calciner gas stream. The ESP cyclone and
underflow ducting include vibrators (400-VB-025/026/027/028/029) and air cannons (400-AC-025/026) to
promote stable solids flow as described for the mill cyclone.
The ESP cyclone underflow material is entrained by calciner gas at a temperature of 730C. The rapid
decomposition of the sesquicarbonate and decimite components quenches the calciner gas to a temperature
below 550C. The stainless steel calciner section provides for a total gas residence time of about 2.5 seconds
in order to support a reduction in the bicarbonate content to <0.4% and heat the solids to a temperature of
400C. It is critical to the availability of the calciner to minimize the contact between solids and the hot
calciner walls in the feed inlet zone in order to limit the potential for coating formation.
The soda ash product is disengaged from the calciner process gas stream in the calciner collection cyclone
400-CY-060, and discharged through the actuated double tipping valve 400-AL-060. Crystallizer feed diverter
400-GA-060 is positioned below the airlock to direct cyclone cleanout material away from the crystallizer
circuit during cleaning operations or when feed to the crystallizer must be stopped immediately. During
normal operation, calciner product passes vertically downward through the diverter valve and is then
discharged through rotary valve 400-AL-065. This rotary valve is utilized to stabilize the flow of material into
the calciner and dampen material slugs generated by the action of the double tipping valve. The ducting
below the feed airlock is maintained at a negative pressure by the crystallizer vent fan to prevent saturated gas
from the crystallizer from condensing in the ducting and creating buildup problems.
Air cannons (400-AC-060-061) and vibrators (400-VB-060/061/062) are included on the calciner cyclone
cone to promote stable material flow if required.
Hot gas for the calciner operation is generated using flash calciner burner 400-BU-050 and the combustion of
heated heavy fuel oil. The fuel rate is adjusted to control the calciner collection cyclone process gas overflow
temperature at 425C, and the ratio of fuel to the air supplied by primary combustion air fan 400-FN-050 is
controlled by the Process Control System to generate a maximum gas temperature of 1600C. This gas exits
the calciner burner and enters a mixing chamber where it is combined with stack gas supplied by dilution fan
400-FN-035 to yield a final mix temperature of 730C. The design of the refractory-lined mix chamber is
such that the tangential entry of the relatively cool stack gas limits the refractory surface temperature to
reduce the potential for the deposition of fine soda ash that is present in the stack gas. The stack gas first
passes through a jacket on the calciner burner to provide cooling of the chamber prior to be introduced into
the mix chamber. The velocity in the jacket is such that particulate present in the dilution air stream will
remain suspended as opposed to settling out and accumulating in the jacket.
The 730C calciner inlet gas passes through air-cooled grid plate 400-CK-050 supplied with cooling air from
grid plate cooling fan 400-FN-055. The primary function of the grid plate is to distribute the calciner inlet
gas across the full cross section of the calciner below the feed inlet location. This even distribution eliminates
gas recirculation zones that would draw the calciner feed material down into the hottest zone of the calciner
and promote buildup formation. The air cooling serves to limit the temperature of the top surface of the
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plate in order to prevent sticking of material that does come in contact with the plate. The cooling air exiting
the grid plate is vented into the calciner above the feed inlet location.
The off gas from the calciner system (overflow stream from the ESP cyclone) is cleaned using a 4-field
electrostatic precipitator (400-EP-030). The cleaned off gas passes through roller mill ESP ID fan 400-FN030. The ID fan damper 400-DA-030 is adjusted to maintain a neutral gas pressure in the top of the flash
calciner vessel. A portion of the ID fan outlet gas is directed to the stack while the balance is pulled by
dilution air fan 400-FN-035 for use in the calciner. In the event that a problem with the ESP results in a
stack particulate concentration >50 mg/Nm3, tempering tee 400-DA-034 is opened to introduce ambient air
to the calciner inlet and prevent high concentrations of particulate from entering the high-temperature
calciner inlet.
Dust collected in the ESP is discharged through screw conveyor 400-SC-040. The discharge from the screw
is normally passed through rotary valve 400-AL-030 and conveyed to a dust recovery circuit (provided by
others). In the event that dust is to be reprocessed in the flash calciner, rotary valve 400-AL-040 is activated
and the dust output is conveyed to dust bin 400-BN-010 using blower 400-GB-040. A manual valve
positioned above 400-AL-040 controls the flow of dust into this circuit while the balance of the dust is
discharged through 400-AL-030. All material collected in the dust bin is discharged through rotary valve 400AL-045 and into the calciner.
1.1 NORMAL COLD START SEQUENCE

1. Inspect the calciner system for signs of material blockages, coatings or accumulation on the grid plate
or in the calciner plenum. Clear as required. Inspect all mechanical equipment and lubrication levels
as per the maintenance manual.
2. Select Start Roller Mill Roller Lubrication System in the PCS. This will energize the oil heating
elements. This command should be initiated at least one hour prior to the target start time to
provide adequate time for fluid heating and to avoid potential delays. This is not required for a hot
restart. Start the ESP hopper heaters.
3. Start the mill classifier lube circuit.
4. Select Start Process Air Group in the PCS. This start sequence will place the associated dampers
in their start position (fully closed) and fully open the tempering tee (if closed) to provide for 100%
ambient air intake. Automatic starting of the following fans will commence in sequence: ESP ID fan,
dilution air fan, combustion air fan, grid cooling fan and mill fan. The operator may also start these
fans manually after ensuring appropriate interlocks are satisfied (dampers closed and the temperature
tee fully open).
5. Select Pilot Only or Oil Firing.
6. Select Purge Start in the PCS. This will send a purge start command to the Burner Management
System. The Process Control System will position the ID fan damper, dilution air fan damper,
combustion air fan damper, mill bypass damper, mill fan damper and mill inlet shutoff damper at
specified open limits to support the purge process. Once all necessary limits are satisfied in the fuel
skid, valve stand and calciner system, the BMS will proceed with the specified system purge.
7. Once the purge process is complete, the PCS will position the ID fan, dilution air fan and
combustion air fan dampers to their low fire positions, close the mill fan damper and close off the
mill inlet damper. Once in position, the BMS will light the pilot. If the pilot flame is proved and
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Pilot Only is selected, no further action will be performed. If Oil Firing is selected, ignition of
the main oil burner will proceed immediately following pilot ignition.
8. The PCS will make adjustments to the fuel rate and air/fuel ratio to preheat the air heater chamber.
This sequence will ensure proper preheating of the chamber refractory lining and establish a calciner
off gas temperature of 300C (System Idle condition).
9. Start the ESP dust purge rotary valve and hopper discharge screw conveyor.
10. Select Start All ESP Fields in the PCS. The PCS will send a command to the local ESP PLC to
energize all fields.
11. Start all cyclone discharge valves (3 rotary valves and 1 tipping valve). Set the product diverter valve
to direct calciner product to the crystallizer circuit.
12. Approximately one hour before the CRS feed start target, start the following mill system
components:
a.
Start the roller mill main drive lubrication system. This will start the circulating lube pump.
b. Start the roller mill hydraulic group. The hydraulic pump will run until the rollers are moved
to there upper position and then de-energize.
c.
Set the classifier speed to 50% and then initiate a start command. Once started, adjust the
classifier speed to the normal level. The classifier grease system is energized by the PCS
once the classifier drive is started.
13. Open the mill inlet damper and then open the mill fan inlet damper to a position of 3%. Hold this
setting while the mill is preheated to a freeboard temperature of 80C. Once 80C is obtained, either
close the damper to hold or immediately proceed with a feed start.
14. Initiate a Start CRS Feed command. Upon receiving this command, the Process Control System
will perform the following actions:
a.
Activate the mill off gas temperature control loop (105C set point).
b. The PCS will issue the prompt Mill Pre-charge Required. If the mill table is void of
material (inspect if necessary), select Yes. The PCS will proceed to start the CRS feed
system and deliver CRS to the mill table for a period of approximately 30 seconds (time
TBD during commissioning).
c.
The mill fan damper is opened to a preset position to develop the required process gas flow
to the mill.
d. The mill main drive is started at the specified speed set point. The roller mill grease system
is started automatically.
e.
The rollers are lowered to the mill table.
f.
The CRS feed system is started at 70% of normal capacity.
g. The hydraulic pump is started if necessary to obtain the target grinding system pressure.
h. Increase the ID fan damper opening.
i.
Increase fuel flow and combustion air fan output.
j.
Increase the dilution fan damper opening.
k. After 20 minutes the mill roller lubrication pumps are started.

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15. The mill table water spray may now be started if required to stabilize the mill operation and reduce
vibration.
The calciner system is now in a Feed Start mode. This mode of operation can be continued or
proceed to the next step to increase capacity.
16. Allow the system to stabilize (1-2 minutes). Engage the following control loops allowing for
appropriate system response and stabilization before initiating the subsequent control loop:
a.
Mill flow
b. Calciner off gas temperature

c.
Calciner inlet temperature
d. Calciner exit pressure

17. Slowly close the tempering tee to recirculated stack gas to the calciner system. This should be
performed over a period of several minutes to allow the system controllers to respond.
18. If normal system operation has required the use of vibrators and air cannons to maintain stability,
activate the cleaning groups.
19. Increase the CRS feed rate in 5-10 mtph increments until the target production rate is achieved.
Stabilize and then adjust control loop set points if needed to obtain target operating conditions.
20. If ESP dust is to be returned to the calciner, set the speed of the dust feed rotary valve to minimum
and then initiate a start command for the Dust Handling Group. If the calciner system is operating
at full capacity, reduce the CRS feed rate prior to increasing the dust feed rate to the calciner.
1.2 NORMAL STOP SEQUENCE

A normal stop sequence is engaged either upon receiving a command from the operator or when a condition
upstream or downstream of the calciner system requires a feed stoppage (i.e. low CRS level in the calciner
feed bin, loss of crystallizer vent flow, etc).
1. Initiate a Feed Stop command. Upon receiving this command, the Process Control System will
perform the following automatic adjustments:
a.
Ramp CRS feed rate down to 70% of normal operating capacity,
b. Reduce calciner exit temperature to 300C,

c.
Stop CRS feed and the mill feed rotary valve,
d. Close mill fan damper and mill inlet damper,

e.
Raise mill rollers,
f.
Stop the main mill drive,
g. Move the tempering tee to the fresh air intake position and adjust the system for System Idle
conditions,
h. De-energize air cannons, rappers and vibrators,
2. If the stop sequence is initiated due to a failure of the crystallizer vent fan, the diverter on the
calciner cyclone discharge duct will be repositioned to divert solids to the soda ash dump bin. If
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safety interlocks prevent access to this bin, the calciner will proceed with an emergency shutdown
sequence.
3. The system can be idled at these conditions until a feed start is required. If a full shutdown is
required, initiate a burner stop command. This command will stop fuel flow to the air heater and
place the system in a cool down mode. Once the air heater chamber refractory temperature
decreases to <150C, all fans can be stopped. The Process Control System will send a stop
command to the ESP to de-energize all fields and stop the screw conveyor five minutes after the last
process fan has been stopped, or the ESP may be de-energized by the operator. Calciner discharge
valves will continue to operate until manually stopped by the operator.
1.3 EMERGENCY SHUTDOWN SEQUENCE

Emergency shutdown of the calciner system is required to protect plant personnel, prevent equipment
damage due to the failure of key components in the system, in response to the presence of process conditions
that will lead to equipment damage, and/or the need to immediately stop the flow of hot soda ash into the
crystallizer circuit when the soda ash dump bin is not available. This mode of shutdown puts extra stress on
the equipment and as such is implemented for emergencies only.
Responses to the following scenarios are described below:
1. Local emergency stop command:
a. Stop CRS feed and mill valve,
b. Stop mill water spray(s),
c. De-energize air cannons, vibrators and rappers,
d. Stop Mill fan and close mill fan and mill inlet dampers,
e. Raise mill rollers, stop mill drive and classifier drive,
f. Stop fuel flow to air heater,
g. Stop all valves and dust transport to calciner (if active),
h. Place ID fan, dilution fan and combustion fan dampers in their Low Fire settings to
maintain cooling airflow to the system.
i. Open the tempering tee for ambient air intake.
2. Combustion air fan failure:
a. Stop fuel flow to the air heater,
b. Start the cooling air fan and open the valve on the duct leading to the burner,
c. Stop CRS feed and mill valve,
d. Stop mill water spray(s),
e. De-energize air cannons, vibrators and rappers,
f. Stop mill fan and close mill fan and mill inlet dampers,
g. Raise mill rollers, stop mill drive and classifier drive,
h. Stop all valves and dust transport to calciner (if active),
i. Place ID fan and dilution fan dampers in their Low Fire settings,
j. Open the tempering tee for ambient air intake.
3. Dilution air fan failure:
a. Stop fuel flow to the air heater,
b. Close the dilution air fan inlet damper,
c. Start the cooling air fan and open the valve on the duct leading to the air heater cooling
jacket,
d. Stop CRS feed and mill valve,
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e. Stop mill water spray(s),

f. De-energize air cannons, vibrators and rappers,
g. Stop mill fan and close mill fan and mill inlet dampers,
h. Raise mill rollers, stop mill drive and classifier drive,
i. Stop all valves and dust transport.
j. Place ID fan and combustion air fan dampers in their Low Fire settings.
4. High/high temperature:
a. Stop fuel flow to air heater,
b. Stop CRS feed and mill valve after a 2 minute delay,
c. Stop mill water spray(s),
d. De-energize air cannons, vibrators and rappers,
e. Stop mill fan and close mill fan and mill inlet dampers,
f. Raise mill rollers, stop mill drive and classifier drive,
g. Stop all valves and dust transport,
h. Place ID fan, dilution fan and combustion fan dampers in their Low Fire settings to
i. Open the tempering tee for ambient air intake.
5. High/high CO:
a. De-energize ESP fields,
b. Stop fuel flow to air heater,
c. Stop CRS feed and mill valve,
d. Stop mill water spray(s),
e. De-energize air cannons, vibrators and rappers,
f. Stop mill fan and close mill fan and mill inlet dampers,
g. Raise mill rollers, stop mill drive and classifier drive,
h. Stop all valves and dust transport,
i. Place ID fan, dilution fan and combustion fan dampers in their Low Fire settings to
j. Open the tempering tee for ambient air intake.
2 CALCINER GROUP
The Calciner Group consists of the Fuel Skid (400-BU-050-F1), Valve Stand (400-BU-050-V1), Burner (400BU-050), Air Heater Chamber (400-FU-050), Flash Calciner (400-FD-050), Air-cooled Grid Plate (400-CK050), Calciner Collection Cyclone (400-CY-060), Calciner Cyclone Dual Tipping Valve (400-AL-060),
Calciner Cyclone Discharge Diverter Valve (400-GA-060), Calciner Cyclone Discharge Rotary Valve (400AL-065) and Burner Cooling Air Fan Circuit (400-FN-054). These components are referenced on the
following C&ID drawings:
8.500742 SHT. 5 (400-02)
8.500742 SHT. 8 (400-05)
2.1 FUNCTIONAL DESCRIPTION

The Calciner Group controls the delivery and combustion of fuel in the air heater to provide the hot process
gas required to support the calcination process, accepts ground CRS from the mill circuit, may accept fines
from the ESP dust handling circuit, performs the high temperature calcination work and delivers calcined
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soda ash to the crystallizer . Select components on the fuel skid and valve stand are controlled by the Burner
Management System to satisfy safety protocols during purge and ignition sequences once a start command is
received from the Process Control System. After the burner ignition sequence is complete and a flame is
successfully detected, control of components in the Calciner Group resides in the Process Control System
until a burner stop is initiated by the Burner Management System as a result of a safety or process interlock
action. A description of the Burner Management System logic is included in Section 3.
2.1.1 BURNER START SEQUENCE

The operator first selects Pilot Only or Oil Firing on the main PCS display. If Pilot Only is selected,
the Burner Start sequence will stop once a pilot flame is proved by the BMS. If the Oil Firing switch is
selected by the operator, the full Burner Start sequence will be performed unless stopped by the operator or
by the BMS as the result of an interlock or a safety action. The PCS defaults to a Pilot Only setting
whenever the operation of the main burner is stopped. Once the Burner Start sequence is stopped at pilot
ignition as the result of a Pilot Only setting, the Burner Start sequence can be resumed upon an operator
Oil Firing selection. A Stop command given by the operator at any time in the sequence will be treated
by the BMS as a safety or interlock failure and reset to the beginning of the sequence.
A Start Purge sequence is initiated from the Process Control System (PCS). Upon receiving a Start Purge
command from the operator, the PCS and BMS will perform the following:
1. The BMS checks for operation of the combustion air, mill, dilution air and ESP ID fans via motor
contacts and pressure switches:
1.1. Combustion air fan: EM0461 contact and PSA-0462.
1.2. Mill fan: EM0223 contact and PS-0202.
1.3. Dilution air fan: EM0323 contact and PS-0302.
1.4. ESP ID fan: EM0321 contact and PS-0301.
2. Check the air heater refractory temperature 400-TIS-4069:
2.1. If <500C, prompt Install Low Capacity Oil Nozzle
2.2. If >500C, prompt Install High Capacity Oil Nozzle
3. Wait for a Correct Nozzle Installed confirmation from the operator ,
4. Check for a ready signal from the BMS,
5. The PCS will move dampers in sequence until they are in their Purge positions as indicated by the
following switch closures:
5.1. ID Fan Damper (400-DA-030), position switch 400-GBS-0310A
5.2. Combustion Fan Damper (400-DA-050), position switch 400-GBS-0460A
5.3. Dilution Air Fan Damper (400-DA-035), position switch 400-GBS-0302A
5.4. Mill Air Fan Damper (400-DA-010), position switch 400-GBS-0261A
5.5. Mill Bypass Damper (400-DA-020) fully open, position switch 400-GBS-0163A
5.6. Mill Inlet Damper (400-DA-015) fully open, position switch 400-GBS-0165
Once these positions are satisfied a ready signal will be issued by the PCS to the BMS.
6. BMS will check the following damper position limits:
6.1. ID Fan Damper (400-DA-030), position switch 400-GBS-0310A
6.2. Combustion Fan Damper (400-DA-050), position switch 400-GBS-0460A
6.3. Dilution Air Fan Damper (400-DA-035), position switch 400-GBS-0302A
6.4. Mill Air Fan Damper (400-DA-010), position switch 400-GBS-0261A
6.5. Mill Bypass Damper (400-DA-020) fully open, position switch 400-GBS-0163A
6.5.1. If satisfied within 10 minutes, proceed with sequence
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8.
9.
10.
11.
12.
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6.5.2. If not satisfied within 10 minutes, alarm in BMS and display in PCS
6.5.3. If not satisfied within 60 minutes, alarm in BMS, reset sequence in PCS and reset BMS
BMS oil flow control valve 400-TCV-0131 Low Fire position check: (position switch 400-GB-0414)
7.1. If valve in position, proceed and lock out PCS control
7.2. If valve out of position, alarm to PCS and recheck position:
7.2.1.
The PCS repositions valve and satisfies limit within 10 minutes, proceed with sequence
and lock out PCS control
7.2.2.
Limit not satisfied within 10 minutes, reset sequence in the PCS and BMS
Purge interval timing in BMS. Ready signal sent to PCS following purge completion,
PCS will re-position dampers in sequence for Low Fire until the following position switches are
closed (the mill bypass damper remains in its full open position):
9.1. ID Fan Damper (400-DA-030), position switch 400-GBS-0310C
9.2. Combustion Fan Damper (400-DA-050), position switch 400-GBS-0460C
9.3. Dilution Air Fan Damper (400-DA-035), position switch 400-GBS-0302C
9.4. Mill Fan Damper (400-DA-010), position switch 400-GBS-0261B
9.5. Mill Inlet Damper (400-DA-015) fully closed, position switch 400-GBS-0165.
PCS Low Fire damper position check:
10.1. All switches closed send a ready signal to the BMS
10.2. All switches not closed alarm and wait for resolution before proceeding
10.3. Stop command from operator reset sequence in PCS and send reset command to the BMS
PCS combustion air flow rate check (400-FFIC-0460):
11.1. If within +/-10% of target set in PCS (TBD during commissioning), send ready signal to the
BMS
11.2. If flow is outside this range, display Combustion Air Flow Out of Range and check flow
indication every 30 seconds and compare to target:
11.2.1. If within +/-10% tolerance, send ready signal to the BMS
11.2.2. If outside tolerance, wait 30 seconds and then recheck
11.3. Stop command from operator reset sequence in PCS and send reset command to the BMS
BMS pilot ignition sequence:
12.1. Start igniter,
12.2. Open pilot gas valves 400-XSV-0440 and 400-XSV-0441,
12.3. Stop igniter,
12.4. Scanner detection of pilot,
12.4.1. If Pilot Only selected at start of sequence, stop sequence and hold
12.4.2. If Oil Firing selected at start of sequence, proceed
12.5. No pilot detection by scanner Burner Start sequence reset in the BMS and PCS
BMS main burner ignition sequence
13.1. Open steam shutoff valve 400-XSV-0422,
13.2. Open oil shutoff valve 400-XSV-0442,
13.3. Close oil bypass shutoff valve 400-XSV-0444,
13.4. Stop pilot gas flow,
13.5. Scanner detection of main burner, Burner Start sequence complete. Proceed to Preheat
sequence
13.6. No main burner detection by scanner Burner Start sequence reset in the BMS and PCS
If ignition sequences are successful, the BMS sends a Burner On signal to the PCS and releases its interlock
on fuel control valve 400-TCV-0131 for PCS control during the Preheat and/or System Idle sequences. If
the ignition sequence is not successful, the BMS will issue an alarm to the PCS and reset. The operator must
now issue a Start Purge command in the PCS.
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Revision 2
2.1.2 BURNER PREHEAT SEQUENCE

Following successful ignition of the main burner, the PCS will make adjustments to the air/fuel ratio in the
air heater to increase the chamber temperature as per refractory preheat specifications. In the case of a cold
system start where refractory dry-out is required, PCS program adjustments will be required to permit manual
operation of oil flow control valve 400-TCV-0131 and combustion air damper 400-DA-050. Dry-out
instructions are provided in the Operating Manual. Once the preheat sequence is complete, the Burner Idle
sequence will establish a calciner off gas temperature of about 300C. If the air heater refractory temperature
(400-TIS-0469) is less than 200C at the time that the main oil burner operation is proved by the BMS, the
automated preheat sequence includes the following:
1. Maintain Low Fire settings until the rate change in the Air Heater outlet temperature 400-TIA-0468
drops below 5C/minute.
2. Increase the combustion air flow to TBD Nm3/h by opening combustion air fan damper 400-DA050. Increase oil flow (400-TCV-0131) to increase the temperature at 400-TIA-0468 by 65C above
the temperature present just prior to the fan damper adjustment and hold this temperature for 1
hour. Continue these 65C step changes until a temperature of 1000C is obtained at 400-TIA-0468.
Hold for 1 hour and then proceed with the System Idle sequence.
3. Adjust the dilution air fan damper position (400-DA-035) during the preheat cycle to limit the
calciner inlet temperature (400-TISCA-0140) to 325C.
4. Adjust the ID fan inlet damper (400-DA-030) to maintain a pressure of -25 mm WG at the calciner
exit (400-PICA-0130).
Once the oil flow rate reaches 25 lpm, the PCS will stop further fuel rate changes and prompt the operator to
Install Large Oil Nozzle. If the large nozzle is already installed, the operator will simply select Large Oil
Nozzle Installed and then the PCS will continue with the preheat sequence. If a nozzle change is required,
the following must be performed:
1. Select Change Oil Nozzle is made by the operator when the technician is ready to perform the
action,
2. The PCS sends a Change Oil Nozzle signal to the BMS. The BMS proceeds to light the pilot and
then close valve 400-XSV-0442 to stop oil flow and returns a ready signal to the PCS. The PCS
displays Proceed with Nozzle Change,
3. The PCS moves the oil control valve 400-TCV-0131 and fan dampers to their Low Fire positions,
4. After the nozzle installation is complete, the operator selects Nozzle Change Complete. The PCS
sends a Resume Main Burner Operation signal to the BMS, which in turn proceeds with the
balance of the Main Burner start sequence.
5. The PCS receives a ready signal from the BMS and adjusts 400-TCV-0131 for an oil flow rate of 25
lph and holds this rate for 1 hour.
6. The PCS resumes the preheat sequence at 65C per hour.
If the refractory temperature (400-TI-0469) is greater than 200C and less than 815C, the PCS will engage in
the following automated preheat sequence following successful ignition of the main burner:
1. Increase the combustion air flow to TBD Nm3/h by opening combustion air fan damper 400-DA050. Increase oil flow (400-TCV-0131) to increase the temperature at 400-TIA-0468 by 65C above
the temperature present just prior to the fan damper adjustment and hold this temperature for 1
hour. Continue these 65C step changes until a temperature of 815C is obtained at 400-TIA-0468.
Hold for 1 hour and then proceed with the System Idle sequence.
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2. Adjust the dilution air fan damper position (400-DA-035) during the preheat cycle to limit the
calciner inlet temperature (400-TISCA-0140) to 325C.
3. Adjust the ID fan inlet damper (400-DA-030) to maintain a pressure of -25 mm WG at the calciner
exit (400-PICA-0130).
If the refractory temperature (400-TI-0469) is greater than 815C at the time that the main burner is ignited,
no preheat sequence is performed. The PCS will proceed with a System Idle sequence.
The system preheat sequences may proceed as long as the following conditions are satisfied:
1. Emergency Stops are not engaged
2. No high temperature states existing:
a. Calciner inlet (400-TICSA-0140)
b. Calciner outlet (400-TICSA-0131,400-TIZA-0161)
c. Roller mill outlet (400-TICSA-0004)
d. ESP outlet (400-TISA-0302)
3. ESP ID Fan running (400-FN-030)
4. Combustion Air Fan running (400-FN-050)
5. Dilution Air Fan running (400-FN-035)
6. Grid Cooling Air Fan running (400-FN-055)
7. Tempering Tee in full open position (400-GIS-0328) for ambient air intake
8. No high CO at the ESP inlet (400-QISZA-0301)
If conditions 2, 6 and 8 are not satisfied, the preheat sequence will be held at current conditions until the
problems are resolved. The remaining conditions will result in a main burner shutdown.
If a failure occurs with the operation of the combustion air fan or dilution air fan after the system is hot, the
PCS will perform the functions described in Section 2.1.6.
2.1.3 SYSTEM IDLE SEQUENCE

Once the Burner Preheat sequence is completed or a chamber refractory temperature (400-TI-0469) greater
than 815C is detected at the time of main burner ignition, the PCS will proceed with an automatic System
Idle sequence. This sequence will move the fan dampers and oil flow controller to preset positions to
establish the conditions required before a CRS Feed Start command can be made. The sequence includes
the following (actual positions to be determined during system commissioning):
1. Move the ESP ID fan inlet damper (400-DA-030) to an open position of TBD%,
2. Move the dilution air fan damper (400-DA-035) to an open position of TBD%,
3. Increase the oil flow rate to TBD lpm. The PCS will automatically adjust the combustion air flow
rate to obtain the normal operating air/fuel ratio in the air heater. A constant air/fuel ratio will be
maintained by the PCS until a system shutdown or Pilot Only command is issued.
System Idle operation may continue indefinitely as long as the following conditions are satisfied:
1. Emergency Stops are not engaged
2. No high/high temperature states existing:
e. Calciner inlet (400-TICSA-0140)
f. Calciner outlet (400-TICSA-0131,400-TIZA-0161)
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4.
5.
6.
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g. Roller mill outlet (400-TICSA-0004)

h. ESP outlet (400-TISA-0302)
ESP ID Fan running (400-FN-030)
Combustion Air Fan running (400-FN-050)
Dilution Air Fan running (400-FN-035)
Tempering Tee in full open position (400-GIS-0328) for ambient air intake
No high high CO at the ESP inlet (400-QISZA-0301)
If a condition in the above list is not satisfied, the main burner will be shutdown by the BMS.
2.1.4 CRS FEED START

A CRS Feed Start command can be issued by the operator once the following preconditions are satisfied:
1. A minimum calciner collection cyclone off gas temperature of 275C (400-XY-0131) is attained
under System Idle conditions,
2. There is not a low CRS level indication in CRS feed bin 200-BN-085.
3. Roller mill start conditions are satisfied (see Section 4),
4. Cyclone discharge valves are started and operating (400-AL-060, 400-AL-065, 400-AL-020 and 400AL-025),
5. The calciner cyclone discharge diverter gate 400-GA-060 is in a closed position (400-GBS-0154B) to
direct solids to the crystallizer circuit, (NOTE: A manual over ride is to be provided to enable a feed
start during system testing when the diverter gate is in an open position)
6. All ESP (400-EP-030) fields are energized,
7. Mill Bypass Damper 400-DA-020 is 100% open.
Once the CRS Feed Start command is issued, the PCS will position fan dampers to support the higher
firing rate required and to satisfy roller mill flow requirements (see Section 4 for roller mill response
information) and heat load imparted as a result of CRS drying, heating and calcination. The PCS will move
oil flow valve (400-TCV-0131) to a set position to provide an HFO flow rate of TBD lpm.
The system will continue to operate with the preset conditions specified for a CRS Feed Start until (1) process
interlocks are satisfied that permit feed rate increases (all control loops engaged and tempering tee set for
stack gas recirculation), (2) a feed stop/System Idle is requested by the operator, (3) a burner stop and system
shutdown is requested by the operator, (4) a mill fault requires a feed stop/System Idle, or (5) a main burner
stop is required due to one or more of the following actions/conditions:
1. Emergency Stops are engaged
2. High/high temperature states existing:
i. Calciner inlet (400-TICSA-0140)
j. Calciner outlet (400-TICSA-0131,400-TIZA-0161)
k. Roller mill outlet (400-TICSA-0004)
l. ESP outlet (400-TISA-0302)
3. ESP fields de-energized (400-EP-030)
4. ESP ID Fan not running (400-FN-030)
5. Combustion Air Fan not running (400-FN-050)
6. Dilution Air Fan not running (400-FN-035)
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2.1.5 CRS CAPACITY INCREASES

The CRS feed rate may be increased manually by the operator once all control loops are engaged. These
control loops include:
1.
2.
3.
4.
400-CTL-01:
400-CTL-02:
400-CTL-03:
400-CTL-04:
Calciner exit temperature (Calciner Group)

Calciner inlet temperature (Process Air Group)
Mill Flow (Process Air Group)
Calciner pressure (Process Air Group)
In addition, no active alarm conditions can be present in the calciner system.

The CRS rate may be increased in increments selected by the operator, up to a maximum rate of 106 mtph (as
indicated by weigh belt feeder 200-FD-085). This maximum rate is password protected in the PCS and
provides protection against over-feeding the system. An over-feeding situation will result in low temperature
alarm conditions, air heater over-fueling, instability and an eventual feed stop condition.
2.1.6 EMERGENCY COOLING AIR

The Calciner Group includes an emergency cooling air circuit to protect the burner and air heater chamber in
the event that flow is lost from the combustion air fan and/or the dilution air fan. Engaging of the
emergency cooling air circuit will occur if the air heater refractory temperature (400-TI-0469) is >200C and
either the combustion air fan or dilution air fan stop. The circuit can be de-energized by the operator
manually once 400-TI-0469 drops below 150C.
2.1.6.1 COMBUSTION AIR FAN FAILURE

If the PCS detects a loss of contact for Combustion Air Fan 400-FN-050 motor 400-EM-0461 or pressure
switch 400-PS-0402 opens due to low pressure when 400-TI-0469 is >200C, the following actions are
performed by the PCS:
1.
2.
3.
4.
Cooling Air Fan 400-FN-054 is immediately energized,

Valve 400-XSV-0471 opened,
Damper 400-DA-050 is closed,
The dilution and ESP ID air fan dampers are moved to their purge positions.
In addition, the BMS will detect this loss of contact and/or pressure switch status change and immediately
stop fuel flow to the main burner.
The automatic response by the PCS will supply cooling air to the burner to protect it from high temperature
damage. If the Combustion Air Fan is re-energized successfully or a manual shutdown command is issued by
the operator (400-TI-0469 <150C), valve 400-XVS-0471 will be closed and then the cooling air fan stopped.
2.1.6.2 DILUTION AIR FAN FAILURE

If the PCS detects a loss of contact for Dilution Air Fan 400-FN-035 motor 400-EM-0323 or pressure switch
400-PSA-0302 opens due to high pressure when 400-TI-0469 is >200C, the following actions are
performed:
FFE Minerals USA
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2.
3.
4.
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BMS: Fuel flow to the combustion chamber is stopped,

PCS: Cooling Air Fan 400-FN-054 is immediately energized,
PCS: Valve 400-XSV-0470 opened,
PCS: Damper 400-DA-035 is closed,
PCS: The combustion and ESP ID air fan dampers are moved to their purge positions.
These actions will supply cooling air to the air heater cooling jacket to protect the inner air heater shell from
high temperature damage. If the Dilution Air Fan is re-energized successfully or a manual shutdown
command is issued by the operator (400-TI-0469<150C), valve 400-XVS-0470 will be closed and the cooling
air fan stopped.
2.1.6.3 ESP ID FAN FAILURE

If the PCS detects a loss of contact for ESP ID Fan 400-FN-030 motor 400-EM-0321 or pressure switch
400-PS-0301 opens due to high pressure, operation of the combustion air fan and dilution air fan will
continue with their dampers moved to their Low Fire positions to provide cooling air to the burner and
cooling jacket. Valve 400-XSV-0472 on the Emergency Vent and the ESP ID fan damper 400-DA-030 will
be opened 100% to alleviate system backpressure resulting from the loss of the ID fan. Valve 400-XSV-0472
will be closed by the PCS when ESP ID Fan operation is again confirmed.
2.1.6.4 DUAL FAN FAILURE

If the PCS detects failures of both the Combustion Air Fan and the Dilution Air Fan and the air heater
refractory temperature 400-TI-0469 is >200C, Cooling Air Fan 400-FN-054 will be immediately energized
and valves 400-XSV-0470 and 400-XSV-0471 opened. The BMS immediately stops fuel flow to the main
burner. These actions will supply cooling air to the burner and the air heater cooling jacket to protect both
areas from high temperature damage. If both fans are re-energized successfully or a manual shutdown
command is issued by the operator (400-TI-0469 <150C), valves 400-XVS-0470 and 400-XVS-0471 will be
closed and then the cooling air fan stopped.
2.1.6.5 COMPLETE SYSTEM POWER LOSS

In the event that all power is lost to the calciner system and the air heater refractory temperature 400-TI-0469
is greater than 500C, steam will be supplied to the main burner and air heater cooling jacket to minimize the
potential for thermal damage. Valve 400-XSV-0424 and valve 400-XSV-0425 will fail in an open position to
direct steam to the two locations, and valve 400-XSV-0472 on the Emergency Vent will fail open to vent the
steam to atmosphere. As soon as power is restored to critical items (up to 20 minutes), Cooling Air Fan 400FN-054 will be energized, steam valves 400-XSV-0422 and 400-XSV-0425 will close, and then valves 400XSV-0470 and 400-XSV-0471 will open. Valve 400-XSV-0426 on the emergency steam purge line will be
closed by the PCS when 400-TI-0469 is <450C and opened when >500C to permit steam flow to the air
heater during a power loss condition only if required.
2.1.7 CALCINER CYCLONE DISCHARGE TIPPING VALVE

The calciner cyclone discharge dual Tipping Valve 400-AL-060 is started manually by the operator via the
PCS. This valve may be started at any time except when an emergency stop is engaged or the unit is locked
out for maintenance work. In either of these two cases, the PCS shall indicate that the valve is not available
for operation. A permissive for a CRS Start Feed command cannot be issued until this valve is operating.
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The valve timing sequence is set in the PCS as per supplier specifications and cannot be changed by the
operator.
The following sequence is performed during normal start, run and stop cycles for the dual tipping valve unit:
1. Check for emergency stop and maintenance lock out. If not present, continue to step 2,
2. Check that the upper and lower valves are in their closed positions. If either closed limit is not
satisfied (400-GS-0151 and 400-GS-0152), issue an alarm indicating position limits not satisfied. If
limits are satisfied, display a start permissive on the PCS screen,
3. The operator manual selects the tipping valve icon and selects Start,
4. The PCS energizes Solenoid A to direct instrument air to the low side of the cylinder and open the
high side to ambient. This extends Cylinder A and moves the upper valve into its open position. If
the open limit switch (400-GS-0151) is not satisfied within 2 seconds after energizing Solenoid A,
issue an alarm indicating position limit not satisfied and remove the start permissive.
5. Energize Solenoid A for a total period of 6 seconds after the open limit is satisfied and then deenergize Solenoid A. This will open the low side of the cylinder to ambient and pressurize the high
side. This retracts Cylinder A and moves the upper valve to its closed position. If the closed limit
switch is not satisfied within 2 seconds after de-energizing Solenoid A, issue an alarm indicating
position limit not satisfied and remove the start permissive.
6. Three seconds after the upper valve reaches its closed position, energize Solenoid B to direct
instrument air to the low side of the cylinder and open the high side to ambient. This extends
Cylinder B and moves the lower valve into its open position. If the open limit switch (400-GS-0152)
is not satisfied within 2 seconds after energizing Solenoid B, issue an alarm indicating position limit
not satisfied and remove the start permissive.
7. Energize Solenoid B for a total period of 6 seconds after the open limit is satisfied and then deenergize Solenoid B. This will open the low side of the cylinder to ambient and pressurize the high
side. This retracts Cylinder B and moves the lower valve to its closed position. If the closed limit
switch is not satisfied within 2 seconds after de-energizing Solenoid A, issue an alarm indicating
position limit not satisfied and remove the start permissive.
8. Three seconds after the lower valve reaches its closed position limit, repeat the cycle until a stop
command is received from the operator, an emergency stop is activated or the local maintenance
switch is engaged.
9. When the valve is stopped for whatever reason, de-energize both solenoids so that the upper and
lower valves return to their closed positions.
2.1.8 TIPPING VALVE FULL OPEN POSITION OPTION

The start menu for the tipping valve also provides an option to position the valve in a fully open position. In
this situation, both solenoids are energized to force the valves into a full open position and then held until a
close command is given by the operator. This option may be exercised during a cyclone cleaning operation,
to impact material flow stability during operation, improve air cannon cleaning effectiveness, etc. This option
cannot be exercised in the following situations:
1. An emergency stop is active
2. The unit is locked out for maintenance
3. The diverter is open to the crystallizer (it must be open to the dump tank)
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Revision 2
2.1.9 CALCINER CYCLONE DISCHARGE DIVERTER VALVE

The calciner cyclone discharge Diverter Valve 400-GA-060 is utilized to divert calciner product away from
the crystallizer during cleanout operations or when a failure of the Crystallizer Vent Fan forces an immediate
stoppage of material flow to the crystallizer. The diverter permits an immediate stoppage of solids flow to
the crystallizer without necessitating a sudden calciner system shutdown. A permissive for a CRS Start
Feed command cannot be issued until this valve is in its closed position as indicated by position switch 400GBS-0154A.
The operation of this valve is permitted in the following scenarios:
1. Manual positioning by the operator when the CRS feed system is inactive,
2. Automatic positioning by the PCS when a failure of the crystallizer vent fan occurs.
Both modes of operation are contingent upon availability of Material Dump Bin 400-TK-060. This bin may
be locked out for safety reasons during discharge and cleaning operations. If the bin is locked out, then a
crystallizer vent fan failure will result in an immediate stoppage of the CRS feed system. If the bin is
available, the diverter valve is positioned automatically by the PCS to direct material to the dump bin, and
then the calciner system is moved into a hot idle mode or normal shutdown mode by the operator.
2.1.10 CALCINER CYCLONE DISCHARGE ROTARY VALVE

The calciner cyclone discharge Rotary Valve 400-AL-065 is utilized to stabilize the flow of solids into the
crystallizer wetting section. This valve may be started at any time except when an emergency stop is engaged
or the unit is locked out for maintenance. In either of these two cases, the PCS shall indicate that the valve is
not available for operation. A permissive for a CRS Start Feed command cannot be issued until this valve
is operating.
The following sequence is performed during normal start, run and stop cycles for the rotary valve:
1. Check for emergency stop and maintenance lock out. If not present, display a start permissive on the
PCS screen,
2. The operator manually selects the rotary valve icon and selects Start from the menu,
3. The PCS send a start signal to the motor starter for 400-EM-0125,
4. The PCS checks for a valve motion confirmation from 400-SSA-0101. If this is not received within 5
seconds after receiving a motor start confirmation from the starter, the motor is de-energized and an
alarm is displayed,
5. Once a successful start is achieved, the valve is de-energized via:
a. A loss of motion detection,
b. Motor fault,
c. Emergency shutdown action,
d. Opening of Diverter Valve 400-GA-060 to the dump bin,
2.2 EQUIPMENT/INSTRUMENT SUMMARY

The Calciner Group consists of the following components and attached instruments and equipment:
Calciner Group
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Description
PCS Display
Fuel Skid
Reference Tag
400-BU-050-F1
Butane Pressure Regulator
400-PC-0400
Butane Pressure Indicating Gage
400-PI-0401
Butane Pressure Switch (Minimum pressure indication)
400-PSA-0402
Butane Pressure Switch (High pressure indication)
400-PSA-0403
Butane Flow Orifice (Local check only)
400-FP-0404
Butane Pressure Indicating Gage
400-PI-0407
HFO Pressure Indicating Gage
400-PI-0408
Instrument Air Pressure Indicating Gage
400-PI-0404
Instrument Air Low Pressure Switch
400-PSA-0405
HFO Pressure Regulator
400-PC-0409
400-PI-0410
HFO Pressure Switch (Minimum pressure indication)
400-PSA-0411
HFO Pressure Switch (High pressure indication)
400-PSA-0412
HFO Minimum/Maximum Temperature Switch
400-TIS-0413
HFO Circuit Heat Tracing
HFO Heat Tracing Temperature Controller

HFO Flow Transmitter
400-TC-0401
X
HFO Flow Control Valve

HFO Flow Control Valve Open/Closed Position Switch
400-EA-0401
400-FIT-0401
400-TCV-0131
400-GBS-0414
400-PI-0415
Purge Steam Pressure Regulator
400-PC-0416
Purge Steam Pressure Indicating Gage
400-PI-0417
Atomizing Steam Pressure Indicating Gage
400-PI-0419
Emergency Steam Purge On/Off Valve (Temperature Controlled)
400-XSV-0426
Burner Emergency Steam Purge Valve (Fail Open)
400-XSV-0425
Burner Emergency Steam Purge Valve Open/Closed Position

Indicator
Air Heater Jacket Emergency Steam Purge Valve (Fail Open)

Air Heater Jacket Emergency Steam Purge Valve Open/Closed
Position Indicator
400-GBS-0425
400-XSV-0424
400-GBS-0424
Atomizing Steam Flow Indicator
400-FI-0418
Atomizing Steam Shutoff Valve
400-XSV-0422
Atomizing Steam Shutoff Valve Open/Close Position Switch
400-GBS-0422
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Revision 2
Valve Stand
400-BU-050-V1
Butane Shutoff Valve #1

Butane Shutoff Valve Open/Close Position Switch
400-XSV-0440
X
Butane Shutoff Valve #2

Butane Shutoff Valve Open/Close Position Switch
400-XSV-0441
X
HFO Supply Shutoff Valve

HFO Supply Shutoff Valve Open/Close Position Switch
400-GBS-0441
400-XSV-0442
400-GBS-0442
400-PI-0443
HFO Recirculation Shutoff Valve
400-XSV-0444
HFO Recirc Shutoff Valve Open/Close Position Switch
Purge Steam Shutoff Valve

Purge Steam Shutoff Valve Open/Close Position Switch
400-GBS-0444
400-XSV-0445
400-GBS-0445
Atomizing Steam Pressure Regulator
400-PC-0446
Atomizing Steam Low Pressure Switch
400-PSA-0420
Burner
400-BU-050
Pilot Flame Scanner
400-XISA-0463
Main Flame Scanner
400-XISA-0469
Air Heater
400-FU-050
Outlet Gas Temperature Indicator
400-TISA-0468
Cooling Jacket Outlet Air Temperature Indicator
400-TIA-0467
Refractory Temperature Indicator
400-TIS-0469
Vent Stack Valve

Vent Stack Valve Open/Close Position Switch
400-XSV-0472
X
Cooling Air Fan
400-GBS-0472
400-FN-054
Burner Cooling Air Valve
400-XSV-0471
Burner Cooling Air Valve O/C Position Switch
400-GBS-0471
Air Heater Jacket Cooling Air Valve
400-XSV-0470
Air Heater Jacket Cooling Air Valve O/C Position Switch
400-GBS-0470
Burner Cooling Air Pressure Indicator
400-PI-0454
Air-Cooled Grid Plate

Cooling Air Flow Indicator
400-CK-050
X
Air Inlet Pressure Gauges

Air Outlet Temperature Transmitters with Local Indication
Calciner Inlet Temperature Control/Indicator
400-FIA-0137
400-PI-152A-F
Flash Calciner
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400-GBS-0440
400-TIA-A-F
400-FD-050
400-TISCA-0140
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Calciner Inlet Pressure Indicator
400-PIA-0139
Grid Plate Differential Pressure Indicator
400-PDA-0138
Calciner Temperature Indicator
400-TI-0101
400-TI-0102
400-TI-0103
400-TI-0104
Calciner Exit Pressure Control/Indicator
400-PICA-0130
Calciner Inlet Carbon Monoxide Analyzer
400-QISZA-0180
Calciner Load Cells (Optional)
400-WIA-0135
Calciner Collection Cyclone
400-CI-060
Off Gas Temperature Indicator
400-TI-0131A
400-TI-0131B
400-TI-0131C
400-TI-0131D
Off Gas Temperature Control/Indicator
400-TICSA-0131
Off Gas Emergency Temperature Shutoff
400-TIZA-0162
Off Gas Pressure Indicator/Switch
400-PISA-0161
Cyclone Load Cells (Optional)
400-WIA-0148
Solids Discharge Temperature Indicator
400-TIA-0150
Cone Pressure Indicator
400-PIA-0147
Dual Tipping Valve
400-AL-060
Upper Tipping Valve Control Solenoid Valve
400-KSV-0151
Lower Tipping Valve Control Solenoid Valve
400-KSV-0152
Upper Tipping Valve Open/Close Position Switch
400-GS-0151
Lower Tipping Valve Open/Close Position Switch
400-GS-0152
Diverter Valve
400-GA-060
Diverter Valve Position Control
400-XSV-0154
Diverter Valve Position Switch
400-GBS-0154A/B
Diverter Underflow Pressure Indicator
400-PA-0156
Rotary Valve
Rotary Valve Motion Switch
400-AL-065
X
Rotary Valve Cooling Water Flow Control Valve

Rotary Valve Cooling Water Temperature Controller
400-SSA-0101
400-TCV-0157
400-TICS-0157
FFE Minerals USA

Revision 2
2.3 CONTROL LOOPS

2.3.1 CALCINER EXIT TEMPERATURE CONTROL
The calciner exit temperature control loop (400-CTL-01) may be placed in automatic by the operator once a
CRS Feed Start has been performed and stable system operation is observed. This is a cascading control
loop in that the combustion air is increased to satisfy a request for a temperature increase immediately
followed by an increase in the fuel flow rate to satisfy the air/fuel ratio set point. When a calciner outlet
temperature decrease is called for, the fuel flow rate is first decreased followed by a decrease in the
combustion airflow to satisfy the air/fuel ratio set point.
The default temperature for this loop is 425C, but this may be adjusted by the operator to maintain the
target soda ash product temperature as indicated at 400-TIA-0150. The PCS will not allow this control loop
to be engaged unless a CRS Feed Start condition is detected (CRS Feed Belt 200-FD-085 operating).
Once successfully engaged, the calciner temperature control loop will look at the maximum calciner cyclone
off gas temperature indicated (400-TI-0131A-D). This function helps protect the system against improper
control response due to an erroneous reading resulting from a damaged thermocouple, coating formation,
etc. The PCS will consider the four temperature indications (400-TI-0131A-D) and select the maximum
temperature reading for the purpose of control (400-XY-0131). Once a maximum temperature is selected, a
temperature indication at another position must exceed the selected position by 5C before a different
thermocouple position will be selected for control purposes. This is required to avoid unnecessary switching.
If more than one thermocouple should indicate the same temperature level, the PCS shall select the first
thermocouple in the A-B-C-D sequence.
If the temperature is below the set point value, the PCS will increase the opening of the combustion air fan
damper 400-DA-050. As an increase in the air flow rate is indicated, the PCS will immediately adjust the
position of the oil flow control valve 400-TCV-0131 such that the flow rate indicated by 400-FIT-0401
satisfies the required air/fuel ratio. If the temperature indication is above the set point value, the PCS will
reduce the flow rate of fuel followed by a reduction in combustion air flow to hold the air/fuel ratio. The
control loop should be tuned to limit calciner cyclone off gas temperature fluctuations to +/-5C.
The PCS will compare the actual air/fuel ratio to the set point level. If the air/fuel ratio deviates from the set
point level by more than -5% at any time, the fuel control valve will be frozen by the PCS until the
combustion air damper positioning and flow rate have the opportunity to respond. Once the deviation is less
than -2%, oil flow rate adjustment may resume. If the air/fuel ratio deviates from the set point level by more
than +5% at any time, the combustion air damper will be frozen by the PCS until the fuel oil control valve
positioning and flow rate have the opportunity to respond. Once the deviation is less than +2%, oil flow rate
adjustment may resume. If the air/fuel ratio deviates from the set point by more than +/-10%, the PCS shall
freeze both valves and issue an alarm. This logic minimizes the potential for an over-fueling scenario that will
result in carbon monoxide formation and burner shutdown on high-high CO at the calciner inlet.
The air/fuel ratio is set in the PCS and may be changed by the operator after password protection is satisfied.
This protection is required to prevent accidental or incorrect adjustment to the air/fuel ratio which will lead
to dangerous operating conditions and poor system performance.
If during the process of adjusting the fuel firing rate the grid cooling air outlet temperature (400-TIA-0152AF) exceeds 435C, an alarm will be issued by the PCS. The operator will respond by instructing an opening of
the grid cooling air fan manual damper to increase the cooling air flow through the grid plate and/or a
redistribution of cooling air using the manual valves positioned on the individual air supply ducts.
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FFE Minerals USA

Revision 2
This control loop is automatically deactivated if the Calciner Group is moved into Low Fire or System Idle
modes, or the system is shutdown.
2.4 ALARMS
Alarm Condition
Burner Management System Fault
Alarm Trigger
Device
Analog Set
Point
Debounce
Value
See Section 3
Heating Jacket Current
High
400-EA-0401
10 sec
Air Heater Outlet Gas Temperature
High
400-TIA-0468
>1650C
0 sec
Air Heater Jacket Outlet Air

Temperature
High
400-TIA-0467
>300C
0 sec
High
400-QISZA-0180
0.5%
0 sec
High High
400-QISZA-0180
1.2%
0 sec
High
400-TISCA-0140
>750C
0 sec
High High
400-TISCA-0140
800C
2 sec
High
400-TIA-0152A-F
>435C
5 sec
High
400-PICA-0130
>25mm WG
10 sec
Low
400-PICA-0130
<-50mm WG
10 sec
High
400-TICSA-0131
>435C
0 sec
High High
400-TICSA-0131
450C
15 sec
High High
400-TZA-0162
455C
0 sec
Low
400-PISA-0161
<-200mm WG
5 sec
High
400-PISA-0161
>0mm WG
5 sec
High High
400-PISA-0161
200mm WG
5 sec
High
400-PIA-0147
-25mm WG
10 sec
High High
400-PIA-0147
0mm WG
10 sec
High
400-TIA-0150
405C
15 sec
Low
400-TIA-0150
390C
15 sec
Calciner Cyclone Discharge Leg

Pressure
Low
400-PA-0156
-50mm WG
10 sec
Calciner Weight (Optional)
High
400-WIA-0135
TBD
TBD
Cyclone Weight (Optional)
High
400-WIA-0148
TBD
TBD
400-EM-0461
Combustion Air Fan Damper Position Closed

Limit Not Satisfied
400-GBS-0460A
Combustion Air Fan Damper Position Purge Limit

Not Satisfied
400-GBS-0460B
Calciner Inlet CO Level

Calciner Inlet Gas Temperature
Grid Cooling Air Temperature
Calciner Exit Pressure
Calciner Cyclone Exit Gas
Temperature
Temperature
Pressure
Calciner Cyclone Cone Pressure
Calciner Cyclone Solids Discharge
Temperature
Combustion Air Fan Motor Failure
FFE Minerals USA

Revision 2
Combustion Air Fan Damper Position Low Fire

Limit Not Satisfied
400-GBS-0460C
Dilution Air Fan Damper Position Closed Limit

Not Satisfied
400-GBS-0302A
Dilution Air Fan Damper Position Purge Limit

Not Satisfied
400-GBS-0302B
Dilution Air Fan Damper Position Low Fire Limit

Not Satisfied
400-GBS-0302C
ESP ID Fan Damper Position Closed Limit Not

Satisfied
400-GBS-0130A
ESP ID Fan Damper Position Purge Limit Not

Satisfied
400-GBS-0130B
ESP ID Fan Damper Position Low Fire Limit Not

Satisfied
400-GBS-0130C
Mill Fan Damper Position Closed Limit Not

Satisfied
400-GBS-0261A
Mill Fan Damper Position Purge Limit Not

Satisfied
400-GBS-0261B
Mill Inlet Damper Position Closed Limit Not

Satisfied
400-GBS-0165
Cooling Air Fan Motor Failure
400-EM-0452
Vent Stack Position Closed Limit Not Satisfied
400-GB-0472
Vent Stack Position Open Limit Not Satisfied
400-GB-0472
HFO Flow Rate Check Out of Spec
Software
Air/Fuel Ratio Check Out of Spec
Software
Grid Cooling Air Fan Motor Failure
400-EM-0124
Low
400-FI-0137
1000 m3/h
0 sec
Low Low
400-FI-0137
500 m3/h
0 sec
400-PIA-0139
400-PDA-0138
>305mm WG
5 sec
>250mm WG
2 sec
Upper Tipping Valve Closed Limit Not Satisfied
400-GS-0151
5 sec
Upper Tipping Valve Open Limit Not Satisfied
400-GS-0151
5 sec
Lower Tipping Valve Closed Limit Not Satisfied
400-GS-0152
5 sec
Lower Tipping Valve Open Limit Not Satisfied
400-GS-0152
5 sec
Diverter Gate Closed Limit Not Satisfied
400-GBS-0154B
2 sec
Diverter Gate Open Limit Not Satisfied
400-GBS-0154A
2 sec
Rotary Valve Motor Failure
400-EM-0125
Rotary Valve Rotor Motion Not Detected
400-SSA-0101
5 sec
Grid Cooling Air Flow

Calciner Inlet Gas Pressure
High
Grid Plate Differential Pressure
High
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FFE Minerals USA

Revision 2
2.5 INTERLOCKS
All interlocks required for the system are listed in tabular format. The output device is listed in the left-hand
column. Interlock Conditions are listed in the middle column as AND Boolean top to bottom, OR
Boolean left to right. The Interlock Type is listed in the right column.
In local control mode devices are operated locally using start/stop, open/close push buttons. In Manual
control each device is started and stopped from the HMI, using device manual control pop-up screen. In
group control mode all the devices in a particular group start and stop, based on sequential start and stop
logic. In Individual group control all devices in a group are started and stopped individually by the operator;
when their start and stop logic is satisfied.
Safety Interlock will shutdown device in local, manual, or group control mode. The failure of a Start interlock
will not allow the device to be started in group control mode or in individual group control mode. The
failure of a Process interlock will cause the system to stop after the system has been started in group control
mode or in individual group control mode. The failure of an interlock will cause the equipment to shut-down
or execute other interlock related actions.
Equipment/Action
Signals
Sample:
(X AND Y AND Z); Z to start, X
AND Y to run, X for safety shutdown
Safety
Start
X
X
X
Refractory Temperature (400-TI-4069)

<815C
Tempering Tee in Full Ambient Intake

Position
Air Heater Refractory Temperature >815C

(400-TI-4069)
System Idle Sequence
CRS Feed Start Sequence
No High High Temperature Conditions
Tempering Tee in Full Ambient Intake

Position
Calciner Cyclone Outlet Temperature (400XY-0131) >275C
ESP Fields Energized (400-EP-030)
Mill Bypass Damper (400-DA-020) Full

Open
Mill Start Permissive
CRS (200-BN-085) Bin Level NOT Low
X
X
BMS Burner On Signal
Process
Z
Preheat Sequence
Interlock Type
FFE Minerals USA
Equipment/Action

Revision 2
Interlock Type
Signals
Safety
Start
Process
Dilution Air Fan

NOT Operating
(400-EM-0323)
Air Heater Outlet Temp >200C (400-TIA0468)
All System Valves Operating and Diverter

Gate Open to Crystallizer Circuit
Diverter Valve (400-GA-060) to
Dump Tank
Cooling Air Fan (400-FN-054)

Start
Cooling Air Fan (400-FN-054)

Stop
Burner Cooling Air Valve (400XSV-0471) Open

Burner Cooling Air Valve (400XSV-0471) Close
Air Heater Cooling Air Valve
(400-XSV-0470) Open
Air Heater Cooling Air Valve
(400-XSV-0470) Close
Emergency Vent Stack (400XSV-0472) Open
24
Dump Tank Available (400-TK-060) as

indicated by Water Flow Switch 400-FSIA1401 (400-XSV-1402 Open)
Combustion Air Fan
NOT Operating (400EM-0461)
Combustion Air Fan

Running
(400-EM0461)
Dilution
Running
0323)
Air Fan
(400-EM-
Air Heater Outlet

Temp
<200C
(400-TIA-0468)
Combustion Air Fan NOT Operating (400EM-0461)
Cooling Air Fan Running (400-EM-0452)
Combustion Air Fan Running (400-EM0461)
Dilution Air Fan NOT Operating (400-EM0323)
Cooling Air Fan Running (400-EM-0452)
Dilution Air Fan Running (400-EM-0323)
ESP ID Fan NOT Operating (400-EM0321)
Air Heater Outlet Temp >200C (400-TIA0468)
Emergency Vent Stack (400XSV-0472) Close
ESP ID Fan Running (400EM-0321)
Air Heater Jacket Emergency

Steam Purge Valve Open (400XSV-0425)
No System Power
Burner Emergency Steam Purge

Valve Open (400-XSV-0425)
No System Power
Emergency Steam Supply Valve

Open (400-XSV-0426)
Air heater refractory temperature (400-TIS0469) >500C
Emergency Steam Supply Valve

Closed (400-XSV-0426)
Air heater refractory temperature (400-TIS0469) <450C
FFE Minerals USA

Revision 2
3 BURNER MANAGEMENT SYSTEM

The Burner Management System (BMS) is comprised of a PLC control system positioned local to the burner
system.

The Burner Management System is a local PLC controller utilized to ensure safety protocols are followed
during the pilot and main burner ignition processes. Operation of the main burner cannot be performed by
the PCS until a signal is received from the BMS indicating that combustion related components satisfy
various limit requirements and a successful purge cycle has been completed. Once main burner ignition and
flame is proved by the BMS, this system continues to monitor the presence of the main burner flame. If
flame status should change at anytime, the BMS will stop the flow of fuel to the burner and alarm the PCS.
Communication between the BMS and PCS is performed over a serial bus. A permissive signal for starting
along with error messaging is handled across this bus.
3.1.1 BMS FUNCTION SUMMARY

The following table summarizes the functions of the BMS, its interaction with the PCS, and operator input
requirements:
OPERATOR INTERFACE
SYSTEM OPERATION
Notes:
The burner management system is designed to be operated from either the local panel or the PCS; however, the PCS must enable local
operation. This procedure assumes that the operator is at the local panel and that the local operation has been enabled. All
pushbuttons referred to n this document have parallel commands fro the PCS. See PCS documentation for information on enabling
local control from the PCS.
NORMAL BURNER STARTUP
1.0
Make sure the correct atomizer has been

installed in the burner. Generally
speaking, the low flow atomizer will be
used for a cold start while the full
capacity atomizer will be used for hot
starts.
1.0
2.0
Press the power on pushbutton.
2.0
This will provide power to the panel. The BMS will

indicate Power On.
FFE Minerals USA

Revision 2
OPERATOR INTERFACE
3.0
Start the following fans:
SYSTEM OPERATION
3.0
ID Fan
Combustion Air Fan
Dilution Air Fan
Mill Fan
Other fans as may be required
by the process
The fan limits for each fan will be satisfied and the
BMS will indicate:
ID Fan On
CA Fan On
DA Fan On
Mill Fan On
4.0
Open the manual inlet isolation valve on

the instrument air.
4.0
The Instrument Air Low Pressure Switch should

now be made.
5.0
Make sure that the following Common

Limits (See Appendix II) are made:
5.0
All Common Limits (See Appendix II) should

now be made.
6.0
Pilot Limits (See Appendix II) should now be made

and the BMS will indicate Pilot Limits OK.
7.0
When the oil pump is on the BMS will indicate Oil

Pump On. When the oil and steam pressures and
oil temperature have reached operating levels, Oil
Limits (See Appendix II) should be satisfied and
the BMS will indicate Oil Limits Ok (See
Appendix II).
Process Interlocks (from PCS)

Process temperature not high
Flame Signal Processor is not in fault
6.0
Open the following Pilot Gas Valves

Pilot gas inlet manual isolation valve
Pilot gas outlet manual isolation
valve
Note: The limiting orifice valve in the pilot line
is set at commissioning and should not require
further adjustment. Deviation from the
optimum setup, either more open or closed, may
cause pilot instability unreliable burner lightoff.
7.0
If Oil Firing is to be the selected firing

mode (see Step 8), the following pumps,
heaters, & valves should be turned on or
opened:
Required oil supply pumps
Required oil heaters
(Note: Refer to Pump & Heater Set
instructions for information on
operating the pumps & heaters).
Oil inlet manual isolation valve
Oil outlet manual isolation valve
Steam inlet manual isolation
Steam outlet manual isolation valve
Condensate manual valves
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FFE Minerals USA

Revision 2
OPERATOR INTERFACE
SYSTEM OPERATION
Firing Mode Selection

8.0
The operator should insure that the

appropriate limits are satisfied. Once the
limits are proven, he should select the
firing mode he wants to operate with
prior to starting the ignition sequence.
There are two choices for Firing Mode
Selection. They are:
8.0
The BMS will not allow a mode selection if both

Common Limits and Pilot Limits are not
satisfied. The BMS will not allow Oil Firing to be
selected if Oil Limits are not satisfied. If the
operator should attempt to make a Firing Mode
Selection prior to the required limits being satisfied,
the BMS will indicate which limit is preventing
further sequencing. Correct the failed limit and
make the Firing Mode Selection again.
8.1
Pilot Firing The system will light

the pilot and will not proceed to
main fuel firing mode. The pilot will
remain lit until Burner Stop is
pressed, a fault occurs, or an
alternate firing mode is selected.
This is the default selection. Pilot
Firing is selected by pressing the
Pilot Select pushbutton.
8.1
The BMS will indicate Pilot Select when Pilot

Firing is selected.
8.2
Oil Firing Oil Firing is selected

by pressing the Oil Select
pushbutton and can be selected at
any point in the sequence. However,
the system will not sequence to Oil
Firing until the system has first
sequenced to Pilot Firing. With
Oil Firing selected and Flame
On, the burner will proceed from
Pilot Firing to Oil Firing and,
once the main flame is proven, the
pilot will shut off.
8.2
The BMS will indicate Oil Select when Oil

Firing is selected.
9.0
The BMS will not allow a Burner Start selection

until a Firing Mode has been selected. If a Burner
Start is selected prior to selecting a Firing Mode,
the BMS will display Select Firing Mode. Make
the selection and press Burner Start again.
Burner Start (From Burner Stop to Pilot Firing)

9.0
Make sure that a Firing Mode has been

selected then press the Burner Start
pushbutton
This pushbutton will initiate the ignition sequence

and the BMS will sequence through all steps of the
sequence without further operator interface through
the BMS. The steps for ignition are as follows:
FFE Minerals USA

Revision 2
OPERATOR INTERFACE
9.1
SYSTEM OPERATION
9.1
When the Burner Start is pressed, the sequence

enters Pre-Purge and the BMS starts the following
timers (see Appendix III):
Pre-Purge Timer
At the same time the BMS sends a signal to the PCS
requesting the following damper/valve positions:
ID Fan Damper high
CA Fan Damper high
DA Fan Damper high
DA Bleed Damper Open
RM Fan Damper Hi Switch
Mill Bypass Damper high
Main Control Valve low
9.2
9.2
The BMS will evaluate the status of the following

limits (See Appendix II):
Common Limits
Purge Damper Limits
Purge Limits
If the limits are proven within the Pre-Purge timing, the
system will proceed to Purge. If they are not proven within
the Pre-Purge timing, the system will go into Alarm and
the sequence must be restarted beginning at Step 8.
10.0
10.0
While in Purge the BMS will evaluate the

following limits:
Common Limits
Purge Damper Limits
Purge Limits
If any of these limits fails, the Purge Timer will
stop and the system will go to Alarm.
10.1
10.1
When the sequence enters Purge, the BMS will

start the following timers (see Appendix III):
Purge Timer
When the Purge Timer times out, the system will
go to Purge Complete.
28
FFE Minerals USA

Revision 2
OPERATOR INTERFACE
11.0
SYSTEM OPERATION
11.0
When the sequence enters Purge Complete the

BMS will send the PCS a signal requesting the
following damper/valve positions:
ID Fan Damper low
CA Fan Damper low
DA Fan Damper low
Main Oil Control Valve low
Atomizing Steam Blocking Valve Open
11.1
11.1
When the sequence enters Purge Complete, the

BMS will start the following timers (see Appendix
III):
Pre-Ignition Timer
This timer will continue to time out until the limits
below are satisfied.
While in Purge Complete the BMS will evaluate
the following limits (See Appendix II) :
Common Limits
Pilot Valves Closed Limits
Main Valves Closed Limits
Flame Not On
The sequence will stop and go to Alarm if any of
these limits fail during Purge Complete.
The BMS will also evaluate the following limits:
Low Fire Limits
Pilot Limits
Atomizing Steam Limits
When these limits are all satisfied, the BMS will go
to PTFI.
If these limits are not satisfied before the PreIgnition timer times out, the system will go into
Alarm and the purge cycle will have to be repeated.
FFE Minerals USA

Revision 2
OPERATOR INTERFACE
12.0
SYSTEM OPERATION
12.0
While in PTFI, the BMS will evaluate the

following limits (See Appendix II):
Common Limits
Low Fire Limits
Pilot Limits
Main Valve Closed Limits
If any of these limits fails, all ignition and valve
outputs will go off and the system will go to
Alarm.
12.1
12.1
When the sequence enters PTFI, the BMS will

start the following timers (see Appendix III):
Ignition Timer
PTFI Timer
At the same time the BMS will energize the ignition
transformer and both pilot blocking valves. The
Pilot Blocking valves will open. The BMS will deenergize the ignition transformer when the Ignition
Timer times out. When the PTFI Timer times out,
the BMS will look for flame. With flame present,
the system will proceed to Pilot Firing. With no
flame present, the system will de-energize the pilot
blocking valves and go to Alarm.
13.0
13.0
When in Pilot Firing firing mode, the system looks

for the following limits (See Appendix II) to be
satisfied:
Common Limits
Low Fire Limits
Pilot Limits
Main Valves Closed Limits
Pilot Valves Open Limits
Flame On
Alarm.
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FFE Minerals USA

Revision 2
OPERATOR INTERFACE
SYSTEM OPERATION
13.1
13.1
While in Pilot Firing firing mode, the system will

continue to energize the pilot blocking valves and
will continue to monitor for flame. The sequence
will remain in Pilot Firing indefinitely until there is
either a Burner Stop request, limit failure, or an
alternate firing mode is selected.
13.2
13.2
If Oil Firing has been selected, the system will

sequence directly to the selected mode as described
beginning with Steps 14.0.
14.0
With Oil Firing selected and with Flame On, the

system will go to MTFI. While in MTFI, the
system will look for the following limits (See
Appendix II) to be satisfied:
Oil Firing from Pilot Firing

14.0
If Oil Firing has been selected, the

system will automatically proceed from
Pilot Firing to Oil Firing. If Oil
Firing has not already been selected,
make sure the appropriate limits are
satisfied (see Step 8.0) and press the Oil
Select pushbutton.
Common Limits
Low Fire Limits
Pilot Limits
Oil Limits
Pilot Valve Open Limits
Flame On
Alarm.
14.1
14.1
When the system enters MTFI, the BMS will start

the following timers (see Appendix III).
MTFI Timer
At the same time, the Atomizing Steam Blocking
valve will energize. After a short delay (2 seconds),
the Oil Blocking Valve and the Oil Recirculation
Valve will also energize. The Oil and Atomizing
Steam Blocking Valves will open and the Oil
Recirculation Valve will close. The pilot valves will
remain energized and open. If at the end of
MTFI", flame is still present, the system will go to
Low Fire Hold. If flame is not present at the end
of MTFI, all ignition and valve outputs will go off
and the system will go to Alarm.
FFE Minerals USA

Revision 2
OPERATOR INTERFACE
15.0
SYSTEM OPERATION
15.0
While in Low Fire Hold, the system will look for

the following limits to be satisfied (See Appendix II):
Common Limits
Low Fire Limits
Oil Limits
Main Valve Open Limits
Flame On
Atomizing Steam Pressure Not Low
15.1
15.1
When the system enters Low Fire Hold, the BMS

will start the following timers (see Appendix III).
Low Fire Hold Timer
At the same time the pilot valves will de-energize
and the Pilot Blocking Valves will close. The system
will remain in low fire hold to prove flame stability
at the minimum fuel valve setting. If the flame is
present at the end of low fire hold, the system will
go to Oil Operation. If flame is not present at the
end of low fire hold, the system will de-energize all
fuel valves and go to alarm.
16.0
16.0
When in Oil Operation the system will look for

the following limits (See Appendix II):
Common Limits
Oil Limits
Main Valves Open Limits
Pilot Valves Closed Limits
Flame On
Alarm.
Note: If the system is also in Pilot Relight, Pilot Valves
Closed Limits are not required.
16.1
32
16.1
The system will remain in Oil Operation until an

alternate firing mode is selected, a limit failure
occurs, or Burner Stop is pressed.
FFE Minerals USA

Revision 2
OPERATOR INTERFACE
SYSTEM OPERATION
Note: The operator should observe the burner firing and
flame shape to insure that the burning characteristics have not
changed. Defects such as plugged nozzles, worn nozzle ports,
broken burner tile, and wet steam can cause flame instability.
Corrective action should be taken when abnormal conditions
are observed.
17.0
If an alternate firing mode is selected

while in Oil Operation, the system will
first re-light the pilot and then (if or
when a main fuel is selected) proceed to
the alternate fuel.
17.0
17.1
To select Pilot Firing while in Oil

Operation, make sure that the
appropriate manual valves are open (as
described in Steps 4 & 6) and press the
appropriate Fuel Select pushbutton.
17.1
The system will enter Start Pilot Relight.
17.2
17.2
While in Start Pilot Relight the system will remain

in Oil Operation and continue to evaluate and
react to the status of the appropriate limits.
17.3
17.3
When the system enters Start Pilot Relight, the

BMS will also start the following timer (see
Appendix III):
Start Pilot Relight Timer
At the same time, the BMS will send the PCS a
signal requesting the following damper/valve
positions:
ID Fan Damper low
CA Fan Damper low
DA Fan Damper low
Main Control Valve low
FFE Minerals USA

Revision 2
OPERATOR INTERFACE
17.4
SYSTEM OPERATION
17.4
The system will look for the following limits in

addition to the limits required for Oil Operation:
Pilot Limits
Low Fire Limits
If these limits are proven within the Start Pilot
Relight timing (see Appendix III), the system will
proceed to Pilot Relight. If they are not proven
within the Start Pilot Relight timing, the system
will leave Start Pilot Relight and revert back to
Oil Operation only. A message will display
indicating that Pilot Relight failed.
18.0
18.0
When the system enters Pilot Relight, the BMS

will start the following timers (see Appendix III).
Pilot Relight Timer
Main Valve Off Timer
18.1
18.1
While in Pilot Relight the BMS will evaluate the

status of the following limits (See Appendix II):
Common Limits
Pilot Limits
Oil Limits
Flame On
18.2
18.2
When the system enters Pilot Relight, the Ignition

transformer and the pilot valves are energized as
described in Step 12.1. When the Ignition Timer
times out, the ignition transformer is de-energized.
When the Main Valve Off Timer times out, the oil
and Atomizing Steam valves are de-energized.
When the Pilot Relight Timer times out, the BMS
will look for flame. With flame present, the system
will proceed to Pilot Firing. With no flame
present, the system will de-energize the pilot
blocking valves and go to Alarm.
STEAM PURGE
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OPERATOR INTERFACE
SYSTEM OPERATION
19.0
Steam Purge should be initiated prior

to a shutdown when it is expected that
the air heater will not be re-started for 20
minutes or more. The objective of the
Steam Purge is to prevent the oil from
hardening in the lines and coking in the
burner.
19.0
19.1
Steam Purge can only be initiated if

the sequence is in the Pilot Firing
state. Relight the pilot as described in
Step 17, then press the Steam Purge
pushbutton.
19.1
If the Steam Purge pushbutton is pressed and the

system is not in Pilot Firing, Steam Purge will not
proceed and the BMS will display a message Steam
Purge Cannot Proceed.
When the sequence enters Steam Purge, the BMS
will start the following timers:
Steam Purge Timer
At the same time the BMS will energize the Steam
Purge Blocking Valve and the valve will open. It will
remain open until the Steam Purge Timer times
out.
19.2
19.2
While in Steam Purge the system will remain in

Pilot Firing and continue to evaluate and react to
the status of the appropriate limits.
19.3
19.3
The Steam Purge will go to completion unless the

Burner Stop pushbutton is pressed or one of the
Pilot Firing limits fails.
CHANGING ATOMIZERS
20.0
When the firing rate has increased to a

level high enough to install the full
capacity atomizer, manually return the
firing mode to Pilot Firing as
described starting with Step 17.
20.0
20.1
Once the sequence is in Pilot Firing,

the operator can remove the low
capacity atomizer and install the full
capacity atomizer. (Refer to the burner
manual for atomizer change out
procedures.)
20.1
The BMS will relight the pilot and shutoff the oil.
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Revision 2
OPERATOR INTERFACE
20.2
SYSTEM OPERATION
Once the full capacity atomizer is

installed, return the firing mode to oil
operation as described starting with Step
14.0.
20.2
The BMS will relight the main fuel and shutoff the
pilot.
BURNER STOP
21.0
To stop the burner, press the Burner

Stop pushbutton momentarily.
21.0
The BMS will de-energize all outputs, and the fuel

flow to the burner will stop.
Note: A Steam Purge should be performed if

the burner will be down for any length of time.
ALARMS & FAULTS
22.0
If the system should go into Alarm, all

outputs will de-energize and the fuel
flow to the burner will stop. The BMS
will detect and display the limit that
caused the fault.
22.0
22.1
Correct the cause of the failure. The

alarm is be reset by pushing the Burner
Stop pushbutton momentarily after the
alarm has been corrected.
22.1
22.3
If the Flame Signal Processor goes into

fault, press and hold the Burner Stop
pushbutton for more than 3 seconds
22.3
At the same time, the BMS will send a signal to the

PCS indicating which device caused the failure and
what sequence state the system was in at the time of
failure.
Pressing and holding the Burner Stop pushbutton

for more than 3 seconds will clear all alarms, reset
the Flame Signal Processor, and return the system to
Idle.
EMERGENCY COOLING STEAM

23.0
36
No operator interface required
23.0
The BMS will control two Emergency Cooling

Steam valves. One is connected to the combustion
air at the burner and the second is connected to the
dilution air. In the event of a power failure, the
output to these will both go off and the valves will
fail open allowing cooling steam to enter the
combustion chamber and the dilution air plenum.
The valves will be closed at all other times.
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Revision 2
3.2 DEFINITIONS
DEFINITION OF ACRONYMS
BMS
Burner Management System
CA
Combustion Air
DA
Dilution Air
ID
Induced Draft
MTFI
Main Trial For Ignition
PCS
Process Control System
PTFI
Pilot Trial For Ignition
POC
Proof of Closure
VCS
Valve Closed Switch
VOS
Valve Open Switch
3.3 DEFINITIONS OF LIMITS

AII.1
The following limits must all be proven

satisfied to complete E-Stop Limits OK.
AII.1
AII.1
E-Stop #1 is closed
E-Stop #2 is closed
E-Stop #3 is closed
AII.2

satisfied to complete ID Fan On.
AII.2
AII.2
ID Fan motor starter running contact (400-EM-0321)

ID Fan Low Pressure Switch (400-PS-0301)
AII.3

satisfied to complete Combustion Air
Fan On.
AII.3
AII.2
CA Fan motor starter running contact (400-EM-0461)

CA Low Pressure Switch (400-PSA-0461)
AII.4

satisfied to complete DA Fan On.
AII.4
AII.3
DA Fan motor starter running contact (400-EM-0323)

DA Low Pressure Switch (400-PS-0302)
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Revision 2
AII.5

satisfied to complete Mill Fan On.
AII.5
Mill Fan motor starter run contact (400-EM-0223)

Mill Fan Pressure Switch (400-PS-0202)
AII.6

satisfied to complete Pilot Valves
Closed.
AII.6
Pilot SSOV #1 POC Switch (400-PSA-0402)

Pilot SSOV #2 POC Switch (400-PSA-0403)
AII.7

satisfied to complete Pilot Valve Open
Limits.
AII.7
Pilot SSOV #1 VOS Switch (400-GB-0440)

Pilot SSOV #2 VOS Switch (400-GB-0441)
AII.8

satisfied to complete Main Valves
Closed Limits.
AII.8
Main SSOV #1 POC Switch (400-PSA-0412)

Main Return VOS Switch (400-GB-0444)
AII.9

satisfied to complete Main Valves
Open Limits.
AII.9
Main SSOV #1 VOS Switch (400-GB-0414)

Main Return VCS Switch (400-GB-0444)
Atomizing Steam Blocking Valve Open Switch
(400-GB-0445)
AII.10

satisfied to complete Exhaust Gas Path
Clear Limits.
AII.1
0
ID Fan On
Vent Stack Damper Closed (400-GBS-0472)
Mill Fan On
Mill By-Pass Damper Open Switch (400-GBS-0163A)
AII.11

made to complete Common Limits
AII.11
E-Stop Limits OK
ID Fan On (400-EM-0321)
CA On (400-EM-0461)
DA Fan On (400-EM-0323)
Exhaust Gas Path Clear
Instrument Air Low Pressure OK (400-PSA-0405)
Process Interlocks (from PCS)
Process temperature not high (400-TSIA-0468)
Flame Signal Processor is not in fault (400-XSIA-0469)
PLC not faulted
AII.12
The following limits must all be proven AII.12

made to complete Purge Damper
Limits
AII.13

made to complete Purge Limits
AII.14

made to complete Low Fire Limits
38
AII.13
ID Fan Damper Hi switch (400-GBS-0310A)

CA Fan Damper Hi switch (400-GBS-0460A)
DA Fan Damper Hi switch (400-GBS-0302A)
RM Fan Damper Hi Switch (400-GBS-0200A)
RM Bypass Damper Open Switch (400-GBS-0163A)
Pilot Valve Closed Limits (400-GBS-0440/0441)
Main Valve Closed Limits (400-GBS-0414/0442)
Main Control Valve Low switch (400-GB-0414)
Flame Off (400-XISA-0463/0469)
Atomizing Steam Valve Closed (400-GB-0422C)
CA Fan Damper Low switch (400-GBS-0460C)
DA Fan Damper Low switch (400-GBS-0302C)
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Revision 2
ID Fan Low Switch (400-GBS-0310C)

Main Control Valve Low Switch (400-GB-0414)
AII.15

made to complete Pilot Limits
AII.16
One of the following limits must be

proven made to complete Pump
Limits (See Appendix II)
AII.16
Pump 1 Motor starter running contact or

Pump 2 Motor starter running contact
AII.17

made to complete Oil Limits
AII.17
Pump Limits
Oil Low Pressure Switch (400-PSA-0411)
Oil High Pressure Switch (400-PSA-0412)
Oil Low Temperature Switch (400-TIS-0413)
Oil High Temperature (400-TIS-0413)
Low Steam Pressure Switch (400-PSA-0420)
AII.18

made to complete Atomizing Steam
Limits
AII.18
Atomizing Steam Valve Open (400-GBS-0422)

Atomizing Steam Pressure Not Low (400-PSA-0420)
Pilot Air pressure not low (400-PSA-0405)

Pilot gas pressure not low (400-PSA-0402)
Pilot gas pressure not high (400-PSA-0403)
3.4 TIMER SETTINGS

Timer
Setting
Oil MTFI
15 sec
Ignition Transformer Time
7 sec
Low Fire Hold Time
15 sec
Purge Start
10 min
Purge Time
15 min
MTFI
15 sec
Pre-Ignition Timer
10 min
Pre-Purge Time
10 min
PRIT
10 sec
PTFI Time
10 sec
Purge Time
15 min
Start Pilot Relight
10 min
Steam Purge Timer
30 sec
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4 ROLLER MILL GROUP

The Roller Mill Group consists of the Roller Mill (400-ML-010), variable-speed Mill Drive (400-EM-0009),
Classifier (400-CI-015), variable speed Classifier Drive (400-EM-0010), Mill Cyclone (400-CY-020) and ESP
Cyclone (400-CY-025). These components are referenced on the following C&ID drawings:
8.500742 SHT. 4 (400-01)
8.500742 SHT. 6 (400-03)

The Roller Mill Group receives wet CRS from Section 200 and generates a dry, partially-calcined ground
material for processing in the Calciner Group. All functions in the Roller Mill Group are controlled by the
PCS.
Primary control and monitoring functions associated with the Roller Mill Group are required for the
following purposes:
1. Ensure adequate gas flow through the mill for proper transport of solids,
2. Particle size control for proper mill product particle size distribution,
3. Protect the mill and classifier from excessive temperature.
It is suggested that oil heaters in the mill grinding roller lubrication subsystems are energized at least one hour
before system startup is planned to ensure fluid temperatures satisfy start interlocks for the Roller Mill
Group. Failure to provide this preheat period may result in a delay of mill startup.
4.1.1 ROLLER MILL PREHEAT

The roller mill must be preheated before CRS processing can begin.
commence until the following have been satisfied:
This preheat operation cannot
1. Calciner Group has successfully entered a System Idle mode of operation to remove the interlock on
the mill fan inlet damper closed position (400-GIS-0261). System Idle mode is confirmed by the
position of the oil control valve 400-TCV-0131.
2. The rollers are in their raised position as indicated by position switches 400-GBS-0007, 400-GBS0009 and 400-GBS-0011 (mill hydraulic system must be activated),
3. The Table Water Spray control valve (400-FCV-0001) closed limit switch is satisfied (400-GBS0001),
4. The Upper Mill Water Spray control valve (400-TCV-0004) closed limit switch is satisfied (400-GBS0002).
The mill preheat process interlock on the mill fan damper is then removed and the operator can manually
position the mill fan inlet damper valve at an opening of 3% to supply gas for the mill preheat after the
mill inlet damper (400-DA-015) is opened. Once a temperature of 77C is detected at 400-TICSA-0004,
the interlock on mill start associated with the preheat requirement is removed. If a temperature >90C is
detected before the start of the CRS feed system, the PCS will force the mill fan inlet damper and mill
inlet damper to a closed position. In the event of a hot mill restart, the temperature at 400-TICSA-0004
may already be >77C and will satisfy the interlock requirement.
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4.1.2 CRS FEED START

The CRS feed is metered into the mill via weigh belt 200-FD-085 through the mill rotary airlock 400-AL-010.
Feed to the mill cannot be started until the following conditions are satisfied:
1. The Calciner Group is operating in a System Idle mode,
2. A minimum calciner collection cyclone off gas temperature of 275C (400-XY-0131) is attained
under the System Idle conditions,
3. There is not a low or low-low CRS level indication in CRS feed bin 200-BN-085,
4. Cyclone discharge valves are started and operating (400-AL-060, 400-AL-065, 400-AL-020 and 400AL-025),
5. The calciner cyclone discharge diverter gate 400-GA-060 is in a closed position (400-GBS-0154B) to
direct the calciner product to the crystallizer circuit (there is a password protected provision to
override this requirement to enable material discharge to the dump tank during system testing),
6. The ESP fields (400-EP-030) are energized,
7. The ESP dust screw (400-SC-040) and discharge valve (400-AL-030) are operating,
8. The roller mill is preheated to an outlet temperature of >77C,
9. There are no interlocks preventing the start of the mill system,
10. The classifier drive 400-EU-0010 is running and classifier rotation is confirmed by speed indicator
400-SI-0010,
Once all conditions are satisfied and a permissive is given by the PCS for a CRS feed start, the operator
provides a CRS Feed Start command. The Roller Mill Group engages in the following automatic sequence:
1. Check the status of 400-EM-0524. Start the mill drive lubrication pump motor if not running.
2. Check the status of the Hydraulic Spring System:
2.1. If activated, continue sequence.
2.2. If not active, prompt the operator to start the Hydraulic Spring System.
Upon activation the rolls will move to their upper position.
3. Prompt operator Mill Precharge Required. Select Yes or No.
4. Operator response to Mill Precharge Required:
4.1. Yes
4.1.1. Start mill rotary airlock 400-AL-010 motor EM0003 if not already operational. Check
for shaft motion at speed sensor 400-SSA-0003:
4.1.1.1. Motion detected within 5 seconds - continue sequence
4.1.1.2. Motion not detected at 5 seconds alarm and stop sequence
4.1.2. Start CRS feed weigh belt 200-FD-085 at a rate of 75 mtph. Run feed belt for
approximately 30 seconds (exact time TBD during commissioning) and then stop.
4.2. No Continue sequence.
5. Start mill rotary airlock 400-AL-010 motor EM0003 if not already running. Check for shaft motion
at speed sensor 400-SSA-0003:
5.1. Motion detected within 5 seconds - continue sequence
5.2. Motion not detected at 5 seconds alarm and stop sequence
6. Automatically activate the upper roller mill spray temperature control loop (400-CTL-05).
7. Open the mill inlet damper 400-DA-015:
7.1. Open limit 400-GBS-0165 satisfied, continue sequence.
7.2. Open limit 400-GBS-0165 not satisfied, stop sequence and alarm.
8. Open the mill fan inlet damper 400-DA-010 to TBD% open to establish minimum mill airflow
requirements. Once the mill cyclone (400-CY-020) differential pressure (400-PDICSA-0200) exceeds
FFE Minerals USA
9.
10.
11.
12.
13.
14.
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Revision 2
50 mm WG the interlock is removed on mill drive 400-EU-0009 and the upper roller mill spray
temperature control loop (400-CTL-05).
Immediately start mill drive 400-EU-0009 and ramp to the set point level at the maximum rate
permitted by the drive (RPM set point can be adjusted by operator):
9.1. Drive at target set point continue sequence
9.2. Drive not at target set point after 30 seconds (may be adjusted during commissioning) alarm,
stop sequence, close mill inlet damper (400-DA-015) and close mill fan inlet damper (400-DA010).
De-energize Solenoid 6S (400-XSV-1103) in mill Hydraulic Spring System 400-HP-010 as soon as the
mill drive is activated to lower the three rolls onto the material bed (this solenoid remains deenergized during normal mill operation). The rate at which the rollers are lowered is adjusted during
commissioning such that the rolls engage the material load on the bed as soon as the mill drive
reaches the set point speed.
10.1. No high roller indication after 10 seconds - continue sequence.
10.2. High roller indication after 10 seconds - alarm, stop sequence, raise mill rollers (see Section
10.1.2), stop mill main drive (400-EU-0009), close mill inlet damper (400-DA-015) and close
mill fan inlet damper (400-DA-010).
After a delay of approximately 30 seconds (exact timing TBD during commissioning), start the CRS
feed weigh belt 200-FD-085 at a rate of 75 mtph.
11.1. Feed weight belt motor running continue sequence
11.2. No motor operation detected alarm, stop sequence, raise mill rollers (see Section 10.1.2), stop
mill main drive (400-EU-0009), close mill inlet damper (400-DA-015) and close mill fan inlet
damper (400-DA-010).
Remove interlock on the Mill Table water spray.
After a delay of 10 seconds (exact delay time TBD during commissioning) following de-energizing of
Solenoid 6S (400-XSV-1103), energize Solenoid 8s (400-XSV-1102) in mill Hydraulic Spring System
400-HP-010 for normal operation. This solenoid remains energized during normal mill operation.
Check circuit hydraulic pressure (400-PISA-1107) this initial adjustment develops a soft grinding
mode of operation to minimize the potential for grinding instability during initial startup:
14.1. If less than 0.8 x accumulator pressure, start hydraulic pump motor 400-EM-1107 in Hydraulic
Spring System 400-HP-010. Stop motor 400-EM-1107 when the target pressure at 400-PISA1107 is obtained.
14.2. If greater than 0.8 x accumulator pressure, de-energize Solenoid 5S (400-XSV-1101) until the
target pressure at 400-PISA-1107 is obtained.
Following a mill operating period of 5 minutes (exact interval TBD during commissioning), adjust
the hydraulic pressure to the operator specified set point.
Following a mill operating period of 20 minutes the roller lube system pump (400-LU-011A, 400-LU-011B
and 400-LU-011C) motors (400-EM-0605, 400-EM-0612, 400-EM-0704, 400-EM-0708, 400-EM-0804, 400EM-0808) are started automatically.
Roller Mill Group operation under Feed Start conditions may continue as long as the following conditions
are satisfied:
1. The pressure differential across cyclone 400-CY-020 as measured by transducer 400-PDISCA-0200 is
greater than 75 mm WG,
2. Mill vibration is below the high-high limit of 15 mm/s as indicated by 400-XISA-0005,
3. The rollers do not reach their low limits indicated by 400-GBSA-0006, 400-GBSA-0008 and 400GBSA-0010,
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4.
5.
6.
7.

Revision 2
Mill motor winding and bearing temperatures are below high-high levels (400-TISA-0020-27),
Mill motor power draw is below the high-high level (400-EISA-I-0009),
Classifier motor power draw is below the high-high level (400-EISA-I-0010),
Classifier bearing temperatures are below high-high levels (400-TISA-0001 and 400-TISA-0002).
If any of these limits are exceeded, the Roller Mill Group is shutdown and the Calciner Group is returned to a
System Idle mode and the operator is prompted with the option for a complete system shutdown.
4.1.3 CRS CAPACITY INCREASES

The CRS feed rate to the Roller Mill Group may be increased manually by the operator once the following
control loops are engaged. These control loops include:
1.
2.
3.
4.
400-CTL-01:
400-CTL-02:
400-CTL-03:
400-CTL-04:
Calciner exit temperature (Calciner Group)

Calciner inlet temperature (Process Air Group)
Mill Flow (Process Air Group)
Calciner pressure (Process Air Group)
The CRS rate may be increased in increments selected by the operator, up to a maximum rate of 106 mtph.
This maximum rate is password protected in the PCS and provides protection against over-feeding the
system. An over-feeding situation will result in low temperature alarm conditions, instability and an eventual
feed stop condition. PCS will prevent increases to the CRS feed rate if a low temperature condition of <90C
is encountered at the mill outlet (400-TICSA-0004).
4.1.4 CLASSIFIER SPEED

The classifier speed set point may be adjusted manually by the operator at any time. An option to password
protect this speed set point should be provided given the importance of particle size control in the process.
4.1.5 MILL FEED ROTARY VALVE

The mill feed Rotary Valve 400-AL-010 is utilized to maintain an airlock on the mill feed inlet duct. This
valve is started automatically when a Start Feed command is issued by the operator unless a local maintenance
switch is thrown. In this case, the PCS shall indicate that a Start Feed sequence is not available. Once a Start
Feed command is accepted, the operation of the rotary valve is proved by the PCS before starting the CRS
feed system (200-FD-085).
1. Check for emergency stop and maintenance interlocks. If not present, display a start permissive on
the PCS screen,
2. The operator manual selects the rotary valve and selects start (Note: the valve will be started
automatically by the PCS if not running at the time that a CRS Start Feed command is given),
3. The PCS sends a start signal to the motor starter for 400-EM-0125,
4. The PCS checks for a valve motion confirmation from 400-SSA-0101. If this is not received in 5
seconds, the motor is de-energized and an alarm is displayed,
a. A loss of motion detection,
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b. Motor fault,
c. Emergency shutdown action,
d. The local maintenance switch is engaged.
4.1.6 NORMAL ROLLER MILL SHUTDOWN

A normal Roller Mill Group shutdown will involve the operator manually reducing the CRS feed rate to the
minimum level of 75 mtph. Once this reduction has been made, the operator selects Roller Mill Shutdown.
The PCS performs the following actions in sequence:
1. Close Upper Mill Water Spray valve (400-TCV-0004) and Mill Table Water Spray valve (400-FCV0001),
2. Deactivate control loop 400-CTL-03.
3. Stop the CRS feed system 200-FD-085 and mill feed rotary valve 400-AL-010,
4. Close the mill fan inlet damper 400-DA-010 and mill inlet damper 400-DA-015,
5. Raise the mill rollers:
a. De-energize Solenoid 8S (400-XSV-1102),
b. Energize Solenoid 6S (400-XSV-1103),
c. Energize Solenoid 4S (400-XSV-1104),
d. Start pump motor 400-EM-1107,
e. Stop motor 400-EM-1107 when roller hit their high limit switches 400-GBS-0007, 400-GBS0009 and 400-GBS-0011,
f. De-energize Solenoid 4S (400-XSV-1104).
6. Stop the main mill drive motor 400-EM-0009.
If the mill is to remain idle for an extended period of time, the following actions should be performed by
the operator:
1.
2.
3.
4.
Stop main drive lube pump motor 400-EM-0524.

Stop the classifier drive motor 400-EM-0010.
Stop the classifier lube pump motor 400-EM-0015.
Stop roller lube system pump (400-LU-011A, 400-LU-011B and 400-LU-011C) motors (400-EM0605, 400-EM-0612, 400-EM-0704, 400-EM-0708, 400-EM-0804, 400-EM-0808).
4.1.7 EMERGENCY ROLLER MILL SHUTDOWN

The Roller Mill Group will be taken offline in the event that one of the following conditions occurs:
1. A burner stop action by the BMS,
2. Any condition that moves the Calciner Group into a Low Firing/System Idle mode of operation or
shutdown (see Section 2.1) including a Feed Stop command from the operator,
3. A high-high mill off gas temperature (400-TICSA-0004),
4. The pressure differential across cyclone 400-CY-020 as measured by transducer 400-PDISCA-0200 is
<50 mm WG for more than 5 seconds,
5. Mill vibration is above the high-high limit of 15 mm/s for >1 second as indicated by 400-XISA0005,
6. Any of the three rollers reach their low limits for >5 seconds as indicated by 400-GBSA-0006, 400GBSA-0008 or 400-GBSA-0010,
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7.
8.
9.
10.

Revision 2
Mill motor winding or bearing temperatures reach high-high levels (400-TISA-0020-27),

Mill motor power draw reaches the high-high level (400-EISA-I-0009),
Classifier motor power draw reaches the high-high level (400-EISA-I-0010),
A classifier bearing temperature reaches a high-high level (400-TISA-0001 or 400-TISA-0002).
When one or more of these conditions occur, the following actions are taken by the PCS:
1. Close Upper Mill Water Spray valve (400-TCV-0004) and Mill Table Water Spray valve (400-FCV0001),
2. De-energize the mill fan motor 400-EM-0223 and close mill fan inlet damper 400-DA-010,
3. Close the mill inlet damper 400-DA-085,
4. Stop the CRS feed system 200-FD-085 and mill feed rotary valve 400-AL-010,
5. Raise the mill rollers:
a. De-energize Solenoid 8S (400-XSV-1102),
b. Energize Solenoid 6S (400-XSV-1103),
c. Energize Solenoid 4S (400-XSV-1104),
d. Start pump motor 400-EM-1107,
e. Stop motor 400-EM-1107when roller hit their high limit switches 400-GBS-0007, 400-GBS0009 and 400-GBS-0011,
f. De-energize Solenoid 4S (400-XSV-1104).
6. Stop the main mill drive motor 400-EM-0009,
7. Stop main drive lube pump motor 400-EM-0524 one minute after stopping the main mill drive
motor 400-EM-0009.
8. Stop the classifier drive motor 400-EM-0010,
9. Stop the classifier drive lube pump motor 400-EM-0015 one minute after stopping the classifier
drive motor 400-EM-0010,
10. Stop roller lube system pump (400-LU-011A, 400-LU-011B and 400-LU-011C) motors (400-EM0605, 400-EM-0612, 400-EM-0704, 400-EM-0708, 400-EM-0804, 400-EM-0808).

The Roller Mill Group consists of the following components and attached instruments and equipment:
Roller Mill Group
Description
PCS Display
Roller Mill
Reference Tag
400-ML-010
Main Drive Motor
400-EM-0009
Main Drive Variable Frequency Drive
400-EU-0009
Main Drive Motor Power Draw
400-EISA-I-0009
Main Drive Motor Winding Temperatures (6)
400-TISA-0022-27
Main drive Motor Bearing Temperatures (2)
400-TISA-0020-21
Mill Louver Differential Pressure
400-PDICA-0035
Roller #1 High Position Switch
400-GBS-0007
400-GBS-0009
400-GBS-0011
FFE Minerals USA

Revision 2
Roller #1 Low Position Switch
400-GBSA-0006
400-GBSA-0008
400-GBSA-0010
Mill Body Vibration Monitor
400-XISA-0005
Mill Differential Pressure
400-PDIA-0001
Mill Feed Rotary Valve Motor
400-EM-0003
Mill Feed Rotary Valve Speed Switch
400-SSA-0003
Mill Off Gas Temperature
400-TICSA-0004
Mill Off Gas Temperature Switch
400-TSA-0005
Dynamic Classifier
400-CI-015
Drive Motor
400-EM-0010
Motor Power Draw
400-EISA-I-0010
Variable Frequency Drive
400-EU-0010
Rotor Speed
400-SI-0010
Classifier Bearing Temperatures (2)
400-TISA-0001-02
Mill Cyclone
400-CY-020
Cyclone Differential Pressure
400-PDICSA-0200
Cone Temperature
400-TI-0203
Cone Pressure
400-PIA-0201
Discharge Rotary Valve
400-AL-020
Discharge Rotary Valve Motor
400-EM-0222
Discharge Rotary Valve Speed Switch
400-SSA-0260
ESP Cyclone
400-CY-025
Cyclone Differential Pressure
400-PDIA-0249
Cone Temperature
400-TI-0243
Cone Pressure
400-PIA-0244
Discharge Rotary Valve
46
400-AL-025
Discharge Rotary Valve Motor
400-EM-0224
Discharge Rotary Valve Speed Switch
400-SSA-0250
Off Gas Temperature
400-TISA-0250
FFE Minerals USA

Revision 2
4.3 CONTROL LOOPS

4.3.1 ROLLER MILL GAS FLOW CONTROL
The roller mill gas flow control loop (400-CTL-03) may be engaged by the operator once a CRS Feed Start
has been performed and stable system operation is observed. The default differential pressure value for this
loop is 104mm WG, but this may be adjusted by the operator (minimum set point of 85 accepted by the PCS)
to control the mill off gas temperature at desired levels as indicated at 400-TICSA-0004. The PCS will not
allow this control loop to be engaged unless a CRS Feed Start condition is detected.
Controller response:
1. If the actual cyclone differential pressure is less than the set point value:
a. Slowly open mill fan damper 400-DA-010 until the set point is satisfied.
2. If the actual differential is greater than the set point value:
a. Slowly close the mill fan damper 400-DA-010 until the set point is satisfied.
This control loop is deactivated only by the PCS when the roller mill is shutdown or by the operator.
4.3.2 MILL OUTLET GAS TEMPERATURE CONTROL

The roller mill outlet gas temperature control loop (400-CTL-05) activated by the PCS during the CRS Feed
Start sequence. This loop adjusts the position of flow control valve 400-TCV-0004 to control the flow rate
of water delivered to the upper mill water spray in order to control the mill off gas temperature measured at
400-TISCA-0004. The default set point for this control loop is 100C, but this value may be increased by the
operator up to a maximum temperature of 110C.
1. If the roller mill off gas temperature 400-TISCA-0004 is less than the set point value:
a. Slowly close water flow control valve 400-TCV-0004 until the set point is satisfied or fully
closed.
2. If the mill off gas temperature 400-TISCA-0004 is greater than the set point value:
a. Slowly open water flow control valve 400-TCV-0004 until the set point is satisfied or fully
open.
This control loop is automatically deactivated only by the PCS when the mill system is stopped.
4.3.3 MILL TABLE SPEED CONTROL

The roller mill table speed control loop (400-CTL-06) may be used by the operators at their discretion. The
function of this loop is to stabilize the material loading in the mill as indicated by the mill louver differential
pressure (400-PDICA-0035) by adjusting the speed of the mill table. As the material loading in the mill
increases, the louver pressure drop increases. This control offers the benefit of reducing the potential of a
low mill loading situation that will allow the rollers to move to a low level position and force a mill shutdown.
Likewise, it also limits the potential for a high mill loading situation that will lead to operating instability, poor
grinding performance and possible mill drive overload. The differential pressure set point is set by the
operator.
1. If the roller mill louver differential pressure 400-PDICA-0035 is greater than the operator set point:
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Revision 2
a. Increase the mill table speed via variable frequency drive 400-EU-0009.
2. If the roller mill louver differential pressure 400-PDICA-0035 is less than the operator set point:
b. Decrease the mill table speed via variable frequency drive 400-EU-0009.
This control loop can be deactivated at the discretion of the operator.
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Revision 2
4.4 ALARMS
Alarm Trigger
Device
Alarm Condition
Low Low
Low
High
400-TICSA-0004
High High
Analog Set Point
Debounce Value
66C
0 sec
77C
0 sec
100C
0 sec
115C
0 sec
High High
400-TSA-0005
115C
0 sec
High
400-XISA-0005
12 mm/s
0 sec
High High
400-XISA-0005
15 mm/s
1 sec
Roller #1 Position
Low
400-GBSA-0006
5 sec
Roller #2 Position
Low
400-GBSA-0008
5 sec
Roller #3 Position
Low
5 sec
Low Low
400-GBSA-0010
400-PDICA-0035
<200mm WG
0 sec
Low
400-PDICA-0035
<400mm WG
0 sec
High
400-PDICA-0035
>700mm WG
0 sec
High High
400-PDICA-0035
>800mm WG
0 sec
Low
400-PDIA-0001
<300mm WG
0 sec
High
400-PDIA-0001
>800mm WG
0 sec
High
400-TISA-0022-27
>120C
0 sec
High High
400-TISA-0022-27
160C
0 sec
High
400-TISA-0020-21
>85C
0 sec
High High
400-TISA-0020-21
90C
0 sec
High
400-EISA-I-0009
>TBD kW
5 sec
High High
400-EISA-I-0009
TBD kW
5 sec
High
400-EISA-I-0010
>TBD kW
5 sec
High High
400-EISA-I-0010
TBD kW
5 sec
High
400-TISA-0001-02
93C
0 sec
High High
400-TISA-0001-02
99C
0 sec
Low
400-SSA-0003
5 sec
High
400-PDICSA-0200
>150mm WG
0 sec
Low
<75mm WG
0 sec
Low Low
400-PDICSA-0200
400-PDICSA-0200
<50mm WG
5 sec
High
400-PIA-0201
>(-700)mm WG
0 sec
Mill Vibration
Mill Louver Pressure

Differential
Mill Differential Pressure

Main Mill Motor Winding
Temperatures
Main Mill Motor Bearing
Temperatures
Main Mill Motor Power
Draw
Classifier Motor Power
Draw
Classifier Rotor Bearing
Temperatures
Mill Feed Rotary
Valve Speed Switch
Mill Cyclone Differential
Pressure
Mill Cyclone Cone
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Revision 2
Pressure
High High
400-PIA-0201
>(-500)mm WG
0 sec
Mill Cyclone Rotary

Valve Speed
Low
400-SSA-0260
5 sec
ESP Cyclone
Differential Pressure
High
400-PDIA-0249
>200mm WG
5 sec
Low
400-TISA-0250
<100C
0 sec
High
400-TISA-0250
>310C
0 sec
High High
400-TISA-0250
325C
2 sec
Low
400-SSA-0250
5 sec
High
400-PIA-0244
>(-75)mm WG
0 sec
High High
400-PIA-0244
>(-25)mm WG
0 sec
ESP Cyclone
Overflow
Temperature
ESP Cyclone Rotary
Valve Speed
ESP Cyclone Cone
Pressure
4.5 INTERLOCKS
Equipment
Signals
Sample:
AND Y to run, X for safety
shutdown
Main Mill Drive (400-EM-0009)
Interlock Type
Safety
Process
No Active Alarms in the Roller Mill Group,

Roller Mill Hydraulic Group or Lubrication
Group
Rollers in High Position (400-GBS0007,0009,0011)
Roller Mill Lubrication Pump 400-EM-0524

Running
Roller Mill Outlet Gas Temperature 400TICSA-0004 >77C
Roller Mill Outlet Gas Temperature 400TICSA-0004 >66C
Mill Cyclone dP 400-PDICSA-0200 >50 mm

WG
50
Start
Motor Power Draw NOT High High (400EISA-I-0009)
Motor Bearing Temps NOT High High

(400-TISA-0020-21)
Motor Winding Temps NOT High High

(400-TISA-0022-27)
FFE Minerals USA
Equipment

Revision 2
Signals
Interlock Type
Safety
No Active Alarm Conditions in the Classifier

and Classifier Lubrication Circuits
Classifier Mill Drive (400-EM0010)
Mill Upper Water Spray Control

Loop
Process
Rotor Bearing Temps NOT High High (400TISA-0001-0002)
No Classifier Lubrication Circuit High High

Temperature Alarms
No Classifier Lubrication Circuit Low Low

Pressure Alarm
No Classifier Lubrication Circuit Low Low

Flow Alarm
Motor Power Draw NOT High High (400EISA-I-0010)
Mill Cyclone dP >50mm WG
Start
5 PROCESS AIR GROUP

The Process Air Group consists of the Combustion Air Fan (400-FN-050), Combustion Air Fan Damper
(400-DA-050), Roller Mill Inlet Damper (400-DA-015), Roller Mill Fan (400-FN-020), Roller Mill Fan
Damper (400-DA-010), ESP ID Fan (400-FN-030), ESP ID Fan Damper (400-DA-030), Dilution Air Fan
(400-FN-035), Dilution Air Fan Damper (400-DA-035), Grid Cooling Air Fan (400-FN-055) and Mill Bypass
Damper (400-DA-020). These components are referenced on the following C&ID drawings:
8.500742 SHT. 5 (400-02)
8.500742 SHT. 6 (400-03)
8.500742 SHT. 7 (400-04)
8.500742 SHT. 8 (400-05)

The Process Air Group controls the flow rate of air into the calciner system, the recirculation of air from the
stack to the calciner inlet, the flow of cooling air to the grid plate, mill air flow, and the calciner exit pressure.
A group start may be performed when all fans are idle or individually by the operator. Starting of a fan is
contingent upon its damper being closed and no related safety interlocks present. All control of the
components in the Process Air Group is performed by the PCS.
5.1.1 FAN GROUP START

A fan group start may be requested by the operator when all fans are off, tempering tee (400-DA-034) is open
for ambient air intake and there are no interlocks present. The following actions are performed by the PCS
when a Fan Group Start command is received:
FFE Minerals USA

Revision 2
1. Close dampers 400-DA-050, 400-DA-010, 400-DA-030, and 400-DA-035. Check closed contacts at
switches 400-GIS-0261, 400-GBS-0130B, 400-GBS-0302B, and 400-GBS-0460B.
2. Move tempering tee 400-DA-034 in its full open position such that switch 400-GIS-0328 is closed.
3. Move mill bypass damper 400-DA-020 to its full open position as indicated by 400-GI-0163.
4. Start ESP ID fan 400-FN-030 motor 400-EM-0321. Wait 60 seconds after contact is proved.
5. Move the ESP ID fan damper 400-DA-030 to 5% open.
6. Start dilution air fan 400-FN-035 motor 400-EM-0323. Wait 60 seconds after contact is proved.
7. Start mill fan 400-FN-020 motor 400-EM-0223. Wait 60 seconds after contact is proved.
8. Start combustion air fan 400-FN-050 motor 400-EM-0461. Wait 60 seconds after contact is proved.
9. Start grid cooling air fan 400-FN-055 motor 400-EM-0124.
5.1.2 INDIVIDUAL FAN START

All fans may be started individually once the tempering tee (400-DA-034) is open for ambient air intake.
Once one or more fans are started, the Fan Group Start option is not available. Once a fan is started, the
operator may manually adjust the position of the fans associated damper until a Start Purge command is
issued by the operator. The PCS will take over full control of all dampers after this command is issued. The
following sequence occurs when an individual fan is started. This example utilizes the ESP ID fan, but the
same sequence pertains to all fan starts except for the grid cooling air fan. This fan has a manual damper that
does not require closure before starting the fan.
1. Select the ESP ID fan (400-FN-030) icon on the display,
2. Select Start from the menu,
3. The PCS checks the position of damper 400-DA-030. If not closed as per a contact in switch 400GBS-0130B, the PCS will actuate the damper and move it to its closed position until the contact is
made,
4. The PCS sends a start command for the motor controller and checks for a contact in motor 400EM-0321 to confirm operation,
5. The PCS waits 60 seconds and then releases control of the damper to the operator.
5.1.3 SYSTEM SHUTDOWN

The following sequence applies to the Process Air Group during a system shutdown situation:
1.
2.
3.
4.
5.
6.
Mill fan 400-FN-020 motor 400-EM-0223 is de-energized,

Mill fan inlet damper 400-DA-010 and mill inlet damper 400-DA-015 are closed,
Combustion air fan damper 400-DA-050 is moved to a position of 20% open,
Dilution air fan damper 400-DA-035 is moved to a position of 20% open,
ESP ID fan damper 400-DA-030 is moved to a position of 20% open,
Tempering tee 400-DA-034 is moved to 100% ambient air intake.
This arrangement supplies required cooling air to the burner and air heater jacket at the minimum allowable
air flow rate.

The Process Air Group consists of the following components and attached instruments and equipment:
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Process Air Group

Description
PCS Display
Combustion Air Fan
Reference Tag
400-FN-050
Fan Motor
400-EM-0461
Fan Motor Winding Temperatures (6)
400-TISA-0482-87
Fan Motor Bearing Temperatures (2)
400-TISA-0480-81
Fan Speed Switch
400-SS-0401
Modulating Damper
400-DA-050
Damper Positioner Motor
400-EM-0460
Damper Position Controller
400-FCV-0460
Damper Position Indication
400-GIS-0460
Damper Purge Position Switch
400-GBS-0460A
Damper Closed Position Switch
400-GBS-0460B
Damper Low Fire Position Switch
400-GBS-0460C
Combustion Air Flow Measurement
400-FFIC-0460
Fan Outlet Pressure Switch
400-PSA-0462
Dilution Air Fan
400-FN-035
Fan Motor
400-EM-0323
Fan Motor Power Draw
400-EIA-I-0323
400-TISA-0335-40
400-TISA-0333-34
Fan Bearing Temperatures (2)
400-TISA-0331-32
Fan Inlet Pressure Switch
400-PS-0302
Fan Speed Switch
400-SS-0302
Modulating Damper
400-DA-035
400-EM-0322
400-GIS-0140
400-TCV-0140
400-GBS-0302A
400-GBS-0302B
400-GBS-0302C
Dilution Air Flow Measurement
400-FIA-0301
Tempering Tee
Motor Actuator
400-DA-034
X
400-HIC-0328
FFE Minerals USA

Revision 2
Motor
400-EM-0328
Position Indication
400-GIS-0328
Position Switches O/C
400-GBS-0328A/B
ESP ID Fan
400-FN-030
Fan Motor
400-EM-0321
400-EIA-I-0321
400-TISA-0316-21
400-TISA-0314-15
Fan Vibration
400-XISA-0312-13
400-TISA-0312-13
Fan Speed Switch
400-SS-0301
400-PS-0301
Modulating Damper
400-DA-030
400-GIS-0130
400-PCV-0130
400-GBS-0130A
400-GBS-0130B
400-GBS-0130C
Roller Mill Fan
400-FN-020
Fan Motor
400-EM-0223
400-EIA-I-0223
400-TISA-0229-34
400-TISA-0227-28
Fan Vibration
400-XISA-0221-22
400-TISA-0225-26
Fan Speed Switch
400-SS-0201
400-PS-0202
Modulating Damper
54
400-DA-010
400-GIS-0261
400-PDCV-0200
400-GBS-0200A
400-GBS-0200B
Damper Differential Pressure
400-PDIA-0262
Mill Bypass Damper
400-DA-020
Bypass Damper Positioner Motor
400-EM-0121
FFE Minerals USA

Revision 2
Mill Bypass Damper Position Controller
400-HIC-0163
Mill Bypass Damper Position Indication
400-GI-0163
Mill Bypass Damper Position Indication
400-GBS-0163A
Mill Bypass Temperature
400-TI-0160
Roller Mill Inlet Damper
400-DA-015

Damper Position Switches O/C
400-EM-0118
X
Grid Cooling Air Fan

Fan Motor
400-FN-055
X
Manual Fan Damper

Fan Inlet Flow Indicator
400-GBS-0165
400-EM-0124
400-DA-055
400-FI-0137
5.3 CONTROL LOOPS

5.3.1 CALCINER EXIT PRESSURE CONTROL
The pressure level at the calciner exit location (400-PICA-0130) is controlled by adjusting the position of the
ESP ID fan inlet damper (400-DA-030). This pressure control loop (400-CTL-04) may be engaged by the
operator once a CRS Feed Start has been performed and has stabilized. The default pressure value for this
loop is -13mm WG, but this may be adjusted by the operator (minimum set point of -5mm WG accepted by
the PCS). The PCS will not allow this control loop to be engaged unless a CRS Feed Start condition is
detected.
1. If the actual calciner exit pressure is less than the set point value:
b. Slowly close the ESP ID fan damper 400-DA-030 until the set point is satisfied.
2. If the actual calciner exit pressure is greater than the set point value:
c. Slowly open the ESP ID fan damper 400-DA-030 until the set point is satisfied.
5.3.2 ROLLER MILL GAS FLOW CONTROL

The roller mill gas flow control loop (400-CTL-03) may be engaged by the operator once a CRS Feed Start
has been performed and stable system operation is observed. The default differential pressure value for this
loop is 104mm WG, but this may be adjusted by the operator (minimum set point of 75 accepted by the PCS)
to control the mill off gas temperature at desired levels as indicated at 400-TICSA-0004. The PCS will not
allow this control loop to be engaged unless a CRS Feed Start condition is detected.
1. If the actual cyclone differential pressure is less than the set point value:
d. Slowly open mill fan damper 400-DA-010 until the set point is satisfied.
2. If the actual differential is greater than the set point value:
e. Slowly close the mill fan damper 400-DA-010 until the set point is satisfied.
FFE Minerals USA

Revision 2
This control loop is deactivated only by the PCS when the roller mill is shutdown or by the operator.
5.4 ALARMS
Alarm Trigger
Device
Analog Set Point
Debounce Value
400-PDIA-0262
500 mm WG
5 sec
High
400-XISA-0221-22
>12 mm/s
0 sec
High High
400-XISA-0221-22
15 mm/s
1 sec
High
400-TISA-0225-26
100C
0 sec
High High
400-TISA-0225-26
110C
0 sec
High
400-TISA-0227-28
85C
0 sec
High High
400-TISA-0227-28
90C
0 sec
High
400-TISA-0229-34
120C
0 sec
High High
400-TISA-0229-34
160C
0 sec
High
400-EIA-I-0223
870 kW
2 sec
High
400-TISA-0480-81
85C
0 sec
High High
400-TISA-0480-81
90C
0 sec
Alarm Condition
Mill Fan Damper Pressure
Differential
Mill Fan Vibration
Mill Fan Bearing
Temperature
Mill Fan Motor Bearing
Temperature
Mill Fan Motor Winding
Temperature
Mill Fan Motor Power
Draw
Combustion Air Fan Motor
Bearing Temperature
High (400-CTL-03
Activated)
Combustion Air Fan Motor

Winding Temperature
High
400-TISA-0482-87
120C
0 sec
High High
400-TISA-0482-87
160C
0 sec
Combustion Air Fan

Pressure Switch
Open Following a Start

Command
400-PSA-0461
5 sec
High
400-XISA-0312-13
>12 mm/s
0 sec
High High
400-XISA-0312-13
15 mm/s
1 sec
High
400-TISA-0312-13
100C
0 sec
High High
400-TISA-0312-13
110C
0 sec
High
400-TISA-0314-15
85C
0 sec
High High
400-TISA-0314-15
90C
0 sec
ESP ID Fan Vibration

ESP ID Fan Bearing
Temperature
ESP ID Fan Motor Bearing
Temperature
ESP ID Fan Motor
Winding Temperature
High
400-TISA-0316-21
120C
0 sec
High High
400-TISA-0316-21
160C
0 sec
ESP ID Fan Power Draw
High
400-EIA-I-0321
825 kW
2 sec
ESP ID Fan Outlet

Pressure
Low
400-PIA-0326
<-100mm WG
5 sec
High
400-PIA-0326
>100mm WG
5 sec
High
400-TISA-0327
140C
2 sec
High High
400-TISA-0327
150C
5 sec
ESP ID Fan Outlet

Temperature
56
FFE Minerals USA
Dilution Air Fan Bearing

Temperature
Dilution Air Fan Motor
Bearing Temperature
Dilution Air Fan Motor
Winding Temperature
Dilution Air Fan Power
Draw

Revision 2
High
400-TISA-0331-32
100C
0 sec
High High
400-TISA-0331-32
110C
0 sec
High
400-TISA-0333-34
85C
0 sec
High High
400-TISA-0333-34
90C
0 sec
High
400-TISA-0335-40
120C
0 sec
High High
400-TISA-0335-40
160C
0 sec
400-EIA-I-0323
350 kW
2 sec
High
5.5 INTERLOCKS
Equipment
Signals
Sample:
(X AND Y AND Z); Z to start, X AND
Y to run, X for safety shutdown
Fan Motor Operation (400-EM0223,0321,0323,0461)
Interlock Type
Safety
Start
X
X
Motor Bearing Temps NOT High

High
Motor Winding Temps NOT High

High
Fan Bearing Temps NOT High High
Fan Vibration NOT High High
Inlet Damper in Closed Position
Tempering Tee (400-DA-034) Open

Switch Contact (400-GIS-0328)
Process Fan Group Start Sequence
Fan Motors (400-EM-0223,

0321,0323,0461) De-energized
Mill Fan Motor Running (400-EM-0223)
Mill Exit Temperature NOT High

High (400-TICSA-0004)
Calciner Operating in a System Idle

Mode
Mill Damper (400-DA-010) Manual
Positioning
Mill Table Water Spray Valve Closed

(400-GBS-0001)
Mill Body Water Spray Valve Closed

(400-GBS-0002)
Mill Outlet Temperature NOT High

(400-TICSA-0004)
Process
FFE Minerals USA

Revision 2
6 ESP GROUP
The ESP Group consists of a 4-compartment Electrostatic Precipitator (400-EP-030), ESP Dust Screw (400SC-040) and ESP Dust Purge Valve (400-AL-030). These components are referenced on the following
C&ID drawings:
8.500742 SHT. 7 (400-04)
8.500742 SHT. 14 (400-11)

The ESP Group removes the fine particulate present in the process gas stream following final solids
collection in the ESP cyclone. The dust is drawn to statically-charged plates located in four compartments
placed in series. This dust cake is periodically removed from the plates by a mechanical rapping system and,
upon release, falls into the lower collection hopper. A horizontal screw collected the material and delivers it
to two potential discharge locations. The first discharge location delivers the dust to a pneumatic conveying
circuit (400-GB-040), which transports the dust to a collection hopper in preparation for calciner injection.
Dust discharged from the second location is transported to a conditioning/wetting circuit.
A carbon monoxide monitor is placed in the calciner plenum. The ESP field power is reduced in the event of
a high CO alarm and shutdown when a high-high level is reached. These precautions are taken to protect the
ESP from damage caused by CO combustion in the unit.
A second monitor is positioned downstream of the ESP in the stack to detect the presence of particulate.
The presence of a high concentration of particulate stops the recirculation of stack gas to the calciner system
to prevent coating problems in the air heater and calciner inlet areas.
The operation of the ESP electrodes, heaters and rappers are controlled within a local PLC called a PIACSDC controller (Precipitator Integrated Automatic Control System for DC Powered Units). The PIACS-DC
requires simple start commands from the PCS to begin normal operation. Adjustments to the operation of
the electrodes and the cleaning circuit are performed locally via the PIACS-DC controller. A description of
these adjustments and the function of the PIACS-DC are described in the ESP operating manual. The
control of the ESP discharge screw and dust purge valve is handled by the PCS.
6.1.1 ESP START

The ESP Dust Screw 400-SC-040 and Dust Purge Rotary Valve 400-AL-030 must be energized before the
ESP fields can be energized. However, once energized, the fields will not be de-energized if a Dust Screw or
Rotary Valve failure occurs.
Approximately 6-12 hours before a CRS feed system start is planned the following start commands are issued
via the PCS:
1. PIACS heating group (hopper heaters are energized).
2. ESP purge air fan (400-GB-030)
Once the calciner system is in idle mode and ESP outlet gas temperature is greater than 100C (interlock
requirement), a start command can be issued to energize the ESP fields. Energizing of the ESP fields is
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Revision 2
performed by the PIACS local PLC upon receiving a single Start command from the PCS. The local
PIACS controller will energize all fields simultaneously at a reduced current and ramp to the target power
settings as per the specified ramp function (required to minimize inrush current). The PIACS will return a
confirmation signal as each field is successfully energized. The field shall be highlighted in the PCS display
once this confirmation is received to give the operator a clear indicator of which fields are active. Once
started, the PIACS controller will adjust field conditions and rapper operation to optimize the overall
performance of the ESP.
Once the PCS receives conformation that all fields are energized, the PCS sends a start command to the
PIACS system to activate the electrode cleaning rappers. The actual rapper operation is then controlled by
the PIACS.
6.1.2 ESP NORMAL SHUTDOWN

The ESP fields may be de-energized by the operator from the PCS when the CRS feeder (200-FD-085) is
NOT running. If any fan in the Process Air Group or Calciner Group is active at the time that an operator
Stop command is received, the operator will be prompted to confirm that field shutdown is desired before
sending a Stop request to the ESP PLC. The plant personnel may consider preventing a shutdown of the
ESP until all fans have been de-energized in order to minimize the potential for significant stack particulate
emissions. The shutdown sequence includes:
1. Send a Stop command to the PIACS system from the PCS to de-energize all fields.
2. Stop the Purge Air Fan (400-GB-030) and Hopper heaters (400-EE-1001/1031/1051/1071/1091) if
the ESP is to be shutdown for more than 24 hours.
3. Maintain operation of the electrode rappers for 2 hours following de-energizing of the fields to
ensure a thorough clean down.
a. If a Stop command is attempted by the operator within 2 hours following field shutdown,
the PCS issues a confirmation request.
6.1.3 ESP EMERGENCY SHUTDOWN

The ESP fields will be de-energized in the following situations:
1. A high high carbon monoxide signal from the CO monitor 400-QISZA-0180,
2. A shutdown request is automatically sent by the PCS in the event of a high high temperature
indication at the outlet of the ESP (400-TISA-0302).
The electrode rappers, hopper heaters, dust screw and dust purge valve will continue to operate until
manually stopped by the operator or the dust slurry system is taken offline.
6.1.4 ESP DUST SCREW

The ESP Dust Screw 400-SC-040 is utilized to convey dust out of the ESP hoppers and deliver the material
to two possible transport routes. This screw can only be started after Dust Purge Rotary Valve 400-AL-030 is
operating and there are no emergency stops active. A permissive for a start of the ESP fields cannot be
issued until this screw is operating.
The following sequence is performed during normal start, run and stop cycles for the screw:
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1. Check for emergency stop or maintenance setting at the PIACS. If not present, display a start
permissive on the PCS screen,
2. Check for operation of Dust Purge Rotary Valve 400-AL-030:
a. If 400-SSA-0330 indicates operation, continue sequence.
b. If 400-SSA-0330 indicates that 400-AL-030 is not active, stop sequence and alarm.
3. The operator manually selects the ESP Dust Screw and selects start,
5. The PCS checks for screw shaft motion confirmation from 400-SSA-0305:
a. If received in <5 seconds, confirm operation and highlight screw icon on PCS display to
denote operation.
b. If not received in 5 seconds, the motor is de-energized and an alarm is displayed.
6. Once a successful start is achieved, the screw is de-energized via:
a. Stop command from the operator,
b. A loss of shaft motion detection at 400-SSA-0305,
c. Motor fault signal from motor starter (400-EM-0306),
d. Emergency shutdown action,
e. Dust Purge Rotary Valve 400-AL-030 is stopped.
6.1.5 ESP DUST PURGE VALVE

The ESP Dust Purge Valve 400-AL-030 is utilized to transfer dust provided by the ESP Dust Screw to the
transport system in the Dust Slurry Circuit (400-BN-040). This valve can only be started after interlocks
associated with the ESP dust slurry circuit are satisfied. In addition, there must no be an emergency stop
action.
1. Check for an emergency stop interlocks. If not present, display a start permissive on the PCS screen,
2. Check interlocks to the dust wetting system:
a. If satisfied, continue sequence.
b. If not satisfied, stop sequence and alarm.
3. The operator manually selects the ESP Dust Purge Valve and selects start,
5. The PCS checks for shaft motion confirmation from 400-SSA-0330:
a. If received in <5 seconds, confirm operation and highlight valve icon on PCS display to
denote operation.
b. If not received in 5 seconds, the motor is de-energized and an alarm is displayed.
a. Stop command from the operator,
b. A loss of shaft motion detection at 400-SSA-0305,
c. Motor fault signal from motor started (400-EM-0306),
d. Emergency shutdown action,
e. Dust wetting circuit interlock status changes.
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6.1.6 ESP HOPPER RAPPERS

The ESP hopper rappers (400-KSV-1001-1008) are started as a group by the operator. A start permissive is
not available until the ESP Screw Conveyor 400-SC-040 is operating as confirmed by speed switch 400-SSA0305. During the start sequence, the operator can adjust the rapper on duration and dwell time. Once the
group is started, the rappers are energized in series subject to the specified duration and dwell time. The
operating cycle continues until a stop command is received from the operator or the ESP Screw Conveyor
stops as indicated by 400-SSA-0305.
6.1.7 ESP OUTLET/STACK GAS OPACITY

The gas opacity monitor is used to continuously monitor the ESP outlet gas stream for the presence of
particulate. When the particulate level exceeds 50 mg/Nm3, the PCS adjusts the position of Tempering Tee
400-DA-034 for 100% ambient air intake. Once this action occurs, a close command is required by the
operator to move the Tempering Tee position for stack gas recirculation.
6.1.8 ESP FIELD LOSS

In the event that one of the ESP fields becomes inactive while the CRS feed system is running, Tempering
Tee 400-DA-034 is immediately opened for 100% ambient air intake. If more than one field becomes
inactive then the CRS feed system is stopped and the calciner is moved into a Hot Idle mode.

The ESP Group consists of the following components and attached instruments and equipment:
ESP Group
Description
PCS Display
Electrostatic Precipitator
Reference Tag
400-EP-030
Automatic Voltage Control (Fields A,B,C,D)
400-HS-1014,30,67,87
TRPC Panels (Fields A,B,C,D)
N/A
Hopper Heaters (5)
400-EE-1001,31,51,71,91
Hopper Heater Temperature Probes (5)
400-TE-1017,46,64,84,89
Hopper Level Probes (4)
400-LSA-1016,45,65,85,90
Hopper Rappers (8)
400-KSV-1001,02,03,04,
05,06,07,08
Purge Fan
400-GB-030
Purge Fan Motor
400-EM-1030
Purge Fan Flow Switch
400-FSA-1099
PIACS-DC PLC
N/A
Inlet Pressure
400-PI-0300
Outlet Temperature
400-TISA-0302
ESP Dust Screw
400-SC-040
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Screw Motion Switch
400-SSA-0305
Screw Motor
400-EM-0306
ESP Dust Purge Rotary Valve
400-AL-030
Rotor Shaft Motion Switch
400-SSA-0330
Valve Motor
400-EM-0330
ESP Dust Gate Valve
400-GA-040
Solenoid Valve
400-KSV-0301
Position Indicating Switches O/C

Opacity Monitor
400-GS-0301
400-QIA-1401
6.3 CONTROL LOOPS

There are no control loops associated with the operation of the ESP in the PCS.
`
6.4 ALARMS
Alarm Trigger
Device
Analog Set Point
Debounce
Value
High
400-QIA-1401
40mg Nm3 equivalent
0 sec
High High
400-QIA-1401
>50mg Nm3
equivalent
0 sec
High
400-TISA-0302
300C
0 sec
High High
400-TISA-0302
315C
0 sec
Screw Shaft Speed
Low
400-SSA-0305
5 sec
Inlet Gas Pressure
Low
400-PIA-0300
-600 mm WG
2 sec
Dust Valve Speed
Low
400-SSA-0329
5 sec
Dust Purge Valve Speed
Low
400-SSA-0330
5 sec
Bin Dust Level
High
400-LSA-1016,
45,65,85
10 sec
ESP PIACS PLC

400-XA1000/1030/1050/1070
Alarm Condition
ESP Outlet Opacity Level
Outlet Gas Temperature
ESP Common Alarm
6.5 INTERLOCKS
Equipment
62
Signals
Interlock Type
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Safety
Sample:
(X AND Y AND Z); Z to start, X AND Y
to run, X for safety shutdown
Process
X
CO Level (400-QISZA-0180) NOT

High
Energize ESP Fields
Start
CO Level (400-QISZA-0180) NOT

High High
Outlet Temperature (400-TISA0302) NOT High High
Outlet Temperature (400-TISA0302) >100C
Purge Air Fan (400-GB-030)

Running
Electrode Rappers On
ESP Dust Screw (400-SC-040)

Motor (400-EM-0306) Running
Manual Shutdown of ESP Fields
CRS Feed Belt 200-FD-085 NOT

Running
ESP Dust Screw (400-SC-040) Motor

(400-EM-0306) Operation
Rotary Valve 400-AL-030 Running
Dust Purge Rotary Valve (400-AL-030)

Motor (400-EM-0330) Operation
Ready Signal from Dust Slurry

System
ESP Rappers
ESP Dust Screw 400-SC-040

Running
7 CLEANING GROUP
The Cleaning Group includes the Air Cannons (400-AC-020/021/025/026/060/061) and Rappers (400-VB020/021/022/023/024/025/026/027/028/029/060/061/062) mounted on the cyclone cones and discharge
ducts for the purpose of maintaining stable solids flow through the system. Several modes of operation are
available for these devices. Components are referenced on the following C&ID drawings:
8.500742 SHT. 5 (400-02)
8.500742 SHT. 6 (400-03)

7.1.1 AIR CANNONS
Air cannons are utilized to clear material deposits from the cyclone cones by injecting a sudden burst of
compressed air. Six air cannons are installed for initial system startup, but provisions must be made to
accommodate the control of 6 additional air cannons should they be required based on commissioning
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evaluations. The cannons remain charged with compressed air at all times unless the manual air supply valves
are closed. The PCS highlights the air cannon icon on the display at the time that the solenoid is being
energized. If set for automatic timed firing, the active cannon icons are highlighted appropriately. The air
cannons may be operated in several different modes as determined by the operator.
This specification does not require the operation of the ESP ID fan to enable air cannon firing. This
interlock should be considered as the operation of the ESP ID fan will place the system under
suction and minimize the potential for nuisance dust emissions when an air cannon is fired.
7.1.1.1 INDIVIDUAL CANNON OPERATION - MANUAL

Each individual air cannon may be selected for firing if an air cannon group operation is not active. This
operation involves:
1. Operator selects the desired air cannon on the PCS display,
a. If no emergency stop active, proceed.
b. If an emergency stop is active, indicate that the air cannon is not available.
2. From the menu, Cannon Fire is selected.
3. The PCS energizes the solenoid for a period of 5 seconds, which allows compressed air
present in the piston retention chamber to exit to atmosphere. When this occurs, the piston
moves to an open position and the compressed air in the tank is discharged into the cyclone.
4. The solenoid is de-energized, which permits the return spring to force the piston into its
closed position, pressurizes the piston retention chamber.
5. Compressed air automatically flows into the air cannon tank through the unrestricted supply
line.
6. The PCS prevents re-firing of the air cannon for 10 seconds to permit ample time for the tank
to recharge. Any other air cannon in the group may be selected immediately and fired.
7.1.1.2 GROUP CANNON OPERATION - MANUAL

A group firing of all or select air cannons may be performed. This operation involves:
1.
Operator selects any air cannon on the PCS display,

b. If emergency stop is active, indicate that the air cannons are not available.
2. From the menu, the Group Cannon box is checked. This is repeated for all air cannons to
select/deselect and generate the target active group.
3. Once selections are made, Group Cannon Fire is selected from the menu that is displayed
when any air cannon icon is selected.
4. The PCS energizes the solenoids for the following air cannons in sequence allowing for a 10
second delay between the actuation of each cannon in the sequence. If an air cannon in the
sequence is not checked, the PCS will skip to the next selected cannon without delay. The
sequence includes:
a. 400-AC-020
b. 400-AC-021
c. 400-AC-025
d. 400-AC-026
e. 400-AC-060
f. 400-AC-061
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5. The manual firing sequence may be repeated after 10 seconds has elapsed from the firing of
the last cannon in the selected sequence.
6. The selected air cannons in the group may be changed after the sequence has been completed.
7.1.1.3 GROUP CANNON OPERATION - TIMED

A group firing of all air cannons may be performed at a specified interval. This operation involves:
1. Operator selects any air cannon on the PCS display,
b. If emergency stop is active, indicate that the air cannons are not available.
2. From the menu, the Group Cannon box is checked. This is repeated for all air cannons to
select/deselect and generate the target active group.
3. The firing interval is specified at any time during this selection process. Once set for one air
cannon, the interval is utilized for all air cannons. The minimum time interval that may be set
by the operator is 5 seconds.
4. Once selections are made, Group Cannon Timed Fire is selected from the menu that is
displayed when any air cannon icon is selected.
5. The PCS energizes the solenoids (5 second duration) for the following air cannons in
sequence allowing for a 10 second delay between the actuation of each cannon in the
sequence. If an air cannon in the sequence is not checked, the PCS will skip to the next
selected cannon without delay. The sequence includes:
a. 400-AC-020
b. 400-AC-021
c. 400-AC-025
d. 400-AC-026
e. 400-AC-060
f. 400-AC-061
6. The PCS will repeat the sequence as soon as last cannon in the sequence has been fired and
the time interval has elapsed.
7. The operator may stop the timed operation at any time. Once stopped, a start command will
start the sequence at the beginning.
Timed automatic firing of the air cannons can only be performed when CRS Feed Belt 200-FD-085 is
operating.
7.1.2 RAPPERS
Rappers are utilized to promote material flow via high amplitude/low frequency vibrations. Thirteen rappers
are installed for initial system startup, but provisions must be made to accommodate the control of 9
additional units should they be required based on commissioning evaluations. The PCS highlights the rapper
icon on the display at the time that the solenoid is being energized. If set for automatic timed firing, the
active devices are highlighted appropriately. The rappers may be operated in several different modes as
determined by the operator:
7.1.2.1 INDIVIDUAL RAPPER OPERATION

Each individual rapper may be selected for operation if a group operation is not active. This operation
involves:
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1.
Operator selects the desired rapper on the PCS display,

b. If emergency stop is active, indicate that the rapper is not available.
2. From the menu specify continuous operation or timed. If timed, specify on and off times.
3. From the menu, Start is selected.
4. The PCS energizes the solenoid at a frequency of 20 cycles/min (operator adjustable within
10-60 cycles/min), which allows rapper to cycle at a rate of 20 cycles/min. If timed operation
is selected, the device will cycle until the on time expires, remain inactive as specified by the
off time, and then repeat the sequence.
The device remains active until a Stop command is received from the operator or an emergency stop action
occurs.
7.1.2.2 GROUP RAPPER OPERATION

The operator may specify a group of rappers and start them as a group. This operation involves:
1.
2.
3.
4.
5.
6.
Operator selects the desired rappers on the PCS display,

a. If no emergency stop or lockout active, proceed.
b. If emergency stop is active, indicate that the rappers are not available.
From each individual menu, specify continuous operation or timed. If timed, specified on and
off times.
Repeat steps 1 and 2 for all devices that are to be a part of the group. Timed settings may be
different for each device. Specify the sequence in which the devices will be activated.
Once the group is formed, select Start Group from any device menu.
The PCS energizes the devices in the order specified. If continuous operation is specified,
then all group devices are started simultaneously and energized as per the specified on time.
The devices remain active until a Stop command is received from the operator or an
emergency stop action occurs.
7.2 EQUIPMENT DESCRIPTION

The Cleaning Group consists of the following components and attached instruments and equipment:
Cleaning Group
Description
Air Cannons on 400-CY-060 Cone
PCS Display
Reference Tag
400-AC-060/061
Solenoid Valves
Vibrators/Rappers on 400-CY-060 Cone
400-XSV-0144/45
X
Solenoid Valves
400-XSV-0141/42/43
X
Solenoid Valves
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400-VB-060/061/062
400-AC-020/021
400-XSV-0204/05
400-VB-020/021/022
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Solenoid Valves
400-XSV-0206/07/08
Vibrators/Rappers on 400-CY-020 Discharge Duct
Solenoid Valves
400-VB-023/024
400-XSV-0271/72
Solenoid Valves
400-AC-025/026
400-XSV-0241/42
Solenoid Valves
400-VB-025/026/027
400-XSV-0245/46/47
Vibrators/Rappers on 400-CY-025 Discharge Duct
Solenoid Valves
400-VB-028/029
400-XSV-0171/72
7.3 CONTROL LOOPS

There are no control loops associated with the operation of the Cleaning Group.
7.4 ALARMS
There are no alarms associated with the operation of the Cleaning Group.
7.5 INTERLOCKS
Equipment
Signals
Sample:
(X AND Y AND Z); Z to start, X AND Y to run,
X for safety shutdown
X
Y
Manual Fire Air Cannons
No Emergency Stop
Auto Timed Firing of Air Cannons
CRS Feed Belt 200-FD-085

Running
Activate Vibrators/Rappers
No Emergency Stop
Interlock Type
Safety
Start
Process
X
X
X
X
8 DUST HANDLING GROUP

The Dust Handling Group includes the ESP Screw Conveyor Airlock (400-AL-040), Dust Gate (400-GA040), Dust Return Blower (400-GB-040), Dust Inlet Tee (400-PN-040), Convey Line, Dust Return Bin (400BN-010), Bin Vent Filter (400-DC-010) and Dust Return Bin Airlock (400-AL-045). The Group transports
dust from ESP 400-EP-030 to the Dust Return Bin 400-BN-010, and then meters the dust into Calciner 400FD-050. Components are referenced on the following C&ID drawings:
8.500742 SHT. 5 (400-02)
8.500742 SHT. 7 (400-04)
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8.1.1 DUST FEED START SEQUENCE
1. The operator selects Dust Return Bin Airlock 400-AL-045 on the PCS display.
2. The PCS provides Start permissive if the system is in a production mode as determined by all
interlocks being satisfied for manual increases to the CRS feed rate.
3. The operator selects Start from the menu. The PCS sends a start command to the motor starter
for 400-EM-0103.
a. If rotor shaft movement is detected by motion sensor 400-SSA-0105 within 5 seconds,
confirm valve operation.
b. If no motion is detected by 400-SSA-0105 within 5 seconds, stop sequence and alarm.
4. The operator adjusts the speed of 400-AL-045 via 400-EU-0103 to obtain the target dust flow rate.
A password protected valve speed limit may be specified in the PCS to prevent overfeeding the
system with dust.
5. When the dust level in Dust Return Bin 400-BN-010 is at a low level as indicated by level switch 400LS-0105, a start command is sent to motor 400-EM-0313 on Dust Return Blower 400-GB-040.
6. Once the PCS confirms a blower start, motor 400-EM-0329 is started on ESP Screw Conveyor
Airlock 400-AL-040:
a. If rotor shaft movement is detected by motion sensor 400-SSA-0329 within 5 seconds,
confirm valve operation.
b. If no motion is detected by 400-SSA-0329 within 5 seconds, stop sequence and alarm,
c. The operator may adjust the speed setting for this valve at any time.
7. Once valve operation is confirmed, the PCS opens Dust Gate 400-GA-040.
8. Once the Dust Bin level reaches a high level as indicated by level switch 400-LS-0104, the PCS
performs the following:
a. Close Dust Gate 400-GA-040,
b. After 10 seconds, stop ESP Screw Conveyor Airlock 400-AL-040 motor 400-EM-0329,
c. Wait 30 seconds and then stop Dust Return Blower 400-GB-040 motor 400-EM-0313,
d. Wait 15 minutes and then stop Dust Return Bin Airlock 400-AL-045 motor 400-EM-0103.
9. Steps 5-8 are repeated by the PCS once the Dust Bin level switch 400-LS-0105 indicates a low dust
level.
10. If the low level switch 400-LSA-0105 remains closed for more than 60 seconds, an alarm is issued by
the PCS.
8.1.2 DUST FEED STOP

1. The operator selects Dust Return Bin Airlock 400-AL-045 on the PCS display and selects Stop
from the menu.
2. If the dust convey circuit is active, dust transport to the dust feed bin 400-BN-010 will continue until
a high level is indicated by 400-LS-0104.
8.1.3 DUST FEED EMERGENCY STOP

1. In the event of an Emergency Stop or interlock action as a result of CRS feed stoppage, the PCS
performs the following sequence:
a. Stop Dust Return Bin Airlock 400-AL-045 motor 400-EM-0103
b. Close Dust Gate 400-GA-040,
c. After 10 seconds, stop ESP Screw Conveyor Airlock 400-AL-040 motor 400-EM-0329,
d. Wait 30 seconds and then stop Dust Return Blower 400-GB-040 motor 400-EM-0313.
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8.1.4 DUST BIN FILTER CLEANING CIRCUIT

The automatic cleaning of the Dust Bin Filter (400-DC-010) is handled by a local control unit that supports
two modes of cleaning: timed cleaning or on demand cleaning. The choice of cleaning mode is made by
manually actuating a toggle switch located on the front of the panel. When timed cleaning is selected,
supplying power to the unit will activate pulse cleaning of the filter as per the frequency specified at the local
panel. When on demand cleaning is selected on the local panel, the pulse circuit is energized when the
filter differential pressure exceeds the local set point value (typically 100mm WG). There is no interface
between the local panel and the PCS.

The Dust Handling Group consists of the following components and attached instruments and equipment:
Dust Handling Group

Description
ESP Screw Conveyor Airlock
PCS Display
Reference Tag
400-AL-040
Motor
400-EM-0329
400-EU-0329
Motion Switch
400-SSA-0329
ESP Dust Gate Valve
400-GA-040
Solenoid Valve
Position Indicating Switches O/C
400-KSV-0301
X
400-GS-0301
400-GB-040
Motor
400-EM-0313
Outlet Pressure Switch
400-PSA-0341
Dust Return Blower
Outlet Pressure Indicator

Outlet Temperature Switch
400-PI-0342
X
Pressure Relief Valve
400-TSA-0343
400-SV-0344
Dust Inlet Tee
400-PN-040
Dust Return Bin
400-BN-010
High Level Switch
400-LS-0104
Low Level Switch
400-LS-0105
Bin Pressure Relief Valve
400-SV-0101
Bin Vent Filter
400-DC-010
Filter Differential Pressure Switch
400-PDIS-0101
Pressure Regulator Bag Cleaning Air
400-PC-0103
Pressure Indicator Cleaning Air
400-PI-0102
Pulse Timer
400-KIS-0101
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Cleaning Air Solenoid (4)
400-KSV-0101
Dust Return Bin Airlock
400-AL-045
Motor
400-EM-0103
400-EU-0103
Motion Switch
400-SSA-0105
Motor Speed Indication
400-SI-0106
8.3 CONTROL LOOPS

There are no control loops associated with the operation of the Dust Handling Group.
8.4 ALARMS
Alarm Condition
Alarm Trigger
Device
Analog Set Point
Debounce Value
ESP Screw Rotary Airlock
No Motion
400-SSA-0329
5 sec
Blower Outlet Pressure
High
400-PSA-0341
0.5 bar
2 sec
Blower Outlet Temperature
High
400-TSA-0343
80C
0 sec
Dust Bin Rotary Airlock
No Motion
400-SSA-0105
5 sec
8.5 INTERLOCKS
Equipment
Signals
Sample:
(X AND Y AND Z); Z to start, X AND Y
to run, X for safety shutdown
Safety
Start
Process
Dust Bin Rotary Valve
CRS Feed Belt 200-FD-085

Running
ESP Screw Rotary Airlock
Blower 400-GB-040 Running
Dust Bin Rotary Valve 400-AL045 Running
Dust Bin 400-BN-010 Level NOT

High (400-LS-0104)
ESP Screw Rotary Airlock 400AL-040 Running
Dust Return Blower
Dust Gate 400-GA-040
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9 WATER SPRAY GROUP

The Water Spray Group includes the Mill Table Water Spray and the Mill Body Water Spray Circuit (400-PP010). The Group provides water for grinding bed stabilization and mill outlet temperature control.
Components are referenced on the following C&ID drawings:
8.500742 SHT. 4 (400-01)
8.500742 SHT. 13 (400-10)

9.1.1 MILL TABLE WATER SPRAY
The mill water spray may be activated at the operators discretion once the CRS Feed System 200-FD-085 is
running for a minimum of 60 seconds. The water flow can be started after this delay when the operator
selects the mill water spray icon and issues a Start command. When this command is received, the PCS
opens flow control valve 400-FCV-0001 to the specified flow rate. This rate can be modified at any time by
the operator. Water flow will continue until stopped manually by the operator or a CRS Feed System stop
(200-FD-085).
The start menu for the mill table water spray includes an option to select Auto Start. If this is checked, the
table water spray flow control valve 400-FCV-0001 will be opened to provide the set point flow rate 60
seconds after the CRS Feed Belt 200-FD-085 is started.
The flow rate measured by 400-FICA-0001 is compared to the set point value. If the actual flow deviates
from the set point flow by more than 25% an alarm is issued by the PCS. This deviation alarm protects
against a failure of control valve 400-FCV-0001 which may flood the mill with water and lead to mechanical
damage.
9.1.2 MILL BODY WATER SPRAY CIRCUIT

The mill body water spray is controlled by loop 400-CTL-05. When this loop is activated and required
interlocks are satisfied, the PCS adjusts the position of flow control valve 400-TCV-0004 to maintain the
target mill off gas temperature at 400-TICSA-0004. There are no provisions to manually adjust the water
spray rate. The PCS automatically starts Pump 400-PP-010 when the control loop is activated.
The flow rate of water indicated by meter 400-FIA-0002 is compared against the flow versus position curve
for flow control valve 400-TCV-0004. If a deviation of greater than 25% is determined, an alarm is issued by
the PCS. This deviation provides an indication of nozzle blockage or control valve failure.

The Water Spray Group consists of the following components and attached instruments and equipment:
Water Spray Group

Description
PCS Display
Mill Table Water Spray

Flow Control Valve
Reference Tag
n/a
400-FCV-0001
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Flow Rate Indicator
400-FICA-0001
FCV Closed Position Switch
400-GBS-0001
Water Shutoff Valve
400-FSV-0040
Mill Body Water Spray
n/a
Water Inlet Screen Differential Pressure Transmitters
400-PDA-0901/02
Water Inlet Screen Differential Pressure Indicator
400-PDI-0901/02
Water Tank
400-PP-010-A
Water Low Level Switch
Pump
400-LSA-0903
400-PP-010
Pump Motor
400-EM-0905
Pump Outlet Pressure Indicator
400-PI-0906
400-SV-0902
Flow Rate Indicator
400-FIA-0002
Flow Control Valve
400-TCV-0004
TCV Closed Position Switch
400-GBS-0002A
TCV Position Indication
400-GIS-0002
Spray Nozzle Inlet Pressure Indicator
400-PI-0002
9.3 CONTROL LOOPS

The Mill Body Water Spray circuit is controlled by 400-CTL-05. This control loop description is provided in
4.3.2.
9.4 ALARMS
Alarm Condition
Alarm Trigger
Device
Analog Set Point
Debounce Value
Screen Differential Pressure
High
400-PDA-0901/02
Factory Set Point
5 sec
Tank Water Level
Low
400-LSA-0903
Factory Set Point
5 sec
Mill Table Water Spray Flow

Deviation
High/Low
400-FICA-0002
+/-25%
5 sec
Mill Upper Body Water Spray Flow

Deviation
High/Low
400-FIA-0002
+/-25%
5 sec
9.5 INTERLOCKS
72
FFE Minerals USA

Revision 2
Equipment
Signals
Sample:
(X AND Y AND Z); Z to start, X AND Y to
run, X for safety shutdown
Mill Table Water Spray Control Valve

Mill Upper Body Water Spray Control Valve
Interlock Type
Safety
Start
Process
CRS Feed Belt Motor 200-EB0806 Running
Mill Cyclone dP >50mm WG
400-CTL-05 Activated
10 ROLLER MILL HYDRAULIC GROUP

The Roller Mill Hydraulic Group consists of components that provide pressurized hydraulic fluid to the roller
cylinders for the purpose of raising/lowering the grinding rollers and maintaining the desired degree of
grinding force. Operation of the hydraulic pump and solenoid actuation is performed by the PCS. An alarm
is issued in the event that the hydraulic pump (400-EM-1107) runs continuously for more than 5 minutes.
A local panel is available to permit local control of basic hydraulic group functions (see the roller mill manual
for more information). The local panel must be set to Auto to enable remote start by the operator prior to a
CRS Feed Start sequence.
Roller Mill Hydraulic Group components are referenced on the following C&ID drawings:
8.500742 SHT. 4 (400-01)
8.500742 SHT. 15 (400-12)
10.1.1 NORMAL START

The Roller Mill Hydraulic Group is started by the operator prior to performing a CRS feed start. If the CRS
feed start command is issued by the operator and the Roller Mill Hydraulic Group is not started, the operator
will be prompted to start this group. A start permissive will only be available if the local hydraulic panel is set
to Auto mode.
10.1.2 RAISE ROLLERS

The rollers are moved to their raised position automatically by the PCS when the Roller Mill Hydraulic Group
is initially started or when the CRS Feed Belt 200-FD-085 is de-energized. This sequence includes:
1. Roller Mill Hydraulic Group start:
a. Start hydraulic pump 400-EM-1107.
b. Solenoids 400-XSV-1104 (4S), 4000-XSV-1101 (5S) and 400-XSV-1103 (6S) are energized.
Solenoid 400-XSV-1102 (8S) is de-energized.
FFE Minerals USA

Revision 2
c.
The pump is stopped by the PCS once the rollers are in their raised positions as indicated by
position switches 400-GBS-0007, 400-GBS-0009 and 400-GBS-0011 and 400-PS-1103
closes.
d. Solenoid 400-XSV-1104 (4S) is de-energized to hold the rollers in the raised position.
e. If a high position indication from any of the three high position switches is lost (400-GBS0007, 400-GBS-0009 and 400-GBS-0011) or switch 400-PS-1103 opens, the hydraulic pump
will be started by the PCS and Solenoid 400-XSV-1104 (4S) energized until high level
indication is obtained and the pressure switch is closed. The PCS will then de-energize 400XSV-1104.
2. The CRS Feed Belt 200-FD-085 is stopped as a result of a normal stop, interlock action or
emergency action:
a. If hydraulic pump motor is not running, a start command is sent to the starter for hydraulic
pump motor 400-EM-1107.
b. Solenoids 400-XSV-1104 (4S), 4000-XSV-1101 (5S) and 400-XSV-1103 (6S) are energized.
Solenoid 400-XSV-1102 (8S) is de-energized.
c. The pump is stopped by the PCS once the rollers are in their raised positions as indicated by
position switches 400-GBS-0007, 400-GBS-0009 and 400-GBS-0011 and closure of pressure
switch 400-PS-1103..
d. Solenoid 400-XSV-1104 (4S) is de-energized to hold the rollers in the raised position.
e. If a high position indication from any of the three high position switches is lost (400-GBS0007, 400-GBS-0009 and 400-GBS-0011), the hydraulic pump will be started by the PCS and
Solenoid 400-XSV-1104 (4S) energized until high level indication is obtained and the
pressure switch closes. The PCS will then de-energize 400-XSV-1104.
This sequence can also be performed manually by the operator by selecting Raise Rollers from the Roller
Mill Start menu. Starting of the main mill drive cannot be performed unless the rollers are in their raised
position.
10.1.3 LOWER ROLLERS

The rollers may be lowered only when the CRS Feed Belt 200-FD-085 is running. This automatic function is
performed as follows:
1. The CRS Feed Belt 200-FD-085 is energized as a result of a Start CRS Feed command.
2. After a period of 10 seconds, Solenoid 400-XSV-1103 (6S) is de-energized to lower the three rolls onto
the material bed (this solenoid remains de-energized during normal mill operation).
3. Pressure switch 400-XSV-1104 closes to confirm that the pressure has been relieved from the lift side of
the hydraulic circuit.
Solenoid 6S will remain de-energized until the rollers are to be raised.
10.1.4 GRINDING PRESSURE CONTROL

The PCS starts and stops the hydraulic pump and energizes/de-energizes solenoids as required to maintain
the target mill grinding pressure. The target grinding pressure is specified by the operator within the
allowable range as determined by the accumulator pre-charge pressure. The allowable range is entered into
the PCS and password protected to prevent operation outside of the acceptable limits. Setting of
accumulator pre-charge pressure and the allowable operating range is specified in the mill operating manual.
The PCS maintains a roll pressure equivalent of 80% of the set point value for the first 10 minutes of mill
74
FFE Minerals USA

Revision 2
operation and then increases the pressure to the set point value. This initial operation at a lower pressure
improves mill stability and reduces the potential for a low roller position fault.
The pressure control sequence performed by the PCS is as follows:
1. Following a delay of 10 seconds after the PCS initiates lowering of the rollers, energize Solenoid 400XSV-1102 (8S). This solenoid remains energized during normal mill operation.
2. Check circuit hydraulic pressure (400-PISA-1107):
2.1. If >1.75 bar below 0.8 x Set Point, start hydraulic pump motor 400-EM-1107. Stop motor 400-EM1107 when the target pressure at 400-PISA-1107 is obtained.
2.2. If >3.5 bar above 0.8 x Set Point, de-energize Solenoid 5S (400-XSV-1101) until the target pressure
at 400-PISA-1107 is obtained and then re-energize.
3. After 10 minutes, adjust the hydraulic pressure (400-PISA-1107) to the set point and maintain:
3.1. If >1.75 bar below the set point, start hydraulic pump motor 400-EM-1107. Stop motor 400-EM1107 when the target pressure at 400-PISA-1107 is obtained.
3.2. If >3.5 bar above the set point, de-energize Solenoid 5S (400-XSV-1101) until the target pressure at
400-PISA-1107 is obtained and then re-energize.

The Roller Mill Hydraulic Group consists of the following components and attached instruments and
equipment:
Roller Mill Hydraulic Group

Description
PCS Display
Hydraulic Reservoir
Reservoir Level Switch
Reference Tag
400-HP-010A
400-LSA-1110
Reservoir Level Site Indicators
400-LI-1111A/B
Hydraulic Pump
400-HP-010B
Hydraulic Pump Motor

Pump Outlet Filter Differential Pressure
400-EM-1107
400-PI-1102
400-PDA-1101
Pump Outlet Filter Pressure Relief Valve
400-SV-1102
Pump Outlet Pressure Relief Valve
400-SV-1103
Return Line Filter Pressure Relief Valve
400-SV-1101
Return Line Filter Differential Pressure
Return Line Filter Differential Pressure Indicator
400-PDA-1100
400-PDI-1100
Lift High Pressure Switch
400-PS-1103
Lift Low Pressure Switch
400-PS-1104
Lift Pressure Indicator
400-PI-1105
Grinding Pressure Indicator
400-PI-1106
Grinding Pressure Transducer
400-PISA-1107
FFE Minerals USA

Revision 2
Solenoid 5S
400-XSV-1101
Solenoid 8S
400-XSV-1102
Solenoid 6S
400-XSV-1103
Solenoid 4S
400-XSV-1104
10.3 CONTROL LOOPS

There are no control loops associated with the operation of the Roller Mill Hydraulic Group.
10.4 ALARMS
Alarm Trigger
Analog Set
point
Debounce Value
Main Hydraulic Pump Tripped
400-EM-1107 Starter
Hydraulic Pump Excessive Continuous Operation
400-EM-1107 Contact
5 min
Supply Filter Clogged
400-PDA-1101
1.7 bar
5 sec
Return Filter Clogged
400-PDA-1100
1.7 bar
5 sec
High
400-PISA-1107
>3.5 bar
Above Set
Point
5 sec
Low
400-PISA-1107
1.7 bar Below

Set Point
5 sec
Low Low
400-PISA-1107
0.9 x Set Point
5 sec
Alarm Condition
Cylinder Pressure
10.5 INTERLOCKS
Equipment
Interlock
Type
Signals
Safety
Sample:
(X AND Y AND
Z); Z to start, X
AND Y to run, X
for safety shutdown
Raise Rollers
Solenoids 400XSV-1104 & 400XSV-1103
76
Start
Process
X
CRS Feed Belt Motor 200-EB-0806 NOT Running
FFE Minerals USA
Equipment

Revision 2
Interlock
Type
Signals
Safety
Start
Process
Lower Rollers
Solenoid 400XSV-1103
CRS Feed Belt Motor 200-EB-0806 Running
Hydraulic Pump
Start (400-HP010B)
CRS Feed Belt Motor

200-EB-0806
NOT
Running (Raise Rollers)
Grinding Pressure Low

(400-PISA-1107)
11 LUBRICATION GROUP
The Lubrication Group consists of the Roller Mill Main Drive Lubrication System (400-LU-010), the Roller
Mill Roller Lubrication System (400-LU-011A, 400-LU-011B, and 400-LU-011C), the Roller Mill Grease
System (400-ML-010A), the Classifier Drive Lubrication System (400-LU-015), and the Classifier Grease
System (400-CI-015A).
Lubrication Group components are referenced on the following C&ID drawings:
8.500742 SHT. 4 (400-01)
8.500742 SHT. 9 (400-06)
8.500742 SHT. 10 (400-07)
8.500742 SHT. 11 (400-08)
8.500742 SHT. 12 (400-09)
11.1.1 ROLLER MILL MAIN DRIVE LUBRICATION SYSTEM

The main drive lubrication system is started either automatically by the PCS when a Start CRS Feed
command is issued by the operator, which precedes the start of the main mill drive motor 400-EM-0009, or
through a manual start command from the operator. Due to a low temperature interlock (400-TISA-0510),
the main mill drive cannot be started until the lubricant temperature is greater than the low temperature
shutoff.
The normal start sequence includes:
1. Start command received from the operator to initiate operation of the Main Drive Lubrication
System or a Start CRS Feed command received from the operator.
2. The circulation pump motor 400-EM-0524 is started and operation confirmed.
3. The PCS checks the fluid temperature in the reservoir (400-TIS-0526). If low, continue lubrication
system operation to warm the lubricant but do not remove the interlock on the mill drive until the
low temperature switch opens.
FFE Minerals USA

Revision 2
11.1.2 ROLLER MILL ROLLER LUBRICATION SYSTEM

The three roller lubrication systems are started automatically by the PCS following a mill operating period of
20 minutes. Roller lube system pump (400-LU-011A, 400-LU-011B and 400-LU-011C) motors (400-EM0605, 400-EM-0612, 400-EM-0704, 400-EM-0708, 400-EM-0804, 400-EM-0808) are started by the PCS and
remain operational until the roller mill main drive (400-EM-0009) is de-energized. Electric heating elements
400-EE-0601/0701/0801 are energized by the PCS if low temperature switches 400-TS-0605/0705/0805 are
closed, and then are de-energized when the high temperature switch closes.
11.1.3 ROLLER MILL GREASE SYSTEM

Roller Mill Grease System (400-ML-010A) pump motor (400-EM-0030) is started automatically by the PCS
when the roller mill main drive (400-EM-0009) is energized. The grease pump remains operational until the
roller mill main drive (400-EM-0009) is de-energized.
11.1.4 CLASSIFIER DRIVE LUBRICATION SYSTEM

Classifier Drive Lubrication System (400-LU-015) is started automatically by the PCS when a classifier drive
motor (400-EM-0010) start command is issued by the operator. The operator may also start the circuit
manually by selecting the classifier icon on the PCS display and then selecting Start Classifier Lubrication
Pump from the menu.
The normal start sequence includes:
1. Start command received from the operator to initiate operation of the Classifier Drive Motor 400EM-0010 or the Classifier Lubrication Pump motor 400-EM-0015.
2. The circulation pump motor 400-EM-0015 is started and operation confirmed.
3. Continue system operation until the classifier drive motor (400-EM-0010) is de-energized. Continue
circulator pump operation for 5 minutes and then stop the circulator pump motor (400-EM-0015).
11.1.5 CLASSIFIER GREASE SYSTEM

Classifier Grease System (400-CI-015A) pump motor (400-EM-0020) is started automatically by the PCS
when the classifier drive motor (400-EM-0010) is energized. The grease pump remains operational until the
classifier drive motor (400-EM-0010) is de-energized.
11.2 CONTROL LOOPS

There are no control loops associated with the operation of the Lubrication Group components.

The Lubrication Group consists of the following components and attached instruments and equipment:
Lubrication Group
Description
PCS Display
Roller Mill Main Drive Lubrication System
400-LU-010
Fluid Reservoir
Reservoir Temperature Switch
78
Reference Tag
n/a
400-TI-0527
FFE Minerals USA

Revision 2
Reservoir Temperature Indicator
400-TI-0528
Reservoir Level Indicator
400-LI-0526
Reservoir Level Switch
400-LSA-0525
Circulation Pump & Motor
400-EM-0524
400-SV-0523
400-PI-0524
Filter Inlet Pressure Indicator
400-PI-0522
Filter Outlet Pressure Indicator
400-PI-0520
Filter Differential Pressure Alarm
400-PDA-0521
Filter Outlet Temperature Indicator
400-TI-0519
Oil Temperature Control Valve
400-TCV-0501
Cooling Water Inlet Temperature
400-TI-0506
Cooling Water Inlet Pressure
400-PI-0506
Cooling Water Outlet Temperature
400-TI-0504
Cooling Water Outlet Pressure
400-PI-0504
Pressure Indicator
400-PI-0503
Drive Inlet Fluid Temperature Element
400-TISA-0507
Drive Inlet Low Pressure Switch
400-PS-0501
Drive Inlet Low Low Pressure Switch
400-PSA-0502
Drive Inlet Pressure Indicator
400-PI-0503
Drive Inlet Pressure Indicator
400-PI-0505
Drive Fluid Temperature Element
400-TISA-0510
Drive Outlet Fluid Temperature Element
400-TISA-0508
Roller Mill Roller Lubrication System (Rollers 1/2/3)
400-LU-011A/011B/011C
Lube Reservoir
n/a
Lube Heating Element
400-EE-0601/0701/0801
Heating Element Temperature Switch
400-TIS-0605/0705/0805
Reservoir Temperature Element
400-TSA-0604/0704/0804
400-LI-0605/0705/0805
Reservoir Low Level Switch
400-LSA-0601/0701/0801
Reservoir High Level Switch
400-LSA-0611/0711/0811
Lube Supply Pump & Motor
400-EM-0605/0704/0804
Lube Return Pump & Motor
400-EM-0612/0708/0808
Supply Pump Outlet Pressure Indicator

Lube Supply Flow Switch
400-PI-0602/0702/0802
X
400-FIA-0602/0702/0802
FFE Minerals USA

Revision 2
Lube Supply Filter Differential Pressure Indicator

Lube Supply Filter Differential Pressure Transmitter
400-PDI-0600/0700/0800
X
Water Supply Filter Differential Pressure Indicator

Water Supply Filter Pressure Alarm
400-PDI-0610
X
Lube Temperature Controller

Lube Return Flow Switch
400-FISA0607/0707/0807
400-PDI-0606/0706/0806
Return Pump Outlet Pressure Indictor
400-PDA-0606/0706/0806
400-PI-0609/0709/0809
Roller Mill Grease System
400-ML-010A
Grease Reservoir
n/a
Grease Pump & Motor
400-EM-0030
Grease Level Sensor
400-LA-0030
Grease Delivery Switching Device
400-GA-0030
Grease Supply Pressure Relief Valve
400-SV-0030
Classifier Drive Lubrication System
400-LU-015
Lube Reservoir
n/a
X
400-LI-0005
Circulating Pump & Motor
400-EM-0015
Pump Outlet Pressure Relief Valve
400-SV-0016
Lube Supply Filters
n/a
Filter Differential Pressure Transmitter
400-PDA-0012
Filter Differential Pressure Indicator
400-PI-0012
Heat Exchanger
400-LU-015-H2
Lube Cooling Temperature Control Switch
400-TS-0014A
Lube Cooling Temperature High Alarm
Lube Temperature Indicator (HT Exch Outlet)
400-TA-0014B
400-TI-0016
Lube Temperature High Temperature Switch
400-TS-0018
Lube Low Low Pressure Switch
400-PSA-0017
Lube Supply Pressure Indicator
400-PI-0018
Lube Supply Temperature Indicator
400-TI-0020
Lube Supply Flow Transmitter

Classifier Grease System
Grease Reservoir
80
400-PA-0601
400-TCV-0603/0703/0803
Lube Return Filter Differential Pressure Indicator

Lube Return Filter Differential Pressure Transmitter
400-PDA-0600/0700/0800
400-FZA-0019
400-CI-015A
n/a
FFE Minerals USA

Revision 2
Grease Pump & Motor
400-EM-0020
Grease Level Sensor
400-LA-0020
Grease Delivery Switching Device
400-GA-0020
Grease Supply Pressure Relief Valve
400-SV-0020
11.4 ALARMS
Alarm Trigger
Device
Alarm Condition
Analog Set Point Debounce Value
Roller Mill Main Drive Lubrication System

Fluid Reservoir Level
Filter Outlet Differential
Pressure
High
400-LSA-0525
>2200 liters
5 sec
Low
400-LSA-0525
<1200 liters
5 sec
High
400-PDA-0521
>2.5 bar
5 sec
Low
Motor Starter
400-TISA-0507
18C
0 sec
High
400-TISA-0507
47C
0 sec
High High
400-TISA-0507
49C
0 sec
Low
400-TISA-0510
18C
0 sec
High
400-TISA-0510
75C
0 sec
High High
400-TISA-0510
85C
0 sec
400-PA-0501
<2.8 bar
5 sec
<2.5 bar
5 sec
High
400-PSA-0502
400-TISA-0508
56C
0 sec
High High
400-TISA-0508
60C
0 sec
Circulation Pump Motor Tripped (400-EM-0524)

Fluid Inlet Temperature
Fluid Temperature
Fluid Inlet Pressure

Fluid Outlet
Temperature
Low
Low Low
Roller Mill Roller Lubrication System (Roller 1/Roller 2/Roller 3)

Low
400-LSA0601/0701/0801
Factory Set Point
5 min
High
400-LSA0611/0711/0811
Factory Set Point
5 min
2.3 lpm
30 sec
1.7 bar
TBD
Fluid Reservoir Level
Return Fluid Flow
Low
Return Line Filter

High
400-FSA0607/0707/0807
400-PDA0606/0706/0806
Supply Line Filter

High
400-PDA0600/0700/0800
1.7 bar
TBD
Supply Fluid Flow
Low
400-FA0602/0702/0802
2.3 lpm
30 sec
FFE Minerals USA
Reservoir Fluid
Temperature

Revision 2
400-TSA0604/0704/0804
27C
30 sec
Supply Pump Motor Tripped (400-EM-0605/0704/0804)
Motor Starter
Return Pump Motor Tripped (400-EM-0612/0708/0808)
Motor Starter
400-PA-0601
TBD
Water Supply Pressure
Low
Low
Roller Mill Grease System

Grease Reservoir Level
Low
400-LA-0030
Factory Set Point
0 sec
Distribution Block
Sequence
Not Complete
400-GA-0030
2 min
Motor Starter
Grease Pump Motor Tripped (400-EM-0030)
82
FFE Minerals USA

Revision 2
Classifier Drive Lubrication System

Fluid Flow Rate
Low
400-FZA-0019
4 lpm
2 sec
Fluid Supply Pressure Switch
Low Low
400-PSA-0017
0.35 bar
2 sec
High High Alarm
400-TA-0014
90C
2 sec
High High Switch
400-TSA-0018
100C
2 sec
Filter Differential Pressure
High
400-PDA-0012
0.35 bar
2 sec
Pump Motor 400-EM-0010

Power Draw
High
400-EISA-I-0010
TBD
TBD
High High
400-EISA-I-0010
TBD
TBD
Fluid Supply Temperature
Classifier Grease System

Grease Reservoir Level
Low
400-LA-0020
0 sec
Distribution Block Sequence
Not Complete
400-GA-0020
2 min
Motor Starter
Grease Pump Motor Tripped (400-EM-0030)
11.5 INTERLOCKS
Equipment
Signals
Sample:
(X AND Y AND Z); Z to start, X AND
Y to run, X for safety shutdown
X
Y
Mill Main Lube Circulating Pump (400EM-0524)
Reservoir Lube Level (400-LSA-0525)

NOT Low
Interlock Type
Safety
Start
X
X
X
Main Mill Drive Running (400-EM0009)
Rollers in Lowered Position (400XSV-1103 de-energized) for 20

Minutes
Roller Lube Return Pump (400-EM0612/0708/0808)
Roller Lube Supply Pump Running

(400-EM-0605)
Classifier Lube Circulating Pump (400EM-0015)
Lube Flow (400-FZA-0019) NOT

Low Low
Roller Lube Supply Pump (400-EM0605/0704/0804)
Process
12 EXTERNAL SYSTEM INTERLOCKS

This section discusses interlocking of external components (outside of the 400 section) with calciner system
components.
FFE Minerals USA

Revision 2
12.1 CRS WEIGH FEED BELT (200-FD-085)

Equipment
Signals
Sample:
AND Y to run, X for safety shutdown
Interlock Type
Safety
Start
Calciner in System Idle Operating Mode
Calciner in CRS Feed Start Mode
Rotary Valve 400-AL-010 Operating
Calciner Collection Cyclone Off Gas

Temperature >275C (400-XY-0131)
CRS Feed Bin (200-BN-085) CRS Level

NOT Low
Roller Mill Drive (400-EM-0009)

Operating
Roller Mill Operating Interlocks Satisfied
CRS Feed Belt Operation at

Minimum Feed Rate (70%)
CRS Feed Belt Manual Rate

Adjustments (Increase/Decrease)
84
Process
X
X
Cyclone Discharge Valves are Operating

(400-AL-060, 400-AL-065, 400-AL-020
and 400-AL-025)
Calciner Cyclone Discharge Diverter Gate

400-GA-060 is in a Closed Position (400GBS-0154B)
ESP Fields Energized
ESP Dust Screw (400-SC-040) and

Discharge Valve (400-AL-030) are
Operating
Transport System Between ESP Rotary

Discharge Valve 400-AL-030 and Bin 400BN-040 is Operating
Mill Bypass Damper 400-DA-020 is 100%

Open
No Active Calciner System Alarms
Calciner Cyclone Exit Temperature

Control Loop (400-CTL-01) Activated
Calciner Inlet Temperature Control Loop

(400-CTL-02) Activated
Mill Flow Control Loop (400-CTL-03)

Activated
Calciner Pressure Control Loop (400CTL-04) Activated
FFE Minerals USA
Equipment

Revision 2
Signals
Interlock Type
Start
Process
Mill Outlet Temperature (400-TICSA0004) NOT Low (If Low, Cannot

Increase)
Mill Outlet Temperature (400-TICSA0004) NOT High (If High, Cannot

Decrease)
Mill Main Motor (400-EISA-I-0009)

Power Draw NOT High (If High, Cannot
Increase)
Classifier Motor (400-EISA-I-0010) Power

Draw NOT High (If High, Cannot
Increase)
No Active Calciner System Alarms

(Applies to Rate Increases Only)
Safety
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
6.11
date
2005-06-30
rev
6.9
Washout procedures roller mill and calciner section
word 10.0
MAGADI PURE ASH PROJECT

FFEM PROJECT NO. 03-51573
ROLLER MILL AND FLASH CALCINER SYSTEM
FFEM DOCU. NO. 5.401354
DOCU. NO. 2076-FF-400-PR-WP-001
DATE: FEB,28,2005
REV. 0
MAGADI WASH DOWN PROCEDURE

General Safety Material within a plugged vessel can remain very hot long
after the air heater is shut down. Extreme care must be exercised when
washing down any vessel with material inside. Hazards include and are not
limited to: steam explosions, hot water discharge, sudden release of
buildup and caustic spent wash water. Wash downs should be done as
infrequently as possible and only by adequately trained personnel
following proper safety procedures.
General Safety It is better to clear blockages with mechanical rappers, air
cannons, and compressed air lances before trying to clear blockages with
water or steam. NOTE: COMPRESSED AIR AND AIR CANNONS CAN
CAUSE LOCAL OVERPRESSURE IN VESSELS. THESE CAN FORCE HOT
FINE DUST FROM INSPECTION PORTS AND DOORS LEADING TO SEVER
BURNS. Automatic air cleaning devises such as air cannons must be
disengaged before opening any access doors or ports. Blow downs should
be done by adequately trained personnel following proper safety
procedures.
Calciner:
1. Stop feed, shutdown and cool system as per the Operating Instructions.
2. Shutdown all fans except the ID fan and prepare system for access as per
the Operating Instructions. Adjust the ID fan inlet damper to obtain 2550mm suction in the calciner plenum.
3. Open one access hatch on the calciner plenum to permit the discharge of
wash water. Exercise caution when opening this hatch as hot material
may have accumulated behind the hatch. Personnel should be positioned
such that the discharge of hot material through the hatch will not result in
personnel injury.
4. Once the hatch is open, clear material away and setup a containment area
to collect wash water discharging through the hatch.
5. Open the uppermost inspection port on the calciner. Perform cleaning as
required, close port and proceed to the next lowest port. Repeat this
procedure until the calciner has been cleaned at all levels above the grid
plate.
6. Open one or more hatches above the grid plate level. Clean the lower
calciner area, feed inlet splash box, and upper grid surface. Close
hatches and secure. This cleaning should be performed without entering
the calciner. If entry is required, follow plant procedures for confined
space entry and ensure that there are no coatings in the calciner that
could break free from the calciner walls and injure personnel.
7. Open the inspection port below the grid plate. Perform a wash down of
the lower plate surface if required and then close the port.
8. Open the remaining hatches on the calciner plenum section while
exercising caution against hot material that may be accumulated on the
back side of the hatch. Wash down the plenum inventory and direct it to
the hatch opening where the containment area has been setup. Use tools
as required to pull sludge and free standing water from the plenum. Once
complete close and secure all hatches.
Calciner Collection Cyclone:
the Operating Instructions. Adjust the ID fan inlet damper to obtain 2550mm suction at the calciner exit.
3. Position the diverter gate to direct cyclone discharge to the dump tank.
4. Activate cycling of the discharge tipping gates.
5. Open an inspection hatch on the cyclone body. Utilize a high intensity
light source to inspect the cyclone interior.
6. If material is observed above the tipping gates and there is no material
flow to the dump tank, close the inspection hatch and activate the cyclone
cone rappers. If this does not initiate material flow, activate the air
cannons. Once it is confirmed that all ports on the calciner system are
closed and no one is working inside the system, fire the air cannons.
7. Once the cone inventory has been discharged and the cone area has
been allowed to cool, proceed with the final wash down.
8. Following completion of the wash down, close and seal all hatches.
Calciner Off Gas Ducting:
1. There are no provisions for wash down of this ducting.
Roller Mill:
the Operating Instructions. Close the mill inlet shutoff damper (if not
already closed) and adjust the ID fan inlet damper to obtain 25-50mm
suction at the mill inlet. Close down the mill bypass damper if required to
generate the necessary mill inlet suction.
3. Ensure that the mill rollers and table are cool before adding water to the
mill as these large castings may crack due to thermal shock.
4. Open the mill body inspection hatch. Wash down the classifier louvers,
mill body and upper inlet louver area as required. Once complete, close
the hatch.
5. Open the mill plenum inspection hatch. Wash down the plenum area and
underside of the louvers as required. Close hatch.
Roller Mill Cyclone:
the Operating Instructions. Adjust the ID fan inlet damper to obtain 2550mm suction at the roller mill exit.
3. Blank off the material discharge duct and remove the blank to the dump
line. Position a collection hopper under the line.
4. Activate the discharge rotary valve.
6. If material is observed above the rotary valve and there is no material flow
to the dump bin, close the inspection hatch and activate the cyclone cone
rappers. If this does not initiate material flow, activate the air cannons.
Once it is confirmed that all ports on the calciner system are closed and
no one is working inside the system, fire the air cannons.
been allowed to cool, proceed with the wash down.
ESP Cyclone:
the Operating Instructions. Adjust the ID fan inlet damper to obtain 2550mm suction at the ESP cyclone inlet.
3. Blank off the material discharge duct and remove the blank to the dump
line. Position a collection hopper under the line.
4. Activate the discharge rotary valve.
6. If material is observed above the rotary valve and there is no material flow
to the dump bin, close the inspection hatch and activate the cyclone cone
rappers. If this does not initiate material flow, activate the air cannons.
Once it is confirmed that all ports on the calciner system are closed and
no one is working inside the system, fire the air cannons.
been allowed to cool, proceed with the wash down.
ESP Plates/Hopper:
the Operating Instructions. Adjust the ID fan inlet damper to obtain 2550mm suction at the ESP inlet.
3. Activate the ESP fines purge rotary valve and ESP screw.
NOTE: The ESP is a source of extremely high electrical voltage capable of
severely injuring or killing personnel. The voltage cannot be seen or detected
in any way without instrumentation. Only properly trained individuals
following all plant and ESP manufactures recommendations for safety shall
clean the ESP.
4. Open an inspection hatch on the ESP body. Utilize a high intensity light
source to inspect the ESP interior.
5. If material is observed above the screw and there is no material flow to the
ESP fines purge circuit, close the inspection hatch and activate the hopper
rappers.
6. Inspect the collection plates. If heavy coatings are observed, close the
unit and activate the plate rappers. Permit several rapping cycles, deenergize and then inspect.
7. Once the hopper inventory has been discharged proceed with the wash
down.
Engineering
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project name
BOM Magadi

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CRYSTALLIZATION
7.1
Process description
7.1.1
Introduction
The crystallization section serves to remove impurities from milled calcined soda ash.
The ground calcine is expected to contain 95.4% sodium carbonate, 3.0% sodium
fluoride, 0.26% sodium chloride, 0.84% sodium sulfate, and 0.5% insoluble material.
The re-crystallization process will include two stages. Both stages are necessary to
achieve the required product purity. In the first stage hot, dry anhydrous soda ash is
slurried with near-saturated sodium carbonate solution to produce sodium carbonate
monohydrate. The anhydrous sodium carbonate dissolves as sodium carbonate
monohydrate crystallizes. The operating conditions provide for the growth of well formed
sodium carbonate monohydrate crystals while the other impurities either dissolve or
remain as very small solid particles. The resulting slurry is then transferred to the first
stage elutriator where the fine impurities are flush out the top while the larger
monohydrate crystals settle and are separated on the first stage centrifuges.
In the second stage process, the sodium carbonate monohydrate crystals from the first
stage are combined with saturated liquor and this slurry is transferred to the anhydrous
reactor, where it is heated above the transition temperature. The monohydrate crystals
dissolve while anhydrous sodium carbonate crystallizes. The anhydrous slurry is then
transferred to the second stage crystallizer where it is cooled below the transition
temperature, causing the anhydrous crystals to dissolve while monohydrate crystals form.
The second stage elutriator separates the fines from the coarse product and the second
stage centrifuges recover the monohydrate product.
Each time the re-crystallization is performed, insoluble impurities are liberated and
separated, resulting in a purer product.
7.1.2
First stage crystallization (PFD 500-01)

The hot calcine will be fed from the flash calciner cyclone via an air lock, calcined feed
chamber 510-CH-010 and calcined feed hydrator 510-CY-012 to the first-stage crystallizer
510-EV-010. The positive air flow with the hot calcined ash feed will prevent steam
condensation and plugging of the feed ductwork after the air lock. First stage vent fan
510-FN-010 will remove water vapor from the crystallizer and provide a means of
crystallizer temperature control. The air and water vapor is exhausted to atmosphere
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through first stage scrubber 510-DC-015 to recover entrained dust and liquor. 510-EV-010
is provided with a wall wash to periodically wash and dissolve any wall accretions.
The scrubber sprayers are fed directly with cold process water. In this way water
condensation in the scrubber is increased which improves the scrubber efficiency for dust
removal.
The scrubber liquor discharge is cooled with process water feed to the hot process water
tank 520-TK-091. In this way heat is removed from the first stage crystallization system:
less water vapor is emitted to atmosphere, and process water feed to the hot process
water tank 520-TK-091 is preheated.
The first-stage crystallizer is circulated by a bottom entry draft tube agitator 510-AG-010.
The agitator induces an internal circulation of slurry up the draft tube and down the
annular region outside the draft tube. The incoming ground calcine is sluiced with slurry in
the hydrator and combined with the bulk circulating slurry in the crystallizer. The calcine
(anhydrous sodium carbonate) dissolves and re-crystallizes as sodium carbonate
monohydrate. Control of supersaturation levels through retention time, recirculation rate,
and crystal slurry density control allows the crystals to grow to the desired average size of
350 microns. The first stage crystallizer will operate at about 97 to 98C and 35% solids
and will provide two hours of retention time. The crystallization chemistry is shown below.
Na2CO3 (calcine) Na2CO3 (aq)
Na2CO3 (aq) + H2O Na2CO3.H2O (monohydrate)
The magma withdrawn from the first-stage crystallizer is pumped to the top of the first
stage elutriator 510-SP-025. Overflow liquor from the first stage settler 510-TK-050 is
pumped to the bottom of the first stage elutriator by first stage settler overflow pumps 510PP-060/1. The coarse crystals descend through the elutriator. A net upward velocity of
about 6 mm/s is required to remove the fine (less than 105 micron) sodium fluoride and
insoluble particles. Some fine (less than 125 micron) sodium carbonate monohydrate will
also be lost. The rejected fines overflow the elutriator to the first stage deaerator 510-DE050. The elutriator will reject approximately 90% of the solid sodium fluoride and 80% of
the insolubles.
The deaerator separates entrained air that would interfere with liquor clarification. Process
water, first-stage elutriated solids, centrate, guar gum and first-stage settler underflow
solids combine and gravity flow to the first stage settler feedwell. Guar is added at a
dosage of 80 g/t solids. The settler underflow at about 20% solids will be pumped by 510PP-050/1 to the paddock slurry tank 900-TK-260. It is predicted that the solids in the
settler underflow will contain about 80% by weight of sodium fluoride, representing
approximately 70% of the quantity entering the process. The first stage settler underflow is
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the main purge of impurities from the first and second stage crystallizer circuit. The high
fluoride slurry will be combined with other waste streams in the fluoride slurry tank. The
slurry will then be pumped back to a separate isolated area on the lake, where the slurry
will be placed in the bottom of the paddock to keep the fluoride containing solids
submerged. Water is lost from the first stage crystallizer by evaporation, monohydrate
formation, discharge of the first settler underflow and discharge of the settler overflow. To
maintain the solution balance it is necessary to replace the lost water with process water.
Some of the required water is added to the deaerator to dissolve fine soda ash that would
otherwise be lost with the settler underflow.
The first stage settler overflows to the first stage settler overflow tank 510-TK-060, where
it will combine with liquor pumped from the second stage filter. The volume of liquor
pumped from the second stage settler to the first stage is controlled by the liquor inventory
in the second stage. Liquor collected in the settler overflow tank is used for density control
in the first stage crystallizer, for flushing in the elutriator and for discharge to the tailings
tank. The sodium sulfate concentration in the crystallizer liquor must be controlled below
about 3% to avoid product contamination. The discharge rate to the tailings tank controls
the sodium sulfate concentration in the first stage crystallizer.
Crystal slurry at 50 to 60% solids density is withdrawn from the bottom of the elutriator
and flows by gravity to the first stage centrifuges 510-CF-035/6. The first stage centrifuges
are an important purification step in the process. The removal of soluble impurities
achieved during centrifuging and washing allows the second stage crystallization to
operate at lower impurity levels than the first stage. The first stage centrifuges will produce
70 t/h of wet crystals at 4% to 5% moisture with an expected analysis of 99.5% sodium
carbonate monohydrate, 0.2% sodium fluoride, and 0.08% insolubles. The crystals will be
collected in the second stage crystallization feed tank 520-TK-005.
Guar is delivered in bags of 50 kg. For the preparation of a guar solution an automated
system is used. Guar is brought into powder storage hopper 510-TK-071, from which it is
dosed on demand by screw feeder 510-SC-070.
Guar solution is prepared by dissolving guar in process water to about 0.3 wt% solution in
guar make-up tank 510-TK-070 with the aid of guar make-up agitator 510-AG-070. The
resulting viscous solution is transferred to the guar storage tank 510-TK-071 by guar
transfer pump 510-PP-070/1. Guar metering pumps 510-MP-070/1 dose the guar solution
to tailings settler deaerator 200-DE-050. Guar metering pumps 510-MP-072/3 dose the
guar solution to first stage settler deaerator 510-DE-050 and guar metering pumps 510MP-074/5 dose the guar solution to second stage settler deaerator 520-DE-050.
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project name
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7.1.3
Second stage crystallization (PFD 500-02)

The first stage crystallizer achieves a major reduction of sodium fluoride and insolubles
but will not reach the targeted 0.02 % purity level for NaF. Two stages of re-crystallization
are required. In the second crystallization stage sodium carbonate monohydrate is cycled
between the anhydrous and monohydrate crystal forms by heating and then cooling. The
theoretical transition temperature from monohydrate to anhydrous sodium carbonate in
the absence of impurities is about 109 C. However, to convert monohydrate to anhydrous
crystals at a reasonable rate, the transition temperature should be taken in practice as
112C. The actual design basis for the second-stage anhydrous reactor of 120C provides
an appropriate operating margin above this transition temperature. In the process the first
stage crystal slurry will be heated to 120C and then cooled by evaporation to 97C. The
heating stage is performed in the second stage anhydrous reactor, while monohydrate
crystallization occurs in the second stage crystallizer.
The anhydrous reactor 520-EV-010 is a forced circulation type crystallizer. The vessel will
operate at about 1.65 to 1.95 bar(a) and will provide two hours of slurry retention time.
The required heating is provided by circulating magma through a steam heated, single
pass, vertical shell and tube heat exchanger 520-HX-010. Anhydrous sodium carbonate
has a steep and inverse solubility. High tube side velocities (>2 m/s) and low shell side
steam pressure (2.2 bar(a)) minimizes tube side fouling. A steam driven thermo
compressor will be employed to economize on steam use. Condensate from the heat
exchanger will flow to the condensate tank 520-TK-045 for return to the boiler.
The crystal slurry in the second stage crystallizer feed tank 520-TK-005 is maintained at
about 50% solids by recycling centrate and filtrate from the downstream equipment. Slurry
from the feed tank is further diluted to 35 wt% with additional filtrate and pumped to the
anhydrous reactor 520-EV-010. The anhydrous reactor heats the incoming monohydrate
slurry above the transition point, generating an anhydrous slurry of about 28% solids. The
product from the anhydrous reactor is transferred to the second stage monohydrate
crystallizer 520-EV-020 that is similar in design to the first stage crystallizer.
The liquid level within the monohydrate crystallizer provides sufficient submergence above
the anhydrous slurry injection point to avoid solution flashing. The evaporation that cools
the monohydrate crystallizer occurs at the liquid vapor interface. A mist eliminator in the
top of 520-EV-020 removes droplets from the evaporated water. A portion of the overhead
vapor flows to the thermo compressor 520-SJ-010, the remainder flows to the condenser
520-HX-020 for water recovery. The condenser will use washery cyclone overflow as the
cooling media. The warm slurry stream (50C) will flow to the tailings tank for disposal to
the lake. Non-condensable gases will be exhausted from the condenser by vacuum pump
520-PP-022/3.
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The magma withdrawn from the second-stage crystallizer is pumped to the top of the
second stage elutriator 520-SP-025. The monohydrate crystal slurry is elutriated with
filtrate from a polishing filter (PFD 500-04). The coarse crystals descend through the
elutriator. A net upward velocity of about 6 mm/s is required to remove the fine (less than
105 micron) sodium fluoride and insoluble particles. Some fine (less than 125 micron)
sodium carbonate monohydrate will also be lost. The rejected fines overflow the elutriator
to the second stage deaerator 520-DE-050. The elutriator will reject approximately 90% of
the solid sodium fluoride and 80% of the insolubles.
Magma at 50 to 60% density is transferred by gravity from elutriator 520-SP-025 to the
second stage centrifuges 520-CF-035/6 (PFD 500-03).
7.1.4
Second stage monohydrate centrifuges (PFD 500-03)

Monohydrate crystals are separated from the brine by centrifuges 520-CF-035/6. These
centrifuges will produce 66 t/h of wet crystals at 4% to 5% moisture with an expected
analysis of 99.96% sodium carbonate monohydrate , <0.03 % sodium fluoride; and
<0.02% insolubles The crystals will be transported to the fluid bed dryer by second stage
belt conveyor 520-CV-040.
Centrate is collected in second stage centrate tank 520-TK-040. The centrate is used to
transport dust from the fluid bed to the second stage feed tank (see section 600). From
centrate tank 520-TK-040 the centrate is pumped by second stage centrate pumps 520PP-040/1 to feed tank 520-TK-005 via the dust system of the 600 section. The surplus of
centrate is returned to centrate tank 520-TK-040..
For flushing lines and washing on the monohydrate centrifuges hot water is pumped by
hot water pump 520-PP-091/2. This water is heated to 90 C in hot process water heater
520-HX-091 by low pressure steam. The pressure in the header is maintained by a
pressure controller in the return line to hot process water buffer 520-TK-091.
7.1.5
Liquor polishing (PFD 500-04)

Deaerator 520-DE-050 separates entrained air that would interfere with liquor clarification.
Guar gum, process water and the second stage elutriated solids combine and gravity flow
to the second stage settler 520-TK-050. Guar is added at a dosage of 5 mg/l. The settler
underflow at an expected 15% solids will be pumped to the fluoride slurry disposal
system. The settler overflow containing an estimated 100 mg/I of suspended solids will
flow to the filter feed tank 520-TK-060.
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Two pre-coat filters 520-FL-060/1 are included in the crystallizer train to achieve maximum
clarity of recycle liquor. The filters each provide 124 m2 of filtration area and reduce the
suspended solids to less than 10 mg/l. The filter elements are vertical leafs consisting of a
stainless steel backing cloth that supports a polypropylene media. The actual filter media
is, however, fine diatomaceous earth. In operation the filter leafs are initially coated with a
thin layer, 3 mm thick, of diatomaceous earth (precoat). Once precoated, the filters are
continuously fed with clarified solution by polishing filter feed pump 520-PP-060/1. A small
flow of diatomaceous earth slurry at 10% solids is metered into the filter to provide a
continuous diatomaceous earth membrane. This addition, termed "filter aid" or "body mix",
maintains filtration rates by preventing the fine suspended solids from blinding the filter
surface. The filters operate until a pre-determined differential pressure is reached,
typically 2.0 bar(a). At that time the filter enters a blowdown and backflush cycle in which
the filter chamber drains and collected solids are sluiced off the leaves. The filter cake
slurry is pumped to the fluoride slurry tank 900-TK-260 for disposal to the lake. The filters
are automated and operate on a batch cycle. The estimated cycle time is 2 to 3 days. This
will be controlled by the clarity of the second stage settler overflow. The diatomaceous
earth consumption will be determined by the clarity of the filter feed solution.
Plate and frame heat exchanger 520-HX-065 will be used to heat the filtered liquor during
start-up. The condensate from this start-up heater will flow to the condensate tank 520
TK-045 (500-02). Condensate from all sources will be pumped from the condensate tank
to the boiler feed water tank.
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7.2
Normal operation
7.2.1
First stage crystallizer (PID 510-01)

The temperature 510-TICA-0001 of first stage crystallizer 510-EV-010 is controlled by the
speed of first stage vent fan 510-FN-010. The speed of the fan increases when the
temperature is above its setpoint. As a consequence more air is sucked into feed
chamber 510-CH-010 and more evaporation of water takes place. The increase in
evaporation rate decreases the operating temperature.
The operating pressure 510-PIA-0001 follows by the physics of the system. It depends on
the operating temperature, the operating capacity, the pressure drop over the hydrator
510-CY-012 and the atmospheric pressure.
The density inside the first stage crystallizer is controlled with the feed rate of liquor from
settler overflow (510-FCV-0001). As a consequence the liquor feed rate to the hydrator
varies with the capacity, because hydrator feed pump 510-PP-010/011 runs at a fixed
speed.
The level inside the first stage crystallizer is controlled with the speed of slurry pump 510PP-020/021.
The wall of the crystallizer above the slurry surface is kept clean with periodic water
spraying. Water is added via an automated timer. In case of insufficient washing, scale
can grow on the wall, which can cause plugging or damage pumps if lumps of scale fall
into the slurry.
Two sets of sight glasses are provided on the crystallizer body. The sight glasses on the
cylindrical wall are used to monitor the level. The proper operating level is between the
two sight glasses, so the bottom one is submerged while the upper one is exposed. The
other two sight glasses are in the top conical section. They are used to view the walls and
the incoming slurry from the hydrator. The wall wash frequency is set based on
observations through these sight glasses.
The dissolved sodium sulfate concentration in the slurry has to be below 3 wt% to prevent
crystallization of berkeite (2Na2SO4.Na2CO3) along with the monohydrate crystals.
Samples have to be taken every 2 hours (check) to analyze the sodium sulfate content. A
too high concentration means more water has to be added to the system, which results in
more blow down from 510-TK-060 (via 510-LCV-0401). This is done by increasing the
water flow rate to the second stage deaerator (520-FIC-0701). If the concentration is
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below 2.5 wt% (check), then the amount of water can be decreased in order to reduce
product loss and water consumption.
Most of the water that comes into the process should be added to the second stage
deaerator. This will maximize the dissolution of impurities from the final product. The
water addition to the first stage deaerator is adjusted to dissolve sodium carbonate
monohydrate solids that come from the first stage elutriator overflow and the first stage
centrifuge.
The first stage scrubber serves to wash out solids from the vapor stream. The scrubber
should typically be operated once through. Process water is added (510-FICQA-0003) at
a typical rate of 20 m3/h. If the process water addition rate needs to be reduced below 20
m3/h, scrubber effluent should be partially recirculated to maintain the flow to the spray
nozzles.
Cold process water is added to the scrubber for the following purposes:
To keep the saturation in the scrubber system below 50%
To dissolve sodium monohydrate crystals in the elutriator overflow, which takes place
in the deaerator 510-DE-050.
As the required amount of the above purposes fits the circulation rate of the scrubber
liquor, cold process water is fed at a fixed rate (510-FICQA-0003), without circulation of
liquor. In this way the scrubber is washed with cold water which is beneficial for dust
removal.
The scrubber effluent liquor is cooled using plate heat exchanger 520-HX-015. Cooling is
provided by process water which is feed to the hot process water tank. The process water
flow rate through the cooler is fixed. During normal operation more process water is
needed for the hot process water tank and is added to 520-TK-091 directly.
7.2.2
First stage elutriator (PID 510-02)

The flow rate of washing liquor from the settler overflow to the elutriator is set with 510FIC-0101. The flow is distributed with manual valves over two inlet connections. The
position of these valves is set during start-up. The flow rate determines the solids
concentration in the bottom outlet, as well as the degree of washing, and the loss of
product in the top outlet.
The level of slurry inside the washing leg is measured with 510-LICSA-0101, which is in
fact a pressure differential measurement. The output signal of this controller is the master
that sets a certain power consumption 510-EICSA-0201/0204 of the first stage centrifuges
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510-CF-035/36. The centrifuge power consumption is proportional to the amount of solids

that are recovered. The slurry outlet valves of elutriator (510-ECV-0201/0204) are opened
to a degree that the power consumption meets the set value.
The wash liquor flows upward through the elutriator, until the overflow rim at the top. It
then flows by gravity to the deaerator. The overflow rim fixes the liquid level in the
elutriator.
7.2.3
First stage centrifuges (PID 510-03)

The centrifuges run at a fixed speed. The power consumption 510-EICSA-0201/0202 is
recorded and sets the supply rate of slurry (see section 7.2.2).
The cake is washed with hot process water at a controlled rate (510-FIC-0201/0202). The
centrifuge is flushed periodically (see section 7.7.14)
7.2.4
First stage settler (PID 510-04)

The first stage settler 510-TK-050 is fed via first stage settler deaerator 510-DE-050. In
this deaerator first process water is introduced. The amount of process water is flow
controlled with a manual setpoint on 520-FIC-0301, based on dissolution of monohydrate.
Next the discharge from the first stage scrubber is fed, followed by the discharge streams
from the sumps. Subsequently the thin slurry streams of elutriator overflow and centrate
are introduced and finally the guar gum and recycle sludge. For a proper distribution the
guar gum is sprayed. All streams to the deaerator are introduced at the inlet section in
order to provide some residence time.
Discharge from sumps is not allowed in case the sumps are contaminated with non
product related materials (like filter aid). See PID 520-08 and 520-09.
The first stage settler is provided with a rake mechanism 510-TM-050. At high torque, the
rake arms are lifted automatically.
The sludge underflow from the tailings settler is pumped by 510-PP-050/051 to paddock
slurry tank 900-TK-260. Part of the underflow is recycled to the deaerator.
The speed of these pumps is manually controlled by 510-HIC-0301/2. Operator
adjustment of the speed is based on the sludge level of the settler, given by 510-LI-0301.
Setpoint for 510-LI-0301 is provided on setting list.
High level (small number of discs can be seen) can mean a lot of sludge inside the settler,
or poor separation (high turbidity). When turbidity is high, several vague discs are seen.
When the level is high, operator has to check the turbidity by sample and analysis.
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The overflow from the tailings settler is collected in the first stage settler overflow tank
510-TK-060.
7.2.5
First stage settler overflow (PID 510-05)

The overflow from the tailings settler is collected in the first stage settler overflow tank
510-TK-060.
Settler overflow liquor is pumped to the calcined feed hydrator 510-CY-012 and to first
stage elutriator 510-SP-025 by first stage settler overflow pump 510-PP-060/1.
Part of the overflow liquor is discharged via 510-LCV-0401 to 900-TK-250 to control the
level in settler overflow tank 510-TK-060.
7.2.6
Guar make-up, transfer and distribution (PID 510-07)

The guar preparation is an automated system. The operator supplies guar to the hopper
510-TK-071 (approx. one 50 kg bag per day).
7.2.7
Second stage crystallization feed (PID 520-06)

First stage centrifuge cake and second stage centrate are discharged into the second
stage crystallization feed tank 520-TK-005. The slurry concentration is approx. 50 wt%.
The total net buffer capacity is approx. 300 ton slurry. Operating temperature is around
97C.
The tank is agitated with second stage crystallization feed tank agitator 520-AG-005.
The slurry density (520-DICA-0002 on P&ID 520-01) of the feed to the anhydrous reactor
is approx. 31 wt%. This density is controlled with the flow of filtrate from 520-PP-065/6.
The second stage crystallizer feed tank serves as buffer tank between first and second
stage. This tank is not under automatic level control. The level and the suspended solids
concentration in this tank will vary depending on the relative production rates of the first
stage and second stage crystallization circuits.
The second stage crystallization feed tank can also provide surge volume for 2 different
situations:
1
First stage is not running or on stand-by, while second stage is in operation
2
Second stage is not running or on stand-by, while first stage is in operation
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rev
The normal slurry level to be operated at should provide a buffer time for unexpected
interruption of production of both first and second stages. If the tank is operated at 70%75%, then a buffer capacity of 1 - 1.5 hours is provided for both cases. In case a stand-by
mode is scheduled for first or second stage, then the tank can be operated at max or min
level, depending on which section will be put on stand-by. A maximum buffer capacity for
failure of the first stage of 2.4 hours is created with a full tank (90%). The maximum buffer
capacity for adding cake from first stage crystallization of about 2.5 hours is created at a
starting level of 55 60%.
7.2.8
Second stage anhydrous reactor (PID520-01)

The slurry feed rate to the anhydrous reactor 520-EV-010 is set with 520-FIC-0001, which
acts on the pump speed of second stage feed pump 520-PP-005/006. The slurry
concentration in feed tank 520-TK-005 is approx. 50 wt%. The slurry is further diluted to
35% with filtrate as controlled with 520-DICA-0002.
The operating temperature inside the anhydrous reactor is 120C. The temperature is
controlled with 520-TICA-0001 that adjusts the steam supply to the anhydrous heater 520HX-010. In order to minimize scaling in the heater 520-HX-010, the following temperature
differences have to be within a narrow range:
1
Temperature Rise - slurry outlet and inlet temperature 520-TDIA-0005 (520-TI0002/0003)
2
Average Delta T - steam side and average of slurry outlet and inlet temperatures
520-TDIA-0006 (520-TIA-0004/0002/0003)
If scale is growing inside the heat exchanger tubes, it adds resistance to heat transfer and
requires an increased temperature difference (delta T) in order to maintain capacity.
Therefore, the average temperature difference (delta T) will be monitored to detect
scaling.
If the average temperature difference for a certain capacity increases, it is possible that
this is caused by scaling, see further in section 7.7.10.
The operating pressure inside is the sum of the saturated vapor pressure of the slurry (1.7
bar(a) at 120C) and the partial pressure of inert gasses (air) that remain from the initial
filling or from accumulating over time. If the operating pressure builds over time, inert
gasses should be slowly purged through the manual vent valve at the top (the vent will
contain primarily steam).
The circulating flow rate of slurry through 520-HX-010 is fixed.
The level inside 520-EV-010 is controlled with the flow rate to the second stage
crystallizer 520-EV-020 (520-LCV-0001A/B)
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.12
date
2005-06-30
rev
Condensate from the anhydrous heater 520-HX-010 is collected in 520-TK-010 and

discharged to the condensate tank 520-TK-045. Vent valves on the shell side of the
heater are partially open in order to prevent accumulation of inert gasses.
7.2.9
Second stage crystallizer (PID 520-02)

The second stage crystallizer 520-EV-020 is kept at boiling conditions at a pressure of
about 0.8 bar(a), which is -0.16 bar(g). The pressure is controlled by regulating the air
inlet (520-PCV-0101) of the vacuum pump system 520-PP-022/023.
The corresponding operating temperature is 97C.
Some of the vapor from the boiling crystallizer flows to the suction side of thermo
compressor 520-SJ-010 and the balance flows to the second stage vent condenser.
The slurry concentration is not directly controlled but is the result of the slurry
concentration being fed to the anhydrous reactor.
The level inside 520-EV-020 is controlled by the speed of slurry pump 520-PP-020/021.
The wall of the crystallizer above the slurry surface and the demister are kept clean with
periodic water spraying. Water is added via an automated timer. In case of insufficient
washing, scale can grow on the wall, which can cause plugging or damage pumps when it
falls into the slurry.
The vapor which is not drawn into the thermo compressor is condensed in the second
stage vent condenser 520-HX-020. The cooling in the condenser is provided by liquor
from the washery and the flow is set via the temperature of the outgoing cooling medium.
The vent from the condenser is connected to the inlet of the vacuum pump. The
condensate from the condenser flows to the condensate tank 520-TK-045 by gravity.
7.2.10
Second stage elutriator (PID520-03)

The flow rate of washing liquor from the filtrate tank (520-TK-065) is set with 520-FIC0201. The flow is distributed with manual valves over two inlet connections. The position
of these valves is set during start-up. The flow rate determines the solids concentration in
the bottom outlet, as well as the degree of washing, and the loss of product in the top
outlet.
The level of slurry inside the washing leg is measured with 520-LICSA-0201, which is in
fact a pressure differential measurement. The output signal of this controller is the master,
that sets a certain power consumption 520-EICSA-0301/0304 of the second stage
centrifuges 520-CF-035/36. The slurry outlet valves of the elutriator (520-ECV-0301/0304)
are opened to a degree that the power consumption meets the set value.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.13
date
2005-06-30
rev
The wash liquor flows upward through the elutriator, until the overflow rim at the top. It
flows by gravity to the deaerator. The overflow rim fixes the liquid level in the elutriator.
7.2.11
Second stage centrifuges (PID 520-04)

The centrifuges run at a fixed speed. The power consumption 520-EICSA-0301/0304 is
recorded and sets the supply rate of slurry (see section 7.2.10).
The cake is washed with hot process water at a controlled rate (520-FIC-0301/0302). The
centrifuge is flushed periodically (see section 7.7.14)
7.2.12
Second stage thermo compressor (PID 520-05)

The pressure of the 15 bar steam supply (520-PICA-0401) is reduced to a fixed value of
14.5 bar(a). This is the drive medium for the thermo compressor. Water vapor from the
second stage crystallizer 520-EV-020 and the condensate tank 520-TK-045 are
connected to the suction side. The superheated outlet of the thermo compressor is
saturated in the desuperheater 520-DS-010.The temperature downstream of the
desuperheater is controlled by the supply of condensate. The flowrate of steam to the
anhydrous reactor heater 520-HX-010 is controlled by setting the recycle flow to the
suction side of the thermo compressor. The pressure is not controlled and is set by the
suction conditions of the steam jet and the compressor efficiency.
7.2.13
Second stage centrate tank (PID 520-07)

The centrate is used to transport dust from the fluid bed to the second stage feed tank
(see section 600). The surplus of centrate is transferred to the feed tank 520-TK-005.
The temperature of the centrate return from the dryer is a few degrees Celsius higher
because of heat of dissolution and the high temperature of the dust. Also the solids
concentration is higher. To prevent overheating and plugging, the dryer fines recycle has
to be shut down when there is no feed of centrate from the centrifuge.
The level in the second stage centrate tank 520-LICSA-0601 is controlled by 520-LCV0601.
7.2.14
Second stage settler (PID 520-08)

Second stage settler 520-TK-050 is fed via second stage settler deaerator 520-DE-050. In
this deaerator first hot process water is introduced. The amount of process water is flow
controlled by 520-FCV-0701 with a manual setpoint (see setting list), based on dissolution
of monohydrate and on the sodium sulfate concentration (see section 7.2.1). Next the
discharge from the vacuum pumps is fed. Subsequently the thin slurry stream of elutriator
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.14
date
2005-06-30
rev
overflow is introduced and finally the guar gum and recycle sludge are added. For a
proper distribution the guar gum is sprayed. All streams to the deaerator are introduced at
the inlet section in order to provide some residence time.
The overflow of the settler is a clear liquid.
High solids concentration in overflow causes high cake growth on the polishing filters and
therefore a shorter operating time. If the overflow liquor is not clear, the following items
should be checked:
Sludge level not too high (520-LI-0701)
Check guar dosing rate
Consider an increase of guar supply and/or underflow recycle
High level (small number of discs can be seen) can mean a high sludge level in the
settler, or poor separation (high turbidity). When turbidity is high, several vague discs are
seen. When the level is high the operator has to check the turbidity by sample and
analysis.
The second stage settler is provided with a rake mechanism 520-TM-050. At high torque,
the rake arms are lifted automatically.
Sludge from the settler is pumped by 520-PP-050/051. The speed of these pumps is
manually controlled by 520-HIC-0701/2. Operator adjustment of the speed is based on the
sludge level of the settler, given by 520-LI-0701. Setpoint for 520-LI-0701 is provided on
the setting list.
The content of the sump 520-SU-095 can be transferred to the first stage settler deaerator
510-DE-050. This is allowed only if the sump contains useable clean liquor or product and
is not contaminated with non-product materials like filter aid, guar, mud etc.
At high level 520-LS-0702 in sump 520-SU-095 sump pump 520-PP-095, is started
automatically and at low level 520-LS-0702 this pump is stopped automatically.
Sump agitator 520-AG-095 is started and stopped by hand locally. The agitator is normally
kept running.
7.2.15
Polishing filter feed (PID 520-09)

The level of filter feed tank 520-LICSA-0802 provides the set point for filter feed flow
controllers 520-FIC-0901/2. In order to let 520-TK-060 act as a buffer and not disturb the
filtration process this is a slow control.
The level in this tank is kept low during normal operation. When the filter regeneration
sequence starts, the level in the tank will increase.
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.15
date
2005-06-30
rev
When regeneration is completed, the tank will be brought back to a low level with
increased flow rate. The capacity of this system is sized for the crystallization unit running
at 100% capacity, one filter being regenerated, and one in operation. It is not possible to
regenerate both filters at the same time, and keeping operating capacity at 100%.
Flow rate over the filter has to be constant in order to reduce damage of filter cake. If flow
is stopped, then the cake may start to fall off.
Therefore, filter feed pumps 520-PP-060/1 are provided with automatic changeover.
The content of the sump 520-SU-100 can be transferred to the first stage settler deaerator
510-DE-050. This is allowed only if the sump contains useable clean liquor or product and
is not contaminated with non-product materials like filter aid, guar, mud etc.
At high level 520-LS-0803 sump pump 520-PP-100 is started and at low level 520-LS0803 this pump is stopped automatically.
7.2.16
Liquor polishing (PID 520-10)

Both filters are operated in parallel. When the cake thickness increases the pressure drop
over the filter will increase. At a differential pressure of 2 bar (520-PDIA-0902/0908) an
alarm is generated and the DCS operator can start the regeneration cycle which is
partially automated.
7.2.17
Polishing filtrate and backflush (PID 520-11)

The level in filtrate tank 520-LICSA-1001 is controlled with the flow to 510-TK-060. In
order to have 520-TK-065 act as a buffer tank this control is slow.
The level in this tank is kept high during normal operation. When the filter regeneration
sequence starts, the level in the tank will decrease.
The capacity of this system is sized for the crystallization unit running at 100% capacity,
one filter being regenerated, and one in operation. It is not possible to regenerate both
filters at the same time whilst operating at 100% capacity.
The filtrate in 520-TK-065 can be diluted with process water. The flow of process water is
controlled by 520-FIC-1001. During normal operation 520-FCV-1001 is closed.
Filter backflush tank 520-TK-070 is used during filter regeneration. The tank is provided
with agitator 520-AG-070 which runs continuously.
The filter hold-up and the amount of water for sluicing and backwashing is more than the
capacity fo 520-TK-070. Therefore 520-PP-070/071 is started automatically during filter
regeneration cycle.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.16
date
2005-06-30
rev
7.2.18
Condensate (PID 520-12)

Condensate is collected in condensate tank 520-TK-045. The sources for condensate are:
Start-up heaters 510-HX-060 and 520-HX-065
Hot process water heater 520-HX-091
Second stage vent condenser 520-HX-020
Anhydrous reactor heater 520-HX-010, via condensate vessel 520-TK-010
Fuel oil heater 900-HX-160
Most of this condensate is hot and flashes in this tank. The pressure is kept slightly above
atmospheric by 520-PIC-1101, which allows venting to atmosphere if required, and
prevents air intake from atmosphere.
The majority of the condensate is pumped to boiler feed water tank 900-TK-040. A small
amount is pumped to thermo compressor desuperheater 520-DS-010. The level in 520TK-045 is controlled by 520-LICSA-1101, which directs the surplus condensate to hot
process water tank 520-TK-091.
7.2.19
Precoat and filter aid (PID 520-13)

The precoat tank 520-TK-080 is used during regeneration of a filter. After regeneration the
tank is refilled with diatomaceous earth and process liquor.
The filter aid tank is in use continuously to which diatomaceous earth and process liquor
are added periodically.
7.2.20
Hot process water (PID 520-14)

The condensate excess from 520-TK-045 is collected in hot process water tank
520-TK-091. A fixed amount of process water (20 m3/h) is added from 510-HX-015, which
is preheated with scrubber liquor. During normal operation approx. 29 m3/h of hot process
water is required. The amount of condensate supplied to 520-TK-091 is approx. 3 m3/h.
The required additional amount of process water is supplied on level control (520-LICA1301). If for some reason too small amount of process water is used, the hot process
water tank overflows and is collected in sump pit 510-SU-100. This can be pumped to
510-DE-050 (and the amount of water added to the settler can be subtracted from the
amount added via 510-FCV-0301).
The temperature of the hot process water is controlled by temperature controller
520-TIC-1301 and safe-guarded with 520-TISA-1302.
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi
doc. no.
2.187.735 -
page
7.17
date
2005-06-30
rev
The hot process water pressure is controlled by 520-PICA-1301. Hot water is transported
via a header. The (discontinuous) users are connected to the header with short
connecting lines to prevent a lot of cold water being forwarded from stagnant lines.
7.2.21
Setting list
Instrument
510-DICA-0001
Unit
kg/m
Normal
Alarm
1530
H 1600
Trip/Switch
L 1400
510-EIA-0001
kW
75
H 105
510-EIA-0002/0003
kW
15
H 18
510-EIA-0004/0005
kW
11
H 14
510-EIA-0008
kW
130
H 200
510-EICSA-0201/0204
kW
50
H 63
510-ES-0202/0205
510-EISA-I-0301
HH 70
Local control
kW
TBD
H TBD
HH TBD
510-FICA-0001
m /h
140
L 50
510-FIA-0002
m /h
150
L 80
HHTBD
H 200
H TBD
3
510-FICQA-0003
m /h
22
L 90% of normal
510-FIA-0004
l/min
L 0.5
510-FA-0005..0010
l/min
510-FIC-0011..0016
l/h
30
510-FI-0017
m3/h
22
510-FI-0018
m /h
22
510-FICA-0101
m /h
160
m /h
10
510-FIC-0103/0104
l/h
30
510-FICA-0201/0202
m /h
3.5
510-FI-0203/0204 (PW)
l/h
510-FI-0102
L 100
L 1
510-FICA-0301
m /h
L 90% of normal
510-HIC-0301/02
RPM
TBD
TBD
510-KIS-0001
min; n/h
1; 1
510-KIS-0002
min; n/h
1; 4
word 10.0
TBD
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.18
date
2005-06-30
rev
Instrument
Unit
Normal
510-KIS-0201/0202
min; n/h
1; 4
510-LICSA-0001
60
Alarm
Trip/Switch
L 35
H 85
510-LICSA-0002
50
HH 90
HH 90
LL TBD
LL TBD
L 35
H 85
510-LI-0003
TBD
510-LICSA-0101
50
L 35
H 80
HH 90
510-LI-0201/0202
TBD
TBD
510-LSA-0203/0204
TBD
TBD
510-LI-0301 (sludge level)
HH 90
L TBD
(corresponds with 1
m clear liquor;3 to 4
discs visible)
510-LICSA-0401
80
L5
L5
H 95
510-PIA-0001
barg
-0.07
L -0.2
H 0.05
510-PI-0002
barg
510-PDIA-0003
mm wc
510-PI-0201/0202
barg
5)
H TBD
TBD
510-PI-0401
barg
510-TICA-0001
97
L 90
H 100
510-TIA-0002
97
L 90
H 100
510-TI-0003
85
510-TI-0004
35
510-TI-0101
93
510-TISA-0201/0202
55
510-TI-0203/0204
55
510-TI-0401
90
510-TI-0402
90
H 60
word 10.0
HH 65
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.19
date
2005-06-30
rev
Instrument
Unit
Normal
Alarm
Trip/Switch
H 9
HH 14
510-XISA-0201/0202
mm/s
Guar dosing
g/ton solids
80
Capacity 510-MP-072/073
m /h
0.1
kg/m3
1500
(0.3% guar solution)
520-DIA-0001
L 1400
H 1600
kg/m
520-DI-0101
kg/m
520-EIA-0001
kW
170
H 200
520-EIA-0002/0003
kW
27
H 36
520-EIA-0101
kW
75
H 105
520-EIA-0102/0103
kW
11
H 14
520-EICSA-0301/0304
kW
50
H 63
520-DICA-0002
1500
L 1400
H 1600
520-ES-0302/0305
1500
HH 70
Local control
520-EIA-0307
kW
TBD
H TBD
520-EIA-0501
kW
TBD
L TBD
520-EISA-I-0701
kW
TBD
H TBD
HH TBD
HH TBD
520-EIA-I-1201
kW
TBD
TBD
TBD
520-EIA-I-1203
kW
TBD
TBD
TBD
520-FICA-0001
m /h
150
L 50
520-FIA-0002
l/min
L 1
520-FIA-0003/0004
l/min
520-FI-0011
m3/h
64
H TBD
520-FIA-0101
m /h
140
520-FI-0102/0103
l/min
10
520-FI-0104..0106
l/min
520-FIC-0107..0110
l/h
30
520-FICA-0201
m /h
160
520-FI-0202
m3/h
10
520-FIC-0203/0204
l/h
30
520-FICA-0301/0302
m /h
3.5
520-FI-0303/0304 (PW)
l/h
L 70
L 0.5
L 100
L 1
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.20
date
2005-06-30
rev
Instrument
Unit
Normal
Alarm
520-FIQ-0401
ton/h
7.5
520-FIA-0402
kg/h
120
520-FIC-0601
NNF
520-FI-0605
m /h
93
520-FICA-0701
m3/h
8.2
L 90% of normal
104
L 80% of normal
520-FICA-0901/02
m /h
m /h
Trip/Switch
30
H 120% of normal
520-FIC-1001
m3/h
520-FI-1101
m /h
520-FIA-1201
m /h
NNF
16
2 (Check)
L 80% of normal
H 120% of normal
520-HIC-0601/02
RPM
TBD
TBD
TBD
520-HIC-0701/02
RPM
TBD
TBD
TBD
Guar dosing: guar
mg/l
concentration in deaerator
liquor flow rate
Capacity 510-MP-074/075
m /h
0.35
520-KIS-0101
min; n/h
1; 0.25
520-KIS-0102
min; n/h
0.5; 0.25
520-KIS-0103
min; n/h
0.5; 0.25
520-KIS-0301/0302
min; n/h
1; 4
520-LICSA-0001
60
(0.3% guar solution)
L 35
H 85
HH 90
520-LICA-0002
60
HH 90
L 35
H 85
520-LI-0003
520-LICSA-0101
60
L 35
H 85
HH 90
word 10.0
HH 90
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.21
date
2005-06-30
rev
Instrument
Unit
Normal
Alarm
520-LICSA-0201
50
L 35
Trip/Switch
H 80
HH 90
520-LI-0301/0302
TBD
HH 90
TBD
520-LSA-0303/0304
TBD
TBD
520-LISA-0501
Variable
L TBD
LL 20
LL 20
L 23
H 95
520-LA-0502
520-LICSA-0601
520-LI-0701 (sludge level)
H 100 (tank starts

overflowing)
1)
64
L 47
L 47
H 77
2
(corresponds with 1
m clear liquor;3 to 4
discs visible)
520-LICSA-0802
1)
28
2)
L L14
85
3)
L 20
28
3)
L 20
85
2)
LL 24
LL 14
H 95
520-LICSA-1001
LL 24
H 35
HH 95
520-LISA-1002
(L 24)
L 24
H 95
520-LICSA-1101
4)
80
LL 0
LL 0
L 15
H 95
520-LISA-1201
85
L 30
H 90
HH 95
520-LISA-1202
85
L 30
H 85
HH 95
520-LICSA-1301
4)
60
L9
L 15
H 77
word 10.0
L9
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.22
date
2005-06-30
rev
Instrument
Unit
Normal
520-PIA-0001
barg
Alarm
Trip/Switch
H 1.5
HH 1.8
520-PI-0002
barg
1.2
520-PDIA-0003
mbar
300
H 400
520-PICA-0101
barg
-0.16
L -0.25
520-PDIA-0102
mbar
2.5
H 20
520-PI-0103
mbarg
520-PI-0104/0106
mbarg
-160
520-PI-0105/0107
barg
520-PI-0301/0302
barg
TBD
520-PICA-0401
barg
14.5 ??
520-PI-0402
barg
-0.16
520-PI-0403
barg
1.2
520-PDIA-0902/0908
bar
0.3 (clean; check)
H -0.05
L 14 ??
H 2.5
2.0 (end of cycle)

520-PI-0905
barg
520-PIC-1101
barg
0.15
520-PI-1102
barg
0.15
520-PICA-1301
barg
4.5
L3
520-QIA-1101
S/cm
20
40
520-SSA-0301
TBD
TBD
520-TICA-0001
120
L 110
H 130
520-TIA-0002
120
L TBD
H TBD
520-TI-0003
121
520-TI-0004
124
520-TDIA-0005
0.7
H 1.0
520-TDIA-0006
H 5
520-TIA-0101
97
H 100
L 90
520-TI-0102
37
520-TIC-0103
55
520-TI-0201
93
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.23
date
2005-06-30
rev
Instrument
Unit
Normal
Alarm
Trip/Switch
H 60
HH 65
520-TISA-0301/0302
55
520-TI-0303/0304
55
520-TI-0401
143
520-TICA-0402
125
520-TI-0501
98
520-TIA-0601
99
520-TI-0901/02
96
520-TI-1001
Ambient to 96
520-TI-1002
80 - 96
520-TI-1003
96
520-TICA-1301
90
520-TISA-1302
520-XISA-0301/0302
mm/s
Timer 520-XSV-1201/1202
520-XSV-1201
H 135
H 102
L 85
H 95
H 95
H 9
HH 14
open and 520-XSV1202 closed: 15

520-XSV-1201
closed and 520XSV-1202 open: 5
1) Presented as percentage of liquid height, measured from bottom of cone
2) At start of filter regeneration cycle
3) At end of filter regeneration cycle
4) Presented as percentage of liquid height, measured from bottom head tangent line
5) mm wc is mm H2O at 4C
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.24
date
2005-06-30
rev
7.3
Logic functions
In this section the logic functions describing automatic actions of valves are described.
The guar make-up sequence is described in section 7.7.2 and the filter regeneration
sequence is described in section 7.7.11.
Process switches
Thermal overload is provided on all electric motors. The thermal overload shuts off the
motor directly (hardwired from MCC).
In the table below logic functions acting on equipment are presented.
Equipment/Action
Start
Stop
Signal
Type
Start/
Switch/
Running
Interlock
condition
400-GA-060
Manual on
Manual on
DCS
DCS (check)
(check)
and
and
automatic
High level on 510-LICSA-
Direct
0001
calcined
Vent fan 510-FN-010 is not
feed to
running
dump tank
If Pump 510-PP-010/011 is
automatic
not running
Agitator 510-AG-010 is not

running
510-PP-010/011
Locally by
Locally by
hand
hand and
Low power on 510-EISA-
510-PP-015/016
Locally by
Locally by
hand
hand
Locally by
Locally by
hand
hand and
Stop
0002/0003 (after times;
automatic
510-AG-010
broken belt detection)

-
Low level of 510-LICSA-
Stop
0002
automatic
510-PP-020/021
510-FN-010
Locally by
Locally by
hand
hand
Locally by
Locally by
hand
hand
High level is activated on
Stop
510-LICSA-0101
-
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.25
date
2005-06-30
rev
Equipment/Action
Start
Stop
Signal
Type
Start/
Switch/
Running
Interlock
condition
510-CF-035/036
Locally by
Locally by
hand
hand and
automatic
Hydraulic pump (510-EM-
0202/0205 and 510-EM0208/0209) is running
Air cooler fan (510-EM-
0203/0206) is running
Low level of 510-LSA-
Stop
0203/0204 activated
High temperature on 510-
Stop
TISA-0201/0202
510-PP-050/051
510-TM-050
Locally by
Locally by
hand
hand
Locally by
Locally by
hand
hand
510-XISA-0201/0202
HH torque on 510-EISA-I0301
Stop
-
Lift rake
(local
control)
510-PP-060/061
Locally by
Locally by
hand
hand and
Stop
510-AG-070
Automatic
automatic
Automatic
LL level of 510-LI-001
Stop
510-MP-070 to
Locally by
Locally by
Stop
075
hand
hand and
510-PP-070/071
Automatic
Automatic
Stop
Locally by
Locally by
High pressure of 520-PISA-
Stop
hand
hand and
activated
automatic
520-PP-005/006
automatic
0001 is activated
High level on 520-LICSA0001
High power on 520-EICSA0101/0102 ???
High level on 520-LICSA0101
Agitator 520-AG-020 is not

running
Low level 520-LISA-0501 is

activated
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.26
date
2005-06-30
rev
Equipment/Action
Start
Stop
Signal
Type
Start/
Switch/
Running
Interlock
condition
520-PP-020/021
Locally by
Locally by
hand
hand and
High level on 520-LICSA-
Stop
0201
automatic
520-CF-035/036
Hydraulic pump (520-EM-
Locally by
Locally by
hand
hand and
0302/0305 and 520-EM-
automatic
Air cooler fan (520-EM-
Low level of 520-LSA-
Stop
0303/0304 activated
High temperature on 520-
Stop
TISA-0301/0302
520-CV-040
Locally by
Locally by
hand
hand and
automatic
520-XISA-0301/0302
Emergency switch 520-EM-
Stop
Stop
0307 is activated

activated
520-AG-005
520-PP-040/041
Locally by
Locally by
hand
hand
Locally by
Locally by
hand
hand and
Stop
automatic
520-TM-050
Locally by
Locally by
hand
hand and
High torque on 520-EISA-I-
0701
(local
automatic
520-PP-050/051
520-PP-095
520-AG-095
Locally by
Locally by
hand
hand
Automatic
Automatic
Locally by
Locally by
hand
hand and
Lift rake
control)
520-LS-0702 Low
520-LS-0702 High
-
automatic
word 10.0
Stop
Start
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.27
date
2005-06-30
rev
Equipment/Action
Start
Stop
Signal
Type
Start/
Switch/
Running
Interlock
condition
520-PP-060/061
Locally
Locally and
Running pump stops
and on
on DCS by
(failure, stop switch)
DCS by
hand and
hand and
automatic
At least one of valves 520-
520-PP-065/066
Automatic
pump
X
XSV-0904 and 520XSV0918 has to be open
automatic
520-PP-100
Start spare
Automatic
Locally by
Locally by
hand
hand and
520-LICSA-0802 LL level
Stop
520-LS-0803 Low
Stop
520-LS-0803 High
Start
520-LICSA-1001 LL level
Stop
Tank level at 520-LISA-1002
Start
automatic
520-PP-070/071
Locally
Locally and
and on
on DCS by
DCS by
hand and
hand and
automatic
Stop
LL
automatic
520-PP-045/046
Locally
Locally and
and on
on DCS by
DCS by
hand and
hand and
automatic
Running pump stops
Start spare
pump
(failure, stop switch)
Stop
LL
automatic
520-PP-080
Locally by
Locally by
hand
hand and
automatic
520-AG-080
Locally by
Locally by
hand
hand and
automatic
520-PP-085
Locally by
Locally by
hand
hand and
automatic
520-AG-085
Locally by
Locally by
hand
hand and
automatic
520-PP-091/092
Locally by
Locally by
hand
hand and
Tank level at 520-LICSA1301 LL
automatic
word 10.0
Stop
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.28
date
2005-06-30
rev
In the table below automatic actions of valves are presented.

Valve
Action
Cause
510-FCV-0001
Close
510-KIS-0001/0002
Close
510-ECV-
Close
0201/0204
520-DCV-0002
Close
520-PCV-0401
Close
520-XSV-
Open
high level is activated on 510-LICSA-0001

high level is activated on 510-LICSA-0001
High power on 510-EICSA-0201/0204 is activated
510-CF-035/036 is not running
If feed pump 520-PP-005/006 is not running

520-PP-010 is not running
520-PP-005/006 is running
0001/0002
Close
520-PP-005/006 is not running

520-LICSA-0001 high level is activated
High level on 520-LICSA-0101
Open
520-PP-022/023 is running
Close
Close
Close
520-KIS0101/0102/0103
520-XSV0101/0102
520-ECV-
Close
0301/0304
520-LCV-0601
Close
520-XSV-1001
Open
520-XSV-1201
Open
Close
520-XSV-1202
Open
Close
520-TCV-1301
Close
520-PP-022/023 is not running

High power on 520-EICSA-0301/0304 is activated
520-CF-035/036 is not running
Conveyor belt 520-CV-040 is not running
Pump 200-PP-005/006 stop
520-LSA-0502 HH level activated
One of pumps 520-PP-070/071 is running
After certain time
After certain time and 520-XSV1202 is open
After certain time
After certain time and 520-XSV1201 is open
High temperature 520-TISA-1302 activated
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.29
date
2005-06-30
rev
7.4
Start-up and shutdown of the crystallization unit
7.4.1
Fill system and start rotating equipment

The start up of the crystallization section is mainly a manual operation.
Crystallizers, elutriators tanks etc. are empty
Process water
15 bar steam supply
3 bar steam supply
Condensate return (see section 7.7.8)
Hot process water (see section 7.7.9)
Purge water
Guar solution (see section 7.7.2)
Cooling liquor from washery section
Tailing tank 900-TK-250 and paddock slurry tank 900-TK260
Instrument air
Electrical power
Instruments are working and calibrated
1
Filling of settler 510-TK-050 and settler overflow tank 510-TK-060.

o Bottom valves have to be closed.
o Use water supply via 510-FCV-0301 (max. flow is approx. 30 m3/h) and hoses if
needed. Fill the settler until it overflows to the settler overflow tank 510-TK-060.
o Continue filling the settler overflow tank until a level of 50% (this corresponds to
40% reading on 510-LI-0401).If the tank is filled up sufficiently, it can be used for
filling crystallizer or elutriator. In that case pump 510-PP-060/061 has to be taken
into operation:
Start first stage settler overflow pump 510-PP-060/061.
o Check valve configuration of 510-HX-060/061 and destination lines (open supply
and return valves on heater, throttle heater bypass valve)
o When not in use, the pumps should have the suction and discharge valves closed
and the drain valve open.
o To start a pump, first ensure the seal purge water is flowing at 1 l/m.
o Close the drain valve and open the suction valve.
o Start pump and then open the discharge valve.
o Only one pump should operate at a time.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.30
date
2005-06-30
rev
o Check valve configuration of 510-PP-060/061 and destination lines (circulate via

crystallizer and elutriator, keep transfer to 900-TK-250 closed).
Filling first stage crystallizer 510-EV-010.
o Venting during filling goes via scrubber 510-DC-015 (fan not running)
o Use water supply from settler overflow tank with pump 510-PP-060/061
o Filling can also be supplemented using wall wash water supply.
o Fill the crystallizer with water until the level is between the lower and upper level
sight glasses, located on the cylindrical wall of the crystallzer. (The level indicator
is calibrated for process slurry so the level indication will not be correct on water).
Filling of first stage scrubber 510-DC-015.
o Bottom valves have to be closed
o Venting during filling goes via fan 510-FN-010 (not running).
For filling use process water supply via 510-FCV-003.
Fill the scrubber with water until the level is midway up the level gauge glass. (The
level indicator is calibrated for liquor so the operating density differs slightly from
water density)
Filling first stage elutriator 510-SP-025
o Use water supply from settler overflow tank with pump 510-PP-060/061. Fill the
elutriator with water until it starts overflowing (visible at first stage deaerator 510DE-050).
o Set flow control 510-FICA-0101 to automatic at 160 m3/h (design rate).
o Adjust flow to bottom through 510-FI-0102 to ~50 m3/h.
Start the first stage crystallizer agitator 510-AG-010
o The crystallizer agitator can be started once the vessel is filled to the proper
operating level.
o First ensure the seal purge water is flowing at 0.8 l/m.
o Then start the agitator.
Start hydrator pump 510-PP-010/011
o Hydrator pump can be started once the first stage crystallizer is filled to the
proper operating level.
o To start a pump, first ensure the seal purge water is flowing at ~1 l/m.
o Close the drain valve and open the suction valve
o Start pump and then open the discharge valve
Start first stage scrubber pump 510-PP-015/016
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.31
date
2005-06-30
rev
10
11
o Scrubber pump can be started once the scrubber is filled to the proper operating
level. The pumps are interlocked with low low level of 510-LICSA-0002 so the
level indication must be working properly prior to operating the scrubber pumps.
o Ensure the manual recycle valve to the scrubber spray nozzles is open and the
level control valve 510-LCV-0002 is closed.
o The scrubber level control can then be put in automatic.
Start first stage scrubber fan 510-FN-010
o Before starting the fan, water should be added to the overflow lutes of both the
first stage crystallizer and the first stage scrubber. This is done by attaching a
hose to the drain valves on the lute and then adding water until water comes out
the overflow. The water in the lutes prevents air from being drawn through the
overflow lines.
o The fan should be started in manual mode at the minimum speed.
Start first stage slurry pump 510-PP-020/021
o Set pump speed manually through 510-LICSA-0001 to show ~40 m3/h flow rate
on 510-FIA-0002.
o Set feed to crystallizer through 510-FICA-0001 to ~70 m3/h (~half of design rate).
o Put first stage crystallizer level control 510-LICSA-0001 to automatic and select a
level setpoint that maintains the level between the upper and lower level sight
glasses on the crystallizer wall.
o If the level in the first stage settler overflow tank is low, additional water can be
added to the circuit by starting the process water addition to the first stage
scrubber through 510-FICQA-0003 (make sure bypass over 510-FCV-0003 is
closed).
o If the level in the first stage settler overflow tank is high, the level controller 510LICSA-0401 can be put in automatic and the transfer to 900-TK-250 can be
opened (ensure bypass valve over 510-LCV-0401 is closed).
Start first stage centrifuge 510-CF-035/036
o First ensure that the seal purge water is flowing at ~8 l/h.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.32
date
2005-06-30
rev
12
13
14
15
o Ensure the oil level is adequate and then start the hydraulic pump motor
o Verify that the oil cooler fan and oil circulation pump have started (these motors
are wired in the MCC to start and stop with the hydraulic pump motor).
o After the hydraulic pump has been running for at least one minute, start the main
rotor motor.
o During normal operation, both centrifuges will operate at the same time.
However, during start-up or at reduced rates it is only necessary to operate one
centrifuge.
o If desired, water can be fed through the running centrifuge and into the first stage
settler deaerator. However, since the first stage elutriator overflows to the same
place, it is not necessary to run the first stage centrifuges on water.
o To stop the centrifuge, first stop the main rotor motor. After the centrifuge comes
to a complete stop the hydraulic pump motor can be stopped.
Start first stage settler rake mechanism
Filling of anhydrous reactor 520-EV-010
o Manual 25 mm vent valve on top of the reactor is opened.
o Open 150 mm process water valve located on the recirculation pipe and fill the
anhydrous reactor to a level that is approximately 1 meter above the recirculation
inlet nozzle. (The level indicator is calibrated for process slurry so the level
indication will not be correct on water). The level can be viewed through the top
sight glasses.
Start the anhydrous reactor pump 520-PP-010
o The anhydrous reactor pump can be started once the anhydrous reactor is filled
to the proper operating level. The allowable operating level ranges from the
center line of the recirculation inlet nozzle (N1) to the top of straight side of the
vessel.
o First ensure the seal purge water is flowing at ~2 l/m.
o Start the pump
Filling of second stage crystallizer 520-EV-020
o Manual 25 mm vent on line from second stage vent condenser is opened to vent
the second stage crystallizer through the condenser.
o Fill the second stage crystallizer through anhydrous slurry transfer lines by
opening 520-LCV-0001A/0001B, along with the block valves in these lines.
o Only one transfer line is in use at a time.
o Put anhydrous reactor level controller 520-LICSA-0001 in automatic and adjust
the level setpoint.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.33
date
2005-06-30
rev
16
17
18
19
20
21
o Continue adding process water to the anhydrous reactor while water is

transferred to the second stage crystallizer. Fill the second stage crystallizer with
water until the level is between the lower and upper level sight glasses, located
on the cylindrical wall of the crystallizer. (The level indicator is calibrated for
process slurry so the level indication will not be correct on water).
Start second stage crystallizer agitator 520-AG-020
o The crystallizer agitator can be started once the vessel is filled to the proper
operating level.
o First ensure the seal purge water is flowing at 0.8 l/m.
o Then start the agitator.
Start the second stage slurry pump 520-PP-020/021
Filling of second stage elutriator 520-SP-025
o Transfer water from the second stage crystallizer using one of the second stage
slurry pumps 520-PP-020/021. The second stage crystallizer level setpoint (520LICSA-0101) can be adjusted to a point which maintains the crystallizer level
between the level sight glasses while water is transferred from the anhydrous
reactor.
Filling of second stage settler 520-TK-050 and polishing filter feed tank 520-TK-060
o Bottom valves have to be closed
o Filling can be accomplished by continuing to supply process water to the
anhydrous reactor and allowing the water to flow through the second stage
crystallizer and second stage elutriator. The elutriator will overflow to the second
stage settler deaerator and then to the second stage settler and finally to the
polishing filter feed tank. Continue filling the polishing filter feed tank until the
level is 50%, which is ~40% level indication of 520-LICSA-0802.
Start second stage settler rake mechanism 520-TM-050
Start polishing filter feed pump 520-PP-060/061 and filling polishing filter
o Ensure filter is ready: check manual valves are set correctly, open feed
connection 520-XSV-0904/0918, open overflow valve 520-XSV-0906/0921 and
all other valves closed
o This pump has automatic changeover in case the running pump fails: when not in
use, the pump suction and discharge valves are open and the drains closed. A
check valve prevents back flow via the standby pump.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.34
date
2005-06-30
rev
22
23
24
25
26

o Ensure valve on tank is open
o Put polishing filter feed tank level control 520-LICSA-0802 in automatic at ~40%.
o When filter is full, open 520-XSV-0913/0931 and close 520-XSV-0906/0921
Filling of the filtrate tank 520-TK-065
o Filling can be accomplished either by adding process water through 520-FIC1001 or by pumping water from the polishing filter feed tank through the polishing
filters 520-FL-060/061 using the filter feed pumps 520-PP-060/061. Continue
filling the filtrate tank until the level is 50%, which is ~40% level indication of 520LICSA-1001.
Start filtrate pump 520-PP-065/066
o Put filtrate tank level control 520-LICSA-1001 in automatic at ~40% (ensure
bypass over 520-LCV-1001 is closed).
Start filtrate feed to second stage elutriator via 520-FCV-0201
o Open manual block valves in transfer line
o Set flow control 520-FICA-0201 to automatic at 160 m3/h (design rate).
o Adjust flow to bottom through 520-FI-0202 to ~50 m3/h.
Start second stage centrifuge 520-CF-035/036
o After the hydraulic pump has been running for at least three minutes, start the
main rotor motor.
centrifuge.
Start second stage belt conveyor 520-CV-040
o Inspect belt conveyor to ensure there are no hazards that result from starting.
o Start belt conveyor with local on/off switch
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.35
date
2005-06-30
rev
27
28
29
30
31
32
o Belt conveyor motor is interlocked with second stage centrifuge feed valves 520ECV-0301/0304 such that valves can only be opened if motor is running.
Filling of second stage centrate tank 520-TK-040
o Water can be fed through the running centrifuge and into the centrate tank
o First ensure second stage centrifuge is running
o Open the block valve in the centrifuge feed line
o Set 520-EICSA-0301/0304 to manual and gradually open 520-ECV-0301/0303
(control valves are interlocked to the respective centrifuge rotor motors such that
valves will only open if the motor is running and will close if the motor is stopped).
Start second stage centrate pump 520-PP-040/041
o Check dust system of 600 section can receive liquor
o Only one pump should operate at a time
o Set 520-LICSA-0601 to 40% in automatic. 520-LCV-0601 will open flow to 520TK-005.
Filling of second stage crystallization feed tank 520-TK-005
o Filling can be accomplished either by pumping water from the filtrate tank or by
running the second stage centrifuge 520-CF-035/036 and opening the centrifuge
feed valve 520-ECV-0301/0304 from the second stage elutriator and then
pumping out of the second stage centrate tank 520-TK-040 with second stage
centrate pump 520-PP-040/041.
o Fill the tank to 50% level (this corresponds to 30% level on 520-LISA-0501 when
on water).
Start second stage crystallization feed pump 520-PP-005/006
o Start pump (discharge valve will automatically open when pump is started).
o Set flow setpoint of 520-FICA-0001 to ~2500 l/m.
o Stop adding process water to anhydrous reactor through 150mm water
connection once operating levels in all second stage vessels is adequate.
Start second stage crystallization feed tank agitator.
Start second stage vacuum pump 520-PP-022/023
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.36
date
2005-06-30
rev
33
34
o Close vent valve on condenser vent line.

o Close 250 mm suction valve to thermo compresser and ensure thermo
compressor bypass valves are closed.
o Fill seal leg on condenser drain line and second stage crystallizer overflow with
water through hose connections.
o Ensure vacuum pump seal purge water manual valve is open.
o Start vacuum pump and adjust seal water flow to ~8 l/m.
o Put pressure control 520-PCV-0101 on automatic.
o Open liquor supply to second stage condenser 520-HX-020 and put temperature
control 520-TIC-0103 on automatic.
Preheat crystallization circuits
o Condensate tank 520-TK-045 is already in use for hot water system
o Once either first stage or second stage crystallization circuits are flowing with
water or brine, the start-up heaters can be used to preheat the system.
o Open valves in and out of first stage / second stage mother liquor heater 510-HX060 / 520-HX-065 and throttle bypass valve in a way that still sufficient water is
circulating.
o Open block valve on 3 bar steam header to mother liquor heater.
o Put condensate level control 520-LICSA-1101 in automatic (ensure bypass over
520-LCV-1101 is closed).
o Continue heating the first stage crystallization circuit with steam until it is heated
to ~80 C and then close steam valve to mother liquor heater. Open manual
bypass valve fully, flush and close process supply and return lines.
o Heat the second stage crystallization circuit with steam until it is heated to ~90 C
and then close steam valve to mother liquor heater. The transfer pumps and
centrifuges should then be stopped until feed slurry is available from the second
stage crystallization feed tank.
Standby second stage crystallization circuit
The second stage crystallization circuit is put in standby mode until the first stage
crystallization circuit is in production mode and the second stage crystallization feed
tank contains slurry.
o Stop the second stage crystallization feed pump 520-PP-005/006, flush both
sides of the automated on/off valve at the discharge of the pump with hot water
for several minutes (this valve closes automatically when the pump stops), close
the valve at the feed tank and open the drain valve.
o Stop transfer from anhydrous reactor to second stage crystallizer by closing valve
at reactor, flushing line with hot water for several minutes, closing valve at
crystallizer, stop flush water and open drain valve of S2 connection. It may be
necessary to set 520-LISCA-0001 to manual to keep the control valve in the line
open while flushing.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.37
date
2005-06-30
rev
o Stop second stage slurry pump 520-PP-020/021, close the valve at the
crystallizer, flush the line with water for several minutes, stop the flush water,
close the discharge valve and open the drain valve.
o Stop the flow to the second stage centrifuge by closing the valve at the elutriator
and flushing the line with water for several minutes. It may be necessary to set
520-EICSA-0301/0304 to manual to keep the control valve open while flushing.
o Stop the second stage centrifuges.
o Stop the second stage belt conveyor 520-CV-040.
At this point, the anhydrous reactor and second stage crystallizer vessels are isolated and
the following function on:
Anhydrous reactor pump 520-PP-010 running
Crystallizer agitator 520-AG-020 running
Vacuum pump 520-PP-022/023 running with automatic pressure control enabled
Cooling liquor flow through condenser with automatic temperature control enabled
Filtrate flow to second stage elutriator
Centrate pump 520-PP-040/041 running
Second stage settler rake mechanism running
Polishing filter feed pump 520-PP-060/061 running with automatic level control on
polishing filter feed tank 520-TK-060
Filtrate pump 520-PP-065/066 running
Condensate pump 520-PP 045/046 running
7.4.2
Start first stage production

Now first stage crystallization circuit is operating with following functions:
Hydrator pump 510-PP-010/011 running
Scrubber fan 510-FN-010 running
Scrubber pump 510-PP-015/015 running
First stage slurry pump 510-PP-020/021 running with crystallizer level control 510LICSA-0001 in automatic.
Liquor circulation to elutriator 510-SP-025 via 510-FCV-0101 at design rate.
Liquor feed to crystallizer via FCV-0001 at ~half of design rate.
Settler overflow pump 510-PP-060/061 running
Feed to centrifuges via 520-LICSA-0101 off
First stage centrifuges 510-CF-035/036 not running
First stage settler rake mechanism 510-TM-050 running.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.38
date
2005-06-30
rev
2
3
4
Open water supply to scrubber and set flow rate via 510-FIC-0003 to ~5 m /h (25%
of design rate) with recirculation valve throttled to obtain ~20 m3/h flow rate on 510FI-0017 (ensure bypass over 510-FCV-0003 is closed).
Open manual valves in process water supply for wall wash and enable wash timers
510-KIS-0001/0002.
Put scrubber fan speed control in automatic 510-TICA-0001.
Start adding calcined feed from calciner unit
The hot (400 C) calcined feed will start increasing the temperature of the first stage
crystallization circuit as well as the liquor concentration and density. As the crystallizer
temperature approaches the operating setpoint of 97 C, the vent fan will automatically
increase speed via temperature controller 510-TICA-0001.
5
6
7
8
As the density increases in the crystallizer, the level setpoint of 510-LICSA-0001

must be increased to maintain the actual level between the upper and lower level
sight glasses in the vessel cylindrical wall.
Open process water supply to deaerator and set flow rate via 510-FCV-0301 to ~2
m3/h (50% of normal rate) (ensure bypass over 510-FCV-0301 is closed).
Start guar pump 510-MP-072/073 and check flow rate.
Open manual valves in liquor transfer from settler overflow tank 510-TK-060 to
tailing tank. Put level control 510-LICA-0401 on automatic (ensure bypass over 510LCV-0401 is closed).
When the crystallizer density increases above 1.30, monohydrate crystals will begin to be
produced. These crystals will then start to be transferred to the elutriator. The elutriator
level indicator 510-LICSA-0101 would be negative when the liquor is below saturation and
give a positive reading when crystals begin to accumulate. As the level indication
increases above 10%, one of the centrifuges should be started.
9
10
Check crystal size and shape. If too many fine crystals are formed, then a portion of
the slurry will be discharged via the elutriator overflow.
Start first stage centrifuge 510-CF-035/036
rotor motor.
centrifuge.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.39
date
2005-06-30
rev
11
12
13
14
15
16
17
18
19
7.4.3
Open hot water flow to centrifuge via 510-FCV-0201/0202.

Start feeding slurry from elutriator to centrifuge via 510-ECV-0201/0204.
Ensure that second stage feed tank agitator 520-AG-005 is running.
When the first centrifuge is operating near full capacity, start the second centrifuge
operation.
Set elutriator level control 510-LICSA-0101 to automatic at ~50%
Monitor sludge level in settler. It will take certain time until a sludge layer is
developed.
Set valve settings of discharge line of 510-PP-050/051 for recycling to deaerator.
Open suction valve and discharge valve. Start pump 510-PP-050/051. Set the
speed according setting list (ratio of frequency and flow rate to be determined during
precommissiong/start-up).
When a sludge layer of 2 m is formed (510-LI-0301 until disk 4 visible), start
discharging sludge to slurry tank 900-TK-260. Keep recycle to deaerator running.
When the first stage crystallizer density approaches the design operating point of
1.53, increase the brine feed flow via 510-FICA-0001 to ~140 m3/h and then put the
crystallizer density control 510-DICA-0001 to automatic.
Start second stage production

The second stage crystallization feed tank 520-TK-005 will receive the centrifuge cake
from the first stage centrifuges 510-CF-035/036. This tank does not have density
indication so the initial indication of solids concentration will be the level increase. The
initial tank level should be ~50% and when this increases to ~80%, the feed to the
anhydrous reactor should be started. This should take 3 to 4 hours with the first stage
crystallizer operating at design rate.
The anhydrous reactor must be heated to the design operating temperature (120 C) prior
to initiating feed. Raising the temperature of the anhydrous reactor using 15 bar steam
through the thermo compressor should occur at a rate of ~0.5 C/min. To heat from 90 C
to 120 C should take ~1 hour.
1
Open motive steam to thermo compressor 520-SJ-010

First ensure anhydrous reactor heater 510-HX-010 has vent valves completely
open.
o Open 15 bar steam valve and ensure steam pressure controller 520-PICA-0401
is in automatic.
o Ensure condensate vessel level control 520-TK-010 is working in automatic.
o Ensure condensate pump 520-PP-045/046 is running and condensate tank 520TK-045 level control via 520-LICSA-1101 is in automatic (and bypass over 520LCV-1101 is closed).
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.40
date
2005-06-30
rev
2
3
o Gradually close vent valves on heater to reduce the amount of steam vent to a
small continuous amount.
Open water to thermo compressor desuperheater 520-DS-010 and put control valve
via 520-TICA-0402 in automatic.
When the anhydrous reactor temperature rises above 100 C, steam will vent
through the manual vent valve at the top. Gradually close this vent valve in a similar
manner to the heater vent valves, leaving a small continuous vent to avoid
accumulating non-condensable gasses.
When the operating temperature reaches 120 C, start second stage crystallization
feed pump 520-PP-005/006
o Start pump (discharge valve will automatically open when pump is started).
o Set flow setpoint of 520-FICA-0001 to ~150 m3/h.
o Adjust flow setpoint as necessary to maintain level in 520-TK-005.
Start automatic density control of feed to anhydrous reactor by opening filtrate flow
to suction of pump 520-PP-005/006 and putting 520-DICA-0002 in automatic at the
design setpoint of 1.50.
Start transferring to the second stage crystallizer via 520-LICSA-0001. First open
the manual valve at the anhydrous reactor, then open the valve at the second stage
crystallizer and finally open 520-LCV-0001 and set to automatic control at the
current operating level indication. As the density in the anhydrous reactor
increases, the actual level will decrease for the same level indication. The desired
operating level is ~1 meter above the recirculation inlet nozzle. The level setpoint
should be adjusted to obtain this.
NB: the density of water is not sufficient to prevent boiling in the transfer line.
Start the second stage slurry pump 520-PP-020/021
o Set the second stage crystallizer level control 520-LICSA-0101 to automatic.
As 120 C slurry is transferred to the second stage crystallizer, the operating
temperature will rise to ~97 C, where the crystallizer contents will begin boiling.
Usually, the operating pressure in the second stage crystallizer will increase when
boiling first occurs until the vacuum system is able to draw out all the air. When the
word 10.0
Engineering
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project no.
405.014
project name
BOM Magadi

doc. no.
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page
7.41
date
2005-06-30
rev
10
11
12
proper operating pressure is reestablished after boiling commences, the block valve
at the suction of the thermo compressor is opened slowly.
The manual valves in the bypass line around the thermo compressor are opened
and the control valve via 520-TICA-0001 is put in automatic control at the design
operating temperature (120 C).
Start the automatic wall wash and demister wash 520-KIS-0101/0102/0103.
Ensure fluid bed dryer is on standby
Start second stage belt conveyor 520-CV-040
When the crystallizer density increases above 1.30, monohydrate crystals will begin to be
produced. These crystals will then start to be transferred to the elutriator. The elutriator
level indicator 520-LICSA-0201 would be negative when the liquor is below saturation and
give a positive reading when crystals begin to accumulate. As the level indication
increases above 10%, one of the centrifuges should be started.
13
14
15
16
17
18
Start second stage centrifuge 520-CF-035/036

First ensure that the seal purge water is flowing at ~8 l/h.
rotor motor.
centrifuge.
Open hot water flow to centrifuge via 520-FCV-0301/0302 (or cold water, to be
verified during start-up)
Start feeding slurry from elutriator to centrifuge via 520-ECV-0301/0304.
Start second stage centrate pump 520-PP-040/041
o Set 520-LICSA-0601 to 50% in automatic. 520-LCV-0601 will open flow to 520TK-005.
When the first centrifuge is operating near full capacity, start the second centrifuge
operation.
Set elutriator level control 520-LICSA-0201 to automatic at ~50%
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.42
date
2005-06-30
rev
19
20
21
22
23
24
7.4.4
Start guar pump 510-MP-074/-75 and check flow rate.

Set 520-FICA-0701 for hot water supply to dearator 520-DE-050 (ensure bypass
over 520-FCV-0701 is closed).
Set valve settings of discharge line of 520-PP-050/051 for recycling to deaerator.
Open suction valve and discharge valve. Start pump 520-PP-050/051. Set the
speed according setting list (ratio of frequency and flow rate to be determined during
commissioning/start-up).
Monitor sludge level in settler. It will take certain time until a sludge layer is
developed.
When a sludge layer of 2 m is formed (520-LI-0701 until disk 4 visible), start
discharging sludge to slurry tank 900-TK-260. Keep recycle to deaerator running.
The water addition rates to the scrubber and both first stage and second stage
deaerators can be set in automatic flow control at setpoints shown in the settings
table and then adjusted as required.
Shut-down
Purpose of this procedure is to shut down for a longer period of time or for maintenance.
Most of the sodium carbonate solids in the crystallization circuits are removed and
recovered and the remaining solids are dissolved.
7.4.4.1
Shut-down first stage crystallization circuit

1
2
3
4
5
6
7
Stop feed from calciner.

Continue feeding liquor to first stage crystallizer via 510-FICA-0001 while pumping
slurry to elutriator until most of the crystals are discharged from first stage
crystallizer 510-EV-010 (this takes approx. 3 4 hours). The density controller 510DICA-0001 will need to be set in manual so that a set flow rate can be maintained
via 510-FICA-0001. This flow rate can be increased as the crystallizer density
decreases.
Stop first stage slurry pump 510-PP-020/021, close valve at crystallizer, flush slurry
transfer line, close discharge valve and open drain valve.
Stop hydrator pump 510-PP-010/011, close valve at crystallizer, flush slurry transfer
line, close discharge valve and open drain valve.
Close settler overflow liquor supply to crystallizer via 510-FCV-0001.
Stop fan 510-FN-010 and scrubber pump 510-PP-015/016 and close process water
supply via 510-FCV-0003.
Take level control 510-LICSA-0101 on elutriator 510-SP-025 on manual, in order to
discharge all solids. When elutriator is empty of crystals, then close elutriator bottom
valves 510-ECV-0201/0204.
Flush front-side of centrifuge screen with hot process water until all solids are
dissolved.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.43
date
2005-06-30
rev
9
10
11
12
13
14
Stop first stage centrifuge and close hot water supply via 510-FCV-0201/0202.
Close process water supply to deaerator via 510-FCV-0301.
Stop guar pump 510-MP-072/073
Stop first stage settler overflow pump 510-PP-060/061 (close discharge valve, keep
suction valve open for seal purging).
Stop first stage settler underflow pump 510-PP-050/051.
Ensure all lines are flushed.
The unit is now stopped, with following functions in operation:

Crystallizer agitator 510-AG-010
Settler rake mechanism 510-TM-050 running
Seal water on instruments and pumps
Whenever possible keep liquor in first stage crystallizer and settler.
Proceed with washout procedure as required for the shutdown.
7.4.4.2
Shut-down second stage crystallization circuit

1
2
3
4
5
6
Maintain flows through second stage crystallization circuit after first stage circuit has
been stopped. Objective is to process the remaining sodium carbonate solids in the
circuit. The suspended solids concentration in the feed tank 520-TK-005, the
anhydrous reactor 520-EV-010 and the crystallizer 520-EV-020 will gradually be
reduced as product is recovered on the second stage centrifuges and centrate is
recycled to the feed tank.
When the density in the anhydrous reactor has dropped below 1.35, close 15 bar
steam supply to thermo compressor 520-SJ-010
Prior to stopping pump 520-PP-005/006, flush line (because otherwise 520-XSV0001/0002 is closed). Stop second stage crystallization feed pump 520-PP-005/006,
flush both sides of the automated on/off valve 520-XSV-0001/0002 with hot water for
several minutes (this valve closes automatically when the pump stops), close the
valve at the feed tank and open the drain valve.
Stop filtrate supply from filtrate tank 520-TK-065 to slurry feed line (close 520-DCV0002).
Continue slurry transfer from anhydrous reactor 520-EV-010 to 520-EV-020, by
putting 520-LICSA-0001 in manual.
When level indicator 520-LICSA-0001 shows ~20% or level is below N1 nozzle,
stop slurry transfer from anhydrous reactor by closing valve at reactor, flushing line
with hot water for several minutes, closing valve at crystallizer, stop flush water and
open drain valve of S2 connection.
Open DN 150 process water connection to anhydrous reactor and fill to high level
(top of vessel straight side) or until density indication 520-DIA-0001 shows <1.30.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.44
date
2005-06-30
rev
9
10
11
12
13
14
15
Stop second stage slurry pump 520-PP-020/021, close the valve at the crystallizer,
flush the line with water for several minutes, stop the flush water, close the
discharge valve and open the drain valve.
When elutriator is empty of crystals, (having level control 520-LICSA-0201 in
manual) close elutriator outlet valves 520-ECV-0301/0304.
dissolved.
Stop centrifuge and close hot water supply via 520-FCV-0301/0302.
Stop second stage belt conveyor 520-CV-040
Close 520-FCV-0701 ( hot process water supply to deaerator 520-DE-050)
Stop guar pump 520-MP-074/075
Stop settler underflow pump 520-PP-050/051
The unit is now stopped, with following functions in operation:

Anhydrous reactor pump 520-PP-010
Crystallizer agitator 520-AG-020
Vacuum pump 520-PP-022/023 with automatic pressure control
Cooling liquor flow through condenser with automatic temperature control
Liquor flow to elutriator via 520-FICA-0201
Polishing filter feed pump 520-PP-060/061
Filtrate pump 520-PP-065/066
Centrate pump 520-PP-004/041
Settler rake mechanism 510-TM-050
Second stage crystallization feed tank agitator 520-AG-005
Condensate pump 520-PP-045/046
Hot process water pump 520-PP-091/092
Seal water on instruments and pumps
Whenever possible keep liquor in second stage crystallizer and settler.
Proceed with washout procedure as required for the shutdown.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.45
date
2005-06-30
rev
7.5
Going standby and restart
7.5.1
Going standby of first stage crystallization circuit

Purpose of this procedure is to keep the crystallization circuits ready for fast recovery of
production (e.g. during calciner cleaning).
1
Stop feed from calciner
2
Stop first stage slurry pump 510-PP-020/021, close valve at crystallizer, flush slurry
transfer line, close discharge valve and open drain valve.
3
Close settler overflow supply to crystallizer via 510-FCV-0001.
4
Reduce process water supply to scrubber via 510-FCV-0003 to ~2 m3/h, with
throttled recirculation valve.
Slurry is kept inside crystallizer with agitator running. Crystals to be transferred from the
elutriator to centrifuge.
5
When elutriator is empty of crystals (take level control on manual), then close
elutriator bottom valves 510-ECV-0201/0204.
6
dissolved.
7
8
Close process water supply to deaerator via 510-FCV-0301.
9
Stop guar supply pump 510-MP-072/073
10 Stop settler underflow pump 510-PP-050/051. Flush lines.
Now unit is standby with following functions on:
First stage crystallizer wall wash timers 510-KIS-0001/0002
Hydrator pump 510-PP-010/011 running
Scrubber fan 510-FN-010 running
Scrubber pump 510-PP-015/015 running
Reduced process water to scrubber via 510-FCV-0003
Liquor circulation to elutriator 510-SP-025 via 510-FCV-0101
Settler overflow pump 510-PP-060/061 running
Purge water on instrument and seals
7.5.2
Going on standby of second stage crystallization circuit

1
2
Close 15 bar steam supply to thermo compressor 520-SJ-010. Keep reactor above
115C.
Prior to stopping pump 520-PP-005/006, flush line(because otherwise 520-XSV0001/0002 is closed). Stop second stage crystallization feed pump 520-PP-005/006,
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.46
date
2005-06-30
rev
3
4
6
7
8
9
10
11
12
flush both sides of the automated on/off valve 520-XSV-0001/0002 with hot water for
several minutes (this valve closes automatically when the pump stops), close the
valve at the feed tank and open the drain valve.
Stop filtrate supply from filtrate tank 520-TK-065 to slurry feed line (close 520-DCV0002).
Stop slurry transfer from anhydrous reactor 520-EV-010 to 520-EV-020 by closing
valve at reactor, flushing line with hot water for several minutes (always flush in two
directions), closing valve at crystallizer, stop flush water and open drain valve of
S2 connection. It may be necessary to set 520-LICSA-0001 to manual to keep the
control valve open while flushing.
Stop second stage slurry pump 520-PP-020/021, close the valve at the crystallizer,
flush the line with water for several minutes, stop the flush water, close the
discharge valve and open the drain valve.
When elutriator is empty of crystals, (having level control 520-LICSA-0201 in
manual) close elutriator outlet valves 520-ECV-0301/0304.
dissolved.
Stop second stage belt conveyor 520-CV-040
Close 520-FCV-0701 ( hot process water supply to deaerator 520-DE-050)
Stop guar pump 520-PP-074/075
Stop settler underflow pump 520-PP-050/051
Second stage crystallizer is now standby with following function running:

Anhydrous reactor pump 520-PP-010 running
Second stage crystallizer agitator 520-AG-020 running
Second stage crystallizer wall and demister wash timers 520-KIS-0101/0102/0103
Vacuum pump 520-PP-022/023 running
Cooling liquor on condenser 520-HX-020 running
Filtrate circulation to elutriator 520-SP-025 running
Feed tank agitator 520-AG-005 running
Centrate pump 520-PP-040/041 running
Filter feed pump 520-PP-060/061 running
Filters 520-FL-060/061 in operation
Filtrate pump 520-PP-065/066 running
Filter aid pump 520-PP-085 running
Condensate pump 520-PP-045/046 running (a certain amount of condensate from
the fuel oil heater is collected in 520-TK-045. Any flash steam will be vented to
suction header of steam jet 520-SJ-010. As the jet is not in operation, steam will be
transferred via second stage crystallizer 520-EV-020 to the vacuum system.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.47
date
2005-06-30
rev
7.5.3
Pre-coat tank agitator 520-AG-080 running

Filter aid tank agitator 520-AG-085 running
Hot water pump 520-PP-090/091 running
Purge water on instruments and seals
Restart from stand-by of first stage crystallization unit

This procedure described situation of restarting after a standby period.
1
2
3
4
5
6
7
8
9
10
7.5.4
Start first stage centrifuges

Start feeding calcined feed to crystallizer
Set settler overflow liquor supply to crystallizer via 510-FCV-0001 according setting
list.
Start first stage slurry pump 510-PP-020/021 and set flow rate according to setting
list.
Set process water supply to scrubber via 510-FCV-0003 according to setting list
Open bottom valves 510-ECV-0201/0202 of elutriator slightly on manual. Check
crystals are coming out. After some time put ECVs on automatic.
Open hot water flow to centrifuge via 510-FCV-0201/0202.
Start process water supply to deaerator via 510-FCV-0301
Start guar pump 510-MP-072/073 and check amount.
Start settler underflow pump 510-PP-050/051 with valves set for recycle to
deaerator and transfer to slurry tank 900-TK-260
Restart from standby of second stage crystallization circuit

1
2
3
4
5
6
7
8
9
10
11
Start 15 bar steam supply to thermo compressor 520-SJ-010

When anhydrous reactor is ~120 C, start second stage crystallization feed pump
520-PP-005/006 and set rate according to settings list
Start filtrate supply from filtrate tank 520-TK-065 to feed tank 520-TK-005 (open
520-DCV-0002).
Start slurry transfer from anhydrous reactor 520-EV-010 to 520-EV-020 by opening
520-LCV0001A/0001B
Start second stage belt conveyor 520-CV-040 and ensure fluid bed dryer is ready to
receive feed (otherwise 520-CV-040 cannot start)..
Start second stage centrifuges 520-CF-035/036
Start second stage slurry pump 520-PP-020/021
Open hot water supply to centrifuge via 520-FCV-0301/0302.
Slowly open elutriator outlet valves 520-ECV-0301/0304 and check crystals are
coming from 520-CF-035/036. After some time put ECVs on automatic.
Start settler underflow pump 520-PP-050/051
Start guar pump 520-MP-074/075 and check amount
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.48
date
2005-06-30
rev
12
7.6
Open 520-FCV-0701 ( hot process water supply to deaerator 520-DE-050) and set
flow rate according setting list (ensure bypass over 520-FCV-0701 is closed)
Preparation of guar solution: add guar from bags

Flow rate of guar dosing pumps
Check purgerators on instruments are set correctly in accordance with the setting list
Check pump and agitator seals:
Flow rate of purgerators is according to setting list
Check that water is dripping from the seal. In case no dripping is visible or if a
continuous flow is visible, maintenance attention by a qualified person is required.
Check sump 520-SU-095/100 (e.g. automatic level switch 520-LSA-0702/0803)
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
7.49
date
2005-06-30
rev
7.6.1
Water balance
The water balance of the first and second stage have to be monitored carefully. Too much
water will result in product loss. Not enough water will result in too high a sulfate content
in the first stage crystallizer and also product loss when monohydrate in the deaerators is
not dissolved. Set points for flows are on the setting list. The settings have to be taken
proportional to the actual operating capacity of the unit.
Water input:
Process water supply on first stage scrubber (510-FIC-0003) (not proportional but fixed
flow rate)
Process water on first stage deaerator (510-FIC-0301)
Hot process water on first stage and second stage centrifuge (510-FIC-0201/0202,
520-FIC-0301/0302).
Hot process water on second stage deaerator (520-FIC-0701)
Process water on wall wash for crystallizers
Process water to second stage vacuum system (520-FI-0102/0103)
Process water via guar supply; negligible
Hot process water on second stage centrate tank (520-FI-0601); normally not in use
Process water on filtrate tank (520-FI-1001); normally not in use
Purge water on pumps and seals (not proportional but fixed flow rate)
Flushing of lines (not proportional)
Wash-out of crystallizers (incidental, not proportional)
Sight glass flush water
Water output:
Evaporation from first stage crystallizer via scrubber to air
Evaporation from second stage crystallizer to condensate
Free moisture and monohydrate water in centrifuge cake
First stage settler underflow (510-HIC-0301/0302) to 900-TK-260
Second stage settler underflow (520-HIC-0701/0702) to 900-TK-260
First stage liquor blowdown to 900-TK-250 (via 510-LCV-0401)
Emptying of filter content to 900-TK-260
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.50
date
2005-06-30
rev
7.6.2
Critical process parameters

Location
Parameter
Tag or analysis
Purpose; target or setpoint
510-EV-010
Density
510-DICA-0001
Product quality;
3
1540 kg/m (35 wt%)

510-EV-010
Temperature
510-TICA-0001
Operating parameter;
97C
510-DC-015
Process water supply
510-FICQA-0003
Prevent scaling of scrubber,

maintain low sodium sulfate
concentration, dissolving
power;
3
22 m /h
510-HX-015
Process water supply
510-FI-0018
Reduce vapor stream to 5103
FN-010; 20 m /h
510-SP-025
Underflow solids
Sample
concentration
Content of insolubles in
Centrifuge performance;
50 wt%
Sample
< 0.1 wt% insolubles
Sample
< 0.3 wt% NaF
Sample
Product loss;
monohydrate crystals
Content of NaF in
510-SP-025
Overflow solids
(510-CF-035/036
Cake moisture
Sample not possible
Product quality;
510-CF-035/036
Centrifuge wash water
510-FICA-0201/0202
Product quality;
concentration
2 wt%
5 wt%)
3.5 m3/h per centrifuge
flow rate
510-DE-050
Process water addition on
510-FIC-0301
510-TK-050
First stage settler sludge
510-LI-0301
level
510-MP-072/073
First stage settler guar

First stage deaerator
Settler performance;
4 discs visible
510-LI-0604
supply
510-DE-050
Water balance, product loss;

4 m3/h
deaerator
80 g/ton solids
Sample / Visual
overflow
Monohydrate in solids
indicates bad performance of
crystallizer/elutriator, or too
small water supply (510-FIC0301)
510-TK-050
First stage settler overflow
Sample / Visual
solids concentration
word 10.0
Product quality;
< 0.1 wt%
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
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rev
Location
510-TK-050
Parameter
Tag or analysis
First stage settler
Sample
underflow solids
20 wt%
concentration
520-TK-005
Level
520-LISA-0501
Buffering volume; TBD
520-EV-010
Density
520-DICA-0001
Product quality;
3
1480 kg/m (28 wt%)

520-EV-010
Temperature
520-TICA-0001
Operating parameter;
120C
520-HX-010
Temperature difference of
520-HX-010
Temperature difference of
520-TDIA-0006
tube wall and bulk
Reduce risk of scaling;

1.6C
520-TDIA-0005
Reduce risk of scaling; 1.2C
520-PICA-0101
Keep crystallizer at boiling
slurry outlet and slurry

inlet
520-EV-020
Pressure
condition; -0.16 barg

520-EV-020
Solids concentration
Sample
Product quality;
3
1550 kg/m (39 wt%)

520-SP-025
Underflow solids
Sample
concentration
Content of insolubles in
Centrifuge performance;
50 wt%
Sample
< 0.02 wt% insolubles
Sample
< 0.02 wt% NaF
Sample
Product loss;
Content of NaF in
520-SP-025
Overflow solids
concentration
520-CF-035/036
Cake moisture
1.5 wt%
Sample
Product quality;
5 wt%
520-CF-035/036
Centrifuge wash water
520-FICA-0301/0302
520-FL-060/061
Filter pressure drop
Product quality;
3.5 m3/h per centrifuge
flow rate
520-PDIA-0902/0908
Monitor filtration time;

Filter to be regenerated at 2
bar
520-DE-050
Hot process water
520-FIC-0701
520-TK-050
Second stage settler
Water balance, product loss;

8.2 m3/h
addition on deaerator
520-LI-0701
sludge level
word 10.0
4 discs visible
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
7.52
date
2005-06-30
rev
Location
Parameter
Tag or analysis
510-MP-074/075
Second stage settler guar
510-LI-0603
supply

Supply guar to a
concentration of 5 mg/l in the
deaerator liquor flow rate
520-DE-050
Second stage deaerator
Sample / Visual
overflow
Monohydrate in solids
indicates bad performance of
crystallizer/elutriator, or too
small water supply (520-FIC0701)
520-TK-050
Sample / Visual
Too much solids will result in
overflow solids
increased cake growth on
concentration
filter and shorter cycle time;

< 0.01 wt%
520-TK-050
Sample
underflow solids
concentration
7.6.3

Refer to Analytical Manual.
word 10.0
15 wt%
Engineering
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.53
date
2005-06-30
rev
7.7
7.7.1
Buffering of slurry in case of capacity variation of first and second stage

Feed tank 520-TK-005 provides buffer capacity in case the capacity of the first and
second stage crystallization differ. If the operating capacity of both sections differ, the
solids concentration in the tank will vary. The normal concentration is approx. 50% (the
tank and agitator are designed for 70%). The solids concentration in 520-TK-005 follows
from the following parameters:
1
Capacity ratio of first and second stage crystallization
2
Moisture content of cake from first stage centrifuges 510-CF-035/036
3
Solids concentration of slurry feed to second stage centrifuges
4
Moisture content of cake from second stage centrifuges
5
Wash water flow rate on second stage centrifuges
A different operating capacity of both sections has consequences for the operating
conditions of the first and second stage. For example, a higher capacity of the first stage
has the following consequences:
1
The level in 520-TK-005 increases
2
The solids concentration in 520-TK-005 increases
3
More filtrate is required to dilute the slurry feed to the second stage. As a
consequence the supply of second stage filtrate to first stage crystallization is less,
which means less blow down from 510-TK-060, so higher sulfate concentration in
first stage. This has to be compensated by adding more water to the second stage
deaerator.
7.7.2
Guar preparation procedure

Guar gum is supplied in bags. Make sure the bags contain guar gum.
The guar preparation is an automated system.
Preparation of 0.3 wt% guar solution in 510-TK-070.
1
The field operator keeps a sufficient guar level inside the hopper 510-TK-071.
2
At low level in 520-TK-070 process water supply valve 510-SV-004 is opened.
3
At normal level following steps are activated:
Agitator 510-AG-070 is started
Screw feeder 510-SC-070 is started and runs for preset time of timer.
Gate 510-MG-071 is opened and stays open for preset time of timer. (Timer of
screw is set at a longer time in a way that the screw runs empty after closure of gate
510-MG-071)
4
At high level process water supply valve 510-SV-004 will close.
word 10.0
Engineering
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doc. no.
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7.54
date
2005-06-30
rev
A third timer is set to provide time for ripening of the guar solution. The timer is
started when guar addition is completed. When the preset time is past, transfer of
solution from preparation tank 510-TK-070 to day tank 510-TK-075 is released.
Transfer of guar solution from preparation tank 510-TK-070 to day tank 510-TK-075.
1
At low level in the day tank 510-TK-075 transfer from preparation tank 510-TK-070
is started (start of 510-PP-070/071). The pump can only start if the guar preparation
process is completed (time for ripening is completed and level in 510-TK-070 is not
low).
2
Transfer pump 510-PP-070/071 is stopped when low level in preparation tank is
reached (preferred operation) or when high level in day tank 510-TK-075 is reached
7.7.3
Guar flow rate measuring procedure

1
2
3
4
5
7.7.4
The guar dosing pump applicable to the calibrating tube is running

Open bottom valve calibration tube. When tube is full, close valve in supply line from
510-TK-075.
Measure time to empty the calibration tube.
Open valve in supply line from 510-TK-075 and close bottom valve of calibration
tube. Make sure the pump does not run dry.
The recorded time in combination with the pumped volume from the calibration tube
gives the guar solution flow rate (vendor info required of the calibration tubes)
Heating process liquor with start-up heater

Section 510
Liquor can be pumped through first stage mother liquor heater 510-HX-060 for heating up
during start-up. During normally operation the flow is bypassing the exchanger. The bypass valve has to be throttled when the heater is used. Open up supply and return liquor
valve of the exchanger always completely to prevent overheating of liquor and scaling.
The liquor is heated to approx 90C with 3 bar steam. Steam supply can be adjusted
locally by reading the local liquor outlet temperature 510-TI-0402. The recirculation flow
rate through the exchanger is significantly smaller than normal circulation rate
(respectively 50 and 300 m3/h).
If the 510-HX-060 is used for heating during normal operation, then open supply and
return liquor valve completely, and throttle bypass slightly, while checking that valve
position 510-FCV-0001 and 510-FCV-0101 remain within control range.
After using 510-HX-060 the steam supply has to be closed, and the line section has to be
flushed to prevent plugging.
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.55
date
2005-06-30
rev
Section 520
Liquor can be pumped through second stage mother liquor heater 520-HX-065 for heating
up during start-up. During normal operation the flow is bypassing the exchanger. The bypass valve has to be throttled when the heater is used. Open up supply and return liquor
valve of the exchanger always completely to prevent overheating of liquor and scaling.
The liquor is heated to approx 90C with 3 bar steam. Steam supply can be adjusted
locally by reading the local liquor outlet temperature 520-TI-1002. The recirculation flow
rate through the exchanger is significantly smaller than normal circulation rate
(respectively 50 and 300 m3/h).
If the 520-HX-065 is used for heating during normal operation, then open supply and
return liquor valve completely, and throttle bypass slightly, while checking that valve
position 520-DCV-0002, 520-FCV-0201 and 520-LCV-1001 remain within control range.
After usage of 510-HX-060 the line section has to be flushed to prevent plugging.
7.7.5
Pump failure of filter feed pump 520-PP-060/061

Flow rate over filter has to be constant in order to reduce damage of filter cake. In case
flow is stopped, the cake might start to fall off. Pumps 520-PP-060/061 are provided with
automatic changeover and check valves are installed to prevent back flow through the
standby pump.
A point worth remembering is that although the filter feed has low solids concentration,
check valves still can fail. If this occurs then a consequence is a too low flow rate to the
filter and the level in 520-TK-060 will increase.
If a check valve fails, the following can be seen:
520-PP-060 or 061 is running
520-FICA-0901/0902 low alarm
520-FCV-0901/02 will travel to full open position
520-PDIA-0902/0908 not high
When the discharge valve of the standby pump is closed, and the flow rate increases to
normal value, the cause of low flow must be the check valve which has to be repaired.
For switching to the spare pump during operation, refer to procedure 7.7.6.2 below.
word 10.0
Engineering
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project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.56
date
2005-06-30
rev
7.7.6
Centrifugal pump start/stop and changeover
7.7.6.1
Centrifugal pump start/stop

from running to spare pump, see procedure below section 7.7.6.2. This is applicable for
centrifugal pumps. For positive displacement pumps refer to procedure in section 7.7.7.
Start of pump
1
2
Check the valves in the discharge line of the pump is set up for the right destination
3
Check suction and/or discharge valve of spare pump is closed.
4
Close drain valve and open suction valve (if pump is empty allow to fill up by venting
on discharge side of the pump).
5
Check discharge valve is closed, start pump and open discharge valve.
Stop pump
1
Close discharge valve and stop pump.
2
Close suction valve.
3
Open flush valve on discharge line upstream of discharge valve, open discharge
valve and flush through discharge valve.
4
Close discharge valve and open suction valve and flush through suction valve.
5
Close suction valve, open drain valve and close flush water valve.
6
Drain pump and leave drain valve open.
7
Close purge water shut-off valve.
7.7.6.2
Use of installed spare pump

For most application an installed spare pump is provided. This can be used in case of
failure or maintenance of the running pump or for routine changeover. Separate
procedures are given for pump failure, and for routine pump changeover.
The procedure applies to centrifugal pumps. See procedure in section 7.7.7.2 for positive
displacement pumps.
1
2
3
Close drain valve and open suction valve of spare pump (if pump is empty allow to ill
up by venting on discharge side of the pump).
word 10.0
Engineering
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project name
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doc. no.
2.187.735 -
page
7.57
date
2005-06-30
rev
4
5
Check discharge valve is closed, start spare pump and open discharge valve
For maintenance, flush and drain pump that failed as described in section 7.7.6.1.
Procedure to changeover with running pumps:

1
Open purge water supply shut-off valve and check flow rate (discharge or suction
valve MUST be open to have flow of purge water)
2
Check discharge valve of spare pump is closed, close drain valve and open suction
valve (if pump is empty allow to fill up by venting on discharge side of the pump)
3
Start spare pump and open discharge valve.
4
Close discharge valve of the original running pump and stop the pump.
5
Flush and drain pump as described in section 7.7.6.1.
Note 1:
As soon as the running pump is stopped, backflow can occur (there are no check valves
installed). Therefore, first close discharge valve of the running pump and then stop this
pump.
Note 2:
Close the purge water supply before the pump is isolated in order to prevent high
pressure in pump and piping.
Note 3:
For pumps with automatic changeover, suction valve and discharge valve of the standby
pump are open. A check valve prevents back flow through the standby pump.
Note 4:
Filter feed pump 520-PP-060/061 has automatic changeover. If the pumps are changed
over manually, special attention is required not to cause pressure variations on the filter
cake. Therefore operate discharge valves slowly when connecting the spare pump and
disconnecting running pump.
7.7.7
Start/stop and changeover of 510-PP-050/051 and 520-PP-050/051
7.7.7.1
Start/stop of 510-PP-050/051 and 520-PP-050/051

from running to spare pump, see procedure below section 7.7.7.2. This is applicable for
positive displacement pumps 510-PP-050/051 and 520-PP-050/051. For centrifugal
pumps refer to procedure in section 7.7.6.
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.58
date
2005-06-30
rev
The pump has to be filled to provide lubrication of the stator (not for priming purpose).
When the pump is stopped, sufficient liquid is normally trapped between the pumping
elements to provide the necessary lubrication for restarting. However, if the pump has
been left standing for a long time or has been dismantled, it must be refilled and given a
few turns before starting, to get sufficient lubrication between the rotor and the stator.
Start of pump
If line and pump are empty:
1
Fill up suction line (open bottom valve of settler and drain valve at pump suction)
2
Fill up pump with water hose via plug on top of the pump and give it a few turns with
tool provided
If line and pump are full, proceed with:
3
Check purge water supply is open and check flow rate (discharge or suction valve
has to be open to have flow of purge water)
4
Check the valves in the discharge line of the pump is set up for the correct
destination
5
Check discharge valve of spare pump is closed.
6
Open suction and discharge valves
7
Start pump
Stop pump
1
Keep pump running during flushing. Open suction flushing connection and open
flush valve.
2
3
4
5
the seal.
Note 1: Never run the pump dry, not even for a few revolutions.
Note 2: Never run pump with a closed suction or discharge valve.
Note 3: Do not vary the flow rate by throttling suction or discharge valve
7.7.7.2
Use of installed spare 510-PP-050/051 and 520-PP-050/051

An installed spare pump is provided. This can be used in case of failure or maintenance of
the running pump, or in a certain frequency. Separate procedures are given for routine
pump changeover and for pump failure.
The procedure applies to positive displacement pumps 510-PP-050/051 and 520-PP050/051. See procedure in section 7.7.6.2 for centrifugal pumps.
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.59
date
2005-06-30
rev

1
2
Open suction and discharge valve of spare pump
3
Start spare pump
4
For maintenance, close purge water supply and flush the pump and the enclosed
suction and discharge line sections.
Procedure for changeover with running pumps.
1
Open suction valve and discharge valve of spare pump and start spare pump
2
3
4
5
6
the seal
Note 1:
Backflow does not occur when the running pump is stopped for positive displacement
pumps
Note 2:
Close the purge water supply before the pump is isolated, to prevent high pressure in
pump and piping.
7.7.8
Start-up and shutdown of condensate tank 520-TK-045

Start-up
1
Check that boiler feed water tank 900-TK-040 is ready to receive condensate.
2
If hot process water tank is not yet ready to receive condensate keep 520-LCV-1101
closed.
3
If second stage crystallization system is ready to receive flash steam from 520-TK045, put 520-PIC-1101 on automatic with setpoint according to the setting list. If
second stage crystallization system is not ready to receive flash steam, keep 520PCV-1101 closed and open manual vent valve on 520-TK-045.
4
Check valve settings of pump 520-PP-045 (520-TCV-0402 on inlet of desuperheater
520-DS-010 closed).
5
Select a pump, keep discharge valve closed, open bottom valve of 520-TK-045 and
suction valve of the pump.
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.60
date
2005-06-30
rev
When sufficient level has built up inside 520-TK-045, start pump 520-PP-045/046
and open discharge valve.
Shutdown
1
Stop pump 520-PP-045.
2
Close suction valve of 520-TK-045
3
Close the incoming condensate lines and destination lines.
4
Close 520-PCV-1101.
5
Tank will pull vacuum when cooling down which is not a problem as it is designed
for full vacuum.
Note: This pump has automatic changeover in case the running pump fails: when not in
use, the pump suction and discharge valves are open and the drains closed. A check
valve prevents back flow via the standby pump.
7.7.9
Start-up and shut down of hot water tank 520-TK-091

Start-up
1
Fill up process water tank 520-TK-091 with 520-LCV-1301 on manual and put on
automatic when the level is near its setpoint (see setting list) (ensure bypass over
520-LCV-1301 is closed).
2
Open process water supply line from scrubber cooler 510-HX-015.
3
Check position of valves at destinations and start pump 520-PP-091/092 and put
520-PICA-1301 on automatic.
4
Close 520-TCV-1301, open steam supply and condensate return of 520-HX-091 and
put temperature controller 520-TICA-1301 on automatic.
Shut down
1
Close steam supply and condensate return of 520-HX-091.
2
Close process water supply line from header and from 510-HX-015.
3
Stop pump 520-PP-091/092.
High feed of condensate to 520-TK-091:
In case the condensate from 520-TK-045 is not returned to the boiler feed water tank 900TK-040 but instead is collected in 520-TK-091, significantly less process water is needed
and less heating. It is possible that the supply to the hot process water tank 520-TK-091
becomes larger than the requirement, and that the tank overflows. It is therefore important
to discharge condensate to the boiler feed water tank.
word 10.0
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project name
BOM Magadi

doc. no.
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page
7.61
date
2005-06-30
rev
7.7.10
Performance monitoring of anhydrous reactor heater

Inside any crystallizer there is a relation between supersaturation and crystal growth. Too
high supersaturation gives chances of crystal growth on parts of the crystallizer causing
scale (hot surfaces, sharp edges) and increased nucleation, resulting in too small crystals.
Inside the anhydrous heater, the growing of crystals on the tube surface can occur if local
conditions allow this (high temperature, surface roughness, low flow rate). Special care is
taken to create a smooth surface of the inner tube walls (bright annealed) and the slurry
velocity is maintained at 2 m/s. These factors are in principal fixed parameters.
During operation the temperature is monitored continuously. The following temperature
differences are monitored:
1
Steam inlet temperature and slurry outlet temperature (temperature difference of
tube wall and bulk): 520-TDIA-0006 is 1.6C
2
Slurry outlet temperature and slurry inlet temperature: 520-TDIA-0005) is 1.2C
3
LMTD (Log mean temperature difference of inlet and outlet streams) (performance
of the exchanger) is 2.1.
The first two temperature differences are controlled with 520-TICA-0001.
The LMTD changes as a function of the operating capacity (heat input). If the LMTD
increases for a specific operating capacity (heat input) there are some possible causes:
Setpoints of 520-TICA-0402 and 520-TICA-0001 are changed
Scaling and/or plugging inside tubes
Inert accumulation on condensate side
Decreased slurry circulation flow rate
Variation in slurry concentration (specific heat, density, circulating flow rate)
The deviation of the LMTD that can be detected as a change, depends on the accuracy
(reproducibility) of the temperature indication. If the inaccuracy of the temperature
indication is 0.1C, a deviation of the LMTD of 10% or more can be detected.
Following actions should be carried out if LMTD is increased:
Check 520-TICA-0402 and 520-TICA-0001 are set according to the setting list
Check vent of 520-HX-010. The manual vent valve has to be open slightly during
operation to purge inerts. Open vent slightly further and see if it has any effect on the
LMTD.
Check trended data of power consumption of 520-PP-010 (520-EIA-0001)
Check trended data of slurry concentration
When no other deviations are found then tubes are probably plugged and a wash out is
required. Unfortunately, as the inaccuracy of the temperature indication compared to the
word 10.0
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doc. no.
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page
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date
2005-06-30
rev
normal value of the LMTD is rather high, a fair amount of tubes may be plugged by the
time it is detected by a change in LMTD.
7.7.11
Filter regeneration
Filter regeneration refers to 4 P&IDs:
520-09
Filtrate feed
520-10
Liquor polishing
520-11
Polishing filter filtrate storage & distribution
520-13
Precoat and filter aid
A break down of the filtration and regeneration cycle is given below:
Description
Applying precoat
Filtration
Emptying filter vessel and
cake discharge
Sluicing
Backwash
Total regeneration time
Unit
min
h
min
Value
15
47
10
min
min
min
10
10
45
The precoat system has to be ready to use (see section 7.7.12). Check the availability of
process water.
In the description below filter 520-FL-060 will be regenerated, filter 520-FL-061 is in
operation. The following actions take place:
If 520-PDI-0902/0908 reaches its alarm point (2 bar), the operator starts the regeneration
cycle when precoat tanks is ready and there is no conflict in operation (other filter
regenerating or other large process water consumer taking water).
1
Disconnect 520-FIC-0902 (feed rate of running filter 520-FL-061) from 520-LICSA0802. (Level in 520-TK-060 will rise because one filter is regenerating)
2
Freeze valve position of 520-LCV-1001 on 520-PID 520-11. (Level in 520-TK-065
will fall because one filter is regenerating.)
3
Close filter feed and filtrate discharge (valve 520-XSV-0904 and 520-XSV-0913)
4
Open 520-XSV-0924 for draining to 520-TK-070, and if 520-XSV-0924 is open, open
vent/deaeration 520-XSV-0903
5
Waiting time. Duration to be set with timer. (few minutes)
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doc. no.
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date
2005-06-30
rev
7
8
9
10
11
12
13
14
15
16
17
Supply process water for sluicing (open 520-XSV-0907). (Second process water
pump will start automatically based on header pressure.) Duration to be set with
timer (approx. 10 minutes). Close 520-XSV-0907.
Supply process water for backwashing (520-XSV-0908). Duration to be set with
timer (approx. 10 minutes)
Waiting time for draining. Duration to be set with timer.
Close vent 520-XSV-0903 and 520-XSV-0924.
Open precoat feed line 520-XSV-0905 and overflow 520-XSV-0906.
Field operator to start precoat pump 520-PP-080 locally.
When filter is full (set time interval, also visible at tundish), open 520-XSV0925 and
close 520-XSV-0906.
Field operator adds 3 bags of diatomaceous earth to 520-TK-080.
Precoating to proceed for approx 15 minutes.
When precoating is done, following actions to take place:
open line to filtrate tank 520-TK-065 520-XSV-0913
close line to precoat tank 520-TK-080 520-XSV-0925
open filter feed line 520-XSV-0904
open 520-FCV-0901 20%
close precoat feed 520-XSV0905 and stop 520-PP-080
ramp setpoint 520-FIC-0901 to 120 m3/h
When liquid level in feed tank 520-TK-060 reaches its normal low setpoint, set 520FIC-0901 to automatic. Reconnect 520-LICSA-0802 (level of 520-TK-060) to 520FIC-0901 and 0902.
When liquid level in filtrate tank TK-065 is at its normal setpoint, unfreeze valve
position of 520-LCV-1001.
The total amount of slurry and water as drained to 520-TK-070 is more then the capacity
of 520-TK-070. Therefore, filter backflush pump 520-PP-070/071 will be started
automatically via level switch 520-LISA-1002 H(S). Agitator 520-AG-070 is kept running
continuously.
If the regeneration process is disturbed for some reason the filter feed tank 520-TK-060
will become full and the filtrate tank 520-TK-065 will run empty. As a consequence, the
production rate of the second stage crystallization section has to be decreased to 50%.
In this case liquor supply to the elutriator is reduced to 50% as well, leading to off-spec
product.
Note: Ensure the bypass over 520-FCV-0901/0902 is closed.
word 10.0
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project name
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doc. no.
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page
7.64
date
2005-06-30
rev
7.7.12
Precoat preparation
Precoat tank 520-TK-080 is filled with filtrate and process water via 520-XSV-1201.
520-XSV-1201 is opened manually on the DCS and closed automatically, when 520-LISA1201 reaches target level of 90% (high level switch).
When starting with precoat application, the filter and the lines are empty. In total an
amount of approx. 25 m3 is required for filling up and the tank level will be reduced from
90% to 30%.
The filter hold-up of approx. 21.5 m3 is the actual loss of precoat liquor, which is approx.
28 ton. The filter aid concentration is 0.5 wt%. On a total of 28 ton loss, 140 kg has to be
added. Precoat filter aid is added manually from bags.
The precoat liquor can be diluted with 10% water to prevent scaling (to be determined
during first start-up).
The field operator is in attendance when filter regeneration has started. When
backwashing is complete, precoat will be applied. There is no waiting time available in the
regeneration time. If the precoat is not started at the right time, or if there is any other
delay in the filter regeneration, the second stage filtration operating capacity has to be
decreased.
Following procedure:
1
Manual valves of filtrate and process water are closed
2
Suction valve of precoat pump is open
3
Open 520-XSV-1201 (by desk operator)
4
Read tank level on 520-LISA-1201
5
Open process water supply and add the required amount (set by timer)
6
Close process water valve and open filtrate valve
7
When target level is reached, 520-XSV-1201 will automatically be closed
8
Close manual valve in filtrate feed line.
9
Start agitator locally by hand
10 Add diatomaceous earth through funnel
11 Flush funnel if needed with water hose.
12 Wait for instruction from the DCS operator to start the precoat pump (520-XSV-0905
or 0919 has to be open).
13 Start pump 520-PP-080
14 The pump is stopped when precoating is completed
15 Stop agitator
Note: Purge water is supplied to 520-PP-080. To maintain a continuous flow, keep suction
valve open and close discharge valve of the pump if pump is not running.
word 10.0
Engineering
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project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.65
date
2005-06-30
rev
7.7.13
Filter aid system

This procedure is based on filteraid preparation of once a day. This corresponds to
approx. 1 m3 of liquor with 150 kg of filteraid.
Filter aid tank 520-TK-085 is filled with filtrate via 520-LSV-1202, which is opened
manually on the DCS and closed automatically, when 520-LISA-1202 reaches target level.
Read tank level
Open 520-LSV-1202
Close 520-LSV-1202 if level increased 5% on the scale (manually)
When filling once a day, the operating level varies 5%. Top up the tank until the normal
operating level of 85% is reached. In case of longer time intervals of filter aid slurry
preparation, it has to be started at the minimum operating level of 30%.
Filling procedure:
1
Agitator 520-AG-085 is running
2
Pump 520-PP-085 is running
3
DCS operator to start filling sequence:
a. Read tank level on 520-LISA-1202
b. Open 520-LSV-1202
c. When level increased with 5%. Close 520-LSV-1202
4
Add 150 kg of filter aid through funnel. Clean funnel with water hose if needed.
During filling of the tank, the concentration decreases to some extent when liquor is added
before filter aid is added. This has no negative effect on the filter cake if this situation does
not exceed duration of 1 hour.
This pump is frequency controlled for speed control and the pump runs continuously. In
order to keep sufficient velocity in the lines, the filter aid flow is switched on and off with
valve 520-XSV-1201/1202.
For timer setpoints see setting list.
Start-up of filter aid system.
This has to be started up shortly after one filter is put in operation.
1
Fill up the tank with liquor, by opening 520-LSV-1202. It closes automatically by high
level switch.
2
Start agitator
3
Add the required amount of filter aid. If 520-TK-080 was completely empty, add
2300 kg of filter aid.
word 10.0
Engineering
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doc. no.
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date
2005-06-30
rev
4
5
Activate timer for 520-XSV-1201/1202

Start 520-PP-085
Shut down filter aid system

In case both filters are taken out of operation, filter aid supply has to be stopped.
1
Stop 520-PP-085
2
Close 520-XSV-1201 and 1202
3
Drain return line by opening flush connection at high point near 520-XSV-1201/1202
back to the tank. Also drain and flush pump discharge and suction line. If possible
keep purge water supply open and the pump suction valve to allow a positive flow.
Note:
If 520-PP-085 fails, back flow from filter occurs when 520-XSV-1201 and 520-XSV-1202
are open. If pump fails, a low flow alarm is generated from 520-FIA-1201. A long duration
of back flow will cause a high level in 520-TK-085 (HH alarm on 520-LISA-1202) in which
case 520-XSV-1201 and 1202 have to be closed.
7.7.14
Flushing of centrifuge
During normal operation, flushing of centrifuges with process water is necessary once
every 8 hours. Flush time is 5 minutes.
7.7.14.1 First stage centrifuges 510-CF-035/036

Slurry feed to centrifuges continues. Open manual washing valves and timer controlled
wall wash valve 510-KIS-0201/0202 (put to manual on DCS).
7.7.14.2 Second stage centrifuges 520-CF-035/036
Slurry feed to centrifuges is interrupted (close 520-ECV-0301/0304). Divert the chute
diverter below the centrifuges to centrate tank 520-TK-040.
Open manual washing valves and timer controlled wall wash valve 520-KIS-0301/0302
(put to manual on DCS).
When done, divert the chute diverter to 520-CV-040 and open 520-ECV-0301/0304.
7.7.15

Spilled liquor and slurry can be pumped to first stage deaerator. This is only allowed if
liquor or slurry is not contaminated (with non-product materials like filter aid).
word 10.0
Engineering
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doc. no.
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page
7.67
date
2005-06-30
rev
Agitator 520-AG-095 runs continuously.

For start-up:
1
2
Open valve towards 510-DE-050 and close valve towards 900-TK-250.
If the slurry is contaminated, then close towards 510-DE-050 and open valve
towards 900-TK-250
3
When sufficient level in the sump, start agitator 520-AG-095
4
For shut down:
1
2
3

Stop agitator 520-AG-095
Note: Flushing of line is required after pumping slurries and near saturated liquor.
7.7.16

Spilled liquor and slurry can be pumped to first stage deaerator. This is only allowed if
liquor or slurry is not contaminated (with non-product materials like filter aid).
Agitator 520-AG-095 runs continuously.
For start-up:
1
2
Open valve towards 510-DE-050 and close valve towards 900-TK-250.
If the slurry is contaminated, then close towards 510-DE-050 and open valve
towards 900-TK-250
For shut down:

1
2

Note: Flushing of line is required after pumping slurries and near saturated liquor.
word 10.0
Engineering
CONFIDENTIAL
project no.
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project name
BOM Magadi

doc. no.
2.187.735 -
page
7.68
date
2005-06-30
rev
7.7.17
Washout procedure crystallization section
word 10.0
Preliminary Washout Procedures

1
1.1
First Stage Crystallizer

Planned Wash-out
Stop solid feed to crystallizer and continue feeding / recycling liquor while drawing off slurry to
elutriator and recovering product solids from centrifuges.
Physical operating level must be maintained between level sight glasses, although level indication from
level transmitter will decline as the density in the crystallizer is reduced. This will require periodically
lowering the level set point while maintaining the automatic level control. The typical operating density
is 1530 while the density after all solids are removed or dissolved is 1300.
After 2 hours of drawing down the density, or at a point when the recovery of solid product from the
centrifuges is significantly reduced, begin diluting crystallizer with process water. Again maintain a
relatively constant physical level in the crystallizer. During this time, the quantity of liquor in the
circuit will increase and may need to be purged.
When solids are no longer being recovered by the centrifuges, the centrifuge feed can be stopped and
the centrifuges can be washed.
When the density in the crystallizer is reduced to 1300, stop the slurry transfer pump, close the isolation
valve, flush the line and allow the level in the crystallizers to increase above the upper level sight glass
or as high as required to cover any wall scale that developed above the normal operating level.
Stop feeding water and allow the crystallizer to be agitated for at least one hour. Monitor the density in
the crystallizer during this time. If a significant amount of solid build-up is being dissolved, the density
may increase above saturation (1300). If this occurs, additional water must be added and if required
liquor removed so that all solid accumulation is dissolved.
Once the crystallizer density is maintained below 1300 for at least one hour, the crystallizer can be
restarted. First open the isolation valve and start one of the slurry pumps to reduce the physical level in
the crystallizer back to the range between the level sight glasses. Then the solid feed can be restarted
and the density is rebuilt.
HPD, LLC
23562 West Main Street, Route 126
Plainfield, Illinois 60544 USA
Tel: 1 (815) 609-2000 Fax: 1 (815) 609-0490
Web site: www.hpdsystems.com
1.2
Emergency Wash-Out
In the case where it is not possible to perform the Planned Wash-Out procedure due to equipment or
power failure, the crystallizer contents can be dumped through the drain valve. The drain nozzle will
usually require flushing with hot process water for several minutes in order to dissolve settled solids.
The crystallizer contents are hot (97C) and there is a large volume to drain (300 m3) so the disposition
of this material must be thought through before draining is performed. The crystallizer agitator cannot
suspend solids once the level is below the top of the draft tube so usually the entire contents must be
removed when draining is used. The level transmitter is not able to detect the level below the top of the
draft tube so the only indication of level for the remaining 70% of the crystallizer contents is when the
vessel is empty and slurry is no longer draining. However, the drain nozzle can become plugged and
give a false empty indication so this must be kept in mind when draining and the nozzle should be
flushed with hot process water to ensure the crystallizer is empty.
Once empty, the equipment repairs can be made and when ready, the crystallizer can be refilled to the
operating level with either water or solids-free liquor.
2
2.1
Anhydrous Reactor
Planned Wash-out
This wash procedure is used for routine cleaning of heat transfer surfaces of the Anhydrous Reactor
Heater. Once refined with operating experience, this procedure should take ~3 hours to perform. The
intent is to perform this Quick Wash at frequent enough intervals to prevent complete plugging of any
heat exchanger tubes. If tube plugging does occur, the plugged tubes will most likely remain out of
service until a complete shutdown is performed with draining the vessel, opening the manways and
performing high-pressure water cleaning of the tubes.
The initial frequency for performing a Quick Wash is once per week. The frequency can be adjusted
based on operating experience.
First stop the slurry feed by closing the isolation valve at the Second Stage Crystallization Feed Tank,
flushing the line with hot process water and then stopping the slurry feed pump.
Stop supplying steam to the Anhydrous Reactor Heater by putting the pressure control valve for the 15
bar steam in manual and closing (520-PCV-0401).
Put level control valve in manual so that slurry withdrawal is continued as the level decreases in the
Anhydrous Reactor (520-LCV-0001A/B).
Monitor the level in the Second Stage Crystallization Feed Tank. The level will increase in the feed
tank as the level decreases in the Anhydrous Reactor. If necessary, stop feeds to the First Stage
Crystallizer, flush the slurry transfer lines and recover the remaining product out of the First Stage
Elutriator through the First Stage Centrifuges and then allow the First Stage Crystallizer to idle. Brine
will also likely need to be purged from the circuit during this time.
Continue to draw down the level in the Anhydrous Reactor at normal operating flow rate for ~ one hour
or until the level transmitter indicates 20% level (~1 meter below RI nozzle). At this point the DN150
process water line to the Anhydrous Reactor should be opened and the vessel should be filled to a high
level. The objective is to reduce the density in the vessel below 1300. Care must be taken to avoid
over-filling the vessel and the pressure should also be closely monitored. The vessel should be
manually vented from the top vent valve if the pressure increases above 1.5 bar-g.
The temperature in the Anhydrous Reactor will decline as the process water is added. When the
temperature goes below 115 C, the slurry transfer to the Second Stage Crystallizer must be stopped and
the line flushed. If the density is still above 1300 when the vessel is nearly full, it will be necessary to
purge material through the drain valve.
Once the density is below 1300, the Anhydrous Reactor is allowed to circulate for at least one hour and
the density is monitored to ensure that the liquor remains below saturation. After one hour below 1300
density is obtained, the system can be restarted by first applying the steam and heating the contents to
120 C, then begin transferring material to the Second Stage Crystallizer and finally restarting the slurry
feed from the Second Stage Crystallization Feed Tank.
2.2
Emergency Wash-Out
Whenever possible, the Quick Wash procedure should be used prior to draining the Anhydrous Reactor.
This dilutes and dissolves the anhydrous sodium carbonate crystals and reduces the temperature.
Attempting to drain anhydrous slurry will result in the instant formation of sodium carbonate
monohydrate solids in addition to steam and hot liquor. If equipment failures prevent a Quick Wash
from being performed, the next best thing would be to first dilute the anhydrous slurry by opening the
DN150 process water connection and filling the Anhydrous Reactor to a high level. Then slurry can be
drained through the drain valve.
When possible, the Anhydrous Reactor can then be filled with process water to the normal operating
level and circulated for at least one hour to dissolve any solid build-up. If significant tube plugging has
occurred, the system will need to be drained of wash water and the high pressure water cleaning system
will need to be used to manually clear the plugged tubes.
2.3
High Pressure Water Cleaning

After completely draining the system, the manway at the top liquor box of the Anhydrous Reactor
Heater is opened along with the manway on the lower section of recirculation piping. The plants
Confined Space Entry procedure must be implemented before manual cleaning of the tubes can begin.
Proper personal protective equipment must be worn by the individuals performing the tube cleaning.
The cleaning is performed using the high pressure water cleaning system, consisting of the high
pressure pump, high pressure hoses, flexible lance and foot operated valve. The operator of this
equipment would stand on the top tube sheet of the heat exchanger and gradually work the flexible
lance down into the plugged tube while the high pressure water cuts through the deposited solids. This
procedure cleans one tube at a time and can take a substantial amount of time depending on the number
of plugged tubes and the nature of the solid deposit. The heat exchanger contains a total of 1378 tubes.
When all the tubes are clean, the lower recirculation pipe should be rinsed out and any pieces of solids
should be removed through the manway. The manways can then be bolted closed and the system can
be re-filled and re-started.
3
3.1
Second Stage Crystallizer

Planned Wash-out
The Second Stage Crystallizer is coupled with the Anhydrous Reactor such that it is not possible to
wash the Second Stage Crystallizer without also washing the Anhydrous Reactor. The only way to
charge a significant amount of dilution water to the Second Stage Crystallizer is through the Anhydrous
Reactor.
Therefore, a Quick Wash procedure should first be performed on the Anhydrous Reactor and then the
Second Stage Crystallizer can be washed. The wash procedure for the Second Stage Crystallizer is
similar to the First Stage Crystallizer. The difference is that water is fed through the Anhydrous
Reactor.
3.2
Emergency Wash-Out
The emergency wash-out procedure, which is primarily and emergency drain procedure, is the same as
the First Stage Crystallizer.
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
8.1
date
2005-06-30
rev
FLUID BED DRYING (PFD600-01)
8.1
Process description
Monohydrate crystals leaving the second stage centrifuges are fed with belt conveyor
520-CV-040 to dryer feed screw conveyor 600-SC-010. In this conveyor the damp crystals
are mixed with dry crystals from the drying section of the fluid bed, supplied via dried
product recycle airlock 600-AL-010 and bucket elevator 600-BE-010. The mixed crystals
are further transported by dryer feed screw conveyor 600-SC-020 to dryer feed distributor
600-FD-010.
Fluid bed dryer 600-FB-010 comprises three baffled compartments containing heat
exchanger tube bundles. In the first compartment surface moisture is removed, and the
monohydrate is heated to about 85 to 90C. The first section is a well mixed deep bed for
receiving and drying the wet feed material. Dehydration is not desired in this first
compartment, as it results in a fragile, low hardness final product and can lead to
excessive heat bundle scaling.
In the second compartment the solids temperature is increased to 150C, and dehydration
is performed. The second section is for dehydration and has a plug flow design.
In the third compartment ambient temperature fluidizing air and circulating water supplied
from a cooling tower are used to reduce the product temperature to 80C. Anhydrous
product containing less than 0.1 % moisture will discharge through airlock 600-AL-040 to
the dryer product conveyor 700-CV-010 feeding the screening.
Fluidizing air will be indirectly steam heated to 180C prior to delivery to the first two dryer
compartments. Air for the first compartment is supplied by dryer air fan 600-FN-010,
preheated with condensate in dryer air preheater 600-HX-010 and heated with steam in
dryer air heater 600-HX-011. Air for the second compartment is supplied by dryer air fan
600-FN-020, preheated with condensate in dryer air preheater 600-HX-020 and heated
with steam in dryer air heater 600-HX-021. The majority of the heat for drying and
dehydration is supplied by the steam heated pipe bundles inside the fluid bed.
The third compartment will receive ambient air from cooling air fan 600-FN-025. The
majority of the cooling capacity is supplied by cooling water that flows through a pipe
bundle in the cooling section.
The dryer includes the integral baghouse 600-DC-010. The dust that originates from the
drying and dehydration section is recovered in the baghouse and is returned directly to the
dryer. About 3.5 t/h of dust removed from the cooling section end of the fluid bed dryer is
removed separately from the dryer, transported by dryer fines discharge screw 600-SC030 and recycled to the second stage centrate tank and to the second stage feed tank.
This dust is discharged via dryer fines airlock 600-AL-030 to dryer dust hopper 600-BN-
word 10.0
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doc. no.
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8.2
date
2005-06-30
rev
030. In this hopper the dust is mixed with air and sucked into dryer dust conveyor
600-CV-030, which is driven by second stage centrate.
Dedusting air from the inlet of conveyor 700-CV-010 is connected to the dryer dust
collector 600-DC-010.
Induced draft fan 600-FN-030 will pull the exhaust air from the dryer through the
baghouse for discharge to atmosphere.
Condensate from the air heaters and the heat exchanger tube bundles is collected in fluid
bed dryer condensate tank 600-TK-010, where it flashes to a pressure between 3 and 6
bar absolute. The resulting vapor is discharged into the low pressure steam header. The
condensate is discharged via the air preheaters to the boiler feed water tank 900-TK-040,
by means of the pressure inside 600-TK-010.
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8.3
date
2005-06-30
rev
8.2
Normal operation
8.2.1
Feed to static fluidbed dryer for pure soda ash plant (PID 600-01)
Via a chute, centrifuge cake from the crystallization section is fed to dryer feed screw
conveyor1 600-SC-010. Part of the dried light ash is recycled from the drying section to
this screw conveyor to lower the feed moisture content and to prevent fouling of the screw
conveyors and the feed distributor 600-FD-010. The dry ash recycle is provided by airlock
600-AL-010 and bucket elevator 600-BE-010 that run at a fixed speed. Therefore the
amount of recycle is fixed, and the ratio of dry crystals to the feed varies with the feed
capacity.
The mixed crystals are fed to dryer feed screw conveyor2 600-SC-020 that feeds the
crystals to the dryer feed distributor 600-FD-010, which distributes the feed evenly over
the width of the dryer. The speed of the feed distributor can be adjusted. After testing
during commissioning and start-up this is set at an optimal value.
8.2.2
Static fluidbed dryer for pure soda ash plant (PID 600-02)
The mixed crystals are fed to the drying section of the fluid bed dryer. The temperature of
the drying section is controlled by 600-TICSA-0101 which controls the steam flow to the
steam tube bundles.
The air flow through the distributor plate is essential for proper fluidization. The air flow
rate is controlled (see P&ID 600-03). In the dehydration section the air flow rate is
distributed over 2 segments. The air flow distribution can be adjusted with manual valves.
The flow rate for each segment can be determined by use of the pressure drop indicators
(600-PDI-0103/0104 and 600-PDI-0105/0106). The total pressure drop across the (clean)
distribution plate and the bed is measured and this is a coarse indicator for the bed height
and air flow rate in that section.
A good indication for the performance of the first two sections of the fluid bed dryer, is the
temperature of the soda ash leaving the dehydration section (600-TICSA-0102). Therefore
this temperature is an important quality parameter.
Cooling of dense soda ash is done partly by the ambient air (from cooling air fan 600-FN025) required for fluidization and for the major part by circulating cooling water through the
tube bundles in the third section of the unit. A correct air flow rate is important for proper
fluidization and for proper de-dusting. The amount of air can be controlled with a manual
valve, and the pressure drop of the bed (600-PDI-0107/0108) can be used as a measure
for the flow rate.
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doc. no.
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8.4
date
2005-06-30
rev
This cooler section is also used for separation of dust. Dust is entrained in the air to the
filter bags and thus carried over beyond the fluid bed part of the unit. The hood of the
dryer is operated at a pressure slightly below atmospheric. This is done for dust control
(both from the dryer itself and for the rest of the plant). To maintain the required negative
pressure in the hood of the dryer, a pressure control valve 600-PCV-0110 is installed in
the suction line of dryer ID fan 600-FN-030. The dust entrained in the fluidization air is
separated in dust collector 600-DC-010. Dust from the dryer and dehydration section is
returned directly from where they are collected. Dust from cooling section is separately
discharged by means of dryer fines screw conveyor 600-SC-030 and dryer fines airlock
600-AL-030 to the dryer dust hopper 600-BN-030. This dust discharge system runs at a
fixed speed.
The filter bags clean the air from the dryer to below the dust level allowed for
environmental release to atmosphere. The dust level in the clean air is monitored with a
dust detector (opacity measurement) and a broken bag detector is installed.
To maintain an acceptable pressure drop across the filter the bags are automatically
cleaned by pulsing with compressed air. This is carried out in cycles, a few rows at a time,
triggered by a timer. The pressure drop is also monitored and at high pressure drop an
alarm is generated so that the operator can start an additional cleaning cycle.
Cooled dense ash is discharged from the dryer through dryer product discharge airlock
600-AL-040 to conveyor belt 700-CV-010. The airlock and conveyor run at fixed speed.
8.2.3
Air supply and air heating for static fluidbed dryer for pure soda ash plant (PID 60003)
Steam (15 bar) is supplied to to air heaters 600-HX-011 and 600-HX-021 for heating
fluidization air for drying and dehydration sections. The temperature of the hot air is
controlled by the steam flow to the air heaters (600-TCV-0201/0202).
The air heaters consist of of a preheating section and a heating section. In the preheating
section cold air is heated with the condensate discharge from condensate tank 600-TK010. Using this condensate air is heated to about 100C and the condensate is cooled to
about 80C. In the heating section the preheated air is heated with steam to 180C.
The flow distribution of condensate to both preheaters can be adjusted with manual
valves, in order to achieve equal the outlet condensate temperatures (600-TI-0203/0204).
One of these manual valves should be fully opened.
Fluizidization air for drying and dehydration sections is supplied by dryer air fans
600-FN-010 and 600-FN-020. The speed of these fans is controlled by flow meters
downstream of the heater (600-FIC-0201/0202).
Fluidization air for the cooling section is supplied by cooling air fan 600-FN-025 which
runs at fixed speed. The amount of air can be adjusted with a manual valve, and the
word 10.0
Engineering
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BOM Magadi

doc. no.
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8.5
date
2005-06-30
rev
pressure drop of the bed (600-PDI-0107/0108) can be used as a measure for the flow
rate.
8.2.4
Monohydrate dryer dust and condensate discharge (PID 600-04)

Dust transport
Dust from 600-AL-030 falls into the dryer dust hopper (600-BN-030).
A fixed flow of liquor is supplied by centrate pumps 520-PP-040/041. Solids and entrained
air are sucked into the jet conveyor 600-CV-030 and transported to the second stage
crystallization feed tank 520-TK-005 and to the centrate tank 520-TK-040. Supplying hot
dryer dust to the liquor stream causes the liquor temperature to increase due to the
sensible heat increase by introduction of hot dryer dust and the heat of dissolution.
Condensate storage and discharge
Condensate from the fluid bed and from the air heaters is collected and flashes from 15
bar to about 3 bar in 600-TK-010. The pressure in this flash vessel is controlled by 600PIC-0302. Flash steam is discharged to the 3 bar steam header. Condensate from 600TK-010 is used in the air pre-heaters and then discharged to boiler feed water tank 900TK-040. The level in 600-TK-010 is controlled by 600-LICSA-0301.
word 10.0
Engineering
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project name
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doc. no.
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page
8.6
date
2005-06-30
rev
8.2.5
Setting list
Instrument
Unit
Normal
Alarm
Trip/Switch
600-FISA-0101
ton/h
24
LL TBD
LL TBD
L TBD
600-FI-0102
ton/h
14
600-FI-0103
ton/h
600-FI-0104
75
m /h
600-FIC-0201
m /h
30800
600-FIC-0202
m /h
50500
600-HIC-0001
600-KIS-0101
600-LICSA-0301
50
H 90
L 20
600-LA-0101
H TBD
600-LA-0102
H TBD
600-LICSA-0301
50
LL 5
LL 5
LL 5
L 20
H 90
600-LI-0302
50
600-LSA-0303
mm
600-PIC-0110
mm H2O-g
-10
600-PISA-0111
barg
14.5
600-PI-0112
barg
14.5
600-PI-0113
barg
14.5
H 200
LL TBD
L TBD
600-PI-0114
barg
4.5
600-PCV-0115
barg
4.5
600-PDI-0101
mm H2O
900 - 1050
600-PDI-0102
mm H2O
250 -300
600-PDI-0103
mm H2O
900 - 1050
600-PDI-0104
mm H2O
250 - 300
600-PDI-0105
mm H2O
900 - 1050
600-PDI-0106
mm H2O
250 - 300
600-PDI-0107
mm H2O
900 - 1050
3)
word 10.0
H 200
3)
LL TBD
Engineering
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doc. no.
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page
8.7
date
2005-06-30
rev
Instrument
Unit
Normal
600-PDI-0108
mm H2O
250 - 300
600-PDISA-0109
mm H2O
125 - 150
600-PI-0201
barg
14.5
600-PI-0202
barg
14.5
600-PI-0203
mm H2O-g
1285
600-PI-0204
mm H2O-g
1285
600-PI-0205
Barg
600-PDI-0201 (0206?)
mm H2O
20
600-PDI-0202 (0207)?)
mm H2O
20
600-PDI-0203 (0208?)
mm H2O
20
600-PI-0301
Barg
600-PIC-0302
Barg
600-QIA-0101
mg/m
Trip/Switch
H TBD
H TBD
<35
1)
H 35 (Check)
mg/Nm
<50
2)
H 50
mg/m3
<35
5)
H 35 (Check)
<50
2)
H 50
600-QIA-0104
Alarm
600-SSA-0001
TBD
TBD
L TBD
600-TICSA-0101
90
H TBD
600-TICSA-0102
150
600-TIC-0103
80
600-TISA-0104
210
600-TIA-0105
90
600-TIA-0106
80
600-TI-0107
30
600-TI-0108
45
600-TIC-0201
180
600-TIC-0202
180
600-TI-0203
85
600-TI-0204
85
600-TI-0301
200
600-TIA-0302
99
HH TBD
L TBD
HH TBD
H TBD
HH TBD
HH TBD
LL TBD
LL TBD
L TBD
H TBD
L TBD
H TBD
H 101
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
8.8
date
2005-06-30
rev
Instrument
Instrument air purgerators
Unit
l/h
4)
Normal
Alarm
10
1) At 90C and 0.95 bara

2) at 0C and 1.013 bara
3) As measured from bottom weld line of cylindrical section
4) At upstream operating conditions
5) at 90C and 0.945 bara (-50 mm H2O-g)
word 10.0
Trip/Switch
Engineering
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project no.
405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
8.9
date
2005-06-30
rev
8.3
Logic functions
The following table shows logic functions acting on equipment.
Equipment/Action
Start
Stop
Signal description
Type
Start/
Switch/
Running
Interlock
condition
600-AL-040
Locally by
Locally by
hand
hand and
Product conveyor running
700-CV-010
automatic
600-AL-030
Locally by
Locally by
Dryer dust shut-off gate
hand
hand and
600-GA-030 is open
automatic
600-SC-030
Locally by
Locally by
hand
hand and
automatic
Rotary valve 600-AL-030 is
running
Dryer dust shut-off gate
600-GA-030 is open
520-CV-040
Locally by
Locally by
hand
hand and
automatic
Product rotary valve 600-
AL-040 running
Fines screw conveyor 600-
SC-030 running
Feed distributor 600-FD-010
running
Feed screw conveyor 600-
SC-020 running
SC-010 running
Steam flow 600-FISA-0101
Stop
LL switch activated
Steam temperature 600-
Stop
TISA-0104 LL switch
activated
Steam pressure 600-PISA-
Stop
0104 LL switch activated

600-BE-010
Locally by
Locally by
hand
hand and
automatic
Feed screw 600-SC-010
running

activated
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doc. no.
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8.10
date
2005-06-30
rev
Equipment/Action
Start
Stop
Signal description
Type
Start/
Switch/
Running
Interlock
condition
600-AL-010
Locally by
Locally by
hand
hand and
automatic
Bucket elevator 600-BE-010
running
SC-020 running
SC-010 running
running
600-SC-010
Locally by
Locally by
hand
hand and
Feed screw conveyor2 600-
SC-020 running
automatic
600-SC-020
Locally by
Locally by
hand
hand and
running
automatic
600-FD-010
Locally by
Locally by
hand
hand and
None
automatic
600-FN-010
Automatic
Automatic
600-FN-020
Automatic
Automatic
600-FN-025
Automatic
Automatic
600-FN-030
Automatic
Automatic
Dryer-FN-030 running
None
The following table shows automatic actions of valves.

Valve
Action
Cause
600-TCV-0101
Close
HH switch of 600-TICSA-0101 and 600-TIS-0105
600-TCV-0102
Close
600-TCV-0201
Close
600-TCV-0202
Close
word 10.0
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project name
BOM Magadi

doc. no.
2.187.735 -
page
8.11
date
2005-06-30
rev
8.4
Start-up and shutdown of fluid bed dryer
8.4.1
Normal start-up (from empty bed)

The fluid bed is empty. The drying section will be filled with dry dense soda ash from
bags. The soda ash will be fed to the dryer feed screw conveyor.
Before starting check that:
There are no foreign materials in the fluid bed
Unit is dry from washout
All manholes, inspection covers and drain valves are closed
Following utility systems have to be ready:
15 bar steam supply
cooling water supply
boiler feed water tank 900-TK-040 ready to receive condensate
3 bar steam header ready to receive flash steam
plant air and instrument air supply
electrical supply
condensate system (see procedure in section 8.6.1)
dust transport (see procedure in section 8.5.1)
Provide 15 ton (300 bags 50 kg) of soda ash for filling up the drying section.
1
2
3
4
5
7
8
Open all manual dampers at air inlet of drying, dehydration and cooling section of
the fluid bed.
Close valves 600-TCV-0101/0102 at steam supply to heating coils
Close manual flaps between drying section and dehydration section
Close product outlet powder gate in the fluid bed outlet section
Start dryer ID fan 600-FN-030 with closed inlet damper and put 600-PIC-0110 on
automatic.
(Overpressure on the dryer and dust collector must be avoided in order to prevent
dust emission. Therefore, Dryer ID Fan 600-FN-030 has to be running before other
fans are started)
Directly when 600-FN-030 is running, start dryer air fans 600-FN-010 and 020 at low
speed and cooling air fan 600-FN-025 and put flow controllers 600-FICA-0201/0202
on automatic. Gradually increase the setpoint to the value according to the setting
list.
Open instrument purgerators and set flowrate according to setting list
Open valve 600-PCV-0115 of plant air supply and activate air pulsation for cleaning
of dust filter
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project name
BOM Magadi

doc. no.
2.187.735 -
page
8.12
date
2005-06-30
rev
9
10
11
12
13
14
15
16
17
18
19
20
Start feed distributor 600-FD-010

Start dryer feed screw conveyor 600-SC-020
Start dryer feed screw conveyor 600-SC-010
Start bucket elevator 600-BE-010
Start feeding soda ash from bags.
Observe 600-PDI-0101/01012. A fluidizing layer is now created in the drying section
of the bed.
When bed is filled up to a level that 600-PDI-0101 is approx. 500 mm WC, open
steam control valve 600-TCV-0101 gradually in manual mode with a small opening
of 5 or 10% and put in automatic after temperature stabilization at 90C (max
110C) (ensure bypass over 600-TCV-0101 is closed).
Open steam supply 600-TICSA-0201 to air heater 600-HX-011 on manual such that
90C bed temperature is reached and put on automatic at the corresponding
setpoint of 600-TICSA-0201 (ensure bypass over 600-TCV-0201 is closed).
Open slide gate above 600-AL-010 manually
Start dried product recycle airlock 600-AL-010 and keep soda ash in circulation
Start 700-CV-010
Start 600-AL-040
Now unit is ready to receive wet feed and the calciner and crystallization section can be
started.
21
22
23
24
25
26
27
Start 520-CV-040.
Adjust temperature setpoint of 600-TICSA-0201 as needed to keep the bed
temperature at 90C.
Monitor bed height, and when 600-PDI-0101 exceeds 900 mmWC, the intermediate
powder gate between drying and dehydration section shall be manually opened. In
this way the dry monohydrate enters the dehydration section of the bed
Put steam to dehydration section steam panel and air heater (600-TICSA-0102 and
600-TIC-0202) to automatic with setpoint of 180C (ensure bypass over 600-TCV0102/0202 is closed).
Monitor bed height, and when 600-PDI-0103 exceeds 900 mmWC, the intermediate
powder gate between dehydration and cooling section shall be manually opened. In
this way the dry soda ash enters the cooling section of the bed
Open isolation valves of cooling water and put 600-TIC-0103 in automatic mode with
a setpoint of 80C (ensure bypass over 600-TCV-0103 is closed).
Check temperature of the sections. The product temperature after the dehydration
section (600-TICSA-0102) has to be above 150C for required conversion. The
product outlet temperature has to be 80C or less.
word 10.0
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project no.
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project name
BOM Magadi

doc. no.
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page
8.13
date
2005-06-30
rev
28
29
8.4.2
Restart from standby

1
2
3
4
5
8.4.3
Check air flow rate in relation to bed height (600-PDI-0107/0108) Adjust with manual
control valve if needed (information provided by vendor)
Take sample of product to check fluid bed dryer performance (moisture content,
particle size distribution and bulk density)
Start 520-CV-040 (steam supply to tube bundles (600-TICSA-0101/0102 will open

automatically)
Monitor the bed heights (pressure drop transmitters) and open manual flaps
between the sections
Check temperature of the sections. The product temperature after the dehydration
section (600-TICSA-0102) has to be above 150C for the required conversion. The
product outlet temperature has to be 80C or less.
Check air flow rate in relation to bed height (600-PDI-0107/0108) Adjust with manual
control valve if needed (information provided by vendor)
Take sample of product to check fluid bed dryer performance (moisture content,
particle size distribution and bulk density)
Shut down (empty fluid bed)

This procedure describes emptying the fluid bed and complete shut down, for washing
down or maintenance activity. Equipment must be emptied completely when stopping for
a longer period of time. Moisture inside the system and from migration from outside can
cause lump and crust formation. It is assumed the liquor supply for dust removal remains
operational. Even when the crystallization unit is on standby, it can still receive the amount
of dust that is released during the emptying of the fluid bed.
1
2
Stop feed from crystallization section (520-CV-040)

Continue operation until the bed is empty as much as possible (open
600-HSV-0101and adjust manual flaps according to information from vendor).
Monitor bed height with pressure drop indicators.
When bed, hoppers, screw conveyors etc. are empty, the unit can be stopped.
3
Close steam supply to the tube bundles (600-TCV-0101/0102) and to air heaters
(600-TCV-0201/0202)
4
Close cooling water supply to tube bundle (600-TCV-0103)
5
Stop 600-AL-010, 600-BE-010, 600-SC-010, 600-SC-020, 600-FD-010
6
Stop dust recycle system (see procedure in section 8.5.2)
7
Stop 600-AL-040 and 700-CV-010
8
Stop liquor supply from crystallization section (see second stage crystallization)
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doc. no.
2.187.735 -
page
8.14
date
2005-06-30
rev
9
10
11
12
13
8.4.4
Stop air fans 600-FN-010, 600-FN-020 and 600-FN-025

Stop dryer ID fan 600-FN-030
De-activate air pulsation system on filter bags
Shutdown condensate system (see procedure in section 8.6.2)
Keep instrument air purgerators running, unless required for the purpose of the
shutdown
Going to standby
1
2
3
Stop feed by stopping 520-CV-040

The steam supply to the pipe bundles (600-TCV-0101/0102) closes automatically
Close manual flaps between sections to keep bed height constant
8.5
Start-up and shutdown Dust transport
8.5.1
Normal start-up
1
2
3
4
5
6
7
8
9
8.5.2
Dryer is not yet running, or is not supplying dust to 600-BN-030.

Check 600-GA-030 is closed
Check manual drain valve upstream of 600-CV-030 is closed. Check automated
drain valve 600-XSV-0301 is closed (reset on DCS)
Check 520-TK-040 has sufficient level, and centrifuge 520-CF-035/036 supply
sufficient liquor.
Check position of 520-LCV-0601 on P&ID 520-06 and the status of 520-TK-005.
Start selected pump (520-PP-040/041)
If pump is running well, then open 600-GA-030
Start dryer fines airlock 600-AL-030
Start dryer fines screw conveyor 600-SC-030
Normal shut-down
1
2
3
4
Stop dryer fines screw conveyor 600-SC-030

Stop dryer fines airlock 600-AL-030
Close 600-GA-030 (to prevent moisture entering the dust system)
If Crystallization section is kept running, then no further action required.
If crystallization section is stopped also, stop running pump 520-PP-040/041.
600-XSV-0301 will be opened automatically when the pump stops.
If crystallization is stopped and 520-PP-040/041 is stopped, then 600-XSV-0301 can
stay open. It is closed by a reset action on DCS.
word 10.0
Engineering
CONFIDENTIAL
project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
8.15
date
2005-06-30
rev
8.6
Start-up Condensate collection and discharge
8.6.1
Normal start-up
1
2
3
4
5
8.6.2
Make sure condensate can be received in 900-TK-040

Set 600-PCV-0302 in automatic mode, with set point according to the setting list.
If tank 600-TK-010 is empty, place 600-LICSA-0301 on manual.
When steam supply is open on the dryer, condensate will be collected in the tank.
If sufficient level is in the tank (approx 50%), open block valve and open
600-LCV-0301 by hand. Bring the level to the desired value (see setting list) and put
controller in automatic mode (ensure bypass over 600-LCV-0301 is closed).
Normal shut down

1
2
If dryer is shut down place 600-LCV-0301 on manual and close it.

Take 600-PCV-0302 on manual and close it.
8.7
8.7.1
Periodic checks
1
3
4
5
6
Pressure drop of fluid bed:

Drying, dehydration and cooling section have separate pressure drop indicators.
Monitor the pressure drop periodically. If the pressure drop is too high (information
provided by vendor), the fluid bed has to be cleaned.
Pressure drop of inlet air filters of air fans:
The dryer air fans and the cooling air fan are provided with air filters. A pressure
drop indicator is installed. Monitor the pressure drop periodically. If the pressure
drop is too high (information provided by vendor), the filter has to be cleaned.
Plant inspection:
Frequent routine checks by field operator for visual inspection
During operation small lumps of soda ash will be accumulated at the fluid bed
intermediate gates. In order to let these lumps escape, the gate must be quickly
opened and closed. After start-up the frequency of this action is twice an hour,
during normal operation 4 times per shift.
Check for fouling on feed screws and feed distributor, check rotating equipment,
check dryer dust hopper air inlet openings are free (every 2 hours)
Take samples, see analytical manual
word 10.0
Engineering
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405.014
project name
BOM Magadi
doc. no.
2.187.735 -
page
8.16
date
2005-06-30
rev
8.7.2
Critical process conditions

Location
Parameter
Tag or sample
Purpose; target or
setpoint
520-CV-040
Moisture content in dryer feed
Sample
from crystallization
600-FB-010,
Bed temperature
600-TICSA-0101
drying section
600-FB-010,
Performance of dryer; <

5 wt%
Drying process;
90-100C
Bed temperature
600-TICSA-0102
dehydration
Dehydration process;
135-150C
section
600-FB-010,
Bed temperature
600-TIC-0103
cooling section
600-FB-010,
80C
Bed height
600-PDI-0101/0102
drying section
600-FB-010,
Cooling process;
Drying process;
See setting list
Bed height
dehydration
600-PDI-
Dehydration process;
0103/0104/0105/0106
see setting list
600-PDI-0107/0108
Cooling process; see
section
600-FB-010,
Bed height
cooling section
700-CV-010
setting list
Product moisture content,
Sample
particle size distribution and
Quality parameter;
< 0.1 wt%
bulk density
250 < D50 < 350 m
> 1000 kg/m3
8.7.3

See Analytical manual.
word 10.0
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project no.
405.014
project name
BOM Magadi

doc. no.
2.187.735 -
page
8.17
date
2005-06-30
rev
8.8
8.8.1
Cleaning of dryer
If the pressure drop over the fluid bed increases too much, the fluid bed has to be cleaned
with water. Fouling is expected to occur mainly in the first section (drying section),
especially in case the feed moisture content is too high. It is expected that this section will
need to be cleaned every 3 months, depending on the control of the process.
Before cleaning, the dryer has to be empty so must be shut down in accordance with
procedure 8.4.3.
1
2
3
Open inspection openings and drains.

Proceed with cleaning operation (see section 8.8.5)
After cleaning, drain the unit well.
After draining the unit has to be dried

4
Start dryer ID fan 600-FN-030 and put 600-PIC-0110 on automatic
5
Directly when 600-FN-030 is running, start dryer air fans 600-FN-010 and 020 and
cooling air fan 600-FN-025 and put flow controllers 600-FICA-0201/0202 on
automatic.
6
Start-up condensate system (see procedure in section 8.6.1)
7
Turn on the steam supply to air heaters with a setpoint of 70C
After some time the unit can be restarted (proceed with item 6 of procedure 8.3.1)
8
Make sure purgerators are running and flow rate is according setting list
9
Proceed with item 6 of procedure 8.3.1
8.8.2
Too low liquor feed to 520-TK-040

If there is no or low feed from the centrifuges to 520-TK-040, then the temperature will
increase in 520-TK-040. The return temperature to 520-TK-040 is monitored with 600-TIA0302. When the temperature is too high (see setting list), an alarm is generated, and the
cause of the high temperature has to be investigated or otherwise the dust supply to the
circuit has to be stopped. When there is no feed from the centrifuges, the flow of cake to
the dryer will also stop.
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project name
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doc. no.
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page
8.18
date
2005-06-30
rev
8.8.3
Pump failure of 520-PP-040/041

If one of the two pumps fail the following automated responses are activated:
600-GA-030 is closed
600-XSV-0301 is opened.
In this way liquor can not enter the dryer system and will drain out of bin 600-BN-030.
Before restart, it has to be verified that the bin 600-BN-030 is empty of liquid and dry.
8.8.4
Dust transport
600-GA-030 is closed when 600-LSA-0303 detects high level and when 520-PP-040 and
520-PP-041 are out of operation (so when flow to 600-CV-030 stops). 600-GA-030 can be
opened by the operator when:
high level 600-LSA-0303 not activated
520-PP-040 or 520-PP-041 in operation
When both 520-PP-040 and 520-PP-041 are out of operation 600-GA-030 is closed and at
the same time 600-XSV-0301 is opened. Valve 600-XSV-0301 has to be closed by the
operator (reset action on DCS required).
Supplying hot dryer dust to the liquor stream causes the liquor temperature to increase
due to the sensible heat increase by introduction of hot dryer dust and the heat of
dissolution.
Supplying hot dryer dust to the liquor stream causes the liquor temperature to increase
due to the sensible heat increase by introduction of hot dryer dust and the heat of
dissolution. Therefore the return temperature of the liquor is monitored with 600-TIA-0302.
When the temperature is too high (see setting list), an alarm is generated, and the cause
of the high temperature has to be investigated or otherwise dust bleed has to be stopped.
word 10.0
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project name
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doc. no.
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page
8.19
date
2005-06-30
rev
8.8.5
Washout procedure of fluid bed dryer
word 10.0
Operation procedure for Fluid Bed Dryer Cooler for Pure Soda ash plant
Document No. MSC/CL/002, Rev.0
Customer:
Magadi Soda Company Limited, Kenya
DT: 22-2-2005
WASHING PROCEDURE
Wash-up of the fluid bed plant
It is expected that the fluid bed can be operated continuously for a longer
period. However it is recommended to make some short inspections during the
operation period while feed & fans are stopped.
After a running period of approximately 3 months the fluid bed should be
evacuated for product and inspected. Washing of steam tubes may be
necessary. In practice this stop typical have duration of 3 shifts.
Once in a year long overhaul shut down should be performed. In addition to
periodic inspection and washing we advice to pull out 1 or 2 stream bundles in
the drying as well as the calcining section. This will allow a walk in on the gill
plate for a closer look of this as well as inspection of the steam tubes.
For the pulling of steam bundles a set of mobile trolley to be placed in
extension to the internal rail in order to support the bundle in the outside
position.
Inspection of the plant is mainly a question of inspecting the plant interior due
to possible problems with the performance of the plant. It is absolutely
essential to have prior permission from concerned in-charge.
Note: Never enter the plant interior in case there is no person
available to supervise from the outside.
After washing it is recommended to let the system dry out before feeding is
started.
L&T-NIRO Ltd., 101 GIDC, Ranoli, Baroda 391 350
Page 1 of 2
Customer:
DT: 22-2-2005
Washing procedure
1. Shut-down the plant as described the steps in the operation procedure
(document No. MSC/CL/001, Rev.0)
2. Open the blind flange provided at the bottom of plenum chamber of drying,
dehydrating & cooling section of fluid bed.
3. Open all manholes & inspection covers of fluid bed & dust collector
manually.
4. All manual valves in the cooling water line of cooling coils for cooling
section of fluid bed are closed.
5. The manual isolation valve at compressed air header at bag filter should be
closed.
6. Steam supply line to the fluid bed drying & dehydration section of fluid bed
are isolated by providing blind at the header.
7. Close valves TCV 0101 & TCV 0102 in manual mode at steam supply line to
heating coils of drying section & dehydration section. All isolation & bypass
valves of steam line supplied to the heating coils of drying & dehydration
section are manually closed.
8. The upstream & downstream system of the fluid bed drying system is
isolated.
9. All air dampers at air inlet of drying, dehydrating & cooling section of fluid
bed are manually closed.
Page 2 of 2
Customer:
DT: 22-2-2005
10.Open intermediate powder gate in the fluid bed from drying to dehydration
section & from dehydration to cooling section.
11.Keep open the slide gate valve above AL-010.
12.Disconnect the heating coils with steam & condensate piping. Place mobile
trolley for the pulling of steam bundles, in extension to the internal rail in
order to support the bundle in the outside position.
13.Pull out heating coil & clean it manually by water jet. Clean all other
heating coils in same manner.
14.Connect flexible water hose at the screw feed (SC-010) & wash the screw
feed. Water should flow through the rotary distributor (SC-020). The feed
screw & rotary distributor (SC-020) may be started during washing.
15.Washing of fines screw (SC-030) & product outlet box can be done by
spraying water from the manhole provided at the product outlet hopper.
Page 3 of 2
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405.014
project name
BOM Magadi

doc. no.
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page
9.1
date
2005-06-30
rev
EMERGENCY SITUATIONS
9.1
Power Failure
During limited power being available to the plant, the power management system (PMS)
automatically shuts down certain sections to allow sections with a higher priority to
continue operation, depending on the severity of the power failure. The order of priority
(highest first) is as follows:
Critical drives: items of equipment that need to be maintained in a safe mode of
operation and to ensure ease of start up after failure of the electrical power supply.
Essential drives: All other items of the pure ash plant that are needed for continuous
operation, excluding the majority of the washery area
Non essential drives: Majority of the new washery area
Applying the above logics provides the following response upon different levels of power
failure:
Level 1 failure: all non-essential drives are stopped, essential drives and critical drives
remain running
Level 2 failure: all non-essential drives and essential drives are stopped, critical drives
remain running
Level 3 failure (total power failure): all drives are stopped, incl. all utilities
The segregation of power supply gives the following general shut-down sequence:
In case of level 1 failure, the washery will be shut down (non essential drives). The roller
mill can be fed from CRS stockpile and so the calciner, crystallization and drying sections
can continue at normal operating capacity (essential drives).
In case of larger shortage of power (level 2), the essential drives are stopped as well, so
the whole plant is basically shut down however, critical drives remain running. This is
especially important to prevent long recovery time because of solids settling and plugging
in critical vessels. Therefore the agitators in tanks (incl. settlers and crystallizers) with high
concentrated slurries are critical drives. Furthermore the utility supply is classified critical
for purge water on seals, steam tracing of anhydrous lines and hot water for flushing.
In case of total power failure (level 3), all electrical drives including utilities are stopped.
A list of the classification of the drives is provided under separate cover.
9.1.1
Consequences for the washery section 200

Level 1 failure:
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rev
Only non-essential drives are stopped and the plant continues to run (with some
disturbances, see section 5.7.6), except the washery section. CRS is supplied to the mill
from the CRS stockpile. Liquor from the dredge continues to be supplied to the ESP
conveying system and crystallization vent condenser after an interruption to make the
supply line from the dredge free of solids. When the supply line is free of solids the liquor
will be diverted to 200-TK-010 (pumps 200-PP-010/011/012 keep running). The liquor
supply to the boiler scrubber is stopped (200-PP-060/061 is stopped).
Level 2:
Essential drives are shut-down as well and the whole plant is shut down. For the washery
now the liquor supply to 400 and 500 section is stopped, as well as the CRS conveying to
the mill. Only the critical drives remain running.
Level 3:
Critical drives (agitators) are stopped.
Note: Of the sections that are stopped as a consequence of an electrical power failure, the
signals to the solenoid valves of all air operated control valves and on/off valves is
removed, so all valves go to the fail safe position.
9.1.2
Consequences for calciner unit 400

For the combustion chamber 400-FU-050 additional shut down measures are taken.
During normal operating conditions the combustion chamber is cooled with combustion air
and dilution air. If one or both of these stream fail, additional measures are taken to
prevent mechanical damage due to high temperature. This can be achieved by using
cooling air fan 400-FN-054 or with steam.
Level 1 failure: no consequences
Level 2 failure
The calciner unit shuts down, except the cooling air fan 400-FN-054
The following responses are activated:
Actions as described in Local emergency stop command, see section 1.3 of FFEM,
which stops all equipment
All solenoids are deactivated, a/o fuel oil feed is stopped
The cooling air fan 400-FN-054 is started (when the combustion air fan 400-FN-050 or
dilution air fan 400-FN-035 is not running and the air heater outlet temperature 400TISA-0468 is > 200C) and valves 400-XSV-0470/0471 are opened. Emergency stack
valve 400-XSV-0472 is opened because ESP ID fan 400-FN-030 is stopped (see
FFEM section 2.5)
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BOM Magadi

doc. no.
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Note: Content of cyclone 400-CY-060 is not dumped

Level 3 failure:
All drives are stopped including the cooling air fan. In this case cooling of the combustion
chamber is provided by steam valves that fail to the appropriate positions.
The Following responses are activated:
Actions as described in Local emergency stop command, see section 1.3 of FFEM,
which stops all equipment
All air operated valves travel to the defined failure positions:
Fuel oil feed is stopped
Emergency vent stack opens (400-XSV-0472)
Steam supply fails open (400-XSV-0425), valve 400-XSV-0426 maintains its last
position which is open during normal operation. Valve 400-XSV-0426 closes when
refractory temperature 400-TIS-0469 is < 450C
Note: Content of cyclone 400-CY-060 is not dumped
9.1.3
Consequences for dumptank 400

Level 1 and 2 failure: No consequences.
Level 3 failure: Diverter 400-GA-060 stays in the direction of the dumptank, if a power
failure is initiated after dumping has started. Process water supply is stopped and a dust
emission may occur. Prior to the dumping of solids, water is present in the tank at a level
of 1 m which serves to cool down the dumped solids.
Since also production is stopped and the air cannons, vibrators and airlock 400-AL-060
stop, no further product is transferred to the dump tank.
9.1.4
Consequences for Dust transport 400

Level 1 failure: no consequences.
Level 2 failure:
The calciner unit shuts down, the dust supply will stop, and process liquor supply will stop.
The following automated response is activated:
400-XSV-1401 will open.
In this case 400-GA-041 cannot be closed.
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9.1.5
Consequences for Crystallization section

Level 1 failure: no consequences.
Level 2 failure:
The electrical drives are stopped, except the critical drives (agitators etc.). Centrifuges
and lines have to be flushed. If this power outage continues then slurry from the elutriator
has to be drained.
Level 3 failure:
Critical drives are also stopped, including purge water supply to the pumps. Lines cannot
be flushed and may become blocked.
9.1.6
Dust transport 600

Level 1 failure: No consequences
Level 2 failure:
The fluid bed dryer has the same electrical priority as the crystallization unit. The dust
supply will stop as well as the liquor supply.
The following automated responses are activated:
600-XSV-0301 will open.
In this case 600-GA-030 can not be closed.
9.1.7
Steam boiler
Level 1 failure:
Soda ash Plant remains in operation, however, no more liquor supply from washery to
boiler scrubber. The hold-up in the scrubber tank is sufficient for 1 hour of operation.
Provide make-up to boiler scrubber from other source.
9.2
Process water Failure
9.2.1
Consequences for the washery section 200

The process water is used for washing the centrifuge cake in 200-CF-070/71. Therefore,
when a failure in the process water supply occurs, the centrifuges may continue operation.
The CRS, however, will not have the required purity. In practice, the higher NaCl can
probably be compensated by allowing more bleed in first stage crystallization section. If
this is not the case then the slurry from the classifier will have to be diverted towards
stockpile 200-ZC-030 (operator action). The roller mill will then have to be fed from CRS
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stockpile and the washery has to be put on standby. In principal solids from the dredgeing
section can continue.
9.2.2
Consequences for calciner section

Depending on the moisture content of the CRS feed, the roller mill can run without the
water spray. If CRS is too dry, the calciner section has to go on standby.
9.2.3
Consequences for Dumptank 400

Failure of process water will cause a dust emission during dumping. The feed diverter
400-GA-060 automatically diverts towards 400-AL-065 and the dust emission is stopped.
9.2.4
Consequences for first crystallization section

The main consequence of this failure is:
lack of washing on the centrifuges 510-CF-035/36 and the produced crystals do not
have the required purity
lack of cold process water to scrubber sprayers and lack of cooling of the liquor
discharge of scrubber 510-DC-015
Furthermore, for longer time scales, no more dilution of process liquor stream and
dissolving of the monohydrate in the deaerator takes place.
The crystallization section has to be put on standby and only a limited amount of hot
process water is available for flushing of lines.
9.2.5
Consequences for second crystallization section

Main consequences of this failure is a that a limited amount of hot water is available for
washing on 520-CF-035/36.
Also cooling water on the vacuum pump fails, therefore vacuum pumps have to stop.
If process water is interrupted during regeneration of the filter, the regeneration cycle
cannot be completed
The second stage crystallization section has to be put on standby but only limited amount
of hot process water is available for flushing of lines.
9.2.6
Consequences for cooling water system

No more cooling water make-up. If level in cooling tower is too low, it will shut down, see
section 9.4.
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9.3
Purge water failure

The purge water pumps are therefore provided with automatic changeover and the purge
water pump drives are classified as critical in case of electrical power failure. Failure of
both pumps gives immediate damage to pump seals. Also instrument readings will
deviate.
In case of a short stoppage of purge water (shorter than 1 minute, e.g. short pump failure)
the plant can keep running. If this happens, some intervals with increased flow of purge
water are needed after resuming normal purge water flow again, in order to clean the
pump seals.
If purgewater is not available for more than 1 minute, the plant has to be shut down,
because otherwise the slurry pump seals are damaged and product will leak through the
seals.
With respect to shutdown procedure, all pumps with purge water on the seals have to stop
as fast as possible.
Most pumps can be stopped right away. For some pumps, a precaution has to be taken:
1
200-PP-011/012: first stop dust supply to 400-BN-040, then stop 200-PP-011/012
2
520-PP-040/041: first stop dust supply to 600-BN-030, then stop 520-PP-040/041
3
510-PP-010/011: first divert feed diverter valve 400-GA-060 to dumptank, then stop
510-PP-010/011
Before restart, pump seals and instruments have to be flushed well and crystallizer
agitators have to be checked. Seals may have to be replaced, requiring emptying of the
crystallizers.
9.4
Cooling water failure

Air compressors will fail as a consequence of cooling water failure. If possible, put process
water on the air compressors. If this is not possible, then the plant is shut down because
of lack of instrument and plant air, see section 9.7
Cooling water failure results in a shut down of the calciner section (Emergency shutdown,
see FFEM section 1.3). Also the fluid bed dryer has to be put on standby.
9.5
Steam failure
Steam failure has the following consequences:
the calciner section has to be shut down (Emergency shutdown, see FFEM section 1.3)
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second stage anhydrous reactor has to shutdown so this section goes on standby
fluid bed dryer has to stop and be put on standby
Close manual isolation valves of steam supply to users.
In most cases steam hold-up in boiler and headers will provide heat tracing on anhydrous
slurry lines.
9.6
Dredge feed failure

When a complete failure of supply from the dredge and emergency lke liquor pump
occurs, the washery will be shut down, and as a consequence, the ESP fines conveying
system fails as does the second stage crystallization section goes on stand-by, because
of lack of cooling liquor on the second stage vent condenser. Also the liquor supply to the
boiler scrubber has to be stopped after some time.
When only the solids supply fails, there are no consequences for the calciner,
crystallization and washery sections. The dry reclaim procedure has to be applied (see
section 5.7.2).
9.7
Instrument air and plant air failure

Instrument air and plant air have a common supply line. If the pressure in the main air line
drops, the supply of plant air stops (900-PCV-1111 closes). When the pressure drops
further, air driven control valves and on/off valves will open, close or remain in their last
position, as presented on the P&IDs. No control is possible and the plant has to be shut
down. The air receivers have a buffer capacity of 2 minutes so if an air compressor can be
restarted within this time, then a plant shutdown is avoided. Otherwise, the low pressure
switch is activated and all solenoids are de-activated. Now all valves go to the fail safe
position, the calciner section is shutdown (see below) and all other electrical equipment is
stopped automatically.
If plant air pressure is low, without any failures of the compressors, then the consumption
is too high. The users that have this high demand have to be located and the air flow
reduced.
Calciner unit 400:
The unit is shutdown according the emergency shutdown procedure FFEM 1.3.
Following responses are activated:
The unit is shutdown (emergency stop section 1.3, FFEM)
Content of cyclone 400-CY-060 is not dumped
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The cooling air fan 400-FN-054 is started

All air operated valves to go the defined failure positions:
Fuel oil feed is stopped
Emergency vent stack opens (400-XSV-0472)
Steam supply fails open (400-XSV-0425), valve 400-XSV-0426 maintains its last
position, which is open during normal operation. Valve 400-XSV-0426 remains open
when refractory temperature 400-TIS0469 is < 450C
Fluid bed dryer
Put the fluid bed dryer on standby:
Stop feed conveyor 520-CV-040.
All valves go to fail safe position (steam valves close, cooling water valve will open,
and inlet damper of 600-FN-030 says put).
The dust conveying system of 600-BN-030 stops as a consequence of the air failure.
Some dust will accumulate.
9.8
Guar solution failure

When a short failure occurs (e.g switching between pumps), the washery and
crystallization operations can be continued normally.
In the case of longer failures, a build-up of impurities in the washery and crystallization is
possible resulting in off-spec product. This means the washery and crystallization sections
have to be shut down.
9.9
Anti foam solution failure in washery section

Failure of supply of anti foam can cause excessive foaming. In this case the washery has
to be put on standby or even shut down if foaming is excessive. Liquor supply to 520-TK005 and 520-TK-010 has to continue in order to be able to keep the rest of the plant
running.
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10
COMMISSIONING AND INTIAL START-UP
10.1
Washery
During commissioning and 1st startup a number of process characteristics have to be
learned.
At several positions in the washery section foaming can potentially occur. Antifoam supply
is provided on the CRS centrate tank 200-TK-070 and is transferred from there to other
parts of the washery.
10.2
Dryer dust transport 400

During 1st start-up it has to be observed if foaming occurs.
Tests for commissioning:
1
Install pressure indicators (0 to 5 barg) upstream and downstream of 400-CV-040.
Check pressure drop with running pump (differential pressure is approx. 2.8 bar).
Pump discharge pressure is approx. 5.1 barg.
2
Start pump 200-PP-012 and watch inside 400-BN-040: check if liquid runs back into
400-BN-040 initially. Determine if a waiting time is required to dry the bin internally.
3
Stop pump 200-PP-012. Now 400-GA-040 closes and automated drain valve 400XSV-1401 is opened. Watch inside 400-BN-040 and check if liquid is running back
into 400-BN-040. Determine if a special procedure is required for drying.
10.3
Crystallization
Amount of process water needed in precoat liquor.
10.4
Dryer
The speed of the feed distributor can be adjusted (600-HIC-0001). During commissioning
and start-up this value is set at an optimal value.
During start-up the underflow outlet is kept shut to ensure that the first section remains full
during build-up of the bed in the rest of the unit.
The operating value for the temperature has to be established in practice. By varying the
setpoint for 600-TICSA-0102 and plotting the corresponding moisture content of the final
dense ash product, the required bed temperature can be established for the final product
moisture specification. In advance, a set value for 600-TICSA-0102 of between 130 and
140C is to be expected.
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10.5
Dryer dust transport 600

Tests for commissioning:
1
Install pressure indicators (0 to 5 barg) upstream and downstream of 600-CV-030.
Check pressure drop with running pump (differential pressure is approx. 3.4 bar).
Pump discharge pressure is approx. 5.7 barg.
2
Start pump and watch inside 600-BN-030: check if liquid runs back into 600-BN-030
initially. Determine if a waiting time is required to dry the bin internally.
3
Stop pump 600-BN-030. Now 600-GA-030 closes, and automated drain valve 600XSV-0301 is opened. Watch inside 600-BN-030 and check if liquid is running back
into 600-BN-030. Determine if a special procedure is required for drying.
10.6
Condensate tank 600-TK-010

1
2
Safety valve 600-SV-0301 will blow-off in case the dryer produces more LP steam
than is used by low pressure steam consumers
Check condensate discharge capacity
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11
MAINTENANCE
11.1
Maintenance inspection
Maintenance inspection is required for a number of critical items. The frequency of this
inspection is once a day. Below a list of items that have to be checked on each routine
tour:
1
Pumps and agitators (vibration, noise)
2
Belt conveyors (tension, vibration, noise)
If a spare pump remains idle for a long period of time, it is recommended that the shaft be
rotated by a quarter turn on a weekly basis. This ensures that static loads and vibrations
are shared equally over all rolling elements, thus avoiding localized deterioration.
11.2
Fluid bed dryer inspection

It is expected that the fluid bed dryer can operate continuously for three months or more.
After running for 3 months the fluid bed dryer should be emptied of product and inspected.
The washing of the steam tubes externally may be necessary. After washing it is
recommended to let the system dry out before feed is re-established. In practice this
stoppage has a duration of 3 shifts.
Once per a year a maintenance shut down should be performed. In addition to normal
inspection and washing 1 or 2 steam bundles may be removed in the drying and the
dehydration sections. This will allow an entry into the vessel for a more detailed inspection
(a/o inspect the gill plate). Special equipment is provided which allows the tube bundles to
be withdrawn, held and replaced.
Inspection of the plant is mainly a question of inspecting the plant interior due to possible
problems with the performance of the plant. In case of internal inspection, it is absolutely
essential to have prior permission from person in charge (confined space entry
procedure).
Note: There shall always be a person supervising from outside when entering the unit
interior.
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11.3
Pump and agitator seals

Gland seals of the bottom mounted agitators and of most of the pumps are provided with
purge water. The purpose is to keep the gland packing free from crystals in between the
packing and the shaft. The supply of purge water is controlled with a purgerator with flow
indication. In case the seal tightening is not correct (no dripping of water, or too much
water coming from the seal), maintenance attention is required.
11.4
Inspection of tanks
Periodic inspections of tanks are required:
Items to check are wind and water line scaling on wall and agitator shaft and scaling in
vent outlets which will have to be cleaned as required.
Corrosion
Fixation of internals
Instrument connections and probes
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Appendix 1
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APPENDIX 1: TROUBLE SHOOTING TABLE FOR 200-PP-050/051, 510-PP-050/051,

520-PP-050/051
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Appendix 2
CONFIDENTIAL
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APPENDIX 2: TROUBLESHOOTING TABLE WARMAN PUMPS
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Appendix 3
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APPENDIX 3: LIST OF ACRONYMS

Abbreviation
Explanation
CRS
Crushed Refined Soda
DCS
Distributed Control System

(for process control)
ESP
Electrostatic Precipitator
FLD
Functional Logical Diagram
MCC
Motor Control Centre
PFD
Process Flow Diagram
P&ID
Piping and Instrumentation

Diagram
PMS
Power Management System
UPS
Uninterrupted Power Supply
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Appendix 4
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project name
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APPENDIX 4: UNIT SYSTEM

The units used are according to the SI system, related units as stated below may be used.
Pressure
: Pa, bar, mbar *)
Temperature
: C
Rate of flow
: Nm3/h, m3/h, kg/h, t/h *)
Length
: mm, m, km *)
Area
: m2
Volume
: m3
Quantity of heat
: J, kJ, MJ, GJ *)
Density
: kg/m3 *)
Power/heat flow
: W, kW, MW, GJ/h *)
Specific heat
: kJ/kg.C *)
Viscosity
: mPa.s *)
Voltage
: V, kV, mV *)
Electrical current
: A, mA *)
Power consumption : kWh, MWh *)
Time
: s, h
Mass
: kg, ton *)
Thermal conductivity : kW/m.C *)
Electrical conductivity : -1m-1, S/cm *)
*)
= micro = 10-6
m = milli = 10-3
k = kilo = 103
M = mega = 106
G = giga = 109
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Basic Operating Manual

Basic Operating Manual Magadi Soda Ash Plant

Magadi Soda Company, Kenya

Larsen & Toubro, Chennai, India

Akzo Nobel Base Chemicals, Amersfoort, The Netherlands

Akzo Nobel Engineering (E-PX), Arnhem, The Netherlands

Mr. van Lotringen

Akzo Nobel Engineering (E-PX), Arnhem, The Netherlands

Akzo Nobel Engineering, (E-SI), Arnhem, The Netherlands

Basic Operating Manual

Basic Operating Manual

INTRODUCTION ..................................................................................................... 1.1

PLANT OPERATION ............................................................................................... 2.1

General description of the process .......................................................................... 2.1

Location, layout and process sections ..................................................................... 2.4

Location ................................................................................................................... 2.4

Plant structure .......................................................................................................... 2.4

Plant operation and control system.......................................................................... 2.5

Operating philosophy ............................................................................................... 2.7

SPECIFICATION OF RAW MATERIALS, AUXILIARY MATERIALS AND UTILITIES

Specification of raw material .................................................................................... 3.1

Lake Magadi Trona .................................................................................................. 3.1

Fines Bank Material ................................................................................................. 3.2

Specification of auxiliary materials ........................................................................... 3.3

Lake brine ................................................................................................................ 3.3

Trisodium phosphate ............................................................................................... 3.3

Morpholine/Ammonia ............................................................................................... 3.3

Biocide ..................................................................................................................... 3.3

Flocon 100 ............................................................................................................... 3.4

Emulsified silicone (antifoam) .................................................................................. 3.4

Diatomaceous earth ................................................................................................. 3.4

Specification of utilities............................................................................................. 3.5

Heavy fuel oil ........................................................................................................... 3.5

Industrial diesel oil (not used) .................................................................................. 3.5

Steam 15 bar ........................................................................................................... 3.6

Steam 3 bar ............................................................................................................. 3.6

Instrument and plant air ........................................................................................... 3.6

Electric power .......................................................................................................... 3.6

Basic Operating Manual

Process water .......................................................................................................... 3.7

Hot process water .................................................................................................... 3.7

Purge water.............................................................................................................. 3.7

Potable water ........................................................................................................... 3.7

Raw water ................................................................................................................ 3.9

Cooling tower water ............................................................................................... 3.10

SAFETY, ENVIRONMENTAL AND HEALTH ASPECTS......................................... 4.1

Material Safety Data Sheets .................................................................................... 4.3

200 SECTION .......................................................................................................... 5.1

Process description.................................................................................................. 5.1

Introduction .............................................................................................................. 5.1

Dredging (PFD 100-01, OSBL) ................................................................................ 5.1

Dredge product receiving and reclaim (PFD 200-01)............................................... 5.1

Classification and centrifugation (PFD 200-02)........................................................ 5.2

Normal operation ..................................................................................................... 5.4

Dredge product receiving (PID 200-02) ................................................................... 5.4

Washery feed cyclones (PID 200-03) ...................................................................... 5.4

Classification (PID 200-04) ...................................................................................... 5.5

CRS wash tank (PID 200-05)................................................................................... 5.5

Classifier overflow (PID 200-06) .............................................................................. 5.6

CRS hydrocyclones and centrifuges (PID 200-07) .................................................. 5.6

CRS centrate (PID 200-08) ...................................................................................... 5.6

CRS stockpile reclaim (PID 200-09) ........................................................................ 5.7