Major projects in 2014 included:
- Upgrade of ammonia synthesis reactors,
- Expansion of the post-calcination gas desulfurisation system through the addition of two new reactors,
- Purchase and assembly of the second 63-7 roller mill facility,
- Exhaust gas treatment unit and upgrade of the EC II CHP plant,
- Production of POLIFOSKA® 21 and ammonium sulfate at the DAP facility,
- Upgrade of the ammonia unit,
- Construction of an industrial wastewater neutralisation unit at the titanium white plant,
- Construction of a decomposition sludge neutralisation unit,
- Change of the DA-HF phosphoric acid production method.
The upgrade of ammonia synthesis reactors is intended to ensure a higher synthetic gas reaction rate, which will reduce the process pressure and, as a result, reduce energy consumption by the synthetic gas compressor (by 0,28 GJ per tonne of ammonia produced).
The project’s budget is PLN 24,400 thousand. Expenditure incurred so far is PLN 22,016 thousand, of which PLN 10,470 was spent in 2014.
The project commissioning and settlement procedures are pending.
The project involving expansion of the post-calcination gas desulfurisation system through the addition of two new reactors was undertaken to improve the efficiency of the post-calcination gas desulfurisation process. It is one of the initiatives designed to ensure compliance with the more restrictive SO2 emission requirements of the IED.
The contract with the project contractor was terminated while the work was in progress. After a settlement was reached, a decision was made that the project would be continued by the same contractor.
The project’s budget is PLN 8,860 thousand. Expenditure incurred so far is PLN 3,925 thousand, of which PLN 1,881 was spent in 2014. Final completion of the project is planned for 2015.
The main objective of the purchase and assembly of the second 63-7 roller mill is to reduce the costs of repair/maintenance and operation of Raymond mills, in particular the cost of electricity consumption.
All construction and process work related to the start-up of the roller mill was completed. The mill is being tested for proper operation. Completion of the project is planned for Q1 2015.
The project’s budget is PLN 5,390 thousand. Expenditure incurred so far is PLN 5,038 thousand, of which PLN 1,379 was spent in 2014.
The aim of the construction of an exhaust gas treatment unit and upgrade the EC II CHP plant is to bring the co-generation operations in line with the SO2 and NOx emissions requirements of the IED (Directive 2010/75/EU).
The project’s budget is PLN 163,700 thousand. As part of the project two boilers were revamped. At one boiler the denitration unit was placed in service, while work at the second boiler is nearing completion, with optimisation of the unit’s operation having been initiated. The modernisation of the CHP plant’s chimney stack was completed. The vendor of technology and flue gas desulfurization equipment was selected, and a building permit was obtained for this part of the project. Final completion of the project is planned for 2016.
Expenditure incurred so far is PLN 109,610 thousand, of which PLN 61,186 thousand was spent in 2014.
The key objective of the project related to production of POLIFOSKA® 21 and ammonium sulfate at the DAP facility is to enable the manufacturing of the products at the DAP facility using waste post-hydrolytic acid.
The project’s budget is PLN 11,000 thousand. The project has been completed and the commissioning procedure has been initiated. Expenditure incurred so far is PLN 10,989 thousand, of which PLN 1,600 thousand was spent in 2014.
The key objective of the upgrade of the ammonia unit is to reduce energy consumption of the ammonia production process and to improve the operational reliability of individual process nodes.
The upgrade will eliminate bottlenecks in the ammonia unit and increase its daily capacity by 200 tonnes.
The project’s budget is PLN 155,600 thousand. Expenditure incurred in 2014 was PLN 6,230 thousand. Final completion of the project is planned for 2016.
The objective of the project involving the construction of an industrial wastewater neutralisation unit at the titanium white plant is to ensure compliance of the sulfate ion emissions to water from the titanium white production plant with the requirements of the IED, which sets the emissions limit at 550kg of SO42 per tonne of TiO2.
The project’s budget is PLN 20,000 thousand. The project has been suspended until the legal requirements of the Integrated Permit are announced.
Expenditure incurred so far is PLN 808 thousand, of which PLN 266 was spent in 2014.
The project involving the construction of a decomposition sludge neutralisation unit was undertaken to reduce sulfate ion emissions to water to 550kg of SO42 per tonne of TiO2, as required by the IED. The project involves adaptation of the 1/F1 filter press systems so that they can be used for the separation and washing of clarifier post-reaction solids (called sludge) from the Black Section Division (GP-GPP-PPC).
The project’s budget is PLN 7,400 thousand. The project has been suspended; design work has been performed and relevant opinions on the project documentation issued by the company’s technical management staff.
Expenditure incurred so far is PLN 400 thousand, of which PLN 313 thousand was spent in 2014.
The project involving change of the DA-HF phosphoric acid production technology was undertaken to raise the efficiency of phosphoric acid production and improve the acid’s quality by reducing impurities content.
The project’s budget is PLN 67,000 thousand. No expenditure has been incurred yet.