Design and build - Aluminum sulfate (ASP I) production plant in Cairo, Egypt

Client: NCIC Period of construction / status: 2004-2005 Subject matter and scope of services: Preparation of draft basic and detailed plant, Supply of equipment, Supervision on site with equipment installation, Inspections at start-up company, Technical Assistance Construction of "turnkey" complete factory in Egypt for the production of aluminum sulfate (ASP I). Plant for the production of aluminum sulphate from crude kaolin and sulfuric acid, with a capacity: 150,000 t / y alumina in solution, and 25,000 t / y solid (grain). The plant was built in previously undeveloped desert area in Al Fayoum region (80 km south of Cairo). As part of this contract with Cairo DABSTER NCIC provided the "know-how" for the process and conduct production, performed a complete, multi-branch technical base and executive project for the factory production of alumina sulphate, including the installation of process plant and its associated facilities and for ancillary services provided also for the planned extension to the complex chemical plant involving the manufacture of sulfuric acid, superphosphate and potassium sulphate. Installations include the park accompanying sulfuric acid storage tanks, liquid tanks park with aluminum sulfate loading systems for road tankers and storage of waste from production, and ancillary services provided for the complex electrical power supply included with the substation, emergency electric power generator, the central control room, boiler room, station cooling water, compressed air and the laboratory. The scope of the contract included the supply by DABSTER all key technological equipment such as enameled reactors, evaporators, condensers, pumps, filters, fans, feeders, bucket elevators, feeders pipe system, conveyor for filter cake, belt conveyor belt with 180 rotation and change angle, pipelines, process fittings, measurement and automation equipment, complete central control system DCS plant and other equipment. For devices made locally in Egypt DABSTER workshop has provided documentation and conducted surveillance of their performance. Given that the contract was governed by a "turnkey", with the exception of the supplies, works and installation of mechanical, DABSTER conducted surveillance of picking equipment supplied by the Client and the execution of all works and then moved his crew to review and test the installation, receive before commissioning, commissioning and acceptance tests of the production plant. Duration of the investment task from the entry into force of the contract DABSTER (started developing the project and at that time also began

makroniwelacj land) to the first run-tech plant was 21 months. The contract value DABSTER: More than 5 million EUR

Aluminium sulfate production Production of aluminum sulfate from crude kaolin is based on the elution contained therein alumina and other metal oxides with concentrated sulfuric acid. The process occurs under conditions of elevated temperature and pressure and takes place in several stages:

Preparation of crude kaolin powder to the consistency of appropriate granularity Mixing kaolin in a mixer to prepare a suspension of water and kaolin Directing slurry into the reactors

Filling the slurry reactor and concentrated sulfuric acid Extraction of alumina from kaolin Neutralization of aluminum hydroxide suspension Emptying of reactors Cooling after-neutralizing suspension in heat exchangers The concentration of the filtrate to filter presses Concentration of the filtrate in the evaporator Crystallization Shredding / granulation

As a result of subsequent operations such as neutralization, dilution and filtration, the solution is obtained with a content of 8% converted to Al2O3, which is a considerable amount of commercial product in liquid form. The remaining part of the solution produced is subject to further processing such as concentration of the process, crystallization, crushing and granulation to obtain a solid aluminum sulfate content of 16-17% converted to Al2O3. This product is packaged in commercial packaging / bags.