CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. PLANT LOCATION Shanxi Qingshui – P. R. CHINA JOB UNIT No. HS0108 ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 1 of 18 0 DESIGN BASIS 0 03-Dec-2020 ISSUE G. BRUSAMONTI D. PINNA P. GUELI Rev Date Issue Prepared b y Checked by Approved by CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. PLANT LOCATION Shanxi Qingshui – P. R. CHINA JOB UNIT No. HS0108 ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 2 of 18 0 SUMMARY 1. BASIS OF DESIGN .................................................................................................................... 3 2. BATTERY LIMITS ...................................................................................................................... 6 3. PRODUCTS OF UREA UNIT ....................................................................................................... 7 4. RAW MATERIAL INFORMATION AT PLANT BATTERY LIMITS ...................................................... 9 5. CONDENSATE EXPORT FROM UREA UNIT ............................................................................... 12 6. UTILITIES INFORMATION AT PLANT BATTERY LIMIT ................................................................ 13 7. METEOROLOGICAL AND GEOLOGICAL CONDITIONS AT SITE ................................................... 16 8. TRANSPORTATION CONDITIONS ............................................................................................ 17 9. UNITS OF MEASUREMENT ..................................................................................................... 17 10. PROJECT LANGUAGE ............................................................................................................. 18 CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS 1. Sh. 3 of 18 0 BASIS OF DESIGN 1.1. Project Description CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co. Ltd. PLANT LOCATION Shanxi Qingshui, P. R. CHINA PROJECT 3300 MTPD Urea Project integrated with Melamine Units 1.2. Numbering procedure The DOCUMENT NUMBERS will be in accordance with SAIPEM standards. The ITEM TAGS will be in accordance with SAIPEM standards. 1.3. Plant Design Capacity The Urea Unit shall be able to produce not less than 3300 tons per day as prilled urea. Licensor standard overdesign will be applied. In particular, the worst scenario between the following three cases will be considered: • the Urea Plant produces 3300 MTPD of prilled urea when Melamine Plants are under shut down; • the Urea Plant produce about 2742 MTPD of prilled urea, provide 23.25 t/h of urea feedstock to one of the Melamine Plant, while the other one is under shut down, as urea melt @ 99.75% wt. The off gas from one melamine plant shall be recycled back to this urea plant; • the Urea Plant produce about 2184 MTPD of prilled urea, provide a total of 46.50 t/h of urea feedstock to both the Melamine Plants as urea melt @ 99.75% wt. The design of Urea Unit shall be made to minimize the biuret formation in order to keep biuret content below 1% wt. The off gas from two melamine plants shall be recycled back to this urea plant. The Urea Unit shall be designed on the basis of the three cases. Material balance, steam and cooling water balance, effluent summary in PDP and expected consumption figures etc. relevant to the three cases as above shall be included. CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 4 of 18 0 1.4. Product Specification The urea prills coming from the Prilling Tower shall comply with the following product specification: Total Nitrogen min. 46.4 %wt, dry basis Biuret max. 0.9 %wt Moisture max. 0.4 %wt 1.5. Gaseous Effluents Flare system for Urea Process Unit is not foreseen; the following cold vent stacks will be considered: • Blow Down • 1st Vent Stack • 2nd Vent Stack Emission Requirement for the Prilling Tower: Local regulation for Prilling Tower emission: Dust - Particulate Matter 30 mg/m3 for Class A Enterprise Ammonia Concentration <40 mg/m3 for Class A Enterprise <50 mg/m3 for Class B Enterprise <70 mg/m3 for Class C Enterprise CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 5 of 18 0 The design basis for the Prilling Tower in this project is as follows: • Air from Prilling Tower outlet (at SAIPEM B.L.) to scrubbing system: Flow rate 1,277,000 Nm3/h Temperature 75 °C Urea Dust, expected 40 mg/Nm3 Urea Dust, maximum 50 mg/Nm3 Ammonia, expected 90-100 mg/Nm3 Ammonia, maximum 120-150 mg/Nm3 • Air from Scrubbing System outlet (outside SAIPEM B.L.): Urea Dust – Particulate Matter 30 mg/Nm3 Ammonia <40 mg/Nm3 SAIPEM shall verify the possibility and adequacy from safety point of view to deliver process vents containing ammonia to the Scrubbing System of the Prilling Tower. Notes: • Acidic Scrubbing for Prilling Tower will not be considered as part of PDP; • Water scrubbing for urea dust will be implemented by Client, through Contractor Chengda. CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS 2. Sh. 6 of 18 0 BATTERY LIMITS The Urea Unit battery limits for the PDP and where the guarantee figures will be checked, are the following: • CO2 at discharge of CO2 compressor; • NH3 at the inlet connection pipe of the Urea Unit; • Product at Prilling Tower bottom; • Air at Prilling Tower top, upstream of water scrubbing; • Urea Solution at P-106 A/B tapping point for DEF Unit; • Utilities at the inlet connection pipe of the Urea Unit; • Off-gases from Melamine Plant(s) at the inlet connection of the Urea Unit; • Urea melt to Melamine Plant(s) at the outlet connection of the Urea Unit; • Any other Melamine Unit interconnection, if any. CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS 3. Sh. 7 of 18 0 PRODUCTS OF UREA UNIT 3.1. Urea Prilled Product Temperature 65 °C Pressure at Urea B.L. atmospheric Mean Prill size 1.9 – 2.0 mm Urea + Biuret 99.75 %wt Balance Water [-] %wt Composition 3.2. Urea Solution to DEF Production of DEF (AdBlue) is foreseen with planned capacity of 300 ton/day starting from urea solution spillage from P-106 A/B. SAIPEM shall provide typical documentation of DEF Unit for the planned capacity. Temperature 98-102 °C Pressure at Urea B.L. min. 5 bar (g) Flowrate 4.06 – as 100% urea basis ton/h Ammonia max. 0.4 %wt Carbon Dioxide max. 0.1 %wt Urea min. 82 %wt Balance Water [-] %wt Composition CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 8 of 18 0 3.3. Urea melt to Melamine Plant for each Melamine Unit Temperature 136 °C Pressure at Urea B.L. 10.5 bar (g) Flowrate 23250 kg/h Urea + Biuret 99.7 %wt Water, maximum 0.3 %wt Oil, expected free Composition CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS 4. Sh. 9 of 18 0 RAW MATERIAL INFORMATION AT PLANT BATTERY LIMITS 4.1. Liquid ammonia Warm ammonia shall be used during normal ammonia plant operation; whereas cold ammonia from liquid ammonia storage tank, after boosting, is to be used when warm ammonia is not available from ammonia plant. Temperature ≤30 °C Pressure at Urea B.L. ≥26 bar (a) Ammonia ≥99.9 %wt Water ≤0.1 %wt Oil ≤5 ppm wt Hydrogen 600 ppm vol Nitrogen 400 ppm vol Argon nil Composition Dissolved Inerts CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. PLANT LOCATION Shanxi Qingshui – P. R. CHINA JOB UNIT No. HS0108 ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 10 of 18 0 4.2. Carbon Dioxide At CO2 compressor discharge: Temperature 120 °C Pressure at Urea B.L. 157 bar (g) Basis as 100% CO2 At CO2 Compressor suction: Temperature 30 °C Pressure 1.50 bar (a) Carbon Dioxide ≥98.70 %vol (dry basis) Hydrogen ≤0.5 %vol (dry basis) Carbon Monoxide ≤1100 ppm vol (dry basis) Methane ≤200 ppm vol (dry basis) Water saturated Sulphur ≤5 mg/Nm3 Nitrogen 0.61 %vol (dry basis) Methanol 200 ppm Composition CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. PLANT LOCATION Shanxi Qingshui – P. R. CHINA JOB UNIT No. HS0108 ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 11 of 18 0 4.3. Off-gas from each Melamine Unit Temperature 143 °C Design Temperature 220 °C Pressure 22.1 bar (g) Minimum Pressure not available bar (g) Design Pressure 29.4 bar (g) Flowrate 23978 kg/h Design Flowrate 26570 kg/h Ammonia 51.21 %wt Carbon Dioxide 38.91 %wt Water 9.57 %wt Oxygen 0.07 %wt Nitrogen 0.24 %wt Composition CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. PLANT LOCATION Shanxi Qingshui – P. R. CHINA JOB UNIT No. HS0108 ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 12 of 18 5. 0 CONDENSATE EXPORT FROM UREA UNIT 5.1. Steam Condensate Temperature Design Temperature Pressure at B.L. - minimum Design Pressure 50 120 5 8 °C °C bar (g) bar (g) Water Quality without process pollution 5.2. Process Condensate Temperature Design Temperature Pressure at B.L. - minimum Design Pressure 45 153 5 14 °C °C bar (g) bar (g) Ammonia expected Urea expected 1 1 ppm ppm 5.3. Urea-Water solution from water scrubbing system Temperature 40 °C Design Temperature not available °C Pressure 4 bar (g) Design Pressure not available bar (g) Flowrate 3000 kg/h Urea 5 %wt Water 95 %wt Composition CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 13 of 18 6. 0 UTILITIES INFORMATION AT PLANT BATTERY LIMIT The following utilities shall be supplied by client. 6.1. Circulating cooling water Water Supply Temperature Water Return Temperature, max Design Temperature 30 40 60 °C °C °C Water Supply Pressure Water Return Pressure, output Design Pressure 4.5 2 10 bar (g) bar (g) bar (g) Chlorine Ion (Cl-) Fouling Factor C.S. Corrosion Rate Flow rate available ≤400 0.000344 <0.075 not available ppm m2K/W mm/a 6.2. Demi-water Temperature Design Temperature Pressure at B.L. - minimum Design Pressure 40 90 5 10 °C °C bar (g) bar (g) pH @ 25°C Conductivity @25°C SiO2 not available ≤0.2 ≤20 µS/cm µg/L Quantity of demi-water during shut down scenario 300 m3 6.3. Power Supply Voltage Frequency 10,000/380 50 V Hz CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 14 of 18 0 6.4. Emergency electric power Voltage Phases Frequency Required Power Wires 380 3 50 500 5 V Hz kWh/h Users of Urea Plant on emergency network are the following: MP-105 A/B MP-110 A/B MP-111 A/B Ammonia booster pumps Steam condensate flushing pumps H.P. washing pumps CO2 Compressor and Turbine auxiliaries (1)(2) Lighting, motorized valves, prilling tower lift MP-116 A/B Carbamate close drain recovery pumps H.P. Ammonia pumps and H.P. Carbamate pumps auxiliaries (1)(2) DCS Battery Chargers (2) DCS (2) (1) to be confirmed by manufacturer (2) out of SAIPEM’s scope 6.1. Medium Pressure Nitrogen Temperature Temperature - design Pressure at B.L. - minimum Pressure - design 30 70 60 72 °C °C bar (g) bar (g) Composition Nitrogen Oxygen Carbon Dioxide Water >99.99 <100 free supplied dry %vol (dry basis) ppm vol (dry basis) CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 15 of 18 0 6.2. Compressed Air Temperature Design Temperature Pressure Design Pressure Ambient 70 8 10 °C bar (a) bar (a) Composition Nitrogen Oxygen 79.1 20.9 %vol (dry basis) %vol (dry basis) Dew Point -40 °C 6.3. HP Steam HP Steam to Hydrolyzer: Temperature 430 °C Min/Max Temperature not available °C Design Temperature 450 °C Pressure 40 bar (g) Min/Max Pressure not available bar (g) Design Pressure 45/FV bar (g) HP Saturated Steam to Process: Temperature saturated Design Temperature 280 °C Pressure 40 bar (g) Min/Max Pressure 36/44 bar (g) Design Pressure 45/FV bar (g) CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 16 of 18 7. 0 METEOROLOGICAL AND GEOLOGICAL CONDITIONS AT SITE Please refer to the following meteorological and geological conditions at site for this project: Temperature Annual average Mean Temperature of the hottest months in recent years Mean Temperature of the coldest months in recent years Extremely high Temperature Extremely low Temperature 8.9 23.9 -9.9 38.9 -28.1 °C °C °C °C °C Rainfall Annual average Maximum annual rainfall Minimum annual rainfall 440.8 819.1 108.6 mm mm mm Snowfall Annual maximum 120 cm Humidity Annual average absolute humidity Month Average maximum relative humidity 7.6 56 hPa % Atmospheric pressure Annual average 91.01 Wind Yearly prevailing direction Wind load at 10 m above ground Annual average wind velocity NW not available 2.1 Seismic fortification intensity VI Maximum Frozen earth depth 146 kPa (abs) m/s Mercalli cm CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. JOB UNIT No. HS0108 PLANT LOCATION Shanxi Qingshui – P. R. CHINA ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 17 of 18 8. 0 TRANSPORTATION CONDITIONS Equipment and materials will be transported to the site by railway and by road with railway transportation preferred. The transportation limitations for single piece of equipment, including packaging are as follows: 9. Loading height not available m Maximum Weight 300 ton Maximum D x L 4.5 x 30.0 m Maximum W x H x L 4.5 x 4.5 x 30.0 m UNITS OF MEASUREMENT All drawings and documents submitted to the BUYER by SAIPEM and his vendors shall use the standard international unit system (SI) and additional commonly used units. The nominal diameters of piping and fittings shall be shown in inches. The main Units of Measurement to be used for the PDP are: Property Unit of measure Temperature Pressure, gauge Pressure, absolute Vacuum Mass Mass weight Volume, liquids Volume, gases (or at flow condition) Flow rates, liquids Flow rates, gases Flow rates, steam Flow rates, solids Heat/Energy Heat Duty Power, electric Heat transfer coefficient Specific Heat Specific Enthalpy Thermal Conductivity Dynamic Viscosity Viscosity °C kPa(g), MPa(g), hPa(g), bar(g) kPa(a), MPa(a), hPa(a), bar(a) Pa(a), mmHg kg, ton kg-mol m3 , L Nm3, L m3/h, L/min, kg/h Nm3/h, kmol/h, kg/h kg/h, t/h kg/h, t/h kJ, kWh, GJ MW, GJ kW, MW W/m2K, kcal/m2°C kJ/kgK, kcal/kg°C kJ/kg, kcal/kg W/mK, kcal/mh°C mPas cP CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed. CUSTOMER Shanxi Qingshui Yinquan Coal Industry Development Co., Ltd. PLANT LOCATION Shanxi Qingshui – P. R. CHINA JOB UNIT No. HS0108 ZA-E-6001 PROJECT / UNIT Rev. 3300 MTPD UREA PROJECT INTEGRATED WITH MELAMINE UNITS Sh. 18 of 18 0 kg/m3 kg/m3 kgmol/m3 mm mm, m inch m2 inch dB N/mm2, kg/cm2 N [-] S % wt % of range Hz A, mA, kA kWh V, kV, mV Wh, kWh h, s m/s Liquid density Vapour density Molecular density Equipment dimension Length Pipe diameter Area Tube sizes (ND) Sound pressure Stresses Force Flange rating Electrical conductivity Product concentration Level Frequency Electrical current Electric work Voltage Work Time Speed Note: The base reference for temperature and pressure will be T= 0 °C ; P= 101.3 kPa(abs). The following powers of 10 are to be used: hecto h 102 centi c 10-2 kilo k 103 milli m 10-3 mega M 106 micro µ 10-6 giga G 109 10. PROJECT LANGUAGE English shall be the language for communication between the BUYER and SAIPEM during execution of the contract. For major written communications both Chinese and English shall be used. Chinese shall also be used in the SAIPEM's written descriptive technical documentation (e.g. Operating Manual, Analytical Manual, etc.) but only English shall be used for the drawings and tables. CONFIDENTIAL This document and the information herein contained are confidential and the sole property of Saipem who will safeguard its rights according to the civil and criminal provision of the law. It shall neither be disclosed to third parties nor used for purposes other than those for which it has been disclosed.