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Page 1 of 10February 2010

Technical Department Monthly Report

February 2010

HEALTH, SAFETY & ENVIRONMENT

SAFETY STATISTICS

No LTI, RW, MT, and FAC were recorded for the month of February 2010 in Technical Department.

HSE ACTIVITIES

Safety talk on the topic Housekeeping was carried out with Technical Department staff.

HSE CHALLENGE 2010

Summary of Progress on HSE Challenge 2010 actions is given in the table below.

* Energy figure is high due to high fuel consumption** Energy related CO2 figure is high due to high furnace oil consumption*** Waste figure is higher than target due to high coke fines

**** Green house gases are high due to high consumption of furnace oil, limestone and coke

HSE IMPROVEMENT PLAN 2010

HSE improvement plan 2010 finalization is in progress

PRODUCTION HIGHLIGHTS

Production for the month at 19,108 tons was 4,881 tons lower than the budget

DA production for the month at 2,835 tons was 2,765 tons lower than the budget because of low market demand

RSB production for the month at 1,515 tons was 585 tons lower than the budget because of low market demand

Sr.

No.

ParametersBase Line

2005

Target 2010

@ 5%

Reduction

Achieved

2009

February

2010

2010 Actual

1Energy (T/T)

0.01414 0.01343 0.01325 0.01396* 0.01400

2Energy related CO2(T/T)

0.7241 0.6879 0.7169 0.8855** 0.9078

3

Reusable waste non-

hazardous (reportable)

(T/T) 0.0240 0.0228 0.0313 0.0339*** 0.01919

4

Fresh water usage

(T/T) 12.8289 12.187 8.786 9.172 9.778

5Acid Gases (T/T)

0.00936 0.00889 0.00158 0.00599 0.00609

6Greenhouse gases(T/T) 1.03485 0.98311 1.0687 1.2579**** 1.286

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Following table shows the production figures for February 2010

February 1st QTR 2nd QTR 3rd QTR 4th QTR YTD

Budget Tes 23,989 36,706

Actual Production Tes 19,108 37,028

Difference (4,881) 322

Maximum Rate AchievedTes / day

800 837

Average Rate Tes / day 682 628

DAILY SODA ASH PRODUCTION

0

200

400

600

800

1000

1200

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Daily Target 1010 tpd

Descon Boiler outage to carry out

inspection and tuning on natural gasLow market

demand

Target 650 tpd

Target 800 tpd

Major Losses with respect to Budget

Jan 10: The production remained higher than the budget

Feb 10: Low market demand, Descon 10 outage to carry out its inspection & tuning on natural gas and partial plantshutdown

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PRODUCTION LOSS DETAILS

Monthly Soda Ash Production

Actual Vs Budget

(Tes)

1910817920

14,847

29,254

25,643

23,857

25,957

25,119

24,459

24,15825,21523,989

12,716

30,377

Jan Feb Mar Apr May Jun July Aug Sept Oct No v Dec

Act Budget

Production loss (Tons) Section Wise

- Feb 2010

7746

Commercial

54 Elec

0 CW

178 SD

85 Instt 149 Mech

455 PS

130 Process

67 Others

0 Civil

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Production loss (Tons) Section Wise

- YTD

9840

Commercial

158 Elec

0 CW

227 SD

145 Instt

281 Mech

2455 PS

301 Process

8506 Others

0 Civil

Production loss (Tons) Equipment Wise

- Feb 2010

123 Others

0 SNGPL

35 Tower

7746

Commercial

41 Compressors

102 Kiln & MOL29 SD Basin /

Brine

82 Calciners

493 Boilers

161 Turbines

52 Abs / Dist

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MANUFACTURING EXCELLENCE PARAMETERS

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

Jan Feb Mar April May June July Aug Sep Oct Nov Dec

OEE Availability Product Rate Quality Rate

PROJECTS

65 KTPA

All the pending DCS issues have been resolved and acceptance document signed off

GT2 chiller process water tie in is in progress whereas the electrical tie ins would be carried out during any

opportunity in coming months

Production loss (Tons) Equipment Wise

- YTD

253 Others

8371 SNGPL

52 Tower

9840

Commercial

52 Compressors

183 Kiln & MOL

29 SD Basin /

Brine

211 Calciners

2610 Boilers

220 Turbines

92 Abs / Dist

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DEVELOPMENT WORK

Reverse Osmosis

Meetings were held with WEMS and Progressive Consultants to finalize the control logic & ELD for the RO

project

Hazard Study team for the RO project has been announced Final draft of the RO contract has been received from ICIs Legal Counsel, final amendments are in progress

Initial draft of the RO newsletter has been prepared

Others

To ensure the TA > 99 % as per international standard, a trial run was carried out at plant with extensive

testing. Since 1st

March 2010 all export product is being supplied with Certificate of Analysis having TA > 99

%. However, it will have an impact of 1 dm3

PTA on energy

Proposal for developing an e Modification Form database is being prepared

Technical and Commercial proposal received for installing a Float Valve on Jhelum water reservoir

Technical and Commercial proposal of liquid online mass flow meter has been received

ENERGY

Following graph shows the energy trend for year 2008, 2009 and YTD 2010.

MONTH WISE ENERGY BUDGET & ACTUAL

Following graph shows the MMBTU PTA consumption trend for 2008, 2009 and YTD 2010

MONTH WISE MMBTU PTA CONSUMPTION TREND

5.00

7.50

10.00

12.50

15.00

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Months

MMBTU

PTA

MMBTU PTA 10 MMBTU PTA 09 MMBTU PTA 08

25

27.5

30

32.5

35

37.5

40

42.5

45

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Months

Energy(DM3PTA)

Budget 10

Actual 10

Actual 09

Actual 08

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COKE EFFICIENCY

PLANT EFFICIENCIES

Coke Consumption

0.097

0.095

0.093

0.097

0.095

0.097

0.09

0.09

0.09

0.09

0.09

0.10

0.10

0.10

0.10

0.10

Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act09 Act 08

TesPTA

Budget

0.08

0.085

0.09

0.095

0.1

0.105

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Months

Coke(Tons

PTA)

Coke 2008

Coke 2009

Coke 2010

Salt Consumption1.54 1.54 1.5361.541.541.54

1.51

1.52

1.52

1.53

1.53

1.54

1.54

Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act 09 Act 08

TesPTA

Budget

Ammonia Consumption

5.4995.261

5.001

5.44.9685.4

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act 09 Act08

KGP

TA

Budget

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OTHER EFFICIENCIES

PRODUCT QUALITY & ISO 9000

ISO 9001

Findings of URS surveillance audit were circulated to all concerned and action completion dates are

being awaited.

Purchased Power Consumption

22.0

8.2

20.8

11.1

15.4

19.5

0

5

10

15

20

25

30

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Bud10

YTD10

Actual09

Actual08

KWHPTA

Diesel Consumption on GTs

0.00.10.10.20.20.30.30.40.4

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Bud10

YTD10

Actual09

Actual08

EqDM3PTA

DGs Power Consumption

1.01.5 1.4

0.9

3.0

1.8

0

1

2

3

4

5

6

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Bud10

YTD

10

Actual09

Actual08

KW

HPTA

Nacl Brine free

0.17

0.200.21

0.200.20 0.20

0

0.05

0.1

0. 15

0.2

0.25

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Bud10

YTD10

Actual09

Actual08

Limestone Consumption

1.250 1.2411.250 1.262 1.2501.238

1.101.15

1.20

1.25

1.30

1.35

1.40

1.45

1.50

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act09 Act08

TesPTA

Bud et

Total Fuel Consum ption

37.08437.549 37.559 37.309 36.6737.724

25.00

27.00

29.00

31.00

33.00

35.00

37.00

39.00

41.00

Jan Feb M ar Apr M ay Jun Jul Aug Sep Oct Nov Dec Bud10 YTD10 Act 09 Act 08

DM3PTA

Budget

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New accreditation certificates of new ISO 9001:2008 version received from URS.

COMPETITORS SAMPLE ANALYSIS

Competitor ICI Olympia China Turkey Russia Magadi Romania Ansac Ukraine

Light Soda Ash

Date Feb-10 28/2/10 5/1/06 19/8/03 19/8/03 15/5/05 23/11/06 22/2/05 17

TA % 99.01 95.60 98.80 97.80 98.20 97.80 97.80 - 98.60 9

Cl % 0.41 0.41 0.20 0.10 0.39 0.33 0.24 - 0.36 0

Fe2O3 % 0.0019 0.0030 0.0018 0.0010 0.0016 0.0060 0.0060 - 0.0016 0.

H2O % 0.21 2.93 0.15 1.29 0.67 1.16 0.66 - 0.54 0

NaHCO3 % 0.25 1.93 0.67 0.34 0.34 0.67 2.60 - 0.17 0

Density gm/lit 560 587 590 535 562 496 484 - 551 5

SieveAnalysis

On 16 mesh 1.40 2.36 0.46 0.55 0.69 1.69 1.91 - 0.95 3

On 36 mesh 1.20 3.30 0.26 0.47 0.57 0.59 4.82 - 0.78 1

On 85 mesh 14.60 7.70 16.25 9.73 9.53 13.13 18.10 - 6.91 1

On 120 mesh 38.30 55.47 37.03 29.50 45.33 33.35 35.70 - 38.18 3

On 200 mesh 29.90 22.76 2

On 240 mesh 5.90 2.13 36.59 45.84 34.11 40.06 28.69 - 44.08 4

Thru 240mesh

8.40 6.32 9.27 14.44 9.76 10.82 10.56 - 8.99 1

Dense Soda Ash

Date Feb-10 31/03/08 10/11/06 23/11/02 21/09/06 20/10/04

TA % 98.99 98.80 98.60 91.00 - 96.20 - 98.80 -Cl % 0.53 0.38 0.20 0.13 - 0.31 - 0.03 -

Fe2O3 % 0.0025 0.005 0.0040 0.0010 - 0.0380 - 0.0010 -

H2O % 0.14 0.25 0.45 - - 1.14 - 0.80 -

NaHCO3 % 0.17 0.34 0.420 - - 3.530 - 0.230 -

Density gm/lit 994 1078 1078 - - 805 - 1000 -

SieveAnalysis

On 16 mesh 2.16 7.40 0.02 2.98 - 1.26 - 0.20 -

On 36 mesh 23.32 48.60 8.57 54.11 - 48.66 - 9.20 -

On 85 mesh 54.71 37.50 68.61 39.93 - 35.59 - 76.50 -

On 120 mesh 12.90 4.40 14.86 1.93 - 9.00 - 9.70 -

On 240 mesh 4.48 1.50 5.74 0.47 - 4.44 - 4.10 -

Thr. 240mesh

2.04 0.50 1.99 0.33 - 1.12 - 0.40 -

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Page 10 of 10F b 2010

CUSTOMER COMPLAINTS

No customer complaint was received during the month of February 2010

PLANT CRITICAL PARAMETERS

Unit Target February Q1 Q2 Q3 Q4 YTD

CB Cl mls N / 20 105. 2 105. 3 105. 5

PB Cl mls N / 20 104. 4 104. 1 104. 4

CW Temp. oC 24. 8 25. 0

CVL test mls N / 20 104 101. 9 102. 7

TE % 40 41 40. 0 39. 9

Mix gas old side % 70 71 67. 5 66. 6

Mix gas new side % 70 71 66. 0 64. 5

Gases PTA M3 PTA 800 820 808 792

Conversion 1 % 72 74 72. 3 72. 0

Conversion 2 % 72 74 72. 1 71. 9

Conversion 3 % 72 74 71. 9 71. 6

PARTICLE SIZE DISTRIBUTION

Cal-1, 2, 3 & 4 Particle size distribution Feb 2010

0

510

15

20

25

30

35

40

45

.+16 .+36 .+85 .+120 .+200 .+240 ,-240

mesh size

particles

Cal- 1 Ash Cal- 2 Ash Cal- 3 Ash Cal- 4 Ash

Documents

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