Silicon 5 - Viridis-IQ Viridis Silicon 5.0... · • Owner engineers and owner project managers • Equipment Specification • Conceptual Engineering • Basic engineering • Detailed

Silicon 5.0

Technology - Engineering – Operations

Technology development and engineering to meet the technical challenges of the Silicon and Ferroalloy industries

Viridis.iQ GmbH Von-Emmich-Str. 4 Konstanz, 78467 Germany www.viridis-iq.de

© Viridis.iQ Confidential

Typical Services Areas of Expertise

Commssioning and Start Up

Training and Knowhow

Market Intelligence Advisory

Plant and Systems Engineering

Electrode Technology

Plant and Process Optimization


Engineering and Technical Services Engineering/Technical Services

BrownField Greenfield

• Process auditing and diagnostics • Best practices assessment and correction • Benchmarking analysis and correction • Equipment assessment and simuluations on quality/cost • Capital cost estimates for upgrades • Thermal simulations • Engineering and design • Transition assessment to other products • Engineering solutions for transitions • Electrode technology review and upgrade • Brownfield expansion/Upgrades

• Project planning and feasibility assessments • Conceptual engineering based on exisiting limits • Furance, off gas, electrode and RMHS, automation,etc. • FEL-1, FEL-2, FEL-3 • Full equipment specifications • BOM, FUM, etc • Project owner engineering team • Full scope process design • SOPs and Process Manuals • Training and knowhow transfer • Commissioning and ramp up

With references in more than 20 countries, Viridis.iQ provides to its clients independent technical services decoupled from technology and equipment providers that integrates real opeational experience with state of the art engineering in greenfield and brownfield Silicon and Ferroalloy projects.



Basic Engineering Detailed Engineering Erection and commissioning

• Process design • Furnace and electrode design

specifications • Best in Class factory design • Technology Assessment • Site assessment • Analysis and validation of system

functionality • Application of VIPs (Value improving

practices) • Basic Engineering multidisciplinary

review (Mechanical, Electrical, Automation, Instrumentation)

• Basic simulations and modelling • Mass and heat balances • General System specifications review • Raw materials audit • Automation Concept design evaluation • Definition of project Mark ups • Recommendations and auditing • Preliminary risk assessment

• Detailed design and/or review • Systems and equipment specifications review • Furnace detailed design evaluation • Electrode column detailed engineering studies,

and simulations • Detailed Engineering multidisciplinary review of

the auxiliary systems and subsystems • Engineering design - Maturity assessment • Utilization of 3D modeling for detailed

engineering validation and interference analysis • Level 1 and Level 2 automation design review. • Criticality analysis(FMECA) • Evaluation and validation of the commissioning

plan, evaluation of the commissioning packages • Evaluation of the project implementation

schedule, Construction Planning, Controls, and Follow Up

• Risk Analysis • Elaboration of process and maintenance SOPs

(Standard Operational Procedures) • Project HAZOP study

• Construction and deviation analysis • Productivity Index Analysis • Earned Value Analysis • Inspection and Diligence, fabrication

inspections, pre-shipment inspections • Support on the mechanical completion

activities • Training of the commissioning team • Checking if the equipment assembly is in

accordance with the final engineering drawings

• Support on the equipment and systems tests

• Cold and hot commissioning • Start Up/Ramp Up support • Risk Analysis



Technical Services Alternative Electrode Design Optimization Services

• In‐depth analysis of selected manufacturing technology and project risk assessment from technology, design and operational perspective (cost reduction, defect elimination)

• Definition of appropriate production equipment and materials (asset utilization)

• Engineering risk reduction and mitigation • Supply chain and logistics analysis • Building and infrastructure requirements for

production • Engineering phase auditor for project owner to

avoid overand under engineering • Technical advisory to owner to mitigate project

costs (CAPEX & OPEX) • Technological/commercial support of project

owner for contract negotiations with EPC suppliers

• Monitoring milestones of the basic /detailed engineering projects and their time schedule

• QM, environmental management and work safety

• Product introduction /customer acquisition and strategy development

• Design and redesign of greenfield plants, brownfield expansions and conversions

• Owner engineers and owner project managers

• Equipment Specification • Conceptual Engineering • Basic engineering • Detailed engineering • Elaboration of the BOM – Bill of materials • 3D modelling • Electrode column components - material

specifications • Design of the casing and fins • Design of the paste feeding system • Installation guide • SOPs and Operational Manuals • Spare parts requirements • Maintenance Manuals • Design integration • Know how transfer • Transitions and technology transference • Production balancing • Operational stability • Reliability Centered Maintenance • S&OP strategy definition

• Process and engineering optimization based on decades of operating experience

• Evaluation of raw materials and applicability to premium grade silicon products

• Conceptual and basic engineering for greenfield projects from mining to final products

• Focus on preliminary project implementation plan and technology concept

• Technology audits and guidance on associated risks to both production and construction phases

• Full scope owner engineers for new project development

• Site evaluation and planning for large scale production

• Reduction of energy consumption, increase of efficiency,increase quality of the final product.

• Production staff training and know how transfer


+1000 furnace ramp ups, warm and cold and start ups

+2.500 Electrode Burn Downs +160 Södeberg electrode transitions

+50 furnace optimization programs 6 full development programs on silicon and ferrosilicon tapping, refining, casting and milling

10 system developments for milling and grinding systems

24 furnace reformations

+8000 furnace tap hole reformations and management

60 Distinct Lean Six Sigma projects 120 Lean Six Sigma specialists trained

Ferroalloy Production Metrics Accumulated Facts and Figures

>1.000.000 tons managed of Silicon and Ferroalloy products

+250 years of accumulated production experience in-house


Silicon 5.0 Technology Highlights

• Silicon 5.0 combines state of the art engineering with decades of operational expertise to bring high efficiency and low cost Silicon smelting equipment design and technology transfer to greenfield projects worldwide

• With a focus on long term operational capabilty and benchmark operating costs, Viridis.iQ 5.0 is a revolutionary improvement on traditional Silicon production design, integrated with actual long term operations and production experience

• Full scope engineering, design specifications, bill of materials, equipment lists, construction support, operations manuals, manufacturing specifications, training and knowhow transfer, SOPs, process manuals, maintenance plans, commissioning and start up support



Smart Factory design based on Industrie 4.0 and the integration of automation and data collection

• Support covering the full life cycle of the project • Project (Engineering) & Process (Operations) integration • Data and information transparency • IoT and IoP • 3D Printing • Augmented reality • Artificial Intelligence • Lean Thinking (5 pillars) • Maximum efficiency production • OPEX/CAPEX balance • Highest final product quality levels • Flexibility in manufacturing • Minimal learning curves • Ideal floor to floor design • Manufacturing, assembly and erection protocols


Viridis.iQ provides full scope technology solutions • Front-End Engineering Design (FEED) • Ultimate engineering tools (BIM, Solidworks, CFD, structural

design, thermal simulations) • Conceptual, basic, detailed and to be constructred

engineering • Innovative plant design (system, equipment, compoents,

sub-components) including full technical specification, interface risk mitigation and material specifications

• Silicon 5.0 concept (engineering-process-operations) • CFD and 3D based engineering • Plant wide operations training and know how transfer based

on breakthrough 3D printing and holographic augmented/virtual reality

• Continuous improvement and process optimization • Commissioning and start up • Process stabilization • Economic and financial modelling





Silicon 5.0 is a revolutionary approach to Silicon manufacturing that incorporates decades of operational experience into engineering and design

• Silicon 5.0 could be applicable/developed in different

constructions or assembly concepts giving maximum cost descretion and control to project owner

• Operational expertise hard wired into the design that allows for optimal final product quality and optimum CAPEX/OPEX balance

• High safety design features are incorporated to avoid commonly known issues in greenfield projects or brownfield expansions

• Smart system that use machine learning concepts in order to generate process interface communication with the automation system, reducing learning curves and increasing quick hits for process excellence achievement strongly impacting plant performance



Electrode Column design • Flexible design for pre-baked and self baking electrode technologies • Low cost electrodes and high quality controls • Open source design • High automation control systems • Artificial intelligence and machine learning design concepts Electrode Management control • Electrical and thermal baking curve control • Pressure controls for low impact slipping • Paste level controls • Electrode controls (pressure, temperature, weight, position, distance) • Interconnected column inclination control • Interconnected shell rotation speed control • Flexibility in slipping process (automated/manual) • Electrode consumption via SMART Electrode Management algorithms • Electrical furnace control (L0 up to L4)



High fire proof protection systems • Electrode column protection system • Vanguard materials used in roof insulation (Fire proof material design) • Air insufflation integrated with automation system • Thermal management of process and equipment • Safety device chain (up to 4 sequential levels) • Machine learning conceptual design that aligns maintenance, safety,

quality and process excellence.

Thermal flow controls and integrated Automation • Automated Refining System – higher hit assertiveness index and lower

operational cost based on ideal gas mixing/consumption • On-line metastatic liquid level control (level + mass) • Mixture, flow and temperature interconnected gas control • Refractory consumption control allowing lower OPEX • Liquid Silicon thermal controls (manual or automatic) • Management of the chemical composition of liquid Silicon (refining

control) during tappping and post tapping operations



Crucible Design • Optimum crucible design based on operational best practices • High thermal recovery design improves reaction zone distribution • High Silicon recovery design for low cost, high output production Continuous Casting • Slag free casting system design • Lower environmental emissions • Increased casting throughput (losses reduction) • Lower segregation in final product • Lower mold maintenance costs • Optimal thermal control Tapping • Smart ladle car concept • Efficient post tapping area design • Ideal tapping platform and tools designed to avoid cross contamination • Various levels of automation and control of tapping process




Off Gas System • Ideal design for maximum operations • Heat recovery systems to minimize energy costs • Computational Fluid Dynamics (CFD) design • High quality Silica Fume by-product production for high profitability

Hydraulics Design • Highest oil specification for safety and operational excellence • Innovative new design for oil temperature controls • Higher ranges of operational pressure from 8-90 bar • Highest accuracy and performance levels • Lower operational risks



Waste Silicon Recycling • Uses low cost Silicon wastes (fines or high contaminants) • Customizable upsizing to various specifications • Innovative process technology design • Wide variability on input materials (Silicon content independent) • Low surface area and low SiO2 surface contamination • Highly flowable with no fines during handling • Very uniform and consistent size distribution • Highly consistent chemistry • Efficient catalyst carrier with 3 dimensional network catalyst • Surface activation of catalyst for specific end uses • Proven technology • High throughputs possible



Robust Engineering Platforms • 4D Project Management concept to control project

costs, schedule and resources using live simulations • Building Information Modelling • Ultimate Engineering software and modelling (Studio

3D, Auto CAD, Solidworks, Hysys) • Model-based cost estimation • Preconstruction project visualization • Improved coordination and interface risk detection • Reduced cost and mitigated risk • Improved scheduling/sequencing • Increased productivity and prefabrication • Safe construction • Stronger Facility Management and project handover


Reference Projects Engineering/Technical Services

Client Location Scope of Work Type of Work

mgSi producer Malaysia Training, design auditing, commissioning and startup and

process stabilization

Engineering and Operations

mgSi producer China Conceptual, basic engineering, technology transfer,

commissioning and start up

Engineering and Technical

services

mgSi producer Kazakhstan Process audit and plant optimization for silicon

production

Engineering and operations

FeSi producer Kuwait Process audit and plant optimization for ferrosilicon

production


FeSi/mgSi producer Slovakia Process optimization, ramp up of new furnace for silicon

and ferrosilicon


Investor Oman Project management, technical and engineering services

for ferroalloy plant


services

Electrode

Manufacturer

Europe Electrode technology comparison, effects on operating

costs, etc for ferroalloy plant


services

Investor Oman Technical design, equipment and engineering review for

silicon furnace equipment and technology for furnace

and plant systems for a 66 000 ton factory.


services

Investor Canada Technical design study for a 33 000 ton per year silicon

and 25,000 ton FeSi factory.

Engineering, Technical, Financial

and Market services


Reference Projects Engineering/Technical Services

Client Location Scope of Work Type of Work

mgSi producer Malaysia Technical review of full engineering documents and

equipment for a greenfield 100 000 tons per year silicon

factory. On site optimization and process improvement

program incorporating process and engineering solutions

and operations teams.


mgSi producer China On site equipment and factory audit for a 50 000 ton factory

being purchased by client.


services

Government Trinidad Technical design study for a 33 000 ton factory including

basic equipment specifications and technology definitions.

Engineering, Technical,

Financial and Market services

mgSi producer Iceland Engineering reviews, conceptual design, project owner

engineer, on-site support, initial operations teams, process

optimization for 33 000 ton per year silicon factory.


Government Brasil Technical study for a 33 000 ton silicon factory. Engineering, Technical,

Financial and Market services

Investor Oman Technical engineering review of project and equipment

supplier bids for a 100 000 ton Ferroalloy factory. Revision

of procurement strategy and identification of key technical

project risks. Project owner engineer services.


services


Engineering & technical support References

Basic, Details and to be built engineering project for 16 Silicon SAFs integrated to a polysilicon plant in China, including waste heat recycling, low cost eletrode technology and state of the art furnace control systems.



Training, Cold and Hot commissioning, process stabilization for greenfield Silicon plant in Malaysia (2xSAF)



Technical project advisor, engineering auditor and feasibility study assessment for a greenfield 40,000 tpy metallurgical silicon factory in Oman


Operational diagnostics execution and implementation of production improvements in 4x16.3 MVA Chinese designed SAF in Malaysia.




Integrated Silicon/Ferrosilicon Hybrid plant for 3 x 40.5MVA SAF in Canada – Pre Ecomomic Assessment pursuant to 43-101 regulations, technical design, captial costs estimtates, evaluations and scaling assessments.


Technical Advisor, engineering auditor, support on conceptual, basic and detailed Engineering, operator training, process and production manuals and SOPs, Cold/Hot commissioning, Know how transfer, on-the-job training and start up of 2 X 42MVA SAF in Iceland.



Diagnostic of operational excellence, supports of furnaces production and alternative electrode technology design during upgrades, commissioning and operation support for 1x22MVA SAF in Solvakia.

References Engineering and Technical Support


Diagnostics of Operation excellence in 2 x 30MVA SAF in Kazachstan, upgrade and engineering audit, operation optmization opportunites.



Operational diagnostics implementation and on site production management for 1 SAF in Kuwait.


29 © Viridis.iQ

Contact details: Eng. Lou Parous Executive Director p: +49 7531 698 4628 m:+49 160 906 81722 e: [email protected] Register Office: Freiburg - Commercial Register No. HRB 708759 Managing Director: Louis C. Parous III, Dr. Wolfgang Herbst

Thank You!

Viridis.iQ GmbH Von-Emmich-Str. 4 Konstanz, 78467 Germany www.viridis-iq.de

Documents

Silicon 5 - Viridis-IQ Viridis Silicon 5.0... · • Owner engineers and owner project managers • Equipment Specification • Conceptual Engineering • Basic engineering • Detailed