CONTRACT FOR THE DESIGN, PROCUREMENT AND

CONSTRUCTION WORKS IN RESPECT OF A PLANT FOR THE

PRODUCTION OF SODA ASH WITH A CAPACITY OF 500,000
TONS PER YEAR AND RESIDENTIAL TOWN IN THE SARYSU
DISTRICT OF THE ZHAMBYL REGION IN KAZAKHSTAN

Appendix IV

Scope of Work

QAZAQ SODA (КАЗАХ СОДА) LIMITED LIABILITY PARTNERSHIP

(Employer)

And

CAMCE-DHDC-SEMARCO Consortium

(Contractor)
 Scope of Work

Scope of Brine Area

 Totally 13 production wells needed, for 500.000 TPY capacity.
 1 water tank 1000 m3, CS Material
 1 raw brine tank 1000 m3, CS Material
 1 mobile oil tank (min. 30 m3) with pump
 Water pumps and brine pumps. The pumps data sheet need to be approved by the Employer.
 Brine pipeline capacity from Brine area to the processing area is 340 m3/h
 Water pipeline capacity from the processing area to Brine area is 400 m3/h
 Underground pipelines for brine and water from brine area to the processing area, are around 10 km,
CS Material, 350 mm diameter
 10 km-length, 5-meter-width gravel, with 20 tonnage load roads from processing area to brine area
 Brine area facilities (offices), cafeteria, maintenance room etc.
 10 kV Overhead transmission line with solar power lighting from processing area to brine area.
 The Employer is responsible for well location, well start-up, leaching and caverns growth
 Min. six production wells and leaching equipment and facilities will be ready at the end of the first
year. (Pipe lines ,tanks ,pumps, electricity ,buildings ,etc…)
 Box Culvert for the pipe lines (liquid waste pipe line, brine and raw water pipe line, artesian water
pipe line ) shall be under responsibility of the Employer.

Scope of Water Intake:

 Underground well water nearby the plant (totally 4 wells) is ready for usage of the Contractor. Total
water capacity of wells is around 400 MTH.
 Lake water from Akgol to plant with a capacity of 1000 MTH under the Employer’s scope
 Contractor will provide the artesian wells process flow diagram and technical datasheet to the
Employer for approval.
 Each well water pump capacity will be min. 100 m3/h. Pump level in the well will be 30-40 m. below
the surface and pump pressure will be sufficient for pumping to brine area.

Scope of Limestone Quarry:

 100 MTH capacity of crushing, screening, conveying and storage capacity plant under the
Contractor’s scope.
 Building and living facilities are also under the Contractor’s scope
 Around 4Km overhead transmission line from Zhanatas to the limestone quarry area also under the
Contractor’s scope
 Around 1Km water pipeline from Zhanatas to the limestone quarry area also under the Contractor’s
scope
 Electricity and water supply projects will be provided by the Employer.
 The Contractor shall be allowed to produce limestone material (for its use in process of Works
performed by the Contractor) from the Limestone Quarry in volume as a limit of 50,000 ±20% t/year
by using the Employer’s equipment. Transportation of limestone material is under Contractor’s scope.
 The location of the Limestone Crusher is fixed as indicated in the Annex 3.1 Limestone Crusher
Layout Plan of the Technical Specification.

STORAGE AREA

Anthracite storage area:

Appendix IV [Scope of Work] 2/7

  Ground covered by limestone for convenient elevation .
 Storage capacity will be 8000 MT.
 Supporting a set of vibrating feeder, vibrating screen and belt scale.
 2.000 MT anthracite will be stored in closed area (with roof) whose floor will be on granular material.

Limestone storage area:

 Ground covered by limestone for convenient elevation.
 Storage area will be surrounded by 2 meters high concrete walls.
 Supporting a set of vibrating feeder, vibrating screen and belt scale.
 Skip–hoist system to feed the lime kilns bunker.
 The screening systems before feeding limestone into the kiln is under contractor’s scope
 Storage area will be open area with a capacity of 11000 MT

Lignite (Steam coal) storage area (if coal changing to gas, this part will be deleted）

 Includes unloading system from railway

 Ground covered by limestone for convenient elevation
 Storage area will be surrounded by 2 meters high concrete walls
 Grinding mill for over screening lignite less than 10 mm.
 Screen and weighing systems
 Bunker and conveying systems
 Storage area will totally have a capacity of 20000MT
 5000MT of coal will be stored in closed area

Lime Kiln Units:

 Use 4 ∅ 7200/5300 vertical lime kilns to meet the production requirements of 500,000MTY.
 The kiln feed system uses bucket lifter system.
 The gas cooling and cleaning system adopts the process of dry dust removal, direct contact gas
cooling and cleaning system and electric dust removal system.
 Lime slaker systems with the size of ∅3000 enable to whole plant with a capacity of 500,000MTY.
 Kiln baking bricks can be used for at least 4 years.
 The lime kiln is lined with fire-resistant pouring bricks.
 The maximum surface temperature of the combustion zone should be 60 ℃.
 Drainage(waste) water from kiln gas cooling and cleaning units will be sent to the storage tank.

Raw Brine Purification Units:

 Raw brine purification units will be composed of two parallel lines.
 Two raw brine tanks, each with a capacity of 2000m3.
 Two purified brine tanks, each with a capacity of 2000m3.
 Muds and waste water from purification systems will be sent to the waste water tank, directly.

Absorption Units (Absorption system will adopt the process technology provided by the Employer):
 Liquid ammonia feeding system.
 Equipped with 3 ammonia brine tanks, each with a capacity of 200m3, GRP material.

Distillation Units (Distillation system will adopt the process technology provided by the Employer)

Carbonation Units:

Appendix IV [Scope of Work] 3/7

  In accordance with the production capacity of 2*250.000=500.000MTY, there are two production
lines, and each production line will be configured according to 4+1 carbonization towers. A total of
10 carbonization towers will be configured to meet the production requirements.
 The Employer shall ensure that the maximum temperature of cooling water in the carbonization tower
is not higher than 20℃.
 The capacity of each column will be the 220 MTD on sodium carbonate base.
 The carbonization tower is produced in the configuration of 5 towers in a group, 4 units for making
soda and 1 unit for cleaning.
 The carbonization tower body is made of cast iron with corrosion-resistance additive material, and the
heat exchange tube in the cooling water box is made of titanium.

Filtration Units:
 One belt filter and its accessories will be provided for each production line (total 2 production lines)
with a capacity of 250.000MTY
 Each set of belt filter accessories includes its supporting vacuum pump, gas-liquid separator, tail gas
absorption tower.
 The washing water with filter machine adopts soft water or condensate, and the consumption is less
than 0.8T/T soda ash.
 Three mother liquor tanks are provided to collect filtrate. Mother liquor tank material is GRP. The
Employer is responsible for the design solution and shall assist contractor by providing drawings.

Compression Units:
 3 identical screw type carbon dioxide compressors must be enough for two production line with a
capacity of 500.000MTY.
 The compressor gas is cooled by direct or indirect contact with circulating cooling water. It will be
discussed during detail engineering.
 Each compressor will be driven by 49 bar(g) steam turbine.
 The Contractor will provide compressor data sheet

Calcination Units:
 One ∅3600 calciner and its accessories will be provided for each production line (total 2 production
lines) with a capacity of 250.000MTY
 Light ash calcination furnace with external soda circulation.
 The cooling and cleaning process of calciner gas is as follows: dry system dust removal and wet
system dust removal and indirect cooling and water washing for ammonia removal. The absorption of
ammonia in the gas from calciner will be discussed during detail engineering.
 Material of the all washing columns and related equipment will be discussed during detail
engineering.
 The heat source used for light ash calcination furnace is 32 bar(g) and 280℃ steam.
 The light ash calciner is equipped with a double shaft mixer before entering the furnace, which fully
mixes the sodium bicarbonate and the return soda and feeds them together into the light ash calciner.

Dense Soda Units:

 One dense soda set will be provided for production line with a capacity of 250.000MTY.
 Dense soda adopts wet dust removal method to collect soda dust. The equipment used is water
washing tower, and the tower body is made of carbon steel or GRP solution to be discussed during
detailed engineering.
 In dense soda production, the hydration machine is used to produce a water and soda, and the material
of the equipment is carbon steel or stainless steel solution to be discussed during detailed engineering.

Appendix IV [Scope of Work] 4/7

  The roller crusher is used for dense soda crushing, and the processing capacity is around 3~4t/h.
Capacity of the crusher will be discussed during detailed engineering.
 The heat source used in the dense soda dryer is 16 bar(g) few degrees higher than saturated steam.
 The finished dense soda is sent to the cooling system and to the finished silos by closed scraper
conveyor with dedusting system.

Silos, warehouse and packaging systems:

 Two light soda silos, each with a capacity of 3000 m3 required. (same design value with dense soda)
 Two dense soda silos, each with a capacity of 3000 m3 required. (same design value with light dense
soda)
 One warehouse having an area 10.000 m2 required.
 One light soda packing machines with a filling capacity of 20 MTH in 25/40/50 kg. .
 One dense soda packing machines with a filling capacity of 20 MTH in 25/40/50 kg..
 Silos will be able to load railway wagon and silo bus at the same time (railroad and truck road should
pass under the silos).
 One big bag packing machine for light soda with a capacity of 10 MTH required.
 One big bag packing machine for dense soda with a capacity of 10 MTH required.
 Soda ash warehouse and packing system equipped with dust removal system.
 All silos and warehouses shall be connected via railway and road. Silos discharge to the warehouse
through free pipe of slope, min. 60 degree, with a vibrator .

Liquid Waste Management System:

 Distillation waste liquor treatment unit.
 Equipped with a waste liquor neutralization (GRP column to be discussed during detail engineering.)
and settling unit: the treated waste and clarified liquid is to be exported to the evaporation pond
outside the plant, and the bottom mud is to be exported to the solid waste storage lined pond outside
the plant. The amount of final solid mud content from mud thickener should be calculated and shared
with the Employer.

Auxiliary Units:
 2 sets of water cooling tower facility each with a capacity of 4000 m³/h for soda production will be
provided.
 Water treatment units will be capable of demineralized and soft water.
 Demineralized water capacity will be the 220 t/h.
 Softening and conditioning capacity will be convenient for plant operation capacity.
 Two steam boilers each with a capacity of 120MTH, 53bars gauge and 485 ℃.
 Two circulating type, fluidized bed coal fired steam boilers are required.
 Two steam turbine with a suction of 3 bar,16bar and 32 bar are required.
 Steam turbines capacity should compensate all plant electrical consumption.
 For a safe operation, 2 or 3 MW steam turbine can be a condensing type, it will be discussed during
detailed engineering.
 Power plant, water cooling and conditioning units should obey the environmental limits as per
Appendix V [Schedule of Contractor’s Performance Guarantees and Test Specifications].
 At least one raw water tank with a capacity of 1.000M3 is required.
 All the other equipment’s, which are necessary for the safe operation of the whole plant, must be
supplied.
 Service air and instrument air systems must obey whole plants requirements
 All maintenance groups (mechanical, electrical, instrumentation civil etc.) workshops and equipment
must obey whole plants requirements.

Appendix IV [Scope of Work] 5/7

  Firefighting systems must obey Kazakh regulations.
 Health and safety systems must obey Kazakh regulations.
 All environmental systems, drainage systems, rainwater systems etc. must obey Kazakh regulations.
 The Employer’s engineering company will supply all necessary Kazak regulations.
 Domestic sewage treatment system.

RESIDENTIAL AREA

68 Bed Guesthouse
 Monolithic Concrete Building with Basement Floor
 An entrance lobby area and restaurant to be placed at entrance floor
 Open Car Parking Both for Staff & Guests
 Furnished Room Floors & Rooms the list of furniture in the rooms will be detailed .
 Clean Floor height of up to 4.5 m at Lobby Zone and up to 3m at room floors for service purposes

6 Blocks of 6 Apartment Residential Buildings

 6 Buildings of each 3 floor and 2 apartments (households) at each floor
 Monolithic Concrete Structure
 Clean floor height will be up to 2.8 m.
 Each household is equipped with 2 bedrooms, a bathroom, a toilet, a living room, a kitchen, 2
balconies and stairs.

2 Single Apartments
 2 Buildings of each 1 floor Monolithic Concrete Structure
 Clean floor height will be up to 3.2m
 Each household is equipped with a master bedroom and a guest bedroom, a closet, a bathroom, a
toilet, a living room, a kitchen, and 2 balconies

Swimming Pool with Small Shopping Zone

 A swimming pool for adults in semi-Olympic standards will be implemented,
 Also a small shopping zone will be designated for employees’ families’ shopping and leisure.

Rain Water Collection Tank

 An underground reinforced concrete rain water storage tank of 1000 m3 capacity will be implemented

Substation Area
 A substation to convert high voltage to low voltage will be implemented in residential zone

Waste Water Treatment Plant 50 m3/day

 Domestic waste water will be treated in plant

Fire Reservoir with Pump Station

 A reservoir with pumps will be constructed to be utilized in case of fire
 2 x 200 m3 capacity will be supplied
 A pump station will be utilized to supply pressurized fire water

Boiler with Diesel Storage Tanks

 A modular boiler with natural gas room to supply heat and hot water to Residential Zone,
 Air conditioning for the houses in residential area will be discussed during detailed engineering.

Appendix IV [Scope of Work] 6/7

General Site Works
 All necessary infrastructure such as firewater supply, household plumbing, power supply, blowdown
pipes, communication cabling, ducting works will be implemented
 Walkways and vehicle roads will be constructed
 Site Greening works are only limited to soil leveling
 Residential zone will be confined with fence and entrance gate to comply with security issues
 A domestic water supply line from process zone will be brought to residential zone.
 The 1.6 km asphalt road between Living Area and Process Plant.
 20 Meters-length, 5-meter-width gravel, with 20 tonnage load road from municipal road to process
area.
 No piling works, dewatering works, or soil replacement works were foreseen with respect to the
limited documentation in the tender documents provided by the Employer during tender preparation.
No subsurface abnormal conditions are foreseeably existed, such as underground rivers, rock stratum
which require explosion, cavities, etc. Any works required to be performed by the Contractor due to
the abovementioned matters during the execution stage shall be subject to Clause 12 [Variations and
Adjustments of the Contract].

Appendix IV [Scope of Work] 7/7