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50 years of experience in design and execution
of industrial investment projects
PROZAP
• About PROZAP
– General information
– Certificates and awards
– Major clients
– Design process
– Risk Management
– Safety
• Major projects:
– Fertilizers: ammonia, urea, AN, AS
– Caprolactam and melamine
– Off-sites
– UAN Production and Storage
– Environment protection
– Chemicals
– Product handling and storage
facilities
Agenda
• Almost 50 years of experience in design and engineering
services for chemical industry: over 40 thousand designs
for over 100 clients
• Highly qualified engineers and technical staff for professional
project design and execution
• Resources to provide sophisticated and technologically
advanced design in all disciplines and a variety of accompanying
services
• Employment: 110, average professional experience:
over 10 years
• Customer oriented, tailored engineering services
PROZAP Sp. z o.o.
al. Tysiaclecia P.P. 13
24-110 Puławy, Poland
www.prozap.com.pl
Tel. +48 81 473 16 00
Fax +48 81 886 25 59
PROZAP – 50 years of experience
Since 1970 - Almost 50 Years of History
• 1970 – Engineering Department of Zakłady
Azotowe Puławy is created
• 1988 – PROZAP Sp. z o.o. is established
• 1990 – first implementation of PDS
(comprehensive, intelligent computer-aided
design/engineering CAD/CAE application)
in Eastern Europe
• +40 thousand designs within the framework of more than
• +30 thousand jobs for over
• 100 clients
Certificates and Awards • Certified Quality Management System ISO 9001, 14001, 18001
• Title of Best Design Company of the Year 2013.
• I Prize in the Modernization of the Year 2011 competition
for Urea Plant Revamping Project acc. to Basic Design by
Urea Casale in Zakłady Azotowe Puławy S.A.
• Nomination in the Modernization of the Year 2012
for „Revamping of the Co-generation Plant by retrofitting
of Flue Gas Desulphurisation Plant in Grupa Azoty PUŁAWY
• Nomination in the Modernization of the Year 2013 for
Modernization of vehicle scales in Grupa Azoty PUŁAWY
• Gold Medal of Rynek Inwestycji Magazine for comprehensive
conversion engineering company into an EPC contractor.
PROZAP has been awarded the title of Best Design Company of the Year 2013
Certificate of Appreciation by Office of
Technical Inspection for high
standards in technical safety and security.
• Ammonia
• Urea
• Ad Blue
• Sulphuric acid
• Sulphur and its compounds
• Nitric acid
• NOx, SO2 , NH3 emission abatement
• Prill tower off- gas dedusting
• Melamine
• Ammonium nitrate
• Caprolactam
• Peroxides
• Units based oil processing
• Waste & Water treatment
• Bulk and liquid fertilizer storage
– inland and harbour
• Heat/power plants
• Bioethanol
Major Reference Projects
Domestic
Anwil S.A.
Polfa Tarchomin SA
International Paper Kwidzyn SA
Metalko
Z.Ch. Luboń
Polfa SA
Grupa Azoty Siarkopol
Z. Ch. Siarkopol
Organika Sarzyna
PCC Rokita
Grupa Azoty ZAK
Wratislavia-Bio
Carbon Black Polska
Elektrownia Rybnik SA
Bałtycka Baza Masowa Lotos SA
Grupa Azoty Police
Orlen SA Boryszew SA
Mostostal Puławy SA
Cersanit SA
Grupa Azoty Tarnów Synthos Dwory 7 Sp. z o.o. S.K.A.
Key Partners Overseas
Achema
Agro Linz
Air Liquide
Casale Group
Chematur Engineering Group
Evonik Carbon Black
Gea Messo AG
GSFC
Khimtekhnologya
LIWA
Lurgi Zimmer
Marsulex
Petrochemishe Anlagen
Rhodia Chemie
Ruwais Fertilizer Industries (FERTIL)
Samsung Engineering
GS Engineering & Construction
SABIC
Sulzer Chemtech
Tecnimont
ZAO Polus
• Market Study
• Feasibility Study
• Selection and transfer of technology
• License Management
• Cost Estimation
• Civil Design
• Basic Engineering
• Detail Engineering
• Cost Control
• Procurement
• Project Execution
• Author’s Supervision
• As-built Documentation
• Training of operating personnel
• Plant operation and maintenance
• Plant optimisation
• Plant upgrading Commissioning
Construction
Design
Project Definition
Specialty Services At every stage of a project life-time
EPC
Contracts „Turn-key”
PMC Project
Management
Consultancy
Specialty Services for Investors and EPCs
• Consultancy regarding local regulations and/or
representation (Power of Attorney)
• Environment Impact Report
• Civil Design as required by Polish Law
• Building Permit application
• Integrated Permit
• Permit to Use
• Local Safety and Security Rules compliance
• Local authority engineering and coordination
• Negotiations with authorities
• Obtaining required decisions and approvals
• Management of contractors
• Large database of proven Polish suppliers
• Possibility to hire local contractors contributing to
local community
EPC Services Integrated Project Execution
The whole project from one hand
• Fewer changes and less implementation work
• Optimized cost effectiveness
• Optimized scheduling and smooth performance
• Increased quality and compliance with requirements
• Increased safety and security
• Improved operability
Off-sites and auxiliary facilities
• Waste and effluent disposal systems
• Water preparation and treatment plants
• Product conveying, storage, packaging and loading/unloading facilities
• Site utilities connections
• Steel and concrete structures, process and auxiliary buildings,
• Electrical power / steam systems
• Process water / air systems
• Cooling and heating systems
• Roads, yards and railway
• Communication, security and surveillance systems
• Site and field lighting
• Personnel facilities and sanitary installations
• Various engineering services: optimization studies, debottlenecking,
capacity increase, etc.
Projects Oriented HR
Disciplines Project 1 Project 2 Project 3
Process
Piping
Mechanical
Instrumentation
Electrical
WSS&HVAC
Civil Engineering
General Plot Plan
Environment Protection
Safety Considerations
PROCESS ENGINEERING
PIPING
MECHANICAL VESSELS & MACHINERY
INSTRUMENTATION
WATER / SEWAGE SYSTEMS
& HVAC
ENVIRONMENT PROTECTION
GENERAL PLOT PLAN
CIVIL ENGINEERING,
ROAD AND RAILWAY
SAFETY CONSIDERATIONS
ELECTRICAL
Matrix System
Appointing PMs and discipline
leaders to prepare the quotation
Receiving of the inquiry / ITB
Acquiring the basic information to produce
the quotation. Defining the scope
of inquiry
Settlment with the client regarding the final
scope of design
Preparing the quotation acc. to PROZAP’s internal
regulations
Signing the Agreement
Issuing the Project Schedule, appointing the Project Team
and assigning tasks
Design Process
Inquiry processing Agreement and execution
of the project
Forwarding the documentation
Periodical project check-ups
Final, formal review
Technical measures
Execution of the Project
External expert opinion Ad hoc consultations
Project Control
The Project Control and Supervision
address specifically:
Following the Project Schedule
• Conformity with the Agreement
• Conformity with the Basic Design
• Conformity with local/state regulations
• Information flow between disciplines
Periodical meetings:
• PM and discipline leaders,
• Following the Project Schedule
• Interdisciplinary settlements
• Delay counter-measures
• Minutes of the meetings available
for all involved
Final, formal review:
• Completeness of the documentation
• Formal requirements
Technical measures:
Automated, immediate check-ups
for collision / interference (civil, framework,
piping, equipment)
External expert opinion:
Documentation approval by the relevant
institutions and authorities
Ad hoc consultations / reviews:
• Discussion over design solutions to be used
• Interdisciplinary settlements
• PM reviews of the produced portions of the
documentation
Periodical project check-ups
Final, formal review
Technical measures
Execution of the Project
External expert opinion Ad hoc consultations
and Verification
Progress Reports
• Monthly / weekly reports - as required by the client / agreement
• To monitor and report all major activities, arising issues and their solutions
• Report contents:
– Summary / Synopsis: major facts summarized and commented
– Work to date: reached milestones, progress percentages by activities
– Issues arising
– Issues solved
– Actions to prevent delays
– Work planned for the next period (month/week)
– Contract / order status
– Invoice status
Project Control
CAD / CAM Systems
ChemCAD+CCTerm,
ASPEN TASC+
Process
Piping & Vessel
Forte, Norma Pro
MS SQL, Oracle, Access
MS Project
Instrumentation & Electrical
Civil, Water, Sewage and HVAC
Cost est.
Database
Project
Visual Vessel Design, Probad
Design Calcs
PDS 3D
Isogen
EPLAN, SEE Electrical Expert, Intools,
ETAP
Smart
Plant
Review
Triflex
MicroStation, AutoCAD CAD
Autodesk ROBOT Structure Analysis Professional, RM
Win, Ventpack, BOCAD 3D, Adv. Concrete
State-of-the-art Design Techniques
SmartPlant
P&ID Instrumentation 3D
Basic Integrator
Risk Management
RISK
Technical
Financial
Market Social & Political
Environment
Safety Management
Safety First
• Safety audits
• Safety assessment
• Safety Task Assignment
• Hazard Elimination
• Lessons learned
• Training
• Safety survey and processing of results
Selected reference projects Fertilizers, chemicals, environment protection
UAN Plant and storage
faciliteis
Liquid ammonia storage Ammonia plant
revamping
Urea plant revamping
Nitric
acid
plant Granulated fertilizer AN plant
Grupa Azoty PUŁAWY Scope of work
Preparing of technical documentation
• Map and Civil Engineering
• Detail Engineering in all disciplines
• Purchasing documentation: ITBs, bid analyses,
technical attachments to contracts
• Operation manuals and registration files
• Evaluation of completeness of Process Design
• Coordination, participation in commissioning,
supervision
AN Based Fertilizer Plant
Status: in progress
Scope of Work
• Complete technical documentation:
• Civil Design
• Area classification
• Multi-discipline Detail Engineering
• Tender documentation: inquiries, technical proposal
evaluation, technical attachments for contracts
• Equipment registration files
• HAZOP and SIL
• Plant start-up and operating manuals
• Supervision, evaluation of equipment documentation,
• Participation in coordination meetings and
commissioning.
1000 MTPD Nitric acid plant Construction of a new production plant (thyssenkrupp),
Grupa Azoty PUŁAWY – in progress
Scope of Work
• Tender documentation:
• technical evaluation of proposals
• preliminary concept with cost estimate
• technical attachments to the contracts
• Environmental Impact Report
• Preparation of Material Requisition
Nitric acid Pre-design work for modernization of existing nitric acid plant
project, Grupa Azoty PUŁAWY – in progress
UAN plant and storage facilities „AGROCHEM ” Sp. z o.o., Człuchów, Poland ( 2014)
Project at a glance
• EPC, Turn key project execution
• Conceptual Design
• Comprehensive Engineering in all disciplines
• Supplies
• Project Management and coordination with
subcontractors
• Supervision
Production Plant and Storage Facilities
of UAN liquid fertilizers, Grupa Azoty ZAK S.A ( 2015).
Project at a glance
• EPC, Turn key project execution
• Conceptual Design
• Comprehensive Engineering in all disciplines
• Supplies
• Project Management and coordination
with subcontractors
• Supervision
Liquid Ammonia Storage
Scope of work
• Concept
• Detail Engineering in process, civil,
electrical, mechanical and instrumentation
• Procurement Management
• Authority Engineering, preparation
of documents required to obtain permits
• Preparation of technical attachments to contracts
• Other engineering services
Capacity15 000 t. with loading-unloading facilities ( 2015 )
Scope of Work
• All documentation necessary to implement the
technology by Marsulex,
• Supervision over execution of contracts with
equipment vendors
• Obtaining required permits,
• General concept and spatial layout,
• Civil engineering design
• Detail engineering in all disciplines
• Operating manuals
• As-built documentation
• Supervision over construction
Flue Gas Desulphurisation Innovative wet, ammonia process in Puławy, Poland
PROZAP: PMC & General Design and Engineering Company
Prill Tower Emission Control
Scope of work
• Basic Engineering
• HAZOP Study
• Detail Engineering
• Procurement
• Supervision + Training
• As-built documentation
• Cooperation with GEA Messo,
provider of the crystallization
technology
Urea dust and NH3 emission abatement, SABIC, Saudi Arabia
Other reference projects:
• Grupa Azoty PUŁAWY
• Anwil S.A., Poland
• Agrolinz, Austria
• Grupa Azoty ZAK
TGU Bulk Loading Facility Al-Bayroni, SABIC, Saudi Arabia
Project at a glance
• Basic Engineering
• Detail Engineering in all disciplines
• As-Built Documentation
• Supplying of equipment
• Supervision services
Status: in progress
FEED Study For New Bagging & Truck Loading Facility in Ruwais Fertilizer Ind., UAE
Project at a glance
• Comprehensive study and and
conceptual design for construction
of a new bagging and loading
facility project
• Front End Engineering Design in
all disciplines
Solid Fertilizer Plant with storage, handling and loading facilities in Grupa Azoty Zakłady Azotowe Puławy
Project at a glance
• Civil Design
• Environmental Impact Report
• Procurement Management
• Detail Engineering in all
disciplines for the storage and
loading complex
• Supervision
PROZAP’s Scope of Work
• Civil Design
• Detail Engineering
• Process Manual
• Procurement management
• Concept of integration of the
new plant with existing units
on site
Air Separation Unit Two separate trains of overall capacity 1,700 MTPD
Integration with existing plants
Project at a glance
• Goal: capacity increase and other
improvements
• Basic Design by Urea Casale
• PROZAP’s scope of work:
– Civil Design
– Detail Engineering
– Other engineering services
Urea Plant Revamping Capacity increase to 1.215.000 MTPY
Scope of work
• Civil Engineering
• Detail Engineering
• Environment Impact Report
• Environment protection approvals
• Product handling
AdBlue production plant Capacity increase to 100,000 MTPY, Zakłady Azotowe
Puławy S.A., Poland
Bulk Fertilizer Storage and UAN terminal, Gdynia Port, Poland
Project at a glance
• UAN storage capacity: 27 000 tonnes
• Bulk Fertilizer storage capacity: 140 000 m3
• Loading/Unloading capacity – 2 000 MTPH
• PROZAP’s scope of work:
– Civil Design
– Detail Engineering
– Other engineering services
Project at a glance • CAN storage with transport, handling, storage, weighing, packing, loading facilities
and roads and yards,
• General concept and spatial layout,
• Process design
• Preliminary impact on environment report
• Civil Engineering Design
• Inquires for handling and packing equipment
• Multi-disciplinary Detail Engineering
• Author’s supervision
CAN Storage Capacity 25,000 t., Wloclawek, Poland
• Pre-design
• Civil Engineering
• Tendering procedures for purchasing
• Detail Engineering and tank registration files
• Detail Engineering
• As-Built Documentation
• Process Manual
• Supervision services
• Other engineering services: inventory, mechanical and
process commissioning documentation, coordination
with Notified Bodies
Chemicals Dosing Station
PKN ORLEN S.A., Płock, Poland
Scope of work
• Basic Design
• Civil Engineering
• Detail Engineering
Selection and installation of a soda tank
Inowrocławskie Zakłady Chemiczne Soda Mątwy S.A.
Scope of work
Project description
Installation of the soda tank including
conventional and pneumatic conveying
systems with conveying scales for railway car
loading of capacity 60 t/hr.
Polyethers Production Capacity Increase
30 000 MTPY, PCC Rokita SA, Brzeg Dolny
• Civil Design including Environment Impact Report to
obtain a building permit,
• Detail Engineering in all disciplines: process, piping,
civil, instrumentation, HVAC, electrical, mechanical
and cost estimation,
• Tendering procedures for the purchase of machinery,
equipment and materials,
• Detail Engineering and commissioning
documentation for vessels and pipelines
• Supervision services
Project characteristics
TDI complex
Job description • Pre-design work including inventory,
• Civil Engineering Design with
Environment impact report,
• Complete Detail Engineering
• Process/operating manuals
• Procurement of machinery and equipment,
• Participation in start-ups and approvals
• Supervision and as-built documentation
• Managing engineering subcontractors, coordination and control
Capacity increase to 60,000 MTPY, Zachem, Poland
Job description
Designs and engineering in all disciplines:
• Civil Engineering,
• Detail Engineering,
• Registration Files,
• As-built documentation
• Author’s supervision.
The revamping was carried out without shutting down of the plant and using only
short maintenance periods. During test runs of the extended TDI plant, all the
technical, quantity and quality parameters of the product guaranteed by PROZAP
were achieved.
TDI complex Capacity increase to 75,000 MTPY, Zachem, Poland
General Engineering Contractor: • Pre-design work including inventory • Cooperation with Basic Design Provider • Civil Engineering Design with the
Environment impact report
• Complete Detail Engineering in all disciplines • Participation in bidding/contracting • HAZOP Study • Participation in start-ups and approvals, • Process/operating manuals • Supervision
130 000 MTPY Methanol Plant „New Second-hand Plant Formula: application of existing equipment
ACHEMA, Lithuania, 2006
Biodiesel plant
Job description
• Environment impact report with an integrated permit application
• Civil Engineering Design with building permit
• Detail Engineering in all disciplines
• Railway system development project
• Feedstock/products storage, loading
and unloading system
Wratislavia-Bio, Wroclaw, Poland
Polyols (Polyols 4) Production Plant PCC Rokita SA, Brzeg Dolny
Project characteristics
• Capacity: 30 000 tonnes / year
• PROZAP's scope of work:
– Technical evaluation of the project,
including the investment cost estimates,
– Civil Engineering
– Environment Impact Report
– Design basis documentation for the equipment and vessels
– Obtaining a building permit,
– Detail Engineering including tendering documentation,
– Detail Engineering and commissioning documentation for equipment
and pipelines
– Supervision services
Sulphonated Chemicals Plant
30 000 MTPY, PCC Rokita SA, Brzeg Dolny
PROZAP - General Designer Company
• The design documentation for the storage and production
parts
• Civil Design including obtaining a building permit,
• Detail Engineering
• Tender and contracting procedures for both parts,
• Supervision services
• As-built documentation of the storage area.
Project characteristics
Melamine Plant
Job description
• Predesign and preparatory works
• Civil Engineering Design
• Environment impact report
• Complete Detail Engineering in all disciplines
• Procurement of machinery and equipment,
• Participation in start-ups and approvals
• Supervision and as-built documentation
• Process/operating manuals
• Managing engineering subcontractors, coordination and control
Capacity 30,000 MTPY, Puławy, Poland
• Civil Engineering
• Tendering procedures for purchasing including
technical attachments to contracts
• Detail Engineering in all disciplines
• Supervision services
• As-Built Documentation
Dry salt plant capacity increase
Soda Polska CIECH, Janikowo, 2016
Scope of work
Thank you