GENERAL COMPANY FOR CHEMICAL INDUSTRIES

GENERAL COMPANY FOR CHEMICAL INDUSTRIES

A PANORAMIC VIEW OF GCCI

INTRODUCTION TO GCCI The construction of the GCCI at Abu Kammash is one of the largest industrial projects carried out in the LIBYAN Jamahiriya. The vital factors of this project to Libya are : The Chemical Complex utilizes Libyan natural resources of brine, oil products and manpower. The main products are Poly Vinyl Chloride ( PVC ), Caustic Soda and Chlorine which is used as raw materials for other industries. The availability of these products are at realistic prices and hence aggravates the industrial growth of the country as a whole. Another important product is the Table Salt. The Chemical Complex provides the total demand of salt for Libya. These high quality and competitively priced products are also exported to international markets.

THE ROLE AND AIM OF GCCI The Chemical Complex has led to the creation of new jobs and the need to provide training facilities. It has provided skilled workers for other industrial projects. The complex is a part of the industrial future of the Jamahiriya and its role is to be recognized as an industrialized nation. Another goal is to supplement the future, the income from the oil industry and eliminate the need to import key chemicals and plastic materials.

HEAD OFFICE OF GCCI

GENERAL INFORMATION OF GCCI The project is based on the utilization of salt lake (brine) which is located in the north west of Libya, and oil products (Ethylene) which is imported from Ras Lanuf. Commissioning of the Complex started in April 1980 and it operates on a three shift basis employing a total of 1,500 personnel. Accommodation for GCCI personnel built at Abu Kammash village (2) consisting of 500 houses and other 112 new houses at Abu Kammash village (1) including all utilities and facilities.

The following are the materials produced: Poly Vinyl Chloride (PVC). Caustic Soda. Table Salt. Chlorine. Hydrochloric Acid. Sodium Hypochlorite. The design of the Complex has been carried out with every effort to minimize the effect of land, sea and air pollution. All waste streams are treated for removal of pollutants and are monitored before discharge to the environment.

BRINE WINNING & PURIFICATION In the summer months brine is pumped from wells by submerged pumps (38 wells in three lines) and in the winter months by pumping from the surface of the Sebkha. The brine is then transferred through an 18 Km pipe line to the Complex and stored in two basins. After settling the brine it is filtered and transferred to the salt plant.

THE SALT PRODUCTION SALT PLANT EVAPORATORS

Salt production is from the brine in a multi stage vacuum evaporation crystallization. The salt is separated from the slurry from the evaporators by centrifuge and part is transferred as wet salt to the electrolysis plant. The other part of the salt is dried, an antic king agent and potassium iodide being added before it is packed into 1 Kg bag and 50 kg bags for sale. The water obtained from evaporation of the brine is used within the Complex as a source of soft water.

AUTOMATED SALT PACKING PACKING OF TABLE SALT

THE ELECTROLYSIS ELECTROLYSIS CELL ROOM

The wet salt from the salt plant is converted into brine, purified by chemical treatment and then electrolyzed in mercury cells to produce chlorine, hydrogen and sodium hydroxide as 50% solution. The chlorine is dried and compressed and the major part utilized for the production of vinyl chloride monomer. The remainder is liquefied for sale in cylinders and drums. The 50% caustic soda solution are concentrated to produce a fused product from which 98% concentration are packed into plastic sacks. Sodium Hypochlorite is produced as a solution by the reaction of chlorine with sodium hydroxide solution. The 50% caustic soda solution is being sold as a final product which is transported by sea, road or tankers.

Loading of bleaching lye and Hydrochloric acid Chlorine Cylinders

THE VCM PRODUCTION UNIT

Ethylene is supplied to the complex by ship in liquid ethylene carriers. The ethylene at present delivered from Ras Lanuf complex, Libya. The ethylene is pumped from the sea bridge to the storage tanks. The ethylene is evaporated and supplied to the chloride monomer plant. Ethylene dichloride is produced by the reaction of chlorine with ethylene in the direct chlorination unit the ethylene dichloride is purified by distillation and then feed to the cracking unit where it is spilt into vinyl chloride monomer (VCM) and hydrogen chloride. The hydrogen chloride is recycled to the ox hydro chlorination unit where it reacts with more ethylene and oxygen, from the air, to form further ethylene dichloride which is purified and cracked in the same way and unconverted EDC. The vinyl chloride is then separated by distillation, dried and stored in spheres. The chlorinated by-products are burnt in an incineration unit to produce 27% hydrochloric acid.

VCM storage spheres Ethylene storage tanks

THE PVC PRODUCTION UNIT

Poly vinyl chloride (PVC) resin is a white powder which is produced in four grades, two of which are types S7054 and S6554. These are soft resins intended for a wide range of uses like cable insulation, footwears and general household goods. The third grade S6858 is intended for pipe manufacturing and other rigid extrusions. The fourth grade S5858 for bottle manufacturing. Polymerization takes place and solid PVC suspension from the reactors is processed to remove the untreated vinyl chloride which is recycled, and the solid separated in a centrifuge and dried. The dry resin is stored in silos and then packed into 25 Kg paper sacks, palletized and shrink wrapped or transported by road tankers.

PVC STORAGE SILOS PVC CONTROL ROOM

AUXILIARY UNITS The Complex is provided with auxiliary units to supply the production plants with essential services. Sea Water intake: The sea water pumping station, located on the sea bridge, provides sea water for cooling purposes and feeds to the seawater desalination unit. Sea Water Desalination: The sea unit provides 220 tons/hour of fresh water for use in the Complex. Water Hardening Unit: This provides drinking water for the Complex and Camps and fire fighting water for the Complex.

Steam Generation Unit: Steam is generated in oil fired boilers. A dematerialization unit is provided in the boiler house for the supply of the boiler feed water and dematerialized water for the production units. Compressed Air Unit. A Compressed air unit is provided to supply compressed air to the production units for use in the processes and for instrumentation. Nitrogen Generation Unit. Nitrogen is used in the production units, It is produced by burning oil or hydrogen. Electrical Supply. Electricity is supplied to the Complex at 30 Kv and then stepped down to 10.8 Kv and / or 0.4 Kv. Emergency generating sets are provided to ensure a safe shut down of the Complex in the event of a power failure.

ANNUAL PRODUCTION OF PLANTS Name of product Annual production in Tons Consumption in Complex Tons For Sale in Tons 1. Table Salt (Sodium Chloride) 120.000 80.000 40.000 2. Caustic Soda (100%) (Sodium Hydroxide) 51.600 2.600 49.000 3. Vinyl Chloride Monomer (VCM) 62.500 62.500-4. Poly Vinyl Chloride 60.000-60.000 5. Chlorine 45.700 40.700 5.000 6. Hydrochloric Acid (HCl) (30%) 9.000 1.000 8.000 7. Sodium Hypochlorite 8.900-8,900

COMPARISON FOR ACTUAL PRODUCTION OF POLY VINYL CHLORIDE FROM THE YEAR 1993-2003 ACTUAL PRODUCTION (QTY BY TONS & AMOUNT BY LD) AMOUNT 15699903 20728047 26486838 16691821 29210977 32141430 28145888 35438890 17782231 26715762 39801571 QUANTITY 41223 43090 49430 41015 42852 56816 48336 52336 41468 36865 50676 YEAR 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003

ACTUAL PRODUCTION OF PVC FROM THE YEAR 1993-2003 60000 50000 40000 30000 20000 10000 0 2003 2002 2001 2000 1999 1998 1997 1996 1995 1994 1993

EVALUATION OF PVC PRODUCTION FOR THE YEAR 1993-2003 45000000 40000000 35000000 30000000 25000000 20000000 15000000 10000000 5000000 0 2003 2002 2001 2000 1999 1998 1997 1996 1995 1994 1993

COMPARISON OF ACTUAL PRODUCTION OF CAUSTIC SODA FOR THE YEAR 1993-2003 YEAR ACTUAL PRODUCTION QUANTITY AMOUNT 1993 36866 11019623 1994 33630 13305968 1995 36404 17935816 1996 30789 13299464 1997 32840 14134388 1998 42733 16079447 1999 36694 13601191 2000 38649 9982008 2001 33364 11952813 2002 28657 6205980 2003 36095 7192297

ACTUAL PRODUCTION OF CAUSTIC SODA FOR THE YEAR 1993-2003 45000 40000 35000 30000 25000 20000 15000 10000 5000 2003 2002 2001 2000 1999 1998 1997 1996 1995 1994 1993 0

EVALUATION OF PRODUCTION OF CAUSTIC SODA FOR THE YEAR 1993-2003 20000000 18000000 16000000 14000000 12000000 10000000 8000000 6000000 4000000 2000000 0 ٢٠٠٣ ٢٠٠٢ ٢٠٠١ ٢٠٠٠ ١٩٩٩ ١٩٩٨ ١٩٩٧ ١٩٩٦ ١٩٩٥ ١٩٩٤ ١٩٩٣

THE PRESTEGIOUS AWARDS OF GCCI

GCCI IS REWARDED WITH Quality of the products which was recognised in several occasions with international awards and certificates for quality. Established and maintains a quality management system relevant for manufacturing of several chemical products mentioned & shown in this brochure. 2-1 Quality Policy (ISO 9001: 2000 / 5.3) General Company For Chemical Industries Quality Policy Is: To provide company products (Chemical Products) and related services with quality that meets marketing requirements, customer satisfaction and comply with technical specification at reasonable price and lowest cost. Continual improvement in the quality of products by using modern technology in chemical industries and effectiveness of the quality management system. Continuous training and performance improvement for all employees to achieve optimum efficiency of processes and activities performance. Working as teamwork using the scientific methods in all working fields to increase productivity and reduce waste of material and time. Company s quality objectives are established by the people s committee and the departmental objectives are established by both departmental general managers and managers and reviewed through management reviews meetings. This policy has been declared at all levels in a manner which ensures the full This policy is reviewed on annually basis during meetings of management reviews for continuous suitability. Approved by: GCCI performance has been consolidated by ISO 9001/2000 certification obtained in 15/1/2002 which was an illustration of its wellness to continue the progress and improvement of the quality system. ) Eng. Nouri Ramadan GerSecretary of People s Committee & Management Representative (