DESIGN CRITERIA FOR GENERAL LAYOUT
PT BORNEO ALUMINA INDONESIA
INDONESIAN BORNEO ALUMINA REFINERY
CONTRACT NO :
PROJECT CODE:
DOC NO : CAS1969-2G00-43-110-001
PURPOSE : ISSUED FOR REVIEW
CONSULTANT :
CONTRACTOR :
Consortium CHALIECO - PT PP (Persero) Tbk
CHALIECO PP BAI/ PMC
REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED APPROVED
A 02/3/2020 IFR
PROJECT CODE :
DESIGN CRITERIA FOR DOCUMENT NO : CAS1969-2G00-43-110-001
DATE : 02/03/2020
GENERAL LAYOUT
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REVISION CONTROL SHEET
REV.NO. DATE DESCRIPTION
A 02/03/2020 1st Issued
EXTERNAL ISSUE CHALIECO-INTERNAL ISSUE
PT BORNEO ALUMINA INDONESIA PROJECET MANAGER
PMC ENGINEERING MANAGER
CONSTRUCTION MANAGER
PROCUREMENT MANAGER
PROJECT CONTROL MANAGER
SHE MANAGER
QC MANAGER
PROJECT CODE :
DESIGN CRITERIA FOR DOCUMENT NO : CAS1969-2G00-43-110-001
DATE : 02/03/2020
GENERAL LAYOUT
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TABLE OF CONTENTS
1 GENERAL .............................................................................................................................................. 3
1.1 Purpose ......................................................................................................................................... 3
1.2 Scope............................................................................................................................................. 3
2 DESIGN BASIS ...................................................................................................................................... 3
2.1 Design Battery Limit ...................................................................................................................... 3
2.1.1 Raw material and product design battery limit ................................................................... 3
2.1.2 Utilities design battery limit ................................................................................................ 4
2.1.3 Roads design battery limit ................................................................................................. 5
3 DESIGN CRITERIA ................................................................................................................................ 5
3.1 General Layout .............................................................................................................................. 5
3.2 Vertical Planning ............................................................................................................................ 5
3.3 Road Planning ............................................................................................................................... 6
3.4 Fence and Gate and Guard ........................................................................................................... 6
3.5 Truck Weigh Bridge ....................................................................................................................... 7
3.6 Pipeline Network ............................................................................................................................ 7
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GENERAL LAYOUT
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1 GENERAL
1.1 Purpose
The purpose of the design criteria is to specify the general design principles of the general layout,
vertical planning, road planning, fence, gate, truck weigh bridge and other sub items for Indonesia's
1,000 KTPA (expandable) smelter grade alumina refinery (SGAR) project.
1.2 Scope
General Layout is responsible for the following design works:
General Layout,
Vertical Planning
Road Planning
Fence, Gate and Guard
Truck Weigh Bridge
Pipeline Network in the Plant
2 DESIGN BASIS
2.1 Design Battery Limit
2.1.1 Raw material and product design battery limit
Bauxite：
Bauxite is transported into the Plant from bauxite mining area by belt conveyor. In between the
bauxite mining area and the Bauxite Stockyard (2P01), there is a blending area where
different bauxites from three mining areas are blended to meet the set bauxite specification.
Tie-in of the bauxite is set at Bauxite Stockyard (2P01) inlet belt conveyor feeding point.
Bauxite mine, blending area and bauxite transportation system outside the plant are not in the
scope of work of Chalieco.
Caustic soda
Caustic soda is offloaded at the IPC port by the Owner. There is no storage facility of caustic
soda in the IPC port. Offloaded caustic soda then is directly piped to the Alumina Plant. Tie-in
of caustic soda is at the discharge point of pump station in the IPC port. Pump line is in
Chalieco’s scope of work.
Lime
Lime will be purchased and transported into the Plant by truck by the Owner. There is a
storage area in the Plant to store the bagged lime.
Sulfuric acid
Sulfuric acid is offloaded at the IPC port and then transported to the Plant by Truck by the
Owner. Sulfuric acid is offloaded into the storage tank by a pump. The tie-in point is at the inlet
of the unload pump and this pump is in Chalieco’s scope of supply.
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Flocculant
Both solid and liquid flocculant are offloaded and transported into the Plant by the Owner.
There is a flocculant storage area for the flocculant powder and a storage tank for the liquid
flocculant in the Plant. The tie-in point for the liquid flocculant is at the inlet of storage tank.
Alumina
50% of product will be bagged and 50% will be bulk material. The battery limits for bagged
alumina will be bagged alumina storage area in the plant and for bulk alumina will be at the
discharge points of each storage silo. Alumina transportation vehicle for bulk alumina and
bagged alumina are in the scope of Owners’ supply. Alumina storage facilities at IPC port are
not in the scope of design by Chalieco.
Coal
Transportation of coal will by 20-tonnes live load dump trucks. The coal storage area at IPC
port designated is by the Owner. Coal will be transported from the port to the Plant and
unloaded into coal storage area. Coal storage area in the plant will be in Chalieco’s scope of
design.
Light Diesel
The battery limit for light diesel starts from the storage area in the plant. Light diesel will be
transported from the port to the Plant and unloaded into light diesel storage tank. The storage
area in the plant will be in Chalieco’s scope of design.
2.1.2 Utilities design battery limit
Power supply:
There is no external power supplied from power grid. Electrical power for the whole plant will
be supplied by the Thermal Power Plant (2D) in the refinery. The Power Plant will be running
at a “Isolated Mode” and no export of power to the grid as well.
Water supply (fresh water)
The design scope starts from the point that water is taken, including water intake facilities of
fresh water, and transportation facilities from the start point to the plant, the physical battery
limit is designed at water intake point.
Storm Water drainage
First flush rain water from the plant will be collected in the Rainwater Collecting Pond, after the
first 10-15 mm rain water, the storm water will runoff to the designated point and discharge
into the river.
Internet and Telecommunications:
The Internet and telecommunication will be connected by the the Owner to the points
designated by CHALIECO.
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2.1.3 Roads design battery limit
The road design includes the plan design of the road in the Plant in which the road structure
contents such as the transportation road, sidewalk and site paving. This part of work will be carried
out by PP company.
3 DESIGN CRITERIA
3.1 General Layout
The site of this project is located to the northeast of the port, south of the red mud stockyard and
Duri river, and west of the raw ore stockyard.
The project is mainly composed of the following parts: alumina plant, power plant, gas station, and
water treatment area, etc. The plant is divided into four areas: As the north side of the site is low,
so the water treatment area is arranged in the north. The alumina plant is arranged in the middle
and west of the plant area to facilitate the transportation of goods. The power plant and the gas
station are arranged in the east of the plant area. The reserved site is arranged in the west side of
the site, taking into account the long-term development.
Main goods for transportation in the plant are bauxite, coal and alumina. Bauxite is conveyed to the
stockyard by belt conveyor from the raw ore stockyard. Raw materials of coal and others are
transported to the plant by trucks. Alumina is transported to the port by truck. Red mud is pumped
to the red mud stockyard by pipeline
3.2 Vertical Planning
The pattern of vertical plan is flat slope arrangement.
The vertical design of the plant is based on the general layout and site leveling design to determine
the elevation of buildings and roads, and also the slope to meet the requirements of road
transportation, drainage, maintenance and other purpose.（For site leveling design, please refer to
CAS1969-2U17-43-021-001 Site Leveling Layout by PP）
The plant area is high in the South and low in the north. Due to the large rainfall and intensity, the
drainage in the plant area adopts the combination of open ditch and concealed pipe. Rainwater is
collected through open ditches and rainwater inlets on the ground and sent to the rainwater pipe
network system in the plant area to avoid water accumulation around buildings and structures
（ Please refer to 《 CAS1969-2G00-51-107-001 TECHNICAL DESIGN SPESIFICATION FOR
CIVIL & STRUCTURE REV A 》（CAS1969-2G00-51-110-001）for the design content of open
ditch. Site Levelling design please refer to the design document of PP company《CAS1969-2U17-
43-021-001 Site Levelling Layout》） .
The rainwater is collected by the open ditch and storm inlet on the ground and then discharged into
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the storm sewer pipe network system in the plant area.
3.3 Road Planning
The roads in the site are mainly arranged in a circular way, and the partial roads are arranged in a
dead end way. In addition to meeting the production and transportation requirements, the roads in
the site are also used as firefighting roads.
The roads in the site are divided into primary road and secondary road, branch road and access
road according to the production and use requirements and traffic volume. The width of the primary
road surface is 9m, the width of the secondary road surface is 7m, the width of the branch road
surface is 4.5m, and the width of the access road is determined according to the door width.
The longitudinal slope of roads in the plant shall not be greater than 6%.
The road clearance in the site shall be designed as 5.0m at least, and the road clearance for fire
trucks shall be designed as 4.5m at least.
The turning radius of curb at Road intersection is set as follows（No less than the value in the table）
Table 33-1: Turning Radius of Curb
Road grade primary secondary branch Access road
road road road
（Main transport workshop）
primary road 15 12 9 9
secondary road 12 12 9 9
branch road 9 9 9 9
Access road（Main 9 9 9 \
transport workshop）
The width of main sidewalks shall be 2 m.
3.4 Fence and Gate and Guard
The south and east sides of the plant area are provided with entrances and guard rooms for truck
transportation and inspection management. The fence gate in the reserved plant area is not
included in the Project.
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3.5 Truck Weigh Bridge
Four 100t truck weigh bridges are set near the entrance and exit of the plant, shared a
weighbridge room for manual operation by every two truck weigh bridges .
3.6 Pipeline Network
The comprehensive pipeline network should be designed in consistency with general layout of
plant, vertical plan and afforestation. The pipeline should be laid out overhead and on the same
rack as possible.
The above ground pipeline can be laid by pipe support, low support, sleeper, building and structure
support. The laying mode shall be determined by comprehensive technical and economic
comparison based on factors such as production safety, medium nature, production operation,
maintenance management, transportation and plant capacity.
Under the conditions of technology, economy and safety, all pipelines shall be arranged with
common frame and common pole in priority, and shall meet the following requirements:
1) In the area with high groundwater level, corrosive foundation soil, shallow bedrock depth and
unfavorable for the construction of underground pipe trench, when it is possible to arrange the
pipeline in a centralized overhead way, the comprehensive pipe support should be preferred.
2) When the land is limited, various water supply pipes can be laid on the integrated pipe rack .
3) Compressed air pipe, oil supply pipe, thermal pipe, process pipe, etc. should be laid in a
centralized overhead way.
4) Gas pipeline should be overhead.
5) The acid and soda pipes should be laid overhead.
6) Rainwater pipeline, sewage pipeline, production wastewater need to be buried directly
underground.
7) Flammable, combustible and explosive gas pipelines shall not be laid together with cables.
8) The clearance height and foundation position of the pipe rack shall not affect the transportation,
firefighting and maintenance
9) Minimum Headroom Requirements on Pipe Rack：Distance from sidewalk: 2.5 m
