The World Bank Public Disclosure Authorized OVERVIEW OF PORT RELATED INDUSTRIES Public Disclosure Authorized by E. G. Frankel G. Panagakos Public Disclosure Authorized G. Mahnken Public Disclosure Authorized 1986 Transportation Department THE WORLD BANK OVERVIEW OF PORT RELATED INDUSTRIES E.G. Frankel G. Panagakos G. Mahnken Abstract This paper is intended as a guide to port planners in the preliminary assessment of the requirements for port facilities, services, and layout to support the requirements of industries which benefit from colocation with a port. The basic characteristics and requirements of each type of industrial plant are discussed, and the demand for port resources is identified. Acknowledgement The authors would like to thank Yr. C. Conway of the World Bank and Mr. Mr. 3. Lethbridge of the World Bank for their contribution in reviewing and editing the final draft and collecting some of the numerous data included in this study. The views and interpretations in this document are those of the authors and should not be attributed to the World Bank, to its affiliated organizations, or to any individual acting in their behalf. TABLE OF CONTENTS Page 0. INTRODUCTION 0.1 Background 0.2 Objective of the Report 0.3 Presentation of the Industries 0.4 Further Development I. IRON AND STEEL I. A Data Sheet . I.A.l Gener a1 I.A.2 Direct Reduction/Electric Arc Furnace I.A.3 Blast Furnace/Basic Oxygen Furnace 1.B Iron and Steel Industry Description I.B.l Iron and Steel Manufacturing Processes I.B.l.l Ir onmaking 1.B.l.l.a Blast Furnace 1.B.l.l.b Direct Reduction Furnace I.B.1.2 Steelmaking I.B.1.2.a LD Steelmaking I.B.1.2. b Electric Furnace Steelmaking ("Minimills") I.B.2 Steel Plant Size and Raw Material Requirements I.B.3 Steel Plant Site Requirements I.B.4 Steel Plant Water and Power Consumption I.B.5 Steelmaking Personnel Requirements I.B.6 Iron and Steelmaking Technology Alternatives I.B. 7 Environment a1 Impact I.B.8 Seaborne Iron Ore and Coal Transport 1.C Steel Plant Descriptions I.C.l ISCOTT Steel Plant I. C. 2 HADEED Steel Plant I.C.3 Fukuyama Iron Works I.C.4 SIDOR Steel Plant Expansion Complex I.C.5 Hunterston Coal/Ore Import Terminal I. C. 6 Tubarao Iron Ore Loading Facility I. D Steel Industry Statistics 11. ALUMINUM 11. A Data Sheet II.A.l General 1I.A. 2 Plant Requirements 11. B Aluminum Industry Description TABLE OF CONTENTS (Cont 'd) Page 11. ALUMINUM (Cont'd) Aluminum Manufacturing Processes Bauxite Alumina Refining Aluminum production Mill and Finished Aluminum Products Power Requirements Plant Site and Size Requirements Water and Labor Requirements Environmental Impact Seaborne Bauxite and Alumina Transport Plant Descriptions Alumina Plant Aluminum Smelter Aluminum Smelter Aluminum Smelter Bauxite/Alumina/Aluminum Complex Self-discharging Alumina Carrier Aluminum Industry Statistics 111. CEMENT Data Sheet General Cement Shipment Cement Industry Description Cement and Its Uses Cement Manufacturing Process Raw Material Preparation Calcination Clinker Processing Energy Consumption in Cement Production Environmental Impact Seaborne Cement Transport and Handling Plant Descriptions New Cement Works in Indonesia Cement Plant Cement Plant Cement Industry Statistics FERTILIZERS IV .A Data Sheet 1v-1 IV.A.l General 1v-1 1V.A. 2 Phosphatic Fertilizers IV- 1 1V.A. 3 Nitrogenous Fertilizers 1v-3 IV.A.4 Potassic Fertilizers 1v-4 IV.A.5 Sulphur 1v-5 TABLE OF CONTENTS (Cont'd) Page FERTILIZERS (Cont ' d) 1V.B Fertilizer Types IV- 6 IV. C Phosphatic Fertilizers iv-10 IV.C.1 Phosphoric Acid Manufacture and Raw Material 1v-12 Requirements IV.C.1.1 Phosphoric Acid Process Alternatives IV.C.1.2 Phosphoric Acid Process Equipment IV.C.1.2.a Grinding IV.C.1.2.b Slurry Reactor IV.C.1.2.c Filtration IV.C.1.2.d Vacuum Evaporation IV.C.1.3 Gypsum Disposal and Cooling Water Treatment IV.C.1.3.a Gypsum Disposal IV.C.1.3. b Cooling Water Treatment IV.C.2 Phosphatic Fertilizer Manufacture and Raw Material Requirements IV.C.2.1 Triple Superphosphate IV.C.2.1.a Non-granular TSP IV.C.2.1.b Granular TSP IV.C.2.2 Single Superphosphate (SSP) 1V.D Nitrogenous Fertilizers IV.D.l Ammonia . IV.D.l.l Synthesis Gas Preparation IV.D.1.2 Shift Conversion IV.D.1.3 Gas Purification IV.D.1.4 Ammonia Synthesis IV.D.1.5 Input Requirements IV.D.1.6 Ammonia Storage IV.D.l. 6.a Fully Refrigerated Storage IV.D.1.6.b Semi-refrigerated and Pressure Storage 1V.D. 2 Nitric Acid IV.D.3 Ammonium Nitrate IV.D.4 Urea 1V.E Other Fertilizers IV. E. 1 Potash Fertilizers IV.E.2 Sulphur Fertilizers 1V.F Environmental Impact IV. F. 1 Phosphatic Fertilizer Facilities 1V.F. 2 Nitrogenous Fertilizer Facilities IV. G Seaborne Fertilizer Transport IV.G.l Phosphate Fertilizers IV.G.l.l Phosphate Rock IV.G.1.2 Phosphoric Acid IV.G.1.3 Finished Phosphate Products IV.G.2 Nitrogen Fertilizers TABLE OF CONTENTS (Cont'd) Page IV. FERTILIZERS (Cont'd) IV.G.2.1 Ammonia iv-63 IV.G.2.2 Finished Nitrogenous Products iv-64 IV. G. 3 Potash . IV- 65 IV. G. 4 Brimstone and Sulphuric Acid 1v-66 IV. H Fertilizers Industry Statistics 1v-67 V. PETROCHEMICALS V.A Data Sheet V.A.l General V.A.2 Olefin Plants V.A. 3 Industry Requirements V.A.4 Shipping V.B Gener a1 Considerations v. C Olefin Plants v.c.1 Ethylene and Its Derivatives v.c.1.1 Ethylene Manufacturing Process V.C.l.1.a Pyrolysis Furnaces V.C.1.l.b Waste Heat Recovery V.C.l.1.c Pyrolysis Gas Conditioning V.C.l.1.d Cryogenic Treatment V-C.1.l.e Fractionation v-C.1.1.f Ethylene Storage v.c.1.2 Ethylene Derivatives V.C.1.2.a Low and High Density Polyethylene V.C.1.2. b Vinyl Chloride Monomer and Polyvinyl Chloride v.c.1.2.c Ethylene Oxide and Ethylene Glycol V.C.1.2.d Ethylbenzene-Styrene-Polystyrene v.c.2 Propylene and Its Derivatives v. C. 2.1 Propylene Manufacture v.c.2.2 Acrylonitrile V.C.2.3 Polypropylene v.c.2.4 0x0 Alcohols v. C. 3 Butadiene v.c.4 Benzene, Toluene and Xylene (BTX) Aromatics V. D Environmental Impact V. E Transportation of Petrochemicals V.E.l Liquefied Petrochemical Gases V. E. 2 Liquid Petrochemicals V.E.3 Solid Petrochemicals V. F Petrochemical Plant Descriptions V. F. 1 Triunfo Ethylene Plant V.F.2 Priolo Olefin Plant V. F. 3 Jubail Industrial Port TABLE OF CONTENTS (Cont'd) Page VI. PAPER V1.A Data Sheet VI.A.l General V1.A. 2 Pulping Processes VI.A.3 Paper-making VI.A.4 Transport V1.B Paper Manufacture VI.B.l Classification of Papers VI.B.2 Fibrous Raw Materials Used in Paper Manufacture VI.B.2.1 Wood V1.B. 2.1.a Softwood VI.B.2.l.b Hardwood VI.B.2.l.c Plantation Wood VI.B.2.1.d Wood Residues VI.B.2.2 Non-wood Plants VI.B.2.3 Wastepaper VI.B.3 Manufacturing Processes VI.B.3.1 Wood Handling and Preparation VI.B.3.2 Pulping Processes VI.B.3.2.a Mechanical Pulping - Stone-ground wood pulp (GWP) - Refiner mechanical pulp (RMP) - Thermomechanical pulp (TMP) - Chemimechanical pulp (W) - Chemithermomechanical pulp (CTMP) - Bleaching mechanical pulps Semichemical Pulping - The cold soda process - Neutral sulphite semichemical pulp (NSSC) Chemical Pulping - The sulphate process - The sulphite process Paper -making Environmental Impact Gaseous Emissions Liquid Effluents Solid Wastes Forest Product Transport Pulpwood Logs Wood Chips Pulp and Paper Ports Handling Forest Products Major Considerations in Planning Pulp and Paper Industries V1.B. 6.1 Alternative Manufacturing Processes VI. B. 6.2 Plant Siting VI. C Pulp and Paper Mill Descriptions VI.C.1 Bleached Sulphate Pulping Mill VI.C. 2 Island Paper Mills, New Westminster, B.C., Canada -vii- LIST OF FIGURES Page IRON AND STEEL Schematic summary of iron and steelmaking Schematic of a typical blast furnace operation Steel plant labor force and annual output Layout of Fukuyama iron works Material and products flow at the Fukuyama iron works SIDOR plant layout Materials flow at the SIDOR DRI steel plant Location of the Hunterston ore and coal terminal Layout of Tubarao iron ore loading terminal Equipment arrangements at the Tubarao iron ore terminal ALUMINUM Schematic overview of aluminum manufacturing process Idealized Bayer process flow sheet Bayer process for producing one tonne of alumina Alumina refining Hall-Heroult process for producing one tonne of aluminum from alumina Material balance for production of one tonne.of primary aluminum Energy consumption in the primary aluminum industry (Western World - 1981) Main energy flows within the aluminum industry (Western World - 1981) Geographical breakdown of bauxite, alumina and aluminum, 1981 General layout of interalumina plant site Layout of Dubai aluminum smelter Location of proposed Indian alumina plant and smelter CEMENT Line diagram of cement manufacturing process Raw grinding department (dry process) schematic Material flows in cement manufacturing Four-stage suspension preheater kiln Thermal energy consumption in various pyroprocessing systems Location of the Semen Andalas works (Lho'nga and Belawan) Layout of the Lho'nga cement works Location map of the Genstar Cement Ltd. plant at Tilbury Island, Canada Flow sheet - Genstar Cement Ltd. - Tilbury plant Plot plan - Samchok plant LIST OF FIGURES (Cont'd) Page -FERTILIZERS IV .B-1 Principles for production of fertilizers IV- 9 IV.