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ENGINEERING & DESIGN SERVICES

CEMENT & MINERALS

Processes Unlimited International

PROCESSES UNLIMITED I N T E R N A T I O N A L

Processes Unlimited (ProU) is a multidiscipline engineering, project management, and design/drafting fi rm. ProU provides services to a diversifi ed market including oil, gas, cement, chemical, alternative energies, building products, power, utilities,

food, beverage, packaging, plastics, minerals, mining, power, and utilities.

The company structure is built on a foundation of quality engineering practices and management procedures, as well as a belief in strong customer service. The services offered by Processes Unlimited range from engineering and design to process and con-struction management. Initially providing mechanical engineering services to the oil and gas industry and other industrial clients, the areas of discipline now incorporate civil, structural, instrumentation, electrical, controls, panel fabrication, process, and chemical engineering.

Because we work in multi-disciplinary, client-centered teams, we offer our clients a single point of responsibility. With this focus on teams, accountability and service, our clients benefi t from more effi cient project execution and coordination. Our hallmark is our ability to clearly understand our clients’ needs and customize our services to meet their individual requirements.

Processes Unlimited International has the breadth and depth of experience to offer your project the expertise needed to ensure confi dence in its successful completion. ProU provides expertise in the following:

Beverage• Building Products• Cement/Lime• Chemical• Energy/Alternative Energy• Engineered Wood Products• Fiber Cement Board • Food• Forest Products• Gas• Green Power/Biofuel•

Kaolin• Manufacturing• Metals• Minerals• Oil• Petrochem• Power• Refi ning• Roofi ng• Textile• Utilities•

ProU General Information


Capabilities

ConceptualBlock FlowMass BalanceEquipment General ArrangementsOrder of Magnitude Cost EstimateSite Selection CriteriaPermit/Code ReviewControl Philosophy

PreliminaryPermitting

Air Emission/BACT/MACT• Storm Water•

Waste WaterEquipment PlansMotor/Equipment ListsClass 10 Cost EstimateSite DevelopmentUtilities

ProcurementEquipment/Material/Construction Specifi cationsProcure EquipmentProcure Construction ContractsExpediting

Engineering/DesignMechanicalBuilding/Foundation/StructuresCivil/Site PermittingMaterials HandlingPiping, Plumbing, HVACPower DistributionInstrumentation & ElectricalControl Systems/ProgrammingLighting/Grounding

Construction ManagementCommissioning PlansStartup ServicesTrainingConstruction Oversight

Engineering SpecialtiesOn-site Project Services

Construction Management• Training• Checkout, Commissioning & Start-up•

Greenfi eld Plant DesignGeotechnical & Topographical Investigation• Environmental Permitting• Grant/Funding/Permitting Assistance• On-site Project Support• Due Diligence• Site Selection & Preparation•

In-Plant ProjectsMaintenance Modifi cations• Process Improvements• Equipment Retrofi ts•

Material Handling and StorageBagging, Palletizing, Super Sacks, WarehousingMechanical ConveyingBelt, Screw, Drag, BucketPneumatic ConveyingDilute & Dense PhaseSlurry TransportPipeline & Bulk ContainerBulk StorageSilos, Bunkers, Hoppers, Live BottomsBulk Loading & UnloadingTruck, Rail Car, Barge, ShipContainers

AgglomerizationBriquettingExtrusionDisk PelletizingRotary DrumsFluidized BedsMixers

Comminuting and Classifi cationRaw Mineral Shredding & CrushingDried & Calcined Mineral MillingRoller MillCage MillWet GrindingScreeningCentrifugationAir Classifi cationJawCone GyratoryTube MillAutogenous MillImpact CrusherVertical Roller MillsRoll Presses

Thermal OperationsDryingRotary, Conveyor, Fluid BedFlash/Pneumatic, SprayCalciningRotary, Multiple Hearth, FlashSolids CoolingHeat RecoveryFluid HeatingEvaporationSingle & Multiple Effect

Solid/Liquid MixingHigh Shear BlungingBlendingPowder/Slurry MakedownHigh Viscosity Paste Mixing

Solid/Liquid SeparationSettling, ClarifyingFlotationCentrifugationFiltration (Pressure & Vacuum)Belt, Drum, Plate & FrameCartridge, AutomaticHydrocyclones

MiningCrude Ore Evaluation & TestingMine PlanningReserves Validation

Dust CollectionSystem DesignEquipment SelectionPlan & Evaluation

Cement & Minerals Experience

Safety ServicesFacilitate HAZOPs & PHAs Process Safety Management Contractor & Construction Safety Behavioral Based Safety Safety Training Program Development & Implementation


PROCESSES UNLIMITEDINTERNATIONAL

CEMENT & MINERALSINDUSTRY

ProU and its staff of engineers and managers list more than fi fty projects for the cement and minerals industry. These projects range from process studies and cost estimating to design and engineering projects and in-plant commissioning and start-up services for

multi-million dollar projects. Our expertise and talents include process and material handling system design, electrical and control systems design, and detailed plant engineering services.

Some of our customers include:

Bessemer Cement•

Box Crow Cement•

CalPortland Cement•

Carmeuse•

Cemex/Southdown•

Chemical Lime Co.•

Dravo Lime•

Eagle Materials•

Engelhard•

Florida Rock Co.•

Giant Cement•

Illinois Cement Co.•

Imerys•

KHD•

Lafarge•

Lehigh Southwest Cement Co.•

Medusa/Citadel Cement•

Mountain Cement Co.•

National Cement Co.•

Nevada Cement Co.•

Polysius•

Quikrete•

South Dakota Cement •

Suez Cement•

Tarmac•

Texas Lehigh Cement•

Thiele Kaolin•

US Lime•

Zemex•

Cement

Bessemer Cement

Box Crow Cement

Cemex (Formerly Southdown)

KHD/Eagle Materials/Mountain Cement

Screening and conveying system•

Blending systems for aggregate•

Tire handling truck dumper system• Centralized air compressor system• Tire conveying system• Plant-wide electrical system study• Construction management (Quarry to Clinker • Cooler)Drainage and paving project• Clinker storage feasibility study•

2,400 STPD—expansion• Six stage pre-heater with kiln feed system• Kiln• Clinker transport• Coal transport and grinding•

Partial Client List


Partial Client ListPartial Client List

Florida Rock Cement

Illinois Cement Co.

KHD

Lafarge

Lehigh Cement

Medusa/Citadel Cement

Gainesville plant design•

400,000 t/yr dry process plant• High effi ciency OSEPA air separator to fi nish mill• Limestone and shale quarry plan, relocated primary • crusher and extended plant belt conveyorClinker storage building• Preheater modifi cation• Modifi ed existing kiln feed system•

Design and structural review of tertiary air ducting • and pyrotop

Cement air conveying system• Water reclaim system• Color plant expansion• Kiln discharge hood modifi cation• Aggregate handling system with crusher, screens, • transfer towers and conveyingPreheater system• Rail car dumper• Power distribution system• Precipitator rebuild• Plant-wide control systems• Tire handling truck dumper system•

Engineer and design fi nish mill transport line purge • air systemEquipment Plot Plans, selection and line routing• Engineer, design and manage install of a Clinker Silo • truck unloading systemB3 FK pump relocation• Clinker transfer tower dust control•

Kiln feed de-aeration system• Replacement ID fan•

Mountain Cement Co.

National Cement

Nevada Cement Co.

Quikrete Companies

South Dakota Cement Plant

Sun Belt Cement/Cemex

Wet to dry conversion of plant to 500,000 t/yr • utilizing a two stage preheater addition to the kiln, new raw feed system, new roller mill for raw grinding6,000-ton rail/truck terminal in Denver, Colorado•

Engineering feasibility study for a Limestone and • Gypsum material handling system.

10,000 ton truck load-out silos, clinker storage • buildingOne stage preheater to kiln #2 blend silo, kiln • feed system

Process tower design•

600,000 t/yr dry process expansion including a • coal handling system and conversion of three existing kilns from gas/oil fi ring to coal fi ringAdded two 2,000 hp fi nish mills,150,000 t/yr • clinker storage building

Rail unloading modifi cation, storage and truck • load-out in Fort Worth, Texas


Holcim Cement

Texas Lehigh Cement

Aqueous ammonia injection system• Conveyor structural analysis•

500,000 t/yr greenfi eld dry process plant• Expansion of plant to 1,000,000 t/yr with • addition of fl ash calciner, new raw mill, and fi nish millHigh effi ciency OSEPA air separator to 3,500 hp • fi nish millAlkali, and sulfur bypass system to preheater • calcinerRoanoke rail/truck transfer terminal 4,800 tons • of storageWaco rail/truck transfer terminal 3,000 tons of • storageHouston rail/truck transfer terminal 5,000 tons • of storageKiln dust conveying system and mill feed system• Clinker conveyor structural modifi cation• Cooler vent relocation and redesign• Cooler vent duct redesign• Proposed combined stack design• Flash calciner, and structural modifi cations• Corpus Christi rail unloading•

Lime

Chemical Lime Co.(over 30 projects)

Dravo/Carmeuse Lime

Hydrator feed bin• Transload terminals• Facility platforms and structure design• Rail pit structure• Rotating Grizzley• Kilns• Limestone dryer• Limestone handling systems• Dust collection system• Coal mills• Plant optimization studies• Kiln baghouse replacement• Electrical studies•

Conveying systems• Baton Rouge terminal • Stone storage• Stockpiling• Screening• Pre-Heater• Lime kiln• Lime handling• Loadout• Lime grinding•




Kaolin

AKI Berhad

BHP Minerals

Burgess Pigment Co.

Caulim Da Amazonia, S.A.

Dry Branch Kaolin Co. (formerly Georgia Kaolin Co.)

Engelhard Corp.

Evans Clay Co.

J.M. Huber Co.

Kaolin International, B.V.

Kentucky-Tennessee Mining Co.

Preliminary design, fl ow sheet development and capital • costing for kaolin plant in China

Due diligence services for an Australian kaolin project • Included crude clay reserves through fi nal product • shipment

Chemical treatment, VOC emissions, thermal oxidizer, and • steam generator

Plant layout and assistance for plant expansion from 360k-• 8,00K t/yrDesign of a “super sack” bulk bagging and shipping• Redesign of blunging operation and addition of second • systemDetailed design and start-up assistance of a single-effect • evaporator system

Design of ship terminal facilities for the import, storage, • and reshipment of kaolin slurries

Spray dryer process and control evaluation• Processing Plant layout; civil estimate and design•

Rotary dryer and roller mill capacity and effi ciency• Baghouse troubleshooting/blinding elimination•

Airfl oat rotary dryer, roller mill, and cage mill combustion • system tests

Design of import terminal for the receipt of dry kaolin • from Brazil, storage, slurry production, and shipment by truck, rail, or barge in Europe and Scandinavia

Rotary dryer effi ciency testing and analysis• Design of a slurry makedown facility for fi nished slurry • from crude kaolin

Para Pigmentos, S. A.

Rio Capim Caulim

Southeastern Clay Co.

Thiele Kaolin Co.

Fullers Earth/Attapulgite

Bennett Mineral Co.

Georgia-Tennessee Mining and Chemical Co.

Oil Dri Corp. of America (Three facilities)

Conceptual design and plant layout for a greenfi eld • kaolin plant in Brazil for the production of 250,000 t/yr of kaolinDesign assistance for a 180-kilometer slurry pipeline • from mine and plant area across an undeveloped area of Amazonia to the drying facility and portPlant start-up assistance•

Design of a product slurry makedown facility• Design of a mine blunging, degritting, storage and • shipping facilityLayout and strategic planning for expansion of an • existing 240,000t/yr plant to 1,000,000 t/yr

Rotary dryer and roller mill effi ciency testing and • analysisRotary dryer capacity upgrade design•

Mine-to-shipping thermal and electrical energy • reduction analysisElectrical rate analysis• Wood fi red heating and cogeneration analyses•

Wood fi ring of rotary dryer (sizing), control P&ID, • furnace and baghouse assistance

Rotary dryer effi ciency and control upgrade• Packaging fugitive dust reduction•

Rotary dryer capacity and effi ciency improvement• Particulate/SO2 scrubber design and upgrade• Scrubber water treatment• Discharge pond design•



Zemex

Other Minerals

Feldspar Corp.

H.C. Spinks Co. (Ball Clay)

Illinois Mineral Co. (Silica)

Mid-western location (Synthetic Gypsum)

U.S. Borax, Inc.

Waverly Mineral Products

Monarch Mountain Marble

Huber

30 t/hr plant expansion• Hear sources controls• CM for plant expansions•

Rotary dryer capacity and effi ciency study•

Detailed design for installation of a used Italian spray • dryer with all auxiliary equipmentBulk loading and bagging operation•

Replacement of existing bag house• Design of a wet ground silica slurry plant, including • design of pilot and production grinding equipment

Design and startup of a greenfi eld calcium sulfi te plant, • including offi ces and storage/shipment facilities

Design of a minerals pilot plant, including purchase of • equipmentPreliminary design and fl ow sheet design for several • greenfi eld industrial minerals plants in the U.S. and abroad

Burner effi ciency tests; recommendations for thermal • effi ciency improvement

Addition to plant in Salido, CO•

Addition to plant in Marble Hill, GA•

Manufactured Products

Crossville Ceramics (Ceramic Tile)

Engelhard Corp. (Zeolite Catalyst)

Kohler Co.(Porcelain Ware)

Lapp Insulator Co. (High Voltage Insulators)

Santerios Azteca (Bricks)

Pigments

Kemira Pigments Inc. (Titanium Dioxide)

Pacifi c Smelting Co.(Zinc Oxide)

Designed a “large particle” system including material • handling and agglomerizationKiln modifi cation• Revision of recycle water system• Expansion of facility•

Mechanical and control upgrade projects•

Tunnel kiln heat recovery• Plant thermal study•

Environmental permitting•

Kiln thermal effi ciency study•

36 electrical, control, and mechanical projects• PSM activities on chloride and sulfate processes• Chlorine/titanium tetrachloride vent scrubber• Slurry process preliminary engineering•

Process engineering for a secondary zinc smelting/• French process zinc oxide facility

www.prou.com

Corporate HeadquartersProcesses Unlimited International Inc.

5500 Ming Avenue, Suite 400Bakersfi eld, CA 93309

1-661-396-3770

Additional Offi ce LocationsAtlanta, GADallas, TXFresno, CA

Pasadena, CAWalnut Creek, CA

Kingdom of Bahrain

Documents

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