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F I V E S

M A R C H , 2 0 1 3

N E W S L E T T E R

SOLIOSGOOD NEWSFOR YOU

EDITO

In 2012, Fives celebrated its 200th anniversary. Fives results from the merger of two companies, Fives-Lille and Cail, both born in the early 19th century. Then from a series of acquisi-tions, the group adapted to the many technical and organizational changes which mark the three industrial revolutions that have occurred overthe last two centuries. From a manufac-turer of bridges and locomotives, Fives transformed itself to become an inter-national industrial engineering group.2012 is another year rich in highlights. A new company, Solios Chemical,joined our group to pave the way into carbochemical engineering. Fives Solios also started-up several of its installa-tions at the Ma’aden Aluminium smelter in Saudi Arabia, secured two new contracts with RTA for their Kitimat smelter in Canada, another one with Emal in the U.A.E and completed other projects in China and Kazakhstan. Meanwhile, the development of the Ozeos technology demonstrates the continuous involvement of the group in Research and Development to further meet new industrial standards in terms of performance and sustainability. Furthermore, on 1st of January, 2013, Fives Solios celebrated ten years of commercial and innovative successes under the Solios brand name. During two centuries, Fives managedto absorb technology disruptions, developed innovative solutions and internationalized itself. Since its origins, the group has been led by the ambitions of the women and men and their sense of entrepreneurship. Our predecessors have shown us how to better unders-tand our customers, how to be their partner, how to develop high-level technical solutions, aiming to design today tomorrow’s plants. Celebrating 200 years of existence, is first to face the future. So, let’s all embark into the next industrial revolution!

Daniel Brunelli-Brondex,C.E.O. Fives Solios

Successful start-upat Ma’aden Aluminium

Fives Solios, 10 years at the heart of the aluminium process

In September, the first good anode was pro-duced at the Green Anode Plant no.1. The second line will start-up in mid 2013. Both plants are equipped with Fives Solios’ latest technologies: Rhodax® for dry material preparation, IMC® (Intensive Mixing Cascade) for paste mixing and cooling, as well as Xelios for anode forming.In October, the first shipment of pitch was unloaded in one of the two tanks of 6,000 tons capacity at the Liquid Pitch Marine Facility supplied by Fives Solios.In mid November, the Maaden Alcoa joint venture’s operation team loaded the first charge of aluminium into one of the ingot furnaces, and then operated the first cast. In the cas-thouse, Fives Solios has supplied five 100-ton furnaces for the ingot casting facility, five 135-ton furnaces for the slab casting facility, three 85-ton furnaces for the billet casting facility and one 90-ton and one 36-ton fur-naces for the remelt facility.In November, the Ma’aden Alcoa joint venture’s

In 2012, several Fives Solios facilities installed at the Ma’aden Alcoa joint venture project in Ras-Az-Khair, Saudi Arabia, were commissioned. Fives Solios imple-mented several innovative technologies to achieve customer’s objectives in

terms of capital and operation costs, environmental protection and safety.

In January 2003, Procedair SA in France, Procedair Industries in Canada, FCB Aluminium in France and Stein Atkinson Stordy in the UK, all members of the Fives Group, joined their expertise in the aluminium sector to provide a better service to their customers. Solios was born with the objective of becoming a major player in the global performance

of the plants. In 2008, Solios became Fives Solios and adopted the new visual identity of the Fives Group.

operation team also took-over the first Gas Treatment Center, allowing the passage of the first hot gas. The official start-up of the smelter took place on 12/12/12. Each of the four Gas Treatment Centers is equipped with 18 TGT filters, the Yprios dual ducting system and a Forced Convection Network for cooling the pot shells. The installation also includes a fresh and fluoride alumina handling system.From the early beginning of the project and all along the construction work on site, Fives Solios has focused on Health & Safety concerns. At the end of 2012, as a result of the great involvement of every person within the site management teams, 9 million construction hours were achieved without any lost time injuries. At peak, Fives Solios was responsible for more than 3,500 people. Their serious commitment was a key factor to reach the shared goal of zero injury.In 2013, Fives Solios will achieve the start-up and ramp-up of all its installations at Raz-Az-Khair. ■

CELEBRATION

FIVES SOLIOS GOOD NEWS FOR YOU, the newsletter of Fives Solios – Solios Environnement SA – 25-27 boulevard de la Paix – 78100 Saint-Germain-en-Laye France – Phone: +33 (0)1 30 87 45 50 – Director of Publication: Daniel Brunelli-Brondex – Editor: Alain Périers – Editorial Committee: Stephen Augostine, Bernard Cloutier, André Pinoncely, Pascal Gautier, Etienne Rigaut, Hugues Vincent – Writers: Hélène Bachellerie, Fabienne Virieux – Thanks for their collaboration: Christian Gonzalez, Jean-Michel Guy, Sam-Philip Maliha, Joël Padwo. – Execution: Christophe Cocquet – Printing: TPI - 34, rue Jean-Lefèbvre - 93530 La Frette-sur-Seine – Registration of copyright and ISSN: 2109-280X. Printed in 1,000 numbers.

Over the last ten years, the ability to provide state-of-the-art technological solutions com-bined with its strong expertise in managing large international turnkey contracts, led Fives Solios to be selected by key customers to be involved in prestigious projects, such as Alba line 5 in Bahrain (2003), Alcoa Fjardaál in Iceland (2005), Sohar Aluminium in Oman (2006), Qatalum in Qatar (2008), Rusal Taishet and Boguchany in Russia (2008), Hindalco Mahan & Aditya (2009) and Vedanta Balco in India (2009), Emal 1 and 2 in the United Arab Emirates (2009 and 2012), Ma’aden Aluminium in Saudi Arabia (2010), Rio Tinto Alcan Jonquières and Kitimat in Canada (2011). Thanks to these numerous references, Fives Solios has continued to develop skills that are essential for managing large-scale projects, es-pecially in the fields of contract administration, site supervision and ma-nagement of a large panel of local subcon-tractors, while always keeping a specific focus on safety.

These ten years of continuous successes are also the results of Fives Solios’ capacity to propose innovative processes and to develop proprietary equipment and know-how that combine sustainable development with indus-trial profit. Through its innovation program, Fives Solios is committed to meet customers’ requirements: high performance, Capex and Opex reduction, energy efficiency, health, safety and sustainability.

Major innovations offered by Fives Solios have become technological references and many trademarks are now widespread on the aluminium market, among which:• Xelios, the high peformance vibrocompacting

unit serving the electrolysis, • Rhodax®, the natural dry mix solution for

anode preparation, • IMC®, Intensive Mixing Cascade to improve

anode quality, • Amelios, an advanced control solution

for your anode quality management, • Yprios, a boosted suction system for lower

fluoride emissions, • Eolios the clean solution for a Green Anode

Plant, • Sea wet scrubbers to

reduce SO2 emissions, • Heat exchangers to

improve Gas Treatment Center efficiency in hot countries, • HeliosRT, a real time

control firing system for anode baking,• Genios, the latest generation of metal

moving system.

In 2012, the Fives Group also celebrated its anniversary: 200 years of industrial progress. Since 1812, and all along its history, Fives has been involved in the major industrial and economic world events. Indeed, Fives is responsible for some of the most impressive achievements of the industrial age, from the first steam and electrical locomotives to many prestigious structures such as the Alexandre III Bridge in Paris, the metal framework of the

Orsay train station and the elevators of the Eiffel Tower. In the mid 20th century, Fives has participated in the reconstruction of France, taking part in the construction of the Tancar-ville Bridge and supplying numerous plants throughout the world. In the 21st century, the group is involved in significant and prestigious projects such as aluminium plants in the Middle East and the most efficient steel production lines in China.Having become the Compagnie de Fives-Lille when Cail and Fives-Lille merged in 1958, the company later changed its name to Fives Lille Cail and Fives Cail Babcock following mergers and acquisitions.Finally renamed Fives in 2007, the Group has developed to become, today, an international reference in industrial engineering.

4 www.fivesgroup.com www.fivesgroup.comDriving progress 1Driving progress

Fives Solios is committed to meet customers’ requirements: high performance, Capex and Opex reduction, energy efficiency and sustainability.

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Gas treatment center with sea water scrubbers

Alexandre III Bridge in Paris

Rhodax®

100 t ingot furnace

2 www.fivesgroup.com FIVES SOLIOS GOOD NEWS FOR YOU 3

TECHNOLOGY CONTRACTS

Kitimat smelter expansionAs part of its project of modernization at the Kitimat aluminium smelter located in British Columbia, Canada, in May 2012, Rio Tinto Alcan awarded Fives Solios with two contracts. The project consists of up-grading the existing plant from Söderberg technology to prebake AP40 technology, in order to increase the aluminium produc-tion capacity and to reduce the smelter’s emission level.In the Carbon sector, the contract includes the supply of a complete mixing line including the preheating screw, the IMC® (Intensive Mixing Cascade), two Xelios, the anodes cooling tunnel as well as the inte-gration of a pitch fume treatment system. A new 42 tph Green Anode Plant will be built, adjacent to the existing one, and connected by a belt conveyor in order to transport dry materials to the new mixing line. This plant will be delivered with pre-assembled modules in order to reduce the construction time on site. Five main modules will be shipped in mid 2013.In the Casthouse sector, the contract consists of the design and supply of three 100-ton capacity tilting Melting and Hol-ding Furnaces with the associated launder systems. The furnaces are equipped with siphon metal transfer systems, and sup-plied with dual fuel combustion systems. The furnaces’ casings were fabricated in the U.A.E. They were pre-assembled before being shipped to Canada in September, 2012.Fives Solios will provide technical support for erection, pre-commissionning and commissioning for both contracts.

EMAL phase IIFives Solios was awarded a contract for the supply of five Melting and Holding Furnaces for the EMAL phase II casthouse in Abu Dhabi, U.A.E., as part of the expansion project.

Ozeos, a high performancesolution for emission abatement

• Continuous monitoring of gaseous fluoride (HF) at each module outlet, which enhances tracking of the GTC performance and helps trouble shooting.

• Control of the gas volume treated by each module through continuous gas flow measurement combined with a modulating filter outlet damper. This is particularly useful when the bags are changed for one module at a time, as new bags offer less resistance to flow.

• Best in class fresh alumina distribution system with a unique offering of three modes of operation that aims at providing the lowest GTC fluoride emission:

- the classic mode uses a distribution box with calibration system and individual air conveyors that ensure an equal distribution of fresh alumina to each reactor

scrubber module. - the Cascade feed mode (patented

technology) enables fresh alumina to cascade from one module to the next, enriching itself in fluoride progressively, thus providing improved HF scrubbing.

- the distribution box equipped with dual outlets allows for the temporary increase of fresh alumina injection at one reactor. It is based on the feedback

from the HF monitoring at each module outlet.

The Ozeos technology has been installed on Phase 1 of the new Rio Tinto Alcan AP 60 potline at its Jonquière site in Quebec, Canada.This new potline will operate in the first quarter of 2013.

Ozeos is the most recent version of the Fives Solios alumina dry scrubber modules with integrated reactor.It features a more compact design that better suits the large gas volume treated by centralized GTCs for modern high amperage pots. It also includes a lower velocity reactor that reduces the risks of scaling, abrasion and alumina attrition. It can be equipped with conven-tional or extended surface type filter bags, both of them using micro- denier polyester for best particulate filtration, with length up to 8 m.Ozeos implements some features to optimize control and maintenance operations, which improve fluoride scrubbing:• Bag leak detection at each module with

automatic tracking of the leaking row.

F ives Solios has developed Ozeos, the state-of-the art scrubbing technology for modern smelters in order to meet customers’ objectives in terms of operation easiness and flexibility.

FOCUS

O n March 1st, 2012, the Fives Group acquired the Carbochemical and Crystallization activities (Proabd® processes) of Litwin’s Mulhouse-based (France) entity. As a consequence, a new company, Solios Chemical, has been created within the Fives Solios brand and has adopted the Fives Group visual identity.

Solios Chemical designs and supplies process equipment and complete plants worldwide and more than 60 industrial plants based on the modern version of the Proabd® processes are in operation in various industries.Coal tar pitch processing, one of the major Proabd® technologies, strengthens Fives Solios’ expertise on the prebaked anode manufacturing process by further integrating the know-how

upstream from pitch unloading and storage facilities, anode forming and anode baking. Likewise, the customers of the Proabd® pitch processes can benefit from Fives Solios’ expertise in anode manufacturing, which constitutes the main application for this specialty product.Fives Solios also continues to support and develop the whole Proabd® portfolio including

the processing of coke oven by-products and Melt Static Crystallization (MSC) purification for the chemical, pharmaceutical and food processing industries.To constantly further improve this process, an in-house laboratory and pilot hall dedicated to Research & Development programs is shared between Solios Carbone and Solios Chemical, in Mulhouse. ■

A new company joined Fives Solios

PROJECTS UNDER ExECUTION

First anodes production at Huolinhe and LianchengIn May 2012, Fives Solios produced the first anode at the Huolinhe greenfield aluminium smelter located in Inner Mongolia. The Green Anode Plant is equipped with a Fives Solios’ twin-table vibrocompacting machine fitted

with vacuum and top back pressure.The first anode was also produced at the Chalco Liancheng brownfield aluminium smelter located next to the existing plant. The Fives Solios’ contract consisted of the supply

of one twin-table Xelios machine for the production of large-sized anodes in order to meet customer’s requirements.Both equipment received the Provisional Acceptance in 2012.

Ozeos implements some fea-tures to optimize control and maintenance operations, which improve fluoride scrubbing.

Baosteel completionIn September 2012, Fives Solios successfully completed the performance tests for the 60,000 tpy pitch granulation unit supplied to Baosteel, one of the major steel producers in China.The customer selected the Proabd® techno-logy for this project due to the reduced envi-ronmental footprint, the low water content as well as the quality of pitch granules produced.Good teamwork between Baosteel and Fives Solios’ teams resulted in the plant exceeding the nominal capacity in a few days after start-up by 30%, thereby demonstrating the potential of the Proabd® process.The acceptance certificate was signed on 21st September 2012.

Pitch granulation unit

KAS Acceptance CertificateIn May 2012, Fives Solios received the Provi-sional Acceptance for the Fume Treatment Center at the Kazakhstan Aluminum smelter located in Pavlodar (Kazakhstan). This contract was awarded by Riedhammer GmbH, a specia-list in the construction of anode baking furnaces. Fives Engineering Shanghai, a member of the Fives Group, was in charge of the filters manufacturing in China.

Throughout the erection and commissioning, Fives Solios has demonstrated its capability to manage the diverse challenges associated with such a turnkey contract, for example the Project team had to deal with extreme climate conditions and language barriers.

Fume Treatment Center

Ozeos filter

Melting-holding furnaces casing