Outotec.al.Project

Outotec – in brief

May, 2010

2/21 Alumina Business Center

Strong history of groundbreaking technologies

and innovation


Outotec‘s experience and solutions


Outotec delivers from equipments to plants and

services


Outotec – global partner


Main Technology Portfolio

Outotec GmbH as PROVEN TECHNOLOGY PROVIDER delivered already as example:

600 Sulphuric acid plants!450 Fluidised bed plants! 400 Sinter plants!60 Pelletizing plants!50 Calciners

…


Fluidization – A Key Technology

Example Rosting


Victor César Ribeiro da Cruz, Alunorte, Brazil “Our goal is to produce the highest quality alumina in the world. In order to reach that we needed two things: the best available technology and the most qualified professionals. Outokumpu Technology provided us with both. Their technology is reliable and easy to work with. The same is true of their people.”

Ma’aden-Alcoa Refinery Project

26.05.2010

Suggested Agenda

1. Brief Status on our currently

implementend Project with Ma’aden

2. Outotec’s Alumina Refinery Capabilities

3. Current Status of Aluminium Project

Offers to Ma’aden, Suggestions and

Discussion


Status Sulphuric Acid Plants

Project Development – Convertible EPC approach

Lump Sum

DESIGN BASIS

BIDDING

ANALYSE/NEGOTIATE/

AWARD

MA’ADEN

EPC CONTRACTOR

Contractor Bid

MANAGE AND CONTROL

ENGINEERING

PROCUREMENT

CONSTRUCTION

ENGINEERING

PROCUREMENT

OPEN BOOK ESTIMATE

CONVERT TO LUMP

SUM

ANALYSE/NEGOTIATE/

COMMIT

Reimbursable

- Engineering services

reimbursable rates

- Agreed profit margin

- Agreement on LD’s

and major commercial

terms

Fix price

May 2006 June 2007

Project Development – Why selected?

Outotec Strength:• strong reference basis

• experience in LSTK implementation

• experience in project development worldwide

Step 1: Development of strong concept for local project implementation and

convince customer about Outotec‘s capabilities to implement large projects in

Saudi Arabia

Step 2:

Open Bidding process for phase 1 FEED (Front-End-Engineering) and OBE

(Open-Book-Estimate) phase won

Step 4:

Professional Engineering work, value engineering and global sourcing concept

applied during phase 1 lead to a sucessful team work with Maaden and it‘s

PMC. A optimised implementation concept for phase 2 had been developed

and contracted

Scope of Services and Supplies

• Outotec‘s Import scope:

Design, engineering, delivery and Commissioning

on a Lump-Sum-Turnkey basis .

• Outotec’s Local scope (via direct contract with local subcontractor):

Local supplies and Construction

• Total Price: USD495M

• Some key data:

Project implementation schedule: 31 month to MC

Total tons of structural steel: 3.800 tons

Total tons of equipment: 25.000 tons

Total cubic meters concrete 23.000m3

Total electrical drives installed: 200

Total cables installed: 350 km

Total engineering hours: 150.000

Total construction hours: 3.750.000

Global Sourcing

Supplies from and Fabrication in

• Europe

• Asia (South Korea, Taiwan, China)

• North America (Canada)

• South America (Argentina, Brazil)

0,0

5,0

10,0

15,0

20,0

25,0

30,0

35,0

40,0

45,0

50,0

55,0

60,0

65,0

70,0

75,0

80,0

85,0

90,0

95,0

100,0

%

Early / Month 0 10, 2,3 4,1 1,3 3,7 2,4 2,4 2,4 3,3 3,2 3,1 3,3 4,3 3,5 2,9 4,5 4,8 2,9 2,5 3,5 3,4 4,6 4,3 3,6 2,6 2,1 1,8 1,3 1,1 1,0 0,8 0,4 0,3 0,4 0,3 0,3 0,3 0,3 0,1 0,1 0,0

Target / Month 0 6,7 4,2 3,5 1,8 3,2 2,4 2,3 2,5 2,7 2,8 3,0 3,1 3,7 3,3 2,5 3,7 4,3 3,6 3,4 3,5 4,5 5,0 4,3 3,4 3,1 3,4 2,2 1,6 1,3 1,3 1,0 0,3 0,3 0,4 0,4 0,3 0,3 0,3 0,1 0,1 0,0

Actual / Month 0 0,0 8,0 3,9 2,5 2,3 2,9 2,0 2,0 7,3 2,4 1,8 5,7 1,7 1,6 2,3 2,7 4,7 3,7 3,4 5,0 4,3 6,0 4,6

Late / Month 0 2,9 6,0 2,9 2,2 2,6 2,3 2,2 2,6 2,2 2,5 2,9 3,0 3,0 3,1 2,2 2,8 3,7 4,3 4,4 3,5 5,5 5,3 4,4 3,1 3,5 4,8 2,6 2,0 1,5 1,5 1,3 0,3 0,3 0,4 0,4 0,4 0,3 0,3 0,1 0,1 0,1

Early cum. 0 10, 12, 17, 18, 22, 24, 26, 29, 32, 35, 38, 41, 46, 49, 52, 57, 61, 64, 67, 70, 74, 78, 83, 86, 89, 91, 93, 94, 95, 96, 97, 97, 98, 98, 98, 99, 99, 99, 99, 10 10

Target cum. 0 6,7 10, 14, 16, 19, 21, 24, 26, 29, 32, 35, 38, 41, 45, 47, 51, 55, 59, 62, 66, 70, 75, 80, 83, 86, 89, 92, 93, 94, 96, 97, 97, 97, 98, 98, 98, 99, 99, 99, 99, 10

Actual cum. 0 0,0 8,0 11, 14, 16, 19, 21, 23, 31, 33, 35, 40, 42, 44, 46, 49, 53, 57, 61, 66, 70, 76, 81,

Late cum. 0 2,9 8,9 11, 14, 16, 19, 21, 23, 26, 28, 31, 34, 37, 40, 42, 45, 49, 53, 58, 61, 67, 72, 76, 79, 83, 88, 90, 92, 94, 95, 97, 97, 97, 98, 98, 98, 99, 99, 99, 99, 10

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

early

target

late

Progress Curve - Total Project

Effective Date MC

• Mechanical Completion Certificates for all 3 plants reached

• Plant erected with highest quality standards and in accordance with the

specification

• Remaining Phosphate Project: Delay of other plants e.g. phosphoric acid

• Mode of contracting of phosphoric acid plants: split between technology

provider and project implementation:

• Technology package by Process Provider

• Lump Sum contract with other Contractor

• Commissioning delayed due to delay of phosphoric acid plant: 1 year (?)

• Plan to cope with time in between MC and commissioning: mothballing by

Outotec experts

Current Status


Outotec’s Alumina Refinery Capabilities

Alumina Production Overview

Alumina

(2t)

Outotec Package

(Mills) (Tube Digestor)

Outotec Package

(Settlers/Washers)

Outotec Package

(Integrated Filtration

& Calcination)

Bauxite

(4t)

DigestionRed Mud

SeparationPrecipitation

Filtration and

CalcinationGrinding

Alumina Refinery


Alumina

(2t)

Outotec Package


Outotec Package

(Settlers/Washers)

Outotec Package


& Calcination)

Bauxite

(4t)

DigestionRed Mud


Filtration and

CalcinationGrinding

Alumina Refinery

Outotec: Grinding

Outotec is designing

and building variety of

mills for various

minerals

Outotec’s scope

covers the range from

the mill up to the full

grinding circuit


Alumina

(2t)

Outotec Package


Outotec Package

(Settlers/Washers)

Outotec Package


& Calcination)

Bauxite

(4t)

DigestionRed Mud


Filtration and

CalcinationGrinding

Alumina Refinery

Outotec: Digestion

Outotec employs tube digestion technology concept, which was developed by VAW and constructed by Lurgi in German alumina refineries in the 1970s

This technology is designed to efficiently deal with a wide variety of bauxites and includes:

• single stream (caustic liquor + bauxite) heating in jacketed pipes:

• thermally efficient

• avoids caustic damage to carbon steel heating surfaces

• reduces silica scaling rates

• high digestion temperature

• suitable for mono hydrate bauxites

• high evaporation rate / m3 of slurry flow

• allows wet oxidation technology

• a holding tube for final extraction instead of an autoclave

• reduced descaling maintenance

• allows safe application of wet oxidation technology

Yarwun Alumina Refinery / Gladstone, Australia

End view of heater trains


Alumina

(2t)

Outotec Package


Outotec Package

(Settlers/Washers)

Outotec Package


& Calcination)

Bauxite

(4t)

DigestionRed Mud


Filtration and

CalcinationGrinding

Alumina Refinery

Principal flow diagram for a Residue Separation and

Washing Plant

Outotec: Red Mud Separation


Alumina

(2t)

Outotec Package


Outotec Package

(Settlers/Washers)

Outotec Package


& Calcination)

Bauxite

(4t)

DigestionRed Mud


Filtration and

CalcinationGrinding

Alumina Refinery

CFB –Calciner world wide

Calciners smaller 2000 tpd Calciners 2000 –3500 tpd and more

4

3

5

7

2+1

1 2

2

1

5

2

3

3

2

3

Outotec: Integrated Filtration & Calcination

Outotec’s integrated Filtration

and Calcination is developed

to provide:

• Constant and high product

quality

• Low energy consumption

• Fuel

• Electricity

• Steam

• Stable operation

• High degree of automation

Washing

and Filtration

Circulated

Fluid Bed

Calcination

Condensate

Hydrate Slurry

Flash

Hot Condensate

Hot Condensate

Filter Cake

Steam

Filtrate

Alumina

Major advantages of the CFB system

very stable plant operation

high availability and low maintenance

low vulnerability to power failures with quick restart

possible

very uniform product quality

favourable partial load behaviour

high flexibility of plant with respect to product quality

and plant capacity

low combustion temperature leads to low particle

breakage

low combustion temperature gives low NOx emission

Process Flow Diagram of the CFB system

Specific Energy Consumption

Source: CSIRO National Franework for Energy Efficiency, 2007

ALUNORTE 6.3 MTPY Refinery

Alcan Gove – Preassembled Modules Manufactored in Thailand and Vietnam

Vedanta, India, 3 x 3300 tpd

Full Automatic Smooth/Easy Operation trough

Feedforward Control ®– Example Alunorte

Rapid load change in a calciner

from 235 t/h to 60 t/h --- Alunorte plant data

Performance Test Results –

Exceeding Client’s Expectation72 hours average

Test

Unit Performance

Guarantees

Performance

Results

Difference Performed

BET m²/g within 60-80 78 +/- 0

Max. Continuous

Ratingt/d min 3300 3500 200

Particle Breakage % max 5.3 3.6 -1.7

Alpha Alumina % max 10 2.4 -7.6

Pick up for Fe2O3 % max 0.003 0.002 -0.001

Pick up for SiO2 % max 0.002 0.001 -0.001

LOI % max 1.0 0.75 -0.25

SEC at hydrate

moisture of 6%MJ/t max 2900 2800 -100

Product discharge

temperature°C max. 70 50 -20

Stretch-out Flowsheet

Secondary Air

Primary Air Offgas

Hydrate

Alumina

Dedusting

Dust Transport

Preheating

Stage 1Preheating

Stage 2

Hydrate

Feed

CFB

FurnaceMix Pot

Cooling

Stage 2

Cooling

Stage 1

FB Cooler

Alumina

Product

Secondary AirSecondary Air

Primary AirPrimary Air OffgasOffgas

HydrateHydrate

AluminaAlumina

Dedusting

Dust Transport

Preheating

Stage 1Preheating

Stage 2

Hydrate

Feed

CFB

FurnaceMix Pot

Cooling

Stage 2

Cooling

Stage 1

FB Cooler

Alumina

Product

Victor César Ribeiro da Cruz, Alunorte, Brazil “Our goal is to produce the highest quality alumina in the world. In order to reach that we needed two things: the best available technology and the most qualified professionals. Outokumpu Technology provided us with both. Their technology is reliable and easy to work with. The same is true of their people.”


Current Status of Aluminium Project Offers (All)

Outotec Offers for Ma‘aden Aluminium Project

Smelter:• 2 x 37,5tph stand-alone Paste Plants :

• LSTK Package

• Rodding Shop 60 anodes/hr:

• Full engineering and Supply of all Equipment (except steel structure)

• Casthouse:

• Key Equipment for sow caster and/or ingot casters (still to be offered)

Refinery:• Tube Digestion/Evaporation Unit as HOT JV (together with Hatch):

• License, reimbursable engineering and purchasing services

• Optional: License, Lump sum Engineering and proprietary equipment supply

• Alumina Calciners (2 x 3.500tpd):

• Full engineering and supply of all Equipment

• Full LSTK

Further Options for the Refinery to Support Ma‘aden

Tube Digestion/Evaporation Unit as HOT JV (together with Hatch):

• Increase of current license and reimbursable engineering and supply services packages to a full LSTK provided by Outotec/HOT

Benefits:

• Full set of guarantees with liability related to a percentage of the LSTK package (no excuses due to interface technology provider/implementation)

• Outotec fully considers the overall refinery standards

• Significantly reduced involvement of EPCM contractor and related savings

• Optimised coordination efforts due to a whole solution out of one hand

• Outotec has proven its reliability and easiness to work with during the Ma’aden Sulphuric Acid Plant Project

• Outotec and HOT prepared to show the estimate in a open-book/closed book manner

Alumina Calciners (2 x 3.500tpd):

• Utilize the same project/site management, infrastructure, construction partner as for tube digestion/evaporation giving the entire savings back to Ma’aden as a price reduction for the Alumina Calciners


Thank you for your attention

Documents

Outotec.al.Project