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Outotec – in brief

May, 2010

Strong history of groundbreaking technologies and innovation

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Alumina Business Center

Outotec‘s experience and solutions

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Alumina Business Center

Outotec delivers from equipments to plants and services

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Alumina Business Center

Outotec – global partner

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Alumina Business Center

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 …

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Alumina Business Center

Fluidization – A Key Technology
Example Rosting

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Alumina Business Center

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.”

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Alumina Business Center

Ma’aden-Alcoa Refinery Project 26.05.2010

Suggested Agenda
1.

Brief Status on our currently implementend Project with Ma’aden Outotec’s Alumina Refinery Capabilities Current Status of Aluminium Project Offers to Ma’aden, Suggestions and Discussion

2.

3.

Ma’aden-Alcoa Refinery Project Status Sulphuric Acid Plants

Project Development – Convertible EPC approach
May 2006
DESIGN BASIS ANALYSE/ NEGOTIATE/ AWARD

June 2007
MANAGE AND CONTROL ANALYSE/ NEGOTIATE/ COMMIT

MA’ADEN EPC CONTRACTOR
BIDDING

ENGINEERING PROCUREMENT

ENGINEERING PROCUREMENT CONSTRUCTION

- Engineering services reimbursable rates - Agreed profit margin - Agreement on LD’s and major commercial terms

OPEN BOOK ESTIMATE

CONVERT TO LUMP SUM

Contractor Bid

Reimbursable

Lump Sum

Fix price

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:  Total tons of structural steel:  Total tons of equipment:  Total cubic meters concrete  Total electrical drives installed:  Total cables installed:  Total engineering hours:  Total construction hours:

• • •

31 month to MC 3.800 tons 25.000 tons 23.000m3 200 350 km 150.000 3.750.000

Global Sourcing
Supplies from and Fabrication in • Europe • Asia (South Korea, Taiwan, China) • North America (Canada) • South America (Argentina, Brazil)

Progress Curve - Total Project
100,0 95,0 90,0 85,0 80,0 75,0 70,0 65,0 60,0

target early

Effective Date

MC

%

55,0 50,0 45,0 40,0 35,0 30,0 25,0 20,0 15,0 10,0 5,0 0,0 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

late

Early / Month Target / Month Actual / Month Late / Month Early cum. Target cum. Actual cum. Late cum.

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 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 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 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 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 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 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, 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

Current Status
• 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

Ma’aden-Alcoa Refinery Project Outotec’s Alumina Refinery Capabilities

Alumina Production Overview
Bauxite (4t)

Alumina Refinery
Grinding Digestion Red Mud Separation Precipitation Filtration and Calcination

Outotec Package (Mills)

(Tube Digestor)

Outotec Package (Settlers/Washers)

Outotec Package (Integrated Filtration & Calcination)

Alumina (2t)

Alumina Production Overview
Bauxite (4t)

Alumina Refinery
Grinding Digestion Red Mud Separation Precipitation Filtration and Calcination

Outotec Package (Mills)

(Tube Digestor)

Outotec Package (Settlers/Washers)

Outotec Package (Integrated Filtration & Calcination)

Alumina (2t)

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 Production Overview
Bauxite (4t)

Alumina Refinery
Grinding Digestion Red Mud Separation Precipitation Filtration and Calcination

Outotec Package (Mills)

(Tube Digestor)

Outotec Package (Settlers/Washers)

Outotec Package (Integrated Filtration & Calcination)

Alumina (2t)

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 Production Overview
Bauxite (4t)

Alumina Refinery
Grinding Digestion Red Mud Separation Precipitation Filtration and Calcination

Outotec Package (Mills)

(Tube Digestor)

Outotec Package (Settlers/Washers)

Outotec Package (Integrated Filtration & Calcination)

Alumina (2t)

Principal flow diagram for a Residue Separation and Washing Plant

Outotec: Red Mud Separation

Alumina Production Overview
Bauxite (4t)

Alumina Refinery
Grinding Digestion Red Mud Separation Precipitation Filtration and Calcination

Outotec Package (Mills)

(Tube Digestor)

Outotec Package (Settlers/Washers)

Outotec Package (Integrated Filtration & Calcination)

Alumina (2t)

CFB –Calciner world wide
Calciners smaller 2000 tpd

Calciners 2000 –3500 tpd and more

2 3

5

2 1 2 4 7 3 2+1 5 1 3 3 2

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
Hydrate Slurry Filtrate

Washing and Filtration
Steam Hot Condensate

Flash
Hot Condensate

Filter Cake

Circulated Fluid Bed Calcination
Condensate 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 Expectation
72 hours average Test
BET Max. Continuous Rating Particle Breakage Alpha Alumina Pick up for Fe2O3 Pick up for SiO2 LOI SEC at hydrate moisture of 6% Product discharge temperature

Unit

Performance Guarantees
within min max max max max max max 60-80 3300 5.3 10 0.003 0.002 1.0 2900

Performance Results
78 3500 3.6 2.4 0.002 0.001 0.75 2800

Difference

Performed
       

m²/g t/d % % % % % MJ/t

+/- 0 200 -1.7 -7.6 -0.001 -0.001 -0.25 -100

°C

max.

70

50

-20

Stretch-out Flowsheet

Preheating Stage 2 Cooling Stage 2 Cooling Stage 1

Preheating Stage 1

Dedusting

FB Cooler CFB Furnace

Hydrate Feed Mix Pot

Alumina Product Secondary Air Primary Air

Dust Transport Hydrate Alumina

Offgas

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 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: • Casthouse:

• Full engineering and Supply of all Equipment (except steel structure) • Key Equipment for sow caster and/or ingot casters (still to be offered)

Refinery: • Tube Digestion/Evaporation Unit as HOT JV (together with Hatch): • Alumina Calciners (2 x 3.500tpd):

• License, reimbursable engineering and purchasing services • Optional: License, Lump sum Engineering and proprietary equipment supply • 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

Ma’aden-Alcoa Refinery Project Thank you for your attention