A TEC WORLDWIDE

World Leader in Cement Pyroprocess Technology

2012
 A TEC WORLDWIDE

Headquarter
Austria
Beijing
PR China

Kuala Lumpur
Malaysia

A TEC America
Mexico

A TEC Greco Brasil

2012 2
 A TEC ORGANIZATION CHART

2012 3
 A TEC BOARD MEMBERS

Dr. Günther Schwaiger

Managing Director
Chief Executive Officer (CEO)
Heading Sales, Marketing and Finance

Dipl.-Ing. Ulrich Kügler

Managing Director
Chief Organizating Officer (COO)
Heading Human Resources, Business
Development and Special Projects

Dipl. Ing. Friedrich Willitsch

Managing Director
Chief Technical Officer (CTO)
Heading Contract Management, R&D, Design
& Construction as well as Process Technology

2012 4
 SAFETY FIRST

Health & Safety – A TEC shows no willingness to compromise.

By means of high standards and safety trainings, A TEC aims to strengthen the
employee’s consciousness for safety at work. But we take on responsibility not only
for us and our employees but also for all other persons, who are involved in a
project.

Our goal is clear: “SAFELY doing the RIGHT THING”

Safety Assurance Persons at A TEC:

Peter Druml (p.druml@atec-ltd.com)
Peter Schamschula (p.schamschula@atec-ltd.com)

2012 5
 A TEC MISSION

2012 6
 A TEC FOCUS

2012 7
 POWER OF A TEC

A TEC offers patented products,

innovative process technologies
and consulting service know-how.

Hands-on experience in planning,

implementation and plant operation -
A TEC is a reliable business partner.

2012 8
 A TEC OPTIMIZATION

ENERGY

EFFICIENCY

ENVIRONMENT

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 CEMENT PYROPROCESS

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 RESEARCH & DEVELOPMENT

Continuous R&D with universities,

research institutes and industrial
partners

Present Projects include

1) Environmental Engineering
“Zero Effluent Policy”
a) Mercury Emission Suppression
b) NOₓ reduction via post combustion
c) CO2 foot print reduction by 100 %
primary fuel free operation

2) Energy Efficiency Improvements

Improvement of patented cyclone
technology for milling systems and
preheater

2012 11
 RESEARCH & DEVELOPMENT

Recently completed Research Projects

ReduDust bypass dust treatment

Converting bypass dust into cement raw

material and valuable base material for
chemical industry

Cooperation with Holcim

Full industrial plant, start up early 2014

2012 12
 A TEC-GRECO COOPERATION

• Brazilian combustion company

• Shared Offices all over the world
• Global solutions for the pyroprocess worldwide
• Managing director: Thorsten Offtermatt and
Adriano Greco

A TEC & GRECO. One team. One organization. Two choices for you.

2012 13
 GRIDLAB COOPERATION

A TEC – GRIDLAB Cooperation:

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• Plant Optimization by Engineering,
Smart Ideas & CFD
• Plant & flow optimizations
• Simulation of single or intricate
multiphase flows
• Computational Fluid Dynamics (CFD)

2012 14
 A TEC PROJECT EXAMPLES

Leube Zementwerk, Austria

STRABAG Greenfield Plant, Hungary
Lafarge Wössingen, Germany
Belarusian Cement Plants, Belarus
W&P Wietersdorf, Austria
Cementizillo, Fanna, Italy
Cemex Assuit, Egypt

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 LEUBE ZEMENTWERK GMBH

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 LEUBE ZEMENTWERK GMBH
MODERNIZATION

Initial Situation
Operation with two kiln lines
Both kilns without tertiary air duct, both kilns four stage Preheater
Limited in alternative fuel usage & both kilns are more than 40 years in operation

Project accomplishments
Usage of 80 % alternative fuels
Improvement of Clinker quality
Reduction of dust emissions, NOx and SO2
Flexibility of product arrangement
Reduction of energy consumption
Modernization without long stops
Arrangements for CO2 reductions
Best econcomic solution

2012 17
 LEUBE ZEMENTWERK GMBH
A TEC SOLUTION

CALCINER Staged Combution Calciner

TAD 4

COMBUSTION CHAMBER
Calciner Burner
Plastics < 150 mm
Sewage Sludge & Fine Coal
TAD 3
TAD 2
TAD 1

Quench Main Burner

Plastics < 20 mm
Shreded Tyres ~ 100 mm
Bypass Animal Meal & Fine Coal

2012 18
 LEUBE KILN1 CALCINER (>80% AF)

2012 19
 STRABAG / LAFARGE HUNGARY

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 STRABAG / LAFARGE HUNGARY

the overall project management

process and plant engineering

sub-contracts tendering & negotiation

ATEC quality assurance and progress control
Scope of Work
supervision for :
manufacturing
erection & commissioning
Training

2012 21
 LAFARGE - WOESSINGEN (>80% AF)

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 W & P – WIETERSDORF, AUSTRIA

Project Period: 16 months

Shut-Down: 69 days

New Preheater & Calciner

• New preheater complete
• New low-NOx calciner incl. Comb. Chamber
• New tertiary air duct,
• New hot gas duct
• New preheater fan
• Kiln shortening
• New kiln inlet sealing
• New kiln inlet chamber

Results
• Production increase from 1000 to 1777 t/d
• NOx <500 mg/nm³ (without SNCR)

2012 23
 W & P – WIETERSDORF, AUSTRIA

2012 24
 CEMENTIZILLO – FANNA, ITALY

Project Period: 12 months

Shut-Down: 65 days

Modification on Preheater & Calciner

• Modify top stage
• New tertiary air duct
• New kiln inlet sealing
• New low-NOx calciner incl. 2 new burners
• New hot gas duct
• New preheater fan
• Cut of kiln by approx. 1,5 meter
• Move of existing kiln inlet chamber

Results:
• Production increase from 1700 to 2450t/d
• NOx reduction to 600 mg/nm³
• 100% pet coke

2012 25
 CEMEX – ASSIUT KILN 2+3, EGYPT

Project Period: 8 months

Shut-Down: 39 days

Modification on Preheater & Calciner

• Disassembly of preheater equipment except
• Cyclone cone stage 2 & 4
• Meal pipes stage 2 & 4
• Installation of new preheater equipment
• Extension existing 2 string calciner
• New hot gas duct

Results:
• Production increase from 4000 to 4500 t/d
with a shut down of only 39 days!!!

2012 26
 CEMEX – ASSIUT KILN 2+3, EGYPT

2012 27
 CEMENT PLANTS for BELARUSIA

Technical Services (Engineering, quality,

manufacturing & shipment control)

3 new kiln lines – 5000 t/d each

Supplier Quality Assurance (SQA)

• Engineering Supervision
• Technical Interface Clarifications
• Quality Controls
• Enforcement of Continuous Certification
• Delivery Schedule Monitoring

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 BELARUSIAN CEMENT PLANT

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 2-STAGE CHLORINE BYPASS

• Quench made completely of

metal (no lining required)
bypass 2nd stage
• Cooling in one step to 200 °C cyclone quench

• Minimum space requirement

mixed gas
duct to filter
• Simple functionality
coarse dust
return

1st stage
quench

2012 30
 P yro P rocess I nvestigation
A package service by A TEC America

We investigate Pyro-problems:

Poor or variable quality clinker

Low clinker production rate
High thermal consumption in kiln section
High pressure losses in preheater

Raw meal blockages in preheater

Pendulum valves sticking
Short life-time of lower stages dip-tubes

High %O2 and high %CO at the same time

Rings or red-spots in kiln operation
2012 Priviledged Information not to be copied. All rights reserved. 31
 PROBLEM SOLVING PPI
Fixing problems is not easy… 1. Problem definition
2. Root cause analysis
There are many symptoms 3. Possible solutions
Which is the root cause? 4. Solution selection
What is possible? 5. Action plan
How much will it cost?

Many inter-related symptoms make fixing complicated!

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 STANDARD PROCEDURES PPI
Investigate issues using a scientific approach, standard process, benchmarks:

… and standard reporting:

INTRODUCTION&&AIMS
INTRODUCTION AIMS
I N TRODU CT ION
I NT RO DU CTI O N
A IM S OF THE I NVESTI GAT ION
A IM S OF THE I N VESTIGA TI O N
SSCCOPE
OP E OF T HE I N VE ST IGATIO N
O F THE I NV ESTIGAT IO N

INSTALLATIONCHARACTERISTICS
INSTALLATION CHARACTERISTICS
P LA NT DA TA
P L AN T DA TA
K IL N LI NE DAT A
K IL N LIN E DA TA

OPERATION&&BENCHMARKS
OPERATION BENCHMARKS
M AIN OP ER ATI NG DA TA
M AI N OPER A TIN G DATA
B E NCHMA R KS FO R K I LN L INE
B E N CHM A RKS FO R K IL N L IN E

RELEVANTPROBLEMS
RELEVANT PROBLEMS

THERMALANALYSIS
THERMAL ANALYSIS
G E NER AL
G E N ERAL
I N PUTS
I NP UTS
OOUTPUT PUT S
UTS
HHEA EAT BALA NCE A DJUSTM EN TS
T BA L AN CE A DJUSTM EN TS
R ESU LT S OF THE H E AT B A LA N CE
R ESU LTS O F TH E H EAT B A LA NC E

CHEMICALANALYSIS
CHEMICAL ANALYSIS
R AW M EAL C O M PO SITI ON
R AW M E A L C OM PO SI TIO N
C IR CU LATIN G E L EM E NT S B A LA NCE
C I R CUL A TING E LE M ENTS B ALA NC E
CCLLIN K ER A N ALYSI S
INKER A NAL YSIS

RAWMEAL
RAW MEALSTORAGE/DOSING
STORAGE/DOSING
E QU IPME N T
E Q UI PM EN T
P RO CESS DA TA
P R OC ESS DA TA
R ECOM ME NDATI ON S R A W M E AL H A N DLI NG
R ECO MM E NDA TI O N S R A W M E AL H AN DL IN G

2012 33
 END-USER BENEFITS PPI
Independent 3rd party evaluation
fresh approach to see problems from a different angle
no political, personal or supplier bias

Professional and experienced personnel

A TEC makes 100 cement plant visits per year
based on “world leader” technologies and calculations
expert opinion regarding new technologies;
open discussions lead to consensus on solutions proposals

Benchmark
against other plants outside operator’s group
against established industry standards

Useful data:
main data and issues in one document
what to do, how to do, what is possible => plan future scenarios

2012 34
 A TEC FOCUS

2012 35
 AMERICAN & ASIAN CONTINENT
America Technical Center & Sales
Austria TEC S.A. de C.V.
Calzada Zavaleta 1306A / 24 Suite 5278
Colonia Santa Cruz Buenavista
72150 Puebla, MEXICO
Tel/Fax: 0052 222 889 7907
E-Mail: inbox@atec-america.com
A TEC GRECO Brasilien Operation
A TEC GRECO Projetos e Equipamentos Ltda.
Av. Brigadeiro Faria Lima 1912 – 11A
01451-001 Sao Paulo, BRAZIL
Tel.: 0055 11 3500 1777
Fax: 0055 11 3500 1778
E-Mail: info.br@atec-greco.com
2012
A TEC Asia Pacific Operation
A TEC Asia Sdn Bhd
Unit 202, Block E, Phileo Damansara I
Jln 16/11, 46350 Petaling Jaya,
Selangor, MALAYSIA
Tel.: 0060 3 7955 3166
Fax: 0060 3 7955 3177
E-Mail: info@atec-asia.com
Office China
A TEC Technology Services (Beijing) Co.
Unit 2205, Chao Wai SOHO, No. 6 B,
Chaowai Street, Chaoyang District,
Beijing, PR CHINA
Tel.: 0086 10 5900 0860
Fax: 0086 10 5900 0837
E-Mail: china@atec-asia.com
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 EUROPE, MIDDLE EAST, AFRICA
Administration, Finance & Sales
A TEC Production & Services GmbH
Kasernstraße 16-18
3500 Krems, AUSTRIA
Tel.: 0043 2732 75680
Fax: 0043 2732 75680 201
E-Mail: sales@atec-ltd.com
Engineering & Technical Center
A TEC Production & Services GmbH
Finkensteinerstraße 9
9585 Gödersdorf, AUSTRIA
Tel.: 0043 4257 3600
Fax: 0043 4257 3600 101
E-Mail: office@atec-ltd.com
2012
Production, Maintenance & Installation
A TEC Plant Construction GmbH
Steirerstraße 17
9372 Eberstein, AUSTRIA
Tel.: 0043 4264 8187
Fax: 0043 4264 8187 301
E-Mail: production@atec-ltd.com
Office Poland
Piotr Laube, MSc Mech. Eng.
Ul. Swierkowa 3
22-100 Chelm, POLAND
Mobile: 0048 661 119 222
E-Mail: piotr.laube.atec@wp.pl
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THANK YOU FOR YOUR ATTENTION
www.atec-greco.com

2012