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

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Fives FCB is recognised by key players in

the cement and mineral industries for its

capacity to design and supply workshops

and complete plants which integrate

sustainable and innovative process

equipment.

The project awarded by JSC Mordov-

cement in Russia for the integration of

an alternative fuel handling system and

successive orders placed by the Holcim

Group in Mexico and Brazil, illustrate the

confidence that these customers put in

our reliable solutions and in our ability

to manage large projects all over the

world.

After the successful commissioning of the

Hermosillo cement plant, the award at the

end of 2011 of the Barroso contract for a

new 4,500 tpd production line confirmed

Fives FCB’s capacity to successfully meet

the requirements and standards of the

Holcim group in terms of performance

and sustainable development.

These new contracts also support Fives

FCB’s world development strategy, with the

implementation of operational entities

in Brazil, India and Mexico. Depending on

markets, these entities will be used to

promote the sale of equipment, services,

and revamping of existing plants and will

offer our customers local service and

optimum reactivity.

Finally, the reliability of the equipment

developed by Fives FCB and its technical

expertise in the fields of grinding and

pyroprocessing are still widely acclaimed.

This is evidenced by the latest orders

and commissioning operations and by

the performance of the Vinaconex Twin

Horomill® grinding plant in Vietnam.

All these achievements illustrate Fives

FCB’s willingness: to be a key partner and

to have a local presence for its customers

throughout the world.

Alain Cordonnier, CEO

Fives FCB

Fives FCB, key supplierfor Holcim

As part of the capacity increase of its Barroso cement plant, located in the state of Minas Gerais, 300 km away from Rio de Janeiro, Holcim (Brasil) SA awarded Fives FCB with an order for the supply and the erection and commissioning supervision of a new 4,500 tpd clinker production line. The contract concerns detailed studies for the engineering of the plant - including civil engineering -, supply of

FIVES FCB GOOD NEWS FOR YOU, the newsletter of Fives FCB – Fives FCB – 50 rue de Ticléni – B.P. 376 – 59666 Villeneuve d’Ascq Cedex – France – Phone: +33 (0)3 20 43 77 77 – Director of publication: Alain Cordonnier – Editor: Jean-Pierre Cornille – Editorial committee: Samir Bekkaoui, Jacques-Olivier Bou, Gilles Cojean, Hervé Cordier, Jean-Pierre Cornille, Serge Jorget, Olivier Vanlerenberghe – Writers: Hélène Bachellerie, Chrystelle Lucidarme – Thanks for their collaboration: Jean-François Bonhomme, Frank Chambord, David Kotrys, Fabrice Lauwerie, Olivier Vanlerenberghe – Graphics and layout: Christophe Cocquet – Printing: Une Impression – 5 rue Jean Moulin – 02880 Crouy – ISSN number: 2106-9883. 500 copies printed.

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mechanical, electrical and control equipment, plateworks, steel structures, and technical assistance during erection and commission-ing. The project includes plants from the raw material crushing plants to the clinker silo and cement silos. They will feature the latest technologies developed by Fives FCB, which are particularly efficient in reducing energy and water consumption and industrial emissions.

Driving progress

On October 31st, 2011, Holcim (brasil) Sa selected Fives FCb for the construction of a new 4,500 tpd clinker production line for its cement plant in barroso, brazil. This is a sign of sustained trust from the Holcim

Group as this contract follows the successful commissioning in 2010 of the Hermosillo cement plant delivered to Holcim apasco, in Mexico.

In 2004, Vinaconex selected the Horomill® technology developed by Fives FCB, which had never before been installed in Vietnam, for its cement grinding plant construction project in Phu My, in the south of the country. The projected capacity - 240 tph at 3,200 Blaine - required the installation of two Horomill® 3800 units.Fives FCB recommended its Twin Horomill® concept: the combination of two similar Horomill® grinding units operating simulta-neously and combined with a unique, large size TSV™ classifier.When production was launched in December 2006, the Twin Horomill® facility fully demonstrated its advantages.

Its operating flexibility makes it possible to:• change product quality in an automated way

in only a few minutes, with no shut-down; the operator just has to select the new recipe and the transition is done with no other required action;

• automatically switch from two grinding mills to just one mill, with no shut-down. Thus, production can continue at half-capacity with just one Horomill® unit, while main- tenance operations are carried out on the other.

At the end of 2011, five years after commis-sioning, each machine totalled 20,000 hours of operation, as the grinding plant’s production depends on the local demand for cement.

Vinaconex teams have gained knowledge on the operating mode and maintenance of the plant, under the supervision of Fives FCB. They systematically operate both Horomill® units at the same time, as this configuration results in the highest level of energy savings. The plant is extraordinarily clean: machines and components (mechanical components, hydraulic power plants…) are periodically maintained in conformity with the strictest standards. This first order for Twin Horomill® has been followed by others. Fives FCB provided the same technology as part of the 4,000 tpd complete cement plant supplied in Thai Nguyen, Vietnam. Two Twin Horomill® systems were also delivered to Rizhao for its steel slag grinding plant in China. These references demonstrate Asian manu-facturers’ interest in the Twin Horomill® technology for applications in the cement and steel industries.

VINACONEX (VIETNAM) Cam Pha Twin Horomill® grinding plant: 5 years of satisfaction

In order to increase the capacity of its Lazaro Cardenas plant, Arcelor Mittal signed a contract with Fives FCB for the audit of 3 SAG mills, diameter: 26’, which were supplied in 1984. This contract is divided into 2 orders: the engineering will be done by Fives FCB in France, whereas the local part will be handled by its new subsidiary dedicated to Services based in Mexico, Fives FCb Services Mexico. The audit includes listing parts as well as conducting mechanical, electrical and instru-mentation expertise. Arcelor Mittal’s objective is to upgrade these mills with updated technologies to operate them with optimum reliability.

ARCELORMITTAL(MEXICO)Grinding expertise

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The Italcementi/Calcia group entrusted Fives FCB with an order for the replacement of a supporting shell with shimming system and tire for the Villiers au Bouin site . A proven solution, the shimming system provided by Fives FCB is used to easily adjust gaps between the shell and the tire and thus maintain the ovality of the furnace shell within tolerances in order to avoid the falling of refractory bricks.These floating shims can be adjusted to all types of existing rotary kilns to avoid cracks on the shell. In the past few years, Fives FCB had already obtained orders from Calcia for the improvement of shimming systems for

the Villiers au Bouin, Couvrot, Beaucaire and CCB Gaurain sites.

CALCIA - VILLIERS AU BOUIN (FRANCE)Order renewal from Italcementi/Calcia group

2 www.fivesgroup.com FIVES FCb GOOD NEWS FOr yOu 3

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In July 2011, Russian cement producer JSC Mordovcement selected Fives FCB for a contract including the design and supply of wooden chips handling systems for its Alekseevskiy, Sengileevskiy and Staroalekseev-skiy sites. The four systems supplied by Fives FCB are intended for feeding seven rotary kilns, includ-ing four in wet circuit, all fitted with Fives

In response to the world economic crisis which emerged in 2008 and to the slow-down in its traditional markets, Fives FCB has decided to deploy its business in emerging countries and strengthen its local presences.

Fives FCB is globalizing its activities in order to place the company at the core of high potential regions, to develop resources and structures where they are required and to capture growth opportunities.Depending on the markets, these entities will serve the cement and mineral industries for the sale of equipment, workshops and complete plants and for the promotion of services.

Fives FCB is already present in many countries through the Fives group offices and engineering subsidiaries. In 2010, Fives FCB set up its own sales office in Brazil and in mid-2011,

F ives FCb is expanding in strategic regions, establishing operational entities in brazil, India and Mexico.

Pillard Novaflam® burners designed for the use of alternative fuels.These facilities will enable JSC Mordovcement to replace up to 40 % of its fossil fuel consump-tion with wooden chips from the furniture industry, residues from forest-based cuttings, railway cross-ties, or down-graded pallets, and to comply with the Group’s program to reduce its costs and environmental impact.

The seven lines are due to be commissioned in 2013.

JSC MORDOVCEMENT (RUSSIA)Fives FCB secured a contract for the supply of alternative fuel handling systems

International Development:Fives FCB is setting up in Brazil, India and Mexico

a full operational team in India dedicated to sales and the management of local projects.

Fives FCB is renowned for its expertise in managing large projects worldwide, in partic-ular on a turnkey basis. These developments are complementary and constitute a way to expand its portfolio of activities in industries where operating locally is a necessity.

It is within this context that Fives FCB opened a Services entity in Mexico - Fives FCb Services Mexico - in 2011. Its objective is to better

support its customers thanks to its local presence and a complete offer of services: technical support, supply of spare parts, audits and ex-pertise, upgrading projects...

This development plan aims to reinforce and promote Fives FCB’s offer, not only with its traditional customers, but also with new players, by deploying its expertise in processes and its capacity to offer innovative solutions worldwide.

EQuIPMENT & uPGraDING

Fives FCb is deploying its expertise in processes and its capacity to offer innovative solutions world-wide

Phosphate grinding plant (Morocco)Fives FCB has supplied a 30 tph phosphate grinding plant to Bunge Maroc Phosphore, to be incorporated into its complete fertilizer production plant at its Jorf Lasfar site.All the erection operations required for the grinding plant were completed in August 2011. Following a number of no-load tests and adjustments, the grinding plant produc-tion started on September 10 th, 2011, with a load at 85%, generating highly satisfactory results. Later, the grinding load was increased to 100%.Performance tests will be conducted when the new fertilizer production line is available.

burning equipment (algeria)To solve recurrent problems with the kiln inlet seal (distorted shell, poor tightness generating loss of materials, significant wear rate, etc.), Société des Ciments de la Mitidja-Meftah awarded Fives FCB with a contract for the supply of burning equip-ment including:• engineering for an optimised design of

equipment and drawings for the local manufacturing of certain parts,

• supply of kiln shell and upstream seal,• installation supervision. Shutdown for the replacement of the seal is scheduled for March 2012.

raw material crushing• 1,400 tph primary crushing with giratory

crusher• 900 tph secondary crushing with 1 sieve

and 2 cone crushers• Additives, correctives and petcoke

crushers.

raw meal grinding• 420 tph raw meal grinding plant equipped

with one Horomill® 4400, the biggest Horomill® ever supplied, and a TSV™ classifier 7000 BF.

raw meal homogenizing• One 10,000 t capacity silo.

Petcoke grinding• One 44 tph petcoke grinding plant

with ball mill Ø 3.8 m - L 9.5 m with pre-dryer L 2.25 m and TSV™ classifier 3000MF.

burning line• One 5-stage single string preheater

with low pressure drop cyclones Ø 9.0 / 9.0 / 8.6 / 8.6 / 2 x 7.0 m

• One Zero-NOx precalciner Ø 5.8 m• One rotary kiln Ø 5 m - L 72 m• One grate cooler - l 4.4 m - L 27 m• One AFR preparation unit.

Clinker storage• One 35,000 t capacity silo.

Cement packing and dispatching• One 21,000 t capacity multi-cell silo

with 5 truck bulk loading spouts• One 10,000 t capacity silo with bulk

loading system and distribution to existing packing system• One palletizing machine.

This new production line, which will be one of the most modern in the world, will enable Holcim Brazil to increase its production capacity by 50% to reach 7.9 million tpy of cement in 2014, thus fulfilling the huge demand from the Brazilian market. Holcim Brazil’s order follows the successful commissioning of the Holcim Apasco complete cement plant, which was delivered to Holcim Apasco in Hermosillo, Mexico, in 2010. The Hermosillo 3,500 tpd cement plant is a true reference in terms of energy savings, environ-mental protection and safety regulations.It features the latest technologies developed by Fives FCB to meet Holcim Group’s require-ments and its goal to comply with the most stringent local and international environmental standards.A real show of trust in Fives FCB’s solutions! ■

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