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Energy, Light Metals andEnvironmental Solutions
Peter Weber, PresidentEnergy, Light Metals and Environmental Solutions business area
Outotec’s Capital Markets DayNovember 15, 2011
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ContentSnapshot ELEHighlights of 2011 project wins
Client focus – case CodelcoWho is Codelco?History of Outotec’s relationship with CodelcoCurrent customer goals – where is the customer today? Outotec technology solutions to respondGoing forward with Codelco in 2011Outotec value proposition - roasting, sulfuric acid and industrial water treatment solutions
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Life cycle offerings with four business areas
Nov 15, 2011
Market Operations
Supply
Business Infrastructure
Strategy
Technology Management
Finance & Control
Legal Affairs
Human Capital
for the processing of copper, nickel, zinc,
lead, gold, silver, platinum group metals, industrial minerals as well as valuable minor
metals
for the production of concentrates, industrial minerals, pellets, sinter, pig iron, direct reduced
iron, ferroalloys, and titanium feedstock
for oil shale, oil sands and biomass processing, light metals and sulfuric acid production, off-gas handling, and industrial
water treatment
providinglife cycle services
Jacobs (Aker), Alcan, Ahlstom, Brochot, FLS, Foster Wheeler, GEA, MECS, Siemens, Solios,
Stultz, Veolia
Engineering companies: AMEC, Ausenco, Bechtel, Chalieco, Enfi, Fluor, Hatch, MCC, NERIN, NFC, SNC-Lavalin, SRK, Worley Parsons
Outotec has no face-to-face competitor, competitive landscapeis fragmented
Peers & competitors:
Non-ferrous Solutions Ferrous SolutionsEnergy, Light
Metals & Environmental Solutions
Services
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Energy, Light Metals and Environmental Solutions = ELE
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Sustainable solutions and new applications of proven technologies
Technology development, lump sum turnkey project implementation, engineering, process equipment design & delivery, automation and complete life cycle services
Expertise Solutions forThermal processingGasificationOil winningHeat recovery & transferProcess gas cleaningFluidized bed applicationsCatalytic conversionRefractory design & engineeringAnode plants for aluminumsmeltersHydrometallurgy
Alumina refineriesCalcinationCarbon plants/Aluminium smeltingRoastingOff-gas handlingSulfuric acid productionBiomass processingOil shale and oil sands processingIndustrial water treatment
Extensive research facilities• Innovative R&D at two
in-house research centers
Nov 15, 2011
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Utilize our market-leading fluidized bed (FB) technology
• Calcination and roasting , i.e. Solutions for de-sulfurization, de-arsenification, chlorination, sulfatizing
Provide roasting technology for a variety of metals Copper, cobalt, zinc, gold, nickel, pyrite, aluminium, molybdenum, etc.
Have over 50 years providing roasters to many global customers
Offering customized solutionsincluding heat recovery (waste heat boiler), steam production (20-70 metric tons per hour) and generation of electrical power (5-15 MW)process design to meet specific requirements for recovery of by-products (gold, silver, rhenium, cobalt) and elimination of impurities (arsenic, lead, chlorine, fluorine, cadmium) handlingGreen field or brown field, modifications, upgrades, process changes, etc.
Outotec‘s value proposition: LM/FB (Roasting)
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Over 90 years in the acid industryMore than 650 acid plants built by OutotecEnd-to-end solution: Smelting, roasting,off-gas cleaning and acid plant from asingle-source supplierUnique expertise in large sulfuric acid plantsbased on all sulfur sources
Largest metallurgical acid plant: 4,200 mtpd (1.5 million mtpy)Largest sulfur-burning plant: 4,800 mtpd (1.7 million mtpy)Largest acid plant complex in a single phase: 3 x 4,500 mtpd (de-bottlenecked 3 x 5,000 mtpd)
Leader in innovative acid plant process solutionsLUREC (processing of up to 25% SO2)
Competitive for new plants (>10% savings)Ideal for revamps with capacity increase of smelter by O2
HEROS (heat recovery originally developed in 1989, in 2011 next generation system with focus on reliability and increased efficiency introduced)
50 percent of low-level heat transferred into valuable steam andThe cooling consumption cut down by as much as well
Emission control (including NOx, Hg, As)
Outotec’s value proposition: sulfuric acid plants
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Outotec’s value proposition: IWT
We can offer customers in need of industrial water treatment (IWT) solutions
Process water re-circulation and effluent treatment;Solid and liquid separation;Integrated concentrate and metals production processes;Customized water treatment solutions
These solutions are supported byOutotec’s deep skills in
R&D (in-house facilities)Decades of experience with water handlingand effluent treatment in smelter, roastingand mining technologyEngineering (design)Project implementation, sales and marketing
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Industrial water treatment and acid mine drainage
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Outotec has process expertise and a vast portfolio of technologies for water treatment in mines and smelters.
Experience in neutralization, removal of heavy metals or toxic elements from contaminated waters.
Pre ssureFilte r
Fe e d M ix ingRe a ctor Ne utra l iza tion
Re a ctor No. 1pH > 10
Ne utra liz a tion Re a ctor No. 2
pH = 10
M ilk of Lim eP re pa ra tion Re a ctor
Lim e Bin a nd Fe e d ing Syste m
W a te rL im e
Thicke ne r
Floccula nt
Efflue nt to tre a tm e nt
P urifie d Efflue nt
Filte r Fe e dTa nk
Filte r Ca ke to Disposa l
S ludge Circula tion
General flowsheet for Outotec’s lime neutralization process for water treatment.
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Carbon plant project wins - 2011 highlights
EPC (Engineering, procurement and construction) contract for green anode plant and carbon scrap crushing based on the latest design as applied in EMAL Phase I EPC contract for anode rodding shop and hot bath removal using Outotec’s latest design with optimal layoutTotal contract value over EUR 100 millionScheduled to be commissioned by end of 2013
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July: two major contracts for Emirates Aluminium PJSC (EMAL) Phase II expansion project: Al Taweelah, Abu Dhabi, United Arab Emirates
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Light metals project wins - 2011 highlights July: Secures contract to deliver alumina calcination technology to Ma‘aden Alcoa joint venture in Saudi Arabia. Represents first modern calciners to be built in the Middle East
Delivery of two calciners to integrated aluminum complex at Ras Al KhairEach calciner will deliver 3,500tonnes of alumina per dayTotal contract value EUR 62 millionCalciners will be built withlowest capacity specific weightof construction materialWill have lowest specific eletrical power consumptionScheduled to be commissioned by 2013Previous work for Ma‘aden involvedbuilding the world’s largest sulfuricacid complex at same location
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Outotec‘s three sulfuric acid lines at Ma‘aden; commisioned in 2011
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Sulfuric acid project wins - 2011 highlights July: Delivery of gas cleaning and sulfuric acid plant for OJSC Almalyk Mining and Metallurgical Company (AMMC) in Uzbekistan
When completed, will produce 500,000 tonnes per yearTotal contract value EUR 30 millionGoal is to substantially improve environmental conditions of the region
November: Engineering for heat recovery revamp for Atlantic Copper
Modification of existing plants to sustainable produce high and low pressure steam from waste heat
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Energy project - 2011 highlights New oil shale pilot plant at Outotec’s Frankfurt R&D center has been successfully commissioned for Enefit Outotec Technology
Allows testing of different oil shales with Estonian, Chinese and Jordanian oil shalesOil sands testing has also been conductedCan produce oil samples to determine oil quality and propertiesA demonstration plant with a throughput of 350 kg/h oil shale is also under construction in Outotec’s R&D center
Agreement with Eesti Energia to deliveroil shale preparation plant
Plant to be completed in 2012 along with main oil production plantTotal contract value exceeds EUR 20 millionTotal plant can produced 4.5 million mtpy of crushed oil shale
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Enefit oil shale demonstration plant
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Case Codelco
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Client focus: Who is CodelcoCodelco - Corporación Nacional del Cobre de Chile - is an autonomous company owned by the Chilean state. Primary business is exploring, developing and exploiting copper mineral resources and by-products, their processing to refined copper and its commercialization.
World’s largest copper producerControls around 20% of the world’s reservesCorporate home is Santiago, ChileSix mining divisionsKey commercial product is LME Grade Acopper cathodesKey numbers (2010)• Assets of more than USD 20.2 billion• Equity of USD 4.5 billion• Produced 1.76 million mtpy of refined copper (11% of world copper production)
About 25% of the production is achieved using Outotec’s VSF solvent extraction technology. Another 30% can be attributed to Outotec’s flash smelting technology
Codelco and Outotec technology
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Outotec’s strong relationship with Codelco
Over 30 years of working togetherSeveral beneficiation solutions and equipment supplied including flotation cells, thickeners, particle analyzers and automation systemsSeveral pyrometallurgical solutionsincluding flash smelter, converter, casting machinesSeveral hydrometallurgical solutionsincluding tank houses and tank houseequipment as well as solvent extraction plantsGas cleaning systems and sulfuric acid plants (partially as licensor)
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Current Codelco goals1. Open new mines (Mina Ministro Hales
(MMH), Chuqui Underground)Existing mines with lower copper concentrations are close to end of life cycle; thus to maintain level of pure metals production, new mines must be openedNew mines have higher grades of arsenic; de-arsenification of concentrates is necessary
2. Adapt existing production facilities tonew emission regulations in ChileRevamp existing smelters to improve SO2 capture
Revamp existing sulfuric acid plants from single catalysis to double catalysis
3. Improve operation efficiencyBring operation cost and efficiency on international standards of private industry
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The Outotec advantageOutotec as a “one-stop shop” with BAT and end-to-endresponsibility
Market leader in roasting technology and among market leaders in gas cleaning and sulfuric acid plant technologies. • Over 650 sulfur plants built• BAT – best available technology – for integrated process solution
including tests with in-house research facilitiesProven project implementation capabilities for turnkey projects. Latest roasting plant reference – Votorantim Metais, Cajamarquilla, Peru • Reliable implementation solution
Operation and maintenance support with experienced specialists including spare parts supply and handling• Reliable solution for start-up and plant operation
Competitive pricing through international procurement via Outotec’s global competence network Outotec has provided support to Codelco for over 30 years with contracts for studies and test work.
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A technology solution for the entire process chain
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RoastingEnergy
RecoveryHot gas
CleaningWet gas Cleaning
EffluentTreatment
EnergyRecovery
AcidPlant
FeedCu, Zn, or pyrite
concentrate
Calcine
ElectricalEnergy Process
Water
SulfuricAcid
CleanWater
Safe Disposal(e.g. As)
BoilerWater
Outotec can provide Codelco with roasting/gas cleaning/effluent treatment/acid plant/energy recovery
Nov 15, 2011 Outotec CMD 2011/ELE
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Codelco’s new mine: Mina Ministro HalesSince 2010 Outotec has been supplying Codelco’s MMH mine with equipment for a concentrator plant and a roasting plant. MMH is a new mine planned to produce copper concentrate – up to 550,000 mtpy. It will produce up to 150,000 mtpy of copper, adding about 9% to Codelco's current production. Water treatment is essential the removal of arsenic and for the neutralization of the effluent to be used again in the mine. This reduces water consumption in the concentrator.MMH project overview:• Concentrator plant consisting of mills, flotation cells,
thickeners and filters• Due to high arsenic content in concentrate
=> partial roasting for arsenic removalnecessaryProcess units
• Fluidized bed roaster, gas cleaning,sulfuric acid plant and a watertreatment plant
Start-up 2013
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Layout of the water treatment plant
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How Outotec’s roasting technology benefits Codelco
Offer to design and build the world’s largest arsenic-removing roasting furnace;Produce clean copper concentrate for a better grade with improved value since approximately 90% of arsenic removal rate will be achieved;Concentrate can be sold to copper smelters at a higher market value compared to concentrates with arsenic;Arsenic content > 0.1 wt.-% in upperconcentrate results in fine and> 0.5 wt.-% is not accepted
Plant solution for Codelco:• Partial roaster and gas cleaning and
sulfuric acid Annual production levels• 550,000 mtpy concentrate• 250,000 mtpy sulfuric acid
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How Outotec’s acid technology benefits Codelco
Seamless technology chain with downstream process gas treatment and acid plant integrated into overall roasting concept
Integrated process gas line with state-of-the-art sulfuric acid plant design guarantees our customers full process control and thus best emission control and lowest energy consumptionAcid plant process design allows transfer of excess heat to roasting process and thus allows highest operation flexibility by minimization ofenergy consumption of fuel oil and cooling waterGas cleaning plant designed for removal ofhighest arsenic contents (As: 77g/Nm³) in reliableway ensuring highest availability of plant complexPlant designed to comply with more stringent future environmental permitting(SO2 < 400 ppm (Vol); SO3 < 35 mg/Nm³)
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How Outotec’s IWT solutions benefit CodelcoEntire effluent concept can be set up and testedin Outotec’s R&D center in Pori, Finland
Only Outotec is in the unique position to analyze the overallprocess and design a customized solution for the effluent plantThe customized OKTOP® reactors for precipitation ofarsenics compounds – designed with CFD modelingUse of HDS - high-density sludge - process to avoidscaling• Sludge recycling improves nucleation and settling and also
avoids scalingSophisticated process control to stabilize arsenic with accurate predictive pH control• Exact pH and process control is key to achieving the desired stable arsenic waste
productUse of our special automatic pressure filter with air drying to come down with the residual water content to less than 25%• The low humidity in the final waste product is vital for transporting and storage
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Current Outotec contracts with Codelco
Roasting plantRoaster, gas cleaning & sulfuricacid plant (lump sum turnkey)
Water treatment plant (lump sum turnkey)
Concentrator plantFiltration (lump sum turnkey)
Several on-going negotiations
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Copper roasting and sulfuric acid plant for Codelco, Chile
€ 116 million
Design and delivery of an effluent treatment plant, Codelco, Chile
€ 18 million
Concentrator technology for Codelco, Chile approx. € 24 million (half in Q2 and the rest in Q3)
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Sustainable use of Earth’s natural resources
•Thank you for your time! Any questions?
THANK YOU!
Our mission:
Sustainable use of Earth's natural resources.
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