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Samarco 3 Pelletizing Plant Project

Turn-key Project Development and Implementation in Brazil 2005 to 2008


Thomas Schwalm Vice President Ferrous Technologies June 5, 2009 / Outotec CMD 2009 Frankfurt, Germany

Outotec Oyj

CMD 2009

1. Basics 2. Project Overview 3. Project Development 4. Project Execution 5. Services Business

Outotec Oyj

CMD 2009

1. Basics 2. Project Overview 3. Project Development 4. Project Execution 5. Services Business

Outotec Oyj

CMD 2009

Basics: Why Pelletize?


From the Mine (Iron Ores) To Product (Iron Ore Pellets)

Pelletizing is the agglomeration of very fine (<100m), often beneficiated raw materials into spherical products of preferably 9 16mm diameter with defined properties for transportation and further processing in blast furnaces or direct reduction furnaces.

Outotec Oyj

CMD 2009

Basics: Pelletizing Market 2004-2009


Technology/Supplier Installed Annual Capacity
45,0 million t/a 9,5 million t/a 19,5 million t/a
Gol-e-Gohar 5.0 Mill. t/a Caofeidian 4.0 Mill. t/a WISCO 5.0 Mill. t/a JSW 3.5 Mill. t/a BRPL 4.0 Mill. t/a Paradeep 6.0 Mill. t/a Tata Pellet 6.0 Mill. t/a LKAB KK4 5.0 Mill. t/a LKAB MK3 4.0 Mill. t/a

Outotec Traveling Grates Other Traveling Grates Grate Kiln

26% 13% 61%

GIC 5.0 Mill. t/a CVRD Sohar 4.5 Mill. t/a Samarco 3 7.3 Mill. t/a MBR 7.0 Mill. t/a Tubaro VIII 7.5 Mill. t/a

Outotec

Other Traveling Grates

Grate Kiln

Plant size >3,5 mtpy, status 04/2009

Outotec Oyj

CMD 2009

1. Basics 2. Project Overview 3. Project Development 4. Project Execution 5. Services Business

Outotec Oyj

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Project Overview - Client


Owned 50/50 by Vale and BHP Billiton The worlds second largest seaborne exporter of iron ore pellets Integrated mining activities include iron ore mining, beneficiation, transportation, pelletizing and shipment

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Project Overview
Production capacity increase from 14 to 21.6 mtpy Total investment USD 1,183 Million New concentrating plant in Germano (MG) New pipeline approx 400 km long New pelletizing plant in Ponta de Ub (ES).

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Project Overview - Highlights


Outotecs Scope
Design, engineering, delivery and construction of the core plant (induration furnace) on a lump-sum-turnkey basis

Contract value
> EUR 160 million (200 USD)

Project implementation time


30 months

Erection Quantities
5.623 tons of steel structure and 11.265 tons of equipment

Origin of Supplies and Services


Approximately 80% from Brazil Approximately 20% from abroad

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Outotec Oyj

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Project Overview - Geographical Location

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Outotec Oyj

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Samarco 3 Project Key Data


Technical Key Data
Capacity Availability Grate Size Grate Factor [t] [dpy] [m] [t/d m] 7.250.000 335 768 28,2 gradual increase to 7,6 mtpy gradual increase to 352 dpy

Commercial Key Data


Total Samarco Investment OT Contract Execution Time 1,183 Billion USD 200 Million USD 30 months

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Outotec Oyj

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Important Project Milestones


First Inquiry Budgetary Proposal Test Work Samarcos Prefeasibility Engineering Proposal 1st LSTK Proposal Final LSTK Proposal Start of Engineering Contract Signature Start of Civil Works Start of Erection Start of Hot Commissioning Mechanical Completion First Production Plant Take-Over December 2003 May 2004 May June 2004 July 2004 August 2004 November 2004 July 2005 September 2005 September 2005 April 2006 August 2006 February 2008 March 2008 March 2008 April 2008
21 months after first inquiry 8 months after project start 11 months after project start 30 months after project start 31 months after project start 31 months after project start 32 months after project start

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Overall View 15/04/2008

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Roller Samarco 3 - General Plot Plan Product Filtration Presses Screening Substation Substation Thickening Slurry Storage Mixing Process Fans Dust Cleaning Process Gas Ducts Green Pelletizing Coal Grinding Oil Heating

Oil Storage Indurating Machine

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Outotec Oyj

CMD 2009

1. Basics 2. Project Overview 3. Project Development 4. Project Execution 5. Services Business

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Project Development

Definition of Sales Strategy Identification and Promotion of Technological Advantages such as Continuous Technological Updates (Energy Consumption, Environmental Relevance, Easy Maintenance ) Availability of Own Fully-equipped Laboratory Facilities for Ore Testing and Plant Costumization Plant Design Experience as Market Leader

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Project Development

Development of a Project execution Concept to Take care of Clients Limited Resources for Project Implementation (->LSTK-concept) Suit Clients Conditions from Project Financing (->maximize local services and supplies)

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Outotec Oyj

CMD 2009

1. Basics 2. Project Overview 3. Project Development 4. Project Execution 5. Services Business

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Outotec Oyj

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Project Execution Task Force



Project-specific engineering with three local engineering companies Technology-specific engineering by technology owner Integrated and harmonized realization of procurement Project specific execution of all site activities

Samarco 3

Tubaro VIII

MBR

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Outotec Oyj

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Project Execution Task Force


situated in Belo Horizonte, Funcionrios Av. Afonso Pena, 4001, 4th floor up to 250 engineers and specialists 210 Brazilians 40 expatriates multidisciplinary task force process engineering plant engineering mechanical engineering civil and structural engineering electrical and instrumentation engineering procurement and expediting

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Project Execution Site Office


situated in Anchieta, Ponta Ubu, E.S., Rodovia ES 060, km 14,4 at Samarcos pellet plant site approx. 20 engineers and specialists 5 Brazilians 11 expatriates construction company Liderana with approx. 120 people erection company Enesa with up to 2.500 people refractory installation company RIP with up to 200 people

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Manpower - Samarco

Engineering and Expediting in Belo Horizonte Outotec up to 15 CRA/SEI up to 60 Civil Works and Erection in Ponta de Ub Outotec up to 20 Liderana 120 (incl. night shift) Enesa up to 2.500 (incl. night shift) RIP up to 200 Suppliers Supervisors up to 10 Other Activities Home Office Support Germany up to 5 Expediting in Brazil up to 5 Total up to 3.000

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Outotec Oyj

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Organization Chart Overall Project

Outotec GmbH Oberursel Germany

Outotec Tecnologia Brasil Ltda. Belo Horizonte Brazil

Outotec Technology Project Task Force Belo Horizonte Brazil

Engineering Contractors Germany Brazil

Equipment Suppliers Germany Brazil South Korea USA

Steel Structure Suppliers Brazil

Erection Companies Brazil

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Outotec Oyj

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Organization Chart OT
Project Manager QM Manager Scheduling & Reporting 2nd Scheduler

Procurement Manager

Commercial Manager

Engineering Manager

Conctruction Manager

Commisioning Manager

Procurement Local Equipment

Contract Management & Invoicing

Plant Engineering

Process Engineering

Deputy Site Manager

Commissioning Engineer 1

Procurement Import Equipment

Cost Control Germany

Mechanical & Piping

Civil & Structural Steel

HSE Manager

Commissioning Engineer 2

Expediting Coordination

Cost Control Brazil Invoice Control

Indurating Hood & Burner Equipment

Electrical & Automation

Supervisor Civil & Steel

Commissioning Engineer 3

Expeditor Mechanical SP Expeditor Mechanical MG+ES Expeditor Steel 1

Refactory Lining & Insulation

Instrumentation

Supervisor Mechanical & Piping

Commissioning Engineer 4

Indurating Maschine & Support Structure

Erection & Site Planning

Supervisor Proprietary Equipment

Mechanical Engineer

Piping Engineering Expeditor Steel 2

Plant Dedusting

Supervisor E&I

Electrical & Autom. Engineer

Quantity Surveyors

Specialists Subsuppliers

Subsupplier Specialists

Process Fans Burners

Process Fans Burners

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Work Breakdown Structure - Total Project


100.000 Units

Commissioning 2,76% Construction/ Erection 19,77%

Project Management 1,36% Engineering 4,81%

Supplies 71,30%

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Work Breakdown Structure - Supplies


71.300 Units

Structural Steel 11,63% Others 32,70%

ESP's 10,83%

Pallet Cars 10,35% Grate Bars 2,76% Cables 2,86% Indurating Hood 3,10% Process Gas Refractory Ducts 5,73% 5,83% Process Fans 7,96% Motors/ Transformers 6,27%

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Progress Curve - Total Project


early

target

late

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Samarco 3 Start of Civil Works

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Samarco 3 DR-Main Installation

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Samarco 3 Start-up

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Outotec Oyj

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1. Basics 2. Project Overview 3. Project Development 4. Project Execution 5. Services Business

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Services Business

24 months technical assistance after plant start-up Contractually agreed supply of commissioning spares and selected other spares Contractually agreed development project for an alternative operator support system including remote monitoring option

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Synergies, Succession Projects



Technical consultancy on capacity increase and technological update for existing plants in 2006/2007 First choice partner for planned expansion projects 4 and 5 from 2011 onwards with an extended scope Benchmark performance for other projects with annual plant availability 6% higher then industry standard energy consumption 20% lower than similar applications Project implementation with extremely low incident/accident rate (considered lowest world-wide) Production ramp-up within 3 weeks after first production

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Overall View Samarco

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Grinding mill at Kittil gold mine in Finland

Q&A More out of ore!


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