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INSIGHT LIMENEWSLETTER OF MAERZ OFENBAU AG April 2016

Genuine Swissness.

As most Swiss, we don’t like to push ourselves into the limelight. We are content knowing that we are well-known and our kilns are in demand throughout the world. To date we have built more than 600 plants for custom-ers in over 60 countries. To make our customers happy we gladly go the extra mile.That’s genuine Swissness. www.maerz.com

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C H A L L E N G I N G P R O J E C T S

Mastering challenging projects is one of the key issues for success in our business.

In this edition of “Insight Lime” we introduce you to a variety of challenging projects we have either already successfully completed or which are under execution right now.

Let’s take the Sibelco project as an example: It is really not our daily business retrofitting an existing lime kiln by preserving its outside steel structure and inserting an entire new kiln into the kiln shafts. This challenge not only kept our engineering department busy, but also required a reliable partner for erection of the kiln. We did it!

Equally challenging was our turnkey project for Schaefer Kalk in Germany: a new Maerz PFR kiln replaced two old mixed fired single shaft kilns. Here, the challenge was not only to keep the existing foundation as well as the charging system, but also the extremely re-stricted space for erection in this brownfield job. Another project we completed on sched-ule and within budget.

Time is the main challenge we face for the erection of the 2 kilns for Chememan in Thai-land. Erection progress is extremely fast and we look forward to commissioning these kilns very soon.

Mastering challenging projects requires pre-cise and efficient work. Genuine Swissness.

Stephan Lechner

S I B E L C O A U S T R A L I A L I M I T E D , A S U C C E S S S TO R Y

Sibelco Australia Limited entrusted Maerz with the conversion of the existing Cimprogetti Twin-D 85 Lime Kiln in Galong (New South Wales, Australia) into a Maerz PFR Double Shaft Lime Kiln Type E4. Maerz was chosen by Sibelco Australia Limited as the key contractor for the supply of engineering, material, technical assistance and commissioning to revamp the existing vertical kiln.

The Maerz E4 PFR Kiln has a capacity of 275 tons per day. The lime kiln is equipped with a brand new coal firing system and a new control system de-signed by Maerz. The coal dust is delivered from Sibelco’s own local grinding plant, the limestone at a grain size of 40 to 80 mm is supplied from Sibel-co’s own quarry.

Every project is unique. In the case of this pro-ject one of the challenges was to ensure the adher-ence to Australian standards in all fields. The task was to reuse the existing steel structure, shafts, skip and blower house with existing blowers and baghouse. Maerz integrated a brand new coal firing system, kiln inlet and discharge table, refractory lining and a Simatic PCS 7 control system according to the Australian safety requirements.

Sibelco and Maerz started the project with a kick-off meeting in April 2014 in the facility in Galong. The first job was to take measurements of all the physical structures of the existing Cimprogetti kiln, always taking into consideration which parts could be reused and which ones needed to be replaced. Wherever possible, Maerz attempted to apply its proven standard solutions of system and equipment design to the new kiln. Wherever necessary howev-er, tailor-made solutions were developed to suit the requirements of the particular situation.

In April 2015 the installation on site started - only 12 months after the kick-off meeting. Sibelco’s con-tractor team revamped and installed the equipment in the previously prepared kiln structure and kiln shafts step by step.

After both engineering and equipment had been delivered on time (the challenging time schedule

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S I B E L C O A U S T R A L I A L I M I T E D , A S U C C E S S S TO R Y

was met at all times), the new E4 type rectangular shaft kiln was successfully commissioned and put into commercial operation recently. It performs and produces quality as shown in the following table:

Kiln capacity (tons/day) > 275

Limestone size (mm) 40 - 80

Heat consumption (kJ/kg) <3’680

Residual CO2-content (%) <2.5

Reactivity of lime (t60 value in sec.) <180

The converted new Maerz Lime Kiln started to pro-duce at a consistent quantity and quality after a project phase of only 18 months. The unwaivering cooperation between the project teams was the key factor for the success of this project

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Mexicana de Cobre S.A. de C.V. placed an order for a second kiln for their existing lime plant in 2012. We reported about this order in our Maerz News of December 2012. In order to increase the plant production capacity, another F2S type fine lime kiln, producing up to 400 tons of quicklime per day with a limestone grain size between 15 and 80 mm, was installed and commissioned successfully by the end of 2014. The kiln currently performs according to the table below.

The EPC contract for the installation of the kiln had been assigned to thyssenkrupp Industrial Solutions Mexico, formerly Polysius Mexico. Within this scope Maerz was entrusted with the supply of engineer-ing services, license, know how and key equipment to the kiln, such as refractory material, process air blowers, the electrical hard- and software, suspend-ed cylinder and more. Furthermore, Maerz provided its expertise services in erection supervision and commissioning.

Limestone size (mm) 15-40 40-80

Kiln capacity (tons/day) 305 405

Heat consumption (kJ/kg) 3329 3558

Residual CO2-content (%) 1.88 <2

Reactivity of lime (t60 value in sec.) 29 30

I M P L E M E N T E D P R O J E C T I N M E X I C O M E X I C A N A D E C O B R E S . A . D E C . V.

Since the beginning of commercial operation right after commissioning the kiln has been producing lime continuously and at very high capacity in order to live up to the demand of the product. The kiln has operated reliably throughout the entire warran-ty period and is still doing so to everyone’s satis-faction

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I M P L E M E N T E D P R O J E C T I N G E R M A N Y S C H A E F E R K A L K G M B H & C O . K G

As we reported earlier in our 2013 edition of “Maerz News”, Schaefer Kalk GmbH & Co. KG of Germa-ny entrusted Maerz with the supply of a new 500 ton per day PFR kiln in their Steeden lime plant. Maerz was chosen by Schaefer Kalk as the turn key contractor for the engineering, supply, erection and commissioning of the new plant.

Together with its suppliers and sub-contractors, Maerz successfully overcame the challenges of im-plementing a new kiln and its auxiliary systems into an existing plant, respecting the latest and most stringent protection and safety requirements for kiln control.

The new R3S type circular shaft kiln, featuring both a gas and a solid fuel firing system, was successful-ly commissioned and put into commercial operation recently. It is performing and producing lime quality as shown in the following table:

Kiln capacity (tons/day) > 500

Limestone size (mm) 60 - 150

Heat consumption (kJ/kg) <3’900

Residual CO2-content (%) <2.0

Reactivity of lime (t60 value in sec.) <120

Due to the very limited space on site, erection was really challenging as you can see in the photos on this page

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O N G O I N G P R O J E C T I N T H A I L A N D C H E M E M A N C O . , LT D .

As we reported earlier in our October 2015 edition of “Insight Lime”, Chememan Co., Ltd. of Thailand entrusted MAERZ with the supply of two additional kilns for their lime production facility in Saraburi, approx. 120 km north-east of Bangkok.

Kiln no 1 refers to a Maerz E5 type PFR lime kiln with a capacity of up to 300 tons of lime per day. Kiln no 2 refers to a Maerz H4 type HPS kiln with a capacity of 200 tons of hard burnt lime per day. The HPS kiln will be the first hard burning lime kiln of its kind in Thailand.

Both kilns can be operated with coal dust or lig-nite dust as fuels. The coal will be ground by Che-meman’s own and recently installed coal mill, as short supply distances are very important for Che-meman. The arrangement of the limestone quarry, the coal grinding, lime burning as well as the lime conditioning plant on the Chememan facilities have been optimised in this regard.

Chememan stands for progress, quality and devel-opment with excellent services in all these areas. These claims are reflected in the way the current project is being run by Chememan. The project management is led by its own project team and managed by its own steering team.

The kick-off meeting for this project took place at the end of May 2015. The engineering of the plant was pushed forward to completion in tight collabo-ration between Chememan’s engineering office in Asia and Maerz in Switzerland.

Soil excavation started after a short period of site preparation, followed by the piling work. The chal-lenging time schedule for the purchasing of long lead equipment and material was successfully man-aged by both of the project teams.

Before the end of the year 2015 the kiln foundation and several silo battery foundations were ready to take loads. Truck by truck the material and equip-ment arrived on site.

Several individual elements of the kiln steel parts could be pre-assembled close to the kiln founda-tions and lifted into place. The assembly of the kiln had progressed so far, that it was ready for the re-fractory lining work to begin. The refractory lining inside the 300 tpd PFR kiln started right on time at the beginning of February 2016. The work is being carried out by a local supplier.

The 300 tpd PFR kiln is planned to be commissioned by the middle of 2016. Installation of the 200 tpd HPS single shaft kiln will start in April and is planned to be ready for commissioning during the second half of 2016

PFR HPS

Kiln capacity (tons/day) > 300 > 200

Limestone size (mm) 35 – 90 20 - 40

Heat consumption (kJ/kg) <8900 <1’150

Residual CO2-content (%) <2.5 <2.0

Reactivity of lime (t60 value in sec.) <120 >360

The site in November 2015 ...

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... and in March 2016

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S E L E C T I O N O F R E C E N T O R D E R S

SHANGHAI CALCIUM

CARBONATE FACTORY CO.,LTD, CHINA

Shanghai Calcium Carbonate factory Co., Ltd signed a contract with thyssenkrupp Industrial Solutions China, formerly Polysius Shanghai, a joint subsid-iary with Maerz Ofenbau AG in Switzerland, for the supply of design, engineering and key equipment of a Maerz H2 type HPS lime kiln for soft burnt lime. The plant is located in the Shanghai area. According to the joint agreement between thyssenkrupp and Maerz, thyssenkrupp will supply part of the equip-ment, while Maerz will be responsible for the major supply of equipment as well as the entire design and engineering.

The kiln will be fired with natural gas, producing 75 tons of lime per day with a limestone grading of 40 to 80 mm. The product emerging from this single shaft kiln ist targeted for the food and pharmaceu-tical industries

TOSYALI IRON & STEEL INDUSTRY

ALGERIE SPA, ALGERIA

Sinosteel Equipment and Engineering Co., Ltd, China, as the general contractor for Tosyali Iron & Steel Company, signed a contract with Maerz for the supply of design, engineering, key equipment and technical assistance during erection and com-missioning of 2 Maerz Parallel Flow Regenerative lime kilns. The 2 kilns, one R1P and one R4P kiln, will form an integrated part of the new extension to Tosyali steel production plant currently under con-struction in Oran, Algeria.

Both kilns will be operated using natural gas. The R1P kiln, fed with dolomite stone of a grading of 40 to 90 mm, will produce 300 tons of dolomite per day, while the R4P kiln’s daily capacity, at a lime-stone feed of a grading of 40 to 90 mm, will be 600 tons of lime. Kiln operation is planned to start dur-ing the first half of 2017

BCB BASLIMANE CHAUX BERRIANE,

GHARDAIA, ALGERIA

Baslimane Chaux Berriane recently signed a con-tract for a natural gas fired 300 tpd Maerz PFR lime kiln of type E5 to calcine its high quality dolomite stone from its quarry close to the city of Ghardaia in central Algeria. Maerz is supplying engineering as well as the major part of the equipment and Mae-rz will also provide technical assistance during the erection and commissioning of the kiln. In a sec-ond step, BCB awarded Maerz with the contract for the handling system upstream and downstream the kiln. The new dolomite plant is a brown field instal-lation replacing a small rotary kiln.

The kiln is currently under construction and is planned for commissioning during the second half of 2016

The International Lime Association holds its next General Assembly and Information Exchange Fo-rum in October this year in Washington D.C., USA.

Maerz will be present with an exhibition booth and a presentation on our latest technology.

Hope to see you there!