Ste. Genevieve Plant Tour

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Ste. Genevieve Plant Tour
Ste. Genevieve Plant Tour
World’s largest single kiln line cement plant
Jeff Ouhl – Vice President / Plant Manager
September 14, 2010
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Agenda
1
Site specific safety training – 10 minutes
2
Quick summary “the making of cement” – 5 minutes
3
Ste. Genevieve plant preview – 40 minutes
4
Plant tour – approximately 60 minutes
5
Questions & answers
6
Depart for hotel at 17:15
2
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Summary – site specific safety training
Safety first
• Holcim believes that the safety and health of all
personnel working at our plant is our number one
priority
• We also believe that zero accidents is achievable and
the only acceptable goal
• You are responsible for staying with your escort and
following the directions of your escort at all times
• If you are unsure about a situation, please stop and get
clarification. 90% of all workplace accidents are the
result of a poor or uninformed decision
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© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Agenda
1
Site specific safety training – 10 minutes
2
Quick summary “the making of cement” – 5 minutes
3
Ste. Genevieve plant preview – 40 minutes
4
Plant tour – approximately 60 minutes
5
Questions & answers
6
Depart for hotel at 17:15
4
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Quick summary – cement and concrete
85%
Limestone
CEMENT
10%
Clay / Sand / Flyash
+
sand
5%
Iron
+
gravel
Add
HEAT
+
water
= Clinker
----------------------------
Clinker
+
5% Gypsum
= CONCRETE
= CEMENT
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Investor / Analyst Capital Markets Event 2010
Cement plant Process Flow
Quarry
Raw Mills
Kiln System
“Burning”
Cement
Grinding
Distribution
ACE
ACE
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© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Agenda
1
Site specific safety training – 10 minutes
2
Quick summary “the making of cement” – 5 minutes
3
Ste. Genevieve plant preview – 40 minutes
4
Plant tour – approximately 60 minutes
5
Questions & answers
6
Depart for hotel at 17:15
7
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Ste. Genevieve plant project goals – simple and clear
• Safety
No fatalities; no serious accidents
No tolerance for unsafe conditions, behaviors, design
• Meet our environmental commitments
• Execute the project: Maximizing Creation of Value – ROI
Meet scheduled start-up dates
Meet capital investment commitment
Meet operational commitments = volume & costs
MAJOR FOCUS = QUALITY Design, Equipment, & Installation
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Zero accidents is achievable!
• Qualified contractors – must meet minimum requirements to bid
work
• ALL construction workers must have
10/30 hours safety training
4 hours site specific training
• 100% pre-employment drug screen / Random testing
• Zero tolerance for certain unsafe acts/conditions
• Financial penalties and rewards to contractors
• Tight access control
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Investor / Analyst Capital Markets Event 2010
2001 – 2004 environmental permitting summary
• > 40 Environmental studies completed
• 8 state and federal regulatory agencies with jurisdiction
• Final permits received – June 2004
• Administrative and legal appeals to issued permits
Defended 3 appeals cases up to September, 2004
Settlement of permit appeals – October 2004
• Main permits:
Appealed
Cleared
USACE §404 Permit
MDNR §401 Water Quality Certificate
MDNR Land Reclamation Permit
MDNR PSD Air permit
• Secondary permits:
MDNR Stormwater Permit
MDNR Dam Safety Permit
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3,900 acre site, 2,200 acre conservation easement area, 61 acres of
new wetlands created
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Investor / Analyst Capital Markets Event 2010
Environmental control – best available control technology (BACT) used
• NOx reduction – multi stage combustion & SNCR
• SO2 reduction – lime injection system when raw mills down
• PM10 reduction
Latest technology fabric filters
Covered storage for material storage areas
Covered belts for material transport
Road paving throughout plant
Haul road watering, paved road washing, truck washing
• Opacity monitors on stacks
• Continuous emission monitoring of combustion exhaust points
• One of the most energy efficient cement plants in the US
• Selective quarrying in combination with mining plan
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Investor / Analyst Capital Markets Event 2010
Cement manufacturing process
The key operational areas of a cement plant are:
• Raw material extraction
• Kiln feed preparation
• Kiln operations – “burning” clinker
• Cement grinding
• Cement shipping
• Quality control
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Investor / Analyst Capital Markets Event 2010
Limestone is the main component
• Main component of cement
plant raw mix is limestone
• Limestone consists mainly of
calcium, a lesser percentage
of silica, and possibly small
amounts of alumina and iron
• Typically 80% - 90% of the
mix
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Investor / Analyst Capital Markets Event 2010
Typical quarry operation
waste
limestone
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Investor / Analyst Capital Markets Event 2010
Raw mills (2) for kiln feed preparation
• 23 m height
• 515 t/h (each)
• Main drive 3,900 kW
• Raw mill fan 3,900 kW
• Table diameter: 5 m
• Roller diameter: 3 m
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Dry process preheater/precalciner
•
•
•
•
•
Drying
Preheating
Calcining
Sintering
Cooling
60%
Fuel Split
40%
Preheater Precalciner Kiln
© Holcim Ltd 2010
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Investor / Analyst Capital Markets Event 2010
Ste. Genevieve preheat tower
• 2 String “hybrid” tower
• Single 10 m ø calciner
• 5 stage quad cyclones
except bottom stage is
dual 8.5 meter ø
• ~ 7 second calciner
retention time
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Investor / Analyst Capital Markets Event 2010
Ste. Genevieve three support kiln system
6.6 Meter Dia. X 93 Meter L
3.6 RPM Nominal, 5.0 RPM Max
Semi-rigid
supports
Tangential
suspension
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Investor / Analyst Capital Markets Event 2010
Kiln station, refractory installation and kiln firing, July 2009
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Investor / Analyst Capital Markets Event 2010
New generation MMC 23x123 clinker cooler
• Cools the clinker from the kiln for transport & storage
• Recovers heat from clinker for firing in kiln and
improves thermal efficiency
• 80 deg + ambient clinker
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Investor / Analyst Capital Markets Event 2010
Coal/petcoke grinding (2) ATOX 27.5 mills
• 37 t/h petcoke or,
• 70 t/h coal
• 740 kW each
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Investor / Analyst Capital Markets Event 2010
Cement grinding – (4 mills)
•
13 m height
•
165 t/h (each)
•
Main drive 3,900 kW
•
Mill fan 2,200 kW
•
Table diameter: 4 m
•
Roller diameter: 2.1 m
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Investor / Analyst Capital Markets Event 2010
Huge investment in quality control – consistent supply automated lab
is key to meeting our goal
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Investor / Analyst Capital Markets Event 2010
Product quality assurance and control – highly automated for quick
response
• Fully automated lab system (Robolab – FLS)
Sampling, transport to lab, preparation of pressed tablets,
analysis, mix control
• 2 PGNAA Cross Belt Analyzers
• New Omni Generation by Thermo Fisher
Remote displays in Quarry Mobile Equipment
• XRF and backup XRF (main oxide analysis) (Panalytical)
• XRD with Rietveld capability (fast free-lime; phase analysis)
(Panalytical) • Particle Size Analyzer (Sympatec)
• Cross-belt moisture analyzer for incoming raw materials and coal
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Investor / Analyst Capital Markets Event 2010
Ste. Genevieve plant story
• A great safety record for the plant continues with more than
480 days without a LTA (Holcim and Contractors)
• We continue to be extremely pleased with our plant
employees – validated by performance!
• Excellent start up continues
Plant staff working extremely diligently to solve startup issues and
optimize the plant
High degree of ownership and therefore performance
• Great production results continue
Achieved goal of high availability first (mills and kiln)
Mill rates running above design, kiln rate now increased
• Excellent quality results continue, preferred product in many
markets
• Excellent emission, operating cost results continue
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© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Our strength is our people – recruiting process was a resounding
success!
• Robust recruitment process yielded a dedicated, talented
team
Hired all employees First for “Attitude and Aptitude”
Multi-skilled organizational design
Mechanical / electrical skills important
• Brought employees on early to provide training in
Soft skills, leadership skills, and team-building skills
Basic technical skills – welding, hydraulics, pneumatics, etc
Specific technical skills – electrical switchgear, FLS equipment
• Result was a highly motivated, trained, and capable team who
commissioned and started-up with:
No major injuries or equipment damage
Excellent OEE on start up
High degree of ownership
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Investor / Analyst Capital Markets Event 2010
Net OEE is excellent compared to Holcim startups worldwide
Startup First Clinker (assumes July 4th startup)
Net OEE
100%
75%
50%
25%
0%
1
2
3
4
5
6
7
8
9
10
11
12
Ste. Geneviève
Months of operation
Startup after Kiln Bearing Issues
Average 13 Kilns
(assumes August 13th Startup)
Net OEE
100%
75%
50%
25%
0%
1
© Holcim Ltd 2010
2
3
4
5
6
7
8
9
Months of operation
10
11
12
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Investor / Analyst Capital Markets Event 2010
GV product is approved for use by DOT’s in the entire river market
GV primary shipping destinations
GV secondary shipping destinations
NDDOT
Approved Jul 24
(no approval applied for yet)
MnDOT
Approved
Trident
SDDOT
WIDOT
Jul 24
Approved Nov 5
IADOT
NBDOT
MIDOT
NYDOT
Jul 7
Approved
Tentative Approval
Skyway Oct 12
Approved
Approved Nov 19
Devil's Slide
Approved
Jul 24
MoDOT
KSDOT
IDOT
Approved Oct 14
Jul 10
St.
Genevieve
Oct 12
Catskill
OHDOT
Approved Approved Approved
Approved Jul 7
Portland
INDOT
Hagerstown Camden
Aug 31
KYDOT Approved Oct 12
OKDOT
ARDOT
TDOT Approved Sept 21
Approved Apr/2010
Approved
Ada
Holly Hill
MSDOT
Aug 27
Approved
Birmingham
Midlothian
LaDOT Oct 5
TxDOT
Approved
Approved Sept 1
Sept 22
ALDOT Applied May ‘10
Theodore
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Investor / Analyst Capital Markets Event 2010
Meeting or exceeding all quality targets
Ste. Geneviève 1- and 28-days Strength
GV Target 6500 psi
7,000
6,521
Strength (psi)
6,000
5,576
5,000
GV Target 2500 psi
4,000
3,000
2,605
2,629
2,000
1,000
0
Concrete 1-Day
Cubes 1-Day
Concrete 28-Days
Cubes 28-Days
STE. GENEVIEVE
Competitor 1
Competitor 2
Competitor 3
Competitor 4
Competitor 5
Competitor 6
Competitor 7
HCA-MISSISSAUGA (Holly Hill)
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Investor / Analyst Capital Markets Event 2010
Although no real maintenance costs realized to date, operating costs
are better than anticipated
Comparison GV actual cost vs. closed/mothballed plants
Clinker Production
[t '000]
Cement Production
[t '000]
Thermal Energy Consumption
[MJ/t clk]
Specific Power Consumption
(excl shipping) [kWh/t cem]
TOTAL Specific Cash Cost
[USD/t]
Fixed Cash Cost
[USD million]
Ste Genevieve
Mothballed/Closed
US Plants
YTD
Full Year
Actual thru August
Actual 2008
1'714
2'628
1'933
2'709
3'122
5'826
94.00
140.00
reduced by
> 50%
reduced by
> 80%
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© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Thermal energy (fuel) efficiency continues to improve – MTBF
improvement is main driver
2,500
1,500
3,177 3,209 3,238 3,255 3,277 3,277 3,289 3,274 3,274 3,323 1,000
K Tons of Ck
2,000
3,310 3,550
3,500
3,450
3,400
3,350
3,300
3,250
3,200
3,150
3,100
3,050
3,000
3,484 MJ/T
Ste. Genevieve Thermal Energy Consumption 12M Roll ending on Jun‐10
500
‐
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Investor / Analyst Capital Markets Event 2010
Environmental – stack tests completed and in compliance with all
requirements
Actual emissions compared to Permit levels and Holcim Emission Reduction Targets (ERT)
Jan 1 2010-July 31 2010
1600.0
1400.0
m g /N m 3
1200.0
1000.0
800.0
600.0
400.0
200.0
0.0
NOx
SO2
CO
THC
309.4
9.31
145.35
20.45
Permit equivalent
667
300
1429
63
Holcim ERT
500
400
Actual
100
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© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Port capabilities & river access
Key element of success for this plant is river access
• Bulk transportation efficiencies (1,500 t barges) for loading
& unloading
• Allows access to low-cost fuels & raw materials
Coal, Petcoke, Gypsum, Fly ash
• Utilizes Holcim’s established network of river terminals and
barge line agreements for transportation
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Investor / Analyst Capital Markets Event 2010
Slack-water harbor on Mississippi River for loading/unloading up to 6M
t/y of materials
Inbound Unloading
North Fleeting Area - 60
barges
South Fleeting Area 23 barges
Cement Loading
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Investor / Analyst Capital Markets Event 2010
Harbor cross section
Loading silos
Barge loading station
16 m
Inbound material
unloading station
Rail
loading
station
Harbor accommodates >16 m
water level fluctuation
36
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Investor / Analyst Capital Markets Event 2010
Harbor water level at normal operating depth with no flooding and all
modes of distribution available
September 2007
37
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Investor / Analyst Capital Markets Event 2010
Harbor depth at above normal level with no affect to any mode of
distribution
April 2008
38
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Investor / Analyst Capital Markets Event 2010
Harbor above flood levels with all rail traffic terminated barge loading
and unloading is not impacted
June 2008
39
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Investor / Analyst Capital Markets Event 2010
© Holcim Ltd 2010
Thank You
40
Investor / Analyst Capital Markets Event 2010
Agenda
1
Site specific safety training – 10 minutes
2
Quick summary “the making of cement” – 5 minutes
3
Ste. Genevieve plant preview – 40 minutes
4
Plant tour – approximately 60 minutes
5
Questions & answers
6
Depart for hotel at 17:15
41
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Agenda
1
Site specific safety training – 10 minutes
2
Quick summary “the making of cement” – 5 minutes
3
Ste. Genevieve plant preview – 40 minutes
4
Plant tour – approximately 60 minutes
5
Questions & answers
6
Depart for hotel at 17:15
42
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Agenda
1
Site specific safety training – 10 minutes
2
Quick summary “the making of cement” – 5 minutes
3
Ste. Genevieve plant preview – 40 minutes
4
Plant tour – approximately 60 minutes
5
Questions & answers
6
Depart for hotel at 17:15
43
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Contact information
Bernhard A. Fuchs
Marco Knuchel
Binit Sanghvi
Investor Relations
Phone +41 58 858 87 87
Fax
+41 58 858 80 09
[email protected]
www.holcim.com/investors
Mailing list:
www.holcim.com/subscribe
44
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Disclaimer
Cautionary statement regarding forward-looking statements
This presentation may contain certain forward-looking statements relating to
the Group’s future business, development and economic performance.
Such statements may be subject to a number of risks, uncertainties and
other important factors, such as but not limited to (1) competitive pressures;
(2) legislative and regulatory developments; (3) global, macroeconomic and
political trends; (4) fluctuations in currency exchange rates and general
financial market conditions; (5) delay or inability in obtaining approvals from
authorities; (6) technical developments; (7) litigation; (8) adverse publicity
and news coverage, which could cause actual development and results to
differ materially from the statements made in this presentation. Holcim
assumes no obligation to update or alter forward-looking statements whether
as a result of new information, future events or otherwise.
As part of Holcim's global commitment to compliance with competition laws,
please note that this presentation has been comprehensively reviewed by
counsel in both the United States and Switzerland.
45
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010
Strength. Performance. Passion.
46
© Holcim Ltd 2010
Investor / Analyst Capital Markets Event 2010