a new integrated solution for industrial minerals in Egypt

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1 Giovanni Biffi Conferences on technological innovation NEW FRONTIERS AND RECENT INNOVATIONS IN THE MANIFACTURE OF BUILDING CERAMICS: TILES, BRICK, SANITARY AND TABLEWARE a new integrated solution for industrial minerals in Egypt Vittorio Costa, Kirollos Soliman, Fabio Granitzio Cairo, 4 TH May 2010

2 Suez Minerals Project: Facts 1. Suez Company for Minerals (S.C.M. S.C.M.) is an italian egyptian JV company formed by Gruppo Minerali Maffei S.p.A. (G.M.M.( G.M.M.,, Italy), and AL SALOMI (Egypt( Egypt); 2. S.C.M. was inspired by a key concept: producers and consumers of raw materials have to closely cooperate, each one with his own experience and know-how to promptly react to market demands; 3. S.C.M. will run the Suez processing plant: : production will start in september 2010; 4. The plant deals with the production of ventilated materials als like feldspars, silica sand, quartz and pitcher, for the production of ceramic bodies and glaze.. The plant will produce also granulated minerals for tile and glass markets; 5. Among the advantages given by the proprietary technology there s s the capacity to produce specifically ly defined ventilated blends of the various materials (for istance Hard Material Component or HMC ).

3 Group Subsidiaries in Europe, Latin America, Africa Mines Facilities

4 Suez Mineral Project: Location The Location Suez Minerals is strategically located in the indutrial district of Ataqua,, Suez. Suez Minerals Plant Cairo EGYPT S.C.M. will be the first company to develope in Egypt the outsourcing concept to satisfy the requirements of the big sanitaryware, glass and tile producers.

5 Suez Minerals Project: Markets End markets for our minerals are: Sanitaryware Tiles Glass Frits& Glazes Paints Sanitaryware and Tableware: feldspar, quartz, pitcher and chamottes for body and glaze; Tiles: clays, feldspar and quartz for gres & monocottura ; Glass: silica and feldspar for both float glass and container; Frits and glazes: feldspar and quartz; Paints: ventilated silica and feldspar;

6 Suez Minerals Project: Products MINERALS Quartz: high purity egyptian quartz from the Marsa Alam and Safaga districts; Silica Sand: low iron silica sand from our EIIMTM Sinai mines K-Feldspar: egyptian potassium feldspar from the Marsa Alam and Safaga districts; Na/K Feldspar: egyptian feldspars from the Marsa Alam and Safaga districts; Na-Feldspar Feldspar: high quality imported feldspar Pitcher: fire clay (BFC) and vetro china (BVC) scraps, from local sanitaryware producers; Chamottes: imported chamottes. Clays: imported Kaolin-based clays

7 Suez Minerals: Product Range PRODUCT RANGE Quartz: high purity ventilated quartz (from 75 µm m up to 45 µm); Silica Sand: low iron silica sand (Fe 2 O 3 up to 100 ppm); K-Feldspar: from 75 µm m up to 45 µm ventilated low iron K- feldspar (K 2 O>10.0%, Fe 2 O 3 <0.30%), available also in granules; Na/K Feldspar: from 75 µm m up to 45 µm ventilated low iron Na/Kfeldspar (Na 2 O>4.5%, K 2 O>5.0%, Fe 2 O 3 <0.30%), available also in granules; Na-Feldspar Feldspar: from 75 µm m up to 45 µm ventilated low iron Na- feldspar (Na 2 O>10.0%, Fe 2 O 3 <0.10%), available also in granules; Pitcher: fire clay (BFC) and/or vetro china (BVC), milled up to 250 µm m or 75 µm m ; Chamottes: milled up to 250 µm. Clays: Kaolin-based clays

8 Suez Minerals Project: Raw Minerals Egypt is endowed with large reserves of ceramic and glass raw materials. However, these minerals are often of low grade so that they need beneficiation before their application in the domestic market. Sabbie Calcari We choose to develope large deposits, with medium to low raw quality, instead of using highly selective mining methods on small and complex deposits. A Cave di calcare Cave di sabbia Campioni Traccia di sezione We choose to process raw minerals with the ultimate technology. Processing methods are developed to give the possibility to push the dressing processes to minimize costs and consequently the price for our customers, having back the proper quality for different products.

9 Suez Minerals Project: Raw Minerals A team of mining experts, geologists and mining engineers, it s full-time involved in deposit exploration and prospect evaluation in Egypt to ensure mineral reserves Exploration activities are regularly carried out at different stages, from grass roots level to mining testworks Our mining department in Italy support the development of our mining projects in all stages, from faseability study to reserve evaluation to pit design 0 m 100 m 200 m 300 m 400 m

10 Suez Minerals Project: The Suez Plant Covered area Total covered volume Production capacity (granulated) Production capacity (ventilated) Storage Silo Capacity Electric power installed Heat power installed Volume of air treated by filtration Some Numbers m 2 m 3 t/h t/h m 3 kw kcal/h m 3 /h , Product Storage Silos Processing Plant Power station Raw Minerals Storage Area Plant Layout

11 Suez Minerals Plant: Equipment Production Scheme Layout: R1 Raw Material Storage (boxes) R2 Drying facility R3 Storage of different material types R4 Fine grinding (roll mills) and ventilation R5 Storage finished product

12 Suez Minerals Plant: Equipment The S.M. plant was designed to implement the latest G.M.M. proprietary technology On site plant management can be assisted also on remote thanks to hardware and software systems managing automatically all the plant sectors Technology of roll mills for fine milling brings several important advantages compared with traditional roll mills, like: -Energy savings and lower maintanance costs; -Low vibration and noise levels; -Fast production turnover according to the requirements of the customer.

13 Suez Minerals: Quality Control In S.M. plant will be set up a fully equipped laboratory to perform the following quality controls: XRF chemical analyses (on pellets and/or beads); Grainsize classification (vibrosieve and alpine air-jet); Moisture determination; Soluble salts (sulphates and chlorates); Melting tests; Metallic iron; To guarantee the chemical stability of products a strict quality control will be implemented: like in other G.M.M. plants worldwide, quality control and lab equipment maintenance procedures are set according to UN-ISO 9001; XRF analyzer

14 SUEZ Co. FOR MINERALS Ready To Change?

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