raw mix design and sampling

F.L.Smidth Inc. F.L.Smidth Process Laboratories 2040 Avenue C Bethlehem, PA 18017-2188 USA Tel +1 610 266 5035 Fax +1 610 266 5109 www.flsmidth.com

MEMO Ref 2003-47097-180-00-25 Date 23 January 2004 Page 1

To S. W. Miller From S. S. Schmidt Copies to S.J.Evans P.J.Riley

Filing AMSCO DREW DOWNES, Lehi, UT

Subject CEMENT RAW MATERIALS INVESTIGATION (4 Raw Materials)

Attached is the Process Laboratories report covering the testing of raw materials received from the Amsco - Drew Downes plant in November 2003.

S. S. Schmidt Chemical Laboratory Supervisor SSS/SJE

F.L.SMIDTH INC.

PROCESS LABORATORIES

LABORATORY REPORT

for

AMSCO DREW DOWNES

LEHI, UT

PROJECT NO.: 2003-47097-180-00-25

JANUARY 2004

PREPARED BY:

STEVEN S. SCHMIDT CHEMICAL LABORATORY SUPERVISOR


SCOTT J. EVANS MANAGER


AMSCO DREW DOWNES Lehi, UT

1.0 OBJECTIVE: Suitability of raw materials for use in a coal-fired preheater/precalciner cement kiln. Burnability and alkali/sulfur volatilities of the designed Type I/II raw mix. Heat of reaction of the designed Type I/II raw mix. Roller mill grindability of the designed Type I/II raw mix. Crushing evaluations of the limestone, shale, and silica raw mix components. Note, the iron ore sample was too fine for crusher evaluation testing. 2.0 CONCLUSIONS: The potential cement which can be produced from the designed raw meal, proportioned from the four (4) raw materials tested, would meet the A.S.T.M. specifications for both Type I and Type II cements. Burnability of this designed raw meal was significantly easier than normal or average. No complications with chloride, alkali and/or sulfur are anticipated, and so no kiln exit gas bypass system is deemed necessary based on these specific raw materials tested. The designed Type I/II clinker has an alkali potential of 0.64%. The theoretical heat of reaction of the designed Type I/II raw meal was -407 kcal/kg including the heat of combustion. In addition, a suitable Type V raw mix can be produced based on the four (4) raw materials received and tested. An appropriate Type V raw mix would be a blend of 84.92% Limestone plus 8.21% shale plus 5.70% silica plus 1.17% iron (assuming 100% coal-firing). This designed Type V raw mixture would most likely be harder-burning than the designed Type I/II raw mixture as a result of the higher silica modulus and the presence of more free SiO2 or quartz. Vertical roller mill grindability testing of the Type I/II raw mixture resulted in a grindability of 8.06 kWh/mt @ 15% retained on 90 micron. Abrasion wear of roller mill tires was determined to be 16.3 grams per metric ton per tire (14.8 gms/st/tire), indicating a mild abrasion tendency. Crushing evaluations of the limestone and shale indicated normal crushability, with low abrasion tendency for impact crushing. The silica material; however, indicates a low crushability, with high abrasion wear. Off Gas Emission testing of the lab prepared raw mixture indicates emissions of NO, and CO from this raw mixture. An NO emission of 566.7 mg/kg feed is calculated. A CO emission of 89.57 mg/kg feed is calculated. Emissions of THC, CH4, and SO2 are minimal.


3.0 MATERIALS TESTED (Tables 1 through 3): On November 11, 2003, samples of limestone, shale, silica and iron were received from Amsco - Drew Downes, Lehi, UT. ---------------------------------------------------------------------------------------------------------------------- A summary of pertinent preliminary data is listed below: Sample Assigned Quantity Bulk As Received Decription Lab No. Received Density Moisture

(lbs.) (lbs/ft3) ( % ) Limetone ** 030753 900 83.5 0.09 Shale 030754 120 69.7 3.10 Silica 030755 120 84.1 0.05 Iron 030756 65 140.6 0.19 ** from Topliff Quarry ---------------------------------------------------------------------------------------------------------------------- Chemical analyses of the raw materials of limestone from Topliff Quarry, shale, silica and iron received from the client is shown in the attached Table 1. A coal from a plant from this general area was used for this study because a coal was not received from this client. The analysis of the coal used can be reviewed in Table 2. The ultimate elemental analysis (for carbon, hydrogen, nitrogen, sulfur and oxygen) of this coal can be seen in Tables 3.


4.0 PHYSICAL DESCRIPTIONS OF RAW MATERIALS: Limestone - Topliff Quarry, Lab No. 030753, is a gray stone with a beige-brown dust covering over all the surfaces. Predominately angular and multi-faceted in appearance, descriptive adjectives include dusty, dense and very hard. The top-size pieces are 4 inches (10.2 cm) by 3 inches (7.6 cm) by 2 inches (5.1 cm) and less than 10% of the total sample (by weight) is fines. This can be considered a high grade limestone. Shale, Lab No. 030754, is primarily gray in color with some noticeable yellow-brown areas throughout. This shale was characteristically typical of most shales, i.e. flat, layered and soft, where fragments could be easily broken longitudinally. Dry and dusty, the largest pieces were 2 inches (5.1 cm) by 2 inches (5.1 cm) by 0.25 inches (0.6 cm) with approximately 10% of this silica/alumina source being a fine powder. Silica, Lab No. 030755, is of an off-white coloration with some sections of yellow, orange and brown in the rocks examined. A partial off-white/beige-colored scale was seen on some of the rocks. Some of the rocks had cracks, striations or fissures on some of the surfaces. Dry, dusty, dense and hard, minimal fines were present. Top-size pieces of 4 inches (10.2 cm) by 3 inches (7.6 cm) by 3 inches (7.6 cm) were noted. Iron, Lab No. 030756, was dusty, dense/hard, and colored black with some yellow/rust brown pieces noticeable. Some of the larger-sized pieces looked to be agglomerations, and some of the smaller-sized pieces were flat and shaly in appearance. The largest pieces were only 0.8 inches (2.0 cm) by 0.5 inches (1.3 cm) by 0.4 inches (1.0 cm).


5.0 RAW MIX DESIGN CONSIDERATIONS (Table 6): Type I/II clinker targets used for our raw mix design were based on the Type I/II cement chemistries produced at other Utah cement plants. A heat consumption value of 720 kcal/kg or 3,010 KJ/kg clinker was another basis for our design. A coal from a cement plant close in proximity was used for raw mix design purposes. Specifically, the clinker parameters used as the design basis and those actually achieved in the F.L.Smidth raw mix design are shown in the Table directly below:

Clinker F.L.Smidth Targets Design

C3S = 60.0 % 60.0 % C3A = < 8.0 7.9 Silica Modulus (SM) = 2.6 2.6

The designed raw mix, shown in Table 4 (Mix No. 1) was tested for burnability/volatilities, heat of reaction and roller mill grindability. Clinker parameters achieved from a Type V designed raw mix blend would be the following: C3S = 60.0% C3A = 4.99% (less that 5.0% ASTM Maximum) 2C3A + C4AF = 20.11% (less than 25.00% ASTM Maximum) Silica Modulus (SM) = 3.21 Alumina Modulus (AM) = 1.20 Total Alkalies As Na2O = 0.57%


6.0 BURNABILITY and VOLATILITIES OF RAW MIX of Laboratory-Prepared F.L.Smidth Designed Raw Mix (Figure 1):

The raw mix with added coal ash, shown in Table 4 was tested for burnability and volatilities. Results of our standard burn test, shown in Figure 1, indicate that this raw meal is significantly easier burning than normal or average. Specifically, the free lime concentration extrapolated to 40 minutes burn time in the tube furnace was 0.46% as compared to 1.40% free lime of our internal standard known to have normal burnability characteristics. Potential total alkali in the clinker is 0.64% as Na2O equivalent.

Volatilities of K2O is higher than average; volatility of Na2O and total sulfur as SO3 are average or normal. Ultimately, 86% of the K2O, 40% of the Na2O and 61% of the total sulfur (as SO3) was lost to vapor. No complications with alkali or sulfur cycles in a preheater/precalciner kiln system are anticipated. The chloride content of 0.003% in the raw meal is well below the critical or threshold level for bypass consideration (based solely on the chlorides present in the designed raw meal). 7.0 HEAT OF REACTION of the Laboratory-Prepared F.L.Smidth Designed Raw Mix (Tables 5 & 6): The theoretical heat of reaction necessary to clinker the laboratory-prepared F.L.Smidth designed raw mix was calculated from testing performed and can be referenced in Tables 5 and 6. The basis used for this calculation was a heat consumption of 3,010 kJ per kg or 720 kcal per kg. A normal value of -407 kcal/kg clinker including the heat of combustion and/or -422 kcal per kg clinker excluding the heat of combustion from the exothermic reactions of carbon, was calculated. 8.0 ROLLER MILL GRINDABILITY of the Laboratory-Prepared F.L.Smidth Designed Raw Mix (Table 7 & Figure 2): Raw mix components were crushed through 1/2 inch (12.5 mm) and blended in the appropriate proportions: 84.38% Limestone, 11.63% Shale, 2.98% Silica, and 1.01% Iron Ore. This mixture was then tested for roller mill grindability in our pilot FRM-4 roller mill system, with results as shown in Table 7, and Figure 2.

Capacity and Power - A product capacity of 624.0 lbs./hr. (283.0 kg/hr.), including 4.2% baghouse dust was obtained. Classifier drive power was normal, and cyclone product fineness averaged 12.5% + 170 mesh (90) and 80.2% -200 mesh (75). The overall grindability determined was 8.06 kWh/mt. Abrasion - Potential wear of main grinding parts (tires and table liners) is measured by weight loss of the roller mill tires. An average weight loss of 14.79 grams per short ton/tire (16.30 g/mt/tire) was obtained from the FRM-4 tires made from mild steel at 178 Brinell.

Free Silica Distribution - Analysis of cyclone product, baghouse dust, and material remaining on

AMSCO DREW DOWNES

Lehi, UT the table at the end of testing indicated an accumulation of free silica in the mill load. This augmentation ratio was calculated to be 1.7x (internal load / cyclone).

Cyclone Product - As shown in Figure 2, free silica in the coarser part of the cyclone product is slightly augmented, with the +325 mesh (45) fraction being 1.2 times higher in free silica content than the whole of the cyclone product.

9.0 CRUSHING EVALUATIONS OF LIMESTONE, SHALE, and Silica:

9.1 Limestone (Tables 8 & 9): Results from the Impact Crusher Abrasion Test (PAC Method) can be referenced in Table 8. An abrasion index of 49 (low) was obtained. Results from the Impact Crusher Wear Test (EV Method) can be referenced in Table 9. This test yielded an abrasiveness of 8.22 g/mt, corresponding to 17.96 g/kWh. The specific power consumption was calculated to be 0.46 kWh/mt. The K50 (2.8 mm) and relative gradient (1.02) both indicate normal crushability.

9.2 Shale (Tables 10, & 11) Results from the Impact Crusher Abrasion Test (PAC Method) can be referenced in Table 10. An abrasion index of 23 (low) was obtained. Results from the Impact Crusher Wear Test (EV Method) can be referenced in Table 11. This test yielded an abrasiveness of 0.51 g/mt, corresponding to 0.94 g/kWh. The specific power consumption was calculated to be 0.54 kWh/mt. The K50 (3.3 mm) and relative gradient (1.04) both indicate normal crushability.

9.3 Silica(Tables 12 & 13): Results from the Impact Crusher Abrasion Test (PAC Method) can be referenced in Table 12. An abrasion index of 9753 (severe) was obtained.

Results from the Impact Crusher Wear Test (EV Method) can be referenced in Table 13. This test yielded an abrasiveness of 443.70 g/mt, corresponding to 665.52g/kWh. The specific power consumption was calculated to be 0.67 kWh/mt. The K50 (1.3 mm) and relative gradient (1.18) both indicate normal crushability. 10.0 OFF GAS EMISSION TESING of Lab Prepared Raw Mix: (Figure 3, and Table 14) Results from out laboratory Off Gas Emission testing conducted on the lab prepared raw mixture can be referenced in Figure 3, and Table 14. Results indicate emissions of NO, and CO from this raw mixture. An NO emission of 566.7 mg/kg feed is calculated. A CO emission of 89.57 mg/kg feed is calculated. Emissions of THC, CH4, and SO2 are minimal.

AMSCO DREW DOWNES

Lehi, UT 9.0 SUMMARY and CONCLUSIONS: The raw materials received and a coal from a cement plant in the general area were tested for suitability to preheater/precalciner clinker production. A satisfactory A.S.T.M. Type I/II raw meal was designed and tested incorporating all four (4) raw materials received. Burnability of the designed raw meal is significantly easier-than-normal-average. A kiln exit gas bypass system is not required at this plant because no complications with chlorides, alkalies or sulfur are anticipated. The theoretical heat of reaction of the designed raw meal was -407 kcal/kg including the heat of combustion from the exothermic reactions of the carbon and pyritic sulfur present in the raw mixture. Vertical roller mill grindability testing of the Type I/II raw mixture resulted in a grindability of 8.06 kWh/mt @ 15% retained on 90 micron. Abrasion wear of roller mill tires was determined to be 16.3 grams per metric ton per tire (14.8 gms/st/tire), indicating a mild abrasion tendency. Crushing evaluations of the limestone and shale indicated normal crushability, with low abrasion tendency for impact crushing. The silica material; however, indicates a low crushability, with high abrasion wear. Off Gas Emission testing of the lab prepared raw mixture indicates emissions of NO, and CO from this raw mixture. An NO emission of 566.7 mg/kg feed is calculated. A CO emission of 89.57 mg/kg feed is calculated. Emissions of THC, CH4, and SO2 are minimal.

Table 1

Chemical Analysis (Wt.%, Dry Basis) Customer: AMSCO - Drew Downs Location: Lehi, UT Project No.: 3-47097-180-00-25 Sample: Limestone Shale Silica Iron (Includes 12.78% Magnetics)

Lab 030753 030754 030755 030756 Analytical No: C030528 C030529 C030530 C030531

Loss @ 105 C: 0.09 3.12 0.05 0.19

SiO2: 5.69 54.56 97.01 1.40 Al2O3 0.76 22.70 0.54 0.71 Fe2O3: 0.30 7.47 1.17 104.18 CaO: 50.76 1.50 0.37 1.07 MgO: 0.83 1.75 0.00 0.26 K2O: 0.22 1.41 0.14 0.03 Na2O: 0.11 0.63 0.06 0.36 SO3(Total): 0.08 0.03 0.02 0.04 P2O5: 0.01 0.23 0.01 0.01 TiO2: 0.05 1.00 0.08 0.00 Mn2O3 0.01 0.13 0.04 1.18 Loss @ 950 C: 40.96 7.98 0.20 -5.17 Total: 99.78 99.39 99.64 104.07 Cl: 0.003 0.004 0.004 0.003 C: 0.06 0.41 0.08 0.50 CO2: Tot.Carbonate as CaCO3: MgCO3: CaCO3: Free SiO2: Loss @ 500 C: Sulfide S: 0.02 0.01 0.01 0.01

Free CaO:

Table 2 Fuel Analysis 14-Jan-04

Customer Name: Customer Location: Lab No.: 980322 Sample: Cyclone Coal Analytical No.: 980320

Bulk Density as Received:

Moisture as Received: 0.19

Proximate Analysis (Dry Ultimate Analysis (Dry Basis) Vol: 42.06 Ult. C: 69.46 Ash: 13.89 Ult. H: 5.01 FC: 44.05 Ult. N: 1.24 Sulfur 0.43 Ult. S: BTU/Lb 12,371 Ult. O: 9.97 Cl: Hardgrove Index:

Chemistry of Ash SiO2: 56.00 Al2O3 7.86 Fe2O3: 2.31 CaO: 23.70 MgO: 1.86 K2O: 0.66 Na2O: 0.88 SO3: 5.41 P2O5: 0.24 TiO2: 0.50 Mn2O3 0.06 Total: 99.48

Date: 01/14/04

Table 3

F.L.SMIDTH INC. FUEL ANALYSIS==================

Client: AMSCO - DREW DOWNESLocation: Lehi, UT

Fuel Type: Cyclone Coal

Project No.: 3-47097-180-00-25

Lab No.: 980322Anal No.: 980320

As Received Basis Dry Basis UnitsMoisture, Total 0.19 0.00 %

ULTIMATE ANALYSIS: Ash 13.86 13.89 % Sulfur 0.43 0.43 %

CHNO ANALYSIS: Carbon 69.33 69.46 % Hydrogen (Excl. H in Moisture) 5.00 5.01 % Hydrogen (Incl. H in Moisture) 5.02 % Nitrogen 1.24 1.24 % Oxygen (Excl. O in Moisture) ** 9.95 9.97 % Oxygen (Incl. O in Moisture) ** 10.12 %--------------- --------------- --------------- --------------- --------------- --------------- --------------- ---------------

** = Oxygen determined by difference from 100%.

Table 4 DATE: 01/23/04

F.L.SMIDTH INC.RAW MIX DESIGN CALCULATIONS

Company: AMSCO - DREW DOWNESLocation: Lehi, UT

Mix No. : 1Component Lab. No. Blend %

# 1: Limestone 30753 84.38# 2: Shale 30754 11.63# 3: Silica 30755 2.98# 4: Iron 30756 1.01

-----------------100.00

LOSS FREE LFRM : 98.49 % RAW MIX RAW MIX FUEL ASH : 1.51 %----------------- ----------------- -----------------

SiO2 14.05 21.84 22.35Al2O3 (1) 3.30 5.14 5.18Fe2O3 (2) 2.21 3.43 3.42CaO 43.03 66.89 66.20MgO 0.91 1.41 1.42K2O 0.35 0.55 0.55Na2O 0.17 0.27 0.28SO3 0.07 0.11 0.23 (3)P2O5 0.04 0.06 0.06TiO2 0.16 0.25 0.25Mn2O3 0.04 0.06 0.06Loss 35.44 0.00 0.00TOTAL 99.77 100.01 100.00

Cl 0.003Alks. As Na2O 0.64%Silica Modulus 2.60Alumina Modulus 1.51LSF 93.67C3S 59.95%C2S 18.85%C3A 7.94%C4AF 10.41%Pot. Liquid 1450 C 25.27%

(1) Does NOT Include P2O5 + TiO2 (2) Does NOT Include Mn2O3 (3) Includes Fuel S

Table 5F.L.SMIDTH INC. LABORATORY REPORT HEAT OF REACTION, Page 1

PLANT: AMSCO - Drew Downes, Lehi, UT LAB NO.: 030753-HOR DATE: 01/22/04MATERIAL: Raw Mix - Laboratory Prepared ANAL NO.: C030547--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------DATA FROM ANALYSES:--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------RAW MIX:--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------CHEMICAL ANALYSIS: Unit MINERAL COMPOSITION: UnitSiO2 % 14.05Al2O3 % 3.30Fe2O3 % 2.21

CaO % 43.03 Water of crystallisation % 1.11MgO % 0.91 Carbon 1) % 0.12SO3 % 0.07

1) Carbon as CO2 is not included.

Loss on Ignition ( LOI ) % 35.44TOTAL % 99.01 CALCUALTED VALUES:

CaCO3 % 76.75CO2 % 35.06 MgCO3 % 2.46K2O % 0.35 Sulfur in pyrites % 0.000Na2O % 0.17 CaSO4 % 0.12

Sulphur, total % 0.028 Si-combined CaO % 0.00--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------FUEL: 100% Coal (from another Cement Plant in this area) Lab No.: 980322 Anal No.: 980320--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------Fuel in percentage of clinker % 10.90 ANALYSIS OF FUEL ASH:Sulfur, total % 0.43 SiO2 % 56.00Ash in percentage of fuel % 13.89 Al2O3 % 7.86Net calorific value, ( Q net,p ) kJ/kg 27661 Fe2O3 % 2.31

kcal/kg 6607 CaO % 23.70Heat consumption, MgO % 1.86

kJ per kg clinker kJ/kg 3015 K2O % 0.66 kcal per kg clinker kcal/kg 720 Na2O % 0.88

--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------RAW MIX ADJUSTMENT:--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------

RAW MIX ADJUSTMENT ADJUSTEDANALYSIS FROM FUEL RAW MIX ANALYSIS--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------

SiO2 % 14.05 0.55 14.60Al2O3 % 3.30 0.08 3.38Fe2O3 % 2.21 0.02 2.23

CaO % 43.03 0.23 43.26MgO % 0.91 0.02 0.93SO3 (total) % 0.07 0.08 0.15K2O % 0.35 0.01 0.36Na2O % 0.17 0.01 0.18

TOTAL % 64.09 1.00 T = 65.09--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------SULFUR BALANCE AND RAWMIX / CLINKER RATIO:--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------Adjusted raw mix, total: | % | T = 65.09Volatilised: U = 50 % of sulfur in pyrites as SO3 | % | U = 0.00SO3 in clinker (calculated): | % | 0.23Raw mix / clinker ratio (loss of dust = 0 %) : F = 100 / (T - U) | % | F = 1.536--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------

Table 6F.L.SMIDTH INC. LABORATORY REPORT HEAT OF REACTION, Page 2

PLANT: AMSCO - Drew Downes, Lehi, UT LAB NO.: 030753-HOR DATE: 01/22/04MATERIAL: Raw Mix - Laboratory Prepared ANAL NO.: C030547--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------

Conversion Calculated contributions:CALCULATIONS: factor RAWMIX CLINKER--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------CONTRIBUTIONS TO HEAT OF REACTION: kJ / kg / % kJ / kg kJ / kg--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------A: DECOMPOSITION INTO OXIDES: Values from page 1 (MINERALOGICAL COMPOSITION) RAW MIXCaCO3 76.75 -17.78 -1364.63MgCO3 2.46 -15.1 -37.17Water of crystallisation 1.11 -42.7 -47.40

Si-combined CaO 0.00 -17.0 0.00Alkali silicates: (K2O + Na2O)RAWMIX 0.52 -14.8 -7.70--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------

HEAT OF DECOMPOSITION: -1456.9 xF : -2237.80--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------B: HEAT OF FORMATION: Values from page 1PROPERTY: COMPONENT:C3S CaO 43.26 -0.46 -19.90C2S SiO2 14.60 21.43 312.88C3A Al2O3 3.38 1.21 4.09C4AF Fe2O3 2.23 2.46 5.49SO3 in clinker from fuel and pyrites 0.08 59.6 4.58--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------

HEAT OF FORMATION: 307.14 xF : 471.77--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------C: HEAT OF COMBUSTION: Values from page 1Carbon 0.12 327.86 39.34Sulphur in pyrites 0.00 129.14 0.00--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------

HEAT OF COMBUSTION: 39.34 xF : 60.43--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------A + B + C: HEAT OF REACTION ( kJ / kg clinker ) -1706

HEAT OF REACTION ( kcal / kg clinker ) -407

A + B: HEAT OF REACTION excl. HEAT OF COMBUSTION ( kJ / kg clinker ) -1766 HEAT OF REACTION excl. HEAT OF COMBUSTION ( kcal / kg clinker ) -422

--------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------

Figu

re 1

FC-860-3 (Revised - 3/14/96)

Table 7 F.L.SMIDTH INC. PROCESS LABORATORIES USA

FRM-4 ROLLER MILL GRINDABILITY

COMPANY

Amsco Drew Downes

LOCATION

Lehi, UT

TEST NO.

04-01

PROJECT NO.

3-47097-180-00-25

DATE

01/20/04

MATERIAL

Lab Prepared Raw Mix

LAB NO.

010753-M

AS RECD:

% MOISTURE

SIZE

LBS/CU.FT.

MILL FEED:

% MOISTURE

0.40

SIZE

1/2X 0

LBS/CU.FT.

84.3

DRAFT, INCHES OF WATER MILL EMPTY MILL LOADED Inlet 0.4 0.4 Above Table 1.6 3.6 After Classifier 3.0 6.0 After Cyclone 13.6 13.9 Gross Mill Motor Power, Watts 0.970 5886 Spring Force, lbs. - - - 581 Inlet, Temp. F 61 75 Exit, Temp. F 60 86 Cyclone Exh. SCFM 733 705

CLASSIFIER

115

RPM

36.9

VOLTS

1.52

AMPS

CYCLONE

10.0

lbs/min.

0.34

%H2O

52.9

LBS/CU.FT.

7.10

% FREE SiO2

75.9

% CaCO3

BAGHOUSE DUST

0.5

lbs/min.

0.52

% FREE SiO2

79.0

% CaCO3

INTERNAL LOAD

11.84

% FREE SiO2

73.7

% CaCO3

ABRASION/TIRE

14.79 g/st/tire(16.30 g/mt/tire)Mild Steel @ 178 Brinell)

PRODUCT CAPACITY LBS/HR

624.0 (283.0 kgs/hr.)

FINENESS: % RET. 200 MESH

19.8

100 MESH

0.7

90

12.5

DISTN

58

35.8% RET.

56

NET TEST MILL MOTOR, KWH/METRIC TON

17.37

GRINDABILITY

8.06

kWh/mt @ 15% +90

COMMENTS:

Dust Rate 4.2%

HARDGROVE: 54.6

Figure 2

ROLLER MILL GRINDABILITY: FRM4- 04-01 FRM-4 TEST MILL FEED: LAB PREPARED RAW MIX

FRM-4 PRODUCT CYCLONE PARTICLE SIZE DISTRIBUTION 45 MIN. CYCLONE PRODUCT

+325 MESH -325 MESH

TOTAL

WEIGHT % 36.4 63.6 100.0

% FREE SiO2 8.78 6.14 7.10

% CaCO3 75.5 76.1 75.9

1020

3040

5060

7080

90100

200300

400500

600700

800900

1000

595

1090

2080

3070

4060

5050

6040

7030

8020

9010

955

982

991

99.5

0.5

99.8

0.2

99.9

0.1

99.9

9

0.01

Particle Size (microns)

Perc

ent P

assi

ng

Perc

ent R

etai

ned

F.L.Smidth Inc. Process LabsGrindability Test Product Size Distribution

1020

3040

5060

7080

90100

200300

400500

600700

800900

1000

595

1090

2080

3070

4060

5050

6040

7030

8020

9010

955

982

991

99.5

0.5

99.8

0.2

99.9

0.1

99.9

9

0.01

Particle Size (microns)

Perc

ent P

assi

ng

Perc

ent R

etai

ned

F.L.Smidth Inc. Process LabsGrindability Test Product Size Distribution

Table 8

F.L.SMIDTH INC.

IMPACT CRUSHER ABRASION TEST

(CHROME MOLY STEEL PADDLE)

CUSTOMER: Amsco

LOCATION: Lehi, UT

DATE: 12/15/03

MATERIAL: Limestone

LAB NO.: 030753

TEST NO.: 03-28

PROJECT NO: 3-47097-180

TEST PADDLE

INITIAL WEIGHT

97.0618 GMS

TEST PADDLE

FINAL WEIGHT

97.0569 GMS

TEST PADDLE

WEIGHT LOSS

0.0049 GMS

ABRASION INDEX (WT. LOSS, GMS X 10000=

49 (Low)

PRODUCT SIZING

SIZE MESH

CUM. % PASSING

1/2" 96.5

3/8" 90.9

1/4" 76.2

4 MESH 64.5

6 MESH 55.0

8 MESH 47.2

12 MESH 40.4

APPARENT

40 MESH 20.9

CRUSHABILITY

70 MESH 14.6

Normal / Average

100 MESH 12.0

200 MESH 8.7

325 MESH 6.9

FC-4039

TABLE 9

F.L.SMIDTH, INC. - PROCESS LABORATORIES IMPACT CRUSHER WEAR TEST

SAMPLE FROM: Amsco - Drew Downes SAMPLE #: 030753 DATE TESTED: 12/16/03LOCATION: Lehi, UT DATE REC'D: 11/11/03 TEST #: 03-10MATERIAL: Limestone WEIGHT TESTED: 2000.0 g PLATE #: RD #119PROJECT #: 3-47097-180-00-25 BULK DENSITY: 77.0 lb/cf SIZE FRACTION TESTED: -5/8" +

5/16"

1st Pass g 2000.0 (a) Comments: COMMENTS: FEED 2nd Pass g 1142.6

3rd Pass g 554.24th Pass g 239.55th Pass g 97.66th Pass g FINES (Particle size distribution curve for -4 mm fraction)7th Pass g K50 mm 2.8 Comments:8th Pass g Relative Gradient, q 1.029th Pass g TITRATION

TOTAL FEED g 4033.9 (b) Plus 4 mm RESIDUE (plus 4 mm) g 41.6 (c) Minus 4 mm CIRCULATION FACTOR 2.060 [ b / (a - c) ]

SCREENING Cumulative BREAKER PLATE WEAR U.S. Mesh Equiv. Standard g % Retained % Retained BEFORE g 154.9189 5/8 " 16 mm AFTER g 154.9028 5/16 " 8 mm DIFFERENCE g 0.0161 (d) 5 mesh 4 mm POWER CONSUMPTION 9 mesh (U.S. 10) 2 mm 97.4 48.9 48.9 [ E = 1/2 m V

2 ] Wh 0.8963 (e) [ b ( 2.222 x 10-4 ) ] 16 mesh (U.S. 18) 1 mm 52.4 26.3 75.2 32 mesh (U.S. 35) 0.5 mm 24.6 12.4 87.6

ABRASIVENESS 60 mesh 0.25 mm 12.1 6.1 93.7 FINES g/t 8.22 (f) [ d x 106 / (a - c) ] 65 mesh (U.S. 70) 0.2 mm 1.7 0.8 94.5 POWER g/kWh 17.96 (g) [ d x 103 / e ] 170 mesh 0.09 mm 6.5 3.3 97.8 SPECIFIC POWER CONSUMPTION -170 mesh -0.09 mm 4.3 2.2 -- kWh/t 0.4577 [ f / g ] Total 199.0 100.0 --

Table 10

F.L.SMIDTH INC.



CUSTOMER: Amsco

LOCATION: Lehi, UT

DATE: 12/15/03

MATERIAL: Shale

LAB NO.: 030754

TEST NO.: 03-29

PROJECT NO: 3-47097-180

TEST PADDLE

INITIAL WEIGHT

96.4960 GMS

TEST PADDLE

FINAL WEIGHT

96.4937 GMS

TEST PADDLE

WEIGHT LOSS

0.0023 GMS


23 (Low)

PRODUCT SIZING

SIZE MESH

CUM. % PASSING

1/2" 100.0

3/8" 95.4

1/4" 72.4

4 MESH 58.6

6 MESH 43.0

8 MESH 34.8

12 MESH 28.4

APPARENT

40 MESH 14.3

CRUSHABILITY

70 MESH 10.5

Normal / Average

100 MESH 8.9

200 MESH 6.3

325 MESH 4.5

FC-4039

TABLE11


SAMPLE FROM: Amsco - Drew Downes SAMPLE #: 030754 DATE TESTED: 12/16/03LOCATION: Lehi, UT DATE REC'D: 11/11/03 TEST #: 03-09MATERIAL: Shale WEIGHT TESTED: 2000.1 g PLATE #: RD #118PROJECT #: 3-47097-180-00-25 BULK DENSITY: 59.3 lb/cf SIZE FRACTION TESTED: -5/8" +

5/16"


3rd Pass g 721.84th Pass g 414.15th Pass g 225.76th Pass g 116.3 FINES (Particle size distribution curve for -4 mm fraction)7th Pass g 55.0 K50 mm 3.3 Comments:8th Pass g Relative Gradient, q 1.049th Pass g TITRATION





Table 12

F.L.SMIDTH INC.



CUSTOMER: Amsco

LOCATION: Lehi, UT

DATE: 12/16/03

MATERIAL: Silica

LAB NO.: 030755

TEST NO.: 03-30

PROJECT NO: 3-47097-180

TEST PADDLE

INITIAL WEIGHT

96.4937 GMS

TEST PADDLE

FINAL WEIGHT

95.5184 GMS

TEST PADDLE

WEIGHT LOSS

0.9753 GMS


9753 (Severe)

PRODUCT SIZING

SIZE MESH

CUM. % PASSING

1/2" 84.5

3/8" 58.6

1/4" 39.6

4 MESH 33.6

6 MESH 28.7

8 MESH 25.8

12 MESH 23.6

APPARENT

40 MESH 17.7

CRUSHABILITY

70 MESH 13.6

Low

100 MESH 11.0

200 MESH 6.8

325 MESH 4.4

FC-4039

TABLE 13


SAMPLE FROM: Amsco - Drew Downes SAMPLE #: 030755 DATE TESTED: 12/16/03LOCATION: Lehi, UT DATE REC'D: 11/11/03 TEST #: 03-08MATERIAL: Silica WEIGHT TESTED: 2000.0 g PLATE #: RD #117PROJECT #: 3-47097-180-00-25 BULK DENSITY: 79.3 lb/cf SIZE FRACTION TESTED: -5/8" +

5/16"


3rd Pass g 999.54th Pass g 630.85th Pass g 381.76th Pass g 216.7 FINES (Particle size distribution curve for -4 mm fraction)7th Pass g 123.0 K50 mm 1.3 Comments:8th Pass g 69.6 Relative Gradient, q 1.189th Pass g TITRATION





Fig

ure

3

Table 14

raw mix design and sampling

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