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

To

S. W. Miller

From

S. S. Schmidt

Filing

AMSCO – DREW DOWNES, Lehi, UT

Subject

CEMENT RAW MATERIALS INVESTIGATION (4 Raw Materials)

Page

Copies to

1 S.J.Evans P.J.Riley

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 PROCESS LABORATORIES

SCOTT J. EVANS MANAGER PROCESS LABORATORIES

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.

AMSCO – DREW DOWNES Lehi, UT 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 Decription

Assigned Lab No.

Quantity Received (lbs.) 900 120 120 65

Bulk Density (lbs/ft3) 83.5 69.7 84.1 140.6

As Received Moisture (%) 0.09 3.10 0.05 0.19

Limetone ** 030753 Shale 030754 Silica 030755 Iron 030756 ** 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.

AMSCO – DREW DOWNES Lehi, UT 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 smallersized 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).

AMSCO – DREW DOWNES Lehi, UT 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 Targets C3S C3A Silica Modulus (SM)

= = =

60.0 % < 8.0 2.6

F.L.Smidth Design 60.0 % 7.9 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%

AMSCO – DREW DOWNES Lehi, UT 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 (90µ) and 80.2% -200 mesh (75µ). 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 (45µ) 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)

Sample:

Lab Analytical No:

Customer: AMSCO - Drew Downs Location: Lehi, UT Project No.: 3-47097-180-00-25

Limestone

Shale

030753 C030528

030754 C030529

Silica 12.78%

030755 C030530

Iron (Includes Magnetics)

030756 C030531

Loss @ 105 C:

0.09

3.12

0.05

0.19

SiO2: Al2O3 Fe2O3: CaO: MgO: K2O: Na2O: SO3(Total): P2O5: TiO2: Mn2O3 Loss @ 950 C: Total:

5.69 0.76 0.30 50.76 0.83 0.22 0.11 0.08 0.01 0.05 0.01 40.96 99.78

54.56 22.70 7.47 1.50 1.75 1.41 0.63 0.03 0.23 1.00 0.13 7.98 99.39

97.01 0.54 1.17 0.37 0.00 0.14 0.06 0.02 0.01 0.08 0.04 0.20 99.64

1.40 0.71 104.18 1.07 0.26 0.03 0.36 0.04 0.01 0.00 1.18 -5.17 104.07

Cl: C: CO2:

0.003 0.06

0.004 0.41

0.004 0.08

0.003 0.50

0.02

0.01

0.01

0.01

Tot.Carbonate as CaCO3:

MgCO3: CaCO3: Free SiO2: Loss @ 500 C: Sulfide S: 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 Vol: 42.06 Ash: 13.89 FC: 44.05

Ultimate Analysis (Dry Basis) Ult. C: 69.46 Ult. H: 5.01 Ult. N:

Sulfur

0.43

Ult. S:

BTU/Lb

12,371

Ult. O:

Cl: Hardgrove Index:

Chemistry of Ash SiO2: Al2O3 Fe2O3: CaO: MgO: K2O: Na2O: SO3: P2O5: TiO2: Mn2O3 Total:

56.00 7.86 2.31 23.70 1.86 0.66 0.88 5.41 0.24 0.50 0.06 99.48

1.24

9.97

Date:

01/14/04

Table 3 F.L.SMIDTH INC. FUEL ANALYSIS ==================

Client: Location:

AMSCO - DREW DOWNES Lehi, UT

Fuel Type: Cyclone Coal Project No.: 3-47097-180-00-25 Lab No.: Anal No.:

980322 980320

Moisture, Total ULTIMATE ANALYSIS: Ash Sulfur

As Received Basis 0.19

13.86 0.43

Dry Basis 0.00

13.89 0.43

Units %

% %

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%.

DATE:

Table 4

01/23/04

F.L.SMIDTH INC. RAW MIX DESIGN CALCULATIONS Company:

AMSCO - DREW DOWNES

Location:

Lehi, UT

Mix No. : 1 Component

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

SiO2 Al2O3 (1) Fe2O3 (2)

LFRM :

98.49 % 1.51 %

RAW MIX

RAW MIX

FUEL ASH :

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

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

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

14.05

21.84

22.35

3.30

5.14

5.18

2.21

3.43

3.42

CaO

43.03

66.89

66.20

MgO

0.91

1.41

1.42

K2O

0.35

0.55

0.55

Na2O

0.17

0.27

0.28

SO3

0.07

0.11

0.23 (3)

P2O5

0.04

0.06

0.06

TiO2

0.16

0.25

0.25

Mn2O3

0.04

0.06

0.06

Loss

35.44

0.00

0.00

TOTAL

99.77

100.01

100.00

Cl

0.003

Alks. As Na2O

0.64%

Silica Modulus

2.60

Alumina Modulus

1.51

LSF

93.67

C3S

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 5

F.L.SMIDTH INC.

LABORATORY REPORT

HEAT OF REACTION, Page 1

PLANT: LAB NO.: 030753-HOR DATE: AMSCO - Drew Downes, Lehi, UT 01/22/04 MATERIAL: Raw Mix - Laboratory Prepared ANAL NO.: C030547 --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- ------------------DATA FROM ANALYSES: --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- ------------------RAW MIX: --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- ------------------MINERAL COMPOSITION: Unit CHEMICAL ANALYSIS: Unit SiO2 % 14.05 Al2O3 % 3.30 Fe2O3 % 2.21 CaO

%

43.03

MgO SO3

% %

0.91 0.07

Water of crystallisation

%

Carbon 1) % 1) Carbon as CO2 is not included.

1.11 0.12

Loss on Ignition ( LOI )

%

35.44

TOTAL

%

99.01

CALCUALTED VALUES: CaCO3

%

76.75

CO2

%

35.06

MgCO3

%

2.46

Sulfur in pyrites CaSO4

%

0.000

%

0.12

K2O

%

0.35

Na2O

%

0.17

% 0.028 --------------- --------------- --------------- --------------- --------------- --------------100% Coal (from another Cement Plant in this area) FUEL: --------------- --------------- --------------- --------------- --------------- --------------Fuel in percentage of clinker % 10.90 Sulfur, total % 0.43

Sulphur, total

Ash in percentage of fuel Net calorific value, ( Q net,p ) Heat consumption, kJ per kg clinker

%

13.89

kJ/kg kcal/kg

27661 6607

kJ/kg

3015

Si-combined CaO % 0.00 --------------- --------------- --------------- ------------------Lab No.: 980322 Anal No.: 980320 --------------- --------------- --------------- ------------------ANALYSIS OF FUEL ASH: SiO2 % 56.00 Al2O3 % 7.86 Fe2O3 % 2.31 CaO MgO K 2O

% % %

Na2O kcal per kg clinker kcal/kg 720 --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------RAW MIX ADJUSTMENT: --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------RAW MIX ADJUSTMENT ANALYSIS FROM FUEL --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------SiO2 % 14.05 0.55 Al2O3 % 3.30 0.08 Fe2O3 % 2.21 0.02

23.70 1.86 0.66

% 0.88 --------------- --------------------------------- ------------------ADJUSTED RAW MIX ANALYSIS --------------- ------------------14.60 3.38 2.23

CaO

%

43.03

0.23

43.26

MgO SO3 (total)

% %

0.91 0.07

0.02 0.08

0.93 0.15

K2O

%

0.35

0.01

0.36

Na2O

%

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= 65.09 % of sulfur in pyrites as SO3 Volatilised: U= 50 | % | U= 0.00 SO3 in clinker (calculated): | % | 0.23 Raw mix / clinker ratio (loss of dust = 0 %) : F = 100 / (T - U) | % | F= 1.536 --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- -------------------

Table 6

F.L.SMIDTH INC.

LABORATORY REPORT

HEAT OF REACTION, Page 2

PLANT: LAB NO.: 030753-HOR DATE: AMSCO - Drew Downes, Lehi, UT 01/22/04 MATERIAL: Raw Mix - Laboratory Prepared ANAL NO.: C030547 --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- ------------------Conversion Calculated contributions: RAWMIX CLINKER factor CALCULATIONS: --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- ------------------CONTRIBUTIONS TO HEAT OF REACTION: kJ / kg / % kJ / kg kJ / kg --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------- ------------------A: DECOMPOSITION INTO OXIDES: Values from page 1 (MINERALOGICAL COMPOSITION) RAW MIX CaCO3 76.75 -17.78 -1364.63 MgCO3 Water of crystallisation

2.46 1.11

-15.1 -42.7

-37.17 -47.40

Si-combined CaO 0.00 -17.0 0.00 Alkali 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 1 PROPERTY: COMPONENT: C3S CaO 43.26 -0.46 -19.90 SiO2 C2S 14.60 21.43 312.88 Al2O3 C3A 3.38 1.21 4.09 C4AF

Fe2O3 2.23 2.46 5.49 SO3 in clinker from fuel and pyrites 0.08 59.6 4.58 --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------HEAT OF FORMATION: 307.14 --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------C: HEAT OF COMBUSTION: Values from page 1 Carbon 0.12 327.86 39.34 Sulphur in pyrites 0.00 129.14 0.00 --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------HEAT OF COMBUSTION: 39.34 --------------- --------------- --------------- --------------- --------------- --------------- --------------- --------------A + B + C: HEAT OF REACTION ( kJ / kg clinker ) HEAT OF REACTION ( kcal / kg clinker ) A + B:

--------------- ------------------xF : 471.77 --------------- -------------------

--------------- ------------------xF : 60.43 --------------- -------------------1706 -407

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

Figure 1

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

COMPANY

Table 7 F.L.SMIDTH INC. – PROCESS LABORATORIES USA FRM-4 ROLLER MILL GRINDABILITY

Amsco – Drew Downes

TEST NO.

04-01

MATERIAL

LOCATION

PROJECT NO.

3-47097-180-00-25

Lehi, UT

DATE

01/20/04

Lab Prepared Raw Mix

LAB NO.

010753-M

AS REC’D:

% MOISTURE

MILL FEED:

% MOISTURE

SIZE 0.40

LBS/CU.FT.

SIZE

1/2”X 0

LBS/CU.FT.

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

733

705

Cyclone Exh. SCFM

CLASSIFIER

115

CYCLONE

84.3

10.0

RPM

lbs/min.

36.9

VOLTS

0.34

%H2O

1.52

AMPS 52.9

LBS/CU.FT.

7.10

% FREE SiO2

75.9

% CaCO3

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)

BAGHOUSE DUST

0.5

PRODUCT CAPACITY LBS/HR FINENESS: % RET. DIST’N

lbs/min.

624.0 (283.0 kgs/hr.) 200 MESH

58°

35.8% RET.

NET TEST MILL MOTOR, KWH/METRIC TON COMMENTS:

HARDGROVE:

Dust Rate – 4.2%

54.6

19.8

100 MESH 56

17.37

0.7

90µ

12.5

µ GRINDABILITY

8.06

kWh/mt @ 15% +90µ

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 WEIGHT % 36.4 63.6 100.0

+325 MESH -325 MESH TOTAL

% FREE SiO2 8.78 6.14 7.10

% CaCO3 75.5 76.1 75.9

10

20

30

40

50

60

70

80

90

100

Particle Size (microns)

200

300

400

500

600

700

900 1000 5

95

90

10

80

20

70

30

60

40

50

50

40

60

30

70

20

80

10

90

Percent Passing

Percent Retained

5

95

2

98

1

99

0.5

99.5

0.2

0.1

99.8 99.9

0.01

99.99

F.L.Smidth Inc. Process Labs Grindability Test Product Size Distribution

800

Table 8 F.L.SMIDTH INC. IMPACT CRUSHER ABRASION TEST (CHROME MOLY STEEL PADDLE) CUSTOMER:

Amsco

LOCATION:

MATERIAL:

Limestone

LAB NO.:

PROJECT NO:

Lehi, UT 030753

DATE:

12/15/03

TEST NO.:

03-28

3-47097-180

TEST PADDLE

INITIAL WEIGHT

97.0618 GMS

TEST PADDLE

FINAL WEIGHT

97.0569 GMS

TEST PADDLE

WEIGHT LOSS

ABRASION INDEX (WT. LOSS, GMS X 10000=

0.0049 GMS 49

(Low)

PRODUCT SIZING SIZE MESH 1/2"

FC-4039

CUM. % PASSING 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

TABLE 9

F.L.SMIDTH, INC. - PROCESS LABORATORIES IMPACT CRUSHER WEAR TEST SAMPLE FROM: LOCATION: MATERIAL: PROJECT #:

Amsco - Drew Downes Lehi, UT

Limestone 3-47097-180-00-25

FEED

1st Pass

g

2nd Pass

g

3rd Pass 4th Pass

g g

5th Pass

g

2000.0 1142.6 554.2 239.5 97.6

12/16/03 03-10 TEST #: PLATE #: RD #119 5 5 SIZE FRACTION TESTED: - /8" + /16"

030753 11/11/03 DATE REC'D: WEIGHT TESTED: 2000.0 g BULK DENSITY: 77.0 lb/cf

DATE TESTED:

SAMPLE #:

COMMENTS:

(a) Comments:

6th Pass

g

FINES

7th Pass

g

K50

8th Pass 9th Pass

g g

Relative Gradient, q

TOTAL FEED RESIDUE (plus 4 mm)

g g

CIRCULATION FACTOR

(Particle size distribution curve for -4 mm fraction) mm

2.8 1.02

Comments:

TITRATION 4033.9 41.6 2.060

Plus 4 mm

(b)

Minus 4 mm

(c) [ b / (a - c) ]

SCREENING BREAKER PLATE WEAR BEFORE g AFTER g DIFFERENCE g POWER CONSUMPTION [ E = 1/2 m V2 ]

Wh

154.9189 154.9028 0.0161

U.S. Mesh Equiv. 5 /8 " 5

(d)

/16 "

5 mesh 9 mesh (U.S. 10)

0.8963

(e)

-4

[ b ( 2.222 x 10 ) ]

16 mesh (U.S. 18) 32 mesh (U.S. 35)

ABRASIVENESS 8.22 FINES g/t 17.96 g/kWh POWER SPECIFIC POWER CONSUMPTION 0.4577 kWh/t

60 mesh 6

(f)

[ d x 10 / (a - c) ]

(g)

[ d x 103 / e ]

65 mesh (U.S. 70) 170 mesh -170 mesh

[f/g]

Total

Cumulative Standard

16 8 4 2 1 0.5 0.25 0.2 0.09 -0.09

g

% Retained

% Retained

48.9 26.3 12.4 6.1 0.8 3.3 2.2 100.0

48.9 75.2 87.6 93.7 94.5 97.8 ---

mm mm mm mm mm mm mm mm mm mm

97.4 52.4 24.6 12.1 1.7 6.5 4.3 199.0

Table 10 F.L.SMIDTH INC. IMPACT CRUSHER ABRASION TEST (CHROME MOLY STEEL PADDLE) CUSTOMER:

Amsco

LOCATION:

MATERIAL:

Shale

LAB NO.:

PROJECT NO:

Lehi, UT 030754

DATE:

12/15/03

TEST NO.:

03-29

3-47097-180

TEST PADDLE

INITIAL WEIGHT

96.4960 GMS

TEST PADDLE

FINAL WEIGHT

96.4937 GMS

TEST PADDLE

WEIGHT LOSS

ABRASION INDEX (WT. LOSS, GMS X 10000=

0.0023 GMS 23

(Low)

PRODUCT SIZING SIZE MESH 1/2"

FC-4039

CUM. % PASSING 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

TABLE11

F.L.SMIDTH, INC. - PROCESS LABORATORIES IMPACT CRUSHER WEAR TEST SAMPLE FROM: LOCATION: MATERIAL: PROJECT #:

Amsco - Drew Downes Lehi, UT

Shale 3-47097-180-00-25

FEED

1st Pass

g

2nd Pass

g

3rd Pass 4th Pass

g g

5th Pass

g

6th Pass

g

7th Pass

g

8th Pass 9th Pass

g g

TOTAL FEED RESIDUE (plus 4 mm)

g g

CIRCULATION FACTOR

2000.1 1236.8 721.8 414.1 225.7 116.3 55.0

12/16/03 03-09 TEST #: PLATE #: RD #118 5 5 SIZE FRACTION TESTED: - /8" + /16"

030754 11/11/03 DATE REC'D: WEIGHT TESTED: 2000.1 g BULK DENSITY: 59.3 lb/cf

DATE TESTED:

SAMPLE #:

COMMENTS:

(a) Comments:

FINES

(Particle size distribution curve for -4 mm fraction)

K50

mm

Relative Gradient, q

3.3 1.04

Comments:

TITRATION 4769.8 31.6 2.423

Plus 4 mm

(b)

Minus 4 mm

(c) [ b / (a - c) ]

SCREENING BREAKER PLATE WEAR BEFORE g AFTER g DIFFERENCE g POWER CONSUMPTION [ E = 1/2 m V2 ]

Wh

154.7321 154.7311 0.0010

U.S. Mesh Equiv. 5 /8 " 5

(d)

/16 "

5 mesh 9 mesh (U.S. 10)

1.0598

(e)

-4

[ b ( 2.222 x 10 ) ]

16 mesh (U.S. 18) 32 mesh (U.S. 35)

ABRASIVENESS 0.51 FINES g/t 0.94 g/kWh POWER SPECIFIC POWER CONSUMPTION 0.5426 kWh/t

60 mesh 6

(f)

[ d x 10 / (a - c) ]

(g)

[ d x 103 / e ]

65 mesh (U.S. 70) 170 mesh -170 mesh

[f/g]

Total

Cumulative Standard

16 8 4 2 1 0.5 0.25 0.2 0.09 -0.09

g

% Retained

% Retained

55.0 26.1 9.7 4.5 0.9 2.1 1.7 100.0

55.0 81.1 90.8 95.3 96.2 98.3 ---

mm mm mm mm mm mm mm mm mm mm

123.1 58.3 21.8 10.1 2.0 4.8 3.7 223.8

Table 12 F.L.SMIDTH INC. IMPACT CRUSHER ABRASION TEST (CHROME MOLY STEEL PADDLE) CUSTOMER:

Amsco

LOCATION:

MATERIAL:

Silica

LAB NO.:

PROJECT NO:

Lehi, UT 030755

DATE:

12/16/03

TEST NO.:

03-30

3-47097-180

TEST PADDLE

INITIAL WEIGHT

96.4937 GMS

TEST PADDLE

FINAL WEIGHT

95.5184 GMS

TEST PADDLE

WEIGHT LOSS

ABRASION INDEX (WT. LOSS, GMS X 10000=

0.9753 GMS 9753

(Severe)

PRODUCT SIZING SIZE MESH 1/2"

FC-4039

CUM. % PASSING 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

TABLE 13

F.L.SMIDTH, INC. - PROCESS LABORATORIES IMPACT CRUSHER WEAR TEST SAMPLE FROM: LOCATION: MATERIAL: PROJECT #:

Amsco - Drew Downes Lehi, UT

Silica 3-47097-180-00-25

FEED

1st Pass

g

2nd Pass

g

3rd Pass 4th Pass

g g

5th Pass

g

6th Pass

g

7th Pass

g

8th Pass 9th Pass

g g

TOTAL FEED RESIDUE (plus 4 mm)

g g

CIRCULATION FACTOR

2000.0 1468.0 999.5 630.8 381.7 216.7 123.0 69.6

12/16/03 03-08 TEST #: PLATE #: RD #117 5 5 SIZE FRACTION TESTED: - /8" + /16"

030755 11/11/03 DATE REC'D: WEIGHT TESTED: 2000.0 g BULK DENSITY: 79.3 lb/cf

DATE TESTED:

SAMPLE #:

COMMENTS:

(a) Comments:

FINES

(Particle size distribution curve for -4 mm fraction)

K50

mm

Relative Gradient, q

1.3 1.18

Comments:

TITRATION 5889.3 37.2 3.000

Plus 4 mm

(b)

Minus 4 mm

(c) [ b / (a - c) ]

SCREENING BREAKER PLATE WEAR BEFORE g AFTER g DIFFERENCE g POWER CONSUMPTION [ E = 1/2 m V2 ]

Wh

155.5260 154.6551 0.8709

U.S. Mesh Equiv. 5 /8 " 5

(d)

/16 "

5 mesh 9 mesh (U.S. 10)

1.3086

(e)

-4

[ b ( 2.222 x 10 ) ]

16 mesh (U.S. 18) 32 mesh (U.S. 35)

ABRASIVENESS 443.70 FINES g/t 665.52 g/kWh POWER SPECIFIC POWER CONSUMPTION 0.6667 kWh/t

60 mesh 6

(f)

[ d x 10 / (a - c) ]

(g)

[ d x 103 / e ]

65 mesh (U.S. 70) 170 mesh -170 mesh

[f/g]

Total

Cumulative Standard

16 8 4 2 1 0.5 0.25 0.2 0.09 -0.09

g

% Retained

% Retained

49.1 19.9 10.9 8.8 2.1 5.9 3.3 100.0

49.1 69.0 79.9 88.7 90.8 96.7 ---

mm mm mm mm mm mm mm mm mm mm

123.8 50.2 27.5 22.3 5.2 14.8 8.3 252.1

Figure 3

Table 14