The document discusses the development of a standard plant design for aggregates and asphalt manufacturing facilities. The goals are to improve safety, quality, cost control and speed of implementation. A standard plant made of modular components would ensure consistency and allow building many small 1,000 ton per hour plants quickly in developing markets. Key features discussed include finger chutes for product balancing, bins above screens, and making plants modular. Preferred manufacturers are listed and example standard plant projects scheduled for 2010-2012 in places like India, China, Ukraine and Poland. Automation aims to optimize processes while avoiding over-automation. Technical drawings and a conceptual design of the standard plant concept are presented.

1. Standard Plant
Project Update
Steve Millburn
November 2009

2. Aggregates and Asphalt
Manufacturing - 2009
Plant Standards Project – Why?
 Safety - Good practice
• Safe – LOTOTO, Housekeeping, Conveyor advisory, WAH - designed in.
• Layout – Traffic management of HME, segregated from pedestrians.
 Cost Control
• Identify the real Capital cost of the right plant
• Process Optimisation – maximise yield value
• Cost saving - Full life and running costs
• Lower carbon footprint / environmental performance
 Quality
• Quality – deliver the right quality. This is our key to success in new markets
• Consider production and crushing but also storage and loading.
• Use Optagg
 Speed of implementation
• Multi-local
 The Global power of formalising best practice, with Local ownership
• Common Language, Aligned to Principles of Action
• Aligned to Rock Performance Modules (Land, PER, Micro Org)
• Same tools in different countries, Clear sign-off procedure
• Improved communication, Knowledge sharing
 Cash - Purchasing benefits
• Bulk buying/supply deals, payment terms
• Use best suppliers for a given region
 Organisation, Spare parts, Service Levels (Metso, Sandvik, Terex)
 Egypt, India and HQLC countries can fabricate structures, conveyors & more.
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3. Aggregates and Asphalt
Manufacturing - 2009
Why a Standard Plant instead of Plant Standards?
 The Standard Plant is a set of modules that will be reproduced ‘as is’
 This will ensure safety, quality, running cost, productivity and
environmental limits are consistently met.
 Vision is to build many tens of these 1ktph plants in developing BU’s
 Speed of implementation is vital
 The scope of many of these markets will be sub base and concrete
aggs, but the Marketing Analysis will drive product split needs.
 After-sales support from WW Manufacturers or Local Sourcing
 The opportunity for HQLC – High Quality, Low Cost sourcing.
 Our competitive advantage, our differentiator, in developing BU’s is
Quality – our plants must deliver
 Our skill is running at low cost per tonne and managing performance
and product/sales balance
 Every plant built from the same drawings saves 5-7% Capital cost.
 The WW Manufacturing Team will approve applications so that a
competent solution is always delivered.
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4. Aggregates and Asphalt
Manufacturing - 2009
We need to avoid these previous mistakes:-
Guards! WAH! House keeping! Dust!
Walkways chutes maintenance No bolts! – Welded!


5. Aggregates and Asphalt
Manufacturing - 2009
Telsmith Primary (for LNA, otherwise local sourcing)
 Complete unit delivered in a ‘ready to run’ state
 Mated to a free standing hopper (to include a walkway)
 Developed for mining but found to be significantly cost effective for US
 100% recoverable asset (excluding retaining wall), compared to 35% civils in
Fixed application
 Bridging event rate of 1:5000. Hydraulic hammer clears blockage

6. Aggregates and Asphalt
Manufacturing - 2009
Key Feature – Finger Chutes
Product / Sales Balance – Cash Flow and Inventory
To dust stock
Or washing plant
To sub base stock
Clears Plant
(concrete aggs/
asphalt agg plant)
Sub-base or
Rail ballast
Re-crush
Finger chutes in the Screening Plant allows product/sales balance to be
controlled during production.
This is working successfully in practice at Joliet, Chicago
Consider appropriate wear materials-chromium carbide, rubber, ceramic
+63mm
-63 +25mm
-25 +5mm
-5mm
63mm = 2 ½”
25mm = 1”
5mm = #4

7. Aggregates and Asphalt
Manufacturing - 2009
Agg Flow – (part)
Clears
Single size
fractions

8. Aggregates and Asphalt
Manufacturing - 2009
Key Feature – Bin on top of Screens
 The extra capital is about
$60k
 If the plant should stop the
belt can recover the crusher
product and dump it in the
bin to:
 Prevent spillage
 Prevent clear up
 This increases safety by
reducing manual handling
and increasing
housekeeping standards
 Prevent the conveyor
being started under full
load
 The bin allows even flow to the feeders ($40k) so that the screens are
evenly loaded and maximise efficiency
 If one screen is shut off the plant can continue to run at a reduced rate as
the bin can still feed the remaining screen.

9. Aggregates and Asphalt
Manufacturing - 2009
Key Feature - The Standard Plant is Modular
Primary
Crusher
Screening
Plant
Secondary
Crusher
Secondary
Crusher
Screening
Plant
Primary
Crusher
Screening
Plant
P
R
O
D
U
C
T
S
•The modules are built ‘as is’ but in a layout to suit the site, market
and mining plan.
•Only 1% to 1½% in re-engineering costs compared to 7% normally,
or more.
•Smaller crushers can be mounted on the same structure for various
outputs – within reason.
•Standard Layout criteria have been identified
•Tele-stackers are a key feature to support quality and minimise
double handling. At $250k installed a 150’ tele will stock 70,000t.

10. Aggregates and Asphalt
Manufacturing - 2009
Preferred Major Crusher Manufacturers
 Gyratory Primaries
 Metso
 Sandvik
 FL Smidt & Co – Fuller
 Jaws
 Metso
 Sandvik
 Terex – Pegson
 Astec Industries – Telsmith
 Impactors
 Metso
 Sandvik
 Terex – Pegson
 Hazemag - APKM 1622
 Cone
 Sandvik
 Terex – Pegson
 Metso - HP 400
 FL Smidt - Raptor XL 400, XL 600
 Astec Industries – Telsmith
 Also - Metso HP100, HP200,
HP300, HP500, Raptor XL 300
 VSI
 Sandvik
 Metso – Barmac
 Terex – Canica 80, 90, 100,
100s, 105, 125
World Wide suppliers
North America suppliers

11. Aggregates and Asphalt
Manufacturing - 2009
Scope of Standard Plant
 Developing BU’s
 China, India, North Africa, Central Europe, Asia
 The plant is designed for 1000 short ton per hour (900tph), but could
use downsized components for say 750tph.
 Double shifting will meet 3Mt.
 The plant has been designed for use in hard rock through extensive
use of dead boxes (rock boxes)
Date Country Site Plant Type Components
2010 India Kalyan JCC - C110, GP200, HP300
2010 Morocco Tetouan Fixed (Portable Jaw) Cone - Cone
2010 China Miaoxi Fixed - 700tph JCC - C140, GP500, GP300 x 2
2010 Philippines Cebu JCH - tbc
2010 Ukraine Klesov Fixed 2 – 3Mt 2 x HP500
2011 China Jintan Fixed JCCV - C125 ,HP300 x 2, VSI
2011 India TBA JCC - C110, GP200, HP300
2011 India TBA JCC - C110, GP200, HP300
2011 Poland Radkowice Fixed 2 – 3Mt JHC - C160, NP1520, HP4
2012 China Fixed JCH - C125, tbc
2012 China Fixed JCH - C125, tbc

12. Aggregates and Asphalt
Manufacturing - 2009
Fixed Plant Automation
 Automation detail started with these aims:
 Process Optimisation – maximise yield value
 Quality – deliver the right quality
 Cost saving - Full life and running costs (including maintenance and
data logging)
 Lower carbon footprint / strong environmental performance
 Identifying best components list
 Drawing up list of specification for each type of plant.
 Aiming for balanced automation, rather than ‘over’ automation. This
follows experience in LNA and South Africa where plant throughput
was automated to the lowest component and resulted in reduced
capacity

13. Aggregates and Asphalt
Manufacturing - 2009
Technical Drawings

14. Aggregates and Asphalt
Manufacturing - 2009
Rendered drawing

15. Aggregates and Asphalt
Manufacturing - 2009
Standard Plant Conceptual Design

16. Aggregates and Asphalt
Manufacturing - 2009
New Joliet Plant – Executed Standard Plant