Magazine for customers of Kopar Oy
NEWS .1/2013
No
“...this is a major step forward in strengthening our expertise and enhancing our professionalism.� Samuli Saarela - Kopar Q&D Manager
EN 1090-1 certified silos Read more on page 3
R & D news on page 5
Project delivery story on page 6
Steam Dryers improve smelting processes
Saudi ilmenite and a new elevator
Experience. Reliability.
Kopar News 1|2013
Editorial
Dear Reader, We live in tough times. The economic situation is rather dark. However, as far as I can judge, luckily Kopar has not experienced the bad period of time in all its severity although our situation could be better. During the almost 25 years of operation, we have experienced both the good and bad but none impossible to overcome. Over the last years we have done our best to make sure we survive the not-so-good times as well. For instance, we have continuously expanded our product range by improving existing products while also designing new ones. The latest Kopar innovation is our first-ever steam dryer that is a major improvement in comparison to the existing drying equipment. We do have great expectations that our dryer will be a success. It improves the drying process while reducing gases and is therefore a vital economical and environmental asset to the customer. In the past few years including the current one we have also invested in our sales network. Many new channels have been opened and while knowing it takes time to establish a new market and materialize results, we are confident that rather sooner than later the investments will prove fruitful. We have new presence in China and India, in Russia and in many of the Balkan states as well as elsewhere in Central Europe. One positive piece of news is the EN1090-certification Kopar received in September 2013 amongst the first Finnish silo suppliers. This was a great achievement and shows the dedication we have in producing quality. The world has become so turbulent and hectic that predicting the distant future is rather impossible but since we have survived even more drastic years and are used to tackle the ups and downs of the business, Kopar continues as a reliable partner and supplier to our enlarging customer base.
Hannu Penttilä, CEO Kopar Group
In this issue
Experience. Reliability.
Magazine for customers of Kopar Oy
NEWS .1/2013
No
“...this is a major step forward in strengthening our expertise and enhancing our professionalism.” Samuli Saarela - Kopar Q&D Manager
EN 1090-1 cERtifiEd silOs
Kopar News 1|2013
Read more on page 3
R & D news on page 5
Project delivery story on page 6
steam dryers improve smelting processes
saudi ilmenite and a new elevator
Saudi ilmenite and a new elevator 6 Lime silo to a gold digger
6
Andritz: a series of repeat orders
7
Kopar - a certified silo manufacturer
3
Smelting Copper 7
Storing bulk materials
3
Pellets in Ähtäri
China - a world of opportunities
4
Appointed 8
Arcon to strengthen customer support
4
Offices integrated 8
Steam dryers improve smelting processes
5
Biathlonist sponsored
7
8
Experience. Reliability.
Kopar News is published once this year. The use of the content is allowed providing that the original source is referred to Editor: Erika Hietamäki
info@kopar.fi
Editorial material: IntComm / Heikki Harri
www.kopar.fi
Layout: Sari Peltomaa Printed by I-Print Oy, Seinäjoki, Finland 2013
Kopar Oy
SITE Teollisuus Oy
Elmomet Oy
Kopar Baltik AS
Head office, Sepänkatu 2
Keskustie 2
Pyöräisentie 2
Uhtna Sõmeru Vald
FI-39700 Parkano,
FI-63500 Lehtimäki,
FI-63500 Lehtimäki,
44202 Lääne-Virumaa
Finland
Finland
Finland
Estonia
Tel +358 3 440 180
Tel +358 3 440 180
Tel +358 207 599 930
Tel +372 32 23028
Fax +358 3 440 1811
Fax +358 6 487 2621
Fax +358 6 527 1743
Fax +372 32 23029
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Kopar News 1|2013
EN1090 CERTIFICATION
The first CE-marked, leaving the Kopar Lehtimäki factory.
Kopar – a certified silo manufacturer Kopar Group is one of the first Finnish manufacturers of silos who have received the European product certification in accordance with the EN 1090-1 standard allowing the CE mark to be attached to silos. This product certification will be required from all silo suppliers for silos that are delivered after July 1st 2014. However, some customers require it already now and so Kopar decided to qualify well in advance. The EN 1090 harmonized standards regulate the fabrication and assembly of steel and aluminium structures and are recognized by the Construction Products Directive. The standard comprises of three parts: 1. Requirements for conformity assessment of structural components (CE marking); 2. Technical requirements for the execution of
steel structures; 3. Technical requirements for the execution of aluminium structures. “There is a lot involved in this process, already in the past but more so in the future. The new standards affect almost every aspect of our fabrication process starting from the design and ending in the final assembly. One particular emphasis is on the welding process,” explains Samuli Saarela, Q&D Manager and IWE (International Welding Engineer). There are many details that need to be addressed in the whole process. The designing includes new tasks, there are new projectrelated requirements, and some parts of the manufacturing process are faced with testing requirements for approval. The most
demanding internal quality control of silo fabrication is to be surveyed by an International Welding Engineer and also by a Notified Body. “For Kopar this is a major step forward in strengthening our expertise and enhancing our professionalism. The achievement gives us confidence by affirming that we are on the top level of manufacturing and providing the highest quality equipment for our clientele. With the CE mark the suitability of the product is ensured,” Samuli Saarela concludes.
growing business
Storing bulk materials – Reactivating old silos and tanks Accumulation of large amounts of ash in power plants and many other bulk materials in other process industry installations may sometimes prove tricky due to the fluctuations in the need of materials by the eventual end customers. Due to more strict environmental regulations and higher dumping cost, reusing many types of bulk materials has become a growing business. One example of this is the cement industry that can easily use ash as raw material. Other such bulk materials include cement, pulverized limestone, quicklime, hydrated lime and gypsum. The main aspect is that the material must be dry, running or very fine. “However, there are cases when the endcustomer’s process cycle does not coincide with the bulk material producer’s production schedule and therefore there are situations when the material requires a place for temporary storing. There might be several reasons like balancing the production and demand, service and maintenance breaks and so forth,” clarifies Unto Kivinen, Sales Director. For instance, the production of ash at power plants is an on-going process and may amount to thousands of tonnes every month but cement factories on the other hand need it only on their peak times dictated by their customers. Somehow and somewhere the
“
When an old structure can be turned into a store it is a very cost-effective investment.
excess material needs to be stored. “A practical solution is to find a relatively flatbottomed old silo, an oil tank or a concrete bunker that can be refurbished and then reused to store the material. Old, abandoned or nonused structures do not exist everywhere but Like in this case, it is possible to convert an old silo to new use with minimum cost in comparison to building a new one.
“
construction a new storage building. The total cost might be as low as 10 % instead of a new one. Technical requirements
In a conversion process there are some basic requirements concerning the building itself. It has to have strong walls and a relatively flat bottom. The bottom needs to be slightly conical with a 7 to 8 degree angle in most cases towards the centre. On the other hand, this is not an overwhelming obstacle, since the material can be discharged to the required direction with fluid slides. From the design point the building needs the unloading system on the top, added with the needed number of pneumatic conveyors, compressors, automation, and the level control, among other gear and equipment.
we have done this type of conversions and know that they can be occasionally found,” he continues. The economy is the key factor. When an old structure can be turned into a store, it is a very cost-effective investment in comparison to
Every conversion project is different and requires quite a lot of design and engineering work. One very important factor in the design and implementation is safety. “There are many safety aspects that need to be taken into consideration. However, Kopar has delivered so many silos and other installations that also in the design of safety features, that we have a proven track-record,” Unto Kivinen emphasises. 3
Kopar News 1|2013
Kopar sales network
China – a world of opportunities As part of the company’s expansion strategy, Kopar is approaching China, too. Kopar is now linked with a Chinese trading house to better serve both global and local customers in the country. Last year Kopar started to co-operate with Ekpac, a trading house with origins in Sweden dating back to the 17th century. Early on, in 1910, the company established itself in China. Today Ekpac has offices in Beijing, Shanghai and Hong Kong. Ekpas offers goods and services in to many industries and Kopar technology complements the Ekpac offering very well.
electricity, for instance. Half of the electricity is produced by coal and environmental issues are becoming more and more important. Here Kopar has the chance in modernizing the existing power plants so that they become more efficient and environmental friendly. In fact, this market segment alone is huge.” Bio fuel is another market segment that has a priority in China. “Kopar has delivered a lot of
equipment and systems to many bio energy power plants and can utilize the expertise in China, as well,” Liu Feng says. Ekpac also plans to contact Chinese exporters. “Companies that export their goods, need to have processes that are quality-wise on a higher level than those who only sell to the home market. “This is another lucrative market area to search,” he concludes.
The representatives of Arcon and Ekpac spent a week in Finland in May 2013.
“China is, naturally, a country where there is a lot and extensive competition, but if there is a company like Kopar that can offer unique technology, the market is open. In China it is also a well-known fact that Finnish products generally speaking represent a very high standard and quality, which naturally helps to market them,” explains Liu Feng, who manages Ekpac’s office in Shanghai. As a target country, China offers quite a few opportunities as Liu Feng clarifies: “China is constantly working on to produce more During the visit they got acquainted with Kopar products both in theory and practise.
Arcon to strengthen customer support in many countries Arcon Overseas Ltd is an international company providing goods, equipment and services through offices in many countries in Europe,. Headquartered in the UK, the main line of its operations is concentrated around different process industries. Recently Kopar and Arcon have co-operated in several power plant related projects providing Kopar technology with local Arcon customer support. Kopar and Arcon are co-operating for instance in the Czech Republic, Slovakia, Croatia, the Balkan region and Russia. The aim of the co-operation is to improve customer service. These countries offer relevant opportunities particularly in the mining and power and 4
energy industries. A group of Arcon executives visited Finland in May, 2013 to learn more about Kopar and its product offering. Here are some comments made by them. “In Russia, there is a huge potential in ash handling processes in power plants. Traditionally, the operations are based on wet ash although the dry ash handling system is much more efficient and friendlier to the environment. The potential is huge due to the fact that in Russia there is only one power plant based on dry ash,” explains Yevgeny Andronov from the Moscow office. Naturally he looks positively to the future.
Zeljko Dedic is Sales Manager of Arcon’s office in Croatia. They also cover the other countries of the former Yugoslavia and Albania. “In our territories there a lot of projects in fly and bottom ash handling. We will be very busy in years to come,” he says. Arcon’s Czech office was represented by Václav Presl and Martin Holík. The office also covers Slovakia. They have provided the market with Kopar technology solutions for five years already. “In the two countries we operate the energy and power sector offers the biggest potential. Particularly ash handling will be in our prime interest,” the Czech gentlemen explain.
Kopar News 1|2013
new kopar design
Steam dryers improve smelting processes After years of intensified thinking and careful engineering Kopar has designed a new type of steam dryer for smelters. The new dryer offers many features that clearly make it a major upgraded step in comparison to existing dryers. The dryer offers saving in energy and in particular, reduces the amount of exhaust gases and is therefore a real environmental improvement. Most smelters produce steam as part of the process, and therefore using steam is also very economical compared to outside energy sources.
This is a typical flow-sheet of Kopar steam dryer application.
Traditionally, many kinds of rotating drum dryers have been used to dry the concentrate before it enters the smelting furnace. Approximately 15 years ago the first generation of steam dryers emerged and also a second generation was designed. “At Kopar, we decided to take the steam dryer concept to a new, third generation level, since the present steam dryers still have quite a few weaknesses,” explains Olli Tiitu, Senior Advisor and the man behind Kopar’s steam dryer development. A lot of new features
The dryer has got two patents, the first one for Finland and the second, in July 2012, by the European Patent Office for “A Rotating Steam Dryer Apparatus”. The patent basically is about the arrangement
of the heat pipe system consisting of heat transfer elements. The heat pipes are corotating, which results in less mechanical wear of steam tubes. “This feature is, indeed, the most important improvement. The construction of the former steam dryer types has not been able to solve the wear factor, and a lot of time and money is spent in replacing the pipes,” Olli Tiitu says. Further improvements features:
include
following
√√ √√ √√ √√ √√ √√
no pressurized pipes in supporting contact; no massive construction inside the dryer; less steam distributing hoses; easy maintenance; high heat area to drum volume ratio; low length to diameter ratio.
In addition to the above technical features, the new dryer also offers many process improvements. The structure allows a lower drying and concentrate temperature decreasing the SO2 contamination and low amount of exhaust gases. Furthermore, the dryer is easy to control and has a high loading degree.
The picture shows the patented steam pipe arrangement without the shell.
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Kopar News 1|2013
saudi arabia
Saudi ilmenite and a new elevator Cristal Global, based in Saudi Arabia, is the world’s second largest producer of titanium dioxide and a major producer of titanium chemicals. In 2012 the company finalized the plan to build a green-field ilmenite processing plant in Jazan Economic City near the west coast. The plant will be contracted on a turnkey basis by the Finnish company Outotec. The value of the contract is over 350 million euros. Kopar is part of the major project, which is scheduled for production in 2014.
significantly. The weight of an elevator is now 25 tonnes, which is 4,500 kg less than earlier. The width is now 2.0 m instead of the earlier 3.0 m. The changes make a clear difference in the space and the supporting structures,
The initial production rate of the titanium slag is estimated 500,000 tonnes but the installation allows the production to increase up to a million tonnes. Simultaneously, the plant produces 235,000 tonnes of high purity pig iron as a valuable co-product. Re-designed granulation elevators
For the project Kopar supplied four elevators with a new design. The drive unit was redesigned by using winch gear systems that allow reducing the weight and width
among other things. Kopar supplies four of these re-designed elevators for handling the granulated titanium slag. The elevators have a height of 20 m and a
capacity of 100 tph. They are made of acid proof steel because of the slag’s high abrasiveness. The elevators are used to transport granulated slag from the granulation tank to the downstream belt conveyors. They are equipped with perforated buckets to remove excessive water from the slag granules. They weigh almost 25t and once installed have on inclination of 40º from vertical. The drive motors are equipped with a system to prevent overheating, which an important feature in Saudi conditions. They also are equipped with automatic lubricators to ensure proper lubrication of all critical points. The elevators are moved up and down with hydraulic cylinders that are installed beneath the elevator. The movements are controlled by inductive sensors but the are also mechanical limit switches as backup. Furthermore, both the lifting and return speeds can be adjusted.
finland The silo in Kevitsa is used for storing lime.
Lime silos to miners The Kittilä mine located in the Finnish Lapland and owned by Agnico Eagle is the biggest gold mine in Europe. The commercial production started in 2009 as an open pit operation but now the mine is working only underground. The mine life is estimated to 2027, so there is a lot to expect from this quite extraordinary operation.
The change was performed as economically as possible. Once the new silo was on the site, the unloading system was removed from the old silo, the customer made the necessary changes to the base and demolished the old silo. Then Kopar erected the new silo and installed the unloading equipment.
Earlier in 2013, Kopar supplied a 200m³ silo to the mine. It was an update project replacing an older 100 m³ silo because of the mine’s need to add more space for storing lime, which is used to control the pH value in the concentration process.
This was not the first delivery by Kopar to mines located in the Finnish Lapland. In 2011 Kopar delivered two 180 m³ silos to the Kevitsa mine owned by First Quantum Minerals.
6
Kopar News 1|2013
Austria
showcasing kopar professionals
Andritz: A series of repeat orders Andritz is an Austria-based international group with presence in tens of countries and a total workforce of almost 24,000 people. Andritz is a globally leading supplier of plants, equipment and services for hydropower stations, pulp and paper industry, metal forming and steel industry, and solid/liquid separation in municipal and industrial sectors, among other things. Over the years, Kopar has co-operated with Andritz in numerous projects and has supplied to Andritz-led projects a lot of equipment. Recently Kopar has received many orders from Andritz to various projects located in the UK and Sweden. In the UK the end-customer was the Workington Mill located in Cumbria, England’s northeast. The mill is part of the Swedish company Iggesund Paperboard, which belongs to the Holmen Group. The mill produces approximately 200,000 tonnes of multi-layered folding box board annually.
project manager
Jukka-pekka huhtamäki
The Kopar main delivery to the site in 2012 included five pneumatic conveyors, a 150 m³ fly ash silo, dry and wet ash discharging equipment and piping. The ash is unloaded to trucks. To one power plant of the Swedish Karlstad Energi Kopar got the order of one pneumatic conveyor to move bottom material, and six pneumatic conveyors to move fly ash, and piping. The project is part of an expansion of the Heden recycling centre located next to the power plant. The delivery takes place in February 2014. The third Andritz order consisted of equipment the power plant of Växjö Energi, also in Sweden. There the scope is to handle bottom ash in their new Sandvik 3 installation. The order included a 75 m³ storage silo with a dry material discharge system, an elevator and a drag chain conveyor, three pneumatic conveyors and a lot of piping. The delivery takes place in the early part of 2014.
Jukka-Pekka Huhtamäki is one of the older Kopar individuals, since he joined the company in 1987. Now he works in the Lehtimäki office as project manager in domestic sales. His specialty is in pneumatic conveying of ash and cement and one of his further specialties is to act as the technical expert in matters where stainless steel is involved.
central europe
“I find my work stimulating. Process industries as a whole are so diverse and every project offers something
MOVING SMELTER DUSTS
new that oftentimes requires my whole brain potential to offer the customer a solution for his particular problem. Almost on a daily basis I can improve my knowledge and enhance my capacity to get the right
During the on-going year Kopar has concluded two large contracts with a major European copper producer. The scope of each delivery includes mechanical heavy-duty material handling equipment used in various parts of the smelter process, namely drag chain conveyors, slag crushers, rotary feeders and bucket elevators.
Further details or the value of the contracts are not disclosed.
answer,” Jukka-Pekka Huhtamäki explains. “My job is almost all about moving powered materials, which is the basic standard element in pneumatic conveying.”
“These types of orders are important to us. The first one of the orders was actually the biggest single order this year and the second order clearly showed that the customer relies on Kopar expertise and equipment,” comments Erika Hietamäki, Export Manager.
“One the most interesting projects in my career was geared around transporting cement from Germany to Finland. In this case it was a question to import special grade cement to Port of Hamina in southeast coast of Gulf of Finland and transporting it by trucks to nearby Kotka where the material was used as an ingredient in the production of cement tubes that were used to construct the North Stream natural gas line from Russia
finland
to Germany. There were many interesting details to solve in the project,” he says.
Pellets in Ähtäri
In his spare time he is a motorcyclist in the summer. He also is an active rabbit hunter but does not shot the animals. Instead, he hunts rabbits only to train hunting dogs.
Ähtäri Energy’s power plant in central Finland is a long-term client for Kopar. The latest delivery was about handling peat pellets. The order consisted of a 60 m³ silo to store pellets. The respective equipment consisted of a feeder, compressors, screw conveyors and piping. 7
Kopar News 2|2012
appointed
Mr Juha Paronen, Master of Science, Mechanical Engineering, has been appointed Engineering Manager of Kopar Group. His initial duties include developing the design functions and coordinating the CAD and documentation processes. He also will develop and implement a modular product structure. He is based in Kopar’s Tampere office. He has a long career in various Finnish companies in design and development functions
Mrs Sari Peltomaa, BBA, joined Kopar in early 2013 as marketing assistant based in the Parkano office. She also assists in sales and export projects. Previously she worked in a newspaper as graphic designer. The BBA theses she performed on behalf of Kopar in summer 2012.
new modern office
Offices integrated Five years ago Kopar acquired two companies, Site Teollisuus and Elmomet to strengthen its product offering and expertise. Both companies were located some 150 km to northeast of the town of Parkano, location of Kopar headquarters. Few years back a group-wide technology centre was established in the former Site office. The distance between the technology centre and Elmomet’s fabrication facilities was 25 km which caused various moments in car while engineering personnel travelled back and forth
Kopar in sports
Here part of the technology centre personnel enjoying the modern and more effective work environment.
between the locations. Fortunately, there was a modern office building vacated in the town of Lehtimäki close to Elmomet and in January 2013 Kopar technology centre moved there. “This change improves internal communication and co-operation. Now that our technology centre is located within walking distance from the workshop, the information flow from design and engineering to manufacturing is much more fluent. Also the new situation makes operations more effective from the R&D point of view,” says Hannu Penttilä, CEO.
Regular training is essential to succeed in biathlon, also in summer.
Biathlonist sponsored Rita Nurmenrinta is a young lady who despite of her 20 years of age has already managed to become one of the top biathlonists in Finland and clearly aims to world top. Rita’s home is in Parkano and Kopar, headquartered in the same town, is sponsoring her. So far Rita has won several gold, silver and bronze metals in the proper biathlon and in its summer equivalent that is done with roller skies. All of this has taken place in national events but the aim now is to enter the international front. “I’m full of driving energy now and have set up the goal for several years ahead. Biathlon is a sport that requires many years to develop if one wants to reach the top. I will be 21 this year and the world top is usually achieved only between 25 and 30 years of age,” she explains. She started competing in cross-country skiing at the age of eight, so the athletic career is already quite long. Rita’s personal life includes plans to study to become a personal trainer with added skills in massaging. Before that however she moves to Lapland to study the Lapp language, a small language spoken in the North. This is because she wants to learn the mother tongue of her mother who originally is from the most northern community in Finland.