1

SLN Ferronickel Slag is a proven construction material with more than 80 years of experience in New Caledonia

FNS: a promisingconstruction materialfor the Pacific Region

Le

L e N i c k e l – S L N

• Stable and homogeneous material over the years: ~ 2 millions tonnes/year

• Stock of 25 millions tonnes available 1,200 nautical miles from NSW

• No processing required for qualification as sand material (O/4)

• No particular risk identified as concrete aggregate (nil free magnesia, no sign of ASR nor DEF in aged concrete)

• No health risk (nil crystalline silica)

• Low sulfate and Chloride content

• FNS helps to reduce your carbon footprint.

53 374

136 years

2 millions

Tonnes of nickel produced in 2015SLN is the world’s largest

ferronickel supplier.

SLN Le Nickel has beenestablished in New Caledonia for

Tonnes of slag produced each year

SLN complies fully with

Wide range of uses

ISO 9001& ISO 14 001

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• Based in New Caledonia, the SLN is now ready to bring to the Pacific market a promising and sustainable material for the construction industry.

• Ferronickel Slag is a by-product of the Ferronickel produced by SLN (leading world producer) at its plant in Noumea for the last 136 years.

• FNS is obtained using a proven method ensuring a building material of high quality and homogeneity.

• “Le SLAND” is a new competitive and environmentally friendly material for the construction.

LE SLAND : A NEW CONSTRUCTION MATERIALCORRESPONDING TO AUSTRALIAN AND EUROPEAN STANDARDS

Physical description 4

Product qualification to European standard 5

A dual use of the SLN Ferronickel slag 7

Product qualification to Australian standard 5

Project timeline 6

Sand replacement 7

Supplementary cementitious material 10

Le SLAND, supporting greenhouse gas emissions reduction

«Le SLAND» is an industrial byproduct. This material can either be part of a supplementary cementitious material or replace natural sand in construction industry. That’s why SLN Ferronickel Slag is an environmental friendly construction material.By using «Le SLAND» your company will reduce its Greenhouse gas emissions (using a by product instead of sand or SCM, less transport emissions by ship than by trucks from a career etc).

CONTACT

Phone : + 687 24 55 55

o.chazalmartin@eramet-sln.nc

www.sln.nc

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60,00

50,00

40,00

30,00

20,00

10,00

0,00

Si02

Sample P1

Sample S1

Sample S5

Sample S6

MgO Fe203

%%%

11

1112

12

3333

3333

53

5352

52

(3) Major and minor components of slag

Physical description

(2)

Screen Xf (%) Tolérance(%)0,063 0,6 210,125 10,25 3 230,5 101 34 242 77 -4 99 -

5,6 100 -8 100 -

Nombre d'analyses

mm

1

SiO2 53,30% Al2O3 2,30%MgO 32,90% MnO 0,50%

Fe2O3 10,90% CaO 0,20%

Résultat de production

Pass

ing

(%)

Elements majeurs et mineurs :

0102030405060708090

100

0,06

3

0,12

5

0,25 0,5 1 2 4

5,6 8

Screen Xf (%) Tolérance(%)0,063 0,6 210,125 10,25 3 230,5 101 34 242 77 -4 99 -

5,6 100 -8 100 -

Nombre d'analyses

mm

1

SiO2 53,30% Al2O3 2,30%MgO 32,90% MnO 0,50%

Fe2O3 10,90% CaO 0,20%

Résultat de production

Pass

ing

(%)

Elements majeurs et mineurs :

0102030405060708090

100

0,06

3

0,12

5

0,25 0,5 1 2 4

5,6 8

Extremely high

homogeneity over time

A by-product of nickel smelting (slag granulated with seawater), SLN Ferronickel SLAG (FNS) is a raw material:• production around 2 million tonnes/year• existing stockpile: 25 million tonnes

• Extremely clean sand (methylene blue test)

• Partical size distribution

• Chemical analysis• Low sulphate and chloride content• Characteristics and properties of a very homogeneous slag (4 samples - from several months to several decades)

Valeur de bleu et d’équivalent de sables.(1)

Sample

No washing required

(Note: 1-2-3 : CERIB, France)

5

Physical description

SiO2 MgO FeO Al2O3 Cr2O3 CaO Mn Ni Co TotalGlass 1 55,31 32,43 8,96 2,81 0,95 0,14 0,31 0,033 0,008 100Glass 2 55,19 32,05 8,83 2,84 0,91 0,16 0,32 0,037 0,009 100Glass 3 58,89 18,00 15,61 4,94 1,82 0,41 0,69 0,000 0,009 100

Forsterite 50,32 41,18 6,38 1,31 0,58 0,05 0,20 0,071 0,004 100Enstatite 55,76 31,49 8,85 3,05 0,90 0,16 0,31 0,021 0,012 100

Si Mg Fe Al Cr Ca Mn Ni Co TotalFerroNickel 0,27 0,34 37,72 0,06 0,08 0,00 0,02 59,78 0,89 100(4)

(Note: 4 : ERAMET Research, France)

• Mineralurgical phases analysis• FNS is mainly made of vitrified magnesium silicate, Forsterite ((Mg,Fe)2SiO4) and Enstatite ((Mg,Fe)SiO3)• FNS contain nil free magnesia (no concrete expansion due to FNS)• FNS contain nil crystalline silica (quartz, tridymite, cristoballite)

Crystalline phases are limited to Forsterite and

Enstatite.No trace of Periclase

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Product qualification to Australian standard

Product qualification to European standard

One study is conducted by the Department of Civil Engineering at Curtin University, Australia for applications as supplementary cementing material and sand replacement.

Preliminary results show that FNS is adapted to civil work applications according to the petrographic testing performed by SGS Australia.

The second study is developped by the Precast Concrete Industry Study & Research Center (CERIB), France for applications as sand replacement material.Both studies aim to assess the compliance of the new product with Australian and European requirements for different types of applications.

So far, all results are probing and very promising.

(5)

Risk Rating for Application Low Mod HighComments (assuming the sample is indi-cative of overall source rock quality)

Concrete Aggregates • Robust material which may be included as aggregate

Unbound Pavements •Suitable for use with Portland cement as binder for stabilisation in road construc-tion and as pavement material

Rail Ballast • Suitably dense and durable material as coarser slag

Asphalt Aggregate • Very hard and offer potential as non slip hot mix asphalt

FNS is considered

a 0/4 coarse sand without any transformation.

(Note: 5 : CERIB, France)

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Project timeline

At Curtin University, Perth, Dr Prabir Sarker* is working on the qualification of FNS to Australian standard.

(*) Preliminary results presented at the 27th Biennial National Conference of the Concrete Institute of Australia, Melbourne, 30 August – 2 September 2015, pp. 788 – 797.- Rahman, M. A. Sarker, P. K. Shaikh, F. A. (2015). Fresh and early age properties of cement paste and mortars blended with SLN Ferronickel Slag.

www.sln.nc

Tests carried out at CERIB, France, show no trace of ASR nor DEF.

Completion of thesis - Supplementary cementing material with FNS “Le Sland”/Curtin Univ

end of 2016

Completion of CERIB concrete testing (apart from durability testing) beginning of 2017

Concrete qualification by CERIBOctober 2017

Completion of thesis - Sand-FNS “Le Sland”/Curtin Univend of 2017

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Sand replacement

It has been shown in the laboratory and demonstrated during highway and rail construction projects (refer to work by Wang and Thompson 2011 and Eemery 1982) that air-cooled, crushed nickel slag is an excellent aggregate in granular road base, rail ballast, engineered Portland Cement fill and hot mix asphalt. Petrographic Inspection Report – GROUNDWORK plus (environmental management and land use planning consultancy specialising in the quarry, mining and urban development sectors)

Traditional construction use (already used by PAMCO, Sumitomo Metal Mining, Posco Cunico, Falconbridge, Larco): backfilling, concrete aggregates (accropode units, road works, block works or precast walls).

• Traditionnal applications

• Workability

Flow values improved with the increase of FNS up to 50% of sand replacement and then decreased

• Normal consistency of paste • Setting time

Reclaiming land or road works Accropodes Sand for blockwork

Flow value test :A • 100% sand B • 50% FNS and 50%

sand

A B(1)

Flow value of mortar mixesBinder with 30% fly ash and 70% cement Binder with 100% cement

Ratio Water/C is kept constant at 0.47

0 20 40 60 80 100100105110115120125130135140

Substitution rate sand by FNS

%

(2)

Decrease of water content with increase of sand replacement

by FNS

(3)

Ni: Not displayed on technical specifications.

Initial setting time (mn)Final setting time (mn)

Sample ReferenceCEM I

ReferenceCEM II

(4)

(Note: 1,2, 3 : Curtin University, AustraliaNote: 4 : CERIB, France)

A dual use of the SLN Ferronickel slag

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• Relationship of FNS content with compressive strength

Compressive strength increases with sand replacement with an optimum ratio of 50%.

• Alkali Silica Reaction (ASR) analysis

From a preliminary analysis, FNS may present risk of ASR in concrete due to the content of flint above 40% (glass component) as per FD P 18-542.Assessment regarding ASR potential of the aggregate has been as well analysed by AS1141.65-2008.

• Image showing three grains of FNS in the concrete mix

Scanning electron microscope observation of a 20 year old accropode unit

(5)

P1 S5 S6

RATIO C/G = 0,5 0,59 0,22 0,44

RATIO C/G = 1,25 0,48 0,18 0,33(6)

(Note: 5 : Curtin University, AustraliaNote: 6, 7 : CERIB, France)

(7)

Sample

Slag 1

Slag 2

Slag 3

No sign of ASRNo sign of DEF

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Supplementary cementitious material

• A NEW PRODUCT developped by the SLN

A hydraulic binder: More than 3 years of ongoing research at Curtin University showing pozzolanic properties.

• Strength activity index of FNS(FNS was ground to a Blaine’s fineness of 500 m2/kg).

Result: Department of Civil Engineering Curtin UniversityActivity index at 28 days is 84% thus above the value required by the ASTM standard (75%).

• Compressive strength of concrete mixes with different percentages of nickel slag replacing cement

Replacing cement with FNS still allows to reach high level of resistance.

• Expansion testLe Chatelier expansion of the mixtures varied from 0,42 to 1 mn, decreasing with the replacement of cement by FNS.

SI No Composition Mean 7 days strength (Mpa)

Mean 28 days strength (Mpa)

Strength activity Index7 days 28 days

1 Control 31 3774% 84%

2 20% slag 23 31(8)

(9)

MPA

Days

Values of expansion are well below 5 mm, which is the limit according to Australian standard.

A Mortar, concrete

(Note:8, 9: Curtin University, Australia)

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Up to 40% of the total cost for mudcrete process are related to the cost of cement.

• Rapid Chloride Permeability Test (RCPT) analysis

Replacement of cement with FNS reduce chloride penetration in concrete.

• Mining backfilling

Where cemented backfilling is used, 10 to 20% of the total operating cost of the mine are related to backfilling. Cement represents up to 75% of the backfill cost.

0 20 40 60 800

0,20,40,60,8

11,2

mm

% cement replacement with FNS

• Mudcrete

(10)

Suitable for harsh

environments

Nil expansionNil free magnesia

TYPEChloride Penetration (Coulomb)

28 Days IonPenetrability 90 Days Ion

PenetrabilityControl 1590 Low 1258 Low

20 FNS 80 C 1520 Low 715 Very Low30 FNS 70 C 1815 Low 958 Very Low40 FNS 60 C 1503 Low 1065 Low40 FNS 10 BS 1120 Low 856 Very Low50 FNS 50 C 1254 Low 713 Very Low65 FNS 35 C 1059 Low 508 Very Low(11)

÷2,5

B Alternative binder

(Note: 10, 11: Curtin University, Australia)

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Japan

Australia

4,371 Miles

1,124 Miles

1,224 Miles

New Zealand

New Caledonia

New Caledonia - Key AdvantagesSLN is a major source of ferronickel slagfor its neighbours in the Pacific Region

French territory

268,767 inhabitants

GDP per capita: $44,442 AUDReal GDP growth rate : + 1.30 %

2015 total exports : $ 1.7 billion AUD2015 ore and nickel metal exports : $1.5 billion AUD 95,276 tonnes (nickel metal) 5.5 million tonnes (nickel ore)

New Caledonia’s currency is pegged to the Euro Major global businesses in New Caledonia :

www.cci.nc

For more information :

www.adecal.nc

www.sln.nc

Le

L e N i c k e l – S L N