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World Leader in <strong>Platinum</strong>Annual Facility VisitANGLO AMERICANPLATINUM CORPORATIONANNUAL FACILITYVISIT1 March 2002A member of the <strong>Anglo</strong> <strong>American</strong> plc group
World Leader in <strong>Platinum</strong>Annual Facility VisitWESTERN BUSHVELDOPERATIONSPeter KinverDivisional Director:West Mines
World Leader in <strong>Platinum</strong>Annual Facility VisitSafetyCurrent performanceKey issues
World Leader in <strong>Platinum</strong>Annual Facility VisitSAFETYWe are making progress :A reduction in fatality rate (FR) and Lost TimeInjury Frequency RateFR = 0.03 (Last year 0.04)LTIFR = 2.95 (3.75) Target 2002 =1.4Rates compare favourably to platinum andgold industry.Behavioural based safety / continuousbusiness Improvement.Mechanisation (quantum improvement)
World Leader in <strong>Platinum</strong>Annual Facility VisitRUSTENBURG SECTIONA good operational year – cost increase / Pt oz refined–2.0%Expansion phase – despite Merensky slow depletionExploit the shallow massive UG2 reserveTake current production from 1.123m oz (4E) to ±1.5moz(4E)Restructured management, greater focus andaccountabilityReduce and dilute fixed central costs and maintain a goodcost performanceInfrastructure investment (shafts, haulages, rolling stocketc)Mechanisation – productivity/costs (it’s working i.e. labouras total % of cost is decreasing)
Select [Install] and installation starts. Uponfinishing installation, Fig. 7 Setup completionscreen is shown.Fig. 7: Set up completionWhen [Finish] is pressed, setup in completed.Upon finishing setup, "YEC FI Matching System"shortcut is displayed on desktop and on startmenu. Program maybe started from thisshortcut.1–6 Copy of base data1–6–1 Copy proceduresCopy the base data stored in the installed CD to“C:\YMS_DATA” manually.Base dataModel yearModelName of base dataKIT ECU2006YZF-R6R6-06_BaseData_00.ycz2C0-8591A-702007YZF-R6R6-07_BaseData_00.ycz2C0-8591A-712008YZF-R6R6-08_BaseData_00.ycz2C0-8591A-802009YZF-R6R6-09_BaseData_00.ycz2C0-8591A-902010YZF-R6R6-10_BaseData_00.ycz2C0-8591A-912011YZF-R6R6-11_BaseData_00.ycz2C0-8591A-922012YZF-R6R6-12_BaseData_00.ycz2C0-8591A-932007YZF-R1R1-07_BaseData_00.ycz4C8-8591A-702008YZF-R1R1-08_BaseData_00.ycz4C8-8591A-802009YZF-R1R1-09_BaseData_00.ycz14B-8591A-702010YZF-R1R1-10_BaseData_00.ycz14B-8591A-712011YZF-R1R1-11_BaseData_00.ycz14B-8591A-722012YZF-R1R1-12_BaseData_00.ycz1KB-8591A-70CAUTION:Any combination of base data and ECU not shown above will generate an error.Always use one of the above combinations.- 4 -
World Leader in <strong>Platinum</strong>Annual Facility VisitBAFOKENG-RASIMONETeam in place – HRDAccelerated development programmeNorth of mine – complex geology; however,deeper and southern ore – good qualityMining and milling rates building upDuring the year will be up to design throughputTrackless Merensky – started.promisingLooks
World Leader in <strong>Platinum</strong>Annual Facility VisitAMANDELBULT SECTIONAn excellent performanceTonnage/grade and recovery upCosts well controlledStarted mechanisation in shallow UG2Exciting safety initiativesSynergy with neighbouring mines
World Leader in <strong>Platinum</strong>Annual Facility VisitCONCLUSIONSolid base productionExpansion in place and deliveringContinuous Business Improvementpaying off
World Leader in <strong>Platinum</strong>Annual Facility VisitWATERVAL PROJECTPeter van DorssenBusiness Manager
World Leader in <strong>Platinum</strong>Annual Facility VisitAGENDASafetyWaterval as component of RPM(R)Mining overviewConcentrator overviewKey benefits
World Leader in <strong>Platinum</strong>Annual Facility VisitSAFETY REPORT TO DATE2001 Ytd CumulativeTotal Man Hours 392 9863 089 0303 482 016Shifts Worked 386 129 49 123 435 252Non Lost Time Injuries 44 0 44Lost Time Accidents(One Day or More)Serious Injuries(14 Days or More)3 0 31 0 1Fatal Accidents 0 0 0
World Leader in <strong>Platinum</strong>Annual Facility VisitWORLD CLASS SAFETY ACHIEVEMENTSCementation Mining:- 4 Star NOSA grading- Won competition for highest 4 stargrading mine in the Bushveld region- 365 injury free days (18 March 2002)Concor/Group Five Civil Joint venture:- 5 star grading from MBA duringsafety audit- Won regional and nationalcompetition for the best safety systemaudited by MBA
World Leader in <strong>Platinum</strong>Annual Facility VisitWATERVAL PROJECTAnnounced in September 2000Brakspruit, Bleskop and Paardekraalvertical shafts – 200 000 tpmWaterval Mine – 200 000 tpmUG2 concentrator – 400 000 tpmCapital cost R1,310 bn (2000 terms)
World Leader in <strong>Platinum</strong>Annual Facility VisitWATERVAL MINEKEY FEATURES200 ktpm of UG2 oreTwo mining sections (East & Central)3 dip roadways/ shaft, changing to 5Room and pillar mining method20 LHD’s and 14 drill rigsEach shaft to be developed 420m on dipFull production from 3 strike levels/ shaft20 months construction to get to full production(December 2000 to June 2002)
World Leader in <strong>Platinum</strong>Annual Facility VisitGEOMETRYReef dip 9ºMining widthRelative density (reef)Steady state production1,8 m3,34 tons/m³268 000 tons
World Leader in <strong>Platinum</strong>Annual Facility VisitSALIENT POINTSEarthworks: 776 000 m³ incl rockCivils: 30 000 m³Steelwork: 3 400tPlatework: 750tPiping:60km
World Leader in <strong>Platinum</strong>Annual Facility Visit400 KTPM UG2 CONCENTRATOR FLOW SHEETWatervalRustenburgSilo5000 tPrimary CrushingRail Bin2 000 tPrimary CrushingStockpile50 000 tWasteFloatsCrushing/DMSSinksSilo11 000t (Fines)ScreeningSilo7 000t (Coarse)
World Leader in <strong>Platinum</strong>Annual Facility VisitORE RECEIVING ANDCRUSHINGPRIMARY MILLINGPRIMARY FLOTATIONSMELTERCONCENTRATEDEWATERINGCONCENTRATESECONDARY MILLINGCONCENTRATESECONDARY FLOTATIONSLIMES DAMTAILINGS THICKENING
World Leader in <strong>Platinum</strong>Annual Facility VisitWATERVAL MINEKEY BENEFITSShallow UG2Dedicated UG2 ConcentratorMechanised miningHigh efficiencies
World Leader in <strong>Platinum</strong>Annual Facility VisitANGLO PLATINUMCONVERTING PROCESS(ACP)Keith Hines – Plant Manager
World Leader in <strong>Platinum</strong>Annual Facility VisitSTRATEGY ‘95Increasing regulatory pressureHistorical role of SO 2 in environmentalismWorldwide trends in smelter technologyMake virtue of necessity- Improve technology- Better process- Lower costs- Solve problem- No “Bandages”
World Leader in <strong>Platinum</strong>Annual Facility VisitSTRATEGY NOWProduction expandingRegulatory pressure hereExternal interest focus- Local environment- Regulators- International groups- <strong>Anglo</strong> <strong>American</strong> plc
World Leader in <strong>Platinum</strong>Annual Facility VisitSTRATEGY NOWDecouple furnace / converting operationsCreates- Operational flexibility- Siting flexibility
World Leader in <strong>Platinum</strong>Annual Facility VisitPROJECT DESIGN CRITERIA -ENVIRONMENTALReduce sulphur emissions- Current situation = 130 tpd SO 2- DEAT requirements < 20 tpd SOImplications- Acid plant downtime = Smelter downtime- Collection and treatment of converter andfurnace off-gas- New acid plant technology- Improved containment- Process robustness
World Leader in <strong>Platinum</strong>Annual Facility VisitPROJECT DESIGN CRITERIA -ENVIRONMENTALHourly SO 2 ground level concentrations (GLC)exceedences < 2 per yearImplications- Collection of substantially all secondaryoff-gas sources and emit via stack(s)- Improved containment at source
World Leader in <strong>Platinum</strong>Annual Facility VisitPROJECT DESIGN CRITERIA - PROCESSIncrease capacity for future production forecastsMaterialWaterval FurnaceMatte (WFM)Union FurnaceMatte (UFM)MinimumAnnual Capacity(tpa)ProductionDesign122 000 tpa 186 000 tpa26 800 tpa 26 800 tpaNickel in Cathode<strong>Platinum</strong>Production *21 000 tpa 30 000 tpa~2.1 million oz ~3.6 million oz
World Leader in <strong>Platinum</strong>Annual Facility VisitMonthly Average Output of Plant for '99Gas EmissionsFugitive22%Waterval ConverterMatte20%WatervalFurnace Slag4%PRESENT DESIGNGas EmissionsControlled28%FUTURE DESIGNNumbers have been rounded to thenearest whole numberSulphuricproduced26%Monthly Average Output of Plant forFuture DesignSulphuricProduced73%Gas EmissionsControlled2%Gas EmissionsFugitive1%Waterval ConverterMatte21%WatervalFurnace Slag3%
World Leader in <strong>Platinum</strong>Annual Facility VisitCOMPARATIVE OPERATIONAL COMPLEXITYNo. of UnitsPIERCE SMITH3 Running, 1 Hot S/by2 RebuildingACP1 Running1 S/by within 7 DaysCapacity2.3 million Pt oz3.5 million Pt ozCycle Time/End Pt7 hrs - 12 hrs (ave)3 hrs (min) O2 Enrich.3% ± 0.5% Fe22% ± 0.2% SFeed MaterialMolten WatervalFurnace Matte andCold UFMGranulated MatteMulti furnace feed
World Leader in <strong>Platinum</strong>Annual Facility VisitPROJECT TIMETABLE2000200120022003 2004First Tap88% Fixation Potent.Stage ATwin streams toAcid Plant 98%FixationPhase 1Design and Construction forGranulation, Converter, AcidPlant and AncillariesPhase 2HotCommissioningand OptimisationStage BPhase 3 Phase 4Design andconstruction forElectric FurnaceGas TreatmentHotCom &Opt
World Leader in <strong>Platinum</strong>Annual Facility VisitPROJECT BENEFITSMeets environmental emission requirements– sustainable developmentMaximises economic recoveryProvides scope to satisfy <strong>Anglo</strong> <strong>Platinum</strong>’sshort and medium term expansion goals
World Leader in <strong>Platinum</strong>Annual Facility VisitANGLO AMERICANPLATINUM CORPORATIONANNUAL FACILITYVISIT1 March 2002A member of the <strong>Anglo</strong> <strong>American</strong> plc group