ANNUAL FACILITY VISIT 5 March 2003 A member of the Anglo American - - PowerPoint PPT Presentation

World Leader in Platinum Facility Visit March 2003

ANGLO AMERICAN PLATINUM CORPORATION

ANNUAL FACILITY VISIT

A member of the Anglo American plc group

5 March 2003

World Leader in Platinum Facility Visit March 2003

POLOKWANE SMELTER

Duncan Wanblad

General Manager: Process Projects

July Ndlovu

Polokwane Smelter Manager

A member of the Anglo American plc group

World Leader in Platinum Facility Visit March 2003 TWICKENHAM MIDDELPUNT HILL PP RUST LEBOWA MODIKWA BARPLATS CROCODILE RIVER HARTEBEESTPOORT RPM RUSTENBURG IMPALA STYLDRIFT

Lydenburg Mokopane Witbank Zeerust Rustenburg Warmbaths

PRETO RIA NORTHAM

WESTERN BUSHVELD EASTERN BUSHVELD

RPM UNION RPM AMANDELBULT WESTERN AND EASTERN PLATS BRPM

ONGOING AND EXPANSION OPERATIONS ORIENTATION

N

Polokwane

DER BROCHEN

World Leader in Platinum Facility Visit March 2003

LOCATION OF SMELTER

World Leader in Platinum Facility Visit March 2003

SMELTER TECHNOLOGY

Key Drivers Capacity Environmental Mineralogy Operability Costs

World Leader in Platinum Facility Visit March 2003

SULPHUR DIOXIDE MODEL

B

Palmie t fon te in Si te

0m 5000m 10000m

125 100 40.46 24.27

20 40 60 80 100 120 140 Concentratio n (u g/m

On-site Off-site Nature Reserve Polokwane

Max Da i l y Gu ide l ines fo r SO2 (µg /m3) South Africa 125 USEPA 365 WHO 125 World Bank 125 EU 250 to 350

World Leader in Platinum Facility Visit March 2003

PARTICULATES MODEL

Max Da i l y Gu ide l ines fo r P M10 (µg /m3)

0m 5000m 10000m

32 10 0.58 1.72

5 10 15 20 25 30 35 Concentra tion (ug/m

On-site Off-site Nature Reserve Polokwane

DEAT Guide l ine 180 ug /m3

South Africa 180 USEPA 150 WHO 150 to 230 World Bank 260 EU 130 to 250

World Leader in Platinum Facility Visit March 2003

MERENSKY AND UG2

Typical mineralogical profiles for the UG2 and Merensky reefs

MINERAL UG2 - % CONTENT MERENSKY - % CONTENT

CHROMITITE 75.00 1.00 PYROXENE 20.00 60.00 FELDSPAR 3.00 34.00 CHLORITE 0.50 1.00 TALC 1.40 2.00 TREMOLITE 1.00 BASE METAL SULPHIDES 0.10 1.00

TOTAL 100.00 100.00

World Leader in Platinum Facility Visit March 2003

FLOWSHEET

From Concentrators Concentrate Storage Slag Granulation Matte Crushing And Storage To LPM Flash Dryer Matte Casting Furnace Furnace Off Gas To Rustenburg A C P Slag Storage

World Leader in Platinum Facility Visit March 2003

FLASH DRIERS

Capacity :

• Wet 70 – 78 tph
• Dry 66 tph

Moisture :

• 10 – 16% (w/w)

Heat release :

• 54 GJ/hr

World Leader in Platinum Facility Visit March 2003

FURNACE

Capacity :

• 650,000 t/a (87 tph)

Power :

• 68 MW (168MVA)

Power density :

• 250 kW/m2

Matte temperature :

• 1,550OC

Slag temperature :

• 1,600OC

World Leader in Platinum Facility Visit March 2003

BAG HOUSE

Inlet temperature :

• 950OC

Dust in:

• 4,400 kg/hr

Dust out :

• 32 kg/hr

Bag area :

• 2,471m3

World Leader in Platinum Facility Visit March 2003

PROJECT SCHEDULE

World Leader in Platinum Facility Visit March 2003

SAFETY STATISTICS

Personnel Employed Personnel Peak Fatality Free Man Hours Total Lost Time Injuries LTIFR Record Days without a LTI

4,323 ± 3,300 6,384,481 6 0.19 145

World Leader in Platinum Facility Visit March 2003

SALIENT CONSTRUCTION FEATURES

1.90 million 60,000 5,700 32,000 380,000 9,700 314 3,200

Earth moved Concrete Structural steel and platework Piping Cable Cable racking Electric motors Light fittings

m3 m3 t m m m No No

World Leader in Platinum Facility Visit March 2003

MAJOR CONTRIBUTORS

Project Management and Design Managing Consultant - Greenblat & Hutton Quantity Surveyors – Professional Cost Consultants Civil & Structural Design – Jones & Wagener HT Electrical Design – EHL Electrical & Instrument Design – iControl Furnace Design – Hatch Construction Bulk Earthworks & Civils – Grinaker-LTA Structural and Mechanical Erector - Group 5 Projects Structural and Mechanical Erector - Tubular Technical Services Piping – Concor Electrical & Instrumentation – Grinaker-LTA MEIP Major Suppliers Steel – Cosira and DSE Baghouse – Howden Flashdriers – Drytech Pneumatic Transfer – Clyde Bergmann

World Leader in Platinum Facility Visit March 2003

CONSTRUCTION PROGRESS OVER 12 MONTHS

Construction start : November 2001

Picture this size

World Leader in Platinum Facility Visit March 2003

Construction progress as at November 2002

Picture this size

CONSTRUCTION PROGRESS OVER 12 MONTHS

World Leader in Platinum Facility Visit March 2003

MAJOR AREAS OF EXPENDITURE

Voted Amount : R 1.31 billion (2001 terms)

Furnace 15% Matte Handling 3% Slag handling 2% Services 1% Electrical infrastructure 2% Dry concentrate handling 6% Off gas Handling 3% Wet concentrate storage 2% Infrastructure 24% Construction 24% Reimburseables 18%

World Leader in Platinum Facility Visit March 2003

COMMISSIONING TO OPERATION

Concentrate Storage Concentrate Off-Loading Truck wash Area Larox Filt er Plant Coal Off-Loading Area Potable Water Tanks Coal Screening Plant Coal St orage S ilo L P G Storage Flash Dryer No 1&2 Plant Offices Slag Thicking & Cooling Slag Granulat ion Plant S tore Plant W orkshops Compressor House Furnace Building Weigh Bridge Gate House Change house Matte Storage Silo

World Leader in Platinum Facility Visit March 2003

Recruited both locally and nationally Battery of assessments to match competencies

with roles

Logical, spatial, musical, interpersonal and

intrapersonal

100% literacy Focus on local communities Engage local structures and institutions Department of Labour

RECRUITMENT AND SELECTION CRITERIA

World Leader in Platinum Facility Visit March 2003

BUSINESS UNIT ORGANOGRAM

Engineering Team Production Team Technical Support HR Team F&I Team SHEQ Team Protection Team Business Leader

Technical Technical Protection Protection Services Services Production Production SHEQ SHEQ Human Human Resources Resources Engineering Engineering Finance & Finance & Info Info

Polokwane Polokwane Business Unit Business Unit Map of Teams Map of Teams

World Leader in Platinum Facility Visit March 2003

BUSINESS UNIT LEVELS

Team Sponsor

Functional leaders Team Leaders Integrated Teams

World Leader in Platinum Facility Visit March 2003

PROFILE OF POLOKWANE EMPLOYEES

HDSA Non HDSA

Total proportion of employees who are female – 25%

World Leader in Platinum Facility Visit March 2003

BUILDING THE COMPETENCY

Interpersonal Competence Functional Competence Vision and Values Personal Competence Intrapreneurial Competence Managerial Leadership Highly capable individual

• Core competency
• Tech & process expertise
• Analytical

Polokwane Way

• Cultural Competency – 5E’s

Personal Leadership

• Integrity
• Trustworthy
• Committed
• Accountable
• Results
• riented

Teamness

• MDWT
• Problem solving
• Diversity
• Team builder

Business Every Job

• CBI
• Opportunity culture
• Social
• Relationship building

Integrative

• Big picture
• Boundaryless
• Inspirational role model
• People development

World Leader in Platinum Facility Visit March 2003

TRAINING

Employees brought on board a year before

commissioning

Industry approved training to gain process

skills

Practical exposure at existing operations Commission with own employees Part of training and knowledge transfer Create early ownership of plant

World Leader in Platinum Facility Visit March 2003

COMMISSIONING

Areas complete are: Concentrate offloading (1st concentrate delivery

• n 1 Feb 2003)

Wet concentrate storage Flash Drier 1 (1st dry conc produced 7 Feb 2003) Dry concentrate storage Furnace cooling water systems Furnace air cooling systems Electrodes LPG Furnace off-gas plant Stack Process water system

World Leader in Platinum Facility Visit March 2003

COMMISSIONING

Furnace heat up started on 20 February 2003 Major milestone to come:

• Furnace switch in: March 2003

World Leader in Platinum Facility Visit March 2003

AREAS OF FOCUS

Knowledge transfer Operations team intimately involved in all

aspects of commissioning

Vendor training using manuals plus rigorous

field training

Seamless handover process from

Commissioning to operating teams

Design validation Intensive vendor and design team support Largely proven technologies

World Leader in Platinum Facility Visit March 2003

AREAS OF FOCUS

Transfer of operational experience Experienced trainers in place Designed a fifth shift for continual training Quality of feed materials Process designed for high chrome Feed blending of materials Optimal ramp up to gain understanding of

UG2 type feed

World Leader in Platinum Facility Visit March 2003

POLOKWANE SMELTER

QUESTIONS

A member of the Anglo American plc group