World Leader in Platinum Facility Visit March 2003
ANGLO AMERICANPLATINUM 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 WanbladGeneral Manager: Process Projects
July NdlovuPolokwane Smelter Manager
A member of the Anglo American plc group
World Leader in Platinum Facility Visit March 2003
TWICKENHAM
MIDDELPUNT HILL
PP RUSTLEBOWA
MODIKWA
BARPLATSCROCODILE RIVER
HARTEBEESTPOORTRPM RUSTENBURG
IMPALA
STYLDRIFT Lydenburg
Mokopane
Witbank
Zeerust
Rustenburg
Warmbaths
PRETORIA
NORTHAM
WESTERN BUSHVELD
EASTERN BUSHVELD
RPM UNION
RPM AMANDELBULT
WESTERN ANDEASTERN 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 DriversCapacityEnvironmentalMineralogyOperabilityCosts
World Leader in Platinum Facility Visit March 2003
SULPHUR DIOXIDE MODELB
Palmietfontein Site
0m 5000m 10000m
125
100
40.4624.27
0
20
40
60
80
100
120
140
Con
cent
ratio
n (u
g/m
3 )On-site Off-site Nature
ReservePolokwane
Max Daily Guidelines for SO2 (µg/m
3)
South Africa 125
USEPA 365
WHO 125
World Bank 125EU 250 to 350
World Leader in Platinum Facility Visit March 2003
PARTICULATES MODELMax Daily Guidelines for
PM10 (µg/m3)
0m 5000m 10000m
32
10
0.58 1.72
0
5
10
15
20
25
30
35
Conc
entra
tion (
ug/m
3 )
On-site Off-site NatureReserve
Polokwane
DEAT Guideline 180 ug/m3
South Africa 180USEPA 150WHO 150 to 230World Bank 260EU 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 - % CONTENTCHROMITITE 75.00 1.00PYROXENE 20.00 60.00FELDSPAR 3.00 34.00CHLORITE 0.50 1.00TALC 1.40 2.00TREMOLITE 1.00BASE METAL SULPHIDES 0.10 1.00TOTAL 100.00 100.00
World Leader in Platinum Facility Visit March 2003
FLOWSHEET
From
Concentrators
Concentrate Storage
Slag Granulation
Matte CrushingAnd 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 HoursTotal Lost Time InjuriesLTIFRRecord Days without a LTI
4,323± 3,300
6,384,4816
0.19145
World Leader in Platinum Facility Visit March 2003
SALIENT CONSTRUCTION FEATURES
1.90 million60,000
5,700 32,000
380,0009,700
3143,200
Earth movedConcreteStructural steel and plateworkPipingCableCable rackingElectric motorsLight fittings
m3
m3
tmmmNoNo
World Leader in Platinum Facility Visit March 2003
MAJOR CONTRIBUTORS
Project Management and DesignManaging Consultant - Greenblat & HuttonQuantity Surveyors – Professional Cost ConsultantsCivil & Structural Design – Jones & WagenerHT Electrical Design – EHLElectrical & Instrument Design – iControlFurnace Design – Hatch
ConstructionBulk Earthworks & Civils – Grinaker-LTAStructural and Mechanical Erector - Group 5 ProjectsStructural and Mechanical Erector - Tubular Technical ServicesPiping – ConcorElectrical & Instrumentation – Grinaker-LTA MEIP
Major SuppliersSteel – Cosira and DSEBaghouse – HowdenFlashdriers – DrytechPneumatic Transfer – Clyde Bergmann
World Leader in Platinum Facility Visit March 2003
CONSTRUCTION PROGRESS OVER12 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 OVER12 MONTHS
World Leader in Platinum Facility Visit March 2003
MAJOR AREAS OF EXPENDITURE
Voted Amount : R 1.31 billion (2001 terms)
Furnace15%
Matte Handling3%
Slag handling2%
Services1%
Electrical infrastructure2%
Dry concentrate handling6%
Off gas Handling3%
Wet concentrate storage2%
Infrastructure24%
Construction24%
Reimburseables18%
World Leader in Platinum Facility Visit March 2003
COMMISSIONING TO OPERATION
ConcentrateStorage
ConcentrateO ff-Loa ding
Truck wa shArea
Larox Filt erPla nt
Coal O ff-LoadingArea
Potable Wate r Tanks
Coal Sc re ening Plant
Coal St orage S ilo
L P G Storage
Fla sh D rye r No 1&2
Pla ntO ffices
Sla g Thicking &Cooling
Sla gGranulat ion
Pla nt S torePla nt W orkshops Compressor House
Furna ce Building
We igh Bridge
Ga te H ouse
Change house
Matte Stora ge Silo
World Leader in Platinum Facility Visit March 2003
Recruited both locally and nationallyBattery of assessments to match competencies with roles
Logical, spatial, musical, interpersonal and intrapersonal100% literacy
Focus on local communitiesEngage 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
TechnicalTechnical
Protection Protection ServicesServices
ProductionProduction
SHEQSHEQ
Human Human ResourcesResources
EngineeringEngineering
Finance &Finance &InfoInfo
Polokwane Polokwane Business UnitBusiness UnitMap of TeamsMap 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
HDSANon 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 capableindividual•Core competency•Tech & process expertise•Analytical
Polokwane Way•Cultural Competency – 5E’s
Personal Leadership•Integrity•Trustworthy•Committed•Accountable•Results oriented
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 commissioningIndustry approved training to gain process skillsPractical exposure at existing operationsCommission with own employees
Part of training and knowledge transferCreate early ownership of plant
World Leader in Platinum Facility Visit March 2003
COMMISSIONING
Areas complete are:Concentrate offloading (1st concentrate delivery on 1 Feb 2003)Wet concentrate storageFlash Drier 1 (1st dry conc produced 7 Feb 2003) Dry concentrate storageFurnace cooling water systemsFurnace air cooling systemsElectrodesLPGFurnace off-gas plantStackProcess 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 transferOperations team intimately involved in all aspects of commissioningVendor training using manuals plus rigorous field trainingSeamless handover process from Commissioning to operating teams
Design validationIntensive vendor and design team supportLargely proven technologies
World Leader in Platinum Facility Visit March 2003
AREAS OF FOCUS
Transfer of operational experienceExperienced trainers in placeDesigned a fifth shift for continual training
Quality of feed materialsProcess designed for high chromeFeed blending of materialsOptimal 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