World Leader in Platinum Facility Visit March 2003 ANGLO AMERICAN PLATINUM CORPORATION ANNUAL FACILITY VISIT 5 March 2003 A member of the Anglo American plc group
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 ONGOING AND EXPANSION OPERATIONS ORIENTATION N EASTERN BUSHVELD WESTERN BUSHVELD MIDDELPUNT HILL Polokwane PP RUST TWICKENHAM LEBOWA Mokopane RPM AMANDELBULT RPM UNION MODIKWA NORTHAM Warmbaths WESTERN AND BARPLATS Lydenburg STYLDRIFT EASTERN PLATS CROCODILE RIVER BRPM Zeerust DER BROCHEN IMPALA PRETO RIA Rustenburg Witbank HARTEBEESTPOORT RPM RUSTENBURG
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 Max Da i l y Gu ide l ines fo r /m 3 ) SO 2 (µg South Africa 125 USEPA 365 WHO 125 Palmie t fon te in Si te World Bank 125 EU 250 to 350 140 125 120 3 ) 100 100 Concentratio n (u g/m 80 60 40 40.46 24.27 20 0 On-site Off-site Nature Polokwane 0m 5000m 10000m Reserve
World Leader in Platinum Facility Visit March 2003 PARTICULATES MODEL Max Da i l y Gu ide l ines fo r /m 3 ) P M10 (µg South Africa 180 USEPA 150 WHO 150 to 230 World Bank 260 EU 130 to 250 /m 3 DEAT Guide l ine 180 ug 35 32 30 3 ) 25 tion (ug/m 20 Concentra 15 10 10 1.72 0.58 5 0m 5000m 10000m 0 On-site Off-site Nature Polokwane Reserve
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
Concentrate Storage Flash Dryer From Concentrators Furnace Off Gas Matte Casting Furnace Slag Granulation Matte Crushing And Storage To Rustenburg A C P To LPM 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/m 2 � Matte temperature : - 1,550 O C � Slag temperature : - 1,600 O C
World Leader in Platinum Facility Visit March 2003 BAG HOUSE � Inlet temperature : - 950 O C � Dust in: - 4,400 kg/hr � Dust out : - 32 kg/hr � Bag area : - 2,471m 3
World Leader in Platinum Facility Visit March 2003 PROJECT SCHEDULE
World Leader in Platinum Facility Visit March 2003 SAFETY STATISTICS � Personnel Employed 4,323 � Personnel Peak ± 3,300 � Fatality Free Man Hours 6,384,481 � Total Lost Time Injuries 6 � LTIFR 0.19 � Record Days without a LTI 145
World Leader in Platinum Facility Visit March 2003 SALIENT CONSTRUCTION FEATURES � Earth moved 1.90 million m 3 � Concrete 60,000 m 3 � Structural steel and platework 5,700 t � Piping 32,000 m � Cable 380,000 m � Cable racking 9,700 m � Electric motors 314 No � Light fittings 3,200 No
World Leader in Platinum Facility Visit March 2003 MAJOR CONTRIBUTORS Project Management and Design Major Suppliers Managing Consultant - Greenblat & Hutton Steel – Cosira and DSE Quantity Surveyors – Professional Cost Consultants Baghouse – Howden Civil & Structural Design – Jones & Wagener Flashdriers – Drytech HT Electrical Design – EHL Pneumatic Transfer – Clyde Bergmann 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
World Leader in Platinum Facility Visit March 2003 CONSTRUCTION PROGRESS OVER 12 MONTHS Picture this size Construction start : November 2001
World Leader in Platinum Facility Visit March 2003 CONSTRUCTION PROGRESS OVER 12 MONTHS Picture this size Construction progress as at November 2002
World Leader in Platinum Facility Visit March 2003 MAJOR AREAS OF EXPENDITURE Voted Amount : R 1.31 billion (2001 terms) Infrastructure 24% Wet concentrate storage 2% Off gas Handling Construction 24% 3% Dry concentrate handling 6% Electrical infrastructure 2% Services 1% Slag handling 2% Reimburseables Matte Handling Furnace 18% 3% 15%
World Leader in Platinum Facility Visit March 2003 COMMISSIONING TO OPERATION Change house Gate House Potable Water Tanks Concentrate Storage Flash Dryer No 1&2 Weigh Bridge Plant Coal Screening Plant Offices Matte Storage Silo Coal Off-Loading Area Furnace Building Truck wash Area Larox Filt er Plant Concentrate Off-Loading L P G Storage Slag Granulat ion Slag Thicking & Plant W orkshops Coal St orage S ilo Plant S tore Compressor House Cooling
World Leader in Platinum Facility Visit March 2003 RECRUITMENT AND SELECTION CRITERIA � 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
World Leader in Platinum Facility Visit March 2003 BUSINESS UNIT ORGANOGRAM Business Leader Engineering Production Team Technical Support HR Team F&I Team SHEQ Team Protection Team Team Technical Technical SHEQ SHEQ Polokwane Polokwane Business Unit Business Unit Map of Teams Map of Teams Engineering Engineering Protection Protection Production Production Services Services Finance & Finance & Info Info Human Human Resources Resources
World Leader in Platinum Facility Visit March 2003 BUSINESS UNIT LEVELS Integrated Teams Team Leaders Functional leaders Team Sponsor
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 Integrative Business Every Job •Big picture •CBI Managerial Leadership •Boundaryless •Opportunity culture •Inspirational role model •Social •People development Intrapreneurial Competence •Relationship building Interpersonal Competence Teamness Personal Personal Competence •MDWT Leadership •Problem solving •Integrity •Diversity •Trustworthy Vision and Values •Team builder •Committed •Accountable •Results Functional oriented Competence Highly capable individual •Core competency Polokwane Way •Tech & process expertise •Cultural Competency – 5E’s •Analytical
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 (1 st concentrate delivery on 1 Feb 2003) � Wet concentrate storage � Flash Drier 1 (1 st 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
Recommend
More recommend
