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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


POLOKWANE SMELTER

Duncan WanbladGeneral Manager: Process Projects

July NdlovuPolokwane Smelter Manager



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


LOCATION OF SMELTER


SMELTER TECHNOLOGY

Key DriversCapacityEnvironmentalMineralogyOperabilityCosts


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


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


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


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


FLASH DRIERS

Capacity :- Wet 70 – 78 tph- Dry 66 tph

Moisture :- 10 – 16% (w/w)

Heat release :- 54 GJ/hr


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


BAG HOUSE

Inlet temperature :- 950OC

Dust in:- 4,400 kg/hr

Dust out :- 32 kg/hr

Bag area :- 2,471m3


PROJECT SCHEDULE


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


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


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


CONSTRUCTION PROGRESS OVER12 MONTHS

Construction start :

November 2001

Picture this size


Construction progress

as at November 2002

Picture this size

CONSTRUCTION PROGRESS OVER12 MONTHS


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%


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


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


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


BUSINESS UNIT LEVELS

Team Sponsor

Functional leaders

Team Leaders

Integrated Teams


PROFILE OF POLOKWANE EMPLOYEES

HDSANon HDSA

Total proportion of employees who are female – 25%


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


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


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


COMMISSIONING

Furnace heat up started on 20 February 2003

Major milestone to come:

- Furnace switch in: 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


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


POLOKWANE SMELTER

QUESTIONS


annual facility visit/media/files/a/...polokwane smelter questions a member of the anglo american...

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