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Specialists in mineral andmetallurgical technology
By Dr Paul Jourdan
Mintek
By Dr Paul Jourdan
Mintek
Presentation to the Parliamentary
Portfolio CommitteeScience & Technology
Presentation to the Parliamentary
Portfolio CommitteeScience & Technology
10th June 200310th June 2003
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Specialists in mineral andmetallurgical technology
Mintek: Adding value to our Natural Resources
Mining,Mining, ResourceResourceProcessingProcessing RefiningRefining
Fabri-cation
Mineral separation, Smelting, LeachingMineral analysis, Special Alloys, Small-scale Mining, Jewellery, Enviromin, etc.
Explora-Explora-tiontion
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Specialists in mineral andmetallurgical technology
6 168
7 494
85 226
121 408
214 128
114 718
9 521
78 160
207 960
Shortfall
Depreciation
Overheads and Operating Expenditure
Staff Costs
Expenditure
Own Income (incl. post-retirement fund interest)
Earmarked funding
Core funding
Income
R’k
FINANCIAL SUMMARY 2002/2003
FINANCIAL SUMMARY 2002/2003
Forex losses (11:1 to 8:1) R2mnAvmin royalty R3mnMindev investment R5mnTransformation R1mnOperating Shortfall R6mnTotal R17mn
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Specialists in mineral andmetallurgical technology
0
50,000
100,000
150,000
200,000
250,000
300,000
350,000
1987
/88
1989
/90
1991
/92
1993
/94
1995
/96
1997
/98
1999
/200
0
2001
/200
2
2003
/200
4
2005
/200
6
MINTEK INCOMEMINTEK INCOME
CoreCore
EarmarkedEarmarked
Non-stateNon-state
TotalTotal
Ran
ds X
100
0
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Specialists in mineral andmetallurgical technology
MINTEK MANAGEMENTMINTEK MANAGEMENT
CHIEF EXECUTIVE OFFICER
Technology
Pyrometallurgy
AnalyticalScience
Bioleaching
MineralsProcessing
Measurement& Control
PhysicalMetallurgy
EngineeringSupport
Mineralogy
High Temp. Technology
Hydrometallurgy
Process Eng.Services
Small ScaleMining Unit
ResearchTechnology
Commer-cialisation
BusinessServices
Human Resources &
Training
Information &Publications
CorporateRelations
Finance(Treasury)
CorporateServices
MESU
Mindev(Mintek Exco)
CEO (50%)
COO
PROJECTS (JVs)HDSA
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Specialists in mineral andmetallurgical technology
MINDEV CORPORATE STRUCTURE MINDEV CORPORATE STRUCTURE
MINDEV BOARD (CHAIR – PP JOURDAN)MINTEK EXECUTIVE MANAGEMENT
MINDEV CEONA BARCZA
(50%)
SUBSIDIARY COMPANIES
ATOLL TOLLSORT MOGALE MUSUKU
Bateman Titaco Mindev
50% 50%
Mindev IMS Eng. SPH B&H
Mindev PGR Atoll BEE(Sebeso)
Mindev Harmony BEE
PUBLIC OFFICERYUNUS OMAR
25%25%25% 25%
30%30%20% 30% (10%DGE Trust)
40%40%20% (Laetoli)
Specialists in mineral andmetallurgical technology
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Specialists in mineral andmetallurgical technology
• Tollsort: with Mikrosort of Germany, to apply new optical sorting technology to improve recoveries in the southern African minerals industry;
• Musuku: with Harmony and BEE company, to beneficiate gold bullion into pure (99.99%) gold and into value-added intermediate products such as salts, wire, alloys, bars and high purity gold for electronics, using Mintek technologies. Musuku is the Venda word for gold.
• Mogale: with management, workers and BEE company, to treat Columbus stainless steel dusts to produce a valuable nickel alloy and to produce ferrochrome using Mintek’s new “Enviroplas” technology, but based on its early DC FeCr technology that was taken over by Samancor in 1993.
• Atoll: with Bateman (outsourcing some operations to BEE companies), was established prior to Mindev’s formation to provide toll processing services to the ferro-alloys industry to recover valuable alloys from slag dumps
MINDEV SUBSIDIARIESMINDEV SUBSIDIARIES
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Specialists in mineral andmetallurgical technology
FEASIBILITY STUDIES INITIATED FEASIBILITY STUDIES INITIATED
• A coastal Electrolytic Manganese Dioxide (EMD) plant based on SA’s abundant manganese ores. EMD is used in the manufacture of dry-cell batteries
• A Hot Briquetted Iron (HBI) plant based on SA’s iron ore fines. HBI is used in steel making
• A coastal ferro-nickel (FeNi) plant based on SA’s cheap electricity and imported laterite ores. FeNi is used in stainless steel production
• A plant to recover platinum concentrate from chromite tailings dumps (the Platdumps project)
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Specialists in mineral andmetallurgical technology
BEE Business Partners BEE Business Partners
• PDI• >51% HDSA• Broad-based (equity)• Tech expertise• Finance (balance sheet)• Biz expertise
• Core BEE partner in broad tech areas (eg DC plasma)
• Local BEE on discrete investment projects
• BEE R&D partners?• BEE IP funding?
BEE dbase
BEE shortlist
BEE Selection
BEE Financing
Advert Informal
Other dbases
BEE Partner
Deposit?
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Specialists in mineral andmetallurgical technology
REGIONAL STUDIES - Completed or underway
REGIONAL STUDIES - Completed or underway
• Mineral potential of the Gariep SDI of the Northern Cape
• Mozambican part of the Beira Corridor and Zambezi SDI
• First phase of a mineral scan for the Nacala corridor in Mozambique, Malawi and Zambia
• A scan of the aluminium downstream industry for the CDC (Coega)
• A titanium cluster study in East London for ECDC in Eastern Cape
• Mintek signed an historic MOU with the ECDC to develop eight mineral based projects in the Eastern Cape
• Mintek is also in discussion with other provinces to help them develop mineral based projects (N.Prov & Limpopo)
• Mintek is co-ordinating The Great African Rift Development Strategy (GARDS) on behalf of COHORT (committee of SA’s Science Councils)Mineral Economics and Strategy
UnitMineral Economics and Strategy Unit
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Specialists in mineral andmetallurgical technology
• The RBSD thesis has been incorporated into the National R&D Strategy
• The overall objective and aim of the RBSD project is to identify the critical factors and necessary conditions (i.e. “lessons”) required for a resource-based economy such as South Africa to make the transition to a high-tech industrialised state
• Study trip to Sweden and Finland to build a research network
• Mining Inputs Cluster
– Mintek has also been tasked with facilitating the development of a mineral processing inputs cluster (consumables, capital goods, services)
– Mintek proceeded to initiate the resuscitation of the South African mining cluster and has received the commitment of various industry, government, science council, and organisational support for this endeavour
• Defining the inputs cluster in terms of key product categories and the type of
goods and services associated with them.
• Putting together a database of leading South African and international firms
associated with the domestic mining and mineral processing sector.
• Funding proposal has been submitted to Fridge
RESOURCE-BASED SUSTAINABLE DEVELOPMENT
RESOURCE-BASED SUSTAINABLE DEVELOPMENT
Mineral Economics and Strategy UnitMineral Economics and Strategy Unit
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Specialists in mineral andmetallurgical technology
MiningMining MineralMineralProcessingProcessingExplorationExploration
expl. capital goods• geophysical• drilling• survey• etc.
exploration services• GIS• analytical• data processing• financing• etc
mining capital goods• drilling• cutting• hauling• hoisting, etc.
mining services• mine planning• consumables/spares• sub-contracting• financing• analytical, etc
processing cap. goods• crushers/mills• hydromet plant• materials handling• furnaces, etc.
processing services• comminution• grinding media• chem/reagents• process control• analytical, etc
knowledge-based resource-inputs industry
1. Beneficiation (RBI); 2. Resource Inputs: Capital Goods & Services
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Specialists in mineral andmetallurgical technology
• Kgabane Project– The Kgabane Jewellery and Craft Project was initiated by the Ministry of
Minerals and Energy to alleviate poverty and create jobs through the creation of a vibrant and inclusive jewellery industry and taking advantage of existing resources
– The project was formally launched in October 2002 during the Mining Week, with a jewellery show. The launch celebrated the Kgabane – Harmony range, which was realised through its partnership with Harmony Gold
– A Production and Training Unit has been set up and is operational. The unit is tasked with the creating a range of jewellery products that will be inspired by rural - indigenous craft designs and will utilise a range of materials ranging from natural fibres, beads, ceramics, precious and semi-precious metals and stones
– Through the Kgabane Rural Development Jewellery Project, seven groups of crafts-women from rural and urban impoverished areas have been set up and are receiving training according to the unit standards qualification set with the Mining Qualifications Authority
RURAL DEVELOPMENT & POVERTY ALLEVIATION
RURAL DEVELOPMENT & POVERTY ALLEVIATION
Mineral Economics and Strategy UnitMineral Economics and Strategy Unit
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Specialists in mineral andmetallurgical technology
ALEXKORALEXKOR
Highlights of Mintek’s management (17 May 2001 - 16 November 2002)
• Eliminationof loss-making activities (mid-sea, closure of some plants)
• Expansion of profit-making activities (shallow marine)
• Implementation of tight cost control on all activities
• Repayment of R25m loan to BOE
• Creation of a permanent, empowered, Alexkor management team
Audited profit from operations (30 June 2003), R millions
1999 2000 2001 2002 2003
-R69,8 -R36,8 -R31,7 R16,0 R32,0** Estimated 30 June 2003
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Specialists in mineral andmetallurgical technology
TECHNICAL HIGHLIGHTSTECHNICAL HIGHLIGHTS
GOLD• Developing local and international codes of best practice for cyanide
use (Au CIP: health & safety and enviro)
• Bioleach amenability tests on sulphide gold concentrates from SA, Zimbabwe, Tajikistan, Dominican Republic, Canada, Kazakhstan and Finland
• Optimisation of gold circuits for clients around the globe
• Project Autek, focussing on new industrial applications for gold, has been expanded rapidly (breakthrough on respirators)
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Specialists in mineral andmetallurgical technology
TECHNICAL HIGHLIGHTS (cont.)TECHNICAL HIGHLIGHTS (cont.)
• Laboratory and pilot milling and flotation work has been conducted for Anglo American, Avmin, Lonmin, Cluff Resources and Aquarius South Africa
• Interest has been expressed in the ConRoast process (smelting of dead-roasted sulphide concentrates in a DC arc furnace) by major platinum producers and new BEE entrants (Cr constraint, enviro)
• New modules of MillStar, PlantStar, FrothStar have been developed for process control (40 sites in 15 countries) and Minstral EAF furnace control (80 sites in 10 countries)
• Significant progress has been made on the development of alloys based on Pt-Al-Cr-Ru for high temperature applications (eg aero-engines with RR)
PLATINUM
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Specialists in mineral andmetallurgical technology
FERROUS METALS• Cluster computer (“LAN”) approach for furnace and slags modelling
• Various projects conducted using DC arc furnace (SS dusts, FeCr, FeMn, Ti-Fe)
NON FERROUS METALS• Testwork and process design on heap bioleaching of low-grade copper
ores (Haib)
• Solvent extraction for recovery and upgrading of zinc
• Liquid Magnesium was produced at atmospheric pressure through Mintek’s new magnesium process
• Zincref- new Mintek Zn refining pilot column commissioned
TECHNICAL HIGHLIGHTS (cont.)TECHNICAL HIGHLIGHTS (cont.)
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Specialists in mineral andmetallurgical technology
INDUSTRIAL MINERALS• Batch jigging for the Fe and Mn industries has been conducted
successfully
• Optical sorting has gained rapid attention in the mineral processing industry (PGM, limestone, dolomite)
SMALL SCALE MINING• Established a small scale mining division
• Involvement in rural development spans over 9 provinces
• Examples are: glass beads, diamond treatment facility,
• iGoli-process for gold recovery, ceramics incubator, etc.
TECHNICAL HIGHLIGHTS (cont.)TECHNICAL HIGHLIGHTS (cont.)
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Specialists in mineral andmetallurgical technology
ALLOCATION OF CORE FUNDINGALLOCATION OF CORE FUNDING
• All core funds for 2003/2004 (R80,9m) allocated to specific activities
• Allocation was achieved via an internal competitive mechanism similar to the Innovation Fund
• Progress reports every 6 months
Allocation as follows:
Technical InnovationTechnical Innovation SMMESMME SET/HRDSET/HRD TotalTotal
R60,4m R6,5m R14,0m R80,9m74,7% 8,0% 17,3% 100%
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Specialists in mineral andmetallurgical technology
EXECUTIVE
02
46
8
1012
1416
2000 2003 2004 2006 2008
NON-DGDG
MANAGERS
02468
10121416
2000 2003 2004 2006 2008
NON-DGDG
PROJECTED TRANSFORMATION From Base Year 2000, to 2008
PROJECTED TRANSFORMATION From Base Year 2000, to 2008
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KgabaneKgabane
MINQUIZMINQUIZ
ADOPT-A-SCHOOLADOPT-A-SCHOOL
Specialists in mineral andmetallurgical technology
EDUMAPEDUMAP
HIV/AIDS programme (Itereleng/Ikageng)
HIV/AIDS programme (Itereleng/Ikageng)
SET WeekSET Week
OUTREACH PROGRAMMESOUTREACH PROGRAMMES
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Specialists in mineral andmetallurgical technology
HUMAN RESOURCE DEVELOPMENTHUMAN RESOURCE DEVELOPMENT
• 53 Undergraduate students – (81% of designated group)
• 17 Postgraduate students – (71% of designated group)
• 44 Technikon training students – (100% of designated group)
• 7 Engineering-in-training students – (86% of designated group)
• Supports the EduMap Programme – (65 core learners and 350 on the programme)
• Adopted a school (Kwadeda) in Zola, Soweto• Science lab, ICT lab, >pass rate
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Specialists in mineral andmetallurgical technology
QUALITY, ENVIRONMENT & SAFETYQUALITY, ENVIRONMENT & SAFETY
• Achieved integration of Mintek’s quality, environmental and safety systems
• Mintek certified on 8 August 2002 to be compliant with the ISO 9001:2000 international quality standard
• Certification to the ISO14001 international environmental standard expected August 2003
• Awarded 3-star rating by NOSA for safety
• Disabling Injury Frequency rate (DIFR) of 1,8 equivalent to 4-star rating. Zero fatalities.
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Specialists in mineral andmetallurgical technology
Molteno/Indwe Field
Nqura
SA Energy Map (gas, oil, coal)SA Energy Map (gas, oil, coal)Selected Mintek ProjectsSelected Mintek Projects
Pande;Temane pipeline
(Sasol/CEF/ENH)
Kudu Pipeline
A-K Field Pipeline
Lily Pipeline (Petronet)
Fe & Mn Fields
Ore Rail
HBI sites
FeNi & SS site
EMD sites
Musuku sites
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Specialists in mineral andmetallurgical technology
SDI’s
R&D
Projects
SDI’s
R&D
Projects
SADC: Key ProjectsSADC: Key ProjectsSADC: Key ProjectsSADC: Key Projects
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Specialists in mineral andmetallurgical technology
www.mintek.co.zawww.mintek.co.za
MintekMintek““helping make helping make
resources catalyze resources catalyze sustainable sustainable
development”development”
Thank you, Ke a leboga, EnkosiThank you, Ke a leboga, EnkosiKanimambo, Dankie, SiyabongaKanimambo, Dankie, Siyabonga