Analyst Visit - October 2005 - Implats · October 2005 Refineries flowsheet ... SULPHATE AMMONIUM...
Transcript of Analyst Visit - October 2005 - Implats · October 2005 Refineries flowsheet ... SULPHATE AMMONIUM...
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Investor visit – Refineries
October 2005
Refineries flowsheet
Overview
BMR flowsheet
PMR flowsheet
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Why Springs?
Infrastructure available
from Geduld Gold Mine
Proximity to Joburg
International Airport
Gas supply
Chemistry and Engineering
skills
Major achievements in safety
0.0 LTIFR including contractors for 25 months
Benchmarking : NOSA – International Top 100, 7 NOSCAR Awards
Won the MMMA competition for second year in 2005
Mine Metallurgical Managers Association
Individual recognition awards from NOSA
Meerkat programme
Currently in “gap analysis” for OSHAS 18 000
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Statistical overview:Refineries health and safety history
0
2
4
6
8
10
12
14
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 20060.00
1.00
2.00
3.00
4.00
FREQ
UEN
CY
RAT
ES
LTIFR Fatality Disease
Benchmarking – LTIFR (200 000 hours)
0.062 0.110 0.124 0.140 0.197 0.213 0.235 0.2760.378 0.382
0.525 0.530
0.727
1.030
0.000
0.200
0.400
0.600
0.800
1.000
1.200
Air Pro
ducts RBM
Eastm
an
Refineri
es (0
6)DOW
Air Liquide (U
SA)
Bayer
Ashlan
d
E.I.Lilly
DuPont
Rhom& H
aas
BOC (USA)
Praxair
Zincor
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Quality
ISO 9002 Quality Management System (QMS) – first certification , July 1997
ISO 9001 revised quality management system (QMS) – first certification, July 2002
12 external surveillance audits have been conducted on site thus far with one re-certification audit (September 2005)
Springs quality forum
Presently Impala chairs the forum
All issues related to the ISO 9001 QMS are discussed at these forums
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Environmental
First received certification in May 2000
Re-certified in November 2004
A total of 8 surveillance audits
Springs Air Forum
Presently Impala chairs the Forum
Working with local businesses and authorities
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Blesbokspruit
Blesbokspruit Forum
Impala is part of the monitoring committee
Grootvaly Trust
developing a framework to develop the centre as an environmental education centre for the Springs area
main aim is to assist environmental affairs with the retention of the RAMSAR status
Employment equity - management
7
6281
50
36
30
20
40
60
80
100
120
140
Snr Management (current) Middle Management (current) Supervisory (current)
Other HDSA
37% in management
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Women employed
Men, 764
Women, 139
0100200300400500600700800900
Women Men
17%
83%
Gross Pt and PGE production
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
4,500,000
FY1995
FY1996
FY1997
FY1998
FY1999
FY2000
FY2001
FY2002
FY2003
FY2004
FY2005
Troy
oz
Gross Pt Gross PGM
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Gross base metal production
-
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
FY1995 FY1996 FY1997 FY1998 FY1999 FY2000 FY2001 FY2002 FY2003 FY2004 FY2005
Tonn
es
Gross Ni Gross Cu
Employees and Pt oz/employee
800
850
900
950
1000
1050
1100
1150
1200
1250
FY1995
FY1996
FY1997
FY1998
FY1999
FY2000
FY2001
FY2002
FY2003
FY2004
FY2005
Em
plo
ye
es
-
500
1,000
1,500
2,000
2,500
Pt
oz
/Em
plo
ye
e
Employees Pt oz/employee
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Refineries unit costs
Refineries Unit Cost per Gross Pt ozFY
95
FY96
FY97
FY98
FY99
FY00
FY01
FY02
FY03
FY04
FY05
R/o
z
Actual Escalated at CPIX Escalated at CPIX-2
Refineries expansion
BMR PMR
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Expansion phases
R398mJul 20052m ozsBMR Phase I
R40mJune 20072.3m ozsPMR Phase III
R300mJune 20072.3m ozsBMR Phase II
R225mJune 20062m ozsPMR Phase II
ValueEndDate
Resultant Capacity
Phase
Jul 2003 R18m1.6m ozsPMR Phase I
Simplified flow diagram
PALLADIUM
PLATINUM
GOLD
RHODIUM
RUTHENIUM
IRIDIUM
NICKEL POWDER
COBALT POWDER
COPPER CATHODES
OR BRIQUETTES
COPPER
COBALT
NICKEL
ELECTROWINNING
REDUCTION
REDUCTIONBRIQUETTING
AND SINTERING
BASE METALS REFINERYDISSOLUTION OF NICKEL ,
COPPER AND COBALT
GOLDPRECIPITATION
IMPALA PLATINUM MINES
CONCENTRATOR
SMELTERDRYING - SMELTING - CONVERTING
MILLING - FLOTATION
DISSOLUTION
ION EXCHANGE
PRECIPITATION
PRECIPITATION
PURIFICATION &PRECIPITATION
MOLECULAR
TECHNOLOGYRECOGNITION
DISTILLATION
HYDROLYSIS
ION EXCHANGEDISSOLUTION
PLATINUM METALS REFINERY
PURIFICATION &PRECIPITATION
PURIFICATION &PRECIPITATION
ACAD DRG No: PRP_STD_P_0240
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Base metals refinery
Base metals refinery
Objective
To upgrade the PGM content of the feed to a level suitable for the refining of the PGM’s in the Precious Metals Refinery, while simultaneously and cost-effectively extracting the base metals – nickel, copper and cobalt – from the converter matte and converting them into quality saleable products
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Base metals refinery flowsheet
MATTE FROMMATTE FROMMINPROMINPRO
NICKELLEACH
NICKELNICKELLEACHLEACH
COPPERLEACH
COPPERCOPPERLEACHLEACH
PGM CONCLEACHING
PGM CONCPGM CONCLEACHINGLEACHING
PGM CONCDRYING
PGM CONCPGM CONCDRYINGDRYING
DESPATCH TODESPATCH TOPMRPMR
NICKELPURIFICATION
NICKELNICKELPURIFICATIONPURIFICATION
COPPERPURIFICATION
COPPERCOPPERPURIFICATIONPURIFICATION
COPPERELECTROWINNING
COPPERCOPPERELECTROWINNINGELECTROWINNING
COPPERPRODUCTCOPPERCOPPER
PRODUCTPRODUCT
NICKELREDUCTION
NICKELNICKELREDUCTIONREDUCTION
COBALTSTRIPPINGCOBALTCOBALT
STRIPPINGSTRIPPINGCOBALT
PURIFICATIONCOBALTCOBALT
PURIFICATIONPURIFICATIONCOBALT
PRODUCTIONCOBALTCOBALT
PRODUCTIONPRODUCTION
NICKEL POWDERWASHING/DRYINGNICKEL POWDERNICKEL POWDERWASHING/DRYINGWASHING/DRYING
AMM SULPHPRODUCTIONAMM SULPHAMM SULPH
PRODUCTIONPRODUCTIONSAMPLE QA
PACKINGSAMPLE QASAMPLE QA
PACKINGPACKING
BRIQUETTINGSINTERING
BRIQUETTINGBRIQUETTINGSINTERINGSINTERING
SAMPLE QAPACKING
SAMPLE QASAMPLE QAPACKINGPACKING SALESSALESSALES
SAMPLE QAPACKING
SAMPLE QASAMPLE QAPACKINGPACKING
MATTEGRINDING
MATTEMATTEGRINDINGGRINDING
Across-the-fence hydrogen
Successfully installed in late March
Required as current H2 reformers too small for the new natural gas feed
18-hour storage in the 110km pipeline gives instant usage after frequent power outages and ample time for compressor or PSA repairs
Very minor capital expenditure
99.999% pure compared with 97% –better reduction kinetics – capacity
Hydrogen plants on care and maintenance therefore no CO2 greenhouse emissions +/- 22t/day
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Across-the-fence hydrogen (cont)
Opportunity cost of Reformer steam (4t/hr or some 7% of total refineries steam consumption) and cooling water to be used for capacity
Less risk in the case of the large boilers becoming incapacitated
Cheaper gas over life of project
Opportunity for credits for third party hydrogen off-take
More constant pressure provision
Zero liquid effluent
Effluent treatment process for the treatment of rainwater run-off
Recycling of up to 900m3 of good quality water a day to the plant (RWB R3.71/m3 Ξ R1.2m/a)
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Precious metals refinery
Precious metals refinery
Objective
To cost-effectively separate the various platinum group metals contained in the PGM concentrate from the Base Metals Refinery into individually pure and saleable metals
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Precious metals refinery philosophy
METAL EXTRACTION
A
METAL PURIFICATION
B
METAL EXTRACTION
B
METAL SEPARATION
B
METAL SEPARATION
A
METAL PURIFICATION
A
METALMETALAA
METALMETALBB
METALMETALAA
METALMETALBB
PURE METALPURE METAL
PURE METALPURE METAL
PURE METALPURE METAL
PURE METALPURE METAL
Classical processlow yields and high inventory
PMR philosophyquantitative and selective
W.I.P.W.I.P.
Precious metals refinery flowsheet
TOTALDISSOLUTION
TOTALTOTALDISSOLUTIONDISSOLUTION
Au SEPARATIONIX
Au SEPARATIONAu SEPARATIONIXIX
Pd SEPARATIONMRT
Pd SEPARATIONPd SEPARATIONMRTMRT
BASE METALSEPARATIONBASE METALBASE METALSEPARATIONSEPARATION
Ru SEPARATIONDISTILLATION
RuRu SEPARATIONSEPARATIONDISTILLATIONDISTILLATION
Pt / Rh / IrSEPARATION
Pt / Pt / RhRh / / IrIrSEPARATIONSEPARATION
Pt PRODUCTPt PRODUCTPt PRODUCT
Au REDUCTIONAu REDUCTIONAu REDUCTION
Pd SALTINGPd SALTINGPd SALTING
BASE METALPRECIPITATIONBASE METALBASE METAL
PRECIPITATIONPRECIPITATION
Ru SALTINGRuRu SALTINGSALTING
Ir SEPARATIONIX
IrIr SEPARATIONSEPARATIONIXIX Rh PURIFICATIONRhRh PURIFICATIONPURIFICATION
Au PRODUCTAu PRODUCTAu PRODUCT
Pd PRODUCTPd PRODUCTPd PRODUCT
BM PRODUCTBM PRODUCTBM PRODUCT
Ru PRODUCTRuRu PRODUCTPRODUCT
Rh PRODUCTRhRh PRODUCTPRODUCT
Ag PROCESSAg PROCESSAg PROCESS
Ir PURIFICATIONIrIr PURIFICATIONPURIFICATION Ir PRODUCTIrIr PRODUCTPRODUCT
Pt PURIFICATIONPt PURIFICATIONPt PURIFICATION
Pt SALTINGPt SALTINGPt SALTINGBARRENS
COLLECTIONBARRENSBARRENS
COLLECTIONCOLLECTION
RESIDUESMELTINGRESIDUERESIDUE
SMELTINGSMELTING
FINAL EFFLUENTFINAL EFFLUENT
RECYCLE TORECYCLE TOBMRBMR
PGM CONCENTRATE
FROM BMR
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Toll-Out production
-20,00040,00060,00080,000
100,000120,000140,000
FY1995
FY1996
FY1997
FY1998
FY1999
FY2000
FY2001
FY2002
FY2003
FY2004
FY2005
Tro
y o
z
-2.04.06.08.010.012.0
Pe
rce
nta
ge
Actual Pt Toll Out % of Gross Pt Production
Pipeline days
2831 138Iridium
91315Rhodium
51108Palladium
3385Platinum
20041995Financial Year
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Annual platinum production
0
5 0 0
10 0 0
15 0 0
2 0 0 0
19 9 7 19 9 8 19 9 9 2 0 0 0 2 0 0 1 2 0 0 2 2 0 0 3 2 0 0 4
Fi nanci al Year s to June
Pt gr oss P t ex mi ne
Annual palladium production
0
200
400
600
800
1000
1200
1997 1998 1999 2000 2001 2002 2003 2004
Financial Years to June
00
0's
ozs
Pd gross Pd ex mine
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Annual rhodium production
0
50
100
150
200
250
300
1997 1998 1999 2000 2001 2002 2003 2004
Financial Years to June
000'
s oz
s
Rh gross Rh ex mine
Impala Refining Services
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Impala Refining Services (IRS)
Officially created in 1998
Dedicated vehicle for toll-refining and metal concentrate purchases
leverage surface assets and expertise
reduce unit costs (through economies of scale)
seek growth through strategic alliances and joint ventures
Key benefits
Key benefits of growth through IRS
reduced exposure to mining risk
lower investment
exploitation of smaller deposits possible
increased process throughput
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How does IRS work?
Confirmation of third party resource
Impurity distribution
PGM grade
Aggregate volume/capacity availability
Equity involvement
Contract establishment
Tolling relationship with Impala Platinum Limited
Wholly-owned subsidiary
Arm's length toll-refining agreement
Metal recoveries
Metal pricing
Processing costs
Metal pipelines
Sampling / Analysis
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Contract structures
Metal purchase agreements
Metal purchase after an agreed processing period
IRS retains agreed proportion portion of metal value
Toll refining agreements
Percentage return of market value
Refining
Smelting
Handling charge
Future growth
Autocatalyst and secondary refining
Everest South / Two Rivers
Mine Concentrates
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IRS: platinum production
0
200
400
600
800
1000
1200
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
('000
t.ozs
)
Mine Concentrates Other Matte
Platinum production profile: matte / concentrate / other
IRS: PGM production
0
500
1000
1500
2000
2500
3000
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
('000
t.ozs
)
Mine Concentrate Other Matte
PGM production profile: matte / concentrate / other
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0
150
300
450
600
750
900
1050
1200
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
('000
t.oz
s)
Other Kroondal Crocodile River WPL ConcentratesMimosa Messina Zimplats MarulaMarikana Two Rivers Everest South
IRS platinum profile by contract
Ambatovy Nickel Project
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Dynatec - 37.5%
Implats - 37.5%
Sumitomo - 25%
Nickel laterite in Madagascar
Mining and ore treatment to mixed sulphide in Madagascar
Refining to cobalt and nickel metal in Springs
Ambatovy
Ambatovy
Nickel - 60 000tpa from Madagascar and 20 000tpa from Implats operation
Cobalt - 5 800tpa
Large ammonium sulphate credit
27-year mine life
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Implats’ motivation
Save on further capital requirements in current BMR operation
Dilute current BMR fixed cost structure over a larger production volume
Leverage skills, infrastructure and hydrogen pipeline
Involvement in a world – class primary nickel producer
Under feasibility study with Hatch – SNC JV in Woodmead
Study complete in February 2005
EIA well progressed submission before December 2005
Metallurgical piloting complete
Current status
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50% gearing
Total project - $2.3 billion
Lowest quartile operating costs
Approximately 12% capital spend at Springs
Pre-feasibility data
Minesite
ProcessingPlant
Madagascar - Ambatovy Project
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JAROSITE
POWDER
STRIPMETAL
Cu / MnREMOVAL
NICKEL
BRIQUETTESNICKEL
POWDER
ZnSO
NaHS
EVAPORATOR
NICKEL REDUCTION
SOLUTION
PLANT
FILTRATION
Co REDUCTION
COBALT
COBALTBRIQUETTES
STEAM
ADJUSTMENTCo SOLUTION
PRESSURE LEACHH O
MILLING
SULPHIDEMIXED
Co / Ni SX
pH ADJUSTMENT& IRON POLISHING
EXIST. PGM BEARING PLANT
ZINC SX
FILTRATION
GOETHITE
COPPER
FILTRATION
TO SMELTER
MIXED SULPHIDEEX. PHILNICO - NONOC ISLAND
FILTRATION
CRYSTALLISER
SULPHATEAMMONIUM
ADJUSTMENT
CEMENTATION
REMOVAL
REFINERY PROCESS
RESIDUE RETURNTO PRESSURE LEACH
Ni
Co
(NH
) S
O
42
28
2
3NH
NH3
ASO4
2H
O0
2
H2
2H
4A
SO
NH3
Investor visit – Refineries
October 2005