PDAC 2015 MDM METALLURGICAL INNOVATION UNLOCKS CLIENT PROJECT VALUE. Listening with Care. Designing with Purpose. Delivering beyond Expectation.

Transcription

1 PDAC 2015 MDM METALLURGICAL INNOVATION UNLOCKS CLIENT PROJECT VALUE Listening with Care. Designing with Purpose. Delivering beyond Expectation. March 2015

2 Introduction MDM Engineering: o Process engineering & project management o 26 years of project execution history o Multi-commodity experience o Africa focused o Provides innovative metallurgical solutions o On the 13 th November 2014 MDM became part of the Amec Foster Wheeler Group 2

3 What we ve done o 79 Bankable/Definitive feasibility studies o Over 96% of BFS' went on to receive third party financing o Constructed 65 metallurgical plants, 63 in Africa o All producing above design capacity o Commodities Gold/Silver - Uranium Base Metals - Ferro Metals PGM s - Industrial Minerals Coal - Diamonds

4 Capabilities: what do we do Project Evaluation through: o Scoping Studies/PEA's o Pre-Feasibility Studies o Bankable/Definitive Feasibility Studies Design: Metallurgical process development and specialised engineering and design of metallurgical plants Construction: Construction and commissioning of metallurgical plants and associated infrastructure Project Management: Total Project Execution - manage small, medium to large size mining projects on an international basis

5 Doing it safely Health & Safety: o Toolbox talks o Safety booklets o Risk assessments o Standards o Procedures o Inductions o Audits o Our site safety record Focus on Zero Harm! Project Man-hours LTI LTIFR TOTAL 24,205, * o Financial year Period Man-hours LTIs LTIFR Apr 13 Mar 14 7,069, * A LTIFR of 0.5 or less conforms to ISO / International norms (calculated for 200,000 man-hours base).

6 Process capabilities Technology Andalusite Au Co Cr Cu Coal Diamonds Mn Nb PGM Sn U Zn Ore Preparation Crushing Screening Scatting Reclaim Milling Slurry Preparation Gravity Separation CIL Leaching Flotation DMS/HMS Recovery RIP Sintering Smelting CCD Concen Final tration Produc t IX SX Precipitation EW

7 Current execution projects PROJECT CLIENT COUNTRY COMMODITY PROCESS TPA VALUE SCOPE Kalagadi Manganese Kalahari Resources (Pty) Ltd South Africa Manganese Crushing, Screening, Sintering 3 Mtpa c US$195 million E(P)CM D-Bank Project Foskor (Pty) Limited South Africa Phosphate Flotation 5.1 Mtpa c US$45 million EPCM BRPM Merensky 250ktpm Upgrade Project Royal Bafokeng Platinum South Africa Platinum ROM handling, Crushing, Grinding, Flotation 3 Mtpa c US$30 million DFS, FEED, EPCM Cullinan Mill Project Petra Diamonds South Africa Diamonds Milling, DMS, Sorting 6 Mtpa c US$120 million FEED, EPC Kalagadi Foskor BRPM 7

8 Featured Projects PROJECTS COMMODITY COUNTRY DATE Maranda Concentrator Cu/Zn RSA 1993 KalGold Heap Leach/CIL Au RSA 1996 Skorpion Zinc Leach/SX/EW Zn Namibia 1998 Eureka Gravity/Heap Leach Au Zimbabwe 1999 Dikulushi Copper DMS/Gravity Cu DRC 2002 Tharisa Concentrator Cr/PGM RSA 2012 Parral Tailings Heap Leach Ag/Au Mexico

9 Metorex s Maranda Project Copper/Zinc Concentrator: (1993) o Small differential float copper/zinc concentrator o No new core sample available for test work o Limited historic core used for metallurgical testing o Developed process design from rougher kinetics flotation tests o Achieved grade for both concentrates in first month of operation o Achieved recovery for both metals in third month of operation o Small budget with extensive refurbished secondhand equipment o Company maker for client 9

10 West Rand Mining s Goldridge Project Gold Heap Leach/CIL: (1998) o Single orebody processed through parallel heap leach & CIL o Initial build of heap leach for oxidised cap o Added milling & CIL plant after 2 years with common crushing o Campaigned ore through crushing to stockpiles o Flexibility on cut-over grade to each plant o Operation was able to survive sharp downturn in gold price 10

11 Reunion Mining s Skorpion Project Zinc Leach/SX/EW: (1998) o Silicate/oxide mineralogy o Original owner unable to resolve silica gel formation in leach o Gentle leach conditions interpreted by MDM solved silica problem o Leach liquor contained significant fluorine o Conventional zinc hydrometallurgy not possible with high fluorine o Adapted Tecnicas Reunidas sx/ew waste process for Skorpion o Original owner Anglo American bought back the project o Highly successful, low cost SHG zinc producer established 11

12 Delta Gold s Eureka Project Gold Gravity/Heap Leach: (1999) o Mill/CIL feasibility (by others) showed disappointing economics o Novel approach proposed by MDM coarse gold recovered by gravity (25%) deslimed crushed ore to heap leach slimes thickened and feed to a 2 tank CIL o Lower capex and opex with high recovery o Early cashflow from gravity gold achieved o Enhanced project economics lead to a successful project 12

13 Anvil Mining s Dikulushi Project Copper DMS/Gravity: (2002) o First new mine after recent civil wars for 40 years o Previous studies show high capital for risky jurisdiction o Required low capital approach to minimise risk o Tested and developed DMS with spirals for fines o Achieved high grade concentrate at high recovery o Greatly reduced capital cost o Plant delivered & product shipped by MDM built barge on lake Mweru o Successful project implemented as company maker 13

14 Dikulushi logistics photos Equipment transport to site o This barge was designed by a nautical engineering company in Cape Town and was partially constructed in sections. The sections were welded together by MDM on the Zambian side of lake Mweru and then sailed across the lake to Kilwa in the DRC. o All of the mining and plant steel, mechanicals etc. were shipped to site via this barge. 14

15 Tharisa Minerals Expansion Project Chromite/PGM Concentrator: (2012) o First integrated concentrator for Cr and PGM for middle group ore o Fast-track development to take advantage of commodity prices o Process developed on limited metallurgical test work o Metallurgical test work followed process design as confirmation o 2 stages of grinding and chromite concentration and 1 of PGM float o Largest world chromite concentrate producer with large PGM credit o Successful project unlocked new resource and company maker 15

16 Gogold s Parral Project Tailings Heap Leach: (2014) o Fine high grade Ag/Au tailings from historic Parral mine in Mexico o Presence of cyanide soluble copper complicates metallurgy o Similar recoveries achieved via tank and heap leach o Higher cement additions of agglomeration lead to too high PH o Agglomerated heap leach of fine tailings only piloted twice before developed process to optimise cement addition, lift height & PH mimimise Cu precipitation remove Cu from precipitate o Successful implementation of project has enhanced company 16

17 Conclusion o Multi-commodity knowledge base encourages innovative approach o MDM metallurgists encouraged to be multi-commodity o Consistently delivered innovative metallurgy solutions for 3 decades o Innovative approach extends to overcoming infrastructure challenges o MDM can provide an optimal metallurgical solution for your project 17

18 MDM staff induction artwork Thank You The MDM team 18