29 september 2011 - merafe resources · this presentation is published solely for informational...
TRANSCRIPT
This presentation is published solely for informational purposes
and does not constitute investment, legal, tax or other advice nor is it to be relied upon in making an investment
decision. Information contained herein has been taken from sources considered by Merafe
Resources to be reliable but no warranty is given that suchinformation is accurate or complete and it should not be relied upon as such. Views and opinions expressed inthis presentation reflect the judgment of Merafe
Resources as of the date of this presentation and are subject to change. Merafe
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2
Legal Notice / Disclaimer
1.
The Day
2.
Operational Overview
3.
Lion I Proven successes
4.
Lion II
5.
Sustainable Development
3
Agenda
1.
The Day
2.
Operational Overview
3.
Lion I Proven successes
4.
Lion II
5.
Sustainable Development
4
1.
Presentation and Safety Video (9:45am)
2.
Lion Ferrochrome Plant Visit (10:30am)
3.
Lunch
(1:00pm)
4.
Depart to Lanseria
(2:30pm)
5
The Day
1.
The Day
2.
Operational Overview
3.
Lion I Proven Successes
4.
Lion II
5.
Sustainable Development
6
Geographical Distribution Provides Competitive Advantage
7
Lion I
Lydenburg
Helena & MagarengThorncliffe
Horizon
BoshoekRustenburg
Kroondal
Waterval
East & West
Wonderkop Johannesburg
10 500 employees
Wonderkop
Boshoek
New Project‐
Lion II
Mototolo
UG2
Impala UG2
K1 & K2 UG2 Eland UG2
EPL UG2
Chrome ore- 9 mines, 245 million tonnes
of mineral
resources, 6 UG2 plants and long‐term
supply agreements with major SA platinum
producers
Ferrochrome- 20 furnaces ‐
1.979 million tonnes
installed
ferrochrome capacity perannum
Recipe for Producing Ferrochrome
1.25t Slag
Furnace Ferrochrome1.0t
8
Chrome ore2.1 – 3.1 t
Reductants0.4 – 0.8 t
Electricity 2.4 – 4.2 MWh
Water 2.5m³/t FeCr
Transport (Internal)
Fixed Costs (Primarily Salaries)
1.
The Day
2.
Operational Overview
3.
Lion I Proven successes
4.
Lion II
5.
Sustainable Development
9
10
Largest single‐phased ferrochrome expansion in the world Description
:
360ktpa Greenfield ferrochrome production
Rationale
:
Lowest cost (opex
& capex) ferrochrome expansion
Capex
:
R1,7billion including the Helena mine
Technology
:
Premus
Location
:
Steelpoort, Limpopo
Province
Recap of Lion I Project
Lion I‐
The Construction Phase
• 8,700 tonnes
steel• 60,000 cubic meters concrete• 29 kilometers pipe work• 2,800 contractors on site (peak)• 6 million man‐hours• LTIFR of 1.33• One Project Management Team
Lion I & II addresses the key challenges facing the SA Ferrochrome industry
Lagging logistics
Increased fine ore
Escalating energy
costs
Skills
shortages
Reductant
shortages
Proximity to Maputo Harbour
750,000 tonnes
pelletising
capacity
Lowest specific energy consumption ca. 37% better than nearest rival
In‐house training centre established
Reduced reliance on coke consumption (20% vs. 60%)
Carbon tax 25% lower carbon footprint
Rising mining costsUse of UG2Close to Mototolo
Premus….Our Competitive Advantage
• Key source of competitiveness
• Xstrata
proprietary technology
• Difficult to emulate and/or retrofit
• High‐skill level required for operation
13
Venture cost per tonne
Lion II uses significantly less electricity compared to other available smelting technologies
2.2
3.5
4.1
4.8
2
2.5
3
3.5
4
4.5
5
Premus *Outotec Conventional DC Arc
14
(Proprietary)
Specific Energy Consumption (MWh/T)
(Conventional)
(Pre pelletiser
Tswelopele)
(Outotec)(pelletiser)
(Conventional)
(pelletiser
Bokamoso)
(Premus) (Premus)
240ktpa
553ktpa396ktpa
720ktpa
Xstrata‐Merafe
Venture anticipated the changes in the South African electricity tariffs
and invested in efficiencies.
2.4
3.99
3.66
3.46
3.29
3.47
3.33.19 3.15 3.19
3.08 3.052.99
2
2.5
3
3.5
4
4.5
2002 2004 2006 2008 2010 2012 2014 2016
MW
h / t
onne
Venture Average Electrical Energy Efficiencies
Note: Electrical efficiencies also a function of which and how many furnaces were operating
Conventional Semi - Closed - 13 Furnaces
Premus
Bokamoso Sinter Plant2007 – ZAR 800 Million
Tswelopele Sinter Plant2012 – ZAR 900 Million
Lion I – Two Large Furnaces2007 – ZAR 1,700 Million
Lion II – Two Large Furnaces2013 – ZAR 4,905 Million
Chrome Recovery Coke Consumption
68
77
9088
65
70
75
80
85
90
95
Convent ional Out okumpu DC Arc Premus
60% 60%
0
20%
0%
10%
20%
30%
40%
50%
60%
70%
Conventional Outokumpu DC Arc Premus
Cons
umpt
ion/
t
Premus
delivers competitive chrome recovery and coke consumption
HotGasHotGas
RAW MATERIALS
BENTONITE
ANTHRACITE
ORE
BATCHINGHOT GAS
DRYING MILLING
SCREENING
MIXING
PELLETIZING
COAL
MILLING
SCREENING
GRANULATION
LUMPYSLAG
CRUSHING
CHAR, COKE, ANTHRACITE
FLUXES
LUMPREDUCTANTS
BATCHING
GAS SCRUBBING
USABLE OFF GAS
PRE-HEATING
ROASTING
The process
Complicated Hot loading
system
17
1.
The Day
2.
Operational Overview
3.
Lion I Proven Successes
4.
Lion II
5.
Sustainable Development
18
Merafe
approved a 20.5% participation in Project Lion Phase II ‐
360,000 tonnes of ferrochrome capacity
Overview
• Construction and commissioning of a 360 000 tonne per annum capacity ferrochrome
smelter in Steelpoort, Limpopo
Province• The project will increase the Venture’s total ferrochrome capacity to over 2.3 million
tonnes • Capital costs budgeted at R4.9 billion (includes R700 million for the concurrent
development of the Venture’s 1.2 million ROM tonne per annum Magareng
mine)• Merafe’s
portion of 20.5% is budgeted at R1 billion
Investment Rationale
• Long‐term fundamentals of ferrochrome remain strong –
stainless steel melt historically
growing at a compound annual growth rate of 5% and forecasted to
grow at
approximately 6% per annum
Financing
• Will be sourced from a combination of:
o Merafe’s
existing cash balanceso Merafe’s
share of future cash flows from the Ventureo Debt 19
Lion II‐
Key considerations motivating the project
Benefits of Premus:
•Lowest production cost relative to other smelting technologies•Lowest energy consumption•Minimum reliance on expensive coke•Superior chrome recovery•Premium product quality (low silicon and sizing)•30% less solid waste (slag and slimes)
Project implementation:
•Same team members as Lion I Project•First production of ferrochrome is expected in H1 2013
Availability of electricity
•The Venture has accepted an approved budget committing ESKOM to allocate electricity
20
21
Job Creation The Lion complex will create 2,197 direct jobs, 6,880 indirect jobs and will
impact some 36,000 people in the region
Total Jobs Created Dependents Total People Affected
Local Steelpoort
Area 1,598 4,795 6,394
Other SA Employees 63 188 250
Suppliers – Other SA 2,052 6,156 8,208
Total 3,713 11,139 14,852
Total Including Lion I 9,077 27,231 36,308
Direct Jobs Including Lion Phase I – 2,197 Direct Jobs Lion Phase II – 1,042
1
Figure includes direct jobs, indirect jobs estimated and estimated impact on rest of supply chain
Lion II construction phase is on track
Artist’s impression of Lion I and Lion II
Activity 4Q10 1Q11 2Q11 3Q11 4Q11 1Q12 2Q12 3Q12 4Q12 1Q13 2Q13
Key tenders
Detail Design
ExcavationPlace Long Lead Items Orders
Civil Construction
Steel Construction
Installation
Commissioning 1st line
Commissioning 2nd line22
Lion II
Lion I
1.
The Day
2.
Operational Overview
3.
Lion I Proven Successes
4.
Lion II
5.
Sustainable Development
23
24
Sustainable development In addition to job creation, low energy consumption and less solid waste, there
are benefits to the surrounding communities
Community Wellness Enterprise Development
Skills Development Community Development
Wellness Centre Lydenburg HCT campaigns (HIV treatment campaigns) Craft & Needlework
centreWelding CentreNkoleng
Poultry
FarmSteelpoort
Business Park
Lydenburg
Smelter
Open DayDistribution of stationery and backpacks at
local schools
Steelpoort
training centre –
120 graduates to dateExpanded to train 130‐150 artisans a year
Some for The Venture’
s own needs, other find employment
elsewhere within sector
Skills training: electricians, fitters, boiler makers
Water Supply Mashishing
Police Department RenovationTribal offices identified for
upgrade
R60 million supplier park for Eastern Bushveld
operationsJVs with local SMMEs
(minimum 25%BEE)1000 jobs by 2012
Assisted the local police department at Mashishing
in
renovating their offices in October 2010
Numerous projects in Limpopo
area undertaken to ensure
access to clean water
14,116 employees participated in the
Wellness Campaigns and 12,916
participated in voluntary counseling and
testing during the wellness campaigns