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New nickel plants – to design production rate and beyond

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Nils Voermann, Global Managing Director, Technologies, Hatch delivered this presentation at the New Caledonia Nickel conference in July 2013. For more information about the event, please visit …

Nils Voermann, Global Managing Director, Technologies, Hatch delivered this presentation at the New Caledonia Nickel conference in July 2013. For more information about the event, please visit www.newcaledonianickel.com

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  • 1. 01/2012 New nickel plants – to design production rate and beyond Nils Voermann
  • 2. 2 01/2012 New Nickel Plants • SNNC • Ravensthorpe • Goro • Onca Puma • Barro Alto • Koniambo • Fenix
  • 3. 01/2012 KONIAMBO Commissioning and Ramp-up
  • 4. 4 01/2012 Purpose of New Technology / Larger Scale • Maximize output: Plant capacity x Availability x Utilization x Recovery • Minimize inputs: Initial investment + Maintenance + Energy + Labour
  • 5. 5 01/2012 5 Implementation performance record [1] Ref.: McNulty, 1998
  • 6. 6 01/2012 6 Implementation performance record [2] 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 1 2 3 4 5 AnnualizedProduction(%ofDesignCapacity) Years of Operation Ni Lat Smelter B (M1/M2, Gen 2) Ni Lat Smelter C (M1, Well Piloted) Ni Lat Smelter D (M1/M2, Gen 2) Ni Lat Smelter F (M4, Gen 1) Ni Lat Smelter A (M4, Gen 1) Ni Lat Smelter E (M4, Gen 1) Second Generation/ More Piloting M0 M4 M1 M2 M3 First Generation/ Less Piloting
  • 7. 7 01/2012 7 Risk factors for new technology implementation: – Too many new elements – Inadequate pilot testing – Over reliance on equipment vendors – Insufficient human and/or financial resources – Inadequately skilled project teams - imbalance of champions and skeptics – Poor project stage gating or phasing – Poor knowledge of overall business case
  • 8. 8 01/2012 8 Implementation performance record [3]
  • 9. 9 01/2012 9 Kennecott Flash Converting
  • 10. 10 01/2012 1 Kennecott Flash Converting Ref.: Mackey and Nesset, 2003 0% 20% 40% 60% 80% 100% 120% 0 1 2 3 4 5 PercentofDesignCapacity Years After Start-up Upgrade of Flash Converting Furnace and anode casting wheels
  • 11. 11 01/2012 Ravensthorpe High Pressure Acid Leach (HPAL)
  • 12. 12 01/2012 PT Vale Indonesia Productivity Increases since start-upFurnacepower(MW) Year Ref.: A. Daenuwy, A. Dalvi et al, 1992
  • 13. 13 01/2012 Retrofit Upgrade Phase Number of Rotary Kilns Number of Furnaces (MW / furnace) Calcine output Per Kiln Calcine input per Furnace Total Calcine Throughput Total Nickel in FeNi produced I 2 2 (80 MW) 160 tph 160 tph 320 tph 50,000 tpy II 3 2 (120 MW) 160 tph 240 tph 480 tph 75,000 tpy
  • 14. 14 01/2012 Incremental addition of production capacity on an existing site CAPEX (US$ million) CAPEX / annual lb. Ni production (US$ / lb. Ni capacity) Greenfield pyro plant 50,000 tpy Ni in FeNi 5,000 45 Greenfield hydromet plant 50,000 tpy Ni 5,000 45 Incremental addition of 25,000 tpy Ni in FeNi 2 kiln + 2 x 80 MW furnaces pyro plant expanded to 3 kilns + 3 x 80 MW furnaces pyro plant 500 - 700 4.50 - 6.30
  • 15. 15 01/2012 Conclusion • Economies of scale have not yet been fully exploited in laterite nickel metallurgical plants to minimize CAPEX and OPEX per unit of Ni production • Recently constructed / started-up and pyromet and hydroment plants have excellent upgrade potential – Adding technology to increase productivity of existing unit operations – Adding additional production line(s) to take advantage of already spent site infrastructure costs. • Incremental expansion of production capacity can be highly cost effective – Debottlenecking to reach design production rate – Exploitation of latent overcapacity in some production steps by upgrading rate limiting unit operations