Data Project PLTU 2x25 MW Mamuju -West Sulawesi - Indonesia
AML-8
1. Tonkolili Iron Ore Project
Project Update
Karl D. Sinko
GM Projects & Oerations
February 2012
2. Monthly Construction Schedule for Expanding to 20Mtpa – February
Milestones On or Ahead of Schedule
Area Monthly Construction Schedule J F M A M J J A S O N D
PORT
Complete chute and bin modifications ✔
Complete ship loaders (1 and 2) ✔
Complete NHI stacker upgrade ✔
Complete 1B materialshandling and port load out ✔
Replace stacker with Stacker-reclaimer ✔
RAIL
Increase number of trains to 6 (3 loco’s* 75 wagons*60 tonnes
per train) ✔
Increase number of trains to 8 (2 loco’s* 70 wagons*70 tonnes
per train) ✔
Increase number of trains to 9 (2 loco’s* 70 wagons*70 tonnes
per train) ✔
Increase number of trains to 10 (2 loco’s* 70 wagons*70 tonnes
per train) ✔
Complete dual tracking and loop at the mine ✔
Complete 2nd line from Pepel yard to Pepel bridge ✔
Complete replacementof old rail ✔
MINE
Complete 2nd train loader ✔
Process Plant 1B Commissioning ✔ ✔
February 2012 2
4. 4
Achievements to Date
February 2012
• [Insert safety achievement]
• [Number of Sierra Leoneans employed]
• [tonnes loaded to date]
• [number of ships loaded]
• [Best loading rate achieved]
• [Reduction in mooring times]
Area Achievement
Safety Constantly increasing man hours and reducing our injury
frequency rate month by month
Butterfly Stacker Fully operational and running at 2,400 tonnes per hour
Second Shiploader Dry commissioning has commenced, will be fully
operational in 4 to 5 days
Chute Modifications Temporary chutes fully operational, permanent
redesigned chute fabrication underway on-site now,
completion end of February
Tonnes Loaded On-Ship YTD 340,231 tonnes
Total Tonnes Exported 565,271 tonnes
Number of Ships Loaded Currently loading 8th ship (3rd OGV)
Current tonnage on-ship 33,627WMT
Best loading rate achieved 3,200tph on the 28/01 (using one shiploader)
5. 5
Moving to 20mtpa
Area Existing Infrastructure Future Infrastructure Date
Inloading 1 x car dumpers 2 x car dumpers Mar 12
Stockyard 1 x Butterfly Stacker
400,000t stockpile capacity
2 x Stacker/Reclaimers
1mt stockpile capacity
Mar/Sept 12
Mar 12
Reclaiming 4 x CAT 992k (BCM operated) 2 x stacker reclaimers
1 x stacker
Mar/Sept 12
Outloading 1 x outloading belt
2 x shiploaders
2 x outloading belts
2 x shiploaders
Mar 12
Transhipment 2 x transhipment vessels 3 x transhipment vessels Aug 12
Inloading at 3,200 tonnes / hour
Outloading at 4,000 tonnes / hour
Transhipping at 2,000 tones / hour
Inloading at 3,200+ tonnes / hour
Outloading at 8,000 tonnes / hour
Transhipping at 3,000 tones / hour
February 2012
8. Pepel Camp Expansion Plan
Description Today End of Feb End of March End of April
Accommodation units from Makeni 12 on-site 20 online 46 online 71 online
Accommodation units from Rogbere 12 on-site 18 online
Refurbished houses (10 per house) 20 in progress 20 online 50 online 70 online
Hawk accommodation units On a ship Arrive in FT 105 online
Kitchen from Rogbere On-site Operational
Offices from Lungi On-site Operational
Electrical Expansions Ongoing upgrades to ensure sufficient capacity for expansion
Waste / Water / Sewage Expansions Current infrastructure inadequate; quotes being sourced
8February 2012
9. Pepel Camp Accommodation Requirements – Sewage is the Critical Issue
People Accommodation
Requirements (Expats Only)
Today End of Feb End of March End of April
AML Operations 122 130 145 155
AML Pepel Construction 7 10 10 10
Sub-Contractors 209 245 256 256
Relocating from Makeni - 30 30 30
Relocating from Freetown / London - - 10 - 15 15
Total 338 415 456 466
Description Today End of Feb End of March End of April
Number of Expat Units 212 270 431 476
Number of Beds 295 388 431 476
Number of People on the Boat 54 ≤27 0 0
Kitchen Design Capacity 200+ 400+ 400+ 400+
Waste/Water/Sewage Design Capacity 120 ? ? ?
9February 2012
11. 11
Rail Ramp-Up
(in ‘000 tonnes)
J F M A M J J A S O N D
5 trains @ 4,500 tonne/train (3 locos*75
wagons*60t)
558
7 trains @ 4,500tonne/train (3 locos*75
wagons*60t)
650
Dual track at Pepel; dual track ,loop and
2nd train loader at the mine all allow
reductions in cycle times from 25hr to 21
hr to 18 hrs.
976.5 945
Increase tonnes per wagon to 70t 1,215
Increase number of trains to 8 @ 5,250
tonne/train (3 locos*75 wagons*70t) 1,323 1,367 1,367
Increase load per wagon to 75t and
number of trains to 9@ 4,5,600
tonne/train (3 locos*75 wagons*75t)
1,680 1,822 1,670
increase trains to 11 consists 2,046
ANNUAL TOTAL 15,620,000 Tonnes
Monthly Operational Ramp-Up Schedule to Deliver 15Mt in 2012 – Slightly
Behind, Rapidly Catching Up, Back On-Schedule by End of March
February 2012
Total tonnes railed
YTD = 318,109
12. 12
Achievements to date
• [Insert safety achievement]
• [Number of Sierra Leoneans employed]
• [tonnes loaded to date]
• [number of ships loaded]
• [Best loading rate achieved]
• [Reduction in mooring times]
Area Achievement
Safety No LTIs from operations to date
Delivery of Locos and Ore Cars 15 loco’s in service; 3 more coming online this week;
2 loco’s on schedule for 26th February delivery
118 ore cars arriving next week (7th February)
Destressing and Final Tamping of
New Rail
Completed first 10km; on track for mid April
completion
Upgrade of Old Rail Commenced upgrade last week ahead of schedule
Tonnes Railed YTD 318,109 tonnes
Total Tonnes Railed 751,946 tonnes
Current Train Operations 4 trains per day consisting 3 loco’s and 80 ore cars
Track Speeds Old Rail 25km/h average speed; new rail 40-50km/h
average speed; destressed rail up to 70km/h
Cycle time 23 hours
February 2012
13. 13
Moving to 20mtpa
Area Existing Infrastructure Future Infrastructure Date
Trains 20 3300HP Diesel
Locomotives
34 locomotives 2 delivered June and 2 per
month subsequently
Ore
Cars
450 20 TAL Bottom
Dumping Ore Cars
450 20 TAL Ore Cars
298 25 TAL Ore Cars
98 July
100 August
100 September
Track 83 km reconstructed
rail
123km new rail
7 Turnouts
Entire route new rail
10 turnouts
Complete mine loop
14km double track
August 2012
18 hour cycle time
70km/h average
track speed
23 hour cycle time
38 km/h average
track speed
February 2012
