Sten Johansson CV1 -2016

Sten Johansson
Principal Process Engineer
Email: stenjohansson027@gmail.com
Cell: +27 82 802 7559
1
Curriculum Vitae
Sten Johansson
Profession:  Principal Process Engineer
Education:  Diploma in Mining and Metallurgical
Engineering, Skellefteå Senior Technical
College, Skellefteå, Sweden, 1964.
 Chemistry 101,102,103 and Geology
101,102,103,
University of South Africa, 1975.
 Management Accounting Course, Wits
Business School, 1991.
 SEM 1 Management Course, 1982.
Registrations /
Affiliations
 Member, South African Institute of Mining
and Metallurgy.
Specialisation
Process engineering and operation. Design and operation of process and beneficiation plants for base
metals, gold, heavy minerals, iron ores and vanadium, chrome, steel and stainless steel production.
Recent and current activities include mining feasibility projects, reviews in support of CPR and due diligence
work as well as trouble shooting in operational plants.
Expertise
Sten has spent his entire career in process engineering since 1966. Experience includes design, research,
operations, project management and consultancy in a broad selection of metals including iron ore,
vanadium, lead, zinc, copper, gold and uranium. Sten has particular expertise in pelletizing, melting and

Sten Johansson
Cell: +27 82 802 7559
2
SAG milling applications. His experience has been applied in studies conducted in Europe, South Africa,
Ukraine, Brazil, Italy and various sub-Saharan African countries.
Sten also contributed to the development of the Carbon-in Pulp process for gold recovery including
managing pilot plant operations at Gencor and the design of the process for the Beatrix and Grootvlei
Plants.
The following are key areas of expertise:
 Iron ore processing
 SAG milling applications
 Pyrometallurgy and pelletizing
 Steel and stainless steel making
 Ferrochrome and ferromanganese production
 Gold and Uranium Production
 Vanadium production
 Base metal floatation and refining
 Phosphate flotation
 Hydrometallurgical processes including leaching, ion exchange and solvent extraction
 Heavy metals recovery
 Sten has extensive experience in the operation of smelter plants over a variety of products.

Sten Johansson
Cell: +27 82 802 7559
3
Employment History
2012 - 2015 Principal Metallurgical Consultant Royal HaskoningDHV (Associated)
2004 - 2012 Principal Metallurgical Consultant Turgis Consulting (Pty) Ltd (Associated)
2002 - 2004 Independent Metallurgical Consultant
1996 - 2002 Process Consultant Columbus Stainless Steel
1986 - 1996 Process Engineer & Consultant Columbus Joint Venture
1985 - 1986 Consulting Metallurgist Samancor Ltd. - Chrome Division
1979 - 1985 Head Metallurgical Engineer Gencor Group Research Laboratory
1977 - 1979 Plant Metallurgist Randfontein Estates Gold Mine
1976 - 1977 Plant Metallurgist Golden Dumps
1974 - 1976 Research Metallurgist Union Corporation Research Laboratory
1968 - 1974 Research Engineer Granges Mineral Processing Laboratory
1966 - 1968 Research Engineer LKAB (Sweden)

Sten Johansson
Cell: +27 82 802 7559
4
Key Experience
 Due Diligence on an off-shore phosphate recovery project in Namibia. This included the
processing design from the production of concentrate to the production of the phosphoric acid
and final products.
 Monitoring of the Northland Project, Sweden for progress and cost control on behalf of the
bankers. Process plant area.
 Technical review of all Xstrata ferrochrome and vanadium smelters
 Independent review of DFS documents (process plant areas) for an expansion project of a
major platinum producer in Zimbabwe.
 Assessment of a gold plant operation in Botswana and recommendation of improvements and
possible changes required for change of ore from oxide to sulphide.
 Scoping design and costing of a phosphate processing plant for the Elandsfontyn phosphate project
Western Cape, South Africa..
 Scoping design and costing of a processing plant for the Kodal project, Norway.
 Insurance assessment for Machadodorp ferrochrome plant and Kato Ridge ferromanganese plant.
 PEA for Duyker Eiland Phosphate scoping study, Western Cape, South Africa.
 Metallurgical review of the process design for the Northland iron ore project, Sweden
 Metallurgical part of a preliminary feasibility study for a gold mining project in South Africa
 Assessment of status of abandoned project for copper/cobalt recovery in an African country
 Due Diligence on a copper mine in Africa.
 Scoping study for a metallurgical plant as part of an iron ore project in South Africa
 Due Diligence on a Ferrochrome Plant in South Africa for prospective buyer.
 Metallurgical adviser to the owner’s team doing a PFS for a Ferrochrome Plant in China.
 Scoping study of four prospective phosphate deposits in South Africa. This was done in two stages. First
stage was evaluation of the four deposits from available data and recommending the best deposit for
further work. The second stage was the preliminary evaluation of the Duiker Eiland prospect to obtain
an indication of the potential as a viable project.
 Due diligence of a uranium project in Namibia.
 Specifying and preliminary costing a sinter plant for a manganese project in South Africa.

Sten Johansson
Cell: +27 82 802 7559
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 Leading an investigation into the best option for sulphur capture from the BCL smelter in Botswana for
the European Commission.
 Due diligence on a Gold Recovery Plant in Ghana.
 Engaged by a Japanese /Korean consortium for a due diligence of a Brazilian company mining and
processing iron ore.
 Reports (43-101) for the Canadian Stock Exchange, metallurgical chapter, for miscellaneous Brazilian
and North American Projects.
 Investigating processing possibilities for a limonitic type iron ore from Kazakhstan
 Contribution to conceptual flow sheet and costing of metallurgical plant for conceptual study of
Ferrexpo’s Galeshne deposit in Ukraine.
 Engaged by SRK, Denver to take part in a review of four iron ore projects in Brazil including Minas Rio
and Amapa. The responsibilities included reviewing metallurgical testwork and proposed flowsheets as
well as already ongoing operations and as a competent person editing the metallurgical section of the
43-101 Reports.
 Plant review and high level capex and opex estimates for the refurbishing of the magnetite processing
plant at Nova Mine, Ukraine
 High level cost estimate for a magnetite process plant in Poltava, Ukraine.
 High level cost estimate for Twistdraai gold project including lay-out, capex and opex.
 Investigation into the cause of a fire at the solvent extraction plant at Konkola Copper Mines, Chingola,
Zambia.
 Assessment of milling layout using existing mills at lower tonnage for a gold mine in Ghana.
 Due diligence exercise for prospective bidder for iron, steel and vanadium works in South Africa.
 Due diligence of Severny Mining and Processing Works owned by Open Joint-Stock Company “SevGOK”,
Krivoy Rog, Ukraine. The responsibilities included reviewing the present process plants regarding
present assets and performance, ongoing investment plan and the strategic plan 2005-2015.
 Operational performance intervention for SMS Demag, Genoa: Inmetco process. The pellet production
during earlier trials did not reach the projected capacity of the plant and the task was to resolve the
problem.
 Commissioned by Uddeholm Technology to investigate the pollution impact from a Granshot iron
granulation plant on the water circuit at Saldanha Steel, South Africa. A sampling programme was
carried out over a period of time, the results were analysed and the mass balances for the main
possible pollutants were calculated and summarised in a report.
 Commissioned by IMS, South Africa, consultancy design, erection and commissioning of a steel plant
waste smelting plant at Columbus Stainless, South Africa.

Sten Johansson
Cell: +27 82 802 7559
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 Consultant, Process Technology, Columbus Stainless. This position was as a full-time employee of
Columbus Stainless.
o Administrate the completion of the Technology Supply Contracts with Krupp Thyssen Stainless,
Nisshin Steel and Uddeholm Technology. The contracts with KTS and Nisshin were completed
and closed.
o Modelling plant throughput based on equipment design capacities and plant experience for
planning of the production build-up to be included in the five-year plan; Columbus Stainless
o Define shortcomings in the processes and carrying out feasibility studies, recommendations
and motivations for board decisions. Some of the equipment motivated and installed including
additional slab grinders, additional cut-to-length line and a heavy plate cut up line.
o Define and recommend future expansions. This includes development of flow sheets,
recommendations of new equipment, estimations of operating cost and capital cost and a cash
flow analysis to prove the viability.
o Direct implementation of an Environmental System that meets legal requirements.
 Process Engineer / Process Consultant for the Columbus Joint Venture Expansion Project.
o Techno/economic comparison study between building a new stainless steel plant or to expand
facilities at Middelburg to 500 000 tpa slab capacity rolled to hot or cold rolled coil. Value of
the final expansion US$1,000 million.
o Coordinate input from technology suppliers (Thyssen, Nisshin, Uddeholm), Project Engineers
and Plant Management to define the scope of the project and choice of processes and
equipment.
o Senior member of the team finalizing the feasibility study for Board approval followed by
vendor negotiations, choice of vendors and final contract negotiations.
o Arranging training at the Technology Suppliers plants and coordinating the Technology Supply
teams during commissioning was also a major responsibility as part of administration of the
contract.
o Scope definition for the BPEO (Best Practical Environmental Option) and negotiating contracts
for supply of process gases.
 Assistant Consulting Metallurgist/Consulting Metallurgist at Samancor Ltd., Chrome Division. Projects
included plants for Chrome and Manganese smelters. Part of the duties was also the Langphos mine in
the Saldanha Bay Municipality in Western Cape. The tasks included the process optimisation of the
plant for producing a suitable phosphate product for the fertiliser market.
 Research Metallurgist Union Corporation/Gencor Group Research Laboratory
o Development of projects to improve processes and products in the fields of concentration, pre-
treatment (agglomeration, roasting, pre-reduction, preheating), smelting and refining. Projects

Sten Johansson
Cell: +27 82 802 7559
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outside the chrome recovery included heavy minerals from sand, titanium pigment, nickel, iron,
zinc and phosphates.
o R&D projects in precious and base metal processing. Supervising a department of 25 including
eight graduates and five technicians. Some of the processes included were flotation of base
metals (zinc, lead, copper), leaching and recovery of gold (especially the CIP process), magnetic
recovery of iron (both low intensity for magnetite and wet high intensity for hematite) and
gravity separation. Crushing and milling was always part of the investigations. Autogenous
milling for quartzitic gold ores was a specialty for the company.
o Acting Metallurgical Manager, Grootvlei Mine. Responsible for the gold recovery process plant.
o Assistant to Group Consulting Metallurgist Office. Compile chapter on carbon-in pulp in the
SAIMM published book on the Extractive Metallurgy of Gold in South Africa. Main achievement
was the development of a computer model for the carbon-in-pulp process for application in the
group.
 Plant Metallurgist at Randfontein Estates Gold Mine.
o Part of the team commissioning the Cooke Plant. Some responsibilities included
commissioning and optimising throughput and recovery of gold and uranium, establishing and
running a metallurgical accounting system for the gold and uranium recovery and responsible
for the dispatch of gold bars to Rand Refinery and yellow cake to Nufcor.
o Process development for the RBM heavy minerals plant.
o Process development for the Union Corporation gold mines to improve recovery.
o Autogenous milling of ores.
o Fluorspar flotation.
o Base metal flotation, including nickel, zinc and lead.
o Due diligence of a vanadium recovery plant in Mpumalanga.
 Research Engineer at Granges Mineral Processing Laboratory in Sweden. Supervising a team of five
permanent research officials and eight temporary workers.
o Iron ore concentration and pelletising projects. The projects were taken from initial tests,
through pilot plant tests to final flow sheet, estimate of operating and capital cost and a final
recommendation.
o Vanadium recovery from titaniferous magnetite project. This was a major project with many
novel process steps.
o Operation of a demonstration plant for production of cement bound pellets (Grangcold
Process) Plant capacity was 20 tph and about 70,000 ton was produced for test in Granges
Steel’s blast furnace in Oxelösund, Sweden.
o

Sten Johansson
Cell: +27 82 802 7559
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 Research Engineer at LKAB Sweden.
o Iron ore concentration and pelletizing project. The main emphasis was on improving the
products from LKAB to be preferred by the main steel makers in the world. This was a period
for major development of pellets to be a preferred feed product in blast furnace iron making.
LKAB took the lead in developing standardized test procedures for pelletizing as well as the
pelletised product. The development included producing pellets in laboratory and pilot scale,
testing of different binders and slag formers, testing of the mechanical properties during the
process as well as for the produced pellets, and testing the product for properties during
reduction, simulating the conditions in a blast furnace. This work established LKAB as a
preferred supplier of pellets to major steel makers in Germany and Japan.

Sten Johansson
Cell: +27 82 802 7559
9
Comments regarding iron ore experience
 Experience prior to association with Turgis/RHDHV
o Working with LKAB, Sweden was during a intensive development time for pelletising. LKAB
required a product that could compete in the market with low cost produced ores from
Venezuela ,Brazil and other low cost open pit ores. The emphasis was to produce pellets
with superior properties regarding strength, reducibility and slag composition. The LKAB
ores are mainly magnetite ores of skarn type but also contain hematite. The ore dressing
included crushing, cobbing, milling followed by both magnetic and gravity separation. Fine
milling of a large portion of the ore was required to achive a good iron grade and hence the
agglomeration of the final concentrate was required.
o The Granges Mineral Processing Laboratory (Minpro) in Stråssa Sweden developed and
project managed the installation of processes both within and outside of the Granges
Group. The experience gained at this laboratory included development of processes to a
number of different ores including ores from Nimba and Tokadeh in Liberia. The LAMCO
operation was run by the Granges Group and all process development and trouble shooting
was carried out at Minpro. A new process including phosphate flotation and reverse
flotation of silicates was also developed for the Grangesberg ore and a new plant was
erected. Managing the operation of a pelletising plant was also part of the experience.
o During the Samancor and Columbus employments the experience of the pyrometallurgical
processes was invaluable regarding the properties of the chemistry and mechanical
properties of the feed materials that affects the process.
 Experience after association with Turgis/RHDHV
o Working on Itabirite type ores in Brazil, including pilot plant testwork.
o Work in Ukraine on Sevgog ore, Krivoi Rog and a number of ores in the Poltava district.
o Northland project in Sweden, reviewing the building of the plant using all the newest
equipment including autogenous milling, tower mills and automatic pressure filters (VPN)
o South African project in southern Mpumalanga. Scoping design and costing of plant.
Comments regarding phosphate processing experience
o As consulting metallurgist for Samancor one of the responsibilities was the Langfos plant at
Langebaanweg, in the Saldanha Bay municipality, Western Cape Province, South Africa. The ore
was typical phosphate sand with cellophane as the phosphate containing mineral and quartz as the

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Cell: +27 82 802 7559
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main gangue. Milling, de-sliming and flotation were applied, producing a concentrate of typically
33% P2O5.
o As principal metallurgical engineer for Turgis Consulting and RHDHV a number of projects has been
carried out including:
 Technical assessment of four potential phosphate deposits for Montero.
 Preliminary assessment including flotation testwork, process and plant design, capex and
opex on a scoping level for the Duyker Eiland project Montero Mining., South Africa.
 Preliminary assessment including process and plant design, capex and opex for submission
of the Mining Works Programme for the Elandsfontein Project, South Africa.
o Leading an investigation into the best option for sulphur capture from the BCL smelter in Botswana
for the European Commission. This work involved:
 Researching technical options and recommending the best solution which was concluded
to be a sulphuric acid plant
 Investigating different sulphuric acid plant designs and estimating capital and operating
costs for different solutions.
 Investigating the possibility to use recovered acid for phosphoric acid and fertiliser
production.
o As part of a RHDHV team doing a review/audit of the processing design including:
 Reviewing the proposed concentration method for the phosphate
 Reviewing the proposed processing plant for production of phosphoric acid from the
concentrate. This is a new process able to produce the phosphoric acid economically from
lower grade concentrates than the conventional process.

Sten Johansson CV1 -2016

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