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Directors’ review of operations – Quality metallurgical anthracite from Somkhele
Operational and financial review Somkhele produced 524,006 tonnes (2010: 467,843 tonnes) and sold 579,087 tonnes (2010: 411,630 tonnes) of anthracite in the year to 30 June 2011. Net profit margins of 25% (2010: 36%) were achieved during the year ended 30 June 2011. The reduction in margins was due to the stronger Rand which reduced revenues by approximately R28 million and the increased mining costs (as previously announced in November 2010, it was anticipated that mining costs would increase due to an increase in strip ratios in the deeper reserves in Area 1). The increased amount of overburden to be moved in this higher strip ratio environment resulted in an increase in mining costs of 56% when moving from a strip ratio of 1.7:1 in Area 2 to a strip ratio of 4:1 in Area 1. The increased production and sales volumes combined with efficiency improvements enabled Somkhele to curtail the impact of these higher costs and achieve a net profit margin of 25%. Mining activities The performance per area is given in the table below:
Waste removal in Area 1 during the period under review was 134,210m3. Plans have been put in place to further improve on this during the coming year, with improved equipment being introduced at the mine. Waste removal in Area 2 was 205,578m3. Mining in Area 2 has been difficult and constrained due to the limited access to the final levels of the pit. During the period under review, coal exposed in Area 1 was 159,730 tonnes, whilst coal exposed in Area 2 was 6,993 tonnes. The total coal exposed was 1,215,460 tonnes whilst 1,250,268 tonnes were fed to the washing plant. The deficit on coal exposed has effectively reduced the available coal exposed from three to two months. Somkhele Anthracite Mine highlights
A mining engineer has been appointed and is finalising the development of a planning department. The planning models are being reviewed to ensure continuity and optimise the current pit designs. Capital expenditure Capital expenditure of R268 million (2010: R81 million) was incurred during the year ended 30 June 2011. R181 million (2010: R57 million) was spent on pre-stripping the open pits in Area 1 in order to ensure sufficient coal is available to feed the second plant once it is commissioned. The main focus of the balance of the capital expenditure was the construction of the second plant and the mineral resource exploration and evaluation drilling programme. Exploration programme Exploration for the B coal seam in Areas 4 and 5 began in August 2010 under the prospecting licences held by Somkhele. The exploration work has followed two concurrent approaches, one to locate new coal blocks and the other to sample by core drilling the KwaQubuka and Emalahleni blocks that had been delineated in previous percussion drilling campaigns, and then to evaluate new blocks located by the regional exploration. Somkhele mining and exploration areas
Grid percussion drilling started in the Ophondweni block, located by regional exploration in a previous prospecting programme, and included testing the strike extremities. In addition to delineating the extent of potential anthracite resources, percussion drilling located and delineated the adjacent Gwabalanda block. Although this drilling achieved its objective, the amount of dolerite in or near the B seam, causing the coal to be badly burnt over large areas in both these blocks, was disappointing. Subsequent geophysical density logging the coal seam and initial wash analyses from two core holes in Ophondweni suggests that these blocks could yield a high-density variety of anthracite away from the burnt areas. The Gwabalanda block lies approximately 1.5km west of Ophondweni and is terminated at its northern and southern extremities by dolerite. The two blocks are separated by a normal fault with a throw of about 600m. The Ophondweni block lies on the strike extension of and about 6km north-northeast of the Emalahleni block across an area of virtually no rock exposure. A series of holes were drilled but intersected extensive dolerite intrusions in the expected stratigraphic position of the B seam. No further work in this intermediary zone is recommended. Exploration for new blocks is now focusing attention on the Tholokuhle, Mvutshini and Gunjanini blocks. Initial drilling has intersected coal correlated with the B seam although faulted and disturbed by dolerite intrusion. The positive correlations will now be tested along strike. Exploration for new blocks has been aided by an aeromagnetic survey over Areas 4 and 5. The objective of this survey is to locate the major west-dipping faults that repeat the east-dipping stratigraphy and present new mining opportunities. The faults cut the dolerite intrusions which in turn alters the shape and intensity of the magnetic field associated with dolerite varieties that are magnetic. Initial examination of the data suggests that the survey has been successful and will be of assistance to the interpretation of the geological structure. The survey has subsequently revealed an unknown increase in dolerite intrusion as north-northwest trending dykes in the northern third of Area 5. Core evaluation drilling of the near-surface Emalahleni and KwaQubuka blocks is almost complete. These holes should be complete in the next 6 months and will enable these previous categorized inferred resources to be upgraded to measured and indicated categories. Extensive percussion drilling of potential underground resources has been undertaken down dip from the open cast areas of Area 1 and Emalahleni. This drilling has been largely successful and is expected to add significant tonnages to the measured and indicated resources for Somkhele once the core drilling and wash analyses of the samples are complete. To date, R10.75 million has been spent on new target location and evaluation, including the open pit resources in Emalahleni and KwaQubuka, and a further R5.6 million spent on evaluating potential resources extractable by underground mining methods. Construction of the second wash plant to double production In July 2010, Petmin announced the expansion of Somkhele to double production through the construction of a second coal washing plant. Construction is progressing according to schedule, with all civil and structural designs completed and the final electrical designs being verified and finalised. The structural and civil contracts were both phased, in order to allow the project team an early start on construction. The civil contract for phase 1 has been completed, as well as all bulk excavations and backfilling. The contract for phases 2-5 for the remainder of civil work was placed and the civil team has already started with the priority areas and is progressing according to schedule. The mechanical contract for phase 1 is on schedule. A decision to do all plate work designs and fabrication earlier in the project has saved time. The contracts for phases 2-5 have been placed and additional teams and site management allocated to complete this work according to schedule. To date, about 75% of the construction costs have been committed with only the electrical contract and the civils to order for the bunkers to be placed. The plant is on track for commissioning at the end of the first quarter of 2012. Market review Global supply Over the past decade, Russian and Ukrainian anthracite has been successfully sold into the western European and Mediterranean markets. The Siberian mines are now looking at markets in Asia, but they are dependent on Russian rail freights remaining at a low level to maintain their competiveness in world markets. Longer term, logistics costs in the CIS region can be expected to rise. Exports of anthracite from China and Vietnam have stabilised and may decline in the future. A decade ago, these countries were keen to export around the world for the hard currency. Now the official policy is to discourage exports of primary commodities in order to supply the domestic demand and develop their economies. Trade continues into “local” Asian markets, mainly Japan and South Korea. China imports from North Korea and Vietnam, mainly for power production and other relatively low-value applications. South African exports are likely to remain stable at the current level and consist mainly of fines to Brazil for ore-pelletising. Opportunities are expected to open up in India for the same application. There is a strong domestic demand for ilmenite and ferroalloys smelting. US production mainly supplies the North American market with limited sales elsewhere. There are efforts to re-finance the larger Pennsylvania mines and enter the seaborne export market. However, the scale of production of the US mines is well below that of those in other countries and so costs probably higher. Summing production is complicated by the inclusion of raw with washed coal by some countries, the variation in what is defined as anthracite around the world, and the complete lack of datareporting in some countries. Nevertheless, “Resource-Net” has arrived at a figure of 153 million tonnes for world anthracite production (saleable) in 2010, increasing by an average of 4.6% per year over the past decade. Anthracite demand Fines are used typically in iron ore sintering and pelletising applications in place of coke breeze. Use in pulverized coal injection (PCI) in the blast furnace is confined mainly to the Far East. Ilmenite smelting needs low-ash, high fixed-carbon fines, but the number of end-users in this sector is quite limited. Lumps are used as coke replacement in lime kilns by the soda ash and sugar industries, primarily in Europe. These end-use sectors are mature, and there appears little prospect for any significant increase in the future. There is also some demand as coke replacement in ferroalloys production, but use tends to be localised near to the supply source such as in South Africa. Anthracite is also calcined (dried and de-volatilised) for use in electric-arc furnace steelmaking and electrode markets, where it competes against calcined petroleum coke. In North America, the lumps market is still dominated by the household fuel sector. In Asia, there is relatively low demand currently for anthracite lumps compared to the rest of the world. Anthracite pricing Due to the variety of grades and applications, anthracite does not lend itself to reference pricing such as that produced by commodity market publishers for steam coal and other carbonaceous products. The only regular (monthly) pricing series for anthracite is produced by “Resource-Net” for the European market (cfr basis northern Europe, lumps and fines, max 3% volatiles). Grades for pulverized coal injection (PCI) in the Far East are sold in line with low-volatile PCI coals from Australia. Until the price spike in coke of 2007-08, anthracite pricing was linked more to the steam coal than the metallurgical coke and coal markets. The lumps price peaked at $325/tonne cfr in the third quarter 2008. While it is often stated that suppliers target anthracite lumps at 60-70% of the blast furnace coke price, our analyses show that:
Demand for Somkhele’s products remained good during the reporting period. Internationally, there has been an increase in demand for carbon feedstock, mainly due to the floods in Australia. Unfortunately, Somkhele could not capitalise on these opportunities as the mine had already been operating at improved and maximum capacity. Supply agreements with key customers have been signed with take or pay agreements for at least 50% of the planned production tonnages for the period 1 April 2012 to 28 February 2013. Local market Our principal local market is the ferrochrome producers which have seen solid demand in the year under review but are increasingly under pressure as Chinese demand for ferrochrome has softened considerably – due primarily to significant quantities of ore being supplied to China from other locations. Our major customers continue to order in line with forecast despite some furnace closures indicating variable and lower supply from other producers. We believe that we may be less affected than most producers given the fact that we form a significant portion of the reductant base for these customers. We expect this trend to continue for at least the first half of the forthcoming year and have planned accordingly. This is however offset by the ‘take or pay’ and guaranteed tonnages embedded in our long-term supply contracts. Sustainable development highlights at Somkhele Health and safety There were no lost time or reportable accidents reported for the reporting period. The LTIFR for Somkhele is zero. The review of all mandatory COPs has been completed. There were no occupational health cases reported during the period under review. Results from the Personal Dust Exposure surveys performed on employees indicated that all exposures were within the occupational exposure limits of 2.0 mg/m3 for coal dust and 0.1 mg/m3 for Alpha-Quartz. Environment There were no environmental incidents reported for the period. Fall-out dust levels and background noise measurements were determined by the Health and Occupational Hygiene Laboratory during the period. All measurements were within the recommended levels. The limits for particulate matter as prescribed by SANS 1929 allow a daily average limit of 75μg/m3 (0.075mg/m3). The levels measured at the operation did not exceed the above limit and averaged from 0.038 mg/m3 to 0.012 mg/m3 during the study. The mine continued to monitor surface and ground water levels in its area of responsibility. The results are reflected in the table below and were all within the accepted standard allowed. Labour relations The Union Branch Committee is fully operational with monthly meetings attended by NUM representatives. The recruitment, training and development of operators for earth-moving machinery as well as plant operators for the new mining areas and the second washing plant is in progress. The recruitment of locals is a matter of priority. The total number of employees on the mine has increased from 338 in 2010 to approximately 700 at the end of June 2011. LTIFR statistics
Somkhele engages with community recognised structures which includes the Mpukunyoni Mining Committee (MMC), Traditional Council, Indunas and Mtubatuba Local Municipality. The mine also conducts roadshows with communities on issues of environment, safety and health, recruitment and community projects updates. During the year under review, Somkhele supported the surrounding communities through the development of two community halls which have been completed, two dip tanks, two food gardens, the upgrading of a 7km community road and a brickmaking plant which employs nine community members. The mine is currently finalizing a baseline needs survey which will inform the projects the mine will support in the next five years. This process will be completed by December 2011, with implementations of the new strategies to start in early 2012. Results of tests performed on borehole water at Tendele
Directors’ review of operations – Profitable sale of SamQuarz Silica Mine
SamQuarz Silica Mine highlights
Operational and financial review SamQuarz produced 1,325,868 tonnes (2010: 1,255,559 tonnes) of silica and chert in the year ended 30 June 2011. Sales volumes increased by 7% to 1,248,989 tonnes (2009: 1,171,355 tonnes). Profit before tax declined by 15% to R33 million (2010: R39 million) as profit margins were squeezed by the effects of long-term sales contract pricing mechanisms that do not match the inflationary increases of mining costs. Management is negotiating contract price adjustments to reverse this negative trend. Mining costs During the period under review, average total cost per tonne was R109.71 compared with R98.83 in 2010. Variable costs were slightly higher due to drilling and blasting costs rising as a result of the tightening up of the burden and spacing on the western side of the pit to reduce oversize material. The reduction of the burden spacing increased blasting costs by 46% within this area. Maintenance costs were also higher because of the five-day plant shutdown in April 2011 and repeated failures on feeder motors.
Fixed production costs were higher mainly due to contractor salaries paid to assist with plant maintenance during the first quarter, and due to increased rehabilitation costs. Capital expenditure Capital expenditure for the period under review was R63 million (2010: R22 million). Expenditure was primarily spent on the development of the open pit, and the completion of the relocation of the old office block to allow for access to additional nearsurface, glass grade ore. Market review The silica market in South Africa is mainly consumed by the glass and metallurgical sectors. The metallurgical market remains the primary consumer of product, taking approximately 50% of supply. The balance is taken up by the glass manufacturing and construction industries, with a small fraction going into the filter media, silica milling and recreational sectors. SamQuarz continues to be the largest producer of silica in South Africa, with about 35% market share. It supplies silica and chert to key blue-chip companies such as PFG, Consol, Xstrata, Samancor and Nampak. Silica sand sales were negatively impacted by reduced demand from some key customers, with the period between February and March particularly affected. The availability of recycled glass in the market also affected the flint sand offtake. Demand from glass customers remained steady during the period under review. The automotive and construction sectors’ soft performance translated into flat glass sales. SamQuarz – LTIFR: FY10-FY11
Overall metallurgical sector demand remained steady, shored up by the steel trend (refer to the Anthracite market review above) and further improvement is anticipated in this sector over next six months. Spot sales of all products into other sectors are being constantly pursued to shore up sales. Sustainable development highlights at SamQuarz Health and safety Two lost time injuries occurred during the period under review:
The mine currently has a lost time injury frequency rate of 0.51 (FY2010: 0.52). SamQuarz achieved a 5* NOSA rating during the audit conducted in October 2010, achieving 92.34%, compared to 92.08% in the previous year. SamQuarz held campaigns to promote awareness and education in critical areas over the review period, including HIV/Aids, safety in the workplace and home and health in the home. Booklets and posters relating to each topic were placed on all noticeboards at the mine; and T-shirts, caps, pens and packets of fruit were distributed to all employees to enhance awareness of these important topics. There were no new cases involving occupational diseases reported during the period under review. Environment No audits were conducted by the DMR for the period under review. Internal self audits were however conducted and action lists were drawn up to address shortcomings. The review of the Environmental Management Programme Report (EMPR) document is still underway following changes to incorporate moving the office block. This process will now be driven more aggressively in order to complete the document for submission to DMR. Labour relations The relationships between management and employees were well maintained during the period. The Company continued to actively manage its formal union and employee communication forums with union meetings held on a monthly basis and future forum and employment equity meetings held on a quarterly basis. NUM members held elections towards the end of the year for the selection of new committee members. Wage negotiations were concluded with a one year substantive agreement with NUM settling on an increase of 10.2%. For further detail please see Performance against the Mining Charter Scorecard performance on page 39.
Directors’ review of operations – Veremo pig-iron development project
The Veremo development project is an iron-ore deposit of Layer 21 of the magnetite layers of the Upper Zone of the Bushveld Complex. It is attractive for the development of a pig iron operation because of the thickness of the orebody, which is up to 60 metres, lateral continuity, exposure, and high titanium dioxide content. This is the first iron-ore layer to be discovered in South Africa that is capable of generating such large resources per hectare. Location and regional geology The Stoffberg Ti-magnetite project is situated approximately 10km north of the town of Stoffberg. The project is located in the upper most portion of the Upper Zone of the Eastern Bushveld Complex. The Upper Zone is comprised of magnetite-bearing gabbro, anorthosite and olivine diorite and hosts numerous interlayered titano-magnetite layers of variable thickness and lateral extent. Layer 21 ranges in thickness from 7m to 60m and consists of cumulus olivine and plagioclase with variable amounts of Ti-magnetite which generally exceeds 50%, particularly in the stratigraphically lower portion of L21. The latter contains minor quantities of pyroxene, mica and ilmenite and is underlain by magnetite gabbro and overlain by olivine diorite. The hanging wall contact is generally gradational while the floor contact tends to be well defined, except for the occasional occurrence of thin, semimassive stringers of Ti-magnetite in the uppermost 50cm to 80cm of the underlying magnetite gabbro. Plagioclase frequently occurs as distinct lensoid, 1cm to 5cm thick, “eye”-shaped accumulations within L21. Veremo development project highlights
Project history and previous exploration work concluded Veremo’s exploration programme on the Stoffberg Ti-magnetite deposit commenced in 2005. The first phase diamond drilling began in February 2006 and was completed in November 2006, during which time 90 BQ cored boreholes, amounting to 6,594m, were drilled. A total of 314 trenches were excavated, amounting to approximately 14km of trenching. All boreholes and most of the trenches were sampled and submitted for analysis. The results of the field work together with the analytical data were compiled during 2007 in a series of technical reports and the data was used to delineate a resource estimate. During 2008, Veremo had the geological and analytical data reviewed and recalculated the resource model. An in-fill drilling and trenching programme to upgrade the deposit to a SAMREC-compliant resource commenced. During 2009 and 2010 Veremo finalised a core drilling and sampling programme together with a trenching campaign as part of a final geological scoping study to delineate a SAMREC-compliant measured resource in selected high priority areas from previous drilling campaigns. The programme consisted of 38 boreholes drilled. A total of 1,176m of core was drilled during this period. The results of this drilling programme were published by Petmin in the 2010 annual report and delineated a SAMREC-compliant measured and indicated resource of 73.35 million tonnes of measured and indicated resource and 12.83 million tonnes of inferred resource in the weathered zone of the ore body. The project area is divided into five fault-bound structural blocks, and the drilling was aimed at defining the thickness of the weathered zone within each of these blocks. A summary of the 38 boreholes is included in the Reserves and Resources section of this report. During the year under review, Veremo submitted a mining licence application over its project areas. An Environmental Management Programme Report in support of this application was submitted to the DMR in May 2011. Value curve – Veremo
Veremo – project development update
Kermas Limited, the ultimate controlling shareholder of Veremo is assessing various development options to produce some 1 million tonnes of pig iron and potentially titanium slag and awaits the outcome of the mining licence application. |
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