GEITA GOLD MINE

SAG MILL

UPGRADE

Johann J van Rensburg

Engineering Manager Met. Plants

AGENDAGeita Mine Profile

Mill Detail

Mill Damage and History

Gearbox History

Upgrade Scope

ManufacturingManufacturing

Installation Planning

Key Dates

Installation

Conclusion

GEITA GOLD MINE PROFILE

GEITA GOLD MINE PROFILEGEITA GOLD MINE PROFILE

357

494485

502 502 502 502

520

500 505516

528539

550

400

500

600

10% Improvement on Base Ounces

10%

308

327

264272

357

286

0

100

200

300

2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

ko

z p

a

GGM History GGM Budget Incremental GGM 5yr Target GGM Actual YTD

GGM 5yr Delivery Target Improvement Rate is 10% from Base Year 2011

Geita

ANGLOGOLDASHANTI GLOBAL

Trans Siberian GoldfieldsRussia

GEITA GOLD MINE PROFILE

Geita positions

itself for

success!

The recent turnaround at Continental Africa Region’s Geita Gold Mine is undoubtedly one of the greatest success stories in AGA.

Geita was once again an outstanding performer during the 4th quarter, delivering 144,000oz at $486/oz despite repairs undertaken to the SAG mill gearbox.

Gary Davies and his team delivered 494,000oz at $536/oz for the year, making it the second-largest contributor in the group and generating significant free cash flow for AGA.

This performance is the culmination of ongoing efforts to turn Geita around and position it as one of the most reliable and lowest cost producers in AGA. the most reliable and lowest cost producers in AGA.

In 2008, Geita’s production dropped to 264,000 oz and costs ended the year at $921/oz. In order to improve this, AGA launched a turnaround plan which has delivered remarkable results.

Evidence of this can be seen in the steady growth in production to 272, 000oz in 2009 – 357, 000oz in 2010 – 494, 000oz in 2011 with the corresponding reduction in cost per ounce. All this was achieved with minimal capital investment.

Even though we’ve had the benefit from improved grade throughout this period, it is the improvement in operating performance that’s given Geita the biggest lift. Amongst some of the most notable improvement projects that assisted Geita in improving its results are the productivity improvements in heavy mobile equipment, throughout improvements in the processing plant, reduction in ore loss & dilution and improvements in gravity gold recovery.

A mine does not operate itself, and its success is owed the people and teams who have committed themselves in helping Geita turn it around! Well done to Gary and the Geita Team, we look forward to seeing more

MILL DETAILMILL DETAIL

MILL DETAIL

� Shell supported mill with 4 Slipper Pads on each side

� 9.14 m diameter and 5,5 m long

� 600t/h Capacity

� Double drive with 2 off kW 4500, 11 kV Induction Motors� Double drive with 2 off kW 4500, 11 kV Induction Motors

� Girth and Pinion configuration for interchangeability.

� Induction Motor with fixed coupling.

MILL END DAMAGEMILL END DAMAGE

and

HISTORY

MILL END DAMAGE and HISTORY

� 2000 - Commissioning shortfalls.

� 2003 - Tanzania drought resulted in water shortage and Mill ran dry

� Oct 2008 - Feed End crack and repaired with designed clamps

� Feb 2009 - Discharge End crack

� June 2009 - Replaced Discharge End that was ordered for Feed End

� Aug 2010 - Collapsed of the Feed End (42 Day repair)

� Gearbox failures (9 months to 4 months)

� Nov 2011 – Gearbox Failure Analysis

MILL END DAMAGE

Cold joint repair / clamps Major crack repairs

Broken Mill end flange Visible balls due to wash

MILL END DAMAGE

Broken Mill end flange Mill end spigot damage

Mill end spigot damage Shell end MPI

MILL END DAMAGE

Mill end removal Halve end removed

Damaged Spigot (end) Damaged Spigot (shell)

MILL END DAMAGE

Identified Cracks Welded shell end surface

Machined shell end surface Spider Jacks

MILL END DAMAGE

Spider installation Spider completion

Journal joint repair Final repair stages

MILL END DAMAGE

Surface Grinding Run-out Measurements

New Mill end

GEARBOX HISTORYGEARBOX HISTORY

GEARBOX HISTORY

� Gearbox failures (deteriorated from 9 months to 4 months)

� Nov 2011 - Gearbox Failure Analysis

� Dec 2011- Assessment Results

� Gear-mesh and Casing frequencies in close range

� Thrust system totally under sized

� Casing stiffing inadequate

GEARBOX FAILURE ANALYSIS

Y

X

ZZ

ACCELEROMETERS

STRAIN GAUGES

UPGRADE SCOPEUPGRADE SCOPE

Upgrade scope

� Shell sections – PSP (Czech Republic)

� Gearboxes – Siemens (Germany)

� Disengagement couplings – Siemens (Germany)

� Drive train couplings – Moventas (Finland)

� Gear guard top half and sealing arrangement – Zenfer (RSA)

� Trunnion bearing housing top half and sealing arrangement – Zenfer� Trunnion bearing housing top half and sealing arrangement – Zenfer

(RSA)

� Radial & thrust bearing pads – USAB (Sweden)

� Gearbox lubrication system – Hydx (Sweden)

� Head end plates – Siempelkamp (Germany)

MANUFACTURINGMANUFACTURING

MILL END MANUFACTURER

Siempelkamp. Germany

MILL END MANUFACTURER

Mill ends. Siempelkamp

300 mm diam, V 20 Engine Castings

Tropicana Mill end

……….they can

MILL END MANUFACTURER

Mill ends. Siempelkamp

Casted end with machining completed (Siempelkamp)

Completed Mill ends (PSP)

MILL SHELL MANUFACTURER

PSP Engineering. Prerov – Czech Republic

MILL SHELL MANUFACTURER

JANA Hotel. Prerov – Czech Republic

MILL SHELL MANUFACTURER

Mill Shell. PSP

From Raw Material…….

……sections of the shell

MILL SHELL MANUFACTURER

Mill Shell. PSP

Slipper pad bearing journal

Sand Submerge arc-welding

MILL SHELL MANUFACTURER

Mill Shell. PSP

Slipper pad bearing journal

Flange support in journal

MILL SHELL MANUFACTURER

Mill Shell. PSP

Continuous heat treatment

Shell Flanges

MILL SHELL MANUFACTURER

Mill Shell. PSP

Shell half jointed

Spider Supported

MILL SHELL MANUFACTURER

Mill Shell. PSP

Flanged shell halve

Shell halve inside

MILL SHELL MANUFACTURER

Mill Shell. PSP

Slipper pad bearing journal welded to shell

Flanged Joint

MILL SHELL MANUFACTURER

Mill Shell. PSP

Completed halve with transport cradle

Other halves completed

MILL SHELL MANUFACTURER

Mill Shell. PSP

Shell loading

Ready for the long road………..

PSP

MILL SHELL MANUFACTURER

Improved sealing arrangements

Girth Sealing arrangements

Bearing Sealing arrangements

GEARBOX MANUFACTURER

FLENDER / SIEMENS. Hern, Bocholt, Voerder - Germany

GEARBOX MANUFACTURER

Gearbox. Siemens/Flender

Load Running tests

Running tests

GEARBOX MANUFACTURER

Gearbox. Siemens/Flender

Gearbox assessment

Dimensional verification

Lubrication Spray

LUBRICATION SYSTEM

Hyd-X. Ystad - Sweden

LUBRICATION SYSTEM

Lubrication System. Hyd-X

Completed system-Example

Geita system installed Geita system installed

TRANSPORTTRANSPORT

TRANSPORT

EUROPEAN LEG – 25 065 kmFinal Europe dispatched destination-Ostrava

Three flights from Ostrava (Czech Republic) to Geita via

Ciaro, Nairobi and Mwanza - 7650 km each

Shell sections

PSP, Prerov - 95 km(Czech Republic)

Head end plates

Siempelkamp,Krefeld - 1129 km. (Germany)

Gearboxes

Siemens,Bochum - 986 km (Germany)

SA LEG – 46 656 km

72 000 km

SA LEG – 46 656 kmFinal SA dispatched destination-

Goteborg/Durban - 17500km

Antwerp/Durban – 15200 km

Durban/Geita - 5478km

Drive train couplings

Moventas - 1693 km(Finland)

Radial & thrust bearing pads

USAB,Morghadshammer - 1636km (Sweden)

Gearbox lubrication system

Hydx, Ystad - 1017km (Sweden)

TRANSPORT

Russian ANTANOV 124 Cargo Carrier. Ostrava-Czech Republic.

Transport

Nose open with platform opening up

Front view with nose open

Transport

Inside fuselage/loading surface

Ramp with sliders in progress

Transport

Shell halve approaching

Shell on ramp OSTRAVA

Transport

Load fully tied down

Pre-designed anchor points

Planning Process

PLANNING PROCESS

• 17 variations of installation planning plans

• 47 days cut down to 32

• 3 x Geita site visits

• Installation review in Australia

• 220 line item activities

• Product break down structure

• Detailed labour, tools, special tools and consumable planning

• Site Layout plan

• Installation Organogram

Step by Step Installation

Step by Step Installation

Step by Step installation procedure

Key Dates

Upgrade scope

• Final completion of all components 16 November 2012

• Last arrival of freight to Nairobi 4 December 2012

• Outotec crew on site from 7 December 2012 – Pre-work start

• Last arrival of freight to Geita 12 December 2012

• Final invoice date 14 December 2012

• Outotec arrive on site 07 January 2013

• Geita shut down mill on 13 January 2013

• Outotec hand over mill to Geita for liner installation 20 Feb 2013

• Final Commission to start 25 Feb 2013

• Start mill 26 Feb 2013

• Planned mill running at day 44 (Excluding final commissioning and hand over 8 days)

Installation

Installation

New Bearing pad and base

New Gearbox in position

Installation

Removal of Old Gearbox

Old Discharge-end

Installation

Feed-end bearing pad base

Bearing pads in position

Installation

Graveyard……..

Storage area

Installation

Start of first lift

Hold on………

Installation

Lower Feed-end in transit

Lower Feed-end in vertical

Installation

Almost in position

Discharge-end in position

Installation

Mill assembled

Mill assembled

Installation

Girth gear joint

Self-disengagement System

Installation

Mill in finalising stages

Installation

New Re-lining machine

Slinging process

Installation

Head post inside Mill

Main Frame supporterd

ConclusionConclusion

Conclusion

SOME INTERESTING FACTS

• Total distance of equipment travel – 72 000 km.

• Total weight of equipment travel in excess of 300 ton.

• Equipment sourced from 8 Companies in 5 Countries.

• Welding in excess of 12 ton.• Welding in excess of 12 ton.

• During dis-assembly and assembly

• Approximately 700 ton handled

• About 1000 bolts handled

• Approximately 50 000 man hours worked.

• Project Estimated Cost – R 125 mil.

Completed Mill

?