Overview
Stage | Production |
Mine Type | Open Pit |
Commodities |
- PGM
- Platinum
- Palladium
- Rhodium
- Iridium
- Ruthenium
- Gold
- Nickel
- Copper
|
Mining Method |
|
Processing |
- Purification & crystallization
- Acid plant
- Smelting
- Ore sorter (multi-sensor)
- Electric furnace
- Hydrochloric acid (reagent)
- Crush & Screen plant
- Flotation
- High Pressure Acid Leach (HPAL)
- Magnetic separation
- Dewatering
- Solvent Extraction & Electrowinning
- Dissolving & Crystallising
|
Production Start | 1993 |
Mine Life | 2097 |
Mogalakwena mine is one of the world’s highest margin PGM producers, in part due to being the only large open pit PGM mine that exists.
The infrastructure comprises five open pits (Sandsloot, Zwartfontein, Mogalakwena south, central, and north). Ore is milled at the on-mine north and south concentrators as well as Messina mine’s Baobab concentrator.
Construction full-scale CPR plant at Mogalakwena (PGMs) was completed and handed over to operations in November 2023. Additionally, an HDS demonstration trial has completed on a portion of an existing TSF at Mogalakwena.
The new solar plant, and the hydrogen plant (nearing completion) it will supply, is making Mogalakwena a strategically important centre for hydrogen production in South Africa’s developing hydrogen valley.
Mogalakwena mine is planning to expand. |
Source:
p. 105
Company | Interest | Ownership |
Anglo American plc.
|
76.99 %
|
Indirect
|
Rustenburg Platinum Mines Ltd.
(operator)
|
100 %
|
Direct
|
Anglo American plc. through its subsidiary Rustenburg Platinum Mines own 76.99% of the Mogalakwena complex.
Contractors
Contractor | Contract | Description | Ref. Date | Expiry | Source |
Eskom Holdings SOC Ltd
|
Power supply
|
Electricity to the mine is supplied by Eskom via an electricity distribution network.
|
Feb 28, 2023
|
|
|
Source:
Summary:
The mine exploits the Platreef, the primary PGM-bearing horizon developed in the Northern Limb of the Bushveld Complex. The reef averages 150m in thickness, with a prominently top- loaded grade profile, hosting optimal Mineralisation in the upper 30m to 40m of the reef package.
The Platreef is developed in the Northern Limb of the Bushveld Complex and can be described as a multiple-pulse mafic magmatic horizon, dominantly pyroxenitic in composition. It averages 150m in thickness, with a prominently top-loaded grade profile, where the optimal Mineralisation is located in the upper 30m to 40m of the package and strikes ~north-south, dipping at an average of 40° to 50° to the west.
In comparison to the Merensky and UG2 reefs, the Platreef is a far thicker and more variable orebody, typified by extensive contact with metasedimentary and granitic floor rocks and assimilation of footwall fragments. The variability of lithology and thickness along strike is attributed to underlying structures and assimilation of local country rocks. This assimilation ranges from shales and banded ironstones in the south, through to dolomites in the centre of the mining area, to granites in the northern portion of the property.
Carbonate floor rocks incorporated into the basal Platreef have been altered to mineralised parapyroxenites and calc-silicates formed during extensive syn-magmatic interaction with high-Mg silicate melts. Towards the north, where the Platreef country rock is Archaean basement granite, partial melting of this protolith has resulted in the formation of a metamorphic rock referred to as a Granofels. The Granofels is present in a prominent interaction zone developed between the base of the Platreef and the underlying basement granite. As a result, the Mineralised horizon defined for the Platreef orebody often incorporates significant portions of the immediate footwall.
The Platreef strikes north north-west/south south-east across the length of the Mogalakwena Mineral Right area, dipping at an average angle of 40° to 50° to the west with local flattening occurring. Within the mining complex, the Platreef is structurally affected by dolerite dykes ranging between 5m and 40m in width and several predominantly lateral fault systems such as the Drenthe, Mohlosane, NM and Pit fault systems, orientated in a north-east/south-west direction, dipping between 60° and 85° towards the south-east.
The fault systems display normal to reverse fault displacements ranging between 50m and 600m, with the up-thrown blocks proving favourable to mine design. The dykes and Platreef adjacent to major fault systems constitute areas of no mineralisation and are discounted as geological loss zones. The Platreef hosts significant dolomite inclusions in the southern region of the mining area and these also constitute geological loss zones.
Source:
Summary:
The mining of the orebody is by open-pit methods whereby material is extracted in vertical benches to create a large open excavation. Benches are mined from top to bottom and are accessed by means of haul roads in the hanging and footwall to connect multiple benches to surface entry and exit points. Open-pit mining is a widely used surface-mining method to extract minerals relatively close to surface by means of drilling, blasting, loading-and-hauling operations. Material is moved by means of truck-and-shovel to the processing plants, stockpiles and wasterock dumps along a network of constructed surface roadways. The walls of the open-pit excavation are mined at the maximum allowable slope angle achievable within the specified geotechnical constraints, and berm-offsets are created between benches to reduce the potential risk of rock falls along the overall slope. The final shape of the excavation is determined by the overall economics of the extraction process and is generally subdivided into three-dimensional phases expanding the open-pit to maximise the potential net present value of the mine within specified constraints.
Mining areas comprise three open-pits: Zwartfontein South, Mogalakwena North and Central. Pit depths vary from 128m in South pit to 283m in North pit. Ore is milled on-mine at the North and South concentrators as well as at Baobab concentrator, which is located some 90km off-site.
Mining of the orebody is currently by open pit methods whereby material is extracted (drill, blast, load, and haul) in vertical benches to create a large open excavation. Benches are mined from top to bottom and are accessed by means of haul roads in the hanging and footwall to connect multiple benches to surface entry and exit points.
Material is moved by means of truck and shovel to the processing plants, stockpiles, and waste rock dumps along a network of constructed surface roadways. These haul roads are gravel and are sprayed with a commercial dust suppressant according to a detailed schedule.
The walls of an open pit excavation are mined at the maximum allowable slope angle achievable within the specified geotechnical constraints, and berm-offsets are created between benches to reduce the potential risk of rock falls along the overall slope. The final shape of the excavation is determined by the overall economics of the exploitation process and is generally subdivided into three-dimensional phases expanding the open pit to maximise the potential net present value of the mine within specified constraints.
Waste rock from the open pit areas is placed in proximity to the open pit activities in dedicated Waste Rock Disposal Facilities. With the exception of Zwartfontein and Sandsloot Pits (which will be utilised for anthropogenic aquifer development), the open pits at MM Complex will remain at closure as final voids.
Mogalakwena Mine intends to exploit the Sandsloot (Zone 1) resources deeper than the current open pit horizons by changing the current mining method from an open pit mining process to an underground mining process (first phase). Studies are currently being undertaken to confirm the optimal development of the underground mine. MM anticipates that the proposed underground operations could extend the life of the mine with ~49 years and will similarly be influenced by market conditions, production rates and future underground mining scenarios.
Simultaneous to the development of the underground, the open pit mining will continue allowing for the final open cuts to continue until optimised shell extent has been reached. South Pit will be extended to bridge South Pit and Central Pit for the further development of the super pit. Pit access ramps for the super pit will be maintained to the eastern footwall wall to provide the shortest possible haul route to the WRD’s, strategic stockpiles and the primary crushing plant. To allow for final open cut / optimised shell extent, one last pushback/cut is planned for the Zwartfontein Pit.
In support of continual combination mining, waste rock material will need to be disposed of on surface. The North Waste Rock Disposal area will be extended in footprint area as well as height and the RS3, and W020 Waste Rock Disposal Area will be extended in footprint and height to accommodate the additional material removed from both the open pit and underground operations. Waste rock will also be utilised to construct anthropogenic aquifers within the Sandsloot and Zwartfontein open pit areas to support future mining operations with water security aspects.
In July 2022, at the Mogalakwena PGMs operation, Anglo American launched the prototype for a fleet of hydrogen powered mine haul trucks – a world first at this scale.
Source:
Source:
- subscription is required.
Processing
- Purification & crystallization
- Acid plant
- Smelting
- Ore sorter (multi-sensor)
- Electric furnace
- Hydrochloric acid (reagent)
- Crush & Screen plant
- Flotation
- High Pressure Acid Leach (HPAL)
- Magnetic separation
- Dewatering
- Solvent Extraction & Electrowinning
- Dissolving & Crystallising
Flow Sheet:
Summary:
There are two mineral processing plants at the mine, Mogalakwena North Concentrator (MNC) and Mogalakwena South Concentrator (MSC).
The mine is currently processing, on average 13 Mtpa (based on 2018 and 2019 figures) through the existing North and South concentrators. The South Concentrator (MSC), with a current milling capacity of 4.2 Mtpa, may be considered for decommissioning once the Third Concentrator (M3C)12 is commissioned in 2030. With the M3C, Mogalakwena Complex will reach a milling capacity of 21.3 Mtpa. Approval for the construction of the M3C was granted in 2021. The M3C will have a milling capacity of 12 Mtpa whilst the North Concentrator will be maintained at 9.3 Mtpa.
Study work on the Mogalakwena third concentrator and associated debottlenecking of downstream processing capacity has been completed. The project should be value-accretive but further work is being postponed while study work on the underground development is prioritised.
Some ore is also processed at the Sibanye-Stillwater Baobab Concentrator which is located approximately 90km offsite. The Platinum Group Metals (PGMs) are extracted from the ore in the form of a concentrate that is transported to the AAP Polokwane Smelter for smelting to produce furnace matte. The matte then undergoes an acid-converting process at the Waterval Smelter Complex in Rustenburg, where after it is initially refined at the Base Metals Refinery (BMR) and refined to the final product at the Precious Metals Refinery (PMR).
Flotation
The separation of the valuable content from the ore takes place in flotation cells where reagents are added to an aerated slurry to produce high-grade PGM-bearing concentrate.
Smelting
Use of electric furnaces to smelt concentrate to produce a sulfur-rich matte with gangue impurities removed as slag.
Slag Cleaning
Converter slag is reduced in an electric furnace to recover PGMs and base metals for recycling back to the converter.
Converting
Oxygen-enriched air is blown through a top submerged lance converter to oxidise sulfur and iron contained in furnace matte to SO2 gas and slag respectively. The resulting converter matte is slow-cooled to concentrate PGMs into a metallic fraction.
Magnetic Concentration Plant (MCP).
Crushed converter matte is milled and the PGM fraction is separated magnetically. This is pressure leached to yield a solid final concentrate that is sent to PMR. Base metal-rich non-magnetic solids and leach solution are processed further in the base metal refinery.
Acid Plant
The SO2 gas is converted to SO3 by passing it over catalytic beds and the subsequent addition of water produces 98% sulfuric acid which is sold to fertiliser manufacturers.
Leaching
Base metal-rich solids are leached in high-pressure autoclaves and contacted with MCP leach solution to yield separate nickel and copper streams.
Purification
The separate nickel and copper streams are purified. During this process cobalt sulfate is recovered.
Electro-Winning
Nickel and copper metal cathodes are produced by passing electrical current through the separate purified stream.
Crystallisation
Excess sulfur in solution is neutralised with sodium hydroxide and crystallised to form a sodium sulfate product.
PGM Refining
Final concentrate is dissolved using hydrochloric acid and chlorine gas. PGMs are sequentially separated and purified to yield platinum, palladium, iridium, rhodium, ruthenium and gold. Osmium is precipitated as a salt.
2021 - A full-scale ore sorting (BOS) unit, which will deliver improved grade feed to plants through the early rejection of waste, reducing energy consumption, water usage, and unit costs in the process, is now operational at our PGMs business’s Mogalakwena North Concentrator. A modular ultra-fines recovery plant has also been constructed there, which will address the industry-wide challenge of reducing ultra-fine mineral losses, with the potential to increase recovery rates by up to 3%.
2022 - A full-scale coarse particle recovery (CPR) plant has been constructed at the Mogalakwena North concentrator, with start-up anticipated in late 2023.
2023 - The bulk ore sorting (BOS) technology was unsuccessful and the roll-out of this technology paused. In addition, the anticipated output from the coarse particle recovery (CPR) technology of ~18koz of PGMs has not materialised requiring further test work to be completed during the first half of 2024.
Hydraulic Dewatered Stacking (HDS)
During June 2023, Anglo American initiated a second trial at Mogalakwena platinum mine in South Africa, targeting the application of HDS into an existing facility.
Bulk Ore Sorting
Anglo American is optimising mining processes through technologies that target the required metals and minerals more precisely, with reduced water, energy and capital intensity, and producing less waste. These technologies include bulk ore sorting (BOS), coarse particle recovery (CPR), fines flotation, dry processing and novel classification, with their implementation integrated into resource development planning.
A full-scale BOS unit is operational at our PGMs’ Mogalakwena North concentrator (c.70% of complex feed). The unit is configured to reject waste prior to entering the concentrator, increasing plant feed grade.
A modular ultrafines recovery plant was installed at Mogalakwena to address the industry-wide challenge of reducing ultrafine mineral losses. Results of the trial indicate that the use of ultrafines recovery technology significantly increases product grades at equivalent metal recoveries. In 2024, ultrafine recovery modules will be implemented at Mogalakwena.
The project allows for ease of transportation and lowers energy footprint, with 30% less mass transported to high intensity downstream smelters. The sensor fusion loop in South Africa has been used to support BOS operations globally, enabling the development of intellectual property on selective mining and ore sorting.
Pipelines and Water Supply
Source:
- subscription is required.
Production:
All production numbers are expressed as metal in concentrate.
Operational Metrics:
Metrics | 2023 | 2022 | 2021 | 2020 | 2019 | 2018 |
Stripping / waste ratio
| 5.7 | 4.3 | 6.3 | 4.8 | 4.7 | 3.9 |
Ore tonnes mined
| 12,786 kt | 16,102 kt | 11,950 kt | 14,050 kt | 14,282 kt | 18,060 kt |
Waste
| 72,653 kt | 68,572 kt | 74,851 kt | 66,821 kt | 67,033 kt | 71,002 kt |
Total tonnes mined
| 85,439 kt | 84,674 kt | 86,801 kt | 80,870 kt | 81,315 kt | 89,062 kt |
Tonnes milled
| 13,656 kt | 13,855 kt | 14,203 kt | 13,531 kt | 13,710 kt | 13,775 kt |
Reserves at December 31, 2023:
Mogalakwena (OP): A 1.0 g/t 4E cut-off grade is used to define Platreef open pit Mineral Resources (excluding both oxidised and calc-silicate materials for which a 3.0 g/t 4E cut-off is applied).
Mogalakwena (UG): A 1.3 g/t 4E cut-off grade is used to define Platreef underground Mineral Resources (excluding both oxidised and calc-silicate materials for which a 3.0 g/t 4E cut-off is applied).
Category | OreType | Tonnage | Commodity | Grade | Contained Metal |
Proven
|
Stockpiles
|
14.6 Mt
|
4E (Pt, Pd, Rh, Au)
|
1.09 g/t
|
0.5 M oz
|
Proven
|
In-Situ (OP)
|
813.1 Mt
|
4E (Pt, Pd, Rh, Au)
|
2.91 g/t
|
76.1 M oz
|
Probable
|
Stockpiles
|
40.9 Mt
|
4E (Pt, Pd, Rh, Au)
|
1.47 g/t
|
1.9 M oz
|
Probable
|
In-Situ (OP)
|
332.9 Mt
|
4E (Pt, Pd, Rh, Au)
|
3.34 g/t
|
35.8 M oz
|
Proven & Probable
|
Stockpiles
|
55.5 Mt
|
4E (Pt, Pd, Rh, Au)
|
1.37 g/t
|
2.4 M oz
|
Proven & Probable
|
In-Situ (OP)
|
1,146 Mt
|
4E (Pt, Pd, Rh, Au)
|
3.04 g/t
|
111.9 M oz
|
Measured
|
Stockpiles
|
2.7 Mt
|
4E (Pt, Pd, Rh, Au)
|
3.28 g/t
|
0.3 M oz
|
Measured
|
In-Situ (OP)
|
188.4 Mt
|
4E (Pt, Pd, Rh, Au)
|
2.22 g/t
|
13.4 M oz
|
Indicated
|
In-Situ (OP)
|
1,451 Mt
|
4E (Pt, Pd, Rh, Au)
|
2.33 g/t
|
108.7 M oz
|
Indicated
|
In-Situ (UG)
|
43 Mt
|
4E (Pt, Pd, Rh, Au)
|
4.78 g/t
|
6.6 M oz
|
Measured & Indicated
|
In-Situ (OP)
|
1,640 Mt
|
4E (Pt, Pd, Rh, Au)
|
2.32 g/t
|
122.2 M oz
|
Inferred
|
In-Situ (OP)
|
264.9 Mt
|
4E (Pt, Pd, Rh, Au)
|
1.63 g/t
|
13.9 M oz
|
Inferred
|
In-Situ (UG)
|
101.3 Mt
|
4E (Pt, Pd, Rh, Au)
|
3.85 g/t
|
12.5 M oz
|
Total Resource
|
Stockpiles
|
2.7 Mt
|
4E (Pt, Pd, Rh, Au)
|
3.28 g/t
|
0.3 M oz
|
Total Resource
|
In-Situ (OP)
|
1,904 Mt
|
4E (Pt, Pd, Rh, Au)
|
2.22 g/t
|
136 M oz
|
Total Resource
|
In-Situ (UG)
|
144.3 Mt
|
4E (Pt, Pd, Rh, Au)
|
4.13 g/t
|
19.2 M oz
|
Commodity Production Costs:
| Commodity | Units | 2023 | 2022 | 2021 | 2020 | 2019 | 2018 |
Cash costs
|
PGM
|
USD
|
885 / oz
|
826 / oz
|
694 / oz
|
520 / oz
|
564 / oz
|
592 / oz
|
Cash costs
|
Platinum
|
USD
|
|
|
|
|
1,325 / oz
|
1,398 / oz
|
All-in sustaining costs (sold)
|
3E (Pt, Pd, Au)
|
USD
|
1,087 / oz†
|
953 / oz†
|
831 / oz†
|
969 / oz†
|
683 / oz†
|
|
All-in sustaining costs (sold)
|
PGM
|
USD
|
|
1,135 / oz†
|
866 / oz†
|
1,118 / oz†
|
729 / oz†
|
724 / oz†
|
All-in sustaining costs (sold)
|
Platinum
|
USD
|
|
|
|
-594 / oz†
|
-429 / oz†
|
286 / oz†
|
† Net of By-Product.
Operating Costs:
| Units | 2023 | 2022 | 2021 | 2020 | 2019 | 2018 | 2017 | 2016 |
Total operating costs ($/t milled)
|
ZAR
| 741 | 663 | 567 | 499 | 496 | 456 | 351 | 428 |
Financials:
| Units | 2023 | 2022 | 2021 | 2020 | 2019 | 2018 | 2017 |
Sustaining costs
|
M ZAR
| 10,498 | 8,294 | 6,656 | 4,848 |
4,240
|
3,313
|
2,193
|
Growth Capital
|
M ZAR
| | | 317 | 77 |
38
|
|
|
Capital expenditures
|
M ZAR
| | | 8,082 | 5,520 |
5,520
|
|
|
Revenue
|
M ZAR
| 32,101 | 40,352 | 56,001 | 28,317 |
25,845
|
18,106
|
16,118
|
EBIT
|
M ZAR
| 11,081 | 22,592 | 36,534 | 15,546 |
12,466
|
6,325
|
5,969
|
EBITDA
|
M ZAR
| 14,349 | 25,341 | 38,612 | 17,447 |
14,375
|
8,249
|
7,700
|
Operating Cash Flow
|
M ZAR
| | 23,457 | 39,294 | |
|
|
|
HME Type | Model | Size | Quantity | Ref. Date | Source |
Drill
|
Sandvik DR410i
|
|
4
|
Feb 14, 2023
|
p.1
|
Drill
|
Epiroc PV-271XC
|
|
3
|
May 10, 2022
|
p.1
|
Shovel (rope)
|
P&H 4800 XPC AC
|
135 tons
|
2
|
Dec 31, 2023
|
p.94
|
Truck (haul)
|
Komatsu 930E
|
291 t
|
40
|
May 3, 2022
|
p.2
|
Mine Management:
Job Title | Name | Profile | Ref. Date |
Concentrator Manager
|
Herman Kemp
|
|
Mar 14, 2024
|
General Manager Sustainability
|
Sam Kgarimetsa
|
|
Mar 14, 2024
|
Mining Manager
|
Mothibe Jerry
|
|
Mar 14, 2024
|
Production Manager
|
Judd Barlow
|
|
Mar 14, 2024
|
Sr. General Manager
|
Willie Noordman
|
|
Mar 14, 2024
|
Sr. Mine Planner
|
Witness Netshikulwe
|
|
Mar 14, 2024
|
Staff:
Employees | Contractors | Total Workforce | Year |
2,381
|
1,368
|
3,749
|
2023
|
2,241
|
208
|
2,449
|
2022
|
2,081
|
251
|
2,332
|
2021
|
2,000
|
244
|
2,244
|
2020
|
1,936
|
272
|
2,208
|
2019
|
1,886
|
282
|
2,162
|
2018
|
1,854
|
412
|
2,266
|
2017
|
1,828
|
424
|
2,252
|
2016
|
1,770
|
557
|
2,328
|
2015
|
Corporate Filings & Presentations: