February / 2012

Anglo American
Barro Alto
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1
1
1970 2012
The deposit was discovered in the late 1960s
2007 Start
Construction
Mar 2011 - Barro
Alto Plant First Metal
Tapping

2002 Anglo American
Acquires the Mineral Rights
2004 Ago./2006
Conceptual and
Feasibility Study
1970 Start Exploration
2004 Start Barro Alto
Mine Operations to
Feed Codemin
2003 - Anglo Base
Metals Completes
Ni Strategy Review
98 2001
First Feasibility
Study
1998 Anglo American
buys the ore deposit
06/12/2006
Project
Approval
Mar 2012 - Barro
Alto Plant production
nominal capacity


History
Anglo American Ferro-Nickel
Background
Project Location Life of Mine Ni Production
TPA
Morro do Nquel Brazil 1962 - 1998 2,500
Codemin Brazil 1982 - 2036 6,000/10,000
Loma de Nquel Venezuela 2001 - 2031 17,000
Barro Alto Brazil 2011 - 2037 36,000
Same basic pyrometallurgical technology
Key Barro Alto Project staff have long FeNi plant operation
and design experience.
Barro Alto Project
Total Capital Expenditure ~ US$ 2 bi
2007 start construction / 2011 production start
Total of 5.500 employees during construction phase
36,000 tons per annum of Ni in FeNi alloy over 26 year
Barro Alto ore total plant feed: 61,885 ktons @ 1.65 % Ni
over 26 years

Codemin
Brazil
Goinia
Braslia
Copebrs
Minerao
Catalo
Barro Alto
Catalo
SP
GO
Gois State
Location
MINING
6
Total mineral resources:
126,088 ktons @ 1.52 % Ni
Barro Alto total plant feed:
74,513 ktons @ 1.60 % Ni over 31 years
Saprolite ore
Highly weathered material
High clay content high moisture content and sticky
Open pit mining without blasting
Typical cross-section:




Nickel Deposit

Mine
Mine
Mine
Mine
Mine
Mine
Mine
Ferro-nickel Plant
FERRO-NICKEL PLANT
16
RKEF (Rotary Kiln Electric Furnace ) process
2.4 million tons of dry ore per annum
36,000 tons per annum of Ni in FeNi alloy over 26 year
Typically 25-30% Ni with 75% Fe
Energy and Water - considerations during design
Plant layout favours solids gravity flow
Kilns waste heat recovery and higher calcine temperature
High efficiency electric motors
Water closed circuits
Plant electrical power requirements
Maximum Demand: 210,0 MW
Total annual consumption: 1,409,180.0 MWh

Ferronickel Plant
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
Plant Feed
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
Primary Sizer
Nominal Production 625 tph
Top size 800 mm
Crushing product - 250 mm
Secondary Sizer
Nominal Production 312,5 tph
Top size 250 mm
Crushing product - 75 mm
Tertiary Crusher
Nominal Production 312.5 tph
Top size 75 mm
Crushing product - 50 mm
Crushing
Crushing
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
Stacker & Reclaimer
Stacker Supplier Bardella
Nominal Capacity 658 wtph
Reclaimer Supplier Bardella
Nominal Capacity 508 wtph
Stacker & Reclaimer
Stacker & Reclaimer
Stacker & Reclaimer
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal

Dryers
Nominal Production 189 tph (each one)
Length 32,000 mm
Diameter 4,600 mm
Speed 2.2 to 4.4 rpm

Dryers
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
Supplier Sandvik
Nominal Production 109 tph
Top size 50 mm
Crushing product 30 mm
Storage Capacity 21,000 t
Quaternary Crushing & Dry Ore Storage
Quaternary Crushing & Dry Ore Storage
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
Pelletizing Discs
Supplier- FEECO
Nominal Production 10.3 tph (each one)

Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
Coal Reception & Crushing
Store Yard Total Capacity 40,000 t
Crushing Nominal Capacity 40 tph

Coal Reception & Crushing
Ptio de Carvo Mineral
Coal Reception & Crushing
Coal Reception & Crushing
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
Nominal Production 147 tph (each one)
Speed 0.8 a 1.2 RPM
Supplier FLSmidth
Length 185 m
Diameter 6.1 X 7 m
Rotary Kilns
Rotary Kilns
Rotary Kilns
Rotary Kilns
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
Electric Furnaces
Slag Tapping interval each 2 hours
Number of Slag Tapholes 6
Number of Metal Tapholes 2
Nominal Power 114 MWA
Active Power 83 MWA
Feed rate 147 tph

SMS Siemag
Size : Length 36,440 mm
Height 7,850 mm
Width 13,240 mm
Metal Tapping Temperature 1,500 C
Slag Tapping temperature 1,650 C
SiO
2
/MgO ratio 1.75
Electric Furnaces
Electric Furnaces
Electric Furnaces
Electric Furnaces
Electric
Furnaces
2 x 83 MW
6-in-line
Process Flow Diagram
Horizontal
Grizzly
Homogenization
Stockpiles
Reclaimer
Dried Ore Stockpile
Refining
Phase 1
Ladle Furnaces
Refining Phase 2
FeNi Metal
Granulation
Pellets
Recycle Dust
from RK and EF
FeNi
Metal
Stacker
Reagents
Addition
Slag to be
Recycled
Dryers
Rotary
Kilns
2 x L185m &
D6.1m
Coal
Stockpile
Kilns Burners
Dryers Burners
Coal
Pulverization
Tertiary
Crushing
Top Size
Control
ROM
Stockpiles
Coal
Crushing
Reagents
Addition
Calcined
Ore
Slag
Granulation
Pellets Dryer
Pelletizing
Primary
Crushing
Secondary
Crushing
Coal
The Crude metal from Electric Furnace
with temperature around 1,500-1,520 C
. Typical Chemical Composition:
- %Ni: 25
- %C: 0.15
- %S: 0.3
- %Si: 0.12
The final ferronickel composition
- Ni: 25%
- Si: max. 0.03%
- C: max. 0.04%
- S: max. 0.06%
- P: max. 0.03%

Refining Process in 2 main Steps:

- Blow Station during metal tapping
reduce with oxygen-lime : %P, %C,
%Si
- Ladle Furnace: Heat / Lime, Al , CaSi,
FeSi reduce %S



Refining
Metal Granulation
The liquid refined metal is water granulated
After granulation the product is classified and
stored for expedition.
The refining slag is stocked for future recovery.
The final ferronickel composition:
Ni: 20 25%
Si: max. 0.03%
C: max. 0.04%
S: max. 0.06%
P: max. 0.03%
Final size distribution between 2 to 40 mm
irregular shape
Refining
Refining
Refining
Dispatch
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