Clients and application references

Tugela is well-positioned to continuously provide the local and international Mining and Metals Industry with fresh processing solutions.

Six processing plants are currently operational in Mpumalanga, Limpopo, and North-West Province of South Africa.

Tugela has a proven track record and ability to re-establish and grow itself in any given geographical area, given the general lack in conventional processing capability.

Tugela’s focus on those areas within the process which are less mainstream and more prone to be overlooked when not focussed on creates many opportunities.

Historical waste dumps present a large opportunity for future processing, and forms part of the Tugela’s vision for the future.

The company’s operating model is focused on the micro-management of certain aspects, often seen as being part of the low-value chain.

Mineral Specific References

FerroChrome is produced through the pyrometallurgical reduction of Chromite Ore containing Oxides of Iron (Fe) and Chromium (Cr). Slag and Metal (FeCr) is produced from FerroChrome Furnaces, which is separated via the differential gravitational properties of each, during the tapping process.

Due to the viscosity of molten slag, some FeCr Metal becomes entrained. After cooling down the Furnace Slag, a process of crushing and wet screening will provide a mixture of highly liberated particles of FeCr and Slag. This mixture, classified into certain particle size ranges, become amenable to gravity separation.

Historically, prior to 2004, size fractions above 3mm in size were recovered and upgraded to a level of cleanliness that would render it to being “saleable”. Process techniques for the -3mm fraction were limiting in the sense that final product quality would not meet “saleable” specification, nor would the quantities, recovered, substantiate a business case to operate a circuit designed for this fraction.

In 2004, Tugela commissioned its first FeCr recovery circuit, suitable for a -1.6mm to +0.075mm particle size range. Recovery of metal was high enough to support a business case, and grade nearly complied with final product specification, although it was already substantially higher than the norm.

Revisions of the technology occurred, and within 12 months Tugela was able to deliver both a “saleable” FeCr concentrate, as well as an amount thereof that surpassed its prior levels of recovery.

This milestone represented an Industry first, and the benchmark against which Tugela’s competitors had to compete.

Being able to supply a premium grade of fine (-1.6mm) FeCr concentrate, markets opened up. Clients were satisfied, and a steady increase in demand took place.

Subsequently, markets drove the demand and other potential clients became interested in this newly recovered high-quality FeCr product.

The Company grew and lead the industry norm as more operations were implemented with various clients, based on the Build, Own, Operate, and Maintain (BOOM) principle. Two operations were built on a Royalty based remuneration, instead of utilising the BOOM principle.

The so-called “Tollmet Process” evolved into a -3mm particle size treatment process, enabling clients to have a single process in place with efficiency surpassing that of 1mm-3mm Jigging, thereby lowering overall cost of production and raising monthly production quantity at once.

As is the case with the Tugela’s other successful references, all test work results are applicable and up-scalable to business models which Tugela uses to provide process guarantees to clients and invest its own capital to build plant and equipment.

Fine (-1mm) Chromite Mine Tailings or Discard Waste, previously treated by conventional processes, is a very viable resource for future treatment. Re-treatment of this type of resource with more up-to-date spiral and elutriation techniques, provides a business case in itself.

Tugela has developed a process whereby this form of fine Chromite can be economically recovered and upgraded.

The following testifies of the level of competence of the process: Various samples were tested and tried in several ways, to the point where Tugela was able to extract Chromite economically from material that was already previously processed by three consecutive processes. (Detail concerning this matter will not be disclosed for the sake of protection of certain role-players in the market.)

The newly designed process was tested repeatedly in order to verify results, with similar outcome.

This opportunity is now available, and will be presented in the near future, to further benefit the Minerals industry.

Track reference and test work results, as executed, will be able to verify the statements that are made herein, and can be disclosed (for verification purposes) on request based on conclusion of a confidentiality and non-disclosure agreement.

As is the case with Tugela’s other successful references, all test work results are applicable and up-scalable to business models which Tugela use to provide process guarantees to clients and invest its own capital to build plant and equipment.

Following process developments during various testwork campaigns, Tugela can state that Fine Coal (-1mm) discard / waste represents a very economically viable source of high-quality Coal, (chemically).

These waste dumps, or resources in this case, normally represent Fine Coal already being previously processed by Elutriators / classifyers, Spirals etc.

Two grades can be produced by the process as utilised by Tugela, in parallel: an Export Grade and a Power Station Quality Grade, while leaving behind a Discard that can be used as a very viable basis for vegetation, stripped of nearly all of its Coal value.

Depending on the inherent integrity of the type of Coal in its purest liberated form, final product can vary greatly between resources.

Essentially the process upgrades Fine Coal to its purest form, by far exceeding that which is obtainable through Dense Medium Separation and conventional processing.

This further enables “sweetening” of mainstream product if the client so desires to upgrade its product with allowable amounts of Fines.

Track reference and test work results, as executed, will be able to verify the statements that are made herein, and can be disclosed (for verification purposes) on request based on conclusion of a confidentiality and non-disclosure agreement.

Utilising (and developing) Tugela’s own Jigging system, the company processed several samples of Coal on an industrial scale.

This system renders an excellent opportunity in the re-processing of Coarse (3mm-37mm) waste Coal in order to de-stone and upgrade product for the use in Coal Fired Power stations.

Abrasive Index can be well managed, as well as undesired Sulphur Content inherent to waste rock substrate.

A CMS system was implemented for NuCoal Pty Ltd at its Tuli Project in Zimbabwe. Upgrading and the de-stoning ability of the system proved to be consistent with test results.

The system is easily re-locatable, as all components are skid-mounted and pre-fabricated.

Modules attach in order to be easily assembled.

In addition to Tugela’s wet processing capability, it implemented a Crushing and Screening (C+S) operation with a capacity of 100ktpm.

Run-of-mine Coal, reduced by a Feeder Breaker system, enters a closed-loop screening and crushing section. Excessive reduction is limited by the use of Roll Crushing.

Tugela executed this service, using its owned plant and equipment, for Silver Unicorn Mining Pty Ltd and Sumo Coal Pty Ltd.

FerroVanadium (FeV) can be produced by the Carbothermic or Metallothermic reduction process of Vanadium oxides, assisted in the presence of Iron.

Due to the viscosity of slag formed, and equilibrium not always being reached, there are still FeV and V-Oxides present in the discarded furnace slag during the smelting process.

These entrapped FeV and V-Oxide bearing particles are prone to certain gravity separation processes.

Tugela employed a combination of Coarse Material Separation (CMS) and Fine Material Separation (FMS) in order to process and extract valuable FerroVanadium Metal from a Furnace Slag resource on behalf of Metmar Speciality Metals Pty Ltd in Gauteng Province.

Metal is successfully extracted and upgraded to saleable quality in this combination process.

Modular in design, this system is easily employed on site and can be swiftly implemented and commissioned.

FerroManganese is produced through the pyrometallurgical reduction of Manganese Ore containing Oxides of Iron (Fe) and Manganese (Mn).

Slag and Metal (FeMn) is produced from FerroManganese Furnaces, which is separated via differential gravitational properties, of each, during the tapping process.

Due to the viscosity of molten slag, some FeMn Metal becomes entrained.

After cooling down the Furnace Slag, a process of crushing and wet screening will provide a mixture of highly liberated particles of FeMn and Slag. This mixture, classified into certain particle size ranges, become amenable to gravity separation.

An FMS process was implemented for Recmix, an affiliate of Excel Minerals Inc, at its (then) owned Recovery Operation in Cato Ridge. This variant of the so-called “Tollmet Circuit” successfully recovered and upgraded fine (-2mm) FeMn metal on a Royalty remuneration basis in exchange to the privilege of utilising the FMS technology.

Tugela bears reference of successful CMS recovery and upgrading of final product to saleable grade on a particle size range of 3mm-10mm.

Solidified FeMn metal droplets, entrained in its slag matrix, tends to be smaller than compared to that evident in FeCr. Crushing to smaller sizes, compared to the FeCr industry, tend to address the issue of liberation, but does not assist if one does not possess an FMS capturing the extra amounts of fines (-3mm) that is generated.

Tugela essentially fulfils in this demand by provision of a sound CMS and FMS combination offering.

As is the case with the Tugela’s other successful references, all test work results are applicable and up-scalable to business models which Tugela uses to provide process guarantees to clients and invest its own capital to build plant and equipment.

Fine (-1mm) Iron Ore Mine Tailings or Discard Waste, previously treated by conventional processes such as magnetic separators and spiral circuits, prove to present a very viable resource for future re-treatment.

Tugela has developed a process whereby this form of fine Iron Ore can be recovered and upgraded economically.

Test work campaigns, using local sources of Iron Ore discards, have enabled Tugela to develop a process very suitable for the re-processing of historical waste dumps.

Class-leading recovery, accompanied by exceptional product grade, will become a very suitable business case once the global economy demands recovers, when using this processing development.

The opportunities herein are moth-balled for the time being, but showcase Tugela’s ability to apply efficiency to the point of creating profitable opportunities.

Track reference and test work results, as executed, will be able to verify the statements that are made herein, and can be disclosed (for verification purposes) on request based on conclusion of a confidentiality and non-disclosure agreement.

As is the case with Tugela’s other successful references, all test work results are applicable and up-scalable to business models which Tugela use to provide process guarantees to clients and invest its own capital to build plant and equipment.

Similar to Iron Ore, Fine (-1mm) Manganese Ore Mine Tailings or Discard Waste, previously treated by conventional processes, such as DMS circuits and spiral circuits, prove to present a very viable resource for future re-treatment.

Treating Low-Grade deposits of Manganese Ore via conventional Coarse Material processes, do not render a competitive feasibility. A lack of liberation hampers proper separation of high- and low-grade mineral, and, further to this, a lack of proper processing technology of fines limits options.

Proper liberation, in conjunction with a competent Fine Material Separation (FMS) process, enables a viable business case whereby product grade becomes (chemically) viable for selling purposes.

Tugela developed an FMS process suitable for the extraction and upgrading of Manganese Ore to benefit from the inefficiency of previously employed conventional processes, as well as to generate viable upgrading of low-grade Manganese Ore.

Test work campaigns, using local sources of Manganese Ore, enabled Tugela to develop a process very suitable for the processing of Manganese Ore, and forms the basis of this statement.

Track reference and test work results, as executed, will be able to verify the statements that are made herein, and can be disclosed (for verification purposes) on request based on conclusion of a confidentiality and non-disclosure agreement.

Tugela has the ability to Test, Develop and Design, Build Own, Operate and Manage customised plants and processes to separate and upgrade Minerals, Industrial Materials and Commodities utilising the basic principles of extractive metallurgy.

Core strength exists in the areas of Gravity Concentration / Separation, Materials handling, Comminution, Size Separation, Dewatering and associated processes.

Specifically, Tugela excels when confronted with process challenges, and therefore prefer scavenging and concentrate-upgrading operations.

Historical Waste Dumps from conventional processes render potentially viable applications for future applications.

Developed processes, specifically suitable for the following applications, are ready for roll-out:

• Recovery and Upgrading of Metal Concentrates from Slag or other forms of gangue such as casting sand
• Recovery and upgrading of fine Chromite Discard from waste streams and resources
• Recovery and upgrading of fine Iron Ore Discard from waste streams and resources
• Recovery and upgrading of Fine and Coarse Coal Discard from waste streams and resources
• Recovery and upgrading of fine Manganese Ore Discard from waste streams and resources and Low-Grade Deposits
• Refinement and upgrading from contaminated industrial minerals such as recycled glass
• Design, Build, Operate, Management and Maintenance of production based plants and processes in legal compliance to government and client based standards.