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Alumina Refinery Bauxite Residue Waste 1. Prima Resources and JV Partners will develop technology to
process Bauxite Residue from all WA Alumina Refineries
2. 225.0 MT of Bauxite Residue stored over last 25 Yrs 25 Yr Program to recover metals in Bauxite Residue $6.0 Billion/Yr Estd annual profit from recycling metals
3. 20.0 MT of Bauxite Residue mud produced annually $13.0 Billion/Yr Estd annual profit from recycling metals
4. Each 1.0 MT/Yr Smelter Module – Capital Cost $1.0 Billion Profit $600 Million/Yr- Payback period on Capital is 2.2 Yrs
5. Feasibility Study reqd - to be completed by Prima Resources
Minerals & Energy 4
Reclamation of Metals from Bauxite Residue 1. 225 MT of Bauxite Residue stored in ponds over last 25 Yrs $158 Billion - Estimated metal value stored last 25 Yrs $6.0 Billion/Yr - Estd Annual Profit from reclaiming metals 3. 20 MT of Bauxite Residue produced annually $15.0 Billion – Estimated metal value produced annually $13.0 Billion – Estd annual profit from reclaiming metals 4. Plasma smelting technology now available to process
Bauxite Residue for multiple metals simultaneously 5. Environmental technology now available to ensure Zero
greenhouse gas emissions & Zero solid waste residue from smelter
6. Total reclamation & elimination of Bauxite Residue storage ponds
Bauxite Residue Reclamation Project 2. Business Description
Minerals & Energy 5
Typical Alumina Refinery WA Bauxite Residue Stored Last 25 Yrs – one refinery 75 Million Tonnes of Bauxite Residue has been stored in Ponds (Bauxite Residue Drying Area = 3.0 MT/Yr x 25 Yrs)
Current Value of Metal stored Bauxite Residue Area : $56.5 Billion If a Metals Recovery Program was Implemented over 25 Yrs Annual Metal Recovery Profit = $2.0 Billion / Yr
Metals Available from 75.0 MT Stored Bauxite
Asset Value of Metal Available to Prima (Profit after Operating Costs and before Tax)
Total Metal Production over 25 Yrs
(MT)
EBIT $ / Tonne
Value of Asset $ Million Per 25 Yrs
EBIT $ Million Per 25 Yrs
Iron 27.4 250 10,960 6,850
Aluminium 5.3 1,650 9,540 8,745
Titanium 1.8 19,000 36,000 34,200
Total Value of Metal Asset 56,500 49,795
Bauxite Residue Reclamation Project 2. Business Description
Minerals & Energy 6
Bauxite Residue Stored Last 25 Yrs – 225 MT (9.0 MT/Yr) Annual Profit $6.0 Billion / Yr (25 Yr Program to recover metals)
Total WA Alumina Refineries
Location Annual Red Mud
Stored MT/Yr No Of Years
Total Red Mud stored MT/Yr
BHPB Worsley Alumina Refinery 3 25 75
Alcoa Wagerup Alumina Refinery 3 25 75
Alcoa Pinjarra Alumina Refinery 3 25 75
Total WA Alumina Refineries 225
Metals Available from 225.0 MT Stored Bauxite Asset Value of Metal Available
(Profit after Operating Costs and before Tax)
Total Metal Production over 25 Yrs
MT
Profit $ / Tonne
Value of Asset $ Million
Per 25 Yrs
Profit $ Million
Per 25 Yrs
Iron 82.1 250 32,840 20,525
Aluminium 16.0 1,650 28,800 26,400
Titanium 5.4 19,000 97,200 102,600
Total Value of Smelted Metal Asset 158,840 149,525
Bauxite Residue Reclamation Project 2. Business Description
Annual Production 20.0 MT/Yr Asset Value of Metal Available
(Profit after Operating Costs and before Tax)
Total Metal Production
MT/Yr Profit $ / Tonne
Value of Asset $ Million
Per Yr
Profit $ Million
Per Yr
Iron 7.3 250 2,920 1,825
Aluminium 1.4 1,650 2,556 2,343
Titanium 0.48 19,000 9,600 9,120
Total Value of Smelted Metal Asset 15,076 13,288
Bauxite Residue Reclamation Project 2. Business Description
Minerals & Energy 8
Advantages of Bauxite Residue Projects 1. Bauxite Residue has previously been mined - (No mining cost) (No environmental impact from mining) 2. Bauxite Residue has previously been crushed and screened - (Minor crushing and screening costs/reclamation costs) 3. Known Quantity - Annual Production & Total Amount Stored - (Value of asset is clearly defined) 4. Consistency – material has consistent size / chemical analysis - (Certainty in designing process/plant/equipment/products) 5. Availability – certainty of supply to market/clients - (225.0 MT - Total WA Stored Bauxite Residue in BRDA’s) - (20.0 MT/Yr - Total WA Annual Production Bauxite Residue)
6. Known Technology - Technology currently used in other industries - Plasma smelter and metals condensation - Minerals sands, metals recycling, nickel, lead, tin, zinc industries
Bauxite Residue Reclamation Project 2. Business Description
Minerals & Energy 9
Poor recovery - only 22% of Ore extracted as Alumina
High wastage - 78% of Ore wasted/stored as Bauxite Residue in Ponds
Large environmental footprint – 24.0 Sq Kms of Residue Ponds
Environmental Impact - 300 Million Tonnes Hazardous Waste stored
Current Total WA Alumina Refinery Profit - $1.6 Billion / Yr ($100 / Tonne )
Current WA Alumina Refinery Operation
Bauxite Residue Reclamation Project 2. Business Description
Minerals & Energy 10
Bauxite Residue Reclamation Project 2. Business Description
Minerals & Energy 11
High Level Cost Model - 1.0 MT/Yr Module - Bauxite Residue Plasma Smelter
Bauxite Residue Smelter Projects: 1. Pilot Plant - 120,000 T/Yr - $400 Million Capital Cost 2. Bauxite Residue Smelters
Implement in 1.0 MT/Yr Modules Capital Cost $1.0 Billion for each 1.0 MT/Yr Module Annual Profit $0.6 Billion for each 1.0 MT/Yr Module
3. Proposed Development in Stages (1) Iron Oxide Extraction - $55 Million Profit / Yr (2) 1.0 MT/Yr Metals Plant – $0.6 Billion Profit / Yr (3) Increase Metals Plant in Stages ( Modules of 1.0 MT/Yr)
4. Jobs (1) Iron Oxide Extraction - 30 people (2) 1.0 MT/Yr Metals Plant Construction : 600 people for 2 x years Operations : 200 People for 25 Years (each 1.0 MT/Yr Module)
Options for Bauxite Residue Project Processing 1. Convert Hazardous Waste to Non-Hazardous Material Material Drying/Classification/NaOH Conversion System (Genesis technology conversion to non-hazardous material) Export bauxite residue material as feedstock to other countries 2. Extract Iron Oxide and Export as Iron Concentrate (Ore) Dynamic Magnetic Separation / Drying (large number of companies supply this technology) 3. Metals Extraction from Bauxite Residue - 1.0 MT/Yr Modules Low Pressure Plasma Smelter (3 x Metals Smelted Simultaneously) (Prima smelter technology study required and pyrotechnical lab work) Metals Distillation & Condensation Purification of Metals by Metal Distillation
Example of Plasma Smelters in other Industries (2 or 3 x metals extracted simultaneously from ores/residues) • Chromite Smelting • Ilmenite Smelting • Cobalt Smelting • Nickel Smelting • Lead Smelting • Tin Smelting • Magnesium Smelting • Electronic/Batteries/Phones Scrap Recycling / Smelting • Metals Scrap Recycling / Smelting • Waste/Tailings Ponds reclamation of Metals
Bauxite Residue Reclamation Project 5. Technology
Minerals & Energy
Typical Plasma Smelter Flow Diagram
Bauxite Residue Reclamation Project 5. Technology
Minerals & Energy
Low Pressure Smelter Pressure 10-7 Bar Aluminium Gas at 1200 0 C Iron Gas at 1400 0 C Titanium Gas at 1800 0 C
Low Pressure Smelter Energy Savings Current Process 0.211 GJ/KG Al LPS Process 0.083 GJ/KG Al Energy Saving 40% (Does not include Syngas Produced ) Total Energy Saving approx 75%