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The safety culture and commitment at Ruashi is showing
pleasing improvements. All of the initiatives previously reported
on such as hazard identification and risk assessments and the
implementation of the safe production rules are becoming an
entrenched way of working. The introduction of a new
integrated SHEC management system for reporting and
control has augmented the safety effort. Total lost-time injuries
for the six months ended 31 December 2010 (“current
period”), were zero, compared to six in the six months to June
2010 (“June 2010”). The lost-time injury-frequency rate for the
12 months to December 2010 (lost-time injuries expressed as
a proportion of man-hours worked) was the same as the rate
for the year to June 2009 when the mine was in construction
and ramp-up. This is a pleasing result as the level of complexity
has increased substantially since then.
Milling volumes increased by one percent for the current period
when compared to June 2010. Both periods were constrained
because of the transformer and rectifier issues experienced at
Ruashi. These issues have been extensively reported on during
the relevant periods in separate market releases. Problems with
the rectifier and transformers caused by external power surges
and substandard transformer design and manufacture, eventually
led to a decision to redesign and replace all of the transformers.
This is in progress and production levels have since stabilised.
The copper and cobalt headgrades remained substantially
constant for the previous six-month period. The confidence
levels in the geological model continued to improve through
the period due to continued infill drilling and grade control
measures. The grades experienced in the current period are
expected to persist into the next financial year.
Copper recoveries improved to 84 percent for the current period
and are a function of both the acid solubility of the plant feed
material and operating efficiencies. The improvements to the
geological model allow Ruashi to control and predict its feed
sources better, while operating efficiencies are subject to a
process of continuous improvement. In addition to the continuous
improvement efforts, the reduced throughput due to the
transformer and rectifier problems allowed for a greater residence
time in the leach section as well as better operational control, both
of which had a positive influence on recoveries. Cobalt recoveries
improved by 20 percent for the current period to 65 percent.
Cobalt recoveries also benefited as per the copper discussion
above, however, cobalt recoveries are very sensitive to feed grade.
The higher grade cobalt fed to the plant therefore also contributed
to the improved cobalt recoveries. Cobalt recovery improvements
will be more modest off the current base.
Notwithstanding the production pressures caused by the
rectifier and transformer issues, copper and cobalt production
improved by eight percent and 28 percent respectively over
the two halves of 2010.
On-mine costs per ton milled decreased by six percent when
comparing the current period to June 2010. However, there
was an offset due to less stripping of pit 1 and pit 2 which
decreased the stripping ratio from 5,5 to 3,5. Stripping costs in
the new pit 3 are being capitalised as mine development costs
in line with the Group Accounting Policies. This reduced cash
operating costs. Copper and cobalt realisation costs increased
by five percent and 28 percent respectively when comparing
June 2010 to the current period. These costs were both
impacted by an incremental US$60/t export charge effective
February 2010. Cobalt realisation charges were also
significantly higher in the current period due to concentrate
moisture levels rising to, as high as, 70%. This was due to the
change to a magnesium oxide-based process as well as
problems experienced in commissioning the cobalt drying
circuit. Extensive modifications to the cobalt drying circuit are
being planned. The mode of export was also changed towards
the end of the year as it was found that transporting on the rail
system was substantially more expensive than by road.
Total cash costs of copper sold net of cobalt credits improved by
14 percent over the first half of the year. The increased cobalt
sales contributed to this cost indicator falling to US$2 228 per
ton of copper in the current period. The overall cash mining profit
of US$73,6 million was a substantial increase of 179 percent
over June 2010. Capital expenditure amounted to US$24 million
in the current period. The overburden stripping at pit 3 is being
capitalised. These stripping operations will ramp up in the
F2011 year and expenditure is expected to reach US$23 million
for the 12-month period. The completion of the acid plant is
proceeding according to plan and accounted for US$6,8 million
in the current period. Capital spend in the coming year includes
US$6 million to complete the acid plant, US$4 million on
exploration drilling and US$20 million in ongoing capital
expenditure.
Ruashi Mine will be stabilising production levels at approximately
3 000 tons of copper per month for the coming year. Production
efficiencies and strategic initiatives should have the effect of
somewhat offsetting certain cost increases such as power,
diesel, taxes and wages. Brownfields drilling will improve the
oxide and sulphide resource base of Ruashi and should
continue to extend the life of the mine as well as increase ore
reserve flexibility.
Key results
| Ruashi |
Unit |
Six months Dec 2010 |
Six months June 2010 |
12 months Dec 2010 |
12 months June 2010 |
12 months June 2009 |
| Tons milled |
(t) |
605 735 |
600 437 |
1 206 172 |
1 232 301 |
485 360 |
Headgrade
– copper |
(%) |
3,0 |
3,0 |
3,0 |
2,9 |
2,8 |
| – cobalt |
(%) |
0,5 |
0,5 |
0,5 |
0,5 |
0,5 |
Recovery – copper |
(%) |
84 |
81 |
83 |
78 |
76 |
| – cobalt |
(%) |
65 |
55 |
60 |
54 |
27 |
| Copper produced |
(t) |
15 467 |
14 323 |
29 790 |
27 531 |
10 378 |
| Copper sold – total |
(t) |
15 297 |
14 702 |
29 999 |
27 740 |
10 351 |
| – into hedgebook |
(t) |
8 100 |
11 700 |
19 800 |
16 992 |
1 |
| – at spot price |
(t) |
7 197 |
3 002 |
10 199 |
10 748 |
1 |
– hedgebook price
achieved |
(US$/t) |
5 972 |
3 900 |
4 748 |
3 900 |
1 |
– average spot price
achieved |
(US$/t) |
8 275 |
6 163 |
7 653 |
6 633 |
1 |
| Cobalt produced |
(t) |
2 008 |
1 572 |
3 580 |
3 050 |
720 |
| Cobalt sold |
(t) |
1 933 |
1 709 |
3 642 |
3 192 |
326 |
On-mine cost per ton milled, net of ore
stock movement |
(US$/t) |
100 |
106 |
103 |
101 |
1 |
| Copper realisation costs per ton of copper sold |
(US$/t) |
670 |
637 |
653 |
615 |
1 |
| Cobalt realisation costs per ton of cobalt sold |
(US$/t) |
6 384 |
4 996 |
5 731 |
4 518 |
1 |
| Total cash cost/ton of copper sold, net of cobalt credits |
(US$/t) |
2 228 |
2 598 |
2 407 |
2 831 |
1 |
| Capital expenditure |
US$’m |
23 |
21 |
44 |
32 |
1 |
| 1Project capitalised during 2009. |
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