Slide 1: Gladstone Overview
Gladstone Overview Phillip Strachan Financial Community Visit – Weipa / Gladstone 31 May to 1 June 2004 Venue safety • Alarm • Fire exits • Assembly point THE GOAL IS ZER “If it’s not safe, don’t do it that way” 2 1
Slide 2: Agenda; Large presence in Gladstone
Agenda • Gladstone overview Phillip Strachan • Comalco Alumina Refinery Chris Birkett • Site Tour • Lunch • Comalco Smelting Ian Smith 3 Large presence in Gladstone Comalco Ownership: 100% Employees: 1700 in Construction (end May) 400 in Operations (incl contractors) Comalco Ownership: 38.6% Employe
Slide 3: Gladstone is strategically important
Gladstone is strategically important • 67 per cent of Comalco’s asset base (10 per cent of Rio Tinto’s) • Four major operations employing over 3,000 people • Growth potential 5 3
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Slide 5: Comalco Alumina Refinery
Comalco Alumina Refinery Chris Birkett Financial Community Visit – Weipa / Gladstone 31 May to 1 June 2004 Site and wharf aerial view 2 1
Slide 6: Comalco Alumina Refinery - Stage 1; Project status - safety
Comalco Alumina Refinery - Stage 1 Product filtration Precipitators Liquor Filtration Plant Operations Centre Alumina Storage Steam Plant Ball Mill Calciners Thickeners/clarifiers Tube Digesters Coal Stockpile Bauxite Stockpile 3 Project status - safety Safety statistics: • Project LTIFR 0.28 (2004
Slide 7: Comalco Alumina Refinery – key facts; Project status – construction
Comalco Alumina Refinery – key facts • Alumina refinery – bauxite to alumina • Stage one announced October 2001 – 1.4mtpa • Contract for engineering, procurement and construction - Bechtel Australia • Planned for 3 stages – to 4.2mtpa • Total cost of stage one US$750 million • Commissioning mid - la
Slide 8: Project awards; Operations
Project awards • Australian Institute of Management Queensland Excellence Awards – Professional manager of the year, Ron Douglas • The John Holland Group – Safety award for 2003 • Thiess Golding - Best project “Civil” in Queensland • Bechtel Corporate – Best rating (95 per cent) achieved by a projec
Slide 9: Sustainable development – our community; our environment
Sustainable development – our community • Sensitised community with industry experience • Strong community and government interest • Indigenous engagement programme • Comalco Community Fund • Announced May 2002 • A$1 million over three years • 8 partnerships • Leveraged A$1.5 million in additional f
Slide 10: Production ramp up
Production ramp up Production ramp up over 12 months 1300 1200 1100 1000 Alumina Production (kt/y) 900 800 700 600 500 400 300 200 100 0 1 2 3 4 5 6 7 8 9 10 11 12 Months 11 6
Slide 11: Comalco Smelting
Comalco Smelting Ian Smith Financial Community Visit – Weipa / Gladstone 31 May to 1 June 2004 Smelter sites Anglesey Boyne Smelters GPS PRODUCT Site Production RTA Share RTA Share of Bell Bay World Production NZAS Aluminium 1.2 Mtpa 0.8 Mtpa 2.9% Power 1612 MW 677 MW 2 1
Slide 12: Smelting structure; Smelting safety
Smelting structure Smelting Boyne Smelters Improvement Energy NZAS • Business strength • Power station interests • Strategy • Power contracts Anglesey • Asset & capital Bell Bay Management Development Sales & Marketing • Cell design • Sales • Energy improvement • Marketing • Technical support • Logi
Slide 13: Smelting environment; Management capabilities
Smelting environment • The Goal is Zero – Target operation at: • Benchmark performance or • Technical Limits – Over US$140M spent in last 10 years to update environmental technical capability • Major Projects Include – Potline Fume Scrubbing at NZAS & Bell Bay – Pitch Fume Scrubbing at NZAS, BSL & B
Slide 14: Technical capabilities; Power efficiency & cell development
Technical capabilities • Research & Technical support – 65 Staff • cell design • cell control & operations • anode production • metal casting • automation • environmental controls • Six Sigma – 137 trained Black Belts or Green Belts. – Plan to continue training around 70 per year • Project managemen
Slide 15: Cell efficiency – P69 cells; Rio Tinto Aluminium cell technology
Cell efficiency – P69 cells 72 Power Efficiency (kg Al / DC MWhr) 70 RTA Plants (average) Non-RTA Plants (average) 68 66 64 62 60 1200 1250 1300 1350 1400 Capital Efficiency (kg / cell / day) 9 Rio Tinto Aluminium cell technology • CD200 Cell – 724 in operation – Joint development Comalco & Dubal –
Slide 16: Production; Value Add Production
Production (indexed saleable tonnes) 1.25 1.21 1.20 1.13 1.15 1.10 1.10 Australasia Incl. AAM 1.07 1.03 1.05 1.00 1.00 0.95 0.90 0.85 0.80 2001 2002 2003 2004 YTD Ann. 11 Value Add Production (indexed – value add saleable tonnes) 1.80 1.65 1.70 1.53 1.60 1.47 1.50 Australasia Incl. AAM 1.43 1.40 1.3
Slide 17: Productivity; Unit Cost
Productivity (indexed – saleable tonnes per FTE) 1.20 1.15 1.12 1.10 Australasia Incl. AAM 1.07 1.04 1.05 1.05 1.02 1.00 1.00 0.95 0.90 0.85 0.80 2001 2002 2003 2004 YTD Ann. 13 Unit Cost (indexed - $/t excl power & alumina) 1.20 1.15 1.11 1.08 1.10 Australasia Incl. AAM 1.07 1.05 1.00 0.97 1.00 0.9
Slide 18: Outlook summary - BSL; NZAS
Outlook summary - BSL Achievements Opportunities • Stable operations across all • Development of Line 1 and Line reduction lines 2 anode assembly • Larger anode for Line 3 • Better than plan performance in all facets • Record production levels • Successful trialling of B32 reduction cells 15 Outlook
Slide 19: Outlook summary – Bell Bay; AAM
Outlook summary – Bell Bay Achievements Opportunities • 2004 Rio Tinto CEO most • 120+ kA growth improved safety award • Drained cell development • Record levels of Value Added production • 114kA project under plan and ahead of schedule • Acquired power block for 120+kA operation 17 Outlook summary
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