Participate in a full scale refinery trial to evaluate processing of bauxite from a new supply source. Topics included impact on production capacity, required modifications in port, refinery and utilities to maintain production capacity, impact on alumina quality, bauxite residue storage, environmental emissions, key process efficiencies, Opex and Capex estimates. The work provided the Client with inputs for deciding on the future use of the trialled bauxite.

Participate in a study for a refinery expansion. Topics included capacity increase selection, process flow sheet development, required modifications in port, refinery and utilities, alumina quality, bauxite residue storage, environmental emissions, key process efficiencies, Opex and Capex estimates, project implementation, economic evaluation and risk assessment. The work provided the Client with inputs for a future investment decision.

Prepare a bauxite beneficiation and refinery processing test program and associated budget. Bauxite beneficiation testing included suitability for kaolin and iron removal, settling characteristics of wash tailings, beneficiation plant flow sheet and equipment selection. Refinery processing testing included the suitability for low and high temperature digestion, break point definition, settling characteristics of bauxite residue, refinery flow sheet and equipment selection.

Prepare a global bauxite market outlook. Topics included bauxite supply options, bauxite market segmentation, traded bauxite suppliers, competitive bauxite pricing considering bauxite quality & shipping cost and reviewing expected market developments. The work served as input for developing competitive bauxite supply options for a specific alumina refinery.

Leading a study to evaluate the implications of a change in the bauxite supply source of a specific refinery. Topics included impact on production capacity, required modifications in port, refinery and utilities to maintain production capacity, process flow sheet development, alumina quality, bauxite residue storage, environmental emissions, key process efficiencies, Opex, Capex, project implementation, economic evaluation and risk assessment. The work provided the Client with inputs for deciding on future bauxite supply.

Techno-economic due diligence and SWOT analyses of an alumina refinery upgrade and re-start project, including a review of bauxite, energy & raw materials supply, refinery, utilities & port facilities, red mud storage & expansion capital, environmental control, production cost, asset condition & sustaining capital, improvement projects & capital cost, re-restart plan and cost, financing plan permanent plant closure, regional alumina market premium, production cost comparison, project economics and project SWOT analyses.

Develop and implement an investigation program to identify the root cause of a repeating electrical hazard on the working floor of a 350 kA reduction line. The origin of the electrical fault was identified and two potential solutions were presented to the Client. Follow-up activities to progress the matter were recommended and implemented.

Comment on a Mineral Resource Estimation Report of a bauxite deposits in Guinea. Also the following project aspects were elaborated: Resource Ownership, Environmental and Social Impact, Infrastructure, Processing, Mining, Resource Tonnage, Further Exploration and Project Development. The work provided the Client with inputs to evaluate the merits of acquiring an interest in the deposits.

Advice on key interactions within a “Mining - Processing - Tailings Storage” System, using the consolidated experience of some 30 bauxite mines and alumina refineries. All operations use hydrometallurgy, what is mineral processing using an aqueous solution to extract product from its ore. Topics were wet & dry tailings storage, fundamentals of hydrometallurgy, System water balance, System impurities balance, tailings washing, heat recovery from tailings and integration of mining & tailings storage. The work provided an oil producer with inputs to accelerate development of oil sand processing.

Participate in a study for a mine and refinery project in West Africa. Topics covered were bauxite beneficiation, bauxite quality and impact on refining technology, process design, operating & capital cost estimates and a review of the competitive position of the project. The work served as input for a larger report, providing a complete project description.

Prepare an overview of dry tailings storage and its application for bauxite residue. Topics included an overview of primary drivers of dry tailings storage, tailings dewatering and pumping of dewatered tailings, storage area design requirements, key equipment review, case studies, a review of design inputs and test methods. Client was introduced to potential supplier of key equipment. The report provided an oil producer with inputs for the development of technology for dry storage of oil sand residue.

Prepare and lead a one-day session for board members, reviewing strategic topics relating to the sale of bauxite assets. Topics included size of deposit & economy of scale, bauxite mining, alumina refining, environmental, infrastructure, locations and country aspects, project economics and project competitive position, potential sales value of the deposits and potential investor review.

Prepare and report an analysis of sales options for bauxite deposits in West Africa. Two options were elaborated: 1. Sell deposits for development an integrated mining & refining project. Topics included deposit size & economy of scale, mining, refining, infrastructure, location and country aspects, competing projects review, potential investor review and project SWOT analyses. 2. Sell deposits for development of an export mining project. Topics included market review, bauxite quality & market acceptance, supply and demand prospects, potential investor review and project SWOT analyses.

Prepare and lead a one-day session for board member, reviewing strategic topics relating to the development of envisaged aluminium smelting, power generating and coal mining project. Topics included a review of smelting technologies, raw materials supply, smelter operating cost, aluminium cost curve, power plant operating cost, buying versus mining of coal, project capital cost, project competitive position and project implementation aspects, such as “Turn-key” technology supply versus “Building blocks”, EPCM, financing, permits, fiscal aspects and profit export.

Carry out a techno-economic due diligence and SWOT analyses for an aluminium smelter and captive coal fired power plant in China. The work provided an independent assessment of key issues, such as technology review, benchmarking, asset condition, pollution control and operating cost. The due diligence report served as input for a bank, providing a loan for building an integrated 100,000 t/y Aluminium-Magnesium alloy facility.

Participate in a study for bauxite mining & land restoration in West Kalimantan. Topics covered were site selection, bauxite wash plant, thickened dry storage of wash tailings and operating & capital cost estimates. The work was incorporated in a conceptual study for a bauxite mine and alumina refinery project in Indonesia.

Carry out a techno-economic due diligence and SWOT analyses of a mining and refining project. Topics included project context, bauxite deposit and mine review, process review, alumina & hydrate quality, environmental & residue storage, infrastructure, capital cost review, operating cost review, socio-political assessment and project SWOT analyses. The work provided an independent assessment of key issues and served as input for an envisaged acquisition of a shareholding in the project.

Participate in a study for bauxite mining & land restoration in Vietnam’s Central Highlands. Topics covered were site selection, bauxite wash plant, storage options for wash tailings, storage of red mud and operating & capital cost estimates. The work provided conceptual solutions for the complications associated with bauxite mining & land restoration.

Audit the preparedness for start-up of a new refinery. Topics included shortcomings in design & engineering, quality of construction work, start-up planning, environmental aspects, operational issues and long term development considerations. The audit provided an independent assessment of the main concerns to be managed in the period around plant start-up.

Advise on operation and modification of a sand filter facility, including filter cleaning, backwash, maintenance and process optimisation. The objective was to make changes to the sand filter facility which would allow forthe passing of an increased flow at higher alumina concentration.

Establish the techno-economic implications of converting an alumina refinery from floury to sandy alumina production and identify the techno-economic consequences for an aluminium smelter when switching to sandy alumina quality. The evaluation served as input for a decision to implement the quality conversion and the associated sharing of costs and benefits.

Participate in a study for a mine and refinery project. Topics covered were bauxite quality and impact on technology selection, process design and operating & capital cost estimates. The cost estimates served as input for an evaluation of the competitive position of the project. The work provided early stage inputs for linking the bauxite exploration program to project economics.

Carry out a techno-economic due diligence and risk analyses for five refineries. For each refinery the topics included business context, process review, environmental & residue storage, alumina & hydrate quality, condition of assets, operating cost review, access to professional skills, options for refinery improvement and plant closure issues & costs. The work provided an independent assessment of key issues and served as input for an envisaged merger.

Provide aluminium industry context and inputs to a specialised consultancy group carrying out an environmental due diligence of four refineries. The work provided an independent assessment of key issues and served as input for an envisaged merger.

Review alumina quality and alumina off-take agreements and make an independent estimate of the operating & capital cost of a mine and refinery project. The work provided an independent assessment of key project issues and served as input for an envisaged project financing agreement.

Provide aluminium industry context and inputs to a specialised consultancy group carrying out an environmental due diligence of a refinery. The work provided an independent assessment of key issues and served as input for an envisaged acquisition of a shareholding in the refinery.

Prepare an operations development plan for a refinery. Topics included bauxite availability, cost & quality, technology review, residue storage improvements, condition of assets review & sustaining capital requirement, operating cost review and the economic evaluation of investing in the development of the operation.

Prepare an operations development plan for a refinery. Topics included bauxite availability, cost & quality, mine operations improvement, technology selection to increase production & to reduce costs, alumina quality improvement, residue storage & environmental improvements, infrastructure improvements, condition of assets review & sustaining capital requirement and the economic evaluation of the operations development plan.

Leading a group of experts, preparing operations development plans for three mines and three refineries. Topics included bauxite availability, cost & quality, mine operations improvement, technology selection to increase production & to reduce costs, alumina quality improvements, residue storage & environmental improvements, infrastructure improvements, condition of assets review & sustaining capital requirement and the economic evaluation of the operations development plans.

Carry out a techno-economic due diligence of a integrated mine and refinery project. Topics included business context, bauxite availability & quality, process review, environmental & residue storage, alumina quality, project infrastructure, access to professional skills, operating & capital cost review. The latter review was an input for the evaluation of the competitive position of the project. The work provided an independent assessment of key project issues and served as input for an envisaged acquisition of a shareholding in the project.

Participate in a council, which was defining the corporate strategy of a major aluminium company. Topics included analyses of strategic objectives, related risks and threats, proposals for strategy adjustment, miles stones for measuring progress towards strategic objectives.

Prepare a conceptual study for an integrated aluminium smelter and gas fired power plant project. Topics included smelter technology selection & process design, spent pot lining processing, power technology selection, power plant design, infrastructure requirements, operating & capital cost estimates and project implementation issues. The study provided an independent assessment of key project issues, to be addressed in the next project phase.

Carry out a techno-economic due diligence of a company active in the renewable energy business in the UK. Topics included business context, review of renewable energy projects, power sales contracts, operating and capital cost review. The work provided an independent assessment of key issues and served as input for an envisaged acquisition of a share holding in the company.

Present and discuss options for greenfield mine and refinery projects for a major aluminium company. Topics included business context, industry trend changes, review of bauxite deposits and their economic merits, country risks and review of potential joint venture partners. The study served as input for corporate strategy development to acquire new bauxite and alumina capacity.

Prepare a conceptual study for a bauxite beneficiation plant including process design, wash tailings storage and operating & capital cost estimates. Also prepare a conceptual study for a refinery, processing beneficiated bauxite, including bauxite quality and impact on technology selection, process design, steam/power plant design, bauxite residue storage and operating & capital cost estimates. The studies provided an independent assessment of key project issues and served as inputs for a government, which was interested to commercialise the associated bauxite deposit.

Participate in a group of experts, preparing operations development plans for two refineries. Topics included bauxite availability, cost & quality, technology selection to increase production & to reduce costs, bauxite residue storage & environmental improvements, condition of assets review & sustaining capital requirement and the economic evaluation of the operation development plans.

Provide aluminium industry context and specific advice on topics such as industry structure & developments, contractual, economic and technical issues relating to the development of the aluminium industry in a country. The development potential included aspects such as bauxite concessions, bauxite mining, alumina refining and aluminium smelting joint ventures, power supply and infrastructure development.

Carry out a techno-economic due diligence and risk analyses for an integrated refinery, smelter and port facilities complex. Topics included bauxite availability, cost & quality, power supply, bauxite residue and spent pot lining disposal, product quality, condition of assets, operating cost review and an evaluation of major investment projects. The work provided an independent assessment of key issues and served as input for an envisaged acquisition of a share holding in the complex.

Participate in a team making an independent project audit of a greenfield alumina refinery project. Topics included process design, capital costs, environmental aspects and project planning. The audit provided an independent assessment of the main concerns to be managed in the project implementation period.

Provide aluminium industry context and inputs to an specialised consultancy group carrying out an environmental due diligence of an integrated mine, refinery, smelter and port facilities complex. The work provided an independent assessment of key issues and served as input for a government who was preparing the complex for privatisation.

Prepare an independent assessment of the value of a smelter and port facilities complex. The work served as input for an envisaged acquisition of a shareholding in the smelter.

Participate in a techno-economic due diligence of a refinery. Topics included process review, residue disposal, alumina quality, and operating cost review. The techno-economic due diligence provided an independent assessment of key issues and served as input for an envisaged acquisition of a shareholding in the refinery.

Participate in a techno-economic due diligence of an integrated smelter and gas fired power plant. Topics included process review, spent pot ling disposal, condition of assets, operating cost review and a valuation of smelter and power plant. The work provided an independent assessment of key issues and served as input for a government who was preparing the operation for privatisation.

Prepare a bauxite market study. Topics included bauxite supply options for the aluminium industry, a historical perspective of the bauxite market, current bauxite market suppliers. The work served as input for competitive bauxite price setting, considering bauxite quality and shipping costs to specific buyers.

Participate in a team, developing flow sheet options for conversion of the high temperature digestion process to the sweetening digestion process. Topics include bauxite preparation, slurry holding, extraction chemistry and digestion heat balance optimisation.

Founded the International Aluminium and Power Conference, bringing together aluminium smelting and related power supply. Defined conference programs and themes and invited speakers. Three conferences were successfully held in Muscat-Oman, Reykjavik-Iceland and Sun City-South Africa.