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Mintek Annual Report 2012
Magazines | Finance 2012-10-08 15:57:52
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    HIV/AIDS Interventions In order to prevent the spread of HIV/AIDS, Mintek continues an education drive by means of outreach programmes, awareness events, and a dedicated team of peer educators and counsellors. All employees are encouraged to make use of the voluntary counselling and testing services that are provided through the Mintek Medical Clinic. During the year, the results of the third HIV/AIDS prevalence survey at Mintek, which was conducted at the end of the previous financial year, were released. The study found a stabilisation in the overall infection rate at 8.3%, and a slight decrease in HIV prevalence in the younger staff category. Currently, there are 21 known employees living with HIV/AIDS, 13 of whom are on antiretroviral treatment (art) and receive monthly meal supplement packs from the clinic. the remaining eight employees receive immune booster packs and food supplements monthly or as required to sustain their energy levels at work and to boost the immune system. Going forward, Mintek will intensify the ART campaign to ensure that as many employees as possible who require treatment have access to it. Quality, Environment, Safety and Health Mintek unfortunately suffered a total of seven lost time injuries during the year. this has unfortunately caused an increase in the Lost Time Injury Frequency Rate (LTIFR) to the Mintek target of 1. Of major concern is that most of the incidents reported were not directly related to the working environment. The Health Incident Frequency Rate (HIFR) remained at 0. The External Client Dissatisfaction Frequency Rate (CDFR), at 13, exceeds the target of 10 but is a decrease over the previous year. Significant effort continues to be expended in assessing the root causes of the dissatisfaction and we are steadily increasing the number of external clients being surveyed. Mintek remains compliant with all its ISO standards. 3.0 2.5 2.0 1.5 1.0 0.5 0 May 10 Jun 10 In Conclusion Jul 10 While the results achieved are worth celebrating, we have to remain vigilant and mindful of the global economic events, especially the ongoing Eurozone crisis, and their possible consequences to the mineral resources sector in South Africa and the world, and ultimately to us as an organisation. For us to continue being a global player in our field of work, we have to continue concentrating on achieving maximum internal efficiencies, in particular cost control, while we continue to research and explore ways to develop new technology not only to provide the company with new revenue streams, but also to ensure that we reduce costs, increase production and enable divisions to deliver on their key mandate. Let me take this opportunity to thank the Minister of Mineral Resources, The Honourable Susan Shabangu and the deputy Minister Godfrey Oliphant, for their guidance and leadership and immense contribution to the successes achieved this year. We also wish to thank Mintek's Board of Directors for their effort and availability to make this year a successful one for Mintek. Our condolences go to Mr Paul White's family following his passing on in November. We also wish to welcome new Board members - Mr Imraan Patel and Ms Setepane Mohale - who joined the Board during the course of the year. In closing, I thank the Mintek management, staff and all stakeholders, whose sacrifices, hard work and dedication have made this another successful year during my tenure at Mintek. What a turnaround! Abiel Mngomezulu President and CEO, Mintek Mintek's Lost Time Injury Frequency Rate (April 2012) Aug 10 Sep 10 Oct 10 Nov 10 Dec 10 Jan 11 Feb 11 LTIFR Target Mar 11 Apr 11 May 11 Jun 11 Jul 11 Aug 11 Sep 11 Oct 11 Nov 11 9 Dec 11 Jan 12 Feb 12 Mar 12 Apr 12 CEO's report mintek annual report 2012

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    Performance Against Objectives 1. StAkehOlder PerSPective Key Performance Area/Objective: Enhance Mintek's visibility and credibility to all stakeholders Programmes Measures/Outcome Performance Indicator Target Actual Comments Integrated marketing and communication functions Enhancing the visibility and credibility of Mintek Annually updated marketing and communications plan approved and implemented Evidence of enhanced Mintek visibility and credibility as a research institution Attained annual customer satisfaction target Annually updated marketing and communications plan approved and implemented # of technical articles in credible publications # of papers presented at conferences # of conference presentations and posters performance against objectives 10 mintek annual report 2012 Updated 1 Plan approved and is being implemented. 26 27 The collective target for papers and conference presentations was achieved. 39 29 (Not all conferences require papers to be submitted). 21 54 # of SA Patents registered 2 3 IP discoveries and patents on target. No # of technology transfers # of discoveries (IPRA) 3 1 0 1 specific technology transfers, in the form of licensing or sale, occurred. Mainly because of economic uncertainty in the world. Annual Customer Satisfaction Rating Index 90 87 Late delivery of work on occasion remains the main contributor to client dissatisfaction. This is being addressed. Enhanced media exposure # of media references for Mintek 440 545 Target met. Enhanced relations with oversight bodies Annual presentation to Parliament on impact of Mintek's work and role Key Performance Area/Objective: Research and develop efficient mineral processing technologies and value added products and services Presented 2 One presentation each to the NCOP Select Committee and to the Parliamentary Portfolio Committee were done. Programmes Measures/Outcome Performance Indicator Target Actual Comments Competitive technologies, products and services for optimal mineral resource utilisation Beneficiation to value added products and services Supporting the technical requirements of emerging minerals resource companies Providing mineral economic data and consulting services Develop analytical and mineralogical methods and services, evidenced by reports Develop new technologies under Science Vote funding Sales of products, plant and equipment Commercial investigations and feasibility studies Develop applications for precious-, ferrous- and base metals in the areas of: - Biomedicine (HIV, cancer, malaria) - Catalysis (chemical processing, fuel cells, environmental) - Nanotechnology (water, health) - Physical metallurgy R&D and metallurgical industry support Develop metallurgical processes and products for base-, light- (titanium, magnesium) and ferrous metals # of methods 10 13 Target met. # of samples 70,000 60,755 Lower volume of samples was compensated Rand value (Rm) R27.8m R30.6m for by higher revenue. Less samples requiring more analysis and time, hence more revenue but less samples completed. # of internal reports 40 62 One of the planned technologies was # of new technologies 5 4 # of prototypes evidenced by reports 4 5 not researched as the PGM R&D cluster was repriorities in favour of the Hydrometallurgy division. # of units of plant and equipment 4 2 Collectively, sales of equipment and # of reports Rand value of control system sales (Rm) 10 R18.0m 13 R25.5m revenue receipts on target. Demand for Minfurn furnaces (targeted under plant units) was lower than anticipated due to Rand value of CRM sales (Rm) R3.5m R3.7m slow gold project market recovery. # of external reports 119 194 Sector recovery from the recession resulted in a high demand for service work, which Mintek was able to satisfy. # of internal reports 2 5 Beneficiation-related R&D progressed well and individual targets were exceeded. # of external reports 140 204 # of internal reports 3 2 There were delays in the equipment modification resulting in delays in testing and reporting within the current financial year. Technical assistance # of reports 10 8 The write-up of two reports was not completed on time. Mineral scans # of reports 9 16 Target met. # of stakeholder workshops 1 1

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    Key Performance Area/Objective: Research and develop green technologies and process to mitigate the impact of mineral development on the environment Programmes Measures/Outcome Performance Indicator Target Actual Comments Water efficient processes Develop water efficient flow sheets to optimise water consumption and enable processing of ore bodies in water stricken areas Energy efficient processes Develop energy efficient processes, flow sheets and control technologies that minimise energy consumption and carbon emissions Waste management and recycling Develop technologies for treating and recycling waste in order to extend mineral resources Rehabilitate derelict & ownerless mine sites # of internal reports 8 5 Certain of the deliverables reported under Waste Management and Recycling below # of external reports 3 3 also pertain to this objective. The science vote relating to the said deliverables was also transferred. # of internal reports 10 11 Industry focus on water, energy and waste is increasing and Mintek is well positioned # of external reports 1 1 to support sustainable processing in general. # of internal reports 7 9 Certain of the deliverables reported under this objective also address Water Efficient # of external reports 1 1 Processing. # of sites 4 4 Target met. Key Performance Area/Objective: Promote the mineral-based economies of rural and marginalised communities through technical assistance and skills development Programmes Measures/Outcome Performance Indicator Target Actual Comments Development of technologies and strategies relevant to rural and marginalised communities Economically sustainable businesses created in rural and marginalised communities Training and skills development interventions in rural and marginalised communities Establish technologies and strategies relevant to small scale operators, for transfer to rural and marginalised communities Develop and support economically sustainable SMME enterprises Provide accredited training in glass bead, jewellery, pottery and brick making, introduction to small scale mining. # of technologies adapted 2 2 Target significantly exceeded due to specific effort to stimulate rural business. # of technologies developed 2 2 # of feasibility reports 3 11 # of new businesses created 10 3 Despite efforts, as evidenced from number of feasibility reports generated and reported above, business creation was restricted due to lack of external funding. # of jobs created from new businesses % of businesses still in existence after 1 year % of businesses still in existence after 2 years Key Performance Area/Objective: Ensure the short-term viability and long-term sustainability of Mintek performance against objectives mintek annual report 2012 144 145 Target met. 73% 100% All 4 businesses established in 2010 are still in existence. 60% 70% 32 of 46 businesses established in 2009 still in existence. # of people trained 300 165 Lack of external funding impacted negatively on the number of people trained. Maintain accreditation Maintained Maintained Full accreditation extended to July 2014. Programmes Measures/Outcome Performance Indicator Target Actual Comments Improved modern facilities that reflect the image of a world class R&D organisation Sustainable funding model secured Implement infrastructure modernisation according to modernisation plan A sustainable funding model agreed and implemented Percentage of modernisation plan targets implemented. Progress towards an agreed funding model and approach 11 Wall Coating of Mintek Premises Develop Model Phases 1 - 4 complete Target achieved 1 Model developed

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    2. FinAnciAl And internAl BuSineSS PerSPective Key Performance Area/Objective: Uphold good governance practices Programmes Measures/Outcome Performance Indicator Target Actual Comments Enhanced fiscal discipline and the effective management of resources Enhanced organisational efficiencies and energy efficiency Enhanced Quality, Environment and Safety Compliance with all national and international regulatory frameworks, and applicable standards Enhanced business integration and organisational effectiveness programme BEE procurement as a % of total discretionary spend Strengthened Internal Financial Controls % BEE Spend of total discretionary spend Sound Debtor Management % Debtors write off of total revenue performance against objectives mintek annual report 2012 45% 36.38% BEE % is lower than expected due to large atomiser capital project, for which non- BEE MDM are the exclusive South African contractor. Unqualified audit Unqualified Improved audit as per target Zero Tolerance on Fraud R0 fraud R0 fraud Average Debtors Days <75 days 63 days <0.5% 0.2% Target achieved due to better debt collection. Total Income Rand Value (R'000) 406,688 420,886 Target exceeded. Net Result (surplus) Rand Value (R'000) 751 43,437 Surplus Target exceeded, operating expenditure lower than anticipated and better investment strategies resulting in higher than anticipated investment income. Optimal Return on Investment Rand Value (R'000) 10,000 16,585 Higher returns achieved due to more reserves available for investment. Total Capital Expenditure Rand Value (Including Funding) (R'000) Maintained balance between R&D and Commercial Revenue streams Maintained balance between TCTC Salary Bill / Total Expenditure Ratio of Research / Total Revenue expressed as a % Ratio of TCTC Salary Bill / Total Expenditure expressed as a % 81,791 70,518 Capital expenditure below that predicted due to negotiated deferred payment schedule for atomiser capital project, which is to Mintek's benefit. 50% 59% Target met. 55% 66% Improved efficiency in other cost elements resulted in increased salary %. Enhanced Liquidity Ratio Liquidity Ratio ≥2.0 2.0 Target met. Revenue per head Total revenue / total # of employees expressed in R/employee Improved cash flows from operations Continual improvement in organisational energy efficiency - achieve energy saving initiative targets QES standards maintained and enhanced Compliance with appropriate standards, regulations and legislation Development and implementation of ICT Master Plan Cash generated from operations after working capital (excluding movements in deferred income) (R'000) R565 000 R590 000 This indicates improved efficiencies (productivity). >1,000 58,390 High cash generated from operations due to high inflow of deferred income. # of kW saved in energy/power 200 kW 356kW Savings result from energy saving light installations. Maintain Mintek accreditation status Achieved Target for fatalities 0 0 Achieved Target for LTIFR ≤1.0 1.0 Achieved Targets for CDFR <10 13 % achievement of compliance checklist Implementation of ICT Master Plan as per agreed milestones IP Act Compliance % Compliance to IP Act Prescripts Maintained Maintained Targets were achieved except for CDFR, which continues to receive attention. Late delivery remains the main contributor to client dissatisfaction. Management is implementing measures to correct this. 92% 100% Compliance with the PFMA and Treasury regulations was ensured. Develop Plan Implementation of RIMS targets Grants and Contracts module completed 12 Phase 1 completed Implementation of ICT Master Plan on track. Planned RIMS module was deliberately not implemented because it was established that the planned module was not suited to Mintek's needs. 90% 100% All requirements were met.

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    3. leArning And grOwth PerSPective Key Performance Area/Objective Build world class R&D excellence Programmes Measures/Outcome Performance Indicator Target Actual Comments Human Capital Development, Attraction & Retention Identify and support potential skills in the scientific and technological fields Enhanced pipeline of skills available to support the Mintek Mandate Transformation of the Mintek Organisation Enhanced Performance Management Effective skills and knowledge transfer Enhanced Skills Development WSP Compliance Report 1 1 Training on target. Enhanced relationships with Institutions of Higher Education and other similar organisations. Science, Technology, Engineering and Maths (STEM) Promotion Effective Undergraduate Bursary Programme Effective Post-graduate Bursary Programme (Masters & PhD) Work-Integrated Learning, Studentships and Internship Programmes Development Programmes for recent graduate scientists & engineers, and for training future career researchers Total spend on training expressed as a % of total Payroll spend performance against objectives mintek annual report 2012 >1.50% 1.8% Number of partnerships in place 10 10 Satisfactory interaction with universities. # of Graduate Recruitment Programmes and other Science Events 8 11 Target met. Annual Minquiz competition 1 1 Target met. # of bursars 80 72 Divisional needs did not require the full 80 undergraduate bursar posts. % Undergraduates Absorption Rate 90% 100% # of bursars 20 20 Target met. % Masters Graduates Absorption Rate Employment Equity Report and Plan Report on compliance with DoL regulations Compliance with Performance Management Policy Enhanced Experience Profile of "Scientists" Proportion of Researchers to Total Staff No. of Staff enrolled for postgraduate (Masters and above) studies 100% 89% 1 of 9 was released as the Industrial partner withdrew. % PhD Graduates Absorption Rate 100% 50% 3 of 6 released from Bio-Med due to withdrawal of the Industrial partner. # of Candidates employed 45 48 28 of the 48 candidates completed their % Trainee Absorption Rate 5% 11% training during 2011/12. Of these, 3 (11%) were permanently employed. Graduate Development Programme pilot pilot Pilot programme has been implemented. Researcher Development Programme pilot replaced by EDP Employment Equity targets achieved 80% 84% % Performance Contracts done and signed (for each employee) % Performance Assessment done and signed (for each employee) Average years of experience in industry of Mintek "Scientists" Average Age of "Scientists" at Mintek 35 34 EDP programme initiated. The Programme commenced in April 2012 due to process delays not anticipated previously. 1 1 Reporting implemented (period 1 Oct 2010 to 30 Sep 2011) and targets achieved. 100% 100% All Mintek employees had up to date performance contracts that were used during 100% 100% annual reviews. 3 6 Situation improved - closing of the salary gaps for all Professionals played a key role. Proportion expressed as a % 35% 43% Researcher proficiency plans on track, with Master and PhD programmes receiving strong # of Staff enrolled 24 46 support. All targets met. % of staff with MSc & MEng % of staff with MSc & MEng 6% 12% % of staff with PhD % of staff with PhD 6% 6% Enhanced staff Retention & Succession % Staff Turnover 10% 9.93% Staff retention has improved generally, but % Staff Turnover of Professionals 4% 4.52% Mintek continues to loose professionals. Status in the implementation of the Retention Strategy Enhanced Coaching and Mentoring Status in the implementation of the Coaching and Mentoring strategy and plan Effective Leadership Development Programme Enhanced Employee Health and Wellness Programme # of employees benefiting from Leadership Development Programme # of Employee Wellness Programme interventions 13 In place 1 Target met. In place In place Staff development programmes are in place and progressing well. 15 26 Target met. 4 4 Target met.

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    Mintek in Brief Profiles of the operating divisions 1. The AdvAnced MATeriAls division (AMd) develops cost-effective metal-based materials through value-addition to South Africa's most strategic metals and minerals (precious, ferrous and base) for use in the fields of biomedical, catalysis, nanotechnology and metallurgy. AMD is a research orientated division with more than seventy per cent of the permanent staff holding post-graduate degrees. The division has strong interactions with local and international higher education institutes (HEIs), and a healthy bursary pipeline. The division's funding is primarily derived from large governmental programmes as well as projects in collaboration with industrial partners. 2. The AnAlyTicAl services division (Asd) provides analytical support to the other technical divisions at Mintek, as well as high calibre analytical services to external clients in the mining and minerals processing sectors. The division comprises three main service groups, based on different analytical techniques. These are the PGM Group (milling, fire assay and trace-ICP, geared around the determination of the platinum group metals), the Sample Preparation Group (including ICP-OES, ICP-MS and AAS), and the Chemistry and X-Ray Fluorescence Group. 3. BioTechnology division's (Bio) activities include the small-scale testing of ores and concentrate samples to verify their amenability to bio-treatment, the generation of flow diagrams for the conceptualisation of complete processes, and the estimation of the economics of such processes. Much of BIO's commercial projects involve conventional heap leaching test work, geomechanical testing of crushed ore for heap leaching, high-temperature heap bioleaching, the gangue chemistry of heap leaching, and the modeling and simulation of the chemical and physical processes of heap leaching. Although the division has historically had a strong international focus dictated by the location of sulphide ores, it has recently expanded its research activities to include topics that are of generic application and are more directly applicable to the South and Southern African needs. Such topics, which include the bioremediation of effluents from mines and processing plants and the biosynthesis of new value-added minerals products and environmentally friendly minerals processing bioreagents, allow greater interaction with other local institutions and broaden the research funding base. 4. The engineering supporT division (esd) primarily supports the other Mintek technical divisions by providing engineering support services which are outside the competency of the routine maintenance function. In addition to providing this internal mintek in brief mintek annual report 2012 support, ESD also designs and fabricates engineered equipment and systems based on Mintek technology for external clients. ESD has the responsibility for marketing and implementing a specialised range of Mintek technologies. The division maintains a core group of specialised skills which it supplements with external resources when necessary. 5. The hydroMeTAllurgy division (hMd) develops and tests appropriate flowsheets for the recovery and refining of metals from ores and concentrates. General market developments provide the trigger for the 1 2 3 4 5 6 14 development work done. Currently the biggest industry demand for hydrometallurgical test work is around REE, which provides a strong stimulus for further development of novel technologies in these areas. Strategic development focuses on areas considered to be important for the future of sustainable development of South Africa's mineral wealth, for example novel rare earths recovery techniques, the recovery of uranium from low grade ores and acid mine water treatment. 6. MeAsureMenT And conTrol (Mac) strives to assist the mineral industry in addressing the challenges of increasingly low grade and complex ores, cost effectiveness, energy efficiency, and minimising impact on the environment through the development of specialised instruments, intelligent process monitoring tools, and dynamic process

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    optimisation control products. MaC develops, demonstrates, and implements advanced process control technology to enhance the competitiveness and sustainability of flotation, milling, leaching and smelting processes where it is regarded as the world leader. Apart from South Africa, the division has a particularly strong presence in South America (Brazil, Chile, and Mexico), India, and Australia. 7. The MinerAl econoMics And sTrATegy uniT (Mesu) provides a selection of services to local industry and state departments, as well as to the other Mintek divisions. The knowledge and skills within the division allows MESU to also provide support services to international agencies, and where required, governments and companies which operate elsewhere on the continent. MESU provides insight into all parts of the mining and minerals value chain and has competence in facilitating the rehabilitation of derelict and ownerless mines across South Africa. 8. The MinerAl processing division (Mpd) undertakes desktop, laboratory and pilot plant scale studies to develop detailed flowsheets for the effective comminution and upgrading of ore to a concentrate or final product. The work falls into the three main disciplines, namely comminution (crushing and milling), physical separation and flotation. The work of the division can be described as falling into two main categories; feasibility tests and incremental improvements to existing plants and flow sheets. 9. MinerAlogy (Mnl) applies the principles of mineral characterisation to understand the processing behaviour of those minerals, thus empowering metallurgists and engineers to obtain optimum recovery and grade in mineral beneficiation. Further to this, mineralogical characterisation is applied to geological exploration, mine planning and remediation efforts, such that the entire spectrum of the minerals industry is served by the discipline of applied mineralogy. The division's commercial activities focus on identifying minerals or materials, and interpreting the data with respect to evaluating a deposit, beneficiating the ore, providing vital information for process design, as well as ongoing support with mineral industry trouble shooting, analysing metallurgical products, and dealing with environmental issues. 7 8 9 10 11 10. The pyroMeTAllurgy division (pdd) develops new and improved high temperature processes using theoretical calculations, laboratory and pilot plant equipment. A particular area of expertise is the use of DC arc furnaces for the smelting of ores and concentrates. This expertise is supported by a range of pilot plant DC arc furnaces capable of smelting at up to 3 MW continuously over periods exceeding a year and treating up to 20 000 tonnes per annum of feed materials. 11. sMAll-scAle Mining And BeneficiATion (ssMB) is a diverse division of multi-skilled professionals that address issues related to the smallscale mining industry. Areas covered are extractive technologies in small-scale mining, beneficiation of resources, training, sustainability and environmental matters. mintek in brief 15 mintek annual report 2012 SSMB's beneficiaries include both existing and aspirant small-scale mining operators and crafters that use mineral and metallurgical resources as a raw material. SSMB supports Small, Medium and Micro Enterprises (SMMEs) in the mineral sector by identifying economically viable opportunities, providing access to appropriate technologies, and providing training and incubation.

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    Research, Development and Technology MinTEK ProvidEs World-ClAss rEsEArCh And dEvEloPMEnT (r&d) expertise, testwork, and process optimisation for the precious and base metals, ferrous metals and alloys, industrial minerals, rare metals and uranium sectors in South Africa and internationally. The activities range from initial bench-top investigations to full process flowsheet development and the design, construction, commissioning, and optimisation of industrial plants. Mintek is strongly committed to delivering highquality results within strict schedules. To this end, our engineers, scientists and technicians work in close liaison with clients and their engineering contractors, who are encouraged to actively participate in project planning and testwork. This interaction enables clients to discuss issues as development work moves forward, and increases Mintek's own capabilities by drawing attention to areas that require focused and applied r&d. The newly acquired knowledge is then fed back into client-oriented services. From left: Nanotechnology SEM The Advanced Leach Facility (ALF), which uses a technique that forms a key part of the gold testwork service. A scientist using handheld potentstat for fieldtesting. Mintek also undertakes medium- and long-term strategic applied r&d, which is aimed at building the organisation's science and technological base and developing new technologies and products for the benefit of the mining industry. This activity is funded mainly by the State Parliamentary Grant to Mintek as a Science Council, and also through supplementary sources such as bilateral agreements and other funding and donor agencies. Most of the projects in this category are undertaken as joint ventures or in collaboration with other research institutions, universities, professional bodies and industry partners locally and internationally. Mintek regards participation in European Union Framework research programmes as being a very attractive, long-term collaborative research opportunity - providing access to an international research network and source of r&d funding. To this end, Mintek is participating in two FP7 mineral processing project proposals. Mintek was successful in securing R150-million of medium-term expenditure framework (MTEF) funding, for the 2012/13 - 2014/15 period, for five key projects, namely: } production of semi-precious gemstones in the Northern Cape; } a rare earths element pilot plant; } a metal atomising demonstration plant; } a facility focusing on mining effluents; } the upgrade of the Mintek infrastructure. GolD InDusTRy The development of gold projects, especially in West Africa, has generated interest in the advanced diagnostic leach capability developed at Mintek. The Hydrometallurgy Division at Mintek developed the Advanced Leach Facility, which uses a technique that is now set to form a key part of the gold test-work service and the strong demand for this service means that the capacity of this facility has to be increased by 300%. Catalysis Project AuTEK Catalysis, which is a public-private research, development and technology 16 mintek annual report 2012 partnership with AngoGold Ashanti since 2000, aims to research and increase the industrial usage of gold through application of gold-based catalysts. Its focus continued to be centered on the use of gold catalysts in emission control, fine chemicals production and petrochemical applications. significant effort has been maintained in the development of an EN403 compliant fire escape gas mask in collaboration with Mintek's commercial partner Spirotek. Capitalising on the learning gained from the EN403 mask, other types of gas masks such as wild fire gas masks, are now being targeted for development. Notable progress has been made in the scale-up of gold catalyst wash-coated ceramic monoliths. These catalysts will ultimately form Mintek's AUROlith range and will complement the existing commercial AUROlite TM catalysts that are distributed globally by United States based commercial partner, STREM Chemicals Inc. Mintek aims to attract further industrial partnership for AuTEK and much effort has been made into developing a number of value propositions. These include a proposal to convert ethanol and glycerol oxidation to value added products, which have been presented to several international and local industries. In a collaboration initiated this year, a series of catalyst supports was sent to Oak Ridge National Lab in the United States. The aim is to understand certain aspects of gold catalyst deactivation. During the year, a total of 19 kg of gold catalyst was ordered by an industrial application developer. Resin-in-pulp for Gold Tailings On the back of the successful demonstration of resin-inpulp for uranium processing, the focus of this technology has now shifted to the economically important elements of this process such as acid and ferric production as well as the maximisation of gold recovery. A particular interest is to develop more cost effective technologies that would render more South African primary uranium deposits and existing gold slimes dams economically viable. nanoscience and nanotechnology The DST/Mintek Nanotechnology Innovation Centre

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    (NIC) comprises of three science councils (Mintek, Medical research Council (MrC) and the Water research Commission (WrC)), and three University nodes (rhodes University, University of the Western Cape and University of Johannesburg). The NIC supports the national system of innovation and encourages the flow of technology and information among people, enterprises and institutions as key to the innovative process. The NIC addresses issues of national importance including the development of research platforms, encouraging and promoting the formation of both local and international collaborative networks, addressing human capital development and bridging the innovation chasm. The NIC develops various nanostructured materials and use them as systems or tools for health (diagnostic and therapeutics) and water (monitoring and treatment) applications, which fit within the social cluster of the national nanotechnology strategy. During the past year, various nanostructured materials including nanofibers, nanotubes, nanocomposites and nanoparticles were produced and some were modelled in partnership with the Centre of High Performance Computing to understand their behaviour. Scaling up of gold nanoparticles reached 40L and more than 100L of gold nanoparticles have been shipped to Germany as part of the Organisation for Economic Co-operation and Development toxicology sponsorship programme. The Water Unit has demonstrated the capacity to develop and scale up bead filter systems for water treatment. Whereas the membrane filter systems developed by either modifying commercial membranes or those produced in-house are further optimised. The Sensors Unit filed a patent on novel fibres (luTTPc) and the development of Measle Sensor prototype reached the proof-of-concept stage. The Biolabels group developed and tested some therapeutic systems at the pre-clinical stage, and optimised lateral flow diagnostic prototypes. In addressing human capital development in the NIC, a total of 16 students (7 Hons, 7 MSc, 2 PhD) graduated out of the 53 students registered (7 Honours, 19 MSc, 22 Phd) and five Post-doctoral fellows. several Mintek researchers and students received special training in the UK, UsA and india towards further skills and technology development. The NIC produced during the past year 87 papers (including two book chapters) published in isi journals. in addition, niC researchers and students received nine international awards and the Biolabels development group was a 2011 nsTF-BhP Billiton finalist under the Category: Research for innovation by a team or individual in a corporate organisation or institution. The NIC hosted a large number of visitors from overseas institutions, which includes Buffalo University (USA), Manchester Metropolitan University (UK), University of Massachusetts (UsA), oxford University (UK), University of liverpool (UK), Universität duisburg-Essen (Germany), and a delegation from Taiwan led by their Deputy Minister of Science and Technology. In addition, the centre hosted a high level delegation from the K.s. rangasamy College of Technologies (KsrCT) nano Centre in india with whom an MoU was signed for joint research on nanominerals Metal-based Therapies for Cancer, HIV and Malaria The Biomed group has continued to expand research activities to other metal centers in addition to gold. Since its inception in 2002, Biomed has grown from a programme focused on gold-based therapies for cancer to a diverse research team investigating metal-based therapies for cancer and hiv. In total, more than 100 compounds were chemically synthesised and tested for biological activity in the past year. of these tested compounds, eight potential hiv-1 inhibitors were identified and have undergone in-depth analysis; with one compound demonstrating useful activity against hiv-1 integrase. Based on these findings, the design of second generation compounds has been initiated and will be pursued over the next financial year. Research aimed at cancer drug discovery within the Biomed group has focused on the modification of a promising lead inhibitor. This compound successfully reached an advanced preclinical stage of investigation through partnership with the National Cancer Institute in the United States but fell short of the exacting requirements needed to transverse further through the drug development pipeline. Over the past year, efforts were aimed at overcoming the limitations of the compound, with more work required to ensure suitability of the compound. To expedite the entire in-house drug discovery process, the Biomed group has constructed a new synthesis facility. Furthermore, a large commercial compound library was purchased to complement the automated robotic system previously acquired. Already, two biological assays have been adapted to the robotic platform, through which the compound library will be research, development and technology 17 mintek annual report 2012 screened in a semi-high throughput manner. Physical Metallurgy The r&d activities of the Physical Metallurgy Group are classed into three broad categories, namely, the Ferrous and Base Metals Network (FMDN) of the Department of Science and Technology's Advanced Metals Initiative Programme (DST-AMI), technology assistance to the foundry industry under the DST's Technology Assistance Programme (DST-TAP) and general technology assistance to the metals-related industries carried out under the Metals Technology Centre (MTC). Under the AMI-FMDN programme, remarkable progress was made under the Metal Dusting and Lightweight steels sub-programmes during the past financial year. Key industry collaborators were brought into the programme such that the on-going research is optimally aligned with the pertinent materials-related challenges in both the petrochemical and transportation industries. This collaborative alignment with industry has enabled the formulation of relevant r&d projects with higher Education Institutions (HEIs), notably, the University of the Witwatersrand, the University of Pretoria, vaal University of Technology and the University of From left; The Biomed research team investigates metalbased therapies for cancer, HIV and malaria. A scientist busy in the Mintek catalysis laboratory. The Nanotechnology Innovation Centre (NIC) boasts a new centrifuge machine. A Biomed scientist working in the Biosafety Level II flowhood.

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    Johannesburg, where papers and presentations were made at a number of local and international conferences. The AMI-FMDN programme has been extended to 2014 with a view of expanding collaborative platforms with other metals-related sectors and HEIs. Under the DST-TAP programme, Mintek continued to work closely with foundries in order to improve their technological competitiveness. During the past year, three major outcomes were realised. Mintek hosted a well-attended five-day workshop on Metallography for the Foundry Industry. The workshop was presented by Mr George van der voort, a world-renowned metallurgist. secondly, Mintek was able to identify, jointly with the foundries, a number of technical areas that have the potential of being upgraded into r&d programmes. These projects are likely to be executed with the foundry industry under the auspices of the National Foundry Technology Network (NFTN) - a Department of Trade and Industry entity. The last spin-off from the DST- TAP programme is the human capital development programme linked to the DST-TAP funded foundries. This programme focused on the N.Dip, B.Tech and M.Tech students that will be placed at foundries in order to From left: Bay 2 pilot-plant furnace and drying plant being constructed to test a client's platinum smelters. Uranium leach testwork. The MetRIX uranium pilot-plant. Platinum flotation pilot plant in Bay 4, Mintek. acquire experiential training. The ultimate goal of this programme is to improve the employment opportunities of these candidates in the foundry industry, with the additional benefit of concurrently elevating the average skill levels in this industry to those approximate with their international competitors. The MTC programme continues to make a difference in the broader metals-related industries where it continues to offer general and specialised corrosion services, such as hydrogen-induced cracking (HIC) testing. Through the MTC's service excellence in HIC testing, it has positioned itself as the sole provider of this service in South Africa. The other area where the MTC has distinguished itself is in grinding media quality control (QC) services. This service offering to the mining industry continues to grow at a rapid pace where Mintek is now offering on-going grinding media QC services to two international mining companies, in addition to the ad-hoc projects. some of the short-term service work projects have matured into fully fledged r&d projects that are being executed jointly with industry partners. The indication is that this service will expand in the next financial year as the MTC continues to receive similar requests for this service from both South African and international mining companies. The MTC continues to be an appropriate training ground for new staff and interns in the Physical Metallurgy Group. The MTC provides these trainees with a unique opportunity to be exposed to a myriad of diverse metals-related projects at any given time. The interns that eventually leave Mintek upon completion of their experiential tenures continue to secure employment in some of the top companies in South Africa PlaTInuM GRouP MeTals (PGMs) InDusTRy uG2 Reef ore Characterisation South Africa is the foremost producer of Platinum Group Elements (PGEs) in the world and this is due to a massive resource base of the Bushveld Complex. Over the last three years Mintek has carried out extensive testwork at laboratory scale for characterisation of UG2 Reef ores. To date, over 50 UG2 samples have been collected from across the Bushveld Complex and characterised at laboratory scale to determine the PGM rate of recovery. This has resulted in the development research, development and technology 18 mintek annual report 2012 of a UG2 database, which can be used to compare the performance of new ores to operations situated nearby. At the development stage is a flotation simulator, which is currently being refined for prediction of continuous flotation performance using batch data. A successful process for waste water treatment in PGM refinery flowsheet using specially adapted ion exchange fibres has been developed and Mintek is experimenting on the different commercial models for this technology. Flotation Testwork Flotation testwork for the PGM and Base Metal industry has continued. With the democratic republic of Congo closing down on the export of unbeneficiated material, further work has been required on potential base metal upgrading options. The metallurgical testwork design is dependent on the mineralogy and processing options available. There has also been a renewed interest into the flotation of graphite, phosphate and PGM's from chromite (LG and MG reefs). sensor-based sorting Mintek undertook an extensive programme of tests using a large range of Platreef PGM samples as part of the on-going research into the use of sensor based sorting. This is expected to develop benchmark data for the various ore types and has significant potential to lower the cut-off grade of Platreef deposits, significantly enhancing the available resources. Water and energy efficiency are regarded as important industry drivers going forward and Mintek is embarking on a strategy to develop itself as a 'centre of excellence' in this area. Mintek regards sensor ore sorting as one of the most important future technology shifts because of the benefits it offers to more complete resource utilisation and reduced energy and water consumption. The tests are made with a view to reducing water consumption within various plant flowsheets by upfront dry waste rejection and reducing size of existing plants by reducing plant feed tonnages. atomising Plant at Bay 2 Mintek is commissioning another demonstration project at a capital cost of R44-million in collaboration with Anglo American Platinum. Once in operation the 12 tonnes per day atomiser plant is expected to run for at least 24 months. The atomisation plant is a further

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