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+0.48The first step in our processing operations involves crushing and milling the ore we mine at our concentrators. We then use a froth flotation process to collectively separate both the base metals and PGMs from other minerals to produce a concentrate.
Our concentrating operations are capable of processing all southern African reefs, and our facilities are designed to handle base metal-rich ores, like Platreef, and maintain efficient chrome recovery from UG2 ores.
This helps us ensure we extract maximum value from diverse ore bodies. We operate seven concentrators and three chrome recovery plants, situated adjacent to each mine.
Our downstream processing flowsheet (smelting, converting and refining) is unique and advantageous. Our converter plant performs the upfront separation of base metals and PGMs using proprietary technology.
This capability enables full compliance with minimum emissions standards, accelerates inventory movement through the value chain, and allows us to process a wider range of feed materials than many of our competitors.
The upfront separation of PGMs and base metals also enables parallel downstream processing, shortening the refining pipeline for each PGM metal. This provides operational flexibility by allowing base metal production and refining capacity to be managed independently of PGM refining.
We operate the largest fleet of smelting assets in the region, with a broad, multi‑geographical footprint.
Concentrate smelting is undertaken at our primary smelters in Rustenburg, Swartklip (Mortimer), Polokwane and at Unki in Zimbabwe. Recent efficiency improvements, particularly through mass‑pull optimisation, have further enhanced the performance and efficiency of our smelting operations.
Across this network, we deploy full SO₂‑abatement technology, a deliberate choice that reflects our values and supports our environmental commitments. We have developed benchmark furnace‑rebuild strategies, enabling rebuilds to be executed more efficiently, predictably and with improved long‑term furnace performance.
In addition, we maintain the ability to balance our own production with third‑party material, allowing us to optimise asset utilisation and maximise value creation.
At our converter plant in Rustenburg, the matte is further processed in an oxidising furnace, which produces converter matte. Our proprietary converter process is uniquely capable of treating solid matte feeds, which ensures we deliver benchmark metal recoveries. Converter slag is recycled through a slag cleaning furnace to maximise PGM and base metal recovery.
The plant has an integrated acid plant, which produces sulphuric acid for our own and industrial uses. The slow-cool process allows for early base metal and PGM separation in converter matte, reducing contamination and speeding up further processing. This converter matte, rich in base and precious metals, is then further processed at our refineries.
Our Base Metals Refinery (BMR) is unique in processing slow cool converter matte, separating base metals from precious metals, and processing base metals into final product, which we supply into the global market. Our final products include nickel cathode, copper cathode, cobalt sulphate and sodium sulphate.
This refinery, the largest producer of nickel cathode in South Africa, is constantly evolving and improving. It houses a mechanised and automated nickel tankhouse and, through innovative modern technology, produces a high-quality electrowon nickel. We are the only producer of nickel cathode in the Southern African PGMs industry and are registered with the London Metal Exchange.
The final PGM-containing concentrate from the BMR is sent to our Precious Metals Refinery (PMR) for further refining. The PMR is one of the most technologically advanced plants of its kind in the world.
Our Precious Metals Refinery (PMR) is the world’s largest refiner of PGMs, supplying a network of global customers with a range of products. The facility uses unique high-pressure chlorine dissolution, solvent extraction and precipitation processes to boost efficiency and purity. Duplicate systems enable resilience, scalability and uninterrupted production. Through these processes, we produce industry-leading high-purity PGMs.
Our processing operations are undertaken in full compliance with all relevant laws and regulations.
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