Director Owner
Prosmelt Ltd
Total years of experience :34 years, 11 Months
United Kingdom and Ireland
Owner of a UK registered Management Consultancy private limited company, with a branch in Ireland, that I currently work out of.
• Providing consultancy services in Project Management, Studies and Plant Optimisation
• Supplying minerals, raw materials and refractories
• Preparing proposals/ bids for mine development studies
• Evaluating project proposals/ bids
• Conducting market analysis for South African Attapulgite Mine
• Sales and business development of minerals, raw materials and absorbents
• Management consulting
• Engineering Management
• Mechanical, Electrical, Piping (MEP)
• Division & Regional Management
Client - Aughinish Alumina Ltd -Dryer Project Guinea /Capital Projects Ireland
Project Lead- July 2017 - Current
July 2017 to June 2019 Project: Bauxite Dryer Facility, Taressa Port, Guinea
The wet Bauxite Dryer Facility- Turnkey engineering procurement and construction project composed of:
• Geotechnical survey and civil works (foundation piles and plinths for the dryer equipment and 600000T dry storage shed)
• Two 276T/hr rotary driers complete with combustion chambers, inlet and out let chutes, forced draft and exhaust fans and stacks
• Baghouse and compressor facilities for each drier
• Diesel operated Thermic oil heat exchanger unit to heat Heavy Fuel Oil for both driers
• 2 x 250m3 Bulk-Fuel storage day tanks for HFO
• Power- Transformer for each Drier
• MCC and Cabling or each Drier
• Port Power house - Factory acceptance testing and commissioning of Boilers, generators, thermal heat exchangers and pressure vessels for the port power house
• Design review and consultation for the main Port Fuel farm
Responsibilities:
• Main point of contact for the client team
• Ensure compliance to the manufacturing schedule and quality plan by the various manufacturing facilities in China, South Africa, Germany, UK and Turkey
• Expediting and factory acceptance testing for all equipment packages
• Coordinate equipment manufacturing schedules to ensure equipment from China and South Africa could be shipped on the same chartered heavy lift ship
• Ensure the owners team had the relevant permits, cranes and heavy road transportation available for the transportation and offloading of equipment at site in Guinea
• Ensure the implementation of the HSE management system at site with reference to their area of operation by the package project manager
• Manage all interface operations and controls between the owner team, engineering team, various manufacturers, on site contractors of various disciplines and other equipment packages
• Manage site teams by monitoring progress against target through weekly progress meetings with all discipline leads and sub-contractors for the monthly stakeholder report
• Participate in construction meetings, define, and set priorities with the owner’s team Project Director
• Overall Management of the project schedule, budget, and critical path
• Coordinate interfaces between the owner’s team, client team, construction groups, disciplines, and other project equipment packages with the aim of limiting work overlaps, effective use of shared resources and on time project delivery
• Assist and co-operate with the Construction Manager and Vendor Project Managers in the ordinary management of subcontracts, in defining extra-works and in the execution of changes during the works
• Ensure the commissioning schedule is followed, optimisation of the drying facility operation is completed, and documented records are kept by the relevant parties
• Ensure operational readiness training is conducted as agreed in the contract and as built documentation and certification is received from the main contractor
• Advise on maintenance care plans and audit the operating facility to ensure correct operation and maintenance procedures are in place after 6 months of running
Client: Aughinish Alumina Ltd (RUSAL) - Bauxite Refinery
Project Lead Brownfield projects at the bauxite refinery
June 2019 - current
Environmental upgrade: For operational licence compliance
• Sea Defence system repair to 100-year-old sea wall in environmentally protected area of the island
• Under water inspection of the effluent system at the ship loading quay
• Bauxite Residue sprinkler system reliability upgrade
• Bund and Ground water integrity project
• Community nature trails and car park facility
• Up Front Engineering to upgrade and modernise 6 Bauxite mud wash thickeners (new increased torque drives, improved rake design and flocculant launder)
• Reline division heads for 3 of Rod and Pebble mills
• Rebuild wobbler feeder
• High pressure digestion circuit reliability upgrade
• Salt cake oxidisation project
Responsibilities:
Liaising with relevant government departments to ensure work is completed within regulatory requirements:
• Oversee and direct capital projects from conception to completion
• Compile project business case, application for funding, scope of work, design stage health and safety plan, schedule deliverables and estimate costs
• Evaluate vendor bids
• Organise and lead project risk assessments with all stake holders
• Ensure all work is completed according to the construction stage health and safety plan and site safety protocols and standards
• Coordinate and direct construction workers and subcontractors
• Ensure correct resources are selected and available to complete the work
• Ensure contractual conditions of performance are met
• Review the work progress on daily basis
• Prepare weekly reports for operations management team
• Negotiate terms of agreements, draft contracts and obtain permits and licences
• Analyse, manage and mitigate risks
• Ensure quality construction standards and the use of proper construction techniques
• Equipment release certification and hand over equipment to operations
Client: Matutu Absorbents South Africa
Consultant - Sales & Business Development
June 2016 - June 2017
Market research and product development.
• Identify markets for Attapulgite in Europe
• Develop products and marketing strategies
Client: Tetra tech - Assarel Medet (copper mine)
United Kingdom and Bulgaria
Consultant - Project
Project: Process Plant Optimization and Prefeasibility study to expand Process plant from 12million t/annum to 15 - 20 million ton/annum (Large project $400, 000, 000)
•Optimize the process and expand existing Process plant from 12milliont/annum to 15 million ton/annum
•Build a separate process plant with 5 million ton per annum capacity
Responsibilities:
•Identify bottlenecks and inefficiencies in the existing comminution circuit and float cells for the process plant
•Prefeasibility study to upgrade and modernise existing process plant comminution circuit and float cells
•Pre-feasibility study to build a new 5 million ton per annum comminution circuit and process plant on a separate site
•Participate in the presentation of the study to the client
Open pit gold and silver mine with 5Mt/year process plant utilising gravity and carbon in leach circuits for gold and Merrill Crowe Circuit for silver.
Collaborating with Asset Management to ensure effective asset management activities with in the PAS55 framework
Coaching, mentoring and delivering project management knowledge to Morobe Mining site personnel
Managing multiple, site-wide modification and improvement projects for per ounce cost reduction of gold and silver - multi-discipline projects ranging in value from AU$100, 000 - AU$10million
Responsibilities:
Managing and recruiting a multidisciplinary MMJV staff team of 4 project Engineers, 2 Draftsmen, 1 Construction manager, 2 Project Supervisors and 20 tradesmen and additional contract resources as required
MMJV contract management implementation. Manage contractual agreements with contractors and sub-contractors
Project team development
Developing and implementing a project management and work management system for small to medium projects that covers ($10, 000 - $10, 000, 000)
Planning and successful delivery of multiple projects at hand
Project initiation, feasibility study and front-end Engineering. Oversee and manage the project front end engineering team for multiple projects
Project Scope Management. Oversee and direct the construction phase to ensure best practise methods are followed and the project meets the objectives
Project Risk Management, ensure risk assessments are conducted and site safety protocol is followed
Project Time and Cost Management. Generate and ensure compliance to the project schedule and spend schedule. Generate progress reports to mine management and Joint venture stakeholders
Forecast and manage changes to project spend schedule to ensure capital is available for payments
Project Resource Management ensure all aspects of the project and project schedule are adequately resourced and coordinate use of shared resources.
Coordinate transport of the equipment to the mine from the port.
Project Procurement, Identify and source suitable equipment suppliers, adjudicate and award work packages
Project Quality Management Ensure equipment manufacture is within the schedule and quality plans are adhered to.
Project integration management and Operational readiness, coordinate operational readiness training,
Commissioning and hand over to operations
Project Close Out
Achievements:
Successfully recruited and trained the engineering / project team
Successfully initiated and implemented a project management framework and work management system for small to medium sized projects
Successfully recruited and trained the project team.
Successfully managed a major crusher installation through all the project management steps from project feasibility through to commissioning and close out. This was a multi discipline project encompassing all aspects of design, procurement, earth and civil work, electrical mechanical and structural installation and it was completed, safely within budget using in house resources
Achieved Cyanide compliance for the mine process plant.
Successfully implemented various projects to achieve the cost per ounce reduction required.
Projects:
Install new run of mine and (800t/hr) crushing station for the Hamata pit.
Cyanide compliance and Cost per ounce reduction - site wide modification and improvement
Complete installation and commission of oxygen generation plant
Bund installation and dual pipe installation for cyanide compliance of the process plant
Relocate Tailings dam pump station and replace Slurry discharge valves
Extend tailings dam dewatering boreholes
Remove and descale existing and run new 3km effluent water pipe
Upgrade thickener underflow pumps
Construct Mobile plant work shop for second mining pit (Hamata pit)
Mill motor changeout
Complete Project punch list activities and close out for Hidden valley run of mine primary and secondary crusher station upgrade (1200t/hr)
Project: Train Unloader Port Expansion Project (155 million tons) Port Hedland (Large Project)
Responsible for ensuring the completion, punch listing and commissioning activities of new infrastructure and equipment in the second in load circuit of Port Expansion project. This project consisted of the installation of two dual tip train unloaders to service the trains from the world’s heaviest haul rail lines. The prime focus of the role was to ensure a seamless integration of new assets into port operations.
Responsibilities:
•Verification of construction completion and punch listing of new infrastructure and equipment
•Identify engineering problems and ensure solutions are implemented
•Weekly reporting of commissioning activities to stakeholder groups
•Development of no load, load and steady state commissioning procedures and schedule
•Commissioning of new infrastructure and equipment
•Preparing cost estimates
•Coordinating vendor engagement during commissioning of OEM equipment
•Night shift Lead on the equipment ramp up to design production rates
•Development and implementation of maintenance strategies and tactics
•Identification and procurement of critical and operational spares
•Handover and acceptance of all project completion and as built documentation
•Review and update of all documentation (procedures, manuals, drawings)
•Update of operating strategies and procedures for the port
•Integration and training of personnel on the new equipment
Achievements:
•Train unloader 2 of Port Expansion project (2nd in-load circuit) successfully commissioned and optimised system handed over to operations ahead of schedule
FMG Port
Responsible for providing technical support in all engineering, maintenance functions, identification and implementation of small capital projects at the port.
Responsibilities:
•To conduct work in a manner that provides visible safety leadership and model positive safety behaviour in all staff
•Work towards zero harm (HSE) in design and formulation of technical solutions
•Develop change management procedures and coordinate all interface and change management activities
•Develop and work to the Project Execution Plan (PEP), ensuring compliance and assurance of delivery against objectives
•Supervision of the materials and equipment procurement process from requisitioning to delivery at site
•Manage and report on progress of projects
•Create strategies for equipment maintenance based on condition monitoring reports
•Participate in optimisation trials of existing equipment
•Propose improvement ideas based on detailed examination of anticipated or recurring problems of a technical or specialist nature
•Achieve targets set for defined sectors of Area budget
•Actively participate in the planning process to ensure that assumptions and targets are feasible
•Apply my expertise to determine root causes of variance from plan and determine the actions to improve the situation w.r.t. complex, highly technical problems
•Monitor quality assurance of critical processes
•Resolve technically complex business improvement problems
•Identify improvement opportunities and implement small capital projects
•Prepare the scope of work and motivate for budget approval for projects
•Monitor and control of project budgets and schedules to ensure targets are met
•Control project costs by approving expenditure, administering contractor contracts
•Contract negotiation with service and equipment suppliers
•Contractor supervision to ensure quality assurance of critical processes
•Review new equipment and/or systems in conjunction with outside experts
•Engineering and technical support to Operations and Maintenance teams
•Develop equipment maintenance strategies based on Reliability Engineering processes such as RCA, failure analysis and condition monitoring
•Mentor and aid development of graduate engineering students
Achievements:
•Conducted a plant wide optimisation study of the existing facility where opportunities were identified, investigated, costed, prioritised and implemented based on project feasibility and payback, resulting in improved safety, reliability and plant performance
•Devised and implemented a simplified change management system that ensured effective technical solutions were identified, responsibility and accountability was assigned, targets were met and stakeholder consensus was ensured
Larox Pty Ltd Acquired by Outotec in 2009
Reporting to: Director Service and Outotek Matrix Management structure
Developing business opportunities by utilising various methodologies incl. market analysis, organic growth and acquisitions, optimising customer relations
Compiled targets and budget for Western Australia
Generating project bids
Financial performance: Full Profit and Loss & financial responsibility
Managing agents, contractors and subcontractors
Managed trained and mentored a team of 5 staff (direct reports) consisting of Start-Up and Commissioning Manager, Flowsys Pump and Valve Sales Manager and Engineers
Ensuring staff are managed and led effectively and enhancing their performance by providing direction, regular feedback and development opportunities
Generated sales and promoted the Larox service Brand and the Outotec brand
Recruitment of team members when required
Initiated contact with customers, negotiated the contracts and service agreements and then sold on service products such as brown fields projects, refurbishment equipment, site shutdowns, equipment modernisations, asset audits, service agreements, new equipment installation and commissioning, training and spare parts agreements
Oversee multiple projects ensuring all deliverables are met on time and within budget
Contract negotiations: negotiating with internal & external customers for service level agreements, vendor supply contracts, asset management contracts and project scope & deliverables
Forecasting, planning and scheduling of all minor & major maintenance projects and service activities in Western Australia
Start-Up, commissioning and handover activities for all new equipment installed in Australia, Papua New Guinea and New Zealand
Developing the target budget for Larox Service products & Flowsys valve and pump products in Western Australia
Developing “Service” products, including equipment modernisation projects, asset management strategies for equipment, service contracts, training and spare parts contracts
Prepare monthly area status reports of activities by collecting, analysing and summarising information and trends with recommended actions required to head office
Ensured customer satisfaction and improved customer relations through a high level of communication with the customer to clearly define the scope of work and expectations
Achievements:
Successfully implemented a change to the management model in my area to give the team more responsibility and a higher profile at the customer
Integrated the Larox service department into the Outotec business model
Captured 100% of Larox service business at 14 of the 16 mine sites in my area
Recorded record turnover in the area for 2 consecutive years while exceeding the budget by 21%. Exceeded the target budget by $1, 500, 000.00, in spite of the 2008 / 2009 Global financial crisis
Retained staff and ensured growth and profitability during the Global financial crisis
Sold and successfully planned, coordinated and managed plant shutdowns, installations, equipment refurbishments and brown fields modernizations at mine sites owned by BHP Billiton, Newman, Xstrata, Newcrest and Norilsk
Salvaged a $55mil capital equipment sale after the sales team had been told they were no longer in consideration
Established a spares exchange service for the customers to capture their non-capital expenditure during capital budget cuts in the global financial crisis
Through business analysis and communicating with the customer successfully developed a plant modernisation project that helped them meet their increased production demand within the time and budget constraints that existed. This project became a success story for the Larox marketing strategy and was used on a global scale
Identified previously untapped business in the South East Asia region
Received the Larox Silver pin as recognition for performance in the Larox Global annual award system (2009)
South Africa
Manufacturer of specialist refractory ceramics and supplier of metals and alloys to the aluminium smelting and foundry industry in Southern Africa.
Reported to Managing Director
Countries travelled to for business from South Africa are Mozambique and Australia
Responsibilities:
• Developing strategies to capitalise on market potential and maximise new sales and business development opportunities
• Implementing QA procedures, product control & production methodologies, optimising stock levels
• Managing all commercial aspects incl. cost of sales and achieving budgets, full profit and loss accountability
• Implementing production changes that reduced product costs resulting in long-term supply contracts
• Product Control. Identified suitable product ranges and trading partners, implemented production methodologies, optimized stock levels
• Product development identified opportunities and developed products to suit
• Business Analysis; reviewed and reformed existing practices, identified opportunities, set targets and implemented plans to achieve the targets
• Implemented quality assurance procedures and process improvements at the company’s Ceramic factory
• Business development: Grew the Non-Ferrous division by developing and improving customer relations with both new and existing clients, improving product quality and developing a culture of service excellence
• Financial management and full budget responsibilities
• Monthly reporting on sales and business development activities to director
• Sales Plan and Strategy: Compiled the sales plan and strategy to achieve sales budgets and targets
Achievements:
• Achieved a growth in the annual turnover of the non-ferrous division from ZAR 3 million to ZAR 6 million a year
• Enabled the Ceramics division to export its products through improved quality control.
• Made production changes that enabled the company to reduce product costs resulting in long term supply contracts at 3 major customers
• Actively enabled the overall growth of other divisions in the company through networking.
• Due to my expertise in the Aluminium industry worked in a consulting role in the design of an Aluminium Alloy casting company, with a view to capturing their future business
Manufacturer and supplier of consumable materials such as refractories, alloys, minerals, fluxes, engineered textiles and coatings to the foundry and smelter industry in Southern Africa.
Countries travelled to for business from South Africa are Mozambique, Germany, Italy, England, the Netherlands and Belgium.
Reported to Managing Director
Responsibilities:
• Business development: developing Non-Ferrous division in South Africa and establish new business into neighbouring Mozambique
• Raising visibility of company, brand development, network development, product development.
• Performing market analysis for product requirements
• Networking and communicating with local and international principal suppliers to promote new business opportunities
• Monthly reporting to directors
• Quality control of manufactured items
• Establishing international technical support base
• Represent the company at international trade shows, conferences and technical forums to establish company brand recognition
• Coordinate Technical conferences
• Developed customer relations with new and existing customers at all levels in the customer’s organisation from executive management to the end user
• Design, test and commission innovative products to increase penetration and market share
• Managed stock levels and ensured on time stock availability while reducing slow moving inventory
• Full autonomy in developing the Non-Ferrous division
• Full budgeting responsibility in my Non-Ferrous division with full profit and loss accountability
• Report on targets and sales to directors
Achievements:
• Achieved a department growth in the annual turnover of approx. 640% from ZAR 6 million a year to ZAR 38.4 million a year after just 5 years
• Sourced new principal suppliers and achieved long term contracts for their products at major customers in the region, including the BHP Billiton Smelters and Hulamin rolled products.
• Successfully introduced a new image for the organisation based on technical expertise and quality products
• Achieved a high level of recognition for the company as a technical solutions provider, resulting in international customer referrals
• Organised successful, bi annual, technical seminars to build customer and supplier networks.
• Developed a new pot start up procedure for our smelter customers that included a new design of pot start up covers and a change in form of a pot cell additive. This reduced the OHS (HSE) incidents by 58% during start-up of potline 2 at Mozal, improved start up success, reduced waste and was cost effective
• Increased market share for the metal filtration systems in the Aluminium Smelters and rolled products Casthouses of the region from 10% to 80%
Bayside Aluminium is a primary Aluminium smelter in South Africa that produces remelt and value-added products in the form of rolling ingot, rim alloy, extrusion billet and rod
Countries travelled to from South Africa for business are England, Italy and the Netherlands.
Responsibilities:
• Process optimisation, conducting process audits and troubleshooting, preparing and updating Standard Operating Procedures
• Applying LEAN methodology, upgrading rolling ingot and foundry alloy Casthouse, change management, evaluating commissioning and accepting new plant and equipment
• Managing the Casthouse cooling water systems
• Training, assisting and advising production personnel on Best Practice methodologies and techniques
• Reliability engineering and continuous improvement, conducting root cause analysis on abnormal occurrences and liaising with clients on technical aspects of product
• Implementing business improvement methodologies
• Technical support to Marketing department
Achievements:
• Using LEAN based methods reduced costs and improved performance throughout the Casthouse
• Introduced Operator training as a change management procedure during implementation of process improvements
• Successfully trained all Casthouse Operators as part of an Operator upgrade and multi skilling program
• Achieved a 30% reduction of rolling ingot casting scrap through initiating the installation of an Oil Removal plant for the Cooling Water plant
• Modernised the metal transfer systems from the furnace to the casting pits, which improved metal quality, improved availability and reduced OHS (HSE) incidents and resulted in the downsizing of the Refractory department
• Designed and installed syphoning platforms which significantly increased Operator safety while filling the furnace with molten metal
• Designed and implemented a new preparation of the furnace casting knuckle which increased reliability and significantly reduced OHS (HSE) incidents from metal spills
• Was able to overcome a 6-month delay in the commissioning of a customer Rolling Mill by designing and manufacturing new casting moulds to enable the casting of 630 x 700 rolling ingot for the Rolling Mill
Project: Slag Plant Environmental and Reliability Upgrade
This was the de-bottlenecking and optimisation of the TiO2 slag milling and screening plant. This entailed structural modifications to the building and equipment changes, including crushers, conveyors, screens, bucket elevators, surge bins, vibrating feeders and dust extraction systems. Reported directly to Project Manager
Responsibilities:
• Identifying the work to be done
• Preparing, developing and freezing the scopes of work
• Preparation and adjudication of tender documents
• Contract negotiation and award
• Planning of shutdowns
• Developing and managing the project execution plan
• Ensuring work complies with the Mines specifications and the Occupational, Health and Safety act (HSE)
• Supervision of contractors, ensuring that work was completed safely, within the specifications on time and within budget
• Managing any scope change through variation orders
• Managing costs and schedules
• Approval of expenses against the project budget
• Commissioning of new plant and equipment and hand over to Operations
Achievements:
• Safely and successfully implemented ZAR 80 million of brown fields projects over a 2-year period. This resulted in a safer, reliable and more efficient plant with an increase in production and a reduced impact on the environment per tonne of product
• Successfully rebuilt Smelting Furnace 2
• Successfully improved the structure and winching mechanism on the floating minerals concentrator
Self-employed Contractor
Clients Mondi Pulp and Paper, SAPPI Fine Paper KwaZulu Natal South Africa
• Conduct mechanical fitting duties during boiler shutdowns
(completion of Practical 4 for NHD)
Group 5 Projects EPC
Group 5 Projects were completing the 1000000 tonne per annum upgrade at Richards Bay Minerals and were awarded the construction, mechanicals, piping and electrical installation of the concentrator plant for mining Pond B
Responsibilities:
• Reporting directly to Site Manager
• Ensuring construction completion, punch listing and commissioning of equipment in the RBM 1000000 tonne per annum upgrade
• Site establishment for the greenfields mining Pond B concentrator
• Material control and material off takes from drawings
• Supervising installation crews - structural steel, mechanicals and piping (SMP) - process plants
• Recording variations and materials used
Achievements:
• Successfully installed the mechanicals, piping and structures in a mining pond concentrator
• Trained an unskilled rigging team to read drawings and plan the material lifts
(up to Practical 3 for ND)
(South African Motor Corporation)
• Facilities Engineering - Design and implementation of equipment for production lines
• Process Engineering - Optimisation of production line speed through maximising work bay efficiency
• Design and Development - Improving existing models through facelifts, performance testing of new drive trains, designing new components
Achievements:
• Upgraded the brake design in the B series Mazda 4x4’s and had it implemented in production vehicles
Bachelor of Engineering - Industrial Engineering
ND T3 Mechanical Engineering
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