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For more information contact TZMI | +61 8 9359 6000 | [email protected] | tzmi.com
ZIRCON ANNUAL REVIEW SAMPLE
NEW EDITION TO BE RELEASED Q2 2014
PROPOSED TABLE OF CONTENTS*
EXECUTIVE SUMMARY
1.0: INTRODUCTION AND ZIRCON MARKET 1.1 Introduction1.2 The global zircon market1.3 Overview of zircon end-uses1.4 Structure of report1.5 Confidentiality and disclaimer
2.0: END-USES: CERAMICS AND SANITARYWARE 2.1 Introduction2.2 Production of ceramic tiles2.3 Zircon in ceramic tiles2.4 Manufacture of sanitaryware 2.5 Segment developments in 2013
3.0: END-USES: SPECIALTY CHEMICALS AND MATERIALS
3.1 Introduction3.2 Zirconium chemicals3.3 Zirconia3.4 Zirconium metal3.5 Segment developments in 2013
4.0: END-USES: REFRACTORIES AND FOUNDRIES 4.1 Introduction4.2 Refractories4.3 Foundries and casting4.4 Segment developments in 2013
5.0: ZIRCON SUPPLY 5.1 Introduction5.2 Zircon supply in 20135.3 Zircon supply by region5.4 Key zircon producers
6.0: ZIRCON DEMAND DYNAMICS6.1 Overview – substitution and thrifting6.2 Zircon demand by region6.3 Demand drivers6.4 Zircon demand by market6.5 Zircon trade in 20136.6 Zircon demand outlook to 2014
7.0: ZIRCON PRICING 7.1 Price forecasting methodology7.2 Overview of 20137.3 Trade7.4 Pricing outlook to 2015
8.0: NEW PROJECTS8.1 New supply8.2 New projects
9.0: STRATEGIC ISSUES AND OUTLOOK
APPENDIX 1 - PRODUCER PROFILES
APPENDIX 2 - CONSUMER PROFILES
APPENDIX 3 – NEW PROJECTS PROFILES
* minor changes may be made to this outline prior to publication
SAMPLE OF 2013 EDITION
THE ZIRCON MARKET AND MAJOR END-USES
DEMAND DYNAMICS
Demand broken down by regions, drivers, growth in end-uses.
Comprehensive analysis of the major end-uses
for zircon
Sections for each
end-use with an examination
of demand drivers
NEW EDITION TO BE RELEASED Q2 2014
For more information contact TZMI | +61 8 9359 6000 | [email protected] | tzmi.com
SUPPLY AND PRICING
Examines supply developments in the past year.
Pricing information targets trends by producer and region.
Trade analysis
across the globe
China’s influence on
the zircon market
Export trade analysis by
country
Regionally, Australia remains the largest zircon producing country, accounting for 36% of global production in 2012. ”“
NEW PROJECTS
STRATEGIC ISSUES
This section includes a synopsis of projects in the pipeline. It also includes an outline of each project and its development status.
Key challenges
in the zircon sector
A discussion of thrifting &
substitution and the impact on the
zircon market
Future issues for
the industry
APPENDICES
APPENDIX 1 Producer profiles
APPENDIX 2 Consumer profiles
APPENDIX 3 New projects profiles
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APPENDIX 1 - PRODUCER PROFILES
Richards Bay Minerals
Operations <<RBMminesdunal sanddeposits inKwaZulu-Natal,SouthAfrica,stretchingfrom10to50kmnorthofRichardsBay.Fourseparateminingplantsprovideacombinedminingcapacityofapproximately115milliontpa.Themostrecentminingplantconsistsoftwodredgesandoneconcentrator,andwascommissionedattheendof1999.Itwasdesignedtocompensateforfallingoregrades.AuxiliarydryminingisalsoemployedatRBM,andnowcontributesanestimated15%ofthetotalvolumeoforemined.Muchofthedryminedoreissourcedfromareasinaccessibletothedredgesusedastheprincipalminingmethod.
Mineralconcentrateistruckedtoacentralprocessingplantwhereilmeniteisextractedbymagneticseparationandthenon-magneticsarefurtherprocessedfortherecoveryofzirconandrutile.Themineralprocessingplantcurrentlyhascapacitytoproduceupto240,000tpaofzirconand90,000tpaofrutile.Upto160,000tpaofzirconareacidleachedtoproducea‘premium’gradezircon.
InitscurrentleasestothenorthofRichardsBay,andinanadditionalleasesouthofRichardsBay,itisunderstoodthatRBMhasreservessufficientformorethan20yearsoperationatcurrentminingrates.Presentmeasuredreserves(expressedintermsofslagproduct)standat24.9milliontonnes,withafurther3.0indicatedandinferredmilliontonnescategorisedasresources.
RBMannouncedinMarch2011thatitintendedtomineitsZultiSouthminingleasearea,southofRichardsBay,extendingminingoperationstoaround2043.Miningoftheareacouldstartasearlyas2016.
InMarch2011,thecompanycommissioneditstailingstreatmentplantandbeganproductioninApril2011.RBMplanstotreat2.2milliontonnesof tailings per year.
Recentdevelopments
InFebruary2012,BHPBillitonLtdagreedtosellits37%stakeinRBMtoRio Tinto.
InFebruary2013,RioTintoannouncedthatitwastakingactionatanumberofitsoperationsandwouldplaceitszirconandrutileprocessingoperationsatRBMoncareandmaintenance,whilemaintainingproductionatthecoreilmeniteminingandsmeltingoperations.ThedecisionfollowedtheannouncementofRioTinto’sannualresultsfor2012.RioTintoreportedaUS$3billionlossforthe2012year,citingaUS$14.4billionwritedownrelatingtoaluminiumbusinessesandcoalassetsinMozambique.
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ZIRCON ANNUAL REVIEW 2013
Richards Bay Minerals
Ownership Rio Tinto, RBM’s managing company, owns 74% of RBM’s shares.
BlueHorizon,aB-BBEEconsortiumholds24%and2%isheldinatrustfor employees.
Address POBox401RichardsBay3900 SOUTH AFRICA
Tel:Website:Email:
+27 35 901 [email protected]
Key personnel Jean-FrançoisTurgeon–ActingManagingDirectorDenis Booysen – General Manager, EngineeringFundiDlamini–GeneralManager,CommunitiesandCorporateRelationsBheki Gumbi – General Manager, Human ResourcesJoeyKunji-Behari–GeneralManager,SmeltingandProcessingJohanJacobs–GeneralManager,Technical
Background In 1971, the Industrial Development Corporation began a detailedinvestigationoftheRichardsBayarea.ACanadianproduceroftitaniaslag(QIT)wasalsolookingformajorilmenitedepositsin1974.Thesetwo organisations, together with Union Corporation (later Gencor now BHP Billiton),formedRBMin1976tomineandbeneficiatethevastmineral-richsandsinthecoastaldunesthatextend17kminatwokilometrewidestripfromjustnorthofRichardsBay.In1985thecompanyacquiredtheminingrightstoadditionalorereservesbothnorthandsouthoftheoriginaldeposit.
During2001,RBMstarteddryminingoperationstosupplementitsdredgemining operations.
LegislationpassedbytheSouthAfricanGovernmentin2004requiresthatmining companies sell 26% of their mines to black investors by 2014. The companyannouncedinDecember2008thatadefinitiveagreementwithaBroadBasedBlackEconomicEmpowerment(BBBEE)consortium,BlueHorizon,hadbeensigned.InDecember2009,therand4.5billion(US$55.4million)dealwascompleted.BlueHorizonacquireda24%equityinterestinRBM,with2%oftheequityheldbypermanentemployeesthroughanemployeeparticipationscheme.Itisthelargestbroad-basedblackeconomicempowermentdealintheregiontodate.
InJuly2008,thecompanyannouncedthatithadapprovedmorethanrand1billion(US$147.2million)infundingforanewMSPtailingstreatmentplantproject.Theprojectisexpectedtoextendminelifebyafurtherfiveyears.RBMalsoannouncedplanstogeneratesufficientelectricityin-housetobeable to supply a portion of the power plants requirements; approximately 6.5 MW by 2011.
FollowingthecompletionoftheBBBEEdeal,RichardsBayMinerals(RBM)consistsoftwoseparateoperatingcompanies;RichardsBayMining(Pty)Ltd,whichisresponsibleforminingoperations;andRichardsBayTitanium(Pty)Ltd,whichisresponsibleforthesmeltingandbeneficiationprocess
InApril2009,RioTintoremovedoneofthefourfurnacesatRichardsBayfromoperationforaperiodoffivemonthsforaplannedrebuild.>>
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SAMPLE PROFILE
SAMPLE PAGES
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ZIRCON ANNUAL REVIEW 2013
Structure of the zirconia, zirconium chemicals and metal industries
ZOCPLANTS
ZIRCON SANDFEED
FUSEDZIRCONIA
CHEMICALZIRCONIA
ZIRCONIUMMETAL
BADDELEYITE
FUSED ZIRCONIA
CHEMICAL ZIRCONIA
Zr CHEMICALS
ZIRCONIUM METAL
© TZMI 2013
Zirconisusedinthesanitarywareindustrytoprovideopacityandwhiteness.Zircononlyformspartofthesanitarywareglazeandrarelyisintheceramicstructureofthesanitarywarebody.Thetypical content of zircon in a sanitaryware glaze is between 15-16%.
Specialty chemicals and materials
Zirconiumchemicalscompriseavariedgroup,eachmembercontainingzirconiumasanactiveconstituent. Themost common intermediate product, fromwhichmany of the others aremanufactured,iszirconiumoxychlorideoctohydrateorZOC,whichhastheformula,ZrOCl2.8H2O.
Anotheroften-usedintermediateiszirconiumbasicsulfate,knownasZBS.
Whiletheyhavesignificantlydifferentend-uses,thetwogeneraltypesofzirconia-fusedandchemical - share a range of characteristics which make them valuable materials in various specialist applications.Theprincipaldifferencesbetweenthetwotypesofzirconiaare:
• Chemicalzirconiaisconsiderablypurerthanfusedzirconia,soittendstobeusedintheapplications which require greater precision of performance;
• Thesurfaceareatoweightratioofthecrystalsofchemicalzirconiaisfarhigher.
Refractories and foundries
Zirconhasahighmeltingpointandhighresistancetothermalshock,makingitasuitablecandidatefor use as a refractory in high-temperature applications. Zirconia, exhibits very similar refractory propertiestozircon,exceptthatithasahighermeltingpointandcanbeusedinapplicationswheretemperaturesexceed1,990°C.
Themainadvantageofzirconasafoundrysandisitsrefractorinessandresistancetometalpenetrationaswellasitsabilitytowithstandhightemperaturesforlongperiods.Thisallowszircontobeusedinfoundriesforthecastingofhigh-alloystainlesssteels,attemperaturesashighas1,650°C.
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EXECUTIVE SUMMARY
Thecombinationofthesecharacteristics(refractoriness,lowthermalexpansionandchemicalstability),makezirconanidealnon-silicafoundrysand.Highpriceshowever,meanitisusedonlyinhigh-endcastingsandspecialisedapplications.
Zircon supplyGlobalzirconsupplygrewby23%in2010from2009levels,reaching1.3milliontonnesandreached1.6milliontonnesin2011amidescalatingprices.Thepriceofzirconsandexperiencedasharpcorrectionduring2012.ProlongedeconomicmalaiseinEuropeandoverstockinginChinawerecitedastheprimarycauses,aswellastheperennialpriceincreaseswithwhichcustomersonbothcontinentshadtocontend.
Inlightoftheworsenedmarketconditions,2012witnessednonewprojectsandthereductionofoutputandmothballingofseveralothers.Investmentcontinues,however,andadditionalsupplyin2014,2015and2016canbeexpected.
Regionally,Australiaremainsthelargestzirconproducingcountry,accountingforapproximately36%ofglobalzirconoutput.Thefollowingfigureshowsthedistributionofzirconproductionbycountry in 2012.
SouthAfricaisthesecondlargestzirconproducingcountry,accountingfor30%ofglobalproductionin2012.Chinaisalsofastbecomingakeyzirconproducingcountry.Accountingfor15%ofglobaloutput,China’szircondemandisnowthelargestintheworldasimports80%ofitszircon.
Ilukaremainsthelargestsingleproducerofzircon,accountingforaround30%ofglobalzirconoutputsince2001oraround300,000tonnes.RichardsBayMineralsisthenextlargestzirconproducer,withestimatedannualoutputof270,000tonnesin2012,followedbyChinawith205,000tonnes.
REF 8691
Australia36%
South Africa30%
US 6%
Mozambique 3%
Ukraine 2%
China15%
India 3%
Vietnam2%
RoW3%
© TZMI 2013 NOT FOR REPRODUCTION
©TZMI 2013
Distribution of global zircon production by country in 2012
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