The world of mining: an inside look

As part of Kumar Sarbayev's Site Visits 2024 program, the final part of the visits took place in September, this time including visits to ERG Kazakhstan's operations in Pavlodar, as well as the operations and branches of our KAZ Minerals group - KAZ Minerals Bozshakol LLC and KMM Astana. The trips are traditionally organized for non-production (office) personnel of our Company. This trip was significant for me on two levels. First, it allowed me to return to my hometown and reconnect with my roots. Second, it offered a valuable opportunity to gain deeper insights into the two main enterprises of ERG Kazakhstan: JSC "Aluminum of Kazakhstan" and JSC "Kazakhstan Aluminum Smelter." Prior to this trip, I had only a limited understanding of these companies, having lived in Pavlodar for many years.

A Journey Home: KAZ Minerals and the renovated Pavlodar railway station

The trip began not only with a business excursion, but also with a personal visit. From Astana, I went ahead to Pavlodar, the city of my birth, upbringing, and education. This trip was also notable for the recent renovation of the railway station, which was sponsored entirely by KAZ Minerals.

As I stepped off the train and into the renovated station, I couldn't help but feel a sense of pride and joy for my city. The station's contemporary design and innovative facilities exemplify KAZ Minerals' commitment to investing in its industrial operations while also fostering the growth of infrastructure and prosperity in the regions it serves. The renovation of the station was celebrated with a grand opening ceremony in April of this year, attended by Jamie Caratti, General Director of KAZ Minerals Bozshakol LLC.

The reconstruction of the station served as a poignant reminder of the remarkable growth and progress my hometown and KAZ Minerals have achieved. It was an ideal beginning to a journey that would blend personal recollections with professional development.

Day one. ERG Kazakhstan

Aluminum of Kazakhstan JSC

Our first destination was Aluminum of Kazakhstan JSC, a company that has been a principal contributor to the nation's aluminum production for several decades. Upon arrival, we were greeted by our guide, who directed us to a beautifully decorated conference-room that is specifically used for hosting purposes. This set the tone for a professional yet welcoming atmosphere, which was further enhanced by an interesting overview of the plant and an informative safety briefing. Following this, we were provided with the necessary personal protective equipment.

Following the briefing, we went ahead with a tour, beginning with a panoramic view of the ore preparation area from the roof of the charge preparation building. From there, we saw the operation of a massive rotary excavator between substantial deposits of bauxite ore, which provided a striking illustration of the size of the undertaking. The excavator operated with precision between the two sides of the dumps, supplying raw materials to the processing stages of the plant.

The tour guide provided an overview of the plant's processing methods, including the use of the Bayer process for grinding ore and the sintering process for processing low and high silica bauxite. This integrated strategy refines aluminum recovery while reducing the reliance on costly caustic alkali. The sintering branch enables the plant to produce caustic lye from soda ash at a lower cost, offering a cost-effective solution.

We were then taken on a tour of the sintering furnace shop. The furnace shop was notable for its size and cleanliness. The expansive hall with its marble floors and columns evoked the image of a pristine palace, rather than a typical workshop. The shop is also equipped with a modern operator's room featuring panels from a Distributed Control System (DCS). One of the employees was kind enough to show us a sample from the kiln, which offered further insight into the technical process in practice.

The most impressive aspect of the tour was the opportunity to gain insight into the company's dedication to sustainability and environmental stewardship. We were given a tour of the first stage of a unique green project, which is dedicated to the reconstruction of two electrostatic precipitators for Furnace No. 1. The new filters, developed with the help of thyssenkrupp , are designed to significantly reduce dust emissions, thereby enhancing the plant's environmental sustainability. The modernization project, which allows the plant to run continuously during the process, exemplifies ERG Kazakhstan Group's dedication to environmental responsibility while supporting best productivity.

Kazakhstan Aluminum Smelter JSC:

Following the conclusion of our visit to Aluminum of Kazakhstan, we tried to Kazakhstan Aluminum Smelter JSC.

Upon our boarding the bus, we were greeted and accompanied by Nikita Kot, Process Engineer of the Electrowinning Shop. Mr. Nikita Kot served as our guide and provided an overview of the plant's operations once we were all settled inside the bus. As you approach the plant on the concrete pavement, you are at once aware of its formidable presence and impressive scale. Furthermore, we noted the presence of well-maintained pathways on the premises, including those within the workshops, which were clearly marked. It was seen at once that workers are using bicycles to travel between shops. While this may seem a minor detail, it is nevertheless evidence of the company's commitment to sustainable development and to the ecology of the region.

One of the most noteworthy aspects of this visit was the emphasis placed on safety. In addition to the standard procedure for the issuance of personal protective equipment (PPE), each participant was provided with a specialized radio receiver to ease best communication with the tour guide. The small but thoughtful gesture ensured that none of us missed a word of the detailed touring. In the electro-winning shop, we also had to wear a respirator mask.

During the tour, we had the opportunity to see two significant production facilities: the aluminum electrowinning shop and the electrode shop. Nikita outlined that the electrowinning shop runs with fully automated processes and a maximum of 18 personnel per shift. We saw the operation of a modern overhead crane manufactured by a German company. I was impressed by the modern design and maneuverability of this crane. These cranes are essential for the seamless transportation of materials between shops, ensuring best production efficiency. This expansive facility houses 288 electrolyzers in a single, continuous row. These are closed-bath processes where alumina is automatically loaded and mixed with molten creolite at 950 degrees Celsius. The next step is to dip the electrodes (anodes) into the creolite at a voltage of 336.5 kiloamperes. When exposed to electricity, alumina undergoes a chemical reaction that results in the splitting of atoms, thereby breaking the bond between aluminum and oxygen. Aluminum ions are deposited on the cathode of the bath. A layer of metal measuring between 10 and 15 centimeters is formed at this point and then automatically transferred to the casting shop, where it is stamped into what are known as pigs.

Our next destination was the casting shop, where we saw the final stage of the aluminum production process. The aluminum is poured into molds, cooled, and then formed into the pigs. The pigs stand for the purest aluminum of grades A7, A7E, and A8, weighing 20 kg each, and are then packed in bags of one ton. One of the most noteworthy aspects of the tour was seeing the dexterous maneuvers of a female forklift operator navigating the shop floor with remarkable precision and speed meticulously stacking packages for efficient delivery. It's no surprise that it quickly became the perfect place for selfies! The gleaming aluminum stacks make the perfect backdrop.

The company's product range is fully covered by the Kazakhstan market, with partial coverage in the CIS region. In addition, the company exports its products to Greece, Turkey, and Italy.

Following the tour of the production facilities, we were afforded the opportunity to walk through the green area of the plant in front of the entrance hall. This area, which boasts a considerable number of trees, made a positive impression on us. The plant serves not only as a center of production, but also as a venue for honoring people and history. One of the most memorable aspects of the visit was the opportunity to view the Walk of Fame, which commemorates the individuals who played a pivotal role in the plant's construction.

We were gratified to discover the name of our colleague, Assel Telzhanova, who had previously been employed at the Kazakhstan Aluminum Smelter before joining KAZ Minerals.

It was such a special experience for me, too. It felt like a trip back in time. Back in 2005, I was just a student when I got the chance to join a student construction crew that took part in team reinforcement during the construction of this very smelter. When I shared this, my coworkers were a bit skeptical, jokingly asking why my name wasn't on the wall. Fortunately, I was able to find an old newspaper article from the family archives at my parents' house that confirmed my involvement in the construction.

Day two. Bozshakol

The next stage of our itinerary took us to Bozshakol, one of KAZ Minerals' most prominent open-pit copper mines, situated to the northwest of Pavlodar. Given my lengthy tenure at Aktogay, followed by a prior period of employment at Bozshakol, I was keen to gain insight into the current state of production and atmosphere at the latter. Upon arrival, we were taken to the Plant Administration Building (PAB), where we received a comprehensive safety induction and an overview of the plant's operations. This established procedure has reinforced our commitment to supporting safety as a core value across all KAZ Minerals operations. The tour began in the control room, which serves as the quarry's strategic operations center. We had the opportunity to meet Kirill Melnikov, a senior engineer dispatcher responsible for monitoring mining operations. The room was equipped with a multitude of screens displaying real-time data from the mine. This data was gathered using an advanced Leica system that provided visual tracking of equipment, traffic, status of the bench faces, and overall pit safety, as showed by Kirill.

The dispatchers proved an exceptional level of control, visibility, and precision in watching the mining operations, ensuring their smooth and efficient execution. Kirill was kind enough to answer all our questions and offer further insight into the management of day-to-day operations at Bozshakol’s Open Pit.

Following our departure from the control room, we went ahead to the open pit, where we received comprehensive information about the mine's layout and operations from Artyom Tsukan (Mine Production Foreman) and Anton Yussupov (Health and Safety Coordinator). The scale of the mine was incredible! I was thrilled to see that it has become noticeably wider since my last visit to Bozshakol Quarry in 2020!

Artyom, Anton, as well as senior dispatcher Kirill, were highly attentive and readily available to answer any questions we had. They provided comprehensive explanations of the production cycle of the mine, including details on the mining, transportation, and processing of ore.

Following lunch, we had gone ahead to the Bozshakol concentrator, where we had the opportunity to tour the grinding plant, flotation circuit, and tailings thickener building. For those of us who work at Aktogay, the concentrator seemed quite familiar, as many of the processes are like those, we are already familiar with. However, what was not similar, and what at once caught our attention, was Glencore's Jameson flotation unit, which had been commissioned just a few months earlier.

The Jameson unit is a unique and valuable part of the Bozshakol concentrator, and the team is especially pleased with the positive impact it has had on recovery rates. The new process not only increased copper recovery, but also had a significant impact on gold recovery. This is an important aspect of the Bozshakol concentrator's operations given the small amount of this metal in the deposit.

Another noteworthy aspect was the tailings thickener at the concentrator, where we had the opportunity to see the complete thickening process, including the addition of flocculants and the operation of underflow pumps.

Meeting Jamie Caratti : a friendly and insightfully perceptive leader.

The most noteworthy aspect of our visit to Bozshakol was our meeting with Jamie Caratti , General Director of KAZ Minerals Bozshakol. Despite his demanding schedule, Jamie was able to accommodate our meeting. He welcomed us warmly and answered all questions (even tricky ones) — technical and non-technical—in a relaxed manner and with a good sense of humor. He managed both technical and non-technical questions with ease and confidence. Jamie also remembered the Jameson unit, and he was really excited about it. He spoke with great enthusiasm about the successful deployment of the new system and the positive results it has already yielded in terms of recovery rates at the concentrator. As the meeting progressed, Jamie was asked a growing number of questions, which he answered thoroughly while also posing questions to the group. He was so full of energy and openness that the meeting felt more like a casual chat between friends than a formal briefing.

Before we left, Jamie kindly offered to take some group photos for us, which captured the warmth and friendliness of our meeting.

Day Three KMM Astana: final stage with presentations and thoughts on the results

The final stage of our itinerary was the KAZ Minerals Management (KMM) branch in Astana, where we attended a series of presentations and meetings. Following insightful tours of the production facilities, it was beneficial to take some time to reflect on the knowledge gained and to discuss the broader vision and goals of such events.

Site Visits 2024 program: A vision from Kumar Sarbaev

The morning began with a presentation by Kumar Sarbaev, Site Visits Organizer, outlining the details of the Site Visits 2024 program. Kumar presented the strategy and outlined the program's achievements to date. It is encouraging to see the program's growth and expansion. It now encompasses not only internal sites but also external companies, such as Kazakhmys and ERG, which have been included in the geographical scope of visits.

Kumar highlighted that these visits are not merely educational excursions; they are also a chance to reinforce connections between various divisions of the company, share best practices, and explore innovative technologies and methodologies. His enthusiasm for the program was clear, and it was clear that these visits were having a notable effect on the company's administrative personnel.

Gaining insight from industry leaders: Presentations from industry leaders:

Following a brief coffee break, we were privileged to attend a presentation by Glen Balog , Director and Chief Geotechnical Engineer at Bogr-Engineering. Glen is an independent consultant with extensive experience. He was kind enough to provide us with a comprehensive and insightful session on geotechnical operations, planning, and maintenance. His presentation addressed the future of safe mining through a pragmatic approach to geotechnical design and risk management. It offered valuable insights into how production performance and safety can be kept simultaneously.

Following Glenn's presentation, we heard from Fernando Flores , Asset Manager. Mr. Flores first thanked Kumar for organizing the program and for inviting him to deliver a presentation. He then invited us to share our travel experiences. He then proceeded to present on the management of planned preventative maintenance (shutdown) at KAZ Minerals. Fernando presented a comprehensive, step-by-step plan outlining the procedures for preparing for a shutdown and its associated features. I found the explanation of the replacement frequency for parts in factories and the rationale behind it particularly insightful. His interactive style was effective in keeping audience engagement. The quiz he used to assess our knowledge was particularly well-received. Fernando's approach was effective in making a complex technical topic more accessible to the audience. The later question-and-answer session eased a more comprehensive understanding of the Shutdown management process at various sites. For instance, he provided an intriguing analogy on the shutdown, emphasizing the significance of thorough planning and consideration. The analogy illustrates the necessity of investing more time and resources into preparation than into the actual task at hand. - Allocate more time on sharpening an axe as opposed to cutting woods.

The next speaker was Heemun Jang , Technical Projects Manager (Principal Projects), who presented on the flotation cells. Heemun's comprehensive overview of the various flotation cell types provided valuable context for the rationale behind the choice of these specific cells for our operations. Additionally, he elucidated the ways in which these technologies enhance recovery rates and improve productivity within the constraints of our existing mining conditions. Heemun primarily discussed DFR units, but the most intriguing aspect of the presentation was undoubtedly Glencore 's Jameson unit, which we saw in Bozshakol. Today, we received a most detailed description of the installation. One notable advantage of DFR units however is their ability to occupy a significantly smaller footprint, both in terms of floor space and height. Furthermore, they consume less air and electricity. The flotation fleet of the Baimskaya project will consist exclusively of flotation cells of this type. The closing section of the report outlined a project to modernize the flotation system at Aktogay through a phased replacement with DFR units.

Innovation Surprise: The presentation by the developers of the DeepL platform.

In addition to the already valuable insights gained today, we were fortunate to receive an impromptu presentation by Nurlan Utkelbaev, Project Manager of the memoQ Group. Mr. Utkelbaev introduced us to the developers of #DeepL, an online service for automated written conversion based on improved artificial intelligence algorithms.

The opportunity to engage directly with the DeepL development team was both unexpected and highly encouraging. Nurlan introduced us to Alex Turnbull from Deepl's London branch, Tore Erik Münkenwarf from the Cologne head office, and Filip Ulovec from office in Munich. As the engineers at DeepL admitted, they were surprised at the amount of traffic coming from our company, which served to increase their interest in organizing this meeting. They provided us with a comprehensive overview of their product, including an in-depth explanation of its advanced features, existing updates, and upcoming products. Additionally, they offered valuable feedback on how we could more effectively integrate the tool into our day-to-day operations at KAZ Minerals. One of the product's most distinctive features was the ability to add your own glossaries. The DeepL glossary offers a more comprehensive approach to word replacement than other machine engines. In addition to replacing individual words, it also adapts them according to context. This includes correctly conjugating verbs, inflecting adjectives, and ensuring overall linguistic accuracy. We were given a demonstration of Deepl Voice, a new product that recognizes voice in presentations in Microsoft Teams for post-processing. It is now possible for participants who speak different languages to attend the same MS team’s session. Deepl Voice's function is to capture and transcribe speech, analyze the text, and deliver the text in the end listener's preferred language in real time. The presentation served as a reminder of how technology continues to drive significant changes across industries, including the automation of virtually any process in today's increasingly digitalized industry sector. The conference focused on two key areas: artificial intelligence as a business tool and data security.

One of the most noteworthy presentations was delivered by Galina Kim of the Central Projects Department. Galina gave us an amazing tour of a recent event, where she told us all about our visits to Kazakhmys' sites earlier in the year. She gave us a fascinating tour of the Annensky mine, the Zhezkazgan smelter, the Nurkazgan underground mine, and the Historical and Industrial Museum in Zhezkazgan. Galina's presentation was excellent. She crafted it well and delivered it with a sense of clarity that helped us re-experience those moments in vivid detail. Her ability to provide both a technical overview of the sites and an analysis of their broader historical significance made the presentation both informative and engaging. As I listened to her, I was reminded of an article I had written following the same trip that Galina was discussing. This article was recently published in our corporate magazine.

Her insights reinforced the value of visiting these locations to gain a deeper understanding of Kazakhstan's rich copper production heritage. The event served as a valuable reminder of the contribution KAZ Minerals and Kazakhmys have made to the growth and development of the #coppermining industry.

After Galina's presentation, Kumar showed a presentation by Temirlan Gaziz, a representative of the SAR 2 project at Artemyevsky mine, who had previously visited Aktogay. Temirlan offered a novel perspective on objects that are commonly taken for granted in Aktogay. One of the most noteworthy aspects of his visit was the Mine Maintenance Area (MMA) at Aktogay, which he highlighted as a distinctive and valuable asset of the site. Temirlan was impressed by the impeccable cleanliness and meticulous organization of the workshop area. He couldn't resist remarking on the immaculate floors, which he joked were so spotless that you could even walk there barefoot all day and by evening, your feet would still be clean!

His observations not only proved the lofty standards kept at the MMA, but also emphasized the importance of diligence and cleanliness, even in a challenging mining environment. Temirlan's reflections served as a valuable reminder of the fundamental principles of professionalism that guide all aspects of KAZ Minerals Aktogay' operations.

Subsequently, Nurlan Utkelbaev presented an overview of emerging technologies currently being implemented in this environment, including Webex, Kudo, Deepl integration with MemoQ, Interprefy, and Interactio.

Closing Thoughts and Looking Ahead

To bring the day to a close, Kumar offered some insights into the history of the Site Visits program. It all began approximately six or seven years ago when Almaty KMM staff showed a desire to visit the Aktogay and Bozshakol sites. Over time, the program has expanded to include external site visits to companies such as Kazakhmys, ERG, Kazzinc, and others. These visits provide opportunities for employees from different departments to network and learn from each other. The opportunity to gain insight into the operations of other industries, particularly copper smelters, proved invaluable. In view of the forthcoming construction of the new smelter by KAZ Minerals, Kumar highlighted that it would be the first such facility to be erected in Kazakhstan during the country's period of independence. Kumar's closing remarks were motivating, encouraging attendees to contribute ideas for future site visits and expressing gratitude to all participants.

As we left the office, we were buzzing with enthusiasm! Not only were we proud of the visits we had made, but we were also delighted by the new professional networks we had built and the valuable insights we had gained. It was fitting that the culmination of our project coincided with the culmination of the Fifth World Nomad Games in Astana. This event symbolizes the convergence of tradition and progress, aligning with our own journey through the industrial and cultural landscape of Kazakhstan. On our route to the airport, we saw a considerable number of cabs arriving from the games. The airport and our plane were also populated by "nomads", who were returning home with the same sense of accomplishment.

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