COMPANY SYNOPSIS

• NCP WAS ESTABLISHED IN 2004.

• NCP STARTED MANUFACTURING NEW MILLS IN 2007 UNDER THE NCP OSBORN BRAND AND HAVE

SUPPLIED OVER 266 MILLS INTO 38 COUNTRIES TO DATE. WE ARE BELIEV ED TO CURRENTLY BE THE

MOST ACTIVE MILL SUPPLIER FOR CAPITAL PROJECTS IN AFRICA.

• WE HAVE COMPLETED SUCCESSFUL PROJECTS IN 17 COUNTRIES THROUGHOUT AFRICA WITH JUNIORS,

START UPS, ESTABLISHED MINES AND BLUE CHIPS.

• NCP HAVE SUPPLIED THE LARGEST GEAR DRIVEN MILLS IN AFRICA – 36FTØX20FT, 13500KW SAG MILL

FOR THE HUSAB PROJECT IN NAMIBIA

• NCP HAVE RECENTLY SUPPLIED ONE OF THE LARGEST GEAR DRIVEN MILLS IN THE WORLD -

36FTØX24FT, 18000KW SAG MILL FOR THE RED 5 PROJECT IN AUSTRALIA.

• NCP DESIGNED AND SUPPLIED THE WORLD’S FIRST TRUNNION-SUPPORTED MILL IN DUPLEX

STAINLESS STEEL (PH<1) – GLENCORE MUMI.

• NCP HAS COMPLETED NUMEROUS TURNKEY FRONT END PROJECTS FOR OUR GL OBAL CLIENT BASE.
NCP GROUP DIVISIONS
NCP MILL OEM SUPPLYING NEW GRINDING MILLS THROUGHOUT THE WORLD

NCP REFURBISHED MILLS MILLING SOLUTIONS FOR CLIENTS WITH LIMITED BUDGET AND/OR TIME CO NSTRAINTS

NCP TURNKEY PLANT SOLUTIONS TURNKEY SUPPLY OF COMPLETE TURNKEY PLANT FRONT END PROJECTS

NCP ENGINEERED SOLUTIONS NCP HAS ACCESS TO THE LARGEST ENGINEERING WORKSHOP IN AFRICA
AND AMONGST THE 4 LARGEST HEAVY ENGINEERING FACILITIES IN TH E WORLD – K5 HEAVY
ENGINEERING WHICH IS WHOLLY OWNED BY NCP’S MD

NCP LUBETECH MILL LUBRICATION SYSTEMS SUPPLIER

NCP AFRICA FOCUSED ON SOUTH AFRICAN BASED BUSINESS ONLY

NCP AIMS TO DELIVER THE BEST QUALITY P R O D U C T W I T H I N T H E B E S T P O S S I B L E TIME, S U P P L I E D T O M A T C H T H E C L I E N T ’ S BUDGET E X P E C T A T I O N S W H E R E

POSSIBLE.
K5 Heavy Engineering Facilities 20,000m2, 200ton lifting capacity, 18m u/h Manufacture of Mill Shells underway in the works
MECHANICAL DESIGN
FINITE ELEMENT ANALYSIS IS COMPLETED WITH A 3-DIMENSIONAL STRUCTURAL FINITE ELEMENT
PACKAGE INTEGRATED TO OUR 3D MODELING PACKAGE.

MILL STRUCTURES ARE SUFFICIENTLY DESIGNED WITH STRESS LIMITS IN ACCORDANCE WITH
AAC323001.

FATIGUE ANALYSIS IN ACCORDANCE WITH BS7608.

FLUID FILM ANALYSIS WITH OUTPUTS INTEGRATED INTO FEA STRESS PREDICTIONS.

GEARBOX DESIGN IS SUBMITTED FOR NCP REVIEW TO AGMA 2101 D04.

NCP specify a Service Factor of between 2.0 - 2.3

Bearing life L10basic > 52,000hrs

NCP SPECIFICATION STIPULATES COUPLINGS WITH A SERVICE FACTOR BETWEEN 2.0 - 2.3

OPEN GEARING DESIGNED TO AGMA 321.05. (STR. F >2.50, DURA F >1.75) OR AGMA 6014.
QUALITY CONTROL
• NCP OPERATES IN ACCORDANCE WITH ISO9001 QA PROCEDURES

• ALL NON-DESTRUCTIVE TESTING IS UNDERTAKEN BY INDEPENDENT SOUTH AFRICAN NON-

DESTRUCTIVE TESTING TECHNICIANS AT SPECIFIED HOLD POINTS

• ALL HOLD POINTS ARE INSPECTED BY NCP PROJECT ENGINEERS & A QA DESIGNATES (ENGINEER)

Inspections include but are not limited to: Casting Processes, NDT, Fettling, Workpiece Set Up, Final Machining, Gear Cutting, Work-piece
Run Outs, Dimensional Inspections, Factory Acceptance Test, Sandblasting, Painting & Packaging, and any other critical manufacturing
points incl full Manufacturing Document Register review.

• EACH COMPONENT CARRIES A DEDICATED QUALITY CONTROL PLAN AND MDR

• FULL MDR ISSUED ON PROJECT COMPLETION

AFTER MARKET

• DELIVERY TO SITE (FREIGHT AND LOGISTICAL

MANAGEMENT)

• INSTALLATION AND COMMISSIONING (COLD AND HOT)

• IN COUNTRY SUPPORT TEAM AND SPARES

CONSIGNMENT

• SPARES SUPPLY AND FULL AFTER-SALES SUPPORT

• ON-GOING MAINTENANCE INSPECTIONS

• UPGRADES OF MILL COMPONENTS

• SUPPLY EXPERTISE TO SOLVE ON-SITE CHALLENGES NCP Going the Extra Mile
Pic – 4mØ Shell, Trunnions &
MECHANICAL ASSESSMENTS & AUDITS Motor Flown to site in an Antonov 124, Northern Canada
PROCESS OPTIMIZATION

• SITE SPECIFIC CIRCUIT SIMULATOR DEVELOPMENT

Reverse Engineered Gearbox Spares Installation of 18x26ft Ball Mill & Matching SAG Mill Site Installation of New NCP Girth Gear 20ft Ø Ball Mill
PROJECT REFERENCE
MILLING IN RAFFINATE
 18x16ft, 2500kW SAG MILL
SUPPLIED INTO DRC FOR MILLING IN RAFFINATE
• NCP designed and supplied the world’s first full duplex stainless steel, trunnion supported SAG Mill
to Glencore Mumi in 2014
• Mumi runs a raffinate WOL solution process and operates the mill at a Ph=1.
• Mill supplied with Siemens VVVF Drive.
REVERSE ENGINEERING MILL PROJECT
REFERENCES
 36’ X 24’ 18 000kW SAG MILL
SUPPLIED INTO AUSTRALIA
MILL COMPONENTS AS IS, STORED AT 60HZ LOCATION IN THE USA

PROGRESS OF THE COMPONENTS DURING RE-ENGINEERING AT MILL FULLY INSTALLED AND COMMISSIONED ON
THE HEAVY ENGINEERING WORKSHOP & FREIGHT TO SITE SITE IN AUSTRALIA
 36’ X 24’ 18 000kW SAG MILL
SUPPLIED INTO AUSTRALIA
MORE INFORMATION ABOUT THIS PROJECT:

• ONE OF THE LARGEST GEAR DRIVEN MILLS EVER

SUPPLIED.
• DUAL DRIVE SLOW SPEED MOTORS DIRECTLY
COUPLED TO PINIONS INCLUDING VVVF DRIVE.
• 4 PAD SELF-ALIGNING BEARINGS
• DELIVERY TO SITE & INSTALLATION SUPERVISION.

REBUILD OF 2X ABB 12M DIAMETER MILL HEAD TRIAL ASSEMBLY

SLOW SPEED SYNCHRONOUS 4 QUARTERS
MOTORS

LUBRICATION SYSTEMS FAT MILL SHELL TRANSPORT VSD TRANSFORMERS PINION BEARING HOUSINGS
 26’ x 43’ 18 000kW BALL MILL
SUPPLIED TO MALI
MILL COMPONENTS BEFORE RE-ENGINEERING
TOOK PLACE

PROGRESS OF THE COMPONENTS BEING RE-ENGINEERED AND UPGRADED NEW VVVF DRIVE AND NEW SPARE GIRTH GEAR
 TWO 24’ x 36’ 12 MW BALL MILLS
DUAL COMBIFLEX DRIVE, SHELL SUPPORTED DESIGNS
MILLS BEFORE RE-ENGINEERING TOOK PLACE STORED IN IN AUSTRALIA, DESIGNED AS 3X360DEG SHELL SEGMENT S

REDESIGN OF SHELLS AS 6X180DEG SEGMENTS AND COMPLETE REBUILD

RE-ENGINEERED
MILLS INSTALLED &
COMMISSIONED IN
KAZAKHSTAN
 REVERSE ENGINEERED
26FT SAG MILL & 15FT BALL MILL
SUPPLIED TO A PLATINUM PRODUCER

Before After

• NCP were issued a severely damaged 26ft SAG Mill Shell, 26ft Heads that
were eventually scrapped due to their poor condition and selected parts of a
used 4500kW Synchronous motor.
• NCP was issued a scrapped 15ft Mill shell, Ball Mill Heads and 2x Main
trunnion bearing housings.
• NCP were contracted to reverse Engineer the mill parts and supply them to
site as fully completed mills with interchangeable parts to the client’s 2x
existing mills.

SEEMED LIKE AN IMPOSSIBLE REQUEST?

• NCP completed the fully re-engineered 26x11.5ft, 4500kW SAG MILL & 15x21ft,
4500KW Ball Mill as required.
• The mills were designed by NCP to carry identical critical components to the
client’s 2x existing mills on site and allowed full interchangeability of parts.
• Project delivered, installed and commissioned successfully by NCP.

IMPOSSIBLE MISSION ACCOMPLISHED

2X REVERSE ENGINEERED 20FT SAG MILLS
& 17FT BALL MILL
SUPPLIED TO ANGLOGOLD ASHANTI

Before After
 2X REVERSE ENGINEERED 20FT SAG MILLS
& 17FT BALL MILL
SUPPLIED TO ANGLOGOLD ASHANTI

LUBE SYSTEMS: BEFORE & AFTER

REPLACEMENT MILL HEADS – REVERSE

ENGINEERED & FITTED ON SITE TO
EXISTING SHELLS

3800kW PINIONS: BEFORE & AFTER

 REVERSE ENGINEERED
2OF 32’ x 14’ 6000kW SAG MILLS
22’ x 38’ 9000kW BALL MILL
GLENCORE, KCC - DRC
• DESIGN AND SUPPLY OF 2X REPLACEMENT 32 X 14FT, 6000KW SAG MILLS

• SUPPLY OF THE CM5 PROJECT INCLUDING 22 X 38FT, 9000KW BALL MILL.

• NCP DESIGNED REPLACEMENT MILLS TO FIT ONTO EXISTING CIVIL PLINTHS AND TO MATCH THE
EXISTING DRIVE TRAIN COMPONENTS.

• REVERSE ENGINEERED AND REPLACED MAIN TRUNNION BEARINGS, SHELLS, HEADS, TRUNNIONS,
LUBE SYSTEMS, TURNKEY SUPPLY INCLUDING DELIVERY TO GLENCORE KATANGA AND FULL
INSTALLATION & COMMISSIONING

• LATER SUPPLIED SPARE GEARS, PINIONS, BEARINGS AND GEARBOXES

O L D O U T D AT E D D E S I G N REVERSE ENGINEERED BY NCP L AT E S T G E N E R AT I O N D E S I G N

 16,5’ x 31’ 3750kW SAG MILL &
22 x 38’ 7500kW DUAL DRIVE BALL MILL
CANCELLED PROJECT – NCP REBUILD
BEFORE
 16,5’ x 31’ 3750kW SAG MILL &
22 x 38’ 7500kW DUAL DRIVE BALL MILL
CANCELLED PROJECT – NCP REBUILD

WORK IN PROGRESS
SIX 18’ x 24’ 4500kW BALL MILLS

• NCP purchased 6of 18x24ft Ball Mills from Bougainville Island, PNG as stock
items.
• We despatched a fully prepared NCP crew, dismantled the mills in 12 months &
shipped them to NCP Works for assessment, upgrade and refurbishment.
• All Mills were reverse engineered, fully upgraded including complete new drive
trains, new lube systems, new liners, new feed chutes, new pinions, supplied
as either LRS or VVVF Driven and sometimes supplied as packages with new
mills.
• All Mill Drives were upgraded from slow speed synchronous motors c/w
Air clutch to conventional motor – gearbox - pinion drives
• Mills were sold to various locations round the world, fully installed by NCP and
are all fully supported as NCP mills.
 PLATINUM PROUCER
4of 21X30ft, 6500kW Ball Mills

• NCP was awarded the contract to assist with the upgrade of four
Metso Outotec Ball Mills within the CLIENT’S group in 2020.

• NCP stripped and reverse engineered the existing Outotec Mills.

• The scope of works included fully upgraded lube systems, supply of
New Girth and pinions, Shells and heads refurbishment, Main trunnion
bearings replacement and refurbishment, new liners, new pinion
bearings, gear changeouts, gearbox refurbishment, gearbox reverse
engineering and replacement with drop-in boxes, main drive motor
assessments, inching drive upgrade with introduction of self-
disengaging couplings, some parts were refurbished on site, selected
component were refurbished at NCP’s manufacturing works, and
numerous items were supplied new.

• In this type of solution, NCP reversed engineered all mill components

allowing the mills to be fully supported by NCP in the future.

• The rebuild and re-engineered mills carry a full NCP warrantee,

equivalent to a new mill warrantee which allows the client to feel
confident in our supply.
 22’ X 42’ 12 000 kW BALL MILL
SUPPLIED INTO KAZAKHSTAN – GOLD PROJECT

• SUPPLY OF A 22X42FT, 12000KW DUAL DRIVE BALL MILL WITH LRS’S.

• THIS WAS A REBUILT ANI MILL, WHICH HAD BEEN PURCHASED NEW AND NEVER INSTALLED FOR 18 YEARS

• THIS MILL WAS RE-DESIGNED BY NCP, REBUILT AND SUCCESSFULLY DELIVERED TO THE CLIENT ON TIME

• THIS PROJECT TOTALS 13X MILLS SUPPLIED TO THIS CLIENT BY NCP.

• THE MILL HAS BEEN SUCCESSFULLY COMMISSIONED AND HAS BEEN OPERATI ONAL FOR 4 YEARS