Walter Magalhaes Filho

Management - Zinc Extractive Metallurgy - Zinc, Lead and Copper Mineral Processing - Operation - Process - Engineering

Belo Horizonte, MG, Brasil

Summary
Leadership : team building & mentoring Plant Commissioning Extractive Metallurgy Mineral Processing Operational Execution Process Development Operational Excellence Process Engineering

37 years of experience with career developed in non-ferrous metals mining and metallurgical segments. Bachelor’s degree in mining engineering and post-graduation in Business Administration. International experience, good communication, negotiation, team building and team coordination. Wide management experience in big companies in Brazil in the following areas: process, project, plant commissioning and startup, strategic planning / execution and continuous process improvement.

Experience

Self-employed professional at Self-employed

Mar 2018 - Present

Process & Production Planning and Control Manager at Votorantim Metais Zinco – Juiz de Fora Smelter

Jan 2017 - Feb 2018

Responsible for the process engineering, process control, chemical laboratory and planning production control . Calculation of overall efficiency, performance evaluation, development of technical standards, manuals and process flowsheets. Establish the monthly production plan, jointly with sales and production departments. Determination of the required product mix, required level of production to the existing resources, consumables and raw materials and production costs estimate.

Production Manager – Polymetallic Plant – Phase 1 at Votorantim Metais Zinco - Juiz de Fora Smelter

Jan 2011 - Jan 2017

Responsible for the Polymetallic Plant operations with 67 employees and annual budget of US$ 8 million. The plant recovers zinc and lead from secondary raw materials (EAF dusts, zinc batteries and other zinc residues) and consists of the following sections: Materials Handling, Pelletizing, Waelz Kiln, Gas Treatment, Crystallization, Desalogenation and Filtration Center. Team coordination involving maintenance, engineering and production people as well as several national and international consultants during the learning curve period of the new plant. Many operational improvements implementation to stabilize process and production as well costs reduction.

Technical Manager at Votorantim Metais Zinco – Juiz de Fora Smelter

Jan 2006 - Jan 2011

Technical manager for two large plants project at Juiz de Fora smelter for metal residues recycling systems (Polymetallic project). The project, with an investment of US$ 200 million, was divided in two phases. The first phase considered zinc, lead and indium recovery from alternative raw materials by Waelz process. The second phase referred to another plant to recover lead and silver from lead sulfide concentrates and batteries recycling. Team building and training (100 people) for the new plant (Phase 1 project). Coordination of the technical staff to support the Engineering Department. Coordination of the training technical missions for the operational people in Taiwan, Poland and Peru. Implementation of High Performance Teams (EAP). Detect possible deviations of capex and opex project assumptions to correct them during the engineering phase. Ensure the preparation of the maintenance plans and spare parts for the new plant. Commissioning and start up coordination of the new plant (Phase 1 project), including the contingency plans to assure the project assumptions.

Acting General Manager at Votorantim Metais Zinco - Tres Marias Smelter

Jan 2005 - Jan 2006

As Acting General Manager, was the responsible for a budget of US$ 80 million / year, with a team of 950 people (employees and contractors) as well as the residential village with 150 houses belonging to the company in Três Marias smelter. Ensure the improvement / maintenance of the Votorantim Management System Implementing the goals of the Strategic Planning Unit and the actions of the Results Recovery Plan due to the of the dollar devaluation. Ensure the expected results of the implemented engineering projects in the smelter

Production Manager at Votorantim Metais Zinco - Tres Marias Smelter

Jan 2004 - Jan 2005

Responsible for the operation and maintenance management for 3 production areas (electrolysis, casting plant and zinc oxide plant), with 266 employees. Coordination of many 6 Sigma projects to reduce cost and improve productivity with relevant results. Implementation of the new organizational structure in all production areas under my responsibility. The results were the reduction of one hierarchical level and elimination of shift supervision function. Coordination of the Production Engineering Team. The team was comprised of representatives from commercial, production and process areas, with the objective of developing new products, improving existing products and critical analysis meetings.

Process Manager at Votorantim Metais Zinco - Tres Marias Smelter

Jan 2001 - Jan 2005

Responsible for the process engineering, process control and chemical laboratory with a team of 30 people. Calculation of overall efficiency, performance evaluation, development of technical standards, manuals and process flowsheets. Coordination of the Zinc Integrated Process Team. The participants of this team were managers and engineers of zinc mines and smelters belonging to Votorantim. The objectives of this group were to find synergies between operations and promote / monitor projects related to the quality of raw materials improvement, usage of alternative raw materials and their impact on processes. Coordination of the scientific and technical contract with Universidade Federal de Minas Gerais - UFMG. This contract allowed the technical staff to complete their master’s degree by developing theses based in Tres Marias smelter cases. Pilot plant and chemical laboratory modernization. Execution of several actions in the industrial plant to reduce the industrial water consumption with significant results.

Site Production Manager at Companhia Paraibuna de Metais - CPM

Jan 1992 - Jan 2001

Responsible for all operating departments on site (Roast, Leach, Electrolysis, Casting and by-products). Responsible to coordinate the feasibility studies to expand the zinc smelter and operational improvements and by-products development projects from 2000 to 2001. Prior to assuming this position in 1996, worked as Hydrometallurgy Manager, from 1994 to 1996, and Process / Planning and Production Control Manager and Total Quality Management Coordinator, from 1992 to 1994.

Sales & Technical Representative at Sibelco Mineração Ltda.

Jan 1990 - Jan 1992

Market development for foundry sand in Minas Gerais State, as well as provide technical support and assistance to customers

Research Development Engineer at Companhia Paraibuna de Metais

Jan 1986 - Jan 1990

Engineer of the Research Center at CPM Smelter, Juiz de Fora, MG. Process route development and start-up of silver flotation to recover this metal from zinc leaching residues, including team building, training and responsible for the start-up of the new plant. Development and implementation of several projects to improve the zinc smelter efficiency like jarosite washing, better germanium removal in neutral leaching and jarosite processes, implementation of the pre-neutralization process, etc.

Production Engineer at Carbonífera Metropolitana

Jan 1985 - Jan 1986

Production Engineer of the Coal Mineral Treatment Plant at Esperança Mine, Criciúma, SC

Production Engineer at Mineração Morro Agudo

Jan 1981 - Jan 1985

Responsible for the Mineral Treatment Division to produce lead and zinc concentrates, at Morro Agudo Mine, Paracatu, MG, from 1984 to 1985. Process steps: Crushing. Grinding, Pb-Zn Differential Flotation, Thickening and Filtration. Prior to this position, worked as Process Engineer during the project phase. The tasks involved concentration process definition according to laboratory and pilot plant tests. Tests coordination in two research centers in Brazil (CETEM, Rio de Janeiro and CETEC, Belo Horizonte) from 1981 to 1984.

Process Engineer at Caraiba Metais

Jan 1980 - Jan 1981

Process Engineer of the Mineral Treatment Department to produce copper sulfide concentrate, at Caraiba Mine, Jaguarari, BA. Process Steps: Crushing, Grinding, Flotation, Thickening and Filtration.

Education

Post-Graduation in Business Administration at Fundação Getulio Vargas (FDG)

Jun 1997 - Dec 1998

Master of Science in Hydrometallurgy (unfinished course) at Pontifícia Universidade Católica (PUC - Rio de Janeiro)

Aug 1989 - Nov 1990

Achievements

 Treatment of Secondary Raw Materials at Juiz de For a Smelter in Brazil

Paper presented at Lead and Zinc 2015 Congress, Dusseldorf, Germany, 2015

 A Precipitação da Jarosita na Companhia Paraibuna de Metais

Paper presented at II Encontro do Hemisfério Sul sobre Tecnologia Mineral, Rio de Janeiro, 1987

Algumas Particularidades do projeto de Beneficiamento de Morro Agudo

Paper presented at I Encontro do Hemisfério Sul sobre Tecnologia Mineral, 1982

 Purificação de um Concentrado de Blenda de Origem Dolomítica

Paper presented at I Encontro do Hemisfério Sul sobre Tecnologia Mineral, 1982

 Expansion Preparations at CPM´s Electrolytic Zinc Refinery

Paper presented at 2000 TMS Fall Extraction and Process Metallurgy Meeting – Lead & Zinc 2000, Pittsburgh, USA, 2000

Tratamento de Concentrados Sulfetados de Zinco

Paper presented at Seminário de Zinco e Suas Aplicações da Associação Brasileira de Metais - ABM, São Paulo, 2000

 Flotação Diferencial Aplicada ao Resíduo de Prata e Chumbo da Companhia Paraibuna de Metais

Paper presented at II Encontro do Hemisfério Sul sobre Tecnologia Mineral, Rio de Janeiro, 1987

 Debottlenecking Experiences at CPM´s Smelter in Juiz de Fora

Paper presented at 37th Annual Conference of Metallurgists of Canadian Institute of Mining and Metallurgy, Calgary, Canada, 1998

 Estudo em Planta-Piloto do Minério de Chumbo e Zinco da Morro Agudo

Paper presented at I Encontro do Hemisfério Sul sobre Tecnologia Mineral, 1982

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