TitanForge — Operations Plan
The mining operations, the smelting and processing, the logistics operations and the organisational build underpinning TitanForge.
Section 12 · Business Plan
Operations Plan
The mining operations, the smelting and processing, the logistics operations and the organisational build underpinning TitanForge.
11.1 Mining operations
Iron Crown operates as a conventional truck-and-shovel open pit with
in-pit crushing and conveying introduced from Year 6 to defend the cost
position as haul distances extend. Steady-state unit costs are planned
in the second quartile of the seaborne manganese cost curve, with the
integrated logistics chain (owned rail and terminal capacity at
cost-based transfer tariffs) contributing the decisive landed-cost
advantage over road-trucked competitors, whose per-tonne logistics costs
run 2–3x rail.
11.2 Smelting and processing
Vulcan’s furnace fleet is refurbished in a staged sequence that keeps
at least 60% of nameplate capacity operating throughout the works.
Energy — typically 35–40% of ferroalloy cash cost — shifts progressively
onto Helios supply from Year 3, with the battery storage component
providing furnace ride-through for grid disturbances, an availability
benefit that historically cost the industry 3–5% of annual
production.
11.3 Logistics operations
Atlas Rail operates on a hub-and-spoke model: unit trains from the
Northern Cape and Mpumalanga origins to Ocean Gate terminal capacity,
with inland hubs consolidating third-party freight. Fleet availability
is contracted under full-maintenance agreements with OEMs at guaranteed
92%+ availability, transferring rolling stock performance risk to
counterparties with balance sheets sized to bear it.
11.4 Organisational build
Headcount scales from approximately 3,500 direct employees in Year 1
to 22,000 by Year 10. The scarce-skills plan concentrates on rail
operations management, furnace metallurgy and high-voltage electrical
trades, with a group academy established in Year 2 and a target of 80%
local-community hiring for operator grades at each site.
Confidential — this business plan is provided to prospective investors and lenders for evaluation purposes only and may not be reproduced or distributed without the written consent of TitanForge Resources & Infrastructure Holdings.