African Mining Brief - July - Sep 2023

Inside...

● Introducing Lean Duplex Stainless Steel

● Unlocking Success in Mining

● Unleashing the Power of Precision

EDITOR

Dennis Ayemba

EAST AFRICA EDITOR

Francis Makari

GRAPHIC/WEB DESIGN

Augustine Ombwa austin@arobia.co.ke

COUNTRY WRITER:

Lindsay Wagner

WRITERS:

Delilah Aisu, Matimu Mahundla

COUNTRY LIAISON

Thuthukile Klaas

ADVERTISING EXECUTIVES

South Africa:

Shepherd Mthethwa, Rachel Molapo

Jacqui Nyangabyaki, Tshegofatso

Mokonyama, Thabiso Shosha

Nigeria:

Seni Bello

East Africa:

William Mutama

Published by Mining & Construction News Network (Pty) Ltd (MCN Network)

African Mining Brief is published 4(four) times a year and is circulated to members of relevant associations, governmental bodies and other personnel in the mining industry as well as suppliers of equipment, materials and services in Africa, the Middle and Far East. The editor welcomes articles and photographs for consideration. Material may not be reproduced without prior permission from the publisher.

Dennis July September 2023, Inside...

The publisher does not accept responsibility for the accuracy or authenticity of advertisements or contributions contained in the journal. Views expressed by contributors are not necessarily those of the publisher.

© All rights reserved.

July - September, Volume 18 No 3

Ayemba Editor’s News 02 ALTSA: Leading the way 03 Duplex Stainless Steel Solutions 06 The Introduction of Lean Duplex Stainless Steel 08 Size Reduction: Unleashing the Power of Precision 12 The Crucial Role of Kidnap and Ransom Insurance 14 The relevance of Kidnap and Ransom Insurance for Expats in Africa in the contemporary mining sector 16

Space of Governance and Public Participation in Sustainable Mining

There has generally been an improvement in the participation by communities in mining projects and in benefits accruing to communities. From a policy-making viewpoint, there have been notable examples of employing the multistakeholder approach as happened in Malawi, Namibia, South Africa and Tanzania.

However, governments generally still see policy-making and regulation of the mining sector as their sole responsibility. Many African countries do not have sustainable development principles in their national mining policies. Local equity participation in mining projects is also not seriously promoted nor embedded in law as is the case in South Africa. As a result, participation of nationals in large-scale mining projects is not common in many African countries.

Countries with empowerment schemes, like South Africa, have fared better, but they are the exceptions. Improvements in community participation have been facilitated by mining companies subscribing to international Community Social Responsibility (CSR) based schemes. While this applies to high profile mining companies, smaller ones are not held to the same standard of accountability. Traditionally, CSR in the mining sector has been voluntary. However, there has been an increasing awareness that CSR must be grounded in some form of policy legislation or other mandatory agreements. Countries that have implemented a legislative approach are increasingly seeking to entrench CSR in their policy frameworks.

Regional Offices

South Africa

MCN Network (Pty) Ltd

14 Ballyclare Dr, Bryanston,Sandton,2191

+27 (0)11 875 4328

E-mail: info@mcnnetwork.co.za

The editor accepts letters and manuscripts for publication from readers all over the world. Include your name and address as a sign of good faith although you may request your name to be withheld from publication. We reserve the right to edit any material submitted.

Kenya Office

Vinodeep Towers, 3rd floor, Baricho Road, Nairobi Tel:+254722525326/+254208000307. P.O Box 10109-00100.

Anew report from Eriez® reveals how a set of Magnetic Mill Liners (MML) are significantly improving safety standards, energy efficiency, and operational longevity at the Nexa Resources N.A. installation in the Central Andes of Peru. This is the latest international success story featuring the MML, a wearresistant steel-encased magnet that combines the best qualities of steel and magnetic liners.

The report highlights the superiority of MMLs over conventional liners by describing the numerous benefits these advanced liners offer. Each MML is composed of individual sections that are much lighter than traditional liners, facilitating safer and easier installation procedures. Weighing only 20 to 40 Kg per section, the MML eliminates the requirement for specialized cranes within the mill, streamlining operations and enhancing safety protocols. Nexa even credits the MMLs installation with contributing to the company’s achievement of a major Peruvian safety award.

As explained in the report, there are considerable environmental advantages associated with the implementation of MMLs. Heavier steel liners require enormous fuel consumption for transportation and material handling while lightweight MMLs can be installed by hand. Additionally, Nexa reports a significant reduction in noise levels with the MML, creating a more favourable work environment overall.

thyssenkrupp

Thyssenkrupp Uhde’s successful completion of an EPC (Engineering, Procurement and Construction) project has enabled a prominent bulk liquid storage provider to transfer commercial crude oil from its state-of-the-art storage and blending facilities in Saldanha Bay to a refinery in Cape Town via an underground pipeline.

“The project required us to connect the customer’s crude oil storage and blending facility to an existing underground pipeline that runs between Saldanha Bay and Cape Town,” explains Joshua Visser, Project Manager at thyssenkrupp Uhde.

Following a feasibility study, the thyssenkrupp Uhde team commenced with project execution which Visser explains happened to coincide with the global logistics crisis. “This understandably presented us with a number of challenges which called for innovative forward-planning to ensure that we met our customer’s deadline. We fast-tracked orders for equipment and materials to allow for early procurement. We also closely monitored shipping and logistics which required a number of interventions from our side to help streamline the process,” he notes.

Global Cooperation Highlighted at the analytica

Africa offers significant opportunities for foreign direct investment, while in turn, international organisations offer a range of solutions to help Africa address key challenges.

This is according to Mr Enrico Brandt, the Deputy Head of Mission of the Germany Embassy in South Africa, who was speaking at the official opening of the three-day IFAT Africa trade show for the water, sewage, refuse and recycling industry, co-located with analytica Lab Africa, the only trade show in South Africa for the of laboratory technology, analysis, biotechnology and diagnostics sectors.

IFAT Africa and analytica Lab Africa, running at the Gallagher Convention Centre in Midrand until 7 July, bring together multiple synergistic industry sectors for networking and discovery. Around 5,000 visitors from across Africa will participate in the events to view thousands of solutions from hundreds of brands over three days, welcoming the opportunity to reconvene after a three-year hiatus due to Covid-19 lockdowns.

Brandt said at the opening ceremony this morning: “Africa offers a broad variety of opportunities for foreign direct investment and cooperation. South Africa, as with any other industrialised nation, faces challenges of limited resources and waste management.” He said a circular economy approach, an area in which Germany is a leader, allows more efficient use of resources and reduces waste generation.

Kal Tire’s Mining Tire Group announced it has received International Sustainability and Carbon Certification (ISCC) PLUS certification verifying that its mining tire recycling facility in Chile processes circular feedstocks.

“Kal Tire is committed to promoting a circular economy where recycled mining tire products are given their highest and best use. “This ISCC PLUS certification ensures customers can confidently source our recycling facility’s outputs knowing they’re 100 per cent derived from waste materials,” says Dan Allan, senior vice president, Kal Tire’s Mining Tire Group.

At Kal Tire’s facility in Northern Chile, end-of-life ultra-class tires are converted to their base elements (carbon black, oil and steel) so they can be reused in new products instead of raw materials. The facility’s thermal conversion processes use heat and friction to induce a process that sees virtually 100 per cent of the tire reused.

The ISCC PLUS certification verifies the Chile recycling facility meets the circular materials standards for reclaimed oil, carbon black and syngas using a mass balance chain of custody approach. ISCC is a global leader in standards development for chemically recycled sustainable materials. Kal Tire is one of just a few mining tire recycling facilities in the world that the company is aware of having achieved ISCC PLUS certification for producing circular feedstocks— generating outputs that are 100 per cent ISCC PLUS compliant.

As more and more organizations look to demonstrate the sustainability and circularity of their supply chain, Kal Tire’s ISCC-certified products will provide thirdparty validation for customers seeking sustainable, circular materials.

Magnetic Mill Liners Reduce Energy Requirements at Peru Mine

Kal Tire Recycling Facility Achieves ISCC PLUS Certification

Lab Africa Opening

Uhde Lets It Flow – From Saldanha Bay to Cape Town

ALTSA: Leading the way with LED

ALTSA as the largest light replacement company in Africa have completed a substantial number of large-scale energy conversions right across Africa in the mining and industrial sector. With a wide network of branches across the African continent we understand the energy situations in different countries across Africa.

Even though lighting is a very small part of the whole energy basket it does amount to a large amount of energy. It is for instance not uncommon for a mine to have a total lighting load of 1-3MW. The interesting fact about this is that 90% of mines in Africa are still running on old lighting technology.

Old technology in general consumes

power of LED technology is truly wonderful considering the fact that light levels can be drastically improved.

ALTSA specialises in lighting in mines as well as energy consumption. It takes a certain level of expertise to install lighting equipment into mines, it’s not just anyone who can do it properly. Equipment should last for at least 5 years in very rugged environments,It is also important to provide equipment that is functional in all kinds of environments for example, underground, haulages, hazardous environments, flooded environments, large mine pits, open mining environments where telescopic lighting tower applications and equipment-based lighting is essential, etc.

2. LED technology is capable of a lifetime of 100,000 hours.

3. LED technology allows us to light up specific objects without wasting energy on areas not needed for example into the sky. Sending lighting into the sky is called light pollution.

4. LED technology provides major versatility. ALTSA is providing all categories of lighting needed for mining including hazardous environments.

5. Solar-enabled lighting in the form of floodlights, streetlights and bulkheads is possible with LED.

ALTSA provides functional models that can operate exactly like normal lighting

install reticulation with power-dependent floodlights.

Providing effective, functional, and sustainable lighting solutions is the way forward to help mines increase their productivity and realise their full potential. ALTSA helps organisations in their transition to sustainable energy through innovative, intelligent, energy-saving LED and Solar solutions. Let us look at the different types of challenging environments:

Underground Mining

Underground mining environments, lighting needs to be very rugged with robust lighting fixtures. It is vital for this environment that the ingression protocol must be at least IP65 Ingress protected. High-impact immunity is needed.anti-theft applications is required, ALTSA can provide lighting solutions with luminaires that can be vandal proof with high impact resistant luminaires that range between IK08-IK10 including ingress protections our luminaires provide that range from IP65-IP68.

Haulages

Lighting in haulages must serve a very elongated asymmetrical pattern. Haulage lights must be rugged, efficient and at the same time provide very good light levels With ALTSA Luminaires we ensure excellent light uniformity with luminaire efficiencies of up to 200lm/W.

Hazardous Environments

There are numerous hazardous environments in mines such as stopes, stopes, and

Development ends where Explosion proof luminaires are vital. We provide luminaires with Ex ratings for all zones(1,2,21,22) that has a coverage over dust and gas environments.

Flooded Environments

In bottom mining haulages flooding is a common risk. In this application, IP68 lighting is required.

Large Mine Pits

A large mining pit can be like a mega stadium. The application is the same however it is just much bigger. Very large floodlights with power from 1kW to 3kW with beam angles as low as 5 degrees is required. Meticulous designs with some rather large structures are needed.

Open mining environments where telescopic lighting tower applications are needed

– Having lighting plants with lighting towers is essential in many open pit mining environments. There are deep mechanical and photometric design issues involved in making these plants effective, and equipment-based lighting is essential.

LED luminaires are an excellent solution for mining facilities as they are highly engineered for durability in challenging environments. This equates to less blackouts and less maintenance due to longer life. LED Luminaires include Strip Lighting, Floodlights, Bulkheads and Portable Ex luminaires are ideal for mines due to their unobtrusive form factor which can be easily mounted even in areas with spatial

constrictions. They range from IP66-IP68 ingress protection rated against moisture and dust intrusion and are IK08-IK10 impact resistant. Incorporating the latest in LED technology, Ranging 10,000 - 20,000 lumens with incredible efficiency of up to 140 lumens per watt.

Lighting solutions for areas that are prone to dust, grime, vibration, consistent use and abuse. Protection from windblown dust and rain, splashing and hose-directed water, and external formation of ice. Lighting is critical to mine workers since they depend heavily on visual cues to see for example fall of ground, pinning and striking hazards, and slipping and tripping hazards. illumination greatly affects mine workers’ ability to perform their jobs safely.

ALTSA provides turn key LED lighting solutions for underground shafts and surrounding areas that endure longevity in luminaires which provide low maintenance and increase energy efficiency. Lighting solutions for environments with

HIGH VIBRATION - where equipment with high-speed moving parts may require robust solutions with low maintenance and/ or repair costs.

CORROSIVE AREAS - protection from chemicals and water.

SPACE CONSTRAINTS - areas with low ceilings, tight spaces and limited footprint potential.

Quality, Comprehensive Lighting Solutions

ALTSA is a specialist in industrial lighting solutions. Our fit-for-purpose, energy-efficient products are of the highest quality, ensuring reliability and longevity. As a specialist in this industry, our solutions cater for all lightingapplications within a mining environment.

1. Hazardous areas

2. Exterior functional

3. Interior commercial

4. Plant and equipment

5. Highbay

6. High masts

7. Parking & pathways

8. Security

9. Roadway

IDEAL PRODUCTS

ALTSA. Leading the way with LED.

ALTSA is the leading South African supplier of cutting-edge, indoor, outdoor and explosive-proof LED lighting solutions & installations for South Africa and the African continent. Set up a free consultation to discuss your energy project.

Contact CEO Gerhard Moolman

E: gerhard@altsa.co.za

W: www.altsa.co.za

Duplex Stainless Steel Solutions:

Revolutionizing Corrosion Resistance in the Mining Industry

The mining industry is at the forefront of supplying the world’s increasing demand for minerals and resources. However, the demanding conditions of mining operations present significant challenges to equipment and infrastructure. Corrosion resistance is a critical factor that mining companies must consider, as it can lead to expensive repairs, maintenance downtime, and safety hazards. Addressing this concern, NDE: a leading supplier of corrosion-resistant products, offers a range of innovative solutions, including duplex stainless steel, specifically designed to meet the rigorous requirements of the mining industry.

With a remarkable track record of 70 years in business as a respected stockist and distributor, NDE has established itself as a key player in both South Africa and Africa. The company’s success stems from its commitment to service excellence, indepth technical advice, and a comprehensive product range sourced from a well-developed global network. NDE’s seven branches and warehouses, all ISO 9001 accredited, ensure fast turnaround times, further solidifying their reputation as a reliable partner for corrosion-resistant solutions.

Duplex stainless steel emerged as a game-changer in the mining industry due to its exceptional properties and unique composition. This two-phase microstructure alloy combines the best attributes of both austenitic and ferritic stainless steels. The result is a material with superior corrosion resistance, high strength, and excellent toughness, making it an ideal choice for the challenging mining environments.

One of the primary advantages of duplex stainless steel is its exceptional resistance to various types of corrosion: including pitting, crevice corrosion, and stress corrosion cracking. These corrosive forms are prevalent in mining applications due to exposure to moisture, aggressive chemicals, and abrasive materials. Duplex stainless steel’s resistance to corrosion not only ensures the longevity of mining equipment and infrastructure, but also significantly reduces the need for frequent replacements and repairs, leading to cost savings and increased operational efficiency.

Beyond corrosion resistance, duplex stainless steel offers impressive strength. Its high tensile strength allows for the use

of thinner sections, reducing weight and material costs while maintaining structural integrity. This aspect is particularly advantageous for heavy-duty mining equipment, such as conveyor systems, crushers, and chutes, where durability, reliability, and cost-effectiveness are paramount.

Furthermore, duplex stainless steel exhibits excellent toughness, making it highly resistant to impact and vibration, which are common challenges in mining operations. This inherent toughness enables the material to withstand the extreme conditions and mechanical stresses experienced in mining activities, contributing to increased equipment lifespan and improved overall operational efficiency.

NDE recognizes that providing technical support is crucial in the successful application of duplex stainless steel solutions. With their team of experts, NDE offers extensive technical knowledge, experience, and advice on grade selection, application suitability, and corrosionresistant solutions. They are dedicated to building close relationships with mining companies, gaining a deep understanding of their specific needs, and providing customized services and stockholding to ensure optimal outcomes.

Prompt and reliable deliveries are another hallmark of NDE’s commitment to customer satisfaction. Their accessible branches and strategically located warehouses enable fast turnaround times for walk-in and collection customers. With a dedicated Exports Division focused on African continent, the company has a holistic and accessible offering for the mining industry. These streamlined logistics ensure that mining companies can rely on a steady supply of duplex stainless steel products (and other grades of stainless steel and aluminium), minimizing downtime and maximizing productivity.

Moreover, NDE goes above and beyond product supply by offering thoughtprovoking interactive presentations on corrosion prevention and engineering excellence. These initiatives not only enhance the industry’s knowledge and awareness of corrosion-resistant solutions but also foster collaboration and the exchange of ideas among stakeholders in the mining sector.

NDE’s success is built on transparent and mutually profitable partnerships with customers: ensuring a constant focus on excellent service, customer satisfaction, and continuous refinement of their product range and systems. Their dedication to communication, trust, dedication, expertise, and ethical values forms the foundation of their long-term customer relationships.

In an industry as dynamic as mining, staying ahead of the curve is crucial. NDE recognizes the importance of keeping up with technological advancements and industry trends to provide cutting-edge solutions to their customers. By leveraging their extensive experience and technical expertise, NDE offers technical consultations on grade selection and application suitability for products, processes, or projects. This level of support ensures that mining companies can make informed decisions and optimize the performance of duplex stainless steel in their operations.

To further enhance accessibility and convenience, NDE offers a wide range of corrosion-resistant products to cater to the diverse needs of the mining industry. Their extensive stockholding and sourcing capabilities ensure a comprehensive range of products to meet the specific needs of mining companies, including:

Duplex and Lean Duplex Flat Product: a central product used in the mining industry, NDE offer a broad range of sheet, plate, coil and 2m wide sheet and plate off-the-shelf –in both duplex and LDX grades, as well as standard stainless steel grades.

Stainless Steel Pipe: NDE provides a comprehensive range of stainless steel pipe that offer superior corrosion resistance and durability in mining applications. These pipes are designed to withstand the harsh conditions and corrosive environments commonly encountered in the mining industry.

Stainless Steel Flanges: available in various sizes and grades. These flanges are specifically designed to withstand corrosive environments and ensure secure connections in mining equipment and piping systems. With their high corrosion resistance and durability, stainless steel flanges contribute to the longevity and reliability of mining infrastructure.

Stainless Steel Ball Valves: resistant to corrosion and provide reliable flow control

in mining operations. These valves are crucial components in mining systems, allowing for efficient and precise control of fluid flow while maintaining resistance to the corrosive substances typically found in mining processes.

Stainless Steel Buttweld Fittings: a wide range of stainless steel buttweld fittings: including elbows, tees, reducers, and caps. These fittings provide leak-free connections in mining piping systems, ensuring the integrity of the infrastructure. With their corrosion-resistant properties, stainless steel buttweld fittings contribute to the overall efficiency and safety of mining operations.

Stainless Steel BSP Screwed Fittings: BSP (British Standard Pipe) stainless steel screwed fittings in Grade 316L offer excellent corrosion resistance and reliable performance in mining applications. They are specifically designed to withstand the demanding conditions and corrosive substances encountered in mining environments.

Aluminium Sheet: including Grade 1050 H14, which is widely used in mining for various applications such as equipment fabrication and structural components.

Aluminium sheet provides lightweight and durable solutions for mining equipment,

contributing to improved efficiency and cost-effectiveness.

Aluminium Tread bright: These feature a raised pattern for improved grip and durability. These sheets are suitable for flooring and walkways in mining environments, where slip resistance and robustness are essential.

Aluminium Tread Plate: These plates come with a patterned surface for slip resistance. They are ideal for use in mining equipment, vehicle trays, and ramps, providing enhanced safety and stability in mining operations.

As the mining industry faces evolving challenges, the importance of corrosionresistant materials cannot be understated. NDE’s duplex stainless steel solutions offer a compelling response to the demanding requirements of mining operations. By providing a comprehensive range of products, in-depth technical advice, and reliable services, NDE is at the forefront of empowering mining companies with the tools they need to combat corrosion, extend equipment lifespan, and optimize operational efficiency.

In conclusion, NDE stands as a leading supplier of duplex stainless steel solutions, catering to the corrosion-resistant needs

of the mining industry. With a rich history spanning 70 years, NDE has established itself as a trusted partner to various industries in South Africa and Africa. Their commitment to service excellence, technical expertise, and continuous refinement of their product range positions them as a reliable and innovative solution provider for mining companies.

By harnessing the unique properties of duplex stainless steel, mining companies can mitigate the detrimental effects of corrosion, enhance equipment durability, and maximize their operational efficiency. NDE’s comprehensive stockholding, competitive pricing, accessible branches, and prompt deliveries ensure that mining professionals have seamless access to the materials they need, when they need them.

With their unparalleled technical support, dedication to customer satisfaction, and commitment to building long-term partnerships, NDE is poised to shape the future of corrosion resistance in the mining industry.

For more information on NDE and their duplex stainless steel solutions, visit their website at https://www.nde.co.za/

The Introduction of Lean Duplex Stainless Steel

Over 15 years ago NDE Stainless Steel introduced a new grade of stainless steel to the African mining sector: Lean Duplex 2101. An innovation that offered a lighter material with better corrosion resistance and less cost than existing choices.

Lean Duplexes (or LDX) are part of the suite of Duplex stainless steels.

Solutions to the mining industry’s highly corrosive processes often require stainless steel’s durable and self-generating corrosion resistance. Grade 316 has been widely used because of its excellent corrosion resistance but can become expensive – especially when nickel prices are high. Another alternative was rubber-lined mild steel, which is heavy and can be problematic in attaching and sustaining the rubber lining.

Then, in the early 2000’s, Basil Goldswain - consulting engineer on NDE’s technical team, was scouring the world for innovative materials. He spotted a new solution in a Lean Duplex grade still under development in the laboratory of a prominent stainless steel mill.

“We spotted LDX2101’s potential for our mining customers while it was still undergoing rolling tests,” says Basil.

As soon as LDX2101 became commercially available, NDE supplied 1 000 tons to an African copper mine, with many subsequent orders across the continent,

leading to NDE’s enduring relationship with African mining for over 15 years.

LDX2101 is used primarily for copper’s Counter Current Decantation (CCD) tanks where the lighter weight also allows for it to be used to construct the rake arms.

Duplex stainless steel grades have a ferritic-austenitic microstructure, offering excellent combination of strength and corrosion resistance, allowing significant reduction of both material thickness and cost.

Other properties include:

• good abrasion and erosion resistance

• good fatigue resistance

• high-energy absorption

• low thermal expansion and

• good weldability

Soon after this game-changing innovation, NDE identified a second new grade in development: LDX2404. Soon followed a record 4 000-ton order to a uranium processing plant.

“This plant was close to the sea on granular sand with a significantly greater corrosion factor,” says Basil. “Each and every corrosive situation must be assessed, with grades carefully selected for local conditions. We supplied LDX2404 only after rigorous corrosion testing to establish the correct grade,” he says. Our technical team are always on hand to best advise on grades for your application.

NDE continues to supply the mining industry with these two LDX grades as well as other stainless steels such as 2205 and 2507.

Karin Eagar, NDE’s Export Manager, is responsible for NDE’s extensive supply and on-time delivery to mining sites across Africa.

“We have offered other Duplex solutions for acid plants and other mining processing. 2205 and 2507 are also suitable for certain requirements. In these grades we supply flat product as well as a range of fittings and pipes,” she says. When you place an order with NDE, you can be assured of the best quality material, a fair price, excellent service and on-time delivery.

We

will find

an NDE Solution for you!”

NDE has a 70-year track record in South Africa and over 15 years exporting into Africa. We have a reputation for providing corrosion resistant solutions including quality stainless steel and aluminium products in a range of grades and sizes. For a full list of our product and service offering, please visit www.nde.co.za

Unlocking Success in the Mining Sector

The mining industry is renowned for its intricate nature and demanding requirements. To extract and process valuable minerals in a safe and efficient manner, a wide spectrum of skills and expertise is necessary. This is where engineering and construction firms play a pivotal role, providing indispensable services and expertise that ensure the triumph of mining projects.

Engineering assumes a critical role in the mining industry as it encompasses the design, construction, and operation of the infrastructure that enables mining operations. Engineers are responsible for designing mine shafts, tunnels, processing facilities, and waste disposal structures. They also contribute significantly to the development of new mining technologies, focusing on devising novel methods for extracting minerals from deep underground and recovering minerals from waste streams.

These complex endeavours require robust infrastructure to support secure and efficient production. From the initial stages of mine planning and design to the actual construction of processing facilities and supporting infrastructure, engineering and construction services prove to be instrumental in turning mining projects from mere concepts to tangible realities. These services encompass a wide range of disciplines, including civil and mechanical engineering, structural design, finite element analysis, and more. By leveraging their expertise and harnessing advanced technologies, engineering firms significantly contribute to the seamless execution of

mining operations, ensuring optimal productivity, safety, and environmental stewardship.

The mining industry holds a vital position in the global economy, providing essential raw materials for various sectors, including construction, manufacturing, and energy. As the demand for these resources continues to surge, the significance of engineering and construction services in the mining sector grows concurrently. Ultimately, engineering and construction are indispensable in the mining industry as they guarantee safe, efficient, and environmentally sustainable mining operations. Engineering firms possess the necessary expertise and experience to navigate the intricate challenges associated with mining projects. Furthermore, they actively seek innovative approaches to enhance mining operations by adopting new technologies that bolster productivity, reduce costs, and enhance safety.

The Engineering and Construction Journey of a Mine

The engineering and construction process for a mine is lengthy and arduous, typically involving several crucial steps:

1. Site selection and evaluation: The initial step involves identifying a suitable site for the mine. This encompasses considering factors such as the geological composition of the area, availability of infrastructure, and the potential environmental impact.

2. Mine planning: Once a site has been selected, the subsequent stage entails

developing a comprehensive mine plan. This document visibly outlines the mine layout, methods for mineral extraction, and environmental management strategies.

3. Engineering design: The mine plan serves as the foundation for developing meticulous engineering designs for the mine’s infrastructure. This includes designing mine shafts, tunnels, processing facilities, and waste disposal structures.

4. Construction: The engineering designs serve as a blueprint for constructing the mine’s infrastructure. This intricate and challenging process often spans several years.

5. Operational readiness: Once the construction phase is completed, the mine must undergo operational readiness preparations. This entails rigorous equipment testing and commissioning, workforce training, and the establishment of operating procedures.

The engineering and construction of a mine demand a diverse array of skills and expertise. The success of a mining project hinges on the engineering and construction team’s ability to deliver a safe, efficient, and environmentally sustainable mine.

The Rewards of Collaborating with an Engineering and Construction Firm

Engaging with an engineering and construction firm for your mining project offers numerous benefits. These firms possess the expertise and experience

required to navigate the intricate challenges associated with mining projects. Furthermore, they are consistently at the forefront of innovation, constantly seeking new methods to enhance mining operations. Moreover, engineering and construction firms can assist in achieving cost savings by designing and constructing efficient and cost-effective mining projects. Engineering and construction services play an indispensable role in the mining industry. By providing high-quality, tailored solutions, engineering firms facilitate the achievement of mining companies’ goals and objectives. Additionally, engineering firms contribute to promoting transformation and empowerment within the mining industry. Through collaborative efforts, engineering firms and mining companies can ensure the long-term sustainability and responsibility of the mining industry. Key among the benefits realized include:

1. Quality Assurance: A Paramount Aspect

2. In the mining industry, quality assurance takes centre stage. Mining companies rely on engineering firms to deliver high-quality projects that meet or surpass their expectations. To ensure the realization of this objective, engineering firms must establish robust quality management systems. These

systems should encompass all project aspects, ranging from design and construction to commissioning and maintenance.

3. Tailored Engineering Solutions for Success

4. Engineering firms must possess the capability to tailor their solutions to the unique requirements of each mining project. This necessitates a deep understanding of the client’s specific needs, the challenges posed by the site, and the regulatory framework in place. By adopting a customized approach, engineering firms can deliver solutions that are both effective and efficient.

5. A Commitment to Transformation and Empowerment

6. Beyond providing high-quality engineering services, engineering firms bear a responsibility to promote transformation and empowerment within the mining industry. This entails actively working towards creating a more diverse and inclusive workforce while supporting the development of local communities. By adopting a holistic approach, engineering firms contribute to ensuring the mining industry’s sustainability and responsibility.

The Future of Engineering and Construction in Mining

The mining industry confronts several challenges, including the extraction of minerals from increasingly inaccessible deposits and the reduction of environmental impacts. Engineering and construction companies are actively developing new technologies and solutions to tackle these challenges head-on. Engineers are exploring innovative methods for extracting minerals from deep underground and recovering minerals from waste streams. Construction companies are devising new approaches to constructing mines in remote and challenging environments while also advancing more sustainable construction methods.

The future of engineering and construction in mining appears promising. Engineers and construction companies continue to forge ahead, developing new technologies and solutions to empower the mining industry and overcome 21st-century challenges.

If you are considering a mining project, it is highly recommended that you collaborate with an engineering and construction firm. With their expertise and experience, they can significantly contribute to the success of your project.

STEEL CONSTRUCTION

Size Reduction: Unleashing the Power of Precision

In the depths of the earth lie valuable treasures and intricacies and cuttingedge technologies that fuel economies and industries worldwide. However, extracting these riches requires sophisticated techniques, and one of the most crucial processes in mining is size reduction.

Imagine a colossal rock filled with minerals waiting to be liberated. Size reduction is the transformative step that converts these unwieldy rocks into manageable fragments, facilitating the extraction of valuable minerals, making it easier to separate the ore from the waste, thereby maximizing efficiency and profitability.

Crushing is the first step in size reduction. In this stage, primary crushers break down large chunks of ore into smaller fragments. This is followed by grinding, where secondary crushers and mills further reduce the particle size. Semi-autogenous (SAG) and ball mills are at the forefront of this process, using a combination of impact, abrasion, and attrition to finely grind the ore. Recent developments in grinding technology, such as high-pressure grinding rolls (HPGR) and stirred media mills, have shown promising results in energy savings and ore liberation.

At the heart of size reduction lies liberation - advanced techniques like sensor-based ore sorting and flotation have revolutionized the industry by increasing the precision of particle separation. These methods use cutting-edge technologies, including X-rays, lasers, and artificial intelligence, to identify and extract target minerals efficiently.

Mining is no stranger to innovation, and nanotechnology has opened up new

frontiers in size reduction. By manipulating materials at the atomic and molecular level, nanoparticles offer increased surface area and reactivity, enhancing the efficiency of processes like leaching and mineral recovery. This improves the performance of additives, such as frothers and collectors, in the flotation process.

While mining plays a crucial role in economic growth, its environmental impact cannot be ignored. Size reduction processes, in particular, consume significant energy and produce large amounts of waste. However, the industry is actively pursuing sustainable solutions to minimize its carbon footprint.

Miners are embracing energy-efficient comminution methods to reduce their overall energy consumption. HPGR and stirred media mills are just a few examples of technologies that offer substantial energy savings compared to traditional methods. Furthermore, integrating renewable energy sources into mining operations is gaining traction, making the processes more ecofriendly.

Mining generates considerable waste, but advancements in waste valorization are unlocking hidden potential. Tailings, the byproducts of ore processing, are now viewed as valuable resources. Technologies like dry stacking and paste fill are helping extract additional minerals from tailings, while also mitigating the environmental risks associated with their disposal.

As demand for minerals continues to rise, the importance of size reduction in mining becomes even more pronounced. With the help of advanced technologies, the efficiency and precision of this process have improved significantly. The ability to crush and grind ore into finer particles not only enhances

resource extraction but also reduces energy consumption and waste generation, contributing to a more sustainable mining industry.

Additionally, stirred media mills have shown promise in achieving finer particle sizes without the need for excessive energy input, further enhancing the economic viability of mining operations.

Apart from energy efficiency, precision in particle separation has also been greatly enhanced through technological advancements. Sensor-based ore sorting techniques, utilizing state-of-the-art sensors and data analytics, allow for better identification and extraction of valuable minerals from the ore stream. This not only increases the overall recovery rate but also reduces the environmental impact by minimizing the amount of waste generated.

Furthermore, the integration of nanotechnology in the mining sector has opened up new possibilities in size reduction. Nanoparticles have unique properties due to their small size, enabling more efficient leaching and mineral recovery processes. Nanotechnology also improves the performance of frothers and collectors, leading to higher flotation efficiency. As the technology continues to evolve, its potential applications in mining are bound to grow.

Despite these significant advancements, the mining industry faces challenges in achieving a truly sustainable approach to size reduction. The energy-intensive nature of size reduction processes remains a concern, and mining companies must continue to explore renewable energy sources to power their operations. Furthermore, waste valorization efforts should be accelerated to transform tailings into valuable resources

and mitigate environmental risks associated with their disposal.

Collaboration between industry stakeholders, researchers, and policymakers is essential to drive innovation and promote sustainable practices in size reduction and the broader mining sector. By investing in research and development, mining companies can stay at the forefront of technological advancements, fostering a culture of continuous improvement.

As the mining industry continues to evolve, the importance of size reduction in unlocking the Earth’s valuable resources becomes ever more evident. The pursuit of precision and efficiency is not only driven by economic factors but also by the urgent need to address environmental concerns. By focusing on sustainable practices and embracing cutting-edge technologies, the mining sector can play a pivotal role in shaping a more eco-friendly future.

The drive towards energy-efficient comminution methods, such as HPGR and stirred media mills, marks a significant step in reducing the carbon footprint of mining operations. These technologies not only minimize energy consumption but also reduce greenhouse gas emissions, making mining processes more environmentally friendly. Additionally, the integration of renewable energy sources, such as

solar and wind, into mining operations is gaining traction, further contributing to the industry’s sustainability.

Waste valorization initiatives are equally crucial in addressing environmental challenges. Transforming tailings, which were once seen as mere waste, into valuable resources not only maximizes the economic potential of mining projects but also mitigates environmental risks associated with their disposal. Dry stacking and paste fill technologies represent innovative solutions that allow for the extraction of additional minerals from tailings, promoting a circular economy approach within the mining sector.

However, to achieve a truly sustainable future, the mining industry must continue to invest in research and development. Collaboration between industry players, academic institutions, and government bodies is essential to driving innovation. Research can lead to breakthroughs in technology, process optimization, and waste management, ultimately paving the way for greener mining practices.

Moreover, the integration of nanotechnology in size reduction processes holds the promise of revolutionizing the industry further. As nanotechnology continues to advance, its potential applications in leaching, mineral recovery,

and even waste treatment will open up new opportunities for resource extraction and environmental protection.

In this pursuit of sustainability, responsible mining practices must be at the forefront of the industry’s agenda. Compliance with strict environmental regulations and ethical mining practices are vital in safeguarding the delicate balance between economic development and ecological preservation.

Sustainable mining practices must therefore take into account the well-being of local communities, respecting their rights, and contributing positively to their development. Community involvement and consultation are vital to ensuring that mining operations align with the needs and aspirations of the people who inhabit the areas where these resources are extracted.

As we navigate the challenges of the 21st century, size reduction in mining stands as a powerful symbol of human ingenuity and adaptability. From the early days of crude tools to the cutting-edge technologies of today, the mining industry has continuously evolved, meeting the demands of a growing global population while facing the imperative of preserving our planet for future generations to come.

The Crucial Role of Kidnap and Ransom Insurance

In recent years, the global rise in kidnapping rates has been a cause for concern, further exacerbated by the economic pressures faced by many individuals. Across the world, kidnap threats vary from country to country, but it is Sub-Saharan Africa that remains a dynamic kidnapping environment, with various hotspots scattered across the continent, including Nigeria, South Africa, Congo (DRC), the Sahel, Mali, Niger, Burkina Faso, and Mozambique. Within this challenging landscape, the mining sector stands out as a prime target for kidnappings

due to its perceived wealth and the potential for paying elevated ransom sums.

Experts in the field underscore the heightened risk faced by expatriates working on mining sites in Africa. The perception of wealth associated with the industry makes these expats especially susceptible to being targeted for kidnappings. Notably, more capable groups have established a troubling precedent by focusing their efforts on mining sites for abductions.

The outdoor nature of mining operations further compounds the risks for expat miners. This setting makes it comparatively

easier for would-be kidnappers to preplan their criminal activities by closely monitoring mining operations, guard shift patterns, and even victim routines.

An Alarming Trend-Extended Kidnappings; while most kidnappings in Africa conclude within one week, mining personnel kidnappings have shown a disturbing tendency to be of longer duration. These distressing events can often last for multiple weeks and, in higher-risk locations, may persist for several months. Such findings are sourced from experts at The Control Risks Group, who provide critical insights

into the evolving kidnapping landscape.

Amidst this challenging environment, Kidnap for Ransom insurance policies have emerged as a lifeline for companies operating in Africa’s mining sector, seeking to protect their workers - both expatriates and local nationals - from the constant threat of abduction. This specialized insurance policy empowers companies to access a network of seasoned response consultants, skilled in navigating the complexities of ransom negotiations and ensuring the safe return of individuals.

Prevention Through Proactivity:

When deciding on the Limit of Indemnity for Professional Indemnity insurance, several factors should be considered:

• Liability Limitation in Contracts: Evaluate whether you limit your liability in contracts with clients, as this may influence the appropriate coverage amount.

• Client Indemnification: Consider if your clients indemnify you for thirdparty claims, as this may affect the extent of coverage required.

• Client Requirements: Be aware of any specific Professional Indemnity limits your clients may demand, as this can impact your insurance needs.

• Project Size: The size of the total project you’re working on should be taken into account when assessing your coverage requirements.

• Potential Losses: Identify the most likely and reasonably possible single biggest loss you could cause to understand the level of protection needed.

• Affordability: While securing adequate coverage is crucial, it is equally important to ensure that the policy’s cost is affordable for your business.

Experts emphasize that K&R insurance policies place a strong emphasis on proactive pre-incident mitigation. Premium bursaries are made available to companies, which can be directed towards comprehensive training and implementing best practices, specifically tailored for high-risk territories. By investing in training and equipping their personnel with vital knowledge, mining companies can significantly bolster their duty of care obligations to their employees, heightening overall safety standards.

One of the most significant advantages of Kidnap for Ransom insurance is the peace of mind it affords companies, knowing that they can support their staff during a crisis without being burdened by the crippling financial consequences that often

accompany such incidents. Kidnappings often demand substantial ransom payments, and without insurance coverage, the financial burden on companies can be overwhelming, jeopardizing their ability to secure the safe return of their employees.

While immediate risks are evident, it is crucial to recognize the enduring threat to expat miners in Africa. The socioeconomic dynamics that enable criminal acts and kidnappings show little signs of abating, signifying that this menace will persist in the long term. Moreover, the mining sector’s perception of wealth continues to render it an enticing target for kidnappers.

Ethics and Responsible Practices:

When it comes to providing or purchasing Kidnap for Ransom insurance, ethical considerations loom large for both mining companies and insurers. Safeguarding the safety and well-being of employees is paramount, necessitating adherence to local laws, customs, and ethical standards. Companies must tread carefully to avoid inadvertently contributing to a cycle of kidnappings, while insurers must design policies that uphold ethical principles.

The availability and scope of Kidnap and Ransom insurance in African countries can be influenced by local laws and regulations. To ensure compliance, companies and insurers must navigate these legal frameworks carefully. This often involves seeking legal advice and collaborating closely with local authorities.

Toward a Safer Future:

While Kidnap for Ransom insurance provides vital protection, addressing the broader issue of insecurity in Africa requires a multi-faceted approach. Governments, security forces, local communities, and mining companies must unite to strengthen security measures, promote responsible business practices, engage with local communities, and support initiatives that uplift security and socioeconomic conditions in vulnerable regions.

As with any risk mitigation strategy, Kidnap and Ransom insurance is not without its limitations. Increased risk perception and targeting, policy exclusions, and the risk of moral hazard demand comprehensive risk management measures to complement the insurance coverage. Mining companies and expatriates must proactively implement robust security protocols, conduct regular risk assessments, and prioritize ongoing employee training.

Insurers play a pivotal role in evaluating the risks associated with providing Kidnap for Ransom insurance in Africa’s mining

sector. Factors such as the specific security situation in a region, historical kidnapping data, political and socioeconomic dynamics, and a company’s risk management practices are carefully considered when setting premiums and designing policies. Insurers rely on their expertise and access to intelligence networks to ensure accurate risk assessments and provide optimal coverage.

Expanding Coverage:

As essential as Kidnap and Ransom (K&R) insurance is for expats in Africa’s mining sector, it is equally imperative for industry professionals in various fields to secure comprehensive coverage against third-party claims. Professional Indemnity solutions offer tailored coverage designed to protect professionals financially against actual or alleged negligence, errors, or omissions within the scope of their professions. The policies cover damage awards, defence costs, and other extensions tailored to suit specific business practices.

There are insurance companies that specialise in crafting bespoke Professional Indemnity policies for industry professionals. With a deep understanding of each profession’s intricacies, they provide comprehensive coverage that meets distinct needs.

Securing Professional Indemnity cover is conducted through independent brokers. For brokers seeking more information about the cover, product experts are readily available to assist.

Its therefore accurate to say that Kidnap and Ransom insurance has become an indispensable tool in safeguarding expatriates working in Africa’s contemporary mining sector. The rising global kidnapping rates, coupled with the dynamic kidnapping environment in SubSaharan Africa, underscore the urgency for robust risk mitigation strategies. K&R insurance offers essential protection for expats in the mining sector by providing access to specialized response consultants, emphasizing pre-incident mitigation, and relieving the financial burdens that can arise from kidnappings. However, addressing the long-term threats, navigating ethical considerations, and promoting comprehensive risk management remain crucial in ensuring the safety and security of expat miners. As the African mining sector continues to grapple with the challenges posed by criminal activities, responsible practices, collaboration, and a proactive approach are paramount in creating a safer future for those working in this high-risk environment.

The relevance of Kidnap and Ransom Insurance for Expats in Africa in the contemporary mining sector

Attribute to Lockton’s Kidnap and Ransom experts.

Kidnap rates globally are on an upwards trajectory not helped by the economic pressures people are facing. Whilst kidnap threats vary from country to country, Sub-Saharan Africa remains a dynamic kidnapping environment with various hotspots across the continent including: Nigeria, South Africa, Congo (DRC), the Sahel, Mali, Niger, Burkina Faso and Mozambique. Mining as a sector is a particular target given the perception of wealth surrounding the industry and therefore its perceived ability to pay elevated ransom sums. Expats working on such sites in Africa are an especially high target for the same wealth perception and more capable groups have a precedent for targeting mining sites for kidnaps. The outdoor nature of mining sites makes it comparatively easier for would-be kidnappers to preplan by monitoring operations, guard shift patterns and victim routines. Also, while the majority of kidnaps recorded in Africa are usually concluding within one week, kidnaps of mining personnel have tended to be longer in duration, often lasting for

multiple weeks and, in higher-risk locations, can last for several months (Source: The Control Risks Group).

Kidnap for Ransom insurance policies can help companies to protect their workers, both expats and local nationals, from the risks of kidnap. The policy allows

companies to access specialised response consultants who can help the process of ransom negotiation and the safe return of individuals. The policies have a focus on pre-incident mitigation with premium bursaries available to put towards training and best practise principles for operating in high-risk territories. This allows companies to put in place practices which support their duty of care obligations to their employees.

While the insurance policies indemnity aspect allows companies the peace of mind that they can support their staff in a crisis without worrying about the resulting financial burden on the company.

The threat to expat miners is likely to remain in the long term given the socioeconomic dynamics, which enable acts of crime and kidnap to persist, show little signs of abating. Moreover, mining as a sector maintains it perception of wealth with the associated higher risk of targeting for kidnap which goes with that.

THE INANDA CLUB, FORREST ROAD, INANDA, JOHANNESBURG

The Joburg Indaba is a highly influential mining industry platform, renowned for its straight talk, refreshing insights and collaborative atmosphere. Since its inception, the Joburg Indaba has developed a reputation as a highly regarded and influential industry platform which unpacks a wide range of critical issues affecting all stakeholders in the mining industry.

This 11th edition of the Joburg Indaba will bring together CEOs and senior representatives from all major mining houses, investment firms, Government, parastatals, communities, organised labour and legal and advisory experts.

Plus, the Gala Dinner will be held on 3rd October, when we will be inducting new members into the SA Mining Hall of Fame!