FINSCH DIAMOND MINE
FINSCH DIAMOND MINE
50 Years, 50 Million Carats
And Counting PRODUCTION: Karl Pietersen
100 years ago, the Fourth General Conference on Weights and Measures adopted the Metric Carat as the official measurement for gemstone weights. 50 years ago, production started at South Africa’s Finsch Diamond Mine. Today, Finsch has produced almost 50 million carats, and with a new mine plan set to extend the life of the mine until at least 2030, it looks like there’s a lot more to come from this shining example of the SA mining industry.
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Located in South Africa’s vast Northern Cape, around 160 km northwest of the mining town of Kimberley, the world-famous Finsch Diamond Mine sits celebrating 50 years of success. Originally discovered by its namesakes, Allister Fincham and William Schwabel, in 1960 while prospecting for asbestos, the Finsch kimberlite pipe has become South Africa’s second largest diamond operation by production, after De Beers’ Venetia mine in Limpopo. General Manager, Luctor Roode says that although this is a major milestone for the mine, it is mostly business as usual with little time for big celebrations. “We might consider our annual achievers award function towards the end of the year as an opportunity to stop for a while and
celebrate this milestone. “For a mine to reach this milestone is significant; you wouldn’t normally have a mine operate sustainably for this long. We’re still going strong and hoping to see many more years added to the life of the mine.” After starting up in 1967 as an open pit operation, the Finsch mine’s underground development began in 1978. The shaft was commissioned in 1982 and, since 1991, the whole operation moved
underground, mining beneath the open pit. After decades of development and consistent supply, the mine received a US $100 million investment in 2008 to upgrade its treatment plant before thenowners, De Beers Consolidated Mines, sold Finsch to London-based Petra Diamonds in 2011 in a deal worth US $200 million. When Petra completed the purchase of Finsch, CEO Johan Dippenaar oozed excitement, saying: “This acquisition is a
//FOR A MINE TO REACH THIS MILESTONE IS SIGNIFICANT; YOU WOULDN’T NORMALLY HAVE A MINE OPERATE SUSTAINABLY FOR THIS LONG. WE’RE STILL GOING STRONG AND HOPING TO SEE MORE YEARS ADDED TO THE MINE//
Mining Services Excellence Group T Mining (Pty) Ltd is a company focused on providing contract mining services to the South African mining industry, specializing in the following areas: • Mechanized lateral development • Cover drilling and drop-raising • Large chamber underground excavation • Mechanized ground support installation • Underground civil construction • Mechanized large scale production Group T Mining (Pty) Ltd Reg No: 1990/004819/07 1st Floor, Block 7 Sunwood Park 379 Queens Cresent Lynwood, Pretoria Postnet Suite 91 Private Bag X9676 Bendor
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Finsch Mine crusher chamber Group T Mining
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landmark development for Petra and a further progression of our strategy to build one of the world’s leading independent diamond producers.” Known throughout the industry for producing rich in gem-quality smaller diamonds, larger +50 carat stones, and a number of very rare fancy yellow diamonds, Finsch’s kimberlite orebody is expected to continue producing value for at least another quarter century and Petra is currently busy implementing a mine plan that will see the underground operation expanded significantly, lifting production from 1.6 million ROM (run-of-mine) carats per annum in FY 2016 to ca. two million ROM carats per annum by FY 2018. “The depth of the pipe goes beyond the horizon which we have
opened thus far, so the life of mine can certainly extend further into the mining of Block 6,” says Roode. In 2016, Finsch delivered 2.21 million carats (an increase of 7% on 2015 figures) and through its entire life, the mine has produced almost 50 million carats, making it one of the most significant diamond mines on earth. The implementation of the current mine plan began five years ago and Roode tells Enterprise Africa that the ambitious project will be one of the most important in Finsch’s history, costing around
, Pretoria,
MINE PLAN “This mine has produced on average approximately two million carats per annum for the past few years but we have supplemented underground production with surface tailings operations, contributing approximately 300,000 to 400,000 carats per year,” he says. “With surface resources being mostly depleted, we will ramp up underground production which come at a higher value per carats as opposed to tailings diamonds which
//WE STARTED COMMISSIONING THE SLC IN JULY 2016 AND WE ARE BUSY IN THE RAMP UP PHASE WITH TWO LEVELS ALREADY IN PRODUCTION//
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have been through a recovery process already and which tend to be smaller, lower-value stones.” To increase the life of Finsch, Petra Diamonds must dig deeper. Over the past couple of years, most of the production was mined from the Block 4 block cave with the production level at 630 metres below surface. Block 4 is a mature cave with a high level of waste rock dilution. Just below Block 4 sits Block 5, expected to contain diamond reserves of 25.3 million carats at a grade of 58.6 cpht (carats per hundred tons). Mining in Block 5 will help extend the life of the mine to at least 2030. Petra plans to use the sub level cave (SLC) mining method over four levels in Block 5 from 700 mL to 780 mL before extending Block 5 to 900 mL from FY 2023-2030. “Initially the 118-million-yearold volcanic pipe was mined as an open pit operation. This went on until September 1990, when this mining method was terminated, at which point the pit had a surface area of 55 ha and a depth of 423 m. From then onwards, the mine’s operations moved underground. Two methods of underground mining are being used at Finsch today – block caving and sub level caving, in a mechanised and automated operation,” explains Roode. “Historically, there were a number of studies to determine the best method to exploit the Block 5 resource. At the time when the transfer of ownership took place, a decision was made to opt for a SLC mining method which would not only give earlier access to the Block 5 ore body but also reduce the geotechnical risk associated with a block cave. The construction of the SLC also included the development and construction of a dedicated conveyor and crusher system for ore-handling to transfer SLC ore
to existing infrastructure at 650 m. Once the Block 4 has been fully mined, it will be decommissioned similar to upper historic levels.” Essentially, block caving is a hard-rock mining method that destabilises an ore body, allowing it to gradually breakdown under its own weight, providing access to higher volumes of ore. With an SLC, tunnels (or drifts) up to 200 m long, are drilled and blasted through the ore body. Walls and roofs are reinforced with several support elements which include roof bolts, welded mesh, and sprayon concrete. Once the production drifts are ready, a set of holes, up to 34 m long, are drilled upwards through the orebody in a semicircular or fan-shaped pattern. Each fan cut or ring blast consists of a set of fourteen to eighteen
drill holes, and each set is 2.0 m apart. In a 200 m long drift, about 100 fan cuts are drilled, with fan cut 100 closest to the haulage rim tunnel. The rings are then blasted and the liberated ore loaded by LHDs in a sequence from 1 to 100, and in sequence with adjacent and underlying or overlying levels. Ore is taken to tip points, where it is transferred through ore passes to jaw crusher, situated in the host rock close to the ore body. Large boulders of ore are either reduced in size using explosives, mechanical breakers or moved to a holding point for later secondary breaking. The performance of the SLC is highly dependent on the extraction sequencing and the discipline in following the sequencing of the drill and blast process and, then, the draw control.
Congratulations Petra Diamonds Finsch Diamond Mine on your half-century milestone! We commend you for investing in the health of your biggest asset – your people. We are proud to be your partner in taking care of your employees’ health.
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“SLC is suitable as you get access to the ore in a shorter period relative to block caving,” says Roode. “It is a more dynamic mining method than block caving, requiring drilling, charging, blasting and loading to happen in a coordinated and sequential manner on a number of levels at the same time. We started commissioning the SLC in July 2016 and are busy with the production ramp up phase with two levels already in production.” In terms of technology, Finsch continues to install industry leading products and systems to ensure safety, efficiency and value. Of course, this means partnering with some of the world’s most prominent organisations. “The SLC requires drilling of long holes and you need a sophisticated drilling machine to accurately drill the holes in a ring formation in a tunnel,” details Roode. “We have partnered with some of the most sophisticated and reputable companies in the business including Sandvik, Atlas Copco, Aard and AEL. With mechanised tunnel development, TNC Mining, Jonrik, and Murray and Roberts were deployed to develop over 22 km of tunnel since the
inception of the project in 2011.” Finsch is also currently busy implementing a MineRP Spatial System to aid in data analysis and to utilise information in the most effective way possible, creating an environment where quality decision making is easy and operational excellence is supported. “I believe the MineRP system can be a LEAP change on how we operate and report in mining. Integrating spatial and tabular data across disciplines will enhance the way we interact and manage at Finsch/Petra. Powerful and intelligent information will become available at your fingertips, wherever you are, and will forever change the way you plan, work and manage for the better,” says Roode.
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DIAMOND REPUTATION With the exciting developments underway at Finsch offering many opportunities for stakeholders to look forward, in the year of the mine’s 50th anniversary, some are also looking
//OUR SAFETY RECORD IS EXTREMELY IMPORTANT TO US, ESPECIALLY WITH OUR NEW MINING METHOD BEING IMPLEMENTED// Minova Africa (Pty) Ltd Isando Tel: +27 (0)11 923 1900 Reg No. 2001/027226/07 Alrode Tel: +27 (0) 11 864 4311 VAT No: 4190204901 www.minovaglobal.com Minova Africa (Pty) Ltd Isando Tel: +27 (0)11 923 1900 Anvil & Brewery Roads,Alrode Isando RegCorner No. 2001/027226/07 Tel: +27 (0) 11 864 4311 52, Isando, 1600 VATP.O No:Box 4190204901 www.minovaglobal.com
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Minova Africa’s vision is to sustainably contribute to the growth and improvement of our Minova Africa’s vision is to sustainably contribute to the growth and improvement of our customers by nurturing andsafe safe environment that enables each of our customers by nurturingan aninclusive inclusive and environment that enables each of our people to people to their potential. realise realise their potential. Minova Africa in in partnership PetraDiamonds Diamonds (Finsch Diamond Mine) has provided Minova Africa partnership with with Petra (Finsch Diamond Mine) has provided product solutions concerns raised, raised, thereby improving Petra’s safety and productivity. thereby improving Petra’s safety and productivity. product solutions to to concerns THE EARTH. UNDER CONTROL.™
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backward, at the reputation that has been developed and how the mine has become known as a world leader. “Finsch Mine has a very good reputation and we often have to fend off visitors from mines that are considering mechanisation, automation and sub-level caving. We still see ourselves as a mine that is at the forefront of technology in terms of mechanised mining,” says Roode. The General Manager also explains that Finsch’s safety record is something which has been extremely closely guarded over the years, contributing hugely to the quality reputation, and this is something which will receive further attention in the future. “Our safety record is extremely important to us, because a safe mine is a productive mine,” he says. “The complexity of mining has increased over time and especially during the development and construction phase, it has been a significant challenge to maintain the safety culture of the mine. We will never rest with regards to safety and will always strive in achieving zero harm.”
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I was transferred to Finsch mine in 2007 in the capacity of Plant Manager, when Finsch was still a De Beers operation. I later transitioned to the position of Production Manager. When the mine was sold, I moved over to Petra Diamonds and was appointed as General Manager in September 2011. I’ve been in the mining industry for more than 20 years, starting my career in 1994 as a graduate trainee.”
GENERAL MANAGER
LUCTOR ROODE The mine has been lauded for its safety success, being accredited with ISO 14001:2004 and OHSAS 18001:2007 certificates, and it has picked up awards from the annual MineSAFE conference as well as the Northern Cape Mine Managers Association for safety excellence. SPARKLING FUTURE Going forward, the outlook for Finsch is positive. The implementation of the mine plan has installed confidence within the operation. Roode puts this down to the investment from Petra that started in 2011.
“The transfer of ownership was a difficult period for the mine with significant skills losses and a high level of uncertainty. Once the transfer of ownership happened, we saw an immediate upliftment of energy and productivity levels, and a new lease of life,” he says. “Sometimes, it’s not a bad thing for a mine to change ownership as the new owners have an appetite to secure the future of the operation and in many cases, bring new innovation and energy to a mature mine into which no significant capital investment was being made.
This was evident very soon after the transfer of ownership; it wasn’t long before the first drill rig arrived on site and we commenced with tunnel development, opening up access to the Block 5 resource,” he adds. Globally, the appetite for diamonds remains; De Beers CEO Bruce Cleaver said in November last year that diamond jewellery consumption was not ‘in a bad place’ and that demand in the major markets (US, China, India, Japan) was ‘reasonable’. De Beers does expect global economic volatility to play a part in the industry through 2017/18,
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//WE STILL SEE OURSELVES AS A MINE THAT IS AT THE FOREFRONT OF TECHNOLOGY IN TERMS OF MECHANISED MINING AND WE HOPE TO LEAD TO THE INDUSTRY IN THIS SPACE// but the long-term looks positive with Cleaver stating that ‘millennials are very invested in the diamond dream and they regard diamond gifting as a very important part of their lives’ suggesting that opportunities will continue to develop. With the SA economy facing its own set of unique challenges, such as downgrading by international credit agencies and entering technical recession, does Roode remain confident about the future? “We are at a point now where a lot of the hard work is done. We are in the process of ramping
up the project to full production and accessing fresh, undiluted and high-grade kimberlite. The improvements are already evident with run of mine grades increasing as the new ore source starts ramping up,” he concludes.
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