CONTENTS NEWS
PRODUCTS
EVENTS
PROFILE
FEATURE
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Tesla joins FCA to improve mining in DRC
Rugged smart devices in mining
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Flotation reagents in the mineral processing
Driver fatigue monitoring systems
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Investors, beware the preliminary assessment
Omnia solidifies position in the mining sector
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TEAM
EDITOR’S COMMENT
Editor Bertha M. bertham@fmdrc-zambia
The Digital push
Sub-Editor Nita Karume Contributing Writer Oscar Nkala, Mfuneko Jack Lindani Mkhize Caroline Thomas Cover Image: Hexagon Mining: HxGN MineOperate OP
COVER STORY: PG 17 Real-time fleet and mine management systems in mining In the mining sector, the main objective of the fleet management system is to optimize mine production and efficiency based on real-time data.
Sales and Marketing Victor Ndlovu victorn@fmdrc-zambia.com +27 11 044 8986 Isabel Isiziwe isabelsiziwe@gmail.com zambia@fmdrc-zambi.com +260 96 187 4888 Advertising Consultants Meshack Ndzendevu Polite Mkhize Gladmore Ndhlovu Leslie Nyembe Production Coordinator Kholwani Dube kholwani@fmdrc-zambia.com Graphic Design and Layout Irene Faith Omudho
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Art Director Augustine Ombwa Arobia Creative Consultancy austin@arobia.co.ke
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he pressure for mining organizations to achieve new levels of performance has never been greater. You want to run safe operations. You want to execute your plans effectively, and make reliable, consistent decisions. You want to improve operational productivity and efficiency, and find the simplest, quickest, and most cost-effective routes to market. Capital projects are becoming more complex, even as budgets and schedules become more constrained. Companies like yours are looking for more value from project delivery. They know that improving engineering efficiency and construction productivity is the way to do it. As a global industry, mining recognizes the need to do things differently, to look beyond the same traditional continuous-improvement approaches. To change. To innovate. To overcome the challenges of today and develop a new mindset for the future: digital technology may be the key to unlocking hidden potential. This issue of First Mining DRC/Zambia looks into Realtime fleet and mine management systems. What are they? How can they work for you? Why do you need them now more than before? Catch this and other insightful features on mining as well as the usual news updates which keep you informed about what is going on in the mining industry across Africa.
Published By Mailing Times Media Circulation/Sales info@fmdrc-zambia.com sales@fmdrc-zambia.com +27 11 044 8986
Nita Karume
Mailing Times Media (Pty) Ltd makes every effort to ensure the accuracy of the contents of its publications, but no warranty is made as to such accuracy and no responsibility will be borne by the publisher for the consequences of actions based on information so published. Further, opinions expressed are not necessarily shared by Mailing Times Media (Pty) Ltd
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NEWS
Tesla joins FCA to improve mining in DRC
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merican electric vehicle and clean energy company Tesla has become a member of the Fair Cobalt Alliance (FCA) to improve the artisanal mining sector in the Democratic Republic of the Congo (DRC). The FCA is a recently founded organisation which will help to boost the appeal of cobalt produced in the DRC. It aims to end the use of child labour at mining sites and improve working conditions in the country. This is according to an updated list of members on the group’s website.
Mining company Glencore announced its membership of the FCA on 24 August this year. In a press statement, Glencore stated: “Glencore, through our support of the FCA, will support legitimate ASM cooperatives in their endeavours to transform their practices and align with international human rights practices, especially in the prevention of child labour.” Other FCA members include Zhejiang Huayou Cobalt, Sono Motors and the Responsible Cobalt Initiative (RCI). In June, Tesla and commodities
trader and miner Glencore signed a deal, pursuant to which Tesla will buy cobalt from Glencore. The cobalt will be supplied from the DRC, where the commodities miner has been operating a copper mine in the Katanga region since 2008. In January 2019, automobile manufacturer Ford, technology major IBM, cathode manufacturer LG Chem and China-based Huayou Cobalt teamed up to launch a blockchain project to track cobalt supplies from the DRC.
Zambia to curb increasing external debt in 2021
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Earlier this week, the government asked for a 6-month debt repayment holiday on 3 Eurobonds due to the economic impact of coronavirus restrictions.
ambia’s finance minister on Friday, September 25, stated the country would not take on new external commercial loans in 2021 and limit existing projects in an attempt reduce spiraling debt. The country’s public debt increased by 4.3% in the first 6 months of 2020, reaching US $11.97 billion in June. According to the African Development Bank (AfDB), the debt already represented around 80% of gross domestic product by the end of 2019.
“Further contraction of new commercial external debt has been stopped,” he added.
An announcement made by Finance Minister Bwalya Ng’andu in a 2021 budget stated that the government remains committed in restoring public debt sustainability. Some of the several initiatives aimed at achieving this objective include cancellation, postponement, and rescoping of projects.
Ng’andu said US $1.1 billion in pending loans had been cancelled and another US $280 million saved through project changes. He reiterated that the government plans to apply for a G20 initiative to suspend debt servicing and said similar relief was being sought from external commercial creditors.
Global giant Glencore – one of Zambia’s largest miners – announced earlier this year that it would cut capital expenditure by as much as a quarter during 2020 due to disruption to supply chains caused by the coronavirus and falling commodity prices. The government has since proposed to up its 10% shareholding in Glencore subsidiary Mopani Copper Mines (MCM) to save jobs. Ng’andu said the government had “offered to acquire additional shares” in MCM and “terms of purchase” were being negotiated with Glencore.
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NEWS
Kazungula Bridge spells new dawn for Southern African Countries
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any stakeholders longed for the construction of Kazungula Bridge and it must now be a relief that the project is near completion. According to Kazungula Bridge consultant and team leader of contractors Kobamelo Kgoboko, the US $174 million Kazungula Bridge will be handed over to the governments of Zambia and Botswana by the end of this month while the onestop border facilities in both countries will be handed over by the first week of October.
are avoided.Local and foreign truckers often complain of delays in clearance at border posts because customs and immigration officers do not bring on board the expected efficiency. The dream of creating an efficient system through the construction of Kazungula Bridge can only be realised if all operatives at the border work according to the aspirations of a new set-up.
Indeed, Kazungula Bridge, straddling Zambezi River, will improve the transportation of goods and services between Zambia and Botswana and the southern region as a whole.Economic growth cannot take place without infrastructure like Kazungula Bridge.
“This is one of the first of its kind in the country and I would like to commend the engineers behind these works. As the board, we are impressed with what RDA has done. This is tax-payers’ money and these facilities need to be looked after properly,” the Road Development Agency (RDA) board vice-chairperson Yamfwa Mukanga.
Now that the bridge is almost complete, stakeholders must streamline border operations at Kazungula and ensure that issues of truckers getting stranded
Residents in Kazungula district also have a role to play in ensuring that the infrastructure is not vandalised. Vandalism to infrastructure is costly to
Government especially that it has to look at other competing needs in other parts of the country .Traders who will be using the facilities also have a role to play in taking care of the facilities.According to the African Development Bank (ADB), the project will help beneficiaries who contribute up to 60- 80 percent of the region’s gross domestic product (GDP). Most of them are engaged in the mining, agricultural and service sectors. ADB notes that Kazungula Bridge is expected to increase opportunities for intra- and extra-regional trade activities, regional economic integration along the corridor and job creation. We hope those in business will take advantage of Kazungula Bridge by increasing exports to the region so that the governments can recoup their investments on the project to attend to other areas of need.
Kabwe Mining renewed License awarded to Jubilee Metals
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ambia’s Minister of Mines and Mineral Development has reinstated the mining license for Jubilee Metals Group’s part-owned Kabwe project. This move serves to pave the way for Jubilee to start its joint venture partnership with BMR Group. They have approved the renewal for ten years and is subject to several customary conditions specified by the minister. Jubilee has also appointed Nicholas Taylor as a non-executive director with effect on October 1. Taylor’s most recent executive role was as European head of
Natural Resources Investment Banking at Royal Bank of Canada from 2015 to 2016. Chief Executive Officer Leon Coetzer says that as Jubilee continues to drive its expansion across both its Zambian and South African operations, the renewal of the license in Zambia is an endorsement of the work that they are doing on the
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ground at Kabwe and the support from government and the Department of Mines. Officer Leon also states that they have made significant progress in Zambia since the acquisition of the Sable Refinery in 2019, particularly in recent months with Jubilee securing access to vast amounts of copper-containing surface tailings.
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NEWS
Ivanhoe announces Kamoa-Kakula feasibility study results addition to feed from Kakula that would fill a 7.6 million tonne/year processing plant at Kakula. The mine has been designed to produce the world’s most environmentally responsible copper, which is crucial for today’s new generation of environmentally and socially-focused investors, according to the co-Chairman Robert Friedland.
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vanhoe Mines Ltd announced the results of an independent definitive feasibility study (DFS) for the development of its huge Kamoa-Kakula Copper Project in the Democratic Republic of Congo. The DFS, together with results from an updated prefeasibility study (PFS), provide more evidence that Kamoa-Kakula has the potential to become the world’s second largest copper mine, with annual output of more than 800,000 tonnes.
In a press statement, Ivanhoe said the feasibility study is an independent verification by nine of the world’s top engineering firms of the robust economics generated by an initial 6.0 million tonne/year starter pit at Kakula where the expected ore feed grade is 6.6% copper. Mine site cash costs are forecast at US$0.48/lb in the first five years of production. The PFS evaluates mining of 1.6 million tonnes annually from the nearby Kansoko mine, in
Kamoa-Kakula will advance in stages until it has four producing mines on site with combined output of 19 million tonnes annually.Ivanhoe shares eased 0.18% or $0.01 to $5.50 on volume of 890,030. Ivanhoe is led by Singaporebased mine financier Robert Friedland, who holds a 17% interest in the company. CITIC Metal Co. Ltd., a subsidiary of the Chinese state-owned CITIC Group, recently agreed to invest an additional $612 million in Ivanhoe at $3.98 a share, raising its stake in Ivanhoe to 29.9% from just under 20%.
Arc Minerals makes advances in Zambia
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on Schirnding, who has more than 25 years’ experience in mining, joined Arc Minerals in 2017. At the time, the company owned several assets, including gold in the Democratic Republic of Congo and Slovakia and copper in the north-west of Zambia. Schirnding has formerly held senior positions at De Beers and Anglo American. Today, the company is focused on the discovery and development of its large-scale copper at its Zamsort and Zaco licences in the western part of the Zambian Copperbelt. According to Schirnding, the last two years have all been about restructuring and they now have a very clear strategy in place. This, he adds, has worked well. Proof of this can be seen in the company’s strong balance sheet and enough funding to carry it through to 2021. According to media reports,
Zamsort and Zaco have licensed a total of areas which cover 872 km2 and include the advanced Kalaba coppercobalt project. Up until now, Arc mineral had identified more than twelve highly skilled prospective targets at Zamzort. In June, Arc Minerals started drilling activities at its Fwiji target in the Zaco licence area. The total diamond drilling programme for the year is budgeted for an initial 8 000 m with hole depths to between 100 m and 250 m below surface. The drilling is initially intended to confirm the interpreted anticlinal structure and mineralisation associated with the hinge component to this anticline. This will then be followed to test the mineralisation in the down-plunge hinge component to the anticline. Consequently, Arc Mineral’s progress has already got the attention of major
companies. To that end, the company has entered into a six-month exclusivity agreement with Anglo American. This means that no other company can approach Arc Minerals to form any working arrangement while the agreement is in place. According to von Schirnding, if test work shows promising results, Anglo American has a variety of options available to it to increase its interest in Zamsort including some sort of commercial agreement or a joint venture.
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EVENT
Angola to host an international forum on the diamond industry
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Last year, the country approved new diamond marketing laws, with Lucapa Diamond Co. holding the first international tender under the new diamond marketing policy at the end of January 2019, marking the beginning of a new era for the Angolan diamond mining industry.
ngola is set to host an international forum on the diamond industry. The initiative by the Ministry of Mineral Resources and Oil is for purposes of attracting direct foreign investments. Minister Diamantino Azevedo will reportedly take part in the international conference to inform about the new governance model for the country’s mining sector and the impact of Covid-19 on the diamond subsector. The officials from the Geological Institute of Angola, the National Agency of Mineral Resources and the sector’s major companies will be in attendance. According to media reports, the president of the board of directors of the National Diamond Enterprise, Ganga Junior, will be one of the keynote speakers at the forum, which will take place under the slogan ‘Leading the world of diamonds in the new era’. Angola is one of the region’s major diamond producers, and it ranks fourth
in terms of karats and fifth regarding value. Earlier on in the year, Sodiam, the Angolan state diamond marketing company, announced the opening of its online registration process to participate in its future competitive sales of rough diamonds. This was following through on Angolan president Joao Lourenço’s intention to fully reform the country’s diamond industry.
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This latest piece of legislation, called another milestone of the new strategy set out by the Angolan Government, allows Angola-based diamond mining companies to directly sell up to 60% of their production, with Sodiam acting as the exclusive single channel for contract sales, competitive sales (i.e. tenders or auctions), and beneficiation manufacturing. The third diamond cutting factory in Angola also opened in September las year. It has a capacity to process 5,000 carats per month and required an investment of US$5 million.
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EVENT
Africa Energy Forum 2020 joins forces with the African Utility Week & POWERGEN Africa and Oil & Gas Council’s Africa Assembly to host Digital Energy Festival for Africa
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Managing Director of EnergyNet Simon Gosling commented; “The impact of Covid-19 has clearly magnified the need
Over 10,000 attendees are expected to register for the Africa Digital Energy Festival, which will employ AI technology to match attendees with relevant content and networking opportunities allowing for a personalised event experience over the four-week period. As well as over 120 programme experiences the event will also feature an online marketplace of products hosted by sponsors and exhibitors.
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The 5th Industrial Revolution theme will explore the relationship between energy and technology with purpose and inclusivity, seeking to understand how technological innovation can work hand in hand with humans to enhance energy security, sustainability and energy access in a post-covid future. We want to help our community harness this potential so the continent doesn’t just recover, it recovers better.”
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Following the impact of the pandemic on the energy sector in Africa, the event will seek to address critical issues such as pivoting to digital, new financial models and innovative power generation sources to allow attendees to make decisions and formulate recovery plans. Under the theme ‘The 5th Industrial Revolution,’ the Africa Energy Forum agenda will look ahead to the digitalisation of the energy sector.
to be able to deliver energy in times of crises.
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he event will take place online from 20th October – 26th November 2020. The digital platform will allow attendees to access content and networking offerings across all three market leading events with one point of entry, making it the largest ever energy event for the African continent marketed to a combined energy database of over 200,000.
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ADVERTORIAL
7Mine® Deep Shaft Mining High-Performance Hoist Rope from Teufelberger-Redaelli C
ontinuously Teufelberger-Redaelli was expanding it’s product portfolio for mining applications and very successfully tested its new High-Performance Hoist Rope for drum winders. The 7Mine was in operation for more than 6 years on several multi-layer drum winders in South Africa and Canada. In all cases, the new 7Mine® hoist rope was able to significantly outperform the previously used triangular strand ropes in terms of rope service life. Furthermore, the rope showed a lot less torque and an improved rope stretch characteristic compared to triangular strand ropes. So far, the deepest shaft equipped with a 7Mine® was in South Africa with a depth of around 2300 m. The two ropes supplied were 54 mm in diameter and had a length of 2700 m each. Teufelberger-Redaelli developed this new high-performance rope to replace triangular strand ropes without any downsides in terms of rope weight and breaking strength. The rope will help mines to improve the productivity of their existing systems by using a modern state-of-the art high-performance hoist rope. Based on the extremely positive field tests, Teufelberger-Redaelli is convinced that it has now a high-performance rope
in its mining portfolio, which can be perfectly used in the deepest mines on earth. Teufelberger-Redaelli is not only expanding its product portfolio for mining applications very successfully, but is also strengthening its presence in the Sub-Saharan zone. With true experts located in South Aftrica, customers will have a direct contact for technical project consulting as well as for first hand rope expertise.
Teufelberger-Redaelli Email: southafrica.wr@teufelberger.com Mobile: +27 6497 587 18 www.teufelberger-redaelli.com
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PRODUCT & TECH
Rugged smart devices in mining
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ining applications require sturdy technology for tasks related to equipment maintenance, GIS mapping and geotagging, machine guidance, data collection, compliance and reporting, and asset management. Where consumer devices fail, rugged mobile computers stand up to the most challenging environments miners encounter — such as constantly vibrating vehicles, airborne dust and mineral particles, variable weather conditions, hard surfaces and humidity, to reduce worker and equipment downtime and improve safety and productivity. Data collection and analytics Mines using wireless equipment monitoring technology benefit from taking a proactive approach to maintenance, saving time and improving worker safety. Rugged handhelds running predictive maintenance software collect and analyze equipment data to identify maintenance needs and recurring trends, as well as to inform mine operators about use. Wireless sensors placed on equipment report maintenance data such as temperatures, load weight, speed, air quality, fuel consumption and hours in operation directly to workers’ tablets or PDAs, allowing them to schedule maintenance tasks and repair components before equipment fails.
processing, built-in data capture tools, easy data entry options and connectivity capabilities allow miners to reliably track assets and manage resources and materials while saving significant amounts of time. Mining fieldworkers use rugged handhelds to track equipment status using barcodes or RFID, or by quickly entering details into digital forms. They can also easily schedule predictive maintenance and keep detailed inspection and maintenance histories. Safety and compliance Mine operators perform site inspections of surface mines and underground mines multiple times per year to identify health, safety and environmental (HSE) risks — both according to their corporate regulatory standards and to stay compliant with Mining Safety and Health Administration (MSHA) regulations. Inspectors require reliable
and fully portable mobile devices to perform compliance checks safely and accurately. Rugged tablets and PDAs can be securely docked in a mining vehicle and used to navigate to sites, then undocked and carried to perform inspections. Miners can hold a lightweight rugged computer and, in many cases, enter data into inspection forms in mining industry inspection software all with one hand, thanks to compact and ergonomic design, easy-to-navigate menus and programmable physical buttons. Data is entered safely, quickly and with a high degree of accuracy. Non-compliance issues can be communicated in real-time and addressed quickly. This process also eliminates the need to re-enter data into an office computer, as data can be stored, transmitted and reported directly from the handheld device.
Mining asset management Mobile computers running asset tracking and production control software are an indispensable part of mining asset management. Secure vehicle ports, fast
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PRODUCT & TECH
GIS and GPS Mining companies operate on large areas of land, and mine operators who use GPS tracking and geotagging to notate and navigate to important locations are saving huge amounts of time and resources. Rugged handhelds equipped with GPS and GIS tools assist with surveying properties, assessing mining conditions, analyzing mineral potential, managing building and resource placement, planning mining infrastructure, determining environmental impact and more. Today’s mining handhelds feature built-in GPS as well as a variety of ports for connecting to external antennas and equipment. They can run robust geo-mapping software with large image files, and display high-resolution visuals on wide, sunlight-readable displays for optimal outdoor productivity. Communication & fleet management Large mining vehicle fleets require reliable communication options to stay productive, efficient and safe. Rugged handhelds allow vehicle operators to
communicate over WiFi and cellular networks and to use V2X systems to communicate vehicle-to-vehicle, as well as to receive instructions from dispatch and control centres. Hardwearing, sturdy vehicle docks keep tablets and PDAs safe and within reach even on constantly vibrating equipment, providing all-in-one communication and task management tools that relay status updates, locations, field-captured data and images in real-time. Vehicle-docked rugged computers equipped with builtin GPS and a variety of connectivity and communications capabilities are excellent fleet management tools that enable and enhance navigation, surveying, communication and inventory management tasks. Digital fleet management systems streamline fleet workflow and increase efficiency and productivity by allowing mining companies to easily and automatically communicate status updates, locations, payloads and other details among fleet vehicles and mine dispatch centres. Fleet management
software also helps mines keep track of legal, environmental and safety considerations related to large vehicle fleets. Machine guidance Mines use rugged handhelds to control and monitor many types of machinery through digital machine guidance systems. Machine guidance software for mines enables highly precise task performance such as digging, shaping, drilling and pumping. Drill-and-blast and other hazardous applications become safer and more accurate when operations are controlled and monitored using machine guidance systems and durable rugged mobile computers. Selective mining with a handheld field controller saves resources and minimizes waste. Machine guidance software also assists with predictive maintenance, monitoring machine performance and repair schedules to reduce equipment downtime and make sure machinery stays safe and functional.
WORK HARD. WORRY LESS. • Cedar CP3 Rugged Smartphone • Collect Data – Communicate – Calibrate – Compute • Water/dust/shock/drop -proof (IP68) • Large, ultra-bright display viewable in sun • All-day, rapid-charge battery
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PRODUCT & TECH
Is Work Better with a Rugged Smartphone? Yes.
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herever you live and work there is extreme weather. Our changing climate often delivers scorching heat, brutal humidity, spontaneous downpours, and even the occasional dust storm. At the mine, these conditions are all in a day’s work. When navigating extreme, hazardous, and dirty environments, reliable communication is not a luxury – it’s a necessity. It can literally mean the difference between productivity or downtime, safety or danger, and completing the job on time – or not. What is a rugged smartphone? The term ‘rugged’ is a classification of durability for computers and mobile phones used outdoors, and is comprised of three categories: semi-rugged, fullyrugged, and ultra-rugged. In general, these terms tell you how well a device will stand up to harsh conditions. Semirugged devices have slightly more protection than a consumer product, and feature a heavy-duty case and spill resistance. Devices that are fullyrugged undergo a higher level of testing to ensure they stand up to extreme temperatures, water immersion, dust
and shock. Ultra-rugged devices can withstand the harshest conditions and are almost indestructible. While it’s logical to think the value of ruggedness is in a device’s durability, there are other features equally important in a rugged device – especially if your job takes you to dirty, dusty, and harsh places. What to look for in a rugged device A rugged smartphone is more than just a mobile phone that doesn’t break if dropped. It provides similar benefits to other rugged computers, but in a smaller, more portable form factor, and with the added feature of phone communication.
‘ruggedised’ smartphones suited to active lifestyles outdoors. They may be sturdier and waterproof, but if your work takes you through extreme weather, rugged terrain, or remote areas, these devices may not be rugged enough. One smartphone that deserves recognition is the fully-rugged Cedar CP3 Rugged Smartphone from Juniper Systems Limited. The newest model withstands temperatures from -30˚C to 60˚C, has an IP68 rating making it waterproof, dustproof, and shockproof, and has been tested against MIL-STD-810G.
The best rugged smartphones also collect data, take high-quality photos, have screens that can be viewed in sunlight, and have long-lasting batteries.
But the appeal of this phone is in the details. It boasts a whopping 6000 mAh battery which lasts up to 16 hours even with constant use. The CP3 also has front and rear cameras; 64 GB of internal storage; and a large, ultra-bright and sharp display that is viewable even in bright sunlight.
Internet connectivity, real-time data collection and transmission, long battery life, and collaboration features are equally important to durability when it comes to rugged mobile devices. Within the last decade, a number of manufacturers have released
Rugged devices that offer more than communications are increasingly becoming the standard for harsh and dirty mining environments. Ruggedness means more than just durability – it means reliability, longevity, capacity, and power.
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FEATURE
BME has maintained supply security and technical assistance through these challenging times, while ensuring safety remains top of mind.
Mining in West Africa steams ahead despite pandemic
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BME to keep three months of stock on site, in line with customer’s expectations,” he said. A number of BME technical personnel have remained on mine sites around the region since the start of the lockdowns in the different countries. In some cases, these personnel have even been able to stand in for mine blasting staff, to ensure that blasting takes place safely.
ith some the world’s highest gold grades, the West African mining sector is generally producing well even under Covid-19 conditions – and are relying on explosives companies to maintain supply security and technical assistance through these challenging times. According to Michael Klaasen – General Manager of West African Operations at explosives and blasting global leader BME, a member of the Omnia group – the Covid-19 pandemic has had minimal effect on its mining clients’ production from a blasting perspective. “Most mine sites are locked down, with access limited to only certain essential deliveries,” said Klaasen. “Some mines were considering reducing production in the event of a shortage of raw materials, but BME has managed to keep clients blasting during this time with sufficient stocks, continued deliveries and dedicated personnel on sites.” Borders between countries have remained open to cargo, allowing
Michael Klaasen – General Manager of West African Operations
BME’s supplies to reach customer sites in Mauritania, Mali, Sierra Leone and Burkina Faso. Goods and raw materials are shipped into Nouakchott in Mauritania, into Dakar in Senegal and into Tema or Takoradi in Ghana. “Our cross-border channels have allowed
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He said BME has applied all the necessary Covid-19 measures required – in line with its own health and safety protocols as well as the customer’s policies and the national regulations for that country. “This generally includes the wearing of face masks, the use of sanitisers, regular temperature checks and ensuring social distancing,” he said. “Our emulsion trucks are also sanitised before entering mine sites to reduce the risk of transmitting the coronavirus.” In addition to supplying emulsion explosives and electronic detonation systems, BME has also assisted customers in West Africa with blast design using its BLASTMAP software.
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BME Managing Director Joe Keenan
BME has managed to keep clients blasting during this time with sufficient stocks, continued deliveries and dedicated personnel on sites.
“This has been done on-site where possible, as well as on-line when necessary,” said Klaasen. “During the Covid-19 lockdown, this on-line assistance has made a valuable contribution to keeping mine operations up and running.” Customers are able to send their blast-related data to the BME office in Bamako, Mali, where its technical managers assist mines with the planning of their blasts. “BLASTMAP allows the blast designs to be conducted anywhere in the world,” he said.
“It just requires the relevant information from the customer.” BME Managing Director Joe Keenan noted that the future will see considerable changes in how suppliers support their mining customers. “The leveraging of technological innovation to keep mine sites safe and efficient becomes an even more vital imperative for technology providers,” said Keenan. With Covid-19 restricting access to mines by senior BME management, contact with customers has been
maintained by regular cellular and internet communication with various tools such as WhatsApp, Microsoft Teams and Skype. Klaasen expected that business would proceed more or less as usual, provided there was no sudden increase in infections – either in the countries where BME is operating or in countries from which it sources raw materials. “It is important that borders remain open for cargo, as closures could impact the supply of stock to sites or to the regions where customers operate,” he said. “The three-month stock availability that we ensure for customers allows them to see through any temporary disruptions.”
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Alpeco is an ISO9001 Quality Assured company
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FEATURE
Flotation reagents in the mineral processing industry
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lotation is the most flexible and adaptable mineral beneficiation technique. Mineral separation by flotation works on physicochemical surface properties of valuable and unwanted gangue minerals. It is being continuously modified for low-grade complex sulfide ores like lead-zinc, leadzinc-copper, nickel-platinum-gold, tin, fluorite, phosphate, fine coal and iron ore at a lower cost with better recovery. The processes are known as froth and column flotation. Froth flotation Froth flotation process produces froth of selective mineral agglomerates and separates them from other associated metallic components and gangue minerals. The physicochemical surface properties of optimum fine size fraction make some specific minerals hydrophobic. The particles turn into water repellent by coming in contact with moving air bubbles in the presence
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of certain reagents. The forth portion moves up leaving other metallic minerals and gangue (tailing) below, stabilizes for a while and collects as concentrate for further cleaning. The mineralized concentrate stabilizes for a while at the top of the cell, overflows and moves to cleaner, filter and dryer in sequence to form mature salable product. The concentrate is the raw material for extracting metals by smelting and electro and chemical refining. There are three main types of reagents used in flotation, namely, collectors, frothers and regulators. Each individual set of reagents plays a specific role in mineral processing. Collectors, also known as “promoters�, are organic compounds which make the surface of certain selected minerals water repellent. These reagents are added to the pulp in the conditioner tank and ball mill. The mineral surface
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absorbs the collectors during conditioning period making them hydrophobic. Froth is formed when they come in contact with flowing air bubbles and float to the surface. Sodium Isopropyl Xanthate and Potassium Amyl Xanthate are the commonly used collectors. Frothers are surface-active chemicals that concentrate at the air-water interface. It prevents air bubbles from coalescing or bursting by lowering the surface tension of the slurry. Frothing properties can be persistent or nonpersistent depending on the desired stability of the froth. Pine oil and alcohols such as MIBC are most commonly used frothers. Regulators or “modifiers� are used to modify the action of the collector by intensifying or reducing water-repellent effect of mineral surface conditions. This is done to assist in the selective flotation of minerals. Regulators can be classed as activators, depressants, or pH modifiers. Regulators may activate poorly floating minerals such as sphalerite by adding readily soluble copper sulfate. Similarly, regulators can depress certain minerals rendering it hydrophilic and preventing their flotation. Minerals like pyrite and arsenopyrite can be depressed by adding sodium cyanide or lime, so that a differential flotation can be performed on a complex ore. Nigrosene reagent is used for maximum depression or elimination of graphitic carbon from zinclead sulfides in graphitic host rock. Separation carbon aids high-quality and lead Chemicals
of graphitic in producing clean zinc concentrates. that change
the pH of the slurry are also used as modifiers. An alkaline condition of medium is preferable in the flotation process where most of the collectors are stable. Alkaline environment minimizes the damage done by corrosion of cells and pipelines. pH modifiers include lime, soda ash and sulfuric acid. It can act as activators and/or depressants by controlling the alkalinity and acidity of the slurry. Modifiers can also counteract interfering effects from the detrimental slimes, colloids, and soluble salts that can absorb and thereby reduce the effectiveness of flotation reagents. The design of mineral processing circuit requires integration and assembly of various unit operations. It starts from crushinggrinding-flotation with generation of valuable concentrates and rejection of tailing in continuous process. It is desirable to conduct laboratory, bench and pilot plant scale test works at the appropriate stages of exploration and mine development activities. It is done before adopting a commercial plant flow diagram of complex mineral assemblages. The representative sample is obtained by compositing duplicate mineralized core covering the characteristics of entire deposit and bulk sample collected from initial mine development. The grind size, concentrate grades and other quality, recovery of valuable minerals, type of reagents and cost parameters are optimized.
First Mining DRC-Zambia 91x135mm FAp.indd 1
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10/09/2020 16:51
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FEATURE
Productivity up by 17%, noise levels down by 75% - Atlas Copco Surface Rock Drills rock!
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Atlas Copco’s new Surface Rock Drills, the SRD range, is everything you want from a tool – reliability, efficiency, minimum maintenance, rapid service and low operating costs,” says Atlas Copco Power Technique’s Business Line Manager for Portable Products, David Stanford. Owing to an ergonomic design, these powerful pneumatic rock drills are light-weight, versatile and easy-tohandle, getting the job done seamlessly, productively and safely. Engineered to perform optimally even under the toughest of working environments, these robust tools are ideal for drilling and breaking applications in construction and quarrying. Fitted with eco-friendly power packs, several drills can be conveniently and cost-effectively operated with a single compressor. Thanks to the smart Solid / Single Body design, the pneumatic tools which are available in 20kg and 25kg versions, boast a world-class power-to-weight ratio making them well-balanced for easy, comfortable operation. The solid housing eliminates leakages and increases cylinder lifecycle while fewer moving parts means less wear. In addition, these one-piece machines are easy to assemble and disassemble, facilitating service and maximising up time.
by opening the flashing valve to allow an additional flow of compressed air through a pathway in the cylinder to flush the drill hole while operating. “This technology can improve productivity by up to 17%!” notes Stanford. Stanford draws attention to Atlas Copco’s a zero-compromise approach when it comes to operator safety and comfort, stressing that Atlas Copco places operators at the core of its tool design. The two-step SOFTSTART™ trigger gives operators full control enabling them to start a cut with surgical precision even under difficult conditions. In addition, these tools are HAPS™ (Hand and Arm Protection Systems) enabled which lessens the impact of vibrations, making it possible to extend working hours up to six-fold. In order to further shrink vibration and wear, the tool’s piston switches on aircushions on both ends of the cylinder,
The SRDs are equipped with Assisted Flushing Technology which is activated
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almost fully eliminating metal-to-metal contact when working off-load. The vibration level of the SRD 25 is 50% lower compared to previous generation tools. Atlas Copco has developed a pneumatic dust collector to protect operators from the large amounts of silica dust produced during drilling and breaking. Powered by compressed air and utilising vacuum technology, the dust collector efficiently removes dust directly at the source, maintaining levels below the permissible exposure limit. The semi-automatic filter cleaning mechanism requires minimal maintenance, the dust collector consumes no more than 12 litres of air per second and its recyclable collection bags will last for an 8-hour shift. The unit is suitable for indoor and outdoor use. High noise levels can affect an operator’s hearing and lead to fatigue. Atlas Copco has developed an improved wear-resistant polyurethane silencer that diminishes the noise levels of the SRDs by up to 75%. “This equates to a 2dB reduction in noise which makes a substantial difference, especially when several drills are operating simultaneously.” Atlas Copco supports the SRD handheld pneumatic tool range with a professional after-sales service portfolio that includes high-quality Air Line accessories such as air hoses, hose nipples, couplings, water separators and Air Oil lubricants.
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COVER STORY
Real-time fleet and mine management systems in mining
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onitoring the company’s activity in real-time has many assets and advantages not to be ignored. This instant management allows us to visualize and know the real situation of the company as well as to monitor its objectives, key figures and performance indicators; it facilitates decisionmaking, manages its daily life more effectively and improves its reactivity and competitiveness. Regardless of the structure size, any good manager must be equipped with the appropriate resources to manage his activity effectively. This means that the positioning of carried out actions and committed budgets should be monitored, for both, quantitative and qualitative objectives. The Fleet Management System (FMS) is a term used to refer to a wide range of solutions for different fleet applications in the fields of transport, distribution and logistics. It includes targeted planning, supervision and control of fleet operation ac-cording to available transport
resources and application constraints. The FMS aims to reduce risks, increase service quality and improve a fleet’s operational efficiency while minimizing costs. FMS is easy to control and optimize, its foundations date back to the 1980s when the computer was integrated with the vehicle and connected to different wireless networks by satellite and terrestrial. In the mining sector, the main objective of the fleet management system is to optimize mine production and efficiency based on real-time data. More specifically, the FMS aims to maximize mine production, minimize stock handling, feed the processing plant at the planned rate and meet quality mixing constraints. The implementation of operational research techniques as the main means of addressing the high cost of transporting equipment to mines has attracted researchers and laid the foundation for
FMS used in different types of mining. They considered the FMS as a real-time decision-making system for materials handling in mining. FMS obtains the required information about mining operations from the database and makes decisions accordingly. These decisions are then implemented in the operation and the FMS is recalled whenever a new decision is required. Commonly, the primary objective of the mine fleet management system is to optimise mine production and efficiency based on real-time data. More specifically, the fleet management system intends to maximise mine production, minimise stockpile rehandle, feed the processing plant at the targeted rate and meet the grade blending constraints. The common approach is a multistage optimisation, where the solution of each step is used in the next step and where the problem is divided into
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COVER STORY
target. The truck assignment problem in mining operation has been dealt with most as an assignment problem or sometimes as a transportation problem. This programming algorithm assigns the trucks to a proper destination by the time the truck asks for a destination at an assignment beacon in a way that minimises the deviation from the production target.
three sub-problems: (1) shortest path model, (2) truck-and-shovel allocation optimisation – upper stage and (3) realtime truck assignment optimisation – dispatching – lower stage. The best path model determines the shortest route for travelling between every pair of locations in the mine. The truck-and-shovel allocation optimisation allocates haulage resources to excavating activities based
on truck-dependent loading rates and maximisation of overall truck productivity. A static scheduling algorithm is implemented to determine the optimal configuration of loaders over the mining faces as well as optimum production rates for each route connecting loading points to dumping points and allocation of truck resources to meet production
Congratulations to our customers for
OPTIMISING
The fleet management system mainly works based on two different set-ups: (1) fixed truck allocation and (2) flexible truck allocation. In fixed truck allocation, at the beginning of each shift, a group of trucks is locked to each transportation route. The trucks allocated to the paths are to work on the same path over the shift period based on several criteria, such as production requirement, availability of the trucks in the fleet, etc. The paths to which trucks have been allocated will not change until a shovel breaks down or a critical event happens.
TRILLION TONNES of HAULAGE over the last 40 years
Leveraging Data and Innovation to Optimise the Mining Value Chain in Real Time
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FEATURE
East Mining Company and Zyfra presented a digitalization project at Solntsevsky coal strip mine
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he East Mining Company (EMCO), one of major Russian exporters of brown coal, in cooperation with Zyfra, Finnish-Russian industrial digitalization leader, held a webinar on digitalization in the coal mining industry. The event addressed the current trends in the development of digital technologies in the coal industry, as well as the data culture, i.e. introduction of the data-based corporate culture. The key point of the webinar was the presentation of the project to implement and customize the Zyfra OpenMine Fleet Management System (FMS) at the Solntsevsky coal strip mine in Sakhalin, the largest island of the Russia, situated in the North Pacific Ocean. The East Mining Company was represented by Stanislav Ploshchenko, Deputy CEO for Business Efficiency, Ruslan Karimov Deputy CEO for IT and Digital Transformation, and Evgeny Grabar, Project Manager for ERP System Implementation. The EMCO specialists presented the first results of the Zyfra Open Mine FMS customization for the needs of the Solntsevsky coal strip mine. The system was put into commercial operation at the mine in December 2019. Almost 9 months of work resulted in a one-time
increase of dump truck load by 10%. With the installation of on-board sensors, it is now possible to control violations of the security zones. Introduction of a modern fast fuelling system for mining haulage equipment helped to reduce fuelling time per unit by 2.5 times and increase the equipment performance. “The main challenges we faced in implementing the system were the size of the company and a large fleet of equipment with almost 150 units inside the mine and about 120 units outside used to deliver the coal from the strip mine to the company’s port facilities of Shakhtersk. So far, all operation modes and procedures have been recorded and most of them are already automated. The next step will be to commission the latest version of the system, which will help to minimize the equipment downtime inside the open-pit and eliminate the lost time of backshovels. We also plan to introduce process KPIs for the dispatchers and operators of the equipment,” commented Stanislav Ploshchenko, EMCO’s Deputy CEO for Business Efficiency. “Efficient operation of modern coal mining companies is impossible without a well-developed transport complex. For this reason, considerable attention is paid to improving equipment productivity,
ensuring savings in all types of material resources, optimising vehicle loads and streamlining the coal grades. These challenges cannot be solved without using modern digital technologies,” noted Pavel Rastopshin, Managing Director at Zyfra. About East Mining Company East Mining Company is the major producer of thermal coal in Sakhalin region, Russia. The company is a among major Russian exporters of brown coal to the countries of Asia-Pacific region. EMCO controls the full cycle from the extraction to the shipment of the products. The Sakhalin coal reserves have more than 300 million tons, and a prospected reserve in Magadan region of more than 100 million tons. About Zyfra Zyfra Mining (formerly – VIST), a mining division of Zyfra Group, Finnish-Russian industrial digitalization leader, has been successful in the mining industry for 30+ years with 80+ mines using the company’s products. The main solutions developed by Zyfra Mining include mine fleet management system, which collects and manages real-time information from mining equipment, autonomous mining dump trucks and drill rigs.
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ADVERTORIAL ADVERTORIAL
Komatsu 730E Haul Truck, photo courtesy of Komatsu
Modular Mining helps iron ore operation increase revenue through payload optimization Introduction Modular Mining introduced its nextlevel support offering, the Performance Assurance (PA) program, to ensure each customer receives maximum sustained value over the life of their Modular Mining technologies. With each PA engagement, a dedicated team of experts collaborates with a cross section of mine personnel to develop tailored, flexible, and proactive solutions to address each operation’s specific challenges. Participating mines have seen numerous benefits, including enhanced truck productivity, shorter queue times, reduced equipment maintenance costs, and more.
payload instances were attributable to the absence of data being sent from the trucks’ onboard payload systems to the DISPATCH® Fleet Management System (FMS). In addition, a significant number of loads under 135t were being registered in the DISPATCH System; a value far less than the planned payload capacity of 190t. As a result, the same hauling effort
How the DISPATCH Payload Optimization solution works The DISPATCH Payload Optimization solution presents loading equipment operators with target payload information. The information conveyed is based on Komatsu PLM IV-OLS data (if present) or a pre-configured target payload that factors truck carryback into its calculations.
consistently yielded fewer-than-expected payload tonnes, per truck, upon arrival at the tipping point. Resolution The PA, ICS, and Mine Operations teams, along with support from Komatsu, collaboratively analyzed and evaluated the payload distribution inconsistencies, which led to the joint decision to implement Modular Mining’s DISPATCH Payload Optimization solution in conjunction with Komatsu’s Payload Meter IV® and Optimized Loading Software (PLM IVOLS) solution.
In addition, for each production record, the target payload, carryback, and measured payload values, are recorded, which further improves the payload data analysis.
Working together, the teams performed the following actions: • Reviewed the health and configuration of the Komatsu PLM IV payload sensors on all applicable trucks, and made repairs or adjustments, as needed • Updated the original equipment manufacturer (OEM) auxiliary software driver version to enable carryback polling functionality • Implemented the PLM IV-OLS solution on the Komatsu 730E trucks and the DISPATCH Payload Optimization solution on the mixedmanufacturer shovels running the Modular Mining ProVision® Shovel System
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Challenge In accordance with a high-level performance improvement initiative, the mine sought to maximize equipment effectiveness and increase the rate of material moved, without expanding the existing fleet. As part of the corporate program, the mine’s Integrated Control Systems (ICS) team identified that the payload size distribution of the fleet’s Komatsu 730E trucks exhibited an unacceptably high zero-payload count, per day. It was further determined that the zero-
Once the truck is stopped and loading, the truck sends the PLM IV-OLS target payload to the DISPATCH FMS for display on the shovel system.
Figure 1. Komatsu 730E TKPH before PA (Jan - Jun 2020) vs. after PA (Jul - Aug 2020) Data Source: DISPATCH FMS
•
Reviewed, updated, and configured the PLM IV-OLS Sprung Weight and Frame Torque parameters to calibrate the trucks’ suspension and control the effects of the empty vehicle weight on payload values
Results As a direct effect of the implemented solution, the site realized the following measurable improvements:
•
The TKPH (Tonnes x Kilometres / Hour) value for Komatsu 730E trucks improved by almost 19%, increasing from 1888t to 2240t, as shown in Figure 1 above:
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Zero-payload counts reduced by 88%, down from 392 instances to 47* instances, per day, as shown in Figure 2 below:
Summary Through the collaborative teamwork of Modular Mining PA, mine personnel, and Komatsu, the site’s payload accuracy increased dramatically – a significant step toward meeting the continuous improvement goals defined at the corporate level. Also, with the near-19% TKPH gained through payload optimization, the mine anticipates an equivalent revenue uplift of nearly $50 million (USD), per annum.
About Modular Mining Founded in 1979, Modular Mining is the market-leading provider of powerful information management solutions for surface and underground mining operations, addressing the key areas of production, machine guidance, equipment health, and operator safety. Employing over 800 employees in 10 globallydistributed offices, Modular Mining has successfully deployed its solutions at more than 270 sites, worldwide. For more information, visit: http://www.modularmining.com/
Figure 2. Comparison of Zero Payload before PA (Jan - Jun 2020) vs. after PA (Jul - Aug 2020) Data Source: DISPATCH FMS
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FEATURE
Driver fatigue monitoring systems for mining
O
perator fatigue is one of the most common causes of accidents in the mining industry today. In openpit mining alone, around 65% of truck haulage accidents are directly related to drivers feeling tired or exhausted, according to data released by Caterpillar Global Mining and Equipment. The sector is all too aware of these dangers and has long been looking for systems and solutions to manage the situation. Enter companies that supply technology that senses if a driver is distracted or falling asleep at the wheel. The Fatigue Monitoring System has been used across the automotive, transport and aviation industries for some time. Fatigue Monitoring System The solution features a unit the size of a laptop, which is placed on the dashboard of a mining vehicle and linked up to cameras which measure operator eyelid behaviour to determine the onset of fatigue and micro-sleeps.
In such instances, the device all supports G-Sensor for fall detection and a panic button. This is ideal for mine workers, drivers in an emergency, or loved ones. Whether your drivers are showing signs of fatigue or you need personal tracking for another reason, you’ll feel safe knowing there is always an extra eye on them while they are working hard.
Using personal monitoring systems for your business and employees puts the responsibility in their hands and yours. That shared understanding of safety will pay off when there is a decrease in accidents, problems, or emergencies due to human error or fatigue. In some packages, wearable tracking devices are available that can receive calls and dialup to three preset phone numbers.
This enables warnings to be given through seat vibrations, or an alarm that alerts site management for direct intervention. By tracking eye and head movements, mining firms can build health profiles on each driver it employs and suggests lifestyle changes, based on these profiles, such as sleeping more, eating well and drinking less alcohol.
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Typical Fleet Management programs utilise many hardware and software applications to help minimise their onroad risk exposure, but unless all of these tools are applied in a coordinated manner, the results will remain less than optimal. DriveRisk is a solutions company offering fleet owners and operators an extensive range of technically advanced products, dedicated human back-up teams and the most sophisticated predictive analytics to enable them to develop strategies to mitigate their on-road risk, protect their capital and human investment and improve their bottom line. And no other company in Africa can do this for you like DriveRisk can – seamlessly, automatically, turning recorded data into easy-to-implement actions needed to reduce fleet risks and operating costs.
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FEATURE
Improving Borehole Survey Accuracy in Mining Exploration The importance of using the correct gyro survey tools and quality controls for borehole trajectory accuracy in mining exploration projects
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oday, when it comes to the exploration of mineral and raw materials in the mining industry, the measurement of the trajectory during drilling – both in the exploration phase and in production – is a key factor that those responsible for the geology, drilling, and planning departments must take into account. Even a slight error in the planning phase can result in the deviation of the well (or borehole), missing the final target body. Many companies and investors fund mineral deposit exploration projects that initially seem very promising. However, as they advance, the results do not always coincide with what was expected. One of the most common causes of this occurrence is the well trajectory missing the target during drilling the borehole. Likewise, the use of incorrect gyro survey technologies, combined with the lack of a robust quality control process used in the selection and operation of these tools, can also result in the well trajectory being off-target. Further, the use of standard data synchronization programs in conventional systems often starts from the final data. In comparison, the technology implemented by Stockholm Precision tools (SPT AB) is based around a rigorous calibration control process for each tool, in addition to measurement checks that compare the In-Run & Out-Run data, which is then automatically processed by the SPT software. Stockholm Precision Tools is the only company in this field of exploration drilling, whose tools are equipped with this intensive quality control process, with the objective of protecting the client’s investment. When it comes to mining exploration, investors seek to obtain the best possible results from their mining projects, whether the target ore is present at
more expensive: renting high-precision true north seeking gyros, such as SPT GyroMaster ™ and Core Retriever™ (Fig. 1 and 2), or the incorrect evaluation of mineral reserves due to the use of a low cost and unreliable gyro survey tool? gyromaster solid state north seeking gyro instrument
Figure 1. GyroMaster™
the said location, or not. This provides them with the required returns to the capital they have invested for the mining project. Unfortunately, this is not always the case. All too frequently, exploration projects overlook the importance of a Quality Assurance, Quality Control (QA/QC) Program for the positional survey data from the start. This is important because the data obtained from the geospatial location and the core sample in its exact origin are key to determine the existence or not, of the target mineral, on which the economic viability of the project heavily depends upon. Advantages of using the correct gyro survey tool An important factor that can affect the quality of a recovered core body sample is the wrong choice of the gyro survey tool, which is often chosen solely based on its price. A detailed analysis is needed around the question: What is
Figure 2. Core Retriever™
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SPT GyroMaster™: High accuracy True North Seeking Gyro Survey Tool What is a Gyroscope? The gyroscope is defined as an object that is in rotation, with two fundamental properties: gyroscopic inertia or “stiffness in space” and precession, which is the inclination of the axis at right angles to any force that tends to change the plane of rotation. These properties are inherent in all rotating bodies, including Earth. Gyroscopic inertia and the force of gravity can be used to make the gyroscope function as a directional indicator or compass. If you consider a gyroscope mounted on the Earth’s equator, with its axis of rotation located in the east-west plane, the gyroscope will continue to point in that direction as the Earth rotates from west to east. Thus, the eastern end will ascend relative to Earth, although it will continue to point in the same direction in space. This resistance or compensation in force makes an opposing movement around the vertical axis, towards the meridian, so that the axis of the gyroscope always points to the true meridian (or to the true north). Due to its operation being based on the rotational force of the Earth and not on magnetism, the GyroMaster™ has multiple applications and its use is increasingly widespread in geology and major mining exploration projects.
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The most important thing is to know how accurate the gyro survey tool that is being used in a project is. (Read more about fundamental principles of a gyroscope here) The wrongly named Gyroscope Reference Gyroscope vs True North Gyroscope. If we take a glance at different measuring equipment that uses gyroscope technology, different classifications such as the True North Gyroscope and the Reference Gyroscope can be seen. The reference gyroscope lacks an accurate sensor that measures Earth’s angular velocity projection; therefore, it is unable to find true north, which means it cannot find the azimuth. Before anything can be done, the collar azimuth needs to be introduced manually. It is not a gyroscope itself, but a reference or indirect measurement gyroscope (Inclinometer) and, of course, it is not a true gyroscope. The inclinometer, as its name implies, is a tool that determines the inclination of a well and does not measure direction directly, but rather takes it from an external point and its data depends on the human factor, which causes the accumulation of errors as you go deeper into the well. It is important to note that the measurement of a tool is not only the inclination but is also the direction (azimuth). Since reference gyros lack the technology and sensors necessary to search for true north and establish azimuth, they do not have the capability to measure vertical wells/boreholes. You can find more information about the difference between a reference gyro, true north seeking gyro, and magnetic survey tool here. Reference gyros are unable to measure vertical boreholes/wells SPT GyroMaster™ is a true north seeking gyro survey tool, that can measure even with angles of +/- 90º. Its operation and accuracy have been proven in extreme conditions. In exploration wells that are in close proximity to each other or in complex reservoirs where precision is an essential requirement, the GyroMaster™ has been the key to the success of the project. Risks of using Reference Gyro Survey
Figure 3. Accuracy of the GyroMaster™, comparing with other tools in the market
Tools in Mining Exploration The use of reference gyro survey tools in extremely important mining projects carries serious risks because their operation depends on human input. If the tool is supplied with the wrong starting data, the geology department risks falsely believing that they have found a low mineral reserve. It is the same case with other gyro survey tools that are true north seeking gyros but are not capable of repeating the measurement data during the descent to the well and the subsequent rise. That is why we have classified them as true north gyroscopes, but with low precision. The use of reference gyro survey tools in mining exploration is as inaccurate as the use of low precision north finders. Low precision gyros are very similar to the reference survey tools. Many times, they even obtain the initial reference point through a magnetic compass. Furthermore, because their method of operation is a single shot, they do not have the ability to measure continuously, these tools tend to accumulate errors between each measurement interval. Evaluation of mineral reserves depends on the measurement of the trajectory Stockholm Precision Tools (SPT ) is proud to have specialized in the development and manufacturing of highprecision gyro technology for more than 20 years such as the GyroMaster™ for the mining sector; the GyroTracer™,
for oil and gas; and, most recently, the Core Retriever™, which is capable of simultaneously taking measurements and recovering cores. The precision data of Stockholm Precision tools in inclination is 0.05º, unlike the value offered by other manufacturers whose equipment works with a calibration that allows an error of 0.3º, which results in the constant inaccuracy of the spatial position of the well. If we add the real deviation to this, the magnitude of the error can be 6 to 10 meters, depending on the depth and inclination of the well: the greater the inclination, the greater the projection, and therefore, the geology department will obtain incorrect data. The main driver for writing this article is to highlight the importance of using the correct gyro technology together with a rigorous quality control process during the operation to avoid the many errors we have seen in the industry for calculating reserves that have arisen as a result of using low-quality tools with no quality control process. Let us take, for example, an ore body which is 5 meters wide with a dip of about 45º and a depth of 1000 meters. If we use a tool whose specifications contemplate a margin of error of 0.3º in the inclination and several degrees in the azimuth, the possibilities of erroneous calculations on the dimensions of the mining body will be high. Therefore, the probability of underreporting the presence of minerals will
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FEATURE
be high too and the subsequent effect on the mining company’s investments could be negatively affected. The following table (Fig. 3) gathers the data and technical specifications of different tools, taken from the websites of their respective manufacturers. Here the error in the final coordinates is evident. Drill trajectory measurement with the use of the GyroMaster ™ true north seeking reduces this error to a minimum; showing, with real data, that Stockholm Precision Tools is the leader in quality control of trajectory measurement. Quality Control in Mineral Exploration In addition to the risks that we have already mentioned with the use of a lowprecision north-seeking gyroscope or a reference gyroscope, there is another concerning factor. This is that those who decide to use these tools in their projects do not always have the mechanism or technology to verify that the value of 0.3º of precision in the inclination, coincides with the reality of the measurement. Many times, it tends to be higher, not to mention the obscure azimuth or direction accuracies stated. When it comes to quality control and quality assurance in using gyro technology for mining exploration projects, Stockholm Precision Tools (SPT AB) has implemented a rigorous model, (see Fig. 4) of controlled checks and audits, making it one of the few companies who have developed and implemented a Quality Assurance and Quality Control (QA/QC) process. This process can be seen in both borehole trajectory measurement and measurement during core recovery in B, N, H, P holes. Understanding the risk for investors of often having millions of dollars invested in mining projects and the devastating effect that this environment of errors caused by the lack of information can have, we are continually ensuring the quality control of our tools and process. Proof of this is also our Gyro RigAligner™, a compact and lightweight tool that looks for True North, and aligns the rig platform in less than 5 minutes. It is also the only 3-axis aligner that works in all directions (vertical, horizontal, and inclined).
Fig. 4. Quality Control Process implemented by Stockholm Precision Tools (SPT AB)
Ways to Check the Accuracy of a North Seeking Gyro Survey Tool There are several methods to check the accuracy of a true north gyroscope or north-seeking gyro, the most effective being the measurement in a deep well (about 1000 meters approximately) and the subsequent comparison between the values of the In-Run & Out-Run. In addition, the initial data is verified by the topography department. Another way to check the precision of a tool is to have a calibration stand, such as the Universal Calibration Stand CF.02 (Fig. 5), designed to work with SPT tools. In other cases, the manufacturer should be required to show the ability to measure vertically, i.e. -89 degrees in continuous mode, and to demonstrate that both down and up values must not exceed 0.15% in the coordinate NS / EW.
Finally, the tool should be tested under harsh environmental conditions. If that opportunity does not exist, it can appeal to the topography department to use the calibration stand to calibrate the gyro tool. The main problem we have detected in our analysis is the lack of a reliable quality control standard for well trajectory measuring technologies globally and that the client is often guided by published specifications, by the ease of use, low prices, or by other factors unrelated to the precision of the tool. Consequently, this can lead to erroneous decision making and financial losses for investors, which could have been easily avoided.
Let’s explain this in more detail: before selecting the gyroscope to be implemented in a project, In-Run & Out-Run measurements must be made to verify that the azimuth and inclination data are repeated according to the specifications declared by the manufacturer. Both measurements must be evaluated, and the data must be the same. It is the best way to check the quality of the tool, moreover, these measurements should be made in different inclinations and directions.
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Fig. 5. SPT Calibration Stand
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Mining - Geotechnical Sale - Rental
DeviGyro
Continuous High Speed Non-Magnetic Survey The DeviGyro is a driller operated survey instrument supporting high speed continuous surveying, overshot mode and even core orientation. With its revolutionary small size and proprietary algorithms the DeviGyro is the perfect choice for all survey applications where efficiency and accuracy are required, independent of hole direction, inclination and location. Surveys can be completed in continuous mode at speeds up to 100 m/min (successfully tested up to 185 m/min) or in multishot mode with short stops at set intervals. No matter the survey mode the data always passes through an automatic and instant go/no-go quality check ensuring the results are always of the highest quality.
Applications
Benefits
• Underground Diamond Drilling; Wireline, Pump down or conventional • Surface Diamond Drilling • Overshot mode • Pilot holes • Reverse Circulation (RC) • Blast & injection holes • Production holes • Geotechnical investigations • Core orientation
• • • • • • • • •
Continuous survey operation In-rod surveying – not affected by magnetics No angle restrictions Automatic and instant quality assurance Same high accuracy in any inclination, direction and location Extremely low weight & size and easy to handle Automatic multi-survey processing Highly robust and reliable Simple and intuitive software
devico.com
FEATURE
Investors, beware the preliminary assessment PEAs also tend to underestimate the costs and complexities of a project
P
reliminary economic assessments (PEAs) are no foundation for production decisions in mining projects, and serve little basis for detailed value-creation forecasts. “The dire state of the global economy may be prompting the considerable number of PEAs being published,” said Roger Dixon, corporate consultant at SRK Consulting. “Investors should be reminded that there is not much value in the detailed value projections that often accompany these assessments.”
“Setting out these indicators in exact dollars and cents tends to belie the many assumptions that must be made at this stage in a project,” he said.
Dixon noted that many PEAs include calculations on envisaged production levels, capital costs, operational costs and even net present values (NPVs) and internal rates of return (IRRs).
He acknowledged that stock exchange regulators do make special provision for PEAs, and that they do have a role in the project planning pipeline. Canada’s National Instrument 43-101, developed
“At best, it is a somewhat fruitless exercise to attach such exact numbers to a PEA – while at worst it could be highly misleading. There are just so many assumptions that are being made at this stage in a development, which have yet to be tested scientifically by technical studies.”
Roger Dixon, corporate consultant at SRK Consulting
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after the 1997 Bre-X scandal, recognises PEAs as one type of economic analysis of a mineral resource’s potential viability. “Regulators highlight, however, that PEAs have severe limitations,” he said. “For instance, they tend to be overly reliant on converting Inferred Resources to Indicated Resources; they may also be misleading if they treat Inferred Resources as Mineral Reserves.” Inferred Resources represent the lowest level of confidence in geological estimation. Reading media reports of mining project PEAs brings home this risk, he says, with some projects showing that a third or more of the mineralised material they employ in their models is in the Inferred Resource category. The NI 43-101 requires that a PEA that includes Inferred Resources in its modelling must have a qualifying statement to clarify that these are too speculative geologically to have economic considerations applied to them. “PEAs also tend to underestimate the costs and complexities of a project, and create expectations for indicators like NPV and IRR that may not be achieved in later studies – such as Prefeasibility and Feasibility studies,” said Dixon. “They also often use overly optimistic metal recoveries and metal price assumptions.” He warned that PEAs were not intended to be the basis for production or investment decisions, but rather to be stepping stones in a much longer and more focused scientific and engineering process. “The way that PEAs are reported in the media – where there is seldom space for all the necessary disclaimers – can also make a project appear more attractive than it should,” he said. “In reality, a PEA does little to demonstrate economic viability, and projects at this stage of development typically have a high risk of economic or technical failure.” He highlighted that there is a wide range of modifying factors – including increasingly important social and environmental impacts – that mining projects had to explore and mitigate before a mine’s viability could be fully assessed.
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et Point Laboratories, a division of Synerlytic Services (Pty) Ltd, an ISO17025:2017 accredited analytical chemistry lab, is best known for being a formidable partner in the mining and water industry. Set Point Labs provides analytical facilities to clients through an extensive network of operations in South African cities of Johannesburg and Cape Town and Namibia, Windhoek. With attentive, personal customer focus and a reputation for efficient turn-around times, making the Set Point brand unique to the industry.
analysis of effluent/wastewater, drinking water, processed water, surface water and groundwater. Servicing clients throughout Africa, Set Point aims to provide each client with a unique service to make their analysis efficient, reliable and cost-effective. In the aim to service clients throughout Africa, Set Point Laboratories assist clients in sourcing logistics solutions. Getting samples to the various laboratories as easily as possible.
As a new and changed world emerges from International Lockdown Measures after the announced Global COVID-19 Pandemic by the World Health Organization, Set Point laboratories have changed as well. In the aim to combat the COVID-19 pandemic we are all currently facing, Set Point Laboratories has introduced alcohol content testing at their facilities. Always, setting the bar high in both the minerals and water industry.
With the vision as an innovative, forwardthinking business that is lead through honesty, high principles and pride in every component of partnerships with clients. Set Point laboratories are operated by highly qualified and motivated staff, who deliver fully comprehensive and professional testing services. These include providing a wide variety of minerals analysis as well as full suite water analysis. Minerals analysis is conducted through X-Ray Fluorescence Spectroscopy, used to determine a range of light to heavy elements by fused disc or pressed-pellet. Borate fusions followed by XRF is most suited to certain ore types such as iron and manganese ores, phosphates, chromite, limestones and major silicates. The samples are fused using automated fusers and are analysed using XRF Spectrometers. Pressed-pellet provides a low-cost testing option, suitable for large sample volumes, examples of application include; Copper, Nickel, determination of Merensky, UG2 and Platreef mineralization of Bushveld Igneous Complex in South Africa, or analysis of uranium hosted by siliceous rocks. Water analysis is also conducted at Set Point Laboratories using various accredited techniques such as; Photometric, Electrometric, Colorimetric, Gravimetric, ICP-OES and ICP-MS and Enzyme Substrates. These techniques are used to obtain the best possible results in chemical and microbiological
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FEATURE
BME recently launched its Blasting Guide application for Android mobile devices
Blasting tech takes mines into the future B uilt on innovation since its inception over 3 decades ago, global explosives leader BME – a member of the JSE-listed Omnia Group – paves the way for mines to leverage the latest technologies for ever-greater efficiencies and productivity. “Harnessing technology as quickly as it develops – and applying it to make blasting safer and more productive – is vital to the mining sector’s sustainability,” said BME Managing Director Joe Keenan. “Mines are seeing the value in closer digital monitoring and control of all their systems and operations. Innovation is therefore an industry-wide imperative that is demanding closer collaboration – not only with mines but between technology suppliers themselves.” Over the years, BME’s success has been based on leveraging technology throughout its product range. This includes cold emulsion explosives – which it pioneered in the South African market – to mobile manufacturing and application equipment, digital initiation systems, consumables and cutting-edge software. Keenan noted that the company’s commitment to digital innovation has
enhanced its resilience during the Covid-19 lockdown – and ensured that customers have continued to be supplied and supported. This has allowed its customers to continue with their blast planning and execution with minimal disruption. BME’s powerful BLASTMAP™ software has facilitated remote blast planning where necessary, and assistance on this platform could continue to be provided to mines with restricted access. “Our systems were able to reduce the points of physical contact to reduce infection risks, including a digital solution that replaced the need for truck drivers to exchange paper documents with mine security staff to gain access to site,” he said. “There is a growing drive from mines to do more with less, so digital technology will continue to be an important tool in achieving increased efficiency.” This digitisation of the mining sector – along with the broader economy – has opened doors to the reskilling of staff into higher-value technology, according to Brian Moodley, BME’s Software Engineering Manager. “The fourth industrial revolution has seen BME generating leading technologies
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BME’s Software Engineering Manager Brian Moodley
with its strong development team, helping drive mine optimisation, data mining and data analytics,” said Moodley. “Our investment in research and development is an important part of the mining sector’s future success, combined with onboarding staff with the capability to meet this demand.” He highlighted that BME aimed to be creators – rather than just receivers – of innovation, so its R&D team was constantly raising the bar. This technology focus is on its internal organisation and systems, and on its products and service offering. “BME is already navigating towards a successful transformation, including a comprehensive organisational technology focused on the transformation of our people, culture and governance,” he said. “This proactive approach ensures we add value to customers’ operations while helping drive the benefits of the technology revolution across the sector.” Much of this progress towards the mine of the future will be achieved by more effective collection, storage and analysis of blast-related data, to feed the continuous improvement loop. To do this, BME integrates its blast design, blast recording and blast delivery systems. “Integration of blast data allows for easier interrogation of results, which guides the drilling and blasting process to produce consistent, quality blasts,” said BME’s Global Manager for Blasting Science, D. Scott Scovira. BME’s BLASTMAP™ specifies explosive
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hole loads and assigns hole firing times, which are downloaded into its AXXIS™ electronic blast initiation system using the AXXIS™ Logger for detonator programming. After the blast, data from the AXXIS™ Logger can be used to compare as-designed versus as-fired initiation information. The accuracy and reliability of the AXXIS™ system has also allowed everlarger blasts, allowing mines to conduct blasting less frequently. This holds major benefits for mine productivity by reducing the disruption caused by blast-related pit stoppages. Record-size blasts have been conducted with AXXIS™ in various mining countries including Australia, Zambia and South Africa.
BME Managing Director Joe Keenan
BME’s recent launch of its Blasting Guide application for Android mobile devices is another example of how the company is embracing the capability of digital technology. This app speeds up work in the field, replacing the traditional paper medium and allowing users to quickly calculate and check blast designs. The free Blasting Guide is available for download from the Google Play Store.
About BME BME, together with Protea Mining Chemicals forms the mining division within the Omnia Group, a JSE listed diversified provider of specialised chemical products and services used in the mining, agriculture and chemicals sectors. Formed in 1984 on the strength of a new cold emulsion technology that has since become an industry standard, BME now offers cuttingedge products and services at every stage in the explosives supply chain and is a leading global manufacturer and supplier of explosives, related accessories and blasting services to the mining, quarrying and construction industries. BME’s footprint covers 17 African counties including South Africa, Namibia, Botswana, Zimbabwe, Zambia, Swaziland, Angola, Malawi, Mozambique, DRC, Sierra Leone, Mali, Burkina Faso, Mauritania, Senegal and Eritrea. The company also has legal entities in Australia, Canada, Indonesia and the USA.
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FEATURE
Omnia solidifies its position as a pioneer in the mining sector Mining division delivers ground-breaking “world first in Africa” solution for purer metals extraction and initiates the largest detonator blast in South Africa BME also supplied other necessary equipment for the explosion, including boosters and surface wire. BME’s ground-breaking AXXIS™ electronic initiation system - which improves the safety, ease of use and accuracy of blasts – was a key contributor to this success. The latest iteration of the initiation system - AXXIS Titanium™ (designed to provide longer lead times, greater control and better data) - is currently undergoing final trials ahead of its market launch, which is planned for later this year.
Seelan Gobalsamy, CEO of Omnia Holdings (for emailing)length (for emailing)
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iversified chemicals group, Omnia Holdings (Omnia), is celebrating record-breaking achievements across Protea Mining Chemicals and BME, which together form the Group’s mining division. Protea Mining Chemicals Copper Production Solution Protea Mining Chemicals has become the first in its field - globally - to develop a solution that helps copper and cobalt mines reduce product contamination (improving metal purity levels) and maximise throughput in the solvent extraction process. This pioneering solution took six years to develop and was done so in partnership with chemicals manufacturers and copper and cobalt mining customers in the DRC. Finding safer, more efficient ways to extract valuable resources and enhance profitability continues to be a priority in the mining sector – which has been particularly constrained by the impacts of the Covid-19 pandemic. This discovery will extend the life of copper and cobalt mines and assist profitability. Protea Mining Chemicals is working closely with
other mines to replicate this success in other regions. “Over the past few decades, many unsuccessful attempts have been made by mining houses, global chemical manufacturers, as well as solvent extraction equipment and process engineers to address this issue of contamination. Needless to say, this has been a very challenging journey and we are delighted by what we have been able to achieve,” added Michael Smith, Managing Director at Protea Mining Chemicals. BME Electronic Detonator Blast Records Protea Mining Chemicals unmatched achievement comes hot on the heels of BME’s record-setting accomplishment. The division recently initiated the largest, single electronic detonator blast in South Africa using 3,780 detonators at a manganese mine near Hotazel in the Northern Cape. Powered by more than 461 tonnes of high-quality emulsion from BME’s Losberg plant in Gauteng, the explosion moved 890,000 tonnes of overburden (soil, rocks, etc.).
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“BME’s ongoing product development has positioned us well to consistently produce quality blasts that deliver on customer requirements. Our versatile and easy-to-use AXXIS™ system facilitates larger less frequent blasts, reducing the disruption caused by blastrelated pit stoppages and improving mine productivity,” said Joe Keenan, Managing Director of BME. BME’s record-setting streak included initiating the biggest, single blast in the world. The division used 7,401 electronic detonators in a large copper mine in Africa, breaking its own record – which was previously held for firing 7,350 detonators in a single blast at a large opencast coal mine in Queensland, Australia. “These are not only great achievements for Protea Mining Chemicals, BME and Omnia Group, but also unparalleled wins for the African continent. This worldfirst discovery and greatly advanced blasting technology are testament to the intellectual capital, innovation and solutions-focused thinking that enables Africans to effectively compete on a global stage. We are also very proud of how our customer-centric partnership philosophy and collaborative approaches continue to translate to compelling solutions,” said Seelan Gobalsamy, Omnia’s CEO.
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FEATURE
Tecknotrove brings VR training to Mines
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afety in the mining industry is a vital issue. Many workers are injured in mine-related accidents and some die every day. Inadequate or insufficient training is often cited as a root cause for many mining fatalities. However, hands-on training in direct working environment provides only limited real-life opportunities and often fails to make a significant impact within the tense working environment itself. Tecknotrove develops Virtual realitybased training programs that enables
trainees to practice in the realmine working conditions without the associated risks. The VR training prepares workers for entry into confined spaces. Trainees acquire all knowledge required to perform in confined spaces safely and efficiently. VR headset and controller immerse the learner quickly into the virtual environment and ensures engagement during training. The VR program allows the trainees to practice repeatedly with in a safe environment until they master the skill. Special
attention is given to gas measurement, personal protective equipment, and emergency procedures during training. Upon successful completion of program trainees are be able to • Assess a confined space for entry, • Prepare themselves for working in confined spaces • Safely use equipment and personal protective equipment, • Work confined space in accordance with procedures • Manage Emergency situations in confined spaces.
Cleaning up liquid spills at mines
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trict health and safety regulations in the mining industry mean that any liquid spills in workshop areas or elsewhere need to be cleaned quickly and effectively. This is where a completely natural, mineral product called Gunge Spunge® is playing a major role. Produced by South African manufacturer Pratley, Gunge Spunge® is the ideal product for cleaning up any liquid spills, including petrol, diesel, oil, sewage and other nuisance liquids. Sawdust and other flammable materials were traditionally used to clean up highly combustible hydrocarbons. This is not only ineffective but also potentially hazardous. In fact, many mines and municipal by-laws now prohibit their use. Gunge Spunge® offers the ideal solution in that it is extremely effective, non-flammable
Gunge Spunge® is the ideal product for cleaning up any liquid spills.
Pratley Marketing Director Eldon Kruger
and eco-friendly, explains Pratley Marketing Manager Eldon Kruger. Gunge Spunge® is processed from a specific mineral that is 100% naturally occurring and is completely non-toxic. Apart from its desiccating properties, whereby it absorbs moisture in confined areas prone to damp, it also has cation absorption properties, allowing it to absorb rather than mask odours. This ensures that odours are eliminated for good. Extensive testing by Pratley’s worldclass research and development team has proven the application of Gunge Spunge® in arduous operating environments such as mines. Gunge Spunge® is supplied in 12 kg bags, although special arrangements can be made for the larger quantities required by the mining industry in particular.
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FMDZ is a bi-monthly magazine for mining industry incorporating, exploration, oil, power, drilling and other large scale extraction, storage, transport, Market and utilisation of Africa’s Copper Belt wealth and resources. First Mining DRC-ZAMBIA is published 6 times per annum: Jan/Feb, Mar/Apr, May/Jun, Jul/Aug Sept/Oct and Nov/Dec.
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