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CONTENTS NEWS

PRODUCTS

EVENTS

Blanket joins elite gold miners league

Becker Mining’s steel arch roof support systems

Atlas Copco’s centrifugal dewatering pump solutions

PROFILE

FEATURE

iRing Releases Searchable Online Knowledge Base

Automated system for loading management

Upgrading of Tippler project for Saldanha Iron Ore

TEAM Editor Bertha M. bertham@fmdrc-zambia Sub-Editor Nita Karume Contributing Writer Oscar Nkala, Mfuneko Jack Lindani Mkhize Caroline Thomas Cover Image: Dy-Mark Global

COVER STORY: PG 19

Non-Flammable marking for mines Dy-Mark Global sees vast opportunities for mining companies in Africa to be had in switching from marking using traditional bucket and brush application to its flagship handheld nonflammable aerosol spraybased marking option.

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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 Art Director Augustine Ombwa Arobia Creative Consultancy austin@arobia.co.ke Published By Mailing Times Media

EDITOR’S COMMENT At the end of the tunnel?

“

The COVID-19 crisis has exposed the siloed nature of mining companies and highlighted the need for integrated operations. This is likely to accelerate the

adoption of digital technologies, artificial intelligence, and analytics in the mining industry. The evolution of technology, from advanced data analytics to artificial intelligence (AI), has always had the potential to transform the mining industry by realizing operational efficiency improvements, enhancing productivity, improving safety performance, empowering employees to do more meaningful work and allowing communities to be more prosperous.” This was published by Deloitte Insights around the end of last year’s quarter. We are now clocking 10 months since this article went up and I do not know about you, but the mining sector, especially in Africa, did take a hit. And with it began the rebuilding, The adaptation of different mining firms to the COVID-19 pandemic. Many changes were made, some sites were closed down for some time, but I dare say that this first quarter has been proof of just how resilient the African mining sector has become. From First Quantum Mining spending upwards of US $1.65Bn in goods and services in Zambia to the Africa Mining Indaba held on 2nd and 3rd February dubbed Resilience and growth: Adopting a new mindset for Africa’s mining industry; I would think it is safe to say that the mining sector is slowly regaining its momentum, and then some!

Nita Karume

Circulation/Sales info@fmdrc-zambia.com sales@fmdrc-zambia.com +27 11 044 8986

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

Blanket joins elite gold miners league

NYSE-listed resources outfit Caledonia Mining Corporation Plc got a major boost last week after it was admitted into the MVIS Global Junior Gold Miners (GDXJ) Index for the first time. The admission, which became effective on Friday, followed the GDXJ Index’s first quarter 2021 review, according to a statement released by the firm whose flagship operation is the Gwanda-based Blanket Mine. “The GDXJ Index forms the basis of various passive gold sector investment funds in the North American market, the most significant being the US$5,2 billion Van Eck Vectors Junior Gold Miners ETF,” Caledonia said. Caledonia chief executive Steve Curtis said the listing of the company’s shares in America had increased the miner’s liquidity significantly and its inclusion on the index should “further raise its profile among retail and institutional investors”. “The listing of our shares on the NYSE American has increased our liquidity significantly and our inclusion on the index should further raise our profile

among retail and institutional investors,” he said. NYSE American, formerly known as the American Stock Exchange and more recently as NYSE MKT, is an American stock exchange situated in New York City. It was previously a mutual organisation that was owned by members. Until 1953, it was known as the New York Curb Exchange. “The addition of Caledonia to the index will be an important milestone for our business and will come at an exciting time for the company with the commissioning of central shaft due to be completed in the first quarter of this year,” Curtis added.

The development comes as Caledonia is in the market for gold brownfields in Zimbabwe. Early October, Caledonia signed a memorandum of understanding with the government of Zimbabwe for boosting investments, including possible takeover of State mining assets. Previously, the company had indicated that it was eying a number of brownfield gold mines in the country, but faced challenges in concluding deals. The company recently secured exclusive rights to explore and acquire mining claims in the gold-rich Connemara North area in the Gweru mining district, as well as at Glen Hume in the same district where airborne geophysics have indicated attractive exploration targets. Currently, the company projects a maximum of 67 000 ounces in production at Blanket Mine at the end of 2021. The shaft, to be commissioned by the end of this quarter, has capacity to produce 80 000 ounces of gold a year.

BeMetals Corp enters joint exploration agreement with JOGMEC over Zambia’s Pangeni Project

eMetals Corp. has entered into a Joint Exploration and Option Agreement with Japan Oil, Gas and Metals National Corporation (“JOGMEC”) that provides an initial investment of US$1.5 million for moneyin-the-ground exploration at the Pangeni Copper Project in Zambia. According to a press statement from BeMetals, JOGMEC will initially invest US$1m into copper exploration at the Project by March 31, 2021, by way of a cash payment to the former for exploration activities completed in the 2020 field program and a further US$0.5m by December 31, 2021 with additional pro-rata funding required for future exploration programs to earn and maintain its interest in the Project. Upon completion of the above investment,

JOGMEC will have earned 27.8% interest of BeMetals’ option of up to 72% interest in the Property, which interest is to be maintained through ongoing 27.8% pro-rata funding of the Project’s future exploration expenditures. This 27.8% interest in BeMetals’ option equals approximately a net 20% stake in the overall Project with BeMetals retaining rights to approximately 52% of the overall Project. In addition provided that JOGMEC maintains certain interest in the Project until December 31, 2024, it shall be entitled to both a right of first offer and a right of first refusal for up to 50% of any mine production from the Property (See sections below for further agreement description and details). The Company

is now designing an accelerated and expanded 2021 exploration program including further aircore and diamond drilling at existing prospects where copper mineralization has been discovered during its previous drilling programs and to test other priority exploration targets. BeMetals President and CEO, John Wilton stated that the joint exploration investment from JOGMEC will enhance an already robust Project team with additional funding and technical expertise. He further emphasized that it will support the company’s soon to commence, 2021 field work for their largest single season work plan to follow up on the encouraging results to date and the testing of other high priority copper targets.

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NEWS

Elevated cobalt prices to persist in 2021 with battery demand

attery metals have risen to the forefront of attention in 2021, as major economies continue to embark on green recoveries from the Covid-19 pandemic. Cobalt, in both its metallurgical and chemical forms play an important role in this increasing transition to greener energy infrastructure and transportation methods. Prices for cobalt remained resilient throughout the uncertainty of 2020, and have trended significantly higher in 2021, with LME cobalt spot prices breaching US $50,000/tonne in February 2021 up from US $32,209/tonne in December 2020, according to media reports. Cobalt demand is driven primarily by batteries, with super alloys in a distant second, Fitch points out. Increased battery demand for autos manufacturing will be accompanied by strengthened demand for cobalt to produce lithium-ion batteries for renewable energy storage and 5G-compatible technology.

Battery storage for renewable energy will be supported by capacity expansions in both solar and wind power, with Fitch’s power analysts forecasting respective global capacities of 807GW and 793GW in 2021. This represents an increase of 43.4% in wind power and 60.4% in solar power capacity since 2018. On the supply-side, continued growth in the DRC’s cobalt mining sector will struggle to keep pace with increasing consumption in the coming quarters, Fitch notes. The DRC will continue to dominate mined cobalt production, accounting for approximately 68.0% of mined cobalt in 2020 even amid the covid-19 pandemic. In 2021, Fitch forecasts cobalt production in the DRC to witness healthy growth of 12.0% y-o-y, aided by ramp-ups and a resumption of work on Chemaf’s Mutoshi processing plant. Supply will also benefit from the increasing formalisation of the

artisanal cobalt mining sector, but the continued closure of Glencore’s idled Mutanda mine through 2021 will limit gains, Fitch says. Increasing technological advances pioneering cobalt-free batteries will pose a large threat to cobalt demand and thus prices in the long-term, Fitch says, adding that it expects cobalt to remain a staple in lithium-ion batteries for the next few years, and then increasing charging infrastructure and low-cost efficiency will cause lower-range, cobaltfree alternatives to become the battery of choice.

Galileo Resources sign agreement to sell Star Zinc to Zambia’s Siege Mining

in the expanding outskirts of Lusaka in Zambia in relatively close proximity to housing, schooling and social amenities.

The deal follows the completion of survey by Galileo, which found that the project is best operated by a local mining company. According to media reports, proceeds from the sale and potential future royalty payments will be used by Galileo for general group working capital purposes and for additional work on its projects.

alileo Resources has signed an agreement to divest the Star zinc project to Zambia’s Siege Mining. As per the deal terms, Siege Mining will pay US $200,000 for the large-scale exploration license in addition to US $550,000 for taking an ownership stake in the project.

The Zambian mining firm will also acquire Galileo’s exploration data in relation to the Star Zinc Project. Galileo will be paid a royalty by Siege Mining on potential zinc sales from the project, based on the zinc grade. Galileo chairman and CEO Colin Bird said: “The Star Zinc project is a small but high-grade deposit situated

He further added that the project lends itself to highly selective mining in a small area and as such is suitable for a small-scale community project involving artisanal mining operations and sorting of ore off-site. Siege Mining is in the process of securing licenses required to undertake mining activities within the Star zinc project area. Galileo said that the divestment will allow it to focus on exploration activities in Botswana. The firm has 15 licences in the Kalahari Copper Belt.

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NEWS

Impala Rustenburg invests R10 million in 18 bursaries and adds new Women in Mining bursary to its successful programme

ighteen 2020 matriculants are on their way to a career in the mining industry thanks to Impala’s hugely successful Bursary Programme for external candidates. This year also sees the addition of a brand-new bursary – The Future Women in Mining Bursary. Impala’s investment in the 2021 intake of bursars over the next four years is R10 million, with the all-inclusive bursaries covering tuition, accommodation, books, and pocket money, as well as paid vacation work for many of the students. Second-year students receive laptops from the mine, and mentoring by Impala’s Bursary Department continues throughout the bursary period. Mark Munroe, CE of Impala Rustenburg, congratulated the new intake of bursars and encouraged them to work hard to build strong and sustainable careers in the mining sector in years to come. He says the bursary programme, which has been running for over 20 years, has made a difference to many young lives in the local communities, creating opportunities for successful careers both at Impala and further afield in the mining industry.

Of the 18 successful bursars in 2021, 16 are from local mining communities. The seven men and 11 women were selected from 11 high schools in the Rustenburg area according to stringent criteria. They will be studying a wide range of disciplines, including mining, mechanical, chemical and electrical engineering, chemistry, geology, teaching, HR and accounting, at various universities, including Wits, Pretoria, University of Johannesburg, and North West University in Potchefstroom. The first Future Women in Mining bursar is Dulcie Kagisho from Paardekraal who achieved an excellent matric pass at Sunrise View High School in 2020 and has been accepted into the Mechanical Engineering degree course at the University of Pretoria. Says Munroe, “It’s crucial for our mining industry to be more representative of our population and to encourage women to pursue the many opportunities available to them throughout the mining processes. We’re already proud of Dulcie’s determination to become a great mechanical engineer, and we wish her well throughout the tough course she

has undertaken. We believe that Dulcie, as well as our 11 other women bursars and any other future Women in Mining graduates, will encourage many more women to work hard to achieve good matric results to be able to embark on an exciting career in the mining industry.” The selection of a candidate for the Future Women in Mining Bursary will take place in the local community every year. Munroe adds that youth development is a key priority for Impala, and the company provides a number of programmes that assist youth to further their careers, which include the robust bursary programme that is contributing to the number of skilled graduates in the country’s mining community; the Cadet programme that develops critical mining skills among unemployed youth within the local communities to increase their opportunities to find employment in the mining sector; a comprehensive Enterprise and Supplier Development programme; wide-ranging support for local schools; and more.

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NEWS

Sonangol celebrates 45 Years in Service of Angola frica Oil & Power (www. A f r i c a O i l A n d P o w e r. c o m) would like to congratulate Sonangol on reaching the impressive milestone of 45 years in operation. The Angolan state-owned oil company has been operating since 1976, and despite experiencing political and economic challenges, the company has remained resilient, and has helped transform the country’s oil and gas sector into a global success story, while building a reputation as Africa’s leading national oil company.

intended to further boost sectoral success and focus Sonangol’s activities on its specific value chain. By restructuring both Sonangol and the sector and transferring the concessionary function to the National Oil, Gas and Biofuels Agency (ANPG), Sonangol was able to become more profitable and efficient. Sonangol’s board of directors recently announced that the company saved, in 2020, $1.441 billion, in which the restructuring was a key determinant, allowing the country to significantly reduce fuel imports.

The Minister of Mineral Resources, Petroleum and Gas, H.E. Diamantino Azevedo, stated that Sonangol has contributed to the growth and sustainability of the country’s petroleum industry – thereby guaranteeing a greater return for the state – and has supported the participation of companies and national staff in the sector’s activities.

As the African continent emerges from the impacts of the COVID-19 pandemic, and oil prices stabilize, Sonangol is prioritizing production capacity increases, boosting international involvement in the hydrocarbons sector, and reinforcing its central role in the national production of hydrocarbons.

By Charné Hundermark, Southern and East Africa Editor

Sonangol has been a major contributor to the socio-economic development of Angola. More recent achievements include the implementation of a series of reforms

Metso Outotec to deliver energyefficient comminution technology to Côté Gold Project in Canada

etso Outotec was awarded an order for key comminution technology for IAMGOLD Corporation and Sumitomo Metal Mining’s joint venture, the Côté Gold Project at Gogama, in northeastern Ontario, Canada. The value of the order exceeds EUR 10 million, and it has been booked in Minerals’ Q1/2021 orders received. Metso Outotec’s delivery consists of two energy-efficient Vertimill® 4500 grinding mills and one MP1250 cone crusher for the Côté Gold Project.

“Low energy and wear part consumption as well as process flexibility were decisive factors for the Côté Gold Project team when selecting the comminution equipment. Metso Outotec was consulted during the pre-feasibility study and supported IAMGOLD on several projects. IAMGOLD’s technical team had solid confidence in the Vertimill® technology, and they were also familiar with the high-performance capability of the MP crushers,” says Andy Lingenfelter, Vice President, Minerals Sales, North & Central America, Metso Outotec.

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NEWS

DRC’s first ‘Cahier de Charge’ approved

Mines generally have community development plans but these are often designed by the mine, which historically had little formalised input from local communities or other stakeholders

n a pioneering step, a large mining company in the Democratic Republic of Congo (DRC) has – with assistance from SRK Consulting Congo – become the first to have its Cahier de Charge (Social Term Sheet) approved. Regulations introduced in 2018 require mines to set out a clear and financiallyprovisioned five-year plan for local social development – a Cahier de Charge – in consultation with local communities and stakeholders. According to Susa Maleba, country manager at SRK Consulting Congo, the key aspect of the new requirement was that effective consultation be conducted. “Mines generally have community development plans but these are often designed by the mine, which historically had little formalised input from local communities or other stakeholders,” said Maleba. “This compulsory consultative process – as part of the Environmental and Social Impact Assessment – ensures that mine initiatives align with the real needs and preferences of those affected by the mine.” The mining company contracted SRK Consulting Congo to work with its DRC

mine on planning and implementing the consultation – which began in 2018 and lasted four months. The final agreement between the communities and the company was signed off, in March 2019. Established a decade ago in Lubumbashi, the local SRK office appointed its stakeholder engagement specialist Philippe Katuta to guide the process. “As an experienced local expert who is well regarded by the mining communities, Phillipe supervised the process with the client – facilitating contact between the mine, three local communities, the ‘chefferies’ tribal structure and provincial government,” he said. He highlighted the importance of having the trust of all parties in the consultation, to ensure frank engagement and effective buy-in. This in turn helped ensure proper implementation of the agreed plan, so that the intended benefits would be achieved. “Essential factors in the success of the process included our experience in stakeholder engagement and our local knowledge – from local language

Susa Maleba, country manager at SRK Consulting Congo

communication to the traditions and customs to be observed,” said Maleba. “Working with mining companies, we emphasise the social licence aspect of their strategy and operations – which prioritises close working relationships with partners, communities and government. It means applying the spirit – not just the letter – of the law.” Among the social development imperatives highlighted by communities during the engagements were transformers to link with the country’s power grid, boreholes for access to water, agricultural extension programmes and trade training for local youth. He acknowledged that it was seldom easy to balance the expectations of communities with the financial resources of the mining company, but this made the relationship of trust a vital foundation for collaboration. He also noted that the new regulations provided for ongoing monitoring of mines’ community development plans – to ensure that what was promised was in fact delivered, in line with a predetermined schedule.

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PRODUCT & TECH

VIRTUAL REALITY: Transforming the mining industry

he dangers of mining operations are very well known . Inadequate training is often a root cause for many mining fatalities. Handson training in an actual mining environment provides only limited reallife opportunities, however virtual realitybased training can expose the workers to real-world working conditions without the associated risks. Hence there is a strong demand for Virtual Reality (VR ) in the mining industry, especially for solutions that can help in training the mining operators effectively to improve safety , increase productivity and reduce costs. Virtual Reality (VR) training in mining allows training the entire team of mining operators, workers, managers in order to make the entire mining process safe and more effective. Training in VR makes it possible to allow teams to practice their skills before they start working in realworld mining sites. How does VR training work? By putting on the VR headset , one experiences a virtual environment that is similar to the mining site. New trainees and recruits get a better understanding of what is expected of them and how to handle different work situations. They can inspect every part of the site and even interact with the different virtual objects around them which directly leads to higher learning retention and better results. Experienced workers get trained on advanced skills and emergency situations. Custom mines developed in virtual environments which are actual replicas of mine sites are being used for accident reconstruction , emergency preparedness and safety training. Currently, VR is being used in numerous scenarios in the mining industry, including: • Mine site familiarisation training • Emergency preparedness training • Working in Confined spaces training ( Video Link ) • Training on equipment familiarisation & operations • Training on machine inspection maintenance The mining industry is also using VR for scenario based training . Three

large-screen projection units create an underground coal mine in the UNSW School of Mining Engineering. Their program is scenario-based and requires trainees to answer various safety-related questions as they “move” through the mine and thereby the story. Trainers interact with the trainees to lead discussion and answer questions, and they can manipulate the progress of the training program.

HOW IS VR TRAINING BETTER THAN TRADITIONAL TRAINING Allows Hands on training There is only so much learning, traditional training can provide people. Videos and pictures do help them understand the right way to do things, however trainees don’t really understand how to do things at work unless they get to perform those procedures or tasks on the field. This can often lead to problems or bottlenecks at work as new employees may take anywhere between weeks to months to operate at their full potential. VR training gives people the opportunity to perform practical hands-on exercises as many times as they want before they get out on the field. Allows to make mistakes and learn from them When you give trainees a safe learning environment through VR training where they can make as many mistakes as they want and actually learn from the consequences of their mistakes, it directly leads to more learning opportunities and better results. It also gives both instructors and trainees much-needed flexibility to solve different problems in different ways, in order to discover the best way forward. After all, even little improvements in productivity can go a long way. Enables Higher learning retention Hands-on and immersive learning directly leads to higher learning retention since trainees are able to better grasp concepts and hone their skills. As compared to classroom training, virtual reality training gives people the opportunity to get a more realistic job experience, allowing them to understand important concepts faster.

Its is Effective and Scalable Training VR training enables effective learning at a lower cost and in less time than many traditional learning methods. The VR training technology allows the management to view and review the performance and training retention of each trainee with the help of the inbuilt objective assessments systems . Because of its portability , VR training becomes a highly scalable form of training as it allows you to deliver standardised training across multiple locations without the need for employees or trainers to travel to the location. The future of the mining industry lies in VR The potential of VR in mining is truly infinite. With even more advancements in VR technologies, it will not only help mining related companies in planning better strategies but also lead to a safer work environment for everyone involved. As one of Asia’s leading VR training & simulation companies, Tecknotrove has vast experience in developing cutting edge solutions for the mining industry for both surface mines and underground mines. Tecknotrove develops customized virtual training solutions for critical training applications for the mining industry. “We develop fully customized VR training solutions that are capable of offering immersive learning experiences which can directly lead to higher productivity and efficiency in mining operations”, says Shantanu Gupta – Director Tecknotrove Systems. Tecknotrove has worked with some of the largest mining companies in the world including Debswana Mines, Rio Tino, Sesa Goa . They also work with some of the largest OEMS like Komatsu, Caterpillar, BEML, Volvo to name a few. For more information you can reach them on www.tecknotrove.com

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PRODUCT & TECH

replacement – emulsion explosives which can be produced in both small and large diameters of charge for large mining operations and construction.

iRing Releases an Extensive, Searchable Online Drilling and Blasting Knowledge Base iRing Inc introduces an extensive, searchable, comprehensive Knowledge Base that provides answers to questions concerning the use of commercial explosives in mining and construction applications including the physics of the detonation reaction and how this is used in mining for fragmenting rock/ore. Knowledge Base | iRing - Library of over 2000 pages with detailed information regarding underground drill and blast mining design and Aegis Designer/ Analyzer The iRing Knowledge Base provides in-depth analysis and descriptions of the use of commercial explosives under many topics including types of explosive products, priming, temperature, and pressure effects along with applications and use of explosives in mining and construction. The material has been collected over years of experience in explosive manufacturing and mining by Christopher J. Preston P.Eng MCP – Consulting Engineer and VP Research and Development iRing Inc. The knowledge concerning the use of explosives as well as case histories and other notes are taken from a broad range of sources including authors skilled in the art as well as personal experience. These works are acknowledged where

appropriate and are presented here to provide answers to the world use of explosives in mining and construction for everyone. Many times, it is just handy to have a place to look up information without doing a rigorous search. Hopefully, some of the information provided here will be useful. We have tried to acknowledge content that came from outside our realm of experience and we have acknowledged those authors who have provided input in the explosives technology public domain who are used as credible references.

Large quantities of bulk explosives can be delivered to the blasthole using pump or auger trucks with loading rates of hundreds of kilograms per minute. Delivery records are not only maintained on the trucks but also in the cloud for strategic data handling to arrive at the lowest cost of production. Extensive use of electronics in mining has affected production levels and in particular safety. Mine communications have improved to such an extent that normal operational activities can be handled by iPhones and/or tablets for production reports and foreman’s logs. Perhaps one of the best technologies introduced during the initial years of this century was the production of electronic blasting detonators giving timing accuracies that allow precision blasting methodologies surpassing traditional practices when blasting close to damageable structures. To use the iRing Knowledge Base, go to www.iring.ca and click on KNOWLEDGE BASE. Under the heading ‘Knowledge Base’, click on Knowledge Base.

The Knowledge Base provided by iRing Inc is an extensive collection of information covering the years 1971 to the present. Over that period, commercial explosive products have changed drastically moving from dynamites and canned explosives such as Ammonal and Nitramon to ANFO, water gels, and emulsions. Much work was completed by Dupont De Nemours and other large commercial manufacturers introducing the water-gel and emulsion families into a stream of safer commercial explosives.

About iRing Inc. & Aegis iRing Inc. is a world leader in blast planning software specific to underground mines and uses a proprietary break model to diagnose and improve blast pattern designs using explosive detonation state and explosion state characteristics as well as dynamic rock/ore parameters. It is our mission to provide leading-edge technologies and solutions for mining blast optimization. AEGIS Designer© and AEGIS Analyzer© are part of a software suite of products from iRing Inc. that completely changes the ring design process (drilling, blasting, and mucking) for underground mines by improving ore recoveries minimizing dilution and ensuring cost saving consistencies from stope to stope, and orebody to orebody.

These could be used in a host of mining operations – from surface blasting, open cast mining, and quarrying as well as construction to underground mining operations. Next followed dynamite’s

iRing INC has won two technology awards from Northern Ontario Business and received a Manning Innovation Nomination from the Ernest C. Manning Awards Foundation.

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PRODUCT & TECH

BMG’s Superbolt® multi-jackbolt tensioners, which form part of the Nord-Lock range, are designed for demanding applications requiring a high clamping force and for tasks with limited space for tightening bolts.

Although the primary benefit of Superbolt is the reduction of torque required, this device also reduces downtime and eliminates unsafe and laborious bolting methods, particularly in harsh operating conditions.

BMG superbolt tensioners safe operation maintenance

MG’s Superbolt® multi-jackbolt tensioners - part of the Nord-Lock range - are designed to reduce downtime in the mining sector and eliminate unsafe and laborious bolting methods, particularly in harsh operating conditions and in areas with limited working space. “These multi-jackbolt tensioners, which replace or retrofit nuts and bolts, only require hand or air tools for the installation and removal of any size tensioner,” says Wean Marais, National Product Manager - Nord-Lock Group, Fasteners Division, BMG. “Bolts need to be easily removable during maintenance procedures, but must resist the loosening effects of vibrations and dynamic loads. “This quick and efficient bolting method is based on a design which splits one big torque into a number of smaller ones. Superbolt, which has numerous advantages over conventional bolting products, ensures joints can be tightened with high accuracy, without the need for specialist skills or heavy tooling. Tightening in pure tension allows higher preloads on the same size bolt than conventional tightening methods. “Generating a preload high enough above the separating forces means bolting will not vibrate loose on properly designed joints and the added elasticity increases fatigue life of the bolted joint, which eliminates costly downtime.

Only small hand tools are required for installation – this means there are no safety hazards from immense hydraulic pressures, no pinching hazards, no lifting of large tools and no risk of sockets breaking under high pressure. “Multi-jackbolt tensioners are easy to install, even in confined spaces and although there are multiple jackpoints to tighten - by using hand or air tools installation times are faster than other bolting methods.” A conventional bolting system, like the sledgehammer, gives little control, is inconsistent and can cause injuries. Thermal tightening, crane and hydraulic wrenching and hydraulic tensioning are often costly, inaccurate, time consuming and unsafe. Superbolt devices are threaded onto a new or existing bolt, stud, threaded rod or shaft. The main thread serves to position the tensioner on the bolt or stud against the hardened washer and the load bearing surface. Once positioned, actual tensioning of the bolt or stud is accomplished with simple hand tools by torquing the jackbolts which encircle the main thread. The jackbolts transfer the preload evenly into the main thread and consequently onto the joint. Jackbolts have a small friction diameter and can therefore create a high thrust force, with relatively little torque input. The main thread is tightened in pure tension.

Superbolt tensioners are used in diverse industries, including mining, hydropower, wind turbines, gas and steam turbines, nuclear, steel, shipbuilding, offshore, chemical and transportation. OEMs specify Superbolt multi-jackbolt tensioners in their design, to improve performance of equipment. The high preload capacity and accuracy of this system has resulted in the design of smaller bolt sizes. Compact dimensions and decreased tooling sizes allow for a reduction in the size of machinery, reducing material and machining costs. BMG offers a technical advisory service to determine the dimensions and load conditions of existing or required bolted joints. Current tightening methods are evaluated and bolt preloads, for absolute reliability and durability, are calculated by the highly-skilled team.

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PRODUCT & TECH

The software publisher CASPEO adds business intelligence capabilities to its metal accounting solution INVENTEO pushing it even more to industry 4.0 standards. As an expert in processes of the mineral industry, CASPEO enhances production and inventory data beyond data reconciliation and mass balance by delivering accurate, timely and valuable insights to generate reports and dashboards and to make better and faster decisions. An opportunity for CASPEO to explain its original positioning on metallurgical accounting.

eading provider of mining software and consulting services to metals, minerals and mining industries, CASPEO announces the availability of data analytics tools in its metallurgical accounting solution, INVENTEO. Metal accounting is one of the main tools for management of metal production industry. It aims to get the most complete and accurate picture of the performance of a plant in order to guide decision making. It combines financial challenges linked to corporate governance and regulations and technical ones regarding process optimization. Metallurgical accounting systems enhance production and inventory data along the mining value chain. However, collect and aggregate data from various sources is not sufficient to provide a reliable metal accounting

system. Sampling and measurement, the foundation for accurate metal balance. Mining companies are required to report accurate and precise data for financial accounts: recoveries and grades, quantity of saleable metals, accurate estimates of inventories (work in progress, intermediate products, stockpiles…). Due to production variability, process inefficiencies, forecasting errors, these tasks are very challenging without an efficient and reliable system to quantify material movements, losses/gains, and emissions. Thus, the starting point of a true metallurgical accounting system is a precise understanding of the process operations, including the follow-up procedures, based on sampling and measurements. It is common to say about metal accounting software that if it uses bad data, it produces bad results,

often summarized as: “garbage in, garbage out”. Pioneer in the implementation of such system, CASPEO has developed, for more than 15 years, a complete offer, called INVENTEO, to help plant management to switch from spreadsheets or database-driven solution to an efficient metal accounting system pushing mining and metals industry to a next digitalization level. Designed for mining, mineral processing, hydrometallurgy, smelting, and refining operations, INVENTEO is quite differentiating in the market. “The application of the AMIRA code P754 that fixes best practices for implementing reliable metal accounting systems is not only linked to the use of a given software package, whatever qualities it may get or functionalities it may provide”, declares

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Marie-Véronique Durance, CASPEO coManaging Director. “That is why we offer, in addition to software, the associated expertise on sampling and measurement which enables the client to be guided towards good practices and to optimize internal processes.” To note: INVENTEO is an off-the-shelf solution for metallurgical accounting, requiring no specific development, only configuration. Thanks to the transparency about the calculation methods (required by the AMIRA code), as well as training and mentoring, teams are able to be more responsive to any change in the processes and to integrate modifications without being dependent on a supplier. Leverage algorithms to improve data Metal accounting platforms performs automatic acquisition of data from existing databases (SCADA, LIMS, Historians…) to create a single basis data to manage metallurgical balance accessible by financial, mining, metallurgy, and operational divisions. True metal accounting systems such as INVENTEO do more by improving data quality thanks to robust data reconciliation algorithms. This represents a milestone in Smart Mining.

“INVENTEO’s embedded algorithm allows obtaining consistent material balance from raw data, improving the accuracy of data by a statistical distribution of measurement errors based on maximum of probability, and allowing data quality checking”, explains Stéphane Brochot, CASPEO other coManaging Director. “Measurement and sampling errors are associated with all material flows and stocks in the plant: products, raw materials, utilities, reagent and effluents.” INVENTEO ensures traceability and workflow all in compliance with the best practice of AMIRA code. The data reconciliation being based on the measurement error, it includes tolerances about the acceptable imbalances. INVENTEO allows to define range of expected values and generate warning when out of it. Business intelligence, the step forward All generated data –basis data and reconciled data– are stored in the INVENTEO database with intermediate calculations allowing auditing. All reports are generated from these data. INVENTEO delivers metal balances for all the streams, metallurgical inventories and work-in-progress, in quantity and quality.

Having the right information, in a single place and at the right time; this is what decision-makers are asking for. It is why CASPEO has decided to boost the reporting part of its metallurgical accounting software by adding business intelligence features. To turn data into insights, a system has been developed that makes it possible to directly query the INVENTEO database and thus to easily create more visual reports (tables, graphs or dashboards). INVENTEO encourages sharing of information, while maintaining the levels of privacy and security that are needed. Thanks to this feature, it can be now interfaced with Business or Operational Intelligence solutions such as Power BI, PI Vision, Tableau… It also facilitates the implementation of Extract Transform and Load (ETL) process, to integrate the produced data in larger data warehouses and make it available for business analysis at a wider scale. INVENTEO also allows the generation of timely reports (month-to-date, quarterto-date…) in addition to fix periods ones attached to financial and legal purposes. It provides stakeholders insights in a timely manner to monitor and assess an operational situation. INVENTEO enables to make faster and better decision.

The perfect connection

n the manufacture of metal bellows couplings, bellows and hub connections are a critical issue. While steel or stainless steel couplings can be combined with a special micro plasma welding process, this method is not suitable for combinations of aluminum and steel. Adhesive bonding processes can be used here, but they can fail under extreme operating conditions (chemicals, very high or low temperatures). Especially in the case of clutches on the input side of a planetary gear, high

temperatures can occur in critical applications which could loosen the adhesive bonds. The JAKOB-developed and long-time patented joining process (crimping-inpress process), on the other hand, is optimally suited for connecting multilayer stainless steel bellows without clearance to aluminum hubs. Here the operation is certainly possible even in temperature ranges from -50 ° C to + 350 ° C.

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PRODUCT & TECH

Heavy duty mining jacks, jack stands and associated accessories Jacking up maintenance levels safely and effectively OEMs are pulling out all the stops to meet evolving requirements of end-users in the mining sector whose urgent focus is on increasing productivity by minimising equipment downtime and enhancing safety.

he last thing African mine operators would loath to encounter is an interruption to production due to downtime to equipment - a situation which is largely avoidable. Thus, tools which can enable them to carry out scheduled maintenance to keep equipment uptime as high as possible are necessity. Pertaining to heavy mining vehicle maintenance, high tonnage lifting hydraulic jack and stands ensure safety and effectiveness when performing maintenance tasks. What do mine operators need to meet the harsh environments in which they operate, where not only do they have to keep their businesses in the black, but also comply with safety and environmental regulations? First Mining DRC sifted through scores of brands from high-profile OEMs for key factors driving trends in hydraulic jacks and jack stands for COVID-19 mining conditions. Admittedly, the process of gathering data was akin to looking for a needle in a hay stack. Where necessary, product managers had to be engaged. Though, understandably, some managers were reluctant to share information, others were eager to provide an update on jacking systems with this publication. Current preferences in jacking systems In the end, it was well worth it. What came to light was that, for all ostensible differences in brands, prominently, there are common preferences amongst endusers in all products, geared towards mainly enhancing safety and efficiency in vehicle maintenance. That is the bottomline. i. Safety Designs have the operator’s safety paramount in mind. This is evident in a number of safety-enhancing features. Some of the features that stand out

include: • The ability to lift and mechanically lock automatically in the unlikely event of a hydraulic failure. • Support stands and extensions to protect employees working under a vehicle or equipment • The use high density steel plate and high strength tubing ii. Speed and power Speed and power are cardinal elements needed for jacks used in a vast range of on-site applications. The applications would include - of course but not be isolated - servicing tires, tracks and other maintenance functions on heavy equipment, lifting and positioning of large constructed elements and many other applications that require heavy lifting equipment in remote locations. iii. Versatility Amongst mine operators when decisions about procurement of jacks are being made versatility in jacks and stands is non-negotiable. In response to this, OEMs have come up with jacks that have the following features as standard: double as vehicle support stands; are compact and portable lifting; extension system that allows lifting at all heights without blocking; and are selfpropelled. Even more interesting, further underpinning versality, some designs combine a cylinder and an electric or airpowered hydraulic pump unit integrated into a mobile cart, above and beyond, an extension system allows lifting at all heights without blocking. Players reshaping product portfolio What emerges is that OEMs are not resting on their laurels. Relentlessly, notwithstanding the dampening effect of COVID-19 on their business streams, key players are reshaping up their current product portfolio through introducing new

and advances technologies, besides innovating new products. Noticeably, increasingly, there is more focus on replacement and aftermarket sales. This augurs well for mines who are launching new greenfield and brownfield projects. The onus on the end-user For all the benefits jacks offer in heavy duty vehicle maintenance tasks, the onus is upon mine operators to do their homework in establishing the integrity of the products that are available on the market. Indeed, while hydraulic jacks do the same work, unfortunately, the reality is that they are not made equal in terms of quality. Some products may appear cheap, but there could be a high price to pay due to high risk of failure, leading to damage to mobile equipment and fatalities – a situation too ghastly to contemplate.

5 reasons hydraulic jacks would be recommended for African mine operators •

•

• • •

Jack operate at a predetermined pressure, so the jacking is bigger to explore the full capacity. Hydraulic jacks enable stable jacking, which requires a large bore, rod and base plate. The jack automatically powers down, which eliminates the possibility of being lowered by accident Best overload protection Hydraulic components last longer due to a better shelf life and rarely do they fall unexpectedly A toggle switch, which is a pneumatic valve situated away from load controls, simplifies operation of a hydraulic pumps.

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MINESUPPLY INTERNATIONAL

MANUFACTURERS REPRESENTATIVES - INTERNATIONAL & DOMESTIC MARKETS

MINING PRODUCTS MINESUPPLY LOADMASTER HD MINING JACKS & JACK STANDS 100 – 350 TON CAPACITY Our full line of equipment will allow the quick removal of tires using our heavy-duty jacks and jack stands. Ex. Air/hydraulic, electric/ hydraulic Power-driven wheels on all MineSupply Loadmaster HD jacks permit service personnel to safely and quickly position the jack. Foam-filled tires on heavy-lift jack equipment facilitate for easy access and mobility, with wider bases on all jacks and stands, for greater stability and security. Two (2) heavy-duty rugged quality extensions provided with each jack or stand at time of original purchase. Jacks come in hydraulic or electric as well we have a mobile mining jack series. MINESUPPLY INTERNATIONAL www.minesupply.com

CONTACT INFO: sales@minesupply.com sherridriscoll@minesupply.com

PRODUCT & TECH

The efficacy of silica monitoring for worker health takes quantum leap forward Nanozen’s DustCount, a FTIR Spectrometer, has made monitoring for respirable dust and silica much easier and cost efficient.

anozen Industries Inc. is a Canadian company based in Vancouver, British Columbia. We have been providing air quality monitoring solutions for Occupational Health since 2007. Nanozen is a leader in the evolution of real-time monitors for detecting and solving problems as soon as they occur. Silicosis has been a particularly deadly health problem, affecting miners and other workers for over 100 years. Regulatory changes to address this danger have been slow to develop. Nevertheless, increasing numbers of class action lawsuits are pushing large corporations to seek better monitoring and mitigation techniques to eliminate this risk. When Nanozen’s DustCount product hit the market in 2016, it was an immediate success with industrial hygienists. Its compact size, high accuracy, real-time digital results, rich feature set, wireless communications and built-in sample filter were exactly what the market demanded. Nanozen manufactures the best realtime, personal wearable particle monitor

DustCount

available, and now our focus has turned to silica monitoring. Enter the portable FTIR Spectrometer: Nanozen has been working with NIOSH in the USA and our distributor in Africa to integrate the DustCount’s built-in sample filter cassette with a portable FTIR spectrometer. Nanozen has developed a standard method to take dust from any mine and custom-calibrate a portable FTIR spectrometer to obtain highly accurate results in a few minutes. Occupational hygienists no longer have to wait days or weeks to determine if workers have been exposed. How it works The worker removes the lightweight DustCount monitor from its charging cradle, puts it on, and wears it throughout their shift. The Nanozen system preloads the DustCount configuration ahead of time for the shift, and the Dustcount starts up automatically to collect and store data during the shift. At the end of the shift, data collection stops, and all data is transmitted to the system.

Built-in Cassette

Insert in FTIR

The worker removes the DustCount and puts it back into the charging cradle. The sample filter cassette is then removed and plugged into a portable FTIR spectrometer. After two minutes, the percentage of silica is determined and provided to the system, adding the silica results to the data for that shift. Monitoring for respirable dust and silica has now become much easier and cost efficient, and the efficacy of silica monitoring for worker health has taken a quantum leap forward! Having rich data from shift monitoring allows much better determination of where and when exposure peak events happen. With the combination of realtime monitors and on-site, portable FTIR spectrometers, mitigation strategies can be custom tailored to the exact cause of exposure. Solutions can be tried and tested within hours!

Nanozen Analysis

Silica data in minutes

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DUSTCOUNT PERSONAL WEARABLE REAL-TIME MONITOR. SAVE UP TO 80% OF SILICA DUST ANALYSIS COSTS!

FINES AND LAWSUITS ARE ON THE RISE WORLDWIDE WITH TOUGHER PARTICLE EXPOSURE LIMITS. (EXAMPLE: $400M USD SETTLEMENT IN SOUTH AFRICA) Thousands of Health and safety experts worldwide are now using the personal wearable DustCount. Worker Favourite - light weight, no bulky cyclone, and fully automated operation. Heath Executives Choice - significantly improving the quality of monitoring through real-time techniques, digital wireless communications, and a built-in sample filter. Company Preferred Approach - realtime automated monitoring allows a drastic reduction in the cost of collecting data and lab analysis. Future-Proof – ready today for Digital Mine and Industry 4.0 initiatives to improve ESG ratings through quantifiable, traceable, occupational health management.

www.nanozen.com

Frank Smith, Oct 21, 2020 - Plant C1 120

100

Each dust spike compromises a workers repiratory system.

0 13:26:24

13:40:48

13:55:12

14:09:36

14:24:00

14:38:24

14:52:48

15:07:12

DustCount helps to quickly focus control measures on high exposure spike events. DustCount and know the air you breathe are registered trademarks of Nanozen Industries Inc.

15:21:36

Engineered Process Solutions

MVR EVAPORATOR A.H. Lundberg’s (AHLS) mechanical vapour recompression (MVR) evaporators can clean effluents discharging from various process industries (Mining, P&P, O&G) and recycle the high quality clean condensate back to the operation for reuse. For sites that do not have steam available or limited by the amount of water available, these units are ideal since they can operate on diesel generators that can drive the compressor and recover over 96% of the effluent as clean condensate for reuse. The AHLS MVR Evaporator has tubular heating surfaces suitable for low total dissolved solids application. The MVR Evaporator capacities can vary from 10 to 100 t/h in a unit. Higher capacities (100 t/h to 350 t/h) are possible for nonmodular units. In the MVR system, the water vapourized (steam) on the tube side is compressed with a lowspeed centrifugal compressor which superheats the steam and increases its saturation temperature. The compressed vapour, a heating medium is used on the shell side to vapourize more water on the tube side. As the latent heat from the compressed steam is released, it condenses and generates high quality clean condensate for recycling to process. Benefits of the AHLS MVR Evaporator System 

Proven technology in various industries.



High quality condensate is generated



Modular system provides the flexibility of moving the unit from one location to the next at a minimum cost.



Truck mounted modular system for quick mobilization and demobilization.



Recovery as high as 96+% is possible for sites limited by water availability because of restrictions or governmental regulations.



Lower effluent volume discharging the system resulting in a savings on transportation and disposal cost



No steam or cooling water is required



Different metallurgy construction is available



Desired installation location can be chosen

For more information contact: sales@ahlundberg.com A.H. LUNDBERG SYSTEMS LIMITED® 5118 Joyce Street, Unit 300 Vancouver, BC V5R 4H1 CANADA

Tel: 604-629-5599 Fax: 604-629-5199 sales@ahlundberg.com www.ahlundberg.com

COVER STORY

Non-Flammable marking for mines A Handheld solution makes marking easy and safe for African mines Dy-Mark Global sees vast opportunities for mining companies in Africa to be had in switching from marking using traditional bucket and brush application to its flagship handheld non-flammable aerosol spray-based marking option. Marketing Manager recommends aerosol spray non-flammable marking paints which are certified and proven to be safe and reliable, as well as meet expected performance standards. He references Dy-Mark Mine Marking Non-Flammable in extra tough cans, as a product that meets all the requirements for safe and highly visible marking in tough mining environments, above or below the ground. “Our non-flammable marking painting solution is fit for purpose in terms of safety and reliability, above and beyond performance,” he assures, demonstrating each of these features. Each batch of Mine Marking Non-Flammable is tested at a NATA accredited laboratory to ensure nonflammability and to meet performance criteria.

ining companies in Africa are in pursuit of different avenues which can enable their operations to be more cost efficient and productive, while ensuring compliance with requisite occupational health and safety and environmental regulations from pit to port. One area where there are potential opportunities to achieve this objective is in the procurement and application of marking paints. When decision makers at mining companies are seeking for ways to ‘streamline’ their operations they focus on very visible and traditional areas like human resources and machinery. While marking with paint may seem trivial at face value, it is vital considering its versatile role. Problems with the bucket and brush At the outset, examining the problems of using bucket & brush marking paints manifest in several ways, makes one appreciate the relevance of a handheld aerosol spray painting solution better.

The use of bucket & brush paints in narrow underground spaces is onerous, timeconsuming, which can cause fatigue and loss of productivity. In addition, bucket paint application exposes personnel to possible bucket splash, spillage, and contact. For the convenience of the end user, an ergonomic can design like Dy-Mark’s Mine Marking, eliminates the burden of marking using a brush. Thus, reducing fatigue when marking above or below ground. Considering the liabilities incurred from using bucket & brush paints for visibility marking, outweighs perceived benefits, adopting aerosol-based marking paints should be a business imperative. Underground Safety First As you would have thought, the conundrum that mining companies might face is separating the wheat from the chaff amongst products the vast range of making painting solutions that have swamped the market. Advising organisations to make informed decision, Jason Hansen, Dy-Mark National Sales

Performance With performance proven in extreme conditions, Dy-Mark Mine Marking Non-Flammable delivers highly visible marking in underground mine and fire sensitive areas. “The paint is available in seven high quality colours with higher opacity to provide bright marks on mining surfaces in low light areas. Industrial grade resins in the paints provide high durability and adhesion to ensure the marks stick to rough surfaces on the first pass,” says Hansen. Most importantly, two elements in the can which help mines improve productivity. Reliable performance in the field reduces downtime wasted on faulty product. Dy-Mark’s specially developed formula ensures no clogging, and the cans empty completely with no wastage. Dy-Mark Mine Marking is available with a 360° valve which enables any direction spray and two nozzle actuator types – horizontal and vertical (inverted and upright) – for comfortable use in the desired application.

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COVER STORY

Aerosol versatile applications Due to its features, Dy-Mark’s Mine Marking aerosol spray is versatile and suitable for marking out survey grid lines, for grading control, noting geological features and for identification of hazardous work areas. Dy-Mark was established in 1964. With a dedicated manufacturing facility located in Brisbane, Australia, Dy-Mark has built a niche as a global leader in aerosol spray paint technology. Currently, Dy-Mark’s growing product range includes marking paints (aerosol and bulk varieties), inks and dyes, industrial markers and stencilling products, protective and decorative coatings, cleaners and solvents, and industrial packaging products.

thinking that they may be saving costs by recommending the procurement of seemingly cheap marking solutions.

Raising awareness for clients in Africa Dy-Mark Global is keen to raise awareness about the quality and relevance of mining-specific nonflammable spray painting solution to potential clients in Africa in 2021 and beyond. The company is telling product specifiers in mining companies to avoid

“There always a price for cheap products, especially in industries where, at all costs, players have an obligation to comply with legislation governing occupational health and safety, environmental practices and the business imperative to increase the bottom-line,” explains Malcolm Davies, Dy-Mark Export Sales Manager. “Mining paints are not made equal, contrary to popular misconception and cheap has an expensive price attached to it,” he adds, informing mining companies to engage suppliers like Dy-Mark whose hand-held marking products have a credible track record in the industry.

Taking safe and easier handheld marking to the African customer Dy-Mark Global sees the African mining sector as the next big growth avenue for its highly regarded Mine Marking Non-Flammable aerosol spray solution. While the flagship miningspecific paint solution’s convenience and safety are highly valued, Hansen believes the company’s strong selling point is its capability to develop and refine aerosol paint technology systems for multiple markets. The company is well equipped to deliver the required volumes to mines in just about any country in Africa. For mines in West Africa, Dy-Mark has a branch in Ghana well stocked and constantly replenished with new products. Customers also have the options of importing directly from the company’s operations in Australia. In engaging Dy-Mark Global, mining companies can be rest assured that they have a solution designed and

developed for the specific needs of rugged environments, thanks to its technological knowhow. Through its robust Research and Developments capability, Dy-Mark can design new fit-for-purpose products, in conjunction with industry professionals, for their intended industry and application. Dy-Mark’s operations are rooted in constant innovation to give customers the best possible marking paint specific to their particular needs. Besides developing new products, the product development team, which includes quality assurance specialists and industrial chemists, can redesign existing products to improve performance. All new products are tested at Dy-Mark’s NATA accredited laboratory. Hansen sums up Dy-Mark ethos in product improvement: ‘It’s about getting the product right at all times.”

The Dy-Mark’s approach of delivering a marking paint solution and not a product has proved to be an overwhelmingly success. Small wonder its products are generally regarded as the gold standard in its niche market, used by both major and junior mining companies with assets in different commodities worldwide. “Clients always give glowing feedback on their experience when they make the change to our marking product solutions,” Hansen indicates. Over and above mining, Dy-Mark’s has been consistently growing a customer base in other industries globally. Besides industrial spray-based paints, the company manufactures and supplies a rich portfolio of products including cleaners and lubricants, inks and dyes, markers, protective coatings and surveying consumables.

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O CH

MINING

DUCT

OICE

BALL

GLOBAL

FEATURE

Becker Mining’s steel arch roof support systems provide reliable tunnel support and safe conditions or tunnel where roof bolting is not sufficient.” Local applications for Becker Mining’s steel arch roof support systems include gold and platinum mines, as well as underground civil engineering projects, like the Gautrain. These steel arch systems are also exported to Australasian and African mines, with Zambia being a key user. In the mining sector, these steel arch roof support systems are used in various tunnel applications, including x-cuts haulages, incline shaft portals and special shafts.

Becker Mining South Africa’s locally manufactured steel arch roof support systems - which can be integrated with other support elements – provide reliable tunnel support and safe working conditions in mining, as well as in underground civil engineering projects – where unstable ground conditions exist.

ecker Mining South Africa’s locally manufactured steel arch roof support systems - which can be integrated with other support elements – provide reliable tunnel support and safe working conditions in mining, as well as underground civil engineering projects – where unstable ground conditions exist. This robust steel arch roof support system, which is suitable for highly fractured rock in tunnels, roadways and underground chambers, plays a critical role in tunnel rehabilitation, void filling and portal consolidation. “Becker Mining’s steel arch supports have a high load carrying capacity and dependable yielding of segments, for enhanced safety and extended service life, even in poor underground conditions,” explains Tom Searle, Senior General Manager: Capital, Becker Mining South Africa (Pty) Ltd. “Due to

The engineered TH29 steel arch profile, with balanced static values, ensure long term stand-up support solutions for friable ground conditions and where pressures are uncertain. Becker Mining South Africa’s arch sets also include clamps and steel lagging plates and ancillary equipment, for secure installation and optimum performance and safety in arduous conditions. Lagging plates recommended for use in friable ground conditions, are folded, seamed and bolted together.

the adaptability of this system, which can be custom-designed and formed for specific requirements, these high strength steel arch roof supports are suitable for any rock or soil types in any shape of excavation.

Locally forged arch profiles are formed at the company’s production plant in Johannesburg. A large stockholding enables quick and efficient manufacture and delivery.

“This steel arch system provides stable roof support and a safe working environment during the clean up of a roof fall, or before and during seismic movements. This system also provides permanent support to portal entrances and maintains critical areas of a mine

Becker Mining South Africa provides a technical advisory and support service, as well as specialised training for correct assembly and ease of installation of this system. In some applications, these steel arch roof supports are reclaimable and reusable.

The world leader in industrial private LTE networks

www.ambra.co sales@ambra.co 22

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FEATURE

Grouser bars for mobile mining equipment Saving thousands and increasing productivity, one grouser bar at a time With tough duties which mining equipment perform, wear protection is a necessity, and dozer shoes are no exception. Grouser bars ensure the dozer maintains optimal performance in traction and power after used to replace a worn bar of a shoe. In the end, a mine eliminates dozer shoe replacement costs, ensures that there is as minimal interruption to productivity as possible, and keeps fuel costs manageable.

here has been increased spotlight on wear protection parts for machinery than ever before as the thrust of mining companies in current times is increasing profitability and reducing operating costs as far as possible. Relating to crawler dozers, the use of grouser bars on track shoes is recognised as one the sure-fire ways of increasing equipment uptime maintaining optimal traction and power. High quality grouser bars offer high toughness and resistance to abrasion. In no doubt, the relevance of grouser bars becomes more evident when the track shoes on dozers are worn down, which often results in loss of traction and power. Due to the loss of traction and power, a dozer loses productivity and fuel consumes more fuel. Unfortunately, replacing the entire shoe doesn’t come cheap, from the viewpoint of unscheduled replacement costs as

well as long downtime. Alternatively, replacing only the worn bar across the length of the shoe is the only practical option - a process called re-grousing. Naturally, the challenge which mine operators in the rugged DRC and Zambia copper mining environment would face is making an informed decision with a range of options of grouser bar brands from all over the world to choose from. And, in those circumstances, this is a key question they have to ask themselves: Does the product deliver extended life, less downtime and increased savings? To get to the bottom of the matter, First Mining DRC and Zambia made a review of grouser bars from manufacturers who target the African mining sector, particularly the copper-rich Zambia and DRC region. A picture of what the endusers’ preferences emerged specifically in terms of the type of material used and mode of installation.

Material used for reliable performance For reliable long-term performance, most of the grouser bars are manufactured heat treated, hardened, quenched and tempered high-grade alloy steel for reliable performance. Of course, manufacturers use different chemistries. The heat treatment processes render much-desired hardness and durability. The convenience of easy installation Typically, for the grousers for mining, where time is of the essence, installation should be easy. This is addressed in the design which allows a prompt and economic welding. Another interesting feature is that, in products where no welding is required, the grouser can be installed into the backhoe within a short time. Thousands in savings, certainty of equipment availability By using a quality grouser bar to replace worn parts of dozer shoes a mining company can be able to save thousands which would have otherwise been spent on shoe replacement costs. moreover, there is evidence that grouser bars can last even longer than a new track shoe, giving certainty of equipment availability. A replacement with heat treated grouser bars can restore the dozer to its original yield in traction and power. Inevitably, there is a point where a grouser wears down after fulfilling its purpose. When that situation arises, regrousing (replacing the grouser) is an option which can also save the end-user thousands of dollars. Finally, by using a grouser bar to replace a part of a worn track shoe a mine can be able to maximise uptime, increase traction and minimising maintenance costs.

Versatility of grouser bar Not only are grouser bars used on dozer shoes, but they also enjoy wide usage in the following areas, they can be used to prolong the life of dozer blades and buckets by providing extra steel reinforcement. In general, they can be used to strengthening, reinforce, and extend the life of a variety of heavy equipment.

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4N Corporation: Quality Grouser Bar, Anywhere in the World 4N is made of high-carbon steel grade alloyed with manganese, chromium, and nickel. Then with the use of proprietary chemistries and an in-house customdesigned heat-treating system, the bar produced is much harder than flamehardened bar.

Grouser bar from 4N is often tougher than the bar that was originally on the track

aunched in the early nineties by steel industry veterans from western Pennsylvania, the heart of the US steel industry, 4N was founded to create the best, strongest, most wear resistant grouser bar in the industry. The entire philosophy of 4N is based on meeting and then exceeding the needs of quality- and profitability-minded mining professionals who demand a tougher bar to get the grip and traction their heavy equipment requires. “When we started our business in the USA almost 30 years ago, we had no way of knowing that Zambia and the Democratic Republic of Congo would be such an important market for us.” So says president and owner of 4N Grouser Bar, Mr. Bernie Nerlich, who pointed out that exports made up a bigger portion of their business in 2020 than ever before. REPLACING THE WORN GROUSER TO REGAIN TRACTION The basic principle of grouser bar is this: when you lose traction and power because the track shoes on your dozers have worn down, you lose productivity and fuel consumption increases. You need to do something fast. You can replace the entire shoe. But that option is expensive – in both time and money. Instead, you can re-grouser – replace only the worn bar across the length of the shoe itself. Yes, re-grousering is a good idea. But you need to employ the right grouser bar that delivers extended life, less down-time, and increased savings. 4N

Grouser bars are your absolute best choice to maximize uptime, increase traction, and minimizing maintenance downtime. HELPING TO REDUCE YOUR TOTAL COST PER HOUR “The global mining industry has grown, and we’ve grown with it,” says Nerlich. “When we began making the toughest grouser bar we could, we were always talking about saving our customers on their cost per ton. These days, the pressure to reduce costs and improve profitability has only grown, and today we talk about constantly improving our product so that we can reduce our customers’ total cost per hour.” One of the early goals 4N set out for itself was to produce a grouser bar that was tougher than the original bar that was on the tracks of the machine. Today, each standard grouser bar from

“THROUGH-HARDENED” GROUSER BAR The key to the success of this hardening process is the fact that the heat is generated evenly around the bar itself for a true, “through-hardened” grouser bar that demonstrably reduces the downtime on heavy equipment while helping to reduce the overall cost-per-hour of the entire mining operation. But what about the other grouser bar out there that goes through a similar induction heating process? Nerlich cites recent independent abrasion tests where 4N was pitted against other induction-heated grouser bars. These tests have shown that the 4N bar is tougher because it achieves a superior micro-structure. In fact, in addition to producing the best bar possible, Nerlich claims their continued success is based just as much on the fact that they are able to build and maintain relationships with their customers that last over the long haul. “And today we’re proud to say that those customers are spread out all over the world in five continents and almost 40 countries.” To reach 4N it is best to contact them through their website “contact us” section at 4NCorp@4ncorp.com.

Re-grousering with the right grouser bar can significantly reduce a mining operations total cost per hour.

Weight

Height

PROFILE

Kg/m

Lb/Ft

820

2.68

1.80

840

4.19

2.82

850

5.66

3.81

Width

inches

25.4

15.9

5/8"

35.1

1-3/8"

19.1

3/4"

41.3

1-5/8"

22.2

7/8"

845

7.24

4.87

38.1

1-1/2"

28.6

1-1/8"

870

8.34

5.61

50.8

25.4

890

10.44

7.02

50.0

1.969"

32.0

1-1/4"

905

12.09

8.126

65.0

2-9/16"

30.0

1-3/16"

910

15.70

10.56

63.5

2-1/2"

38.1

1-1/2"

912

18.83

12.67

71.1

2-3/4"

41.3

1-5/8"

911

21.18

14.24

82.6

3-1/4"

41.3

1-5/8"

913

26.16

17.59

88.9

3-1/2"

44.5

1-3/4"

800

1.98

1.33

15.9

5/8"

15.9

5/8"

855

2.84

1.91

19.1

3/4"

19.1

3/4"

875

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825 Hex 835 Hex

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FEATURE

3D laser-based truck volume measurement Accurate and cost-effective volumetric payload measurement Accurate and cost-effective, 3 D volumetric laser technology removes guesswork out of mining payload measurement of moving trucks. It offers to Africa mine operators a viable alternative to time-consuming and error prone conventional payload measurement techniques.

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Cost containment, enhancing safety and improving efficiency’ is the mantra in contemporary mining operations from pit to port. True to form, mine operators are going to great lengths by ensuring that no stone is left unturned in pursuit of ways through which these three objectives are met. One of the avenues they have identified is truck load weighing of bulk material where alternative techniques are being sought. Indeed, accurate measurements of bulk materials in a mining operation are vital in ensuring the correct amount of product is being hauled. First DRC-Zambia Mining has observed, with keen interest, a shift from manual load weighing techniques towards volumetric 3D laser scanning, with the technique increasingly being used on mining sites in the past five years.

Woodmead’s Bulkmeter is a typical example of a 3D volumetric laser scanning/epitomises what 3D volumetric scanning offers in bulk material weighing applications in moving haul vehicles. One would really appreciate the benefits of 3D laser volumetric laser scanning better, by analysing the limitations of manual, conventional weighing. Challenges with conventional measurement More an exercise of guesswork than the certainty of precision, conventional measurement poses a number of challenges to mining companies who are focused on getting more from their ore. First is incorrect readings can result in inflated costs, whose ramifications can cut across the entire supply chain/ with ramifications across the entire

supply chain. Secondly, conventional measurement created a climate for load theft, skimming and substitution in bulk mining. Hard to take but true is the fact that once the truck loads ore from the stockpile there is guarantee that the ore will reach the destination. No doubt, there is a need for methods and systems that prevent excessive losses that the numbers are consistently accurate and cannot easily manipulated. Mining companies have to make a hard choice between the familiar conventional, loss making payload weighing methods and the new methods. Bulkmeter as an alternative By using cutting-edge laser technology, bulkmeter is capable of delivering high precision and reliable measurement

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of bulk materials loaded on open-top containers without operator intervention. The system enables measurement of bulk materials such as chips, biomass, coal and any other bulk material. Convenience Bulkmeter is more convenient for bulk material measurement, specifically due to the following features: • It is quick and easy to install, configure and transport. • An auditing system that allows reviewing the details and results of each measurement. It is possible to retrieve the measurement details, the laser profiles, load pictures, license plate picture, and load reports for each measurement. A volume of benefits Compared to conventional haul truck measurement techniques, Bulkmeter offers immense benefits, both direct and indirect, to mining companies: i. Direct benefits What can be cited as direct benefits include but are not isolated: • Accurate estimation and measurement of different characteristics of the material being

• • • •

transported; Inbound and outbound real time truck information; Auditing records for 100% of inbound and outbound trucks; Reduction of processing time associated with manual measurements; and Reduced number of operators involved in the measurement and supervision process.

ii. Indirect benefits • Improves the interaction with suppliers or clients: The measurement of the volume is accurate, objective, and transparent, thus eliminating subjectivity. • Reduction in measurements times: The automatic and fast measurement reduces the time associated to controlling each load, eliminates the necessity of personnel dedicated to control tasks, and the risks related to the manual inspection of loads. • Savings in transportation costs: Vehicles are scanned while driving through the scanning frame/portal, no long waiting lines. Travel time efficiency is increased.

Informed business choices Indeed, mine operators in Africa have to make informed business choices when it comes to payload measurement. As they aim to contain costs and improve efficiency in order to increase profit in their operations from pit to port, unquestionably, 3D volumetric bulk material measurement is the way to go.

Woodtech’s Support and maintenance service Woodtech provides a complete support and maintenance bulkmeter system, which allows operational continuity as well as excellent performance and reliability. The support plan includes remote monitoring to evaluate key performance indicators and allows taking preventive actions. The company offers the optional services based on the needs of the customer. Woodtech has over twenty years of experience in the development of measurement systems mainly for the forestry industry. Its main customers are located in Chile, Argentina, Brazil, the United States, and Germany.

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FEATURE

Automated system for loading management in mining industry Digitalization of real-world in more intelligent and efficient loading processes Bulkmeter has an auditing system that allows reviewing the results of every measurement in detail, such as 3D images of the truck, images of the load, vehicles ID, loading reports, among others.

rocess management becomes critical when it comes to increase productivity and profit through operational efficiency. In Woodtech we developed Bulkmeter, an automatic system that obtains in real time reliable and accurate information of raw material truckloads, allowing operators to take timely corrective actions in the loading process. Among its main contributions to the mining industry, Bulkmeter allows for consistent traceability of raw material movements from the mine to the crusher and real-time warnings, which help to achieve a better productivity. Its state-of-the-art laser technology allows the user to identify in real-time oversized rocks on the loading surface of the truck and reduce the risk of damaging the crushing machines. The

reporting system of Bulkmeter delivers valuable information such as loading distribution reports, which offer relevant operational insights to optimize the loads in each trip, avoiding over or under loaded trucks. Also, the system allows for comprehensive inventory control, among other benefits. “We are a technological company, specialists in industrial processes. This expertise enables us to develop solutions that can show key operational administration data to create efficiency. Bulkmeter requires minimal intervention in current operational environment and easily integrates into existing customers systems, for example, ERPs. This is widely appreciated by our clients.” said Carlos Bussinger. CEO of Woodtech.

Bulkmeter benefits • Information of all incoming and outgoing trucks to the plant • Auditable evidence for 100% of incoming and outgoing trucks • Accurate volume measurement for each truckload • Less time needed for truck inspections • Oversized rocks detection and realtime warnings Successful case Recently, Woodtech developed a new solution for one of its biggest mining clients in Brazil. It is based in is a control system that allows measuring the volume of material removed over a large area. 9 #Bulkmeters are organized in 4 control points arranged in a wide area. In real-time, this system could perform up to 12,900 dump trucks’ closed-loop measurements every day. “We are very glad, because we could respond to the need of accurate and traceable information”, said CEO of Woodtech. Woodtech is a technological company, specialist in industrial processes, with more than 10 years of experience. We like to work closely with our clients by understanding their needs at the plant and adding value to their processes. Our solutions are present in several countries around the world, including Chile, Brazil, Mexico, Germany, the USA, and Australia. Learn more about our Bulkmeter in https://www.youtube.com/h?v=2VknFbG l9gY&list=PLdTvmaaRrKY43ZLelEKkms ggBIeBR_S5B&index=1 www.woodtechms.com

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FEATURE

Real time bulk materials analysis systems for mines

nbelt analysers provide insights into process performance that are unobtainable to traditional sampling system results. Minute by minute measurement in real-time enables adjustment of process systems and empowers plant operators to minimize losses in efficiency from process excursions. Ore sorting has been used in the coal and iron ore industries for many years and is now being more widely applied in other mineral processing industries. More accurate and efficient detectors along with enhanced analysis algorithms, which in turn has meant more compact analyser designs can use smaller sources. These improvements in analyser performance now means that low throughput operations can also consider these new technologies, which in the past could only be justified in the large operations of the major miners. In uranium processing for example, the GammaScan analyser developed by Real Time Instruments (RTI), can measure U3O8 to better than 50 ppm and is able to be employed to identify high, medium and low-quality ore grades, so that each can be diverted & processed separately. Online analysers permit accurate bulk

designed to use analysers to monitor the coal quality and the good quality coal is diverted from the mainstream and not fed to the washplant. This is known as a bypass application. Straightforward estimates reveal that bypassing less than 10% of the total coal, improves wash plant efficiency and pays for the onbelt analyser within a matter of months. Paradoxically, the yield increases, if the good quality coal does not have to be washed; more consistent coal quality leads to higher yields, even though the average quality of the coal feed is poorer. RTI’s AllScan analyser, based on Prompt Neutron Activation Analysis (PGNAA), measures the elemental composition of a range of ores every minute as the ore flows along a conveyor belt. Some of the industries using the

ore sorting, to improve metal recovery. This improvement is achieved by mining from an ore body with a lower average grade, identifying and then redirecting the high-grade portions, that would otherwise could have ended up in waste dumps. As an example, in the coal industry, sorting ROM coal before the washplant has long been a standard application. ROM coal which is of good quality does not need to be washed. Thus, plants are

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PGNAA process control include iron ore, phosphate, bauxite, manganese and nickel producers. The zinc industry uses the onbelt AllScan elemental analyser to identify gangue in the ROM feed. By removing even a few percent of gangue from the stream coming into the plant, the increase in yield and plant efficiency, will pay back the AllScan investment in a few months. Further, the onbelt AllScan can also be installed in blending, sorting and product control applications across the plant eliminating bottlenecks and minimizing the risk of out of spec processes. A new development has seen the AllScan being used as a slurry analyser as well. In this application, the technology can measure the elemental concentration of the slurry as it passes through the AllScan’s measurement zone. The minerals industry also understands the benefits of onbelt microwave monitors being used to provide operators with moisture analysis of their ore every second. For example, metal accounting is problematic without accurate knowledge of the moisture content at each stage of the processing. Gold miners use RTI’s MoistScan to ensure precise reconciliation calculations. Analyses are updated every minute, which, along with average values, are communicated to the plant usually via 4-20 mA current loop outputs.

Unit No Sorting Sorting Mt 145 145 Ore Mined Mt 195 235 Mining Cut Off Grade %Cu 0.4 0.35 Grade %Cu 0.73 0.66 Strip ratio W:O 0.74 0.62 Sorting Feed Mt 0 235 Sorting Rejection %wt 0 30 Sorting recovery % 100 90 Input Copper kt 1,423 1,563 Output Copper kt 1,423 1,406 Output Tonnes Mt 195 165 Processing Process Feed Mt 195 164.5 Head Grade %Cu 0.73 0.85 Cu in Feed kt 1,423 1,406 Plant Recovery % 90 90 Cu in Concentrate kt 1,280 1,266 Summary Tailings kt 193,720 163,234 Total Copper kt 2,115 2,115 Sent to Waste/Left in Pit/Tailings kt 835 849 Recovery % 61 60

Waste Mined

months of extreme rain and during the long, hot dry season. They are aware that this strategy leads to errors in processing and accounting, and so they are looking to install moisture analysers to have an understanding of the day-today moisture variability.

In most industries, when the ore becomes very wet, it becomes sticky and may cause blockages as it cannot flow through the plant. Such blockages are a major problem. Having access to real time results means that operators are able to stop receiving ore when it is very wet. One of the most common moisture monitor applications in recent times has been to monitor ore shipments as they are being loaded, so as to ensure that the moisture content is less that the transportable moisture limit (TML). TML represents the maximum safe moisture content before the shipment is at risk of toppling. Data from an onbelt moisture monitor can alert the operators of a high moisture content during the loading, who many then decide to stop the loading.

Please contact Michael Edwards, RTI’s African Sales Manager, MichealE@ rtiaustralia.com, to discuss your particular application.

RTI is aware of at least one copper plant, where, because of difficulties collecting representative samples, they assume an average moisture content of their ore of about 4%, even during the couple of

Case Study for Sorting Application This case study examines a large copper deposit mined as an open pit under two operational scenarios – the first without bulk ore sorting and the second with ore sorting applied. The mine maps below assume 5 Mt in each block. The assumed copper quality, in red, are based on RTI’s experience working at copper mines in Chile. It is further assumed that

there is a 30 percent waste rejection and 90 percent recovery from the bulk ore sorting plant. Given typical plant heterogeneity in ore quality, a 1,200 mm belt running at 3 m/s, we calculate, with and without sorting: When ore sorting is applied, ROM is fed directly to a bulk ore sorting plant. The rejected waste material is rehandled and disposed of along with waste from the mine, while upgraded material is fed to the processing plant. Assuming that the processing plant has a capacity of 10 Mtpa and a recovery of 90%, then it is calculated that: However, every orebody will exhibit different bulk ore sorting performance based on its in-situ grade variability and must be evaluated on a case-by-case basis.

No Sorting Sorting Mine Life (yr)

19.5

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increase of 0.12%

Copper Contained (ktpa) 72.9

85.5

increase of 12.5 ktpa

Recovery (%)

Cu in Concentrate (ktpa) 65.7

76.9

increase of 11.2 ktpa

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FEATURE

Zambia copper mining It looks good for Zambia’s copper miners The global shift towards renewable energy, as well as rising copper prices, augur well for Zambia’s copper mining sector. However, the country needs to remove barriers to investment in the sector, not least double taxation.

opper has been synonymous with Zambia’s economy and will remain like that in the foreseeable from the look of things. Due to futile or halfhearted efforts to diversify the economy, the country’s economic dependence - or rather over dependence - on copper has been akin to putting all proverbial eggs in one basket. Past and recent events indicate that a slowdown in the copper sector has widespread ramifications in the entire economy. Consequently, it is only rational that the Zambian government should create conditions conductive for the growth and future sustainability of copper mining activities. Is Zambia going all-out to ensure that its copper mining sector makes the most of a bullish global market? What shapes the trajectory At first, it has to be acknowledged that the trajectory of Zambia’s copper sector is directly shaped by both domestic and international matters – the former in the country’s own hands, the latter driven by international events.

i. Domestic factors Domestically, it is inevitable that challenges that affect the economy have not spared copper mining companies, as highlighted in African Development Bank’s Zambia Economic Outlook 2021 (Macroeconomic Performance and Outlook). One trend which has had a direct bearing in the past two years is rationing of electricity – a phenomenal called load shedding – due to low generation capacity. Zambia relies most of its power supply from a hydropower plant at Kariba Dam, whose 1,626 Megawatts of generation is shared between Zambia and Zimbabwe. Unfortunately, in the past two years, drought conditions reduced water levels in Kariba Dam which affected hydropower generation capacity, which meets 85 percent of Zambia’s needs (based on a USAID 2020 Power Africa report). It was only to be expected that mining, as an energy-intensive sector was not spared, being hit the hardest in the past three years. This has prompted organisations

to use diesel as an alternative source of energy to sustain production, which has resulted in increase in operating costs (of which energy constitutes a third). Encouragingly, there have been a number of projects aimed at meeting the shortfall in power generation. Notwithstanding the risk of drought, evidently Zambia still believes in hydropower as it is developing the Batoka Gorge Hydroelectric project together with Zimbabwe. Implemented according to the Build Operate Transfer (BOT) transfer final model, the project is expected to inject an estimated 2400 megawatts into the power grids of Zimbabwe and Zambia. Also, in a bid to diversify its energy sources and reduce the precarious dependence on hydropower, Zambia has added renewable energy sources such as solar. Eligible Independent Power Producers (IPPs) to embark on building power plants have been identified and project implementation plans are at an advanced stage.

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The diversification of energy mix augurs well for the future of copper mining in as far as the supply of power is concerned. Indeed, sourcing power should be the least of mining companies concerns. Nevertheless, the lingering reality is that, for now and at least the next two years, copper miners have to embrace power rationing as a reality, and have to have contingency plans in place. Granted, this will come at a hefty cost to mining companies who elect to go the self-generation route. Dependency on completion of project may backfire as there could be unforeseen circumstances that could hamper their completion. Anther areas the government should resolve is the contentious double taxation of mining companies, who are obliged to pay both royalty tax of 7.5% as well as corporate income tax. The Zambia Chamber of Mines has been lobbying the government to review this practice, which it warns will hinder investment which is needed now than ever as the country is seeking ways of recovering from effects of COVID-19 pandemic. This remains unresolved to this day.

ii. International factors In the past three years, the impact of global copper prices on Zambian economy, have occasioned slower mining activity, reducing output. COVID-19 was a last straw that broke the camel’s back of sorts, resulting in record plummeting of prices. Three factors are set to change Zambia’s fortunes in copper mining, after the relative doldrums of the past two or three years – growing demand for a metal that is used in electric vehicles and improving prices. Even more interesting, in a report, Bloomberg Intelligence analysts, Grant Sporre and Andrew Cosgrove, predict what should be good music in the ears of the Zambia’s ministry of mining.

Increasing production In the face of persisting challenges, more small mines are coming into production. Zambia expects to produce 1 million tonnes of copper from a planned 880,000 in 2021, as Reuters reported recently, quoting the country’s minister of mining, Richard Musukwa. However, to unlock more opportunities, the government has to decisively address the double taxation connundrum. When all is said and done, prospects look good for Zambian copper miners.

Their report, Copper Fundamentals Can Support a New Supercycle, predicts that within a decade copper may be a most sought-after commodity to meet the demand from renewable power projects and electric cars. About $100 billion of investment in mining projects is needed to meet projected 10 million tonnes in global demand for copper. There is concern that failure to address the supply deficit could result in steep rise in prices.

Interestingly, it has dawned on the government of Zambia that depending on copper, a commodity susceptible to developments on the world economy, is dicey. Thus, the country has embarked on diversifying the mining sector beynd copper, eyeing opportunities in gemstone and industrial minerals. This is documented in the Seventh National Development Plan (7NDP).

Beyond copper

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FEATURE

Consider it pumped with Atlas Copco’s centrifugal dewatering surface pump solutions

Efficient pumping with Atlas Copco PAS fully automatic dry self-priming centrifugal open-frame pump

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The Covid-19 pandemic has irrefutably placed tremendous strain on our country’s already struggling economy, prompting customers to now, more than ever before, focus on maximising their productivity and production while reducing operating costs wherever and whenever possible and as much as possible,” says David Stanford, Business Line Manager for Atlas Copco Power Technique’s Portable Products. “We are aware of these challenges our customers are facing so we have made sure that we are able to offer products that deliver exactly what they need. For those customers who require pump solutions, we offer a range of high performance, super-efficient, robust, compact, versatile and easy-toservice products that get the job done seamlessly while being considerate to the environment.” Stanford stresses

that the pumps’ high performance capabilities do not compromise on what he considers to be one of the most essential factors for reducing Operational Expenditure (OPEX) and lowest total cost of ownership, namely efficiency. Atlas Copco’s rugged PAS dry self-priming and PAC H high head dewatering surface pump series features smart design, cutting-edge technology, quality components and advanced manufacturing to deliver bestin-class pumping solutions. The PAS range of fully automatic dry self-priming centrifugal open-frame pumps serves as a prime example of Atlas Copco’s commitment to developing smaller, lighter products that are easy to use, easy to move and easy to maintain. Also available in a canopy version, the PAS range comprises four high flow (HF) and five medium flow (MF) models delivering

a maximum flow capacity of 2100 m3/h, with a maximum head of 75 m and an outlet size of 100 - 300 mm. These fit-for-purpose diesel pump systems are equipped with several features that render them ideal for mining applications. With the ability of working with clean or dirty water and handling trash and fibrous materials with ease, these pumps can pump, raise and transport liquids with solids of up to 100 mm in suspension over long distances without the risk of clogging. This exceptional solids-handling capability is due to the inclusion of a centrifugal pump with a semi-open impeller and an abrasion-resistant pump casting. The robust PAS pumps’ dry prime capabilities enable the user to start pumping immediately with a simple flip of the switch, ensuring reliable operation in stringent conditions where start-up can often present a challenge. The pump

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system’s high-capacity diaphragm pump makes automatic priming possible; the air in the pump is separated from the liquid by the large SuperDuo separator which is then sucked by the vacuum pump. Moving on to Atlas Copco’s innovative PAC H high head series, Stanford says that these high value pumps are exactly what the market has been waiting for. Part of Atlas Copco’s renowned Head series, the PAC H series combines performance and efficiency in one smart package. Featuring a maximum head size of 150 m, a maximum flow of up to 1200 m3/h and a solids-handling capability of up to 89 mm, the PAC H series is particularly suited to industrial applications such as water transfer and will benefit industries such as oil & gas, quarrying, surface mining and construction as well as the municipal sector. “Equipped with a high efficiency hydraulic end, our pumps consume very little fuel irrespective of the operating conditions,” notes Stanford. “Moreover, thanks to a modular design, one pump is capable of covering multiple requirements. With fewer pumps required and fast easy manoeuvrability thanks to compact dimensions coupled with a light weight, uptime and productivity is boosted.” There is a direct correlation between equipment availability, associated uptime and production, and the speed in which service and maintenance work can be carried out. So Atlas Copco has ingeniously centred the design of its PAS and PAC H pump series on simplified serviceability. If performed regularly by trained technicians using OEM parts, service will improve pump reliability, prolong life cycle, maximise uptime and reduce maintenance costs, all factors that are fundamental to operational efficiency, ultimately adding to the enduser’s bottom line. The hinge kit available on the PAS range, simplifies and speeds up pump maintenance. The pump is fitted with a hinged cover that provides fast easy, access to components, enabling an industry-leading three-minute clean up and restart. The service and maintenance process on the PAC H pumps is facilitated as wear components can be serviced or replaced without

PAC H high head series combines performance and efficiency in one smart package

the need to dismantle the pump. These include Atlas Copco’s semi-cartridge seal design, hinge kit, bolted wear plate and link belts, The semi-cartridge seal, which is normally an optional extra on other pumps in the market but standard on the PAC H, makes the lip seal and impeller easily accessible. The innovative hinge kit includes a ‘swing door’ that allows quick and easy access to the pump’s internal workings and a single bolt to remove the impeller. Stanford explains that by using link belts to enable changeovers without having to dismantle the entire wet end of the unit

reduces MTTR (mean time to repair) by up to 30%. Service packs including Preventive Maintenance Kits, Wear Part Kits, Seal Kits and Gasket or O-Ring kits as well as high-performance long-lasting lubricants especially engineered to match pump maintenance specifications and provide optimal pump protection, complete Atlas Copco’s end-to-end pump solutions. Atlas Copco also supplies a range of eleven VAR wet self-priming centrifugal pumps available in open-frame and canopy versions.

PAS pump boasts dry prime capabilities enabling user to start pumping immediately with a flip of the switch

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FEATURE

Energy provider gives mines the spark they need in 2021

ower supply might be what energy companies are known for, yet in 2021 the world’s leading mobile power provider Aggreko also wants to be recognised as an investor in life-ofmine projects. Aggreko Australia Pacific Managing Director George Whyte said traditionally where Aggreko may have been engaged on a mining project as a contractor, it could now partner as a long-term investor and help miners navigate the energy transition. “Investor partnerships can support the rapid changes in technology and emissions compliance that our mining customers are facing. Investing millions of dollars in capital for a mine’s power plant is a risk for any company, and as a partner, Aggreko takes on this risk instead of the mining company. It is a smart way for miners to do business in the post-COVID and renewables era,” Mr Whyte said. Aggreko has built an almost 60-year-long reputation for powering many sectors around the globe. It has also supplied power and underground cooling to the mining sector for more than 35 years and has evolved into life-of-mine contracts and renewables, as well as high-profile event experts including the upcoming Tokyo Olympics. In its latest report – which details its future energy transition – Aggreko cites

mining as a major growth sector. Mr. Whyte stated that their global team’s unique offering is with build-own-operate investments across all continents.

As well as continuing to invest upward of AU$450 million (£250 million) annually in technology and innovation, the company is ready to further boost its investments in the natural resources industry. “We believe there is an opportunity to transition energy and our customers to a better future. The world’s reliance on power – particularly renewables – will grow significantly in the next 30 years as more countries focus on decarbonisation and population demographics change,” Mr Whyte said. Aggreko’s Global Head of Mining, Rod Saffy, said miners struggling to get funding for capital expenditure (CapEx) were looking to outsource and there was a trend toward creating partnerships with providers.

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“Partnerships provide more value beyond de-risking project finances,” Mr Saffy said. “There are technology and emissions risks, so by partnering with us for example, we aren’t just supplying equipment and labor, we share in decision making and project milestones, we invest and update technology on-site and navigate social and environmental impacts together.” The trend for junior miners particularly to seek joint ventures and increase partnerships is outlined in the Deloitte Insights: Tracking the Trends 2020 report. According to the report: “Given the size of CapEx projects in the mining sector, their location in remote regions, and the growing complexity associated with accessing many ore bodies, companies of all sizes can benefit from partners to finance projects, source critical skills, build local relationships, and share risks.” Mr Saffy said companies looking to build power stations for the first time particularly benefited from supportive partnerships with Aggreko. “Power stations are our core business, and they have become much more complex on mine sites than they have been in the past. It is challenging to get funding to build power stations, and miners are needing support to integrate renewables into their plans immediately or in the future, or needing solutions designed from scratch,” Mr Saffy said. “Partnering with us is a sustainable and beneficial business solution. Miners are wanting hybrid power stations that might utilise a mix of energy sources such as diesel, gas, solar or battery, for example. They also want that power to be scaled up or down and upgraded as their needs change and new technology comes online.” Mr Saffy said mines throughout the world were becoming less dependent on mass-scale thermal plants to deliver baseload power through national grids.

One such example is the Gold Fields Salares Norte Mine in Northern Chile where Aggreko has become a major investor, and partner for the mining project for at least 10 years. The mine is located 190km from the nearest town and is 4500m above sea level, and Aggreko is creating a unique and market leading off-grid hybrid power solution, comprising of diesel and solar for the harsh environmental conditions. Aggreko estimates the mine will experience $7.4 million in cost energy savings across the 10 years. Mr Saffy said the benefits for Aggreko in partnering and investing with miners from the beginning of their project to the end of the life of mine, was beneficial for both parties. “As a partner, Aggreko derisks the threat of future innovation and technology for miners,” he said.

“Our build, own, operate and maintain model frees up working capital without increasing the debt ratio for mining projects. Modular equipment also gives miners the ability to leverage innovation at low risk and not be concerned about having the latest equipment.” “We benefit too, by showcasing our expertise and innovations throughout a project’s lifecycle and support mining companies to reduce emissions and increase their operational efficiencies.” Late last year Aggreko committed to achieving net zero emissions by 2050. The company operates in more than 80 countries including Australia, Africa, North America, Canada, South America, Africa, and South East Asia.

“With the cost of renewable power generation falling, there is also growth in localised microgrids, which means less dependence or complete independence from the grid. Miners in Australia, Africa and South America, where there is less infrastructure in remote locations, are finding it particularly helpful to partner with us from the start of a major project,” he said.

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FEATURE

Rand-Air provides efficient dewatering at Northern Cape mine

outh Africa’s mining and industrial sector operates in diverse weather conditions: heat, cold, rainy or sunny. While mining operations in the typically hot Northern Cape operate mostly in hot, dry conditions, the province has experienced unusual and prolific rainfall since late last year - with the resulting water volumes and flooding affecting several mining and industrial operations. To mitigate the effects of this exceptional rainfall - and to ensure vital operational continuity – a Northern Cape mine recently required a fast and efficient dewatering solution on site. Established leaders in the field of portable air, power, flow and lighting solutions, and part of the global Atlas Copco Specialty Rental division, Rand-Air took to this challenge like a duck to water, supplying a quality solution – the high-performance PAS150 HF 300 dewatering pump. “Flooding, either via the ingress of ground water, or surface run-off and on-site pooling through unprecedented rainfall (as in this particular case) can cause significant losses to equipment, productivity and revenue. Even more seriously, severe flooding could also result in loss of life, as well as environmental damage,” advises RandAir sales representative Denise Olivier. “With this in mind, we dived right in providing an agile and robust solution for the customer in the form of the PAS150 HF 300, thereby ensuring access to a safe and dry site; as well as smooth operational continuity – ‘uptime’ secured!” she says. “The PAS150 HF 300 high-flow vacuum prime centrifugal pump is extremely versatile, and suitable for many industries, including general dewatering and emergency applications, such as flood clean-up operations – which is exactly what the customer required in this instance,” emphasises Olivier. The pump, which was originally hired for a week in mid-December, has been in operation at the customer’s site for the past two months. Pending further rainfall

and potential flooding conditions, the pump will remain in operation indefinitely. “True to Rand-Air’s ethos of making agility count for the customer, we were able to deliver the pump with a fast, same-day turnaround without delays; and we also provided additional support to reduce delays in production,” says Olivier. “The customer was very satisfied with the reliability, as well as the high-flow, volume pumping capabilities of the PAS150 HF 300,” she adds. “This pump, which has been designed and developed with reliability and ease of use in mind, also features another important advantage – a high-flow performance of 510 m³/h, or 8 500 ℓ/ min,” Olivier points out. She further explains that the pump features a high-efficiency pump wetend, which is equipped with a diaphragm vacuum pump and separator. The centrifugal pump and separator enable air to be separated from the liquid and to be sucked by a vacuum pump. These components allow for an automatic and fast priming process and trouble-free operation. Moreover, even if the on-site operations have suction heights of several meters, the machine rapidly evacuates the air from the suction pipe and starts to pump. Meanwhile, the pump’s modular design offers flexibility in terms of transportation and manoeuvrability, while the easy servicing of the wear components allows for less downtime and more pumping. Other features of the pump include a dry running system, and a control panel. The pump unit also has an integrated control and power cubicle, comprising a digital controller with standard warnings, shutdown, stop/start function, an emergency stop, as well as easy-toaccess and read diagnostics. Furthermore, a configurable set point via transducer controls the pump’s Stage 3B engine speeds.

As part of Rand-Air’s service offering in providing comprehensive technical knowledge, Olivier advised and supplied the customer with the correct information regarding the appropriate class of discharge pipe matching the pressure of the pump. This particular hire is the second longterm pump hire by Rand-Air since the company introduced the pumps offering to its existing rental equipment portfolio. Despite the PAS range of pumps only recently being made available, Olivier – in keeping with her proactive and energetic approach - reached out to customers when the first drops of rain hit the Northern Cape, to better inform and educate them about Rand-Air’s pump offering. “Our sound industry knowledge and inherent intuition in sourcing and providing appropriate equipment tailored to the customer’s specific needs - complements our proactive approach in anticipating new needs as they arise - and having the required equipment available. “This is demonstrated by our pump performing a critical dewatering function in this instance – and also proving that no matter the customer’s challenge, Rand-Air can rise to the occasion with excellent product quality and service,” says Olivier. In a further reflection of the company’s innovative approach, Olivier notes that Rand-Air currently has two pumps on hire; the second pump was recently rented out to a customer in the iron-ore mining sector. “Currently – due to water or rainfall affecting operations throughout the country, we are receiving enquiries about our pump rental solutions; and customers are becoming increasing aware - and confident - of our pumps’ capacity and performance. “To this end, Rand-Air continues to ensure that our solutions will keep customers’ operations dry, safe and ‘afloat’,” Olivier concludes.

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FEATURE

Reliable pipework for decades Piping systems that reduce your TCO The total cost of ownership (TCO) of a piping system depends on several factors such as material, design of pipes and fittings and maintenance intervals. The Plas-tics Experts from AGRU Kunststofftechnik GmbH manufacture pipes and fittings at the cutting edge of technology, improving processes and optimising results for more than 50 years.

ggreko, the world’s leader in mobile, modular power has committed to net zero emissions by 2050 and is partnering with the world’s biggest miners to use greener energy like solar, wind and natural gas. The company has vowed to invest AU$450 - $600 million (£250 million £350 million) each year to support its energy transition, including big spends in what it sees as a major growth area for its business: mining. Thermoplastic piping systems in PE 100-RC, PP, PVDF and ECTFE have been proving their value for decades in industrial plants around the globe. Let us see how pipes and fit-tings affect the total cost of ownership of a piping system. How to minimize head loss in your piping system A pump should always operate at its best efficiency to minimize the total cost of ownership. If a piping system loses hydraulic capacity, it will result in longer pump hours and increased energy costs. Impacts on the hydraulic capacity of a piping system are incrustations e.g. biofilms that grow over time, the roughness of the inner pipe surface, the hydraulic de-sign of fittings and

ineffective de-aeration due to failures in pipeline design. Biofilms and incrustations occur with all different piping materials and have a negative im-pact on the internal diameter of the pipe. If a pipe becomes overgrown from the inside, the flow rate decreases due to the reduced diameter. More pressure and therefore more energy will be necessary to maintain the flow rate. Pipe cleaning by the means of pigs is neces-sary. In this case, thermoplastic pipes and fittings are much easier to clean than conven-tional pipes because of their very smooth internal surface that prevents a strong adhesion of lime, shells or other organic materials. The roughness of the pipe’s interior surface determines the friction loss in a piping system. If the pipe’s internal surface is rough, the fluid flow causes friction on the pipe wall and a higherpressure loss is the result. Depending on the transported liquid, also abrasion of the pipe walls can occur. Thermoplastic pipes do have a very high abrasion resistance which results in a reduced influence to the surface roughness of the piping system. It is a known fact that metallic, concrete and stoneware pipes develop a rougher inside sur-

face due to corrosion and abrasion over time. In contrast, plastic piping systems offer the advantage of a long-term slick inner surface that reduces friction and therefore head loss significantly. Reduced head loss means less power consumption, cutting down the total cost of ownership of a pipeline. The optimised design of AGRU plastic piping systems al-lows space saving installation on the job site. This saves cost in industrial operations. Another aspect is the hydraulic design of fittings. The hydraulic performance of AGRU pip-ing systems is mainly based on the expert fittings design which was accomplished within 55 years of research and development. AGRU has been producing injection moulded fittings since 1966 and has flow-optimized them in every aspect. The extensive product range between OD 20 mm and OD 3500 mm offers a high pressure resistance up to SDR 7,4, superior flow properties and a vast material range for outstanding chemical and tem-perature resistance. The job site proven joining methods such as electrofusion welding, heated tool butt-welding and infrared welding are further key competences of AGRU, The Plastics Experts. The welding technology and consulting for

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FEATURE

every material and diameter of their piping components is state-of-the-art. A piping system for every application AGRU Kunststofftechnik offers a vast assortment of piping systems characterised by out-standing operational reliability, easy installation and extremely low maintenance overheads. Be it the leakage-monitored double containment piping system PolyFlo, the abra-sion-resistant multilayer system MINELINE, or the ECTFE system, which is even resistant to nitric acid, AGRU has the best solution for virtually any industrial application in its portfo-lio. Below you will find an overview of the AGRU piping systems: PE 100-RC piping systems AGRULINE pipes and fittings made of the innovative material PE 100-RC are extremely resilient and resistant to cracks. They are used for water, wastewater and gas transport and can be installed without cost intensive sand bedding. Universal welding machines connect pipes made of PE 80, PE 100 and PE 100-RC with AGRULINE fittings to create leak-proof joints. All components of the system are available in sizes from OD 20 mm up to OD 3500 mm. Since the pipes and fittings come from one factory, they fit with highest accuracy. Ad-ditionally, AGRU technicians consult you personally on your project. Since AGRULINE is a maintenance free pipework, that is homogenous, longitudinally forelocked and leak-tight, you will experience very low costs of ownership. Many AGRULINE pipelines are still intact and in operation 50 years after their installation, meaning the investment intervals for PE pipes are calculated in terms of several decades. Polyethylene has a further advantage: ease of installation. In comparison to steel or concrete pipes, PE pipes are a featherweight and often allow direction changes without fittings due to the flexibility of the material. The smooth inner surfaces prevent adhesion and offer perfect flow characteristics, reducing head loss of the pump. AGRU only processes certified materials in accordance to PE 100+ Association guidelines. Because of this, pipes and fittings possess high rupture strength, extreme resistance to crack growth, pressure surges and seismic activity.

PP piping systems AGRU plastic pipes in PP-R and PP-H and fittings in PP-R have been proving their value for decades in every area of industry. PP is characterised by its superior strength, stiffness, hardness and its temperature and chemical resistance. This thermoplastic is used in a temperature range between -5 °C and +95 °C. PP piping systems also play an important role in reverse osmosis, which is applied in desalination plants. Long-term resistance to corrosion, salts and minerals, as well as the smooth inner surfaces, ensure decades of maintenance-free operation. As high operating pressures are typical in plants of this type, PP – with its high creep strength – is the most popular material. AGRU provides pipes, mul-ti fittings, extended fittings, short spigot fittings, segmented fittings, socket welding fittings, electrofusion welding fittings and valves for industrial use in various dimensions. Fluoroplastic piping systems PVDF is a thermoplastic homopolymer with excellent media resistance, a high level of me-chanical strength, and maximum purity without additives or stabilisers. This makes it physiologically safe and suitable for use in ultra-high-purity applications. It also offers high me-chanical strength and excellent chemical resistance, working well at temperatures between -20 °C and +120 °C. For applications involving temperatures between -30 °C and +140 °C or very aggressive chemicals, ECTFE is the right choice. ECTFE consists of an alternating arrangement of ethylene and chlorotrifluoroethylene. This makes it the ideal material for applications involving high temperatures and extremely aggressive media. When transport-ing aggressive media like concentrated sulphuric acid (H2SO4), nitric acid (HNO3) or oxidis-ing agents such as hydrogen peroxide (H2O2) and sodium hypochlorite (NaClO) as well as concentrated alkalis, ECTFE is the only resistant plastic with an excellent price-performance ratio. Even when these media are transported under high pressure or at high temperatures, the AGRU ECTFE piping system remains permeation-resistant and leak-proof. The excellent surface quality and abrasion resistance make

fluoropolymers the ideal materials for use in the petrochemicals industry, life sciences and the food industry. Electrically conductive (antistatic) plastic piping systems Electrostatic charges in the pipework must be prevented when flammable media is being handled. If the pipeline passes through a potentially explosive atmosphere, a single spark can cause an explosion. ESD (electrostatic discharge sensitive) plastics such as HDPE-ESDel offer safety by dissipating electrostatic charges in a controlled manner. These ma-terials are electrically conductive due to the addition of carbon black whilst retaining the known benefits of polyolefines, such as chemical resistance and easy processing and installation. Double containment piping systems in PP-R and PE 100-RC Pipes and fittings of the reliable PolyFlo double containment piping system are extruded seamlessly using PP-R or PE 100-RC granules. Its compact design with a small annular gap and low weight, allows the easy and quick installation even in confined spaces by us-ing simultaneous welding. PolyFlo doubles the operational safety due to the simultane-ously extruded media and protective pipe as well as the leakage monitoring of the annular gap after installation. AGRU also offers prefabricated double containment pipes up to OD 800 mm made of PE 100RC, PP, PVDF and ECTFE in various pressure ratings. Abrasion-resistant piping systems The three-layer MINELINE piping system was developed to transport very abrasive media (e.g. slurries). Economic operation due to a longer service life, minimal thermal expansion because of the white surface, and high operating reliability are the system‘s most important properties. An abrasionresistant inner layer inside the pipes and fittings protects the pipe-work against fast and heavy abrasion. Designed for the toughest use in mining, MINELINE is also the best choice for other rugged applications. For more information about AGRU piping systems please visit the website www.agru.at

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AGRULINE FITTINGS & PIPES R E S I STA N T TO C R AC K S LONGER SERVICE LIFE crack resistant PE 100-RC HIGH ECONOMIC EFFICIENCY sandbed-free installation LASTING CONNECTIONS better welding results ONE STOP SHOPPING complete PE 100-RC piping system

agru Kunststofftechnik Gesellschaft m.b.H. | Ing.-Pesendorfer-Strasse 31 | 4540 Bad Hall, Austria | T +43 7258 7900 | sales@agru.at

FEATURE

Upgrading of Tippler project for Saldanha Iron Ore with total drive solution from Bauer The 750kW gearboxes, two parallel drive systems and three parallel and tandem drives, will be installed on a sacrificial conveyor and a 283m long overland conveyor respectively. The 185kW units will drive an adjustable shuttle conveyor. Compliant with necessary and important thermal criteria, the 750Kw gearboxes are equipped with a cooling and forced lubrication system with dual oil pumps, one serving as a backup unit. Derek explains that in addition to machine longevity, this system is also a safety feature, keeping the drive temperature to below a safe-touch of 70°C.

One of the five 750kW gearboxes from Bauer for Tippler upgrade project at the Saldanha Iron Ore export Plant

auer Geared Motors, a business division of Hudaco Trading (Pty) Ltd. Company, is delivering a total drive solution that includes five large sized 750kW industrial gearboxes and two 185kW units for the Tippler upgrade project at the Saldanha Iron Ore Export Plant. Weighing up to 15 tonnes each, the 750kW gearboxes are the largest machines ever supplied by Bauer to date. Bauer has been a market leader in electric drives since 1984, initially specialising in geared motors. The Hudaco power transmission division later diversified, expanding its portfolio to include industrial gearboxes and transmission solutions. Bauer joined the Hudaco group in 2002 and, in the same year, became a supplier to Saldanha providing slew and bucket wheel drives. Bauer upgraded these drives after ten years of operation and in 2020 supplied a third slew drive with planetary gearboxes, and an overland conveyor. When Derek Gilmore joined Bauer as Managing Director - Drives and Motors, in June 2019, the Tippler upgrade

project for Saldanha Iron Ore port fell under his auspices. Derek explained that the company responsible for overseeing the project favoured a total solutions supply chain through a single sourced provider. “The fact that Hudaco is a listed supplier to the Saldanha Port operation paved the way for Bauer, as part of the Hudaco group, to put in a bid on the drive requirements for this project.” Bauer proved compliance on design and all critical criteria as specified by the main consulting house. The full scope of supply from Bauer includes industrial gearboxes, medium voltage electric motors, drive base plates, high and low speed couplings, brakes, actuators, parts and spares as well as condition monitoring. “We will also be responsible for torque arm and complete drive assembly,” adds Derek. “Our industrial gearboxes are manufactured by India-based OEM, Elecon Engineering Company Ltd., one of the largest manufacturers of industrial gear units in Asia,” continues Derek. These rugged and reliable gearboxes boast a service factor >2 and 100 000 hours design life.

Bauer will also be responsible for providing the condition monitoring sensors to facilitate remote monitoring of the gearboxes including motor speed and motor windings temperatures, brake wear and temperatures, oil levels and flow pressures, as well as bearing wear and vibrations. “Early detection allows for a planned shutdown to do the necessary maintenance, thereby avoiding critical failure and costly downtime,” notes Derek. He adds that Bauer is also supplying large 710mm diameter hydraulic disk brakes for the sacrificial and shuttle conveyors in collaboration with supply partner, Magnet Service Binder. While the main contractor for the project will be responsible for installation and commissioning of the drives in conjunction with Saldanha Port authorities, Bauer will supply consumable spares such as filters, oil, etc. required during the commissioning process. “During commissioning, we will call on supplier partners like Magnet Service Binder to assist with training on brakes,” notes Derek. “We will offer support during and beyond warranty, including the supply of critical and fiveyear running spares and will assist with operator training.” Alongside local assembly, service and repair capabilities on all its products, Bauer also has the capabilities to service and repair competitor gearboxes

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to OEM standards. “Our industry-leading 24-month warranty bears testament to our suppliers’ commitment and provides ultimate customer peace of mind, assured of superior quality, reliable and efficient products.” Bauer received the order for the complete drive solution for the Tippler upgrade project in early May 2020 when the first wave of the Covid-19 pandemic was sweeping over the Northern Hemisphere. “This set us some tough challenges, forcing us to come up with innovative solutions,” states Derek. “It was most fortunate that Elecon was able to continue operating although output was understandably affected, with subsequent delays.” The next challenge was how to conduct witness testing at the Elecon factory in India given that the pandemic prevented travel. “We realised that we had to tackle this from a completely different angle. Making full use of digital technology, we held technical discussions, viewed instruments and meter readings as well as actual tests on video clips and images, even finalising factory acceptance tests, all via e-meetings.” Derek points out that by having a permanent digital record, they can conveniently reference this electronic library from anywhere at any time. “In addition to saving money in terms of travel costs, we also saved loads of time and subsequently realised a much quicker turnaround.” Knowing that they can efficiently do this type of work remotely and taking into account all the benefits, Derek encourages this approach going forward. When the gearboxes were ready for shipment from Mumbai to Durban harbour, Derek and his team faced yet another challenge, finding space on a vessel for their 20 ft and 40 ft containers as the pandemic forced shipping lines to reduce their fleets. The shipment finally left Mumbai on 28 October 2020, reaching Durban harbour 14 days later. “High winds delayed docking for a further five days, putting us under immense pressure to get the drives up to Johannesburg for assembly and presentation to the customer for inspection, within our promised endNovember 2020 deadline,” says Derek. “But the Bauer and logistics support teams managed to pull a rabbit out of the hat and got all the prep work done so

Total drive solution from Bauer_five large sized industrial gearboxes & two 185kW units for Tippler upgrade project

that once the units arrived, they were off loaded immediately.” Ready for delivery to site at the end of March 2021, the gearboxes are currently being stored at Tomco Rewinders. Derek explains that they selected Tomco as a business partner as their facilities, conveniently located around the corner from Bauer, are well equipped to handle and conduct no-load testing on large sized gearboxes. According to Derek, they see a great deal of potential in large sized gearboxes in the mining industry across the SADEC region. “Our success in supplying large gearboxes to the Tippler upgrade project at Saldanha Iron Ore showcases our capabilities and competencies to realise our ambition of entering this space.” Derek reveals that Bauer recently signed a sole distributor agreement with the

Elecon Group, adding sole supply of the Radicon industrial worm gearbox range. “We already have an installed base of smaller sized industrial gear units at Rustenburg gold and platinum mines, where we have a strong foothold, as well as in the SADC region and beyond into Egypt, Eritrea and the DRC. In line with this new agreement, the welcome addition of the Elecon range of power transmissions up to massive 9MW drives further opens up the large gearbox market for us. Moreover, we are also perfectly positioned to supply our customers in these regions with new bevel helical Elecon drives or drop in retrofit solutions for older gear units. We add further value by offering local content, assembly, testing and commissioning.” Wrapping up Derek says that they are extremely proud of this out-of-the box drive solution at the Saldanha Iron Ore Tippler upgrade project. “Despite facing numerous challenges, we found creative ways to get the job done while adhering to all Covid-19 protocols.”

Weighing up to 15 tonnes each, the 750kW gearboxes are the largest machines ever supplied by Bauer to date

Derek extends a sincere thank you to the dedicated Bauer management, Elecon, the main contractor and their supportive team including supplier partners, as well as the end customer for their commitment and contribution to ensuring a positive outcome and achievement with all

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FEATURE New South African Agent - Transfer Point Optimisation Australian based company, Kinder Australia, are pleased to welcome their exclusive agent Mngeniseni “Lucky” Nkosi. Enhancing their growing list of international Lucky is after partners, the load transfer point based in Felixton and can service South African bulk handling sites. He brings an impressive set of technical skills and is well acquainted with the servicing and maintenance of and make conveyors. any necessary

New South African Agent

Kinder Australia has over time developed an excellent reputation and established a proven adjustments. history of designing transfer points and engineering solutions that resolves our customers’ most challenging bulk materials handling problems effectively. Not to mention creating opportunities for further productivity gains, through extension of production assets, minimising shutdowns and labour resources. K-Dynamic Impact

Transfer Point Optimisation

ustralian based company, Kinder Australia, are pleased to welcome their exclusive agent Mngeniseni “Lucky” Nkosi. Enhancing their growing list of international partners, Lucky is based in Felixton and can service South African bulk handling sites. He brings an impressive set of technical skills and is well acquainted with the servicing and maintenance of conveyors. Kinder Australia has over time developed an excellent reputation and established a proven history of designing transfer points and engineering solutions that resolves our customers’ most challenging bulk materials handling problems effectively. Not to mention creating opportunities for further productivity gains, through

Belt and Belt extension of assets, minimising shutdowns Support System, are both The spotlight is often turned onto maximising performance during these periods of production down-time. In reality, paying time and attention to improving and maximising the engineered effective and labour resources. expertly and performance of a plant’s conveyor system can have many long-lasting positive profitability Mechanical maintenance and productivity benefits. designed to allow better teams are sensitive It’sand well regarded that transfer points are instrumental for conveyor belt systems running absorption of energy and efficiently, integral to this is incorporating Mngeniseni “Lucky” Nkosi an exceptionally designed and executed transfer quick to notice a decrease chute. The key to measuring efficiency of transfer points involves the requirement for even provide an weight teams to continually monitor and assess the conveyor system both before and in productivity on site. maintenance This after the load transfer point and make any necessary adjustments. dispersion of the conveyed often occurs when frequent K-Dynamic Impact Belt Support System and K-Flexal® Elastic Belt Support System, areAdditional both bulk material. cost expertly engineered and designed to allow better absorption of energy and provide an even production down-time occurs weight dispersion of the conveyed bulk material. Additional costadvantages advantages are also realised, are also realised, such as improved wear life of the conveyor belt and components and reduction in conveyor over long periods. Other belt maintenance costs, which can assist quarry operational bottom line. as improved wear life such factors affecting production Kinder Australia’s exclusive agent, Lucky is eager to provide anof in-depth and theevaluation conveyor belt and stoppages include cleaning recommendation on transfer point design optimisation for customers in South Africa. For further information he can be contacted via email at: mngehn@kinder.com.au components and reduction up time due to material in conveyor belt maintenance spillage and repair to costs, which can assist quarry damaged conveyor belt and structure. operational bottom line. It’s well regarded that transfer points are instrumental The spotlight is often for conveyor belt systems Kinder Australia’s exclusive turned onto maximising agent, Lucky is eager to performance during these running efficiently, integral provide an in-depth evaluation periods of production down- to this is incorporating an and recommendation time. In reality, paying time exceptionally designed and on transfer point design and attention to improving executed transfer chute. The optimisation for customers in and maximising the effective key to measuring efficiency South Africa. of transfer points involves the performance of a plant’s conveyor system can have requirement for maintenance For further information he ABN: 28 006 489 238 teams to continually monitor many long-lasting positive Issue: 202103 Page 1 via email profitability and productivity and assess the conveyor can be contacted benefits. system both before and at: mngehn@kinder.com.au Mechanical maintenance teams are sensitive and quick to notice a decrease in productivity Support System on site. This often occurs when frequent production down-time occurs over long periods. Other factors affecting production stoppages include cleaning up time due to materialElastic K-Flexal® production spillage and repair to damaged conveyor belt and structure.

ADVERTISER’S INDEX 4N Corporation.......................................................................................................................25 Africa Mining Convention................................................................................................07 Agruline.....................................................................................................................................41 AH Lundberg Systems......................................................................................................18 Ambra Solutions...................................................................................................................22 BAUMA Africa....................................................................................................................IBC Dy-Mark Global......................................................................................................................21 Endress + Hauser..............................................................................................................IFC

Juniper Systems...................................................................................................................33 Komatsu....................................................................................................................................27 Mine Supply International...............................................................................................15 Nanozen....................................................................................................................................17 Ritmo......................................................................................................................................OBC Woodtech S.A........................................................................................................................29

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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OUR NETWORK, YOUR OPPORTUNITY. bauma CONEXPO AFRICA, Johannesburg, Gallagher Convention Centre, Midrand, October 13-16, 2021 Sub Saharan Africa’s Leading Trade Fair for Construction, Building Material, Mining, Agriculture & Forestry Machines, Machinery and Vehicles

Showcase your solutions, position your brand as the leader in your sector and reach the continent’s top industry decision-makers! Exhibitor Sectors NEW

All around construction

Production of building materials

Mining, extraction and processing of raw materials

Who will you meet?

Component & service suppliers

Agriculture machinery & vehichles

NEW

Forestry machinery & vehicles

NEW

Plant and equipment hire

2018 Stats 455

Exhibitors

14,167

Trade Visitors

Contacts Betty Sichivula Project Director betty.sichivula@mm-sa.com Tel: +27 11 476 8093 Mobile: +27 63 680 2657

Lisa Schenkl Junior Exhibition Manager lisa.schenkl@messe-muenchen.de Tel: +49 89 949 20253

Stand allocations on first come first serve basis.

EARLY BIRD CATCHES THE WORM!