First Mining Drc-Zambia Nov/Dec 2020 by Mailing Times Media

CENTRAL AFRICA'S PREMIER BUSINESS TO BUSINESS MINING MAGAZINE

VOL 13 | ISSUE 6 | November - December 2020

Mining Road Safety Selecting a suitable Vehicle Restraint System

In this issue... DRC officially in the clear of Ebola epidemic Pg 03

Bagging an environmental game changer Pg 21

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Ivanhoe Mines forges ahead Pg 38

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CONTENTS NEWS

PRODUCTS

EVENTS

Zambia records increased copper output amid debt

Mining and quarry dump truck bodies

BMGâ&#x20AC;&#x2122;s maintenance-free HD couplings and wedge belts

PROFILE

FEATURE

ORICA & epiroc unveils automation prototype

Industrial plant for oxidative of gold sorption

First underground TOMRA sensor-based sorter

CENTRAL AFRICA'S PREMIER BUSINESS TO BUSINESS MINING MAGAZINE

VOL 13 | ISSUE 6 | November - December 2020

TEAM

EDITOR’S COMMENT

Editor Bertha M. bertham@fmdrc-zambia

Stepping into 2021

Sub-Editor Nita Karume Mining Road Safety Selecting a suitable Vehicle Restraint System

In this issue... DRC officially in the clear of Ebola epidemic Pg 03

Bagging an environmental game changer Pg 21

Ivanhoe Mines forges ahead Pg 38

Contributing Writer Oscar Nkala, Mfuneko Jack Lindani Mkhize Caroline Thomas

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Sales and Marketing Victor Ndlovu victorn@fmdrc-zambia.com +27 11 044 8986

Cover Image: HIGHWAYCARE

COVER STORY: PG 17 Mining Road Safety - selecting a suitable Vehicle Restraint System Highway Care will provide correct product selection advice based on sound principals of Engineering, product crash testing data and in-field performance knowledge. www.fmdrc-zambia.com

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

hile the COVID-19 outbreak has been a truly disruptive, global event, the mining and metals sector has managed to weather its impact extremely well, thanks in no small part to the governance and culture that was already in place throughout the sector.

Several mines have managed to remain operational and productive during the pandemic, despite having less people on site. However, business continuity has come at a cost due to the added expenses of new processes, procedures, protocols, health testing equipment and support for the workforce. Therefore, it is clear to see that as we move into 2021, COVID-19 will continue to impact all industries, including mining and metals. While some markets are beginning to show a semblance of economic recovery, others – particularly those in significant mining geographies – remain heavily affected by the virus. We at Fmdz are hopeful that things are going to look up, based on the economic outlook of 2021 as well as the good news of several miners renewing mining contracts and even forging new partnerships that will see the output of the mining sector increase exponentially. Catch the latest news and features to get a feel of the last quarter of 2020 as well as a rough projection of how 2021 will be. To all our Advertisers and readers-FMDZ wishes to thank you for your support during this year - have a wonderful break and 2021 be much kinder to us! See you in the new year.

Nita Karume

Mailing Times Media (Pty) Ltd makes every effort to ensure the accuracy of the contents of its publications, but no warranty is made as to such accuracy and no responsibility will be borne by the publisher for the consequences of actions based on information so published. Further, opinions expressed are not necessarily shared by Mailing Times Media (Pty) Ltd

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NEWS

Zambia records increased copper output despite foreign debt

ambia, Africa’s second-largest copper miner, produced 646,111 tonnes of the metal in the first nine months of 2020, up from 590,321 tonnes in the same period last year, official figures show. The country’s mines and minerals ministry attributed the 9.45% rise to increased mine output. He said the East African nation now expects total production for the year to reach 820,000 tonnes, driven by rising copper prices. This comes as good news to Zambia, which missed a US $42.5m interest payment on part of its international debt last week, becoming Africa’s first bond default during the coronavirus pandemic. President Edgar Lungu’s government, which is battling for re-election next year, has blamed covid-19 for problems managing the country’s US $12Bn debt. While it seeks a compromise with bondholders, the government has

announced it has no plans to sell its shares in mining companies it has stakes in to raise cash. Zambia’s mining assets have been in the spotlight as the country’s financial situation deteriorated this year and the pandemic prompted Glencore (LON: GLEN), one of the biggest miners operating in the country, to shut its Mopani Copper Mines (MCM). The move angered the government, which threatened to revoke Mopani’s mining licenses and temporarily blocked its chief executive officer Nathan Bullock from leaving the country. Glencore reacted by putting its 73.1% stake in the operation on the table, hoping to reach a deal with authorities. No plans to sell mining stakes Zambia said earlier this week that negotiations with Glencore about increasing the government’s stake in

Mopani were nearing a conclusion, although no information about the size of the stake that state-owned ZCCM Investments Holdings is trying to acquire was given. The government, which was in arbitration over mining assets it seized last year from billionaire Anil Agarwal’s Vedanta Resources, lost an important battle in the case on Friday. A local court ordered a halt to liquidation proceedings KCM to allow owners Vedanta and ZCCM-IH to proceed to arbitration.

DRC officially in the clear of Ebola epidemic

he DRC has declared an end to the epidemic of Ebola in Northwestern Équateur Province, which began in June, 2020.The U.S. Agency for International Development (USAID) congratulates the Government of the DRC, its international and local partners, and the Congolese people for having stopped two outbreaks of the deadly disease in one year. National authorities declared that a previous outbreak of Ebola in the Eastern DRC – the second largest in history – ended on June 25, 2020, after nearly two years. In total, the U.S. Government, through USAID, has provided nearly $366 million in life-saving humanitarian assistance to fight Ebola in the DRC and neighbouring countries since 2018. This includes more than US $18m used in Équateur Province to track Ebola cases, train workers on the prevention and

control of infections in health facilities, promote safe and dignified burials, conduct community-engagement programs, and communicate accurate information on the disease. According to media reports, the American expertise and funding played a critical role in helping the Government of the DRC and its partners bring an end to both outbreaks of Ebola this year. As part of these efforts, USAID deployed a Disaster-Assistance Response Team to the DRC.

This team of experts will continue to work with the Government of the DRC, the U.S. Embassy in Kinshasa, the U.S. Centres for Disease Control and Prevention within the U.S. Department of Health and Human Services, and humanitarian partners to address any secondary impacts of the disease, reduce the stigmatization of Ebola survivors, and support rapid-response capabilities to ensure the Congolese Ministry of Health can contain any possible flare-ups or new outbreaks quickly. Working together with partners and the Congolese Government, USAID aims to have the capacity and infrastructure in place to allow them to detect rapidly and respond effectively to any new outbreaks of Ebola or other infectious diseases, should they occur, while building better and more resilient health institutions.

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NEWS

EGC signs agreement with Trafigura for cobalt mining in DRC

“This partnership responds to the will of the Government through its initiative for the defence and promotion of national artisanal production. For our country to benefit from the intrinsic value of cobalt, currently boosted by the development of carbon-free energies, it was essential that measures be taken to support the formalisation of this industry. In fact, by cleaning-up this sector, which has been subject to recurring illegality and fraud for several years, and of which our artisanal miners are the first victims, society stands to benefit as a whole.

ongolese mining company Entreprise Générale du Cobalt, or EGC, signed an offtake agreement with commodity trading group Trafigura in a bid to fomalise artisanal and smallscale cobalt mining in the Democratic Republic of Congo (DRC). According to media reports, the trading agreement includes the provision of finance by Trafigura to fund the creation of strictly controlled artisanal mining zones, the installation of ore purchasing stations and costs related to the transparent and traceable delivery of cobalt hydroxide to Trafigura on an export cleared basis. Further, EGC will ensure that the ore marketed by Trafigura complies with OECD Due Diligence Guidance for Responsible Supply Chains of Minerals from Conflict-Affected and High-Risk Areas-under the supply terms. In support of this agreement, EGC will establish a Technical Committee through which Trafigura and the international non-profit organisation Pact, among others, will promote responsible sourcing diligence.

Pact works alongside local communities in nearly 40 countries to eradicate poverty, notably by making artisanal and small-scale mining formal, safer and more productive. In 2018, Trafigura and Pact first piloted an approach to the responsible sourcing of cobalt from semi-mechanised operations at the Mutoshi concession in the DRC. “Today’s announcement is very important for the Congolese artisanal cobalt sector,” says EGC MD Jean-Dominique Takis Kumbo.

Trafigura’s executive chairman and CEO, Jeremy Weir, comments: “Cobalt has a vital role to play in the world’s energy transition and electrification. Artisanal mining or ASM, provides an important livelihood in the DRC. Ultimately, the legitimacy of efforts to formalise and bring controls to the sector will depend on broad-based consultation and assurance that OECD standards will be upheld. We will continue to engage and collaborate with stakeholders to be part of the solution to supply cobalt responsibly.”

Jubilee Metals secures rights to copper/cobalt tailings in Zambia

ubilee Metals Group has secured the rights to an additional about 115m tonnes of copper- and cobaltcontaining surface tailings in Zambia. These transactions are in line with its stated strategy to expand operations in the country and are in addition to the about 155m tonnes of tailings that have already been secured. According to media reports, the duallisted Jubilee has secured the exclusive processing rights to the material through its subsidiary Braemore Platinum, by entering into tailings supply and process development agreements with some privately held entities that collectively hold both the mining rights to the tailings and the property title on which the tailings are located. The agreements include both the formation of a development partnership with a well-established Zambian private

entity that has invested in securing various tailings assets, as well as securing the rights to the processing of the tailings from the resource owners. The agreements give Braemore the exclusive right to process the about 115-million tonnes of tailings through the implementation of a copper and cobalt processing facility. Moreover, the project benefits from detailed resource analyses and vast historical process test programmes performed by the tailings partners through the appointment of various independent well-established consulting firms, Jubilee points out. It notes that this allows it to interpret these results and incorporate its inhouse expertise and intellectual property to significantly accelerate the project development cycle. Jubilee’s secured pipeline of copper projects in Zambia places the company on track to

deliver its stated objective of expanding its copper-producing capacity to over the equivalent of 25 000 t/y of copper units. The combined magnitude of the total secured copper tailings resources and related projects, together with Jubilee’s Sable Refinery, offers the potential to deliver long-term sustained quality earnings making a significant contribution to Jubilee’s existing earnings from its platinum group metal (PGM) and chrome operations in South Africa, the company acclaims. The Sable Refinery is operationally ready and able to significantly enhance its capacity alongside the expected production build-up, without incurring any significant new capital expenditure, the company notes.

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NEWS

Liberum Capital to work with Pensana on ESG

iberum Capital has been appointed as a consultant and joint broker to Pensana Rare Earths, with a particular focus on environment, social and governance (ESG) matters. The Chairman, Paul Atherley, said that the London broker is looking to help establish the world’s first fully sustainable mine to magnet supply chain for the burgeoning EV and offshore wind industries. He further added that from the outset they are designing in the very highest standards at both the Longonjo project in Angola and the proposed downstream processing facility in the UK from the outset. Liberum is exceptionally well placed to help position us as a highly attractive sustainable investment with

huge leverage to these important new industries. Founded in 2007 as a wholly staff-owned business, since inception Liberum Capital aims to provide insight, honesty and a highly personalised approach to all their clients. Companies receive unrivalled advisory work from our trusted and experienced banking team. Institutional investors hunting for ideas receive direct access to our seasoned sales team and research analysts, along with introductions to companies, innovators and thought leaders. Traders wanting high or lowtouch execution from multiple venues, with proper performance benchmarking, deal with us daily.

Tanzania’s approval for permit of first rare earths mine in the works

anzania is in the final stages of approving a permit for the country’s first rare earths mine to Australian company Peak Resources as the government seeks a bigger share of revenue from natural resources. According to media reports, the State is also finalizing on a gold-mining

license for another Australian company, OreCorp at the Nyanzaga project in the northwest of the country.Tanzania is Africa’s fourth-biggest producer of the precious metal and plans to increase mineral earnings by at least a third during the next three years. It also has vast deposits of coal, rare-earth metals,

iron ore and gemstones. Rare earths are used in components for electric vehicles, smart phones, renewable energy equipment and defense applications. Gold mining, now Tanzania’s leading foreign-exchange earner, is recovering following a slump after a crackdown on smuggling and a drawn-out dispute between the government and a unit of Barrick Gold froze exports. The government intends to increase mining revenue to US $303.3m in 2023/24, from a projected US $227.5m in the current fiscal period. Minister Biteko said that the mine will see Tanzania increase revenues from the mining sector by 33%” by boosting production and exports, curbing smuggling and ensuring closer supervision of the industry. Last month the government received its first cash dividend of US$ 40m from a 16% stake in a joint venture with Barrick. Tanzania plans to use the Barrick partnership as a model when negotiating joint-ownership deals with all major mining companies, including with AngloGold Ashanti, in line with mining laws passed in 2017.

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NEWS

VW joins Cobalt for development initiative in DRC

said that for VW’s e-mobility strategy, sustainable and responsible sourcing of raw materials is of the utmost importance. Cobalt plays a vital role for the carmaker, despite a decreasing amount of the raw material in newer generations of batteries for electric vehicles.

olkswagen has joined the “Cobalt for Development” initiative to support improving artisanal cobalt mining conditions in the Democratic Republic of Congo. The pilot project intends to strengthen legal compliance and improve health and safety conditions as well as social well-being in the south of the Democratic Republic of Congo. Other members include Tesla who joined with an aim to end the use of child labor at mining sites and improve working conditions in the DRC. The group is also backed by Glencore Plc and major Chinese cobalt refiner Zhejiang Huayou Cobalt Co. According to the media reports, the first trainings for mine operators and miners have begun. The project is being implemented by GIZ and financed by BASF, BMW Group, Google, Samsung Electronics, Samsung SDI and

Volkswagen. Almost three-quarters of the world’s cobalt comes from the Congo and demand is forecast to surge in the coming years. However, artisanal cobalt, produced by small-scale miners who often dig by hand, has become a divisive issue. Ullrich Gereke, Head of Procurement Strategy at the Volkswagen Group

He further added that they are seeking to establish artisanal mining in the Democratic Republic of Congo as a strictly sustainable cobalt source, because the existence of many local communities depends on this sector. Currently, Volkswagen does not accept cobalt from artisanal mines. Training curricula on more sustainable working conditions are currently being prepared, initially for 1,500 miners from 12 artisanal cobalt mining cooperatives in and around Kolwezi in the Democratic Republic of Congo, the company said.

Alarm as blood samples from residents of Kabwe town show high levels of lead and calcium

eople in Kabwe Town, Zambia, show very high blood levels of lead and cadmium, which are a direct consequence of the now-closed Broken Hill mine. The operation was owned by Nchanga Consl. Cu Mines Ltd. According to a study published in the scientific journal Chemosphere and conducted by researchers from Japan’s Hokkaido University and the University of Zambia, not only people in Kabwe have high levels of toxic heavy metals, but they also exhibit clinical symptoms of lead and cadmium toxicity. Located in central Zambia, Kabwe’s economy is centred around mining. In fact, Broken Hill was the largest leadzinc mine in the country for some three decades until the early 1930s. Even though it has been closed for a long time, artisanal miners still extract metals from the mine tailings. These tailings are highly toxic and can potentially affect not just the miners, but their families

the Kabwe region. They collected BMI data, measured blood levels of each metal, and assessed blood, liver and kidney toxicity.

and communities as well. A previous report by the Blacksmith Institute named Kabwe one of the 10 most polluted places on Earth and other studies have shown that blood lead levels in children in the region are much higher than the WHO-prescribed reference levels. However, levels of other heavy metals had not been investigated in people in Kabwe until now, as neither were the effects of their toxicity. Thus, the Hokkaido and UNZA scientists decided to assess the effect of lead, zinc and cadmium in a sample of 504 individuals across 40 study areas representative of

They found that lead levels in blood (PbB) were higher in those who lived closer to the mine; moreover, infants had the highest Pb-B overall, and children (up to 17 years) had higher Pb-B than adults. Conversely, cadmium levels in blood (Cd-B) were higher in adults (18 years and above) than in children. Researchers say that this is the first report on the clinical outcomes of individuals affected by multiple metal exposure in Africa and that significant correlations were found between blood metal levels and clinical parameters especially for adult participants, indicating potential adverse health effects due to metal exposure in Kabwe.

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EVENT

Global software summit explores the future of mining innovation T housands of mining and exploration professionals from around the world are expected to join a global technology summit, hosted by international mining software developer MICROMINE, on 17 November 2020.

More than 25 speakers will feature in the three-hour online mega-event which will be available in separate languages and timezones for audiences in Australia/ Asia, Europe/Africa, North & South America, Russia & Central Asia. 2020 Unpacked will showcase the next generation of mining and exploration software as MICROMINE unveils the latest versions of its integrated suite Micromine 2021, Pitram 5 and Geobank 2021. Micromine CEO Andrew Birch recently commented “rapidly changing markets, evolving geopolitical dynamics and the Covid-19 pandemic had created unprecedented challenges for mining companies, driving a thirst for evidencebased innovation”. “Technology is evolving at warp speed, and the pressure is on us to ensure our users have quick access to the best tools available,” said Birch. Launching the latest products comes after an in-depth Beta testing program, that saw almost 150 testers globally trial the new software.

“Attendees will see the new features our teams have been working on over the past six months and share the digital transformation experience with exploration and mining clients from around the world who are partnering with MICROMINE to improve efficiency and profitability. “Access to new and innovative data modelling and analytics is essential in helping the industry advance the safety and efficiency of its processes, reduce costs, and meet increasing social and environmental standards.” Said Birch Delegates will be treated to a free 1 month license of the latest release of

the award winning modelling software, Micromine 2021, which is currently used on 2,000 sites in more than 90 countries around the world. Technical product managers will run interactive group demonstrations, while additional feature workshops and one-on-one sessions (by appointment) will be available for MICROMINE clients after the event. Registration is free at www. micromine.com/2020unpacked.

About MICROMINE MICROMINE is a Global software developer and a leading provider of advanced technology for the exploration and mining sector. The company’s products are in use at more than 2,000 sites in over 90 countries. The integrated, modular software suite covers the entire mining lifecycle, from geological exploration and data management, to resource estimation, 3D mine design, planning and production control and includes world leading products such as: • Geobank geological data management • Micromine 3D modelling, estimation and mine design tools • Pitman fleet management and mine control solution

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EVENT

Amid Continuing Uncertainty, Investing in African Mining Indaba Announces Cancellation of the 2021 Edition and Launches a Virtual Event.

nvesting in African Mining Indaba (MI), part of Hyve Group PLC, announces with regret the cancellation of the 2021 edition, due to take place 1-4 February 2021 in Cape Town, South Africa. The event will return on 7-10 February 2022. Mining Indabaâ&#x20AC;&#x2122;s sister event, Africa Oil Week, has also been cancelled and will return 1-5 November 2021 in line with its regular dates.

Seven months since the World Health Organisation declared a global pandemic, the continuing uncertainty is a primary contributor to the cancellation of the 2021 event. Additionally, international travel limitations and current restrictions for hosting events in South Africa which prevent larger gatherings mean the organisers can no longer be certain of delivering Mining

Indaba to the high standard to which their audience is accustomed. The 2022 event will take place, in accordance with the latest health & safety and government guidance. The wellbeing of speakers, delegates, sponsors and exhibitors will remain a top priority. As always, the eventâ&#x20AC;&#x2122;s objective will be to gather the most influential

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decision-makers in African and global mining to network, make deals and shape discussions crucial to the future success of the industry. Simon Ford, Portfolio Director of Investing in African Mining Indaba and Africa Oil Week, said: “Bringing people together is at the heart of what we do at Mining Indaba. However, based on current uncertainty caused by the COVID-19 pandemic, we took the view that our delegates’ ROI and ROTI would have been significantly impacted at an in-person event in February 2021. Our focus is now on delivering an unbeatable live event in February 2022, which will reunite and regenerate the industry, as well as, provide the leading platform to help rebuild the future of African mining. We would like to thank all those who have supported us throughout the years.” Furthermore, Mining Indaba is delighted to announce the launch of Investing in African Mining Indaba Virtual ‘Resilience and Regrowth: Adopting the New

Mindset for African Mining’ taking place 2-3 February 2021. Recognising the role that Mining Indaba plays in connecting the global mining community and its significance in shaping the industry for the year ahead. The virtual event will feature free high-level content streamed online, including pioneering insights

from the industry’s heavyweights, multistakeholder strategic conversations, keynote addresses and more. For further announcements, please check the website – www.miningindaba.com.

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PRODUCT & TECH

Rand-Air generators and lighting towers shed light on manganese mine’s production

s part of the global Atlas Copco Group and widely recognised as the local equipment rental leader, Rand-Air delivers portable air, power, lighting and flow solutions into a variety of industries; while its agile, customer-centric service, safety and quality consistently assists customers to successfully meet their operational requirements. A case in point was the recent long-term rental to a major manganese mine. The development of the mine began as a green fields project in June 2019 - with manganese the prime commodity - and an iron ore portion planned for phasing in during the first quarter of 2021, says Denise Olivier, Rand-Air’s sales consultant whose technical knowledge and customer support secured this important hire. Olivier explains: “Since the mine was new in my area, it came to my attention that they were interested in purchasing equipment and were currently exploring this option.” However, Olivier says that once she explained the benefits of hiring over purchasing, and the additional advantages of using Rand-Air, the customer was extremely interested in her proposed solutions. “I pointed out that we take all the effort out of equipment hire, leaving the customer to focus on their core business. We also offer 24/7 technical support, maintenance and even replacement equipment if required. This option made much more sense to the customer, rather than outlaying significant capital to purchase equipment,” she explains. As the mine is expanding, their strategy has been to introduce two shifts - night and day - and, for the night shift, reliable and robust lighting was required. “I submitted the quote and almost immediately, delivered the first two lighting towers in April 2020, on a longterm hire that will roll-over year-to-year.

As the partnership grew steadily, so did the customer’s order, and we are currently supplying five lighting towers and two generators into the mine.” Given every business’s desire to operate as cost-effectively as possible – particularly this year - Olivier believes that this hire is not only a win for RandAir; but she knows that she offered the best solution to meet the customer’s needs, by advising them to hire rather than purchase equipment. “By offering a solution to their specific requirements – as well as professional and knowledgeable feedback to queries – the customer was satisfied that the Rand-Air option was the best,” she remarks. The lighting towers comprise heavy-duty LED lamps with more than 50,000hrs of life expectancy, offering 5000m2 light coverage, which is perfect for adhering to the stringent safety standards required on the mine. Easy to transport, the compact lighting units come with a stable hydraulic vertical mast capable of extending to a maximum height of 8m and rotating 340 degrees. “The lighting units are used to illuminate the nightshift operations and the two Atlas Copco QAX generators, one 20kVA and one 100kVA, are ideal to supply uninterrupted power and mobility to the office complex, processing plant and weighbridge,” Olivier explains. “The customer required the generator supplying electricity to the office complex to switch over between solar power during the day, to generatorsupplied power during night-time. This was achieved through the installation of a change-over switch,” she says. “Aside from Rand-Air’s technology, technical expertise and advice, our reputation for exceptional customer service and providing timely solutions will endure, as our generators and lighting towers keep the lights on at night and the mine’s production running smoothly!” Olivier concludes.

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PRODUCT & TECH

ORICA and epiroc unveil prototype system for first stages of underground automation Melbourne, Australia: Orica (ASX: ORI) and Epiroc Rock Drills AB (“Epiroc”) have successfully co-developed a prototype of the world’s first semi-automated explosives delivery system.

ustomers in the underground mining industry can look forward to safer, efficient and more productive development blasting as early as the end of 2021, as Orica and Epiroc commence commissioning on Avatel™, the first-of-its-kind, industrydriven explosives delivery system in coming weeks. A sought-after technology by customers in the underground hard rock mining sector, Avatel™ will deliver a completely new way of approaching development blasting operations by eliminating charge crew exposure at the face. The solution provides safe access for an operator in cab to execute the development cycle while reducing the reliance on costly, time-consuming and at-times ineffective controls put in place to manage the risks to personnel working in one of the highest risk areas of an underground mine. Orica’s Chief Commercial and Technology Officer Angus Melbourne said: “The mining industry is moving rapidly toward a digitally integrated and automated future, and Avatel will fulfil our shared vision of developing safer and more productive blasting solutions. “Achieving this significant development milestone, despite COVID-19 disruptions, shows the strength of our collaboration with Epiroc and our collective ability to deliver the future of mining.” Epiroc’s President Underground division Sami Niiranen said: “With this

A key enabling technology of Avatel™ and Orica’s automation vision is WebGen™, the world’s first fully wireless initiation system. When combined with Orica’s LOADPlus™ smart control system, specifically designed onboard storage, assembly, digital encoding capability and Subtek™ Control bulk emulsion, Avatel™ provides customers with complete and repeatable control over blast energy from design through to execution. Built on the foundation of Epiroc’s proven Boomer M2 carrier, and integrated with Orica’s latest explosives technology, Avatel™ is a twin boom, semi-autonomous and fully mechanized development charging solution that allows a single operator to complete the entire charging cycle from the safety of Epiroc’s enclosed Roll-Over Protection Structure (ROPS) and Falling Object Protective Structure (FOPS) certified cabin.

partnership, we continue to raise the safety bar by combining world leading technologies that will make a difference in underground mines. “The Avatel prototype represents the first step towards autonomous charging – a vital step in the journey toward safer and more productive blasting operations underground. We are looking forward to bringing this ground-breaking solution to customers worldwide.”

Avatel™ is equipped with the most sophisticated version of Epiroc’s acclaimed Rig Control System (version 5). Through its intuitive interface, with a large touchscreen and dual multifunctional joysticks, and combined with Epiroc´s computer assisted boom positioning features, it can be easily handled. Integrated with Orica’s LOADPlus™, charge plans and other important data will be communicated between the systems. The advanced and robust feed design of Avatel™ builds on Epiroc’s solid application design experience, further adapted to match conditions this new solution will face. Future developments can be extended to other Epiroc carriers including battery driveline. Other key advantages include flexibility at the face through Epiroc´s dual diesel/electric plug-in power solution. The convergence of these technologies ultimately ensures that the right explosives will be safely delivered into the right holes and given the right timing to achieve optimal efficiencies and the desired outcomes. Extensive trials of Avatel™ will take place throughout 2021, before the first commercially available systems are expected to enter service. Orica announced in November 2019 that it had entered a partnership with Epiroc to develop a semi-automated explosives delivery system.

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PRODUCT & TECH

Tilt Level Control for Hazardous Areas

he Model CT, as manufactured by Conveyor Components Company, is comprised of a Control Unit and Tilt Probe which senses the presence or absence of material. The intrinsically safe cULus Listed Control Unit is enclosed in a rugged cast aluminum housing with external red and green LED status indicator lights and surface mount printed circuit boards. Weatherproof, Dust-Ignition Proof and Explosion Proof models are available. Optional black epoxy powder coating is available for corrosive environments. The tilt level controllers (CT-105, CT-106 or CT-107) have an intrinsically safe output to the tilt probe and are cULus listed as intrinsically safe when used with the cULus listed tilt probes. The Model CT is commonly used when other controls won’t work due to bin vibration, or actual bin walls aren’t available for mounting other controls. Typical applications include level detection in hoppers, silos, stackers, crushers and conveyor transfer points. The CT tilt probes are available as a compact 6” tilt probe or the standard 9” tilt probe and have 25 feet of electrical cable. Stainless steel probe housings are available as an option. Float ball and paddle accessories also available for fine-grain materials. If you would like additional information on this or other products that Conveyor Components Company offers please contact their sales department toll free 800-233-3233, fax 810-679-4510, e-mail info@ conveyorcomponents.com or visit their website at www. conveyorcomponents.com.

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REPORT

Economic mining outlook for 2020 A

n event without precedent in living memory, the COVID-19 pandemic is challenging several long-held truths about mining. Many miners, some for the first time, are experiencing the downside of global supply chains, ultra-lean operations and specialisation. But the pandemic is also highlighting the sectorâ&#x20AC;&#x2122;s resilience and the role that miners play in supporting communities and the broader economy. The global economy is entering uncertain times, with the International Monetary Fund predicting a 3% contraction

in the global economy for 2020. But the Top 40 are in an excellent position to weather the storm. On the back of a solid financial performance in 2019 and prudent capital expenditure, the worldâ&#x20AC;&#x2122;s Top 40 miners face the crisis with strong balance sheets and the flexibility to respond. The Top 40 have shown they can innovate, adapt and respond to this crisis along with the best. Now is a good time to assess which of those tactics were effective and should be codified to help miners prepare for future disruptive events.

In some respects, the mining sector is well-situated in the wake of COVID-19. However longer-term impacts remain uncertain, and ongoing disruption is likely. Top 40 miners should take advantage of their current position of financial stability to revisit their strategies; consider a collective step up in ESG behaviors, metrics and reporting disciplines; and undertake a review of cyber risk within the broader remit of safety first. These measures will ensure their businesses can enhance their resilience over the long term and meet the demands of the global economy to maximise the opportunities to resource the post COVID-19 future. Four key trends characterise the changing strategic imperatives in the global mining industry over the last 12 years. Where expansionary strategies

First Mining DRC-Zambia 91x135mm FAp.indd 1

10/09/2020 16:51

were the order of the day during the commodities boom of 2009-2011, priorities quickly shifted to cost optimisation efforts as global oversupply dampened metals prices. Now, the increased focus on new technologies and the promise of digital over the past five years is being eclipsed by the almost ubiquitous drive to increase stakeholder value and to leave a positive legacy beyond the life of mine. This is driven, in part, by the tough questions from institutional investors on how mining companies demonstrate a measurable impact on the well-being of host communities and other stakeholders. Mining companies across the globe have shown in recent years that you can play and win in the current context by ensuring the benefits of mining are shared broadly.

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FEATURE

Mining and quarry dump truck bodies

ith dumping times typically faster than traditional rear-dump trucks, ejector bodies improve off-loading efficiency by forcibly ejecting materials at a steady rate. They are not dictated by the angle of the body or gravity, and the operator of the truck is in complete control of the discharge. Rear-eject bodies can also safely dump materials while the truck is in motion, spreading material as it ejects to reduce dozing and spreading time. Additionally, pushing materials out the back, backed uphill, can be done safely due to the low center of gravity of the load – even with the truck at rated capacity. This allows for offloading in conditions where standard trucks are unstable and unsafe, such as on slopes and locations with softer underfooting.

Operator safety Standard dump trucks put a significant amount of a truck’s load over the rear axle while unloading, sometimes causing the front of the truck to raise off the ground due to the improperly balanced load. As the load drops out the back, the truck and driver slam back to the ground. This repeated process stresses the truck chassis, as well as the operator who, over time, can suffer from back and/or neck issues caused by the repeated impact. Because the blade of a rear-eject body pushes materials out at a steady rate – unlike the uncontrolled mass that drops from a gravity-fed dump body – the truck maintains a lower and more balanced center of gravity.

Overhead obstacles Because rear-eject bodies eliminate the need to raise the body, the truck can safely dump materials near overhead barriers, such as electric lines, bridges, pipelines and support beams, as well as in enclosed areas or underground mines. Additionally, because the bodies do not raise, they can be built wider than standard dump bodies, resulting in higher volumetric capacity. From improved dump control to increased capacity, rear-eject bodies outperform standard end-dump truck bodies in a variety of applications and are manufactured to fit most makes and models of articulated trucks, as well as some rigid-frame trucks.

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COMMITTED TO THE LONG HAUL Terex ÂŽ Trucks off-highway articulated and rigid trucks Terex Trucks has been designing and manufacturing off-highway trucks since 1950, delivering to customers all over the globe. Fully supported by a solid distributor network, Terex Trucks are committed to the long haul, providing a range of tough and reliable trucks that deliver the lowest cost per tonne in the most extreme environments. Full range of articulated and rigid off-highway trucks Backed up by a Terex Trucks distributor network Focused team dedicated to developing and supporting Terex Trucks

Call +27 11 966 2000 for more info or visit www.eiegroup.co.za www.fmdrc-Zambia.com

FEATURE

DT Hi-Load high performance dump truck bodies

atching the optimal mining equipment to the application can provide substantial gains when striving for ambitious load and haul production targets at opencast mining operations. The most fundamental requirement is maximising the payload hauled by the truck fleet every cycle. Have you considered the mass of your dump truck bodies and the potential payload gain if they were lighter yet still durable? The DT Hi-Load dump truck body, characterised by its curved and flexible

structure, provides the opportunity to maximize the payload on your haul truck without exceeding the original equipment manufacturerâ&#x20AC;&#x2122;s gross vehicle weight limitation. Manufactured completely from anti-abrasion steel, the structure provides high strength for impact resistance while flexing slightly to effectively dissipate energy during loading, reducing fatigue damage. The curved floor assists to automatically centre loads, with the curved canopy discouraging canopy loading and improving operator safety.

Desarrollos TecnolĂłgicos S.A. was founded in Santiago, Chile in 1994 with the idea to make a lighter design for dump truck bodies. The following 20 years saw 10 development phases of the DT HiLoad product resulting in increasingly lighter and more durable dump bodies for many of the largest mine sites across the globe. DTSA ensures optimal payload for various applications and loading equipment by offering custom designed bodies which can be fitted to all original equipment manufacturer truck models ranging from 40 ton to 380 ton (including Hitachi, Caterpillar, Liebherr, etc). Total

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cost of ownership is competitive as the modular construction of the body allows for individual component replacement at overhaul stage while replaceable liner tiles protect against abrasion. The DT Hi-Load product entered the Southern African mining market in 2014 through a partnership with Komatsu South Africa, shipping bodies in kit form from Chile to be assembled in country. Subsequently Komatsu South Africa’s local fabrication partner has become a licensed manufacturer of the DT Hi-Load dump body allowing for a completely African built product, which can be shipped complete or nested in a split pack fashion for easier transportation to site. Over one hundred and eighty DT Hi-Load bodies have been locally manufactured for Southern African mining customers to date, where full overhaul and component replacement services are offered.

A large opencast mine in Southern Africa requested assistance in maximising productivity of their 295-ton rated payload haul trucks. Through Komatsu’s continuous improvement engagement with the customer and assessment of the operation, it was found that large fragmentation and abrasiveness of the loaded material had resulted in the addition of substantial steel plates to protect and reinforce the standard dump truck bodies. This had resulted in a very heavy dump body with frequent material remaining stuck in the body after dumping (carry-back), further reducing efficiency. Komatsu’s continuous improvement team identified that this site was operating at the lower end of the payload spectrum when benchmarking average payload against global operations utilising the same truck model. Through ongoing engagement with the mine, a custom DT Hi-Load body was designed to withstand

the sporadic impact from large material fragmentation and the high abrasion conditions unique to this operation. The DT Hi-Load body introduced weighed 38 tonnes, 18 tonnes lighter than the reinforced bodies on site. Continuous monitoring of payload across the fleet indicated superior performance of the DT Hi-load body. Slight changes to the liner package protecting the body were collaboratively developed with the mine for subsequent bodies as the benefits of payload maximisation became apparent. Over the following three years, half of the fleet had been converted to DT Hi-Load bodies and average payload increased by seven percent for this fleet. Through sustained effort in optimizing dump body mass, maintaining durability and overhauling their dump bodies, the mine managed to achieve their production targets at a competitive total cost of ownership rate on their dump truck bodies.

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COVER-STORY

Mining Road Safety - selecting a suitable Vehicle Restraint System Broken & buckled guardrail – failed to contain the impacting vehicle

hen building a new road, or even when auditing an existing road, we follow good road design practice. We ensure suitable, well maintained road surfacing and drainage. We consider the right posted speed limits for the straights and curves;

providing additional lighting and signage to warn of intersections or other possible hazards. We even make efforts to keep animals off the road. But, often not enough thought and consideration is given to what happens for when things go wrong, and a vehicle leaves the road.

Vehicle Restraint Systems, typically referred to as barriers are the crucial last line of defense to providing road safety when that happens. The consequence of not using one or using the wrong one could be fatal, or at least seriously life changing; sometimes to several people in just one collision incident! But, when selecting the barrier to use, do we really know enough about them to enable the proper selection and implementation? Just placing a “standard” barrier by the side of the road is not the solution. Several aspects must be considered when selecting the right barrier solution and these are determined by the hazard that we are protecting the road user from, the environment, the expected traffic (both type and density) and economic constraints. Longitudinal barriers that we see at the roadside should be crash tested, typically to either of the two most referenced

Ezy-Guard crash tested at 100kph and 25° angle

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FEATURE

international standards. These are the European, known as EN1317, or American, known as MASH or previously NCHRP350. Both refer and test based on road going vehicles commonly used within those territories. A key difference, which is important to the Mining market, is that the American testing includes performance testing using a pickup. Very important because the bakkie and other 4X4 vehicles that are so common on roads leading to the mines, are by nature taller, so have a higher center of gravity, and will interact with your intended barrier system very differently to a car or truck. Using a crash tested barrier system that is suitable for the type of vehicle and posted speed limit on the roadway is the only way that you can ensure that it will work in the moment of need. Crash testing helps you determine the required performance parameters needed for proper placement. If the barrier performance is unknown and not suitable, then it could fail and become a more serious hazard than the one that you are trying to protect the road users from, such as causing the vehicle to jump, roll over, redirect aggressively into oncoming traffic, or even for the structure of the barrier to spear the passenger cabin! Selecting an untested or unsuitable barrier is not only dangerous, but simply money wasted. It is important to begin by looking at the desired vehicle containment level, typically decided by the type of vehicles and the posted speed limit. Then reviewing the hazard to be protected from, the available space to place the barrier system, and then considering the environmental conditions and budgetary constraints. Barrier systems may be chosen to be permanently installed, for long term protection, or temporarily installed to protect for a short to medium time frame, such as portable barriers used in work zones or when future upgrade works are planned. Looking at permanent barriers - they may be very rigid, which is ideal where there is little room for barrier deflection or its working area (known as â&#x20AC;&#x153;working widthâ&#x20AC;?), but the trade-off is a higher likelihood of injury to vehicle occupants through a harder collision, determined by the Accident Severity Index (ASI).

Ezy-Guard - pickup is safely contained and redirected

Such barriers could be concrete barriers, or very well anchored steel barrier systems. On the other side of the spectrum, there are flexible systems, such as high-tension cable barriers. These have the least impact severity, and are typically cheaper to install, but then need more working width for redirection of the impacting vehicle. In the middle of this choice sit the semirigid systems like the steel guardrail options, which offer a reduced working width, typically reasonable cost, but may have an increase in the ASI. Regarding temporary barriers, the options are concrete, portable steel barrier systems or portable water-filled plastic, with some hybrid variants. The concrete and plastic options are free

standing and reliant on the system weight to redirect a vehicle. Portable steel options are typically anchored into the ground which can provide flexibility to vary the working width and control the ASI of the barrier. Highway Care will provide correct product selection advice based on sound principals of Engineering, product crash testing data and in-field performance knowledge. The best advice being that which is tailored specific to the projectâ&#x20AC;&#x2122;s specific requirements. Our industry knowledge and contacts combined with our product portfolio enables us to ensure suitable solutions are used and that you have the confidence in their performance.

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FEATURE

Bagging an environmental game changer

lobal geological supply company, Dynamics G-Ex, is addressing the ban on plastic bags in the African region through a range of compostable and biodegradable sample bags. Many African mining & exploration companies are paying a premium through tariffs and duties imposed to discourage the use of single use plastic sample bags. Company co-founder, Spencer Dormer stated, the new range of bags are based on cornstarch, a natural organic product. They can now be buried in-situ at the drill site, and they’ll compost and biodegrade back to organic matter over a 12-18 month period. There is no longer any need to empty and dispose of the bags in landfill sites around the country saving significant time, money and most importantly our environment. “Samplex Enviro Bags will save 3 million plastic bags from entering landfill every year, and the movement just started: our next goal is 90 million bags by 2030.” Independent testing has been carried out by AngloGold Ashanti to prove the bags in the harsh mining environment. “You need to have it so you can leave it on the ground and go back months later and still find it intact so that they can resample,” he said.

“So, with AngloGold, they went back eight months later, and the actual integrity of the bag was as robust as previously; it hadn’t lost any of its strength.” “But when buried the micro-organisms in the soil will mean the bag composts back to organic matter, win win situation” The Samplex® Enviro Bags will be available locally to explorers in Zambia, DRC & Tanzania region through the African distribution channels. This movement follows Dynamics recent shift to manufacturing the Discoverer® range of Plastic Core Trays from Kerbside plastic. Spencer said sample bags and core trays accounted for 80% of the products they exported around the world to local distributors. “Africa remains one of the biggest dumpsites for the world’s waste, and we want to stop this, and ensure that kerbside plastic is made into something useful.” “An obvious choice was to make it into a Core Tray. But no ordinary Core Tray, one with a Lifetime Warranty to show Geologists we stand behind the quality of our product in the African climate.” “There is so much pressure on the miners nowadays to take care of their corporate-social and environmental

responsibility and protect their image and social license to operate.” “Discoverer Core Trays are saving 1.5 million kilograms of kerbside plastic from entering landfill every year, and the movement just started: our next goal is 25 million kilograms by 2030.” The Discoverer range of Core Trays are available through local distribution channels in the Zambia, DRC & Tanzania region. These product ranges give mining companies an easy, obvious, and commercially viable way to demonstrate that they are doing the right thing by taking the socially responsible and environmentally sustainable approach to mining.

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FEATURE

Industrial plant for oxidative roasting of gold sorption leaching tailings Engineering Dobersek GmbH: Ph.D. A. Dobersek, N. Wotzka, Ph.D. O. Mishina

t present we are observing a growth trend in the world gold prices along with a noticeable decrease in reserves of rich and easily processed raw materials and consequently an increasing interest in involving of particularly refractory goldbearing ores into the processing. The extraction of gold from such ores using standard operations does not meet modern requirements. The most used way to improve the gold recovery rates from the refractory gold-bearing ores is their pretreatment using one of the conditioning methods before processing via standard cyanidation process. The best-known conditioning methods are pressure and biological oxidation, ultrafine grinding followed by oxidative leaching of sulfides in atmospheric conditions, as well as oxidative roasting. Most of the above methods ensure the releasing of primarily gold, which is finely disseminated in sulfide minerals, for example, in pyrite or arsenopyrite, due to their more or less complete oxidation. However, there is another important

reason for the refractoriness of the gold ores: the high sorption activity of the ore minerals, which causes significant losses of metal with solids of cyanidation process tailings. In most of cases, this sorption activity can be attributed to the presence of organic carbon in the ore. Oxidative roasting ensures almost complete oxidation of the both â&#x20AC;&#x153;problemcausingâ&#x20AC;? components: organic carbon and sulfidic sulfur. In case of especially high refractoriness of the ores, the use of combined oxidative technologies for the processing of particularly refractory gold-sulfide ores to achieve the satisfactory gold extraction rates could be necessary. Sulfide ores of the Kokpatas and Daugiztau deposits (Navoi Mining and Metallurgical Combine, Uzbekistan) belong to this type of ores. The sequence of the treatment process of the Kokpatas and Daugiztau sulfidic ores is as follows: First, the process of biological oxidation of the flotation concentrate takes place. Then the

gold associated with sulfide minerals is released, which is recovered at the subsequent stage of sorption cyanidation. The main part of arsenic dissolves and then becomes solid in the form of insoluble scorodite (FeAsO4). Further, the solid product of sorption leaching with low arsenic content is subjected to oxidative roasting, whereby organic carbon and residual concentrations of sulfide sulfur and (partially) arsenic are removed; as a result, at the final stage of sorption cyanidation from the roasted material (calcine), a significant amount of gold is extracted. 2007-2011 the biological oxidation plant was implemented at the Mining and Metallurgical Plant -3 (GMZ-3) of the Navoi Mining and Metallurgical Combine (NMMC) with the involvement of company Engineering Dobersek GmbH (Germany). Before deciding on the construction of a roasting plant, a multi-stage research

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METALLURGY 29

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SMELTING ROASTING ELECTROLYSIS

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ENGINEERING DOBERSEK GmbH is a German engineering company for planning, constructing and commissioning of turnkey plants and plant components. The results of our almost 4 decades‘ international experience in plant engineering is presented by a huge number of successfully completed projects. Worldwide. We offer the entire spectrum for turnkey plants: Research & Development, Engineering, Procurement, Construction and After Sales Service. This includes Project Management, Quality Management and Financing Models.

Engineering Dobersek GmbH Vorster Straße 493 41169 Mönchengladbach Germany

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ContiSmelt®System

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FEATURE

The roasting plant – sorption tailing roasting system (STR System) - consists of the following main units and facilities:

• • • • • • • • • • •

works was carried out, including both laboratory and semi-industrial tests. After the numerous investigations, the circulating fluidized bed furnace (CFB) for the roasting stage was favourited. This type of equipment provides a high capacity of the roasting process with high removal degree of the abovementioned elements, which are the reason for the resistance of the material to the cyanidation process. In addition to the roasting tests, all the preparation steps before roasting were investigated, such as dewatering of the tailings with washing the filter cake from cyanides, drying the filter cake, granulating the dried filter cake under conditions as close as possible to the actual conditions of the industrial plant. Based on the data obtained during the test works, the components of the main

Filtration station of input slurry Intermediate filter cake storage Filter cake drying unit Filter cake granulation unit Roasting unit of granulated material Dry dust collection unit Wet gas cleaning unit Calcine grinding unit Water cooling system Process and instrument air Electrical equipment, instrumentation and controls, automated control system

The wet cleaning unit also deserves special attention, whereby a multi-stage gas cooling and washing process was implemented, ensuring compliance with the requirements for the remaining content of harmful impurities in the exhaust gas, such as arsenic and sulfur, at the outlet of the plant.

technological equipment of the industrial plant for the oxidative roasting of sorption tailings were calculated. The results of the above-mentioned works are provided by extensive patent protection.

Commissioning of the roasting plant took place in August 2019. The implementation of the oxidative roasting process in the circulating fluidized bed furnace (CFB furnace) at the Mining and Metallurgical Plant -3 (GMZ-3) of the Navoi Mining and Metallurgical Combine ensures additional increasing capacity at the plant by about 10%.

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FEATURE

“The programme on this PLC has sitespecific trip condition pictures that automatically indicate the area where a fault has occurred and also includes pictures of the actual components. For user convenience, next to these pictures, is a guide for fault finding and immediate access to the circuit diagram drawing. The system also provides technical support contact details and to assist our customers with easy ordering of the correct spares, a list of components used in that specific panel, with allocated part numbers, is provided.

Becker Mining South Africa has recently launched a new upgraded chairlift Programmable Logix Controller (PLC) panel that enhances reliability of Becker chairlift systems, which are used to safely transport personnel on mines throughout the world.

Becker Mining’s new upgraded Chairlift PLC panels increase safety

ecker Mining South Africa has recently launched a new upgraded chairlift Programmable Logix Controller (PLC) panel that enhances reliability of Becker chairlift systems, which are used to safely transport personnel on mines throughout the world. These locally manufactured chairlift PLC panels, which are programmed to automatically show trip conditions of a chairlift system, comply with all the latest requirements of South Africa’s Department of Mineral Resources (DMR) in terms of stringent regulations of the Mine Health and Safety Act.

- including emergency contact details, wired diagram drawings and a parts list is installed on the PLC panel and can be easily updated at any time.

Becker Mining South Africa’s chairlift systems are designed to transport up to 900 personnel per hour, quickly, efficiently and safely in all underground applications, including difficult mining conditions. Becker’s modular, low maintenance chairlift systems, which encompass the latest technology and manufacturing trends, meet stringent quality and safety regulations in the mining sector. These chairlifts, with a simple, yet robust structure, are installed in underground sites with steep inclines up to 45◦ and long haulages up to 2 000 m, at drive speeds between 1,5 m/s and 3 m/s. In emergencies, the chairlift system can be used for transporting injured workers quickly and safely back to the surface. Safety features include a rope slip sensor and a fail-safe brake system, which is spring-activated and hydraulically released on the drive wheel brake path. Secondary and primary brakes are capable of holding the entire out of balance load. Other critical safety devices are the passenger override sensor and an intelligent pull key system.

“The new Becker PLC panel features a user-friendly 12-inch display, that not only clearly indicates a trip condition, but also guides the user in quick and effortless fault finding. This is a critical safety advantage in the mining sector,” explains says Tom Searle, Senior General Manager: Capital, Becker Mining South Africa (Pty) Ltd. “The upgraded PLC panel, with expandable options, uses an intelligent pull key system to show all trip conditions. Critical chairlift information

“If users want to upgrade their system further, they have the option of connecting the chairlift panel to the control room via installed networks. The PLC can then connect to a surface system, allowing it to send an SMS to designated numbers, in the event of trip conditions. The user is also able to log in remotely to view these trip conditions and send out artisans to assist with breakdowns.”

Critical chairlift information - including emergency contact details, wired diagram drawings and a parts list - is installed on the PLC panel and can be easily updated at any time.

Chairlift underground transport systems can be supplied with dependable diesel driven generator sets, to ensure the absolute safety of miners in the event of a power outage. Becker Mining is committed to providing the latest product designs, impeccable manufacturing standards and cost efficiency, as well

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as enhanced safety and total reliability of these underground transportation systems. Every chairlift installation is custom-designed to suit every specific application and drive units are selected based on the length and gradient of the installation. The company is also responsible for erecting the chairlift drive house, mechanical and electrical installations and all civils work. Becker Mining offers a full range of spares for chairlifts, as well as a support service, which includes a maintenance and on-site repair service. The companyâ&#x20AC;&#x2122;s service also comprises audits of running installations, where assistance is provided in identifying areas that require attention. Recommendations are given about necessary maintenance requirements and the safe use of the system. Becker Miningâ&#x20AC;&#x2122;s chairlift systems are designed and manufactured at the companyâ&#x20AC;&#x2122;s Alrode facility, according to stringent local and international mine haulage safety regulations.

The programme has site-specific trip condition pictures that automatically indicate the area where a fault has occurred and also includes pictures of the actual components. Next to each picture is a guide for fault finding and immediate access to the circuit diagram drawing. Technical support contact details and a list of components used in that specific panel, with allocated part numbers, is also provided.

Congratulations to our customers for

OPTIMISING

TRILLION TONNES of HAULAGE over the last 40 years

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FEATURE

BME’s RCT is a good reflection of the safety culture within the business

safety interventions contributed to this progress, he said, including Visual Felt Leadership, Process Safety, near miss reporting, driver awareness programmes and fatigue management to name just a few. These aligned with the Omnia Vision of zero harm and positive impact through responsible business practices.

Electronic detonators are inherently safe from extraneous electricity, reducing the risk of misfires.

Operational excellence, safety are two sides of same coin

he key to an improved health and safety record in the mining workplace lies with integrating safety firmly as part of operational excellence. This is according to Ramesh Dhoorgapersadh, General Manager for Safety, Health, Environment, Risk and Quality (SHERQ) at blasting and explosives leader BME, a member of the JSE-listed Omnia Group. He highlighted BME’s Safety for Life brand, which focuses on the triple bottom line: safety for people, the environment and the commercial sustainability of the business. The key objective is for all employees and contractors to go home in the same condition that they arrived at work, having delivered quality service

and products to the customer with no harm to the environment. “The success of implementing Safety for Life is reflected in our recordable case rate (RCR) dropping steadily in recent years to just 0,06 during the third quarter of 2020,” said Dhoorgapersadh. “Our RCR is a good reflection of the safety culture within a business, as the downward trend over the past three years demonstrates.” BME was recognised for responsible care at the Chemical and Allied Industries Association (CAIA) Awards last year, based on its year-on-year SHE performance improvement. Several

“The drive for safety is a neverending process of analysing even minor incidents and generating fresh ideas to reinforce our Safety for Life interventions,” he said. “It is also vital to report and understand ‘near misses’, which are valuable indicators of where we can prevent incidents before they occur.” As a leading producer of emulsion explosives, BME imbeds a range of process safety elements into its manufacturing operations, in line with global best practice for chemical industries. This focuses on asset management in ways that protect employees, the environment and the broader community. “Moving ammonium nitrate through our value chain, for instance, demands that we constantly learn from international experience – and this helps drive our safety culture,” he said. He noted that BME also identifies the United Nations’ Sustainable Developmental Goals as relevant to its safety efforts – particularly those linked to industry, innovation and infrastructure; decent work and economic growth; responsible consumption and production; and partnerships for the SDG goals. “As an example, we launched our new Blasting Guide mobile app earlier this year as part of our continuous innovation

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– leveraging digital technology to allow users to rapidly calculate and check blast designs,” he said. Indeed, enhanced safety has been a perennial consideration in the development of all BME’s products and services, to ensure the safe and efficient use of explosives in the field. BME’s Global Manager for Blasting Science, D. Scott Scovira, emphasised the company’s extensive use of electronic – rather than electric or non-electric – detonators for firing blastholes. “Electric detonators have the safety concern of being susceptible to extraneous electricity and run the risk of unexpected detonation,” said Scovira. “Non-electric detonators, while immune to extraneous electricity hazards except lightening, do not have detonator circuit testing capability and rely on the user to make 100% correct connections to prevent misfires.” By contrast, electronic detonators are inherently safe from extraneous electricity except for lightning, and each detonator in

as encroachment of settlements close to blasting sites like quarries, by minimising the risk of flyrock. “Assisted by specialist technology providers like BME, quarries and mines can today employ specialised electronic and software tools that enable the field measurement of blast hole deviations and measurement of the amount rock in front of the blast holes,” he said. “Actual field measurements are compared against the engineered blast design and adjustments are then made to the design to ensure a safe blast.” Ramesh Dhoorgapersadh, General Manager for Safety, Health, Environment, Risk and Quality (SHERQ) at BME

the blasting circuit may be checked for functionally before firing – thus reducing the risk of misfires. He noted that, in comparison to many other ultra-hazardous occupations, field blasting professionals have an excellent long-term safety record. They have also adapted well to modern demands such

As BME has operated through the Covid-19 pandemic, Dhoorgapersadh pointed out that risk assessments have been adapted in line with company, group and customer health and safety policies, as well as Department of Labour requirements. “All our Covid-19 interventions have worked well, with internal audits and departmental inspections confirming this on a regular basis,” he said.

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FEATURE

BMG offers maintenance-free heavy-duty couplings and wedge belts for enhanced operating reliability in the most demanding environments. maintenance-free feature of this series is a major advantage where there is a shortage of skilled labour. These maintenance-free wedge belts, with a wrapped chloroprene rubber construction, have a two-ply higher modulus polyester cord outer jacket to reduce belt elongation and improve stability in tough operating conditions. Conventional belts installed in dusty environments tend to stretch unevenly and slip and jump out of pulley grooves and belts can even melt if they are unable to cope with extreme temperatures.

he BMG team works closely with industry to achieve a more efficient and sustainable environment and a highly productive and globally competitive region. “BMG optimises productivity and enhances process plant operating reliability through its critical focus on entire production processes. This service encompasses an extensive range of quality branded components, engineering solutions and technical expertise,” says Carlo Beukes, Business Unit Manager, Power Transmission division, BMG. “The company’s commitment to be a complete process solutions provider to all sectors of industry means companies can access all essential products and services from one reliable supplier. This integrated approach guarantees lower production costs and higher efficiencies.”

BMG launches new products and systems on an ongoing basis to meet market requirements and has secured the exclusive supply, service and distribution agreements with many of the world’s most respected engineering manufacturers. Important components in the company’s Power Transmission division are recently launched Fenner Quattro Plus Twin Wrap (TW) wedge belts and maintenance-free heavy-duty engineering couplings. Fenner Quattro Plus TW wedge belts, which transmit 30% more power than conventional belts, cope extremely well in harsh African conditions. The

“A cornerstone of BMG’s initiative is reliable engineering – a philosophy aimed at keeping a plant in a fully productive output for as long as possible, without unnecessary maintenance or unplanned stoppages. As a result, output capacities are increased without investment in additional production lines and machinery.”

With the installation of appropriate belts, which are designed to adapt to the specific application and environmental conditions, maintenance staff is able to spend more time on preventative maintenance, rather than proactive maintenance. The asymmetric weave double jacket of Fenner Quattro Plus TW belts is heat and oil resistant, offering increased durability and improved abrasion resistance in harsh conditions. Other important features include high performance, maximum drive efficiency and extended service life. These flexible belts, which offer up to 96% energy efficiency at optimum performance, have been designed for easy installation as a permanent replacement, with minimal downtime. No dismantling of equipment is necessary. BMG’s Fenner Quattro Plus TW belts, which are suitable for counter-bending, back-tensioners and clutches, can withstand an extended temperature range of between -30°C and 80°C. Fenner’s PB® (Precision Build) technology, eliminates the need for matching. This range conforms with all international standards, including BS 3790, ISO 4184, DIN 7753 and American Petroleum

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Institute specifications. Fenner Quattro Plus belts also meet the highest standards for static conductivity (ISO 1813 standards).

contact between the hubs. This prevents any possible damage to the ironware during an element failure. The urethane insert can be easily changed without moving the hubs or shafts and no realignment of components is necessary.

These belts are particularly well-suited for heavy industrial applications, including crushers, heavy duty conveyors, waste compactors and pumps. Timken Quick-Flex maintenance-free couplings “The primary purpose of couplings is to transmit torque from a driving shaft to a driven shaft and to accommodate shaft misalignment during operation. Couplings also dampen vibration, torque fluctuations and torsional shock loads, even in arduous applications,” explains Brandon Bouillon, Product Manager, Power Transmission division, BMG. “Through careful and accurate product selection, correct installation and with the appropriate care of couplings, substantial savings can be made in reduced maintenance costs and minimal downtime. These procedures also increase the L10 lifetime of the product.” Timken Quick-Flex couplings consist of two steel coupling hubs which are attached to the drive and driven shaft. A urethane element wraps around the two hubs and provides a simple, yet effective, drive mechanism. The only spare part required is a standby element that can be quickly changed when necessary. Inserts, which are resistant to chemicals, are manufactured from different grades

of urethane to suit various industries. The red insert is suitable for high-speed applications with high levels of vibration. The stiffer blue insert is designed for higher torque applications and the black insert can withstand extremely high torque requirements, replacing grid and gear couplings. An advantage of these flexible couplings over conventional units is direct replacement with virtually all equivalent sized couplings. Quick-Flex couplings require no lubrication and are also easy to install and maintain. Due to the high torque capacity of this range, the selected Quick-Flex solution is often smaller than the replaced coupling. This results in substantial weight saving on the drive and reduces stress on other components. These couplings accommodate angular misalignment up to 2º and parallel shaft displacement up to 7.92 mm. Once the two coupling hubs, insert and cover have been installed and aligned for the first time, the coupling hubs do not need to be moved again for the life of the equipment. Unlike a standard jaw-type or gear couplings, there is no metal-to-metal

Quick-Flex couplings are compatible with shaft sizes from 10 mm to 286 mm and can accommodate a wide speed range – from below100 rpm, to 12 000 rpm. Torque ratings range from 43 Nm to 188 795 Nm, depending on the selected element and cover design based on the blue element specifications. BMG has a team of mobile technicians with specialist technical skills and equipment to conduct breakdown and routine maintenance on site. This team carries out trouble shooting and advises on possible productivity improvements, to ensure the highest level of plant output and reliability. Specialist services include installation, adjustment, replacement and maintenance of components, shaft and pulley alignment, balancing, condition monitoring, oil sampling and analysis and critical equipment inspections and lubrication schedules. Maintenance training and fault diagnosis also form an important part of BMG’s field services. The company is committed to providing a 24-hour customer process support for production efficiency and reliability centred maintenance. This is enhanced by advanced technical and design support across all functional disciplines.

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FEATURE and show signs of fatigue, the alarms will continue to sound in a high-pitched tone followed by voice alerts.

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Increasing driver alertness, reduce collision risk and improve overall fleet performance with DriveAlert Distributed by DriveRisk in Africa, DriveAlert is able to perform fatigue and distracted driving monitoring 24/7 in all weather, light conditions, including if driver is wearing tinted sunglasses. The DriveAlert system proactively monitors and alerts Drivers on Distractions, Possible and Critical Fatigue in an aim to prevent Collisions and improve driver safety.

he ability of a driver to self-assess his or her fatigue level diminishes as he or she grows more tired. Research has established that 80% of vehicle accidents are directly related to driver fatigue and distraction. For organisations in mining and related sectors the litigation resulting from injuries or fatalities, damage to expensive equipment, in addition to loss of productivity could be a huge cost burden to bear. And so, recognising the impact of collisions on business operations, DriveRisk has introduced DriveAlert, a solution to help organisations manage the problem of fatigue and distraction among drivers in their fleet of vehicles. DriveAlert is a fatigue and distracted driving monitoring solution with an audible alarm that increases in volume and frequency to force a driver to take note of his dangerous fatigue level and stop the vehicle before a possible collision or to redirect his attention from any distraction. The unit looks like a camera but incorporates a highend infrared camera, microprocessor, memory modules and alarm system.

DriveCam compatibility and early warning service Linked to DriveCam, DriveAlert not only warns the driver in cab but generates video in the form of an exceptions-based incident, allowing the opportunity for an active coaching engagements with the driver, whether cell phone use, sleep apnoea or other driver distractions. Linked to DriveRisk’s Early Warning service, real time alerts via SMS or telephone call (severity dependent), DriveRisk will timeously warn the fleet owner enabling preventative intervention. DriveAlert incidents linked to DriveCam further enhance the behavioural risk profiles of each driver, this provides a comprehensive understanding of the frequency and severity of risky incidents.

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Automatic driver scanning on vehicle start-up On each start-up of the vehicle the DriveAlert will scan the driver’s eyes and facial features in order to identify Fatigue and Distraction during the trip. DriveAlert is able to identify fatigue and distracted driving monitoring 24/7 in all weather, light conditions, including if driver is wearing tinted sunglasses. This makes the system handy in the prevention of driver fatigue related vehicle accidents. Revival of economic activity after the lockdown is the perfect opportunity for industry to enhance the safety of vehicles used in their business operations through the adoption of technologies like DriveAlert.

DriveAlert’s notable features

• Capabilities The main capabilities of DriveAlert are the ability to monitor eyes and face, DriveCam compatibility, early warning, as well as automatic driver scanning on vehicle start-up.

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Monitoring eyes and face An early warning system, DriveAlert recognises fatigue and distracted driving by actively tracking a driver’s retinas and facial features. Using the PERCLOS measure of alertness, it detects fatigue even before the driver closes his eyes. When detecting these signs an audio alarm will sound to alert the driver of their fatigued state. If they continue to drive

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Not affected by drivers wearing glasses or tinted sunglasses Functions with drivers of all skin colours Driver’s vision will not be obscured or blocked in any way The unit is configurable to start monitoring at speed intervals of either 20 km/h, 30 km/h or 45 km/h The unit will be installed into a tamper proof case and then mounted in position to avoid tampering, setting adjustment and power disconnection etc. Components can operate between -10 degrees to +50 degrees Celsius. Alarm sensitivity and volume is adjustable

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FEATURE

It’s a further 2 years on a Senegalese gold mine for Lincoln Lubrication’s Africa Export Team!

xcellent service on the lubrication systems of mobile equipment on a gold mine in West Africa over the past two years has delivered increased uptime and substantial cost savings, earning Lincoln Lubrication South Africa’s Africa Export team an extension of their service contract by another 24 months. When the Senegalese gold mine started losing mobile equipment with subsequent frequent costly downtime due to a lack of proper lubrication maintenance planning, they called on the Africa Export Lincoln team for a solution. “In October 2018, the mine accepted our proposal for a 24-month service contract on the lubrication systems on all their mobile equipment,” says Lincoln Lubrication South Africa’s, Export Sales Manager, Joseph Kumwimba. Kumwimba, together with team member, Obakeng Malao, who is responsible for customer service, took complete control of the lubrication systems on all the mine’s mobile equipment over the two year period. “By maintaining and repairing lubrication systems, we reduced grease consumption, increased equipment uptime, avoided equipment failure, and saved on maintenance man-hours, ultimately delivering tremendous cost savings and ensuring optimum protection of our customers’ assets,” notes Kumwimba. He adds that the customer’s CAPEX (capital expenditure) was also reduced due to the repair of pumps and injectors for reuse.

contract came to an end in October 2020, the mine, recognising the benefits, immediately extended the contract for a further 24 months. “We are particularly proud of what we managed to achieve, especially taking into account that all countries where under strict lockdown measures 16 months into the first service contract which presented us with numerous challenges. The fact that we have a technician in Senegal for six months definitely worked in our favour.” In line with the new contract, the Africa Export Lincoln team will continue servicing the factory-fitted CentroMatic Lube systems on 52 machines including excavators, wheel loaders, crawl dozers, bulldozer, graders and mine trucks. The CentroMatic Lube system complete with the South Africa manufactured AutoLube controller, includes SLV, SL-1, SLV-X, and SL-11 injectors with PowerMaster and FlowMaster grease pumps. “We provide some modification where necessary to fit the tough African conditions and in some instances we install new lubrication systems,” notes Kumwimba, adding that they also have the capabilities should the mine decide to add more machines for lube service.

The tremendous value adds that customers and endusers stand to gain makes implementation of a lubrication service contract a no brainer. The optimal functioning of lubrication systems reduces costly unplanned lubricationrelated downtime, ensuring high availability and smooth operation of their mobile machines. So when the first lubrication service

“The fact that we have a permanent presence on the mine site means that every time a mobile machine pulls into service bay, we are on hand ready to conduct a complete check of the status of the lubrication systems.” The full scope of work includes checks on pump operation and sufficient pressure build-up and the functioning of metering devices and SL-V Injectors. “Following inspection and identification of requirements, we make recommendations on necessary repair and replacement work on each machine. Once we have completed the repairs we make sure that the machine is in 100% working order complete with a written report.” To ensure prompt repairs, the team holds a certain level of stock consignment on site, setting up a low level for replenishment. As part of the service contract, on-the-job training is given to mine technicians. Lincoln Lubrication South Africa established the Africa Export Lincoln team four years ago with the objective of becoming the leader in the lubrication industry in various markets throughout sub-Saharan Africa. “Our mandate is to increase revenue as well as to ensure smooth operation throughout sub-Saharan Africa’s export industry,” says Kumwimba. He points out that the lubrication business requires a great deal of time and patience to develop and even more so in the African market. “Trust needs to be earned before the end-user can even consider looking at the solution proposition. The market requires perseverance, consistency, regular customer visits and mental toughness and, most importantly, a purposedriven personality,” he concludes.

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FEATURE

Hybrid solutions are the most effective way to deliver reliable clean power to remote off-grid mining operations in Africa by Tarik Sfendla, Market Development Manager, Africa chez Wärtsilä Energy Business

he energy markets are undergoing a massive transformation as governments around the world transition away from fossil fuels towards the integration of renewable energy. This trend is clearly visible in the mining industry as demonstrated by recent power projects in South America and in Australia. According to Bloomberg New Energy Finance, in 2018, mines purchased 1 GW of renewable energy generation assets; this amount tripled to reach approximately 3.5 GW in 2019, 90% of which consist of hybrid solutions. Electricity demand for the mining industry is expected to increase significantly in the coming years as increased mine depth, harder rock and greater water desalination needs lead to higher energy intensity for the industry. Whilst electrification of operations and vehicles is reducing certain emissions and generating cost savings, stakeholder targets to reduce emissions as part of the EESG (Environmental, Economic, Social & Governance) plans, is increasing the renewable share of the energy mix, which of course requires high flexibility in generation to balance intermittent renewables. In Africa, the mining sector faces inherent challenges, access to the power grid and grid reliability being the most significant. With most electricity supply coming from conventional power plants (coal, oil or gas), operators are challenged on the one hand with highly volatile operating expenses due to rising fuel costs, and by inefficient, unreliable power supply leading to costly production disruption and revenue losses on the other. Weak infrastructure and water availability compound the challenges for mines, particularly in remote, off-grid locations. The combination of these trends and particularities of the African markets are setting the scene for the integration of renewables for the mining sector. A recent study by McKinsey[1] showed that moving to renewable electricity sources is becoming increasingly feasible, even

Tarik Sfendla - Wartisla Energy Business Africa

in off-grid environments, as the cost of electricity storage is set to decline by 50% from 2017 to 2030. This is especially good news for Africa where the cost of solar energy generation could be among the lowest in the world. It also represents a huge opportunity for operators in Africa, where Wärtsilä has developed a range of competitive strategies to deliver efficient and reliable power supply solutions to support the mining sector on its path towards a renewable energy future. In Tanzania, the Geita gold mine, was experiencing reliability issues and power shortages as its aging power plant was reaching the end of its useful life. It needed a reliable power generation solution to support its growing operations. Wärtsilä delivered a 40 MW flexible power plant and agreed a 10year operation and maintenance (O&M) package, integrating technology with lifecycle services to provide “always-on” power. The plant secures uninterrupted off-grid power supply, eliminating revenue losses from power shortages, while the O&M agreement is tailored to the mine’s day-to-day performance requirements.

Maintenance schedules are optimised to minimize costs and production downtime and enhance fuel efficiency. As a result, fuel savings of around 4%, representing $2 million USD, were achieved in the first year of operation. The flexibility of the installation will also facilitate the transition to renewables over the project lifetime. In Burkina Faso, Wärtsilä has delivered a 15 MWp solar photovoltaic (PV) power plant to the independent power producer (IPP) Essakane Solar SAS, which supplies the Ekkasine gold mine. The solar PV plant was constructed next to a 55 MW power plant running on heavy fuel oil. The engine power plant provides backup, while the solar farm produces energy during the day. The capability to control and optimise the usage of the solar PV power and engines enables the gold mine to reduce its fuel consumption by an estimated 6 million litres per year and its annual CO2 emissions by 18,500 tons. Energy Storage technologies are the true game changer The integration of energy storage technologies will be the real game changer, enabling the industry to take

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full advantage of cheap and plentiful solar power. They have the unique ability to provide a buffer between supply and demand by delivering or storing energy whenever it is most needed. They will become the key building block of the stable infrastructure needed to improve grid reliability and security. Hybrid solutions, combining flexible thermal generation with storage and solar power operations are now a realistic and costeffective solution, as the levelled cost of electricity (LCOE) is lower than ever, and costs of storage are set to decline. In Mali, at the Fekola mine, located in a remote area with no connection to any larger grid, Wärtsilä is providing an off-grid hybrid solution to provide and maintain microgrid stability. The project combines a 30 MW solar PV plant, a 17.3 MW / 15.4 MW energy storage facility and GEMS, Wärtsilä’s advanced energy management system, with the mine’s existing 64 MW power generator to improve power reliability, reduce heavy fuel consumption, save costs and reduce CO2 emissions.

GEMS is a ground-breaking tool, using smart algorithms to dispatch energy storage and multiple generation assets (thermal and renewable) with the right reserve level to maintain high grid reliability for the mine. Gensets are switched off as solar output increases and are restarted based on forecasted data including load demand and weather. The sophistication of GEMS enables energy production optimization to ensure the lowest LCOE. In addition to ensuring microgrid stability, the project is expected to generate longterm annual savings of 13.1 million litres of heavy fuel oil and reduce the mine’s carbon footprint by approximately 39,000 tons per year. This hybrid storage project is the first of its kind in Mali and in the mining sector, demonstrating the growing case for clean energy and its sustainable and economic potential for mines in Africa and elsewhere. Increasing energy reliability and lowering operating costs are essential for the mining sector. The optimal

solution to solve the power challenges must allow for fast starting with high offgrid availability, high fuel efficiency, fast load following and part-load efficiency to allow high penetration of renewables. The answer lies in a combination of advanced flexible energy generation strategies and the smart use of renewables to guarantee the delivery of efficient and reliable power in remote off-grid locations. Advanced energy management systems are the key technological element required to support the huge inflows of power from intermittent sources. With an extensive portfolio of energy storage and flexible solutions for energy intensive operations, in Africa and the rest of the world, Wärtsilä, is the partner of choice to support the mining sector achieve its sustainability and cost saving goals.

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8/21/20 2:33 PM

FEATURE

Ivanhoe Mines forges ahead I

vanhoe Mines chairs’ Robert Friedland and Yufeng Sun announced underground development at the Kamoa-Kakula Copper Project in the Democratic Republic of Congo (DRC) totalled 2,172 metres in October. This marks another new monthly record and brings total underground development to more than 24.7 kilometres – approximately 7.9 kilometres ahead of schedule. Mr. Friedland and Mr. Sun also noted that mining crews produced a combined 194,000 tonnes of ore in October from the Kakula and Kansoko mines, which was 48% higher than achieved in September. The project’s pre-production surface stockpiles now contain approximately one million tonnes of high-grade and medium-grade ore at an estimated grade of 3.47% copper.

The monthly total of 2,172 metres of underground development in October was comprised of 1,809 metres at the Kakula Mine and 363 metres at the Kansoko Mine, which is located at the Kamoa Deposit – approximately 10 kilometres north of the Kakula Mine. At Kakula, both main access tunnels (drives) being advanced from the southern decline, and the spiral access drive being advanced from the northern decline, have recently accessed the high-grade zone near the centre of the deposit grading approximately +8% copper Kakula’s main access drives between the northern and southern

The enormous amount of pre-production development completed to date at both the Kakula and Kansoko mines has positioned the project for a significant acceleration in the tonnage, as well as a marked increase in the grade, of ore added to the project’s surface stockpiles beginning this month.

declines have less than 100 metres remaining before they are connected (holed) in the high-grade centre of the deposit. The holing will significantly increase ventilation to the centre of the orebody, allowing for additional mining crews to begin highly-productive mining operations in Kakula’s high-grade ore zones. Accordong to Mark Farren, the imminent joining of Kakula’s northern and southern main access drives will be a major milestone in the mine’s development. Once this is achieved, the opening up and ledging of the drift-and-fill blocks can commence in the high-grade core of the deposit, where the average grade is projected to exceed 8% copper. Kakula’s second underground ore bin (the west tip bin) is undergoing commissioning. Installation of Kakula’s ventilation shaft #2 also is progressing well, with the first of three high-capacity surface fans installed by the contractor. The gabion wall for the surface bulk reclaim tip system that is located near Kakula’s main northern decline has been

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testing, physical distancing, wearing face masks, frequent hand washing and contact-tracing measures are still in place to protect the safety and health of the workforce and community members. All expatriate employees are still required to quarantine for two weeks upon arrival at Kamoa-Kakula.

constructed and preparation has started for the civil works required at the top of the wall. The bulk reclaim tip system will be used to feed ore from Kakula’s surface stockpiles (and ore from the Kansoko Mine when second-phase operations begin) to the processing circuit. Underground development at the Kansoko Mine currently is in low-to-medium-grade ore zones, grading approximately 3% copper. In October, mine development work intersected the first exposure of siltstone, marking the transition to higher copper grades at Kansoko. Siltstone is a rock type with a strong influence on copper mineralization at Kamoa-Kakula. Phase 1 copper production from the Kakula Mine is scheduled to begin in July 2021. Kakula is projected to be the world’s highest-grade major copper mine, with an initial mining rate of 3.8 Mtpa at an estimated average feed grade of more than 6.0% copper over the first five years of operation. Phases 1 and 2 combined are forecast to produce

approximately 400,000 tonnes of copper per year. Based on independent benchmarking, the project’s phased expansion scenario to 19 Mtpa would position Kamoa-Kakula as the world’s second largest copper mining complex, with peak annual copper production of more than 800,000 tonnes. In accordance with health guidelines from the DRC government, and in line with the country’s lifting of restrictions, KamoaKakula’s Congolese workforce has gone back to normal work rotations. Rigorous

The project has established a COVID-19 isolation facility at the Kamoa camp. Potential symptomatic patients are moved to this facility, where they will be isolated, tested and treated. Once patients have recovered and are deemed no longer infectious, they can return to work only after an additional quarantine period determined by the project’s medical staff. As the pandemic evolves, the medical team at Kamoa-Kakula continues to review and update its risk mitigation protocols. The project’s preventative measures are at the highest international standards and, if there was a case internally, the risk of spreading or crosscontamination is considered to be very low.

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FEATURE

Mathilde Robben, Key Account Manager at TOMRA Sorting Mining

First underground TOMRA sensor-based sorter starts operation at K+S rock salt mine

+S Minerals and Agriculture, a major salt producer, turned to TOMRA Sorting Mining for a solution for the replacement of the existing sorting system at its rock salt mine in Grasleben, in Lower Saxony, Germany. The two companies have a long-standing research and development relationship, focused on exploring the application of TOMRA’s technologies to salt sorting. K+S Minerals and Agriculture operates in a sector that is recording a growing trend. According to the “Global salt market size 2019-2025” report published by market and consumer data provider Statista, the

global salt market was valued at about 28 billion U.S. dollars in 2019 and is forecast to exceed 32 billion U.S. dollars by 2025. The industry growth is driven by a rise in the demand for salt applied in the chemical manufacturing industry – especially in chlorine-alkali chemicals production. The challenges of rock salt sorting at the Grasleben mine At the Grasleben mine, rock salt is extracted from a high-quality underground deposit that stretches across two Federal States. It is processed into a wide range

of products, from de-icing salt for winter road services to food-grade table salts and lick stones for livestock and domestic animals. For K+S, consistently achieving certified and guaranteed high purity, compliant with the strict standards of the food industry, is a priority. “The sorting of rock salt is complex and demanding due to its crystalline properties. This leads to strong fluctuations in the appearance of the material”, states Sven Raabe, Technische Büro Mechanik, K+S Minerals and Agriculture. TOMRA recommended using COLOR sorting technology: “with a customized set-up of the light sources we can detect the difference in transparency of the different particles, ensuring the high quality of the rock salt,” explains Mathilde Robben, Key Account Manager at TOMRA Mining. The team also advised installing the sorter in the underground mine, so that “after an initial underground sorting stage, only the coarsely crushed rock salt undergoes further grinding and sieving above ground. Only the valuable product needs to be transported in the shaft, and the final result is high-quality, pure rock salt products in various grain sizes, which are ideal for this application. Furthermore, waste rejects can be backfilled underground, avoiding storage and emissions on the surface.”

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FEATURE

resource conservation. It is possible to react quickly and individually to changing situations during dismantling. We expect this to be more effective, and the ease of use of the system was also convincing.”

Testing the solution at TOMRA’s Demonstration and Test Center in Wedel TOMRA conducted a demonstration of the proposed solution at its Demonstration and Test Center in Wedel. Sven Raabe attended the test with colleagues from K+S’s technical team, Florian Lieske, Stephan Meiberg and Sven Lindner. Seeing the technology in action was decisive: “The tests were very well

prepared,” says Sven Raabe. “The onsite team quickly developed a feel for our product. The uncomplicated adaptation of the program to the different material qualities also convinced us.” “An important factor in our purchasing decision was the positive test result achieved with the system, using transmitted light to obtain more efficient separation. This has the added benefit of

The order was placed and installation completed on schedule Following the positive experience at the Test and Demonstration Center and the results of the test, K+S placed the order for TOMRA’s solution, with installation planned for September 2020. The negotiations were conducted via video conference due to the Covid-19 travel restrictions and lockdown. The order was entered in TOMRA’s production plan and the Factory Acceptance Test was conducted on September 23rd. The sorter was transported to the Grasleben mine, where it was placed in position underground on September 30th and installation was completed on schedule. “This is the first solution we provide for underground sorting, which raises specific challenges due to the dimensions and weight limitations of the mine shaft,” concludes Mathilde Robben. “In this project we also had to contend with the difficulties created by the Covid-19 pandemic. I am very pleased that we have been able to meet K+S’s requirements and deliver on schedule.”

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FEATURE

SKF Zambia’s Non Destructive Test works increases mobile equipment availability, delivers massive savings for Zambian Copper Mine

SKF Zambia’s NDT solution which was rolled out in June 2020 included both traditional as well as advanced techniques. Ultrasonic Testing, Magnetic Particle Penetrant Testing, Eddy Current Testing and painting and coating inspection are some of the traditional methods applied by SKF Zambia.

DT (Non Destructive Test) works carried out by SKF Zambia on more than 90 mobile mining machines and equipment operating on one of the country’s largest copper mines, delivered massive savings for the customer over a six month period. The mine, which is located in Zambia’s North-Western Province, is a key longterm customer of SKF Zambia. “We share a solid 15+ year relationship with our customer, supplying the mine with SKF bearings and seals as well as Lincoln Lubrication solutions over the years,” confirms Key Accounts Manager at SKF Zambia, Mel Patel. Internal cracks on mobile machines are a chronic issue on the mine where heavy equipment operates round-theclock. NDT works are thus fundamental to the mine’s predictive maintenance strategy planning. In addition to averting unnecessary downtime, huge parts procurement costs can be avoided through better planning around stocking of larger parts with longer lead times.

Some results following testing work included the identification of frame cracks on various dump trucks and excavators. “We filed a report for repairs and, following the necessary repairs, we conducted a second inspection to ensure that all was in order,” says Patel.

SKF Zambia team conducts NDT works on 90 machines on the copper mine every six months

The SKF Zambia’s specialist team conducts NDT works on 90 machines on the copper mine every six months, completing two to five units per day.

Patel explains that SKF Zambia has added further value for the customer by placing a skilled team on the mine site. “Our team is on standby, ready to respond immediately to any requests from the mine’s maintenance manager for necessary machine or equipment inspection.”

These include the mine’s most critical machines such as Articulated Dump Trucks (ADT’s), Mine Haul Trucks, drill rigs, rock breakers and excavators that operate 24/7 as well as equipment including excavator buckets and booms. Additional inspections are also carried out on other components on the mine as required by the end-user. “Our NDT scope of work is comprehensive comprising aspects such as inspection of welds, castings, forgings, components, plates and rolled product piping; coating inspection covering all aspects of surface finishing; mining truck frame inspection; holiday testing, and Corrosion Under Insulation Detection using Lixi Profiler,” notes Patel.

w“By pinpointing issues and enabling the necessary repairs to be done before catastrophic failures, we delivered tremendous cost and time savings benefits to our customer.” In addition to keeping repair costs to a minimum, equipment availability is optimised while uptime, and subsequently productivity, is increased. These advantages present a solid argument for the vital role that NDT works play in predictive maintenance which is fundamental to the future sustainability of a mine or plant.

Cracks detected by Non Destructive Testing carried out by SKF Zambia on a large mine truck

“Forging long-term partnerships with customers and delivering turnkey solutions rather than just selling products add good value to our overall strategic focus on Rotating Equipment Performance (REP). Our solid NDT works have strengthened our customer’s trust and have presented future opportunities for online monitoring of mobile machines on the copper mine,” concludes Patel.

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AP_PACK-CARRIERE.GBa_180x130.indd 1

18/08/2020 16:31

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Junipers Systems ...............................................................................................................37 Komatsu ...................................................................................................................................17 Modular Mining ....................................................................................................................27 NTN ............................................................................................................................................44 Oxylance ..................................................................................................................................24 Redline ......................................................................................................................................09 Schaunberg ............................................................................................................................35 Sunace ......................................................................................................................................13 Terex ..........................................................................................................................................15 Tomra .........................................................................................................................................41 Wurth .........................................................................................................................................29

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Introducing the SuperStack® Wet Sizing Screen Up to 3X the capacity of the 5-Deck Stack Sizer® Derrick® has once again redefined high capacity, fine particle wet screening with the introduction of the SuperStack®. With 8 decks operating in parallel and a 35% increase in the effective width of each deck, the SuperStack has a demonstrated capacity equivalent to 2½ to 3 times that of its precursor, the 5-Deck Stack Sizer®. All this added capacity comes with only a slight increase in the space required per machine, significantly reducing CAPEX and OPEX for any screening installation. Offering high productivity, low operating and maintenance costs, convenient serviceability and durability, the SuperStack is built to last and backed by a worldwide support team available 24/7.