Fmdrc zambia March/April 2016

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1 MINING Central Africa’s Premier Business To Business Mining magazine March-April 2016 > Issue 17 > Vol.7 #

DRC-ZAMBIA

Mining rms ‘must get used to’ higher electricity tariffs in zambia -5 Global Firm Explores Mining, Agriculture Investments, in Nigeria, Kenya, Others -26

ALSO...

75 000 tonnes of non-compliant resources exist in dumps and tailings adjacent to Matala deposit

F MD R C - Z A MB I A

www.fmdrc-zambia.com

Contents MINES & MINERALS

27

ISOKA identi ed as budding mining town

FEATURED DEVELOPMENTS

HI TECH

09

WIRELESS temperature monitoring for detecting damage to bearings

INNOVATION

07 Alecto Minerals secures partners for Zambia gold project 26 Global rm explores mining, agriculture investments, in Nigeria, Kenya, others 28 Kibali Gold Mine to increase production with new Osborn equipment 29 75 000 tonnes of noncompliant resources exist in dumps and tailings

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ROOF BOLTING in underground mining: a state of the art review

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FROM THE EDITOR

Cover P&H Shovel Photo Courtesy of www.emmersonprocess.com

Editor Bertha M. editor@fmdrc-zambia.com

Contributing Writers Anne Thomas, Mfuneko Jack, Lindani Mkhize and Caroline Thomas

Sales & Marketing Russou Billiard sales@fmdrc-zambia.com +27 11 044 8986

Graphic Design and Layout Que Gibson

Sithandile Mpofu Editor

Published By Mailing Times Media sales@fmdrc-zambia.com www.fmdrc-zambia.com

Circulation/Sales Officer Mthokozisi M info@fmdrc-zambia.com +27 11 044 8985

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Mining provides the building blocks for human development. e supply of metal and mineral products has underpinned human endeavour through millennia and will continue to play its role in meeting society's needs. e need will remain strong, so satisfying demand requires nding and developing new mines, even as resource use becomes more efficient and recycling systems ramp up.

Fortunately the geological supply of metals within the Earth remains robust and new technologies will help bring new deposits on stream. But these will increasingly be located in more remote regions, raising production and investment costs. e future is bright for mining in Africa. Over 30% of the world's global mineral reserves are found in Africa, yet less than 5% of the total global mineral exploration and extraction budget is invested in the continent. e potential for a burgeoning mining industry across these emerging regions is immense.

Many countries in Africa have either recently introduced or are working on new mining laws that seek to encourage investment. ese are the rst steps towards the formation of a world-class mining industry that has the potential to contribute signi cantly to economic growth and employment prospects in the region.

In this edition of the 1st Mining DRC-Zambia March/April 2016 series, we discuss the key trends that mark today's mining and metals industry and, without attempting to predict the future, consider the where, the what, the who and the how of the mining industry today and as it goes forward into the future.

We take a look at the underground mining equipment, technology and services sector. Underground mining is a complex task which takes place in hostile environment that has been around since times immemorial. e underground mining industry uses a wide variety of machines. ese machines range from earth movers, and dumpers, monitoring tools, to underground support systems.

We also give more insights on the Zambian Mining Industry looking at e Matala mine deposit project, the new mining royalty tax, and Alecto Minerals securing partnership.

Although safety has always been a consideration in the process of extracting precious resources from the Earth, it has never been as prominent as it is today. To emphasize on mine safety, we talk about alcohol testing and its importance in the mining sector.

We welcome readers to this publication, and hope they will be informed by the articles in this magazine.

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MINING NEWS

Mining rms ‘must get used to’ higher electricity tariffs in Zambia M

INING companies operating in Zambia would have to get used to higher power tariffs because the government could not afford to subsidise them and needed to encourage private investment in generation to alleviate a chronic supply shortage, Mines Minister Christopher Yaluma said. “e tariffs have been very, very low and far from costre ective,” Mr Yaluma said in an interview at the recent Mining Indaba in Cape Town . e mining companies “want us to pay. ey must be realistic.” e government increased electricity charges for mining companies to 10.35 US cents a kilowatt-hour from January 1.

While it reversed a 200% increase in charges for commercial and industrial customers on February 6, two months aer it came into effect, no concession was announced for the mines, which use more than half of the Southern African nation's power.

Zambia, Africa's second-biggest copper producer, gets most of its electricity from hydropower plants, which have been hobbled by drought. Some power is being imported at a cost of 19c/kWh, meaning mines are still being subsidised and the government will consider further price increases, Mr Yaluma said.

“We must get cost-re ective tariffs, so we allow independent participants in power generation to come in,” he said. “We have liberalised but they can't come in because of the low tariffs.” e old electricity prices differed from mine to mine.

Vedanta Resources said last month the charges at its Zambian unit, Konkola Copper Mines, increased 25%, adding $3m a month to its costs.

In 2014, mining companies led a lawsuit challenging proposed power tariff increases, a case that is still being considered by the Lusaka High Court.

Mr Yaluma said power shortages would ease when the 300MW Maamba coal- red project came into operation in June.

“By next year, we'll have adequate power to cater for our mining needs,” he said. “It will be from renewables, it will be from coal. We are getting another 120MW from hydro. e only problem is if we don't have sufficient water.” e minister also said the government was still evaluating proposals from the nation's chamber of mines to introduce a new sliding-scale mine royalty system, with the levy that operators pay determined by metal prices.

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MINING NEWS

ABB to supply hoists for South African diamond mine expansion ABB will provide four hoists to the Venetia Mine, South Africa's largest producer of diamonds ABB will supply one double drum hoist for personnel and material conveyance, two friction hoists for production, and one single drum hoist for service duty. ABB will provide the design, supply, manufacture, installation and commissioning of all four hoists, including hoist mechanicals, motors, and electrical drive and control, all certi ed to the highest safety integrity levels (SIL). is is the rst time that multiple, turnkey large friction mine hoists are delivered to the South African mining industry. e installation will commence in July 2018. All four hoists are due to become operational in April 2020.

“With mineral deposits becoming increasingly difficult to access, increasing productivity while ensuring safety and reliability are key customer requirements,” said Roger Bailey, Managing Director of ABB's Process Industries business. “ABB is the only supplier with the unique capability to design, supply, install and provide long-term service and support of entire mine hoist systems. Leadership in supplying power and automation for site is a key component of ABB's next level strategy. “ Open pit mining is due to continue until 2022, and it is expected that underground mining will extend the site's operational life into the 2040's, with the potential to deliver an estimated 94

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million carats. (18.80 metric tons).

De Beers, which is 85% owned by Anglo American, the balance by the Republic of Botswana, is sinking two new shas adjacent to the existing open pit in order to access deeper ore reserves that cannot be reached through conventional surface mining techniques................................... e project represents De Beers' biggest capital investment in South Africa. Since hoisting forms a critical aspect of underground mining, particularly with respect to safety, ABB believes it is the supplier best suited with a solid track record in installing such complex systems.....................................................

ABB has worked with De Beers previously and believes it was selected for its proven ability to provide a complete mechanical and electrical hoist package, as well as its expertise in installing SIL compliant systems ................................................. .

ABB (www.abb.com) is a leader in power and automation technologies that enable utility, industry, and transport and infrastructure customers to improve their performance while lowering environmental impact. e ABB Group of companies operates in roughly 100 countries and employs about 135,000 people.

MINING NEWS

Alecto Minerals secures partners for Zambia gold project Gold and base metals exploration and development company Alecto Minerals has signed an agreement with Chinese mining equipment manufacturer Yantai Xinhai Machinery and South Africa-based turnkey solutions provider PenMin for the proposed construction and nancing of mining operations at Alecto's Matala gold project, in Zambia. is followed the positive outcome of a feasibility study (FS) for the project. PenMin had delivered the FS, which demonstrated positive economics for a 400 000 t/y oxide and transitional openpit operation with a mine life of about four years and eight months, at $1 200/oz of gold, with exploration upside and underground potential. e estimated capital cost for the plant and infrastructure was $14.4-million, while the project's net present value stood at $28.6-million at an 8% discounted rate. e parties had signed an agreement to enter into a proposed design, build and operate (DBO) contract under International Federation of Consulting Engineers (Fidic) 'Gold Book', 2008, standards for the process plant and associated infrastructure. Xinhai had agreed to arrange vendor nancing for the DBO contract. PenMin would be appointed as the employer's representative under a Fidic 'White Book' client / consultant agreement.

During the operational phase, Xinhai and PenMin would jointly manage the plant's operations, the control of which

would be transferred to Alecto on conclusion of the term of the contract. Proposed vendor nancing would be by way of a loan, allowing Alecto to remain the sole owner of the project.

Financing, asset procurement and operating agreements remained subject to agreement on pricing and detailed contractual terms.

Alecto CEO Mark Jones noted that the signing of the agreement and Xinhai's commitment to arrange vendor nance signi cantly de-risked the Matala project and was “testament to the excellent opportunity that the project represents for stakeholders”. He added that PenMin and Xinhai had provided con dence for all parties to successfully deliver the development and operational phases of the project. “ere remains a lot of hard work to be done before we can commence development on the ground, but considering how far we have come since the acquisition was completed just ve months ago, I am con dent that we will deliver further progress in the months ahead.”

Alecto Minerals plc is an African focussed, gold exploration and development company quoted on AIM, with projects in Zambia, Mali and Burkina Faso. e Company has a clear vision: to rapidly become a gold producer in Africa.

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Drug and alcohol testing in the mining industry Employees impaired by drugs or alcohol not only affect the production and efficiency of the workplace, but also pose a threat to themselves, their co-workers and the public.

Mining facilities, by their very nature, would be considered safety sensitive industrial settings. Employers in this industry have a right to impose drug and alcohol testing policies on those employees who occupy safety sensitive positions, namely those in which the employee's duties involve an element of responsibility for the employer's safe operations.

With Health & Safety Managers reluctant to cut actual breath testing numbers knowing that an effective program not only leads to a safer workplace but saves companies money through less down time, reduced damage to plant and equipment, prevents compensation claims, and in the extreme cases prevents possible shut down of entire sites, the focus has turned to potential cost savings within existing AOD programs.

PASSIVE TESTING Passive testing for alcohol, where no mouthpiece is used on the breath testing unit during the test, involves the test subject simply “talking to” or blowing across the breathalyser instrument, has become increasingly popular, particularly for zero tolerance sites implementing “blanket testing” of all workers prior to sign on. e obvious cost saving comes from a signi cant reduction in the use of mouthpieces, arguably this also comes

with additional bene ts to the environment and logistical savings around used mouthpiece disposal.

But as with most things in life, every advantage comes with corresponding risks and potential disadvantages. Passive alcohol testing is no different, and the introduction and widespread use of passive testing can dramatically reduce site safety and workplace efficiency if careful planning and training does not accompany the introduction of this type of testing.

PASSIVE TESTING: TRUTHS AND MYTHS A passive test cannot provide an accurate BAC reading: 1. A passive test can detect alcohol in the ambient air surrounding an instruments inlet port, not the concentration of that alcohol; 2. Once a passive breath sample leaves the person's mouth, it rapidly mixes with the air around the breath tester and any alcohol present is diluted; 3. e further away from the breath tester the sample is delivered, the lower any displayed alcohol reading, and the less likely any alcohol can be detected. is is why no alcohol breath tester should display a BAC reading when operated in passive mode. Any such reading is simply not accurate, nor does it meet the Australian Standard AS 3547; 4. In most instruments, the tester is required to manually activate the breath tester to take a sample of ambient air as the

subject speaks or blows. If the timing of this button push to take the sample does not accurately coincide with the delivery of breath from the subject, a zero result is most likely, regardless of whether alcohol is present or not (Note: Police conduct extensive training to ensure their officers are pro cient at this “passive testing skill” and similarly, Alcolizer conducts speci c training with industry testers to ensure that they have mastered the essential coordination required to maximise the chances of detecting any alcohol during passive testing; 5. A failed passive test do es not automatically indicate the subject has a blood alcohol concentration. It simply indicates the presence of alcohol in the air around the breath tester. is can be the result of but not limited to: · Alcohol already present in the surrounding environment e.g. some cleaning compounds, fuels, aershave or perfume; · Certain medications; · Some innocent food sources – meat lovers pizza, some confectionary even children eat, fruit cakes, some ethnic foods As a result of all and any combination of the above, the only valid result from a correctly conducted passive test is zero.

A ny t h i n g o t h e r t h a n z e ro requires a mouthpiece be tted and an immediate follow-up test conducted.

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A retro t that saves you money Wireless Adapter front

Wireless temperature monitoring for detecting damage to bearings

Incidents which cause a system to shut down may not only lead to costly repairs but may result in considerable losses.

An Endress+Hauser customer producing more than 880,000 tons of heavy plate annually, ranging from 5mm to 125mm in thickness, was able to retro t the Endress+Hauser wireless solution at a lower cost than expected. ey are con dent that they now have an optimum overview of the status of the roll neck bearings and that they can maintain the system and replace bearings according to schedule, regardless of any faults.

Every company has an interest in making sure that its processes are running at optimum levels. Incidents which cause a system to shut down may not only lead to c o s t l y r e p a i r s b u t m ay r e s u l t i n considerable losses. is heavy plate

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and two back-up rolls, which transfer toll pressure to the work rolls. e four-high stand has a maximum rolling force of 80,000 kilo newton. is situation is very demanding, even for roll neck bearings. e roll neck bearings are located on the operating and drive side of the upper and e Results § Detection of any damage to the lower back-up rolls. ese are known as Morgoil® friction bearings. A lubrication friction bearings § P r e d i c t i v e m a i n t e n a n c e circuit ensures that the Morgoil® bearings get the lubrication they need while the intervention § Protection of the extreme costly temperature of this circuit is monitored at the inlet and outlet. friction bearings

manufacturer optimises their plant availability through recoding temperatures at the roll neck bearings and a straightforward implementation using WirelessHART.

e challenge e four-high rolling stand at this heavy plate manufacturer comprises of two work rolls which reshape the steel slabs directly,

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An increase in the temperature differential indicates a higher degree of friction inside the bearings which may result in damage. However, the ambient

conditions which prevail at the rolling stand make it difficult to wire up the necessary temperature sensors securely. e solution For temperature measurement, TR15 resistance thermometers with a weld-in thermowell and replaceable insert are used. ese have already proven their w o r t h a t h o u s a n d t i m e s ov e r i n challenging industrial applications. Each temperature sensor is tted with an adapter which enables wireless data transmission based on the WirelessHART standard. Due to space limitations and possibly restricted radio communication, installing the adapter directly on the temperature sensor is not advised. e adapter is therefore installed remotely and connecter to the temperature sensor using a short cable. e adapter not only facilitates data transmission, it also powers the connected device via the battery integrated in the adapter.

Each adapter works as a transmitter and receiver, ensuring the data can be transmitted to the WirelessHART g a t e w a y, e v e n i f d i r e c t r a d i o communication is not possible. e WirelessHART gateway forms the central access point to the WirelessHART

network and manages communications. e gateway automatically assigns the communication paths in the network as well as the times for the data packets. is means the new measuring points can be retro tted easily.

From the gateway via Modbus RTU, the measured values are displayed on a Memograph RSG40 graphic display recorder. From there, they can also be transferred to downstream control systems. e eight measured values are monitored permanently. If a set threshold is exceeded, an alarm is triggered via the control system. is solution ensures that, with little effort in installation and commissioning, any

impending damage to the friction bearings is detected and a maintenance intervention is initiated in a predictive manner. is type of friction bearing, its installation and removal as well as the associated production downtime, is extremely costly.

For more information, please visit http://bit.ly/1Qwtdj5 Enquiries: Benjamin Mlangeni Product Manager Temperature System Components & Registration Endress+Hauser (Pty) Ltd Tel: (011) 262 8012 Fax: (011) 262 8062 info@za.endress.com

Endress + Hauser People for Process Automation

Fieldgate SWG70

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Maxam on-site operators conducted MIC calculations and studied history blast data to ensure the project design met the environment vibration limits.

BLASTING OF TASMANIAN SPILLWAY DAM WALL MEETS VIBRATION LIMITS radco, the specialist mining, civil construction, environmental and heavy haulage services supplier, contracted blasting solutions provider Maxam in July 2015 to provide full blast design, support and loading services to create a tailings dam spillway in the MMG-owned Rosebery mine in Tasmania.

Rosebery mine is an underground polymetallic mine, located in the town of Rosebery, on the pristine west coast of Tasmania, approximately 300km northwest of Hobart and 125km south of Burnie. It has operated continuously since 1936, with its current mine life running to 2024.

Gradco hired Maxam to provide safe, meticulous blasting solutions that required stringent blast control to ensure vibrations were kept under 25mm per second (25mm/s) at the spillway dam wall, located less than 30 metres from the proposed blasting area.

The contract terms included breaking the rock sufciently to allow excavation while not exceeding the previously mentioned

G

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vibration limit. To safely and efciently deliver this requirement, Maxam on-site operators conducted maximised instantaneous charge (MIC) calculations and studied extensive history blast data to ensure the project design met the environment vibration limits.

The rst blast was performed on 23 July, 2015, two weeks after the initial site visit. The nal two blasts were red a week later on the same day, thanks to the success of the rst blast results and design parameters.

The three operations were carried out using RIONEL initiation systems, Maxam’s leading edge technology assembled at its Baldivis, Western Australia facilities. All blasts delivered outstanding results, not only in performance but most importantly in achieving vibration levels below the limits set by the construction brief.

Maxam’s proven experience carrying out similar projects around the world made it a natural t for special operation projects such as this one performed in Rosebery mine. Its global logistics system, which relies

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on production plants located on all the ve continents, reinforces the company’s ability to supply state of the art products to meet a wide variety of challenges, while its in-house developed technology ensures conditions that are both safe and achieve efcient results.

Maxam has been operating in Australia since 1988, when one of its predecessor companies ERT acquired ETS, a small, local company.

Today, Maxam employs over 150 people in the country. Since its establishment in Australia, the company has supplied blasting solutions to large mining and extraction companies, such as Holcim and Hanson, and has achieved a majority share of the quarry market.

With its headquarters in Brisbane, and with production facilities in Bajool (Queensland) and Baldivis, Maxam provides technical assistance services, as well as products (civil explosives and initiation systems) to large mining and quarrying companies throughout Australia.

Source: Maxam Australia

PROFILE

MMG MMG Limited is a global resources company which explores, mines and develops base metals deposits around the world.

We mine to build wealth through the development of our people, the investments we make in improving local capacity and the value we deliver to our shareholders.

In 2012, we established our presence in Africa with the acquisition of the worldclass Kinsevere copper mine in the Democratic Republic of Congo (DRC). We

also now have a signi cant exploration program in Zambia across the African Copperbelt.

We also have operations and projects in Australia, Laos and Peru as well as signi cant exploration projects and projects across Australia and the Americas.

MMG is headquartered in Melbourne, Australia and listed on the Hong Kong Stock Exchange (HKEx 1208).

A long-term outlook, our pride in mining, our commitment to shared international standards and our respect for people, land

and culture We are MMG and we mine for progress.

Website: www.mmg.com Zambia Exploration OďŹƒce Plot M33, Lake Road Lusaka, ZambiaPO Box 320232 Woodlands, Lusaka, Zambia

PROFILE

Some of the senior managers of Stefanu

Stocks Mining Services. They are (from le ):

EugĂŠne NortjĂŠ, Marke ng/Es ma ng Manager; Ross Cooper, Director, who runs Tailings Opera ons; Craig Morris, Financial and Admin Director; Freddie Strydom, Director, who heads Contract Mining; and Mike Smith, Managing Director.

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PROFILE

SCANTECH's ON-BELT GEOSCAN-M IMPROVES PLANT PERFORMANCE Demand has grown for Scantech's on belt GEOSCAN-M elemental analysers in the copper, iron ore, manganese, zinclead and phosphate industries.

Mining companies have purchased GEOSCANs for new and existing mines and processing plants. e analysers provide critical ore quality results every two minutes. Operators reduce their costs by optimising their plant by using real time process control. Much of the cost for routine sampling and laboratory analysis required in the course of running the plant is also reduced.

Further, the total cost of operations decreases due to better asset management via improved process control of raw material and operations.

A GEOSCAN-M is used by a copper mining company to manage blending of copper ores. Plant feed rate is controlled by utilising the GEOSCAN's real time analysis of crushed copper ore. In

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addition, millions of dollars in metal losses have be avoided by controlling the ore feed based on copper metal tonnes rather than ore tonnes.

Several African iron ore producers are using GEOSCAN analysers.

Applications include monitoring of the raw ore, to control blending at the mine, monitoring the feed to the jig plants and then the products from the jig plants, to control the operations of those plants in real time.

In addition to the GEOSCAN, Scantech has continued sales of its TBM200 Series microwave moisture monitors to the minerals industry. Demand in metal accounting applications, particularly in the platinum industry, has demonstrated the value these simple and inexpensive units can bring to treatment of high value ores.

S c ante ch's core business is t he development, supply and support of on

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belt analysers for the resources sector, world-wide. Scantech rst supplied the coal sector in the early 1980s and now supplies a range of real time technologies to the cement, minerals, power and steel sectors.

In the minerals sector, real time analysis allows mines to optimise all phases of quality control and process efficiencies, from mine face to train loading.

Immediate feedback of the quality of the ore to plant personnel provides real time data to control the operation. is proactive control allows maximum extraction of the in-ground resource, optimum bene ciation to maximise saleable product, and assurance that customer speci cation targets are achieved. e analyser results compare well against the laboratory results because the analysers are based on transmission technologies, which measure all of the ore.

Over 1,000 Scantech instruments have been sold in 55 countries. In Africa, the analysers are maintained by a group of engineers based in South Africa, who install, commission and then provide ongoing support for analysers in the region.

Contact: Michael Edwards Sales and Marketing Manager Scantech International Pty Ltd Tel: +61 8 8 375 1933 email: m.edwards@scantech.com.au website: www.scantech.com.au

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PROFILE

40 years

Party time - Neil Robinson, managing director of Africa's leading condition monitoring specialists WearCheck, gets into the spirit as the company celebrates their 40th birthday this year.

of condition monitoring excellence 2016 is a very auspicious and exciting year for l e a d i ng c ond it i on mon itor i ng specialists WearCheck, as they proudly celebrate their 40th birthday this year.

From small beginnings as a soil-testing laboratory in the founding director's garage in Durban in 1976, WearCheck has grown into THE condition monitoring company in Africa, operating eleven laboratories in seven countries across the continent and beyond, with further expansion in the pipeline.

With the fundamental goal to save money

and time for customers, WearCheck has evolved into a convenient “one-stop-shop” for any mechanical or electrical operation that can bene t from reliability solutions services. e optimisation of plant performance management is facilitated by a range of services offered by WearCheck, some of which include the scienti c analysis of used oil, the analysis of fuels, transformer oils, coolants, greases and lters. Other monitoring techniques are also employed, such as the testing and control of the efficiency of combustion, heat transfer,

t her mog raphy, v ibrat ion ana lysis, balancing, laser alignment and milling.A wide range of industries has bene ted from WearCheck's services over the past 40 years, and continues to do so. WearCheck's laboratories process in excess of 600 000 oil samples per annum from many operations, among them mining, construction, transport, electrical, shipping, industrial and aircra. e highly-quali ed team of diagnosticians has amassed an invaluable databank of results and trend information over the four decades of the company's lifetime. is information is key to providing a benchmark in many cases, and is referenced frequently in the diagnostic process, as well as for training purposes and case studies.

WearCheck recently joined the Torre Industries family – an exciting development with lots of potential for business growth.

Surface and underground pumps Pumps, in their many different designs, perform a large number of vital tasks within the mining industry and as such they can be responsible for certain aspects of mine safety. However, with so many pumps in operation they can also make a considerable contribution towards improving the efficiency of the mine, especially in terms of energy consumption.

Mine safety, whether above or below ground, is the highest priority for all operators and maintaining a high standard requires considerable effort from all parties involved. is includes the manufacturers of equipment that forms part of the safety apparatus, requiring them to meet stringent performance criteria and successfully complete extended periods of testing.

With ever-tightening margins, the efficienc y of individual pieces of equipment as well as that of operational and maintenance processes becomes more important. Making the right decision in terms of pump design can produce signi cant bene ts for the safe and efficient operation of the

As the mining industry evolves and becomes more complex, so does the technology used in mining equipment. A number of different pumps, are now used throughout the mining process to increase performance and cost efficiency whilst reducing necessary maintenance and downtime.

Safety First It is important that the pump design incorporates the necessar y safety features, including a safety relief valve to protect against a dead head situation, when the system demand for ow has stopped, causing the pressure to rise instantly. e safety valve should be designed to allow the entire pump capacity to ow, while the opening point should be set at 10% above the operating pressure. In addition, the pipework associated with the safety relief valve should be properly sized to ensure adequate ow conditions.

A pump's sealing system is equally important when considering its safety as well as overall p er for mance and

r e l i a b i l i t y. F o r h i g h p r e s s u r e reciprocating pumps the task is typically performed by the stuffing box, which contains packing and lubricant in various con gurations depending on the application. is packing is a service item and should be able to be replaced without too much interference with the main pump assembly.

Efficiency & reliability Energy consumption ranks as one of the highest production costs and so adopting more energy efficient motors to power various pumping systems can have a s i g n i c a nt e ff e c t on t h e ov e r a l l pro tability of the mine.

However, an incorrectly speci ed pump, even with a high efficiency, can be worn signi cantly in a short period of time, negating the improved efficiency and ultimately incurring higher costs. Most pump problems arise because the pump's performance characteristics don't match the application requirements, either from the initial speci cation or as a result of a change in circumstances.

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p u m p s

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is lack of application awareness results in higher power consumption and shorter bearing and wear life and ultimately higher operating costs. e system parameters and pump performance must be matched carefully t o e n s u re e ffi c i e nt , t rou b l e - f re e operation.

For h i g h pre s s u re ap p l i c at i on s , reciprocating pumps offer additional bene ts as the design offers greater mechanical efficiency, which means that a smaller prime mover can be used and less energy is consumed. By carefully s ele c t ing t he cor re c t motor and matching it to the pumping system, a more efficient combination can be created, resulting in lower TCO for the client.

Achieving an efficient design is one thing, but making it suitably reliable for a mining application as well requires a higher level of development. is requires a certain degree of 'overengineering'; using materials and design concepts that may exceed the original speci cation, but which will afford a much greater level of reliability.

In today's climate of matching plant equipment performance exactly to d e m an d, t h e re i s l e ss s c op e for engineering a machine to exceed targets.

In heavy industries, such as mining, building something to last can make the difference between catastrophically expensive downtime and ultimate pro tability.

Peristaltic pumps Due to the mining industry handling corrosive and toxic materials with high speci c gravities, peristaltic pumps can offer their propensity for handling abrasive, viscous and aggressive liquids where other pumps cannot. Peristaltic pumps have no valves, deals or glands that could leak, clog or need to be replaced and pumped uid does not touch the pump itself, but is piped using a high-pressure hose capable of sustaining pressures up to 230psi. ese particular pumps operate on a positive-displacement principle shared by the human digestive system. Within the pump housing, rollers compress the

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hose against a semi-circular track. As the pressure points move along the hose, the uid is pushed along in kind. As the pressure point moves forward, the hose resumes its previous shape, causing more uid to be sucked forward in its place.

Peristaltic pumps can present huge advantages to the mining industry as a result of their design. As the material itself only comes into contact with the interior of the tube, which can easily be cleaned or sterilised, there is no contamination. e lack of valves, seals and glands make them comparatively easy and cost-efficient to maintain whilst being able to handle a multitude of materials and slurries.

Piston-diaphragm pumps e notion of a piston-diaphragm pump is to prevent the transported materials from coming into contact with the pump's pistons and seal components which, especially in the mining industry, can lead to unnecessary wear and damage. e volume of chambers in the pump head is changed so that liquid enters through an inlet check valve during decompression and exits through an outlet check valve during compression, operating in a similar manner to conventional piston pumps.

High-temperature pumps Mining operations, such as gold and nickel re ning which use slurry can climb to temperatures ranging between 160 and 210 degrees celsius.

It is important that pumps selected for use in these operations are capable of maintaining their properties under this intense heat. e common high-temperature pump uses a motor between ve and 25hp to drive the material forward and is designed with a stainless steel sha to handle the heat of the slurry passing through.

An iron propeller and volute are also used, while the pump itself is mounted to a heavy steel pedestal to compensate for its weight.

As the pumps are oen centrifugal and bearings located outside of the material

owing through, little maintenance is necessary Slurry pumping Slurry pumps and pipelines form a crucial link between the mine itself and the processing and shipping operations.

As such, the pumps must perform reliably in order for the mine to maintain operations. However, due to their size, energy consumption can be considerable and so improvements to their efficiency can have a substantial impact on operating costs. e m i ne r a ls are t r ansp or te d i n suspension, in many cases over very long distances and the pumps must be designed to cope with large solids as well as corrosive uids. ese very harsh working conditions demand regular maintenance procedures to be conducted in order to keep the pump operating at its most efficient.

More recent designs are improving maintenance accessibility as well as using more durable materials to improve wear resistance and efficiency. With the aid of more sophisticated computer design systems, the development of slurry pumps is set to achieve efficiency levels close to those of clean water pumps.

Maintenance efficiency is also being improved with the introduction of condition monitoring technology which provides an early warning to the maintenance engineers about a potential issue. By addressing these before they develop into a serious breakdown, the downtime is greatly reduced, further improving the operating efficiency of the pumps.

Dewatering operations Keeping any mine dry is a crucial aim for the operators and should form one of the key health and safety targets within the organisation. As such, the dewatering aspect of the mining operation requires very high levels of reliability which depends on selecting the most appropriate design and construction for the application in question.

For most requirements, the centrifugal pump remains the tried and tested s olut i on . Howe ve r, t he ne e d for

improved efficiency and lower operating costs has led to some operators moving away from traditional centrifugal pumps and opting for alternative technologies such as oscillating discharge pumps.

As underground mine depths increase so the dewatering pumps have to be speci ed to cope with the new challenge. is can oen come in the form of multistage, high pressure units, operating at around 100 bar, which are capable of maintaining the desired water levels.

All pumps and their associated pipework are affected by the uids that they are required to transport, with solids content and pH posing a constant threat to reliable performance. Advances in materials technology have seen great improvements, with the use of chrome steels, duplex steels and high quality elastomers being used for more acidic applications.

In some applications, deposits can build up in the pipework which, if not resolved, can cause increased friction losses and therefore additional energy costs and a reduction in energy efficiency. One s olut i on i s to mo d i f y t he pu mp arrangement to increase the uid velocity, causing a scouring action to be created and, if properly managed, the rate of deposition can be equalised with the scouring rate.

Although this may increase the energy costs in order to attain the increased uid velocity, this should be balanced against the maintenance costs of replacing or cleaning of all the dewatering pipework on a regular basis. ese costs should also include the gures for lost production if the mine cannot be safely operated without the system under maintenance in operation.

More recent developments have seen the introduction of on-board electronics in dewatering systems designed to help with energy saving and reducing pump wear.

Pump manufacturers are pursuing design improvements that can reduce the Total Cost of Ownership (TCO) and improve reliability.

p u m p s

Roof support systems While the dewatering pumps manage with water levels, so it is equally

FMDZ | March - April 2016 |

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important to ensure that the roof of an underground mine remains in position while the minerals are being mined. is responsibility falls to the roof support systems that are powered hydraulically by a number of high pressure pumps. e principle of longwall mining is the use of a large cutting head or shearer which traverses the coal seam breaking it up and depositing the coal onto an armoured conveyor to transport the coal away from the face of the mine. is operation is protected by a series of hydraulic roof supports which prevent the mine roof from collapsing by applying huge pressures to support the rock above.

E a ch ro of supp or t i s c ap abl e of independent movement so once the shearer has passed by, the support can lower itself away from the roof and advance forward to ll the space le by the shearer. In this way the roof support system maintains a safe haven for the

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miners and their equipment to operate in, all the time moving forward as the coal seam is mined and allowing a controlled collapse of the roof. e efficient operation of the roof support system directly affects the safety and productivity of the mine; any downtime on the system in such a difficult operating environment would be very c ou nte r- pro du c t ive. e rel i abl e performance of these systems is essential if the client is to maximise output from the mine and see a return on investment.

High Pressure Pump Design Due to the high pressures required to operate the roof support structures, the pumps use a reciprocating piston principle, usually powered by a midsized electric motor. A reciprocating pump discharges liquid by changing the internal volume of the pump and uses non-return valves (NRVs) at both the inlet and outlet ports of the pump.

| March - April 2016 | FMDZ

Typically these pumps can produce 1,000 bar in pressure, in this application they will typically be operating at around 350 bar. e major bene t of the reciprocating pump is that it produces a xed volume of uid displacement at a given speed and provides a constant ow, regardless of pressure. is means that variable capacity can be achieved by changing the pump speed. In contrast, the centrifugal pump would be forced up and down the performance curve, varying the ow which may cause problems for the application.

Due to the fundamental design of the reciprocating pump, it is bene cial to control the pumps by a variable speed controller which allows accurate control of the output pressure. For applications requiring increased ow rates, one or more pumps can be added in parallel to the original to produce the desired ow rate at the same pressure rating.

MOVERS & Shakers

Mining stakeholders welcome new Zambia mineral royalty tax Several mining stakeholders have welcomed the new Zambia mineral royalty tax, aer it was revised in April 2015.

As a means to improve public understanding of the Zambia mineral royalty tax and to promote informed comment, the Zambia Chamber of Mines has urged Zambians to download its report on Mineral Royalty Tax. is follows strong endorsement by leading business personalities, who said the report would promote greater understanding of a complex issue which affects them. e report, “A guide to understanding Mineral Royalty Tax”, has already been distributed widely, and is available free of charge on the Chamber's website.

Stakeholders who have welcomed its publication, saying it will help to promote informed comment, include Osbert Sikazwe, Dean of the School of Mines at the University of Zambia; Maybin Nsupila, CEO of the Zambia Association of Manufacturers; Yusuf Dodia, chairman of the Private Sector Development Association; prominent Lusaka businessman Mark O'Donnell; and Jackson Sikamo, country manager for Chibuluma Copper Mines.

Osbert Sikazwe, Dean of the School of Mines, said the report will help the public to understand the wider operations of the mining sector, and to appreciate the challenges faced by the industry. It will also help people to understand how policy is formulated to enhance the growth of the industry, he said.

Maybin Nsupila, CEO of the Zambia Association of Manufacturers, said any measure intended to promote debate and understanding of MRT is welcome. “e discourse by many people has been on the physical contributions the sector makes to the country's economic growth, without understanding how the linkages ultimately bene t the country. e MRT report will give people a broader and more informed perspective.”

Yusuf Dodia, chairman of the Private Sector Development Association said mining plays a pivotal role in economic growth. While there have been challenges on policy as well as tax changes, there has been little or no understanding of the challenges faced by the industry. “e MRT report will widen debate and promote a more informed view.”

Moreover, Jackson Sikamo, country manager for Chibuluma Mines, a division of Metorex, said the report will help all stakeholders to appreciate what MRT is, and what its implications on scal policy are. “It will lead to better-informed dialogue and debate, which are necessary for the country to come up with equitable taxation policies,” he said.

Prominent Lusaka businessman, and chairman of Union Gold Investment, Mark O'Donnell, welcomed the release of the report, given the competition Zambia faces from other commodity-producing countries. ese include the Democratic Republic of Congo, which has “maximized the bene ts

realised from the mining sector, spurred by various incentives which have increased foreign direct investment”.

Meanwhile, Chenai Mukumba, international centre coordinator for Consumer Unity and Trust Society, described the release of the report as timely. “e initiative will help ease the misunderstanding among various players, especially the citizenry, who lack information yet are the ultimate bene ciaries of the mineral wealth.”

Peter Sinkamba, Development Planner/Environmental Protection Activist on the Copperbelt, said the MRT report will help to strengthen citizens' awareness, and promote dialogue on challenges, contributions and shortcomings on policy formulation that might sti e the effective contributions of the mining and copper sector to the country's growth.

In January 2015, newly inaugurated Zambian President Edgar Lungu revealed the country's new tax regime which at the time included increasing levies for open cast mines from 6% to 20%, while those for underground mines would rise to 8%.

In April however, the royalty was dropped to 9% across the board – Zambia's response to severe outcry from industry and its negative impact on mining pro ts, closures and job losses. e mine tax system also re-introduced a 30% corporate income tax on mining operations.

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MOVERS & Shakers

Global Firm Explores Mining, Agriculture Investments, in Nigeria, Kenya, Others Quantum Global Group has announced plans to expand its investment to countries in Africa and the Middle East. e expansion move, according to the company was aimed at increasing i nv e s t o r s ' a c c e s s t o A f r i c a ' s v a s t development potential and establish new offices in Nigeria, Angola, Kenya and Mozambique to give investors access to its portfolio of Mauritius registered funds in Mauritius, which offers one of Africa's strongest legal and regulator y environment. e company in a statement obtained by THISDAY, said the funds are basically setup to target high growth industry sectors in Africa that include agribusiness, timber and mining, healthcare and mezzanine investments.

As part of the expansion plan, the company has also begun the legal registration process to open a representative office in Dubai, saying that the new office will offer nancial advisory services to Asian and Middle East investors looking to tap into the development potential that Africa uniquely offers.

According to Quantum Global, it will broaden the scope of its investment services in these marks by offering

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nancial advisory services, actively sourcing deals and managing the local private equity investments.

"Quantum Global will leverage Mauritius' economic and political stability and sound regulatory framework to attract high quality foreign investments into Africa.

With excellent infrastructure and Double Taxation Agreements (DTAs) with most African countries, Mauritius has caught the attention of several global funds, investment houses and advisors from across the world to establish their investment vehicles on the country.

Commenting on the Group's expansion plans, Founder and Chairman of the Advisory Board, Jean-Claude Bastos de Morais said: "With Africa offering enormous development potential, global investors including Asian and Middle Eastern, are increasingly looking to capitalise on investment opportunities in the region in a low risk environment that Mauritius has to offer. "Building on Quantum Global's African heritage, we can really bring considerable investments into the region. We are therefore extremely thrilled about expanding our presence across Africa and the Middle East," he said.

Focused on high-growth sectors on the

| March - April 2016 | FMDZ

African continent, Quantum Global's Mauritius registered portfolio comprises of a mezzanine fund and dedicated private equity funds in the infrastructure, hospitality, agriculture, healthcare, timber, and mining sectors. "e island nation of Mauritius has a lot of strategic advantages. It has become a promising, transparent international nancial center for inbound and outbound trade, and investments into Africa. At Quantum Global, we plan to play a crucial role in building a nancial ecosystem in Mauritius that will see the creation of a nancial 'Center of Excellence'. e Center aims to increase investment knowledge w h i l e p r ov i d i n g A f r i c a n f o c u s e d investment products to global investors," Bastos de Morais said.

Quantum Global is an international group of companies active in the areas of private equity investments, investment management, private wealth management as well as macroeconomic research and econometric modelling.

Its private equity arm manages a family of funds targeting direct investments in Africa in the sectors of Agriculture, Healthcare, Hotels, Infrastructure, Mining and Timber - as well as a sector agnostic structured equity fund.

MOVERS & Shakers

Isoka identi ed as budding mining town GOVERNMENT says Isoka could be a new mining town in the next few years once exploration of phosphate and 15 other Rare Earth Elements (REE) at Nkombwa Hill swings into full-scale production.

Isoka District Commissioner Evenwell Mutambo disclosed that thousands of jobs will be created once mining activities begin at Nkombwa Hill.

“African Consolidated Resources and Zambia Phosphate (Zamphos) have been carrying out explorations since 2010. We are told that phosphate used in manufacturing fertiliser, and 15 other rare earth metals, have been discovered at Nkombwa Hill,” Mr Mutambo said.

Mr Mutambo explained that the lifespan of the mine is expected to be over 100years.

He noted that Zambia would soon become a producer of phosphate, a major component in fertiliser production.

Mr Mutambo further added that Zambia will in future stop importing fertiliser once mining commences. “is will also create employment for our people in the region and it will also economically thrust the country into a major producer of phosphate, in turn fertiliser and the REE metals,” Mr Mutambo said.

A consultant geologist, Dr Houda Bouammar of Zimbabwe, has revealed that exploration works show signs of possible mining activities to start in the near future.

Dr Bouammar said the main minerals under investigation are phosphate and REE, and so far, samples tested have revealed 30 percent value.

“R are earth elements are essential components of fuel re nery catalysts, catalytic converters, fuel cell alloys, batteries, high quality optical glass, uorescent lights and TV screens, tablets, mobile phone touch screens, and high strength alloys for aircra engines and lighter cars,”Dr Bouammar said.

“is mountain hosts two components of deposits; one of them is phosphate, the other is a group of commodities, and much sought aer rare earth elements categorised in 15 minerals altogether,” Dr Bouammar said.

Tapuwa Mtetwa, a consultant geologist on site, also disclosed that one of the rare minerals discovered at Nkombwa is Isokite, which is composed of monoclinicprismatic mineral containing calcium, uorine, magnesium, oxygen, and phosphorus.

Dr Bouammar noted that China controls approximately 97 percent of the world's rare earth element market and 57 percent of current known reserves.

According to Dr Bouammar, rare earth elements comprise the family of lanthanides on the periodic table of elements, and are separated into light rare earths magnets. e exploration works are taking place at the apex of Nkombwa Hill, approximately 1,000 metres above sea-level.

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MOVERS & Shakers

Kibali Gold Mine to increase output with new, OsbornEquipment crushing stations A signi cant export order for jaw crushers and apron feeders for Kibali Gold Mine in the Democratic Republic of Congo has been awarded to Osborn by Randgold Resources.

Export sales manager Joe Sequeira says that the company netted this order for two 42” x 48” single toggle jaw crushers and two 1.8m x 5m apron feeders based on the proven track record of Osborn's robust machines in similar underground applications. “We have successfully built and installed the same set up for underground crushing stations at the Somilo Mine in Mali and at Petra Diamonds' Cullinan Mine. We also recently supplied Petra Diamonds with a further eight Osborn apron feeders for Cullinan Mine's underground silos and crushing stations. In Ghana, at Anglo Gold's Obuasi Mine, an Osborn vibrating grizzly feeder and 42” x 48” jaw crusher have been operating successfully underground for about 15 years,” he explains.

Kibali's new Osborn machines will be employed at two new underground crushing stations established to increase the mine's output, Sequeira says. With a reserve base at 11.6Moz and still growing, Kibali ranks as one of the largest gold mines in Africa.

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“Osborn's tough, longwearing machines are ideally suited for the arduous operating environment at Kibali, which is situated in the very remote Moto gold elds of the north east DRC, some 560km north of the city of Kisangani.

Our single toggle jaw crushers are designed for high capacity throughput due to the elliptical movement of the swing jaw, which also assists in the discharge of the crushed material. Osborn apron feeders capably handle heavy, lumpy and abrasive materials, and provide a reliable means of controlling the feed rate to prevent surge loads to primary crushers, belt conveyors and other plant and equipment.”

Osborn will supply the jaw crushers for Kibali Mine with split frames, in order to facilitate their transport underground into the crushing stations. Sequeira explains that this is a standard Osborn offering.“e sections will be half the weight with split frames, and will be easier to manoeuvre underground and li with a crane.”

He notes that Osborn apron feeders can also be supplied as a split frame, but this has not been necessary on the Kibali order. “ey will t under the cage when transported underground.

We will however remove the head and tail sha, including the feeder pans, due to weight restrictions. e units will then be reassembled underground.

MOVERS & Shakers

75 000 tonnes of non-compliant resources exist in dumps and tailings adjacent to Matala deposit

Z

ambian aspirations have been boosted – as it identi ed further surface gold resources within its Matala mine project, which could enhance the economics of early operations.

Alecto sampling has validated a 1984 report from the Zambian Industrial and Mining Corporation (ZIMCO), which estimated that an additional 75,000 tonnes of noncompliant resources exist in dumps and tailings adjacent to the Matala deposit.

Chief executive Mark Jones told investors: “Since acquiring the historical Matala and Dunrobin mines in November last year, our team has worked swily to understand the full potential of these deposits and progress our exciting Matala mining project, such that our goal of Alecto becoming a medium term cash producer, is becoming increasingly achievable.

“Establishing that we have additional high-grade tonnage sitting on surface that can be processed with minimal mining cost is a real bonus and will be a signi cant boost to the economics in the early phases.” e ZIMCO work revealed the potential for resources of 75,000 tonnes at a weighted average of 2.83 g/t gold, for around 6,800 ounces of gold.

Alecto conceded that to be classed as a JORC resource, a full audit of the report veri ed by an independent third party would be needed.

Elsewhere, the rm said it had found high grades in its sampling of the Matala deposit, including 3.87 g/t to 8.37g/t gold at the mill tailings and 0.39 to 7.96 g/t gold from the scree rubble dump.

Alecto shares added 2.22% to 0.07p.

FMDZ | March - April 2016 |

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Embracing TECHNOLOGY

Tramp Metal Detector Smart 100 Reliable- Superior Performance A technically advanced metal detection system is vital in assisting mining companies in eliminating the damage caused to machinery by tramp metal. Such system would save mines costly downtime and repairs to damaged processing equipment such as crushers and mills.

Unfortunately, many available tramp metal detectors false trip on ores such as copper, iron ore, manganese, gold, platinum, etc. due to conductive and sometimes magnetic properties of the ores.

PJ Tech has just the solution to address such challenges faced by the mines in detecting tramp metal in the form of their SMART 100 system. It detects for magnetic and nonmagnetic pieces of tramp metal while ignoring the conductive and even some magnetic properties of various ores. is system has a strong set of basic features, and is designed to operate in a very wide and difficult range of applications. It is even compatible with steel corded belts as well as the belts where the steel clips are used for splicing.

SMART 100 tramp metal detector systems are custom made to suit each user's particular application. Each

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| March - April 2016 | FMDZ

detector system is subjected to extensive testing both at the sub-assembly level and aer nal assembly to ensure compliance with performance and electrical safety standards. e transmitter and receiver antennas are manufactured to withstand even the harshest environments. ey are encased in impact resistant, weatherproof breglass. e upper antenna swings away to protect from large overburdens.

Pressure dye spray system marks the location of tramp metal on a conveyor. e marking device marks the exact location of metal which trips the detector. is feature helps to nd even buried metals and saves search time thus improving production.

Overall it is the most advanced tramp metal detection system available worldwide that can be used in a very wide and difficult range of applications.

Peter Nowakowski Director Tel.: +27 (011) 704 7088 Cell.:+27 (082) 377 9405 www.pjtech.co.za

Mining stakeholders in Africa set to have a Common Law e push by various mining stakeholders in Africa to have a common mining law is set to be achieved as a model mining law is set to be launched in Kenya this week.

Once adopted, the law, which is a product of a synthesis of case studies, will solve a number of issues affecting communities living in areas endowed with natural resources. "e studies were carried out in communities in ve countries among them Angola, DRC, South Africa, Zimbabwe and in Kenya [where it] was carried out in one of the oldest mining areas, the Kenya Fluorspar Mining in Kerio Valley," said International Alliance on Natural Resources in Africa (Ianra) coordinator Anne Mayher. e document is a product of case studies on human rights impact as per the African Charter on Human and Peoples' Rights (African Charter), she added.

"We have been having complaints on infringement of human rights at community level. at is why we decided to carry out research at grassroots level so as to have legislation owned by community," read a press statement sent to newsrooms.

PROCEDURE FOR LAND ACQUISITION Among the principles in the document are setting procedure of acquisition of land and resettlement of people whenever minerals are discovered in their ancestral land.

It also calls for easy and quick access to justice with calls for the State to bear the primary responsibility by setting up independent and accessible grievance mechanisms composed of a panel of environmental, legal and social experts which shall be established through a community consultation process.

Natural Resources Alliance of Kenya (KeNRA) officer Mwambi Mwikamba, described the document as one of the best legislations if adopted adding that it will end atrocities experienced in all mining areas, not only in Kenya, but in other parts of Africa.

Mr Mwikamba said the principles are part of the proposals which have been included in the Mining Bill 2015 which is waiting for assent by the president. "e document comes at a time when Kenya is in the process of changing from colonial mining law to a new legislation which tries to adopt some of these principles. "e Bill, which has passed different stages, tries to address some of these issues, if not all," said Mr Mwikamba.

"We shall continue to lobby for the adoption of these principles to end con icts being experienced between various mining stakeholders, among them governmentCommunity, community-investors and government-investors," he added. e new law is set to be launched at Ngondi in Naivasha on Wednesday, April 27, 2016.

FMDZ | March - April 2016 |

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Embracing TECHNOLOGY

Remote monitoring of underground mining equipment

Underground mining is a complex task which takes place in hostile environment that has been around since times immemorial. e underground mining industry uses a wide variety of machines. ese machines range from earth move rs , and du mp e rs , to d i e s el generator sets for backup power. is means that we have a huge industry which is completely unaware of how their equipment are being used, when they require maintenance, and the effects that the surrounding conditions have on them. Needless to say, a remote monitoring solution is the best option for mine owners and operators to make informed business decisions, and increase their operational efficiency.

Problems with underground mining Underground mining is not an easy job. ere are a wide variety of issues, some of which are: Productivity issues e following issues cause loss in

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productivity either in terms of mining or in terms of Downtime Engine health issues and breakdowns cause equipment to be le standing idle causing loss in productivity. While equipment downtime has multiple reasons, most of them are avoidable in nature.

Operator inefficiency Operators are inefficient either because of lack of training, unfamiliarity with the equipment, or in extreme cases due to laziness. Operator inefficiency can have more serious repercussions for the people working in the mine.

Operational leaks Operational leaks are issues that increase the operational overheads of the mine. is ends up encroaching on the pro ts generated.

Fuel thes Fuel thes plague a lot of mines throughout the world. e easiest way

| March - April 2016 | FMDZ

to steal fuel is to ll less than expected.

In extreme cases, fuel is siphoned aer it has been lled.

Skewed liter per hour consumption ratio Old, abused, or unmaintained equipment ends up consuming more fuel as compared to the output given. is is another form of operational leak that can be plugged easily.

Equipment abuse Equipment abuse happens due to young or untrained operators. Unfamiliarity with the equipment also causes abuse to the equipment. ankfully, this can be easily remedied by proper training and guidance.

Miner safety issues Underg round mines are pres ent dangerous working conditions for miners. Fatigue and stress can cause accidents that result in loss of life.

Digging conditions Underground mines are hot and humid places, full of toxic chemical gases. e equipment faces a high degree of vibration and consequently, wear and tear. Needless to say, underground mines exhibit some of the harshest working c o n d i t i o n s .

not depend on Internet will have to be used. e most feasible communication will be RF based. us when a user goes near the device with a Hand Held Unit (HHU), the device should automatically transfer all the stored data to the HHU. ere are two ways to go about this, namely:

How the solution should work An ideal solution would consist of a single device that could t on the equipment without taking up too much space. is device should get inputs from the Engine Control Unit (ECU).

Once the device is installed, it will get various values of speed, fuel, temperature etc. for the remote monitoring. as Internet connection won't be available the device needs to have internal storage to store data received from the equipment on the board itself.

However without Internet connection fetching the recorded data and uploading it to a cloud application is not an easy task. In order to upload the data, a wireless technology that does

BLE based data fetching e device would have a Bluetooth Low Energy (BLE) module attached in order to transfer data. A special BLE based mobile application would turn any normal smartphone into a HHU. When the user goes near the device with the mobile phone, the device will autoconnect and transfer the data of the equipment to the mobile phone. Once the mobile phone establishes Internet connection via either GPRS or Wi-Fi, the application will automatically upload the data to the cloud application.

RF based data fetching RF bands especially the Sub1 GHz band, is a high range, high penetration band. e monitoring device that is installed

on equipment can have a RF transreceiver to transmit data collected by the device. When a person enters a mine with a RF enabled HHU, the data from the devices can be collected automatically. e HHU can be a customized hardware device, or it could be a mobile phone, with a small protocol convertor that can be attached to it. e RF based solution can also use a Data Concentrator Unit to automatically collect data at given intervals. e solution will need multiple signal repeaters in order to cover devices that are far away, and whose data cannot reach the DCU. Conclusion Underground mining uses a wide variety of equipment, and remote monitoring them is a logical step for mine owners and operators. Remote monitoring will help not only with increasing the pro ts via informed policy decisions, but also reduce instances of accidents, and loss of life and productivity. With the mining market growing at astonishing rates, a robust, reliable, and eld-tested solution can make all the difference.

Remote monitoring of underground equipment

Mining office

sms / email alerts GroHEMS cloud servers

Cellular connectivity

Rf-Cellular gateway

Real-time monitoring

Mining equipment with GeoHEMS having RF+Mesh capabilities

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Embracing TECHNOLOGY

Roof bolting in underground mining: A state of the art review Perhaps the most signi cant development in mine ground control during the last century was the introduction of roof bolting during the late 1940's and 1950's.

From an engineering standpoint, roof bolts are inherently more effective than the wood timbers they replaced. Roof bolts promised to dramatically reduce the number of roof fall accidents, which then claimed hundreds of lives each year, and they were initially hailed as “one of the great social advances of our time.”

Roof bolting also emerged at a time of rapid technologic transformation of the coal industry, and greatly accelerated the transition to trackless, rubber-tired face haulage. e safe and optimal installation of roof support remains one of the biggest challenges in underground mining today.

Tr a d i t i o n a l h a n d - h e l d , r o o  o l t

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installation in conventional mining has b een replaced, in a lot of mining operations, by mechanized equipment. is was a rst step to moving the operators out of the unsafe working environment and a start on the trend toward a changed support regime in mechanized mining. However, the challenge of handling of the drill steel itself, as well as inserting resin cartridges and bolts, remains a major hazard and the cause of many lost-time injuries.

Mining has always been regarded as a dangerous profession, and there are few places more hazardous than below an unsupported section of ground. Falls of ground oen results in severe injuries or death and brings undue pain and suffering to the workforce and their families.

Although safety has always been a consideration in the process of extracting precious resources from the Earth, it has never been as prominent as it is today.

Mining houses, original equipment

| March - April 2016 | FMDZ

manufacturers, and regulator y and legislative authorities all put safety in the forefront when it comes to mining.

Driving in uences b ehind to day's mechanized bolting Reliable roof support in underground mining operations is essential for worker safety and the mining operation as a whole.

Rock reinforcement methodologies through the ages have gradually moved away from the conventional 'hand-held' type bolting operation to the use of mechanized mining equipment used to complete the entire roof support or rock reinforcement process. e initial major drivers for bringing mechanized mining equipment into the equation were based on improving productivity and overall production targets, and reducing dilution. However, the spin-off in improved operator safety was soon evident.

Legislation and regulations around mining are becoming more stringent as time

passes. It is because of this growing need for a safety-conscious environment in underground mining, and because of the development and evolution of mechanized low-seam mining in the South African platinum group metals and chrome mining industries, that the need for lowpro le mechanized bolting equipment arose.

Developing mechanized rooolting in particular can address and optimize the following factors, which can improve safety, reduce dilution, and improve reliability and production, in underground mining: · Improved ergonomic designs and man-machine interface considerations offer a more comfortable and less strenuous working environment for the operators, reducing fatigue and allowing for ultimately increased productivity · Continuously minimizing the time that the operator needs to spend in unsafe working areas, through mechanizing the bolting equipment, thus improving the safe working conditions even further and improving productivity

·

Precise drilling patterns and superior installation techniques of mechanized bolting rigs ensure safer advances as well as consistently higher bolting quality, resulting in safer roof support and improved production capabilities · Drill hole deviation and misalignment can be avoided through proper feedback controls.

Mechanized bolting – the way forward With continued demand from regulatory authorities, mining houses, and OEMs to ensure safety in underground mining operations and from mining companies to increase productivity, rock reinforcement rooolters have had to prove that they can meet the challenges of underground hard rock support needs in mines – safety, bolting quality, reliability, performance, and exibility.

Protecting the operator and the machine and maximizing production are top priorities, with a fundamental focus on safety and ergonomics, including reduced vibrations, ease of ground-level service, improved lighting, soundproo ng, and superior operator comfort.

With continuing investigations and developments, roof bolting today can in most cases successfully reinforce the mine roof in underground mining. In order to cope with the increasing use of roof bolts, efforts should be made to maximize the safety and minimize the cost.

With regard to mechanical bolting, two i mp or t ant p ar am e t e r s n e e d m ore advanced improvements and study, namely, optimum design of the shape and type of expansion shell and optimum bolt tension for a speci c bolt pattern.

For the fully grouted resin bolt, the most critical requirement is to develop a fastsetting, low-cost, intoxic, in ammable grouting material that can be used in the high speed mining cycle. It should be noted that geological conditions such as the strata type, rock properties,in situ stress, and planes of weakness play an important role in the successful application of any roof bolting system. ese factors should be speci ed as accurately and quantitatively as possible in the design of any roof bolting system.

Finally, proper and careful installation and continuous monitoring are imperative for the success of any roof bolting system.

Reliable roof support in underground mining is essential

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Optimise your thickener efficiency for maximum pro tability Once extracted from the ground, mined ore is subjected to a complex series of steps before it can be converted into its purest state ready for use. The continual improvement of these process steps is critical to on-going profitability of mine operations.

to be minimised reducing the energy and chemicals needed for extraction to an absolute minimum.

A key step in most ore re ning operations is the physical separation of process water from the useful extract or tailings. e optimisation of this process is critical for several reasons: 1.

2.

3.

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e availability of large volumes of process quality water in South Africa is always limited and expensive making the use of rec ycled water attractive.

Energy and occulant costs is a major contributor to process costs.

In many cases, tailings can be reprocessed to extract ne traces of precious metals. However, for this to be economically viable the water content of the tailings needs

4.

Impure waste water can leach into ground water and waterways polluting water supplies. South African regulations determine acceptable levels of impurities that can be discharged.

Large tanks, known as thickeners are used to separate ne suspended mineral p ar t i cl e s f rom t he pro c e ss w ate r, producing a stream of clari ed water from the top of the thickener over ow and a thick sludge of settled solids (under ow) from the bottom. Flocculants are mixed with the solid – liquid suspension in the entry feedwell of the thickener. e occulants aggregate the ne particles, which speeds up settling of the solids.

| March - April 2016 | FMDZ

ickeners are used in many mineral re ning processes, including alumina, gold, nickel, mineral sands and coal washeries. In fact, most minerals go through a solid – liquid separation in a t h i c k e n e r at s om e p oi nt i n t h e i r processing.

Most mining process operators agree that one of their major challenges is to accurately and reliably monitor the bed level and bed mass of their thickeners which in conjunction with other critical process parameters allow the optimisation of thickener efficiency.

Bed level: e 'bed level' is the interface between the aggregated solid material and the process water. Incorrect measurements can lead to water being drawn out through the under ow, sludge spilling over in the over ow or incorrect occulation. ere

is unnecessary expense involved in all cas es due to waste d o cc u lent or reprocessing costs.

Depending on the application conditions, different techniques are employed to determine a thickener's bed level: ·

·

·

·

eoretical bed level based on the calculation of the average density of a constant height using a hydrostatic pressure sensor Submerged ultrasound sludge blanket transducer to sense re ections from the solid bed Turbidity sensor, either at a xed height or attached to a motorised cable spool.

B u o y a n c y b a s e d electromechanical system

Hydrostatic pressure measurement essentially reports the mass of the liquid column pressing down on it. Since the height of the liquid is limited due to the constant over ow, a calculation based on the force acting downwards divided by a constant height factor provides an estimation of the bed level. As the liquid height is xed and the density of water is known a second calculation provides information on the total amount of solids in the thickener. is information can be used to increase or decrease the in ow rate. e sensing element of this device is very vulnerable since the slurry can cause abrasion and larger suspended matter can impact and damage the stainless steel diaphragm. Problems with the pressure sensor and diaphragm can only be detected during plant shut down when the tank is drained and the pressure transmitter has been removed, checked and recalibrated, that's assuming that it isn't already damaged beyond repair. e hydrostatic pressure sensor is at the heart of the thickening process – a faulty sensor could therefore cause an inefficient process to run for a long time before being detected, resulting in water wastage and unnecessarily high pumping costs. e best way to overcome these problems is through the use of highly robust,

r e t r a c t a b l e p r e s s u r e t r a n s d u c e r.

Transmitters with ceramic sensing elements are highly resistant to abrasion – several times that of stainless steel.

Retractable transmitters are speci cally designed to be attached directly to the bottom of the tank. Assembly consists of an isolation ball valve and a retracting mechanism allowing the unit to be extracted, cleaned and validated without shutting down the process. e insertion length of the sensor mechanism can be varied to match the thickness of the tank wall and to ensure optimal sensor depth once inserted in the tank. High quality assemblies are speci cally designed to prevent operator injuries during the validation process. Due to the requirement of the extension of the sensor into the process in this style of transmitter, the use of a ceramic sensor avoids long oil lled capillaries between the sensors and transmitter that are used in metal type sensors. is means a more robust solution with improved long term accuracy and stability.

In processes with slow and predictable settling behaviours, using only the hydrostatic pressure technique can be adequate. However processes prone to disturbances from variances in chemical make-up or with varying ow rates oen require additional measuring systems to provide reliable results.

A submerged ultrasound sludge blanket transducer can be used to provide a pro le of all interfaces within the thickener. A sound impulse is emitted and a receiver circuit monitors the timing and amplitude of re ection echoes to respectively determine the depth and concentration of layers. is measurement supplies information about the bed level depth as well as the thickness of any emulsion or turbid layers which may be present above the bed-level. Applications that are susceptible to poor separation with gentle density slopes or that don't have layering of interfaces, would normally use either the turbidity or buoyancy methods.

A turbidity sensor which is either

positioned at a xed height or attached to a motorised cable spool determines the turbidity of the process water. Used in a xed height system, it can be used to initiate the reduction of the in ow rate should turbidity levels increase. On a motorised cable spool, it can provide a turbidity pro le to the operator. is measurement is targeted at turbidity pro ling as well as bed-level detection. If only bed level measurement is required, then the buoyancy principle is more cost effective. e 'buoyancy based electromechanical system' uses a sensing weight which is lowered on a measuring tape into the thickener to detect the bed level. Typically, the sensing weight is a light, hollow container lled with the bed level material.

When the container is lowered, it sinks in the water but ' oats' when it reaches the bed. At this point, the bed level can be measured. Once the bed level has been located, the weight is reeled back up to the surface. To overcome issues related to the use of rakes in settling tanks, device measurement cycles can be automated so that measurement takes place in between rake rotations. is more straightforward measurement principle offers a greater ease of operation. Since all the active components are located outside of the process, it is more Bed mass: e 'bed mass' is effectively the density of the settled sludge. e higher the density, the less process water is pumped out of the thickener's under ow. e optimisation of water content in the under ow allows for maximum recycling of process water while still keeping the under ow slurr y sufficiently liquid to be managed by the under ow pump. If the thickener's under ow is destined for a tailings dam, the optimisation of the slurry density helps to reduce negative environmental impacts through leaching at the dams.

Bed mass is calculated based on the total volume of combined water and solids in the tank and the total hydrostatic pressure measured near the bottom of the tank. As the speci c gravity of water is a known

FMDZ | March - April 2016 |

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constant, the mass of the solid content can be calculated.

Vo l u m e t r i c m e a s u r e m e n t o f t h e thickener's in ow: Accurate volumetric measurement of the thickener's in ow is vital to ensure the clarity of the recovered process water.

Essentially the in feed ow rate can be controlled based on high clarity of the over ow. So the clearer the out ow, the faster the in ow feed rate which leads to o p t i m i s e d t h i c k e n e r t h r o u g hp u t .

Combined with the mass ow measurement of the occulent, precise ratio control of the occulent dosing is achieved. is enables automated, continuous occulent dosing which further increases process efficiency and reduces costs when compared to semibatch type operation.

Mass ow measurement of occulent: Flocculants are used in most thickeners to obtain concentrations of over ow solids that will allow water to be reused or to comply with government regulations if the over ow is to be discharged. Recycled

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water containing 200 mg/L to 1% solids is generally acceptable. Most thickeners can achieve this level of concentration by using a occulant. Although occulants are used in relatively small quantities, they are expensive. e accurate measurement of occulant mass ow allows precise dosing pump control. Combined with other system parameters, the use of 'just enough' occulant can be ensured minimising occulant usage and optimising process costs. Depending on the process this measurement can be made using high accuracy Coriolis mass ow instruments, or more economical volumetric electromagnetic ow meters.

accounting of mineral recovery as well as waste.

Accurate measurement of all of these important parameters allows precise thickener process control which can lead to signi cant increases in thickener efficiency. ese efficiency gains translate directly into overall re ning process cost reductions and increased pro tability.

Enquiries: Susan Buitendag Industr y Manager – Primaries Endress+Hauser (Pty) Ltd

Out ow density and volumetric measurement: Constant out ow density and volumetric ow me asurements are imp or t ant parameters which can be fed back to the variable speed drive controlling the out ow pump, optimising pump speeds, reducing wasted energy and improving efficiency. e combination of density and volumetric ow rate provides an integrated mass ow rate which is useful for

| March - April 2016 | FMDZ

Tel: (011) 262 8000 Fax: (011) 262 8062

info@za.endress.com

Endress + Hauser People for Process Automation

Verlinde Cranes & Hoists expands its southern African presence e growing Verlinde Cranes & Hoists dealer network has been expanded to include Expert Mining Solutions and Pirtek as the designated dealers for Namibia and Limpopo. is growth is part of Verlinde Cranes & Hoists' ongoing effort to extend its product and ser vice offering to customers, irrespective of location.

Warren Shankland, MD of Verlinde Cranes and Hoists, said: “Both Namibia and Steelpoort in Limpopo are territories to which we have been trying to gain access. We are ecstatic to build our relationship with Expert Mining Solutions and Pirtek so that we can extend our service offering to all our customers in these areas.”

Expert Mining Solutions, situated in

Namibia, has a strong support following and a reputation for delivering while maintaining safety as a core value in their business. e company operates both locally and across borders.

In November 2015, Expert Mining Solutions acquired Pirtek Steelpoort, which has a rm foothold in Limpopo.

“It is an exciting time to be a part of both companies, we look forward to being a part of their business growth,” said Shankland.

“Our company values and promise on service are in line, we run a business built on relationships and we are committed to delivering solutions that meet business needs and are a sound investment.”

Expert Mining Solutions will represent Verlinde Cranes & Hoists in Namibia, while Pirtek Steelpoort will do so in

Steelpoort and its surrounding area. is is just part of the planned expansion of Verlinde Cranes & Hoists, which aims to build on its already extensive dealer network in 2016.

Locally, Verlinde Cranes and Hoists is now represented in the Free State and Mpumalanga through EBJ Construction, in Limpopo through Pirtek Steelpoort, in the North West through Jynco Hydraulic World, in the Northern Cape through Dezzo Equipment and in the Western Cape through Maniload.

In the rest of Africa, there are dealers in Botswana (EBJ Construction), Namibia (Expert Mining Solutions), Zimbabwe (Kromona Investments) and Mozambique.

Negotiations are under way to penetrate other African territories.

FMDZ | March - April 2016 |

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PRODUCT Releases

Filter Focus:

real-time monitoring leads to improved asset health management Filter Focus says that industrial operations can optimise oil drain and sampling intervals and improve asset health state awareness using the Trident QM 3100. e Trident QM 3100 is a real-time, in-line uid quality monitoring device that can also clearly identify contamination events, proactively detect the need for oil changes and top-ups, and verify proper lubrication system maintenance. e Trident QM 3100 is developed by Poseidon Systems and was officially introduced into the local market in early 2016 by wear control specialist Filter Focus. e online sensing device uses electrochemical impedance spectroscopy (EIS) technology to measure uid properties and provide insight into uid health. Filter Focus COO Craig FitzGerald says EIS technology measures a uid's impedance spectrum and tracks its health. “e EIS method injects a signal into the uid via one electrode and receives a response signal on a secondary electrode. e impedance spectrum provides multiple condition indicators which can be used to assess the lubricant's additive package health, monitor breakdown and identify oil top-ups, contaminants and contamination events. It is ideally-suited for engine oils and gearboxes,” he explains. e Trident QM 3100 can measure uids ranging between temperatures of -40 oC to 150 oC, and is sealed according to

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| March - April 2016 | FMDZ

IP67 speci cations, with a maximum operating pressure of 10.3 bar. e device has no moving parts, is easy to install, and is compatible with CAN-J1939 and RS485-Modbus RTU communications platforms. “e QM 3100 provides users with the control to improve their health management practices by enabling informed maintenance decisions based in real-time information,” FitzGerald concludes.

USA-based Poseidon Systems develops and manufactures real-time condition monitoring solutions that provide users with reduced overhead and maintenance costs and improved asset reliability.

Its core expertise is in uid diagnostics, particularly metallic wear debris monitoring and oil condition monitoring. Poseidon also supports the design and production of customer-speci c sensing and monitoring solutions.

7 of e Biggest Mining Projects in Sub-Saharan Africa Africa is rich in minerals. It has a third of the mineral reserves in the world and twothirds of the global deposits of diamond.

Trade in gold, oil, diamonds, copper and other minerals is a key pillar of many African economies.

Leading mining and exploration companies in the world have undertaken big projects across the continent. Some of these projects drive the economies of the nations they are located in and have had infrastructure projects and even cities developed around them.

Here are some of the biggest mining projects in Africa;

Simandou Project - Guinea

Above: Kamoa Copper Project DRC

Simandou Project – Guinea It is an iron ore mining site located in Simandou, a mountainous region in Southern Guinea e ore holds about 2.25 billion tonnes of iron. e project is proposed to cost US$20 billion.

Infrastructure is poorly developed in this part of the country and the construction of a port and a 650 kilometer railway are part of the project.

Exploration rights for the mine were granted to Rio Tinto Group, one of the biggest mining groups in the world, in 1997. It has however been held back by corruption, battles between Rio Tinto Group and B eny Steinmetz Group Resources of Israel, several court cases and

political disputes in successive regimes.

Commercial production of the ore is set to start in 2019. It will have the potential of doubling the country's Gross Domestic Product. is will be the biggest iron ore mine in the world.

Kamoa Copper Project – DR Congo It is found in Katanga, Democratic Republic of Congo. Kamoa Copper mines contain 43.5 million tonnes of copper. It is considered the biggest copper mining proj e c t in Af r ic a and t he big gest underdeveloped copper discovery in the world. e cost of the project is US$1.2 billion. It started in July 2014 and commercial production is set to start in 2017. e project will be operational for 30 years. e DR Congo government granted mining license to Ivanhoe Mines of in August 2012. It holds 95 percent of the exploration rights. In May 2015, Zijin Mining Group Co. Ltd of China bought 49.5 percent stake in Kamoa Holding, at US$ 412 million. is is Ivanhoe Mine's unit that has majority rights in the copper project.

Tenke Fungurume Project – DR congo It is found in South-eastern part of Democratic Republic of Congo. is is one of the world's largest copper-cobalt

Below: Tenke Fungurume Project DRC

FMDZ | March - April 2016 |

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reserves. e project started in 2006 and has two phases. e rst one cost US$ 1.8 billion. It involves construction of three open pit copper-cobalt mines and construction and operation of an oreprocessing plant with a production capability of 115, 000 tonnes of copper cathode and 8, 000 tonnes of cobalt metal annually.

Lundin Mining Corporation, a Canadian metals mining company holds a 24 percent stake in the project. Other partners in the project are the Democratic Republic of C ongo gover nment and Fre ep or tMcMoran Copper and Gold of United States of America.

Lumwana Mine – Zambia It is a copper mine, located in Zambia's North Western Province. It is one of the largest copper mines in Africa. It has two main deposits; Chimiwungo and Malundwe. e project cost over ZAR 4.3 billion. e mine has over 3.3 billion pounds of copper and has an operational lifespan of 37 years.

It started copper production in December 2008. Equinox Minerals, a Canadian mining and exploration company was granted mining licence by the government of Zambia in January 2004. e licence is valid for 25 years. In July 2011, the company was acquired by Barrick Gold Corporation of Canada for US$7.3 billion.

Catoca Diamond Mine -Angola It is found in Lunda Sul Province, Angola.

Catoca mine is the h biggest diamond

mining project in the world. It contributes six percent of diamond production in the world annually. In 2012, it produced 6.7 million cataracts of diamond. It started commercial exploration in 1993. e mine is operated by Sociedade Mineira de Catoca which is owned by Angola's diamond company, Endiama, AOA Alrosa of Russia, Sonangol EP of China and Odebrecht SA of Brazil.

Rossing Uranium Project – Namibia It is located in the Nabib Desert, Namibia.

Rossing Uranium project is an open pit mine. It is the world's h largest uranium project. It contributes nearly eight percent of the uranium produced annually in the world. Commercial exploration of uranium oxide started in 1979. Rio Tinto Group owns 69 percent in the project.

Other stakeholders are the Government of Namibia, Iranian Foreign Investment and Industrial Development Corporation of South Africa.

Venetia Diamond Mine – South Africa It is the biggest diamond mine in South Africa, located in Limpopo Province. It is the sixth largest diamond mining project in the world. It cost US$400 million to develop. It is operated by De Beers Group, a diamond exploration, mining and marketing company. Exploration started in 1992. It has an operational lifespan of more than 20 years. In 2015, the company started a US$ 2 billion project to convert Venetia Diamond Mine from open mining to underground mining. e project will be complete in 2021.

Catoca Diamond Mine- Angola

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Venetia Diamond Mine- South Africa

Lumwana Mine- Zambia

Rossing Uranium Project Namibia

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