st
1 MINING Central Africa’s Premier Business To Business Mining magazine Jan-Feb 2017 > Issue 21 > Vol.8 #
DRC-ZAMBIA Randgold’s secret for Congo mining: Fly people in, gold bars out -10
Power Crisis and the Solar Energy Nexus in Zambia -14
ALSO... Mine shafts become killing elds in syndicate turf wars -6
F MD R C - Z A MB I A
20
www.fmdrc-zambia.com
www.za.endress.com/primaries
www.za.endress.com info@za.endress.com susan.buitendag@za.endress.com
Contents MINES & MINERALS
13
Cape Lambert seals DRC JV, sets eyes on Zambia
HI TECH
20
FEATURED DEVELOPMENTS
Fatigue Risk management System
INNOVATION
05 Consolidated Nickel Mines wins top honours in Investment Battle eld Competition 12 KSB invests in Zambia 26 World’s largest acid mine drainage plant in SA to relieve water crisis 8 Governments urged to craft tting policies for mining industry 34 Collision Warning Systems in Mining
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De Beers unveils next generation diamond veri cation tech
Jan - Feb 2017
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FROM THE EDITOR
1st MINING Central Africa’s Premier Business To Business Mining magazine Jan-Feb 2017 > Issue 21 > Vol.8 #
e year is inching forward and I am not sure how many of us are still keeping their thumbs on their new year's resolution so far. How many boxes can you think of with great satisfaction and pat yourself on the back and say, 'yes I have done it'? Welcome to our rst 2017 edition of 1st Mining DRC- Zambia, hoping to still give you the freshest and informative news in the mining sector. We seek to provide in-depth coverage of the most important mining and exploration projects in Africa as well as information on technologies and developments in mining and processing equipment. We look at the current power crisis in Zambia which presents a chance for solar energy. e power crisis in Zambia might be suited for introducing large-scale solar power to Zambia. Mines as the main power consumers might even nd interest to contribute to this development. Our feature on technologies and equipment we talk about e De Beers International Institute of Diamond Grading & Research (IIDGR ) next generation diamond veri cation technology. Around ten times faster than its predecessor and with a substantially reduced referral rate, the AMS2 that has been recently unveiled by e De Beers International Institute of Diamond Grading & Research (IIDGR) has the ability to process smaller sizes and all shapes of polished diamonds will revolutionise the diamond industry. On exploration projects, Australian company Cape Lambert has ventured into a joint venture with Democratic Republic of Congo's (DRC) Paragon Mining to exploit the country's cobalt and copper. e JV is to develop the Kipushi cobalt-copper tailings project, the Kasombo copper-cobalt project and operate the Kipushi processing plant. We also feature issues to do with workers health like fatigue, collision warning systems, and light in mines. For more stories and insights, visit our website www.fmdrc-zambia.com
DRC-ZAMBIA Randgold’s secret for Congo mining: Fly people in, gold bars out -10
Power Crisis and the Solar Energy Nexus in Zambia -14
ALSO... Mine shafts become killing elds in syndicate turf wars -6
F MD R C - Z A MB I A
20
www.fmdrc-zambia.com
Cover Mine Headgear
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
Bertha M. Editor
Graphic Design and Layout Que Gibson
Published By Mailing Times Media sales@fmdrc-zambia.com www.fmdrc-zambia.com
Circulation/Sales
Mailing Times Media (Pty) Ltd makes every effort to ensure the accuracy of the contents of its publications, but no warranty is made as to such accuracy and no responsibility will be borne by the publisher for the consequences of actions based on information so published. Further, opinions expressed are not necessarily shared by Mailing Times Media (Pty) Ltd
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Consolidated Nickel Mines wins top honours in Investment Battle eld competition Zambia-focused Consolidated Nickel Mines (CNM) won the rst Investment Battle eld Competition for junior miners at this year's Investing in African Mining Indaba, with Sula Iron & Gold in second place. CNM, a subsidiary of Consolidated Mining and Investments, is planning to restart the 4 500 t/y brown eld Munali nickel mine, 70 km south of Lusaka, where operations were stopped in November 2011, owing to low nickel prices and poor operational performance by its previous owners. CNM CEO Simon Purkiss said that while the decision to compete in the Investment Battle eld was rather last minute, the results have been “fantastic”. “Presenting, and then winning, has meant that there was a lot of discussion about the company and the project following the results, which has continued since the Mining Indaba. “e message we were presenting was that we were raising the funds to restart the mine and so the exposure came at just the right time. e feedback from the judges, not only to us but to the audience on the merits of the project, was very well received." Sula Iron & Gold, meanwhile, is an Aim-listed company focused on the exploration for gold, iron-ore and coltan in Sierra Leone. e Mining Indaba introduced the Investment Battle eld platform to support Africa's new generation of emerging miners, giving 16 junior mining companies the opportunity to pitch their projects to a panel of expert investors, competing for prizes that will support the development of new projects.
www.axis.com/critical_infrastructure
“Identifying the best junior mining companies for investors and supporting the development of new projects is at the core of Mining Indaba, and will be a growing part of the Mining Indaba in the future,” said Mining Indaba MD Alex Grose. Total prizes, valued at more than £15 000 include free attendance passes, an exhibition stand and hotel accommodation for the 2018 Investing in African Mining Indaba.
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MINING NEWS
Mine shas become killing elds in syndicate turf wars Turf wars between international crime
Benoni. e rest were found on Monday on the
arm themselves against gangs that wait for them
syndicates are behind the deaths of more than
banks of a nearby stream. ey are believed to
on the surface and have shopped out their
200 illegal miners murdered in the killing elds
have been killed elsewhere before they were
protection to hired guns.
of South Africa's mines over the past four years.
dumped.
is, say researchers, security companies and
e latest casualties are 14 illegal miners,
e UN institute's 2016 report says in 2011 the
monitoring groups, has increased the violence,
known as zama zamas, who were killed at the
world's illicit gold trade based in South Africa,
with shootouts oen occurring.
weekend on Gauteng's East Rand.
Democratic Republic of Congo and Peru
West Rand illegal miner Lenmore Mwarera
e area has become the epicentre of a global
accounted for US$2.3-billion.
said, “ere are people now that are self-
battle between gangs for control of tons of
Behind the violence are armies of heavily armed
appointed, who guard the entrance of all the
precious metal in disused mine shas.
thugs, allegedly including police, who help
places we go into. ey are there to make sure no
At the centre of the war are an estimated 30 000
syndicates wage a war for control of the highly
one goes down there with anything that can
illegal miners who, say the UN's inter-regional
lucrative underground turf.
harm another person (guns, knives, sticks),
crime and justice research institute and the
e majority of victims are Zimbabwean,
because there used to be a lot of crime before.
Mineral Resources Department, are used by
Mozambican and Lesotho nationals used by the
Frans van der Linde, whose company Blue
syndicates to steal about R7-billion worth of
syndicates for their mining skills and years of
Hawk Security works on several East Rand
gold a year from South Africa.
knowledge on the layout of disused mine shas
mines, believes in the past 18 months nearly 150
e 14 bodies were found on Sunday and
littering the Reef, the Free State and
people have been killed by gangs seeking
Monday, laid out in particular patterns. On
Mpumalanga.
control over mine shas.
Sunday six were found along a railway line in
Miners, fearing for their lives, have started to
“Month on month we nd these guys' bodies.”
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| Jan - Feb 2016
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MINING NEWS
worse. e police would wait for the guys and
in all sorts of crimes around illegal mining,
zama zamas as they emerged from the shas.
rob them and sell off their gold.”
including violence”.
Van der Linde claimed that, in December, as his
Mbangula believes that criminal gangs
“ese investigations are sensitive. ere are
He said they had witnessed police robbing the
officers tried to arrest 12 zama zamas, police
cottoned on to what the police were doing and
several major operations under way.”
opened re on them, allowing the miners to
began running their own extortion rackets.
In October Deputy Mineral Resources Minister
escape.
“We are seeing this gangsterism. With this
Godfrey Oliphant told parliament 80% of those
“ey ran to the police car, loaded their bags in
gangsterism, they started the killings.”
involve d in i l licit mining c ame f rom
the vehicle, and ran away,” he said. Van der
Gauteng police spokesman Colonel Lungelo
neighbouring countries.
Linde believes the latest killings could be linked
Dlamini failed to answer questions over
“A study estimates that about 10% (R7.3-billion
to a rival gang trying to claim control of the area.
allegations that police were involved.
for 2013) of gold production is stolen and
He said the strength, in terms of weapons the
“Police have tasked a team of detectives to
smuggled out of the country annually.
gangs carried, was not to be underestimated.
investigate the murders,” he said.
“Illegal mining is largely fuelled by highly
“We have engaged these guys in some serious
He said the motive for the killings was
organised, dangerous, well- nanced and
gun battles before.”
unknown and that none of the dead had been
complex local and international crime
Mining Affected Communities United in
identi ed.
syndicates which have up-to-date maps of
Action national co-ordinator Meshack
Dlamini said all investigations into illegal
mining operations.”
Mbangula, who works closely with zama zamas
mining were being conducted by the Hawks.
Wits University's illegal mining expert, Robert
and other small-scale miners throughout the
Hawks spokesman Brigadier Hangwani
ornton, said a “smorgasbord of international
country, said the syndicates attacked the miners
Mulaudzi said they were running numerous
characters were involved in illicit mining,
as they emerged from the shas.
investigations into the operation of illegal
including Israelis, Chinese, Indians and
“ese things didn't happen in the past, but
mining syndicates “looking at the involvement
Pakistanis”.
with the involvement of police it has become
of all sorts of people, including police officers,
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MINING NEWS
Governments urged to cra tting policies for mining industry Poorly thought-out mining policies are impacting Africa's mining sector, the annual mining jamboree Mining Indaba in Cape Town, South Africa has heard. Sharing the same sentiments, stakeholders said uncertainty and inconsistency are hampering the search for new mining investment on the continent. In addition, the policies have cast a shadow over the continent's longer-term economic growth. e world's largest mining investment conference highlighted a subdued investor mood in mineral-rich South Africa, Africa's largest mining destination “Amid signs that the commodity cycle may be turning, South Africa will not be positioned to take advantage of the green shoots of spring, or the heat of summer, unless the environment for mining is conducive to private-sector investment. And the [South African Mineral Resources] minister's bland speech was frighteningly short of any sign that he had understood investors' concerns about the regulatory environment for mining – or that he had intentions of doing anything about these
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| Jan - Feb 2016
concerns,” noted Johannesburg nancial newspaper, Business Day, during the Mining Indaba. e publication further said there are other much easier and more attractive destinations for mining investment, by junior or senior miners, and international investors are increasingly passing South Africa by. Meanwhile Botswana still shines as a model mining-investor destination by international standards. However, the serious investor concerns are not limited to South Africa but virtually all African mining destinations – Zambia, Ghana, Guinea, Tanzania and the Democratic Republic of Congo (DRC). To a large extent, these concerns stem from sudden and unexpected changes made by many mineral-dependent African countries to their mining regimes aer the 2008-09 global nancial crisis. Hit by the twin hammers of lower revenue and rising debt, countries attempted to extract more money from their mining sectors at a time when they could least afford it. “Many African countries made rash and unpredictable changes to their mining
| FMDZ
regimes, creating regulatory uncertainty and harming investor con dence,” said Peter Leon, a partner at the global legal practice Herbert Smith Freehills. Ghana, for example, announced in 2012 that it would impose a 10% windfall tax on gold mining and review its scal stability agreements with foreign mining companies, but failed to follow through on these measures. en in 2014, Ghana amended its mining law to replace the xed 5% royalty with 'wide executive discretion' to prescribe new rates. e resulting regulatory uncertainty 'weighed on sentiment', and considerably affected Ghana's ranking in the authoritative Fraser Institute's annual review of the investor att rac t iveness of t he world's mining destinations. “Ghana fell from its enviable 2011 ranking of 17th in the world to 38th in 2012, and then uctuated from 30th in 2013 to 44th in 2014 and 31st in 2015,” said Leon. Another notable example is the DRC, Africa's largest copper producer, the world's largest cobalt producer and a major source of diamonds, gold, tantalum and tin. While the country's 2002 mining code “strikes a
MINING NEWS
relatively reasonable balance between the interests of the state and the private sector”, the industry was suddenly thrown into turmoil in 2012, when the government announced drastic reforms. ese included increasing the state's free carry from 5% to 30%, doubling royalties on copper, cobalt and gold to 6%, and imposing local bene ciation quotas. “In the face of strong industry resistance, these reforms were never implemented, and at the 2016 Mining Indaba, the DRC's mines minister announced they had been formally abandoned,” says Leon. e prolonged investor uncertainty “hobbled investor con dence”, and saw the DRC plunge in the Fraser Institute rankings, from 54th place in 2011 to 75th in 2012 and 2013. It recovered to 67th in 2014 and 60th in 2015. “Similar dynamics played out in Guinea, Tanzania, Zambia and, of course, South Africa, where amendments to the Mineral and
Petroleum Resources Development Act proposed in 2013 have entered the fourth year of legislative limbo…,” Leon said. Leon's reference to Zambia relates to the numerous changes made to the country's mining legislative framework and mining-tax regime in the past decade. ese changes culminated in the ill-fated 20% Mineral Royalty Tax proposals of 2014/15, which nearly brought the Zambian mining industry to a standstill and threatened its very existence. Leon argues that for African countries to get the best out of their mining industries, they should heed the guidelines of the Africa Mining Vision. is vision was adopted by the African Union heads of state in 2009 as a roadmap to “transparent, equitable and optimal exploitation of mineral resources to underpin broad-based sustainable growth and socio-economic development”.
www.cmscepcor.com
e African Mining Vision Guidebook recommends collaborating with the private sector and other stakeholders to develop “clear, transparent, predictable and efficient legal and regulatory frameworks”, which would require “adequate protection of property rights, an effective judicial system, and independent enforcement and oversight bodies”. Following these guidelines would yield better results than the “hasty and haphazard adoption of bolt-on reforms with which many African governments have experimented in the past ve years”. Leon further said: “If African governments begin to embrace the essential conditions for investment in the mining industry, and if mining companies accept the principle of mining-led sustainable development, there is no reason to think that mining cannot signi cantly transform the economies of Africa's key mineral producers.”
MINING NEWS
Randgold’s secret for Congo mining: Fly people in, gold bars out Randgold Resources had to haul heavy
scale deposits.
to the mine.
equipment more than 1 000 miles to build the
“ey've done this a long time and they know
One of the company's new mines will be in
roads and hydropower plants needed to
they need to re-shine the halo,” said Clive
Senegal, according to Randgold CEO Mark
construct its Kibali gold mine, the biggest in
Burstow, who helps manage about $475 million
Bristow, who has promised the company, which
Democratic Republic of Congo.
of natural-resource assets at London's Baring
is also exploring in Ivory Coast, will de ne three
e sprawling facility in a remote corner of a
Asset Management including Randgold shares.
new projects in the next ve years. Another may
country the size of Western Europe is a high-
“I certainly wouldn't bet against them nding
be in Congo, in an area next to Kibali: e
tech operation. In one tunnel deep
something, but don't forget it's getting harder to
Moku-Beverendi gold project, a joint venture
underground, a $1.3 million, 68-metric-ton
nd these big elephant-sized deposits they talk
with Moku Goldmines AG controlled by Israeli
remote-controlled digger heaves ore out of a
about.”
billionaire Dan Gertler.
Dinner Plates
million-ounce deposits,” Bristow said in Cape
cavernous blast hole. e ventilation system hums as 50-ton loads are slowly humped along
We are looking for “world class 10-plus-
the 3-kilometer track back to the surface.
e key to making Kibali work: e company
Town in February. “We think Moku has that
e best-performing gold miner of the past
and its partners built everything in sight,
potential.”
decade, Randgold has built its success on
including housing for more than 4 000 resettled
getting complicated projects like Kibali into
families and an international airport where
production on time and within budget. It's the
personnel y in and gold bars y out. At the
Moku is one of four joint ventures Randgold has
third major mine the company has brought on
high point of construction, Kibali received as
signed in Congo in the past 18 months as it
stream in ve years, and it has indeed been a
many as 400 40-foot containers a week across
looks to replicate Kibali's success.
Four Ventures
gold mine: It accounts for about a h of the
the border from Uganda.
A partnership between Randgold, AngloGold
company's production, which tripled between
Everything from the plates and cutlery in the
Ashanti Ltd. and state-owned Sokimo, Kibali
2010 and 2015 as revenue doubled to more than
large canteen to a plant that processes as much
shipped 642 720 ounces of gold worth more
$1 billion.
as 7 million tons of ore a year has been driven in
than $700 million in 2015. at helped increase
Now, with Kibali nearing full production and
across more than 1 120 miles of road from
production of the precious metal in the country
no new discoveries since 2011, the miner needs
either Mombasa, Kenya, or Dar es Salaam,
from almost nothing in 2011 to more than 25
to nd guaranteed output growth to impress
Tanzania. ree hydropower projects will
tons a year.
investors wary of the shrinking pool of large-
ultimately provide 42 megawatts of electricity
Production last year fell to 585 946 ounces aer
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| Jan - Feb 2016
| FMDZ
MINING NEWS
technical challenges in the rst six months, but
little, dare I say, sovereign state, far removed
miners have failed to overcome. “You can always talk, you can always negotiate.”
output is scheduled to peak at 750 000 ounces in
from regional issues.”
2018 as the underground operation reaches full
Randgold began due diligence on Kibali in
Gold prices hit $1 257 on 27 February, well
capacity, Randgold says.
2006, months aer historic elections brought a
below a record high of $1 921.17 an ounce in
Other miners have been less successful in
nal conclusion to a violent civil war that le
2011. Randgold, which says all of its mines
Congo. Randgold's partner, AngloGold,
millions of Congolese dead. It acquired the
make a pro t at a price of $1 000, has avoided
s u s p e n d e d op e r at i ons i n 2 0 1 3 at t h e
asset in 2009 through a purchase of Moto
the worst of the slump so far: It has returned
Mongbwalu project, also in northeastern
Goldmines Ltd.
more than 500% to shareholders in the past
Congo, saying that it couldn't make the
“Before Moto every major gold company in the
decade.
economics of the project work. In the past
world had this asset and did nothing,” Willem
at's more than double the second-best
decade, mining majors Rio Tinto Group, BHP
Jacobs, chief operating officer for central and
performer on the Bloomberg senior gold miner
Billiton Plc, Vale SA and De Beers have all held
east Africa, said at the site in November. “It is
index and one of only six out of the 16 biggest
and abandoned mining licenses in Congo for
very hard for big companies to do what we have
gold members to have given shareholders
different minerals without making headway.
done here.”
positive returns over the period. Competitors AngloGold Ashanti, Barrick Gold Corp.,
Doing business
Negotiation possible
Newmont Mining Corp. and Kinross Gold
Congo was ranked 184th out of 190 countries
A new project would bene t from the
Corp have all lost money for shareholders.
on the World Bank's ease-of-doing business
infrastructure Randgold has built and the
“For a long time they were realistically one of
survey in 2016, but Randgold was able to bring
lessons the company has learned since 2009,
the only invest-able gold names listed in
Kibali from feasibility in 2010 to rst gold less
making it easier to replicate Kibali's success,
London if you were a large-scale investor,” said
than four years later.
Jacobs said. “Every country has its own
Baring's Burstow. at's a title slowly coming
“It's been way more successful than most people
challenges, but the Congolese government is
under pressure from miners such as Acacia
thought,” said Hunter Hillcoat, an analyst at
enormously commercial,” he said of the
Mining Plc and Centamin Plc, Burstow says.
Investec in London. “ey operate their own
complicated operating environment that many
“People have con dence that they can deliver. We just have to watch them carefully.”
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COMPANY NEWS
KSB invests in Zambia Global pump manufacturer, KSB Pumps and Valves, has established an independent operation in Zambia to ensure that its rapidly expanding customer base has full access to the company's world-class sales and support services. Having previously been represented by a network of agencies and dealers throughout the country, the growing number of pumps in the eld, as well as burgeoning demand from the agricultural and mining sectors, has prompted the company to invest in more suitable infrastructure within the region. According to KSB Pumps and Valves regional sales manager, David Jones, the formal establishment of KSB Zambia is aimed at taking the market to an entirely new level with improved stock holdings, shorter lead times for the procurement of pumps, improved price stability and onsite service and support for customers. Zambian solutions “We rather elected to buy a controlling share in Kitwe-based pump company, Aqua Africa, that is well-established in the copperbelt and is a well-liked company in Zambia.
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| Jan - Feb 2016
“Simultaneously we also established a branch in Lusaka that will cater largely for the agricultural market, as well as being well positioned to support water and i n f r ast r u c tu r a l re qu i re me nt s of t he residential and industrial markets. Now that the bricks and mortar are in we are planning to double our efforts and reach out to existing and new customers and we think the market is going to like what they see.,” says David. KSB Z ambia managing director, Alf Jacobsen, says when KSB approached him it was an easy decision to make as it was a move in the right direction for his company, as well as for the Zambian pump market. “Right now agriculture is in a strong position and there is a lot of room for us to grow that part of the market. Similarly, mining will always be a strong focus here in the copperbelt and with full access to the entire range of KSB pumps and slurry pumps it bodes well for us to grow this sector in future. Growing forward “We want to become a one-stop-shop for pump, valves and uid transfer requirements across all industries and will steadily build a
| FMDZ
stock holding of pumps and parts that is appropriate for the market. is has the potential to quadruple our footprint world class products and support locally, as well as from KSB South Africa and the global network of experts. “From a customer point of view, it will be encouraging to know that they are now dealing directly with one of the world's major contenders in the pump market and that support and backup will be in line with world standards,” Alf says. KSB dealer manager for sub-Saharan Africa, Andreas Gremels adds that the move into Zambia is the rst in a number of investments that the company plans to make within the sub-Saharan Africa region. “ ere is considerable investment going on in Africa in terms of both infrastructure and industry. KSB S out h Af r ic a w i l l supp or t t his development with further investments into countries in East, Central, West and Southern Africa with a emphasis on countries that already have large KSB pump populations such as Angola, Namibia, Mozambique, Botswana and Tanzania, eventually covering all major countries in Sub-Sahara Africa.
Cape Lambert seals DRC JV sets eyes on Zambia Australian company Cape Lambert has
“Cape Lambert has built a successful record of
According to the company a feasibility study
ventured into a joint venture with Democratic
identifying commodities and projects at the
for Kasombo was scheduled within the next 18
Republic of Congo's (DRC) Paragon Mining to
right time. By applying our technical and
months, and mining activities within the next
exploit the country's cobalt and copper.
marketing support, we can add immediate
24 months. e partners will also work to
e JV is to develop the Kipushi cobalt-copper
value to these projects and return signi cant
identify and secure other copper, tin, zinc and
tailings project, the Kasombo copper-cobalt
value to the company, its shareholders and all
cobalt projects in the DRC and Zambia.
project and operate the Kipushi processing
stakeholders,” said Cape Lambert, Executive
At Kipushi, Cape Lambert will be responsible
plant.
Chairperson Tony Sage.
for providing all the necessary technical
In addition, operate the fully constructed and
Lambert is optimistic that cobalt, as a
resources to enable exploration and mining,
commissioned Kipushi processing plant to
commodity, has an extremely positive future.
and will fund 100% of the working capital and
process the Kipushi tailings and treat
“We believe we are well placed to bene t from
capital costs to start mining, while also sole
additional hard rock cobalt and copper
signi cant demand and price increases in this
funding any requirements to upgrade the
material.
commodity sector.”
processing plant.
Commissioned last year, the processing plant
e two companies will each hold a 50%
While at Kasombo, Cape Lambert will be
which was has a one-million-tonne-a-year
interest in the JV, and will aim to start mining
responsible for sole funding the costs of
otation plant designed to produce 4 000 t/y of
activities at Kipushi within the next six months,
exploration and feasibility studies to start
cobalt, 10 000 t/y of copper and 2 000 t/y of zinc
and to immediately start exploration activities
mining and, if necessary, upgrade the Kipushi
in concentrate from the tailings material.
at Kasombo.
processing plant to process ore from Kasombo.
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Jan - Feb 2017
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Page13
COUNTRY focus
Power crisis and the Solar Energy Nexus in Zambia Zambia is currently facing a severe power crisis. Traditionally, electricity was available in Zambia in abundance from am or t i z e d hy d ro - p ow e r p l ant s at extremely low prices. In the last years, droughts have dried out many damns, which has led to a severe restrictions of power generation capacity. e mining industry is consuming more than 50% of the electricity in Zambia. In order to resolve the situation, Zambia begins rationing electricity supply to mines. At the same time, mining is the backbone of the Zambian economy. Many mines are facing additional challenges such as falling copper prices in the world market and changing tax policies in Z ambia. More and more mining companies public think about closing down their mines in Zambia. Currently, mine production is affected by load shedding and power outages. Sometimes the only remedy is the usage of
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| Jan - Feb 2016
back-up diesel gensets for generating baseload power. is is extremely expensive. In addition, the power price for mining companies has almost double at the beginning at the year. e Zambian government has initiated emergency measures and buys expensive conventional energy from neighbouring countries and private suppliers. At least short-term, the situation is expected to persist as the damns are not lling up signi cantly. New power infrastructure projects are being realized rather slowly while large investments in mining assets in recent years is expected to double the output capacity of the copper mines until 2020. In 2014, Zambia had a total power consumption of 10,720.5GWh. Mining was with 54.8% by far the biggest consumer of electricity. Mining consumed more than twice as much electricity as all households together. Electricity prices
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used to be extremely low in Zambia. Due to low water levels the hydro production has been extremely low in recent years. e country has to cope with load shedding and power outages. e mining industry is severely affected. To some extent production decreases of major Zambian mines are linked to missing electricity supply. Solar energy for powering mines in Zambia e power crisis in Zambia might be suited for introducing large-scale solar power to Zambia. Mines as the main power consumers might even nd interest to contribute to this development. In light of the mining crisis it does not seem very probable that many mining companies want to invest their own money, however they might commit to long-term power purchase agreements (PPA) in order to secure their electricity supply. Solar power
country FOCUS
plants have the advantage that construction time is extremely short. Solar energy can be very cost efficient in Zambia. e bid tariffs for two 50 MWp PV plants start at US¢6.02/kWh16 and are thus well below the power costs that the Zambian government had for emergency measures and below the new energy tariff for mines of 10.35US¢/kWh17 that is expected to constantly increase over the coming years. e solar power plants could be either built centralized and provide power through the grid or decentralized, i.e. in proximity of a mine with a direct power line to the mine. In the second case, the solar power plant would be part of a microgrid. Back-up diesel gensets or stationary energy storage such as batteries could also be a part of the microgrid which is also called solar-diesel hybrid power plant. In recent years, the te chnic a l fe asibi lit y of ele c t r icit y generation for mines through solar powered microgrids has been proven as well in large scale applications.18 Connecting the mining microgrid to the
national power grid might be advisable as diesel genset usage can be reduced considerably. In the microgrid, diesel gensets are very likely to be the generator with the highest dire c t costs and w it h t he big gest environmental impact. In the gridconnect microgrid scenario diesel generators provide only missing gap between the solar output and the load from the mine which is not available from the grid. is might be the case during loadshedding. e objective of the microgrid is to provide robust and stable power to the mine. Energy storage solutions, e.g. in the form of batteries, can further stabilizes the microgrid by shaving peak loads and providing peakpower. Critical processes are oen secured with UPS-system already today. Some manufacturers aim using the UPS storage system for the microgrid. e combination of microgrid and national power grid might also have additional advantages in the future. If the solar power plant generates more electricity than the
FMDZ |
mine consumers, the energy might be fed back into the grid. e decentralized microgrid solution ensures that the grid is utilized less by the mine. e current power crisis in Zambia presents a chance for solar energy. Many mining companies see the risk that arises from power outages and load shedding in form of higher energy costs or production losses. Electricity costs are expected to further raise in Zambia. Aer a long period of inexpensive energy from abundant hydro power the paradigms have changed in Zambia. Solar power can be installed extremely quickly and can contributed to save costs in comparison to power from e x p e ns ive b a c k - up d i e s e l ge ns e t s immediately. Energy costs advantages can be an important differentiator in the very competitive copper market which be characterized by supply surplus due to falling copper demand from China. More and more mining companies have a strategic look at energy.
Jan - Feb 2017
|
Page15
INNOVATION
De Beers unveils next generation diamond veri cation technology e De Beers International Institute of
PhosView.
maintaining trust in trade transactions.”
Diamond Grading & Research (IIDGR)
“e AMS2 is the most technologically-
e IIDGR was established by the De Beers
unveiled its next generation automated melee
advanced, efficient and cost-effective melee
Group of Companies to provide a premium
screening instrument - the AMS2.
diamond veri cation instrument available. Its
service and proprietary equipment to the
e AMS2 diamond veri cation instrument
industry-leading low referral rate has
diamond industry.
will provide diamantaires with a more efficient
signi cant economic bene ts to users, greatly
Based in the UK, Belgium and India, and run
and cost-effective diamond veri cation
reducing the need for additional and costly
by the world's top diamond experts, the
technology solution for melee-sized
secondary testing," said IIDGR president
IIDGR offers a range of expert services and
diamonds, De Beers announced in a statment
Jonathan Kendall.
works only on diamonds that meet the
this week.
“Con dence is everything in the diamond
requirements of the United Nations' mandated
Around ten times faster than its predecessor
sector and the AMS2 will play a big part in
World Diamond Council Kimberley Process.
and with a substantially reduced referral rate, the AMS2 has the ability to process smaller sizes and all shapes of polished diamonds. It will cost $45 000, which is cheaper than the rst generation AMS. Available from June 2017, the new device will be unveiled the International Diamond, Gem and Pearl Show in Hong Kong, taking place between 2 - 6 March. e AMS2 was developed by De Beers' inhouse research and development team, which also created the broader suite of diamond veri cation technology sold by IIDGR, including DiamondView, DiamondSure and
Page16
| Jan - Feb 2016
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www.auscoproducts.com
HEALTH & safety
Protect your noggin and avoid falling objects says expert Falling objects can deliver a hey blow to the head, resulting in injury or even death warns a safety authority. is is why WorkSafe is cracking down on companies that fail to control the risk of falling objects, with a round of almost 1000 inspections throughout the next three weeks. Top targets will be construction companies operating in the industrial, residential and commercial sectors. According to WorkSafe statistics, more than 860 construction workers have been injured since 2010 by falling objects. Injuries are commonly caused by falling building materials such as bricks, tiles, concrete and timber. WorkSafe says simple steps to avoid falling objects include securing loose building materials and tools at building sites, and could make the difference between life and death. “Each year WorkSafe investigates serious injuries and countless near-misses involving falling objects at construction sites,” WorkSafe health and safety executive director Marnie Williams says. “We know that even a small tool or a bolt
Page18
| Jan - Feb 2016
falling from a building site can cause lifethreatening injuries. at's why every builder must assess their site throughout the day and identify materials or objects that could fall in or outside of the site boundaries.” Materials placed close to the edge of an incomplete upper level or le unsecured pose a very high risk. “Materials that are blown from structures by
| FMDZ
wind or tools and equipment knocked or dropped from ledges not only pose a risk to workers but the general public in the streets below,” Williams says. “Any object, no matter how small, can be deadly if it falls from a height so builders need to const ant ly ass ess t he work b eing undertaken to ensure these kinds of materials are secured.”
www.us-tech.co.za
HEALTH & safety
Fatigue is inevitable. Incidents aren’t. Most Comprehensive Fatigue Risk Management System
dragged on, operators were increasingly
inattentive and impaired. Some even dozed o
in the driver's seat.
Tired, distracted machine operators are a
cause cannot be identi ed. Upon further
leading cause of accidents in the earth-moving
investigation, these same customers found the
world. e problem, rooted in human
scheduling demands of miners' 24/7
physiology, is insidious, cumulative and
operations were playing havoc with the sleep
complex. But the new fatigue and distraction
patterns of a small, but signi cant percentage
risk management solution from Caterpillar is
of their employees – including some of their
showing customers ways to mitigate the
most talented heavy equipment operators.
hazard – and proving that the company's
Many of those affected were having difficulty
commitment to innovation goes 'beyond the
synchronizing their internal clocks with job
iron.'
schedules that required them to work during
For years, some of our customers have been
the night and to sleep during the day. So they
puzzled over what they call “unexplained
weren't getting enough rest and were starting
incidents” — accidents where there is no
shis already fatigued. e effects were
apparent fault in the machine, and the root
Page20
| Jan - Feb 2016
insidious and cumulative, so as the work week
| FMDZ
“ese customers had tremendous risk that they didn't know how to address,” says David Edwards, Safety Technology Manager with Caterpillar Safety Services. “ey told us bluntly, 'We have operators falling asleep at the wheel in our big haul trucks.'” Traditional OEMs probably would have redirected the conversation towards selling more iron, but Caterpillars Safety Services instead responded to this challenge with a solution that combines technology and cultural development to help customers see, mitigate and manage fatigue on the job site. Because the underlying issue – the circadian rhythm – is hardwired into humans, the
health & SAFETY
problem of fatigue, particularly with night-
vulnerabilities and avoid them.
Fatigue Practice Manager. “It's a resource that
time work, cannot be eliminated entirely.
e Cat Driver Safety System (DSS) monitors
gives customers and their employees the facts
Caterpillar's fatigue solution, however, helps
second-by-second fatigue and distraction data
and data to make improvements to their
minimise its effects throughout jobsites.
using a non-intrusive in-cab camera with
processes.”
Bringing together the best anti-fatigue
patented eye and head tracking algorithms.
Caterpillar fatigue consultants and safety
technologies on the market with Caterpillar's
Able to detect operator fatigue and distraction
advisors work together to correlate data from
deep expertise in safety improvement and
in real-time, the DSS can immediately alert
the DSS, Smartband and FAST with machine
change management, the Fatigue Risk
an operator to signs of fatigue before an
telematics data, to produce a detailed
Management SystemTM gives customers a
incident occurs. e data is also viewed by
management report that clearly outlines the
comprehensive way to measure risk, mitigate
Caterpillar safety advisors in the 24/7 eet
scope of risk in operations. Armed with the
it and manage the hazard.
monitoring centre, who classify potential
details and facts the technologies provide,
fatigue events and will follow site speci c
Caterpillar consultants like Dawson work
e Fatigue Risk Management System:
incident response protocols, alerting job site
with customers to implement organisational
ree best-in-class technologies – brought
management if necessary.
changes needed to improve operators' tness
together in a unique suite by Caterpillar –
“To ensure a valid analysis and support the
for duty every time they climb into a cab.
form the front end of the Fatigue Risk
integrity of the process, each event is double-
We nd that the best results come from
Management System (FRMS).
classi ed, meaning it is reviewed by two safety
combining technology with people solutions.
e Cat® Smartband is a wrist-worn device
advisors before a call is made to the site,” says
So, along with on-site manager workshops
that tracks mental fatigue in real time and
Danielle Mackie, safety monitoring
that increase customers' awareness of fatigue
provides visibility to sleep quantity and
supervisor.
and distraction and help them build their
quality, on and off the jobsite.
e point is not to implicate operators, but to
overall safety culture, Caterpillar uses digital
e Fatigue Avoidance Scheduling Tool
increase everyone's visibility of a naturally
analytics to pinpoint and quantify trouble
(FAST), helps organisations model different
occurring risk. “It's not a punitive tool,” says
areas. en, empowered with the data, we help
shi schedules to determine fatigue
Todd Dawson, A Caterpillar Safety Services
our customers see, mitigate and manage risk.
FMDZ |
Jan - Feb 2017
|
Page21
tormac@tormacpumps.com
www.tormacpumps.com
HEALTH & safety
Collision Warning Systems in mining An average of 13 mine workers are killed each
Radar Systems
re ected energy.
year by being run over or pinned by mobile
Radar technology is one of the most
e technology is well suited to collision
mining equipment. At surface mines, these
established methods of obstacle detection.
avoidance applications because it is not
accidents commonly involve large dump
Many types of radar are used in collision
affected by rain, snow, dust, or even a
trucks that drive over a smaller vehicle or a
warning systems, including pulsed or
moderate buildup of mud on the antennas.
person that is in the dump truck's blind spot.
ultrawide-band, Doppler, and frequency-
Many collision warning systems are based on
A collision warning system consists of some
modulated continuous wave (FMCW).
radar technology. e systems consist of a
type of sensor that detects the presence of an
Some of the newer systems for highway
radar antenna(s), processing electronics, and
object, an interface that provides an audible
applications operate at even higher
an operator interface or alarm display.
and/or visual alarm to the equipment
frequencies. A radar system operates by
e radar unit is mounted on the vehicle and
operator, and wiring between the two.
emitting electromagnetic energy and
directed toward the area to be monitored. If
Potential sensor technologies include
detecting this energy when it is re ected from
an object of sufficient cross sectional area is
ultrasonic echo detection, infrared re ection,
an object or target. Information about the
within the beam pattern of the radar antenna,
radar (radio detection and ranging), video
target, such as range and direction of
the signal is re ected to the unit and is
cameras, and radio-frequency identi cation
movement, can be acquired by analysing this
processed. If certain criteria are met, an alarm
(RFID) systems.
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| Jan - Feb 2016
| FMDZ
health & SAFETY
is generated. e type of alarm varies with the
be provided as long as the detected object is
antennas. However, radio signals can be
type of display.
not immediately next to the antennas. Systems
affected by interference from multipath effects
e most common type of radar used in
using this type of radar can sense the presence
and other radio signal sources.
collision warning systems employs Doppler
of an object whether there is relative motion
ere are two types of tags: passive and active.
shi detection. ese systems only detect
or not.
For passive tags, the tag reader constantly
Radio-frequency Identi cation Systems
within range. e tag then answers with a
transmits a signal that activates a tag if it is
relative movement of objects by sensing a frequency shi in the re ected signal. For the system to activate an alarm, either the object within the transmitted beam
Several companies have applied RFID systems
unique signal that is detected by the tag
to the collision avoidance problem. e
reader.
pattern must move toward the stationary
systems typically consist of a tag reader, tags,
e advantages of passive tags are that there is
vehicle, or the vehicle must move toward the
and an operator interface or alarm display.
no requirement for external power, they need
object. If both object and vehicle are not
e tag reader detects radio transmissions
little maintenance, and they are very
moving, no alarm is activated.
from a tag if the tag is within its reading
inexpensive. e disadvantage is that they
is has the advantage of providing alarms
range.
oen have a more limited reading range than
only when a vehicle is moving and a collision
e tag reader is mounted on the mine
active tags. With active tags, the reader can be
is imminent. However, it has the disadvantage
equipment, while tags are mounted on any
passive and just listen for the unique
of not providing an alarm that allows
item that is to be avoided. ese items can
transmissions from the tag.
sufficient time to stop if a stationary object is
include other vehicles, pedestrian workers,
e disadvantages include the need for
very close to a vehicle that starts moving.
power and utility poles, or even a building.
batteries and increased cost and size when
Other types of radar, such as FMCW, can be
e small cost and small size of most tags
compared to passive tags. If a reader detects a
con gured to operate in this manner also.
allows them to be mounted on hard hats,
tag within its reading range, signal processing
Pulsed radar is also used for collision warning
personnel belts, or anywhere on the exterior
soware analyses the signal to determine
systems. Because of the pulsed nature of the
of a vehicle. e nature of radio-frequency
signal strength and integrity. If the acquired
output signal, the average power output by the
signals makes this technology ideal for harsh
signal meets alarm criteria, then an audible
radar is extremely low (microwatts). Also,
environments because radio transmissions are
and/or visual alarm is indicated at the alarm
time of ight for the re ected signal is easily
not adversely affected by harsh weather, dust,
display. e alarm thus warns an operator that
measured, and accurate range information can
or moderate amounts of mud buildup on the
a tag is in proximity to the equipment.
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Jan - Feb 2017
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Page25
PROJECTS
World’s largest acid mine drainage plant in SA to relieve water crisis e Gauteng government is hoping to relieve
its kind in the world, with the capacity to clean
treated, it is released into nearby water sources‚
the province's water supply tensions with the
110 megalitres of a water a day, and send the
such as wetlands‚ streams and dams.
opening of a new acid mine drainage (AMD)
water back into the Vaal River system.
“e problem of acid mine drainage cannot be
plant in Springs, outside of Johannesburg.
e polluted water is extracted from the mine
le unattended. It has persisted for centuries
Minister of Water and Sanitation, Nomvula
void in the region and sent to the three
and we have taken steps to address the
Mokonyane has opened the Eastern Basin Acid
treatment plants. Once the water has been
challenge‚” Mokonyane said.
Mine Drainage Treatment plant, which is the third high-density sludge treatment plant in the Province that will help secure water for the next 30 years. “By producing fully treated water that will signi cantly increase water supply to the Vaal River System, the opening of the Springs AMD plant will respond to the pollution of freshwater, and stop polluted mine water from reaching a certain level below the surface‚ which affects the country's water sources.” said Mokonyane e two other operational plants are the Central Basin in Germiston‚ and the Western Basin in Krugersdorp, which have been operational for a few years. e pricey but lasting solutions are said to have cost the country an estimated R10 billion to R12 billion, as the province and country intensify their water saving efforts. Mokonyane has said that e Eastern Basin is the largest of the three plants and the largest of
Page26
| Jan - Feb 2016
e minister of Water and Sanitation, Nomvula Mokonyane, at the launch of the Eastern Acid Mine Drainage Treatment Plant in Springs
| FMDZ
www.copperzone-resources.com
csrome@copperzone-resources.com
PRODUCTS & services
More digitalised underground drilling rollout Working within budget and on time is the envy of every mine operator and Sandvik Mining and Rock Technology continues to facilitate such results with its technologies. e company recently upgraded its digitalized underground drilling to improve drilling accuracy, cycle times and reduce operation costs. e new system offers accurate visual information an improvement to the mining process. With ten years on the market, Sandvik AutoMine has been used by numerous underground mines. Now customers are able to signi cantly upgrade through the new intelligent rigs, led by Sandvik DD422i development jumbo, which include long hole drills and bolters. In addition, new 3D scanning technology makes drilling and bolting more efficient by bringing in new tools and methods for continuous quality control. On the other hand blasting quality, overbreak and underbreak analyses together with continuous mine mapping increase overall drill and blast process efficiency signi cantly. e new equipment is supported by the Sandvik OptiMine information management platform which provides a powerful tool for creating a true transparency and integration of
Page28
| Jan - Feb 2016
underground mining operations. Over the years, Sandvik has successfully delivered highly automated underground drilling systems for selected customers for many years. “e company is now busy nalising the commercialisation of these offerings into global markets. is will bring Sandvik AutoMine-type tele-remote capabilities into new underground mining applications, including long hole and development drilling.” e company assures customers of data driven productivity now that Sandvik underground drilling equipment is fully compatible with Sandvik OptiMine
| FMDZ
monitoring. “e connectivity comes standard for new equipment but retro t kits are also available for existing equipment out in the eld.” Scalable Sandvik automation solutions allow customers to choose the level of automatisation they're ready for, starting with tele-remotely controlled operation through to full eet automated operation. According Sandvik customers are assured that the equipment if used efficiently, the results meet the most demanding production requirements. As a result of wide range of automation options built into Sandvik drill rigs and bolters.
products & SERVICES
Volvo’s 55 tonne articulated hauler for off-road applications When it comes to hauling huge loads off-road in
and tested throughout the Volvo ADT range.
short orientation course will be needed,” says
mining and quarrying environments, the large
As the biggest articulated dump truck in the
David Vaughan director: Equipment, Babcock.
Volvo A60H articulated dump truck is a
world, the A60Hoffers stability, comfort and
Babcock will introduce the new articulated
popular solution.
high hauling speeds, despite its size. ese
dump truck into the Southern African market
It offers various features, including a lower cost-
features are underpinned by the matched
early in the new year.
per-tonne ratio, fuel efficiency, and increased
drivetrain, automatic drive combinations, all-
Vaughan adds that technicians who regularly
production.
terrain bogie system, hydro-mechanical
service other Volvo haulers will have knowledge
e A60H has a 55 tonne payload and is
steering, on board weighing system and active
of many of its elements.
equipped with a 33,6 m3 bin thereby increasing
suspension thus optimising production and
“Similar elements include a front grill that
production and lowering the cost per tonne
minimising operational costs.
swings down, opening up a service platform
ratio.
As the A60H shares similar features with the
with anti-slip steps, and an electric hood that
Although the A60H is a substantial step up
A40, no major operator training will be
opens to 90 degrees, allowing full and safe
regarding size when compared to the A40 it
necessary. “It will be an easy transition for
access to the engine compartment,” explains
shares a number of typical features already tried
operators familiar with the A40, and only a
Vaughan.
FMDZ |
Jan - Feb 2017
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Page29
PRODUCTS & services
Integrated Pump Rental responds to client’s emergency efficiently Integrated Pump Rental efficiently delivers a
eet covering all needs, with the requisite
units, for example, are ideal for dredging and
rental service around the clock to the standards
technical support for installing and
cleaning water capture areas where silt or slimes
that customers requires, says MD Lee Vine.
commissioning on site as a vital part of the
are encountered, while the SlurryBlaster hydro-
“Actually delivering a rental service all day,
service and support offering.
mining equipment offers optimum
every day, to the standards that the customer
Integrated Pump Rental provides turnkey
performance coupled with reliability.
needs, is the core of our business model,” Vine
pumping solutions for small, medium-sized
A recent addition to the rental range is the Sykes
notes. “When a customer is in dire need, with a
and large projects, ensuring that each project is
diesel-driven pump, suitable for all applications
dewatering problem for instance, they need a
carefully assessed to ensure the appropriate
where electrical power is not available; these
quick turnaround time with the right product
response.
reliable pumps are engineered to offer market
available. is is what we do."
“While we do have off-the-shelf options
leading efficiency and are extremely robust.
He says the reality is that customers are in
available for rent, our approach is to understand
Vine says that Integrated Pump Rental secured
operation 24/7 and there are not many rental
the customer's needs and then recommend a
the agency for Sykes for southern Africa and all
companies that can assist on this basis. Vine cites a recent case of a surface coal mine
t-for-purpose solution,” says Vine. “It is not a
Sykes products are available for either sale or
case of one-pump- ts-all when it comes to the
rental. is includes diesel and electric driven
customer urgently needing to dewater a large
type of pumping environment in which we
self-priming units.
section of the pit.
operate.”
Pump and hose otation devices and custom
installation of nine diesel pumps with 2 000 m of
Pump eet at a glance
available for all pumping applications.
lay- at hose, including ttings,” he says. “e
Integrated Pump Rental's
eet includes
Industries across Africa served by Integrated
call came in at 2 pm on a Saturday; by the early
submersible drainage and dewatering pumps,
Pump Rental include mining, quarrying,
hours of Sunday morning, the installation had
slurry and sludge pumps, diesel-driven pumps,
construction, wastewater and energy.
“e requirement was for the supply and
engineered automation systems are also
been completed and our customer was more
dre dg ing units,
ot at ion de v ices and
“Our pumping solutions are engineered to deal
than satis ed.”
accessories. All pump rental solutions available
with the harsh operating conditions on the
He highlights the accessibility of equipment as
from Integrated Pump Rental are ISO 9001
continent and options include short-term,
key to the success of Integrated Pump Rental.
certi ed.
medium-term and long-term turnkey rentals,”
e company maintains a comprehensive rental
e locally manufactured SlurrySucker Dredge
says Vine.
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| Jan - Feb 2016
| FMDZ
products & SERVICES
New dust monitoring tool to reduce contaminant burden on communities A new tool for monitoring and analysing dust plumes – particularly those containing potentially harmful contaminants – will improve our understanding of, and help reduce, the impacts on affected communities. Research con rming the effectiveness of the Coherent Doppler Lidar system has been published by the Cooperative Research Centre for Contamination Assessment and Remediation of the Environment (CRC CARE). e study, performed in collaboration with Curtin University, trialled the Lidar (short for Light Detection and Ranging; also known as 'laser radar') in Port Hedland, which has a history of high dust levels related to the loading of bulk commodities for export and mining activities. Project leader John Sutton, now with Aeolius Wind Systems, says that the Lidar system allows real-time monitoring of dust emissions and wind elds. “is information can be used to identify dust emission sources, track dust plumes, provide insight into the way wind transports
Page32
| Jan - Feb 2016
dust, and determine community exposure,” Mr Sutton said. “In shor t, t he system a l lows b etter management of contaminant plumes, which in turn helps to reduce impacts on communities.” e technology can be used at ports and mine sites for routine monitoring, health risk and occupational safety studies, validation of modelling, and evaluation of dust mitigation strategies. Mr Sutton says that the new system has numerous advantages over both modelling and traditional point monitoring. “By allowing real-time measurement of contaminant plumes, Lidar gives us an idea of what's happening in the real world,” he said. “It provides information about the source and shape of contaminant plumes, and the concentrations of contaminant particles – and therefore information on who is being or will be affected.” M r S u t t o n s a y s t h at t h e r e a l - t i m e information helps environmental managers
| FMDZ
make better decisions, including identifying the location of a plume source and how best to dampen it, as well as the effectiveness of the dampening. is gives industry an objective idea of how well its abatement strategies are working. “is sort of capability simply isn't possible with traditional point monitoring, which may gather data from three or four monitoring points,” Mr Sutton said. “e Lidar system effectively measures thousands of points and, what's more, it works over a large area of up to 300 km2.” According to CRC CARE Managing Director Professor Ravi Naidu, the Lidar system offers an excellent example of why the Commonwealth Government established the CRC Program – to develop better tools for industry. “is is a new, improved technology that provides unique capability for identifying industrial dust plumes,” Professor Naidu said. “In turn, this shines a light on pathways for reducing impacts on local communities.”
www.tammermatic.com
www.tammermatic.com
Liing mechanisms in mines- Hoists Hoist by de nition means to haul or to raise
TYPES OF HOIST
an object to higher altitudes. Hoists are
e hoists can be classi ed based on the
mechanical or electromechanical devices used
liing medium, and the source of powering
industries. 3.
Pneumatic: e powering of these hoists is through pneumatic
to move an object from one point to another,
the hoist.
medium. Compressed air is used to
which would be otherwise physically
Liing medium:
run the motor or the engine to
challenging. e object can be raised, lowered
Manual: e load is hoisted using
deliver a liing torque. ese hoists
or moved depending on the necessity. e
1.
manual operation. It is the oldest
have an advantage of being lighter,
hoist work on the basic principle of balance of
type of hoist where humans, and
safer and use less energy to do the
forces where an equal and opposite force is
animals where used to haul the
same task.
applied on the load force. e applied force
loads. Such schemes where used
can be reduced by using a pulley system.
during ancient period for the
Powering source:
e hoist technology is believed to originate
construction of buildings.
Chain: Utilizes link or roller chain as its liing
from the lever system where a large force can
Nowadays these hoists are used to
medium.
be countered using small force by proper
li light loads.
Wire rope: Utilizes wire rope as the liing
placement of the fulcrum. e block and tackle pulley invented by Archimedes allowed
2.
Electric: Electric power is used to
medium
hoist the load. is technology
Strap: Utilizes polyester or nylon straps as the liing medium
sailors to move heavy objects with ease that
overtook the manual operation
would otherwise be very difficult. is
during the industrial development.
e hoist can be further classi ed into drum,
invention is considered as a precursor to the
Such hoists are faster and more
friction, and Blair multi-rope type.
modern hoist technology.
powerful and thus forms a huge percentage of the hoists used in the
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| Jan - Feb 2016
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Drum type:
In Drum type hoisting devices, the liing
Single drum hoists are found to be more
gears and pulleys. Developed by Frederick
medium is continuously wrapped around a
efficient than double drum hoists for most of
Koepe in 1877, the liing medium is not
drum. Unlike the friction type where the load
the applications.
wound on a drum, and hence multiple hoists
Friction (Koepe) type
require more routine maintenance than drum
can be used near to each other. Friction hoists
is directly hoisted from the top, in drum type hoist the pulling mechanism is connected to a drum, which is to the other side of load across
Unlike drum hoists, friction hoists are
hoists and are not suitable for hoisting from
the headframe and sheaves. e headframe
economic options for shallow shas. ey are
multiple loading pockets on different horizons
and sheaves are required to center the hoisting
mounted right above the mine sha or at the
within a sha.
medium in the sha compartment. Drum
top of headframe, thus requiring less space
hoists are the most common hoists used in
than drum hoists. e liing medium is
Blair multi-rope type
North America, South Africa and South
passed over a pulley with the load connected
e Blair multi-rope hoist system is used for
America. ey also require the least amount of
to the one end of the liing medium. e
accessing much deeper mines and can be
maintenance among all hoist types.
friction between the pulley and the liing
found in many of the world's deeper mines,
medium aids the hoisting. e friction
such as in South Africa. One of the mines that
Single drum: In a single drum hoist, a rope is
between the pulley and the liing medium
use this type is the Moab Khotsong Mine
attached to a drum and wound and is used to
prevents the load from sliding in the opposite
where it is used up to 3,150m. It has a capacity
hoist the load through an overhead pulley.
direction when the weight is pulled up using
to access a depth of up to 5,000m.
www.bmgworld.net
EMBRACING tech
Gas Sensing Technology Improves Mine Safety Gas in Mines: an Omnipresent Hazard An underground mine is an inhospitable place in which to work. Gas poisoning and explosion is a major hazard, with many different types of gas commonly present in mines. Black damp, a mixture of carbon dioxide and nitrogen, is formed as the result of corrosion in enclosed spaces so removing oxygen from the atmosphere and potentially causing suffocation. Fire damp mainly consists of methane, a highly ammable gas that explodes at concentrations between 5% and 15% or, if it does not explode, at 25% concentration it causes asphyxiation. Methane ignition can trigger the much more dangerous coal dust explosions because the shock wave raises coal dust from the oor of the mine galleries to make an explosive mixture that is highly susceptible to spontaneous combustion. Stink damp, so called because of the rotten egg smell of the hydrogen sulphide gas, can explode and is also very toxic. Carbon monoxide, toxic even at low concentrations, is another major hazard. Gas sensors are the critical operating
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component of all gas detection instruments. ey transform a gaseous concentration, typically measured in ppm, into a change in electrical voltage or current that provides a reliable, stable and repeatable input for the detection instrument. With so many different gaseous hazards potentially present, effective gas detection is critical in protecting life and equipment underground. Apart from gas-related hazards, underground mining dangers include suffocation, gas poisoning, roof collapse and gas explosions, while open cut hazards are principally mine wall failures and vehicle collisions. Most risks are greatly reduced in modern mines, and multiple fatality incidents are now rare in most parts of the developed world. However, according to the Bureau of Labour Statistics, mining remains the second most dangerous occupation in America, with 30 deaths in a typical year due to mine accidents. e Bene cial Impact of Modern Technology on Fatality Rates Modern technology employed in mines
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throughout the developed world, has dramatically improved safety. Improvements in mining methods such as automated longwall mining, effective hazardous gas monitoring, gas drainage, better electrical equipment and improved ventilation have reduced many of the risks of rock falls, explosions, and unhealthy air quality. In less developed and developing countries, many more miners continue to die annually, either directly as the result of accidents in mines, or indirectly as the result of illnesses contracted from working under poor conditions. e C h a l l e n g e s Fa c i n g G a s S e n s o r Manufacturers In deep coalmines, extreme temperature changes, rapid humidity variations and signi cant pressure changes are experienced as miners travel down from the surface. In both deep and open cast coal mines methane gas is an ever-present hazard. Speci c regional issues are a further complication, for example, in South African mines, hydrogen cross-
sensitivity is a particular concern. Super cially, a gas sensor might appear to the untrained eye to be no more than a simple small cylinder, 20mm in diameter and 17mm high, with two or three electrodes. In fact, nothing could be further from the truth. Such an unremarkable looking component is the operating heart of all gas detection equipment, which saves countless lives and prevents damage to property worth billions of dollars. Oxygen Sensors Gas sensors are in fact complex pieces of equipment: 4OXV, the new oxygen sensor, is constructed from more than 20 individual components, which are manufactured to exceedingly tight tolerances and assembled to create the nished product on an automated assembly and test line. As an example of the technology behind the design of gas sensors, consider the 4OXV oxygen sensor that is used in portable gas detectors in mines. Humidity changes are another signi cant cause of false alarms. 4OXV features an integrated moisture protection membrane to prevent the ingress of humid air into the chamber. e implications in the mining environment are self-evident.
Bump testing for personal gas detection equipment, in which the instrument is exposed to its target gas to check for correct operation, would normally take place on the surface. Descending in high speed lis to the working levels will result in rapid increases in temperature and humidity, potentially causing the instrument to false alarm, with a consequent loss of time and con dence while the issue is sorted out. Instruments tted with 4OXV do not suffer from such issues, improving efficiency and reducing down time. Carbon Monoxide Sensors “Speed is of the essence”. A truism applied to many different situations, but a statement that is arguably critical in mining life safety applications, where delay can literally prove to be fatal. Carbon monoxide, a colourless, odourless, tasteless, and initially nonirritating gas is very difficult for people to detect. Exposure to 100 ppm or greater can be dangerous to human health, and as the symptoms of mild exposure include lightheadedness and confusion, while larger exposures can lead to death, the provision of
an effective CO detector is an imperative for personnel who may encounter it during the course of their work. CO is commonly found in mines, so a fast and effective CO detector is an essential piece of equipment. e Future Without doubt, today's sophisticated gas detection technology has saved many lives in what is still one of the world's most dangerous industries. Gas detection instrument manufacturers typically rely on gas sensors from specialist manufacturers. Ty pi c a l l y b a s e d on e l e c t ro c h e m i c a l technology, the characteristics of the gas sensor itself determine, to a great extent, the instrument's performance and reliability in use. To offer their users reduced lifetime cost of ownership, enhanced performance and features that improve the functionality, reliability and effectiveness of personal and xed gas detection, OEMs require the gas sensor manufacturers to innovate sensors that have better stability, greater resistance to cross-contamination, longer life and faster response.
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Shredding light on the mine site Proper design of haul road lighting systems is essential to the efficient and safe operation of an open cut mine. At a surface mine covering many square kilometres of land; where work is carried out round the clock; systematic arti cial lighting is necessary in order to provide a safe and efficient working environment. Haul roads within the pit are one of the most critical areas for lighting at an open cut mine. One of the most important issues is that haul road lighting installations are not permanent due to regular advancement of the working face. Another major problem is dark surroundings and low surface re ectance. Due to these reasons it is very difficult to maintain lighting standards speci ed by various regulatory bodies. A good lighting system is one which can distribute an appropriate amount of light evenly with uniformity values from 0.25 to 0.40 and with a colour rendering index of at least 60. Good lighting will use energy efficient lamps in suitable luminaries. Mine safety guidelines suggest a minimum
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horizontal illuminance level of 0.5 lux in haul roads however in reality uniformity ratio is also essential in the design of illumination systems for uniform distribution of light and to provide sufficient illumination for visual tasks. In these conditions, the use of compact uorescent lamps (CFL) with a stand-alone lighting system is perfectly acceptable. Standalone photovoltaic lighting systems provide exibility for changing the location of poles according to changes to surface mine haul roads. However CFL's electrical requirements are not easily met by hard-switched inverters due to higher switching losses at higher frequencies. e difficulty in meeting the complex electrical requirements, such as preheat and ignition voltage of CFL, results in lower efficiency. In order to make a successful photovoltaic lighting system, the rst step is to select a well-suited high-frequency inverter and a series interrupting type charge controller for producing good light while maintaining reliability.
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PRINCIPLES OF HAUL ROAD LIGHTING MOUNTING HEIGHT Luminaire mounting height depends on the lighting arrangement and effective road width. e effective width is the horizontal distance between the luminaire and the far curb. To achieve a good distribution of light across the roadway, mounting height in general is kept equal to the road width or around it. SPACING Luminaire or pole spacing for a given lighting arrangement and luminaire light distribution is dependent on the mounting height and the longitudinal uniformity planned for the installation. e greater the mounting height, the larger can be the spacing for a given longitudinal uniformity. Longitudinal uniformity is the ratio of minimum to maximum illuminance along a line parallel to the road axis through the observer's position. However, in practice, excellent illumination is considered to be
when pole spacing is not more than 8 times the mounting height. OVERHANG Poles are generally installed somewhat off-set from the road edge (curb) to provide clearance to the vehicle. Luminaire is mounted on the ranging arm to adjust the distance between it and the curb. Sometimes, projection of the luminaire lies inside the road from the curb, which is known as overhang. e main purpose of overhang is to provide better uniformity of light across the road. INCLINATION Inclining or tilting the luminaires up from the horizontal is done to increase light coverage across the road width at a given mounting height. However too much tilting will diffuse the light and reduce its distribution along the longitudinal direction of the road. It is recommended that the angle of tilt, with respect to the normal height of mounting, be
limited to an absolute maximum of 10°, a top limit of 5° being preferable. In general the angle varies from 10° to 15°. UNIFORMITY e even and uniform distribution of light across the area being illuminated is known as uniformity. It is represented on lighting plans by the symbol UO and is a ratio of the minimum illuminance level to the average illuminance level. A UO value of 0.4 or 40% is recommended to ensure that lighting installations do not create dark patches next to lighter patches. e evenness of light distribution is almost always more important than the levels of illumination being achieved by the system. COLOUR RENDERING Colour rendering indicates the extent to which a light source is capable of making objects appear their true colour. Colour rendering is determined by the spectral power
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distribution or spectrum of the light source. e colour rendering ability of lamps is measured on the Colour Rendering Index (CRI) or Ra scale. e scale varies from 0 to 100, where poor colour rendering lamps have lower values while good colour rendering lamps have high values. One hundred is as good as a black body radiator of the same colour temperature. Conclusion Lamp selection should be made mainly based on efficacy and suitability to each situation. A series parallel resonant mode sine wave inverter is well suited for meeting a compact uorescent lamp's complex characteristics. To ensure uniform light output throughout the operating voltage range on input DC battery voltage variation from full charge voltage to lower charge limit voltage, inverter frequency will change automatically by voltage to frequency converter, towards the resonant frequency.
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