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1 MINING Central Africa’s Premier Business To Business Mining magazine July-Aug 2016 > Issue 19 > Vol.7 #
DRC-ZAMBIA African Trade Bludgeoned By Rubber Stamps -5
How to unlock mining investment in Zambia -8
ALSO... Endress+Hauser shows you how to work smarter, not harder! 36 F MD R C - Z A MB I A
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www.fmdrc-zambia.com
Contents MINES & MINERALS
28
IVANHOE MINES’ Kamoa & Kakula greatest copper discoveries
FEATURED DEVELOPMENTS
HI TECH
36
MICROPILOT FMR5 Work smarter
INNOVATION
06 The key economics of the mining industry 10 800 plus exhibitors at Electra Mining 2016 19 New generation crane girder revolutionises load handling 35 Universal Mining invests K70bn in iron ore plant 41 Sentinal Mine - a game changer
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INNOVATIVE Lock-out hazards to prevent accidents July - Aug 2016
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FROM THE EDITOR 1st MINING Central Africa’s Premier Business To Business Mining magazine July-Aug 2016 > Issue 19 > Vol.7 #
e mining and resources industries affect all of our lives: From the cars we drive, to the cell phones we use, the utensils we eat with, and the money we spend – all rely on the extraction of valuable minerals, metals and resources from the earth. Today there are literally thousands of mines operating worldwide, extracting the stuff we use to make practically every product on earth. st We welcome our readers to yet another exciting edition of 1 Mining DRC-ZAMBIA, where we strive to bring fresh news from the industry in order to remain relevant. e mining industry continues to face a host of unresolved challenges from tumbling demand and declining grades to mounting stakeholder expectations and a lack of nancing. At the same time, miners must content with a range of constantly mutable issues including the innovation imperative, and shiing regulations. Operation excellence remains at the forefront of mine productivity and industry leaders are involved in a continued investment and innovation. We feature the Mineware Syncromine system. e Syncromine places all business tools in one easy to nd interface. In the case of mines, these tools include production, safety monitoring, bonus calculation, ore accounting and costing soware modules. As part of a programme planned to eventually overhaul and boost output from a total of three hydropower plants, Ivanhoe Mines has begun supplying electricity from the rst of three hydropower plants that it is upgrading in the Democratic Republic of Congo. Other in depth stories include: How to unlock mining investment in Zambia? Electra Mining, e key economics of mining etc. Remember to visit our online portal www.fmdrc-zambia.com.
DRC-ZAMBIA African Trade Bludgeoned By Rubber Stamps -5
How to unlock mining investment in Zambia -8
ALSO... Endress+Hauser shows you how to work smarter, not harder! 36 F MD R C - Z A MB I A
19
www.fmdrc-zambia.com
Cover M & R Cementation At Lubambe
Editor Bertha M. editor@fmdrc-zambia.com
Contributing Writers Anne Thomas, Mfuneko Jack, Lindani Mkhize and Caroline Thomas
Bertha M.
Sales & Marketing
Editor
Russou Billiard sales@fmdrc-zambia.com +27 11 044 8986
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
info@fmdrc-zambia.com +27 11 044 8985
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MINING NEWS
African Trade Bludgeoned By Rubber Stamps
In Competitive Global Mining, It Is Essential To Cross Borders In A Fast And Efficient Manner, But Alas, Most Of Bureaucracy Does Not Support African Business. Despite growing importance of intra-Africa trade, on transport routes that have for many centuries been key drivers of economic development and growth, these arteries are usually blocked, slowing African trade to a trickle. Border posts have even stopped some trader commodities entirely. From a mining viewpoint, if a primary crusher has a breakdown, and spares are on the way, inordinate delays at border crossings could cost miners dearly. Beit Bridge; 48 Hours Beit Bridge border post is the SADC region's busiest. It links South Africa and its largest African trading partner, Zimbabwe. It is also the conduit for goods moving further north, to Zambia, Malawi, Tanzania, Kenya and Uganda. Some 1500 trucks pass these gates each day. Clearing customs on the South African side is quick and easy, as documents could be completed prior to setting off, and goods are then pre-cleared. However the Zimbabwe side can be a nightmare. ere are frequent power outages, computer systems are oen down despite power, officials are unhelpful and inefficient. e average time for a truck to clear both sides of the border is 48 hours. Sa To Moz Via Lebombo Lebombo is a very busy border post between South Africa and Mozambique, supposed to be the forerunner of a Maputo Corridor deal. Large sums were spent in
upgrading N4 toll road, rail links, bridges and transport logistics. However the border post is still lagging development of the corridor. On average, 6600 vehicles pass through this border every day, of which over 1000 are trucks. e plan to convert this into a one stop border post is still 'under implementation', despite 2009 being the nalization target date. Part of the problem lies in getting officials, through various trade unions, to keep the border open for longer hours. Only recently have opening hours been extended from 12 hours per day to 16 hours. On the SA side, goods are not cleared at the Lebombo border post, but 4km in, on the N4 highway, in a facility built in 1998 at an old airport, and still named 'Airport'. Commercial traffic is inspected in Komatipoort. is facility and its operations have improved, thanks to provision of more infrastructure for commercial processes and to the shi of cargo processing to these facilities. e commercial facility has an area for clearing agents and facilities for many people crossing the border, contributed to decongestion at the border post. Zambia To Drc Via Kasumbelesa; 3 Days Plus e border post between the Zambian Copperbelt and the Democratic Republic of the Congo (DRC), has oen been in the news for the wrong reasons. It is a key entry point f o r m i n i n g e q u i p m e nt , s p a r e s a n d consumables to copper and cobalt mines in DRC. Likewise it is a key exit point for copper, cobalt and concentrates to various
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Southern African ports. In September 2009 year, trucks queued for up to 5km before the gate, and crossing time was 12 days to 20 days. Currently it takes 3 days to clear both sides. Ad hoc government action from DRC side, and inefficiency of officials, could oen push this out to 8 days or 10 days. Corruption is rife, power supply intermittent, and systems oen not functional. Logistical Illogic Truckers and freight forwarders say the SA sides are not the problem. Goods can be cleared before departure, and electronic document interchange (EDI) is accepted by SA customs authorities. Officials are reasonably efficient, and corruption is not a major problem. However at borders of other countries, the picture is bleak. ere is no single administrative document to clear customs, and EDI systems are not working. Border posts are not open around the clock, roads are narrow, there is insufficient parking for trucks. Officials are corrupt, inefficient and unhelpful, aided by power outages and systems failures. Delivery times could not be given with any degree of certainty. Hot Collars Intra Africa trade is at the mercy of a few rubber stamps and back pockets. Suppliers, customers, freight forwarders, logistics agents, and the South African government, should exert signi cant pressure on African neighbours to open their borders for longer hours, x their systems, use electronic clearance methods, upgrade their border officials, and allow Africa to live, instead of suffocating the goose that lays golden eggs.
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MINING NEWS
e key economics of the mining industry Mining involves the identi cation and extraction of valuable minerals from the earth. Mined products include precious metals such as gold, silver and platinum; industrial metals such as copper, nickel and iron; food and agricultural minerals such as potash, phosphate and salt and other materials such as coal, gravel and sand. Exploration Drilling Helps To De ne e Scope And Quality Of Mineral Resources. Exploring to identify mineral resources is the rst step in a mining project. Geologists – specially trained scientists who are familiar with the properties of materials that make up the earth, including those of mineral containing rocks – help to identify locations that have the potential to contain large mineral deposits. Soil and rock samples from a promising location are tested in special labs to verify the composition and concentration of desired minerals. When results are encouraging, exploration drilling is undertaken to unearth more information about the potential size and quality of the mineral deposit. Exploration drilling penetrates the earth at depth in order to extract a core that can be analysed for mineral properties. e drilling process can be long and costly. Drilling equipment is expensive and requires
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highly skilled operators. Because of the high cost involved, exploration drilling is usually conducted in stages. e initial stage is focussed on obtaining information on mineral containing deposits over a broad area. In order to cover a broad area at a minimum cost, there are usually large gaps between exploration drilling points at the initial stage. When results are encouraging, more capital is allocated for drilling at tighter distances. Further drilling activity is concentrated on speci c locations that show the greatest mineral potential. Drilling at tighter distances helps to create a better understanding of the structure and quality of the mineral containing ore body under the earth. e exploration process can take up to several years to complete. Depending on the size of the prospective area and the level of detail required, the cost of exploration drilling can range from tens of millions of dollars to several hundred million. e construction and development of a mine is a highly capital intensive venture that is unlikely to go ahead without in-depth information about the quality and scale of recoverable mineral resources. e analysis of drilled rock and soil samples helps to provide an estimate of mineral resources contained in a deposit. e resource statement also provides
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information about the quality of the mineral deposit. e quality largely depends on the grade or concentration of minerals. For example, a good iron ore deposit may contain 60% iron content and a good gold deposit may contain 5 grams per ton of ore (i.e. 5g per 1,000,000g of ore). e resource statement is a scienti c best guess of the size and quality of a mineral deposit. is is because it is not economically feasible or practical to drill every inch of the prospective area in order to obtain more complete mineral information. e lack of complete information means that there may be surprises about the properties of the deposit that can only be uncovered when actual mining activity begins. e Commercial Viability Of Mines. When Does It Make Economic Sense To Exploit Mineral Resources? When the exploration process yields adequate resources of desirable quality, a feasibility study is undertaken to decide on whether building a mine to extract the mineral would be commercially viable. Feasibility studies involve deciding on the appropriate mining technology (based on the properties of the mineral deposit) and estimating the cost associated with constructing a mine and providing all the
MINING NEWS necessary infrastructure. e feasibility study would also estimate the production pro le (a schedule of annual mineral production), as well as, the cost of production over the projected life of the mine. For a mining project to be commercially viable or economically attractive for investors, it has to generate sufficient cash ows to pay an attractive return on the large amounts of capital required to build and operate a mine. Mine construction together with the installation of associated infrastructure is the most capital intensive phase of a mining project. e cost of developing a mine depends on the size of the resource, the annual production target, accessibility (remoteness and depth) of the mineral deposit, access to electricity and water and costs associated with transporting products to end markets. Depending on these factors, the total cost of developing a mine could range from tens of millions of dollars to several billion. Due to the high cost of developing and extracting mineral resources, it may not be economically viable to exploit all large and high grade mineral deposits. For example, in traditional gold mining countries such as Australia, Ghana and South Africa, a number of large and high grade gold deposits are le unexploited because aer several decades of mining, the high cost associated with accessing these deep gold deposits – some as deep as 3km – makes them uneconomic to mine. For bulk minerals such as iron ore, bauxite and coal, because of the high cost associated with developing adequate rail and port infrastructure for transporting bulk minerals to end users, some rich deposits – especially when they are located in remote regions – may remain unexploited. Mining Is A High “ xed-cost” Industry. A substantial proportion of the services and labour employed in operating a mine is “ xed” in nature and not directly linked to short-term changes in the quantity of minerals produced or changes in mine revenue. Costs incurred in extracting minerals include: the cost of powering and maintaining mining equipment and
associated infrastructure, the cost of mine supplies such as chemicals used for metal processing and explosives used for rock blasting, and the cost of labour employed in providing the extensive range of services that are critical to a mine's operation. Mining involves a high level of team work. Inadequate staff or services in one area of a mine can have a major knock-on impact on the productivity as well as the safety of the entire mine. As a result, a considerable proportion of the labour cost or employee base of a mining operation is “ xed” and not affected by short-term changes in production levels. Because of the high “ xed-cost” nature of mining, a modest reduction in revenue (from falling metal prices or declining production volumes or both) can translate into a disproportionately large drop in pro ts. On the other hand, in periods of rising prices (and higher production), the “ xed-cost” nature of mining can amplify pro t growth. e Mining Commodity Cycle. For the most part, mining companies produce undifferentiated products (commodities) and therefore they have limited scope to in uence prices in an industry that is global and highly competitive. Commodity prices are largely determined by the level of demand for metals and other minerals in relation to the available production capacity (i.e. supply) at a particular time. In periods of robust global economic growth, commodity prices can rise sharply in response to higher demand for metals and other commodities. In an environment of rising or high commodity prices, mining becomes more pro table and there is greater appetite for expanding production at existing mines and developing new mines. e process of expanding the production capacity of existing mines (i.e. brown eld expansion) may take several years while the process of prospecting, exploring and developing a new mine (i.e. green eld projects) can be much longer. e long period of time involved and the large amount of capital required to expand existing mines and to develop new ones restrict supply growth in the short-term. In
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an environment of strong global demand, the inherently slow supply response can help sustain high prices over extended periods and generate attractive returns for investors in the mining industry. However, over the long term, as existing mines complete their multi-year expansion projects and newly developed mines come into production, commodity prices may fall to more sustainable levels. e Productivity And Pro tability Of A Mine Declines With Age Mines are designed to access the richest and most pro table parts of a mineral deposit in the early years of production. is means that, in an environment of stable commodity prices, the pro tability of a mine will decline over its operating life. Furthermore, because of the non-renewable nature of the resource, once the minerals in one part of the deposit have been extracted, mining activity will be restricted (i.e. production will fall) unless miners have access to other – and oen deeper – parts of the ore body. e process of creating access to unmined portions of the mineral deposit is usually very expensive and takes time. As a mine ages, it tends to be less pro table (or more costly to operate) because the richest and most accessible deposits have been depleted. Because of the non-renewable nature of mineral deposits, the stated annual pro t of a mine, as shown in nancial statements, may not represent a sustainable measure of pro tability. Stated pro ts may overstate the cash generation potential of a mine because the method of computing pro ts for nancial reporting purposes does not account for the high capital intensive investment required to provide access to new mining areas, an essential expenditure, without which production levels cannot be sustained. e cash generated by a mine, aer accounting for the capital expenditure required to maintain production levels, provides a more accurate measure of sustainable levels of pro tability. e economics of the mining industry share many similarities with that of the petroleum industry. Both industries are concerned with extracting useful non-renewable resources from the earth.
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MINING NEWS
How to unlock mining investment in Zambia What are the main factors Zambia needs to address to make the country an attractive mining destination, unleash billions of dollars of foreign investment and create a stronger economy? e question featured prominently in this year's Zambia International Energy Conference and Exhibition (Zimec), in Lusaka on 23-24 June. A s t a b l e m i n i n g p o l i c y re g i m e – particularly taxation of mines – is probably the most important factor, because it affects the willingness of investors to commit their capital to new mining ventures. Ina Ruthenberg, Zambia country manager for the World Bank Group, said Zambia's mining policy had changed several times in recent years. She described policy instability as a “vicious circle” that reduces investment, raises costs, stalls new projects and raises the regulatory burden on the industry – which ultimately leads to more policy instability. Calling for the building of trust and common interest between the parties, she said: “e World Bank stands ready to help. But leadership must come from government and the industry.” Jyoti Mistry, director and tax specialist at PriceWaterhouse Coopers in Lusaka, cited
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Chile and Botswana as good examples of countries with stable mining policy regimes. ey had used their mining revenues over the years to build up considerable stabilisation funds, which have proved useful during commodityprice downturns. Mistry said a sound, stable mining policy is all the more important as the mining industry competes for investment with other less risky sectors, such as the digital economy. Mining is considered a high-risk investment and takes many years to produce a return, while the digital economy can produce higher returns in less time. A reliable and affordable energy supply emerged as a second key factor for increased mining investment in Zambia. Mining consumes about 50% of the country's energy supply, and powergeneration capacity has not been able to keep pace with economic and population growth – barely 22% of the Zambian population has access to electricity. Clement Sasa, manager at the Office for Promoting Private Power Investment (part of the Ministry of Energy and Water Development), unveiled a range of power generation projects planned for the next 5 to 10 years, and beyond. ese range from
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coal and hydro projects both large and small, to solar, geothermal and biomass. Manda Mwale, s enior manager in renewable energy from the Copperbelt Energy Corporation, said: “e power shortage has created a new momentum to redouble investments in the energy sector, and private capital and investment are expected to play a key role. It is not not possible for government to do it alone.” ese new power projects cannot come soon enough for the Zambian mining industr y. Matt Pascall, director of operations at First Quantum Minerals (FQM), Zambia's largest mining company, said the company's new Sentinel mine in North-Western province was still not receiving electricity through some 600 km of new powerlines it had built, at a cost of $95 million. is has constrained the mine's ability to operate at full capacity, affecting output and jobs. e administrative efficiency of government is another factor which helps to unlock mining investment – and indeed, investment in general. e faster various government departments are able to grant land-title to potential investors, and approve the various permits and licences, the sooner new business ventures can get off the ground. Untenable delays, on the
MINING NEWS other hand, can try the patience of investors and put projects at risk. FQM's Pascall said a number of potential investors in Kalumbila, where the Sentinel mine is based, had given up starting shops, farms, hotels and other businesses because it had taken more than four years to approve land-title. In response to a question, Clement Sasa, manager at the Office for Promoting Private Power Investment, also conceded that land-title could be problematic for the mini-hydro projects that are being planned, as many of them are situated on traditional land. Mining investment is one thing, but it is equally important for a country to make the most of that investment so that it bene ts its citizens – and that is all about scal policy. is point was made by Anand Rajaram, Zambia country director for the International Growth Centre
(IGC). Fiscal policy involves the decisions that a government makes about the collection of tax revenue, and how that revenue is spent. Rajaram cited the scal policy of Chile, a major copper-producing country, as a good example. ere, stringent scal rules ensure government does not overspend during periods of high copper prices, and that surpluses are put into a stabilisation fund and a pension reserve fund. ese surpluses had generated savings of $14.8 billion by April 2016, protected social programmes during the downturn, and ensured that infrastructure and portfolio investments were efficiently invested. In contrast, Rajaram said that Zambia had not “grasped the opportunity” of the mining-investment boom of the last 15 years. Acording to him, despite high copper export revenue and high levels of
tax revenue from mining, Zambia's de cit and debt levels had grown sharply, and there had been no saving during the boom to help cushion the country in a downturn. Rajaram's conclusion was that “Zambia needs to strengthen institutions for scal management; make binding commitments to de cit reduction; and make some hard choices to eliminate waste and inefficiency.” e p o i n t w a s e c h o e d b y To b i a s Rasmussen, resident representative of the International Monetary Fund (IMF). He said that Zambia needed “credible plans” to control government over-expenditure amidst reduced revenue earnings, which was responsible for the surging scal de cit. “What's key at the moment is to have that medium-term plan which in a c re d i b l e w ay a d d re s s e s t h e s c a l imbalances,” he added.
MINING NEWS
800-Plus Exhibitors showcase their products, services at Electra Mining 2016 It has become increasingly important for mining equipment and service providers to attend trade shows to bene t from increased marketing opportunities amid the difficult operating conditions in the global mining industry. More than 850 local and international exhibitors from the mining, industrial, electrical and power industries showcased their products and services across the net 38 000 m2 indoor and outdoor exhibition area of Electra Mining Africa 2016. e biennial event took off from September 12 to 16 at the Expo Centre, in Johannesburg. “Ranked as one of the world's largest mining shows and the biggest mining, industrial, electrical and power trade show in Southern Africa, its . . .
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credibility has ensured its having consistently attracted more than 34 000 visitors at each of the past ve shows”, says Electra Mining Africa 2016 show organiser Specialised Exhibitions Montgomery MD Gary Corin. He states that the event puts South Africa's renowned mining goods and services in the spotlight, with the trade show having consistently attracted international visitors seeking out local products, machinery, services and technology. “e show is also a recognised gateway into Africa for local and global businesses looking to expand their footprint on the continent in the mining, industrial, electricity and power sectors by exporting their goods and services to other African
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countries”, adds Corin. e global mining equipment sector is forecast to grow at a compound annual growth rate of 7.9% between 2016 and 2022 to exceed $150-billion by 2022. is is according to 'World Mining Equipment Market – Opportunities and Forecasts, 2015 to 2022', a report published in July by global market research company Allied Market Research. e report highlights that the major factors boosting demand for mining equipment include the rising demand for metal and mineral commodities, and the increasing consumption of natural resources such as coal, diamonds and uranium.
Embracing TECH
Eaton Demonstrates eir Turn-Key Solutions To Address Growing Energy Requirements Power Management Company Eaton participated in this year's Electra Mining Africa exhibition that took place from the 12th to 16th September 2016, at the Expo Centre Nasrec, Johannesburg, South Africa. e company showcased a top selection of their safe and efficient turn-key solutions that help customers effectively manage electrical, hydraulic and mechanical power to increase uptime in critical operations. Eaton - the only company providing crossbusiness solutions continues to leverage its expertise and capabilities in Africa through its manufacturing facilities, extensive distributor network and a dedicated team of over 900 employees across the continent. e company is continuously focused on supporting its c ustomers in s olv ing t heir p ower management challenges through wideranging and world renowned products and solutions. “We pride ourselves on being the go to provider of reliable, safe and efficient products within the mining ecosystem, through our balanced portfolio of best-inclass technologies. Our 89 year history in Africa demonstrates our expertise in helping our customers to better manage costs and capital, mitigate risk and work safely by providing innovative solutions to manage power in key industry segments “said Trevor Sansom, Head of Mining, Africa. Products that where launched at Electra Mining include: Power Xpert CXH – a low
volt age motor cont rol and p ower distribution solution which is designed to deliver superior performance in the most demanding operations. Powered with industry-leading motor control and protection component technologies, the Power Xpert CXH provides a level of reliability and safety that exceeds IEC standards. Its broad array of sophisticated features ensures fewer process interruptions and greater con dence in the safety of operation. Its modular design provides the ability for a t-for-purpose low voltage switchgear system with ratings up to 6300A. An additional feature of the Power Xpert CXH is that it is equipped with the Power Xpert C445 motor management relay designed to give users the intelligence to monitor and protect their system with unrivaled accuracy. e Power Xpert C445 has the highest level of monitoring accuracy and protection for the entire power system-from the incoming power source feeding the motor all the way to the individual pump or load. C445 helps customers provide the highest level of motor protection for their motors while maximizing uptime. e bene t of the Power Xpert C445 is the user de nable alarm and trip levels and the programmable delays that provide the most protection while avoiding downtime
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and nuisance tripping. Other products launched are the Series NRX Low Voltage Air Circuit Breaker designed to meet the needs of low voltage power distribution applications. e compact size minimizes non-revenue generating oor space, and the modular design and common accessories allow for easy panel and switch board integration, and the L112 belt conveyer control system. e L112 is a belt conveyer control system designed for harsh and hazardous environments like that of the mining industry. Its standard features include voice communications, signaling and prestart warnings. To ensure risk reduction the L112 is equipped with the SIL3 certi ed safety coupler utilizing emergency shutdown, misalignment and pull rope switches, with an integrated encoding c i rc u it for i d e nt i c at i on . A l l t h e e q u i p m e nt i s c e r t i e d a s p e r E x requirement, equipment group 1, for mines endangered by re damp. Eaton also has a modular solution available, e Power Xpert Modular™ was designed and developed by Eaton's engineers focused on leveraging performance with the best cost bene t. e modular and scalable design allows Power Xpert Modular™ to operate in complex environments, integrating the customers complete power assembly requirements. e design also allows for easy transport via truck, reducing cost and optimising time for the energy, mining infrastructure, data center and construction segment needs.
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Embracing TECH e Roto-Fire-Pac and various extinguishers and systems
Latest environmental solutions to be unveiled at Electra Mining Africa 2016 Exhibiting for the rst time at Electra Mining Africa 2016, leading environmental solutions company I-CAT will launch a range of water, re and dustsuppression technologies. I-CAT Marketing Director Lourens Jansen van Rensburg comments that the agship exhibition is an ideal forum to showcase the company's services and products to potential new clients. “I-CAT has been in existence for ten years, and our exponential growth in the last ve years has underlined our unique offering to clients in the mining industry.” “We operate in a very competitive industry, and Electra Mining will afford us the opportunity to offer mining operators an alternative to their current service and product providers. Due to the prestige and sheer size of Electra Mining, we expect it to draw a much more focused visitor pro le dedicated speci cally to nding solutions and suppliers for their speci c requirements,” Jansen van Rensburg stresses. e R-SDR (Retractable Stockpile Dust Ring) will be showcased as the latest
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innovation from I-CAT Dust Solutions. Introduced to address dust issues at conveyor discharge points, the R-SDR system creates a virtual curtain around material ow for outstanding particle containment. e I - VA P S y s t e m ( Wa s t e Wa t e r Evaporation Cannon) from I-CAT Water Solutions is capable of handling 500 m3 per 12-hour day. e evaporation rate is 60% to 65%, depending on the ambient weather conditions. e Roto-Fire-Pack (Backpack Fast Response System) from I-CAT Fire S o l u t i o n s m a k e s u s e o f T- R o t o r technology, currently the leading misting technology internationally. It extinguishes all classes of res by using foam mist as the agent. In addition, I-CAT will also be exhibiting its standard range of products for dust suppression and environmental services, including RDC 20 and GreenBit. A range of re extinguishers, vehicle protection and localised protection systems will also be showcased. Visitor participation and interaction will
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be encouraged by on-site demonstrations of the Roto-Fire-Pack and various extinguishers and systems, together with a working model of a dust suppression ring and a full-size evaporator. “I-CAT will have an expert from each division on-site every day, together with a representative from top management. ese will be able to answer any questions and carry out demonstrations where needed,” Jansen van Rensburg elaborates. “A l l m i n e s n e e d t o c o m p l y w i t h environmental and OHS regulations, and most of our services and products are aimed to offer speci c solutions in this subsector. We believe our brand is becoming well-known in the mining fraternity, and want to underline its relatability to 'excellent service' and 'superior products',” he concludes. Visit I-CAT at P17 on the Outside Promenade at Electra Mining Africa 2016 from 12-16 September at Expo Centre Na s re c i n Jo h a n n e s bu r g . Fu r t h e r information can be found at www.electramining.co.za
I-VAP 500 SPEC SHEET > GENERAL SPECIFICATIONS > 32,000 square meters coverage. Custom automated user-denable oscillation up to 359° option. Includes integrated turntable bearing that enables user to manually override oscillator and quickly reposition fan barrel. Adjustable angle of throw (7° to 45° height adjustment). Integrated fan and nozzle ring design. Premium efciency motor. Low energy-use to evaporation ratio. ELECTRICAL SPECIFICATIONS > 3 Phase / 37 kW fan / 525 Volt / 60 Hertz. 3 Phase / 55 kW pump / 525 Volt / 60 Hertz. 0.10 kW oscillator motor with oscillation option. 30 meters 50 mm electrical cord. Other options available. No male plug, “bare wired” is standard (any other plug is optional extra). Stainless Steel Cabinet with control panel. Wye-Delta start. WATER SPECIFICATIONS > Maximum pressure delivered by pump is 10 bar (145 PSI). Strainer is included and should be used at all times. Contact us for recommendations when using non-potable water. 1½” (40 mm) cam-and-groove quick disconnect female coupling for high pressure hose provided on machine. 38 x PVC nozzles (also available in stainless, brass and nylon). 21,3 L per minute, per nozzle, measured at 10 bar pressure. Droplet size of 150 – 180 microns. Throw distance of 80 to 110 meters. Follow us
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I-VAP 500(continued) SPEC SHEET > MAINTENANCE > If using potable water, nozzles need to be inspected quarterly. Fan motor and high-pressure pump should be greased every 1,000 hours. Oscillator bearing should be greased on a regular maintenance schedule, or as needed.
NOISE LEVELS > WITHOUT BOOSTER PUMP Control Panel Side – 83 dB. Back Side of Fan – 84 dB. Opposite side – 83 dB. Discharge side – 85 dB.
DIMENSIONS > ON STANDARD SKID MOUNT. 2,105 mm Wide. 2,600 mm Long. 2,510 mm High/Tall. 1,480 kg. WARRANTY > Unit is covered by a 3-year or 3,000-hour warranty.
www.i-cat.co.za
The I-VAP 500 is built from composite materials to prevent rust, making it light, durable and mobile.
086 112 4228
Embracing TECH
Are you interested in seeing the Markforged Mark Two live & in action e revolutionary Mark Two prints highquality nylon parts while reinforcing them with composite bre, giving them the strength of aluminum. is allows you to achieve the dependability of CNC (Computerized Numerical C ontrol) parts and the exibility of 3D printing Materials available on the Mark Two include the following: ● Fib erg l ass (t he most costeffective material). It's as strong as Carbon Fiber, but 40% as stiff, and 2X the weight. Suited to everyday applications where you need strong parts ● Carbon ber has the highest strength to weight ratio, as well as, the highest thermal conductivity. Perfect for applications requiring
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the greatest possible stiffness and strength. Kevlar has the best abrasion resistance and is the most exible material. For when you need parts that are durable and resistant to impact. High Strength, High Temperature (HSHT) Fiberglass is a material uniquely designed for users who need strong parts in higher temperature environments (over 105°C, with a heat de ection point of 140°C). Our newest material, Onyx, is a step up from other 3D printing plastics. Combining nylon with micro-carb on b ers, we've created a lament that's not only tougher than other 3D printing plastics — it's also stiffer, has a
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h i g h e r h e at t ol e r an c e an d dimensional stability. Come see the Mark Two in action at Electra Mining Africa 2016! We'll be demonstrating the Markforged Mark Two at our stand at Electra Mining 2016. Come take a look at how things work, watch how it prints and ask us questions you want to know. It's an ongoing demo! See the 40% faster ber printing speed in action. We'll have parts with bre reinforcement available for you to see. Visit our stand at Electra Mining 2016, Hall 9, stand H04 Pauline Bullock Tel: 086 100 0185 www.rapid3d.co.za
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one-stop solution for engineering consumable and PPE needs 2016 North Safety Products Africa will showcase its full range of products designed to mitigate various hazards that mining workers are exposed to at Electra Mining Africa 2016, including its latest engineering and consumable products. is will be the second time that North Safety has had a presence at Electra Mining, Head of Marketing Lizette Kasselman points out. “Electra Mining is a platform that grants any personal protection or mining supplier in the industry the opportunity to meet operational personnel and decision-makers. It also allows us to showcase our broad product spectrum, which caters for every requirement.” is ranges from standard dust to hazardous particles, dangerous chemicals and ash re protection, encompassing a head-to-toe protection offering. “North Safety has been a supplier of protective apparel for the past 60 years, and therefore it has garnered considerable expertise in terms of the industry's overall safety requirements.” A particular focus at Electra Mining Africa 2016 will be North Safety's addition of critical engineering and consumable products to its current range of safety protective apparel. “is decision was based on our customers requesting a one-stop solution to their needs,” Kasselman explains. e new engineering products include Reinol hand cleaners and industrial chemicals, Spanjaard industrial lubricants and sprays, liing machinery and repairs, liing tackle and slings, Megaroller conveyor idlers and scrapers, allied screen and lter products, Petrozorb oil absorbents and oil-spill kits, industrial valves and slurry pumps, and specialised nuts and bolts. New consumable products on offer include waste rags, silicone, grinding discs and general mining supplies. “North Safety probably has the best infrastructural footprint in the country, which has been strengthened by adding these additional product lines. We are now able to offer ideal one-stop solutions to any industry requiring engineering, consumable and PPE products,” Kasselman reveals. e entire North Safety team, from sales experts to contact specialists, exports team and management will be present at Electra Mining Africa 2016, including CEO Craig Garvie. “Our main aim is to ensure that all parties within the mining industry are aware of our vast product range and the expertise that complements our solutions,” Kasselman concludes. Visit North Safety Products Africa at P17 at Hall M1 Stand 45 at Electra Mining Africa 2016 from 12-16 September at Expo Centre Nasrec in Johannesburg. Further information can be found at www.electramining.co.za
North Safety Products Africa Contact Lizette Kasselman Group marketing manager Phone: (031) 705 6085 Email: marketing@northsafety.co.za www.northsafety.co.za
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North Sales and Marketing Manager Lizette Kasselman
Craig Gravie with staff outside the new PBM store
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Product RELEASE
Breathe easy with the revolutionary new respirator from North e lightweight and highly-portable CleanSpace2 is world's smallest powered air purifying respirator, which is designed to provide the breath of life to users in a wide variety of applications – ranging from home DIY projects to heavy industrial projects. It was exclusively launched at the Electra Mining Show in September 2014 by North Safety Products Africa. e compact unit weighs less than 500 g, and combines the mobility of a passive inhalator with the added reliability of a positive air powered respirator. North marketing manager Lizette Kasselman notes that the CleanSpace2 features no hoses or auxiliary units to provide comfortable respiratory protection. “e one-piece unit incorporates a so silicone mask and cushioned power unit that ts around the back of the neck. is ensures that the user is screened from hazardous particle matter, including gases
and vapours of 0.3 micron (μm) and above. To prevent contamination, the breathresponsive respirator intelligently adjusts air ow, thereby maintaining positive pressure inside the mask,” she explains. is also serves to maximise lter life by only purifying air that the user breathes in. e CleanSapce2 is compatible with welding and safety helmets, goggles and spectacles, face shields, and hearing protection, and can support work in the harshest conditions with a continuous running time of six hours. Kasselman reveals that this can be increased to 11 hours with the CleanSpace2 Endurance Pack. “ese features make the CleanSpace2 ideallysuited to a broad range of applications, such as DIY, as well as more heavy industries, including; mining, smelting, construction and agriculture, to name a few.” Even with intensive use, proper
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maintenance will ensure a long operational lifespan of the respirator. “Care is made easy with an improved lter cover for quick and intuitive replacements, and the mask can be washed in warm soapy water or on the top shelf of a dishwasher,” observes Kasselman. In terms of mechanical maintenance, the CleanSpace2 should operate service-free for up to three years with a battery life of 500 cycles (or three years), and a motor life of ten years. Kasselman indicates that the CleanSpace2 delivers signi cant bene ts, while remaining cost-effective and userfriendly. “e CleanSpace2 respirator boasts simple operating modes that minimise the time required for training, handling and cleaning. As the sole Southern African distributor, North is proud to offer this revolutionary respirator to customers seeking an exceptional air purifying solution,” she concludes.
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PROFILE
e Endress+Hauser Group Endress+Hauser is a global leader in measurement instrumentation, services and solutions for industrial process engineering. e Group employs 13,000 personnel across the globe, generating net sales of more than 2.1 billion euros in 2015.
Structure With dedicated sales centers and a strong network of partners, Endress+Hauser guarantees competent worldwide support. Our production centers in 12 countries meet customers' needs and requirements quickly and effectively. e Group is managed and coordinated by a holding company in Reinach, Switzerland. As a successful family-owned business,
Endress+Hauser is set for continued independence and self-reliance.
Products Endress+Hauser provides sensors, instruments, systems and services for level, ow, pressure and temperature measurement as well as analytics and data acquisition. e company supports customers with automation engineering, logistics and IT services and solutions. Our products set standards in quality and technology.
Industries We work closely with the chemical, petrochemical, food & beverage, oil &
gas, water & wastewater, power & energy, life science, primaries & metal, renewable energies, pulp & paper and shipbuilding industries. Endress+Hauser supports its customers in optimizing their processes in terms of reliability, safety, economic efficiency and environmental impact. History Founded in 1953 by Georg H Endress and Ludwig Hauser, Endress+Hauser has been solely owned by the Endress family since 1975. e Group has developed from a specialist in level measurement to a provider of complete solutions for industrial measuring technology and automation, with constant expansion into new territories and markets.
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People for Process Automation
Product RELEASE
New-generation
crane girder
revolutionises load handling Demag's newly-launched V-Type crane girder can easily manage more than 500 000 load changes, more than double the
service life of a conventional box-section girder – making it a game changer in the local materials-handling sector. Launched in early 2016, Demag's V-Type girder delivers impressive load-handling r at e s c ombi n e d w it h h i g h s afe t y. “Regardless of the model type selected, the V-Type crane girder can be adapted easily to any building shape. It is the ideal solution both for existing buildings, as well as for new construction projects,” Demag Senior Manager Sales & Marketing Richard Roughley explains. Built with safety in mind, the V-Type girder allows 30% more light to pass through, enabling personnel to better see their surroundings, while brightening the workspace. is improved view ultimately results in a safer and more attractive working environment. e V-Type girder also has a shorter time
cycle, helping to increase productivity and overall output. It boasts several liing points for safer installation of the load and has more clamping and attachment points for lamps. What's more, the tapered diaphragm joints also replace the solid box-section design of conventional cranes. Tapered diaphragm joints accommodate pressure and tensile forces more effectively to reduce resonant frequency by 30%. On average, the V-Type is 17% lighter than comparable cranes with box-section girders. is not only reduces the forces transmitted to the existing support superstructure, as well as providing architects with greater freedom when planning new building layouts, but it also improves the relative deadweight-to-loadcapacity ratio.
CASE Construction Equipment announces a new exclusive CASE announces agreement with Hyundai Heavy Industries for the production and development of mini-excavators. Under the agreement, which exclusive mini-excavator also includes OEM supply, component and spare parts supply to CNH Industrial, CASE will be able to produce models of up to ve relationship with Hyundai tons at its plant in San Mauro, Italy. e two companies will also start a joint development program for new models introduction. Heavy Industries is agreement applies globally, excluding the South Korean market, and has a ten year term with the option for renewal. In a rst phase, CASE will launch a brand new range of mini excavators that will be further extended over time. e new models will be designed in collaboration with Hyundai Heavy Industries. Once fully realized, the scope of the mini-excavator product range will run up to six tons. e styling, quality nishing, controls and cab layout, which will be developed also in collaboration with the CNH Industrial Design Center, will be consistent with all the machines in the CASE product line up, so that operators will feel immediately familiar with the new models. “is agreement is the latest step in our strategy to strengthen the CASE brand, consolidate its position in the markets and secure its long-term future,” explains Andy Blandford, Vice President CNH Industrial Construction Equipment for Europe, Africa and the Middle East. “It follows the new agreement we signed with Sumitomo for crawler excavators and the redevelopment and rebranding of the San Mauro and Lecce plants to create the CASE European Excavator and Wheeled Equipment Hubs.” e strategy to strengthen the CASE brand also saw a renewed focus on its historic core values of expertise, strength and a practical, hands-on approach.
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Product RELEASE
A Better Brake System for Toyota Land Cruisers in Underground Mining e Toyota Land Cruiser is the leading utility truck used in underground mining across the world. Its rugged and simple design lends itself well to harsh and abusive mining life. However, one problem area for the mining Land Cruiser is brakes. Abrasive slurry coats the rotors of caliper brakes causing excessive wear on pads, and corrosive liquids can damage the rotor and caliper rendering the brake useless. Drum brakes fare even worse. Water lls the drum with mud that packs the drum full, while parking brake cables quickly corrode and become inoperable. e result is high maintenance cost, high downtime, and safety problems.
e LC Brake is a wet, multi-disc brake with service brakes that operate off the OEM brake master cylinder. e brake also includes spring appliedhydraulic release parking. e brake design is exible enough to be used in either 2 wheel or 4 wheel systems.
e Toyota Land Cruiser is widely used as a utility vehicle underground but the OEM brakes suffer in the harsh mining environment causing high cost of ownership and safety issues.
ere have been attempts by various companies to solve these problems, but the existing systems suffer from overheating, brake fade, speed limitations, and difficulties in installation or service. None of the solutions yet offered solve all of the problems, and/or they require a major overhaul of the vehicle for installation. e overall cost of ownership is still not acceptable. Ausco Products in Benton Harbor, Michigan USA is a leading manufacturer of custom designed brakes for the off-highway industry. ey recognized the need for a better Land Cruiser brake. Using multi-disc wet brake technology they developed for their core customers like John Deere, Caterpillar, CNH, and JCB, Ausco designed a new product called the LC brake that addresses all of the known brake issues with the Land Cruiser OEM brake system. e result is a product that is virtually maintenance free, lighter than competitive solutions, easy to install on the backkie without major changes, and offers either a four wheel system with service and parking at all wheels, or a less expensive rear only two wheel brake system that is primarily intended to address drum brake and parking problems of the OEM rear brakes.
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Test Lab Results Testing at Ausco showed that even during abusive braking, the product maintained acceptable temperatures that would overheat and fail competitive products. e brake is also capable of handling speeds as high as 120 kph without trouble, something that competitive multi-disc brakes in this application cannot do. For corrosion protection, a special hard coat anodize layer has proven to be superior to anything else in the market, and Ausco's mine-proven grease barrier hub seal virtually eliminates problems of water intrusion and internal corrosion. Field Testing: A Case Study When it came time to eld test the product, Ausco made contact with JS Redpath of North Bay Ontario Canada, a mining contractor with brake problems on Land Cruisers. Redpath has experience with an enclosed brake manufactured in Australia and had a mix of trucks using the Australian brake and OEM brakes in their eet. is made them an excellent candidate for eld testing, since there was a direct comparison available between the three different brake systems. Ausco personnel traveled to Redpath's shop in North Bay, Ontario to assist in the installation of the rst system and to train their technicians. e test truck was a personnel carrier that transports up to 15 miners from the surface down into the
mine and back. e Australian brakes were removed from the truck, and the Ausco system installed without issue. Redpath was pleased with the service provided by Ausco Products. e vehicle was commissioned into service at a zinc and gold project at the Hudbay Minerals Lalor mine located near Snow Lake, Manitoba Canada. Here, the vehicles were stored outside in the Canadian cold with temperatures as low as -30°C, and the vehicles were driven up to around 3 km above ground in those temperatures. e Lalor mine is an underground ramp access mine with operations 950 meters below the surface with a 1218% grade through wet and corrosive conditions all the way down. In other words, the mine is deep, wet, and steep. e LC brake equipped vehicle went into service for a 2,000 hour test. Ausco personnel followed up periodically on the installation, and Ausco even sent an engineer on-site to inspect the product and interview the drivers. e drivers reported excellent braking performance stating that the brake seemed to have the same stopping power whether the vehicle was loaded or unloaded. Brake pedal feel and control was reported to be very good – the operators really liked it!
ese discs showed virtually no wear aer eld testing, which alleviates the cost of lining maintenance. e oil immersed multi-disc design held up amazingly well in a steep, deep mine that can causing glazing and wear in competitive products.
Aer 2,000 hours, an on-site inspection of the brake showed that the linings were virtually new with negligible wear. e Caterpillar TDTO oil used to cool and lubricate the linings remained in good condition with no signs of heat, oxidation, or contamination. And the special hard coat anodizing used to protect the aluminum housing was completely undamaged. When the slurry from the mine was power washed off the brake, the anodizing looked as good as it did when it le Ausco's factory. In other words, the harsh mining environment had not damaged the brake's housing, seals, or linings – the brake had performed magni cently! e only maintenance performed on the brake was to grease the hub seals monthly and change the standard Caterpillar TDTO4 oil every six months.
Ausco's LC Brake uses a special hard coat anodize process that stands up well to harsh, corrosive mining environments. is unit came off the test at Snow Lake aer 2,000 hours. When power-washed, it was in excellent condition.
Comparing Systems: Cost Savings Since Redpath operates OEM brakes and Australian brakes in their eet, this gave Ausco an opportunity to compare various systems in actual eld conditions. In the Redpath test, the Ausco LC brake required hub seal greasing every month and changing the standard Caterpillar TDTO4 oil every six months at a cost of parts and labor of $250 per year. e linings had negligible wear, negating any cost to service those components. By comparison, Redpath was operating three Land Cruisers with standard OEM brakes at this mine with caliper disc brakes in front and drums in the rear. Redpath had extensive maintenance records on these vehicles. Over a nine month period, the vehicles went out of service for brake repair an average of 18 times each with an average of 91 labor hours per truck for brake maintenance. Using this data with OEM parts pricing from a local source and $45 per hour for labor (standard for Redpath technician time), the cost of maintaining the OEM brakes on each of these trucks was $20,400 per year, not to mention the hundreds of hours of vehicle downtime. With costs like that, it is easy to understand why the market needs a better product! Redpath also used the Australian brake product on some of their trucks. Unlike the four wheel Ausco LC brake, the Australian brake was a rear only system with caliper brakes still operating on the front of the vehicle. Redpath records indicated that repairs on the front calipers were occurring four times per year at a labor and parts cost of $2,300 annually. In addition, maintenance records indicate that Australian product gets rebuilt twice a year (every six months). e cost parts and labor to do two rebuilds annually is $2,250. Moreover, the Australian brake uses a special cooling uid that needs to be changed every 250 hours, which is about one month in the Redpath mine application. Unlike the Ausco LC brake, which uses readily available Caterpillar TDOT4 oil, the Australian brake uses a proprietary uid. Redpath indicated that the uid is very expensive at $175 per 5L with each brake change requiring 2L for two brakes. At 12 changes a year, the cost of parts and labor to maintain the special uid is $1,350 annually. Redpath also reported that the Australian brakes experience periodic lining glazing, which necessitates regular service and maintenance. e brakes were also known to be susceptible to broken mounting bolts, if the operator attempted to drive through the brake creating yet more downtime. It is notable that none of these cost were captured in the eld testing, but based on reports, they are de nitely there.
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Product RELEASE
Cost Comparison Over a 3 Year Vehicle Life OEM Brakes Front Caliper Brakes Rear Drum Brakes Initial Investment Annual Oil Change Cost Lining Repairs Parts/Labor
None OEM Configuration $0 Dry Brakes $20,400 per year
Ownership Cost 3 Year Life
$62,100
Australian Solution Front Caliper Brakes Rear Australian Brakes $8,000 *
Ausco LC Brake 4 Wheel Enclosed Brakes
$1,350 Uses Special Fluid $2,300 per year Front Calipers $2,250 per year Rear Australian brake $25,800
$250 Uses Cat TO4 $0
$13,400 **
$14,900
*
Estimated installed street price of two rear Australian brakes based on data from a dealer of this system in Canada. e cost of the pump pack was not included in this analysis, since the truck was already equipped with this item.
**
MRSP of four installed Ausco LC brakes. e cost of the pump pack was not included in this analysis, since the truck was already equipped with this item.
e results of the case study speak for themselves. e cost of ownership over three years for the Ausco LC brake is 76% less than the OEM brakes and 42% less than the competitive Australian brake. Since this test was completed, Ausco has performed similar eld test studies at six other mine locations in Canada and Australia and all have yielded very similar results. e Ausco LC brake holds up better and costs far less to own and maintain than other existing systems. Aer the Snow Lake mine test, JS Redpath approved the Ausco LC Four Brake system as standard equipment on the Land Cruiser eet. In response to the support by Ausco, Don McCarthy, JS Redpath Mobile Shop Foreman stated, “anks for everything Ausco has done great service.” Also, Merv Borgford, JS Redpath, Mobile Fleet Maintenance Superintendent stated, “I really appreciate all the effort Ausco has put into proving this product; the aer sales service has been outstanding!” Merv Borgford again commented in summary of this project, “Over the past year in my dealings with Mike Page22
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Pedue and Ausco Products, Mike has been instrumental in helping our company convert our Toyota Man carrier eet over to the Ausco Wet Disc Brakes. During the conversion time, he has been very attentive to details, and extremely prompt in any aer sales Service or Warranty concerns. I am extremely pleased with the performance of the product, and with the way Mike handles business. Anybody willing to make the switch on the Landcruiser units from the traditional brake set ups will greatly bene t from reduced downtime and huge cost savings in parts. It has been a pleasure to see this type of service... it is not seen oen enough!” Conclusion With greatly improved cost of ownership and superb brake performance, the Ausco LC has met all of its design objectives. Ausco is now marketing the product aggressively throughout Canada as a “best in class” product. With eld test results and customer satisfaction like was experienced at Redpath, the LC brake should prove a popular product with miners and mine owners alike. For more information, contact Ausco Products (001 269 926 0700).
Correct bulk materials handling technology essential ere is still a drive worldwide to improve on existing methods of mining. e demand is for mining volumes to be increased while the productions costs must be reduced. Without proper bulk materials handling technology, all coal mines will experience carry-back, resulting in material ow challenges that reduce production levels. ese days, “mining material handling” means the material management of raw materials. e main task is to make the required amount of raw materials available in the required quality at the speci ed time. Continuous haulage system e continuous haulage system serves the requirement to mine underground mineral deposits in a way that increases the efficiency of a continuous mining machine by maximizing the machine utilization, which means eliminating the waiting for an intermittent material clearing system in the likes of a shuttle car. e continuous haulage system will serve as a permanent connection between the continuous mining machine and the
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permanently installed underground material handling system of the mine. e continuous haulage system follows the continuous mining machine throughout the entire cutting process. During this mining process the continuous miner cuts the material out of the mining face and transports it via onboard loading devices and conveyors to the back of the machine where it is discharged into a hopper car. is hopper car, as an integral part of the continuous haulage system, loads the Sicon conveyor system which transfers the material at its discharge end onto the permanently installed underground material handling system, which in the case of a coal mine will typically be the section conveyor. During the retreating operation of the continuous miner, the continuous haulage systems also backs up out of the mined area, always maintaining the connection of the material ow between the miner and the section belt conveyor system.
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Punch mining system e punch mining system serves the requirement to mine underground mineral deposits in a way that cuts short straight distances (punches) into the deposits, taking only a short period of time, and to have the complete mining system retrieved out of those nished punches, before permanent strata control measurements (roof/rib bolts) become necessary. ose short straight distances, or so-called punches are currently limited to a length of 200 metres and can be cut/mined within a period of 2 two 8-hour shis, whereas the retrieving of the whole system, including a new set-up for a new punch in an adjacent section, will take 1 one 8-hour shi. e punch mining system combines a continuous mining machine, and a continuous straight line conveyor system, to cut a coal or ore deposit and to transport the mined material from the cutting face to the permanently installed main underground material handling system, which clears the material out of the underground section.
Measure, Control, Improve ... minute by minute On-belt Real Time Analysers · Base metals (Cu, Zn-Pb, Ni) · Iron ore, manganese, bauxite, phosphate · Coal · Moisture · More than 1,000 installations worldwide · Accurate, low maintenance, safe and reliable · 30 years of proven performance in Africa · Local support by experienced engineers · Performance guarantees, no risk
Contact us: Australia +61 7 3710 8406 Zambia +260 212 222 606
sales@scantech.com.au www.scantech.com.au
INNOVATION
Fuel-Flexible Turbines An Eco-Friendly Partner To Renewable Energy Companies in Sub-Saharan Africa looking to bene t from the independence and cost savings of renewable energy can be le in the dark when the weather is uncooperative. However, a solution combining intermittent wind, solar and hydropower with supplemental fuelexible turbines can ensure thes e companies have the environmentally friendly and reliable power generation they require. is is according to Colm Quinn, regional sales director at APR Energy – the world's leading provider of fast-track mobile turbine power. Quinn says that as electric utilities and energy-intensive industries throughout the developing world invest in power infrastructure, they are under increasing pressure to consider the environmental costs associated with the use of higher-polluting fuels such as diesel, coal and heavy fuel oil (HFO). He says power generation using advanced fuel- exible turbines can switch seamlessly between natural gas and other cleanerburning fuels such as LPG (liquid petroleum gas). “As a result, these modules produce 38-94% less nitrogen oxide (depending upon use of water injection) and 20% less noise than diesel power
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modules, offering a great t for environmentally conscious operations with stringent regulatory controls.” e ability of the turbines to switch seamlessly between LPG, natural gas and other fuels provides electric utilities and e n e rg y - i nt e ns ive op e r at i ons w it h unprecedented exibility to manage costs by optimising fuel pricing and availability, he adds. Besides being able to use more environmentally friendly fuels, fuelexible turbines also take up far less land space than renewable energy power plants. “e signi cant amount of land required is oen an important consideration for companies weighing the emissions advantages of renewable energy. A 50MW solar farm would cover approximately 430-500 acres, while 50MW of wind turbines start off at around 100 acres if installed on a ridgeline in hilly terrain and range to 2,500 acres if installed across open, at terrain,” Quinn says. “By comparison, a modular 50MW plant using compact, power-dense turbines is an ideal solution for operations with space constraints, only requiring a footprint of around 1.4-acres – approximately onethird of the space needed for the same
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electricity output produced by reciprocating generators, depending on whether on-site LPG fuel storage is required,” he adds. Perhaps the biggest bene t is that a fuelexible turbine solution is not subject to the intermittent nature of sunshine, wind and rain as it can generate reliable power, 24 hours a day, 365 days a year. ere are a multitude of other advantages of mobile fast-track power solutions in addition to the environmental bene ts and exibility of fuel type, he says. “Due to minimal construction and setup requirements, mobile turbine solutions can be installed within 30 to 90 days and are easily transportable via land, sea or air. ey are also entirely scalable to the requirements of the company and can be scaled up or down at any given time depending on the power generation needs.” He says these solutions can also be installed close to the demand, reducing the need for transmission and distribution infrastructure, while also cutting the power loss that occurs as electricity travels long distances.
MOVERS & Shakers
Ivanhoe Mines’ Kamoa & Kakula Africa’s greatest copper discoveries
e Kamoa copper project — a joint venture between Ivanhoe Mines and Zijin Mining Group Co. — may have been independently ranked as the world's largest, undeveloped, high-grade copper discovery; but this looks set to change. e latest drilling results from Ivanhoe's Kakula discovery, situated on the southern portion of the Kamoa tenement, is revealing 'phenomenal' mineralisation and grades which could see it take the top position as Africa's most signi cant copper discovery ever made. Compiled by Laura Cornish. It has been well over 10 years since Ivanhoe geologists rst started looking at Kamoa. e rst exploration programme on site was initiated in 2003 which at the time was nothing more than an unknown grassroots prospect generated by the company's geological team and covered with a thin layer of Kalahari sand – sitting in a previously unrecognised district within the Central African Copperbelt. It took those geologists ve years to make the rst signi cant discovery in 2008 and another ve to prove its status as one of the
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richest copper deposits on the African continent. To reach that point, “it took more than 12 years of dogged exploration, dedicated geological and geotechnical expertise [as well as] a total investment of several hundred million dollars,” Ivanhoe executive chairman Robert Friedland recalls. Kamoa is now proven to be a very large, near-surface, stratiform copper deposit with adjacent prospective exploration areas within the Central African Copperbelt, approximately 25 km west of the town of Kolwezi and about 270 km west of the provincial capital of Lubumbashi. Having identi ed its potential, Ivanhoe did not wait long to st ar t e arly-st age construction and on-site development, awarding the boxcut construction to Lubumbashi-based Mining Company Katanga Sprl in 2014. DRC local company Byrnecut Underground Congo SARL was awarded the contract in 2015 to deliver support for the boxcut and construction of the rst 1.2 km for two declines. e rst blast at the
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twin declines took place on 12 May 2015, officially marking the beginning of underground mine development. e twin declines, incorporating both a service and a conveyor tunnel, have each advanced more than 130 m since. Development of the underground mine is designed to reach the high-grade copper mineralisation at the Kansoko Sud deposit during the rst quarter of 2017. e development is ahead of schedule and within budgeted costs. Kamoa and contractor teams are also currently focusing efforts and equipment on the necessary critical activities such as the steel sets required for roof support which were installed in each decline in June 2016 as well as ventilation fans which were also installed recently. “Sourcing and securing local contractors from the DRC is important to Ivanhoe and Kamoa's development and will secure longterm partnerships with the local residents,” says Louis Watum, Kamoa Copper's general manager and Ivanhoe Mines DRC Operations MD. Kamoa project outline In February this
Movers & SHAKERS year, an independent prefeasibility study (PFS) – based on probable mineral reserves for the rst phase of Kamoa's development – was prepared by OreWin, Amec Foster Wheeler E&C Ser vices and SRK Consulting. e report re ects a base case, initial phase of project development and describes the construction and operation o f a 3 Mt p a u n d e r g r o u n d m i n e , concentrator processing facility and associated infrastructure. e rst phase of mining will target highgrade copper mineralisation from shallow, underground resources to yield a highvalue concentrate. e planned second phase would entail a major expansion of the mine and mill, and construction of a smelter to produce blister copper. At its initial 3 Mtpa production rate, the project will average a grade of 3.92% copper concentrate over a 24-year mine life, resulting in annual copper production of approximately 100 000 t. Impressively, the initial capital cost, including contingency, is US$1.2 billion, approximately $200 million lower than estimated in the Kamoa 2013 preeconomic assessment. e life of mine (LOM) average cash cost is estimated to be $0.75/lb of copper, contributing towards an aer-tax net present value (NPV) at an 8% discount rate of $986 million and an aertax internal rate of return (IRR) of 17.2% and a payback period of 4.6 years. e initial capital cost includes a $104 million advance payment to the DRC stateowned electricity company, SNEL, to upgrade two hydro power plants (Koni and Mwadingusha) which will provide Kamoa with access to clean electricity during the initial phase of operations. e upgrading work is being led by Stucky, of Switzerland, and the advance payment is expected to be recovered through a reduction in the power tariff once Kamoa is in operation. In parallel with the Kamoa 2016 PFS, an alternative mining method – controlled convergence room-and-pillar mining, developed by Poland-based KGHM – was investigated for its suitability for use on the Kamoa Kansoko deposits. e u s e of t h i s m e t h o d h a s b e e n successfully used by KGHM Polska Miedź
S.A. (KGHM) at its copper-mining operations in Poland for the past 20 years. Based on detailed analysis by the company's research and development centre, this mining method appears to be well suited to the Kamoa deposit and, if implemented, potentially could provide signi cant cost savings – reducing the average cash cost to $0.61/lb in the rst phase – as there would be no requirement for cemented back ll and ore extraction ratios would increase. is would also improve the aer-tax NPV at an 8% discount rate to $1.182 billion, the IRR to 18.9% and the payback period to 4.3 years. An increase in production, of up to 4 Mtpa from the proposed initial mining area, with only limited adjustments to the orehandling and ventilation systems, would also result in a more efficient use of capital. e great Kakula It was only in January this year that Ivanhoe rst revealed the nature of its 60 km2 Kakula discovery, which is situated approximately 10 km south-west of the Kamoa project's planned initial mining are a at Kans oko Su d. e re su lt s discovered in the timeframe since and the consequent eff orts Ivanhoe has injected into verifying the project's full potential are indicative of its high-level attraction. “Given the remarkable exploration success we have had to date at the Kakula discovery, we believe that this new copper discovery is substantially richer, thicker and more consistent than other mineralisation that we have found elsewhere on the Kamoa project. And the results speak volumes – the Kakula discovery is a complete game changer in our planning for the development of the Kamoa project,” highlights Frieland. e primary objective of the drilling programme currently underway at Kakula is to con rm and expand a thick, atlying, bottom-loaded zone of very highgrade, stratabound copper mineralisation at the southern part of the discovery area. As a result of the on-going success of the Kakula programme to date, the Kakula drilling programme has been expanded by an extra 9 000 m, to a total of 34 000 m of
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exploration drilling. As the full extent of the discovery becomes apparent, further expansions to the programme will be accelerated. Drilling results thus far support ndings that mineralisation at Kakula is consistently bottomloaded, with grades increasing downhole toward the contact between the host Grand C onglomerate and the underlying Mwashia sandstone. e highest copper grades are associated with a siltstone/sandstone unit occurring within t he Grand C ong lomerate, lo c ate d approximately 1 m above the top of the Mwashia sandstone unit. To help advance the on-going exploration and delineation of the Kakula deposit, the Kamoa technical team is proceeding with the engineering and preparation of tender documents for the construction of a boxcut to accommodate decline ramps that will provide underground access to the deposit. “To date, the deposit has grown with virtually every step-out hole we have drilled,” says Watum. “In a country known for its highgrade copper deposits, Kakula is quickly establishing itself as the exceptional discovery.” It has the potential to be amenable to bulk, mechanised mining and have a signi cant, positive impact on the Kamoa project's future development plans. Ivanhoe expects to have an initial independent mineral resource estimate prepared for the Kakula discovery imminently. MRA Kamoa's Engineering Expert In February 2016, MDM Technical Africa, as part of Amec Foster Wheeler, completed a PFS for the rst phase of development of the Kamoa copper project which re ects the initial phase of project development and describes the construction and operation of a 3 Mtpa concentrator processing facility and associated surface infrastructure. Kamoa has further tasked MDM to complete some surface infrastructure early works engineering and a scoping study for a signi cantly larger concentrator to match the exciting and newly found Kakula-Kamoa copper discovery.
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MOVERS & Shakers
Kipoi’s cobalt can be recovered -study A study into the viability of the cobalt resource at the Kipoi copper project, in the Democratic Republic of Congo, has delivered positive results. ASX-listed Tiger Resources said that the study concluded that, based on the expected nameplate copper cathode production level of 32 500 t, there was sufficient cobalt potential within the current Kipoi copper leach circuit to justify further studies. "We have a latent amount of cobalt in the system that we've known about for many years, and until recent times the cobalt price hasn't been sufficient to make putting this into production worthwhile. But the price is now pretty attractive," Tiger MD and CEO Michael Griffiths said. e study, undertaken by Mintrex, identi ed two potential cobalt process routes, including an intermediate recovery and cobalt re ning. e processing pathways could be developed progressively or in stages, and Mintrex has recommended the development of a cobalt hydroxide circuit to produce a cobalt hydroxide intermediate product as a rst step, with capital costs for this estimated at around $22-million for a 1 000 t/y circuit. Tiger said the company would scope a metallurgical test work programme to con rm the commercial process ow sheets and to rm-up the capital cost and estimate likely operating costs. is test work was expected to be completed by December. "We are looking at cobalt as being something that will add signi cant value to the operations over the 16 year life-of-mine at Kipoi," Griffiths said.
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Movers & SHAKERS
Ivanhoe Mines begins hydro-power supply from rst of the rst of three upgrade projects Ivanhoe Mines has begun supplying ele c t r icit y f rom t he rst of t hre e hydropower plants that it is upgrading in the Democratic Republic of Congo. Ivanhoe Mines reported on Wednesday that the Mwadingusha hydropower plant began supplying an initial 11 MW of power to the national grid in the DRC. e upgrading is part of a programme planned to eventually overhaul and boost output from a total of three hydropower plants – is being conducted by Ivanhoe Mines and its joint-venture partner, Zijin Mining Group, in conjunction with the DRC's state-owned power company, La Société Nationale d'Electricité (SNEL). Ivanhoe Mines notes that the completed upgrading programme could produce a combined 200 MW of long-term, clean electricity for the Democratic Republic of Congo's (DRC's) national grid, while also s u p p o r t i n g t h e d e v e l o p m e nt a n d production of copper from the Kamoa project. At Mwadingusha, electricity now is being produced by the No. 1 turbine generator the rst of six installed at the dam's power plant that are being upgraded and modernised. It is the rst step in a programme based on an initial 2011 memorandum of understanding, and subsequent 2014 agreement, between Ivanhoe and SNEL. Completion of the full upgrading and
modernisation of Mwadingusha's ve other generating units is underway is expected to restore Mwadingusha to its installed output capacity of approximately 71 MW of power for the national grid, since originally being commissioned in 1930. e upgrading work is being undertaken by a partnership between SNEL and Ivanhoe Mines Energy DRC, a subsidiary of Kamoa. A ceremony last week marking the resumption of output from the rst generator was attended by prominent officials, including the Governor of HautKatanga Province Jean-Claude Kazembe Musonda; Haut-Katanga's Minister of Mines Professor Willy Kitobo Samsoni; and members of the senior managements of SNEL and Ivanhoe Mines. Ivanhoe Mines executive chairman Robert Friedland says a dependable power supply is essential to planned production at Kamoa. is rst installation of modern power generating equipment at Mwadingusha is an important milestone in helping to secure long-term, sustainable and clean electricity for the Congolese people and for the development of Ivanhoe's major, new copper mine at Kamoa, he says. “Mining and the supply of reliable energy are inseparable and we are committed to implementing energy-efficiency measures
and supporting cost-effective ways of generating clean energy, Friedland adds. Hydropower, with the virtues of being clean and renewable, is among the best energy solutions for the industry living with the realities of climate change. Upgrading of the other two existing hydroelectric power plants, Koni and Nzilo 1, is expected to begin once upgrading work at Mwadingusha is completed. Meanwhile, construction and commissioning of a 120-kV power line to connect Kamoa to the national grid now completed. Construction of a 20-km-long, 120-kV transmission line to supply construction power to the Kamoa site from the KolweziKisenge line, where it crosses the northern boundary of the Kamoa mining licence, was completed in late August. In addition, a local company is constructing 8 km of 11kV overhead p ower lines, cabling reticulation and ve mini-substations for distributing 11-kV of electricity to the Kamoa mine development declines at Kansoko Sud, camps, offices and dewatering boreholes. Power from the national grid is expected to be available to the Kamoa site in October 2016 aer the nal testing and commissioning of the 120-kV and 11-kV overhead powerlines and electrical substations at Kamoa.
INNOVATION
Lock-out hazards to prevent accidents
At any given time in South Africa, three million workers are exposed to the hazards posed by volatile energies such as gas, uids or steam, which are contained in various types of machinery undergoing routine servicing and maintenance. Cra workers, electricians, machine operators, and labourers are injured and even killed on the job from exposure to hazardous energy. e most effective means of minimising these risks is by securing and controlling the energy sources with an effective lock-out/tag-out (LOTO) system. A LOTO system prevents unexpected start-up or release of stored energy by securing a padlock to a clamp in order to lock the machine being serviced or maintained. Aer being locked, a tag is placed on the machine to indicate that it should not be turned on. North exports manager Hayley Arnesen explains that LOTO systems are used in industry and research settings to ensure that dangerous machines are properly shut off and not started up again prior to the completion of maintenance or servicing work, in order to avoid danger.
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“e lack of a LOTO system, or improper handling of the system, may result in injuries that include; electrocution, burns, crushing, cutting, laceration, amputation, or fracturing of body parts. e unexpected start-ups can also cause extensive damage to the machinery itself, adding to the expense of equipment repairs and replacement to the total cost involved,” she warns. Arnesen stresses that trained personnel should always manage the LOTO system. “For instance, if a steam valve automatically gets turned on, it might burn t h e w o r k e r s w h o a re re p a i r i n g a downstream connection in the piping. Another scenario is the sudden release of a jammed conveyor system, which can result in the crushing of workers, if not properly managed,” she says. According to Ar nes en, it is t he responsibility of the employer to develop and implement an energ y control procedure that provides authorised and affected employees with the same level of protection as a personal lock-out or tagout device. “A good LOTO system consists not only of
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clearly labelled energy sources and easyto-follow procedures, but also quality and accessible lock-out tools to ensure smooth and quick maintenance and servicing activities,” she continues. North offers a wide variety of padlocks that are available in nylon, aluminium, steel and brass body options. Nylon body padlocks are best-suited to electrical applications, due to the non-conductive properties of the material. Temperature and corrosion-resistant aluminium body padlocks are ideal for high-temperature outdoor applications up to 580 °C. Due to their strong physical resistance characteristics, steel body padlocks are designed for severe physical environments, while spark-resistant brass body padlocks are ideal for use in ammable applications. e North range of padlocks feature shackle diameters ranging from 4,7 mm to 7 mm, and have shackle heights ranging from 20 mm to 75 mm. North Safety Products Africa Contact Lizette Kasselman Group marketing manager Phone: (031) 705 6085 Email: marketing@northsafety.co.za www.northsafety.co.z
Embracing TECH
Mineware's Syncromine System A Must Have Celebrating twenty years in the mining and related industries, MineWare Africa has been producing soware solutions that improve business and production systems since 1996. “Everything on one screen,at your nger tips” MineWare Consulting has a selection of soware tailored to the Southern African mining and related industries. All MineWare soware suites work together to create a set of interlinked systems, which can all be interfaced on one screen. e most comprehensive of these is the Syncromine system. Syncromine places all business tools in one easy to nd interface. In the case of mines, these tools include production, safety monitoring, bonus calculation, ore accounting and costing soware modules. e production module hosts all production information such as short term planning, daily bookings, tramming and hoisting, as well as eet planning.
e safety module is linked to the production module, enabling the safety department to schedule audits on planned workplaces as well as ad hoc safety audits on surface workplaces and engineering workplaces. PCC/Safety compliance scores are calculated for every workplace by drawing input from various critical measuring points. is module has a valuable safety checklist, which can be customized to suit any client's requirement, and greatly enhances safety control over all levels of an operation. e bonus calculation system can be fully customized to set up bonus schemes to bene t the mine or workplace. e system integrates with the human resources department as well as the time and attendance and systems, enabling managers to keep control of staff resources and maximize productivity. e ore accounting module connects to Scada systems, logging all belt readings
and ow meters, enabling accurate and real-time monitoring of process. Should the plant not have the requisite monitoring equipment, data can be captured manually. e costing module allows the capability to setup a standards and norms from which planned mining activities can be measured against money spend, affecting the bottom line in real time. Syncromine brings all these sectors together, showing the data on one screen, offering veri able information in a secure, accessible and affordable way. Syncromine is currently active at Sibanye Gold, Sibanye Platinum and Gold elds mines, where it is used for short interval control. Placing all this functionality under one system, allows these mines to spot problems or trends, make better management and production decisions, thereby giving them a competitive edge. All MineWare soware is developed in consultation with the client, and includes a period of training and trouble-shooting.
Movers & SHAKERS
Universal Mining invests K70bn in iron ore plant Universal Mining and Chemical Industries Limited is investing K70 billion into mining iron ore west of Kafue, says Dr Julius Kaoma. In a recent interview, Dr Kaoma, who is UMCIL Kafue Steel Plant executive technical director, said the mine would help reduce importation of steel into Zambia.
In the same light UMCIL sales manager Benjamin Belemu says a lot of steel being imported into Zambia is produced at Kafue Steel Plant. e steel nds its way back to Zambia aer being exported to South Africa. Local steel merchants are more inclined to importing steel as opposed to sourcing it locally this is according to Mr Belemu. “Scrap metal is in short supply, we are investing in iron ore 60 kilometres west of Kafue at Sanje hill, 15 kilometres east of Nampundwe Mine,” Dr Kaoma said. He added that there was so much talk about Copper when Zambia had a lot of iron ore. Dr Kaoma, who was in Livingstone for an international conference on infrastructure development and investment strategies for Africa, said the Kafue Steel Plant was now producing 120,000 tonnes of steel, more than half below its installed capacity of 250,000 tonnes. UMCIL was also in talks with the constructors of the Kazungula Bridge to use steel from Kafue on the bridge. He added that the constructors of the bridge were surprised at the quality of the steel from Kafue. “Some metal from Kafue is exported and it ends up being resupplied back into the country. What is important is to meet on quality,” said Belemu, who, however, noted that some experts such as quantity surveyors were not helping the steel plant as they were not recommending steel from Kafue.
Specialises in: *Schools & Institutionalised Catering * Industrial Catering *Mine Village Management * Club Canteen Management *Special Event Catering *Daily Delivered Traditional & Western Meals *Weddings * Premix Tea * Ofce Ingredients *Water Dispensers & Coffee Machines *Industrial & Commercial Food Service Equipment 38
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Providing Cost-Effective Professional Catering Solutions
P.O Box HR10584, Harare, Zimbabwe Tel: (263-4) 620301-9 Fax: (263-4) 620300 Mobile: +263 772 565 823/824/825
E-mail: servcor@servcor.co.zw
Website: www.servcor.co.zw
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www.servcorshoppingcart.co.zw
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Micropilot FMR5 family
Endress+Hauser shows you how to work smarter, not harder! Dust formation, abrasion and high temperatures: reliable level measurement in clinker silos can be quite the challenge. Find out how a cement company mastered this challenge with the help of Endress+Hauser and its self-learning smart sensor Micropilot FMR57.
Cement is a fundamental part of life, and demands are high in respect to the quality of this construction material. Different varieties are created by joint grinding of the basic clinker with a gypsum anhydrite mixture, with gypsum rock or blast furnace slag and other aggregates. e current construction market situation demands a high level of exibility and fast switching of varieties from production plants. is is why system availability and storage capacity in the clinker silos are becoming more and more important. However, clinker silos differ from typical bulk solids silos in terms of their size and the stacking and discharge systems associated with this. is means that it is fairly common for a central column to be
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incorporated in the silo, with various openings. As well as being abrasive, clinker typically forms ne dust clouds during storage. And as the clinker is transported directly out of the kiln and into the silo via the cooler, the bulk solids have a high residual heat – temperatures which may exceed 100°C. All these factors make reliable level measurement very challenging. is is particularly true as the installation location for the measuring technology is oen de ned by local factors. One clinker silo at a Cement Factory presented particularly challenging application conditions for measuring technology. In addition to dust formation, abrasion and high temperatures, massive structures impeded reliable level detection. Strong false echoes occurred
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caused by the lling device via a anged central column in the clinker silo with various openings. To date, these problems were frequently resolved by means of an electromechanical plumb line system. e disadvantage of this contact-based measurement system as far as abrasive media are concerned is the high amount of maintenance required. To reduce this, ultrasound devices are frequently used which are contact-free. But this technology in turn has its physical limitations in terms of very strong dust formation. e solution for this cement factory: the Micropilot FMR57 bulk solids radar measuring device from Endress+Hauser. Because this free-space radar device combines the no-contact approach and the resistance to dust. False
Micropilot FMR57
echoes are also no problem for the smart sensor which features multiple echo detection and uses clever evaluation algorithms to compensate for these disruptive factors. e self-learning soware algorithms in the Micropilot are capable of monitoring and characterising up to 20 microwave re ections simultaneously: i. level signals ii. interfering signals iii. doppler signals iv. ground signals e signal type is de ned by evaluation of the various re ection properties, such as re ection height, re ection position, re ection speed and direction of travel. ese unique evaluation algorithms make it possible for the rst time to reliably evaluate a signal re ection even beneath interference masking and regardless of radar operating frequency. Using the Micropilot FMR57 with the technological package of innovations allows the system operators at this plant to view information at any time – including during lling – on the current level and hence the availability of the clinker. e new measuring technology also reduces the amount of maintenance required for this silo compared with the electromechanical system. But being a smart solution does not mean that the sensor makes any compromises in regards to safety. As all devices in the Micropilot FMR5x range were developed in accordance with IEC 61508. is high quality allows the radar devices to be used to meet SIL 2 requirements. Development in accordance with IEC 61508 makes it possible to achieve SIL 3 with two radar devices with homogeneous redundancy. And when it comes to secure data management, just rely on HistoROM, the ingenious Endress+Hauser data management concept for two-wire devices like the Micropilot FMR57. is permits lots of functions which are important for safe system operation.
Permanently connected to the transmitter housing, it automatically stores all data belonging to the measuring device. But that is not the only bene t HistoROM offers. Because the automatic data backup allows time to be saved when replacing electronics without having to recalibrate. When the electronics are replaced, the device data from the last parameterisation are loaded automatically by the HistoROM memory chip into the new electronics, and the device automatically resumes its measurement operation. Parameterisation via the display or downloading the device data on a laptop is not required. e data is also stored in the display as a backup. If a parameterisation process fails, the previous settings can be restored and the relevant HistoROM data will be overwritten with the display data. e “data duplication” option permits parameterisation of devices in the same applications, and here a set of parameters can be transferred from one device to the other. As a result, all requirements are met in an elegant fashion. e effect: greater reliability in system operation, with reduced costs. anks to a smart solution- t for our digital age.
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Challenging level measurement: e clinker silo at the cement factory is 40.8 meters high, more than 16 meters wide and is fairly demanding in terms of measuring technology: • another platform is located beneath the cover • in the middle of the silo is a anged central column with various openings. False echoes occur here • a lot of dust is formed during lling e Micropilot FMR57 free-space radar with multiple echo detection and intelligent evaluation algorithms can handle these difficult conditions with no problems. For further information, please visit http://bit.ly/2aFBAv0 or www.za.endress.com/fmr57 Enquiries: Jan Gerritsen Product Manager Level Pressure Endress+Hauser (Pty) Ltd Tel: (011) 262 8000
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Movers & SHAKERS
Rare Group bags distributorship for Uk’s Polypipe Civils range Pipeline solutions provider Rare Group has recently attained exclusive distributorship for Polypipe Civils' range of Ridgidrain, Ridgiduct and Ridgistorm XL (HDPE) structured wall pipes for South Africa and Zambia. With over 20 000 product lines, Polypipe is the UK's largest plastic pipe systems manufacturer. Polypipe views the relationship with Rare as an integral part of its overseas business. For Rare, it means an extended product offering to the mining and infrastructure market segments, with the company now able to supply large diameter – up to 3 000 mm – structured wall pipes and ttings, which are not yet manufactured in Southern Africa. Polypipe provides plastic pipe systems for a variety of gravity and pressurised applications, which provide solutions to a number of mining processes, including transport infrastructure, water delivery and distribution, dewatering and storage, processing, water treatment, as well as welfare infrastructure. “In mines, where mineral extraction processes rely heavily on water, e ffe c t ive w ate r m an age m e nt i s essential,” says Rare Pipeline Services Manager, Carl von Graszouw. Ridgidrain is ideal for non-pressure sub-surface draining applications with
both non-perforated, half-perforated and fully perforated options available. Manufactured in HDPE, Rigidrain boasts excellent internal and external abrasion resistance, protecting the pipe against sediment in the wastewater and the rugged mine environment. Von Graszouw states that tailings management facilities are essential in ensuring the mine operates in an environmentally-conscious manner, and adds that the Ridgidrain system allows for the controlled seepage of treated water. e system can also deal with unpredictable uctuations, owing to factors such as storm water. Polypipe International Business Development Manager Philip Wood explains that plastic piping systems, such as Ridgidrain, are up to 94% lighter than concrete alternatives, making them safer to install and easier to move around. Plastic piping also offers considerable environmental bene ts. “Production and transportation are simpli ed and use less carbon. e product can also oen be reused elsewhere when a project ends. ese factors are key considerations for mine operations and also make the product more cost effective. For these reasons, Ridgidrain is growing in popularity in the African mining market.” Polypipe's solution for sub-soil
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drainage is in operation at the tailings management facility of a gold mining project in the Democratic Republic of C ongo. C anada-bas ed B anro Corporation's Namoya mine houses a substantial tailings management facility to process the leover materials and wastewater from the extraction of gold. e Ridgidrain drainage system was selected to provide effective subsoil drainage. Polypipe supplied 1 386 m of 500 mm diameter Ridgidrain thinwall pipe and 190 m of the product in 600 mm diameter. e product has also been installed in the rst phase of the infrastructure work at the Marampa iron-ore mine project, in Sierra Leone. e work involved installing a pipeline that will drain water from the tailings dam to a local water treatment area. Rare and Polypipe state that they will work closely together to further develop and improve market awareness of the UK group's products in the Southern African market. Rare will act as installation partner where projects require supply-andinstall turnkey solutions. Contact e Rare Group Lesley Geyser Marketing Assistant P: 016 362 2868 www.rare.co.za info@rare.co.za
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Mining and the environment e impact of the mining industry on the environment has been a public concern, with growing appreciation of the natural environment and increasing awareness of the possible harmful effects that the industry's activities can cause. e industry and government have responded with a number of initiatives and regulations to protect and manage the environmental effects of mining activities. e extractive nature of mining operations creates a variety of impacts on the environment before, during and aer mining operations. e extent and nature of impacts can range from minimal to signi cant depending on a range of factors associated with each mine. ese factors include: the characteristic of the ore body; the type of technology and extraction methods used in mining and the on-site processing of minerals; and the sensitivity of the local environment. e environmental impacts of mining, although signi cant, are generally
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con ned to local areas. Apart from direct physical impacts of extractive activities, contamination of air, land and water may also result. However, mining in isolation may not be the main land use that upsets ecological systems, as environmental effects are cumulative in nature and other past activities or events may have contributed to these effects. is article brie y discusses the main environmental impacts of mineral mining, such as wastes, and the rate of resource use (where the supply of minerals depends on the rate of resource use, which is affected by the economic life of mineral deposits and the rate at which new reserves are discovered). e article also summarises environmental management initiatives, such as the use of legislation, environmental impact assessments, environmental protection expenditure, rehabilitation and industry self-regulation. mpact of the mining industry on the
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environment Mineral exploration Mineral exploration can impact on the environment. Its effect depends on the scale of exploration and what equipment is used in the exploration phase. Initial exploration may involve the use of satellites and aerial photography, with the latter impacting through noise and proximity to wildlife areas when conducted at a low altitude. Activities at ground level oen require the use of bore holes, excavation pits and transect lines. e use of support equipment also leaves an impact on the environment; exploration vehicles require access tracks, and even helipads, if le unrehabilitated, can have medium- to long-term effects. Mining operation Environmental impacts may also occur through mine establishment, ore extraction, mineral concentration and
associated transport, provision of infrastructure (which may include whole townships) and downstream processing. Inherent to mining and mineral processing operations is the generation of wastes. ese are mostly in the form of waste rocks, including surface waste rocks, rocks between ore bodies or layers and other unwanted material. is form of waste contains low or nil concentrations of the material desired and is oen relatively toxic. Normally, waste rocks are stockpiled or dumped adjacent to or near the excavation area, to be used later as back ll during reclamation. Mineral processing produces wastes in grain sizes of ne sand, silt and clay fractions. Referred to as mine tailings, this type of waste contains signi cant concentrations of minerals that are not amenable to recovery at the time of initial mining. Tailings are usually disposed of in specially lined tailings dams, which are
normally capped and revegetated to prevent the release of environmentally harmful materials. Other wastes from mining may be in the form of water and air pollution. e majority of air emissions associated with the mining industry include dust, oxides of nitrogen, sulphur dioxide and carbon monoxide. Some of these come from mining vehicles and on-site plant machinery. Water quality may be affected by: Acid mine drainage - when large quantities of excavated rock containing sulphide minerals interact with water and oxygen to create sulphuric acid. Heavy metal contamination and leaching - heavy metals occur naturally in many ores, and are oen released in the mineral extraction process. Metals (i.e. arsenic, cobalt, copper, cadmium, lead, silver and zinc) contained in an excavated or exposed rock may be
leached out and carried downstream by owing water. Processing chemical pollution - spilling, leaking or leaching of chemical agents (i.e. cyanide, sulphuric acid) from the minesite into nearby water bodies. Erosion and sedimentation - erosion of cleared land surface and dumped waste material resulting in sediment loadings into the adjacent water bodies, particularly during rainfall. Environmental impacts resulting from mining are not limited to current mining operations. Mining residues and scars at old mining sites may also impact on local environments. e legacy of abandoned, unrehabilitated minesites has required comprehensive remediation efforts paid for with taxpayers funds.
Movers & SHAKERS
Sentinel Mine – A game changer $2.1 Billion venture at forefront of global mining technology According to the Zambian Chamber of Mines, Sentinel is a blueprint for the future of mining in Zambia, by virtue of its technological sophistication and because it shows that it can be economically viable to mine a low-grade copper deposit. e new US$2.1 billion Sentinel copper mine, situated in a remote corner of Zambia's NorthWestern province, is the Zambian mining industry's most ambitious venture ever, and the single largest upfront infrastructure investment in the country since the Kariba Dam. Sentinel is located in the town it gave birth to – Kalumbila – and for this reason is oen referred to as Kalumbila mine. It started operating in September 2015, and is currently producing around 150 000 t of copper a year. It expects to reach full production of up to 300 000 tpa in 2017;
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of both concentrate and plated copper. Owned by First Quantum Minerals (FQM), the mine took ve years to build. ousands of contractors were employed, and more than 265 000 t of equipment were transported to the site, in 14 500 massive truckloads. ere was no existing power grid, so more than 600 km of power lines had to be constructed, running halfway across the country down to the west of Lusaka. Some 7 000 ha of woodland had to be cleared as well. Instead of burning the timber, FQM built a sawmill which employs 120 people and uses the wood to make fence poles, furniture and other wood products. Eventually, timber will be exported. e Sentinel project consumed prodigious quantities of cement, fuel and food; launched many local businesses large and small; created employment; and kick-started the creation of an entire local
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economy where none previously existed. e new town of Kalumbila already has more than 5 000 inhabitants, the country's second-longest airport runway and a bold plan to become a thriving, diversi ed economy by the time Sentinel reaches the end of its commercial life in 25 years' time. “Sentinel mine puts Zambia at the forefront of global mining technology,” says John Dean, commercial manager. “It sets new standards in efficiency, productivity and training, and sets a precedent for future copper-mining ventures in Zambia.” Sentinel is a lowgrade, open-pit mine – the ore contains only 0.51% copper. Yet the mine is anticipated to produce a long-term return on investment because it has been designed from scratch, carries no legacy issues, and uses the most sophisticated mining technology in the world. “ Sentinel mine puts Zambia at the forefront of global mining technology. It
Movers & SHAKERS sets new standards in efficiency, productivity and training, and sets a precedent for future copper-mining ventures in Zambia,” Technologically advanced Everything is advanced – the big drill rigs allow explosives to be placed at greater depths; the trucks are gigantic, and carry heavier loads; the steel-ball mills are the world's largest and grind larger quantities of ore; the conveyor belts are long and carry more material further; the world's largest semi-mobile rope shovels scoop out 120 t of ore at a time from the pit, and can ll a 250 t truck in under a minute. e entire operation runs around the clock. By night and day, the open pit resembles a massive amphitheatre where people, machinery and payloads move in a seamless, non-stop motion. “It's all about speed, efficiency and economies of scale,” says Dean. “e mine would not be viable without this level of technology.” e technology is expensive – and dangerous – and proper training is
required. For example, the drivers of the heavy haul trucks learn their cra in sophisticated equipment in state-of the art simulators which use virtual reality to replicate real-world conditions. In one simulator session, a driver is learning to drive in heavy rain and muddy terrain. In a room alongside, the rest of the team watch the session in real time on a bank of computer screens. All drivers have to do simulator training every two years as a refresher course, if they've been away from work for more than a month, or if their daily driving reports show too many errors. “Sentinel is not just about sophisticated technology,” says Dean. “It's also about operations, maintenance, working practices, employee productivity – and having access to affordable and reliable energy.” Energy is an emotive issue at Sentinel. Despite having built nearly 600 km of power lines, Sentinel has yet to be fully
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connected to the national grid by electricity supplier Zesco. e mine is currently running on reduced supply, and needs about 30% more energy to operate at full capacity – especially as most of its sophisticated machinery and equipment uses electric power rather than diesel fuel. Nevertheless, even at current production levels, Sentinel's contribution to national output con rms North-Western province's reputation as the country's largest copper-producing region. Its three mines – FQM Sentinel, FQM Kansanshi and Barrick Lumwana – together produce nearly 500 000 t of copper a year, which is about 70% of Zambia's annual production of 711 000 t. “Fieen years ago, there was no mining industry to speak of in North-Western province,” says Dean. “Today, several billion dollars of investment later, that has changed completely. e province has become the new Copperbelt. Sentinel is the most recent example of that shi."
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Movers & SHAKERS
One Of Zambia's Most Successful Mines Is Also One Of Its Smallest IT ACCOUNTS for less than 2% of annual Copper production, yet Chibuluma Mine, situated on the Copperbelt, is one of Zambia's most successful mines in safety, productivity and pro tability. Chibuluma Mine has had “only” one fatality in eight years. Its copper output per employee is 50% higher than the Zambian industry average, and its agship Chibuluma South project was pro table barely two years aer production, which is unusual for the industry. e mine has paid corporate tax every year since 2007, with a total of US$112 million paid to date. Chibuluma is a highly mechanised underground mine just outside Kalulushi, about 22 km from Kitwe. It produced 13 300 tonnes of copper in 2015 – a fraction of the country's output of 711 000 tonnes. “We mine one of the highest-grade copper deposits on the Copperbelt,” says chief geologist, Narendra Shekhawat. “at means we do proportionately less work to produce the same amount of copper.” Although the ore body is not very big, it has an average copper grade of 3%. is contrasts with large open-pit mines such as Barrick Lumwana or FQM's new Sentinel mine, where the grade is
so low (barely 0.5%) that colossal quantities of ore have to be unearthed and treated, at considerable cost, to extract the copper. Chibuluma' s smaller operation means not only lower costs but a simpler work set-up – problems are easier to spot and x, approvals happen faster and turnaround times are shorter. Despite its enviable track record, Chibuluma has not escaped the effects of the current mining downturn. Like Zambia's other mines, it had to shed workers in 2015, embarked on major costcutting and scaled back production. At the height of the copper boom in 2013, Chibuluma produced 18 000 tonnes of Copper a year; that is now down to 10 000 tonnes. However, the biggest challenge is that the current mineral deposit will be mined out within the next few years. “Unless our ongoing exploration nds a new copper deposit worth exploiting soon, Chibuluma will probably close sometime between 2020 and 2022,” says Eustus Munsaka, Head of Finance. “All mines have a natural lifespan, and we are about to reach the end of ours.” Already, a $4.4 million rehabilitation programme is under way to restore the landscape to its original state. Even though closure is still a few years off, Chibuluma has developed an enviable track record in its contribution to Zambia since it was privatised in 1998. e Mine has paid taxes to government, uplied the community through its Corporate Social Responsibility programme, and stimulated the local economy and job creation through the spending power of its employees.
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| July - Aug 2016
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Embracing TECH
Yokogawa Releases Plant Resource Manager (PRM®) R3.31
–Improving maintenance efficiency– Yo k o g a w a E l e c t r i c C o r p o r a t i o n announces the September release of version R3.31 of its Plant Resource Manager (PRM®) soware tool for the centralized management of large amounts of data from plant monitoring and control d e v i c e s a s wel l a s m anu f a c tu r i ng equipment. PRM R3.31, an upgrade to R3.30, includes a new function that enables PRM to link with a computerized maintenance management system and a new data display function that enables eld maintenance personnel to access data that is useful for locating and responding to device failures. With this latest PRM release, Yokogawa aims to capture a larger share of the plant maintenance market by offering companies a solution that enables their maintenance personnel to work more efficiently. Manufacturers are constantly looking for ways to improve maintenance efficiency by using soware tools like PRM that can centrally manage large amounts of maintenance information and other types of data from plant monitoring and control d e v i c e s a s wel l a s m anu f a c tu r i ng equipment, and there is a constant need to quickly identify device failures that can interfere with the safe operation of plants. To better meet such needs, Yokogawa has reinforced the functions of PRM. is latest PRM version enables the seamless management of the process of detecting and responding to device failures. is has been achieved by linking PRM to a computerized maintenance management system that is used to draw up maintenance plans and manage the progress of maintenance tasks. With this new PRM version, eld maintenance personnel can also access key performance indicator (KPI) repor ts on device availability and other indices that until now have been mainly available for use by m a n a g e m e nt . i s f a c i l i t at e s t h e
identi cation of failure causes so that appropriate countermeasures can be taken. Enhancements 1. Linking of instrument status information with maintenance work information e PRM works with Maximo®, an IBM® maintenance solution. Upon detection of a device failure, PRM issues an instruction to Maximo to draw up a task plan and begin the process of managing the progress of task execution. With PRM R3.31, a symbol (maintenance mark) is displayed over the device icon in the device navigator window that communicates the current state of the task that is being managed by Maximo. is ensures s eamless management of the failure detection and res olution pro cess. PRM R3.31 is compatible with the latest Maximo versions, 7.5 and 7.6. 2. Efficient access to eld asset KPI reports Field asset KPI reports*1 contain data about the availability of instruments, the number of instruments that are in an abnormal state, warning status, other states, and the number of alarms and events and their ranking. Until now, this information has been used mainly by m an a ge m e nt . Wit h P R M R 3 . 3 1 , maintenance personnel can now directly access eld asset KPI reports via the PRM user interface, and this information can be used to detect potential device abnormalities, identify and analyze failures, and consider necessar y countermeasures. 3. Compatible with new I/O device In June 2016, Yokogawa released a new I/O device for the CENTUM® VP R6.03 integrated production control system that simpli es the task of upgrading from CENTUM CS, CENTUM CS 1000, or CENTUM CS 3000. PRM R3.31 supports
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this new I/O device. When PRM R3.31 is linked to this I/O device using the HART communications protocol*2, failures and other device statuses can be quickly identi ed. *1 Reports that are generated by Field Asset KPI Report, a soware tool for use with Yokogawa's InsightSuite® AE service for optimizing the effectiveness of plant assets. *2 A eld network communications protocol for control applications that is advocated by the HART Communication Foundation About Plant Resource Manager (PRM) PRM is a soware package that centrally manages large amounts of status and maintenance information from plant monitoring and control devices and manufacturing equipment. With PRM, users can monitor the status of their devices and perform online diagnosis via a network. In addition, PRM centrally manages maintenance information, including device ledgers, in a database, and supplies maintenance information for plant eld devices and equipment to maintenance personnel. About Yokogawa Yoko g aw a ' s g l o b a l n e t wor k of 9 2 companies spans 59 countries. Founded in 1915, the US$3.7 billion company engages in cutting-edge research and innovation. Yokogawa is active in the industrial automation and control (IA), test and measurement, and aviation and other businesses segments. e IA segment plays a vital role in a wide range of industries including oil, chemicals, natural gas, power, iron and steel, pulp and paper, pharmaceuticals, and food. For more information about Yokogawa, please visit www.yokogawa.com/za.
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| July - Aug 2016
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