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1 MINING Central Africa’s Premier Business To Business Mining magazine May-June 2016 > Issue 18 > Vol.7 #
DRC-ZAMBIA
Mining in Zambia: Africa’s safe haven -10 Contract mining offers edge in depressed market -12
ALSO... Ivanhoe Mines’ exploration team makes major new copper discovery at the Kamoa Copper Project 32
F MD R C - Z A MB I A
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Contents MINES & MINERALS
36
KIBALI GOLD pushes through challenges for full production
FEATURED DEVELOPMENTS
HI TECH
23
SAND SLURRY ow monitoring
INNOVATION
08 Construction underway at Hounde Gold Projects 09 Solar-Diesel microgrids in Zambian mining 12 Contract mining offers edge in depressed market 28 AECOM unveils ‘2020 Strategy for Africa’ 41 Overwhelming mining support for DRC mining sector
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INNOVATIVE power devices tackle drought related electricity constraints
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FROM THE EDITOR 1st MINING Central Africa’s Premier Business To Business Mining magazine May-June 2016 > Issue 18 > Vol.7 #
We are excited again to bring you yet another edition of First
DRC-ZAMBIA
Mining DRC-Zambia, this year, highlighting the movements and hurdles in the mining industry. We strive to feature topical information on mining and exploration projects in Southern Africa and beyond, focusing on the entire
Mining in Zambia: Africa’s safe haven -10
mining value chain, not only focusing on methods and research but on the greatest achievements.
Contract mining offers edge in depressed market -12
All industries have to evolve, grow and change with times and mining is no different. Mineral bounty identi es the wealth of a country, creating businesses and opportunities, however, the ability
ALSO... Ivanhoe Mines’ exploration team makes major new copper discovery at the Kamoa Copper Project 32
to properly and safely mine has become the new standard. F MD R C - Z A MB I A
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Diversi cation has bene tted mines, while the best of them produce a range of resources, a number of them now require entirely
Cover
different methods of extraction.
Photo Courtesy of Variant
roughout the Southern Africa Power Pool – where Angola, Democratic Republic of Congo, Malawi, Mozambique, Namibia, Zambia and Zimbabwe rely on hydropower for 71 to 99 percent of
Editor
their electric generation, widespread drought has signi cantly
Bertha M.
reduced the region's ability to generate electricity. In this edition we
editor@fmdrc-zambia.com
highlight Innovative Power devices need to tackle drought related electricity constraints.
Contributing Writers
We also look at the construction at Houndé Gold Projects in
Anne Thomas, Mfuneko Jack,
Burkina Faso. In addition we give you a snipper of the new report
Lindani Mkhize and Caroline Thomas
the global mining equipment market. is edition is packed with many interesting articles. Remember to visit our online portal www.fmdrc-zambia.com
Sales & Marketing Russou Billiard sales@fmdrc-zambia.com +27 11 044 8986
Bertha M. Editor
Graphic Design and Layout Que Gibson
Published By Mailing Times Media sales@fmdrc-zambia.com www.fmdrc-zambia.com
Circulation/Sales Officer
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
Mthokozisi M info@fmdrc-zambia.com +27 11 044 8985
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MINING NEWS
Banro sets new production records at DRC gold mines Canadian gold producer Banro has achieved new production records at both its operating assets in the Democratic Republic of Congo (DRC), producing a combined 49 673 oz of gold during the second quarter ended June 30. So far this year, total production stood at 93 865 oz of gold, which was in line with the 2016 production guidance, the company advised, with the second half expected to deliver the bulk of production. Twangiza, the company's rst mine in the DRCs South Kivu province, produced 26 218 oz of gold, also in line with guidance, with the mine plan requiring mining lower-grade ore during the rst half of the year, at lower recoveries compared with recent quarters. e second mine, Namoya, produced 23 455 oz of gold in the period, with a record 9 201 oz produced in June. "We are very pleased with the continued ramp-up at Namoya during the second quarter, culminating in over 9 000 oz of gold being poured in June. is positions the Namoya operation for steady-state production during the second half of the year," stated Banro president and CEO John Clarke. He noted that management was focused on replacing the senior secured notes maturing in March 2017 with a longer-term instrument. “Resolving the impact of the senior secured notes would provide the company with long-term opportunities and bene ts,” he advised. Spread over its two low-cost openpit mines and four projects on the Twangiza-Namoya gold belt, Banro held 2.9-million ounces of gold in reserves, with 7.73-million ounces in the measured and indicated categories, and 5.27-million ounces inferred.
Global mining equipment market to reach $156 billion by 2020
According to the study, titled “World Mining Equipment Market – Opportunities and Forecasts, 2015 – 2022”, the Asia–Paci c region accounted for the highest revenue of over $50 billion in 2015, followed by Latin America, the Middle East and Africa (LAMEA). According to the analysts, the market growth is likely to be driven by increasing demand for coal in electricity generating applications, growing demand for technologically advanced mining equipment, and rising construction of roads and railways through hilly areas. e metal mining segment occupied a major share of around 39%, followed by mineral mining in 2015. e metal mining segment is anticipated to witness the fastest CAGR of 10.3% during the forecast period, owing to increasing demand of base metals such as copper, nickel, lead, zinc and others. Moreover, coal mining is anticipated to witness impressive growth in developing economies such as China and India in the coming years. e segmentations by type include mineral processing equipment, surface mining equipment, underground mining equipment, mining drills & breakers, crushing, pulverizing & screening equipment, and other mining equipment. Surface mining equipment accounted for the maximum market share of around 31% in 2015, as they are extensively being used in application areas such as coal mining. From a growth perspective, mining drills and breakers is projected to be the fastest growing segment due to increasing application in metal mining. In 2015, LAMEA was the second largest market followed by North America. Asia-Paci c would continue to dominate the overall market throughout the forecast period owing to increasing demand of mining equipment from countries such as China, India Indonesia and others. Key ndings: · Asia-Paci c would continue to be the dominant market for mining equipment throughout the forecast period. · Metal mining application segment is forecast to witness fastest CAGR during 2016-2020. · Surface mining equipment accounted for the largest share of the overall market in 2015. · Mining drills and breakers segment is expected to exhibit fastest growth during the forecast period. Product launch and acquisition are the key growth strategies adopted by the leading market players to strengthen their foothold in the market. Key companies pro led include Caterpillar Inc., Komatsu Ltd., Sandvik, Joy Global Inc., Hitachi Construction Machinery Co. Ltd., Atlas Copco, AB Volvo, Doosan Heavy Industries & Construction, Metso, and Liebherr Group.
e global mining equipment market is expected to garner $156 billion by 2022, increasing at a compound annual growth rate (CAGR) of 7.9% during 2016 – 2022, a new report published by Allied Market Research shows.
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MINING NEWS
Mining company funds armed men in eastern Congo gold rush while state loses tax windfall Armed groups in Shabunda territory, eastern Democratic Republic of Congo, received gis of arms and cash from a Chinese mining company and made up to $25,000 per month extorted from local miners during a recent two-year gold boom. In just one year, up to $17 million of gold produced by Kun Hou Mining, the Chinese-owned company, went missing and was likely smuggled out of Congo into international supply chains, Global Wi t n e s s r e v e a l s t o d a y (http://www.globalwitness.org/river-ofgold-drc). At the same time, the Congolese state lost out on tax revenues on up to $38 million of artisanal gold produced per year during the gold rush, due to smuggling and misconduct by provincial authorities. e gold rush focused on the Ulindi River reached its peak in 2014 and 2015 and continues to this day. Evidence gathered by Global Witness also shows a provincial authority colluded with armed groups in illegal taxation of miners while another altered official export documents so gold looked as though it was coming from legally-operating mines. Global Witness' investigation reveals the extent of the problems in eastern Congo's artisanal gold sector. Eastern Congo has seen an uptick in gold production in recent years, the revenues from which could have been used to address the region's desperate poverty but have instead oen funded armed groups and corrupt officials. Most of eastern Congo's artisanal miners - around 80% - work in the gold sector. Recent international reforms have aimed to stop Congo's mineral wealth funding armed groups. Global Witness warns today that
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the Congolese government needs to hold companies and government officials involved in such abuses to account in order for these reforms to work. Armed groups, known as Raia Mutomboki, received at least two AK-47 assault ri es and $4,000 in cash from Kun Hou Mining, which operates mechanised gold dredging machines along the Ulindi River in Shabunda territory, South Kivu province of eastern Congo. In addition, the armed men taxed artisanal miners o p e r at i n g l o c a l l y - m a d e d r e d g e r s extracting gold along the river. Local authorities also collaborated with the Raia Mutomboki, through a tax sharing deal. e taxes collected by authorities appear to have disappeared, depriving Congo of much needed revenue which could be used for health and education. “ere were over 500 cases of malnutrition reported in Shabunda town in 2014 and yet the signi cant revenues generated by this gold boom bene tted armed men and predatory companies instead of the Congolese people” said Sophia Pickles, Senior Campaigner at Global Witness. “e Congolese government must enforce its own laws to ensure that companies in its gold sector do not produce or trade gold that has funded armed groups. Any company breaking these laws must be held accountable for their actions. Provincial mining authorities that fail to properly govern the minerals sector must also be held liable.” Global Witness' research shows that almost half a million dollars' worth of Kun Hou's gold was exported to a Dubai company through official channels. e rest of the company's estimated $17
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million of gold production is likely to have been smuggled out of the country. Global Witness has also found evidence that mining officials in the provincial capital, Bukavu, deliberately falsi ed documentation to obscure links to Shabunda. Officials changed the gold's origin on official export documents to show instead it came from the handful of legally-operating artisanal mines in South Kivu. is pattern has been repeated with other mines in the province. As a result, it is much more difficult for international buyers to be sure that gold has not funded armed groups. “Provincial authorities overseeing Shabunda's boom have, by their actions ove r t h e p a s t t wo ye ar s , d i re c t l y undermined international and the national government's efforts to reform eastern Congo's artisanal gold trade,” said Pickles. “States have a responsibility to ensure that companies do no harm, including checking supply chains for links to con ict and human rights abuses – Congo and the United Arab Emirates have dramatically failed in this respect.” Global Witness's report River of Gold also shows that: · South Kivu's provincial government and mining authorities continued to support Kun Hou Mining despite repeated legal violations by the rm and repeated requests from Congo's national government in Kinshasa to shut down its operations. · Mining officials in Shabunda town working for SAESSCAM, a governmental body mandated to support artisanal miners, ran an illegal taxation racket in areas where the local dredgers operated,
MINING NEWS including in collaboration with Raia Mutumboki armed groups. · Gold from Shabunda's boom was sold on to a gold trading house in Bukavu that then sold it to their sister company, Alfa Gold Corp DMCC, in Dubai. Neither rm carried out supply chain due diligence to international standards, which would have revealed that the gold had been obtained in direct contravention of Congolese law and UAE Guidelines. Alfa Gold Corp DMCC has a wholly owned UK subsidiary registered in London's Hatton Garden jewellery area. Alfa Gold in Dubai and London did not respond to request for comment. · Documents show that a French citizen Frank Menard, who worked for Kun Hou Mining, is deeply implicated in the company's wrongdoing. Raia Mutomboki armed groups wrote to Menard in February 2015 to thank him for the two AK-47 assault ri es and $4,000. Menard also signed an official document con rming the sale of Kun Hou's gold to Alfa Gold's Congolese office. Global Witness' attempts to contact Franck Menard were unsuccessful.
In recent years there have been signi cant international efforts to tackle the link between violent con ict, human rights abuses and the minerals trade in Congo and elsewhere including international supply chain guidance set out by the Organisation for Economic Cooperation and Development (OECD) ve years ago, which has been a legal requirement in Congo since 2012. e US also passed a law and most recently industry supply chain guidelines based on the OECD standard were agreed in China. e Chinese guidelines set a precedent for Chinese companies to recognise and reduce supply chain risks and if adhered to should allow companies sourcing minerals from high-risk areas to do so responsibly. Kun Hu Mining refused to comment in response to three requests from Global Witness. SAESSCAM have strongly denied that its agents collaborated with armed groups. Global Witness.
Innovative technologies fuel the mining industry New advances in technologies and equipment are quickly contributing to the performance and management of the mining industry. It is especially apparent in open pit or surface coal mines where the objective is to remove an abundance of material as quickly and safely as possible. Improvements in equipment design can signi cantly increase productivity, and are key factors to the safety of miners. On board machine guidance systems are playing a major role by delivering realtime information that can be used to monitor ore bodies, bench height, cycle times and volume of material cut and lled. Mine planners can also use these
systems to map mines, create terrain models, and locate machine position, as well as track volume and productivity with absolute precision. e productions of monitoring tools are just as signi cant. ey provide site planners with dragline information, such as individual bucket loads, and dump locations. By observing the performance and productivity they can decrease operating costs and best utilize dragline output. In cab displays are making it easier for dragline operators to extract coal helping them move material accurately by showing the position of the buck and tub relative to
the design plan. Machine health data is also available in the cab, so operators can identify potential problems and act quickly to prevent failures. Top priority in all mining situations is safety. New technologies are producing machines that include in-cab digital displays of avoidance zones and surfaces, in addition to turning out tools that can alert workers to hazardous situations before accidents can happen. e skills and knowledge required in the mining industry has changed drastically in view of these developments and they continue to progress through the many challenges facing the industry.
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MOVERS & Shakers
Construction under way at Houndé Gold Projects Endeavour Mining started construction of its 90% owned Houndé gold project in western Burkina Faso on April 11, the same day that True Gold Mining's Karma mine poured its rst gold in north-central Burkina Faso. Endeavour acquired True Gold in a transaction that was approved at special meetings of the companies' shareholders on April 21 and that closed on April 26. Acquisition of Karma adds 110,000 to 120,000 oz/y to Endeavour gold production over a projected mine life of 8.5 years based on current reserves. e Houndé project is designed to deliver average production of 190,000 oz/y of gold
over a 10-year mine life at an all-in sustaining cost of $709/oz, based on current reserves. e project is an open-pit mine with a 3-million-mt/y gravity/carbon-in-leach plant. Initial capital cost to develop the project is estimated at $328 million, inclusive of $47 million for an owner-operated mining eet. Project capital spending in 2016 is expected to be approximately $180 million, with the remainder scheduled for 2017. e current upfront capital cost estimate is based on power supply from Sonabel, the Burkina Faso national electricity utility, consisting of a 38-km, 91-kV overhead power line. When the Houndé project reaches full pro du c t i on i n 2 0 1 8 , E n d e av ou r ' s
company-wide gold production rate will increase to about 900,000 oz/y, and its average all-in sustaining cost will drop to below $800/oz. e overall duration of Houndé project construction is estimated at 18 months. Endeavour plans to self-perform 72% of the project build, with Lycopodium contracted to focus on the processing facility, which is the remaining 28% of the total capital commitment for the project. Houndé has proven and probable reserves totaling 31 million mt, grading 2.1 g/mt and containing 2.1 million oz of gold; measured and indicated resources totaling 38 million mt, grading 2.1 g/mt and containing 2.5 million oz; and inferred resources totaling 3 million mt, grading 2.6 g/mt and containing 300,000 oz.
Embracing TECHNOLOGY
Solar-Diesel Microgrids in Zambian Mining Industry In recent years, an ongoing drought has caused a severe power crisis in Zambia. e new analysis “Power crisis and consequences for solar energy in the Zambian mining sector” from the Deutsche Gesellscha für Internationale Zusammenarbeit (GIZ) GmbH in its role as facilitator of the Project Development Programme (PDP) and the energy shows that the framework conditions for investments in solar have become more attractive. e power crisis has caused Zambia to take emergency measures at extremely high costs to close the gap between generation and electricity consumption. e mining industry is by far the biggest consumer of electricity in Zambia and is suffering greatly. Production is impaired by load shedding and power outages. Sometimes the only remedy is to use stand-by diesel gensets for baseload electricity generation. Power from diesel is expensive, and so is grid power for mines. At the beginning of the year, the rates for miners have been raised to 10.35US¢/kWh, with further increases expected—and this in a country that used to have an abundance of inexpensive electricity from huge hydropower plants.
A sustainable improvement of this situation is not in sight, as some new power plants will be completed in the next few years, but at the same time, the output capacity of the Zambian mines is expected to double, as signi cant investments have been made in past years. A recent solar tender by Zambia's Industrial Development Cooperation for two 50 MWp solar power plants has caught the attention of the mining i n d u s t r y. e b e s t o ff e r w a s a t US¢6.02/kWh, which is a signi cantly lower price than Zambia pays for emergency solar power and then mining companies pay for either grid or diesel electricity. e analysis shows that local solar-diesel hybrid microgrids have become an interesting alternative. “We have also observed in other countries of the region that industrial players, such as mining companies, lose large amounts of pro t due to an unreliable power supply,” says Tobias Cossen, Project Manager for Southern Africa at PDP. “In Zambia, the negative effects are twofold: severe production losses and higher electricity costs at the same time.” is development drives mining companies to become more
self-sufficient. Zambia has excellent sun irradiation, which has a positive effect on electricity prices from photovoltaic (PV) power plants. “e recent PV tender comes at the right time,” adds omas Hillig, founder of the consultancy THEnergy. “It shows what development solar energy has made in the past few years; 6.02US¢/kWh is competitive with any kind of conventional energ y, especially in a region that suffers from a lack of peak power during the day.” Decentralized power generation in the form of solar-diesel hybrid microgrids has advantages beyond price. It allows for a robust power supply in off-grid or weakgrid areas, such as Zambia, where the grid sometimes poses severe reliability issues. In microgrids, solar power, grid electricity and diesel back-up power can be integrated. Typically, solar energy has priority in these power plants, as hardly any direct cost is associated with the operation of a PV system. e mines can invest their own capital or can secure long-term solar power supply through p ower purchas e ag re ements w it h investors who build a PV plant and sell the electricity to the mine.
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Mining in Zambia: Africa’s safe haven
Zambia has long been regarded as the safest place in sub-Saharan Africa in which to invest and operate. It seems set to remain so in the years ahead, despite the headwinds that currently beset mining in general, as well as problems speci c to the country itself. Rod James reports. Mining is a major contributor to Zambia's economy. Copper is responsible for around 80% of the foreign earnings, and despite the metal's low prices, BMI Research forecast a real GDP growth of 6.0% in Zambia over 2015. BMI's report, published in July, concludes that private and government consumption are likely to remain key drivers of that growth, and a resilient domestic demand, coupled with a stable in ationary environment, will help offset any export weakness. Challenges to come However, the report also makes clear that Zambia will face some challenges along the way. e country's "current account" will
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end 2015 signi cantly further in the red, having almost doubled to $711m, as the de cit as a proportion of GDP grows to 3.3%, up from 1.5% the previous year. ough this will drop to 2.4% in 2016, it will not be in the black for another two years. e sharp decrease in global prices for copper, which has seen it trading close to its support level, has been a signi cant factor in this, and so too has falling production. But of late, the Zambian mining sector has had two quite different concerns altogether - politics and power.
Mineral policy e country's president, Edward Lungu, won a narrow victory in January 2015, having stood on a populist manifesto which supported earlier moves to scrap corporate income taxes but force royalties of 8% on underground mines and 20% on open-cast operations. e threatened hike in royalties brought widespread warnings of closures and huge job losses before the
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standoff was eventually broken by the reinstatement of income tax and a major reduction in royalty rates - though both at slightly higher rates than before. Some have speculated that the next presidential election, due in 2016, might see taxation and mineral policy again feature strongly in the campaign as it has elsewhere across the continent, with governments attempting to get a greater share in their natural resources. However, Zambia perhaps more than most is unlikely to want to bite the hand that feeds it. Mining accounts for 12% of GDP and 10% of employment, and according to industry gures, from 1997 to 2013 it drew $12.6bn of foreign investment, helping to turn the country into one of Africa's top performing economies.
Common sense prevails "Zambia is keen to encourage more mining, and with the sector key to the economy the government can ill afford to
discourage mining," says John Meyer, analyst and partner at SP Angel. Meyer says that the royalty rate hike was speci cally aimed at stopping Vedanta, and possibly Glencore, from taking advantage of transfer pricing, but the unintended consequence was for an unsustainable rise in taxes for all miners, even though the government claimed some miners might be better off. With the issue now resolved, he says that they do not expect to see any further radical changes over the next few years. "Zambia is a sensible economy," he says. It is a sentiment broadly echoed by Jeremy Wr at ha l l, he a d of Gl ob a l Natu r a l Resources London, and mining team leader at Investec Bank. "e Zambian Government have always shown themselves to be pragmatic - that's always been their way - and certainly since privatisation in 2001 they have tried to impose ridiculous taxes. ey haven't worked, and they've responded to the industry." Wrathall does not think that there is anything to suggest that they will stop listening in future. Underpowered Unfortunately, no amount of political pragmatism is a match for the vagaries of nature, and with water levels at the country's hydro electric plants perilously low aer drought, the country's miners have been forced to confront the prospect of restrictions of supply. It has already seen the power allocations to First Quantum Minera ls' Kans anshi and S ent inel operations cut by almost a quarter, leaving both operating at reduced capacities and
facing signi cant potential cuts to production. e immediacy of the situation should, of course, be remedied once the rains come, but it highlights a more persistent legacy of decades of underinvestment by the staterun Zambia Electricity Supply Corporation that has le capacity insufficient, transmission losses high and reliability low. Now, however, there are major moves afoot to combat the shortages and improve and extend the network infrastructure, with a number of new power stations being developed and a range of projects planned, including a 2,300km interconnector to bring energy from Kenya to Zambia. While there is clearly still some way to go transmission and distribution losses currently amount to over 16% and are not predicted to fall below 13% until 2024 BMI take the view that "the outlook for Zambia's power sector is generally positive" which, by extension, is good for mining too. Future prospects ere will, nevertheless, be some changes for the industry. Wrathall feels that the copper prices we are seeing now will be here to stay for at least the next three years, and that this will put pressure on grade, rendering some of the particularly lowgrade ore bodies effectively uneconomic. He thinks that with many of the existing operators curtailing exploration, and the nancial climate unfavourable for another Sentinel or Konkola deep to be developed, the focus will be on smaller deposits. is will, he suggests, be the pattern the world
over, and it will have major implications for copper mining in general and for Zambia in particular, since he believes that it will be the making of the next cycle. "e copper market is probably oversupplied for the next couple of years, but not massively, and nothing like the same as iron ore or coking coal or aluminium or nickel. Copper's fundamentals are pretty attractive still and if you get companies pulling in their horns, not pre-stripping, and cutting cap-ex, and not building these mega-projects, then the copper market will become under-supplied quite quickly [by] 2019/20. So it starts to look very attractive and the market will start to think about that in 2016/17," Wrathall predicts. Investment potential So what does that mean for future investment? Jackson Sikamo, country manager at Chibuluma Mines, is upbeat on that question. "Foreign direct investments will continue to play a major role in the mining industry," Sikamo says. Looking beyond today's commodity price and power supply problems, he believes that the medium to long-term prospects are bright. Wrathall agrees. He says that when people start looking to invest in new copper mines, they will look to Zambia. “In my view, it still remains one of the most attractive places to do business, because the government is sensible; they're accommodating. It's a very, very safe country to work in. It's still geologically prospective. So yes, I think it's still a great destination, probably one of the best destinations in Africa, if not the best for base metals."
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Contract mining offers edge in depressed market ere is a direct correlation between the market size of contract mining and the commodities cycle/prices and investment patterns in capital projects Historically, mining was a highly protected industry and had a low propensity for outsourcing, but more operations are being outsourced across Africa, says global consultant and adviser Deloitte. is is owing to mines not having access to robust mining systems and processes, expertise and the ability to control the entire mining value chain, limiting the realisation of a project's operational potential, asserts Deloitte associate director Mahendra Dedasaniya. “ere is a direct correlation between the market size of contract mining and the commodities cycle/prices and investment patterns in capital projects. Amid current market conditions, many mining operations have started to
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consider outsourcing part of or all their operations to the best contractor to achieve the best cost and productivity possible,” Dedasaniya comments. He notes that using contract-based mining services is a strategic, long-term decision and must be integrated into a mining company's business and operational strategy to achieve the best possible outcome. Contract mining is used not only to implement rapid strategic change but also to assist in providing a competitive edge in the global market, Dedasaniya points out. He illustrates that many mining companies in South Africa, Namibia, Botswana, the Democratic Republic of Congo and Zambia have outsourced their mining operations, such as Kimberley Diamonds, Kalagadi Manganese and Langer Heinrich, as well as the zinc mines of Black Mountain. e decision to outsource is normally
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based on operational cost, capital efficiency, exibility, relationship and competency, as well as the owner's current status in terms of the age of the eet, required skills availability, productivity, overhead cost, the type of mining operations and the mining method employed, Dedasaniya adds. Contract Criteria He emphasises that, when considering outsourcing mining services, it is important to weigh the organisation's options in terms of the type of contract, selection of the right contractor and the measurable output requirements while balancing socioeconomic considerations. e selection of a contractor should be based on their past safety statistics, alignment with business and corporate strategy, shared values and cultural t, as well as understanding the potential risks associated with contract mining and the
as 15% to 20%, adding that there could also be a loss of intellectual property since there is no continuity in knowledge, which ultimately affects the decision-making process. erefore, should the contract be prematurely terminated, the entire operations cycle will be disrupted, resulting in revenue loss. He also notes that an inadequately de ned scope and responsibility matrix leads to con ict and unhealthy relations between the parties, affecting the targeted outcome of the outsourcing business case.
probability of mitigating these risks based on actual requirements. He puts forward that selecting the right business partner, in terms of the type and form of contract, will result in de ning balanced commercial terms involving the incentive of shared bene ts between owner and contractor and exibility with regard to changing the contract scope. In terms of output control, Dedasaniya says de ning the mining company's objectives and goals in terms of outsourcing plays an important role in ensuring that the contractor will be able to perform accordingly. He notes that by de ning the dependencies that other operations could have on a contractor's performance and how to reduce this reliance when output is at risk, will also assist in preparing recovery plans. “Once you enter into a contract, it's very difficult to exit without disturbing operations. It is, therefore, of great importance to chose the right business
partner who shares a company's values and envisions the same end goal,” he declares. Outsource Models Dedasaniya asserts that there are various models available when selecting contractors that will best meet the requirements of a project and those of a company. ese models can be identi ed as full outsourcing or partial outsourcing models, he says, explaining that full outsourcing includes all project needs such as equipment, labour, materials and infrastructure. Partial outsourcing is when the equipment and infrastructure is supplied by the owner, with the contractor supplying labour and, at times, maintaining equipment. Disadvantages Dedasaniya notes that, if outsourced mining is not part of a business's operational plans, it could result in the cost of mining being higher by as much
Advantages Dedasaniya highlights that, when contract criteria are met and the best model has been selected for an operation, outsourcing has many advantages, such as the achievement of production targets within budget and on schedule. Additionally, he says contracts can also be structured to allow for operational costs to be converted from xed costs into variable costs during times of low production volumes, reducing the risk of negative pro t margins. “e mining environment has an in uence on many variables, such as ground conditions and market conditions, which sometimes erodes the business case; however, outsourcing provides exibility and scalability in [a mining company's] model to meet everchanging production requirements, resulting in a smooth transition between mining methods such as openpit to underground mining.” Dedasaniya points out that the effective use of resources and the deputation of a subject-matter expert from one operation to another is also an added advantage. “Outsourcing should emphasise and create bonds and networking in an organisation to ensure it achieves the best possible production at the pre-agreed production cost, while achieving higher capital efficiency and exibility [at] mining operations,” concludes Dedasaniya.
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Embracing TECHNOLOGY
Innovative Power devices need to tackle drought related electricity constraints
roughout the Southern Africa Power Po ol – w here Angol a, Democratic Republic of Congo, Malawi, Mozambique, Namibia, Z ambia and Z imbabwe rely on hydropower for 71 to 99 percent of their electric generation, widespread drought has signi cantly reduced the region's ability to generate electricity. e mining sector has been among the hardest hit by the dramatic decrease in hydropower, and unless something is done to address the need for power supply to the region's mines, these countries and their mining companies will face further economic hardships. “e current drought has underscored the vulnerability of Southern Africa's
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mining sector and the region's economy, with such a heavy reliance on intermittent sources of electricity such as hydropower,” says Paul Marcro, APR Energy Director of Sales Operations and Strategic Planning. To make matters worse, the annual rainy season that normally runs from October through April did not begin this year until late February. While rain will eventually fall and water levels will rise across Southern Africa, the more systemic problem of an inadequate and unreliable power infrastructure will continue to hamper the mining industry. “A lack of reliable electricity is
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unacceptable in an industry where lives depend on uninterrupted power for essential processes like ventilation and dewatering,” says Marcro. “Beyond safety, a constant ow of electricity is required so smelters don't go cold, allowing molten metals to solidify inside extremely expensive processing equipment.” Marcro points to Zambia, Africa's second-largest copper producer, as a microcosm of what the mining industry faces throughout the region. “Zambia's mines consume more than half of the country's power and are now being charged an increased tariff for electricity, resulting in increased operational costs and decreased
Embracing TECHNOLOGY
production,” says Marcro. “is is leading to job losses and re du c e d re ve nu e s , w h i c h h ave signi cant downstream impacts on Zambia's economy and the welfare of its people.” Even without the drought, access to reliable electricity can be a challenge for mines, which oen operate in remote locations far from the local grid system. “Mines need a solution that provides reliable power fast to ensure they can continue to operate safely and remain pro table,” says Marcro. Marcro says that fast-track, turnkey power is a readily available and affordable solution for the mining sector that could eliminate vulnerability to an unreliable supply of electricity. “Unlike permanent power sources, this distributed power solution uses easily transportable modules to provide the mine with
dependable and dedicated electricity when and where it is needed, in as fast as 30-90 days.” He explains that fast-track turnkey power features state-of-the-art gas turbine technology and diesel- and gas-powered reciprocating engine generators. “ese pop-up power plants are scalable from 10-100 MW (or more) providing the exibility to ramp up supply based on the user's requirements. ese mobile power plants can be an ideal solution as they require minimal capital investment from the mine, which needs only to provide the land and fuel.” In addition, the capacity can be located near demand, reducing the need for t r an s m i s s i on an d d i s t r i but i on infrastructure, while also cutting the power loss that occurs as electricity travels long distances across the grid, says Marcro
e ability to self-power can be extremely bene cial to a mining operation when the national grid is under pressure, when transmission lines or power stations are down due to maintenance work, or when the mine is based in a remote location awaiting development of transmission and distribution infrastructure. When it comes to cost, it is understandable that mine operators in Southern Africa may hesitate at the idea of paying for a turnkey, selfpowering solution – whether as supplemental or stand-alone generating capacity – when they are accustomed to inexpensive hydropower. “However, the region's mine operators ultimately must weigh the signi cant bene ts of self-powering with reliable and safe mobile generation against the heavy cost of lost production and revenue,” says Marcro.
Measure, Control, Improve ... minute by minute On-belt Real Time Analysers · Base metals (Cu, Zn-Pb, Ni) ·I ron 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 ·L ocal 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
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Optimise your thickener efficiency for maximum pro tability Once extracted from the ground, mined ore is subjected to a complex series of steps before it can be converted into its purest state ready for use. The continual improvement of these process steps is critical to on-going profitability of mine operations.
A key step in most ore re ning operations is the physical separation of process water from the useful extract or tailings. e optimisation of this process is critical for several reasons: 1.
e availability of large volumes of process quality water in South Africa is always limited and expensive making the use of recycled water attractive.
2.
Energy and occulant costs is a major contributor to process costs.
3.
In many cases, tailings can be reprocessed to extract ne traces of precious metals. However, for this to be economically viable the water content of the tailings needs to be minimised reducing the energy and chemicals needed for extraction to an absolute minimum.
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4.
Impure waste water can leach into ground water and waterways polluting water supplies. South African regulations determine acceptable levels of impurities that can be discharged.
Large tanks, known as thickeners are used to separate ne suspended mineral particles from the process water, producing a stream of clari ed water from the top of the thickener over ow and a thick sludge of settled solids (under ow) from the bottom. Flocculants are mixed with the solid – liquid suspension in the entry feedwell of the thickener. e occulants aggregate the ne particles, which speeds up settling of the solids. ickeners are used in many mineral re ning processes, including alumina, gold, nickel, mineral sands and coal washeries. In fact, most minerals go through a solid –
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liquid separation in a thickener at some point in their processing. Most mining process operators agree that one of their major challenges is to accurately and reliably monitor the bed level and bed mass of their thickeners which in conjunction with other critical process parameters allow the optimisation of thickener efficiency. Bed level: e 'bed level' is the interface between the aggregated solid material and the process water. Incorrect measurements can lead to water being drawn out through the under ow, sludge spilling over in the over ow or incorrect occulation. ere is unnecessary expense involved in all cases due to wasted occulent or reprocessing costs. Depending on the application conditions, different techniques are employed to determine a thickener's bed level:
·
·
·
·
eoretical bed level based on the calculation of the average density of a constant height using a hydrostatic pressure sensor Submerged ultrasound sludge blanket transducer to sense re ections from the solid bed Turbidity sensor, either at a xed height or attached to a motorised cable spool. Buoyancy based electromechanical system
mechanism allowing the unit to be
positioned at a xed height or attached to a
extracted, cleaned and validated without
motorised cable spool determines the
shutting down the process. e insertion
turbidity of the process water. Used in a
length of the sensor mechanism can be
xed height system, it can be used to
varied to match the thickness of the tank
initiate the reduction of the in ow rate
wall and to ensure optimal sensor depth
should turbidity levels increase. On a
once inserted in the tank. High quality
motorised cable spool, it can provide a
assemblies are speci cally designed to
turbidity pro le to the operator. is
prevent operator injuries during the
measurement is targeted at turbidity
validation process. Due to the requirement
pro ling as well as bed-level detection. If
of the extension of the sensor into the
only bed level measurement is required,
process in this style of transmitter, the use
then the buoyancy principle is more cost
of a ceramic sensor avoids long oil lled
effective.
capillaries between the sensors and
e 'buoyancy based electromechanical
transmitter that are used in metal type
system' uses a sensing weight which is
sensors. is means a more robust solution
lowered on a measuring tape into the
with improved long term accuracy and
thickener to detect the bed level. Typically,
stability.
the sensing weight is a light, hollow
In processes with slow and predictable
container lled with the bed level material.
settling behaviours, using only the
When the container is lowered, it sinks in
hydrostatic pressure technique can be
the water but ' oats' when it reaches the
adequate. However processes prone to
bed. At this point, the bed level can be
disturbances from variances in chemical
measured. Once the bed level has been
make-up or with varying ow rates oen
located, the weight is reeled back up to the
require additional measuring systems to
surface. To overcome issues related to the
provide reliable results.
use of rakes in settling tanks, device
A submerged ultrasound sludge blanket
measurement cycles can be automated so
transducer can be used to provide a pro le
that measurement takes place in between
of all interfaces within the thickener. A
rake rotations. is more straightforward
sound impulse is emitted and a receiver
measurement principle offers a greater ease
circuit monitors the timing and amplitude
of operation. Since all the active
of re ection echoes to respectively
components are located outside of the
determine the depth and concentration of
process, it is more
Hydrostatic pressure measurement essentially reports the mass of the liquid column pressing down on it. Since the height of the liquid is limited due to the constant over ow, a calculation based on the force acting downwards divided by a constant height factor provides an estimation of the bed level. As the liquid height is xed and the density of water is known a second calculation provides information on the total amount of solids in the thickener. is information can be used to increase or decrease the in ow rate. e sensing element of this device is very vulnerable since the slurry can cause abrasion and larger suspended matter can impact and damage the stainless steel diaphragm. Problems with the pressure sensor and diaphragm can only be detected during plant shut down when the tank is drained and the pressure transmitter has been removed, checked and recalibrated, that's assuming that it isn't already damaged beyond repair. e hydrostatic pressure sensor is at the heart of the thickening process – a faulty sensor could therefore cause an inefficient process to run for a long time before being detected, resulting in water wastage and unnecessarily high pumping costs.
layers. is measurement supplies
e best way to overcome these problems is
information about the bed level depth as
through the use of highly robust, retractable
well as the thickness of any emulsion or
pressure transducer. Transmitters with
turbid layers which may be present above
ceramic sensing elements are highly
the bed-level. Applications that are
resistant to abrasion – several times that of
susceptible to poor separation with gentle
stainless steel. Retractable transmitters are
density slopes or that don't have layering of
speci cally designed to be attached directly
interfaces, would normally use either the
to the bottom of the tank. Assembly consists
turbidity or buoyancy methods.
of an isolation ball valve and a retracting
A turbidity sensor which is either
Bed mass: e 'bed mass' is effectively the density of the settled sludge. e higher the density, the less process water is pumped out of the thickener's under ow. e optimisation of water content in the under ow allows for maximum recycling of process water while still keeping the under ow slurry sufficiently liquid to be managed by the under ow pump. If the thickener's under ow is destined for a tailings dam, the
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optimisation of the slurry density helps to reduce negative environmental impacts through leaching at the dams. Bed mass is calculated based on the total volume of combined water and solids in the tank and the total hydrostatic pressure measured near the bottom of the tank. As the speci c gravity of water is a known constant, the mass of the solid content can be calculated. Volumetric measurement of the thickener's in ow: Accurate volumetric measurement of the thickener's in ow is vital to ensure the clarity of the recovered process water. Essentially the in feed ow rate can be controlled based on high clarity of the over ow. So the clearer the out ow, the faster the in ow feed rate which leads to optimised thickener throughput. Combined with the mass ow measurement of the occulent, precise ratio control of the occulent dosing is achieved. is enables automated, continuous occulent dosing which further increases process efficiency and reduces costs when compared to semibatch type operation. Mass ow measurement of occulent:
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Flocculants are used in most thickeners to obtain concentrations of over ow solids that will allow water to be reused or to comply with government regulations if the over ow is to be discharged. Recycled water containing 200 mg/L to 1% solids is generally acceptable. Most thickeners can achieve this level of concentration by using a occulant. Although occulants are used in relatively small quantities, they are expensive. e accurate measurement of occulant mass ow allows precise dosing pump control. Combined with other system parameters, the use of 'just enough' occulant can be ensured minimising occulant usage and optimising process costs. Depending on the process this measurement can be made using high accuracy Coriolis mass ow instruments, or more economical volumetric electromagnetic ow meters.
wasted energy and improving efficiency. e combination of density and volumetric ow rate provides an integrated mass ow rate which is useful for accounting of mineral recovery as well as waste. Accurate measurement of all of these important parameters allows precise thickener process control which can lead to signi cant increases in thickener efficiency. ese efficiency gains translate directly into overall re ning process cost reductions and increased pro tability. Enquiries: Susan Buitendag Industry Manager – Primaries Endress+Hauser (Pty) Ltd Tel: (011) 262 8000 Fax: (011) 262 8062
Out ow density and volumetric measurement: Constant out ow density and volumetric ow measurements are important parameters which can be fed back to the variable speed drive controlling the out ow pump, optimising pump speeds, reducing
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info@za.endress.com
Endress + Hauser People for Process Automation
HAZLETON PUMPS comes out top at the SADC Annual Quality Awards as only company to win two main awards. e sixth SADC Annual Quality Awards presentation ceremony was held on the evening of the 16th March 2016 in Gaborone, Botswana. e aim of the SADC Annual Quality Award competition is to recognize and appreciate organizations and individuals who are contributing to quality advancement in all sectors of industry by having measurement and quality systems, procedures and processes that are in line with local, regional and inter national b est
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practices. e Award is divided into the following categories for Large Enterprises as well as Small and Medium Enterprises: Category 1: Company of the year Category 2: Product of the year Category 3: Service of the year Category 4: Exporter of the year Category 5: Individual Award e Southern African Development Community is a Regional Economic Community comprising 15 Member States; Angola, Botswana, Democratic
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Republic of C ongo, L es otho, Madagascar, Malawi, Mauritius, Mozambique, Namibia, Seychelles, South Africa, Swaziland, Tanzania, Zambia and Zimbabwe. Established in 1992, SADC is committed to Regional Integration and poverty eradication within Southern Africa through economic development and ensuring peace and security. Niël Wehmeyer, Marketing Director, HAZLETON PUMPS (middle) with the two trophies awarded for winning the two main SADC awards for
Company of the Year and Product of the Year 2016. Hazleton Pumps, a Small/Medium family owned enterprise located in Centurion, Gauteng (South Africa), won the Company of the year. e approach followed by this company is to build long-term committed sustainable customer relationships. Speci c, specialised pumps are designed, developed and manufactured in collaboration with customers in order to meet their individual and customized requirements. e HIPPO Slurry Pump range is capable of handling liquids containing both abrasive as well as corrosive solids and the pumps are therefore manufactured from various materials such as 28% Hard Chrome for abrasive applications and Duplex Stainless Steel
Alloys (CD4MCu) for acidic/and corrosive environments. Marius Sunkel anked by two HIPPO H i g h Vo l t a g e S u b m e r s i b l e Slurry Pumps ready for Export to Canada HAZLETON PUMPS also won the Product of the Year Award for the design and development of a slurry pump range that can operate under the harsh mining conditions in Southern Africa branded as the HIPPO Pump Slurry range. e technology has since been developed and adapted for mining and v ar i ous ot he r appl i c at i ons worldwide. e world's rst Medium/High Voltage High Head Submersible Dewatering Pump Range – capable of being used in explosive environments and complying to IEC 60079-1. is range consists of 5
models capable of pumping up to 350 l/s at a head of 200 meters with an installed power of 1200kW and can operate on both 50Hz and 60Hz power supply. is HIPPO Medium/High Voltage; High Head Submersible Pump Range using a single stage design was designed, developed and manufactured for acid mine dewatering and is mainly used underground. e unique feature of this pump is the utilization of Medium and High Voltage Power whilst being manufactured from speci c materials which enables the pumping of acidic liquids containing s o l i d s . HA Z L E T O N P U M P S i s currently marketing the HIPPO Submersible Slurr y pump range internationally with more than 70% of all pumps being exported and Canada being the biggest user at present.
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Sand Slurry Flow Monitoring NonContacting Sensor works from Outside the Pipe CanFrac Sands Ltd. of Lloydmister Saskatchewan (Canada) needed a owmeter that could accurately measure sand slurry ow without being damaged by this highly abrasive product. ey selected the Greyline DFM 5.0 Doppler Flow Meter with a clamp-on ultrasonic sensor mounted on the outside of a pipe. CanFrac produce “fracturing sand” used by the oil and gas industry. is special type of sand is pumped into an oil or gas well to help keep fractures between layers of rock propped open to allow hydrocarbons to ow to the wellbore. CanFrac consulted Tarpon Energy Services of Calgary, Alberta for solutions when their inline owmeters were damaged by the abrasive sand. Tarpon proposed the Greyline DFM 5.0 Doppler Flowmeter.
In this application a mixture of recycled water and frac sand is pumped at 1600 gpm (2 m/sec velocity) through a 10” carbon steel pipe. CanFrac use the owmeter's digital display to monitor ow rates and take daily readings from the meter's built-in totalizer. Greyline Doppler Flow Meters and Flow Switches are ideal to measure ow of “difficult” liquids including mining slurries, wastewater and aerated liquids. For complete information visit www.greyline.com.
P TR R
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PRODUCT Releases
Peristaltic pump to be launched at Electra Mining e Southern Africa launch of the VerderFlex Vantage 5000 peristaltic cased pump will take place at this year's Electra Mining Africa at the Expo Centre in Nasrec, Johannesburg, from September 12 to 16, says pumps supplier Verder Pumps South Africa (VPSA). Electra Mining is the biggest mining trade show in Southern Africa. It features exhibitions from 850 local and international companies, with international pavilions for delegations from China, France, the UK and Turkey. It attracts more than 40 000 visitors, making it the perfect platform to launch a product. Peristaltic pumps manufacturer VerderFlex Pumps Netherlands marketing manager Lekha Bodhe explains that the Vantage 5000 is a highly advanced peristaltic cased pump, with intuitive touch screen technology that offers superior levels of dosing accuracy at high discharge pressures. Its main mining applications are chemical dosing and water treatment. She states that the Vantage 5000 is one of the few available pump systems with enough memory to save up to 30 dosing and batching programmes and enables users to back up jobs les through its USB data port. “It also has a smart tube-burst sensing system to detect leaks, ensuring highly
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| May - June 2016
reliable performance, compared with standard, basic cased pumping systems,” Bodhe notes. Aside from its precision dosing, she says the Vantage 5000's main features include high ow per revolution, enhancing the pump's tube life and reducing maintenance, as well as advanced touchscreen technology with icon-based menus and a range of remote-control options, including wireless and Ethernet. e pump also offers almost double the ow rate (up to 6 600 mℓ/min at 7 bar) of other leading brands, Bodhe adds. She notes that the Vantage 5000 was developed and manufactured in the UK, and will be distributed throughout Africa by VPSA. e division operates and supplies Zimbabwe, Zambia, Ghana, Côte d'Ivoire, Mali, Egypt, Sierra Leone, Burkina Faso, Mauritius, Mozambique, Tanzania, Uganda and Namibia. Africa Still Key VPSA MD Keith Gass says the African mining sector is an important market for the company – based on 2015 nancial results, about 70% of its turnover can be attributed to mining projects on the continent. He points out that, owing to the recent decline in commodities demand and the resulting impact on VPSA's business, the company has expanded into new export
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markets and geographies to offset the loss in revenue from traditional markets, including South Africa. As such, VPSA has refocused its attention on the rest of Africa. Gass states: “VPSA undoubtedly sees huge growth potential in Africa, which has more than one-quarter of the world's arable land and 11 of its countries ranked among the top ten sources of at least one major mineral, for example, Zambia for copper and South Africa and Ghana for gold.” He comments that, as part of its expansion drive in other African countries, VPSA has bid for work at numerous mining projects and has progressed to the nal stages of the approval process for a copper processing plant, in Zambia. Once the contract has been awarded, VPSA will supply peristaltic hose pumps to the processing plant. Further, VPSA marketing manager Elaine van der Westhuizen emphasises that the company's service and product offering can effectively enhance almost every mining process, owing to its expertise and technological capability. She advises any business seeking to bene t from the growth prospects in Africa to rst identify its target country and sector of interest in that country, as each country and sector presents its own challenges and opportunities.
Embracing TECHNOLOGY
LED luminaries lend themselves to mine applications and hold many advantages over traditional HID lighting THE ENVIRONMENTAL AND FINANCIAL bene ts of LED lighting technology have been well documented and continue to be a top priority when it comes to new construction or retro t lighting proj e c ts. Howe ver, w hi le oen overlooked, LED lighting upgrades are also frequently a simple and cost effective solution for improving safety. is is especially true throughout the industrial and hazardous location world and particularly so for mining companies that operate in some of the most demanding environments. In the mining industry, it is imperative that all equipment holds up in these demanding applications, which oen includes hazardous locations where ignitable dust is present and Class IIcerti ed equipment is required. Traditional lighting technologies such as high-intensity discharge (HID) types including high-pressure sodium, cannot provide the balance of a pure
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white light source while meeting temperature rating requirements and providing value in total cost of ownership due to frequent bulb failures and excessive energ y consumption. HID light xtures are also oen bulky and heavy in weight, causing installation and maintenance challenges that typically require multiple personnel. LED luminaries on the other hand lend themselves perfectly to these dustlled applications and hold many advantages over traditionalHID lighting. In addition to lasting years longer than traditional light sources, LEDs are able to offer superior Tratings (measure of the surface temperature of the xture) due to the fac t that the y r un co oler than traditional technology. e lower the surface temperature, the higher or safer the rating. For example, a T3rated xture has a maximum surface temperature of 200 degrees Celsius
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while a top rated T6-rated device has a maximum surface temperature of 85 degrees Celsius. Where a typical metal halide xture can produce up to 572degrees Fahrenheit (T2, the lowest rating possible), most LED xtures for hazardous locations operate at just 212 degrees Fahrenheit (T5rating). LED luminaires also have a mechanical advantage in mining applications with constant shock and vibration. Since LED light sources are small solid state devices with no glass or laments to break, they are inherently resistant to extreme vibrations and allow for low pro le and lightweight xture designs w h i l e st i l l mai nt ai n i ng U L 8 4 4 standards. From a safety perspective, this means easier and safer installations with the added safety bene t of secondary retention. COOL LIGHTING e nature of LED xtures to run cool is also key to explaining LED's
Embracing TECHNOLOGY exceptional lifetime. Industry leading LED solutions with custom integrated power supplies have L70 rated lifetimes – a measurement of when the xture's initial lumen output reaches 70 percent and the recommended time for replacing facility lighting – of greater than 100,000 hours and warranted periods of 10 years. In contrast, HID and uorescent xtures have rated lifetimes between 16,000 hours (metal halide) and 24,000 hours (highpressure sodium). While uorescent manufacturers in particular have directed engineering efforts towards extending lamp lifetimes and are now offering solutions with lifetimes up to 45,000 hours, premature failures remain a problem in mining applications where extreme vibration and widely uctuating ambient temperatures are present. e longevity and reliability of LED lighting has a twofold safety advantage. First, it ensures that facility lighting levels stay within recommended guidelines throughout the xtures' lifetime. e Illuminating Engineering S o ciety of Nor t h Amer ica s ets standards for lighting levels depending on the application, and these standards play an important role in ensuring safety across multiple areas of a mine. In contrast to LEDs, metal halide lamps suffer dramatic lumen depreciation in their rst six months of operation and therefore run the risk that light levels
will drop to potentially dangerous levels. RELIABILITY AND LONGEVITY Second, LED's reliability and longevity gre at ly reduce t he s afety r isks associated with maintenance activities. With conventional lamps requiring frequent replacement – as oen as every few months despite a muchlonger rated performance – maintenance crews are more oen exposed to situations with elevated safety risks. Luminaries are frequently mounted in hard to access areas where crews are required to tie-off or where operations must temporarily be suspended. In hazardous locations, maintenance crews also oen require specialized equipment to perform relamping activities. LED lighting's reliability and 10-plus years of lifetime eliminate the need to perform such maintenance tasks and is the best way to improve safety by effectively removing the risk altogether. C ompared to other traditional technologies, LED lighting also has the bene t of being easy to control. is is especially true for xtures with inhouse designed and integrated power supplies and for manufacturers who account for additional safety bene ts like emergency battery backup models when designing new products. In the case of loss of power, emergency
battery backup models will illuminate exit pathways. Since LEDs are lowwattage solutions, they are able to provide brighter illumination for longer periods when compared to traditional lighting xtures with battery backup. LED's instant-on ability also avoids the warm-up and re st r i ke probl e ms e x p e r i e nc e d withHID xtures. QUALITY OF LIGHT e quality of lig ht is another important point where LEDs have a clear safety advantage over traditional HID lighting. With Color Rendering Index (CRI) values between 70 and 90 on a 100 point scale, personnel are better able to distinguish true colors and prevent mistakes which may cause injuries. is can be crucial when workers must identify different colored wires, safety plaques, liquids, smoke or other obj e c t s . Work i ng u nd e r L E D ' s daylight-quality light also provides a more comfortable environment with less eyestrain, which in turn helps workers maintain alertness. O n t h e ot h e r h an d, nu m e rou s traditional light sources struggle when it comes to color quality. For example, high pressure sodium lamps have CRIs between 20 and 30 and are infamous for their orange colored light while mercury vapor's bluish-green light also d i s t or t s c o l or s t h at c a n c au s e potentially dangerous scenarios.
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AECOM unveils ‘2020 Strategy for Africa’ Integrated professional and technical services company AECOM unveiled its ‘2020 Strategy for Africa’ at a media brie ng at its Centurion head office on ursday 7 July.
Carlos Poñe, newly-appointed Chief Executive - Africa, AECOM.
Speaking to editors and journalists from the trade press at the event, newlyappointed Chief Executive – Africa Carlos Poñe highlighted that AECOM is looking to double its revenue from African projects. “Our vision for AECOM in Africa is that we foresee revenue on the continent being at least as good as in South Africa. us we could be doubling our revenue in a very short space of time,” Poñe reveals. “ere is an incredible amount of enabling infrastructure that goes along with large-scale private sector projects. If you look at a Green eld mine, for example, there oen is no power, roads, housing or water and sewerage. Everything has to be built from scratch, and this represents huge opportunities for potential investors,” Poñe explains. Poñe brings a wealth of experience and expertise to his new role at AECOM, which he took up in October 2015. is
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ranges from being MD for a major mechanical construction company in Moz ambi qu e i n 1 9 8 2 , to b e i ng production manager for a major South African pump manufacturer in 1985. From 1993, he held various positions at ABB Sub-Saharan Africa, including VP and CEO. He also spent close to three years in the United Arab Emirates as CEO of ABB UAE and Middle East, overseeing part of the Middle East, and nally becoming an Executive Director at AECOM UAE. While Poñe is focused rmly on Africa, he stresses that AECOM is not neglecting South Africa, where it opened new offices in both Durban and Cape Town to service the local market. “South Africa may not be the biggest economy in Africa anymore, but it is still the most sophisticated,” he reiterates. “In terms of investment, infrastructure, banking and insurance, it is number one in all of these areas. Secondly, it is much easier to source engineering skills here for the rest of
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Africa. erefore our aim is to deploy the global competitiveness of AECOM to assist our customers in terms of all of our capabilities. With the devaluation of the rand, it has also meant that we have become even more cost-competitive,” Poñe adds. AECOM originally entered the South African market in 2010 with the acquisition of Davis Langdon, following which it absorbed multi-disciplinary rm BKS in 2012. While these two legacy companies form the basis of AECOM South Africa, it is the intention of Poñe to ensure that AECOM becomes as well-known, and entrenched, as it is in the rest of the world. One of Poñe's aims is to change the perception of AECOM in the local market, where he admits it has been something of a “hidden secret” to date. “We need to get away from this idea that we are a construction consultant or company,” he concludes.
MOVERS & Shakers
Renico Staff
Leading Plant Hire Company in South Africa Counts on Case for its Rental Fleet Nico Louw, founder and managing director of Renico Group, started Renico Plant Hire with an old backhoe loader in 1998. Since then, the company has established itself as one of the leading plant hire companies in the North West area of Johannesburg and its rental eet has remarkably grown up to today's count of over 200 earthmoving machines and tipper trucks. “Reliability is a key factor in our business,” says Nico Louw. “Our results depend on the equipment performance and having minimum downtime is essential. Since its foundation, our company has been relying on the proven reliability and performance of Case equipment”. Renico Plant Hire is part of Renico Group which comprises various companies in the elds of construction, property investment, quarrying and crushing, civil
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engineering and earthworks in addition to plant hire. e Group represents a truly South African success story. Started off as a real estate agency in 1992, the company has gone from strength to strength, investing in different sectors and dedicated companies as Renico Plant Hire. e eet encompasses a total of 38 Case tractor backhoe loaders, 14 excavators from 21 to 29 tons, four recently purchased motor graders and several skid steer loaders and telehandlers. All supplied by Case distributor, CSE. e units are deployed on various job sites throughout South Africa and Namibia and they have played a crucial role in the development of large-scale civil engineering projects, including shopping centres, office developments, casinos, highway upgrades, mining and various other projects.
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“For example, there is a 21 ton Case excavator working on the upgrade the Northern sewer in Johannesburg while several backhoe loaders are used for upgrading the K90 road at the Waterford Estate. Furthermore, our 29 ton excavators will be soon starting some civil works at Empire on the hill,” says Louis Nel, responsible for Operations, Technical & Procurement at Renico Plant Hire. “Ease of use is a very important factor for our customers,” adds Nel. “We are committed to provide them with turnkey equipment solutions that perfectly ts their needs and applications.” Technical support and parts availability are also critical. “CSE is always available when we need them and they resolve any issues at speed,” highlights Nico Louw. “What's more, when we need to renew or expand our eet, we get from them excellent
MOVERS & Shakers
Nico Louw, Leon Schelvis, Louis Nel, Jonathan Clark, Andrea Rapali, Corne Coetzer, Mark Webster
advice on the model that will t best with our needs.” CSE, which is part of South African based investment holding and management company Invicta Holding Ltd, has an extensive network of branches and dealers which cover the major centres of South Africa and some bordering countries. It provides Renico Plant Hire with sales support, technical expertise and parts supply. “We are committed to offer the best equipment that better ts our customers'
applications, with consistent bene ts in terms of performance and minimum downtime,” says Brenton Kemp, CSE Managing Director. “Our company is also well positioned to support our customer base with extensive sales, technical and aermarket services.” “In terms of quality, Case products rate amongst the highest in the marketplace,” adds Kemp. “In South Africa, there is a high demand of equipment from the compact line but there are also speci c industries and sectors in which the
market is dominated by products from the heavy line, such as excavators and motor graders, as the ones we have provided to Renico, but also other machinery like wheel loaders that are part of the full Case offering. A loyal Case customer since the early beginnings of his business, Nico Louw looks with con dence at the future, based on the certainty of the high levels of success achieved through the years. “And we know we can always count on Case and CSE,” he concludes.
MOVERS & Shakers
Ivanhoe Mines’ exploration team makes major new copper discovery at the Kamoa Copper Project KOLWEZI, DEMOCRATIC REPUBLIC OF CONGO — Robert Friedland, Executive Chairman of Ivanhoe Mines (TSX: IVN), and Lars-Eric Johansson, Chief Executive Officer, announced today that the Kamoa exploration team has made a new tier-one, high-grade and at-lying stratiform copper discovery, ideally situated for low-cost me chan i z e d m i n i ng , i n t he Ka ku l a exploration area, approximately ve kilometres southwest of the currently de ned resources at the Kamoa copper deposit in the Democratic Republic of Congo (DRC). e Kakula Discovery is situated within the 400-square-kilometre Kamoa Mining Licence area and represents a major extension of the Kamoa copper deposit, which the company discovered in 2008. e Kamoa Copper Project is a joint venture between Ivanhoe Mines and Zijin Mining. Two exploration drill holes completed in late 2015 in the Kakula exploration area — DKMC_DD996 and DKMC_DD997 — rank among the highest-grade and highestgrade-thickness intersections drilled to date within the Kamoa copper deposit licence area. DKMC_DD996 intersected 24.16 metres
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(24.13 metres true width) of 3.48% copper, at a 1% copper cut off. At a higher cut-off of 2% copper, the intersection was 13.16 metres (13.14 metres true width) of 5.26% copper. DKMC_DD997 intersected 18.75 metres (18.47 metres true width) of 4.64% copper at a 1% copper cut-off and 15.17 metres (14.94 metres true width) of 5.33% copper at a 2% copper cut-off. e two holes were drilled into an area of thick, high-grade copper mineralization rst identi ed in 2014 — now called the Kakula Discovery area — within the large, 60-square-kilometre Kakula exploration area. e two holes represent 400-metre step-outs north and east from the highgrade copper intersected in drill hole DKMC_DD942 (13.50 metres (13.49 metres true width) of 4.15% copper, at a 2% copper cut off ). Completion of an 800-metrespacing in ll grid over the Kakula Discovery area is planned for 2016. “e Kamoa copper deposit already is distinguished as the world's largest, undeveloped, high-grade copper discovery,” said Mr. Friedland. “e Kakula Discovery has the combination of signi cant thickness, high grades and strike length that holds promise for signi cant and rapid expansion
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of the Kamoa copper deposit. “e Kakula discovery not only shows the potential to substantially increase the size of the Kamoa C opper Deposit, it also highlights the potential for new discoveries to the west of Kolwezi in the Congolese copperbelt.” Kakula Exploration Target Signi cant mineralization in the Kakula area was discovered in 2014 by a wide-spaced exploration program. By the end of 2014, 21 holes had been drilled in the area, of which six had intersected signi cant copper mineralization. Based on the wide-spaced drilling results from the 2014 program, Ivanhoe de ned three areas of exploration potential at Kakula, covering a total area of 60 square kilometres. e central Kakula Discovery area covers 19 square kilometres and is the primary focus of the current exploration program. e planned Kakula exploration drilling program consists of 19,000 metres in 58 holes, of which approximately 10,000 metres of drilling is planned on an 800metre in ll grid at the Kakula Discovery area. e other approximately 9,000 metres of drilling will be used to test the other two
MOVERS & Shakers areas of exploration potential within the Kakula exploration area. Using the results from the eight holes drilled i n t he 1 9 - s qu are - k i l ome t re Ka ku l a Discovery area, Ivanhoe has de ned an exploration target of between 580 million and 870 million tonnes at grades ranging from 1.5% to 2.3% copper. Ivanhoe cautions that the potential quantity and grade of the Kakula Discovery target is conceptual in nature, and there has been insufficient exploration to delineate a mineral resource. It is uncertain if further exploration will result in the target being delineated as a mineral resource. Mineralization at Kakula appears to be consistent in nature with downward vertical zonation from chalcopyrite to bornite to chalcocite in every hole. Mineralization is consistently bottom loaded, with grades increasing downhole toward the contact between the host Grand Conglomerate and the underlying Mwashia sandstone. e highest copper grades are associated with a siltstone/sandstone unit and the base of an overlying diamictite unit. ese units overlie a less mineralized, thin, sandy clast-rich diamictite above the Mwashia sandstone contact. Kamoa Copper Project description e Kamoa Copper Project is a very large, stratiform copper deposit with adjacent prospective exploration areas within the Central African Copperbelt, approximately 25 kilometres west of the town of Kolwezi and about 270 kilometres west of Lubumbashi. e original Kamoa copper deposit was discovered by Ivanplats in 2008, which subsequently adopted the Ivanhoe Mines name as par t of a cor p orate restructuring in 2013. In August 2012, the DRC government granted mining licences to Ivanhoe Mines for the Kamoa Copper Project that cover a total of 400 square kilometres. e licences are valid for 30 years and can be renewed at 15-year intervals. Mine development work at the Kamoa Copper Project began in July 2014 with construction of a box cut for the decline ramps that will provide underground access to the initial high-grade mining area in Kansoko Sud. In December 2012, an independent Mineral Resource estimate was prepared by Amec
Foster Wheeler E&C Services of Reno, Nevada. Based on this estimate, the Kamoa copper deposit was ranked by Wood Mackenzie as Africa's largest high-grade copper discovery and the world's largest undeveloped high-grade copper discovery. As of January 2013, Ivanhoe Mines had reported Indicated Mineral Resources at the Kamoa Copper Project totalling 739 million tonnes grading 2.67% copper and containing 43.5 billion pounds of copper, plus Inferred Mineral Resources of 227 million tonnes grading 1.96% copper and containing 9.8 billion pounds of copper. A 1% copper cut-off grade and a minimum vertical mining thickness of three metres were applied in each classi cation. e true thickness of the Kamoa copper mineralization within the currently de ned resources varies from 2.4 metres to 17.6 metres, at a 1% copper cut-off. e deposit is relatively at lying, dipping between 0 and 20 degrees. e deposit dips generally west to east and at its deepest has been intersected at more than 1,500 metres below surface. High-grade bornite-chalcocite mineralization remains open down-dip to the east and along strike to the south. Today, Ivanhoe Mines owns a 49.5% share interest in Kamoa Holding Limited (Kamoa Holding), an Ivanhoe subsidiary that presently owns 95% of the Kamoa Copper Project. Zijin Mining Group Co., Ltd. owns a 49.5% share interest in Kamoa Holding, which it acquired f rom Ivanho e in December 2015 for an aggregate cash consideration of US$412 million. e remaining 1% interest in Kamoa Holding is held by privately-owned Crystal River Global Limited. A 5%, non-dilutable interest in Kamoa Copper SA, the Ivanhoe Mines subsidiary t hat ow ns t he Kamo a Proj e c t , w as transferred to the DRC government on September 11, 2012, for no consideration, in accordance with to the DRC Mining Code. Ivanhoe also has offered to transfer an additional 15% interest to the DRC government on terms to be negotiated. Constructive and cordial negotiations between Ivanhoe Mines, Zijin and senior DRC government officials have been continuing in this regard. e 2013 Kamoa preliminary economic assessment (PEA), available at
www.sedar.com, presented a two-phased approach to development of the Kamoa Copper Project (https://www.youtube.com/watch?v=Tb3v8 OBHhs0). e rst phase of mining will target high-grade copper mineralization from shallow, underground resources to produce approximately 100,000 tonnes of contained copper per year in a high-value concentrate. e Kamoa PEA estimated that the pre-production capital required for the project's rst phase of development would be approximately US$1.4 billion. e proposed second phase will entail a major expansion of the mine and mill, and construction of a smelter to produce approximately 300,000 tonnes of blister copper each year. e Kamoa pre-feasibility study is progressing and the completed report is expected to be nalized in early 2016. e updated Independent Technical Report based on the pre-feasibility study also will include revised exploration target information. Quali ed Person and Quality Control and Assurance e scienti c and technical information in this release has been reviewed and approved by Stephen Torr, P.Geo., Ivanhoe Mines' Vice President, Project Geology and Evaluation; a Quali ed Person under the terms of National Instrument 43-101. Mr. Torr has veri ed the technical data disclosed in this news release. Ivanhoe Mines maintains a comprehensive chain of custody and QA-QC program on assays from its Kamoa Project. Half-sawn core is processed at its on site preparation laboratory in Kamoa, prepared samples then are shipped by secure courier to Bureau Veritas Minerals (BVM) Laboratories in Australia, an ISO17025 accredited facility. Copper assays are determined at BVM by mixed-acid digestion with ICP nish. Industry-standard certi ed reference materials and blanks are inserted into the sample stream prior to dispatch to BVM. For detailed information about assay methods and data veri cation measures used to support the scienti c and technical information, please refer to the current technical report on the Kamoa Copper Project on the SEDAR pro le of Ivanhoe Mines at www.sedar.com.
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MOVERS & Shakers
Kibali Gold pushes through challenges as it heads for full production Gold major Randgold Resources says the development of its underground mine at the Kibali gold mining complex in the Democratic Republic of Congo is on track. Randgold Resources affirms that the giant Kibali gold mining complex in the Democratic Republic of Congo (DRC) will remain a work in progress until its underground mining component is completed towards the end of 2017, despite the challenges it faced at the mine. H o w e v e r, i n t h e m e a n t i m e , i t s management is making signi cant progress in dealing with transitional challenges, says Randgold CEO Mark Bristow. As ant icip ate d, Br istow s ays t he complexity of dealing with multiple ore types from different sources has affected throughput, recovery and grade in the rst half of the year. “is issue is being resolved, however, and management have taken measures and revised the mine plan to keep Kibali gold
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on course to meet its plus 600 000 oz production target for the year." According to Bristow the development of the underground mine is on track and the sha is currently being integrated with the decline section, where commissioning is scheduled for July 2017. Meanwhile, the team is also focusing on opening two high-grade satellite pits in 2016 and 2017 which will greatly improve operational exibility. Power for Kibali e constr uc tion of t he Ambarau hydropower station is back on track and is expected to start generating electricity in the fourth quarter of this year. Work is already underway on Azambi which will be Kibali's third hydropower station. Despite the operational challenges, management has continued to focus on developing a team consisting entirely of host country nationals, as at the company's other mines, as well as building up a strong
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corps of local contractors and suppliers. Management is also maintaining the e mp h a s i s o n K i b a l i ' s c o m mu n i t y programmes, ranging from capacity building to agribusiness start-ups. “During my recent motorbike trip through the DRC as part of Randgold's Boyzonbikes fundraising safari, it became clear to me that the country faces many challenges, as does Kibali which is a real factor in the Congolese economy,” says Bristow. He continues, “I was encouraged, however, by the very positive vision of the DRC's future which has been presented by the president. An investor-friendly regime is essential for the development of the economy in general and the mining industry in particular.” “As for Randgold, we continue to expand our footprint in the DRC, most recently through the Ngayu and Moku joint ventures.”
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Since energy is a commodity and a need, more choices are better for all parties in the industry IF “GREED” WAS THE BUZZWORD 20 YEARS AGO, one could argue that today it is “choice.” In choice, there is power. When our founder, Jerry Dyess, had the vision for Choose Energy, his goal was to demystify the utilities business for the average consumer. Quite simply, energy is a commodity and a need. And, the more choices, the better it is for everyone involved. Traditional retail companies have long thrived by providing consumers with options. e proliferation of online marketplaces has given consumers the ability to make smart choices and save money on everything from car insurance to healthcare. However, until recently, consumers didn't have a choice when it came to energy – one of the few things that they literally can't live without. In states where energy deregulation is becoming more and more prevalent as it has in other countries, many of the consumers in these states either do not know that they have
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options, and if they are aware, they likely do not know what or how to choose. at is where the power of the energy marketplace comes in. At Choose Energy, we not only provide the online platform to purchase the commodity of energy, but we act as a connector and facilitator, allowing customers to compare and shop for their electric, natural gas and other energy providers. Energy marketplaces provide consumers the ability to see all of the energy supplier's offers in one convenient place so they can compare one offer with another, side by side. Oen these same consumers receive offers from energy companies that sound like a good deal but there is no way for them to compare the costs or the bene ts with alternative options. We help them nd the right place and the right planwhether they are looking for a xed plan, a shortterm option, cost savings or a greener choice. Finally, the consumer doesn't have to blindly pay their
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energy bill and feel like they have no choice when it comes to the provider who keeps their lights and their heat on. We also help the energ y suppliers communicate their services through a trustworthy platform so they can attract and retain the right consumers. Suppliers now are competing for the customer's business, which puts the consumer in the driver's seat. Energy marketplaces bene t the consumer and the provider, by offering services such as comparison, transparency, ease of enrollment and strong customer service while guiding consumers through the decision-making process of comparing and/or switching suppliers. Imagine 20 years ago – even 10 – being able to go online and shop for energy needs. We are currently in eight deregulated electricity states and just announced in January that we have expanded into six deregulated natural gas states, with plans to launch our services in three more states this month. Education is a key factor in the expansion
of energy choices and the deregulation process. In deregulated energy states in the United States (in which more than half the U.S. population lives), once consumers were given a choice in energy providers, t h e y m ay h av e f o u n d t h e m s e l v e s overwhelmed with monthly mail inserts, door hangers, or multilevel marketing agents ringing doorbells and phones. ese channels were the only option the energy companies had – but now retail energy suppliers are reviewing their marketing budget allocations and realizing that the changes in regulation have brought new options and new marketing channels, which bene t them. is complexity behind the energy sales and marketing processes create confusion for the consumer, and is the reason that education is paramount. In addition, education varies by market. For example, Texas, Pennsylvania, Connecticut and Illinois have reached greater than 50 percent deregulated electricity market adoption over the past few years. ere is
currently more education in these deregulated states on electricity options, so we are building on that awareness to inform consumers that natural gas choices are also available. One of the great things about Choose Energy is that people can switch electricity and natural gas in one place, at one time (in states where available). With this winter's energy bills substantially higher due to the much-reported “Polar Vortex” and other weather extremes across the country – consumers are paying more attention to their energy bills. Many states are also experiencing rate hike announcements, so we expect more and more consumers to take control of their energy options. Choose Energy is growing over 100 percent a year in all of our markets. While cost is important, energy choices aren't limited to price. Some consumers have made the decision to change providers because they want a renewable plan as part of the “green movement.” Until
fairly recently, renewable choices were challenging for consumers to access. Today, up to 20 percent of Choose Energy's customers have chosen offerings that come from renewable sources. While not always the least expensive, it is perfect for those who are committed to making environmentally conscious shopping decisions. Others are searching for the best price or a way to manage their budgets, removing the risk of energy price increases. e typical consumer in a deregulated market can save as much as much 25 percent on their yearly energy bill. is is truly a game changer for the utilities business. Deregulation has provided people with the ability to choose energy providers. With the platform to pair the consumer with the provider based on their individual needs down to the details of region, climate, psychographics, demographics, economics and priorities – energy marketplaces have the power to personalize that choice.
Overwhelming support for DRC mining sector THE concluded Democratic Republic of Congo Mining Week has been described as a success aer attendance doubled from the previous edition. Held in the country's mining hub of Lubumbashi, a record number of more than 500 visitors from 35 countries attended the conference and exhibition. Some 94 local and international companies showcased their technology and services for the sector in the indoor and outdoor exhibition areas. e exhibition included a large South African pavilion brought to the event by the South African Department of Trade and Industry. "Creating the DRC Mining Week and combining the longstanding mining events
iPAD DRC and Katanga Mining Week have proven hugely successful," says the event director, Elodie Delagneau, "e visitor numbers and the support from the industry show that we have once again provided a forum that is meeting the needs of the mining sector." DRC Mining Week provided four days of high-level networking, free training and the latest technologies, including a Power Focus Day, two-day conference, busy technical workshops, indoor and bigger outdoor expo, the Mining Industry Awards, CEO roundtables, B2B speednetworking and site visits. e newly-appointed Provincial Minister of Mines from Haut Katanga, H.E. Kitobo Samsoni, made a welcome appearance and
attended the closing session of the strategic conference. e current governor of Katanga Province, Jean Claude Kazembe, attended the opening session and handed over the Lifetime Achievement during the DRC Mining Industry Awards to Louis Watum, Managing Director of Ivanhoe Mines. Ivanhoe also won the Clean Energy Project of the Year while Tenke Fungurume was named Mining Company of the Year for the second year in a row. e Banro Fo u n d at i o n w o n t h e C o m mu n i t y Development and Local Content category. It is the third year that mining pioneers and leading companies in the DRC were rewarded at what have become coveted DRC Mining Industry Awards.
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EVENTS
Advertisers index 02 Spectrometer Technologies 08 MMG 15 SCANTECH 16 Endress+Hauser 21 CMS Cepcor 22 Rigaku 23 Greyline Instruments 25 Inter Clean 27 Royal Corporate Clothing 29 VR Steel 31 DPI Plastics 34 Tormac Pumps 37 FMDRC-Zambia 37 Servcor 39 BMG 40 AEL 43 MMI Steel 48 Jetstream Cutting Solutions Page42
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