Highly commended 2011 PICA Cover of the Year - B2B Publishing
www.miningne.ws
MEDIA
THE KNOWLEDGE YOU NEED
ining FROM THE INDUSTRY EXPERTS
HOT SEAT
Jane March, Marsh Africa mining divisional executive, on the merger with Alexander Forbes Risk Services
GOLD
Bluetooth demolition robots
The investment attraction is back
PLATINUM Players push production pipelines
TECHNOLOGY Advancements in underground robotics ISSN 1999-8872 • R35.00 (incl. VAT) • Vol. 5 • No. 3• March 2012
CONTENTS
T H E K N O W L E D G E YO U N E E D
ining
March 2012
FROM THE INDUSTRY EXPERTS
Highly commended 2011 PICA Cover of the Year - B2B Publishing
www.miningne.ws
16
MEDIA
THE KNOWLEDGE YOU NEED
ining FROM THE INDUSTRY EXPERTS
HOT SEAT
Jane March, Marsh Africa mining divisional executive, on the merger with Alexander Forbes Risk Services
GOLD
ON THE COVER
Husqvarna Demolition blue tooth robots P6
Bluetooth demolition robots
The investment attraction is back
PLATINUM Players push production pipelines
TECHNOLOGY Advancements in underground robotics ISSN 1999-8872 • R35.00 (incl. VAT) • Vol. 5 • No. 3• March 2012
EDITOR’S COMMENT
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28
Raise your glass – a toast to Indaba 2012
MINING NEWS
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Top mining stories headlining this month
HOT SEAT
10 Marsh and Alexander Forbes Risk Services A merger of great mining minds
PRECIOUS METALS: PLATINUM
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12 Eastern Platinum’s meritorious Mareesburg 16 Platinum Australia’s pipeline progresses 18 Zimbabwe’s platinum gem 24 Platfields pleads for cash PRECIOUS METALS: GOLD
26 Cons Murch – still an attractive asset 28 Barberton gold dump reclamation – a Phoenix equivalent
32 Perseus the great – Edikan strikes gold CONSULTING & PROJECT MANAGEMENT
40 Consultants with management flare 44 ADP Projects – delivering engineering excellence FINANCE
48 Handpicking the ‘cream of the crop’
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TECHNOLOGY
56 Robotics – the future of underground safety and productivity
59 Solving AMD with dissolved air flotation 60 The tail of Two Rivers PROJECT DELIVERY: PUMPS
66 Pumping up on pump performance Inside Mining 03/2012
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Editor’s comment Publisher Elizabeth Shorten Editor Laura Cornish laura@3smedia.co.za Creative Chief Executive Frédérick Danton Senior designer Hayley Moore Mendelow Sub-editor Patience Gumbo Marketing Manager Martin Hiller
RAISE YOUR GLASS
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South Africa: R350.00 (incl VAT & postage) SADC countries: US$80 Foreign: US$100 ISSN 1999-8872 Inside Mining Copyright 2012. All rights reserved. ___________________________________ All material in Inside Mining is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the the publishers.
A toast to Indaba 2012 For most of us, this year’s Mining Indaba is already a long-gone memory, but one that will probably last a little longer than others. I may not have been attending the conference for as many years as most of Inside Mining’s readers have, but I have frequented it enough to know that 2012 was ‘hustling and bustling’ like never before. Apparently, there were over 7 000 delegates in attendance, and I can believe it since one couldn’t find parking at the Cape Town International Convention Centre after mid-morning. Walking between the aisles of exhibitor stands was like wading through a dense sea of miners and investors, a constant ‘networking buzz’ in the air. Honestly, I needed a weekend to recover fully from Indaba, but looking back I can say one thing with certainty – the African continent is on everyone’s top priority list and everyone wants a piece of the pie. Metaphorically speaking, Africa is the flame, and the global mining industry, the moth – attracted to nothing else! And evidence of a ‘healthy’ mining industry can be seen in the very pages of our March issue. The array of new and expansion projects underway seems almost infinite, I only wish I had an infinite number of pages to include and write about them all. The gold industry is re-emerging into its own – even low grade and ‘old lady’ revivals are getting the nod. My Cons Murch story on page 26 and Pan African Resources story on page 28 are prime examples of this. Our technology feature brings home the physical necessities, largely in the gold sector, for ensuring the sustainability of our old, deep-level gold mines. The CSIR is investing largely into robotics and robotic technology to reduce the ‘human element risk’ necessity at extreme depths. The industry still has some way to go to implement such technology, but it seems South Africa has the potential to lead the mining industry forward in terms of robotics specifically for the mining industry. Should this be the case, South Africa’s mining
status will re-gain some of its prestigious reputation – from a global context. And even though it is said that our platinum industry is one of our
Metaphorically speaking, Africa is the flame, and the global mining industry, the moth – attracted to nothing else! greatest strugglers at present, it appears that investment is nowhere near short supply. Ngezi’s growth plan seems endless and even Eastern Platinum’s long-term expansion strategy is significant. I suppose this is not true for juniors like Platfields though – MD Bongani Mbindwane says banks and investors remain reluctant to invest in start-up ventures such as his. Perhaps this would explain why there are so few juniors left, outside of the coal sector anyway. Will Platfields become another Chinese mining target? It’s possible in my opinion, but only time will tell. In honour of the successful Indaba, raise a glass and toast the mining industry’s current successes! May the Indaba represent a year of fruition, and plenty more exciting stories to share with you. Laura Cornish
Inside Mining 03/2012
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Mining news www.miningne.ws
Top mining stories headlining this month SOUTH AFRICA
Harmony sells Evander Evander shaft
compiled by Ameerah Griffin
Source: www.businessday.co.za
| EUROPE | $90 billion merger for Xstrata and Glencore Source: www.miningne.ws
After years of courting, mining company Xstrata PLC and commodities dealer Glencore International PLC have agreed to marry in a $US90 billion (about R681.98 billion) deal that will create the world’s fourth-largest natural resources group. The combined company will control a chain of businesses from mining to refining, storage and shipping of basic commodities like coal, copper and corn.
billion, has applied for a large strip of prospects in the wilderness of South Australia around an area more associated with copper, uranium and gold mines than iron ore. Last year, Fortescue lodged its interest in the 10 exploration licences, covering 4 654 km² in South Australia, a company spokesman said. He declined to specify the type of raw materials that the company hopes to find in the area.
Gold and platinum company Pan African Resources and gold explorer Wits Gold have teamed up to spend between R1.5 and R1.7 billion to buy the Harmony Gold’s Evander mine. Harmony recently restructured the loss-making mine, which has a 34 Moz resource, of which 8 Moz are in the higher confidence category of reserves. Harmony is in effect selling these resources for $US5/oz, far cheaper than the typical price of $20US/oz to $US30/oz. Harmony CEO, Graham Briggs, says the company had been at pains to make sure the consortium was buying a sustainable asset that would be cash generative from the start. Harmony sold the Orkney mines to Pamodzi Gold, which went into liquidation, and those mines have since been stripped of assets and left idle.
| SOUTH AMERICA | Vale wins injunction in Brazil tax dispute Source: www.online.wsj.com
| AUSTRALASIA | Fortescue eyes new mining plans outside iron ore Source: www.marketwatch.com
Fortescue Metals Group plans to explore for new commodities in an area of Australia not known for iron ore, quietly laying the foundations for a possible diversification away from the steel-making material, and signalling its intent to compete for new markets in Asia. The company, with a market value of more than $US17
Mining giant Vale SA has won a court injunction in a dispute with the Brazilian government over taxes on overseas profits, and the Finance Ministry’s tax council will have to examine the issue again. The Brazilian government demanded $US5.6 billion in taxes on profits made by Vale’s foreign subsidiaries, plus penalties and interest after what Vale described as “unfavourable rulings” at the administrative level. In a statement, Vale said there was no time frame for resolving the dispute.
Pan African Resources CEO, Jan Nelson SOUTH AFRICA
Wits Gold CEO, Philip Kotze
A CEO to be remembered
It is with sadness that we take leave of a great leader in the mining industry. Neels Engelbrecht passed away on 14 January 2012 at the age of 52. He died of a sudden heart attack while cycling in the Hartebeespoort dam area. Neels Engelbrecht, CEO of RSV ENCO Consulting (ENCO), president of RSV USA Consulting, director of RSV Australia and executive director of RSV Limitada, will be remembered for his role as CEO of ENCO and the successful coal projects it brought into the RSV Group stable. His go-getter attitude was often the reason for being at the forefront of development that helped to establish new business on foreign soil for the RSV Group of Companies since 1998. Our condolences go out to his colleagues, friends and family.
Neels Engelbrecht
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Inside Mining 03/2012
Harmony Gold CEO Graham Briggs
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Cover story: Technology
HUSQVARNA’S NEW BREAKTHROUGH
Bluetooth demolition robot Husqvarna Construction Products (South Africa), a part of global construction and stone industries specialist, Husqvarna, has launched a new range of Bluetooth-assisted robotics that could help revolutionise underground safety in the mining industry, GM for Construction Products, Pieter Smuts, tells Laura Cornish.
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Inside Mining 03/2012
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Cover story: Technology
H
usqvarna Construction Products (Husqvarna CP) has extended its core-cutting range of construction products to incorporate a brand-new range of DXR remote-controlled, Bluetooth-operated robots whose applications in the mining sector specifically could promote safety substantially. “Even though the machines were developed primarily as demolition robots suited to the construction industry, we realised the
enormous potential for their use in underground and surface mining applications,” says Smuts. The robots are compact in design, offering impressive power-to-weight ratio and capable of manoeuvring into small, difficult-toaccess areas, and are able to access areas on or along steep inclines where typical larger underground machines cannot go. They are also ideal for going into areas after blasting to clean up blasted rubble, and are not susceptible to potential fatality situations which could be caused by loose overhanging roofs or walls. The machines also work with extremely hot materials, while still in operation, whose performance is also not impacted by extremely hot conditions. “While underground robotic machines are not a new concept in the industry, Husqvarna CP is the first company in the world to
year, the first Husqvarna demolition robot was launched in Sweden in 2009 with the second and third models following hot on its heels in 2010. The concept and development began when Husqvarna’s Swedish head office made the decision to supply the entire robot, as opposed to just the arm applications tools. “Although we have yet to sell a machine into the mining sector, we have received phenomenal interest from the platinum and coal industries in particular. We are already looking at adapting the machine to accommodate specific tools and applications that certain potential clients have requested,” explains Smuts. However, the company has sold two units to refractory installation specialists, Trident Refractory. Trident is the first company in Africa to purchase and use these machines and will use them across various
While underground robotic machines are not a new concept in the industry, Husqvarna CP is the first company in the world to launch an industrial Bluetooth, remote-controlled machine launch a Bluetooth, remote-controlled machine. This means no wires, and control up to 100 m away,” Smuts explains. The robot is designed to accommodate different tool attachments fitted to its arms, such as drilling, scaling, and breaking tools – making it a multi-purpose, technologically advanced machine. The user-friendly remote control is the heart of the DXR demolition robots. Most functions are carried out using the two ergonomically designed joysticks. The control box has an easy-to-read 3.5-inch colour display. With one-hand control, the tower and arm can be operated while the machine is being moved. Every robot is robust, stable and durable. Baseplates are cast in a single piece without welded-on components, and steel housings are strong and impact resistant. Additional features include reliable LED lights that can handle up to 20 000 hours of operation, and a comfortable stable harness with the remote control mounted on a curved aluminium bar that is worn over the shoulder – increasing safety and ease of operation. Although the robotics range was officially launched in South Africa in January this
ABOVE AND LEFT Husqvarna demolition robot launch, January 2012
industries around Africa, mainly for the demolition of cement and lime kilns, arc furnaces and industrial processing furnaces. Although the machines are manufactured in Sweden and imported into South Africa, Husqvarna is fully equipped to maintain the robots, and repair them when necessary. “We are focusing on establishing local service centres in all the main regions in
Inside Mining 03/2012
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Cover story: Technology
South Africa so we can assist our clientele more quickly and efficiently,” Smuts notes.
The DXR range is available in three versions that can tackle a wide range of jobs: • DXR 310: Perfect for demolition and smaller excavation work, the DXR 310 has a long high-quality excavation arm with a range of approximately 5.5 m. This offers step-less slow motion operation that ensures precision. It can be equipped with a number of different tools, further increasing efficiency, versatility and profitability. Individually controlled outriggers enable it to work on uneven surfaces and close to walls. Only 78 cm wide, it fits through most doorways and is equipped with a 22 kW electric motor. The track widener facilitates transport on uneven surfaces. • DXR 250: The DXR 250 is compact and light (1 620 kg) with a 18/22 kW electric motor, making it the most powerful in its class. Ideal for use in confined spaces, it comes with a fixed arm with a range of 4.5 m and ‘turn-able’ and extendable dozer blades that also function as outriggers. The robot’s low height allows the user good vision over the machine during operation and helps to give it a low centre of gravity. • DXR 140: The most powerful machine in its class, the
The DXR 310
ABOVE Husqvarna demolition robot launch: Dylan Lane, MD, Husqvarna SA; Pieter Smuts, GM, Husqvarna SA CP
DXR 140 is also the smallest and lightest. Its compact design and light weight (just 975 kg) make it easy to transport and manoeuvre in tight spaces. It climbs stairs easily and operates on uneven surfaces and close to walls, due to the individually controlled outriggers. The DXR 140 is recommended for light demolition and smaller excavation work. The fixed arm has unlimited rotation, reducing the need to move the machine between different steps of a job. The DXR 140 has an output of 15 kW. A wider range of mining-
Dylan Lane, Pieter Smuts, Daniel Lundberg and Malcolm Corns
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Inside Mining 03/2012
applicable tools within the mining sector, Husqvarna CP offers a variety of solutions particularly suited to surface infrastructure renovations. The company’s hand-held power cutting tools are ideal for cutting at great depths, up to 390 mm. “We have in fact been assisting in a hostel renovation for a mining company, cutting walls up to 200 mm in thickness. Its core drilling machines are also used underground, particularly in shaft collapsing scenarios. Contact For more information on Husqvarna, visit www.husqvarna.co.za For more information on Trident Refractory Specialists, visit www.tridentrefractory.com
Daniel Lundberg, Husqvarna HQ, Sweden
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Your symbol of confidence
Hot Seat: Risk management
MARSH AND ALEXANDER FORBES RISK SERVICES
A merger of great mining minds NYSE-listed Marsh & McLennan subsidiary, Marsh, has acquired Alexander Forbes’ brokerage business, Alexander Forbes Risk Services (AFRS) – a deal aimed at benefiting some of Africa’s major business sectors – mining being one of them, writes Laura Cornish.
T
he new entity, Marsh Africa, officially established on 1 January 2012, sees the emergence of a greater, stronger risk management company capable of best servicing the African
branches in Malawi, Mozambique, Nigeria, Uganda and Zambia – subject to the completion of due diligence and regulatory approvals. This is expected in the first half of this year.
The merger has combined two of the biggest and strongest mining teams in Africa, and globally
Guy Jameson, Marsh Africa head of sales and marketing
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Inside Mining 03/2012
continent, says Guy Jameson, Marsh Africa head of sales and marketing. Also included in the acquisition are Alexander Forbes’ broking operations in Botswana and Namibia, which will further be followed by the company’s sub-Saharan
“The combination of Alexander Forbes’ well-established South African operations, its regional network and respected team, together with Marsh’s existing South African business, global solutions, resources and placement skills, will bring dramatically
Hot Seat: Risk management
enhanced benefits to all our clients. Companies in the rapidly developing African region are increasingly looking for insurance brokers and risk advisers who can help them protect their vital assets and grow. This transaction, which is driven by our growth ambitions to be a pan-African leader, gives us a powerful platform to meet these expectations,” explains Jameson. “While Marsh already holds a very substantial market share of the global mining and metals insurance broking business, the acquisition has, practically overnight, increased its geographical footprint to include a vast amount of African mining business as well,” Jameson continues. “We are looking to grow our client base proactively in the African region using the real depth of resource we have locally and access to international placement capabilities that are clearly capable of providing a top quality service.” According to Jane March, Marsh Africa mining divisional executive, Alexander Forbes was one of the leading African mining brokers before the acquisition, and the
the acquisition, will benefit both us and our clients,” she explains. Marsh Africa’s substantial risk consulting business comprises engineers and specialists within respective business sectors, including mining, an industry that produces some of the most complex insurance claims. March says South Africa alone has 23 mining experts and specialists dedicated entirely to Marsh Africa’s mining and metals business, with strong support from specialist risk consulting experts and environmental resource professionals across Africa, and the globe. Internationally, there are over 200 mining specialists. Because they understand the intricacies and needs of the industry, they are able to deliver tailor-made, miningspecific structured risk programmes, assessments and advisory services. “Broadly speaking, the market is undergoing a difficult period currently, with pressure on pricing and retention levels, but we have
“Broadly speaking, the market is undergoing a difficult period currently, with pressure on pricing and retention levels”
it is offering the mining sector an “incomparable” level of mining expertise, with advice and services based on internationally recognised and accepted benchmarks. “Our approach is to partner with our clients to design programmes pertaining exclusively to them. By doing this, we are able to provide our clients with the best risk and insurance coverage at the most economical rates, ensuring we retain our clientele base – the most important component of our business,” March explains. On closing the transaction, Marsh retained its Level 3 status in its Broad-Based Black Economic Empowerment (BBBEE) scorecard rating. “Through focused investment and support, Marsh has made significant achievements in its levels of BEE. The combined Marsh entity will remain strongly committed to continuous improvement in its BEE performance levels,” Jameson concludes.
Jane March combination has brought together two very substantial mining portfolios. Within the present and immediate future, companies across the world are looking at the African continent to expand their mining businesses. It has become the mining continent of choice. “The merger has combined two of the biggest and strongest mining teams in Africa, and globally. We are seeing a lot of investment into Africa, and are expecting substantial growth from the region, which, thanks to
not seen a major reduction in capacity from the mining insurance market,” March notes. “And in comparison to the international mining arena, the South African mining book in particular, has been running well.” Thanks to Marsh Africa’s international connections,
The Marsh Africa mining team leaders: Jane March (left), Debbie Geraghty (right)
Inside Mining 03/2012
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Precious metals: Platinum
EASTERN PLATINUM’S
Meritorious Mareesburg TSX/AIM/JSE-listed platinum major, Eastern Platinum (Eastplats), owner of the Crocodile River mine is on its way to bringing a new mine on stream with the development of its Mareesburg project, GM for Eastplats’ Eastern Limb projects, Dave Marsden, speaks to Laura Cornish about the project’s revival.
E
ven though platinum prices are fairly volatile, and not as high as we would like, Eastplats is in a strong growth phase, and although there is substantial development expansion opportunity across all of our operations, our priority is to ensure our R1.8 billion Mareesburg project officially moves into production early in 2013,” Marsden says. It will increase Eastplats’ overall annual production to 225 000 oz in 2014. In January 2010, the company raised $US350 million (about R2.65 billion) for the project, and in January this year, announced it had also secured a $US100 million finance debt facility, meaning the company is very well financed to project completion and beyond. Situated on the southern part of the Eastern Limb of the Bushveld Complex close to Steelport, the project was first
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conceptualised as a 180 000 tpm run-ofmine (ROM) project, incorporating a new concentrator and underground development of its Spitzkop operation. “The recession forced us to revise the project completely, taking a more conservative approach to its development,” explains Marsden. The Mareesburg project now includes the development of a 90 000 tpm UG2 plant (with an upgrade design in place for a further 90 000 tpm) on its Kennedy’s Vale site, to process ore from the Mareesburg open pit deposit. New order mining rights for both Mareesburg and Spitzkop have been obtained. Once operational, the project will last about six and a half years, and deliver grades to the plant around 4 g/t. Marsden is hoping that the potential European economy financial crisis will
Project highlights: • M&I UG2 resource – 15.9 Mt at 3.92 g/t (3 PGE + gold) • Eastplats interest – 75.5% • Average grade of measured resource – 5.26 g/t • Feasibility study completed in 2010 • New order mining rights granted • Mining permits granted • EPCM well underway for new 90 000 tpm concentrator and open pit mine • Commissioning start-up – Q4, 2012 • Official production – Q1, 2013 improve by 2013, and enable the company to recommence with the Spitzkop underground mining development to contribute to group production. To date, the Mareesburg project is well underway, with R782 million committed.
Precious metals: Platinum
As of December 2011, the detailed engineering for the plant was 81% complete, construction of the plant 12% complete, and in terms of the overall project – 22% complete. The ore will be hauled by road some 30 km from the Mareesburg mine to the plant, which is planned to deliver 19 000 tpm of PGE concentrate at 185 g/t (for 100 000 ozpa) to Impala Refining Services in Springs. The off-take sale arrangement has already been concluded. “We will also produce about 200 000 tpa of chrome, as a by-product,” Marsden adds. An existing power line currently provides 800 KVA across the Mareesburg property – adequate to run administration and workshop/maintenance facilities and 3 MVA has already been secured for the construction phase of the concentrator. The company has applied for 40 MVA in total from Eksom, which will be required to run the concentrator and the Spitskop underground operation as well. Because the processing and plant aspects of the Spitskop project were quite far advanced when it was launched in 2008,
Our priority is to ensure our R1.8 billion Mareesburg project officially moves into production early in 2013 especially with regards to long-lead item procurement, the development since reinstating these aspects of the project has gone extremely smoothly, and meeting deadlines are well within reach. Both mills were purchased from a closed operation in the Philippines, and are currently being refurbished locally by Metso.
“With regards to employment, we have already hired our plant manager, HR manager, head of safety, environmental officers and the vast bulk of senior staff. Because there is huge pressure to employ locals, we initiated an apprenticeship programme, which has already seen 48 locals qualify to work in various positions on a mine. They are currently
LEFT Crocodile River process plant RIGHT On-site construction at Mareesburg
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