Inside Mining October 2015 by 3S Media

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 9 • No. 10 • October 2015

www.miningne.ws

AF R IC AN U PDATES ON TH E

MINERALS PROCESSING

Rock-eating bacteria produce gold

G RO UN D A N D UN D E RG RO UN D

TECHNOLOGY

Virtually safer training

VISITING A GRAND DAME

Lace Diamond Mine about to start production

FOR COMMUNITY DEVELOPMENT A look at expectations and delivery

contents Endorsed by

Af r ic a n u pdates on th e

October 2015

g rou nd a nd u nderg rou nd

on the cover Miners operating in Africa are finding various ways to address local community expectations by developing infrastructure, which strongly benefits communities during and after mining operations.

Editor’s Comment

Shine bright like a diamond

Africa Round-up

News from around the continent

Economics, Finance & Risk

Current status of the 2008 MPRDA Amendment Act

Projects

Total solution, total success

Commodities | Diamonds & gems

Visiting a grand dame

Bell fleet shines bright for diamond miners

IT, Communication & automation

Localised uniform conditioning: A hot topic

Managing data for smarter decisions

Virtual experiences for better outcomes

Virtually safer training

Mine Community development

A holistic approach to community development

African mine community expectations

Minerals Processing

Rock-eating bacteria produce gold

Pyrometallurgy & Hydrometallurgy

A refined alternative

Electrical Control & Instrumentation

Driving towards energy savings

Events

A first for Africa

In sid e M in in g 1 0 | 2015

editor's comment

Shine bright like a diamond As consumers, we often only see a final product on the shelf, not realising all the hard work, and sometimes blood and sweat, that goes into the process to deliver the end product. Neither do we ponder on its resource status.

n example of our mindless thoughts is the discovery of a 507.55 carat diamond a few years back in Southern Africa, and recently unveiled in Hong Kong. The final product was a spectacular 104 carat, ‘D’ colour, internally flawless brilliant-cut diamond, set in an extraordinary masterpiece. Chinese diamond expert Chow Tai Fook designed a neckpiece that can be worn in 27 different ways, with this gemstone as the focal point. The final product was launched about a month ago. All the focus was placed on this brilliant diamond and, of course, the equally stunning jewellery piece. But, the actual location of the diamond wasn’t revealed – the only comment regarding this was “responsibly sourced diamonds of the highest quality… discovered in Southern Africa.” I completely understand, though, why they want to keep the location secret; however, it did make me think of various other factors as well. We often buy things without knowing exactly where it originated. Ten years ago, blood diamonds were a hot topic of discussion. In the meanwhile, various governments implemented regulations and companies are practising ethical standards to combat amoral behaviour. At my recent site visit to Lace Diamond Mine in Kroonstad, I had the privilege to experience the workings of a diamond mine at first hand. Just thinking about how much work goes into the discovery and unveiling of a diamond is phenomenal. And, I can only imagine the surprise and excitement when a gemstone of such beauty and quality is found in a diamond mine. This is when we have to stop and think about the fact that there are only 30 years’ worth of diamonds to be unveiled on Earth – making diamonds a rare commodity. In the meanwhile, Paydirt’s 2015 Africa Down Under Conference, which recently took place

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Publisher Elizabeth Shorten Associate publisher Martin Hiller Editor Mientjie Kleinhans Journalist Mpinane Senkhane Head of design Beren Bauermeister Designer Frédérick Danton Chief sub-editor Tristan Snijders Sub-editor Morgan Carter Contributors Sanusha Govender, Tony Stone, Georges Tadonki Client services & production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Marketing & digital manager Philip Rosenberg Financial manager Andrew Lobban Administration Tonya Hebenton Distribution manager Nomsa Masina

in Perth, Australia, focused tremendously on special projects taking place on the African continent in the near future. One of the conference announcements stated that an Australian company will be at the forefront of developing three large electricity projects in Botswana. These three projects are all centrally located within the Southern African Power Pool transmission grid; however, the exact details were not revealed as yet. Also from the 2015 Africa Down Under Conference, Phil Hoskins, CEO of IMX Resources, said that the company is committed to fast-tracking the Chilalo graphite project, in south-east Tanzania, into a world-class flake graphite project. And, Aly Ngouille Ndiaye, the Senegalese Minister for Industry and Mines, said Senegal plans to exploit its mining potential to ensure the emergence of industries structured around its resources. Several other interesting and positive stories emerged from the conference as well, and we will be watching the space to see how many of the projects will assist Africa in rising from poverty. In South Africa, we saw many launches and rubbed shoulders and networked with the best at Bauma. We met some fascinating people and we are definitely looking forward to the Mining Indaba early next year. In the meanwhile, relax, and read some of the interesting stories that we found to share with you. Don’t forget to follow the link to MiningNe.ws for even more articles.

Mientjie Kleinhans

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africa round-up

Mining news Botswana 2015 growth cut to 2.6% Botswana

Sluggish sentiment in the market has seen both De Beers and Botswana’s Okavango Diamond Company sales falling by over 20% in the first half of this year. De Beers trimmed production targets for 2015, due to globally weaker diamond demand last month.

has halved its 2015 growth forecast, due to anticipated weakness in the diamond market, the country’s finance ministry said in a 2016/17 budget strategy paper. Botswana’s government now expects the economy of the world’s biggest diamond Ghana producer to grow by 2.6% this AngloGold and year. In February, Minister of Randgold to jointly Finance Kenneth Matambo redevelop Ghana mine had announced a growth Africa’s biggest gold producer, target of 4.9% for AngloGold Ashanti, 2015. said it has signed a The country is now deal with Randgold seen posting a deficit Resources to jointly of P4.03 billion redevelop its aging ($394 million), or Obuasi mine in 2.61% of the GDP, Ghana. Randgold against a previous said the joint Botswanan estimate of a surplus Minister venture would not of P1.23 billion, or spend more than of Finance Kenneth Matambo 0.8% of GDP. $1 billion on the “The domestic redevelopment. economy is forecast to grow AngloGold stopped by 2.6% in 2015, underpinned production in November last by an expected decrease in year and cut jobs at Obuasi, demand for diamonds in the which holds about 5 million global market,” the strategy ounces of gold reserves paper said. but has not been profitable “A higher growth rate of in a decade. AngloGold’s 4.9% is projected for 2016. chief executive, Srinivasan However, the downside risk Venkatakrishnan, said it to these projections continues was difficult for a single to be the country’s high company to bear the cost of dependence on diamonds, redeveloping a mine in a lowwhose demand and prices are price environment. subject to global fluctuations.” The price of spot gold has The maintained weakness fallen almost 20% from its of the diamond market 2014 peaks, to just above throughout 2015 has seen $1 000 per ounce, forcing diamond prices softening, companies to sell mines, cut while annual output targets Obuasi mine, Ghana have also been trimmed.

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spending, and shed jobs. “When capital is constrained for mining, sharing the cost of capital is perhaps the most prudent way to go,” Venkatakrishnan said. AngloGold jointly owns two mines with Randgold in Mali and the Democratic Republic of the Congo (DRC). Randgold’s chief executive, Mark Bristow, said a team from their Kibali mine in the DRC would arrive in Ghana to begin work on Obuasi in September.

Philip Falzon Sant Manduca, Paragon’s executive chairman. “In any event, with the approval now granted, we can progress the acquisition and development of Mothae.”

Nigeria Miners incensed by N24 billion loans claim The managing director

of the Bank of Industry, Rasheed Olaoluwa, is in hot water with Nigerian miners, following his claim that the bank had provided the solid minerals sector with N24.6 billion, from Lesotho 2009 to date. Government Olaoluwa made the claim approves Paragon while trying to explain how Diamonds’ Mothae his organisation has been acquisition The Lesotho helping the development of government has approved the nation’s solid minerals Paragon Diamonds Limited’s sector. However, the acquisition of a majority president of the Progressive stake in the Mothae mining Miners Empowerment project, the mining explorer Association of Nigeria, Sunny announced in late August. Ekozin, told journalists The company has agreed to during a chat in Abuja that pay Lucara Diamond Corp the claim was a shock to $8.5 million for its 75% Nigerian miners and that stake in the mine, subject Olaoluwa should provide the to government approval public with details of those and a successful closing of who got the loans from his the acquisition. In addition, bank. Ekozin said if N24.6 Lucara will receive 5% of the billion had been invested in profits obtained from the sale the solid minerals sector from of any polished diamonds 2009 to date, the impact from Mothae and 5% of the would have been there for all profits achieved from the to see. sale of rough diamonds not “That claim by Mr Rasheed selected for polishing. Olaoluwa is unimaginable. Mothae is located in the Several operators in the same cluster of diamondsector have been fighting for bearing kimberlites as funding and getting little Paragon’s Lemphane and Gem or no attention. Therefore, Diamonds’ Letšeng. hearing the news “The process that N24.6 billion to obtain formal was actually given approval to acquire as loans to the Mothae took longer sector, by the than all parties Bank of Industry, anticipated, having was a surprise to received verbal us. We demand a approval from the The Bank of breakdown of who minister at my Industry's the BoI has given meeting with him on Rasheed this money to. Who 22 June 2015,” said Olaoluwa

africa round-up

from around the continent has benefited from this loan? Who are the miners involved in exploration? Who is involved in beneficiation? Who that is involved in actual mining operations has benefited from this money?” Ekozin said.

Tanzania Opposition vows to review mining and gas contracts Main

sector, and use part of its stake in gas reserves as collateral for loans to finance construction of natural gas infrastructure,” Lowassa said. Tanzania estimates it has more than 55 trillion cubic feet of recoverable natural gas reserves off its south coast. BG, Statoil, Exxon Mobil, Ophir, and Petrobras are players in Tanzanian energy while miners include Acacia Mining Plc, AngloGold Ashanti, and Petra Diamonds Ltd.

opposition presidential candidate Edward Lowassa, 62, said he would review mining and gas contracts, and also scrap ‘unnecessary’ tax exemptions for mining companies, if elected Zambia president of the East African Kwacha nation in October. goes into The former prime minister, freefall snubbed as the ruling Zambia’s currency, party’s candidate last the kwacha went into freefall month, switched to become in September, as prices the opposition coalition’s for its copper exports hit contender. He could pose a a one-month low, feeding tough challenge for fears that mining the CCM, which has giant Glencore ruled since 1961. might further rein “My government in its extensive will review all operations there. major energy and The kwacha was mining contracts down more than and rectify shoddy 17% against the Tanzanian presidential deals,” Lowassa said dollar at one point, candidate late in a televised its biggest oneEdward Lowassa statement, without day fall on record, giving specifics. further hampered by a rating Some in the opposition say downgrade from credit contracts with foreign firms agency Moody’s that the are too generous, although government criticised as investors’ terms are fair. unsolicited. Experts say last year’s weak “Copper prices continue response to a licensing round to soften, and production indicates that Tanzania needs targets are really at risk to tread carefully to avoid because of the Glencore deterring investors. Investors news,” said Kevin Daly, in Tanzania, Africa’s fourth portfolio manager at biggest gold miner, with Aberdeen Asset Management plans to develop huge new in London. gas finds, have complained Glencore’s Mopani Copper of shifting goal posts in Mines is the second-largest contracts with the state. employer in Zambia, but “My government will also fears over the mining and eliminate unnecessary tax trading company’s ability to exemptions in the mining withstand a prolonged fall in

metals prices sent its shares tumbling 25% in the end of September. Moody’s, which cut its sovereign rating to B2 from B1, in the same month, said it expected Zambia’s fiscal and debt positions to worsen, and Daly said it might now have “little choice but to turn to the IMF”. In May, the International Monetary Fund said Zambia’s economy was at risk from budget imbalances, lower copper prices, and policy uncertainties. Finance Minister Alexander Chikwanda told Reuters, last month, that the economy was likely to grow less than 5% this year, undershooting a 6% forecast. Mopani Copper Mines notified the government, in September, of its plans to lay off more than 3 800 workers, aiming to take 400 000 tonnes of copper out of the market to boost prices. Daly said Zambia was particularly vulnerable because around 70% of its foreign earnings came from copper. “You could very easily see a double-digit fiscal deficit this year,” he said. Zambian authorities said they were mindful of the need to keep debt at sustainable levels, but that the Moody’s downgrade was unauthorised.” Analysts suggested criticising Moody’s was illadvised. “Zambia should assure investors that they are taking steps to alleviate the rampant power crisis,” said Irmgard Erasmus, Cape Town-based Zambia analyst at NKC African Economics. “The central bank will have to tighten liquidity. Without this, there will likely be an increase in panic-buying.”

Zimbabwe Policy interventions key to assisting the gold sector The Chamber of Mines of Zimbabwe has announced that an estimated $600 million would be needed to recapitalise largescale mines over the next five years. About $130 million of that amount is immediately needed to ramp up production, retool, and enhance efficiency. The chamber said viability challenges in gold mining are expected to affect the 2015 output, now projected by miners at 10 150 kilogrammes. This is lower than the government estimate of 15 000 kilogrammes. Gold production has taken a plunge from a peak of 29 tonnes in 1999. Zimbabwe received $2 billion from minerals last year. Already under pressure from weak prices, lowered production capacity could see Zimbabwe failing to realise its mineral potential. The initiatives producers are calling for include reducing royalties and power tariffs. Miners have urged government to cut royalties to between 2% and 3% from 5%. The producers are also calling for a reduction of electricity tariffs to 6.7 cents from 12.8 cents per kilowatt hour. Reducing power tariffs would provide savings of about $83 per ounce, while cutting royalties would result in cost savings of $22 per ounce. Granting the producers their request to reduce production cost structures could help save the sector. In sid e M in in g 1 0 | 2015

Economics, finance & risk

2008 MPRDA Amendment Act

The current status The Mineral and Petroleum Resources Amendment Bill B15 of 2013 has been causing concerns within the mining industry and has not yet been made law. Sanusha Govender (left) discusses the concerns raised by the president and the changes that may come into effect.

outh Africa’s mining sector has made headlines on an almost daily basis over the last three to four years, sadly not for positive reasons. There are many factors that have collectively contributed to the downturn of this once booming industry. These factors, among others, include continuous labour unrest, plunging commodity prices, China’s slowdown, and the current legislative uncertainty. This has a direct effect on investment, which, in turn, has an effect on our economy. Over the last few years, we have seen a decrease in the number of large mining deals. It is a wellknown principle that one of the key elements investors consider when investing in a country is a strong regulatory framework. While the Mineral and Petroleum Resources Amendment Bill B15 of 2013 has been approved by Parliament and sent to the president for signature, the bill is not yet law and has been referred back to Parliament, by the president, for consideration. The president raised concerns about certain constitutional and procedural issues. The concerns raised by the president are: • Th e definition of the Act has been amended to include the terms of the right, any directives issued, the Codes of Good Practice for the South African Minerals Industry, Housing and Living Conditions Standards for the Mineral Industry, and the amended Broad-Based Socio-Economic Empowerment Charter for the South African Mining and Minerals Industry. The amendment will give the above policies the status of national legislation. National legislative authority is vested in Parliament and there are certain

to land for the purpose of ascertaining whether any mineral or geological information exists after notifying and consulting with the owner, instead of requiring the owner’s consent – a customary law principle. The Traditional Leadership and Governance Framework Act No. 41 of 2003 requires any parliamentary bill that impacts on customary law to be referred to the National House of Traditional Leaders for comment, and this was not done. What is more concerning is that it has been almost nine months since the president’s announcement and there has been no talk about the status of the bill. Whether or not it will become law in its current form or be amended is unknown. Perhaps the reason for this may be that government’s focus has moved towards compliance with the Mining Charter over the last few months.

In my view, the bill being passed in its current form may result in dire consequences for an already struggling industry

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constitutionally mandated procedures that must be followed when amending legislation. The potential unconstitutionality relates to the bill empowering the minister to amend legislation without having to adhere to the constitutionally mandated procedure. • Th e minister may impose quantitative restrictions on exporting minerals in order to promote beneficiation, as well as the price at which such minerals must be sold. This may result in a breach of international trade agreements to which South Africa is a party. • The period for public participation in the National Council of Provinces was not fully complied with. The president was of the view that the public was not given a meaningful opportunity to participate in the National Council of Provinces process. • The bill impacts on customary law. It empowers the minister to grant access

Two legal cases There are currently two cases that have been referred to the High Court of South Africa for adjudication. The first case has been instituted by the Chamber of Mines. An order is sought on the interpretation of the ownership element of the Mining Charter and whether the ‘once empowered always empowered’ rule applies to mining companies that are now no longer compliant with the ownership element of the Mining Charter for various reasons. The Mining Charter provides that at least 26% of a mining company’s shares should be held by historically disadvantaged South Africans (HDSAs).

Economics, finance & risk

an applicant would only apply for an enviFurthermore, Section 26 now provides The second case relates to the setting aside ronmental authorisation once rights were that the minister may initiate or promote of the Mining Charter on the basis that granted. This is a costly process and it is beneficiation of minerals and may preit is unconstitutional, vague, and contrasubmitted that junior entrepreneurs wantscribe the levels required for beneficiation. dictory. Non-compliance with the Mining ing to enter this sector may not have the It is not clear what is meant by prescribCharter could result in a holder’s right funding necessary to carry out this process. ing levels of beneficiation. However, takbeing suspended or revoked. The DMR is Finally, regarding the renewal of applicaing the definition into account, one can taking this seriously, and has recently istions, an applicant will need a certificate assume that it may relate to the different sued a number of non-compliance notices issued by the Council of Geoscience constages of beneficiation that may be applito various mining companies. firming that all prospecting information cable to different minerals. The current debacles notwithstanding, has been submitted. the MPRDA has been amended by the Mineral and Petroleum Resources DevelReconnaissance permission opment Amendment Act No. 49 of 2008 The duration has been reduced from two Mining right (2008 Amendment Act). A proclamation years to one year. If an application relates to land occupied was published on 31 May 2013 announcby a community, the minister may impose ing that the 2008 Amendment Act would conditions that are necessary to promote Prospecting rights come into effect on 7 June 2013. Then, the rights of the community, including conThe MPRDA provides that the regional on 6 June 2013, a further proclamation ditions requiring the participation of the manager (RM) must not accept an appliwas published amending the previous community (this also applies to prospecting cation if another person holds a right with proclamation to clarify that the 2008 right applications). It is not clear whether respect to the same mineral and over the Amendment Act would come into effect this requirement is in addition to the ownsame area. This has been amplified and, on 7 June 2013 save for the following ership element in the Mining Charter. It is now, further provides that the RM must sections: sections 11(1) and 11(5) not clear what other conditions the (relates to the transfer of rights); minister may impose, as community Beneficiation Section 38B (relates to environmendevelopment is generally dealt with A definition of beneficiation has been tal); Section 47(1)(e) (relates to the in the social and labour plan. inserted, which divides beneficiation into four minister’s right to suspend or cancel stages, namely: rights); Section 102(2) (relates to Mining permits • the primary stage, which relates to the amendments of rights); and Section The hectares granted by mining process of recovering, winning, and 106(2) (relates to exemptions from permits have been increased from extracting minerals certain provisions). 1.5 hectares to 5 hectares. Further• the secondary stage, which relates to the Below is a summary of some (but more, an RM may not grant an appliaction of converting a concentrate or mineral not all) of the changes that have cation if it will result in the applicant product into an intermediate product come into effect, in terms of the being granted more than one mining • the tertiary stage, which relates to 2008 Amendment Act. permit on the same or adjacent land. further converting that product into a While the reason behind having this refined product amendment is noted, in practice, it Effective date • the final stage, which is the action of may not be feasible. In addition, the The date on which a right comes into producing properly processed, cut, applicant will have to show that it effect is the date on which the relepolished, manufactured products or articles can comply with the provisions of the vant permit is issued or the right is from minerals. Mine Health and Safety Act No. 29 executed. Prior to this amendment, of 1996. a right came into effect on the date on not accept an application for the same minAs mentioned, this a brief outline of which the environmental management eral and same area if a prior application for some of the changes that have come into plan/programme was approved. In practhe same mineral and same area has been effect and should be considered in contice, the environmental management accepted by the RM but has not yet been junction with the entire 2008 Amendment granted or refused. The applicant needs plan/programme was approved on the Act. It is clear, from the above, that the date on which the right was executed. to give effect to Section 2(d) of the MPRMPRDA, as amended, has not provided DA (participation of HDSAs) in respect of much clarity but, rather, more uncertainprescribed minerals. This was previously at Registration periods ty. In my view, the bill being passed in its the discretion of the applicant; however, in The period in which to register rights at current form may result in dire consepractice, this principle was applied. the Mineral and Petroleum Titles Regisquences for an already struggling industry. The definition of ‘prescribed minerals’ is tration Office has been increased from 30 Therefore, it is imperative that yet to be published. The minister can refuse days to 60 days. government makes the finalisation of to grant an application if it will result in the the bill its top priority, so that there is applicant and its associated companies havResidue stockpiles and legislative certainty, which, in turn, will ing a “concentration of mineral resources”. residue deposits give investors confidence in our mining This is a subjective test and it is not clear These definitions now make reference regulatory framework. how the DMR will apply this section. An to include ‘old order rights’. Prior to this applicant has to apply for an environmenamendment, historic dumps – those creat*Sanusha Govender is an admitted attorney, notary tal authorisation and a prospecting right ed prior to 2004 – were not regulated by public, and conveyancer, specialising in mining law and commercial law. Email: sanushagovender@icloud.com simultaneously. Prior to this amendment, the MPRDA. In sid e M in in g 1 0 | 2015

projects

Total solutions, total success

Project: Kinsenda Client: Metorex

Located near the town of Kasumbalesa in the south of the DRC, the Kinsenda project began in April 2013 and was successfully handed over to the owner in June 2015. This project An international, multidisciplinary organisation and one of consisted of a new box-cut the largest project management enterprises in Africa, mining and decline shaft as well as a new concentrator plant super house DRA has set the bar with a number of successful and mining infrastructure. Some of the project projects. Inside Mining looks at some impressive examples. challenges have been poor ground conditions during mine development and ageing primary product quality is required. The Project: Tweefontein mine infrastructure associated with slimes are pumped to an adjacent slimes Client: Glencore this 40-year-old mine in addition to the dam, where they’ll be stored and be relencore’s Tweefontein normal project execution challenges covered in future for beneficiation and coal processing plant, currentassociated with that country. recovery. Products are stockpiled on a ly under construction in MpuThe project was completed ahead of 600 000 t capacity stacker/underground malanga, South Africa, is ratschedule and below budget. DRA says reclaim stockpile, and will be fed to a rail ed at 13.6 Mtpa ROM, 2 200 tph (nominal the project has met strict performance load-out bin at a rate of 5 000 tph. Product 2 000 tph + 10% design allowance) while criteria, despite delays caused by the qualities of 5 800 kcal/kg to 5 900 kcal/kg the crushing plant is rated at 2 400 tph. above-mentioned challenges. Ongoing (export) and 21.5 MJ/ kg to 22 MJ/kg are The four-stage crushing plant is demine development and stoping is targeted outputs. signed to handle reclaimed pillared coal currently managed by the owner. as well as normal mined coal, whilst the process plant uses standard Witbank coal processing technolProject: New Liberty Gold ogy in a double-stage wash Client: Aureus Mining configuration utilising DRA will complete 1 150 mm via DM cyconstruction of the 1.1 Mtpa clones (much like processing plant for the Phola and DMO, but New Liberty Gold project in a different configuduring 2015. The project is ration) and spirals. The located 120 km north-west cyclone plant dissimilar to Phola and DMO, can be left Kinsenda run as a single-stage washmain Tweefontein coal ing plant if, for instance, a lower processing plant

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projects

of Monrovia, Liberia. The design of the greenfield plant has been completed old construction is currently under way. We have completed the design of the greenfields plant and are currently busy with construction. The process consists of a two-stage crushing circuit and a primary mill with regrinding using VERTIMILL® technology. Gold is leached in the carbon-in-leach circuit, and gravity gold is leached with an intensive leach reactor.

Project: Karowe Client: Boteti Diamonds Boteti Diamonds (a subsidiary of Lucara Diamond Corporation) contracted DRA Mineral Projects to provide a complete EPCM service for the design and construction of a diamond milling, DMS and recovery plant and associated crushing, screening, and thickener systems for the AK06 (Karowe) Mine located in central Botswana. The $126 million AK06 diamond plant was designed to process 2.5 Mtpa of ROM kimberlite ore per annum with a single 200 tph DMS module. The concentrate material from the DMS is subsequently treated through a 2.5 tph wet X-ray recovery plant for material reduction and diamond winning. A unique feature of the AK06 mine is the autogenous (or AG) milling technology utilised as part of the circuit, previously seen only in Northern Hemisphere diamond plants. An AG mill can accomplish the same size reduction work that normally takes multiple stages of crushing, screening, and grinding methods, which accounts for its popularity.

Minopex has managed, operated and maintained the processing facility since it became operational in March 2004.

Project: Edikan Gold Plant Client: Perseus Mining Edikan Gold, located 300 km northwest of Accra, the capital of Ghana, was an equal joint venture between DRA Mineral Projects and Group Five Projects, and involved the engineering design, equipment procurement, SMPP fabrication, logistical delivery to site, SMPP and E&I construction, as well as commissioning of the 5.5 Mtpa gold processing plant and ancillary infrastructure. DRA was responsible for all the engineering designs, all equipment procurement, and commissioning. Jungle clearing started in mid-June 2010 and the client’s first gold was poured on 21 August 2011. This equates to 14 months – from 0% on-site to 100% construction and commissioning complete and the first gold poured for the client. The processing plant includes a primary jaw crusher, single-stage SAG

mill, gravity circuit, flotation circuit, regrind ball mill and concentrate CIL circuit and elution circuit. DRA’s sister company, Minopex, which specialises in contract operation and maintenance, assisted DRA with the commissioning of the plant and provided training of the client’s operators prior to the start of commissioning.

Project: Kibali Client: Randgold Resources DRA has completed the gold plant design for Kibali Gold Mine, one of the largest gold mines in Africa. The design consists of two separate plants – one for the treating of oxide ore, and the other for the treating of sulfide ore. The new mine, owned by Randgold Resources, AngloGold Ashanti and Congolese parastatal Sokimo, produced its first gold in the last quarter of 2013. Located in the Province Orientale of the DRC, it will build up to an annual production of 7.2 Mtpa. top Kibali Gold Mine below New Liberty Gold

Project: Letseng Diamond Mine Client: Letseng Diamond Company Located in landlocked Lesotho, DRA was responsible for designing and building a 350 tph DMS plant at Letseng Diamond Mine, which is fully enclosed to accommodate extreme weather conditions. The plant complex includes primary crushing and scrubbing, secondary crushing and re-crushing, 800 mm cyclones, wet X-ray recovery, and integrated workshops and stores. In sid e M in in g 1 0 | 2015

Diamonds & gems

Visiting a grand dame

“This means we can take immediate action and make urgent decisions, when necessary,” explains Loudon. He calls it an unconventional, but radically rational management style.

Lace Diamond Mining was founded in 1902 and was named after Josephine Dale Lace. The mine has produced some spectacular diamonds over the years and is, once more, on its way to full production. Mientjie Kleinhans investigates what the underground developments entail.

he mine is now called Lace Diamond Mines and has been undergoing underground developments in preparation for the full production of diamond mining, once again. In short, the mine was stopped in 1931 when diamond prices crashed, and was purchased in 2005 with the intention to mine diamonds once again. Once the company managed to find financing, the full-scale development plan A view of the on-site processing plant

1902 - 1908

Lace Diamond Mining

was set in action. Today, management is proud to say that the mine is almost ready to start production, but the underground developments must first be completed. “It is almost like watching paint dry,” laughs Paul Loudon, CEO of Lace Diamond Mines. Not scared to get into the full underground gear and take visitors underground, this CEO means hands-on action. His ideology is that the top-level management of the mine stays on the mine, and that the corporate global head office also be located on the mine.

New developments

The previous miners started an open-pit mine, took it down to 100 m and discovered that the mine was delivering higher-quality diamonds as they went deeper. They, therefore, went underground and developed to the 300 m level. But because kimberlite is very soft and the old infrastructure is very dangerous, the new management started new developments underneath the old workings. “Our first mining block will be longhole, open-stoping, bottom-up, and the second phase is one of three block caves over the life of the mine,” says Loudon. In the first stage, the Upper K4 block will be mined on Level 47, which is 470 m deep, the second block cave will be at 670 m, and the third at 850 m. As kimberlite contains a lot of internal waste, the mine is investigating installing a waste sorter in the crushing circuit to remove waste before it reaches the plant, which means this will be pushing a higher grade of material through the plant. “We are currently running test works of three different types of X-ray and optical waste sorters. We will be looking at ore coming in on the conveyor belt, examining it with high-frequency X-rays, and then

Lace Mine owners 1908 - 1939 1939 - 1996 1996 - 2005

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Crown Mines

De Beers

Christaan Potgieter

2005 - Present Lace Diamond Mines

Diamonds & gems

sending a real-time signature back to tell the difference between kimberlite and waste. Some designers add an optical side to re-examine the ore. “This provides the potential to significantly increase the rate at which we mine,” says Loudon. He reckons that, if the waste sorter works out, it means that they will be able to concertina 25 years' life of mine into 18 years and will see a big impact on cash flow and operating margins.

Conveyor belt The conveyor belt will start underground and will surface close to the conventional media separation plant with a capacity of 400 tph at 1 m/s. The plant runs at 200 tph and, therefore, will never have to wait for the conveyor belt to feed it.

The ore will go through a 300 mm jaws crusher underground and a second jaw crusher on the surface, before entering the processing plant. To save costs, as a junior miner, the mining company invested in rebuilding big equipment instead of buying brand-new equipment. Some of the rebuilds include scoops, dump trucks, and drill rigs. “With the exception of one new drill rig, we acquired equipment for low amounts and spent between R2.5 million to R3 million per unit by rebuilding them with new components. Therefore, each machine is mostly new,” explains Loudon.

Biggest challenge Loudon explains that the biggest challenge for them has been opening up

an old kimberlite mine. “It is not for the faint-hearted. Because of the friable (crumbly) nature of kimberlite, the ground falls easily; therefore, we had to work slowly and very cautiously. We had to install a lot of secondary support.” He adds that another big challenge for the company, as a junior miner, has been raising capital. All evidence shows that Lace Diamond Mines can produce type 2A diamonds, which are super white, D colour with no nitrogen impurities. There is also potential for pink and lilac diamonds at the mine. With at least 25 years' life of mine remaining, who knows what beautiful gemstones may yet be unearthed at this mine.

above The conveyor belt surfacing, still under construction right Paul Loudon inspecting the kimberlite stockpile below The old main shaft is now a temporary ventilation shaft

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Diamonds & gems

Bell

Fleet shining bright for diamond miners The alluvial diamond mining areas of the Northern wo young Cape have proved, over alluvial diamond miners the years, that they are are certainly not places for the faintconfident that they can hearted. This goes for make it there and are not afraid to roll up their man and machine.

sleeves to make it happen. Jonathan Lloyd and Dale Hohne have been successfully mining diamonds in the Windsorton district for the past three years and have recently started mining an area within the Vaalbos diamond fields close to Barkly West. Both hail from families who have mining in their blood and Jonathan has worked in diamond, gold, and base met-

al mining, with six years spent in Sierra Leone doing just that. Dale Hohne is the fourth generation in his family to choose mining as a profession. Both have, however, always had the urge to be self-employed and are doing so under the banner of their company, Mogale Operations.

Never say die “This type of mining is all about moving earth and for that you need earthmoving equipment,” says Hohne. “One of the first pieces of equipment we bought was

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a well-used Bell L2206 wheel loader that had been fitted with the engine normally found in a Bell L2208 machine, and which had done a remarkable 24 000 hours at that time.” According to Hohne, they have added another 15 000 hours to the machine, which is still being used daily. “This should tell you that we have pretty much based our fleet of earthmoving machines on those sold and maintained by Bell Equipment,” Lloyd adds. “For this operation at Vaalbos, we are using two Bell HD2045 excavators, a Bell L1806C and Bell L1806E wheel loader, respectively, and three Bell B30D articulated dump trucks (ADTs).” Although all this equipment was sourced on the pre-owned market, it was done through the Bell Equipment Customer Service Centre in Kimberley, with sales representative Eric van der Merwe, who has first-hand knowledge of alluvial diamond mining, guiding and advising Mogale Operations’ owners. Mining takes place using the Bell HD2045 excavators, which first remove the topsoil and overburden, with both materials being stockpiled for later use in rehabilitation. Diamond-bearing gravels at Vaalbos vary in depth, as there is some red ground that offers shallower pits as opposed to some lime-rich ground, which, in turn, demands deeper digging.

Once exposed, the gravels are loaded on to the Bell B30D ADTs for a short haul to the screening plant, and eventually fed into a dual set of 16-foot pans where the concentrate is removed. Final sorting of the diamonds, out of the concentrate, takes place off-site.

Rehabilitation

The Bell L1806 wheel loaders feed the screening plant and load the Bell B30D ADTs with the discarded material, which is then hauled back to the pit for the rehabilitation of the mined-out areas. “Fuel consumption is obviously important to us, as we constantly aim to lower our production costs per tonne of earth moved,” Hohne explains. “Even with running full loads from the mining pit to the plant, and back again, we are seeing fuel consumption figures of 20 to 23 litres an hour, which is impressive, given the tonnages moved.” Equally light is the fuel consumption of Mogale Operations’ two Bell L1806C and L1806E wheel loaders, which only use 9 to 10 litres an hour. “These are still early days for us on Vaalbos and, depending on our yields in the long term, we may have to consider bigger haulage machines, like the proven Bell B40D ADTs,” says Lloyd. “We have an estimated three years on this ground and time will reveal all we need to know.” Both partners agree that, although their fleet of Bell earthmoving equipment is not new, they are ensured of fleet longevity, through solid technical back-up and the sustained availability of essential original parts, all supplied by the Bell Equipment Customer Service Centre in Kimberley. top One of two Bell HD2045 excavators, which are used by Mogale Operations at their Vaalbos operation to remove topsoil and overburden and load the company’s three Bell 30D articulated dump trucks with diamond-bearing gravels left (Left to right) Bell Equipment sales representative Eric van der Merwe with the owners of Mogale Operations, Dale Hohne and Jonathan Lloyd, together with the team leader at Bell Equipment’s Customer Service Centre at Kimberley, Shaun Malan

IT, Communication & Automation

Localised uniform conditioning

A hot topic

One of the topics at the Danie Krige Geostatistical Conference, organised by the Southern African Institute of Mining and Metallurgy (SAIMM), was uniform conditioning and localised uniform conditioning. Mientjie Kleinhans spoke to Kathleen Hansmann (left), one of the presenters, to find out more about the topic.

athleen Hansmann, senior geosciences analyst at Datamine Software, describes uniform conditioning (UC) as a non-linear estimation technique that determines a recoverable resource, giving an estimate of expected grades and tonnes for a set of cut-offs, taking a Gaussian change in support model into account. “A recoverable resource is the portion above a cut-off grade of an in situ resource that one can take out of the ground in logical mining blocks. If one is able to mine at a point support, one can separate and extract all the high- or low-grade resources; however, at a mineable block support, each block contains a mixture of high- and low-grade material that must be taken out together,” explains Hansmann. High- and low-grade resources are obviously intermingled with some waste in

the orebody itself. When one mines, one is limited to a minimum size mining block for extraction, because of the large equipment used for mining. One has to take out all the ore and waste that is inside the block – UC allows for an accurate assessment of this. “So, it also considers how much waste is inside a block, to be able to adjust expected grades that one can realistically mine,” says Hansmann. She explains that UC is a hot topic, as traditional linear methods of resource estimation can be problematic when there is not enough drilling information. The purpose of trying new estimation approaches like UC is to calculate a mineral resource estimate that is as close as possible to what is in the ground. “UC is a method that came about in 1994, from work by Rivoirard; in 2006, a localisation extension was added

through work by Abzelov – allowing UC to be used more practically,” says Hansmann. SAIMM recently awarded Abzelov with the first ever Danie Krige Medal, for his 2014 paper, entitled ‘Localised uniform conditioning (LUC): method and application case studies’, which appeared in the March 2014 volume of the SAIMM Journal. She adds that it is very difficult to use a uniform conditioning model for mine planning, as the data is presented in big blocks and describes the grade distribution within the block. Localised uniform conditioning (LUC) is a practical tool that allows the big block to be broken up into smaller blocks, which can be better used for mine planning, mine optimisation, and scheduling. Hansmann defines LUC as an add-on to UC that spatially locates the conditional distribution of SMU (smallest mining unit) block grades within panels, and places these SMUs at plausible locations within a panel. “The localisation process does not improve the accuracy of the Uniform Conditioning result, but rather presents the result in a more practical format,” explains Hansmann. Hansmann’s paper at the Danie Krige Geostatistical Conference explained that UC is suitable when there is sparse drilling information, in conditions where traditional estimation methods sometimes give a poor result. It can be used for estimating metal grades on normally distributed grade deposits – such as copper – or on skew to record normally distributed grade deposits, like iron ore or gold. In sid e M in in g 1 0 | 2015 13

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IT, Communication & Automation

Managing data for smarter decisions The rise of the computer was meant to make life easier for everybody. And it has, in a way; but, at the same time, we have been creating mountains of data. In today’s technologically advanced world, one would assume that we’ve mastered data management to a T. By Mientjie Kleinhans

lthough most mines accumulate tremendous amounts of data on a daily basis, they don’t necessarily manage the data in line with making smarter decisions. In most cases, data is managed in silos. According to Frederik Verhoef, solutions director: Global Mining at Bentley Systems, an intelligent mine is a mining operation that applies technology in such a way that every miner or piece of mine equipment is constantly collecting data on variables such as speed, position, weight, distance, and volume – through normal operation – with the data being fed back to a control centre. “It is then from the control centre where the real-time decisions (or near enough to real time) are made to adjust the mine plan, maintenance schedules, and so on. We are not there yet, but

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are moving in that direction – some faster than others,” says Verhoef. Nick Roos, business solutions executive for Micromine, explains that an intelligent mine would use intelligent data as strong validation at the entry or capture stages to ensure data integrity. “Data needs to be visual and pliable to achieve certain required outputs. Strong reporting interfaces will then share data with the relevant stakeholders to aid in the decision-making process. In addition to this, strong data security is vital to ensure that only authorised personnel have access to data relevant to their roles,” says Roos.

Leveraging data The question remains: how can the leveraging of data assist companies in making smarter decisions? Verhoef reckons that we can base decisions on our ‘gut feel’ or even sometimes completely blind. “Smart decisions are based on insight and insight is the result of a thorough understanding of the data. A lack of data, therefore, leads to poor insight and suboptimal decisions.” Roos agrees and adds that the leveraging of data is a crucial component in any decision-making process and is essential to the successful future of any organisation. “In addition to accurate data, automation can also play a key role in increased productivity in terms of built-in functionality, such as complex calculations, validation, and resource calculation,” says Roos.

He adds that the majority of his clients, on a large scale, have a robust database solution, as they understand the need – in a stringent market – in terms of efficiency, accuracy on reporting, and output information, among others. The database is usually managed by a qualified database manager who also understands the implicit needs of a geological database. Verhoef tells how many mine operators have complained to him about the lack of data available after the completion of major projects. “Others collect large volumes of data, but are unable to gain that all-important insight into the data. “It is rare to find miners of whom one can confidently say they value the data and use it to inform their decisions. Change is upon us, though, as the leading miners have started to understand the importance thereof; they have also started to identify and apply appropriate principles found in other industries,” explains Verhoef.

Data problems All is good and well in an ideal world. But, how would a company know if it is experiencing data problems because of software? Verhoef says that there are a number of tell-tale signs. “Two of my favourite clues are that bad systems breed more systems and silos of data. Data might be in systems, but are frequently not available outside of the specific department,” explains Verhoef.

IT, Communication & Automation

Pieter Fourie, training and support consultant for Micromine, says that some of the problems with inaccurate data are visible, others, unfortunately, are not. “Visible signs may include lost data; challenges with data access, integrity, and reporting; plus endless QC issues. “The hidden implications cost companies millions – through inaccurate modelling or decision-making, a loss of productivity, and a high total cost of ownership, to name a few. This should be highlighted along the various steps of data collection and validation. Lothology logs, for example, should not be allowed to exceed the end-of-hole depth in collars data and, therefore, flags should be raised – in the beginning stages – when the data is captured,” says Fourie. He explains that data loss at a later stage should be kerbed by standard disaster recovery procedures, such as regular backups to a separate server, hard copy

backups stored off-site with copies of the software, and so on.

Handling data “It is one thing to collect massive amounts of data, but another to be able to analyse the data, and share it with the rest of the organisation. This is where a common data

tool for a company is to standardise the nomenclature associated with all aspects of the mining process – from lithological, structural mineralisation to geotechnical codes during logging. This can easily be achieved by fixed-from-data-entry templates that may be specified and set, as well as altered as needed by the database administrator from within our products. “Another common issue that plagues most old projects is the incorporation and/or translation of historical codes that may be remnants of a handover from exploration to resource classification and production, or the previous ownership of the project,” says Roos. There are various experts in the fields of data management that can assist mines with the ideal solution to a unique problem. The bigger challenges are first to identify a problem in the system and then to find the perfect programming partners.

“Data needs to be visual and pliable to achieve certain required outputs.” environment comes in to play a massive role in ensuring the data is shared to all areas within the business that may require access to it,” says Verhoef. He adds that the operational and predictive analysis tools also assist with optimising operational efficiencies. Roos reckons that mines can equip themselves to handle massive amounts of data. “Perhaps the most important

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IT, Communication & Automation

Virtual experiences for

Virtual reality has many applications in the mining industry, some of which were discussed at the recent Virtual Reality Conference, organised by the Southern African Institute of Mining and Metallurgy, held at the University of Pretoria. Mientjie Kleinhans spoke to two of the presenters about the use of virtual reality in mines.

irtual reality may, in the minds of some, conjure up scenes from Star Wars movies, and the interesting fact is that virtual reality started off with computer games in the 1990s. Today, however, virtual reality is a low-cost tool with high resolution, developed for various industries. Jovan Harrod, senior technical officer at the School of Mechanical and Mining Engineering, University of Queensland, defines virtual reality as a computer-based interaction or something where a user can interface with a computer-based environment. “In the mining industry, we can define it as a computer-based mechanism for users to visualise mining information and data, as well as recreating intricate scenarios, such as mining disasters or safety training, and risk management systems. Overall, it is a visualisation system – it is a more tangible way of visualising and interacting with mine data. For instance, one can now interact with computers by using one’s hands,” explains Harrod. He explains that, with this new technology, one’s hands

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can ‘touch’ or ‘grab’ an object, scroll through information, or pick up instruments. One such application could be to test ventilation speed or air flow in a shaft. It boils down to working with 3D objects, instead of in file format, giving an object a data value or certain characteristics, which one then manipulates to interact with mining instruments. “This will give a user a good visual idea of how an object or instrument will be used in real life in a mine,” says Harrod.

Mining applications Other virtual reality applications in the mining industry are mine planning and design, designing mining equipment,

training, and incident reconstruction, according to Etienne van Wyk, principal lecturer at the Tshwane University of Technology. In the white paper he co-authored and presented at the Virtual Reality Conference, titled ‘Applying virtual reality to prevent repeat incidents’, Van Wyk remarks that the use of virtual reality offers mines an opportunity to develop tools and systems, for a variety of purposes, that can improve knowledge and an understanding of hazards associated with the work environment. He further points out the huge role that virtual reality can play in reconstructing an incident that occurred on a mine. By visually experiencing a reconstructed incident, people are able to understand a situation better. In the paper, Van Wyk highlights that an animated reconstruction simulation of an incident can have the following visual components: • a virtual environment, with animated scenes depicting details regarding exactly what occurred – i.e. the sequence of events

“This will give a user a good visual idea of how an object or instrument will be used in real life in a mine.” Jovan Harrod, senior technical officer, School of Mechanical and Mining Engineering, University of Queensland

IT, Communication & Automation

better outcomes Successful Training Safe Environment

Competent Workers

Benefits Van Wyk’s list of benefits in using virtual Profitable reality in a training Industry environment: • an ideal tool to train equipment operators • provides the trainee with viewpoints from different angles • emergency scenarios and dangerous situations can be reconstructed • visually represents highly technical content • provides a high-retention 3D virtual environment • provides an opportunity to explore a wide variety of scenarios • an opportunity to perform real-life tasks in the virtual world.

• scenes indicating the cause(s) of the incident by highlighting the erroneous actions undertaken or depicting failed defences • scenes indicating the correct procedures for such circumstances. The reconstruction of an incident can be played back in video format from different angles and at different speeds. This allows the relevant people to analyse the information for further use.

Virtual training Another huge application in the mining sector is virtual training. Harrod explains that virtual reality training focuses on risk management and is, specifically at the university, for those students thinking of

Effective Management

Social Responsibility

Sustainable Production Effective training has far-reaching impacts on businesses

opportunity, through virtual reality, to going into the mining industry. look behind the hydraulic shields, or get“These students have very little ting up close to the longwall shearer in operational experience before an underground coal mine. This provides going into a mine. Therefore, students with a perspective on underwe need to give them that kind ground mining systems that cannot be of experience without having to provided in reality. take them there. Currently, it is Whether it is for mine planning and difficult – due to financial readesign, to reconstruct an incident, to sons – to go underground and it create safer environments for the workis not always practical or possier, or to offer a new training environble,” explains Harrod. ment, virtual reality is a new tool to With virtual reality, peosimplify the lives of people working ple from all over are able in mines. to experience the mining The various applications ofenvironment with a better fer solutions to mining prounderstanding of overall fessionals to make better decioperations. In the white sions and, as with most cases, paper ‘Enhancing mining will most probably keep on education through developing to offer even the use of virtual better solutions. reality learning and assessment tools’, which Harrod presented at “Virtual reality can improve our the Virtual Realunderstanding of hazards in the ity Conference, he points out an work environment.” Etienne van Wyk, example of stu- principal lecturer, Tshwane University of Technology dents getting the In sid e M in in g 1 0 | 2015 17

IT, Communication & Automation

simulators allow the operator to practise for a range of possible emergency situations,” says Anthony Bruce, regional vice-president for Africa, Europe, and CIS at Immersive Technologies. “Many of these situations are too dangerous, too difficult, or too expensive to test in an actual mine. Operators can also be shown, and assessed for, the proper operating technique much more quickly and accurately than through the traditional in-machine approach. “This allows new operators to practice many skills before being placed into a production circuit. As operators are consistently shown and assessed on the proper operator techniques, they have a better understanding and knowledge of the real machine,” explains Bruce. Willie Haasbroek, manager of the Operating Academy at Barloworld, agrees: “Because the operator doesn’t use a real machine, the simulator training is safer and more cost-effective.” The ability to train operators to react correctly during potentially life-threatening situations is invaluable in mining, according to Bruce. Simulators provide equipment operators with a better understanding of possible hazards. Many of these situations are too dangerous, too difficult, or too expensive to replicate in an actual mine. “Really dangerous situations rarely take place in mines, so for training operators to understand proper protocol in a safe environment is essential for mining operations to be assured their operators are better prepared and can react appropriately with confidence,” says Bruce.

Virtually safer training Virtual reality training offers a safer environment for operator trainees, for various reasons, as well as tremendous cost savings. Mientjie Kleinhans

discovers why virtual reality training isn’t just a futuristic nice-to-have, but rather a necessity.

irtual reality simulator training for operators includes training on more than just new technology and autonomous machinery. Major manufacturers understand the need for simulator training and have partnered with IT companies to develop training for machine operators. The benefits of simulator training outweigh the training costs incurred by mining and construction companies, with safety most probably the biggest driving force for simulator training. “Simulators provide operators a safe environment in which to learn and practise their skills. Our company’s

Cost implications Bruce adds that simulator training allows operators to be shown and assessed without the need to borrow machines from production. Machine availability is an ongoing challenge in the mining industry. Poor operator behaviours and operational practices, such as abusive shifting, engine overspeed, and brake abuse contribute

TOP Cat M Series grader interior left A Cat dozer simulator station

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IT, Communication & Automation

to a loss in production while machines machine. Rich graphics create a virtual are down. world as trainees move through a suc“Reactive maintenance is an inefficession of exercises that test and record cient way to address fleet availability their progress. and companies are more likely to suffer Core metrics are built into the profrom heightened maintenance costs, gramme for all Cat simulator malonger periods of unplanned equipment chine classes. For Cat M-Series module, downtime, and lost mine productivity. these include: Properly trained operators can direct• c ontrols familiarisation ly reduce unscheduled maintenance •n umber of blade-ground contacts costs and increase site productivity,” • t otal blade-ground contact time says Bruce. • t otal time spent in reverse He reckons that targeted simula• average speed tion training from his company de• highest gear used livers, in the field, an average of a • number of collisions 62.2% reduction in brake abuse, a • number of blade-tyre contacts. 69.8% reduction in abusive shift“In addition to proven machine profiing, and a 54.4% reduction in ciency, we will only certify operators engine overspeed. if they can demonstrate – via theoretHaasbroek adds that one canical and practical examination – that not compare the cost they have a comprehensive of simulator training understanding of the corto real, in-machine rect techniques required to training; the simulaachieve safe and optimum tor only uses power production. This includes and one needs to dean understanding of how preciate the capital these techniques can posoutlay – it may cost a itively impact on machine few hundred rand per health and availability,” hour. “The real opersays Haasbroek. ating machine costs “Many of these situations are too millions of rands and The challenge dangerous, too difficult, or too its running costs per He explains that the bighour are much more gest challenge in moving expensive to test in an actual mine.” than the hourly cost from a simulator to a real of a simulator. And, machine will be the difone also has to bear ferent types of environments in mind the loss of production of the that the operator will work in. Anothmachine, while training takes place. er challenge for the older generation “We have found that the use of of qualified operators, interested in simulators greatly enhances downupskilling themselves, is moving from stream proficiency and efficiency at steering wheels to joysticks. “Younga time when the industry is looking er operators, accustomed to the virtual for ways to save on operational exworld of 3D gaming, may pick up the penditure and maximise the cost per techniques slightly faster; but, in the tonne utilisation of existing fleets,” end, the playing field is levelled by the explains Haasbroek. nature of the training programme,” concludes Haasbroek. Simulator training is safer and much Proficiency from TOP A demonstration on the training more cost-effective than conventionThe question remains: how true to the cab interior al in-machine training. It is also a new ‘real McCoy’ are the simulator training An example of an immersive training technology that can be updated at a sessions? Haasbroek explains that once environment more affordable cost than the purchase on-board a Cat simulator, realistic conThree different types of simulator training price of a new machine and the cost trols ensure that the operator gains fafacilities of downtime. The future of simulator miliarisation and muscle memory using A typical example of virtual training for training awaits. the same hardware found in the actual machine operators In sid e M in in g 1 0 | 2015 19

Mine community development

A holistic approach to community B development The Mining Charter demands that mining houses contribute to their host communities. Exxaro's Ramesh Chhagan discusses the company’s successful holistic approach to fulfilling this requirement – building sustainable communities, and spending approximately R80 million a year on community development. By Mpinane Senkhane

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lack-owned and diversified group Exxaro Resources has adopted a unique approach to community development. Ramesh Chhagan, group manager: Community Development at Exxaro, says the group has always made it a point to prioritise the community as much as it prioritises the bottom line. “You must understand, mines operate under a completely different set of rules. Community development is not just a ‘nice to have’ thing that we do for philanthropic reasons. It was the case many years ago but, now, it is a specific requirement of the Mining Charter, which says one must produce a social and labour plan that is linked to one’s mining licence to operate,” Chhagan says. With major business operations and projects across South Africa, and interests in Botswana, the Republic of the Congo, and Australia, Exxaro places great importance on supporting communities in its business operations. According to Chhagan,

Mine community development

national priorities as reflected in the National Development Plan are taken into consideration, followed by provincial government and local government priorities. Chhagan serves on numerous forums – particularly in Limpopo and Mpumalanga – to ensure that all initiatives address real needs. He says the key is trying to understand the challenges plaguing the communities and collaborating with government to identify what Exxaro needs to focus on – in this way, the company can then develop its social and labour plan. More often than not, mining houses are accused of exploiting the communities that host them, and alienating these very communities as the stakeholders they are. However, Exxaro has built engaging relationships with government – from the provincial level down to the municipal – and with the people themselves, to the mutual benefit of all. Chhagan says, “We take the National Development Plan and look at its national priorities. We also engage with provincial governments – I sit on forums of the relevant premiers. Particularly in Limpopo and Mpumalanga, we aim to understand the drivers, or what government is trying to do at various levels. We then speak to the municipalities. So, having spoken to all three legs of government, we get an idea of what the national challenges are and what it is that we (Exxaro) main As at 31 December 2014, Exxaro had assets of R47.4 billion and a market capitalisation of R23 billion below right Exxaro is one of the largest South Africa-based diversified resources groups

says that a sustainable community is one need to focus on – we use that as a basis to where the money circulates at least five develop our social and labour plan.” times in the same community. However, if South Africa’s second largest coal promoney only leaves the community, then it ducer has a number of initiatives geared is left in a depressed state,” Chhagan says. towards the creation of sustainable communities. Chhagan emphasises that, if you want a community to be sustainable post Ease of movement stimulates mine closure, there are certain ‘levers’ that the economy mining houses need to work on – especialInfrastructure development plays a key ly if the community is a rural one. role in the advancement of any economy Often, post-mine-closure com– and the Mining Charter reflects the munities are left to deterigovernment’s desire to build orate once the resourccommunities. Improving rees that come with gional infrastructure conmine operations nectivity across towns are cut off. Excreates the platform plaining that for a community’s this is the very economy to grow. matter Exxaro Chhagan says Exxaro aims to curb, has always noted how Chhagan says, important infrastruc“You have got to ture is to building the improve the capacity of its rural community’s host communities. Often, post-minecapacity to be “We not only sustainable. built roads for the closure communities are “Educating Maropong townleft to deteriorate once ship, which is in the people creates the the resources that come Lephalale itself, possibility we also built the with mine operations that they may major road that are cut off. This is what links the town to start their own business Maropong and we Exxaro aims to curb initiatives in provided a water the future. treatment plant They can, then, give back to that society. as an infrastructure establishment, We look at skills development because, which provides water to the entire town,” beyond basic education, we want these explains Chhagan. people to have very specific skills that will Currently, Exxaro is part of a R250 milenable them to generate an income. We lion project, in the form of a public-private believe that enterprise development is at partnership with the Roads Agency of the heartbeat of development. Research Limpopo, where it will build a network of

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Mine community development

roads linking the rural areas to Lephalale – a project that should take five years to complete.

Infrastructure is more than just building roads

longevity and growth in the community. The community should continue to grow long after the mine has been closed.

Gaining community trust

Mining has often seen rifts between host Aside from actually building infrastructure, communities and mining houses but, Exxaro has gone a step further and in Exxaro’s case, the company has manis creating the capacity to build the community. “If you fail to demonstrate aged to build relationships with its host communities. “I believe it is a value chain, with responsibility to the “We have developed a Community Risk education as the bedrock – if schools and Issue Management (CRIM) policy; are not producing educated individcommunity, conflicts will this acknowledges that a mine is a disuals, there is a major problem movbe inevitable.” ruptive force as well as a force for good. ing forward. One must be a part of Ramesh Chhagan, group manager: Community We disrupt the traditional way in which this, if the ultimate goal is to create Development, Exxaro things happen in an area by suddenly a community that can sustain itself – bringing in economic activity and monwhich is, in my opinion, the focus and ey, where some people have access to it and some do not. All the spirit of the Mining Charter. It is about the mining houses this contributes to stresses and tensions within communities,” using their considerable influence and power to really transform Chhagan explains. communities,” Chhagan says. He adds that, as much as mining makes a positive impact But, beyond that, Exxaro has seen the need to focus its attenon the people and the economy, those that live in the immetion on skills development. It built an enterprise development diate proximity of mining operations suffer some of the negsystems hub in Lephalale in a bid to hone any entrepreneurial ative effects, such as dust and noise. So, Exxaro has adopted skills people of that community have. Exxaro also facilitates fia process whereby the mine reaches out to its stakeholders nancial assistance for entrepreneurs, giving them the opportuniin a coordinated way to address and mitigate these negative ty to start their own businesses. Essentially, it is not just about environmental and other issues. creating jobs while the mine is in operation and then leaving a “The mine goes on a mapping process to ask who the affected depressed state when it closes, but rather it is about creating parties are. We then get them together to understand their issues and concerns, capture them at the mine level, and then the mine manager is responsible for locating solutions within the departments and communicates them back to the communities. If you fail to demonstrate responsibility to the community, conflicts will be inevitable,” he says.

The bottom line With its numerous ventures, one has to wonder how Exxaro has managed to prioritise its bottom line and contribute to host communities on such equal footing. To this, Chhagan The group has spent millions on social and labour plans and other community-related projects, mainly on education for teacher and learner development, enterprise development, and infrastructure such as building roads and houses

22 In sid e M in in g 1 0 | 2 0 1 5

Mine community development

Exxaro currently produces over 39 million tonnes of coal per annum

says, “The organisation went through a process where we asked what exactly our role is in the community and we agreed that we are part and parcel of the community. It is not about us and them. We have created a paradigm shift where we say the prosperity of the community is our prosperity, because we see this as a dynamic, interdependent relationship. So, we captured all of this in a document called the ‘Social Compact’ – which is like a philosophical treatise on how we think we should be dealing with our communities – and it is on this that our strategy is based.”

Social return on investment

The Mining Charter states that mining communities form an integral

part of mining development. There has to be a meaningful contribution towards community development, both in terms of size and impact, in keeping with the principles of the social licence to operate. Stakeholders must adhere to the following: • Consistent with international best practices in terms of rules of engagement and guidelines, mining companies must engage in consultative and collaborative processes with community and local municipalities prior to the implementation/development of mining projects. • Mining companies must conduct an assessment to determine the developmental needs in collaboration with mining communities and identify projects within the needs analysis for their contribution to community development in line with the municipality’s Integrated Development Plan, the costs of which should be proportionate to the size of the investment.

Over the last five years, Exxaro spent a large amount of money on its social and labour plan, and Chhagan says soon after the five years were up, the question of whether the company made a difference arose. “Our goal was to create a sustainable community; are we getting that? We found it was very hard to answer that question. It is not like we could say, ‘Well, we built Social Return on Investment (SROI) is a methodology developed a road and people are using it – we have by Exxaro in conjunction with KPMG for measuring the real social value and made a difference’. We didn’t have anyimpact of the company’s community development initiatives. thing to back up that claim.” Subsequently, Exxaro partnered with the numbers financial services firm KPMG, who intro • Exxaro spent R221 million on industry-related training initiatives during 2014, duced to the mining house a methodoloranging from ABET training to postgraduate studies. This training involved some 800 youth candidates, of whom 80% were historically disadvantaged gy that could be used to quantify return South Africans selected for learnerships, internships, bursaries, and various on social investment. “There was nothing skills programmes. like this in South Africa, so we said let • Over 600 learners from 16 schools benefited from Exxaro’s Grootegeluk us see if we can develop something. The holiday school programme in Lephalale and surrounding areas. social return on investment (SROI) meth• Exxaro’s talent pipeline and feeder schemes enabled over 800 jobless youth to odology essentially says whatever you do obtain qualifications, in-service training, and employment. follows a theory of change, which simply • Through the Grootegeluk Medupi Expansion Project, 2 000 people received implies that the situation was something skills training, 11 500 temporary construction jobs were created, and 490 like that before, and has now changed to permanent jobs were provided. something like this. So, let us measure • There are currently 88 bursars studying at South African institutions at a cost the factors that created that change,” of R8.6 million per annum. Over two-thirds are historically disadvantaged Chhagan describes. South Africans and 23% are women. The system separates all factors that • Exxaro pays for voluntary ABET programmes at all operations, investing R4.5 could have contributed to a change, and million in 2014. During last year, 87 employees and 111 non-employees or eventually works out what your contripeople from the communities completed various ABET levels successfully. bution was. Furthermore, the SROI prois to embed SROI into all aspects of Exxaro’s community developcess can turn this measurement into rands and cents, making ment initiatives, a challenge he believes will be completed by the it quantifiable. end of this year. “So, we say for every rand we spent on a particular project, what “The trustees who approve projects will now only approve prohas been the social return on that? Then, we can say we got a rejects that have gone through the SROI – where value is clearly turn of X rand. We can now start to quantify the kind of changes shown. It is becoming entrenched in the way we do business, as a we made to the people that we are speaking about,” he says. company in the community development space.” SROI has enabled Exxaro to have an objective perspective about As a tenant of these host communities, Exxaro must be comthe kind of impact it is making in communities. Chhagan says it mended for building mutually beneficial relationships. The group is through this very system that Exxaro is able to establish a prohas set an example that says sharing in the success and measuring jected SROI, making it that much easier to determine potential it is a key to success. future impact and make changes where needed. He says the goal In sid e M in in g 1 0 | 2015 23

Mine community development

egative reports on these issues pose a reputational risk that a responsible company cannot overlook in our changing world. A simple look at the map of mining sites in sub-Saharan Africa reveals the underlying moral point that, in spite of the mineral wealth, the majority of the people living around these operations remain in extreme poverty, by all standards. The Africa Progress Report 2013 put forward a few illustrious Africans, such as Kofi Annan and Olusegun Obasanjo, to “steward Africa’s natural resources for all”. It was a call along the lines of responsible mining and greater social returns to indigenous communities – an issue now at the centre of controversies and

African mine

community expectations

above Community water access near Frontier Mine, Sakania below School Kakanda – donated by Boss Mining

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Extractive mining operations in Africa are facing growing pressure from multilateral institutions, NGOs, and international and local interest groups around financial transparency, human rights, environmental degradation, and sustainable development. By Georges Tadonki*

Mine community development

amended mining regulations. How can mining companies improve their contributions towards sustainable returns in community infrastructure establishment?

Revised mining codes While this is not strictly new to the mining industry in Africa, it now carries more complex expectations from the people and regulatory changes with significant operational impact, going much further than compliance. Consistently, since the World Summit on Sustainable Development in Johannesburg in 2002, revised mining codes have included requirements for mining operations to plan, budget, and report progress towards the sustainable development of affected communities, given the non-renewable nature of mined resources. In June this year, Burkina Faso adopted a new mining code that now obliges mining companies to pay either 1% of their monthly turnover excluding taxes or 1% of the value of the extracted mineral into a local development fund. In the Democratic Republic of the Congo, existing and expected amendments to the mining legislations and regulations emphasise “adequate environmental and social standards”. Non-compliance to such environmental and social obligations may lead to the forfeiture of mining rights (amended articles 179 and 182). Similarly, in the DRC, the mining law requires companies to make specific commitments

to communities for sustainable development; EIAs must include a sustainable development report and budget (Article 451, complemented by articles 126, 127, 207 and 242). In Burkina Faso, Minister of Mines and Energy Boubacar Ba justified the spirit of the new code by the need to “move to a code that encourages community development” rather than being attractive for the mining companies. This has far-reaching implications.

figure 1 Mining and poverty in Africa, 2015

A changing landscape Today, this mindset is generally shared by African governments. It constitutes an important parameter for extractives industries. However, the issue seems not to be the principle of “giving back” to the communities but rather how to do this. In

20 years, the mining landscape has dramatically changed in sub-Saharan Africa. The end of state monopolies was followed by a scramble for mining rights, which established a new context dominated by private investors, especially transnational entities. This also coincided with the end of apartheid in South Africa and the expansion of its mining actors into the rest of the continent. Consequently, the South African presence is quite visible in sub-Saharan African countries, hence the importance of African mining sustainability issues for South African companies. Sub-Saharan mine operations are often established in a complex environment, characterised by a fragile state, poor infrastructure, and high social expectations, in which they become a polarising factor. In the DRC, the question of mineral resources and mining exploitation thus generates passions and scandals around the myth of a just return of mining wealth to the poor people of the country. In the past decade, there has been a considerable shift towards questioning the role of foreign investors in the mining sector. Consequently, mining companies have had to rethink their business models. Mining companies insist that their role is to mine and not to build a country or to provide social services, and they point to a failure of governments to do their part after collecting substantive tax income. However, the pressure has increased on the mining industry to do more in order

In sid e M in in g 1 0 | 2015 25

Mine community development

to close the social gap incurred by a failure in governance, because they are perceived as having the financial resources to do so. Corporate social responsibility for mining companies has, therefore, become quite complex, particularly when equated with a key role as a catalyst for sustainable development in the impoverished and neglected areas where they operate (such is the case for the Katanga Copperbelt).

Sustainable development What is sustainable development and what is expected from mining companies? That has remained vague, giving way to free interpretation by the government and mining companies. It is likely that the perceived lack of clarity is not due to ignorance, as argued by some analysts. Instead, the open meaning of ‘sustainable development’ or ‘community development’ is intentional, as it provides the state and other national entities a powerful leverage for negotiation, in order to obtain more from mining operations. It also leaves open the expectations and frustrations of what could be called ‘beneficiaries’, ‘receiving communities’, or, traditionally, ‘affected communities’ living in mining areas. This is further complicated by the involvement of third-party monitors of human rights and development issues. The mining law of the DRC does not clearly define the responsibilities of mining Community training centre for unemployed young girls, Kakanda – funded by Boss Mining

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companies in terms of sustainable development. However, it implicitly sets the stage for a dual-state role between the state and the mining companies, where the latter are perceived as having the resources to build schools, hospitals, and roads; provide energy and clean water; and many other services that the affected communities may need. It may cost a company that fails to maintain adequate environmental and social standards dearly. Historically, the DRC state company Gécamines, which had a post-colonial monopoly in Katanga, played a paternalist role of giving back, deeply rooted in the culture. Today, social expectations have increased proportionally with the exponential demographics around mining operations in the region, aggravated by artisanal mining. People expect the new private owners of the redistributed mining assets to do more than what Gécamines used to do. They want better jobs, roads, hospitals, schools, electricity, water, and sanitation. They want a better future for their children, in proportion to the mining benefits. That is how they define community or sustainable development. How can that happen today? Companies’ contributions to community infrastructure development are perceived through such social lenses, further complicated by human rights environmental challenges.

Establishing sustainable community infrastructure Today, most mine managers and engineers that I meet are more aware and engaged

in discussing community development issues around their operations. However, they also confess that it is a complex topic; it is not always clear where it ends. For example, the corporate discourse on CSI responds by providing a list of achievements through tangible metrics, such as jobs, income, education, health, water hygiene and sanitation, roads and power infrastructure, as well as other deliveries to the communities. Often, this is done in good faith and the financial amounts can be quite high (up to $4 million directly invested in a community of 40 000 people on-site in Katanga, in 2014). The issue is that such interventions and their impacts are based on development theories and approaches that have consistently failed to produce long-term or sustainable changes in Africa. There’s need for a paradigm shift – an opportunity for the creative mining companies and the communities to transcend what has been largely a failure of governance, resulting in poverty. Let’s illustrate this simply using the Katanga region in the DRC.

Two-way trap In the Kolwezi-Likasi-Lubumbashi-Kasumbasela area, the recent arrival of private extractive mining operations brought a substantive change to the quality of, and traffic on, the major roads linking these cities and into Zambia. Mining companies also renovated or built new schools and hospitals for their workers and communities. They provide clean water and other support services. However, when considering the demographic pressure of people attracted by opportunities offered in these areas, two issues generally arise: Is it enough? When will it end? A double trap. In the context of poverty, a lack of infrastructure, and the absence of – or poor access to – basic social services, CSI of mining companies in southern Katanga are faced with the pressure exerted on all their infrastructure rehabilitation or new infrastructure developments for the communities. High demographic growth rates associated with rural exodus make it difficult to calibrate these programmes. The capacity in these hospitals and schools is beyond the demand, despite all efforts.

Mine community development

This has a significant impact on costs and the effectiveness of delivering mining community infrastructure for basic social services as well as a sustainable ecosystem of local actors initially anchored on the supply chain of mining companies. Although it is a sustainable development requirement, the planning process suffers from a lack of statistical data, therefore rehabilitations and new infrastructures are based on discussions between companies and community leaders. Priorities are established that way and not on the basis of a proper planning appraisal process. A practical approach is to rehabilitate existing infrastructure whenever possible, rather than building anew.

Katanga’s unsustainable case

Hospital equipment, Kakanda – donated by Boss Mining

increase in African countries like the DRC and Burkina Faso. Supported by international organisations, pressure groups, and the civil society, governments will tend to share the responsibility of sustainable development directly with mining companies. This dual-state system is replacing the old welfare system of state companies. This requires a paradigm shift in the way mining companies in sub-Saharan Africa

Current efforts by mining companies will produce more results by relying on a deeper understanding of the complexity of sustainable development challenges where they operate.

In the case of Katanga, many mining operations are a revival of Gécamines operations where old infrastructure can be Conclusion: a long-term vision found. Companies made a clever move to In Katanga, the mining manager can just rehabilitate these hospitals and schools, look around to understand the future. such as in Kakanda. New schools and There are so many community infrahealth services structures in are developed decay. When In spite of the regional mineral wealth, the where they are funding dried lacking or the caup, the inmajority of the people living around these pacity is severely frastructure exceeded. Such an collapsed and operations remain in extreme poverty, by approach is more the trained all standards on the mitigatpersonnel ing humanitarian were in disengage affected communities in terms-of side, in view of the ambient poverty. It array. These communities’ infrastructure sustainable development around their is also more suitable for short-term CSI, revived today is likely to go the same way, operations. A clever approach is to estabwhich should be aligned with long-term unless serious consideration is made for lish such interventions within a smart goals in order to maximise social returns. sustainability. With mining operations business model that articulates shortThe catch is that without robust, longbeing activities of limited duration, a susterm interventions with long-term outterm planning, short-term interventions tainable mining community infrastruccomes. Mining community infrastructure are disconnected and fragile. In the short ture programme should include a strong should be implemented with a long-term term, there is an evident benefit to the exit strategy. vision based on a realistic strategy to emsocial licence to operate, as communities This provides a way to address a proper power the community out of poverty. enjoy rehabilitated and new infrastruchandover to the community, including When the provision of communiture provided by mining companies. partnering with local and internationty infrastructure does not address the However, they soon realise that it is not al private business to ensure that these long-term transfer of the community’s enough, while mining companies are schools and hospital are rooted into the responsibility to maintain such basic serfaced with spiralling operational costs on community rather than in the mining vices, it gets trapped in the vicious circle their CSI. It is not unusual for a mining company’s CSI. of dependency. It, therefore, leaves the company in Katanga to report annual exSustainable development is not about community with the expectation that the penses in millions of dollars in communineeding to receive gifts, it is about being company will maintain it as long as it opty infrastructure and support within a 30 able to live without them. erates in the area. That way, mining comkm radius of their operations. Yet, social munity infrastructure does not survive demand keeps increasing. *Georges Tadonki is an honorary professor at Unisa’s Department of Geography, in the College of the end of the mining operation. As such, In the current context, it is likely that Agriculture and Environmental Science, and is the it is, therefore, vital to see the bigger picthe right to ask for mining community former head of the UN Office for the Coordination of Humanitarian Affairs. ture when talking about sustainability. infrastructure delivery will continue to In sid e M in in g 1 0 | 2015 27

Language barriers. 9.8 million injury free man-hours. Minimal infrastructure. Political instability. A 7.2 Mtpa gold plant delivered 3 months ahead of schedule. Impossible? Not for DRA. Kibali Gold in the DRC produces 600 000 oz of gold every year. Acknowledging the community, 4000 homes were saved and relocated. Started in 2012, completed in 2014, three months ahead of schedule with exceptional safety statistics, under budget for our client.

DRAglobal.com

100052HM

Extraordinary Possibilities

minerals processing

Rock-eating bacteria produce

gold

What do mine fissure organisms, microbes, and minute worms have to do with mining? Much to the surprise of many, it’s the new ‘technology’ in metals recovery, methane management, and carbon storage. By tony Stone

TOP INSET The Devil’s worm, which goes by the scientific name Halicephalobus mephisto The NASA-sponsored research team on its way to find the Devil’s worm

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rior to the 2011 landmark discovery of the Devil’s worm – scientifically known as Halicephalobus mephisto – at terrestrial depths of 3.6 km underground, in the Mponeng mine, nematodes were not thought to live beyond tens of metres deep. Only microbes were known to exist beyond a kilometre underground. But, as it turns out, these microbes are the food of the 0.5 millimetre long Devil’s worm. Since these discoveries, much has been learnt about these methaneand rock-eating organisms. However, much is still to be learnt and it cannot be said that enough is known at this stage. Manipulating or impacting nature can be disastrous – for the organisms and for us – as climate change has so pertinently demonstrated.

Bioleaching Nonetheless – and quick off the bat – miners and biotechnologists are using these organisms to leach copper, zinc, lead, arsenic, antimony, nickel, and

minerals processing

molybdenum, as well as gold, silver and cobalt from low-grade ore. Bioleaching involves numerous ferrous iron- and sulfur-oxidising bacteria, including Acidithiobacillus ferrooxidans and Acidithiobacillus thiooxidans. A current application of this technology is to process old tailings dumps and neutralise sulfides and acid rock drainage. Ross Orr of BacTech explains. “The process stabilises toxic elements such as arsenic, cadmium, and bismuth. Tailings are delivered to a flotation tank where a concentrate is produced. This concentrate contains sulfide minerals and metals. From this process, 95% of the tailings are sent to a processed tailings pile as harmless inert rock. The balance of concentrate, approximately 5%, goes to a series of bioleaching tanks containing sulphide-loving bacteria such as those mentioned above. As the bioleaching process generates heat, the tanks are cooled, and, over the course of a few days, what these bacteria do is quite astounding. They literally eat rock and produce a metal-rich concentrate that contains FeS2 (pyrite) and FeAsS (arsenopyrite), which the bacteria thrive upon. “The bacteria split the toxic molecules so that iron and sulfur become water soluble. This liquor, as it is referred to, is moved to a thickener where solids and liquids are separated. Gold and silver are sent in one direction, to a conventional metals recovery plant, while iron, arsenic, and base metals are sent in another direction, to a neutralisation circuit. Here, limestone is added, effectively neutralising the iron and arsenic to facilitate the selective recovery of Cu, Co, Ni, and Zn. After filtering, non-toxic by-products are delivered to the processed tailings pile. These include gypsum and ferric hydroxide. At the end of this process, water is recycled. It’s all a rather clever way of using nature to clean up man’s mistakes and, at the same time, making it pay dividends.”

Ongoing research Clearly, flipping the old proverb on its head, one man’s poison is another man’s meat. The question, though, is: while contained in a closed-circuit system, these bacteria are manageable, and very useful, but what will happen if we take

“It’s all a rather clever way of using nature to clean up man’s mistakes and, at the same time, making it pay dividends.” Ross Orr, CEO, BacTech Company them out of their natural or controlled environment? According to Princeton University’s Professor Tullis Onstott, “We don’t know nearly enough about these bacteria, their environment, and what the implications are of letting these bacteria loose, intentionally or accidentally, in our environment.” This being said, ongoing research is being conducted by a team of NASA-sponsored scientists from the USA, Belgium, and South Africa, with a rather interesting twist. Halicephalobus mephisto, the species of nematode discovered in 2011 – by professors Gaetan Borgonie, a nematologist from Belgium’s University of Ghent; Onstott, himself a geomicrobiologist; Esta van Heerden, a geotechnologist from the University of the Free State; and others – is a fascinating little creature. It is of the family Panagrolaimidae and measures about 0.5 mm in length. These tiny nematodes are the deepest-living terrestrial multicellular organisms on Earth. This species is remarkable for surviving in such an inhospitable, oxygen-deprived environment. Carbon dating indicates that the water in which this species lives has not been in contact with the Earth’s atmosphere for the last 4 000 to 12 000 years. And, besides its

connection to mining, the discovery of H. mephisto in Earth’s deep subsurface is significant because it may have important implications for the discovery of life at similar subterranean depths on other planets – and mining, if and when we get there.

Latest expedition Assisted by Rachel Lee Harris and Chui Yim ‘Maggie’ Lau from Princeton University, Jan G Vermeulen, Cumisa Manzikazi Mlandu, and Corinne Fourie (all postgraduate students from the University of the Free State), Onstott recently led an expedition 1 350 m into the depths of Beatrix Mining Operations’ No.3 Shaft to find out more about the life

INSET Maggie Lau collecting organisms RIGHT Prof Tullis Onstott fitting the tailor-made sampling dispenser to the borehole release valve

In sid e M in in g 1 0 | 2015 31

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Tenova Delkor is an industry specialist in solid / liquid separation and mineral processing applications for the minerals, chemical and industrial markets. Offering flotation, sedimentation, filtration, screening and gravity separation systems, Tenova Delkor services range from test work, process trade-offs and flowsheet design, to installation, commissioning and aftermarket support.

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minerals processing

underground for power production,” Onrecovering gold from low-grade ores, and times of the Devil’s worm, its microstott explained. and even old tailings dumps, a comparbial food and environment, and to find This is just one aspect of the ongoing reative analysis of bioleaching and the traany possible cousins. search into these fascinating organisms. ditional cyanidation process, even with This particular expedition’s purpose As we have already covered, bioleaching the advances developed by DRDGold was to run a set of experiments designed is another, and who knows what else will – which specialises in recovering gold to determine how bacteria feeding on bibe discovered during Onstott and the from tailings dumps – clearly shows that ogenic methane produce their biomass, and why it is, with so few methanogens present, their activity is able to support 100 times more bacteria. These are fundamental but crucial questions if these bacteria are to be further exploited. In order to find the answers to these questions, the team needed to assemble the genomes of the key species – that which is responsible for supporting so many bacteria. To do this, they used three Niel Pretorius, CEO, DRDGold different approaches, in the hope that these differing methods would yield conteam’s research into these amazing little sistent results: bioleaching, as a process, has got to be a creatures and their environment. Metagenomic binning: The process serious contender in future mine develof grouping sample reads or contigs (a opments, and even mineral processing set of overlapping DNA segments that, plant upgrades. Comparative advantages together, represent a consensus region As DRDGold discovered in the comTo drive home the advantages of biof DNA), and assigning them to operapany's mineral processing plant, small oleaching and illustrate the benefits tional taxonomic units. pyrite particles, containing some 40% of going micro, and even nano, in Single cell genomics: Examof the gold, did not respond ining the sequence information as well as expected to the trafrom individual cells with optiditional CIL (carbon in leach) mised next-generation sequencprocess. While high-grade ores ing technologies, providing a were abundant, yields were higher resolution of cellular difmore than satisfactory. But, ferences, and providing a better with low-grade ores or tailings understanding of the function waste, one has to be a little of an individual cell in the consmarter. So, to find the solutext of its microenvironment. tion to solve the problem, they NanoSIMS: Nanoscale secreworked the process. ondary ion mass spectrometry In summary, gold-bearing ore (nanoSIMS) is a nanoscopic is crushed and fed into tanks of scale resolution cyanide solution. chemical imaging The cyanide disABOVE Renowned photojournalist mass spectromesolves the gold. The João Silva joined the team in its ter based on secnow pregnant soludescent into Beatrix No. 3 Shaft ondary ion mass tion is transferred RIGHT Prof Onstott discussing a spectrometry. to a series of tanks, sample test with Cumisa Manzikazi Mlandu and Corinne Fourie “The key point where carbon is here is the small added. The gold BELOW Jan G Vermeulen taking a much-needed break population of methis adsorbed on to anogens found in the surface of the underground wacarbon. The carter fissures are acbon, with gold attively producing tached, is removed huge amounts of by screening. The methane, much of gold-bearing carwhich is consumed bon is then introby other bacteria. duced into a heated This is particularsodium-hydroxly important if you ide-cyanide-water want to mitigate solution, where the methane release gold is dissolved. or store methane This concentrated

“Since DRDGold added its recently developed finegrind and flotation circuit at Ergo, the plant has produced more gold than before.”

In sid e M in in g 1 0 | 2015 33

Innovative Technology Solutions for Africa

Tenova TAKRAF is a key supplier of equipment and systems for open pit mining and bulk handling solutions, having provided hundreds of complete systems, as well as individual machines, to clients all over the world in all terrains and climatic conditions. Leading-edge comminution systems are available for crushing requirements in mining and mineral processing. Globally sourced air pollution control, specialized handling equipment, and technology for the cement and fly ash industries ensure selection of optimal processing options. A comprehensive after sales service is provided, with in-house maintenance teams.

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minerals processing

solution is passed through a series of electrowinning cells, where the gold quickly plates, in about three minutes, on to the stainless steel cathodes. The gold is washed from the cathodes, with high-pressure sprays, dried, and melted – to be poured into moulds for gold ingots. This process works well where cyanide finds exposed gold. The answer to the problem was the problem itself. The additional step of fine-grinding or milling the flotation concentrate realised an improvement in recovery efficiencies of

Realising possibilities...

Bioleaching, as an alternative to the CIL process – considering the evidence at hand – is a better solution 8%. With a targeted high-volume and low-risk throughput of between 2.0 Mt and 2.1 Mt, a substantial amount of additional revenue is expected. Even so, research is ongoing. DRDGold’s target is to achieve an even higher increased recovery rate – 20% by the third quarter of 2017. “Since DRDGold added its recently developed fine-grind and flotation circuit at Ergo in Brakpan, to extract a further 0.03 g/t, or three parts per 100 million, the plant has produced more gold in March 2015 than in any month before, since it was recommissioned about eight years ago,” Niel Pretorius, CEO of DRDGold, said. However, fine-grinding the ore is a mechanical process. Advances in the grinding technology will need to be developed in order to grind the flotation concentrate into even smaller particles. Time will tell whether this is possible. In the meantime, bioleaching, as an alternative to the CIL process – considering the evidence at hand – is a better solution.

...from mine to market.

In conclusion Precious metal extraction using the cyanidation process, and/or its variants, has been around since 1899 and remains the process of choice for gold and silver extraction from oxidised ores. However, cyanide is well known for its toxicity. Bioleaching, on the other hand, is about 200 times less toxic than cyanide, which is a major advantage; not to forget bioleaching’s main advantage of working practically at the micro and nano levels. In addition, there is the reality that the costs of containment and treatment, and time spent on environmental impact studies associated with cyanidation plants, have skyrocketed. This increases the economic barriers to be overcome in justifying a mine. With bioleaching being an environmentally acceptable alternative and clearly able to reduce the economic and environmental risk profile of a mine, the mine’s classification as a ‘quality’ asset, and its value, will be greatly enhanced. What is more, and from a profit perspective, preliminary results indicate that chemical reagent costs could be as much as 80% lower than cyanide. In anybody’s books, the bioleaching solution reads well.

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Pyrometallurgy & Hydrometallurgy

A refined alternative Kell hydrometallurgical refining is an alternative to smelting, used predominantly in the recovery process of platinum group metals. Keith Liddell (left) wrote a white paper on this technology, comparing it to conventional pyrometallurgical PGM smelting.

he biggest benefit of using the Kell process is realising a reduction in energy consumption and CO2 emissions. In the paper, Liddell describes the process as an alternative to smelting that is totally insensitive to the chromite content of the feed concentrate and comprises three commercially proven unit operations. The dissolved metal streams for the base metals and precious metals are each

futher processed to recover the payable metals through existing refining technologies practised by the PGM and base metals industries – the exact processes and products being site-specific and dependent on the user. The solids waste streams are impounded in a tailings storage facility, solution streams are recycled with any bleed streams being neutralised, and gaseous emmissions are scrubbed before

The three stages of Kell hydrometallurgical refining (according to Liddell) •S tage 1 The first stage is aqueous pressure oxidation in an acidic sulfate medium, to dissolve the sulfides and remove the base metals, while minimising dissolution of the precious metals. The conditions used are standard for base metal dissolution, with rapid leach kinetics giving an autoclave residence time of approximately 30 minutes. • Stage 2 The second stage sees the use of pressure oxidation residue to condition the PGM mineral phases, rendering them amenable for subsequent leaching. Since the sulfides have been removed in the pressure oxidation stage, the roaster off-gases contain minimal SO2, eliminating the need for an expensive acid plant. • Stage 3 The third stage is atmospheric leaching of the precious metals in chloride media, in the same manner as is typically used in PGM refineries to prepare the PGM for separation and refining.

Reduced energy and greenhouse gasses Liddell states that the Kell process makes it possible for PGM producers to reduce energy consumption, greenhouse gas emissions, and installed power requirements. Comparing smelting and refining, the savings are calculated as: • total energy consumption: 50% reduction • electrical energy consumption: 84% reduction • energy consumption costs: 76% reduction • CO2 emissions: 70% reduction • installed power requirement: 92% reduction. Liddell elaborates on the three energy consumption areas in the Kell process: • Roasting consumes fuel, such as coal or gas, with coal being used in this simulation. • Various stages in the hydrometallurgical circuits consume energy, in the form of steam, for heating the process slurry and solution streams. • Electrical energy is consumed by electrowinning of base metals, drives of rotating equipment – such as pumps, agitators, fans, and blowers – and other ancillary equipment. In his study, the sizes of major drives have been estimated and installed power and consumed energy increased by a further 30% to allow for minor drives. In addition, an allowance has been made for drives in the PMR.

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release – thus minimising environmental impacts from the solid, liquid, and gaseous phases. Liddell explains that a key feature of Kell is that the leaching of the base metals and precious metals is kept entirely separate, with no mixing of the sulfate and chloride process streams. “This allows process conditions and materials of construction to be optimised for each metal suite, reduces reagent and water consumption, and provides flexibility in plant design and operation.” In the paper, Liddell explains the PGM smelting process and singles out the PGM smelting facilities in South Africa, which treat blends of Merensky, UG2, and Platreef concentrates. He then further discusses the Kell process simulation and energy calculations. “The simulation model is a mass and energy balance, considering all major unit operations at steady state. All significant process streams are included and balanced, as per a typical process flow diagram. The model was constructed using the IDEAS simulation software, supplied by Andritz Automation,” writes Liddell. He further describes how the main greenhouse gas emission from both smelting/refining and Kell is CO2, arising directly from the on-site combustion of coal and fuels and indirectly from the use of electricity. With comparative tables, he clearly indicates the huge saving in CO2 emissions by using the Kell process.

Conclusion In the conclusion of the white paper, Liddell states that the Kell process replaces a smelting furnace with a roaster treating a non-sulfidic feed. “By removing the need to smelt PGM concentrates, the Kell process provides the opportunity for existing and new PGM producers to significantly reduce

Pyrometallurgy & Hydrometallurgy

their energy consumption and, in particular, their consumption of electricity. “Energy costs, greenhouse gas emissions, and installed power requirements are also much reduced. The data obtained from simple laboratory batch amenability testing can be readily applied to the Simulus mass and energy balance simulation procedure to determine energy and reagent consumptions, equipment selection, and process optimisation,” writes Liddell. He concludes the paper by stating that existing producers can install Kell adjacent to either the smelting or refining facilities, or on mine sites, to enable production to be increased without having to significantly increase installed power. The concentrate feed balance to the smelters can be changed to better optimise the overall energy efficiency and metal recoveries.

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figure 1 Simplified block flow diagram of the Kell process Denotes sulphate media

Flotation Concentrate

Denotes chloride media Solution flows Denotes chloride media

Pressure oxidation & solution treatment

Base metal recovery

Solid – liquid separation

Ni, Cu, Co

Roast, 900°C

O2, H2SO4

Fe tailing

Chlorination

Cl2, HCl

Precious metal recovery

Solid – liquid separation

PGM, Au

Siliceous Tailing

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In sid e M in in g 1 0 | 2015 37

ALG Relining and Rubber Lining CC

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Electrical Control & Instrumentation

Driving towards energy savings With the current energy crisis, saving energy has become a priority in the mining sector. MPINANE SENKHANE explores the energy-saving capabilities of variable-speed drives

sing variable-speed drives (VSD) can save up to 50% on energy and optimise process control. In many applications, including mining, VSDs can lead to a substantial reduction in energy use, which subsequently results in the cutting of operational costs. In the mining industry, VSDs service various types of applications including pumps, fans, hoists and conveyors. The need to cut production costs in the local mining sector is higher than ever. Energy costs represent roughly 30% of mining houses’ operating costs. Most of this energy consumption is geared towards electric motors. The main reasons for this is that most of the motors used in mining operations are still operating at a fixed speed.

the speed of the flow, accordingly, in the process-demand and system parameters. In mining slurry, pumping is a significant part of operations and, because slurry pumps deal with abrasive substances,

also indicates that the maintenance on VSDs can be higher than usual – however, these can be mitigated, to an extent, by correct application and maintenance. Another disadvantage identified is that most VSDs have limits to protect the drive and, consequently, the motor – but too low a setting can cause trips. And, too high a setting may cause damage in high ambient temperatures. In the end, even with the disadvantages considered, the excellent control of motor speed, torque, and power, and the

figure 1 Variable-speed drive

Benefits of variable-speed drives Fixed-speed motors are currently the most commonly used in the industry – this method consumes a large amount of energy and also wears out equipment. The VSD approach, however, moderates flow by adjusting the speed of the motor to operate at best efficiency point (BEP). This method not only saves energy, but is also an environmentally friendly alternative, giving the equipment a longer lifespan, subsequently cutting costs. Not only do VSDs higher process quality and efficiency, they also increase productivity. VSDs also assist in the reduction of carbon emissions – a big plus for the environment. A study by the RC Rossin College of Engineering and Applied Sciences indicates that “when the load is halved, the savings are obvious”, adding that “the application peak load reduced after extended hours without variable drives; thus applying variable-speed drives not only control the load and flow for fans but also reduce carbon dioxide emissions”.

VSD applications The use of pumps takes up about 20% of energy consumption on mine operations. VSDs in pumps help control and adjust

pumps tend to wear and tear at a faster rate, creating higher maintenance costs and energy consumption in the process. Conveyors play a significant role in mine operations and are used in various applications. ABB details how the use of VSDs in conveyors “provide[s] accurate torque and speed control. This reduces the stress on mechanical equipment such as gearboxes, pulleys, and belts”. Using VSDs provides the opportunity to adjust the conveyor speed to the production capacity. In underground mining, a hoist’s main application is to raise and lower conveyors within the mine shaft. These hoists are normally powered using electric motors, historically with direct current drives utilising solid-state converters; lately, modern hoists use VSDs. ABB indicates that controlling mine hoists by using electric VSDs provides safe and reliable operation.

quick response to changes in load, speed, and torque commands that these drives offer still make VSDs the preferred option. Further to this, the energy savings versus the cost of the drive, its installation, and maintenance help make the decision to use VSDs even easier.

Disadvantages The initial drive cost tends to be higher than normal drives – however, evidence suggests that there is, over time, value for money in energy savings. Evidence In sid e M in in g 1 0 | 2015 39

Events

he theme for the summit, which is to be held on 25 and 26 November 2015 in Istanbul, Turkey, will be ‘Africa Towards Better Mining Practices’. The summit is held in collaboration between the Ministry of Energy and Mineral Resources in Turkey and GRV Global. The idea is to bring African ministers in charge of mining, high-profile CEOs, thought leaders in the industry, development partners, financial institutions, technology providers, and experts from the private and national sectors together for discussions.

Keynote speaker

“To this end, the African Union Commission (AUC) will be launching the Decade of Seas and Oceans. Among the major areas on the AIM is the keen interest by Africans to explore how to benefit from oceanic resources, including deep-sea mining,” says Glenn Fitzpatrick, programme director of GRV Global.

The keynote speaker will be Dr Nkosazana Dlamini-Zuma, the chairperson of the AUC, in addition to: • a smorgasbord of VIP speakers • captains of industry • international experts and mining specialists • mining ministers from Africa • numerous mine owners • investors • operators. They will discuss ways to drive the way forward for the mining industry and share insights into global market prospects and investment opportunities elsewhere in Africa are objectives of the summit. “It is aimed at introducing African state representatives to practical solutions that tackle the challenges facing the mining sector. They are gathered in recognition of the urgency of the summit, as Africa is at the stage of building its infrastructure at national and regional levels, which is geared towards achieving a sustainable future for Africa,” explains Fitzpatrick. In addition to the speaking sessions, there will be pre-scheduled one-to-one meetings, facilitated networking zones, and a gala dinner.

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Main topics Some of the main topics of discussion are the two major initiatives that are endorsed and currently being implemented by the heads of state and the African Union, namely the Africa Mining Vision and Dr Nkosazana the Africa Maritime Dlamini-Zuma Strategy (AIM).

The first ever Africa Mining Summit will feature speakers to discuss various challenges that mines face in Africa.

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