Inside Mining April 2013 by 3S Media

www.miningne.ws

Highly commended 2012 PICA Cover of the Year - B2B Publishing

THE KNOWLEDGE YOU NEED

ining

MEDIA

FROM THE INDUSTRY EXPERTS

HOT SEAT

SACRM chairman Ian Hall on South Africa’s looming energy deficit P10

COAL

Endless possibilities, endless challenges

Maseve advances in mechanised mining with

SANDVIK

COMMINUTION

Playing in the big league

PYROMETALLURGY The mushroom effect

ISSN 1999-8872 • R40.00 (incl. VAT) • Vol. 6 • No. 4 • April 2013

Applications • Drilling blasting holes and anchor holes. Advantages Greatly reduced health hazards to users • Low vibration and less noise • Lower weight and no oil vapor emissions Faster drilling • Easy starting, accurately positioned holes • High drilling performance • Quick, effortless extraction of the drill rod Higher blasting yield • More accurate drilling • Exact drilling pattern • Precisely controlled blasting Lower operating costs • Lower energy consumption than conventional drilling systems • Longer periods of use thanks to significantly longer service intervals • Higher reliability Highlights The world’s first hand-guided, explosionprotected electropneumatic drilling system for use in potentially explosive atmospheres.

Performance Data Rated voltage / rated current

220-240 V ~ /15 A

Torque (TE MD 20 LS /TE MD 20 HS)

100 Nm/85 Nm

Power input / supply frequency Single impact energy

Speed of rotation (TE MD 20 LS /TE MD 20 HS) Dimensions / weight

Drill bit diameter / drill rod length

Protection against water and dust

2200 W/50-60 Hz 28 J

205 r.p.m. / 250 r.p.m. (counterclockwise) 770 210 230 mm /23 kg 32–42 mm /up to 2.4 m IP 66, IP 67

Protection class

Explosion protection

I M2 / II2 G94 /9/EG EEx d I / IIA T4

Storage temperature (cooling water drained) Right of technical changes reserved.

–20°C to +55°C

CONTENTS

T H E K N O W L E D G E YO U N E E D

ining

April 2013

FROM THE INDUSTRY EXPERTS

Highly commended 2012 PICA Cover of the Year - B2B Publishing

www.miningne.ws

ON THE COVER

MEDIA

THE KNOWLEDGE YOU NEED

LQLQJ

Maseve advances in mechanised mining with Sandvik

FROM THE INDUSTRY EXPERTS

HOT SEAT

SACRM chairman Ian Hall on South Africa’s looming energy deﬁcit P10

COAL

Maseve advances Maseve Mas in mechanised mining with

Endless possibilities, endless challenges

SANDVI SAN S DVIK DVI K

COMMINUTION Playing in the big league

PYROMETALLURGY The mushroom effect ISSN 1999-8872 • R40.00 (incl. VAT) • Vol. 6 • No. 4 • April 2013

The development of Platinum Group Metals’ Maseve project is advancing rapidly, which can be largely attributed to the ‘perfect’ working relationship between the company, OEM Sandvik and mine developer.

EDITOR’S COMMENT

Identifying, acknowledging and solving the great coal challenges

HOT SEAT

10 Looming energy deficit – it could happen HOT TOPIC

14 Two Rivers’ tertiary milling plant – a perfect upgrade

COAL

20 Continental Coal’s budding opportunities 24 An uncertain demand for coal 26 Coal of Africa’s downside and upside 30 Engineers tip the scales with coal 32 Ntendeka’s two-year wait is over 34 Powering up Medupi

COAL BENEFICIATION

38 A quick-fix solution for Eskom 42 Dewatering dreams available on lease 45 Serving students for the future COMMINUTION

46 Crushing the market 48 The benefits of fines screening 50 Coal discard in eMalahleni on route to Eskom 54 The future of minerals sorting 57 Improving screen efficiency

PYROMETALLURGY

58 Ferrochrome flourish 62 Ferroalloys fever 64 Refractories revised MATERIALS HANDLING

66 Big on BEE, big on rollers 69 Conveyor belt fire protection 70 Turnkey crusher technology exceeds 4 000 tph Inside Mining 04/2013

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 Editor's comment Publisher Elizabeth Shorten Editor Laura Cornish Journalist Reggie Sikhakhane Head of design Frédérick Danton Senior designer Hayley Mendelow Designer Kirsty Galloway Chief sub-editor Claire Nozaïc

THE GREAT COAL CHALLENGES

Identify, acknowledge and solve

Sub-editor Patience Gumbo Marketing & online manager Martin Hiller

I always get excited about Inside Min-

Production manager Antois-Leigh Botma

ing’s coal features – Eskom is scrabbling for coal, and exports are fuelling the sector on a global scale. This creates a very wide platform for great stories and new projects. Unfortunately, I have not been able to cover the ‘usual suspects’ and their current projects. Exxaro was plagued with strike action during March and a fatality at one of Anglo American Thermal Coal’s mines meant no site visit for me. But I like to think of myself as a ‘glass half full’ person, which means I have ‘put my wide angle lens on’, and taken a holistic approach to the industry. This means this issue contains a variety of great reads dealing with the underlying issues our coal industry is currently facing and what the future holds in store. In the Hot Seat this month is none other than the South African Coal Roadmap Society’s chairman, Ian Hall, known by some as an industry ‘pot stirrer’ and unafraid to voice his opinions, thoughts and research on the dire situation Eskom will find itself in if it is unable to source a vast amount of coal over the next few years. Continental Coal’s Don Turvey discusses his uncertainty over the status of coal as a strategic mineral and the negative impacts this could have on the country. Ikwezi’s David Pile highlights how difficult it is to get a water use licence – his company had to wait just over two years to get one. Considering Eskom cannot buy coal from any operation without a water use licence, this creates further problems for new coal miners. The outcome of all this is a positive future I believe – the first step to solving problems is to identify and acknowledge them. Only then can the right people go about fixing them. The issue also delves into coal beneficiation; it seems that the need to process and use coal fines is giving rise to new companies, focused on meeting such needs. Technologies are evolving and in some cases are already proving their value – I do enjoy it when all the relevant role players come together to ensure our industry remains a lucrative one, but can still grow in the face of a tough economy. Our comminution feature reveals exciting developments as well. Pilot Crushtec’s distribution agreement with Sandvik is paying off – already – and I can’t lie, I’m really impressed. The deal saw them drop the Terex Finlay brand, but Bell Equipment has already scooped that up. Change is as good as a holiday, so this space will probably continue to reveal interesting developments. The pyrometallurgy industry is also making a grand entrance back into the market, having evolved since its last appearance. Energy efficiency is the name of the game and the specialists are clearly getting it right, or heading in the right direction at least. To our avid readers, be sure to sign up I find it fascinating how our mining industry, along with its and get the latest updates and inside scoop from the mining industry. Check out what we equipment and technology providing partners, continues to are talking about on our website, Facebook make such great progress and strive to do things faster, more page or follow me on Twitter and have efficiently and with great enthusiasm. your say.

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Inside Mining 04/2013

 Cover story

THE STARS ALIGN

Maseve’s mechanised magic

While the platinum majors continue to face economic and financial difficulties, the junior sector is thriving, particularly on the Bushveld Complex’s Western Limb. The development of TSX-listed Platinum Group Metals’ (PTM) Maseve project is advancing rapidly, which can be largely attributed to the ‘perfect’ working relationship between itself, the OEM and the developer, writes Laura Cornish.

he shallow, high-grade US$506 million (R4.68 billion) Maseve project, commonly referred to as the Western Bushveld Joint Venture (WBJV) Project 1, may be only one of a few new platinum mines under construction, but is developing with such speed that it

Inside Mining 04/2013

will undoubtedly emerge as the first new producing platinum mine in the area – delivered by a junior. The project’s mining right application was granted in April 2012 and the 275 000 ozpa 4E PGM project’s construction has been advancing ever since. First production through

the North twin decline system is scheduled to ramp-up through 2015, with a targeted full 20-month ramp-up to 160 000 tpm runof-mine (ROM) nameplate capacity. Based on current resource and reserve figures, the mine’s lifespan (for both Merensky and UG2 ore) is 22 years.

 Cover story

ABOVE A Sandvik DD311 single boom drill rig in the conveyor drive area LEFT Decline development commences at the North decline

and user-friendly, for both operators and maintainers. The machines are delivering to our expectations, particularly the double boomer DD321,” explains Maharaj. PTM COO Peter Busse reiterates Maharaj’s sentiment, indicating that the Sandvik employees on-site have integrated well with the company and are critical “in terms of meshing with our vision and what we want. Right from the feasibility stage, we wanted a 100 m/month system decline development advancement rate. The Sandvik team has really supported us, believed in our vision and have become an integral part of our current and future success,” Busse emphasises. “Construction of the 21 m deep North boxcut started in May 2011 and was completed in October the same year. Development of the twin North decline system (at a minus nine degrees dip) commenced directly after, which reached 1 000 m in March this year. The first reef drive lateral

75 and 80 m/month, if not lower, underground mining developer JIC Mining Services is achieving in excess of 100 m/month using the Sandvik fleet,” Maharaj notes. Sandvik Mining and Construction RSA (Sandvik) is providing the necessary primary underground equipment for the mine’s decline development as well as maintaining the fleet through an ‘Asset Reliability’ team of 14 people on-site who ensure the machines are available and at peak performance at all times. “We chose a mechanisation development plan and knew only one OEM that could supply the equipment and services needed to achieve our underground advancement targets. Sandvik drilling machines were our first choice as they are high in quality

Top development rates PTM project manager Pran Maharaj and Sandvik trans4mine operations manager, Andre O Smit, believe the development rates achieved at Maseve are the best in the South African industry. Although the slow six-month ramp-up period for the North decline development was scheduled to allow for orientation, site establishment came perilously close to resulting in overall project delays. Today, however, Maharaj is “ecstatic” about the development rates being achieved. “The quality of the performance is reflected in the rates being achieved. While the industry average is generally between

Development Results 300

Total Meters Developed

System Advance

Planned Advance

250

200

150 101 100 71 50 21

March

April

100

104

101

0 Jan

Feb

May

June

July

Aug

Sep

Oct

Nov

Dec

2012

Jan

Feb 2013

Inside Mining 04/2013

 Cover story The mechanised Sandvik machines North decline shaft Sandvik machines: • 1 x Sandvik DD311 single boom drill rig (spare) • 1 x Sandvik DD320 double boom drill rig with split feeds • 1 x Sandvik DD321 double boom drill rig • 2 x Toro 400 LHDs (old version 9 t loader) • 1 x Sandvik LH410 (10 t loader) • 1 x Sandvik LH514 and (14 t loader) • 3 x EJC 533 underground trucks • Over the next six to eight months, another six DD321’s and a DS311 roof bolter will be delivered to site

development is planned to start in April 2013 and Phase 2 shaft infrastructure equipping is now under way.” DRA Projects is the EPCM contractor for the surface infrastructure, plant design and build, and value engineering for the mine plan is being done on an ongoing basis by various specialist consultants. Development of the South twin decline BELOW The Sandvik DD320 double boom drill rig

commenced in February this year and decline development is targeted to reach 1 000 m towards the middle of 2015. “In addition to the equipment, we have further provided PTM with invaluable human resources such as Garry Brooks from our trans4mine advisory services division, who advises the on-site team on the fasttracked implementation of best practices, enabling the company to confidently assure the market that it is meeting its delivery requirements,” says O Smit. “Brooks and Sandvik's senior accounts manager, Kobus Labuschagne, are part of the key people, among a few others, who have been integral in setting us on a path to our success in achieving exceptional development rates. We are one team on-site, Sandvik, JIC, DRA and PTM,” Busse highlights. O Smit continues: “The trans4mine operational coaches have only one goal, and that is to ensure that our customers meet the production and safety targets promised to them from the Sandvik fleet on-site through a collaborative approach. It requires buy-in from all stakeholders on-site,

While the industry average is generally between 75 and 80 m/month, underground mining developer JIC Mining Services is achieving in excess of 100 m/month using the Sandvik fleet from machine operators right through to management level. This is exactly what has happened at the Maseve project, making the project such a great example of what a common vision among people can achieve.” A lot of praise must be given to the main contractor, JIC Mining Services, Busse states. Headed up by the company’s COO, Neels Sutherland, “they have managed to integrate PTM’s vision so successfully that even the relationship with the unions, such as NUM’s branch secretary Elizabeth Saka and branch chairperson, Alfred Twane, onsite is the best observed by the trans4mine team to date.” Ultimately, both Sutherland and O Smit agree that a lot of the success lies behind the “unique” way mine owner PTM has and continues to operate on site. The company

Inside Mining 04/2013

C Cover overr story stt o r y

Maseve at a glance

sets targets to be achieved, such as decline development rates, which in no uncertain terms are expected to be met. “But it is also equally involved in working with us on site in all day to day operations, engaging with the main contractor as one of its own team members, enabling them to get on with the job of achieving the 100 m system advance. It’s a very mature approach and one that certainly delivers results.” Busse also believes that mining companies that show confidence in their contractors by encouraging them to make decisions at the face, reap significant benefits. “These are the people with substantial experience. Our contractors bring brain power to the project and we utilise it to our benefit.” Both Sandvik and JIC are committed to making sound decisions and will ensure development remains two years ahead of production requirements to provide sufficient mining flexibility. “Our performance delivery was key to raising the second round of finance we needed to continue with the completion of the project construction. Sandvik and JIC’s performance and unified teamwork can largely be attributed to our ability in achieving this,” Busse highlights.

ABOVE Front view of the twin declines at the North box cut BELOW Gary Brooks shows the true meaning of working together

body. In essence, we will have two separate mines being developed, which have immediate access to good grade ore sections,” explains Busse. Concentrator construction is also under way – activity on-site started in January 2013 and will be commissioned in Q4, 2014. Plant EPCM contractor DRA Minerals Processing is responsible for its construction. The majority of all major equipment items needed has been ordered already.

• PTM has a 74% interest in the Maseve project. Wesizwe Platinum owns the remaining 26%, representing the company’s BEE partner • Resource: 2.8 Moz (measured) and 5.4 Moz (indicated) • Reserves: 1.8 Moz (proven) and 2.9 Moz (probable) • Peak construction period: Q4, 2013 • 10-year Merenksy lifespan, followed by a twoyear UG2 blending period and only UG2 ore for its remaining life • Concentrator designed to handle both ore types upfront • Life-of-mine: 22 years • Reef depth: ranging between 150 and 600 m underground • Mining development: mechanised footwall, conventional on reef • Mining method: conventional breast stope mining, with conveyors and trucking only in the footwall • Number of employees on-site at full production: 2 500 • Operational methodology: contractor operated, owner managed • Economical valuation of chrome content to be investigated in 10 years • Additional project ounces: 2 Moz in reserve ounces under the Ledig town.

The Maseve project Unlike its neighbours, the Maseve project is a shallow operation, meaning the most cost-effective and fastest development method (decline development) is being implemented. “Two identical twin declines are necessary to ensure we extract the most flexibility and value from the ore In each issue, Inside Mining offers advertisers the opportunity to promote their company’s products and services to the appropriate audience by booking the prime position of the front cover, which includes a feature article. The magazine offers advertisers an ideal platform to ensure the maximum exposure of their brand. Please call +27(0)11 465 5452 to secure your booking.

Inside Mining 04/2013

 Profile

DEVELOPING DECLINES AT MASEVE

An unparalleled achievement Underground mining contractor JIC Mining Services is proving that the outsourced contractor model remains as successful as ever. Its decline development rates at Platinum Group Metals’ (PTM) Maseve project is perfect evidence of this, writes Laura Cornish.

host of new platinum mines, owned largely by juniors, may be emerging on the Bushveld Complex’s Western Limb horizon – all in varying stages of development. Its rapid underground decline development programme allowed Maseve to be at the production forefront. Neighbouring Royal Bafokeng Platinum’s Styldrift development project and 26% co-owner Wesizwe’s Bakubung project, the 275 000 ozpa 4E PGM Maseve project could be considered the most attractive. It is shallow, therefore lending itself to declines rather than vertical shafts. In terms of the project’s current development status, the construction of its two twin decline systems (North and South) remains a priority and will represent a major milestone in the mine’s overall progression, thanks to its ‘impressive’ advancement rates. In June 2011, JIC Mining Services (JIC) was awarded the contract to develop the twin 1 000 m underground decline tunnels into the centre of the deposit using LEFT Aerial view of North box cut with twin decline MIDDLE A close-up view of the start-up of the twin decline entrances at the South box cuts RIGHT Sandvik ADT533 (30 ton) dump truck in operation at the North box cut

Inside Mining 04/2013

mechanised mining methods. Despite a slow start-up, the company is currently achieving excellent ‘above-industry standard’ advancement rates. JIC’s CEO, Jacques Roux, highlights that there were a lot of inexperienced people at the start, meaning a substantial amount of upfront training was required. “Coupled with the PTM’s ‘world-class requirements’, we had to align ourselves with PTM’s vision and come together as a unified team to achieve the desired output. We accepted the challenge and with the establishment of a close working partnership with PTM and mechanised OEM Sandvik, we are meeting and often exceeding the advancement rate requirements. “Right from the start, we embarked on travelling side by side with PTM on its journey towards production. We wasted no time adjusting our mining system to ensure the twin decline development reached its daily development targets, which included moving from three eight-hour shifts to two

12-hour shifts per day. This alone reduced a significant amount of downtime during shift change,” explains Roux. Due to the perfect alignment established between PTM, JIC and Sandvik, the companies have been achieving PTM’s 100 m/month system advance consistently ever since – considered to be at least 20 m/ month faster than the South African industry average. “In addition to our commitment and underground mining expertise, the Sandvik mechanised machines have also contributed substantially towards our success,” he continues. Having recently completed development on the North declines, JIC has commenced with lateral reef development, targeting 80 m/month, as well as development on the South declines. “The client empowers us regularly and believes in us because we accepted the challenge to make this work, which has only encouraged us to deliver further. “Achieving such impressive advancement rates can also be attributed to the time and

 Profile energy we have spent on improving our advancement rate per blast, which we increased from about 2.7 to 3.4 m. We average three blasts per day.” Achieving such rates is new ground for JIC and the company intends to continue delivering to the same standards moving forward. The biggest challenge is to duplicate the successes achieved for the North declines at the South declines, which will

Following the award of the JIC contract, PTM president Michael Jones announced: “We are pleased to award this contract to JIC. Following a competitive tender process, it clearly was the right choice on many factors including price, skills and experience. JIC has a good safety record at all its operations and has invested in an accredited training facility locally. The estimated primary underground development cost ABOVE New arrival – Sandvik TORO514 (14 ton) LHD

“Coupled with the PTM’s ‘world-class requirements’, we had to align ourselves with PTM’s vision and come together as a unified team to achieve the desired output.” Jacques Roux comprise a new JIC team. “We have and continue to learn invaluable lessons on-site and have overcome significant challenges. This contract has become one of the most important contracts within the JIC stable,” Roux pronounces. “JIC’s ultimate aim is to transition from developer to miner at Maseve.”

based on the JIC bid is below our feasibility study estimate. We have been able to utilise the actual contract pricing for primary decline development, power and water delivery and initial civil site work to add confidence to our feasibility model for banking discussions. As a result of the positive PGM outlook, attractive margins on the project

and ongoing project implementation, banking interest has been strong.” JIC is currently operating as one of the largest underground mining contractors at Royal Bafokeng Plat's BRPM, immediately adjacent to Maseve, and operates as an underground mining contractor on another three platinum mines, one chrome mine and one uranium mine in South Africa, employing approximately 5 000 people. The company employs about 150 people on the PTM site, of which 40% are from the local area. This number is expected to more than double as the project grows.

 Hot seat

LOOMING ENERGY DEFICIT

It could happen Despite the rapid introduction of renewable energy sources into South Africa’s power grid, the country’s reliance on coal as the primary energy source remains indisputable into the foreseeable future. As many eMalahleni-based coal mines reach the end of their lives by 2020, another looming energy crisis seems imminent, writes Laura Cornish.

enewable energy sources are a welcome relief for South Africa – they are clean and will position the country equally with first world countries already using it extensively. They will also help offset the country’s high carbon footprint. The reality, however, is that South Africa depends on coal for up to 90% of its electricity requirements. This will reduce gradually as renewable energies ramp up, but coal will c remain the largest contributor to electricity generation b both in South Africa and worldwide b beyond 2030. Electricity

demand growth will continue on the back of increasing urbanisation, particularly in developing countries such as South Africa. “This leads to an impending crisis,” says Ian Hall, chairman of the South African Coal Roadmap Society (SACRM). “Our power stations are reaching the end of their planned lifespans and the coal operations that supply them will also be depleted around 2020. Since we cannot replace these stations in the short- to medium-term, Eskom plans to extend their lives by 10 to 15 years. This means we need to source anywhere between 60 and 120 Mtpa of new coal supply before then to

“In my opinion, the reality is that we could be electricity supply-constrained, as we are today, for the next 15 to 20 years.” Ian Hall 10

Inside Mining 04/2013

sustain these power stations and the new plants under construction. “The scale of investment required by the electricity sector to supply even a medium growth trajectory is mind-boggling. Maintaining coal supply is in itself a significant challenge. In my opinion, the reality is that we could be electricity supply-constrained, as we are today, for the next 15 to 20 years.” Finding sufficient coal resources is not the dilemma. The updated Coal Resources and Reserves Study of South Africa (CRRSA), not yet released but in final consultation stages, suggests that the country still has over 60 billion tonnes of recoverable coal reserves – enough to continue feeding coalfired power stations for over 200 years. “But the regulatory process to build a new mine is not aligned: it can take up to three years – and in most cases significantly longer – to attain the necessary mining right, environmental authorisations and licences to

Pic courtesy of BHP Billiton

 Hot seat

Objectives of the SACRM • To serve as a fact-based overview of the current South African coal industry – including a review of national and international issues affecting coal across all elements of the value chain. • A platform for the sharing and dissemination of knowledge – to align all stakeholders and their objectives and collectively support societal and economic objectives: accelerated growth, employment, environmental responsibility, capital and social investment. • Use scenarios to evaluate the impact of various trajectories and signals that a particular future is evolving. • A fact-based analysis, which aims to support policymakers and stakeholders going forward, together with some common actions to be undertaken for coal to contribute to a flourishing South Africa. develop a new coal mine. Various processes remain discretionary and outcomes uncertain. From this perspective alone, and coupled with the length of time necessary to complete feasibility studies, secure the necessary investment and construct the mine and plant, it appears that seven years to deliver such significant new capacity to Eskom is simply not enough time,” Hall outlines. And these issues are just the beginning. Some new mines can be developed relatively close to the existing ones in Mpumalanga, although these remaining resources are of poorer quality, requiring additional processing and infrastructure costs. But a large share of the remaining 60 billion tonnes lies in the Waterberg region, which is recognised for its significant coal volumes, but also for its poor in-situ quality. “The coal will need to be washed in a ‘waterless’ region and transported to the existing power stations hundreds of kilometres away, which will add

ABOVE Construction at Medupi continues BELOW Kendal power station

significantly to its overall cost.” Excluding Exxaro, which is already active in the area, companies are only now investigating potential opportunities in the Waterberg. It isn’t all bad news though. Transnet Freight Rail is looking to increase the capacity of the railway line to connect the Waterberg to the eMalahleni area, where the majority of the power stations are situated. The construction of a water pipeline is also a priority on the government’s infrastructure development programme. “If all these issues are resolved and aligned, the Waterberg will provide a secure supply option to Eskom. “Other priorities include policy direction on what will be the next baseload power station after Kusile. The future generation mix is defined in the IRP 2010, but this needs to

be updated. Will another coal plant be required in the medium term? If so, planning must commence now to avoid a future crisis, such as the one caused by delays in the current build plan.” A key factor to secure the development of new mines is to create a supportive investment environment. “Uncertainty around the implications of coal being declared a strategic resource, as well as other aspects of the MPRDA Amendment Bill, such as provisions for domestic use and beneficiation, must be clarified.” Considering that almost 75% of local production is used domestically, principally by Eskom but also in Sasol’s coal-to-liquid process, South Africa already has the most advanced coal beneficiation programme in existence. Increasing this must be balanced against its carbon mitigation strategies. Conversely, limiting exported volumes could be

Inside Mining 04/2013

Pic courtesy of BHP Billiton

 Hot seat

Immediate actions

Eskom requires some +60 Mtpa of new capacity before 2020

Secure contracts for coal supply to existing and new power stations

• agreement on an appropriate coal pricing model to Eskom • early infrastructure planning if coal for power stations is to be sourced from the Waterberg

Create an environment conducive to mining investment

• aligning policy and legislation processes for establishment of new mines • obtaining clarity on carbon tax • MPRDA amendments and practical implications if coal is declared a strategic resource

Resolve Central Basin • acceleration of Eskom’s current road-to-rail migration and concoal supply and transport veyor infrastructure programme challenges • identifying alternative employment opportunities for coal truck drivers who are thereby displaced.

dire for the economy. In 2011, coal exports comprised 27.2% of total coal production, but contributed R50.5 billion or 57.5% of total value in much-needed foreign revenue. The SACRM used a scenario-based approach to develop alternative pathways for the industry to 2040. But whichever trajectory is followed, coal remains at the forefront of our energy requirements going forwards and remains a vital necessity, locally and globally. “Whether South Africa diversifies its energy mix and joins the global leaders in emissions mitigation, meaning no further significant new investment in the coal or related sectors beyond the currently-projected needs, or if it continues towards a more coal-reliant future, coal is required to play an important part,” Hall points out. All scenarios clearly point to a series of common immediate (see table), short-to-medium and longer term actions required. Longer term strategies would seek to introduce advanced coal power station technologies, assess whether carbon-capture-and-storage (CCS) challenges can be overcome and plan for closure of mines and power stations in the Central Basin.

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 Hot topic

TWO RIVERS’ TERTIARY MILLING PLANT

A perfect upgrade The construction of a new tertiary milling plant at the Steelpoort-based Two Rivers PGM mine is progressing rapidly and is set to come on stream towards the middle of this year. It will offer significant value in terms of additional PGM recovery, making it an attractive project, writes Laura Cornish.

he tertiary milling plant’s (TMP’s) sole purpose will be to re-treat secondary rougher tailings to recover PGM material not recovered from the initial Two Rivers metallurgical process plant,” explains Ken Dyamond,

projects director at EPC project company Basil Read Matomo. Having completed a project feasibility study at the beginning of last year, Basil Read Matomo was awarded the turnkey contract in March 2012 to design, build and

Committed to the community Basil Read Matomo is well on its way to achieving its targeted Level 4 BEE status in the second quarter of 2013. “Contributions to local community upliftment and enterprise development have become key to our business going forward. In terms of enterprise development, we are ready to provide funding to a small local community project for the construction of an embankment,” Dyamond notes. Basil Read Matomo has been supporting a secondary school based in an informal settlement in Daveyton for a number of years, including the equipping of a library. Other Corporate Social Investment projects include the supply of solar flood lighting in the Eastern Cape with a second future project for lighting in the Steelpoort area to be undertaken later this year. “Our enterprise development programme was resurrected at the end of 2012 in the Eastern Cape where a number of small HDSA-owned businesses (some of which are 100% women owned) that operate in the construction or engineering consulting business in the Port Elizabeth area have been identified.” These businesses have been supplied with various equipment which ranged from a vehicle to computer equipment and software packages and will be followed up with mentoring and coaching in an effort to make these up and coming businesses sustainable.

Inside Mining 04/2013

commission the 250 000 tpm TMP, which remains on schedule to be completed and commissioned mid-2013. The Two Rivers mine is a joint venture between African Rainbow Minerals (55%) and Impala Platinum (45%). It is situated on the farm Dwarsrivier on the southern part of the Eastern Limb of the Bushveld Igneous Complex. The mine delivers, on average, about 149 000 ozpa of platinum. “The plant will reprocess current arisings from the primary process plant, which will then be pumped via a tailings line through a tertiary milling circuit and flotation circuit,

 Hot topic

ABOVE Construction of the thickener RIGHT 3D image of completed plant BELOW The tertiary milling plant will be commissioned mid-2013

finally being returned to the main plant for further upgrade,” explains Erik Bruggink, MD at Basil Read Matomo. African Rainbow Minerals’ business development manager, Stompie Shiels, says the project’s primary function is PGM enhancement. “It will remove chrome and we expect a 1% recovery improvement overall,” he adds. Despite having encountered one or two minor challenges on site, the impact on the project’s timeline has not altered. “We hit more under-surface rock than expected and as a result had to make various high adjustments to the terraces and to the foundations for the mill,” Dyamond continues. “Because of the flat Basil Read Matomo management structure, and our general ‘can do’ attitude, challenges are quickly addressed and overcome, and in this particular case, with the hard work of the team under project manager Mark Wagner, we should bring the plant in ahead of the contractual completion date.” To date, the majority of the civil works has been completed, with the installation of all major mechanical equipment having

commenced in January this year. The majority of the major equipment is on-site, which will facilitate a smooth erection process. The peak construction phase will start in the second quarter of this year, with about 160 people on-site. Located adjacent to the main plant, the TMP has been designed on a small, compact footprint and has been optimised in terms of power consumption, requiring only 3 MW to run at nameplate capacity. The plant is designed to last between 20 and 30 years at its current size, which will not cater for future expansions. “It is designed for a specific purpose and will

deliver on precise specifications. At Basil Read Matomo we offer throughput guarantees, meaning our clients are assured their plants will deliver according to their exact needs provided the plants have the specified feed.” TMP’s main contractors Mill Civils Spirals SMP Thickener Pumps

New Concept Projects M3 Construction Multotec and Metquip DC Construction MIP Process Technologies (30 m diameter) First Africa Pumps

Inside Mining 04/2013

 Hot topic

BREAKING THROUGH UNEXPECTED BARRIERS

TMP’s solid foundations While the upfront earthworks for the Two Rivers new tertiary milling plant could be considered a challenging project aspect, civil engineering construction company M3 Construction’s expertise and dedication to the job ensured the project suffered no delays as a result, writes Laura Cornish.

he 250 000 tpm tertiary milling plant (TMP) will retreat secondary rougher tailings to recover PGM (and chromite) material not recovered from the initial Two Rivers metallurgical process plant. It is on track to be commissioned towards the middle of 2013.

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 Hot topic OPPOSITE PAGE Early stage development of the tertiary milling plant RIGHT Construction of the TMP is welladvanced

In September last year, EPC contractor Basil Read Matomo awarded the complete earthworks and civil works TMP contract to M3 Construction. The project scope included all major earthworks for the TMP platform, as well as all civil structures for the thickener, spiral plant, flotation plant and mill base, as well as a concrete slab foundation for a product stockpile area. The company also completed the construction of a tar road leading into the new plant area. “By the middle of November we had already completed all the bulk earthworks and immediately commenced with the civil works portion of the contract. We remain on track to complete all project work at the end of March,” explains M3 Construction’s director, Terry Darlow. This is a remarkable achievement considering the unexpected challenges encountered during the TMP’s early earthworks establishment. “We encountered a lot of unexpected hard rock on the project site, meaning we

couldn’t blast, as is custom for a project with this scope of earthworks. We had to break the rock with machines instead, which necessitated a lot of additional, unplanned-for mechanical time. The design of the platform and

“For us the accolade was not just overcoming an unexpected obstacle, but doing so without impacting on the project’s time frame” mill foundations were also altered to accommodate the situation, which saw the amount of backfill used increase from the original 4 500 m³ to about 15 000 m³,” says Darlow. “This was a big upfront challenge, which we were able to overcome together with Basil Read Matomo. For us the accolade was

not just overcoming an unexpected obstacle, but doing so without impacting on the project’s time frame, especially considering our contract is towards the bigger end of our capabilities.” To date, all of the structures have already been completed, with only the stockpile area slabs incomplete. At peak contract phase, M3 Construction had 12 dedicated senior personnel working on the project together with 80 general skilled labourers. “We are particularly pleased to be associated with Two Rivers and the TMP, having completed various other projects at the mine since its establishment. This is the fourth time we have returned to site.” Darlow believes M3 Construction’s competitive edge in the mining industry is a result of its hands-on management approach, which he attributes the company’s growing mining project portfolio to. “We currently have contracts in place with Xstrata’s Tweefontein coal mine and Randgold Resources’ Kibali mine in the Democratic Republic of the Congo, and we are further involved in the construction of a new acid mine water plant in Germiston, South Africa.”

 Hot topic

TMP FABRICATION

Two Rivers has it covered Steel fabricator DC Construction has established a solid relationship with the Steelpoort-based Two Rivers PGM mine, having worked on numerous other projects prior to its new tertiary milling plant, writes Laura Cornish.

he tertiary milling plant will retreat secondary rougher tailings to recover PGM material not recovered from the initial Two Rivers metallurgical process plant – a project that is expected to improve the mine’s overall recovery. DC Steel Construction was awarded the contract to complete all steel fabrication and site installations for the new plant. According to DC Construction managing member Tobie Oosthuizen its contract is on track to be completed towards the middle of the year.

“This is our first time working with EPC company Basil Read Matomo, and we want them to walk away from the project a satisfied customer. We are delivering on our promises and ensuring Basil Read Matomo can rest at ease,” he continues. DC Construction first became involved with Two Rivers six years ago when it completed the contract for the mine’s north decline run-of-material conveyor structure. “It was our first step into the ‘big league’. The company successfully completed the project four months early and the rest is history.”

ABOVE DC Construction is overseeing all fabrication work at the TMP project

Oosthuizen prides the company’s ability to deliver to the highest standards, quality, delivery times, etc. “We appreciate that our involvement is contributing towards our clients’ needs – attaining revenue from untapped streams.” Mining is DC Steel Construction’s core business, which contributes the majority of its revenue. The company is currently involved in other projects and has provided its services to Impala Platinum, Total Coal South Africa, Anglo Platinum and Aquarius.

 Coal

COAL DEMAND

Bursting with opportunities

South Africa’s coal sector was the highest mining revenue earner in the country during 2011, generating more than R87.8 billion. Continental Coal’s CEO, Don Turvey speaks to Reggie Sikhakhane on the future of coal and his views on the Department of Mineral Resources’ strides towards making coal a strategic mineral.

ith state-owned power utility Eskom under pressure to ensure sufficient coal supply for its power stations, a demand by Asian and Indian markets for lower-grade coal, previously dominated by the domestic market, coupled with the need for swift intervention in the transportation of coal, the mineral remains an ongoing discussion point. The Department of Mineral Resources (DMR) indicated in 2011 that it intended to classify coal as a strategic mineral, upon realisation that lower-grade coal was being largely accepted by economies such as India and Asia for power generation. Coal

Inside Mining 04/2013

miners were also getting higher prices for lower-grade coal in comparison to domestic sales – a major threat to Eskom. Turvey explains, however, that coal has always been a strategic mineral in South Africa. “I don’t think it is clear yet what is meant by coal becoming a strategic mineral and, by the same token, what the impact on the sector will be. Coal has been a strategic mineral all along, unless it means that it will come with certain restrictions to coal exports, which would make no sense at all.” There is a misconception in the coal market about achieving a balance between domestic use and export. “The domestic supply of coal is being subsidised by exports

TOP Delta processing plant ABOVE Mining at Vlakvarkfontein

and works hand-in-hand. In many businesses, the capital from exports covers the costs for domestic supply.” Nonetheless, Turvey points out that Continental Coal (ContiCoal) is unsure whether the outcome of the status of coal becoming officially labelled as a strategic mineral, will affect it. “In our case, we believe it may not be an issue because we supply coal directly to Eskom from our

eMalahleni-based Vlakvarkfontein coal mine, which is essentially a domestic mine. “The coal is of a higher grade at our Ermelo coal operations and is suitable for the high-grade export market. Because we do not fully understand how coal’s reputation as a strategic mineral will impact us, along with the rest of the coal industry, it brings a level of uncertainty, which is not good for investors,” he says.

Company developments In the beginning of March, ContiCoal announced that the settlement of the sale of its shareholding in Vanadium and Magnetite Exploration and Development (VanMag) had been completed. The company confirmed that total sale proceeds of about US$10 million (R90.72 million) from the off sale of its shareholding in VanMag will be used by ContiCoal towards purchasing all outstanding minority interests in coal miner Mashala Resources. Mashala Resources has steam coal operations in Mpumalanga – Penumbra coal mine, which has about 10 Mt of saleable coal; the De Wittekrans coal mine, which produces about 250 Mt of coal; and the Geluk anthracite mine in KwaZulu-Natal, which produces about 10 000 Mtpm. “To be able to conclude the sale of one of the company’s non-core assets and use the proceeds towards the finalisation of acquiring the outstanding minority interests in Mashala is a significant positive for the company and its thermal coal business in South Africa,” Turvey adds. “We have, over the past three years, invested heavily in establishing a South African

“I don’t think it is clear yet what is meant by coal becoming a strategic mineral, and by the same token, what the impact on the sector will be.” Don Turvey

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thermal coal production, development and export business that includes the Vlakvarkfontein and Ferreira coal mines and now, following the commencement of mining activities at the Penumbra coal mine, we anticipate increased returns for our shareholders in the coming years.” Following the acquisition of the outstanding interests in Mashala Resources, ContiCoal will hold 100% interest in the operating Ferreira coal mine and Penumbra coal mine. Both these mining operations produce a high-quality thermal coal that is exported through the Richards Bay Coal Terminal and sold under existing off-take agreements into the Asian markets. Further to its developments in March, ContiCoal revealed that it had entered into binding funding agreements with JSE-listed diversified miner and exploration company Village Main Reef (VMR), adding that it believes VMR will further strengthen the company’s growth strategy and operating credentials in South Africa. “The introduction of such a strategic and cornerstone investor to our share register demonstrates the value proposition of our operating coal mining business and our coal project development opportunities. VMR is an established and profitable dividend paying mining company and as this is its first investment in the coal

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 Coal

TOP Pollution control dams at Penumbra ABOVE Penumbra conveyor belt

sector, positively reflecting on the quality of our portfolio. We are pleased to have secured this strategic and long-term relationship with VMR and to have the opportunity to work with its dynamic and successful management team,” he explained. The private placement transaction with VMR translates to VMR agreeing to subscribe for 100 million ordinary shares in Continental Coal at an issue price of AU$0.08 (R0.76) per share, raising a total of AU$8 million. “Our investment in ContiCoal reflects VMR’s continued diversification strategy while maintaining our requirement to invest in strong, cash generating assets. We think Continental Coal is at an inflection point in terms of its development. The company has a strong portfolio of projects and has demonstrated its ability to develop and operate mines and we look forward to working and supporting the management team as production continues to increase and as greater value is recognised within the company,” says VMR’s joint CEO, Marius Saaiman. Meanwhile, the company also notes that its discussions and negotiations regarding a potential long-term off-take agreement, strategic partnership and stand-alone funding agreement for its De Wittekrans coal project has advanced significantly over the past two months. In November last year, ContiCoal announced that an optimisation study on the

Inside Mining 04/2013

De Wittekrans project had delivered positive results. As a result, discussions with parties that had previously submitted indicative funding and off-take proposals have intensified, particularly with India-based coal and power utility companies and major global commodity trading groups. A secure partnership and funding arrangement will allow ContiCoal to fully fund the development of a planned initial seven-year opencast mine, along with the forecasted 30year underground mine development. Turvey adds that the company will also secure a long-term strategic off-take partner for the planned exports of a thermal coal product ideally suited for the Asian markets. Further update on the progress of these negotiations and the status of the company’s discussions with the five parties should be announced in the current quarter.

Operations The company’s Penumbra underground coal mine in Mpumalanga is on track for a successful ramp up in thermal coal production for the 2013 financial year, with monthly production reaching 14 000 t in January, compared to 2 694 t during December 2012, representing a more than 400% increment. Export sales also dramatically increased

the main ventilation shaft fans and shaft, is scheduled to be completed in April 2013. Mine operations at the Ferreira coal mine, situated just outside of Ermelo, continued to perform strongly in January 2013 following the establishment of a new opencast mining area. During January, the mine achieved ROM coal production of 56 886 t. Vlakvarkfontein also continued its strong performance in 2013 with ROM production in January of 103 751 t, which is in line with the average monthly ROM production achieved in the December 2012 quarter.

Outlook Despite the current climate overshadowing the mining industry – fluctuating prices, global economic uncertainty and labour relations turmoil – Turvey is optimistic and believes the coal sector will again perform beyond expectations this year. “The South African domestic market seems strong and I don’t see a reason for change as we all know that Eskom needs more supply of coal.” He admits, however, that financing expected growth may be challenging. “There will be a need for more coal mines as we seek to assist in the domestic supply of coal to Eskom, although I believe the biggest challenge will be financing such operations.” Regarding the export market, Turvey concedes that there is also a large potential for growth, especially owing to recent developments in other coal-producing regions such as Australia and Colombia.

“The South African domestic market seems strong and I don’t see a reason for change as we all know that Eskom needs more supply of coal” from 5 212 t in January, compared to 854 t in the previous month. Penumbra is forecast to produce 750 000 tpa of ROM (run-ofmine) coal over a 10-year life period. Penumbra, which is yet to be fully operational, is busy with the development of underground mine infrastructure and services at the base of twin declines. The company has successfully increased ROM production owing to the development of more coal panels, greater underground flexibility and a shift in focus towards production in the first of the two underground continuous miner sections. Completion of outstanding mine development and construction activities is ongoing. The remaining underground capital development and surface infrastructure, including

“We have seen strikes in Colombia’s coal sector, the first time in almost 23 years, which should have a large offset on other coal producing regions. We are also aware of the challenges experienced by the coal sector in Australia regarding infrastructure – all of these factors could open up opportunities for South Africa-based coal miners,” he explains. Turvey highlights that demand for energy has not declined as most had expected, despite a ramp-up by many countries to invest in renewable energies. “The global demand for energy has instead risen, opposed to falling and this, coupled with the everincreasing population dynamics, will see the demand for coal to fire power stations remain for years to come.”

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 Coal

UNCERTAIN DEMAND FOR COAL

What does the future hold? One of the biggest challenges facing the local and international thermal and coking coal markets is the uncertainty of the global economic situation, which has resulted in many capital projects being shelved or postponed. Inside Mining speaks to Gerrit Lok, Hatch Africa’s director for coal.

oupled with the global economic uncertainty are supply and demand factors stemming from major economies such as the US and China, which have had an impact on coal pricing. “Looking to thermal coal, the US has increased its thermal coal exports due to an increase in the country’s use of gas as an alternate energy source; China has seen most of its energy coming from hydropower sources in 2012, owing to an extremely wet season; and Indonesia dumped large volumes of coal on the market at much lower prices than anticipated. These factors saw an overall softening of prices on the back of demand in the market during 2012. Looking to 2013, pricing predictions for thermal coal is around US$110/t (R1 013.98) for coking coal and US$180/t for thermal coal,” explains Lok. The underlying long-term demand factors for thermal and coking still stem primarily from China and India, with the urbanisation of China being one of the major drivers. Tough, modest growth in thermal and coking coal demand is expected in the medium term. “In order to maintain this modest growth, three factors need to be met, which include: the continuation of the Chinese 12th fiveyear development plan; maintaining or improving the financial situation in Europe and sustained recovery in the US,” Lok continues. Looking to South Africa, he points out that the supply of thermal coal is firmly fixed in the government’s national planning. In order to secure the long-term supply of South Africa’s coal needs, two challenges need to be overcome, namely: the firming up of the contracted Eskom coal supply for the long

Inside Mining 04/2013

term and the development of the Waterberg complex in the Limpopo province. According to Lok, development of the Waterberg complex, in itself, also poses certain challenges, of which a large capital outlay on infrastructure is one. “Demand for coking and thermal coal will continue to rise in volume, although the percentage use of coal as part of the energy mix may come down. “Globally everyone wants a lower carbon future; however, the realities of

Looking ahead, Lok stresses the importance of collaboration and research in the coal industry. The Coaltech 2020 Research programme is one such example that has been very positive. Coaltech 2020 is a collaborative programme that has been formed by major coal companies, universities and the Council for Scientific

“More effort needs to be placed on managing our strategic coal resources in South Africa, especially given its importance as an energy source and foreign exchange earner.” Gerrit Lok the situation show how difficult it is to find a suitable replacement for coal. Nuclear power is also set to remain an important part of the energy mix. If South Africa wants to reduce its carbon footprint in terms of baseload, nuclear power will be one of the few options that the country can look at.”

and Industrial Research. Another research programme of importance is the South African Coal Road Map. “More effort needs to be placed on managing our strategic coal resources in South Africa, especially given its importance as an energy source and foreign exchange earner.”

 Coal

COAL OF AFRICA

The downside and the upside The past six months have not been easy for mid-tier coal producer Coal of Africa (CoAL), with poor production output, wage strikes and a high LTI rate. But it’s not all bad news; prospects at its Makhado project look first rate, writes Laura Cornish.

atalities, lost time injurys (LTIs) and strikes have impacted the coal sector, including CoAL. It seems unfortunate that in a period when the world, and South Africa in particular, is in desperate need of coal, the sector cannot deliver. Thanks to the Matola port derailment, which CoAL relies heavily upon, as well as an asset closing and another up for sale, the company has delivered unhealthy production statistics for its six-month period to December 2012, with no promise for a brighter short-term future.

A restructure or a sale The eMalahleni-based Vuna colliery’s coal reserve was due to be depleted by the end

Inside Mining 04/2013

of March 2013, at which time the supply of ROM coal to the Woestalleen complex will cease. While the company continues to assess various options to restructure the Woestalleen processing complex, it has already engaged all stakeholders in a section 189(A) process, notifying the 274 affected employees of the pending closure of the Vuna colliery and its impact on the complex. CoAL has also started a tender process for the sale of this asset and various offers are already being evaluated. The situation at Mooiplaats is equally dismal. Four of the eight LTIs recorded at the company’s Ermelo Mooiplaats colliery resulted from an incident involving a mine vehicle transporting employees. CEO John

Wallington says the focus on improving safety management at the mine has intensified as a result. Operations at Mooiplaats also were temporarily suspended at the end of September 2012 when the 176 National Union of Mineworkers (NUM) members, of the 368 people employed at the colliery, embarked on a protected wage-related strike. A wage agreement was subsequently reached resulting in employees returning to work on 1 November 2012. The strike action at Mooiplaats was primarily responsible for ROM production decreasing by 41.4% to 388 100 t while coal processed declined from 804 000 t to 388 000 t. As part of the initiative to address the long-term viability

 Coal OPPOSITE AND RIGHT Makhado has the potential to be a world-class hard coking coal mine. The project's definitive feasibility is due to be published Q2, CY 2013

The six months under review

of the operation, CoAL is assessing various strategic restructuring alternatives, which may include disposal. Following the derailment on the Matola Corridor on 18 February 2013, production at Mooiplaats will continue until stockpile capacity is reached.

The upside The good news is that mining researcher and consultant Wood Mackenzie has confirmed that CoAL’s Makhado project has the potential to be a world-class hard coking coal product, with the potential to produce approximately 2 Mtpa of hard coking coal and 3 Mtpa of thermal coal. The Soutspansberg coalfields-based Makhado project represents CoAL’s initial project within the greater Soutpansberg coalfield area and is currently finalising the additional external verification processes required for the definitive feasibility study (DFS) on the opencast mining area. The DFS includes both hard coking coal and a thermal coal fraction and since Q3, calendar year (CY) 2012, has been upgraded to provide greater operational certainty and reduced project risk. The study is expected to be published Q2, CY 2013. “The confirmation of the product quality as a hard coking coal supports our technical assessment and augurs extremely well for placing this product into the market and the future development of the project,” says Wallington.

• ten LTIs during the period, including a vehicle incident at the Mooiplaats thermal coal colliery in July 2012 where four employees were injured • 2.6 Mt of ROM coal and just over 1 Mt of export quality coal produced during the six months • reduction in export coal sales to 636 264 t due to the reduction in production volumes after the strike action that lasted for six weeks at Mooiplaats, and the impact of tippler upgrades at the Matola terminal in Maputo, Mozambique • ongoing pressure on index linked RB1 export quality thermal coal prices, which declined from an average of US$100/t during the six months ended 30 June 2012 to an average of US$87/t for the period ended 31 December 2012 • sales of export quality coal on the domestic market during the six months decreased by 13% to 341 685 t • sales of middling coal increased by 25.9% from 375 768 t in the six months ended June 2012 to 473 154 t for the December 2012 period. A new one-year supply agreement was concluded with Eskom for the supply of coal on improved terms • agreement concluded with BHE wholly owned subsidiary, Haohua Energy International (Hong Kong) • total gross equity capital raise of US$53.5 million through a placing of US$44.8 million with institutional investors and an equity derivative facility of US$8.7million with Investec Bank.

Wood Mackenzie has assessed the typical quality of the coking coal at Makhado to be hard coking, based on its specifications relative to other international coking coal products. The consideration was based on the global outlook for coking coal and the coal quality parameters that contribute to Makhado’s value-in-use in order to estimate the attractiveness of the coal in selected target markets. These markets are closely aligned to the key growth destinations for seaborne coking coal. The Vele coking and thermal coal colliery achieved 1 000 fatality-free production shifts during the reporting period and continued to produce export grade thermal coal to offset costs while the test trials on potential metallurgical coal are being concluded. The mine produced 449 000 t of ROM coal and 439 000 t of coal was processed during the period, yielding 126 318 t (FY 2012

H2: 46 066 t) of saleable export quality thermal coal. The intended plant expansion at Vele is expected to deliver improved yields and operational efficiencies. It has been divided into two phases: • Phase 1 – will allow for the dewatering of the ultra-fines product by installing filter presses eliminating the need for the temporary slurry pond and is scheduled for completion early in the second quarter of CY 2013. • Phase 2 – construction is expected to commence in CY 2013 and be completed in the

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 Coal second half of CY 2014. The approval of Vele Phase 2 by the board is subject to the completion of product testing currently under way. This phase includes the installation of a permanent ROM tip and crushing facility, primary and middlings coal wash plant modules as well as a fines recovery plant. Production at Vele colliery has been temporarily suspended following the derailment primarily to reduce operating cash costs during this period and the lack of stockpile capacity. Commenting on CoAL’s performance over the past six months ended December 2012, Wallington says: “The key development of this period was the strategic partnership agreement signed with Beijing Haohua Energy Resource Company Limited (BHE) through the equity placement of US$100 million (R924.7 million). The partnership with BHE has significantly strengthened the financial structure of the company, which will aid in the development of CoAL’s projects. The exchange of technical and operational expertise will facilitate the growth and development of CoAL and the coking coal industry in South Africa.”

Beijing Haohua Energy Resource – CoAL’s strategic partner At the end of September 2012, BHE – through its subsidiary Haohua Energy International (HEI) submitted a binding offer to provide the company with US$100 million of equity funding, with the transaction to be executed in two stages: • an initial placement of US$20 million, completed during the reporting period • a conditional placement of US$80 million. All necessary Chinese, CoAL shareholder, regulatory and statutory approvals required for the conditional placement were satisfied in January 2013 and HEI subscribed for a further US$80 million of shares in CoAL at £0.25 (R3.49) per share. The parties have commenced discussions regarding cooperation on commercial, technical and operational matters, enabling the company to draw on BHE’s expertise during the development of the Makhado project as well as the Chapudi, Mopane and Makhado extension projects. Hopefully, the next reporting period will deliver a better performance. A completed restructure of operations, an export route back on track and the progression of its Makhado project are worth looking forward to.

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 Coal

AN ENGINEERING EVOLUTION

Tipping the scales with coal The significance of the coal sector, particularly in South Africa, is growing each year as the demand for its use as the primary energy source continues to escalate. The subsequent need for highly specialised coal mining, processing and engineering experts is on the rise as well, writes Laura Cornish.

ost mining engineering houses have carved themselves expert reputations within certain commodity sectors. TWP Projects earned its industry-recognised standing primarily in the platinum field, although diversification across all minerals has ensured its ongoing success over time. “Having recognised the strategic importance of the coal sector, we embarked on an initiative five years ago to accrue and develop our skills and service offering to this specific industry sector. In two years, our coal human resources team has grown to include highly specialised coal mining, processing and engineering skills, and our coal portfolio has been growing,” says TWP Projects’ coal portfolio manager, Brad Rip. Today, the coal project team includes numerous certificated mine managers, engineering managers and a pool of well-qualified and suitably experienced civil, mechanical

Inside Mining 04/2013

and electrical engineers, the former having held management positions at various collieries prior to joining TWP. “And our intention is to keep these scarce and unique coal mining and processing skills within this portfolio only.” The portfolio is further supported by project management and project services skills, including project planners and schedulers, cost controllers, capital cost estimators and operating cost modellers from within the TWP Projects’ office. Looking towards the future, the company’s coal business has a multifold growth strategy

aimed at increasing its turnover contribution to the group. Following the acquisition of the company by global engineering company WorleyParsons, its platform for such growth could stretch far beyond South African and even African borders. Rip explains the division’s multifold growth strategy and has categorised it as follows: • Pursue major corporate coal clients, undertake their feasibility studies and meet their subsequent project roll-out needs. The company is already a Tier 1 service provider to the Anglo American group of companies, which includes Anglo American Thermal Coal.

ABOVE TWP’s relationship with Continental Coal started in 2009 – Penumbra conveyor LEFT First production at Penumbra was achieved in December 2012 RIGHT Continental Coal’s 1 Mtpa Penumbra operation

 Coal • Approach and do business with the growing mid-tier sector, which already includes Total Coal South Africa and, more recently, Continental Coal. • Pursue emerging producers and take their projects from study phase through to implementation. • Pursue on-mine stay-in-business projects with these clients. • Pursue large-scale international projects. “We are in the right place to take on projects of this nature. WorleyParsons brings global exposure to the company, particularly beyond our current Southern African focus. We will leverage off their global footprint in other coal producing regions of the world, such as Columbia, Indonesia and Australia.” With WorleyParsons’ infrastructure experience, the group can now offer a “pit-to-port” solution to its clients.

Already an impressive portfolio: Continental Coal TWP Coal most recently completed the EPCM contract for the development of Continental Coal’s new 1 Mtpa run-of-mine (ROM) Penumbra mine near Ermelo, which will supply both the domestic and export markets. The full EPCM contract included the management of sinking twin declines and the construction of all surface infrastructure, including a water reticulation system, an electricity distribution system and all surface buildings. First production was achieved in December 2012, just over a year since its execution began. TWP Coal’s relationship with Continental

Coal and the Penumbra project started in 2009 when it undertook the project feasibility study and then provided assistance in raising finance to develop the mine. “We came in phenomenally close to budget and

Anglo American Thermal Coal In 2012, TWP Coal completed a pre-feasibility study for Anglo American Thermal Coal’s life expansion project at the New Vaal colliery, which supplies coal to the Lethabo

With WorleyParsons’ infrastructure experience, the group can now offer a “pit-to-port” solution to its clients within acceptable tolerances on the schedule against the original plan,” Rip notes.

Exxaro Looking ahead, Rip proudly explains that the company recently secured its first project with one of the largest coal players in the country: Exxaro “We landed the feasibility study contract early in 2012, which entails the selection and design of an underground bunker for the replacement of Matla No 1 mine shaft.” The bunker has been designed to receive coal from five mechanised mining sections at a rate of up to 5 000 tph, and transfer the coal from the bunker at a steady state of 3 500 tph. “We went through a simulation process and considered alternative bunker designs such as the mechanised horizontal bunker and the more traditional vertical silo bunker. Having chosen a 60 m underground horizontal bunker, which will be 11 m high and 6 m wide, it is a massive undertaking.” TWP Coal is in the process of delivering the final feasibility study and expects the project to take between 12 to 18 months to complete once construction begins.

power station in Vereeniging. “The project looks specifically at the long-term expansion potential of the mine. In 2012 we completed the pre-feasibility study, which, if approved, will see the supply of coal to Lethabo from a new opencast pit and new underground mine for an additional 20 years,” Rip explains. The next phase will be a feasibility study (with detailed design), which Rip believes is imminent. “Implementation could start as early as late-2014.” The expanded areas will produce 10 Mtpa of coal. New Vaal currently produces 18 Mtpa of coal. “Late last year we completed and delivered the definitive feasibility study for a company with prospecting rights in the Tete basin of Mozambique.”

Total Coal South Africa The coal division’s longest relationship is with Total Coal South Africa. “We have been a service provider to this company for many years and have been a pivotal role player in its Forzando project’s various brownfields expansions (Forzando South and Tumelo). More recently, we have been involved with stay-in-business projects at Forzando, including a new co-disposal discard dump and tailings facility and upgrading of its stockpile reclaim and rapid load out arrangement.”

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 Coal

IKWEZI’S NTENDEKA

The two-year wait is over ASX-listed coal junior Ikwezi Mining is only three months away from production start-up – following the recent grant of its water use licence that it first applied for over two years ago. And CEO David Pile can’t wait to start mining, writes Laura Cornish.

kwezi Mining’s 70% owned local subsidiary, Ikwezi Holdings, together with its BEE partner (which holds 30% of primary asset Ntendeka), is about to start mining. The company first acquired the project’s mining right in February 2012. It is situated in northern KwaZulu-Natal.

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A frustrating delay Ntendeka’s mining right has been secured, its 170 000 tpm (ROM) wash plant is complete and commissioned, the opencast pit stands ready (a mining contract agreement has been signed), the purchase of the land on which the siding for the old Ngagane power station is located is complete and the

main haul road to the siding has been upgraded as well. An off-take agreement with the Vitol group of companies, which will purchase a total of 3.96 Mt, subject to Ikwezi putting in place a R200 million funding facility, has also been concluded. “Until now, we have been waiting for our water use licence, with nothing to do, for

 Coal OPPOSITE Ntendeka will supply 1.25 Mtpa of saleable product RIGHT Ntendeka's 170 000 tpm ROM wash plant BELOW Ikwezi has allocated about 40% of its production for niche markets and has modified the plant to accommodate this

over two years. The biggest challenge we encountered as a result of this ongoing delay is the anticipation we have created for employment in the area. Now that we have our licence, such challenges will soon be resolved, to an extent,” says Pile. The general KwaZulu-Natal area has a 76% unemployment rate and its population is desperate for work. “We have posted 300 job positions and received over 30 000 applications and many, both men and women, are suitably qualified.” The Department of Water Affairs’ (DWA) website states: “Your licence can take anything from three to 12 months to process, depending on the complexity of the licence, its benefits to the nation and its possible impacts,” Pile states. Following the licence grant, Ikwezi will use the three-month startup period to construct a water pipeline, pollution control dams and bulk water storage dams and commission its mining contractor (Stefanutti Stocks Mining) to site to construct the necessary box cut. Following the completion of these outstanding elements, Ntendeka becomes an operational mine. The project has been designed to supply 1.25 Mtpa of saleable product at nameplate capacity, primarily into the export market. The plant, however, has been designed to accommodate an additional second stage unit, which will increase its total capacity to 340 000 tpm. The expansion, which will increase annual production to 2.5 Mtpa, correlates directly with the need for an increase in overall Eskom power supply to the project, as well as the necessity to convert the mine from opencast to underground, which is anticipated in 2015.

The market There is an upside to Ntendeka’s start-up delay, Pile believes. “The coal cost curve

is depressing at the moment. The United States’ increase in shale gas consumption has seen the continent become a major coal exporter, which will likely continue into the immediate future. The US has good pipeline (distribution) infrastructure and is selling coal to the world’s largest importer, India, as well as to Europe.” The result? Domestic coal prices are bringing in more money than export prices. Taking this into account, Ikwezi has set its sight on the peas and nuts market, which according to Pile “attracts premier pricing. By focusing on speciality niche markets, our expected cash generation is more secure.” The company has allocated approximately 40% of its production for niche markets and has modified its plant slightly to accommodate this. Pile has also identified synergy opportunities between Ntendeka and Eskom, particularly in relation to the Tutuka and Majuba power stations. “Ntendeka can supply Eskom on the existing rail network, i.e. we are on the main Johannesburg-Durban rail line on which both Majuba and Tutuka are located. A large proportion of the coal is currently trucked from the Witbank area to these power stations, which is expensive. Coal from Ntendeka will be a lot cheaper due on rail and will travel a shorter distance. Transnet is in the process of building a line from the Witbank area directly to these power stations, which will result in coal being able to be railed instead

of trucked. Once the rail line has been constructed, in approximately three years’ time, Ntendeka will still have a shorter haul distance but some of the competitive advantage will fall away as both will be on rail and will not have the more expensive trucking cost.”

Down the line In addition to its core project, Ikwezi has another exploration asset (Dundee) in the KwaZulu-Natal area and one in the Springbok Flats. The company has, however, changed its viewpoint on the remaining unmined Witbank coal fields. The Department of Mineral Resources (DMR) executed the company’s prospecting right covering some 3 998 ha in the Ermelo coal field in Mpumalanga. According to historic borehole information, the project is said to contain approximately 150 Mt of coal. “We have adapted our strategy to meet our needs. We will blend the Mpumalanga coal with our KwaZulu-Natal coal to balance out its high sulphur content.” Ultimately, Ikwezi has retained its growth outlook: to achieve a 5 Mtpa coal production rate in the next five years. “We definitely need the regulatory licence grants process to be faster and more streamlined, and we believe better collaboration between the DMR and DWA would deliver fast results and encourage new mining investment and quicker project start-ups,” he concludes.

Inside Mining 04/2013

 Coal

UNCOMPROMISED COMMITMENT

Powering up The construction of Eskom’s Medupi and Kusile power stations remains one of the biggest and most complicated developments in South African history. This means that even the smallest contracts on-site, especially those aimed at speeding up construction time frames, are critical, writes Laura Cornish.

outh Africa has been watching the Lephalale-based Medupi power station take shape since Eskom first announced its development in 2005. Despite encountering numerous unforeseen challenges and difficulties over the years, the project has started gaining momentum as the boiler 6 commissioning period grows closer.

Medupi In July 2011, steel, mechanical, piping and platework (SMPP) fabricator and erection specialist Steval Engineering (Steval) was appointed to provide labour and supervision to the project. Its mandate was to speed up the erection time of Medupi’s boiler 6. “This entailed steel modifications and the pre-assembly of structural steel onsite, away from boiler, thereby enabling the cranes around the boiler to operate in an optimised manner,” explains Steval project director Roger Bester. LEFT The Medupi construction site

And what started out as a relatively small project scope has continued to grow, expand and evolve ever since. “We are now also responsible for the erection of ancillary plant piping and certain mechanical items, as well as the erection of certain components of the mainframe and sidewalls and welding of ducting for boilers 2, 3, 4, 5 and 6,” Bester continues. Steval is further providing assistance with bolting protocols on boiler 6, which Bester explains have to be at a specific torque setting. In addition to this, Steval is also responsible for the installation of most of the floor grating and hand railing at boilers 5 and 6. To date, Steval has erected the ash hopper on boiler 6 (completed in June 2012) and boiler 5 (completed in November 2012) and is currently erecting the mainframe and sidewalls on boiler 4. “Steval is a relatively small entrepreneurial company whose philosophy is centred on the supervision of its labour. Our supervisor/labour ratio is higher than the average industry norm, which equates to improved

Medupi at a glance • • • • • • • • • • • •

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based in Lephalale coal-fired power station will comprise six boiler units total installed capacity of 4 788 MW Medupi means “rain that soaks parched lands, giving economic relief” the boilers are scheduled to be commissioned at six-monthly intervals, in line with international practice the power station will include a supercritical plant, able to operate at higher temperatures and pressures than previous generation boilers, and operate with greater efficiency the supercritical design is a first for Eskom, and the higher efficiency will result in better use of natural resources such as water and coal, and will have improved environmental performance Medupi will be the biggest dry-cooled power station in the world the boiler and turbine contracts for Medupi were the largest contracts that Eskom has ever signed in its 86-year history the planned operational life of the station is 50 years the site measures 883 ha and was previously used for game and cattle grazing.

 Coal Kusile at a glance

Aerial view of Kusile

• based in the Nkangala district of Mpumalanga close to the existing Kendal power station • coal-fired power station • will compromise six boiler units • total installed capacity of 4 800 MW • it will be one of the largest coal-fired power stations in the world • the Kusile site is about 1 344 ha in size • the power station will be the first in the country to have flue gas desulphurisation (FGD) installed – a state-of-the-art technology used to remove oxides of sulphur from the exhaust flue gases in power plants that burn coal or oil • it will receive coal from Anglo American Thermal Coal’s New Largo and Zondagfontein mines • the combination of the resources will yield no less than 800 Mt over a period no shorter than 47 years. on-site control and a higher work standard and level of productivity. The size and nature of the company also empowers us to make quick decisions and quickly react to situations on-site.”

While Bester admits that the greatest challenge on-site is “sticking to” its core focus and strengths, Steval’s work standard has never been compromised and its delivery remains of the highest quality.

Its 380-strong labour force, approximately half of which is locally sourced, is split between a day and night shift. The day shift is responsible for achieving outset tasks while the night shift is responsible

 Coal Other recent Steval projects Beira Petroleum products storage terminal Client: Glencore Location: Mozambique Duration: 14 months Completed: 2013 Scope: Turnkey project – tanks, piping, separators, pumps, truckloading and offloading station, firewater, structural steel and civil works Konoko Copper (Konkola) Client: DRA Minerals Projects Location: Zambia Duration: 12 months Completed: 2012 Scope: Fabrication and erection of structural steel, steel platework, and mechanical installations. for optimising the progress achieved onsite. “The ongoing extension of our original appointment is testimony alone to our service delivery standard. This project now represents one of our largest contracts to date, which we hope will continue going forward,” Bester notes.

The company’s safety record is also worth acknowledging, having only recorded a single lost-time-injury (LTI) in almost two years on-site.

Kusile Steval’s positive contribution to the Medupi project has carried through to Eskom’s second new power station, Kusile. In February 2013, the company was awarded a bolting protocols contract for the boilers with the installation of structural steel, floor grating and hand railing to follow. One hundred

Aerial view of Kusile

costing, which has already carried over to our Kusile contract. Our job performance

“Our supervisor/labour ratio is higher than the average industry norm, which equates to improved on-site control and a higher work standard and level of productivity” employees have been allocated to site for the project. “Medupi has taught us invaluable lessons, particularly with regards to

is incentive driven, which we believe will drive our employees to perform to the highest standards.”

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 Coal beneficiation

RIVER ENERGY SA

Eskom’s quick-fix solution South Africa’s coal reserves may be depleting, but its need for power is not. Until recently, coal fines have been considered uneconomic, environmentally hazardous and difficult to process. Thanks to new environmental legislation and Eskom’s need for additional coal resources, companies are entering the market aiming to create a viable coal fines beneficiation industry, writes Laura Cornish.

iver Energy South Africa, established in 2009, is one such company and is offering the coal market one-of-a-kind technology capable of upgrading discarded coal fines, thereby providing mines with a new cash-generating stream and the country with a solution to its depleting coal resources.

The formation of River Energy SA ASX/OTCQX-listed White Energy Company is the exclusive licensee of a patented technology for upgrading and binderless briquetting of coal fines and high-moisture low-value coals through a low-cost process of dehydration and compaction. Together with its financial partner, Black River Asset Management, White Energy established River Energy JV in Mauritius in order to focus on African coal opportunities. River Energy South Africa was then set up as the first in-country subsidiary to pursue opportunities with South Africa-based coal mines.

Delivering a world-class, cash generating solution to a coal deficit crisis Dale McLean, general manager of River Energy SA, believes the South African company’s timing could not have been better. “While our initial focus and target was to provide coal mining houses with an additional revenue stream, we believe South Africa’s environmental legislation and increasing need to secure additional coal for energy generation will intensify the demand for our unique coal fines beneficiating technology.” The coal sector contributes over 90% of South Africa’s electricity needs, and this figure is unlikely to change in the foreseeable future. The countries’ larger coal mines, however, are maturing; many are on a pathway

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to closure within the next 10 years. Eskom’s capacity expansion budget is R385 billion to 2013 and is expected to grow to more than a trillion rand by 2026. The state-owned entity will ultimately double its capacity to 80 000 MW by 2026. This presents a massive coal shortage crisis. Considering there are millions of tonnes of coal fines in the ground in addition to what is on surface in tailings facilities, a technology that can deliver a viable product from such material could offer Eskom significant relief in the near future. “We are actively targeting Eskom. It needs to find a solution. We believe that River Energy is an important cog in this solution for Eskom.” It is estimated that there are more than 1 billion tonnes of fine coal slurry discard in South Africa. With 350 Mt to 400 Mt of coal being mined every year, there could be up to 30 Mt of additional fine coal slurry created every year – assuming around 7.5% of fine coal slurry discard is created in the coal mining and processing value chain in South Africa. “What we are offering is a solution to South Africa’s looming energy crisis – new and untapped coal,” McLean outlines.

River Energy’s BCB technology Briquetting of fine coal is not a new concept; briquetting coal using binders has been around for at least a century. However, the use of binding agents to hold the fine coal together has always been problematic. In addition to the cost of sourcing an expensive additional element to add to the fine coal, the combustion profile, physical and chemical properties of the briquettes can change, making the product difficult to market to the end users. Briquetting without the use of binders has always promised to deliver the ideal product, but has met with limited success historically – until recently.

River Energy, is offering a binderless coal briquetting (BCB) technology, which offers exactly what its name states: the ability to recover and upgrade coal fines to form a briquette without a binding agent. It is a patented technology developed by the Commonwealth Scientific and Industrial

Pic courtesy of Jonathan Carroll (Newcastle Herald)

 Coal beneficiation Research Organisation (CSIRO) in Australia and refined by White Energy and has been commercialised under an exclusive global licence by River Energy’s parent company. “Simply put, it involves an uncomplicated thermal drying process, followed by the pressing of the briquettes that are held together by the natural bonding mechanisms of coal.” The most effective way to use the technology for current arisings is to integrate it into a wash plant and use it to dry and compress discarded coal fines into higher energy coal. Because the price of coal is based on its energy content, with the highest calorific count bringing in the most dollars, River Energy’s technology doesn’t just upgrade coal’s heat value, but also its price.” The company is able to cost-effectively process and upgrade current arisings through a fine coal circuit which is enabled by the Baleen Filter, a patented micro filter technology from Australia to which River Energy has exclusive access in the coal industry. McLean does not, however, shy away from any fines upgrading technologies. “The key issues with

commercialising any form of ultra-fine coal are moisture and handleability, and our BCB process can accept feedstocks from any type of dewatering and/or beneficiation process in order to produce a product that can be handled using the same materials handling equipment and methods that are currently employed to handle coarse coal. There is no change required to existing stockpiling, loading or conveying solutions employed by coal mines.” According to McLean, River Energy JV is one of only a very few global companies looking to successfully commercialise the BCB technology. “In South Africa, we have made good progress and offer the platform of leading technologies in the beneficiation and binderless briquetting of ultra-fine coal.”

BELOW River Energy's demonstration plant in Australia

Putting BCB into practice River Energy South Africa has already tested and evaluated numerous coal deposits in South Africa – in the traditional coalfields as well as the emerging Waterberg region – and has established relationships with all the

The characteristics of binderless briquetting are: • no additives to the fine coal, thus no increase in the cost of the briquetting circuit feedstock • a consistent burn profile of the briquette and the host coal • no effect on the volatiles of the briquette compared to the host coal • the ash profile remains essentially the same as the host coal • low variable cost of production with advantages of scale as briquette production volume is increased • proven plant scalability is a major competitive advantage for the River Energy process • the ability to take high moisture ultrafine coal feed material (including feed to thickener) and produce extraordinarily low moisture briquettes.

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Advances (and advantages) of the technology Developments in binders used for briquetting as well as binderless briquetting technology have created the ability to: • beneficiate and upgrade low-grade feedstock • reduce moisture content to improve economics (sub-bituminous and bituminous) • recover fines (waste) and create a saleable product • solve materials handling challenges typically associated with fines • create large, scalable briquetting plants • tailor briquette characteristics according to market requirements • create products that customers will buy • reduce carbon dioxide emissions • lower the risk of combustion • reduce volume of slurry • improve performance at power stations • enhance transport efficiency • reduce sulphur content. major coal players in South Africa, as well as Eskom. “We have a number of parties that are interested in our solutions and are now on the brink of securing a deal with one of the major coal companies to build a 500 000 tpa BCB plant, situated in the Witbank coalfields. We are pushing to have it up and running before the end of 2014. It will demonstrate the full capabilities of the company’s Briquette product delivered by conveyor to the stockpile technology and represent a major milestone for River Energy, delivering an operational plant in South Africa,” says McLean. Anticipation is that various projects will kick into gear to use this technology afterwards. “We are comfortable with joint venture arrangements, and would look to go this route with the mining companies. Financially, we are well supported by our holding companies and are so confident of the BCB technology that we will financially support the plant’s development and construction. What the coal companies bring to the joint venture is the security of ultra-fine coal feedstock for our plants.” McLean sees endless opportunities with the production of both export grade briquettes and product that is in short supply in the South African market – aggregating resources and feeding it to a central briquetting site could drive high volumes, ideally suited to a user such as Eskom. A key objective for River Energy lies in building a sustainable presence as an “industrial champion” of binderless coal briquetting in South Africa. More than 85% of the capital required for a BCB plant will be spent on sourcing equipment and expertise from South African suppliers, and a typical 500 000 tpa plant will require between 35 and 50 people to operate it. A training plan for the acquisition of scarce skills to operate the plant will simultaneously lead to employment opportunities for communities in which the plants are located becoming a reality. The initial goal, McLean continues, is to establish production capacity within South Africa of between 5 and 10 Mtpa of binderless coal briquettes. “Our technology is nimble and can be rapidly deployed. While the scalability is uncapped, we feel that 500 000 tpa plants are the ideal size for the South African market.”

 Coal beneficiation

DEWATERING DREAMS

Available on lease When the mining industry is financially struggling, the need to develop a ‘mean and lean’ business model becomes essential. Often overlooked are the innovations and services OEMs are offering to help them streamline their businesses, improve production and generate more cash while protecting the environment, writes Laura Cornish.

ewatering systems and filtration specialist Filtaquip has aligned its business strategy to assist mining companies remain operationally sustainable and established a business service offering aimed at allowing mines to reap the benefits of its equipment and technology without the upfront capital outlay required to purchase it.

“Our priority as a service provider to the mining sector is to assist mining companies to focus primarily on their core business, production. With this in mind, we established a financial lease division that can supply plant and equipment for up to 60 months, to approved customers, on a capital lease contract,” says Filtaquip’s MD, Kobus Boshoff.

“This allows us to offer tailor-made financial packages to suit our clients’ needs. We saw the opportunity for off-balance sheet funding for equipment that doesn’t form part of a mine’s core business or which has perhaps not been budgeted for. This provides them with the flexibility to use premium equipment that they haven’t necessarily budgeted for.” Boshoff explains that the lease process is no different to purchasing a car. After the stipulated lease time frame, the equipment belongs to its lessee. It can also be paid off in full at any period during the lease period. Also added to the company’s services is a ‘maintain and operate’ division, which offers plant operations on a cost per tonne basis. Today, Filtaquip already has its first lease contract in place – it included the supply of a full dewatering plant, which is already installed and in operation. “Our contract for one of the country’s largest coal companies is a milestone achievement for our new business unit. Not only were we provided

TOP Fully automated filter press installation at a large acid water neutralisation plant LEFT Turnkey coal fines filtration plant at a coal plant in Mpumalanga – 35 tph of dewatered coal fines

Inside Mining 04/2013

 Coal beneficiation Fully automated filter presses “Filtaquip’s philosophy focuses on a search for balance between the productive requirements of a modern company and environmental protection,”says Boshoff. The filter press dehydrates the solids in the feed sludge by squeezing all the liquids out of it (up to 90%) by means of a high-pressure feed pump, which provides the driving force for the dewatering process. The products are clear press filtrates suitable for recycling into the process or for further processing, and a dehydrated filter cake, which is easy to handle. These presses have capacities ranging from 10 to 45 000 l/h of solids each. Press technology features include: finite element design of frames that can withstand hydraulic forces up to 20 bar for extended periods; HPT – feeding up to 16 bar, accelerating the filling of the press chamber and providing exceptional dehydration force; the use of specialised pumps, a clearing cycle of less than four minutes for a 160 plate press, designed and manufactured for filtration purposes; a shaker gasser plate shaking system; proper selection of filter cloth; and a hydraulic system operating pressure of 300 to 400 bar.

with an entire turnkey lump sum contract – from concept, design and upfront test work, through to installation and commissioning; but we will also operate and maintain the plant as well.” The plant includes two 1.5 m filter presses, each equipped with 120 plates, complete with discard conveyors and filtrate recovery systems, all fully automated. It can deliver up to 35 tph of dewatered coal fines. Recently commissioned, the plant’s filtrate is recycled and reused in the mine, reducing consumption of freshwater by up to 40%. The dry fines product contains a moisture content of less than 20%, meaning it is less environmentally hazardous if discarded to tailings dams or alternatively, in some instances, it can be sold as well. Filtaquip systems are predominantly aimed at the recycling/recovering of plant effluent water by producing clean water suitable for reuse in the plant or process, while producing a dry cake with a moisture content less than 20% which is easy to handle. As Filtaquip designs equipment and processes to suit the

customer’s exact requirements, dewatering processes and plants that can process in excess of 100 tph can be supplied. “Our systems are perfectly suited to the industry’s growing needs for greater environmental responsibility. We are offering the opportunity to do away completely with settling ponds, which is in line with requirements from the Department of Environmental Affairs. This continues to be a critical industry issue at present which is generating a lot of business for us as a result,” Boshoff outlines. While Filtaquip designs and manufactures filtration equipment locally, it also partners with a high technology (Matec) company in Italy, which ensures continuous evolution

of the company’s technology and equipment. The high-pressure technology (HPT) plate and frame filter press design and technology permits the press to work at pressures of up to 16 bar, enabling the unit to

“We saw the opportunity for off-balance sheet funding for equipment, which doesn’t form part of a mine’s core business or which has perhaps not been budgeted for” process even the most difficult-to-dewater sludges. This press functions without the use of flocculants and is fully automated. An added benefit is increased water recovery as the dewatered fines are drier than those encountered in other types of filter presses. The company also has extensive experience in the dewatering of precipitates generated in neutralising of acid effluents. Recent results achieved at such an application yielded a gypsum cake with moisture of less than 15% and a press cycle time of less than 14 minutes using only a high-pressure feed pump and no membrane squeeze or core blow. The pump has not required any spare parts for a period of six months.

INSET Filtaquip has full in-house 3D design capabilities RIGHT 1 500 mm plate press, equipped with 120 plates during installation

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WATER AND LIQUID RECOVERY PLANTS FOR PROCESS AND ENVIROMENTAL REQUIREMENTS

• - No More Time Consuming Troublesome Membrane Squeeze Required – No Flocculant Required o High capacity - up to 40 tons/hour achievable per press

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o High pressure Feed Technology o Short clearing cycle 3 - 5 minutes o Lowest residual moisture-up to 95% recovery of water/liquid from slurries o Fully integrated cloth washing - 5 minutes for a press with 180 plates o Shaker gasser plate shaking system for eĸcient material release • Process Pumps • Fully Automated Flocculant Plants o No operator involvement • Complete Turn-Key Plants 17 Bisset Street, Jet Park, Gauteng South Africa Tel: +27 (011) 397 2121 Fax: +27 (011) 397 2126 Email: info@¿ltaquip.co.za

 Coal beneficiation

IKA C5000 AUTOMATED BOMB CALORIMETER

Serving students for the future On its quest to improve coal beneficiation, the Southern African Coal Processing Society has donated a specialised piece of equipment to the School of Chemical and Minerals Engineering, North West University.

he IKA C5000 Automated Bomb Calorimeter was set up in 2012 and has proven to be an essential investment. It will continue to have a positive impact on the success of all coal projects mainly from a timing perspective and for a long time going forward,” says Prof Quentin Campbell of the Coal Processing Research Group at the university’s Faculty of Engineering. “It is a routine analytical tool but, without it, research progress will be much slower and more expensive.” This special piece of equipment measures the heat values of coal, which is used in almost all coal-related research to quantify characteristics. It can also be applied to other combustibles, like biomass. For the undergraduate and postgraduate students working and operating the machine, the benefits are endless. Calorific value (CV) measurements are standard and routine for any coal work, but students can now perform quick and accurate analyses for their projects. Analyses would have to be done externally otherwise. “The experience that the students will gain, which will stand them in good stead for the future, has two levels,” explains Campbell. “The first is the basic use of laboratory equipment,

procedures and safety. The second is the advanced understanding of coal characteristics and its relationship with the utilisation effect of CV on conversion processes, e.g. combustion and even gasification.” In its endeavours to raise funds through its conference sponsorships, attendance and membership, the SACPS hopes to continue with projects such as this to benefit the coal industry as a whole. Effective and economical beneficiation of fine coal is generally viewed as the next major contribution to solving problems in coal mining. Further studies to reduce the negative impact of environmental slimes ponds and discard dumps can be undertaken with

further funds – challenges the industry is crying to resolve and improve on. The society’s vision is to continue growing its support for engineering faculties to further improve environmental conditions. Efficiency, coupled with profitability, is essential for the industry’s survival in Southern Africa. The organisation will be holding its next conference in Secunda in July 2013 and is appealing to the industry to continue with its valued support. Should you wish to join the society in its endeavours or attend the conference, please contact Ann Robertson at annrobertson@absamail.co.za. Various sponsorships are available. Ann can also be contacted on +27 (0)11 433 0063.

Southern African Coal Process Society’s chairman, Mark Cressswell, and Prof Quentin Campbell with the IKA Automated Bomb Calorimeter, donated by the SACPS

Inside Mining 04/2013

 Comminution

A STAR ALLIANCE

Crushing the market

Thanks to Pilot Crushtec’s new distributor agreement for Sandvik Construction’s mobile range of crushers and screens, effective from October 2012, the company is achieving never-before-seen levels of business, writes Laura Cornish.

ilot Crushtec’s share of the mobile and semi-mobile crushing and screening market has always been a significant one, which until now has only been limited by its machines’ size, volume and capacity capabilities. The alliance follows an approach by Sandvik Construction – which offers the world’s widest range of rock drilling, rock excavation, processing, demolition and bulk materials-handling equipment – for Pilot Crushtec to take over the regional distribution of its full range of mobile crushing and screening products. This has given the company instant access to a much larger pool of equipment and business. “In just a few short months, the results of this partnership are already living up to our expectations. New doors have opened and opportunities for higher volume applications (up to 1 000 tph) are overflowing,” says Pilot Crushtec sales director, Graham Kleinhans.

Inside Mining 04/2013

While it took less than a month for the company to sell its first Sandvik machine, it is the number of units sold in the first three months of 2013 that is noteworthy. “Since January this year, we have already delivered 17 Sandvik units, mostly to the mining industry.” Kleinhans believes this success is attributable to a combination of factors: a

screen unit that caters to high volume aggregate producers. It boasts 40% more screening area than its “little brother” – the market leading QE340.

“Since January this year, we have already delivered 17 Sandvik units, mostly to the mining industry” Graham Kleinhans thriving iron ore and manganese sector; robust, heavy-duty, high-capacity Sandvik machines capable of handling the typical hard rock materials associated with these metals and a “savvy sales approach unlike no other”. There has also been much success in the Northern Cape and Zimbabwe diamond markets with the massive QE440 scalping

The stockpiling conveyors are both wider and higher to deal with both the increased production capacity and facilitate larger stockpiles. “In a nutshell, it is cost effective to operate and is well-suited to receiving mass tonnages and move large volumes.” “There are a number of sound reasons why Sandvik Construction considered Pilot Crushtec as a business partner. Pilot

 Comminution

The Sandvik range includes: LEFT A Sandvik QE440 mobile scalping screen working in tandem with a Sandvik QJ341 mobile jaw crusher ABOVE A CDE plant was recently sold to a customer that produces premium grade sand

Crushtec has a reputation for being a dynamic and successful company, an independent business that is a major player in local and Southern African markets. The company has the technical expertise and field service capabilities to support the Sandvik brand and we share similar values,” Duncan McGregor, Sandvik product area president: mobile crushers and screens said when the alliance agreement was first announced.

Accommodating and preparing for substantial growth “Pilot Crushtec’s business grew by 25% in our last financial year, largely due to the mining sector. Our target for this year is another 25% growth, which we will probably exceed. Our current order book is already indicating the likelihood of this,” says Kleinhans. Specific sales targets of 100 units for 2013 have already been outlined for the

Sandvik range. Considering the company comfortably sold well over 100 units of the Terex Finlay range, Kleinhans believes such targets are “very achievable”. Pilot Crushtec’s strategic alliance with Terex Finlay has subsequently been terminated. With the continued anticipation for so much growth in the pipeline, the company is investing heavily in both logistics and its manufacturing facility. “We are retraining staff and are expanding our field service and aftermarket service offering. We are also adding a second floor to our spare parts department.” Future growth will also be driven through attaining more business in Africa. “We believe regionalising is the key to doing this right. Priority countries include Zambia, Tanzania, the Democratic Republic of the Congo, Zimbabwe and Namibia. “Looking ahead, we remain hungry and on the lookout for more products, both internally and from a diversification point of view. We will, however, always be first and foremost a mobile and crushing screen specialist.” Sandro Scherf, CEO of Pilot Crushtec, reiterates: “Pilot Crushtec is constantly evolving, and this new association with Sandvik is consistent with our own forward thinking.”

Strength in sales Kleinhans believes Pilot Crushtec’s success remains solidly grounded upon one key factor: sales. “It’s basic sales’ 101

Mid-range mobiles: Jaw crushers: QJ 340, QJ 330: QJ 240 Cone crushers: QH 440, QH 330 Impact crushers: QI 440, QI 340, QI 240 Screen: QA 450; QA 440, QA 430, QA 340, QA 331, QA 240, QA 140 Scalper: QE 440, QE 340, QE 330, QE 140 Heavy-range mobiles: Jaw crushers: UJ 640, UJ 540, UJ 440i, UJ 440E Cone crusher: UH 640, UH 440i, US 440i Scalper: QE 440 Wheeled-range mobiles Cone crusher: UH 421, UH 320 Impact crusher: UV 320 Screen: UF 320 principals that deliver results – you have to go out and find the work and you have to save your clients money by finding and offering them economical, cheaper, leaner processes and methods. Our customers welcome this approach and partnerships are then easily established.” The company also prefers to keep machines in stock, which its peers may consider a ‘gamble’. “Companies are no longer able to plan far ahead, in terms of equipment orders and what they do, but we believe in our business and are prepared to carry the risks associated with stockholding. When a client needs something we can get it to them quickly as a result.” Pilot Crushtec personnel will also be responsible for all Sandvik maintenance and will ensure a vast spare parts stockholding is always available. South African OEM Bell Equipment has been granted distribution rights by Terex Finlay for its range of mobile crushing, screening and recycling equipment in South Africa.

Inside Mining 04/2013

 Comminution

FINES SCREENING

Meeting the market’s needs

Where Derrick screens can be found

As the mining industry matures, so too does the need for high level, technologically advanced equipment. Easy-toprocess PGM ores are largely depleted and the need for energy generation from low-quality fine coal is becoming urgent. Suppliers that can offer solutions to either or both of these industry challenges will thrive, writes Laura Cornish.

ine vibrating screen specialist Derrick Corporation and its sixyear-old South African subsidiary are offering such technology, equipment and methodologies to both these market sectors. As a result, its South African company is performing extremely well locally and in neighbouring countries. Regional manager Nic Barkhuysen believes the company’s growing success is attributable to its patented technology and cost-saving production-enhancing screening equipment. “We can screen very efficiently down to 45 micron apertures with polyurethane surfaces and down to

Inside Mining 04/2013

35 microns with wire deck technology. I don’t believe any competitor can screen so finely at high capacity, very high frequencies and very low amplitudes,” he says. The benefits of machines capable of handling and screening fine material at high feed rates on small footprints (with capacities of between 40 and 500 tph), for both wet and dry applications, are obvious. Because the platinum’s increasingly high UG2/chrome material has smaller sized PGM minerals and increasingly higher dissociation of PGM minerals from the larger and hence more easily floatable sulphide minerals, its processing

Derrick screens are suited to any processing plant, including iron ore, gold, platinum, gold, chrome, base metals, phosphates, silica and mineral sands. • PGM, gold and diamond mines in South Africa and Namibia • Gold mines in Namibia and Ghana • Mineral sand operations across Africa • Base metals (copper) mines in the Democratic Republic of the Congo • Fluorspar mine in Namibia (Okorusu) • Iron ore mines – Derrick Corporation South Africa has 60 dry screens installed at an iron ore mine in Mauritania • Uranium mine in Namibia

ABOVE There are over 1 800 Stack Sizers operating around the globe

capabilities will still prosper with fine screening equipment. The coal sector, which is frantically evaluating technology that can viably extract fines for upgrading, will also benefit from screening technology that can handle very fine material. “It is easy to see why our patented Stack Sizer – a high capacity, efficient, fine wet screening machine – has become our local flagship product. It provides solutions to our local industry’s immediate needs.

 Comminution The fact that there are over 1 800 installed and operating across various international mining operations is sufficient proof of its market attraction. Thanks to their process performance enhancements, Barkhuysen says the Derrick machines have a payback period no longer than a year, in some cases as low as a couple of weeks.

Taking on the Southern African coal sector While the local gold and platinum sectors are already reaping the benefits of the Derrick Stack Sizer, Southern Africa’s coal sector will soon realise the benefits it has to offer. Derrick Corporation South Africa recently secured its first major coal contract: to supply 12 x 5 deck 200 tph Stack Sizer machines to a major coal operation in Mozambique. “The screens will be manufactured at our parent company’s highly automated facility in the US and shipped directly to site. We will send a commissioning team to site to ensure they are assembled, installed and commissioned properly when delivery starts in November this year,” Barkhuysen explains.

Replacing cyclones in a closed circuit The Stack Sizer screens are popularly used to ‘close the mill circuit’ – an application that Derrick Corporation promotes to clients, Barkhuysen continues. “Our Stack Sizers can replace cyclones within the milling circuit, significantly increasing their throughput by reducing the circulating load inherent in closed circuit milling. It further reduces flotation reagent consumption, overall mill power consumption and decreases the volume of slimes material, thereby offering environmental advantages as well.” For UG2 operations, Barkhuysen adds that the combination of cyclones and screens can deliver optimal results. The company has two five-deck Stack Sizers installed and operating at a tailings stream overflow for one of the major local platinum company’s UG2 operations.

Reducing ash content The Stack Sizer also offers the advantage of significant ash reduction in clean coal spiral circuits. Fitted with Derrick 100 micron urethane screen panels and months

The foundations of Derrick Corporation Derrick Corporation is an American family-owned business, which was established 60 years ago. Its head office and manufacturing facility are situated in Buffalo, New York, and it has another office in Huston, Texas. Its South African company is the only office established outside of the US and will focus on the African mining markets. of continuous production, the Stack Sizer has confirmed its ability to consistently produce a clean coal fraction that typically halves the ash content. A typical example of a five-deck Stack Sizer operating today produces approximately 33 short tonnes per hour of clean coal containing about 9% ash. This represents a clean coal yield of about 75% and an ash reduction of about 50% from the feed slurry. “Ultimately, this means that what has been considered a tailings product up until now can be converted into a saleable product – the financial benefits and increasing demand for coal makes this particular application extremely attractive.”

Fine Screening Technology High open area Polyweb Screens as fine as 45 microns!

www.Derrick.com

Hall: B2 Stand: 123

 Comminution

COAL DISCARD IN EMALAHLENI

On route to Eskom Xhawula M3’s diversified strategy includes the recent mobilisation of a Catpowered Metso Lokotrack crushing and screening plant set up to reclaim a discard dump for downstream processing and sale as power station coal.

perating throughout the Mpumalanga coalfields, the eMalahleni-based Xhawula M3 group of companies provides multidisciplinary umbrella services to blue-chip concerns as a surface and underground contractor, coal transport and logistics operator, in addition to solutions that include plant hire, earthmoving, weighbridge management and labour hire to the mines.

Inside Mining 04/2013

This scope will soon be expanded to include full-scale mining for Xhawula M3’s own account once pending South African government licence approvals have been granted. The initial downstream project scope, in conjunction with joint venture partners, includes the acquisition of an existing surface mine that will subsequently mature into an underground development. Later, there could be potential for an investment in open-cut greenfield sites.

In all respects, Xhawula M3’s pure coal focus is being constantly refined through strategic diversification into niche markets. This includes the company’s coal washing business. The group already operates a washing plant at its Rondebult site and recently invested in an additional facility at Doornrug to support a new coal dump processing project at Landau colliery’s Schoongezicht mini-pit operation, near Ogies.

 Comminution

Xhawula M3 has secured the sole mandate for this dump, which is continuously being expanded with the addition of current arising material flowing from the mining programme. In its present form, the dump contains approximately 4.9 Mt of in-situ material, mainly coal with allied shale and sandstone compositions. “Once crushed and screened, this dump has the potential to yield around 2.5 Mt of saleable thermal coal after being washed and blended with a higher quality coal ‘sweetener’, thereby meeting the required ‘C’ grade power station specification,” explains Xhawula general manager, Sean Klopper.

ABOVE Average material sizes being fed through Xhawula’s Metso Lokotrack LT1213 impact crusher range between 400 and 500 mm, with a final product size of approximately 50 mm LEFT The Metso Lokotrack ST4.8 is an ideal choice for the accurate classification of up to four end product fractions: threesized and one dependant on throughput from the reject grid

The dump has variations: the top level is typically weathered coal, yielding around 14 CV (Calorific Value) while deeper levels have 16 to 17 CV. C-grade coal has a specification of approximately 22.5 CV, hence the need for blending at the beneficiation stage. At full ramp-up, Xhawula M3 anticipates that it will crush and screen an average

Based in Tampere, Finland, Metso is a world leader in rock and mineral processing and pioneered the development of track-mounted, fully mobile crushing and screening plants some 25 years ago with the introduction of the Lokotrack series. Each unit is purpose built to deliver the lowest cost per tonne and downstream product quality. On-site at Schoongezicht, the Lokotrack LT1213 is fed by a Cat 336D L hydraulic excavator, with two Cat 966H wheel loaders performing their specific tasks, one to pick up material under the belts, plus stockpile management, and the other for loading into one of Xhawulu M3’s awaiting coal transportation trucks, each equipped with 33 t side tipper trailers.

“Once crushed and screened, this dump has the potential to yield around 2.5 Mt of saleable thermal coal after being washed and blended with a higher quality coal ‘sweetener’” of 80 000 tpm, with the capacity to increase this to around 100 000 t on a 24/7 shift operation. Processing these volumes is the task of a dedicated Metso Mobile track-mounted plant comprising a Lokotrack LT1213 impact crusher and a Lokotrack ST4.8 triple deck screen, supported by a Cat earthmoving fleet for the materials handling and loading requirements. (Barloworld Equipment is the Cat and Metso Mobile dealer for Southern Africa.)

Average material sizes being fed through the crusher range between 400 and 500 mm, with a final product of approximately 50 mm. This stockpiled material is then fed through the ST 4.8 for final sizing, with the triple deck screen having a top, middle and bottom section configuration of 55, 25 and 8 mm, respectively. This is a highly efficient screening process and the percentage of oversize is less than 1%. Sandstone and shale recovered is collected by the mining contractor

Inside Mining 04/2013

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ABOVE Xhawula general manager, Sean Klopper (left), with Barloworld Equipment Metso Mobile sales consultants Grant Gehrung (centre) and Lantie van der Merwe

on-site and sent back to the pit as rollover material for the mine’s rehabilitation phases. Expanding on the features of the Lokotrack LT1213, Barloworld Equipment Metso Mobile’s sales consultant, Grant Gehrung, says a key advantage is that contractors can crush both blasted rock and any mineral-based demolition debris where the need is for constant high capacity. Built around Metso’s proven NP1213M impact crusher, the LT1213 comes to market with two feeder selections, as well as an optional vibrating feeder under the crusher. “Nordberg NP series impact crushers feature a unique combination of heavy-duty rotor, wear material and crushing chamber design elements,” explains Gehrung. “This combination has proved revolutionary in improving capacity, product quality and reducing overall operating and wear costs.” The Lokotrack ST4.8, in turn, is an ideal choice for the accurate classification of up to four end product fractions: three-sized and one dependant on throughput from the reject grid. Both units operate seamlessly via their real-time onboard IC (Intelligent Control) automation software and are remotely operated for maximum on-site safety. “Automation makes it possible to run machines at constant, specific performance rates to achieve the most efficient and preset production outputs,” Gehrung continues. “Additionally, the IC system also prevents overloading caused by process fluctuations, as well as damage caused by misuse. Advanced fault diagnostics immediately pinpoint any potential problem so there’s minimal standing time.” The IC300 intelligent controller on the ST4.8, for example, monitors all functions during the screening process, with immediate machine shutdown activation – as on all Lokotrack units – where a critical fault is identified, safeguarding the overall mechanical system. Screen speed and amplitude, in conjunction with conveyor speeds, are constantly monitored and adjusted, giving higher production rates and more accurate end products. Having the mobility to deploy these Lokotrack units where and when they are needed is certainly one of the greatest cost savings. For Xhawula M3, this in-situ crushing and screening capability means that only commercially viable materials pass over the mine’s weighbridge, while the waste stays behind for collection as rehabilitation material. Klopper points out that it’s a sustainable win-win situation. “Processing the discard dump creates employment opportunities while contributing to South Africa’s energy demand.”

Crush The Coal. Not Your Bank Balance!

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 Comminution

PARTNERSHIPS AND R&D

The future of minerals sorting Sensor technology is emerging as a current trend in minerals sorting worldwide. Comminution and sorting specialist IMS Engineering’s MD, Paul Bracher, speaks to Reggie Sikhakhane on how the company is working toward achieving maximum mineral sorting results with its latest developments.

MS Engineering, part of the Hazemag group of companies based in Germany, has revealed that as a result of inaccuracies leading to loss of valuable materials in the minerals sorting industry, the company has been observing global trends in its efforts to provide mines with value-add solutions. “We have been working on engineered solutions that will improve problems currently experienced in minerals sorting, with our core focus being comminution and separation. IMS Engineering has spent the past few years working extensively towards developing technology that is a ‘first in Africa’, which will give mining houses more value from their operations,” says Bracher.

Sorting solutions The company, which recently signed a joint venture agreement with Cologne-based

Inside Mining 04/2013

Steinert Elektromagnetbau, has developed technology that will allow the separation of minerals using X-ray transmission (XRT) and X-ray fluorescence (XRF) sorting or XSS, optical colour sorting, 3D laser sorting (shape recognition), induction sorting (recognition of particle electromagnetic properties) and near infrared (NIR) sorting, which analyses the reflected NIR spectrum. The XSS-T (transmission) ‘sees’ through the materials, recognising different material densities and components containing halogens and organic components. Composite materials and internal adhesions are also detected. This allows ore-bearing rock to be sorted from the non-ore-bearing rock. XSS-F (X-ray fluorescence) is used to differentiate alloys, metals and ores based on their surface characteristics. In essence, the technology works on X-ray absorption – the larger the atomic mass and the thicker the

ABOVE The Allmineral Allflux operation at an iron ore mine in Swaziland BELOW The new IMS test plant

material, the greater the absorption. “We are very excited with developments regarding this technology. The XRT and XRF are able to measure the atomic property of material using X-ray and infrared,” explains Bracher. A common feature of all Steinert sorting systems is that every single particle in the material flow is recognised and classified. The long, fast-running belt ensures that the particles are ‘singulated’ and homogeneously distributed. As they pass the X-ray source and camera, they are recognised and classified in a fraction of a second according to preset criteria programmed in the flexible system software. If classification matches the previously defined criteria, the particle is ejected by a powerful blast of compressed air out of fast-action compressed-air valves. Bracher says that the accuracy of the XRT and XRF technology will significantly lessen the loss of minerals and ore experienced during normal crushing and separation, saving mining houses time and improving their profits. He adds that the technology can be applied to various minerals, including gold, platinum and coal. Steinert’s global product manager for mining, Johan van Zyl, says he is confident that IMS will make a success of the venture. “IMS

Africa ’s leader in natural resource and development solutions

Engineering is a thoroughly professional organisation with vast experience in the comminution industry in this region.” He adds that the technology will also help junior miners. “This makes our technology ideal in tougher economic periods for more marginal mines where it has been shown to make the difference between closing down and being able to continue profitably. It is perfect for Southern African conditions.”

Allmineral IMS Engineering has also confirmed the integration of Germany-based Allmineral, a leading manufacturer of advanced sorting technology, into the organisation. Hazemag’s parent company, Schmidt, Kranz & Co acquired the controlling share in Allmineral in 2011 and, after a year of strategic planning and preparation, the integration has now been executed. Allmineral already has an existing customer base in South Africa, and IMS sales manager Shannon McKewan says that the synergies between IMS and Allmineral run deep. “The addition of Allmineral to the stable, which already includes Steinert, gives us the opportunity to create a focused and powerful separations business unit.” IMS says the integration of Allmineral, which is recognised as a world expert in the beneficiation of gravel and sand, will enable the company to offer a comprehensive set of

separation technologies and solutions to the regional market, drawing on the power of these two companies. McEwan says that where Steinert specialises in magnetic separation and sensor sorting, including X-ray and 3D sorting, Allmineral provides low-intensity magnetic separation (LIMS), medium-intensity magnetic separation and wet high-intensity magnetic separation (WHIMS). “What makes this arrangement so advantageous to all involved – especially to our customers – is that there is no conflict between the two companies. In fact, their portfolios dovetail perfectly, complementing each other to fill any gaps in IMS’s offering. The tripartite relationship between IMS, Allmineral and Steinert makes us one of the powerhouses in separation technology in Africa,” boasts McEwan. The four flagship products of Allmineral are the Alljig (wet jigging machines for density separation), Allflux (for the separation of slurried fines), Allair (air jigging machines for separation without water) and Gaustec (WHIMS). IMS has already invested in installing Allmineral technology in its test centre in Spartan, Johannesburg. At the industry-leading centre, IMS engineers conduct informative tests with clients’ materials, to ensure that they are able to pick the right sorting solutions for their specific materials. “Sensor sorting is, in general, much more

Tel: + 27(0) 11 441 1111 www.srk.co.za

One of IMS Engineering's new XSS machines

cost-effective than traditional sorting methods,” says Van Zyl. “Apart from saving on water, less energy and labour is required and, perhaps most importantly, because one can sort at the point of extraction, only the ore containing the mineral needs be transported, thus saving significantly on transportation costs. On the partnerships, Bracher adds that the Allmineral/IMS/Steinert union creates a significant advantage. “XSS T works best with particles of 40 mm or bigger and Allmineral’s dry jig works best with particles of less than 40 mm, enabling us to provide an unbeatable overall solution,” he says.

Research and development IMS says its recent research and development exercise, in collaboration with Kawasaki, has resulted in the next generation CYBAS cone crusher, the CYBAS-I.The company says this new design allows for a higher percentage of material passing the setting in the first pass, resulting in lower recirculating loads, which reduces operating costs and energy consumption. Changes to the CYBAS crusher include a redesigned (steeper and longer) crushing chamber, resulting in higher capacity, redesigned crushing plates for improved utilisation, heavy-duty mantle core for increased crushing forces and redesigned drive system for increased power transmission. In addition, the company says the curved crushing chamber of the CYBAS-I enables inter-particle crushing resulting in a cubically shaped product and a high set under, while the grooved inlet ensures that it can crush large lumps of material smoothly and simultaneously and with less slippage. The hydroset design uses a heavy-duty hydraulic cylinder to support the main shaft. This feature, combined with the significant flexibility of the automatic control system, allows easy and automatic crusher setting, tramp relief and crusher utilisation, optimisation and monitoring during operation. However, while the crusher is able to accommodate a substantially larger motor size, the overall weight has been reduced slightly. It has the same footprint and external interfaces as the original enabling retrofitting into existing structures.

A test plant with merit At IMS’s test centre, its engineers conduct informative tests with clients’ materials to ensure that they are able to pick the right sorting solutions for their specific materials. Bracher says that the new IMS test centre will provide initial material testing for XSS sorting. “We take a bucket full of waste and a bucket full of product and check that the sensor can ‘see’ the difference. If it can, we know that more extensive testing, which may entail the installing of a machine on-site, can be undertaken,” he concludes.

 Comminution

NEW VIBRO OPTIMAX WIRE

Improving screen efficiency Following months of research and development, FLSmidth has launched a unique new wire under its Meshcape Screen Media product line, specifically for screening in the quarrying and mining sectors.

he new Vibro Optimax wire was developed by FLSmidth in conjunction with Scaw Metals Group, and the latest trials confirm a significant increase in the life of the screens compared with existing and opposition wire screens. With the innovative new wire, it allows for a reduction in wire thickness and an increase in the open area of the screen that, in turn, improves the screen’s efficiency while maintaining the original life of the screen. FLSmidth added the Meshcape Screen Media product range to its extensive portfolio when this leading global organisation acquired Ludowici in 2012. Ian Hewat, FLSmidth’s Meshcape Screen Media industrial manager, explains that continuous R&D remains a key focus with this product line. One of the specialities has always been developing customised screen solutions for specific customer applications. “The recent acquisition by FLSmidth means we now have access to the kind of robust backing that underpins our R&D strategy.” Hewat adds that there is a real need to reduce costs in the quarrying sector, and one of the major ways to achieve this is by reducing the production cost, hence reducing the cost per tonne. He says this can very often be achieved by a full-scale professional audit

of the plant machinery to balance and maximise its performance and identify the best possible screen solution, relative to cost. This kind of audit will, among other things, identify optimal machine settings, such as speed and stroke, to obtain the correct g-force and minimise pegging and blinding. “There’s also a definite lack of skill when it comes to selecting the most appropriate screen media for quarrying operations, while precise installation of screen media is also very important to mitigate costs,” he continues. “Consequently, our field service team is in such demand that we regularly need to add new members. This team works alongside our customers on-site to reduce costs, resolve issues and increase operating efficiencies and to support maintenance contracts and offer site-specific solutions. Team members have the unique advantage of being able to draw from the broadest range of screening media in the country from a wide variety of applications. “We call this solution-oriented approach ‘value added selling’ – where the added value lies in our extensive technical know-how that ensures the correct screen media are in place, that efficiencies remain high and quarrying personnel receive the necessary training. We have more than 100 years of service in

ABOVE Meshcape Vibro Optimax screens awaiting dispatch to a customer INSET This photograph illustrates a correctly installed double camber application (Note there are no J bolts on the screens)

the quarrying and mining sectors and have encountered just about every operational issue possible. FLSmidth also has the in-depth expertise to offer viable screening solutions every time.” With branches in Kimberley, Durban, Port Elizabeth and Cape Town, as well as sales representation in all other areas throughout South Africa and in the rest of Africa, FLSmidth produces its Meshcape Screen Media at its comprehensively equipped ISO certified manufacturing facility in Edenvale. This facility manufactures, distributes and exports polyurethane screen media, perforated material, wedge wire, woven wire, fine mesh, wear resist products and wire belt products, providing screen media to a broad cross section of other markets, such as food, architectural, petrochemical and heavy engineering.

Inside Mining 04/2013

 Pyrometallurgy

FERROCHROME FLOURISH

Fuelling ferroalloys The market for local beneficiation of chromite ore at South Africa’s ferrochrome smelters has mushroomed recently, thanks to the volume required to make stainless steel (18%) and the country’s vast chromite reserves – the largest in the world. An Inside Mining exclusive.

articipating in this growth, Metix has emerged as one of the world experts in ferrochrome smelting technology and the Southern African specialist for ferroalloy AC submerged arc furnaces. “Thanks to our merger with SMS Siemag at the end of 2011, we have also been able to combine our reference lists,” says Metix’s MD, Reinier Meyjes. “And while SMS Siemag has hundreds more references than us, if you look at the combined references for the past six years, a significant percentage is ours,” he adds. Metix’s marketing director, Pat Davies, and Meyjes started working together at chrome mining and ferroalloys producing Samancor back in 1974. “We built an 81-MVA ferromanganese furnace in Meyerton in 1978. At the time, the company intended to build several more, but only one was ever completed. Ferromanganese is used in most carbon steels in the 2% range. At the time, however, it seemed more cost-effective to export the ore for processing closer to overseas steel

Inside Mining 04/2013

plants than to export ferromanganese,” Meyjes explains. More recently, Metix has started adding numerous new ferroalloy projects to its portfolio. The recently completed upgrading of International Ferro Metals’ two 66 MVA ferrochrome furnaces included new copper centre sections for the furnace roof, additional charging chutes equipped with solid copper feed chute tips and modifications to the four furnace gas cleaning plants. The uprating of the electrode columns on two existing furnaces at Xstrata Alloy’s Lion ferrochrome plant and the replacement of electrode columns on another two furnaces at Xstrata’s Wonderkop plant is another impressive feat for Metix. A 600 000 tpa chromite ore pelletising and sinter plant, part of the Tswelopele project being constructed for the Xstrata Merafe PSV in Rustenburg, is the sixth chromite pretreatment plant constructed by Metix since its formation in 2003. Globally, Metix technology and design engineering is the basis for the biggest

silicomanganese furnace in China for mining and beneficiation company CYMCO, which is now in production in Jianshui. The 67.5 MVA furnace is equipped with the full range of Metix technology equipment: a set of electrodes, a furnace roof with a copper centre section and a furnace shell with a freeze lining. Describing Metix’s modern furnace technology, Meyjes cites the recently completed IFM refit: “Energy efficiency has become more important than anything else in the furnace industry in recent times. By using less energy, you can produce more from a plant with a given installed capacity. This results in a double competitive advantage because by using less energy, the operating cost per tonne also decreases proportionally,” he explains. And while improving energy efficiency is important, another key driver is to improve the availability of the plant. Downtime kills profitability and all furnaces need to be constantly running at near to their installed capacity in order to remain competitive.

 Pyrometallurgy LEFT Energy efficiency has become more important than anything else in the firnace industry Photograph courtesy of Bloomberg RIGHT 10 MVA single phase transformers for No 2 furnace at Zimasco

“Because the IFM furnaces were originally not one of our designs, the first thing we did to improve their efficiency was to improve the incoming feed of the furnace burden.” In ferroalloy furnaces, the feed material (burden) is fed into the furnace through charging chutes around the electrodes at the top. The ore is heated, melted and reduced as it moves downwards. Then the molten ferroalloy and slag are tapped off via tap holes. The smelting (reduction) process gives off very hot carbon monoxide (CO) gas, which rises up through the solid material of the burden. “Typically this gas is above 1 000°C and by transferring as much of its sensible heat as possible to the burden entering the furnace, the smelting efficiency of the whole process benefits in two ways. First, less electrical energy is required to smelt the hotter burden, and second, less energy is transferred to the water in the scrubbing plant,” Meyjes explains.

Using 3D modelling for burden profiles and CFD for gas flow analysis, the shape of the burden surface and potential for improvement of gas flow above the burden is studied. Through this process, Metix is able to determine the best arrangement and number of feed chutes into the furnace, even out the burden profile, maximise the recovery of

sensible heat from the off-gas and reduce the temperature of the gas entering the scrubbing plant by several hundred degrees. In addition, because the roof is a fully enclosed design, the CO off-gas is not combusted in the furnace. After scrubbing, it can therefore be used to generate power. IFM has installed a cogeneration plant to make best

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 Pyrometallurgy LEFT Preassembled Hernic roof copper sections

use of the energy available from combusting this off-gas. It uses 10 gas engines to recover a total of 11% of IFM’s power demand. “If you don’t use this gas, it would simply be vented to the atmosphere and flared after scrubbing, but every megawatt that you can feed back into the grid indirectly reduces the energy consumption of the furnace and the investment moves into cost-effective territory,” Meyjes suggests. As an additional spin off, by reducing the temperature of the off-gas as it comes through the burden, the performance of the gas scrubbing plant is enhanced. Because of emissions legislation, producers are not allowed to run a furnace unless the gas is cleaned. “A shutdown in the gas scrubbing plant results in the furnace being shut down,” he continues. Metix has introduced an improved design to quench the off-gas leaving the furnace, “which allows the venturi system removing the particulate from the gas to become more effective.” Typically, in the venturi system, gas is accelerated through a narrow opening BELOW Modified IFM furnace

Inside Mining 04/2013

of the venturi where it is contacted with water. The energy in the venturi throat breaks up the water into small droplets about the same size as the solid particles in the gas,

“By using less energy, you can produce more from a plant with a given installed capacity. This results in a double competitive advantage because by using less energy, the operating cost per tonne also decreases proportionally.” Reinier Meyjes which reduces the surface tension of the individual droplets facilitating efficient capture of the small dust particles. If the temperature of furnace gas entering the venturi scrubber is too high, it evaporates the small water droplets (into steam), which then cannot capture small solids that form solid accretions in the duct following the venturi. The quencher’s

role is to reduce the off-gas’ inlet temperature to enable the venturi to do its job properly. The duct between the quencher and the furnace is designed to be removed for easy, safe cleaning and ducts after the quencher are kept clean by continuous water sprays. “Because IFM no longer has to regularly shut down its gas scrubbing plants to clean out dust build-up, furnace availability is significantly improved,” says Meyjes. The big development for ferrochrome and silicomanganese furnaces, however, involves closing the roof, and Metix’s use of copper, which improves the reliability of closed furnaces. “Almost all new furnaces are built with a closed roof, but we still have many that were previously built using a semi-closed roof design,” Meyjes advises. “These are ready for upgrading, but a rebuild takes time

(up to three months) and the downtime cost is a killer for such projects.” For the ferrochrome sector, semi-closed furnaces have fallen out of favour due to the formation of toxic chromium-six compounds. There is no way to avoid the formation of these compounds in a semi-closed furnace. By converting a furnace to a fully closed design the benefit is two-fold: avoiding forming and dealing with chromium six and preventing burning CO in the furnace gas to CO2, which is ideal for cogeneration. Published performance improvements at IFM as a result of Metix’s recent upgrade to the company’s two 66 MVA ferrochrome furnaces show that by January of this year, the company had already achieved 12% of its target production cost savings. Also, according to IFM reports: “The furnace rebuilds were all completed within budget and on schedule.” SMS Siemag technical sales director, Dr Rolf Degel, says: “Due to the remarkable success of Metix in the local market over the past eight years, SMS Siemag is fully comfortable with the current management and structure of Metix. The SMS Group has full confidence and trust in the capabilities of the Metix management team.”

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 Pyrometallurgy

FERROALLOYS FEVER

Expertise meets client support Tenova Pyromet, a Tenova Mining & Minerals company, has launched a worldwide client support service to the users of its key technologies, providing post-project and aftermarket assistance to enable furnace operators to maximise their operational efficiencies.

omprehensive client support service ranges from on-site technical assistance through to supply and installation of copper products and spare equipment, on-site assistance during shutdowns and rebuilds, close-out of capital projects and support to clients with cold and hot-commissioning. Operational training for clients on furnace equipment and technical training on equipment maintenance are also offered.

“Tenova Pyromet’s client support service brings together the company’s existing aftermarket/post-project services, which fall into three broad areas: post switch-in technical support, copper products and spare equipment, and technical assistance with close out issues. With each of these having the shared objective of maximising reliability and efficiency of clients’ smelting operations, integrating them into a singular client support service makes great sense,”

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 Pyrometallurgy says Werner Roberts, manager: Tenova Pyromet Client Support. The new service offers the furnace industry Tenova Pyromet’s in-depth knowledge and experience in ferroalloys and base metals smelting processes, complemented by its extensive list of successful furnace projects worldwide, through people who have deep and broad smelting and maintenance backgrounds. “Tenova Pyromet boasts a unique source of process, engineering and development capabilities, a key advantage of the client support service, with this expertise immediately on-hand to resolve client technical issues,” notes Roberts. “As a specialist in the supply of AC and DC furnaces and complete smelting plants, we have developed an intimate understanding of our clients’ technology and technical support needs through leveraging off the client knowledge and understanding that we have gained through our ongoing client interactions. This enables us to provide a proactive service for ensuring that clients’ furnaces operate at optimum availability.”

The service also provides Tenova Pyromet with an invaluable channel for clients to feed technical information relating to their experiences back to the company’s furnace process design and technology capabilities areas. This enables Tenova Pyromet to stay at the forefront of industry improvements and developments. “In this highly cost-sensitive industry, we see a strong need for continuous improvement in our process design and technology capabilities. Experience from the field and client collaboration is critical for our achievement of this,” says Roberts. Tenova Pyromet is committed to rapid enquiry response handling and to providing full progress reporting throughout the duration of any service process, such as the delivery of spare equipment. “Tenova Pyromet’s spares service is not limited to the supply of proprietary spares. It also covers a full range of industry spares, providing clients with the ease of ordering their full suite of start-up and operational spares needs from a single source. In addition, the company offers clients full contracting flexibility, based

on clients’ general preference for turnkey solutions, ranging from manufacture and procurement of spare equipment through to installation and commissioning,” notes Roberts. The Tenova Pyromet Client Support Service is being promoted via roadshows, which will be held at the beginning of every year. “Our aim is to liaise with our clients through these roadshows in order to give them sufficient time to assess their needs for our services, in time for their rebuilds and outages, which traditionally take place from May to August in South Africa,” concludes Roberts. Who is Tenova Pyromet? Tenova Pyromet is a leading company in design and supply of high-capacity AC and DC furnaces and complete smelting plants for production of ferroalloys, base metals, slag cleaning and refining. Tenova Pyromet also designs and supplies equipment for material handling and pretreatment, alloy conversion and refining, granulation of metal, matte and slag, furnace off-gas fume collection and treatment, and treatment of hazardous dusts and waste. Tenova Pyromet has several technologies to reduce operating costs and production power consumption.

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 Pyrometallurgy

REFRACTORIES REVISED

130-year-old Verref’s face lift The Verref group of companies has positioned itself to meet the needs of the pyrometallurgical industry through its revised business model and new business units – all aimed at providing cost-effective solutions to a wide range of refractory-related problems.

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 Pyrometallurgy

ur strategy is to provide the industry with solutions to its refractory problems, from design, specification, installation and use through to disposal. This is achieved by building long-term relationships and partnerships with suppliers, customers and any third party involved in the value chain,” says Verref Shaped’s MD, Dennis Braizer. Vereeniging Refractories, better known as Verref, has been supplying the Southern African pyrometallurgical industry with refractory products for over 130 years. Over the past six months, as part of a renewed strategy, the refractories company has been unbundled into three separate entities, which according to Braizer will better serve the refractory industry. “This process will result in business units that are focused on developing refractory solutions within their areas of expertise.” These business units are Verref Shaped, Verref Elgin and Verref Trade. Verref Shaped will produce a range of Basic and aluminosilicate refractory bricks out of its Vereeniging and Springs plants. In addition to refractory brick, a range of

basic monolithic and recovered refractory products, hollowware products, acid-resistant brick and tiles, and insulating bricks are also available. A technology centre, staffed by metallurgists and refractory engineers, is available for all refractory test work needs form the industry. In addition, refractory training courses have been developed to assist in improving the skills of customer employees in refractories. Verref Elgin produces aluminosilicate monolithic products out of its Springs operations. In addition, the business unit has a precast and installation section for small to medium refractory items and installations. This feature has become important with monolithic products where installation can impact on ultimate product performance. Verref Trade is a new business unit that trades in refractory products sourced locally and from China. These products range from basic and aluminosilicate bricks, silicon carbide products, basic monolithic products, certain refractory raw materials, slag conditioners and graphite products. Verref Trade has entered into a joint venture agreement with Yingkou Heping Samwha Minerals Company, based in China, for the supply of

LEFT Verref's expansive footprint in Vereeniging ABOVE Inside the Verref facility

the majority of the products. “The needs of our customers are changing faster than ever before, and we are well positioned with our new strategic focus to exceed these consistently,” Braizer concludes.

 Materials handling

BIG ON BEE

Big on rollers The official March 2013 announcement of a 25% +1 share BEE transaction, in relation to its South African operations, signals the emphasis that internationally recognised conveyor equipment manufacturer Melco places on transformation, says its marketing and sales director, Craig Warmback.

elco acknowledges the importance of maintaining its competitive edge with customers by ensuring that it can assist them in reaching their procurement compliance targets set out in the Broad-Based Socio-Economic Charter for the South African mining and minerals industry, Warmback outlines. Melco is a major conveyor equipment manufacturer and since 2006 has been a member of Rulmeca – a worldwide group of companies that specialises in the production of rollers/idlers, motorised pulleys, fabricated pulleys and components for the bulk handling industry. “Melco is committed to complying with the ownership requirements of the Department of Trade and Industry, BEE Codes of Good Practice, and has and will continue to participate in opportunities to facilitate significant and sustainable growth for the business, as well as for individuals in the surrounding communities of Melco’s operations,” he says. As a result, Melco has established a broadbased community trust – the Dukathole Community Trust – that became a 25% + 1 share shareholder in Melco on 4 March 2013. The participation in the equity of

Inside Mining 04/2013

Melco is aimed at expanding opportunities in the community, particularly for individuals in the community. Warmback adds: “Melco looks forward to partnering with the Dukathole Community Trust in furthering its objective of development of the community and its business.” Melco idlers have been successfully utilised in numerous bulk materials handling applications in over 75 countries throughout the world and are installed on belt widths from 200 to 3 000 mm. The Melco roll product range is comprehensive, ranging from 89 to 215 mm in diameter, with bearing and shaft arrangements from 25 to 60 mm diameter.

Strength in surface mining applications The company has established a particularly strong reputation for being a preferred supplier of idler sets for overland conveyors, plant conveyors, stackers and reclaimers to surface mining operations in Africa, with a significant portion of the company’s business being generated by high-profile clients in the coal, iron ore, manganese and diamond mining sectors of the market. Melco supplies complete idler sets to the mining industry, which are all produced

ABOVE Conveyors from the input crushers to the ROM bunker BELOW Melco is a preferred supplier of idler sets for overland conveyors

locally at the ISO 9001:2008 accredited Melco manufacturing plant in Germiston, Gauteng. Warmback highlights the fact that the frames are manufactured from either structural angle steel or tubular steel, to the customer’s exact specifications. “Melco was the first local manufacturer to make the belt-friendly frame that significantly reduces the risk of damage to the belt.” According to Warmback, Melco’s range of state-of-the-art retractable V-returns idlers has gained increasing popularity in surface mining applications. “The Melco retractable V-return idler design consists of a permanently installed main frame, sloping at a 10-degree angle to the horizontal belt, with end plates and a cut out. The roller is attached to a retractable frame that slides into the main frame at a 6-degree angle, which

The most valuable resource that comes out of the mine each day is the one that goes in.

ensures that it drops away from the belt as it is retracted. This ensures improved safety due to the fact that the belt does not have to be lifted.” Warmback points out that this innovative design enables a single workman to pull out a roller frame, which can be more than 1 m long, while standing on a standard 750 mm walkway. “In order to undertake this process, the workman needs to unbolt the sliding frame from the side of the main frame and pull out the sliding frame. After replacing the roller, the frame is returned to its operating position,” he continues. The Melco retractable V-return idlers are installed on conveyors at Exxaro’s Grootegeluk coal mine, which will supply Eskom’s Medupi power station in the Limpopo province with an average 14.6 Mtpa of thermal coal over the next 40 years. Grootegeluk is expected to be the largest coal operation in the world, producing up to 33 Mtpa of thermal, coking and steam coal. Melco’s overall scope at the project is divided into two phases, namely: • Phase 1: This includes the supply of six conveyors, including belt feeders, moving heads, garlands and impacts, 1800 BW and 2100 BW, 140 retractable idlers, 7 646 rolls and 2 144 frames. • Phase 2: This includes the supply of 65 conveyors, 600 BW to 2100 BW, 1 322 retractable idlers, 51 000 rolls and 13 125 frames. Warmback explains that the stringent safety requirements at the mine necessitated the need for return rollers to be safer to replace when damaged or worn. “The return belt runs directly underneath the loaded trough, and Melco was approached in 2010 to design a retractable idler that would make it easier and safer for workers in this challenging working environment.” To replace a roller, a team of workmen wearing safety harnesses has to climb inside the conveyor gantry, lift the return belt clear of the roller, then uncouple and remove the heavy roller. There are also sometimes other complications to take into account, like underpans, which prevents any material from the loaded belt from falling to the ground. What’s more, Melco has supplied R2.3 million worth of conveyor components to the US$3 billion (R27.88 billion) Cut-8 extension at the Jwaneng opencast diamond mine in Botswana, which is the

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 Materials handling

“As investment continues to rise in numerous industrial sectors in Africa, so too will the demand for high-quality operational equipment.” Craig Warmback largest by value in the world. This establishment of the Jwaneng Cut-8 project represents the single largest private investment in the history of Botswana and will extend the life of the mine to at least 2025, while unearthing diamonds worth an estimated US$15 billion during that time frame.

The scale of the Cut-8 extension project has catapulted Jwaneng to ‘super-pit’ status, as the depth of the mine will increase from 330 to 624 m by 2017. In total, more than 700 Mt of waste earth is expected to be removed in order to reach the kimberlite deposit. Melco’s involvement in the project began in December 2009, and to date the company has supplied the project with 1 700 frames and 6 250 rolls for 1 200, 1 500 and 1 800 mm belt widths with an approximate mass of 110 t. Warmback points out that the company was contracted by material handling solutions expert FLSmidth Roymec, which placed the orders for the idlers in April LEFT GG7 & GG8 plants at Grootegeluk in the foreground with the older GG plant in background

2010, with the manufacture and supply of the idlers being completed by September 2010. Melco has been supplying products to Debswana since 1995 and the company has worked on at least 12 different projects since then. Looking to the future, Warmback is optimistic of the general outlook for the African bulk handling industry. “As investment continues to rise in numerous industrial sectors in Africa, so too will the demand for high-quality operational equipment. With this in mind, I believe that Melco can experience measurable growth in the long-term, thanks to the company’s excellent reputation in the industry,” he concludes.

 Materials handling

FOOD FOR THOUGHT

Conveyor belt fire protection The movement of materials for mining is of critical importance and conveyors continue to showcase their advantages. The need to protect them against fire is equally as important.

imply put, conveyor systems are the ideal solution to transport managed sized material from one processing point to another, such as an underground mining operation to a processing refinery or from a silo to a packing plant. The reliance on manpower is minimised and reliability is maximised with the use of conveyor systems, provided protection measures are taken to reduce the chance of mechanical or electrical failure. A key protection area considers the issue of a conveyor belt system fire. Methods for

the protection of conveyor belt systems have improved immeasurably in some areas, but have largely stagnated in others. The essential philosophy behind conveyor belt fire protection revolves around the preservation of the conveyor belt system structure. A fire can weaken the metal structure, in some cases to a point of collapse. Detection methods have evolved since the 1940s thermocouple hoods. The use of spark and ember detectors has proved ineffectual. They often cause false alarms from reflective light or solar emissions. Also the monitored

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bandwidth that would result in an alarm is quite narrow and early stage combustion cannot always be detected. The sources of conveyor belt fires result from static heat build-up from friction caused by belt movement over a jammed idler, for example, or moving fire on the belt itself. For early detection of static type fires, linear heat detection cable has proven to be reliable when correctly installed. Combined, linear heat detection cable and thermal energy black body fire detectors offer the most comprehensive solution to detecting fires on conveyor belt systems. If installed properly, they can be integrated into a water extinguishing system.

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 Materials handling

TURNKEY CRUSHER TECHNOLOGY

Exceeding big tonnage expectations ThyssenKrupp Materials Handling (TKMH), a division of ThyssenKrupp Industrial Solutions South Africa, supplies a wide range of robust stationary, semi-mobile and mobile crushers with throughput rates exceeding 4 000 tph to meet primary and secondary crushing requirements.

he Level 4 BEE South African subsidiary of the worldwide operating group ThyssenKrupp Fördertechnik is a specialist manufacturer and supplier of bulk materials handling equipment and plant to the local mining and processing industries for over 50 years. “We offer turnkey solutions, from 2D and 3D CAD design, FEA and DEA, to final commissioning and after-sales service, supported by our vast engineering expertise,” says TKMH’s sales manager, Matthias Göing. The company’s extensive crusher range includes jaw, mineral sizers, cone, gyratory,

Inside Mining 04/2013

jaw gyratory as well as mineral crushers (horizontal and vertical shaft) and hammer mills. “Our crusher expertise extends to design, manufacture, import, assembly, installation, commissioning, manufacture as well as export,” continues Göing. The range of efficient single-toggle and double-toggle TKMH jaw crushers are ideal for the primary crushing of medium-hard to very hard material, such as blasted rock pile. “Depending on the blast method used, these jaw crushers can achieve edge lengths of more than 2 000 mm,” explains Göing, adding that fields of application include

quarries, ore mines, recycling plants and gravel works. In cases where a high-size reduction ratio and cubical stress-free end product are required, such as limestone, gypsum, slag, overburden and aggregate materials, Göing recommends impact crushers. “With an operating range that includes both coarse and fine crushing of medium-hard to hard material, the impact crushers are designed for throughput rates extending to above

TKMH impact crusher

 Materials handling 4 000 tph and is ideally suited for various materials and applications in quarries and mines.” According to Göing, the numerous features of the TKMH crusher range offer cost and time saving benefits for rapid return on investment and lower total cost of ownership over the machine’s life time. These include: • robust construction and a best possible and uniform stress distribution ascertained by means of the finite element analysis, extend crusher service life • high throughput rates, thanks to an optimised geometry of the crushing chamber, prevent arching and material build-up • automatic or semi-automatic gap adjustment (depending on customer demands) ensures best possible product quality • registration of the operating data by a control- and diagnosis system (visual crusher) increases the availability rate and records data for further development of the machines • standard or heavy version options, ensuring smooth adaptation to hardness and compressive strength of the feed material

• quick and easy maintenance, which reduces downtime and optimises productivity. TKMH capabilities also extend to the supply and installation of ancillary equipment such as structures, chutes and feeders, screens including grisly screens, separators, pit civils and front-ends, cyclones, liners, etc.

“From planning and design; manufacure and delivery to site; on-site commissioning, supervision and annual shutdown service; maintenance contracts and the supply of spares; components and wear parts; the scope of our services ensures complete turnkey solutions,” concludes Göing.

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FLSmidth is your One Source for crushing, grinding, classifying, thickening, clarifying, slurry handling, flotation, mine shaft systems, pyroprocessing, material handling, automation, screens, centrifuges and complementary products, engineering, metallurgical testing and modernisation services. FLSmidth offers you a complete line of equipment and services with proven reliability and enhancing performance from the leading brand names of ABON, Buffalo, CEntry, Conveyor Engineering, Dawson Metallurgical Laboratories, Decanter Machine, Dorr-Oliver, EIMCO, ESSA, FFE, Fuller-Traylor, KOCH, Knelson, Krebs, Ludowici, Maag Gear, Mayer, Meshcape, MIE, Möller, MVT, PERI, Phillips Kiln Services, Pneumapress, RAHCO, Raptor, Roymec, Shriver, Summit Valley, Technequip and WEMCO. Enjoy increased recoveries while saving time and money on your next project! Let us help you tackle your specific requirements. For more information contact us Tel no. +27 (0)10 210 4000 • flsm-za@flsmidth.com • www.flsmidth.com

Breakthrough mining solutions.

Long recognised for our ability to engineer efficient and reliable equipment, Joy Global is taking mining to even higher levels through the enhancement of cost-focused technologies. Our proven solutions and worldwide customer partnerships allow us to continue to lead the way in developing results-driven equipment and unmatched customer support â&#x20AC;&#x201D; all at the lowest cost for mining operations. joyglobal.com