Inside Mining April 2015

www.miningne.ws

af r ic an u pdates on th e

in the

spotlight WOMEN IN MINING Overcoming prejudice

MINING 2015

g ro un d a n d un d e rg ro un d

MINTEK

Setting the pace of

innovation

Mergers & acquisitions

IRON & STEEL Supply exceeds demand

GREENFIELD

Dealing with trees

simandou

The El Dorado of iron ore

AFRICA

Dormant opportunity

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 8 • No. 04 • April 2015

contents Endorsed by

Af r ic a n u pdates on th e

April 2015

g rou nd a nd u nderg rou nd

on the cover

www.miningne.ws

a fr ic a n u p date s o n t h e

IN ThE

SpOTLIGhT WOMEN IN MINING Overcoming prejudice

MINING 2015

gro u n d a n d u n d e rgro u n d

MINTEK

Setting the pace of

innovation

Mergers & acquisitions

IRON & STEEL Supply exceeds demand

GREENFIELD

Dealing with trees

SIMaNDOu

The El Dorado of iron ore

aFRICa

Dormant opportunity

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 8 • No. 04 • April 2015

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P4

Proudly among the world’s leaders in technological development, you will find South Africans. Taking its place in this group is Mintek, an organisation whose exemplary work has produced a number of significant technological innovations.

EDITOR'S COMMENT

3 Steeling the future COVER STORY

4 A leader in pyrometallurgy Africa round-up

8 News from around the continent in the spotlight

9 Women in mining ECONOMICS, FINANCE & RISK

12 Mergers and acquisitions 15 Steel: Supply exceeds demand FERROUS & NONFERROUS MEALS

16 Coal and steel: A match made in heaven 19 The El Dorado of iron ore 16

epcm

21 Dormant opportunities PROJECT MANAGEMENT

24 The key to success drilling & blasting

25 Innovative safety and productivity improvement MINERAL PROCESSING

27 Integrated solutions 28 Waterless vertical roller mill 29 Order from chaos 32 Energy breakthrough TECHNOLOGY

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34 Dealing with trees 35 Planning a crane lift 36 Plastic: The better option 37 A mill of a different kind 38 Preventing arc flash HEALTH & SAFETY

42

39 PPE inequalities 40 Preventing injury and death 41 Seeing at depths, and in the dark 42 Defying gravity 44 Mine rescue preparedness In sid e M in in g 0 4 | 2015

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editor's comment page strap Publisher Elizabeth Shorten Editor Tony Stone Editorial assistant Mpinane Senkhane Head of design Beren Bauermeister Designer Ramon Chinian Chief sub-editor Tristan Snijders Sub-editor Morgan Carter Contributors Quintin Hobbs, Robbie Cheadle, Mpinane Senkane Client services & production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Marketing & digital manager Esther Le Roux Marketing specialist Philip Rosenberg Financial manager Andrew Lobban Administration Tonya Hebenton Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham Printers United Litho Johannesburg Tel: +27 (0)11 402 0571 ___________________________________ Advertising Sales

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South Africa: R550.00 (incl vat & postage) African countries: US$80 Foreign: US$100 Email: subs@3smedia.co.za ISSN 1999-8872 Inside Mining Copyright 2015. All rights reserved. ___________________________________ All material in Inside Mining is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the publishers.

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Steeling the future

W

hile knowledge is powerful, knowledge ignored is stupid. In this case, it’s excess capacity. The question is, did we do our homework (market research)?

As we learn from Ernst & Young, about 300 million tonnes of steelmaking capacity needs to be closed for the global industry’s profit margin to reach a sustainable level, and raise the capacity utilisation rate for the sector, from below 80%, to more than 85%. However, who will be willing to close down their steelmaking capacity?

This problem could – and no doubt will – unleash a gaggle of problems for the industry. Nevertheless, in this case, a Darwinian ‘survival of the fittest’ applies. In modern speak, it means being ‘productive’ and ‘comThe next 12 to 18 petitive’, not just on price but on product quality and service. An example of this is our own homemonths will see some grown mineral research organisation, Mintek – the merger and acquisition 80-year-old collaboration between government, the University of the Witwatersrand, and the Uniactivity, with junior versity of Cape Town. miners on the menu This leading provider of minerals processing and metallurgical engineering technology has delivered outstanding innovations over the years, some of which have been utilised around the world, such as the DC arc furnace. May they forever continue their good work! No doubt, over the last 80 years, there have been good times and bad times. Economically speaking, and in analysing the data, we discover a truth: what goes down goes up again. Right now, it seems, we are down but looking at the climb ahead. It’s at times like these that we need to be sensible, yet bold and confident. What is that old adage? When the going gets tough, the tough get going? Even so, the next 12 to 18 months will, without a doubt, see some merger and acquisition activity, with junior miners on the menu. It would be good to bear in mind the fact that, despite the challenges, real entrepreneurs never give up. They make a plan, and pull through.

One group of people who have fought the fight and have never given up are women. Since their emancipation way back when, women have proved their worth time and time again. Even so, with mining being a traditional man’s world, especially in South Africa, women are beginning to feature, more and more.

Even deep underground! Sadly, though, in a country that is governed by an internationally acclaimed constitution, and where equality before the law is paramount, with no discrimination allowed, cultural prejudice rears its ugly head. Women are told by men that they do not belong underground. These men are wrong. These men must be educated, and need their attitudes changed. What is even more abhorrent is that (at least two) women have been raped underground. This cannot be allowed. The perpetrators must be brought to book and punished to the full extent of the law. Moving on from this unfortunate reality, South Africa has much to offer Africa and the world in terms of technology and human resources. There are many examples that highlight why local companies are being bought out by international players. Fortunately, some of our innovators, such as BME, remain proudly South African. We must be sure to retain our skills and not throw the baby out with the bathwater; otherwise we will be left with very little, which the incompetent, by virtue of their limited capabilities, will make a botch-up of.

@mining_news www.facebook.com/ pages/Mining-News

In sid e M in in g 0 4 | 2015

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cover story

A focus on

upgrading UG2 ores Marikana platinum mine

High-calibre research by Mintek enables the effective utilisation of natural resources through the development and adoption of new technologies, as well as the reapplication of existing technologies in new operations.

T

he strategic vision in the 70s, within the industry, was that there was going to be an increased demand for platinum to support the expected growth in the autocatalyst industry, as environmental issues became more important. It was considered unlikely that the demand could be met by the depleting Merensky reserves or from the Eastern Bushveld, where significant infrastructure investment would be required. Attention was thus focused on the extraction of the PGM values from the UG2 ore. At the time, the major concern about the UG2 ores was that it would be difficult to treat the concentrate in a traditional matte sulfide process, as the Cu-Ni sulfide values were low and the chromite values high. Furthermore, the poor association

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in certain cases of the PGMs with the base metal sulfides (BMSs) and the small PGM sizes was interpreted as indicating that the concentration of the PGM values into a flotation concentrate would be difficult.

Over an extensive period, Mintek, in conjunction with Lonmin, was able to show that a process could be developed to exploit the UG2 ore commercially. In the process, Mintek developed expertise in characterising the UG2 ore, developed mineralogical and assay techniques, and demonstrated proficient pilot plant building and operating capabilities. As the UG2 ore became an increasingly important resource in the industry, Mintek continued to invest in understanding the mineral processing of this orebody. Extensive research work in understanding the interaction between the

gangue minerals and reagents was undertaken.

An innovative approach to UG2 processing plant design was the introduction of the mill-float-millfloat (MF2) concept, and the removal of a chromite fraction from the primary rougher tail. Both developments were based on mineralogical observations that indicated that the bulk of the PGM values in the ore were liberated at a coarse grind of 35% (75 μm), and there were significant associations of PGMs on the grain boundaries of base metal sulfides. A significant portion of the PGMs were locked in the silicate phases and required fine grinding for liberation. It was also shown that the chromite grain size enabled the production of a high-grade chromite product by spirals that did not contain significant PGM values.

From laboratory work on plant cleaner tail streams, it had been demonstrated that the PGMs could be recovered by the addition of high depressant dosages and the use of long flotation residence times.

From this observation was born the concept of the ‘Mintek Process’, which uses a single integrated cleaning circuit with the production of high- and low-grade concentrates to improve the PGM recovery to the overall concentrate by up to 5%. The concept that there were fast and slow floating PGM and gangue values in an ore was used to design the flotation plant configuration such that the fast floating PGM values were removed to the high-grade concentrate, and the slower floating PGM values to the low-grade concentrate. The subtleties of the process were the realisations that one needed to accentuate the differences between the slow floating PGMs and gangue through depressant addition, but that one also needed to create the appropriate froth

cover story

structures to facilitate adequate froth drainage to minimise chromite entrainment into the concentrate. Coupled with this concept was the realisation that one should not recycle any streams to the rougher circuit and that one should minimise the recycle loads in the cleaning circuit to ensure high overall PGM recoveries. It was felt that the highest probability of floating the slow floaters was during its first pass through the cleaning circuit and every effort should be made to recover it and, if allowed to recycle, it would probably be lost to an eventual bleed out to the final tail. At the same time, it was also realised that, to run long residence times in the cleaning circuits, one needed very tight control of froth height and air rate to ensure that the pulp carry-over into the flotation concentrate was minimised. Out of this knowledge, Mintek developed the Floatstar platform, which controls operating flotation pulp levels more consistently than previous manual attempts.

After a quiet period where the then producers continued development independently, Mintek reactivated its interest in PGM mineral processing flowsheet development when Craton Resources approached Mintek in the mid-90s on behalf of Aquarius, an Australian junior mining company, to assist in the evaluation of some UG2 orebodies in the Kroondal-Rustenburg area. As a small potential PGM producer, with limited access to capital, Kroondal needed to be innovative in its approach to the mining and metallurgical aspects of the project.

Mintek was intimately involved with Dowding Reynard and Associates with regard to the metallurgical performance of the process. Through various pilot plant campaigns, it was shown that dense media separation was a viable process for the rejection of barren waste rock. It was also shown that rod mills could be used effectively to produce grinds of 35% (75 μm) and that the bulk of the PGMs was liberated at this grind. It was also shown that the plant could start up with a single-stage mill rather than the more expensive option of two-stage milling. As Kroondal had difficulties in finding a market for its concentrate, attritioners were installed to enhance the product quality.

A significant database of experience at Mintek has indicated that there is no generic UG2 deposit or flowsheet, hence validating the need for piloting testwork.

During pilot campaigns, spirals, attritioners, dense medium separators and fine grinding mills were integrated into UG2

Some of the highlights of the work conducted include: • development of the ‘Mintek Process’ for maximising PGM recovery for UG2 ores • development of a flotation predictor, based on detailed autoSEM characterisation • conversion of the UG2 milling circuits to open circuit • development of a robust pilot plant facility for use in plant design studies • use of dense medium separation as a waste rejection option • use of attritioners in flotation circuits • development of a flowsheet for Platreef ores • use of sensor-based sorting technology for upgrading platinum ores • use of a mini-plant for reagent optimisation studies.

flotation circuit flowsheets, each being supported by the specific mineralogy of the ore or stream being treated. As the experience in processing technology for UG2 matures, process optimisation, to make marginal incremental improvements in recovery and reduce costs, continues. Some of the technology improvements include the move to open-circuit secondary milling and the use of sensor-based sorting technology.

Commercial milling circuits saw many mills being operated in closed circuit, with the mill discharge being classified and the coarse product returned to the mill to be reground. Operating mills in this manner achieves energy efficiency while also achieving product specification. Mineralogical and chemical analysis of the secondary float tails showed that it contained a significant portion of coarse, unliberated silicates that contained

PGMs either locked or attached to grain boundaries. Size and assay investigation of the secondary mill discharge indicated that the chromite had a finer particle size distribution than the silicates and was being over-ground due to a dense media effect occurring in the classifying cyclone.

As a result of the high recirculating load of the chromite to the mill, the silicates were being displaced in the secondary mill, leading to inefficient milling of the silicates and hence increased PGM losses to the final tail.

Upfront waste rejection in a UG2 plant has two potential benefits, which, for an operating plant, in which the plant is the bottleneck, is the ability to increase the PGM ounce production for a relatively fixed operating cost. The second benefit is to mine more economically and safely by using mechanised and wide mining techniques.

Recent technology advances have allowed sensor-based sorting to be considered for this application. Further developments of this technology, exploiting optical as well as multi-sensor technology, exist and are presently being developed and tested.

Mintek has maintained its position as a leader in the PGM mineral processing field by application of its early research and the continued investment in projects to improve the effectiveness of these circuits.

The project areas on UG2 ores that have been identified for active research are: the production of very high PGM grade, and low chromite grade concentrates; flotation using non-mechanical type flotation cells; improving recovery from plant streams using ultra-fine grinding techniques; secondary mill energy efficiency improvements through improved classification and milling conditions; and the development of sorting and concentration technologies.

TOP Platinum flotation at Impala Platinum BELOW A rock driller in action

In sid e M in in g 0 4 | 2015

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Mintek – a global leader in minerals and metallurgical research and development

Today This cenTre of Technological excellence, with its teams of highly trained and experienced scientists, engineers, researchers and specialists, continues to develop and provide advanced technology for the more effective extraction, utilisation and beneficiation of our mineral wealth.

Mintek provides expertise in all commodities and metallurgical fields:  one of the world’s longest-running and largest minerals technology facilities — based in Johannesburg, south africa.  Metallurgical support throughout all stages of project development.  “one-stop shop” service — spanning all metallurgical disciplines.  Unique, proprietary technologies and products.

 Very large integrated test and pilot plant facilities.  comprehensive accredited analytical and mineralogical services.  extensive knowledge database of southern african and worldwide mineral resources.  80-year track record in providing quality work.

80 years of excellence in mineral and metallurgical innovation.

200 Malibongwe drive, randburg, south africa.

Private Bag x3015, randburg 2125, south africa.

Phone: +27 (011) 709 4111 fax: +27 (011) 709 4326 e-mail: info@mintek.co.za http:// www.mintek.co.za

A global leader in mineral and metallurgical innovation

Hydrometallurgy

The chemistry of innovation Committed to providing the mineral processing industry with innovative processes and equipment, Mintek’s Hydrometallurgy Division will continue its contribution to a sustainable future for the mining industry.

M

intek’s Hydrometallurgy Division can arguably be traced back to 1936, with the appointment of the first chemist – taking the personnel compliment to 14. The division has grown to around 85 staff members and has been assisting in mineral dissolution across the entire mineral beneficiation field.

Although the early work was no doubt driven by the booming gold processing industry, the scope of research gradually broadened with new focus areas emerging such as the so-called uranium extraction period between 1946 and 1958. With time, the importance of hydrometallurgy grew at Mintek, culminating in perhaps the golden years of the 1980s and early 90s. During this period, a number of paradigm-shifting technologies and processes were either developed at Mintek or made breakthrough contributions to these technologies and processes: • carbon-in-pulp/carbon-in-leach • solvent extraction (SX) reagents like Nicksyn, as well as processes and equipment • ion exchange (IX) materials, resin-inpulp and the multistage continuous IX contactor – Nimcix • Minataur SX-based gold refinery • leaching – pressure, heap and bio-leaching • mechanisms of sulfide leaching • electrowinning of base metals.

From this extensive scientific base, the Hydrometallurgy Division has been able to build a portfolio of unique products and services, as supplied to the South African minerals processing industry and the rest of the world, and, after almost 80 years of pioneering work, enjoys an enviable reputation in the industry the world over.

Although a large number of developments took place in the last 10 years, a number of highlights stand out.

Even though the gold industry in South Africa no longer holds the prominence that

it commanded in its heyday of the 80s and 90s, the Hydrometallurgy Division continues to build its gold processing expertise through the development of advanced instruments such as the Cynoprobe (developed with the Machine and Control Division), for on-line cyanide measurement, as well as innovative infrastructure such as the advanced leach facility (ALF), capable of providing real-time understanding of the leaching potential of gold ore.

The division also leverages a vast body of test-work data generated over of the last 80 years with the development of intelligent decision support platforms such as the AuSimPro gold process advisor. Not only do these advisors embed all the historical processing knowledge for future use, but they are also used to good effect in order to add value to client test-work programmes while keeping costs down to a minimum.

In line with demand in the gold industry to treat difficult to process refractory ores, a state-of-the-art continuous pressure oxidation pilot plant had been installed in the Hydrometallurgy Division. Although primarily aimed at gold processing, the flexibility of design makes it applicable to other areas of hydrometallurgical processing as well.

All these developments are backed up by a Sanas and ISO 17025 accredited Cyanide Centre, capable of analysing the complete range of cyanide species in process streams.

A further significant area of expertise is IX/SX processing, which has particular application in uranium processes. Also, a number of patented processes such as high-efficiency RIP, uranium recovery from siliceous pulp, as well as the Metrix Technology, for the recovery of uranium from low-grade ores, have been developed in the division.

Another important application for IX and SX is in the recovery and purification of rare earth elements (REEs). Mintek started

ABOVE Bench scale equipment used for studying gangue chemistry of ores

work on REEs in the late 60s, but really accelerated developments in this field from 2009 onwards. The work carried out in this period, including projects spanning almost all the important REE projects in the world, led to an unsurpassed understanding of the behaviour of the different ore bodies and resulted in the Hydrometallurgy Division taking a leading role in the processing of REEs. During 2014, the development work culminated in the design and construction of a state-of-the-art solvent extraction pilot plant aimed at separating the REEs into individual elements.

The main focus of current developments in the Hydrometallurgy Division remains providing technical solutions for metal recovery processes, in order to enable the economic exploitation of available resources.

However, the focus has shifted significantly in the last number of years towards the integrating of available technologies to treat waste streams as well as reducing secondary pollution from waste deposits. The patented Savmin acid mine drainage treatment process forms the centre of a philosophy of intelligent integration of proven technologies, and the utilisation of waste materials, to recover valuables from wastes, while at the same time rendering the resulting final waste product much less harmful to the environment by reducing its further waste generation potential.

The future awaits.

In sid e M in in g 0 4 | 2015

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africa round-up

Mining news

from around the world in association with Zimbabwe Diamonds to merge Zimbabwe’s diamond industry will soon be controlled by a single firm, as top government officials behind the country’s major diamond mining companies have agreed to comply with a ruling that forces them to merge.

President Robert Mugabe’s

folded into a single entity, minister Chidhakwa told AFP. “We are very clear, this is a regulatory matter and we have said to them the only way you can participate in diamond mining in Zimbabwe is by being in this company,” he said. Rio Tinto owns 78% of Murowa mine, which last year increased diamond output by 7% to 344 000 carats.

zambia Zambia aims to resolve mine royalty row

Zimbabwe mines minister Walter Chidhakwa

government is pursuing a black economic empowerment programme, known locally as indigenization, which requires foreign-owned companies, including mines, to sell 51% of their shares to black Zimbabweans.

The government had previously said it wanted to merge some of the diamond companies operating in the Marange area to the east of the country, in which it already owns half the shares, to enhance transparency.

However, mines minister Walter Chidhakwa told a committee of parliament that all the mines would be merged, including Rio Tinto’s Murowa diamond mine in south-central Zimbabwe.

A total of seven companies operating in Marange, including one wholly-owned by the state and Rio Tinto’s Murowa mine, would be

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Zambia’s President Edgar Lungu has appointed a team to end an impasse with mining firms over higher mineral royalties in a bid to prevent looming job cuts and mine closures. Zambia hiked mineral royalties for open pit operations to 20% from 6% this year, prompting an outcry from the industry and threatening foreign investment in Africa’s second biggest copper producer.

Lungu has shown willingness to compromise on Zambia’s tax tussles with

Zambia’s President Edgar Lungu

the crucial mining sector by directing his cabinet to engage with mining firms and saying he would not allow a single mining job to be lost over the disputes.

Amos Chanda, speaking on behalf of Lungu, said the committee is led by the president’s economic advisor and includes officials from the revenue authority and ministries of finance and mines.

“Mining companies are making recommendations, which will be evaluated by the committee, and we hope that this matter can be put to rest by the end of this month,” Chanda told Reuters.

Last month Lusaka relaxed rules that have prevented $600 million in tax refunds being paid to mining firms such as Glencore and Vedanta Resources. Zambia’s rows with mining firms comes at a time when copper demand from big importer China is falling, hurting the Southern African nation’s kwacha currency.

Gabon Gabon’s new mining code kicks off Gabon’s newly approved mining code, which seeks to attract investors and increase the state’s share in projects in an oft-neglected sector, took effect this month.

Gabon’s President Ali Bongo signed the new code into law on 30 January and it was set to become applicable once published in the country’s official journal toward the end of February. The former OPEC member-state was once dependent on oil which represents about 60% of its gross domestic product.

However, maturing oil fields and little new discoveries has seen output fall steadily, hitting state revenues.

Gabon’s President Ali Bongo

Government, through SEM (Societe Equatoriale Des Mines), will get a free stake of 10% of all mining projects in the production phase with an option to buy an additional 25% at market value (solely for future projects).

egypt Egypt sets price for shale gas Egypt has signed its first contract to extract gas by hydraulic fracturing, or fracking, in a deal with Apache and Shell Egypt in December that includes investments of $30 million to $40 million, the oil ministry said this month.

“The shale gas agreement signed with Shell Egypt and Apache Corporation provides for a price of $5.45 per mmBtu of gas extracted,” the official, who declined to be identified, told Reuters.

Under the contract, three horizontal wells as deep as 14 000 ft in Western Sahara fields will be drilled.

“The shale gas agreement is at an experimental stage for a year while we make sure the search for shale gas is feasible,” the source said.

This is one of the ways Egypt aims to boost domestic production and foreign imports to help address persistent energy shortages.

IN THE SPOTLIGHT

Women Mining’s untapped resource As the old saying goes, behind every successful man is a woman. What the 6th Annual Women in Mining conference revealed was that behind every successful mine lies a flock of women, making it all happen. By Mpinane Senkhane

L

ast month, I attended the much-anticipated 6th Annual Women in Mining conference at Gallagher Estate and, being a woman myself, I must admit I was floored. While research does show that South Africa’s mining industry ranks tops for gender diversity in the boardroom, there’s still more that needs to be done for women to make their mark, above- and underground. Being new to the industry, I couldn’t help but notice how male-dominated it is. On numerous occasions, since my time with Inside Mining, I have walked into a room and have been one of two women, if not the only one. That being said, walking into a conference hall full of oestrogen was quite refreshing.

The conference included discussions on key strategies

relating to building your career (as a woman) within the mining sector; what it takes to get women into critical, executive positions; and fighting the different levels of gender, race and disability discrimination. Boasting some of the South African mining industry’s most respected and hard-working women, at all levels, the conference was inspirational, to say the least.

Day 1: Prejudice against women In her keynote address, chief director of the Department of Mineral Resources Setepane Mohale drove home how important it is for women in the industry to capitalise on opportunities lying in wait for them with respect to small-scale and artisanal mining. Quality assurance superintendent at Petra Diamonds Nokuzola

Moemise shared ideas with the ladies regarding how they could build successful careers within the mining industry. An issue much debated in the industry, one that sees women constantly sidelined, is the belief that mining is an industry for men, and not a ‘woman’s job’.

Itallia Boninelli stood out for me as she addressed the question, “How do we get women into critical executive positions – what does it take?” As executive vice-president: People and Organisational at bullion producer AngloGold Ashanti, and by tapping into her own personal experiences, her address highlighted the many ways women can move to the forefront of the mining industry, and be noticed. One of the methods she stressed was how important it is for the senior management to familiarise themselves with their organisation and, essentially, get to know the talent lower down.

An age-old concern that continues to rear its ugly head is why women continue to be compensated significantly less than men in the same positions. To this,

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IN THE SPOTLIGHT

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above A female dump truck operator, as capable as any man

Boninelli said: “We need to actively address this [problem], otherwise we will never fix the issues of gender equity.”

Boninelli promoted networking as a vital strategy women can utilise to get ahead and be noticed in the industry. Through an exercise – a series of scenarios that challenged the women to see how many key contacts they could rally for various different scenarios, key projects, serious personal issues, and executive contacts – Boninelli highlighted just one of the challenges faced and some of the women in the venue gasped when confronted with the differences in numbers between men and women. Her exercise showed how men were able to gather more than 100 executive contacts at senior level without challenge; whereas women fell significantly short of that, gathering less than 10.

She encouraged women to speak more, generate contacts and make themselves more visible – by generating contacts internally first, then making their way out from there. Asking how you can attract women to your company, Boninelli outlined pull factors companies need to adopt in a bid to attract women to the industry: • Right job challenge: It is key to give women the opportunity to be challenged in their work environments.

• Decent compensation packages: It is paramount for women to earn as much as men do, especially given the increasing statistics regarding single-mother households.

• Work/life balance: This is a concept that is often overlooked. Boninelli showed how important it is that this concept is realised.

• Job stability: This is highly important and

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2

and Global Business Services, Rio Tinto, discussed how women could best handle pregnancies in the mining sector.

Many of the mines do not accommodate women, let alone pregnant women. Bogopa highlighted how pertinent it is that miners ensure that women are afforded facilities to relates back to single parenting, and family support them should they face difficult pregand financial commitments. nancies, or miscarriages.

• Training and development opportuniOften times, women are not afforded septies: This gives women the chance to grow in arate toilet and ablution facilities to enforce their roles in the industry. their right to privacy on the mines. Bogopa National Union of Mineworkers’ (NUM) implored the miners to consider ways to be Women Structure national secretary increasingly sensitive to the basic human Phumeza Mgengo evoked intense emotion rights of women on these mine sites. as she detailed some of the gross violations “Announce your pregnancy promptly,” to human rights that women in lower-level was some of the advice Bogopa gave wompositions, above- and underground, were en, be it at executive positions or on the exposed to. Presenting footage that saw a sites. Letting line managers know that group of women sexually harassed by dozyou would have to be away from work in ens of male miners at an undisclosed mine, the near future is a crucial part of working with your employer towards a positive “Transformation working environment. demands consultation, Animosity towards pregnancy in the industry is still communication, a concern; most women often commitment and planning. find it hard to announce their But, most importantly, pregnancies, fearing loss of respect among male peers, or effective implementation.” even loss of employment. Bogopa suggested mines adopt Rio Tinto’s policy of often reassigning Mgengo urged women in executive posiwomen to different, safer roles for the dutions to urgently deal with issues of sexual ration of their pregnancy. harassment and violations of dignity in the In her conclusion, Bogopa added that it mines. Essentially, mines must take care of is part of an organisation’s responsibility their women. Just this month, a woman was to build stronger communities. “Comparaped at a mine in Rustenburg with the susnies need to make sure that the family unit pect entering the changing room holding a is sustained; in the past, mining has been screwdriver. He forcefully ordered the womknown to break family structures.” an to undress and threatened to kill her if she Bongi Ntsoelengoe, manager: Technolresisted. Mgengo revealed how, in most casogy and Strategy at Anglo American’s es, incidents of this nature went unreported, Kumba Iron Ore, discussed the hot topic and are given next to no media coverage, in of the conference – investing in the edua bid to protect the male figures that often cation of young women who are passionrepresent the mines on ground level. ate about the mining industry. Citing her Nkuli Bogopa, manager: Group Property

IN THE SPOTLIGHT

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Nkuli Bogopa

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Patricia Makhesha

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Itallia Boninelli

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Mpumi Zikalala

Maritjie Lancaster, senior manager: Human own personal experience, and how she was Capital at Sibanye Gold, dealt with the ageintroduced to the industry, Ntsoelengoe old issue of discrimination. She revealed emphasised that, “Women choose mining shocking statistics including how 76% of because it blends into the engineering diswomen in the South African workplace have cipline, and provides the opportunity to experienced sexual harassment and, of that impact communities.”

76%, only 8% of cases have been reported.

As a young woman coming out of matric, Lancaster gave valuable advice: should you she detailed how, on numerous occasions, she was told how her pursuit of a career in mining, was “not for a “Young women coming young lady”. Relating some of her experiences in entry-level posiout of matric are often tions, earlier on in her career, her told 'mining is not a theme encouraged young women career for young ladies'. to never be intimidated by the industry, never be afraid to get This is wrong!” your hands dirty, and, most significantly, be assertive and find yourself a coach or a mentor. be sexually harassed, be clear, do not blame In her address, Ntsoelengoe advocated yourself, always keep a diary of incidents, technical knowledge. She pressed that, as a and gather witnesses; she encouraged womwoman, technical knowledge is paramount en to always file a complaint. to getting the respect you deserve in the Judging by the standing ovation she reindustry. Without technical knowledge, ceived prior to her presentation, Nompuwomen are often sidelined and trivialised in melelo Zikalala, board director and senior the industry. That and characteristics such vice-president of De Beers Consolidated as acumen, diligence, leadership, being reMines, was unquestionably the highlight of sults-oriented, and presence in the moment the conference. The well-liked Zikalala dealt are essential to women in the industry. with the matter of educating up-and-coming women engineers interested in mining.

“This conference should not just be a talk Day 2: Solutions needed shop – let’s strategise and implement; guys Dr Patricia Makhesha, managing director at do that,” she started.

Platreef Resources, responding to the need Appointed general manager at just 28, for job creation in mining, said, “TransforZikalala urged women to gain as much mation is a journey, not a once-off event.” technical knowledge as possible; that, Detailing how “the process [to transformacombined with an assertive nature, Zikaltion] demands consultation, communicaala said, helped her move into leadership tion, commitment and planning; but most roles promptly. The challenge, however, importantly, effective implementation to is that it is increasingly difficult to attract show that we [the mining industry] can turn and retain women in the mining industry. our strategy into actions.”

above Women underground are just as

important as female executives

Some of the reasons she cited are: Education: There is a need for companies to invest in education; not only at university level, but as early as high school.

Reputation around the industry: Although most of the things said about the risks in mining are true, there is a great need to tell the good stories too.

Lack of skills: There is a shortage of skills among women, and men, across the mining industry.

Location: Unfortunately, mining locations are not always attractive, and are usually in small, secluded towns.

Work/life balance: An issue Boninelli covered.

Outdated traditions: The traditions and culture of the industry need to be dismantled and redefined, as most of them have never catered for women.

She concluded that, as a leader herself, she saw the value in encouraging women at all levels to grow in the industry, and she encouraged all the ladies to actively follow suit. This conference is highly valuable, and is becoming increasingly more so. It gives women the platform they need to share ideas and receive encouragement.

Through conferences like this, companies are met with the reality that small changes can have a big impact when it comes to furthering women in the industry. With more companies employing women at all levels, there has been some progress in the last decade, and women are not as underrepresented in the industry as they were before.

Building a career as a woman in the mining industry is difficult but not impossible.

In sid e M in in g 0 4 | 2015 11

Economics, finance & risk

Mergers &

acquisitions

The mining industry is set for major restructuring in 2015, with both large and small companies being affected. It is, without a doubt, going to be an interesting year. By Quintin Hobbs*

V

olatility and uncertainty will continue to constrict deal activity until price stability and, in turn, confidence returns. The timing and pace of recovery will vary from commodity to commodity.

However, the strategic imperatives that compelled some companies to undertake deals in 2014 are primed to intensify in 2015, setting the scene for new competitors and diverging business models.

Sell-side • Distressed selling: Price weakness, particularly iron ore and coal, will test companies’ gearing levels, while junior companies will continue to face funding challenges.

• Portfolio optimisation: Major producers will continue to review and optimise portfolios as market conditions change, leading to divestments, spin-outs and divergent strategies.

Buy-side • Private capital: Depressed equity valuations, signals of price stability and the pipeline of divestments will see the deployment of funds and the potential emergence of major new industry players.

• S upply security: Industrialising nations will continue to seek opportunities to secure strategic mineral supplies, while trading houses will look to secure physical production to feed their marketing operations.

• J oint ventures: Companies will seek

12 Ins i de Mi n i n g 0 4 | 2 0 1 5

opportunities to gain competitive advantages and synergies with minimal capital outlay via strategic partnerships.

The question remains as to when the major producers will have both the confidence and permission to invest in the next wave of growth. But, standing still is not an option.

Trends

malaise was the number of megadeals (>$1 billion), which dropped almost 40% during the year, from 18 in 2013 to just 11 in 2014.

• Contributing factors: There remains a lack of impetus from both the buy and sell side to make deals happen. Weak

$22 49%

• M&A’s malaise: 2014 marked the fourth consecutive year of declining M&A activity across the sector, with overall value down 49% to $44.6 billion, from $87.3 billion in 2013 (excluding the merger between Glencore International and Xstrata). Deal volumes also dropped 23%, from 702 to 544.

• Megadeals, minor appetite: Perhaps the most significant indicator of the

billion worth of divestments and spin-offs across the industry completed in 2014 decrease in the value of mining and metals deals during 2014

commodity prices and the uncertain outlook have created nervousness around valuations, compounded by a focus on capital discipline among producers.

• Pressure for the majors: Pressure to sell tended to be behind the larger deals undertaken, mostly aimed at returning

Graph 1 Volume and value of deals by size (2004–2014)

economics, finance & risk

Graph 2 Share of deal value by acquirer type

and a close contender in terms of value ($9.7 billion). The majority of Canadian deals were junior-level strategic mergers aimed at conserving cash.

• Government buyers step back: There has been a significant drop-off in acquisitions by state-owned entities, particularly from China, in recent years, likely due to ongoing economic reforms in the country. However, there were several examples this year of governments nationalising, or renationalising, assets that have been underperforming or left undeveloped by previous owners.

Outlook value to shareholders, either through asset divestments or spin-offs. Glencore’s much-anticipated $7 billion Las Bambas divestment – the largest deal of the year – was a compulsory sale due to a Chinese anti-competitive ruling. Buyers, particularly in steel, saw some low-risk synergies with existing assets and opportunities to diversify into new markets.

• Distress for the minors: The large number of sub-$10 million deals indicates distress among juniors and opportunistic buyers entering the market.

Outlook Deal activity shows little sign of picking up in earnest, with M&A activity continuing to be driven by asset divestments as a result of portfolio reshuffles or distress.

We expect to see more joint ventures emerge as a way of sharing the costs and risks associated with accessing new markets, to realise synergies, as well as among Asian acquirers looking to secure supply.

There could also be a flurry of opportunistic buying as companies fall under the weight of widespread price volatility.

Who is buying?

• Sector buyers dominate: Interest in the mining and metals sector came Graph 3 Share of deals flows by volume

largely from within, during 2014, with 82% of deal value and 71% of deal volumes undertaken by industry acquirers.

Those already operating in the sector are better placed to understand and manage deal risks, and take a longer-term view of market conditions during a downturn.

• Financial investors back off: There was a slight drop-off in the volume of activity undertaken by financial investors, down from 23% in 2013, to 17% of overall deal activity in 2014. There is a sense in the market that these acquirers believe there is further softening of values ahead, so a patient stance is being adopted.

• China and Canada spending it up: Chinese buyers topped the list of acquirers by value, with $10.6 billion of deals executed in the year. However, this was dominated by the $7 billion Las Bambas acquisition

by MMG. Canada was the most prolific buyer in terms of volume (191 deals)

Long-awaited funding from private capital funds should begin to deploy across the sector as sellers align their value expectations with the market, and assets

29% 43%

of deal volume was undertaken by acquirers from outside the industry of deal value and volume was undertaken by North America-based acquirers

continue to be sold by the large cap producers in search of optimum portfolios.

Until then, most industry acquisitions will be mergers between equals and consolidation opportunities that provide synergies to both parties.

For the most part, the large cap producers are unlikely to make significant ac-

60% 72%

of deal volume and 51% of deal value targeted assets in developed regions such as the US, Canada and Australia of deals targeted assets within the acquirers’ regions

quisitions any time soon, preferring to seek out remaining asset disposal and spin-off plans. The exception may prove to be Glencore, as the market waits to see whether it will continue its pursuit of a merger with Rio Tinto in 2015.

Where are they buying?

• Staying local: The ratio of cross-border to domestic transactions based on volume remained virtually unchanged year-on-year, with 58% of deals targeting domestic assets. Intra-regional deals increased slightly to 72% of deal volume, from 69% year-on-year as buyers continued to focus on operational synergies within familiar territories.

In sid e M in in g 0 4 | 2015 13

Economics, finance & risk Table 1 Value of deals by target region ($ million) 2009 2010 2011 Target region 2008

2012

2013*

2014

North America

14 520

15 420

22 200

54 187

13 306

26 923

13 364

Latin America

16 924

12 139

23 957

22 084

13 872

2 792

11 911

Asia-Pacific

29 611

20 505

38 955

38 297

41 055

25 365

8 520

Europe

26 432

4 608

6 613

3 564

10 424

3 863

5 820

Africa

1 844

3 285

16 657

20 282

19 940

2 927

3 294

CIS

3 553

3 836

3 718

23 894

5 418

17 939

1 687

-

-

1 605

131

-

7 500

39

126 884

60 035

113 706

162 439

104 014

87 309

44 636

Middle East Total

YoY change* -50% 327% -66% 51% 13% -91% -99% -49%

* Excluding the Glencore Xstrata merger

Graph 3 Share of deals by target commodity ($ billion)

• The developed market’s attraction: North America was the most targeted region, with 35.3% of deal volume and 30% of deal value invested in the US and Canada. The Asia-Pacific region followed closely with 34.9% of deal volume, but this represented just 19% of value, reflecting a proportionally high volume of distress-priced junior/explorer acquisitions in Australia and several high-value North American steel divestments during the year.

• L atAm deal value boosted: The value of deals into Latin America quadrupled this year to $11.9 billion, from $2.8 billion, buoyed significantly by the $7 billion Las Bambas acquisition by MMG.

Outlook Chinese companies will recommence looking abroad on the easing of government approvals processes and China’s need to secure supply in the face of a difficult domestic mining environment. We expect to see continued interest in advanced projects in developed countries with amenable regulatory conditions and established infrastructure, especially while most industry participants remain disinclined to increase capital expenditure significantly. Any renewed

14 Ins i de Mi n i n g 0 4 | 2 0 1 5

interest in emerging/frontier regions will likely be via joint ventures with infrastructure partners to help spread capital risk.

• Gold volume reflects distress: Gold remains the most-targeted commodity by volume at 173 deals. The largest of these was the joint acquisition of Osisko Mining Corp by Yamana Gold and Agnico Eagle Mines for $3.6 billion. The majority (88%) of gold deals, however, were valued at less than $50 million, reflecting distress among gold juniors on the back of squeezed margins.

• High-volume, low-value deal activity between mineral explorers: This suggests many players are combining assets to improve their ability to access capital in order to advance projects.

Outlook

We expect to see significant restructuring and distressed assets enter the market What are they buying? over the next 12 months, particularly • Copper bright in value: Copper was in the North American iron ore and coal the most-targeted commodity by value, sectors on the challenging supply and dewith $10.6 billion worth of deals unmand outlook. This may prompt a spate dertaken during 2014. This represents of opportunistic buying and some consolidation between peers to stay afloat. Statebacked enterprises from of steel deals by value were Asia, looking to secure a divestments or spin-offs supply of bulk industriof 2014 deal value al commodities, may be targeted copper active acquirers as their domestic operations are an increase of 20% on the previous year slowly rendered uneconomic under curlevel, although $7 billion of this can be rent conditions. attributed to MMG’s acquisition of Las Similarly, trading houses are likely to Bambas from Glencore. continue securing supply for their vast • Steel still strong: Steel followed marketing operations, particularly via closely behind copper with $9.8 billion joint ventures similar to the acquisition of deal value – a 66% increase on 2013 of a 50.1% stake in Clermont by Glencore levels. At least $9 billion of these deals and Sumitomo Corporation. was the result of companies looking to restructure, dispose of assets, or due The author to other unique deal drivers such as *Quinton Hobbs is a partner at nationalisation or the re-acquisition Ernst & Young Transaction Advisoof assets. ry Services, Johannesburg

69% 24%

economics, finance & risk

Excess capacity

threatens steel sector

Steel producers need to test the vulnerability of their business models and the resilience of their strategies to ensure sustainable growth.

W

Excess supply leads to lower market value

Table 1 The top 20 crude steel production countries for 2014

Country

‘000 tonnes

Country

‘000 tonnes

China

822 700

Kazakhstan

3 678

Japan

110 665

Belarus

2 514

United States

88 347 Luxembourg

2 226

India

83 208

Venezuela

1 466

South Korea

71 036

Colombia

1 269

Russia

70 651

Hungary

1 152

Germany

42 946

Peru

1 144

Turkey

34 035

Chile

1 119

Brazil

33 912

Greece

998

Ukraine

27 170

Libya

968

Graph1 Steel ($/tonne) [Source: EIU Economic and Commodity Forecast, February 2015]

hile there are signs that the outlook for demand is slowly improving, excess capacity remains the biggest threat to the steel sector. The sector is straining under the relentless pressure caused by years of excess steelmaking capacity and low profit margins.

Although some capacity is expected to be removed over the next decade, the announced addition of capacity by steelmakers out to 2020 shows that investment is still alive and well. To counteract the investment in new steelmaking capacity, it is estimated that about 300 million tonnes of steelmaking capacity needs to be closed for the industry’s profit margin to reach a sustainable level, and raise the capacity utilisation rate for the sector globally from below 80% to more than 85%. Permanent shutdown of capacity is the only real solution to bring balance to the market, but in the short term it is difficult to see this happening given state participation in many countries and additional political incentive to retain employment, regardless of profitability.

The overall net effect, however, has been an increase in steelmaking capacity, despite the Chinese government mandating 80 million tonnes of capacity to be removed by 2018. With the restructuring and consolidation in the Chinese market, a handful of large Chinese steel players will emerge, leading to global competition intensifying.

“Frenetic production in Asia flooded global markets with cheap steel, pushing prices down in 2011, which fortunately bottomed out in 2014.” Michael Elliott, leader: Global Mining & Metals, Ernst & Young

In sid e M in in g 0 4 | 2015 15

Ferrous & nonferrous metals

W

Coal and steel

hat is steel; or rather, what’s in steel? Steel is an alloy of iron and carbon, whose characteristics are determined by the other elements in addition to carbon. Steel is produced via two main routes – integrated smelting involving blast furnace iron-making, followed by basic oxygen furnace (BOF) smelting; and electric arc furnaces (EAF). In the integrated route, raw materials comprise iron ore in various forms, a reductant, coke, and various fluxing minerals such as limestone and dolomite.

A particular type of coal – ‘coking’ or ‘metallurgical’ coal – is used to prepare the coke. The coking coal is first crushed and then heated up in a coke oven – without oxygen – over several hours. This drives off volatiles and some of the impurities, leaving a solid, sponge-like mass of carbon-rich material. The iron ore is also prepared prior to use and is converted into sinter and pellets. The coke, together with iron ore and limestone, is then charged into the blast furnace and heated so that the coke becomes gasified, producing a combination of carbon monoxide and carbon dioxide.

The residual coke is pushed out of the oven by pusher car, through a guide, into the coke bucket. The red-hot coke is taken to the coke dry-cooling plant for cooling.

A match made in

heaven Steel is a critical necessity in modern life. Industries such as information telecommunications, transport, energy, health and sanitation, and food production, all depend on it. And, critical to steel is coal.

“Coal will continue to play a major part in the manufacture of the world’s steel for the foreseeable future.”

1

16 Insi de Mi ni ng 0 4 | 2 0 1 5

The carbon monoxide reacts with the iron ore to form a high-quality molten iron known as ‘hot metal’. The hot metal is collected from the base of the furnace and transferred to the BOF. Other elements, such as nickel, chromium and molybdenum, may be added in the BOF to give particular properties to the final steel.

Oxygen is blown through the molten metal bath inside the BOF, causing excess carbon to be oxidised and emitted, leaving liquid steel with low carbon contents.

Some steel plants use electric arc furnaces to generate steel, where recycled material or steel scrap is melted and then reformed for further use. The recycled steel is loaded into the furnace with some iron

Ferrous & nonferrous metals

ore, often in a partially reduced form, and high-intensity electrical power is supplied to electrodes, forming an arc of electricity to raise the internal temperature and melt the scrap.

In both cases, some additional refining may be carried out to achieve the required steel specification. The integrated route offers the most capability for achieving the highest-quality steels, whereas the EAF route is limited in what it can produce by the quality of the scrap. The liquid steel, whether it is produced in BOF or EAF, is then processed via rolling mills to form a variety of products – from rails to bars, and wires to pipes – which are then further transformed for their end use.

2

3

4

5

A vital building block for development Steel facilitates economic growth and poverty alleviation, and is a major element in improving quality of life. Coal is an essential input in the production of steel. Steel is a man-made alloy of iron and carbon – and that carbon usually comes from coal.

Almost 70% of the steel produced today relies directly on metallurgical coal, also referred to as coking coal. The remainder is produced by recycling scrap steel (itself originally produced directly using coal) using electricity – often generated using affordable and reliable steam coal.

Increasing demand for steel has, over the last 35 years, seen worldwide steel production nearly double – from less than 600 million tonnes (Mt) in 1970 to around 1.7 billion tonnes in 2014. The period 2003–2014 has seen unprecedented growth, with global figures rising over 71%.

While China’s economic growth has cooled by as much as 4%, much of the demand for steel is still being driven by the country’s strong economic growth, along with that of India. In 2014, economic

growth rates in those countries were 7.3% and 7.85% respectively. With a population of over 1.24 billion in India, and almost 1.36 billion in China, the demand for products and services has fuelled an almost insatiable demand for steel. China and India together consumed over 905 Mt of steel in 2014 – around 54.5% of total global crude steel consumption. This is set to continue as India is projected to eclipse China in population size by 2025, and the two countries will account for around 37% of the global population. Rapid worldwide urbanisation is driving demand still further; as cities grow, housing, water and electricity are urgently required. Transport links must be expanded to meet the

Graph1 Crude steel production 2003 to 2014

geographical growth of urban and peri-urban areas. The availability and reliability of modern communication systems also becomes ever more important as urban economies become more sophisticated.

Around 4.9 billion people are expected to be urban-dwellers by 2030 – 60% of the world’s population. This will place huge pressure on existing infrastructure and create significant demand for housing, better transport systems, communications networks, energy, sanitation and health care.

Coal will continue to play a major part in the manufacture of the world’s steel for the foreseeable future. Metallurgical coal can be delivered worldwide, facilitating the manufacture of steels that will ultimately deliver the goods and services that growing economies demand.

For a full list of references, please contact the editor at tony@3smedia.co.za.

1

Molten steel being poured from a vat

The residual coke is pushed out of the oven by pusher car, through a guide, into the coke bucket. The red-hot coke is taken to the coke dry-cooling plant for cooling 2

3

Steel billets moving along a castor

4

Coil of red hot sheet steel

5

Coils of sheet steel ready for shipping

In sid e M in in g 0 4 | 2015 17

–

–

–

–

–

–

– – –

–

Ferrous & nonferrous metals

Simandou

Called the El Dorado of iron ore, Simandou is the world’s largest known untapped deposit. It has enough ore to sustain an annual production of 200 million tonnes, 7% of global iron ore output, for more than 25 years.

T

he Simandou mountain range stretches along southern Guinea, forming a vital ecosystem in West Africa that holds a wealth of natural resources. At one end of the mountain range is a vast iron ore deposit that promises sustainable economic prosperity when connected to the capital port city of Conakry and its access to world commerce.

The responsibility for connecting these two distant locations with a new cross-country mine-to-port heavy haul freight railway, and a new deep water port, fell on the shoulders of AECOM’s team of 450 design engineers, scientists and planners from 14 AECOM global offices.

“The Simandou project is a greenfield development of the largest integrated iron ore and deep water port infrastructure in Africa.” (says Geoffrey Fosbrook, senior vice president AECOM USA.) Upon completion, the project is expected to double the gross domestic product of Guinea, providing broad social and economic gains, including employment opportunities for skilled and non-skilled Guineans during construction and operation of the mine and port.” AECOM provided the feasibility studies and is leading the detailed engineering phase for this integrated railway and deep water port project based in the Republic of Guinea.

Experts from AECOM’s Perth and Melbourne, Australia, offices are leading the

ports work, with additional expertise from the United States and Canada. The project calls for designing, developing, constructing and linking a new 670 km heavy haul freight railway originating in the eastern part of Guinea’s Simandou mountain range with a new deep water port being constructed in the country’s capital city of Conakry.

With the first shipment of iron ore slated for mid-2015, the new infrastructure will enable the Guinean government and the project’s owner, Rio Tinto, a leading mining company, to access and bring to market the country’s vast iron ore resources, expected to be approximately 95 million tonnes of iron ore per year.

• development of cost estimates for project analysis.

Simandou is just one of several major mining projects around the world where AECOM is providing key design, engineering, environmental, programme and construction management services, including the Argyle diamond mine expansion in Australia; Bloom Lake mine rail complex in Canada; and several mining operations in Brazil.

“At AECOM, we are fortunate to have the capacity and expertise to work on such large and important global projects as Simandou, providing the technical leadership and project management very few companies can match,” concludes Fosbrook.

Detailed design engineering on the railway is currently underway and includes:

TOP Simandou Mine

• developing the technical specifications for rolling stock • designing the workshop and provisioning facilities for the locomotives and railway vehicles • designing track, civil structures, tunnels, signalling and communications systems • environmental and geotechnical assessment • value engineering • constructability • staging all major works to achieve a viable economic outcome

BOTTOM Simandou Matakang railway, approximately 670 km long, along which iron ore is transported from mine to port

In sid e M in in g 0 4 | 2015 19

Ferrous & nonferrous metals

Flexibility, power and gears

O

ddly enough, mines often have space constraints. This in turn creates all sorts of challenges when it comes to mounting motors and gearboxes.When implementing drive solutions for large conveyors, travel drives and bucket elevators, flexibility is really important. In some instances, a horizontal mount is needed and in others a vertical mount.

Either way, installing the right drive power is critical.

So, what is it we want and need when buying a new drive solution? First of all, as time is of the essence, we want it delivered timeously. Any customisation (horizontal or vertical mount) that needs to be done should be capable of being done quickly and easily, with a simple installation procedure.

Mounting accessories, such as protection caps should be a breeze and handling during installation should not require Herculean effort. The selection of an optimal gear unit for our specific application should be straightforward. We also need stronger

20 Ins i de Mi n i n g 0 4 | 2 0 1 5

shaft support for surface The P4 aerators, mixers etc. As for invertible power and reliability, we gearbox want better lateral load distribution, with lower noise and vibration levels. This means a better strength/surface durability rating balance, with optimal load capacities as well as optimal transverse and lateral load distribution.

We want all of this as a cost-effective solution that delivers value for money and a long, trouble-free working life. Last, but not least, we want a little touch of quality and forethought, and bearings should be safely lubricated from the start.

The P4 range excels in low noise and vibration levels as well as minimal weight. For a given output, a Hansen P4 is just one-fifth of the weight of its 1950 ancestor. Hansen P4 multistage units come in 19 sizes from 6 kNm to 1 100 kNm. The Hansen P4 singlestage range caters for five sizes, in two mounting positions, for mechanical powers from 100 kW up to 4 MW.

P4 Multistage Units • mounting pads for motor base on the top of the unit • strong oval lifting lugs for easy handling • standard fixation points for easy mounting of accessories on the side of the gearbox (e.g. cooling systems) • provisions for crowbar on smaller housing for easy alignment during installation • provision for easy removal of covers to perform service on the spot when needed • rounded external design, ensuring a smooth surface without dirt or moisture retaining cavities • drain plug at lowest position and system of internal drain holes and channels provide complete oil drainage • central filling connected to internal oil distribution system to ensure all parts are lubricated before start-up • large inspection cover with reusable O-ring • horizontal split-housing for easy maintenance.

EPCM

Waiting for the green light

A confluence of factors, including surging demand and a more favourable investment climate, has contributed towards a swelling of interest in Africa’s natural resource bounty. But, this bounty remains largely dormant. Why? By tony stone

I

n Africa, many countries have formulated plans but fail to implement them. South Africa’s National Development Plan (NDP) is one of these. “If South Africa wants to emulate Asia, the implementation of the NDP is key,” says Matome Modipa, for Business Report.

Simon Freemantle, an economist with Standard Bank, says, “Africa has a dominant share in a number of core commodities. Currently, Africa holds 95% of the world’s platinum group metals (PGM) reserves, 90% of chromite ore reserves, 85% of phosphate rock reserves and more than half of the world’s cobalt.

Meanwhile, Africa’s potential is equally alluring in a range of commodities for which future production prospects are elevated.

Africa possesses roughly one-third of global bauxite reserves, but accounts for only 8% of global bauxite mine production. Between 2006 and 2010, copper production in Africa increased by 75%.

By some estimates, Africa could hold

more than one-third of the world’s accessible oil reserves and one-quarter of global accessible proved gas reserves.”

But, little happens unless foreign direct investment takes the initiative. A key component in the economic growth equation is infrastructure. In a paper written for the Southern African Institute of Mining and Metallurgy, G Smith and F da Lomba of Anglo Platinum said, “Infrastructure plays an important role in the social and economic development

Without infrastructure, the poor will remain poor and natural resources dormant of communities. Areas without access to effective infrastructure are inevitably characterised by high levels of poverty.”

They are absolutely right. Without infrastructure, the poor will remain poor

and a country’s natural resources will remain dormant. Sadly, where these resources are extracted, there are often problems. By the very nature of mining natural resources, many mining companies have operations in some of the most remote and inhospitable areas in Africa, which are very often coupled with the vagaries of human behaviour – such as corruption.

Recognising this, the Extractive Industries Transparency Initiative (EITI) was established as a global standard to promote open and accountable management of natural resources. The organisation seeks to strengthen government and company systems, inform public debate, and enhance trust. In each implementing country it is supported by a coalition of governments, companies and civil society working together.

Stepping up to the plate Mining companies have an impressive track record for delivering continuous improvements in safety and risk In sid e M in in g 0 4 | 2015 21

EPCM

Table 1 The list below perhaps is indicative as to why certain countries attract foreign direct investment more than others. It’s all about trust and confidence

The Extractive Industries Transparency Initiative (EITI) countries (2015) Compliant

Burkina Faso

Candidate

Ethiopia

Compliant

Cameroon

Candidate

Madagascar

Compliant

Chad

Candidate

Senegal

Compliant

Côte d’Ivoire

Compliant

Democratic Republic of Congo

Suspended

Central African Republic

Compliant

Ghana

Compliant

Guinea

Noncompliant

Angola

Compliant

Mali

Noncompliant

Benin

Compliant

Mauritania

Noncompliant

Botswana

Compliant

Mozambique

Noncompliant

Gambia

Compliant

Niger

Noncompliant

Guinea-Bissau

Compliant

Nigeria

Noncompliant

Kenya

Compliant

Republic of the Congo

Noncompliant

Namibia

Compliant

Seychelles

Noncompliant

South Africa

Compliant

Sierra Leone

Noncompliant

Somalia

Compliant

Tanzania

Noncompliant

South Sudan

Compliant

Togo

Noncompliant

Uganda

Compliant

Zambia

Noncompliant

Zimbabwe

governance standards. Mines also work with local government, community leaders and NGOs to contribute to community needs, from housing and infrastructure to health care, education and recreation. But, the emphasis here is local.

Infrastructure beyond ‘local’ needs to, and must, be addressed by national government. One such country stepping up to the plate is Zambia.

Speaking about infrastructure development, Zambia’s Finance Minister, Alexander Chikwanda, said in his 2015 budget speech, “Infrastructure development is an indispensable pillar in the government’s efforts to raise the productivity of businesses, diversify the economy, and promote inclusive growth.

In this regard, the government has made tangible progress in developing key infrastructure in the transport, communications, and energy sectors. We [the government] are continuing to implement the road infrastructure programme, and are expecting to rapidly accelerate this project in 2015.”

As was stressed at the 2015 African Mining Indaba, mining is a long-term investment. As such, any continuing foreign direct investment in the mining industry of a country is a vote of confidence

in that country, and bodes well for the future. Sandvik Mining and Sandvik Construction have invested in Zambia and are currently in the process of having a distribution and support hub constructed in Kitwe. With personnel, stock, spares and equipment, this is not – and will by no means be – a small investment.

The sandvik facility includes: • a 1 320 m² two-storey office building • a 3 090 m² workshop, within which

will be a gymnasium, offices and training facility • a 3 000 m²warehouse, within which will be a mezzanine floor consisting of offices and additional storage • a 100 m² security hub located at the entrance of the site • a 730 m² welding and hot-area workshop • a degrease and wash-down area • a sandblasting area and painting booths • site works, including bulk services, road upgrades and cut-to-fill operations, etc.

Stefanutti Stocks is the EPCM contractor. Stefanutti, too, is looking to participate in the Zambian economy. It has an exemplary track record in a number of mining-related projects in Southern Africa, which includes the construction of transport facilities, township, mining and environmental infrastructure – including roads, bulk earthworks, landfill sites, decline shafts, terraces for new developments, and municipal services. Stefanutti Stocks Mining Services specifically provides professional engineering services in open-pit contract mining, bulk materials handling, and waste residue disposal and recovery facilities. Contract mining opportunities such as the Blackthorn Kitumba copper mine project in west-central Zambia will no doubt be persued. The mine has an estimated 439 Mt in situ ore at a 0.25% Cu cut-off, comprising 164 Mt of indicated mineral resource and 275 Mt of inferred mineral resource.

With foreign direct investments such as these, and the confidence shown in the Zambian economy by international companies who bring more than just money, and with coalition of governments, companies and civil society working together, Zambia looks set to succeed in its efforts to reduce poverty and create a better life for its people.

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project management

Realising possibilities...

The key to

success By tony stone

A

...from mine to market.

Resource Evaluation

Mineral Processing

Mine Planning

Tailings & Waste Management

Mining & Mine Development

Smelting & Refining

Materials Handling

Environment & Approvals

Transport to Market

Non-Process Infrastructure

WorleyParsons adds value through our full scope of services from pit to port including studies, mine planning, impact assessments, permitting and approvals, project management, construction management and global procurement.

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countries

166

offices

37,500

people

ppointing the right project manager for your mining project is more crucial than you think.

Why? Because a wrong decision will cost you a lot of money, and more! James Brown, of PricewaterhouseCoopers, in an address to the Americas School of Mines, stated that 70% of mining megaprojects failed to meet at least one key criterion of success.

These criteria failure thresholds include: • cost overruns: 25% • schedule overruns: 25% • cost competitiveness: 25% • schedule competitiveness: 50% • severe operational problems after two years: Yes. The price of failure goes beyond the direct impacts associated with increased costs or schedule delays. It means a loss of revenue associated with missed production targets, inefficient capital allocations that result in the need for short-term financing, claims and disputes with vendors, and most importantly a loss of shareholder confidence with the associated impact on share price.

An explanation of the causes to these problems can be found in Read and Napier’s paper, titled ‘Project Management, and the design of shaft-sinking projects’, in which they state, “Traditionally, shaft-sinking projects have been managed by conventional operational techniques, which have often involved large cost and time overruns.” They go on to promote project management as the solution.

The Project Management Institute (PMI) says a project is “a temporary endeavour to create [and/or produce] a unique product, service or result.” Every successful project involves good project management – “the application of knowledge, skills and techniques to execute projects effectively and efficiently.” And the most important technique for executing those projects is to break things down into manageable steps.

By understanding each step, we can better understand the processes required, the costs, the durations, the risks, and the resources needed for each point along the way.

Then, we can understand the relationship between these steps. In doing so, we can make better decisions towards our goal – achieving the desired outcome that meets everyone’s expectations, within the scheduled timeframe and budget. Two skills that are crucial to a successful project outcome are communication and proactive problem solving. However, when choosing a project manager, having the theory may be wonderful, but nothing carries more weight than experience and a track record of successful delivery.

www.worleyparsons.com

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drilling & blasting

Innovative safety and productivity improvement Working underground at depths is dangerous. Accordingly, when adding explosives to the equation, this simply escalates the risk. Even so, ingenuity knows no bounds, as we discovered at the Tumela mine in Thabazimbi. By tony stone

A

s part of its modernisation strategy, Anglo American Platinum’s Tumela mine partnered with blasting firm BME in a pioneering initiative to introduce emulsion explosives at its mine near Thabazimbi in Limpopo province. The emulsion explosive will be dispensed using some 54 BME portable charging units (PCUs).

In pursuing maximum safety and productivity, BME also opened its on-site training and maintenance facility where some 180 underground personnel will be trained in the use of new equipment.

BME’s PCU is designed primarily for use in the confined narrow reef mining environment. The PCU is compatible with BME’s surface-to-work face emulsion systems. In order to optimise use in confined environments, the PCU can be operated by a single operator, minimising labour requirements. The system eliminates waste while simultaneously delivering a

1

predetermined mass of double-salt emulsion and sensitising agent to each blast hole, sensitising the emulsion as it enters the blast hole. The PCU is manufactured for rough underground conditions but is also light and compact enough to be carried and operated by mining personnel.

Weighing just 14 kg, the pump component is carried separately from the 20 kg emulsion bags, of which multiple bags can be filled.

The sensitiser tank is also in a separate container, latched on to the pump just before charging, and renders the emulsion ready for blasting as it enters the blast hole. “Our closed emulsion system prevents emulsion contamination and waste through the use of dedicated bag-filling stations, located underground close to the work face,” says BME senior operations manager Selwyn Pearton.

“These stations are supplied from transfer cassettes, which bring the emulsion down from our facilities on the surface.”

The explosive characteristics of pumpable emulsions, and the improved transmission of energy to the rock mass surrounding the blast hole, lead to more efficient blasting. And while being classified as UN Class 5.1 emulsion makes them subject to fewer legal restrictions when being transported and stored.

“We aim to drill 12% fewer holes using this technology, saving us time at the rock face,” says Tumela production manager Pierre Prinsloo.

“Emulsion is safer to transport than traditional explosives, as it only becomes classified as an explosive once it is in the blast hole. We also expect to use fewer explosives and transport cars underground, consume fewer drill steels, and have more flexibility with our shaft infrastructure.”

Radio frequency identification (RFID) technology is employed to track the location of pumping units at all times.

Tumela mine’s Shaft 1 near Thabazimbi

Filling emulsion bag from emulsion filling station 2

3 Carrying the emulsion bag and PCU is comfortable enough 4

Loading blast holes is a simple process

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2

3

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In sid e M in in g 0 4 | 2015 25

page strap

IT PAYS TO TALK TO A SPECIALIST

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

Tenova Delkor Sub-Saharan Africa 58 Emerald Parkway Road, Greenstone Hill Ext. 21 Johannesburg, South Africa +27 11 899 9111 enquiries.TMM@tenova.com www.tenova.com TENOVA MINING & MINERALS is a total integrated technological solutions provider to the mining, bulk materials handling and minerals beneficiation industries.

26 Ins i de Mi n i n g 0 4 | 2 0 1 5

mineral processing

An integrated solutions provider

T

enova Delkor is an industry specialist in solid-liquid separation and mineral processing applications for the minerals, chemical and industrial markets. It offers flotation, sedimentation, filtration, clarification, screening, and gravity separation systems.

Services range from testwork, process tradeoffs and flowsheet design, to installation, commissioning and aftermarket support.

Products include: • The high-rate thickener, a proven performer in a variety of different applications around the world, is part of the company’s range of thickeners, with designs up to 100 m in diameter. The thickeners cater for a variety of applications in the minerals, industrial, chemical, water treatment and wastewater industries.

• The clarifier range includes pinned bed clarifiers and sludge bed clarifiers. The sludge bed clarifier is typically used when overflow clarity is critical, while the pinned bed clarifier is a unique process for hydrometallurgical plants where solution clarity is important.

• The belt linear screen was developed to solve a major problem in the CIP/CIL process – the effective removal of waste material from slurries. The unit is capable of screening between 150 to 2 000 microns, and is widely used in removing tramp material from fine mineral or chemical slurries. The belt linear screen operates with no vibration. This prevents realignment of oversize material with the cloth aperture, ensuring retention of all oversize material. The screen is primarily suited to scalping coarse oversize material from process slurries.

• Flocculant plants are designed for 1 kg/ day up to 10 000 kg/day and can use salt water as a solvent. Modular units allow for simple installation on-site and lower transportation to site costs.

• BQR flotation cells range in size from 0.5 m3 (BQR5) to 150 m3 (BQR1500).

The BQR flotation cells are used in roughing, scavenging, cleaning and re-cleaning unit and pilot cell applications to process a range of minerals and commodities.

Filtration technology and know-how is founded in the belt filter and the company remains the supplier of the world’s largest individual machine and filtration plants.

BQR flotation cells achieve optimum operation through purpose-designed levels of solids suspension, air-rate adjustment, easy froth-cone positioning and a stable pulp-froth interface.

Used in roughing, scavenging, cleaning and re-cleaning, unit and pilot cell applications – to process copper, zinc, platinum group metals, phosphates, graphite slag and effluents – the number of cells required depends on the application. Cells feature an overhung stator, open inlet to the rotor, adjustable air flow rates and froth-cone settings, and a launder – external to the pulp zone – to yield an excellent

combination of process, operational and cost benefits.

The technology’s advantages include simple process optimisation: • easy start-up under load • low downtime and easy maintenance • simple design reduces cost of spares • enhanced power efficiency • low maintenance cost.

In the case of the Iron Mountain iron ore mine, the reverse flotation circuit process forms part of a two-stage magnetic separator circuit. The non-magnetics – silicates and apatite – are removed as floated product, and pumped to a 20 m diameter tailings thickener. The magnetics are pumped to a 16 m diameter concentrate thickener.

Tenova Mining & Minerals is a total integrated solutions provider to the global mining, bulk materials handling and minerals beneficiation and processing sectors, offering innovative solutions and full process and commodity knowledge across the mining and minerals industry value chain.

LEFT High-rate thickener BELOW BQR flotation cells

In sid e M in in g 0 4 | 2015 27

Mineral processing

Waterless roller mill

A

vertical roller mill can process many materials such as clinker, slag, gypsum, fly ash, or limestone to produce various cement types of various fineness.

The mill is part of a process that begins at the quarry.

Only after the initial material has been through the raw material grinding, preheater, kiln, and the cooler, it reaches the finish mill where additives are added and the final product is obtained. Both Loesche and its customers are essentially concerned with this final product and its properties, which are influenced by all stages of the cement making process. Material enters the VRM via a rotary feeder that poses as an air lock, then moves down the feed chute to what is the centre of the rotating grinding table. The product is then driven outwards by centrifugal forces to underneath the rollers, where the grinding takes place. Ground material moves over the dam ring and goes up with the gas flow to the classifier. The material

In some parts of the world, the cement industry is not permitted to utilise water, or its use is limited. Loesche has been working on a system that can provide grinding without the need for any water injection. By tony stone

has either reached the required fineness and leaves the mill towards the bag filter or is sent back for further grinding, via the grid cone onto the grinding table.

Lumps, which escape the rollers and are too heavy to rise with the gas flow, drop through the louvre ring to a reject system The Loesche LM 56.3+3 vertical roller mill

and are then fed back via the reject system. Raw mills or coal mills operate using the same size of rollers. What is typical for Loesche cement mills is the 2+2 or 3+3 system, which features a combination of different sizes of rollers.

Even though this mill can operate without any water, and even if some water is available, the main aim is a grinding system that can be run without the need for the permanent operation of a hot gas generator. In cement, a system fan provides the draft through the machine and different sources of hot gases can be utilised if required. Furthermore, a wide range of feed materials is tolerated and conveyed to the mill via the feeding scheme.

While Loesche’s reference projects include various cement raw meal mills and coal mills, the new LM 56.3+3 mill is designed for the production of 200 tph Portland cement Type I at 3.600 Blaine as well as 150 tph Portland cement Type III at 4.500 Blaine.

28 Ins i de Mi n i n g 0 4 | 2 0 1 5

MILLING & CLASSIFICATION IS OUR BUSINESS E V E N 1 0 0 Y E A R S O F B E I N G A N I N N O V AT O R A N D

EVERY DAY

FROM INVENTING BETTER SOLUTIONS

Are you looking for cost-effective size-reduction and classification of ores, industrial minerals and concentrates?

Contact Loesche SA to find out the advantages of the Loesche Grinding System for your beneficiation process.

Tel: +27 (0)11 482 2933 | Fax: +27 (0)11 482 2940 | Email: umeyer@loeschesa.co.za | Web: www.loesche.com

Loesche six roller Mill

MARKET LEADER DOES NOT KEEP US

mineral processing

Order from chaos Entropy, the natural law of chaos, is neutralised, in part, by the metallurgical subprocess of particle separation, which uses linear vibrating screens to create order, from chaos.

M

ost metals occur in nature in mineral form, although a small number of metals (e.g. Cu, Ag, Au, Hg, Pt) may occur in their metallic state. This means extracting the metals from the mineral from. This extraction process may involve one or more of three types of metallurgy: pyrometallurgy, hydrometallurgy and/or electrometallurgy.

Without going into a long explanation, metal ores are concentrations of the above metal compounds mixed with other unwanted minerals (gangue), such as silicates. Separation of these materials can be performed in a variety of ways: • Particle Size: The separation of particles according to size is effected by the use of physical barriers and screens or by the differential movement of solid particles through fluids: rake classifiers, sedimentation classifiers, and hydrocyclones.

• Density: The sorting of particles as a function of their density may be performed in unit operations and devices such as Humphrey spirals, shaking tables, jigging and tabling operations, or dense-medium separation.

• Surface properties (flotation): Air bubbles, which are blown through a pulp, attach selectively to the valuable particles (e.g. various sulfides) and float to a froth which is skimmed off and collected as concentrate. The flotation process is carried out in cells, columns, and air-sparged hydrocyclones. Flotation cells are arranged in banks that are interconnected so as to produce maximum recovery.

• Magnetic and electrostatic sorting: These techniques (wet or dry)

TOP A combined grinding and screening plant BOTTOM A schematic of a linear vibrating screen

utilise the magnetic (e.g. with magnetite), electrical conductive, and induced electrostatic properties of various minerals and materials to separate the valuable mineral or material from the surrounding gangue.

• X-ray sorting: When certain materials (e.g. diamonds) are irradiated by X-rays, they become luminous and can then be detected electronically and sorted from the gangue material.

• Solid-liquid separation: The recovery of solids from liquid media, either to clarify solutions for hydrometallurgical treatment or to dewater pulps for pyrometallurgical operations, can be performed in drum, leaf, and sand filters; thickeners; as well as decanting and centrifuging processes.

• Gas cleaning: Gas cyclones, bag filters, and electrostatic precipitators are used to clean gases

or to recover valuable minerals from flue gases from pyrometallurgical operations, before they are vented in to the atmosphere. In this instance, we are specifically focused on vibrating screens. With these screens, oversized or undersized materials mixed with impurities and other foreign matter, or materials of the same composition, are sorted into different grain sizes. To do this, the vibrating screen drives can either be unbalanced motors, unbalanced exciters or magnetic vibrators that provide the linear vibration in the upper part of the rigid screen frame. They are usually built with an inclination and fitted with extra-long

In sid e M in in g 0 4 | 2015 29

PARTICLE SEPARATION PSS - the leaders in the development of screening technology.

Particle Separation Systems ( PSS ) was formed in 1997 and entered the metallurgical market with the introduction of the Pansep Screen Pansep Screens The Pansep screen is a revolutionary development which can perform a particle separation on size basis using both sides of a specially woven steel mesh.

Rotaspiral Screens The Rotaspiral Screen is a Rotary drum with multiple build in spirals and a tensioned Pansep Crimped steel mesh. : Rotaspirals are ideal for fine screening.

Commett Fine grinding mills PSS developed the Commet mill for in ultrafine grinding. The Commett mill uses a centrifugal type impeller in the form of a polyurethane disc , centred in a split hinged mill barrel allowing for ease of maintenance.

Parsep Drying The Parsep Drying technology is a patented technology which applies vacuum under a woven Steel belt whereby the product to be dried is subjected to Medium Wave Infrared Radiation.

For more info contact Tel: 011 412 2100 Fax: 086 553 8088 Email: pss@parsep.co.za or visit www.parsep.co.za Follow us on

mineral processing

Table 1 Metals and minerals

Substances

Examples

Elements

Au, Ag, Cu, As, Sb, Bi

Sulfides

CuS, Cu2S, PbS, ZnS, NiS, Cu5FeS4, CuFeS2, FeS, FeS2, MoS2

Oxides and hydroxides

Fe2O3, Fe3O4, FeTiO3, FeCr2O4, TiO2, MnO2, SnO2, Al2O3, Al(OH)3, AlOOH, FeOOH

Halides

NaCl, KCl, CaF2, Na3AlF6, KMgCl3· 6H2O, Cu2Cl(OH)3

Carbonates, nitrates, and borates

MgCO3, CaCO3, FeCO3, MnCO3, ZnCO3, CaMg(CO3)2, Cu2CO3(OH)2, NaNO3, Na2B4O7· 10H2O

Sulfates, chromates, molybdates, and tungstenates

BaSO4, PbSO4, CaSO4, CaSO4·2H2O, KFe3(SO4)2(OH)6, CaWO4, FeWO4

Phosphates, arsenates, and vanadates

(Ca, Ce, Nd)PO4, (Ce, La, Th)PO4

Silicates

ZrSiO4, ZnSiO4, SiO2, LiAlSi2O6

perforated plates, which have stepped fields to break up the screening bulk.

Different types of screens are available for different applications: Linear vibrating screens reliably separate small from large, heavy from light, solid from liquid, and mixtures of different shapes or materials as well. Linear motion vibrating screens differ from other screening systems mainly via their linear oscillating motion and compact design. Very low mounting heights can be achieved by means of horizontal installation.

Due to the large selection of screen insert types, the linear vibrating screens can be used almost universally. They are usually equipped with a maximum of three screen decks. Unbalance motors, unbalance exciters or magnetic vibrators can be used as drives. Linear vibrating screens can be 9 m long, 4 m wide and have a flow rate of 750 m3/hr.

Grizzly screens are characterised by great robustness and durability. They serve as discharge units with integrated screening functions below the silo or bunker discharge, as feed units upstream of crushers, conveyor belts, screening, or for loading or simple screening. Depending on the task, the units are protected with wear plates at the inlet section and have two or three bar grate levels. Each bar grate insert is tapered in the conveying direction. This increases the gap and prevents bulk materials from becoming wedged. Grizzly screens can be 6 m long, 2.5 m wide and have a flow rate of 1 500 m3/hr.

Banana screens are particularly suitable for the screening of large flow rates with a high separating cut. In most cases, they are individually designed to suit customers’ requirements. Banana screens are characterised by their very rugged construction and the banana-like arrangement of the screen panels, and they are typically driven by exciters.

Banana screens can be up to 10.8 m long, 4.5 m wide and have a flow rate of 4 000 m3/hour.

Dewatering screens are used to separate liquid-solid mixtures. The aim of the preliminary separation of liquids is to do away with subsequent processing stages of the bulk material. The most important point here is the energy savings in drying processes. Depending on the grain size and grain shape (round or crushed), up to 12% of residual moisture can be saved with dewatering screens. For this purpose, the choice of screen insert is crucial. Our dewatering screens are constructed according to requirements with single- or multi-deck designs. Dewatering screens can be up to 5 m long, 2.8 m wide and have a flow rate of 200 m3/hr.

Circular vibrating screens classify coarse grained bulk materials (5 mm to 300 mm), to provide protective screening and dewatering. The indirect excitation of the entire screening mesh moves the screening frame and generates a circular oscillation with low acceleration of the screened material. Higher transport speeds can be adjusted by inclination of

ABOVE A schematic of a circular vibrating screen

the screening surface between 15 to 30 degrees. Classification can be performed on a wet or dry basis. The circular-motion vibrating screen is powered, via a propeller shaft, by an electric motor. A simple and inexpensive alternative is vibrating with only one drive, which is mounted above the rigid screening frame. These screens work with circular or elliptical paths of oscillation, and are used preferably for less abrasive screening materials with lower bulk density. Circular vibrating screens can be up to 9 m long, 4 m wide and have a flow rate of 750 m3/hr.

Most separation processing will benefit from a closely sized feed, since it will reduce the effect of particle mass and allow whichever physical characteristic is being utilised to be the dominant physical force involved, resulting in a greater degree of order from chaos being achieved.

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mineral processing

Hydrogen production breakthrough International scientists focusing on the challenges in developing fuel cell materials and membrane electrode assemblies for transport and stationary applications have made a breakthrough.

A

research team from Hydrox Holdings announced their revolutionary new hydrogen production method recently. This breakthrough consists of a radical newly designed electrolyser and operating system which totally eliminates the use of a membrane in the production of hydrogen.

This promises to greatly reduce the costs of producing hydrogen in utilisable form. The process of electrolysis employed in producing hydrogen is well-established and relatively simple – by applying an electrical current across two electrodes immersed in water, hydrogen and oxygen are produced. In traditional practise, a membrane is then used to separate the hydrogen and oxygen gases produced. The challenge in this methodology is that the membranes are expensive and are prone to breakdown and failure.

There are two predominant kinds of electrolysers: • Alkaline electrolysers which are the most mature and durable technology but due to their ability to only operate effectively at low current densities they are huge in size and for this reason very costly and not ideal for residential usage.

These electrolysers cannot, due to the membrane limitations, operate at high current densities and they are also

“This breakthrough consists of a radical, newly designed electrolyser and operating system, which totally eliminates the use of a membrane in the production of hydrogen.”

Corrie de Jager, Hydrox CEO 32 In sid e M in in g 0 4 | 2 0 1 5

mineral processing

not suitable for renewable energy sources with variable energy inputs.

• Proton exchange membrane (PEM) electrolysers are very effective and compact, but the requirement of platinum-based electrodes makes its capital costs extremely high. An additional limitation is the limited lifecycle before replacement of membranes and electrodes. PEM’s are also not suitable for renewable energy sources with variable energy inputs and the huge costs are beyond the average person.

Both these systems employ membranes that not only contribute to the high costs but also create certain resistance and ohmic drop issues across the electrodes resulting in over-potential (an increase in electricity beyond what is theoretically required for electrolysis). Membranes are also known to be brittle, cannot handle high pressures and temperatures and can lead to gas crossover.

The unique Hydrox electrolyser uses alkaline technology but due to clever re-engineering of the electrolysis process, Hydrox‘s scientists have created an electrolyser which is simplified, robust, highly effective and which does not use any membrane nor expensive electrodes at all. Due to the total elimination of a membrane, the Hydrox electrolyser is capable of achieving extremely high current densities using only inexpensive nickel electrodes.

The Hydrox electrolyser not only matches the performance of more expensive electrolysers, but even surpasses them as it does not suffer from the threshold limitations caused by membranes. A small Hydrox electrolyser is capable of producing large volumes of hydrogen, making it the ideal unit for renewable energy sources such as solar or wind. Although it has been in development for some fifteen

years, over the last two years, the Hydrox technology has been extensively tested

by DemcoTECH Engineering, as well as by scientists from the North West University, who confirmed the enormous potential of this groundbreaking method of hydrogen production. The Hydrox team is currently preparing a technical research paper with full details of the invention for publication.

Corrie de Jager, CEO of Hydrox Holdings, says: “Our team of engineers are now working towards achieving their ultimate goal – a green-energy household using solar energy to obtain hydrogen through the Hydrox electrolyser. The hydrogen will be stored in a tank and a fuel cell will not only provide electricity, but the excess hydrogen will be able to run an electric fuel cell car, and even earth moving equipment. A major benefit of this is that there will be no carbon emissions at all.”

The expected completion date is by 2015.

The Hydrox technology is also ideally

Evaporating gaseous globules (EGGs) emerging from pillars of molecular hydrogen gas and dust

suited for the desalination of seawater, and this project is also being investigated by the team. Future possibilities are the electrolysing of contaminated acid mine water, turning dirty water into pure water.

This technology will result in an increase of sales of fuel cells, which, in turn, will be very beneficial for the country as fuel cells use a lot of Platinum. The HySa team from the University of the Western Cape recently announced the successful development of a locally produced fuel cell.

“The Hydrox Technology will change the way in which hydrogen is made in the future. It will unlock the hydrogen era, making it more accessible and affordable. We have barely scratched the surface of the enormous potential this technology presents,” says De Jager.

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Technology

Greenfield

Dealing with trees In Africa, mining operations in highly vegetated areas require responsible environmental management. Setting up a mine often requires clearing, especially of trees. Here, miners can learn from foresters. By MPINANE SENKHANE

M

any of the mines in West and Central Africa are located in highly vegetated areas, where tree felling becomes inevitable. With the unpredictable rains along the equator being a big factor, efficient and productive equipment is essential. As a part of mine operations in such areas, tree felling using efficient excavators is a must and finding ways to do this in a timely manner is of high priority.

Operators play a significant role in the productivity of any mine site, a competent operator, coupled with efficient machinery, contributes to the success of any project. This year, Komatsu launched the next-generation XT-3 Series track feller bunchers and harvesters, which have been developed to provide significant improvements in operator comfort, ease

34 In sid e M in in g 0 4 | 2 0 1 5

of operation, productivity and reliability.

This series meets all the requirements to make tree felling in a mine project painless, both from a productivity standpoint and for the ease of operation. With its attention to detail, the new cab design shows Komatsu’s focus on improving operator productivity.

Changes include a sloped roofline that increases headroom above and in front of the seat, and reduces debris build-up. A 10% larger floor-to-ceiling front window and larger side windows provide a wider field of view for operators. For night operations, sometimes an essential part of mining, 11 brilliant white LED lights deliver two to three times more illumination in all directions.

These new features maintain the reputation of Komatsu’s track feller bunchers and harvesters, but now also offer improved serviceability and durability, as well as more attention to detail.

technology

Planning a crane lift By frank kazenske

C

rane planning is an integral part of the pre-construction process, which adds another layer of safety while lowering costs and increasing productivity of field operations. Sufficient planning and supervision are necessary in preventing crane accidents. If something goes wrong, the result is likely to be disastrous – severe damage to property with the risk of injury or loss of life are real possibilities. Good planning protects cranes and the people working around them.

Cranes are one of the most versatile pieces of equipment on a construction site and, when used correctly with a trained and competent crew, can be extremely safe, productive, and cost-efficient. But, this needs planning. Broken down into stages, the planning of a safe lifting plan, no matter how complex, can

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be straight forward. However, there are a few basic, yet important, questions to answer before you start. These are: What type of load will you be lifting – forms, precast deck panels, or bridge deck girders?

Are the net and gross load weights known? Did you remember to factor in the weight of a crane load block; jib; rigging; hook, ball, and swivel; all cable below boom point; and other accessories?

Are there any hidden contents that could affect load weight and stability, or that could be hazardous if spilled? Is the centre of gravity marked on the load?

Is the crane site suitable? Is the crane next to a haul road? Can the crane’s superstructure rotate 360 degrees without coming into contact with any object that may create a trapping point between the counterweight and the fixed

Coralynne & Associates +27 (011) 849 3142

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M

Y

CM

MY

object? Can the crane be assembled and disassembled with outriggers or crawlers fully extended in accordance with manufacturer specifications?

Is the ground on which the crane is to sit firm and level? Is it capable of withstanding the ground-bearing pressure of an outrigger jack or a crawler crane track with the load suspended over the corner of the track or outrigger? Are there any hollow structures under the crane pad? Are crane mats needed to stabilise any soft ground conditions? Information on ground-bearing pressures can be obtained from the crane supplier and manufacturer. After answering these questions about the loads and the location of the crane, a competent person should choose the right crane for the job and plan each step of the lift, taking every factor into account.

CY CMY

K

In sid e M in in g 0 4 | 2015 35

We deliver a SMART lift!

Tel: +27 11 455 9222 or 0860 CRANES | www.jch.co.za

Technology

plastic

The better option

I

n many applications, plastic pipes – such as polyvinyl chloride (PVC) or high-density polyethylene (HDPE) – plastic valves, and plastic filters are a good replacement for metal equivalents. Recent estimates show that about 25% of the expenditures for metal pipes, valves and filters would be better spent on plastic equivalents. And, in a lot of these systems, plastic would, in fact, be the best medium for the job. The corrosion resistance of plastics over metal is unequivocal.

More than just being low maintenance, a plastic valve will never jam, stick or fail because of rust or corrosion. Neither will plastic pipes burst because of corrosion.

Another oft-overlooked benefit of corrosion resistance is that plastic filter vessels never have to be painted to withstand corrosive environments or harsh climatic conditions. They can be installed and

and service life. Exotic metal alloy systems can cost up to 13 times that of a plastic system. Even carbon steel can be almost twice the cost of PVC – depending on the size and complexity of the piping system involved. Flow rates are another area where plastic piping has an advantage. The interior of plastic piping is smooth and clean, and it will stay that way year after year. Metal pipes rust, corrode, and scale – resulting in reduced flow rates and higher pressure drops over time.

By tony stone

used right out of the box in places where a metal valve would have to be epoxy coated just to survive.

Another benefit is cost. The total cost of an installed system using plastic pipes, valves and filters is cheaper than metal when considering freight, installation,

table 1 Comparing PVC pipe with steel Characteristic

PVC

Steel

Solvent wieldable

Yes

No

Weight (per cubic foot)

36 kg

206 kg

Chemical resistance

Excellent

Poor

Flow coefficient

150

65 to 110

Modulus of elasticity

28 000 k/cm2

2 000 000 k/cm2

Maximum service temperature

60oC

538oC

Tensile strength

400 kg/cm2

4 200 kg/cm2

Maximum design stress

140 kg/cm2

1 400 kg/cm2

Relative impact resistance

1

6

36 Ins i de Mi n i n g 0 4 | 2 0 1 5

Leading manufacturer of quality piping systems for mining and industry

MINEFLO

High impact PVC pressure pipe

DUROFLEX

SANS1283

Flexible PVC mining Hoses

SANS1086

Johannesburg : +27 11 345 5600 Cape Town : +27 21 957 5600 36 Ins i de Mi n i n g 0 4 | 2 0 1 5

info@dpiplastics.co.za www.dpiplastics.co.za Member of the Dawn Group

technology VERMEER ADDS A MEASURE OF PRECISION

Whole-tree

TO SURFACE MINING.

solution By tony stone

Q

uite simply, if a tree (or trees) is in the way of establishing a mine, it needs to be cut down.

However, there are biodiversity, land management and conservation issues that need to be addressed. In this vein, trees that are cut down should be used or organically recycled so that there is no waste. In speaking of the latter, trees can be chipped or turned into sawdust for compost, and used on and around the mine or in community horticultural projects.

The HG8000TX horizontal grinder from Vermeer boasts the largest infeed opening in its class, helping to increase your productivity and expand job possibilities. Powered by a 950 hp (708.4 kW) CAT Tier 2 engine, this unit handles large diameter wood and big, brushy debris with ease.

Plus, its innovative design incorporates several features to help reduce material spillage and jobsite clean-up time. The HG8000TX is equipped with a tracked undercarriage with 28 (71.1 cm) wide double or triple-grouser track pads. Designed to tackle tough jobs, the HG8000TX enables productivity for the long haul. Complementing a tree feller-buncher, the horizontal grinder will make short work of your land clearing needs, and put something back into nature.

The Wermeer HG 8000TX

THIS IS WHERE THE NAME ON THE MACHINE MATTERS MOST. Whether you’re facing the hassles of blasting or hammering, Vermeer and our global dealer network will be right beside you. We know the conditions you face are demanding – that’s why we make sure our equipment is up to the task. The Vermeer Terrain Leveler® surface excavation machine helps you get more value from the mine, while reducing the need for costly support equipment. So when it’s tough going out there, look to Vermeer – the trusted name for proven equipment and reliable support.

Equipment Suppliers (Pty) Ltd. Southern Africa

VERMEER.CO.ZA | +27 (0)11 608 0893

PROTON PARK, PROTON STREET (OFF OSSEWA ST), CHLOORKOP EXT.65 GAUTENG, SOUTH AFRICA

I n s i d e M i n i n g 0 4 | 2 0 1 5 37

Vermeer, the Vermeer logo and Equipped to Do More. are trademarks of Vermeer Manufacturing Company in the U.S. and/or other countries. © 2014 Vermeer Corporation and Equipment Suppliers (Pty) Ltd. Southern Africa. All Rights Reserved.

technology

Arc flash

prevention An arc flash is an electrical release of energy hotter than the surface of the sun and capable of exploding with the strength of eight sticks of dynamite. It causes terrible injuries and even kills people. Can it be prevented? By tony stone

T

o overcome fear, one needs a positive, can-do attitude, especially when working in a dangerous environment or with dangerous equipment. By observing an applicable set of rules, one can work quite safely in such an environment. But, one of the problems of doing this every day is that we develop a robot-like approach that unfortunately leads to complacency; this is when accidents happen. Add two more ingredients to the pot, communications failure and worker ignorance, and you have a recipe for disaster.

Research carried out by the Institute of Electrical and Electronics Engineers (IEEE) and the National Fire Protection Association (NFPA) illuminates the phenomena and dangers of arc flashes. This is one of the most serious electrical hazards that can occur in a workplace. The immense energy released, with heat of up to 20 000°C and a shockwave that can throw a nearby worker several feet through the air, is an alarming danger to people close to the flash, and it can even be fatal. South Africa averages at least one arc flash incident per month, with at least one fatality every two months.

An arc flash occurs when an electrical current leaves its intended path and travels through air to another conductor or to the ground. Dropped tools, equipment failure, bad installation or even dust and condensation near an energised electrical conductor can cause an arc flash incident. Mine workers and contractors need to be aware of the dangers of arc flashes, and the importance and function of labelling equipment, procedures and protective

38 I n sid e M in in g 0 4 | 2 0 1 5

equipment. We simply cannot take arc flashes lightly. When an arc flash hazard exists, the mine should: • ensure safe working procedures (i.e. lockout, testing, demarcation, use of correct tools, etc.)

• provide the proper PPE and clothing • implement engineering interventions (e.g. internally arc rated electrical apparatus, reduce tripping times, remote operating of breakers).

This should be done in accordance with the South African Bureau of Standards’ published SANS 724 and the SANS 984, which are the IEEE guides for performing arc flash hazard calculations. These standards provide techniques for workers and facility operators.

arc guard Becker Mining Systems’ (patent pending) arc-resistant electrical equipment, branded Arc Guard Mine Power Center, provides an added degree of protection above standard MSHA requirements.

Arc Guard is the first and only mining arc-resistant power centre. The patented design of Arc Mitigation Open Frame Equipment eliminates potential arc flash injury, complies with ANSI IEEE arcresistant requirements, encompasses all underground/surface electrical equipment, and has been independently tested at KEMA laboratories. In addition to bolted faults, the Arc Guard is designed and performance tested to ANSI/IEEE C37.20.7 to provide protection from the hazards of internal arcing faults.

health & safety

PPE

inequalities Hardworking gear for hardworking people BRANCHES: Women are biologically different.

KWAZULU-NATAL

Poor fit and discomfort of PPE apparel

Pinetown - H/O Tel: +27 (0) 31 705 6085

designed for men predisposes women

Pinetown - Sales Tel: +27 (0) 31 705 7652

to occupational injuries and ill-health.

Pietermaritzburg Tel: +27 (0) 33 342 0854

This in turn affects productivity, which prejudices women. By tony stone

T

he internationally acclaimed South African Constitution places women as equals to men, and rightly so. However, in a previously, and still, male-dominated environment such as mining, there are a number of inequalities. One of these is in personal protective equipment.

Notwithstanding the Constitution, Section 6(2) of the amended Mine Health and Safety Act (MHSA) No. 29 of 1996 stipulates that every manager must ensure that sufficient quantities of all necessary PPE are available so that every employee required to use that equipment is able to do so, effectively. The problem with the MHSA is that it does not regulate the provision of PPE for different gender groups.

With available PPE suits designed specifically for the male physique, women have a problem. With obvious anatomical differences, PPE provided for women needs to be aligned with their body structures and should be based upon female anthropometric data. Ill-fitting PPE is a hindrance to productivity and unfairly prejudices women in mining.

The photograph of women grader operators in training, taken at the Sishen mine in the Northern Cape, clearly illustrates the problem. This is no fault of the mine but rather PPE manufacturers who have failed to keep up with the times, the Constitution and women’s needs. This, then, is a wake-up call to PPE clothing manufacturers. Change or go bust.

I n s i d e M i n i n g 0 4 | 2 0 1 5 39

Richards Bay Tel: +27 (0) 35 789 2245 GAUTENG Isando Tel: +27 (0) 11 974 7062 Pretoria Tel: +27 (0) 12 804 1693 Vanderbijlpark Tel: +27 (0) 16 931 9750 NORTH WEST Rustenburg Tel: +27 (0) 14 596 5083 LIMPOPO Steelpoort Tel: +27 (0) 13 230 3220/1 WESTERN CAPE Cape Town Tel: +27 (0) 21 510 7078 EASTERN CAPE Port Elizabeth Tel: +27 (0) 41 487 2311

www.northsafety.co.za

health & safety

Preventing injury and possible death

W

hat we know about underground blasting is that cumulative damage is non-linear and that the blast damage to the rock mass is anisotropic, having different physical properties in different directions. The degree of damage to the rock mass within the charging range is maximal and the stronger the charge, the more severe the damage.

What poses a distinct threat to safety in underground tunnelling – after blasting – is rock stratification and/or structural abnormalities in the rock mass. To improve safety through the prevention of rock falls, especially after blasting, rock anchors and steel mesh are usually be put in place, but this in itself carries its own dangers. The geologist may request the spraying of a quick-setting, but thin, hard concrete layer before the rock anchor and steel mesh placement process

begins. Thereafter, a final, thicker layer may be applied. Depending on environmental circumstances, this involves choosing between a wet or dry spraying process, the right mix design, and the right weighting of early strength development and durability of the sprayed material, based on the requirements.

The sprayed concrete is a composition of cement, aggregate, water and admixtures – the latter to extend its properties and applications. What is important is not to change too many parameters at the same time during fit-for-purpose testing. Only a technically correct and economically viable solution will satisfy the requirement. Concrete admixtures are used to improve and/or change concrete properties, which can or cannot correctly be controlled by the cement, aggregate and water components. Admixtures include: • Accelerators: These control the start of

the setting process after the sprayed concrete is applied.

• F low control agents: Better known as plasticisers or superplasticisers. These are used to control the specified water content while simultaneously guaranteeing the required fresh concrete consistency (plasticity).

• C onsistency stabilisers/setting retarders: These are used to control (retard) hydration.

• M ix stabilisers: These improve the workability (pumpability) of the concrete.

Requirements for setting strength development, depending largely on the point of use of the sprayed concrete, vary between ‘very early’ strength (up to an hour) and ‘early’ strength (from an hour to a maximum 24 hours). After that, strength development must be comparable to structural concrete.

Sprayed concrete has replaced traditional methods of lining tunnel profiles, and has become very important in stabilising excavated tunnel sections. Modern tunnelling without sprayed concrete is inconceivable.

Especially when considering the risks of injury or even the deaths of miners.

40 Ins i de Mi n i n g 0 4 | 2 0 1 5

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health & safety

Seeing in the

“

T

depths and the dark

he Mine Health and Safety Act, No. 29 of 1996, Regulation 16.5 (Emergency Preparedness and Response) requires that the employer of every underground mine shall, inter alia, be part of a mines rescue scheme. To comply with these regulations, Mines Rescue Services (MRS) administers a rescue scheme whose membership is open to mines and affiliated mining companies,” Christo de Klerk, CEO of Mines Rescue Services, explains.

MRS South Africa is one of the founding members of the International Mines Rescue Body (IMRB) and hosted the first International Mines Rescue Body Conference in South Africa in 2003. De Klerk says that due to the fact that South Africa has some of the deepest mineshafts in the world, there are a number of incidences of miners falling down the shafts. In order

to provide a rescue service, it is necessary to lower the brigadesmen into the shaft to assess situations and rescue the fallen miners.

“However, this was a very risky procedure since brigadesmen were in essence going into the shaft without prior knowledge of the environmental conditions and possible dangers. Previous deaths of brigadesmen during rescue operations prompted us to consider a solution to our existing rescue plan. In order to expedite rapid and safe rescue missions, we decided to deploy cameras to first assess the situation and then guide our rescue teams during the rescue process,” says De Klerk.

MRS discussed their idea with wireless IP convergence company MiRO and a shaft inspection solution using a Vivotek surveillance camera was borne. The first prototype, developed in 2011, was capable

of being lowered to depths of 1 200 m and has been used extensively in shaft inspections throughout the country.

De Klerk highlights the incident where 22 illegal miners were trapped in a Welkom shaft in May 2012. Using the Vivotek shaft camera, all 22 illegal miners were located and safely lifted to the surface. “Apart from its excellent image resolution, the Vivotek camera is extremely robust, making it the ideal choice for the harsh and demanding environment encountered in the mining industry,” adds De Klerk.

“We are very dependent on the performance of the Vivotek cameras and believe that their high levels of quality and reliability have made an extremely positive contribution to MRS’s ability to protect the lives of the brigadesmen and the miners they are deployed to rescue,” De Klerk concludes.

In sid e M in in g 0 4 | 2015 41

health & safety

Defying gravity As with all things, gravity has its good points and its bad points. In speaking of the latter, the bonebreaking thud of a human body hitting the ground, in that fraction of a second, is so crushingly final.

Fortunately, it can be prevented. By tony stone

S

even hundred and forty eight metres below ground level, a group of men work at the bottom of a ventilation shaft, on their way to a final depth of nine hundred metres. They drill, blast, clear and secure three metres at a time, in ventilated temperatures of 57°C cooled down to a more manageable 30°C. The only way to reach these men is to take a ride in a kibble (an oversized steel bucket) lowered or raised via a 40 mm steel rope attached to, and operator-controlled by, in this case, a Siemens winder.

This particular kibble is graded to carry a maximum of 10 tonnes per load. By the time the shaft reaches its final depth, the kibble will have lifted approximately 27 000 tonnes of rock and travelled roughly 4 300 km. Naturally, the wear and tear on the kibble becomes more noticeable as time goes on and the shaft gets deeper.

The kibble itself is attached to the steel rope via a bollard and four steel chains.

The reinforced steel O-rings that connect the chains to the kibble are more than strong enough but, in leaving nothing to chance, the engineers, in their wisdom, have attached secondary chains, also with an O-ring, to each of the four main chains, to which each miner attaches his or her harness lanyard. If any or all

42 Ins i de Mi n i n g 0 4 | 2 0 1 5

of the reinforced steel O-rings connecting the four main chains to the kibble snap, and the kibble tilts or falls, the miners – wearing their safety harnesses with attached lanyards – will be safe, albeit dangling from the chains.

Needless to say, it would be quite an experience. Of course one would assume that the fall prevention solution – the harnesses – would be of an appropriate quality to function as was intended and save the miners from falling down the shaft to their deaths.

Safety first MSA, a safety company that has been in business in South Africa for 75 years, has a solid reputation. Its gravity suspension harness, similar to a parachute harness, is lightweight, comfortable, of highstrength design and of superior quality.

A close examination of the harness will reveal just how well designed it is, with stitched reinforcing at all stress points.

In a fall arrest, the miner’s body will be fully supported in a way that protects the spine. The miner will be held in a slightly angled but upright position, for better control, enabling him or her to see down, from side to side, and even up.

The harness features: • triple-locking, 23 kN steel carabiners

TOP Life-saving chains ABOVE Climbing into the kibble – an oversized bucket

• five steel D-rings for anchor point connection – two in front, one on each side of the waist, and one high up on the back • fully padded leg loops to provide comfort and protect blood flow • quick-release buckles to allow a miner to easily free him/herself in an instant, when needed • fully breathable material • purpose-designed, multi-layered padding to dissipate pressure from the webbing to reduce fatigue when working for long periods of time • additional shoulder padding to protect the neck from unnecessary discomfort caused by neck chafing • radio frequency identification (RFID) to allow the harness to be traced, which, in rescue operations, is critical, and could mean the difference between life and death.

Quite simply, when it comes to human life, there is no settling for compromise or second best. Doing it right the first time has to be rule number one. The RFID-enabled, lightweight gravity harness is a must for every miner.

MSA’s Workman Tripod is easy to use.

Built for durability and versatility a simple setup procedure makes the process quick and promotes correct use.

Features that improve ease of use include: • Legs automatically lock in the open position for added safety.

• A maximum height indicator provides quick and easy identification of the maximum leg extension length.

• There is no need for a separate pulley/bracket assembly, which makes hoist attachment easier and faster.

• Accessories can attach to any leg for faster setup.

• Aluminium leg and head design reduces weight, improving portability.

• Telescoping legs do not tangle when the unit is collapsed, for easier transportation and storage.

Head Protection Protecting what eyond Comparison matters most

MSA’s Workman Tripod is easy to use. Built for durability and versitility a simple setup procedure makes the process quick and promotes correct use. Features that improve ease of use include: • Legs automatically lock in the open position for added safety.

• A maximum height indicator provides quick and easy identification of the maximum leg extension length.

• There is no need for a separate pulley/bracket assembly, which makes hoist attachment easier and faster.

• Accessories can attach to any leg for faster set up.

Head Protection Head Protection ond Comparison Workman d Comparison Workmans Tripod Tripod

• Aluminium leg and head design reduces weight, improvingportability.

• Telescoping legs do not tangle when the unit is collapsed, for easier transportation and storage.

y it before you buy it! Once you experience the MSA V-Gard Helmet, you’ll • We get you home safely derstand why it is the best-selling industrial hard hat available today. MSA’s• A global leader in the manufacture and supply of safety products since mple program youato experiencerange the MSA V-Gard before purchasing.• 1914,allows MSA offers comprehensive of reliable andHelmet comfortable d, with an safety array solutions of options features, can customize MSA V-Gard Helmet• thatand exceed industryyou standards.

Experience,the on-going • research and development ensure we keep you protected from harm. fit your individualized needs.

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Supplied Air Respirators & Escape Devices Air-purifying Respirators Head, Eye & Hearing Protection Please visit our newly launched website: Fall Protection Thermal Imaging Portable Gas Detection Permanent Gas Detection

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Comprehensive service and training – We complement our experience head protection beyond comparison, 'Try it before you buy it!' products with a full-service back-up and maintenance programme, Call us today for more information on MSA’s complete range ntact MSAsupported customer service at 1-800-MSA-2222 today. is ready for by personalised training to ensure equipment use in any situation that demands fail-safe protection.

buy it! Once you experience the MSA V-Gard Helmet, you’ll s the best-selling industrial hard hat available today. MSA’s ore you buy it! Once you experience the MSA V-Gard Helmet, A • 1-800-MSA-2222 / ID 5666a wsNorth you America to experience the MSA V-Gard Helmet before purchasing. erstand why it is the best-selling industrial hard hat available options and features, you can customize the MSA V-Gard Helmet 0861 SAFETY SA’s samplePhone: program allows| +27 you11to610-2600 try the| www.MSAsafety.com MSA V-Gard Helmet rchasing. And, with an array of options and features, you can the MSA V-Gard Helmet to fit your'Try indivualized protection beyond comparison, it before needs. you buy it!'

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health & safety

Emergency preparedness Are you ready to deal with a mine disaster? By failing to prepare, you are preparing to fail. And, in failing, the costs of lost lives, or even injuries, cannot be justified.

A

re you ready to deal with a mine disaster? By failing to prepare, you are preparing to fail.

And, in failing, the costs of lost lives, or even injuries, cannot be justified.

Mining, from the beginning of time, has always been, and always will be, subjected to the inherent dangers of this practice.

Man’s relentless need, and obsessive desire,

for these resources has always outweighed the risks that obtaining such great rewards has presented. We have, out of a necessity for survival, developed ways to reduce and minimise the exposure to such risks. It is fair to say that the protection of the most important resource, human life, in this harsh environment, has improved exponentially through the ages. Sadly, we have not yet eliminated the risks entirely, and until that day, and possibly even then, we will probably still need to prepare for the worst while hoping for the best. The first ever mine rescue volunteers were the colleagues of trapped victims (friends and family members). Thus, even before

the 1800s, the need for organised, trained and competent rescue members, with specialised equipment to rescue and recover miners, was identified. Today, legislation in all countries requires trained, competent and well-equipped permanent, and volunteer, rescue personnel to assist during fires and disasters.

No one can measure the impact these men and women have had on their country, society and/or organisations, or the sacrifices they have made to save colleagues, friends or family. We will be forever indebted to those who have endangered themselves when lives or assets have been in danger. Mines are much safer today compared to 100 years ago. Safety precautions are always improving, but it is evident that emergency preparedness will still be necessary 100 years from now, as it seems we will never be able to plan for every contingency.

Thus, your mission, as a mine, is the same as Gryphon’s mission, as a service provider, which is to provide a sustainable, reliable and professional rescue service by equipping them with the necessary skills, knowledge, resources and expertise to save lives and minimise asset loss.

Emergency preparedness is a service, which will hopefully never be required, but, which is absolutely necessary during fires and emergencies. Legislation requires it, corporations expect it and employees depend on it.

How long can you afford to be without it?

TOP Miners in training BOTTOM At 3.9 km deep, the Mponeng mine is the deepest mine on Earth. It is so deep that temperatures at the bottom reach 55°C, and powerful air conditioning is necessary to keep the air at a safe temperature for miners. Rescuing miners at this depth will be an extreme challenge

index to advertisers Johnson Crane

35

Particle Separation Systems

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Rio-Carb 33

A-OSH Expo

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Loesche SA

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Stefanutti Stocks

22

Becker Mining

38

Minopex 32

Tenova Delkor

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DPI Plastics

36

Mintek 6

ThyssenKrupp Industrial Solutions

Gryphon Rescue

IBC

MSA 43

Vermeer Equipment Suppliers

Hansen Industrial Gearboxes

20

North Safety Products

WorleyParsons 24

Insurance Underwriting Managers

IFC

Osborn Engineered Products

AECOM SA

44 Ins i de Mi n i n g 0 4 | 2 0 1 5

18

39 2

30

OBC 37

AFRICAN MINES EMERGENCY PREPAREDNESS

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FIRE

RESCUE

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