www.miningne.ws
af r ic an u pdates on th e
g ro un d a n d un d e rg ro un d
Leading Sibanye to new operating profits
Vanadium – the new gold?
The impacts of Industry 4.0
Unlocking operational efficiency
ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 10 • No. 04 • April 2017
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contents
a f r i c a n u p dat e s o n t h e g ro u n d a n d
u nde rground
New automation division for BBE 10 Editor’s Comment 3 Great leadership
Underground development
Cover Story 4 Leading Sibanye to new heights
Mining infrastructure & construction
Africa Round-up 6 News from around the continent
24 Impacts of Industry 4.0
Bushveld Minerals 8 Believing in vanadium
26 Unlocking efficiency in mining
18
22 New technology to replace drill and blast
Engineering specialist in mine ventilation, refrigeration and energy optimisation BBE has established a new Automation Division to extend its services.
Tyres, parts & maintenance
28 Prolonging tyre life
Fossil Fuel Foundation 10 Rehabilitating with bamboo
2017
Nuts, rods, bolts & bearings 31 Split cylindrical roller bearings
Coal Mining 12 Lining up for take-off
ON THE COVER p4
Education & Training 32 Training for safety’s sake
Coal Processing 16 Managing coal quality
www.miningne.ws
Market News
Mining in Africa 18 Bakubung’s timeline update
35 The latest news form the African
Underground development 20 Increasing production with machinery
FOOD FOR THOUGHT
AFR IC AN UPDATES ON THE
GROUND AND UNDERGROUND
mining industry Leading Sibanye to new operating profits
39 A two-sided approach
Vanadium – the new gold?
The impacts of Industry 4.0
Unlocking operational efficiency
ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 10 • No. 04 • April 2017
22
32
CEO Neal Froneman shares his thoughts on running Sibanye, and the company’s record annual operating profits of R10.5 billion for the 2016 financial year.
@mining_news www.facebook.com/pages/ Mining-News
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editor's comment
Publisher Elizabeth Shorten Editor Mientjie Kleinhans Journalist Phila Mzamo Head of design Beren Bauermeister Chief sub-editor Tristan Snijders Sub-editor Morgan Carter Contributors Tobias Becker, Rosemary Falcon, John Ffooks, Neil McCoy, Tendani Ndwamise, Jay Seals, John Sims Client services & production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Marketing manager Mpinane Senkhane Head: e-commerce Roxanne Segers 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 Annemarie Prins Tel: +27 (0)11 233 2600 annemarie@3smedia.co.za ___________________________________
No. 9 3rd Avenue, Rivonia 2191 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 www.3smedia.co.za ___________________________________ Annual subscription: 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 2017. 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.
Great leadership We have seen great leaders in our lifetime – people who stand out from the crowd, who take a country or a company forward to the next level. There are so many ideas and opinions on the ideal traits of great leaders.
A
T THE END OF the day, great leaders don’t just deliver lip service. Their actions are proof of what they believe in and this is what makes people love or hate them. Africa has many leaders who we can be proud of, both in politics and in the mining industry. From this issue onward,
Inside Mining will feature the leaders from mines who clearly make a difference. Our first leader is Neal Froneman, CEO of Sibanye and vice-president of the
South African Chamber of Mines. He talks to Inside Mining about the Deal of the Year Award that Sibanye won for the proposed US$2.2 billion acquisition of the Stillwater Mining Company. Froneman also discusses the challenges of his two roles, as well as Sibanye’s future plans. He also talks about what he thinks is fundamental to the economy of a country and possible perceptions that mining is a sunset industry. Read more about how this leader plans to take the company forward on page 4. Fortune Mojapelo is the CEO of Bushveld Minerals, a company that has invested in various commodities, of which the most valuable for them is vanadium. He believes that the vanadium market is in a structural deficit, that supply is concentrated mainly between South Africa, China and Russia, and that South Africa has the highest share of primary resources. Mojapelo also discusses the company’s four-pillar approach when considering new projects. They are currently also investing in coal, tin and iron ore, and their projects are in South Africa, Namibia, and Madagascar. Read Mojapelo’s story on page 8. Although Exxaro hasn’t yet started operations at the Leeuwpan coal mine in Mpumalanga, it has spent much time and money developing the local community. Besides creating permanent jobs, the mine also created temporary jobs during the construction phases of the housing project and the multipurpose centre. Exxaro has also developed the community through means of skills training and learnership programmes, about which more can be read on page 12. There is much more to read in this edition: from how bamboo can be used in mine rehabilitation to the Fourth Industrial Revolution and how it is affecting us today. We experience many distractions these days and those who embrace and master the art of overcoming distractions will prevail. Everybody will agree that tyres are one of the
To our avid readers, be sure to sign up and get the latest updates and inside scoops from the mining industry. Check out what we are talking about on our website and Facebook page, or follow us on Twitter and have your say.
highest expenses for a mine. In this issue, Inside Mining also looks at how mines can prolong the life of tyres on page 28. Don’t forget to subscribe to www.MiningNe.Ws for current news about the mining industry.
@mining_news
Mientjie Kleinhans
www.facebook.com/pages/ Mining-News
In sid e M in in g 0 4 | 2017
3
COVER STORY
Leading Sibanye Sibanye announced record annual operating profits of R10.5 billion for the 2016 financial year, which included a maiden contribution of R376 million from its Platinum Division (Aquarius Platinum and Rustenburg assets). This excludes the Mimosa JV in Zimbabwe, which is equity accounted and earned R254 million. Neal Froneman, CEO, Sibanye, shares his thoughts on running the company.
By Mientjie Kleinhans Underground at Kroondal
O
NE OF THE company’s
industry participants. Although there are
latest achievements
no financial benefits from the award,
is winning the Deal of
I believe that it provides additional
the Year Award at the
momentum, which is positive.”
Ansarada DealMakers annual gala for the acquisition of the Stillwater Mining Company in the USA. The Stillwater Mine
Benefits of acquisition
is a mechanised, low-cost and high-
The acquisition of Stillwater is
grade business, with at least 25 years
transformational for Sibanye. First of
life of mine. The transaction is expected
all, it will deliver real value for the
to be finalised in Q2 2017. “Winning the
shareholders by providing an additional
award was pleasing as it means the
high-quality earnings stream and
transaction has been recognised by
diversifying the commodity mix and
other leading, independent parties as
geographic exposure of the company.
a good acquisition, which reinforces
“Operationally, it gives us much more
our confidence in the value that it
flexibility compared to assets in South
creates,” says Froneman. “The award, which was adjudicated by a credible panel and organisation, reflects that The shaft at Kloof
explains Froneman
the transaction has been recognised by our peers and other
Africa where you can have protracted strikes, difficult operating conditions, uncertain regulation and so on. In North America, we are removed from that. “The stability and diversification that Stillwater provides means that our market rating will be assessed on a global platform. We will also have more of a palladium bias than other PGM producers – and palladium is becoming more and more sought after. Strategically, those are important considerations,” says Froneman.
Africa Froneman says that the company has been looking for
4
Ins i de Mi n i n g 0 4 | 2 0 1 7
COVER STORY value-accretive acquisition opportunities for some time, globally and in Africa, and will continue to do so. However, there are few PGM mines outside of South Africa and Zimbabwe, and he believes
Neal Froneman, CEO,
that Zimbabwe is not the right place
Sibanye, South Africa
to go to at the moment. “We will continue to assess gold opportunities in
We have no
Africa, but under current gold market
hidden agenda
circumstances, there is limited scope
– it is about doing
for a value-accretive transaction, so
the right things, and we
it doesn’t fit into our current strategy,”
are doing that through the
says Froneman.
Chamber as well,” he expands.
Juggling two roles
Stakeholder relationships
As CEO of Sibanye, and recently
Froneman believes that mining is
appointed vice-president of the
fundamental to the economy of South
Chamber of Mines in South Africa,
Africa, and any perception that it is a
Froneman has to manage two roles. He
redundant, sunset industry is completely
jokes by saying that he does the one at
incorrect. “However, it will become
day and the other at night, but then gets more serious. “The two roles are very much integrated, and for us to deliver on our strategy at Sibanye, as a long-term player in South Africa, we have to contribute to changing the way
perceived and operates as part of a modernised
value for all
a sunset industry unless certain
stakeholders, not
changes take place. The
just shareholders.
first change that has to
“I believe that we will achieve an improved market rating over time, which will make us more competitive on a global scale.”
in which business is
A view of Kloof at night
occur is to build trust between business,
Once we get buy-in from all stakeholders and they realise what their role in
government and
achieving the vision is, and how
other stakeholders,
they can benefit, we can move on
which needs
to the third step, which is a social and
to improve
economic compact agreed on, and
significantly if we
adhered to, by all stakeholders.
are to achieve a
The compact defines the new
mutually beneficial
value equation in terms of how all
outcome.” This has been captured to some extent in a document,
stakeholders contribute to and derive value from the mining operations. Investors need to make profits as a
mining industry in South Africa. Since
the “Zambezi Protocol”, which was the
return on their financial commitment;
this needs to be a collective approach
outcome of a meeting of senior mining
communities need to develop and
by organised business, it has to be
industry thought leaders drawn from
grow socially and economically
driven through the Chamber of Mines.
across Africa in 2016, initiated by the
in respect of the conducive social
The two roles are complementary and
Brenthurst Foundation. Trust between
platform that they provide to the
the workload taxing. Essentially, I have
stakeholders has been recognised
mining operations; and so on. All
two full-time jobs, but they are both
as a major hurdle to change and
stakeholders need to benefit from
equally important.”
cooperation. Once you address the trust
the success of the industry, including
issue between business and government,
government, which will receive more
opportunity to play a role as a champion
for instance, the resulting regulatory
tax and foreign exchanges as a result
for South African mining and effect
environment will become more
of an enabling regulatory framework,
positive changes within the industry. “We
certain and conducive to investment
so it is a win-win situation for everybody.
need to assist the Chamber to develop
in new mining projects by local and
But, until we fix the trust issue, we are
and implement a new strategy, which I
international investors.
not going anywhere,” says Froneman.
He adds that Sibanye has the
think we have done successfully so far.
Stillwater Mine •H igh grade 20 g/t • Palladium biased (78% palladium) • 25+ years life of mine • Mechanised operations • Low-cost operations at <US$500/2E oz
If the trust deficit between business and all stakeholders – not just government but
Future plans
organised labour, communities and so
Sibanye wants to be a South African
on – can be addressed as the first crucial
champion that is internationally com-
step, it creates a platform for developing
petitive on the global mining stage,
a real, common vision for a sustainable
while remaining proudly South African.
industry that will deliver sustainable value
“I think that we are well on our way to
to all stakeholders. This is the second step
that destination through the value-ac-
towards realising the aims of the Zambezi
cretive growth we have secured during
Protocol. “It is important to note that this
our short history as an independent listed
vision involves the creation of superior
company,” concludes Froneman.
In sid e M in in g 0 4 | 2017
5
Mining news
from around the continent
Kenya
Acacia strikes gold in West Kenya
Nigeria’s now private Ajaokuta Steel Company operates in all the major markets in the country
Acacia Mining has discovered an es-
Nigeria
Ajaokuta Steel to function privately The Ajaokuta Steel Company is to
timated 1.31 million ounces of inferred gold resources in Western Kenya,
any. The minister’s appearance before
function as a purely private entity, the
valued at US$1.65 billion, at the com-
the committee on 13 March 2017 was
Minister of Mines and Steel Develop-
pany’s project on the Liranda Corridor.
a result of a communication written by
ment, Dr Kayode Fayemi, said during
“This is one of the highest-grade pro-
Senator Alphonso Gaye of Grand Ge-
a facility tour of Abuja Steel Mill, a
jects in Africa today and we believe
deh County requesting his colleagues to
subsidiary of African Steel Company
that this initial resource is a first step in
investigate circumstances surrounding
Fayemi. He stated that government
the delineation of a multimillion-ounce,
the pull-out of Putu Mining. The Grand
is putting a lot in place to ensure that
high-grade corridor,” said Brad Gor-
Gedeh County lawmaker also requested
the Ajaokuta Steel Complex is revived
don, CEO, Acacia.
the government to state whether or not
and that the company would no
the concession company has complete-
longer be run as a public concern.
The mining company hopes to in-
He said experts with proven
crease the initial size of 12.1 g per t re-
ly ceased its operation in the country
source to 2 m oz after spending US$12
and, if so, what had led to their
million this year in the Liranda Corridor
closure. He also requested
and nearby sites with mineralisation
information about whether
deposits. The mining house said, in a
or not Putu relinquished its
press release, that the site had “multi-
rights to the concession
scheme through a
ple lodes open laterally and at depth”.
or is still clinging on to it.
transparent, com-
track records and required financial capability would be encouraged to key into the
The company planned to drill 45 000
petitive bidding
m using six rigs this year and carry out
process. The minis-
a study on a potential underground operation.
Liberia
Minister confirms Putu Mining exit from Liberia
Mozambique
Vale Mozambique ends 2016 off on a bad note Vale Mozambique, a subsidiary of
ter said government is committed to ensuring Ajaokuta works because it believes that a functional Ajaokuta Steel com-
Brazilian group Vale, had an operating
plex would greatly assist the country’s
loss of US$105 million in 2016, compared
developmental drives.
Russian steel giant Putu Mining has
with a loss of US$508 million in 2015,
pulled out of Liberia, revealed Liberia’s
said the mining group as it published its
of the country as energy and power,
Minister of Lands, Mines and Energy,
accounts for the fourth quarter of 2016.
and advised that, since government
Patrick Sendolo, during an appearance
The document said the improvement
is putting the necessary infrastructures
at the Liberian Senate. Minister Sendolo
was owing mainly to the reduction of
in place to address these needs, steel
said the company left because it could
costs and expenses in the amount of
companies operating in the country
not handle the mining process single-
US$344 million and growth in prices,
should continue to maintain high
handedly. He said the company tried
which increased the company’s
product quality and put them out at
looking for partners, but could not find
turnover by US$140 million.
reasonable prices for consumers.
He identified the most crucial needs
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In sid e M in in g 0 4 | 2017
7
BUSHVELD MINERALS
Believing in
vanadium
Bushveld Minerals has a four-pillar approach to assist it in choosing new commodity projects and the value thereof. Believing strongly in the vanadium market, it has also invested in other commodities such as coal, tin and iron ore.
By Mientjie Kleinhans
F
or Bushveld Minerals, the fun-
decrease constantly. “Some commod-
processing technology risks are very low
damental element in choosing
ities are more vulnerable than others,
and that the capex requirements are
vanadium is the current market
but the one insurance that you want
not high. “If it means that you can get it
opportunities. The market is in a
to have with any project is to have the
into production on a small scale – those
structural deficit, supply is concentrated
lowest-cost producers because if you
are the considerations for us.”
(mainly between South Africa, China
are a low-cost producer and in the first
and Russia), and South Africa has the
quarter, technically you need about
mately, we still want an exit as a junior
highest share of primary resources.
75% of supply before you are out of
company, and the thing that will give
money. Therefore, positioning on the
us the exit is a project that has scale. If
when looking at new projects.
cost curve is very important – in terms of
you have a project that doesn’t have
Typically, the first thing that we want to
insurance – so that the project is sustain-
scope for scaling, you will never be of
look at is that we have the right com-
able. For that reason, we typically try
interest to the big players, which means
modity choice by which I mean that
to target projects that we believe are
the structure of the market, and the
possible,” explains Mojapelo.
“We have four pillars to our approach
ing. According to Mojapelo, mining is a
get into production – meaning that min-
“We have four pillars to our approach when looking at new projects.” Fortune Mojapelo,
cyclical game and prices increase and
ing the orebody is relatively simple, that
CEO, Bushveld Minerals
supply demand picture, are favoura-
The third pillar is a realisable path to
ble,” says Fortune Mojapelo, CEO:
production. Mojapelo says that this
Bushveld Minerals.
means the company needs to ensure it
The second pillar is cost-curve position-
8
The fourth pillar is scalability. “Ulti-
Ins i de Mi n i n g 0 4 | 2 0 1 7
is a project with a very short timeline to
BUSHVELD MINERALS that you will be at risk for running the
is to try and package the Namibian
project for 10 to 15 years or so. With
and South African assets together,
vanadium, it ticked all four boxes,”
get it into production, show that we
explains Mojapelo.
can produce tin and spin it off as a
Other commodities
standalone platform. We think that it will be well received in the market,”
He says that the second most important
reveals Mojapelo. The third commod-
commodity for the miner is tin. “Similar
ity that the company is interested in
to vanadium, tin has very good funda-
is coal. It has acquired a project from
mentals. It also has a relatively concen-
Lima Resources in Madagascar with
Uses of vanadium •T o strengthen steel •V anadium batteries • Energy storage could make up as much as 20% of vanadium consumption by 2030
a 36 Mt resource. “Our focus there
I always say that a good project will
is to get a PPA with the Madagas-
always have a future. We also keep
“Our approach to tin is to
can government and then package
a lean structure. Although we have
target areas of historic tin pro-
that as a mine-to-power project,”
a number of projects, our executive
says Mojapelo.
team consists of only three people,”
trated supply, which is good. It has been in deficit for five years or so.
duction. We’ve secured our licences where previous tin mining operations were
Supporting communities
says Mojapelo.
stopped owing to low
The company uses a proactive en-
Future plans
price levels. It didn’t
gagement model with recognised
Mojapelo says that the immediate plan
leadership in the communities and
is to finalise the vanadium project. “Our
to mine. There are
generally likes an approach that tar-
ambition has always been to build an
areas with significant
gets two areas:
integrated vanadium platform and
tin resources availa-
• the economic participation of
mine processing going as deep down-
make sense for them
ble,” says Mojapelo. He says that the company has two
the community in the projects the company spearheads • making sure that the participation
stream as possible. “The vanadium plant produces a well-beneficiated product and we are
tin deposits in Moko-
is leveraged to the maximum in the
also looking to introduce things like
pane with three
communities in which it operates.
electrolyte. We have a company called
targets in the licence area. It has the potential to grow from the current 18 000 t a year to a possible 50 000 t a year. “We are also looking to acquire a project in Namibia that used to supply all of Iscor’s tin plate requirements.
“That requires strategic, proactive
Bushveld Energy, which is looking at
engagement. With that structure, we
introducing vanadium flow batteries
have to ensure that when the eco-
into the market.
nomics starts flowing, we have the
“Regarding tin, similarly, our main plan
desired impact on the communities,”
is to get the team into production in
says Mojapelo.
Namibia. In Madagascar, our immedi-
Secret to success
ate plan is to get our PPA licence finalised and be a strategic partner so that
“Our secret to success is a combi-
we can start the path to developing a
Estimates are that there could be
nation of good-grade commodities
coal-based power plant in Madagas-
over 100 000 t of tin. Our view on tin
and finding a good-grade project.
car,” concludes Mojapelo.
Vanadium has a variety of uses, and because of the current supply and demand in the global market place, it is an ideal commodity for the company to invest in
In sid e M in in g 0 4 | 2017
9
Fossil Fuel Foundation
Rehabilitating with bamboo Abandoned mines in South Africa have left a series of unfortunate environmental legacies throughout the mining community in the form of health hazards such as water, land and air pollution, land degradation and illegal mining activities. Professor Rosemary Falcon* discusses how bamboo cultivation can assist in mineland rehabilitation.
O
ne of the biggest environ-
of these mines are located in rural areas
– from tropical to cold climates. The wo-
mental problems is that of
with high unemployment levels and poor
ven mat nature of the roots within the
abandoned asbestos mines.
infrastructure. Therefore, solutions to the
soil helps in aggregating the particles of
The process of cleaning up
environment will also have to take the
soil, thereby promoting soil stability and
asbestos mine dumps is currently one of
soci-economic aspects into account.
preventing landslides.
the most important tasks being addressed
Previous studies have shown that bam-
Research
boo can grow in a wide range of soil
The history of abandoned mines – par-
Research now being undertaken – in an
conditions – from dry soil with low mois-
ticulary asbestos mining – is that the min-
association between Mintek and the Uni-
ture-retaining capacity – to wet and well
ing peaked and took place during the
versity of the Witwatersrand Clean Coal
drained, sandy loam soils. In addition, Sin-
time when there were no environmental
Research Centre – is the testing of bam-
gh (1999) claimed that Dendrocalumus
regulations forcing mining companies to
boo as a viable vegetational cover on
strictus planted on mine waste attained
take control of their waste materials. Be-
mine rehabiliation land. It has been found
similar biomass yields and higher net pro-
yond the environmetal challenges, many
to offer many benefits including erosion
duction levels compared to that of native
control, acid mine neutralisation and the
dry forest within the same short period.
extraction of heavy metals from the soil
Bamboo as a natural CO2 sink also con-
by the Department of Mineral Resources.
Bamboo growth Bamboos are a large group of rapidly growing woody grasses mainly found in the Indo-China regions of the world that can be sustainably managed in shortcycle harvesting schemes. The study has indicated that it is possible to grow bamboo in the Penge area of Limpopo based on physioclimatic conditions and the most sutiable bamboo species have already been identified.
(which concentrate in the roots, or culms,
tributes to greenhouse gas reduction,
and can be extracted for commercial
which counterbalances emissions when
use). Bamboo also has good building and
combusting fossil fuels.
architectural properties for construction
As a biomass fuel source, the carbon
activities and can be used as feedstock
density of bamboo in China ranges from
for bioenergy as biofuel, thereby reduc-
168.7 t/ha to 259.1 t/ha carbon, which
ing the carbon footprint when co-fired
is higher than the average global forest
with coal. It is also a source of material for
carbon density of 38 t/ha and 86 t/ha
the manufacture of a number of market-
respectively. In South Africa, indigenous
able goods such as furniture, plates and
vegetation cover is continually being
ornaments, food and clothing materials.
tested to rehabilitate thousands of
If successful in South Africa, it is hoped
hectares of abandoned and operating
this approach will lead to sustainable mi-
mine sites but, to date, the practice has
cro-industries and employment, thereby
not proven sustainable. Investigations
addressing some of the socio-economic
conducted at Mintek have shown that
issues within the communities surrounding
indigenous vegetation (usually grasses)
rehabilitated mine land on both currently
simply controls erosion and does not
operating and abandoned mines.
provide development for communities.
The successful use of bamboo in reha-
In essence, the growth of bamboo
bilitating mined sites and preventing de-
could provide an opportunity for major
forestation is owing to its physicochemical
impact on the environmental, ecological,
and biological properties. Bamboo has
socio-economic and energy sectors in
been proven to be the fastest-growing
the mining regions of Southern Africa.
grass in the world, at “about 30 cm to
10
Ins i de Mi n i n g 0 4 | 2 0 1 7
48 cm per day”. Its highly fibrous root
*Professor Rosemary Falcon is from the
system enables it to control soil erosion
Fossil Fuel Foundation and Clean Coal
and to adapt to a wide range of climates
Research Centre, Wits University.
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Coal mining
Lining up for take-off While Exxaro is preparing for construction and waiting for outstanding environmental approvals and mining right consolidation at the Leeuwpan LIFEX optimisation project, it has been involved extensively with local community development.
tender,” says Van Stelten. Currently, the mine employs 600 people, which excludes contract workers. The mine makes use of modified terrace configurations, and truck-and-shovel operations in the conventional open-pit to mine seams 2 and 4. They will crush and screen the coal and then process close to Delmas, Mpumpalanga – contains measured mineral resources of
T
separation technologies.
54.8 million tonnes and 3.7 million in
Community development
the inferred category. “Outstanding
While the mine is waiting for all the nec-
environmental approvals and mining
essary licensing approvals, it has been
right consolidation will slightly delay
hard at work with community develop-
the start of construction,” explains
ment over the last decade. It has been
HE PROPOSED OPEN-pit mine
Bram van Stelten, general manager:
able to create over 150 temporary
will produce an estimated
Mpumalanga, Exxaro. The construction
jobs through community projects. “We
2.5 million tonnes a year of
is expected to start in Q2 2017,
have spent over R25 million on local
thermal and metallurgical
as the legislative approvals are in
economic development projects,” says
their final stages.
Van Stelten.
coal for the domestic and export markets once it is in full operation.
12
the coal by means of dense-medium
“The project team is continuing with
One of the projects that the mine
Exxaro plans to spend R522 million
the project to ensure that it is ready
has been involved with is the school
on the optimisation of the mine,
for construction. And construction
improvement project, where the mine
which has an expected 10-year life
work that is on the critical path is
has spent more than R10.5 million over
of mine. The mine – which is situated
ready to be issued to the market for
the lifetime of the project. “Besides
Ins i de Mi n i n g 0 4 | 2 0 1 7
Coal mining
the investment in people’s education, there are various benefits to the community with this project.
Botleng housing project “The Botleng housing project
Taking education another step forward, the mine also built a TVET college for the community
of the centre was R1.7 million, and the project created 30
Not only will pupils have an increased
started by the mine
opportunity to qualify for Exxaro talent
means that 25 families
pipeline university bursaries, but qualify-
were able to benefit from
ing grade 12 pupils will be offered bur-
the project, and more than 50
the community is the Delmas Creche.
saries as well,” says Van Stelten.
temporary jobs were created for local
“This creche means that the commu-
people as well,” says Van Stelten. He
nity doesn’t have to worry about its
efits such as tuition fees, allowance for
adds that R6.7 million was spent on
children during the day,” says Van
books, residence fees and meals, prac-
the project and the houses were all
Stelten. A local supplier was used in
tical work for bursary holders as pre-
certified by the National Home Builders
the construction of the project, which
scribed by the institution of study, and
Registration Council.
cost Exxaro around R700 000. The early
He adds that the bursaries offer ben-
professional in-training programmes
temporary jobs during the construction phase.
Another significant project for
childhood development programme is
after completion of the pupils’ studies.
Multipurpose centre
“To date, more than 10 students from
Besides the housing project, Exxaro
Mpumalanga have benefitted from the
also invested in a multipurpose cen-
forward, the mine also built a tech-
programme,” says Van Stelten.
tre for the community. The total cost
nical and vocational education
utilised at the creche. Taking education another step
Truck-and-shovel operations will be used to mine the resources
In sid e M in in g 0 4 | 2017
13
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There is an estimated 2.5 million tonnes a year of thermal and metallurgical coal reserves
Over 150 temporary jobs were created through the community projects
and training
Skills training doesn’t
college for the
stop there for the mine.
community. The train-
It has developed a one-year
or long-term contractors,” says Van Stelten. The learner-
ing centre cost R6.38 million
structured programme where learners
ship programmes are offered
to build, and will further benefit to the
receive surface excavation compe-
to workers and include artisan trades
community facilitating skills transfer.
tencies, licences, and fundamental
such as diesel mechanic, electrician,
“During construction of the college,
safety training. “These are offered in the
fitter, and millwright. It is a three-year
we employed 20 contract workers from
areas of mining and plant production,
programme that is finalised in a regis-
the community,” explains Van Stelten.
with entry level opportunities for staff
tered trade test.
TABLE 1 Learnership programmes YEAR
INITIATIVE
BENEFICIARIES
COMMENTS
2012
Skills programme (dump truck and plant)
10
All appointed permanently
2013
Skills programme (dump truck and plant)
10
All appointed permanently
2014
Skills programme (dump truck and plant)
10
All appointed permanently
2014
Internships (electrical, geology)
3
Two appointed permanently, one writes trade test in September 2017
2015
Skills programme (dump truck)
26
Eight appointed
2015
Vacation work students
2
Back at university
2016
Skills programme (dump truck)
22
2016
Internships
5
Partnership with other Exxaro BUs
2016
Work-integrated learning
3
Partnership with other Exxaro BUs
2016
Engineering learnerships (electrical, diesel mechanics)
5
Still in training, will write test in April 2018
2017
Engineering learnerships (electrical, diesel mechanics)
5
Commenced institutional training
2017
Internships
5
Commenced in March 2017 and July 2017
2017
Work-integrated learning
3
To commence 2017
In sid e M in in g 0 4 | 2017
15
Coal processing
Managing coal quality The quality of coal, as well as the knowledge of the coal properties, is extremely valuable information for mines and power plants. Delivering uniform coal quality to clients requires real-time monitoring of coal stockpile quality.
T
HE TECHNICAL paper
Methodology
Finally, the coal is retrieved by the
‘Coal quality manage-
The authors write that the proposed
reclaimer and transported outside the
ment model for dome
technical approach for the
dome to the silos located at the power
storage (DS-CQMM)’
development of the DS-CQMM is
plant. In addition to the reclaimer, an
based on the technological process
emergency reclaimer is installed at
designed at a surface coal mine
floor level to reclaim coal in case of the
operated by one of the largest coal
reclaimer’s failure or maintenance,”
companies in the USA.
describe the authors.
by MA Badani-Prado, V Kecojevic and D Bogunovic studies the development of a user-friendly interface for dome storage coal quality management.
“The system consists of a hopper,
The authors continue that the
crusher, coal analyser, conveyor belt
coal analyser provides coal quality
system, transfer towers, dome, stacker,
information in real time, every minute,
reclaimer, and emergency reclaimer.
for each batch of coal. A stacker stores
A truck dumps the coal through the
the coal inside the dome and has one
hopper into the crusher. Crushed coal
degree of freedom in the rotational
is transported by belt conveyor 1 to
(azimuthal) angle.
transfer tower 1 and belt conveyor 2
A reclaimer that reclaims coal
and then to transfer tower 2, which
from the dome has two degrees
is designed to direct coal to either
of freedom: one in the rotational
the emergency stockpile, power
angle and the other one in the
plant silos, or dome.
elevation angle. Ultrasonic sensors
“The process at the transfer towers is conducted by the actuation of fastacting proportional flop gates located on the towers. Coal quality and timestamps are recorded by the coal analyser, which is located above belt conveyor 1. The coal flow directed to the dome by belt conveyor 3 is delivered to the stacker. The boom of the stacker rotates and steers the coal to its final location through a built-in belt conveyor.
are used for measuring the level of the coal stockpile, and encoders for determining the angular position of the stacker and the angular position and elevation of the reclaimer.
Delay time application It is necessary to know, for each batch of coal, what its quality tags and timestamp are, and when it will reach the boom of the stacker to assign the angular position of the boom and the quality tags.
Stacker application Mine operators need to know and visualise the actual quantity (volume and tonnage), location, and properties (heating value, moisture, ash, and sulfur) of stacked coal inside the dome. To accomplish this task, the first step is to determine the angular position of the boom of the stacker inside the dome.
Coal quality is a major concern for mines
Reclaimer application “One of the objectives of the DSCQMM is to develop a user-friendly interface for determining the coal
16
Ins i de Mi n i n g 0 4 | 2 0 1 7
Coal processing
For the research, the authors used existing technologies in a surface coal mine, merging automation technologies with information technologies and mathematical modelling. Their specific aims, as published in
290˚
the paper, were as follows: • Create multiple user-friendly
Emergency Reclaimer
200˚
applications based on the Windows OS for the process of stacking and reclaiming coal flow into a
Live Stockpile
dome storage.
0˚
• Establish the connection between the applications, the coal analyser, and the distributed control system (DCS) room databases to retrieve and store necessary data for building a DSCQMM model.
Schematic view of live stockpile and emergency reclaimer
• Develop an algorithm for retrieving data from the DCS room database containing the velocities of different conveyor belts and calculate the
quality distribution inside the dome.
coal properties during the stacking
time remaining for a given batch of
Therefore, the reclaimer application
process and reclaiming process
coal coming from the crusher and
should have a configuration that allows
based on the reclaimer’s operations
belt conveyors to the boom of the
the operator to navigate through the
were developed, and a useful tool to
applications with minimal training,”
forecast the coal reclaiming process
write the authors.
was designed.” They continue that the model can
stacker inside the dome. • Formulate a three-dimensional mathematical model for developing a stacking algorithm that will assign
Conclusion
be helpful in the process of managing
The authors conclude that the coal
coal quality. “If we know the quality of
quality management for the dome
the coal stored inside the dome and,
storage (DS-CQMM) model developed
most importantly, where it is stored
the coal volume that is being stacked
through the research provides a
and how many tonnes are available,
into the dome and assign quality
graphical and numerical distribution
then the process of blending the coal
properties for presenting values, in
of coal quality and its relative position
coming in from the mine and retrieved
inside the dome by integration of a
from the dome can be accomplished,”
variety of technologies.
conclude the authors.
shape and relative position of the coal stockpile inside the dome. • Create an algorithm for calculating
tonnes, for the user interface. • Formulate a mathematical model for developing a reclaiming algorithm that will show the operator the
“Mathematical models for different DS-CQMM applications were
This paper was first published in the
different ranges of values of different
developed and interaction between
Southern African Institute of Mining
quality tags of the remaining coal
these applications and databases
and Metallurgy Journal. Read more
inside the dome. In addition, it needs
was established. Algorithms for
at: www.saimm.co.za/Journal/
to show the remaining shape of the
three-dimensional assignment of
v116n07p699.pdf
coal stockpile after reclaiming. • Build a tool that implements a set of
The proposed technical approach for the development of the DS-CQMM is based on the technological process designed at a surface coal mine operated by one of the largest coal companies in the USA
tables with numerical values of coal quality and tonnage for forecasting future reclaiming processes. • Develop multiple simulators for each created application to test the model.
In sid e M in in g 0 4 | 2017
17
mining in africa
Bakubung’s timeline update The main shaft is still under construction
T
he next step to commissioning
positioning itself to start with. “The stop-
the main shaft over the next cou-
ing operations will start in December
ple of months is to get the perma-
2018, starting with ledging, equipping
nent waste pass system in place.
and then stoping. Then there will be a
The mine will have to open up 69 level
three-year build up towards full produc-
and 72 level tip excavation with some
tion, which will be reached in June 2022.
raise bore holes, which will interconnect
We are primarily focused on reef devel-
69 level to 72 level to 77 level; 77 level is
opment,” explains Terblanche.
the bottom loading system, which feeds the flask on the main shaft. “The next big thing for us is to get V1, a
Shaft systems The two shaft systems are independent,
ventilation raise bore of 6.1 m diameter,
but need to be connected. The servic-
in place from the surface to 72 level. We
es shaft is equipped to provide mining
are limited in terms of moving tonnages
supplies, transport men and materials
out of the mine until V1 is in place, as it is
and links to the main shaft. The main
the main upcast shaft. The services shaft
shaft is the main production shaft, which
and the main shaft are two downcast
will take down men and material, hoist
shafts,” says Dewald Terblanche, pro-
broken rock, facilitate dewatering, and
duction manager, Wesizwe.
send down water, electricity cables and
Another milestone is to start with reef development, which Bakubung is
other shaft services required. “We have finished with the shaft steelwork below the surface, and are now
Working towards full production in 2022, one of the key milestones of Wesizwe’s Bakubung Project is to commission the main shaft in July 2017. The next big task will be to get the first ventilation (V1) raise bore in place, with V2 and V3 to follow before production commences.
By Mientjie Kleinhans
finalising the changeover from sinking conditions in the head gear where we
in July 2017. The main shaft has three
will reposition the sheaves and install
winding parts. The first is the main man
permanent steelwork. The main con-
and material winder with a single-deck
veyor services, which still need to be
cage that will transport man and materi-
installed, will operate for the 35-year life
al. The second winder is the rock winder
of mine,” says Cornelius Chimbanga,
with a payload of 20 tonnes on each of
engineering manager, Wesizwe. The
the two skips. The third winder is the ser-
mine plans to commission the main shaft
vice winder, to be used predominantly for maintenance and small material, to take people to critical levels, such
Wesizwe's Dewald Terblanche (left), production manager, and Cornelius Chimbanga, engineering manager
18
Ins i de Mi n i n g 0 4 | 2 0 1 7
as the pump chambers, and transport the engineering crews that work in the shaft system. “All those winding plants
The four-level mine consists of • • • •
69 72 77 81
level level level level
(690 (720 (770 (810
m) m) m) m)
Timelines • J uly 2017 – main shaft commissioning • Q1 2018 – commissioning of first ventilation shaft • December 2018 – start of stoping operations • June 2022 – reach full production
says Chimbanga. Part of the infrastructure development still to be completed is the development of the underground pump chambers. “There will be one major pump chamber on 81 level, which we are currently mining, and the plan is to have the pumps installed by late 2018, or early 2019, to enable the extraction of water from the mine,” explains Chimbanga.
Mechanised mining The mine will be fully mechanised with a hybrid system in the stoping; therefore,
Working hard underground to meet key timelines
it is important to finalise the ventilation in the mine as soon as possible. “For a mechanised mine, ventilation becomes crucial due to the heat and fumes
are installed. We just need to finalise the
generated by the machines. The com-
infrastructure and head gear before
missioning of the first ventilation shaft
connecting the ropes and starting with
will give us the ability to increase the
the commissioning,” says Chimbanga.
number of machines that we can send
Production figures The mine is designed to produce 250 000
down, and allow us to speed up the development to ramp up. “The mine development is mech-
t of ore per month. The development will
anised, and the plan is based on
be on reef and there will be minimum
low-profile equipment consisting of a
waste generated, estimated at about
single-boom drill rig, a 10 t load haul
15 000 t per month. “For the first seven
dumper, and a 30 t dump truck. We
years of full production, from 2022 to
are also looking at a type of a bolter to
2029, we are going to produce 15 000 t
complement the suite of equipment,”
of waste per month on a 3 million tonnes
says Terblanche. The advanced strike
per year operation,” says Chimbanga.
drive will also be mechanised and
Bakubung will mine both Merensky and
handheld pneumatic drills will be used
UG2, focusing on Merensky for the first
in the 29 m long panel.
few years at a 90%/10% split. To support the mining, there are es-
Underground workers in the safety bay
Water
sential services still to be rendered.
The mine is designed to use 1 t of wa-
“We need to supply power to the un-
ter to 1 t of rock blasted. The off-take
derground system, with underground
agreement with Magalies Water is
substations on each level. We want to
1.6 Mℓ/day, of which 0.8 Mℓ is for the
install substations on 77 level and 81
mining, but the water supply from
level, and once both 69 level and 72
Magalies Water will not be used for
level hole into main shaft, we will install
drilling. “The supplied water will be used
substations on those two levels as well,”
mainly for the change houses, offices, infrastructure, and for drinking. Where
“For the first seven years of production, from 2022 to 2029, we are going to produce 15 000 t of waste per month on a 3 million t per year operation.”
possible, we will use recycled water
Cornelius Chimbanga, engineering manager, Wesizwe
treatment plant on the lower portion
underground. Two hot and cold water
Construction of office buildings in progress
wells will be constructed in 2018, which will be used as our main recycling facilities on surface to send drilling water underground,” says Chimbanga. Part of the water secured from Magalies Water will be used for the housing project, consisting of 802 units that are still under construction. “We are also looking at constructing a sewer of the mine,” concludes Chimbanga
The material and main shaft
In sid e M in in g 0 4 | 2017
19
Underground development
Increasing production with
mechanised machinery
S
Mechanised mining, high-performance teams and strong relationships are three elements that have assisted Redpath Mining (South Africa) in obtaining more work at Platinum Group Metals’ Maseve Project. With increased production, the mine should reach steady state later this year. ince June 2016, Redpath Mining took over the mining operations at Maseve, and in particular bord and pillar
mining, in addition to its long-haul stoping operations. The bord and pillar portion will take place at Block 11, and the company will also do associate development with the mine. “It is an exciting project for us. We are currently busy with the mining reef build-up to get monthly production to approximately 110 000 tonnes. Several contractors have been engaged to assist with achieving this target,” says Ockert Douglas, managing director,
install, operate and maintain a 1.0 km
who sees it as an investment. The
conveyor towards Block 11, linking into
company will recoup its investment
underground silos and the existing 1.4
by way of a per tonne charge now
km conveyor to surface, and 1.7 km
being negotiated. In addition, the
conveyor system into the mill.
company has also added four units
“We agreed to install an extended
“The mining rates in the months
This is a capital investment from Redpath with a guaranteed return on
ahead are scheduled to continue
investment. Once production begins,
improving as Block 11 is further
we will get payback in tonnage on
developed; and during 2017, Block
our investment. The conveyor belt
11 is scheduled to build up to 70%
should be complete by April. Once
to 80% of mined ore flow. At full
the conveyor is installed, we will
production, Block 11 is planned to
achieve the next ramp-up targets and
provide up to 76 000 tonnes of ore a
get ourselves to steady state,” says
month,” says Douglas.
Douglas. The cost for the conveyor
Redpath Mining (South Africa). The company has also entered into a letter of intent whereby it will
to the trucking fleet on a rental basis to ensure efficient ore transport.
conveyor belt down the mine.
He explains that bord and pillar
installation, which is estimated at R25
mining is a method that uses drill
million, will be borne by Redpath,
rigs to drill out a portion of rock as
Table 1 Estimated resources
Merensky – Mining cut Resource category
Cut-off
Tonnage
4E
20
Grade
Metal
Pt
Pd
Rh
Au
4E
4E
Reef width
cmg/t
Mt
g/t
g/t
g/t
g/t
g/t
kg
Moz
cm
Measured
300
9.266
3.35
1.41
0.21
0.26
5.23
48 461
1.558
152
Indicated
300
12.552
3.65
1.54
0.23
0.29
5.71
71 672
2.304
141
Total
300
21.818
3.53
1.49
0.21
0.28
5.51
120 133
3.862
146
Ins i de Mi n i n g 0 4 | 2 0 1 7
Underground development
stipulated by the rock
At full production, Block 11 is planned to provide up to 76 000 tonnes of ore a month
company cross trains miners with additional engineering
engineers, load it with
skills to look after and
LHDs and then use trucks
maintain equipment. The
to take the reef to a specific
transfer of knowledge is not
point in the mine. From there, the material is loaded onto a conveyor
only from the engineering side to the
belt and the conveyor belt takes it out
mining side, but also from the mining
of the mine. The hybrid mining has not
side to the engineering side. “The methodology that Redpath
yet commenced and the company is in discussions with the mine about
employs on the majority of its projects
where hybrid mining is required.
is to make use of mechanised mining methodology and high-performance
Mining equipment
teams. We believe in innovation and
A portion of the equipment used at
mechanisation. And we believe our
Maseve belongs to Redpath, but the
combination of the two improves
majority is owned by the mine and
production and safety and makes us
supplied to the mining contractor to
a market leader,” says Douglas.
develop the underground mine.
Success story
The company’s success to date can be attributed to the current long-haul
“As far as Maseve is concerned, it is a
stoping being fully mechanised, and
success story to date and we believe
the use of high-performance teams.
it will be a success story going forward.
A remote control load haul dumper
We are still in the build-up phase and
(LHD) is used, and the teams are
believe that the mine will reach steady
highly trained and 40% smaller than
state and be in full production within
normal labour.
the second half of the year.
“This combination proves to be very
Maseve Mine facts •A n underground platinum mine • L ocated about 35 km northwest of Rustenburg •M ining from the Merensky and UG2 reefs • L ife of mine is over 20 years •P latinum Group owns 83% of the Maseve Mine
“The good relationship with the
successful in the long-haul stoping
client means that both companies
section, where it is easy to work with
are working together to achieve a
smaller teams as it is not as labour
common goal. The methodology, the
intensive. We also have our own
way we work together, the planning
accredited training facility with the
we do and the relationship we have
majority of the people being artisans,”
are pivotal for the success of the
says Douglas. He explains that the
project,” concludes Douglas.
Table 2 Estimated resources
UG2 – Mining cut Resource category
Cut-off
Tonnage
4E
Grade
Metal
Pt
Pd
Rh
Au
4E
4E
Reef width
cmg/t
Mt
g/t
g/t
g/t
g/t
g/t
kg
Moz
cm
Measured
300
8.496
2.29
0.94
0.36
0.04
3.63
30 841
0.992
140
Indicated
300
14.183
2.46
1.01
0.39
0.04
3.90
55 314
1.778
136
Total
300
22.679
2.39
0.99
0.38
0.04
3.80
86 155
2.770
137
In sid e M in in g 0 4 | 2017
21
Underground development
New technology to replace
drill and blast
A
The need to access viable ore bodies faster – and realise a quicker ROI – is prompting companies to be increasingly innovative. As a result, there are a number of new technologies being developed and becoming available in the market to assist mining houses and investors in this regard. By Neil McCoy* CHIEVING A quicker return on investment by accessing the orebody faster, and starting to mine
sooner and more efficiently is what adapted or
tional drill and blast methods are being
designed by taking
optimised through continuous improve-
these technologies into
ment initiatives and tweaks to the tech-
consideration.
nology; however, the need to get fast-
In order to overcome these
rock cutting-type machine with on-board bolting systems. This will be a single piece of equipment that can replace multiple track-
er full-system advancement in the mine
challenges, Sandvik Mining and Rock
less pieces of equipment. It is currently
development phase outpaces these
Technology has used the development
being tested for operational readiness
step-by-step improvements. There is
of disruptive technologies and a bet-
at an underground mine in Austria.
an opportunity, in certain operations,
ter understanding of customer needs
Thereafter, it will be trialled at a South
to introduce disruptive technologies
in particular applications. With this in
African mine to test full-system capa-
that will transform projects that can be
mind, the company looks at addressing
bilities. This continuous mining type of
system solutions rather than individual
machine will offer rapid development
components of the mining cycle. An
rates and potentially far outperform the
example of this could be to remove op-
current drill, charge, blast, ventilate,
erators from high-risk areas and provide
load and support cycle. Other options
them with a safer working environment,
for automation currently available
such as a control room on surface or at
from Sandvik include fully autonomous
an operator station remotely in a well-
equipment and plug-and-play solutions
lit and -ventilated area. By addressing
that allow for flexibility in different min-
a component like this, it enables the
ing applications. These systems enable
mining cycle to be optimised. “Rapid
equipment to be operated during
access development” has become
shift-change periods, when no people
the new buzz phrase in the industry
are underground. The machine can still
and Sandvik is manufacturing a Rapid
be operated remotely from a control
Mine Development System (RMDS),
room on surface or be programmed to
Niel McCoy, key account manager
22
which is a hard-
shareholders consider essential. Tradi-
Ins i de Mi n i n g 0 4 | 2 0 1 7
Underground development
perform the work autonomously. There are reference sites where the introduction of this technology has been used, resulting in the utilisation of two hours between cycles during shift change.
New technology A lot of the new technologies are machine-based; however, this does
When we look at technology, we look for something that will provide a step change that can actually work
not mitigate the need to have good skills and mechanical appreciation in
the mine and have a live or near-live
operations. In this regard, Sandvik has
view of operations at any time. Produc-
developed a product to have real-time
tion and maintenance supervisors will
information, from the work face, that
know where the equipment is, what
enables transparency in processes
the status is and how the equipment
and systems designed to optimise the
is performing in relation to the mine
mining cycle. The development of
plan and maintenance schedules. This
mechanised mining skills are essential for the sustainability of this industry in South Africa and Africa. There are
provides a real-time tool at their fingertips, which enables productivity levels to be achieved and optimised on an ongoing
many new pro-
basis against the
jects coming
mine plan.
up in the next four years that will require these unique skills on an ongoing basis. Urgent investment in these resources and the development of these skills will
Face time optimisation During shift changes, many activities need to take place. The monitoring and tracking of these activities can lead to longer
address potential short-term challeng-
face time. One of the biggest problems
es. Through application knowledge,
traditional mines have is that these ac-
years of mechanical data collection
tivities run overtime, resulting in a loss of
and global benchmarking, Sandvik has
productivity time. By having a system
created Trans4Mine, which is an offer-
like OptiMine in place, operations will
ing that assists its customers to close
have a clear understanding of what is
these broadening gaps.
happening at any time.
Looking at a surface mine, one can
DRILL AND BLAST •T he buzz phrase in the industry is “rapid access development” •T he Rapid Mine Development System is a hard-rock cuttingtype machine with on-board bolting systems • F ully autonomous equipment, and plug-and-play solutions will soon be in high demand
include options with these technologies
stand on the high wall to observe the
Adoption of technology
operations from any point and view
Many African and South African min-
the various activities. It is not possible
ing operations see the need to rapidly
*Neil McCoy is the key account man-
to do that in an underground oper-
adapt and embrace new technology.
ager: Business Development at Sandvik
ation. The idea is to take the roof off
Many of the feasibility studies now
Mining and Rock Technology.
taken into consideration.
In sid e M in in g 0 4 | 2017
23
Mining infrastructure & construction
The impacts of Industry 4.0
The mining industry has much to catch up on when it comes to adopting the Fourth Industrial Revolution and the internet of things. Where the oil and gas industry has been the thought leader in adopting new technologies, historically, mining has always been a bit behind. By Tobias Becker*
W
HY DO WE still send peo-
still has this exploration kind of mindset.
profitability in mines go up and will help
ple into harms’ way if
It is very mechanical and, therefore,
mines weather the ups and downs of
they could sit in a much
people think that it is all about ‘hard
the cycle in a better way than in the
more value-adding seat
boys and hard tools’ but the reality is
past. It will give the commercial arm of
in an office and control mining equip-
that all industries – step by step – have
the mining industry much better control
ment from there, rather than in the
been going through mechanisation,
of inventory and it can be seen with
middle of where all the hazards are?
electrification, automation and now
big data nowadays.
The Fourth Industrial Revolution means
the Fourth Industrial Revolution.
taking information, or the cyber aspect
24
They all become more abstract, a
Visualisation
of real mining equipment, merging it
numbers game, an economy of scale
With the new revolution, we can visual-
with all the automation and electrical
game, and a productivity game. Some
ise a stack of ore as it comes out of a
that we have already introduced in
industries have embraced that faster
mine as well as the quality and distribu-
the mining industry, and bringing it to
than others. I see the mining indus-
tion in a way that has never been there
the 21st century. The mining industry
try embracing that, which will make
before. While the mining industry might
Ins i de Mi n i n g 0 4 | 2 0 1 7
With the new revolution, we can visualise a stack of ore as it comes out of a mine – as well as quality and distribution – in a way that has never been there before
the market comes back. It makes it much more efficient and profitable. The mining industry is almost in a pioneering mode, but in all honesty it has to change to a modern sophisticated industry. All the tools and technologies are there and the good examples are there to copy and paste from.
Future of mining The mine of the future is a thinking concept. It will be a mine where people
Operators of the future will operate equipment from an air-conditioned control room
take a breather, it is possible to start
are taken away from the operation
analysing what to do, what is available
itself physically, taken out of harm’s
in the deposits, the inventory, the ideal
way. There will be a process floor, with
way of blending that, and then bring it
much less personnel and more per-
back to the marketplace. It also allows
sonnel at the top side. The mine of the
operate the drone, getting a much
companies to work on efficiency, pro-
future will feature equipment clad in
quicker overview of what is going on,
ductivity, and on yield rates during a
sensors, taking in enormous amounts
with much more precise data, infrared
time when the industry is working only
of data that allows the ability to pre-
data, and visual inspection data, and
on slow steam. When it all goes up into
dict how long particular equipment or
then be able to recommend to the
full mode again, you are better pre-
machines will be functioning, when it
mine operations much more precise
pared. This is what has happened in so many other industries.
needs to be serviced or maintained, whether it is still
For a mining communi-
running in an optimal point, or if it needs
ty out in the country-
some tuning
side, it means that the kind of jobs will
or calibration.
be different than
For instance,
what they are
interventions on the conveyor system.
Conclusion The Fourth Industrial Revolution will – in my eyes – help to eliminate some of those negative surprises, such as unforeseen down cycles, and will allow
the data col-
mines to use the down part of the cy-
today, but what
lected with
cle to invest time and brainpower into
goes along with
sensors and
optimising the mine to save costs and
it is no longer jobs
analytics allows
prepare the higher outputs needed in
that go from 100%
for the guid-
to 0% just because
ance of machines
the economic cycle
much more precise-
of that particular mineral has gone down. The problem is that in the upswing,
ly for long loads, optimising the mix of ore that comes out, and to find additional
the upswing. Old, or established, mines do not need to replace all the equipment. Mines that are deeply invested can place sensors on existing machinery. One can actually refurbish a plant
when output is all that matters, the
ore streams of other minerals accom-
with sensors and smart technology to
miner’s thinking is: “I don’t care about
panying the main mineral in a much
bring it to the next stage. An existing
wear and tear, energy efficiency,
better manner.
mine can be changed and it can
productivity and all those things because I get paid.”
Take for example a minerals opera-
be augmented.
tion with a lot of conveyors. In today’s world, a person could walk every day
*Tobias Becker is the senior vice-presi-
doesn’t hold water. It is much better
the 12 km along the conveyor while
dent and head: Africa at ABB.
to work on productivity, energy ef-
looking at the bearings, listening and
ficiency, and resource efficiency at
try to figure out if something is wrong.
a time that a mine can afford to do
Drones can do the same job. The same
this. It helps to drive up output when
person can sit in a control room and
During the downturn, this thinking
The four industrial revolutions: •1 st L ate 18th century to early 19th century • 2nd 20th century • 3rd Late 20th century to early 21st century • 4th It is now and it is here
In sid e M in in g 0 4 | 2017
25
Tyres, parts & maintenance
Unlocking efficiency in the mining industry
A
In today’s environment, where cost reduction is key, businesses rely on equipment working harder, and for longer. Businesses are looking to extend equipment life, while simultaneously spending less on maintenance. By Tendani Ndwamise*
s a result, there is a need
management can help reduce costs by
are exposed to the elements in extreme
to start looking beyond lu-
5% or more, but this is an undervalued
conditions, and where contamination
bricants that just meet OEM
opportunity due to the fact that fewer
poses a significant challenge.
specifications, but also to
than 10% of the 60% realise that the impact of lubrication could be up to six
customers in the mining industry, Shell
sion protection, piston cleanliness and
times greater. Lubricant product selec-
Lubricants understands the challenges
extended oil life. Our company believes
tion or management can impact many
companies face in the current climate.
that there is potential for lubrication to
elements of a company’s maintenance
Falling commodity prices, together with
deliver significant business value by con-
budget. Seizing the cost-saving opportu-
uncertainties about demand and over-
tributing to improved productivity and
nity depends on addressing two equally
supply lead to cost-competitiveness be-
reduced costs. Many times, the potential
important elements:
ing a top priority.
impact of lubricants is significantly under-
• selecting the right lubricant or grease
estimated and can result in a negative
• effective lubrication management – in-
apply TCO evaluations to measure
cluding the right storage and handling,
operational performance, knowing
the right place, the right time, the right
that reducing TCO over the lifetime of
cants on TCO, it is important to consider
amount, the right monitoring and the
machinery enables them to extract the
the ‘end-to-end impact’ on mainte-
right people.
best possible value from the asset. The
impact on total cost of ownership (TCO). When evaluating the effect of lubri-
Many mining companies already
nance budgets and processes, as well
Each piece of mining equipment made
impact of lubrication on TCO is too often
as any costs related to lost production
by different OEMs has its specific lubri-
underestimated. In general, lubricants
during equipment downtime. Optimising
cation requirements. OEMs define the
account for around 5% of total mainte-
lubrication can have a significant impact
minimum requirements for lubricants or
nance expenditure.
on component life, maintenance costs,
greases, but not all products that meet
and unplanned downtime and can con-
these standards deliver the same level
helped mining companies achieve
tribute to cost savings far higher than the
of performance.
savings that equal their total lubricants
Our company’s technical experts have
Grease application in the mining
spend by adopting the right approach
sector can be a specialist technical
to lubrication. They further believe that
area, where selecting the right grease
lubricants can offset up to 30% of the
According to an international industry
for the right application can be critical
maintenance budget. These savings
study commissioned by Shell Lubricants
to avoid costly equipment failures and
are derived primarily from lower mainte-
global, 60% of companies recognise
unplanned downtime. This is particularly
nance costs, reduced equipment down-
that effective lubricant selection and
true for open-gear applications, which
time and productivity improvements.
price of the lubricant itself.
Impact of lubrication
26
After decades of working closely with
lubricants that deliver increased corro-
Ins i de Mi n i n g 0 4 | 2 0 1 7
Lubricant selection
Underpinning good lubrication manage-
Choosing the correct lubricant or grease
ment practices is industry knowledge
often depends on a combination of the
and expertise. One of the core lubri-
equipment’s design characteristics, op-
cation management services offered
erational parameters, and environment.
by our company is building technical
Factors like temperature, humidity, and
competency across a customer’s organ-
location (altitude/depth) all pose differ-
isation. This is delivered through lubricant
ent challenges for lubrication.
technical advisors, supported by a team
cant supplier, whose technical teams
of global product application specialists
play a key role in identifying and
Selecting a less effective lubricant rarely results in immediate equipment failure, but can lead to increased maintenance
and lubricants services experts.
• A good relationship with the lubri-
delivering value. • A comprehensive analysis to identify,
expenses over time. These mounting
Monitoring and analysis
costs can be far greater than the savings
Regular monitoring and analysis helps
projects. Importantly, aligning on how
from selecting a lower-price lubricant.
ensure the lubricant or grease is function-
value is measured enables savings to
56% of mining companies acknowledge
quantify and prioritise TCO-related
ing well and remains fit for purpose. Lubri-
be recorded accurately. For example:
that unplanned equipment shutdowns
cant analysis is vital to business continuity.
•W hat is the hourly cost of mainte-
in the last three years have been due
Owners and operators of mission-critical
to their incorrect selection or manage-
assets need advance warning of me-
ment of lubricants.
chanical problems that are likely to dam-
By selecting the best-performing lubricant or grease, mining companies can realise TCO savings that reach
age equipment, reduce productivity and increase maintenance costs. A look at companies who have
far beyond any savings related to the
successfully implemented structured,
price of the lubricant itself. As such,
TCO-driven lubrication projects together
lubricant product selection should al-
with Shell reveals a number of initial ac-
ways be based on a well-considered
tions that help drive success.
TCO calculation. A high-quality oil or
• Senior management support of the
nance and time required for repairs? • What is the cost of replacement parts? • What is the benchmark failure frequency? • What is the monetary value of downtime for each piece of equipment, in terms of lost production? • Setting measurable targets to ensure that progress can be tracked. These steps will help companies form a
grease that keeps equipment clean of
TCO-driven approach to lubrication,
strong foundation from which to
deposits and effectively protects against
to help overcome challenges such as
successfully incorporate a TCO-driven
wear and corrosion can help extend
resourcing alongside the demands
approach to lubrication in their daily
of daily operations.
operations, carry out lubrication i
equipment life, reduce the frequency of breakdowns, and increase the machine’s availability. This could
• Appointing a project lead and allocating appropriate time
significantly decrease spend on spare parts and maintenance.
mprovement projects, and realise the associated cost savings.
and resources to a
Optimising lubrication can have a significant impact on component life, maintenance costs and unplanned downtime
team tasked with implementing changes.
*Tendani Ndwamise is the marketing manager at Shell Lubricants.
In sid e M in in g 0 4 | 2017
27
Tyres, parts & maintenance
Prolonging the life
Tyres are undoubtedly one of the major expenses at mines. Therefore, prolonging tyre life should be a top priority in the industry. One of the main methods to get more out of a tyre is preventative maintenance. By John Sims and Jay Seals*
28
Ins i de Mi n i n g 0 4 | 2 0 1 7
Tyres, parts & maintenance
T
YRES ARE A huge cost to any
correct tyres in terms of the construction,
Tyre inflation
mining operation, and there are
size and overall diameter of the tyre, as
It is not the tyre that carries the load but
many factors that can affect tyre
well as rotating tyres from the front to the
the contained air inside, making pressure
life. Tyre management is essen-
rear and the spare for matching purposes.
maintenance essential. Maximum tyre
Other factors that can prolong the life
life, or performance, is achieved when
tial to ensure the effective running of tyre-related fleets and we work with our
of a tyre include:
the tyre is inflated to the appropriate cold
clients to find the most effective way of
• preventative and corrective repairs of
pressure set for the specific load it carries.
running these fleets in their operations. Some of the main factors that can prolong the life of a tyre include selecting the correct tyre for the application. Ensuring correct pressure maintenance is also fundamental to keeping tyres working for longer. Much can be said about matching
tyre damages or cuts • retreading of tyres assists in reducing the number of tyres being scrapped, • operational area maintenance is also key • providing operator awareness training and workshops
Under-inflation causes excessive deflection of the tyre, creating mechanical stresses. These stresses cause heat levels in the tyre to increase, leading to reduced tyre life and/or premature failure. Overinflation, on the other hand, restricts the natural deflection of the tyre and can lead to damage and premature failures.
• conducting ongoing
Correct tyre pressure is
tyre-failure analysis, which will identify
essential for all these rea-
the root cause or
sons as well as contributing
problem areas
to increasing productivity
• establishing a tyre
owing to reduced vehicle
committee that has regularly scheduled meetings to discuss and evaluate results while imple-
downtime for tyre repair caused by incorrect inflation. Incorrect tyre pressures will dramatically reduce tyre life, causing
menting continuous measured
new tyres to be purchased prematurely.
improvement strategies.
As mentioned, with poor pressures, failure
Benefits of maintenance
is inevitable, which can be dangerous.
Not only does the correct maintenance
Tyre failure
of tyres increase tyre life, it also increases
There are many factors causing tyres to
machine availability owing to decreased
fail, which include rock impacts, over-
tyre-related downtime. This, in turn, allows
loading, under- or overinflation, poor
the machine to be available further for
haul road designs, underfoot conditions,
production. Effective tyre maintenance
elevations, and heat where tyres run over
will also increase the life of a tyre and,
their recommended tons kilometre per
thereby, reduce new tyre purchases.
hour (TKPH) rating.
It also means less tyres going to the scrap heap. Training people to ensure that they are
The first typical maintenance procedure that mines neglect, which causes tyre failure, is correct tyre pressure. This
qualified in selecting the correct tyre for
greatly decreases tyre life and is the
the application – to mount, demount,
most common issue when tyre mainte-
strip and fit the tyre and wheel compo-
nance programmes are not in place. The
nents correctly and safely as well as be-
mismatching of tyres is also a common
ing able to assess positive and negative
factor on many mines, which puts in-
operating parameters and recommend
creased strain on a tyre that is larger than
corrective action – will also go a long way
its dual partner.
to in saving tyre life.
A tyre can be overloaded, not just by
Tyres operate under huge pressure and
overloading the dump truck but having
personal injury, or even fatality, can hap-
tyres that are mismatched. Tyre fitment
pen by tyre bursts owing to over inflation,
techniques are a major factor in how tyres
poor fitment techniques and lack of train-
run and bad fitments can cause tyres to
ing. Tyres of this size can be dangerous if
fail early. Other areas of neglect include:
the correct tyre management procedures
• site severity studies (study of the oper-
are not in place. We have a learning management sys-
ations to identify how and where tyres are damaged)
tem for all team members globally, which
• weight studies
covers more than 250 online courses, fol-
• daily/weekly/monthly inspections
lowed by dozens of hands-on task-
• preventative repairs on damaged tyres.
specific field assessments and moves
An effective tyre maintenance pro-
through three levels of progression.
gramme as well as haul roads and pit
In sid e M in in g 0 4 | 2017
29
Tyres, parts & maintenance areas kept clean and tidy by correctly
different tyre with a different ply or star
utilising the support equipment – such
rating. Many trucks have sideboards
as graders and dozers – can
also play a big part in tyre damage; therefore, the haul road must be well maintained and the correct material should be used.
Overloading
• lowering the hourly tyre operat-
the volume of the load,
ing cost as it can be put back
Tyre management is essential to ensure the effective running of tyre-related fleets
density material, will overload the trucks’
into service • reducing the number of tyres being dumped as tyres last longer
recommendations
• increasing tread utilisation
as well as the tyres.
• adding value to tyre operations.
Also, offset loading
Tyre maintenance is essential in
will overload tyres
contributing to successful mining
causing potential early failure. It is important to
Tyre injuries
on many mines, which puts
operations and to ensure that tyre maintenance is done safely, tyres should only be fitted by trained personnel. There are many methods to increase
the tyre out of its working capabilities
The sizes of the tyre injuries that are
tyre life, such as machine mainte-
and can lead to failure. The vehicle is
repaired will depend on the position
nance, which is the first area where we
designed to carry a specific load, so it
of the damage. Rock impacts and
experience issues Not to forget wheel
is argued that the tyre should be able
sidewall cuts are the most common
alignment, which can also cause the
to do the same. Overloading and un-
damages on tyres during operation.
tyres to wear unevenly, resulting in ear-
der-inflation is exactly the same thing:
Repairing the tyres will result in:
ly removal if they are not monitored.
the air contained in the tyre is not suffi-
• extending the life of the tyre as it
cient to carry the load.
can continue to run
It is sometimes possible to eliminate or reduce the problem by using a
30
which, in higher-
keep this in mind.
Overloading is a problem
used as tyres are running longer
(Greedy boards) fitted to increase
prevent these tyre failures. Underfoot conditions
• reducing the number of new tyres
• providing spares for the matching of duals
*John Sims is the managing director at Kal Tire South Africa and Jay Seals is the technical support manager at Kal Tire.
Ins i de Mi n i n g 0 4 | 2 0 1 7
TOOLS & EQUIPMENT
BMG offers an extensive range from an unrivalled distribution network. It is our commitment to being a valuable part of every customers process that makes us an industry leader. Our service offering in our product range is bolstered by the ability to source non-stocked tools & equipment countrywide within 24 hours. OUR RANGE OF PRODUCTS INCLUDE: • Lifting & Rigging
• Locks
• Hand Tools
• PPE
• Spanners & Sockets
• Abrasives
• Power Tools & Cutting Tools
• Electrical Equipment
For more information contact your nearest BMG branch.
BEARINGS • SEALS • POWER TRANSMISSION • DRIVES & MOTORS • MATERIALS HANDLING FASTENERS & TOOLS HYDRAULICS • PNEUMATICS • FILTRATION LUBRICATION • VALVES • TECHNICAL RESOURCES • FIELD SERVICES
Nuts, rods, bolts & bearings
Split cylindrical roller bearings O
NE COMPANY that offers split cylindrical roller bearings as part of a comprehensive range is BMG, with
its HKT range of bearings. The company's series of split cylindrical roller bearings is designed for efficient installation, simpli-
fied maintenance and reduced downtime in arduous applications. “These split cylindrical roller bearings have a robust clamp ring design that offers cage alignment and simplified maintenance procedures. Split bearings are recommended for improved performance in difficult applications, particularly when the replacement of standard mounted bearings involves the removal
Bearings come in so many different shapes and sizes – for various applications – that it can be daunting to choose the right bearing for a specific application. One example is split cylindrical roller bearings that can be found in bucket-wheel excavators, among others.
of machinery and components, like large
SPLIT BEARINGS Split bearings are made in two halves for simple assembly, without the need for conventional axial threading and special mounting requirements of solid bearings.
Split cylindrical roller bearings with a robust clamp ring design that offers cage alignment and simplified maintenance procedures
bearings are available with a housing and support, and alignable split cylindrical roller bearings with a standard plummer
gearboxes and couplings,” says Rouff
– thus reducing downtime,” says Essop.
block. The range consists of series for light
Essop, general manager: Bearings, BMG.
He adds that the spilt roller bearings can
applications, heavy industries as well as
withstand operation in arduous condi-
extra-heavy and high-speed applications.
bearings are made in two halves for
tions where dust, moisture, chemicals,
Components include a bearing that has
simple assembly without the need for
heat and dirt would normally affect
two halves, consisting of the outer and
conventional axial threading and special
performance. Split bearings cope with
inner ring, the clamping ring, cylindrical
mounting requirements of sold bearings.
high radial loads, have greater speed
roller and cage assembly, housing (car-
This range is designed for inter-change-
capabilities and operate efficiently at
tridge) and support (pedestal).
ability with competitor split bearings to
elevated temperatures.
“The main components of these split
enable quick and easy replacement – be it for the bearing, housing or pedestal
“If split roller bearings are used in conjunction with suitable lubricants, service life is further extended.” Rouff Essop, GM: Bearings, BMG
The outer and inner rings have angle
“If split roller bearings are used in con-
joints to ensure contact continuity with roll-
junction with suitable lubricants, service
ers and the two halves of the inner ring are
life is further extended, maintenance
fitted on the shaft by two clamping rings.
requirements are minimal and downtime
There should be a gap at the joint (be-
is significantly reduced. As the volume
tween 0.35 mm and 0.55 mm) to ensure full
of the grease injection varies according
contact between the bore of the inner ring
to specific operating speeds, different
and shaft. The auto-locking cage is made
bore sizes and the various types of seal-
of aluminium or brass, and the steel clips
ant applied, it is important to get pro-
attached in each half of the cage provide
fessional advice.” Split cylindrical roller
the self-locking mechanism.
Split bearings are recommended for improved performance in difficult applications
Education & Training
Training for safety’s sake
W
hether it be training for snake handling, basic
A variety of safety training courses are available through I-CAT
fall-arrest, or specialised confined-space training,
workers from all levels are exposed to sit-
and gradually progresses through to fall
uations where they need to know how to
protection planning, rope access (Lev-
react in potentially dangerous situations.
els I to III), bolting and rigging.
One of the training houses that offer
“Level III rope-access training is an
training to personnel on-site or at their
eight-day course, while the basic
own premises is Skryriders Access Spe-
fall-arrest course is only one and a
cialists, which has an in-house training
half days,” says Mike Zinn, marketing
facility in Midrand. The training provided
manager, Skyriders Access Specialists.
begins with basic fall-arrest technician,
The company is awaiting SETA accreditation to enable it to offer specialised
Louise Dercksen, group HR manager, DRA
confined-space training. A confined space is defined as an enclosed, restricted, or limited space that includes any equipment, machinery, or object in which dangerous liquids or concentration of gas, vapour, dust or fumes may be present.
Safety remains one of the mining industry’s biggest challenges, and proper staff training around safety issues will assist in reducing fatalities. With many training programmes available in the market, there is no excuse for placing peoples’ lives at risk anymore.
“Training in this regard is critical for the mining industry,” comments Zinn. Con-
concrete inspection, maintenance and
fined-space training is the latest to be
repairs, application of coating systems,
offered by the company, which con-
working-at-height safety systems,
tinually updates the training on offer in
welding, and confined-space rescue
order to cater for the changing needs
and standby.
of the marketplace. “We look forward to the official
New training facility
launch of two new services in 2017,”
Another training facility that opened
Zinn reveals. Current services include
its doors recently is environmental solu-
non-destructive testing and inspection,
tions company I-CAT. Its new premises
Skyriders offers rope-access training from levels I to III
we are also capable of hosting events such as business breakfasts.” External training courses commenced in March 2017, with the initial focus on environmental management. Jansen van Rensburg explains that
I-CAT’s new training facility hosts training, product launches and functions
Phillip De
I-CAT plans to schedule three environ-
Weerdt and An-
mentally-oriented external courses, work-
tonio Da Gama Tex-
shops or seminars a month, with other
eira, two project engi-
divisions using the facility for external
neers at DRA who recently
training for two to three days per month.
completed their MBA studies,
“Since our company is a firm believer in
will be functioning as project
continual skills development, the training
sponsors for the two-year programme
facility is mostly booked up at present.”
and will ensure its success. The graduates will also be appointed discipline-specific
Graduate programme
mentors to ensure their development
DRA is launching a two-year graduate
in all required proficiencies of the pro-
in Pretoria will form part of a range of
programme that will see the firm taking
gramme. Dercksen says the Engineering
external, environmental-oriented short
on eight graduates across several disci-
Council of South Africa (ECSA) has a five-
courses and workshops. The new training
plines in the next year. This will increase
year practical experience requirement,
facility in Pretoria had its official launch
the number of qualified graduates with
and the two-year graduate programme
at the end of 2016, after which it was
practical experience in the industry.
contributes towards this.
successfully used for product launch
Louise Dercksen, group human resourc-
“There is a skills shortage in the broad
events and in-house training. “During the
es manager, DRA, says the group will
engineering sector and DRA saw an
first two months of 2017, we meticulously
hire graduates from each engineering
opportunity to contribute towards de-
developed policies and op-
discipline – mechanical, electrical, process and
erational procedures in
civil. “We have ap-
an effort to ensure we fulfil the high-quality objectives we have set for the facility,” says Lourens Jansen van Rensburg, business development and marketing director, I-CAT. “Since its in-
“In the end, training allows people to improve themselves and their earning capability as they progress upwards.” Mike Zinn, marketing manager, Skyriders Access Specialists
ception, we have effectively hosted a range of product launch events for the Fire Solutions Division,
veloping talent within the industry,” says Dercksen. The skills shortage is not limited to South Africa.
proached the uni-
According to Manpower Group’s an-
versities, as well
nual talent shortage survey for 2016, en-
as a graduate
gineers are ranked fourth out of the top
recruitment
ten difficult positions to fill due to lack of
agency, and
skills. The survey goes on to say that the
the two-year
four top reasons why it is hard to fill posi-
programme
tions include:
will start this
• A lack of applicants – 64%
year and finish
• A lack of hard skills or technical
in 2019,” she says. Participating students had to send through a short
resume, and their latest study results. They also had to go
competencies – 19% • A lack of experience – 19% • A lack of soft skills (workplace experience) – 11%. Dercksen says the DRA programme can help alleviate this. “During the pro-
as well as external fire training,” notes
through an interview process and com-
gramme, the students will be exposed
Jansen van Rensburg. Furthermore, the
plete a psychometric test.
to all elements of the work we do, going
facility has been utilised for various in-
“We didn’t look solely at academic
through a rotational programme. There
house divisional training sessions and
results. We’re looking for candidates
will be ongoing evaluation of their per-
think-tank sessions.
who are keen to innovate, possess peo-
formance as they work their way through
“As our facility also has an additional
ple skills and show potential in business
the different engineering disciplines and
chill room, complete with a coffee nook,
acumen – all-round students who can
also learn about cost control, budget
workstation, laptop station and lounge
add value to our company and the in-
management, quality control and the ins
area that can accommodate 30 people,
dustry,” says Dercksen says.
and outs of site work,” she says.
In sid e M in in g 0 4 | 2017
33
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MARKET news
market news
from around the continent New Automation Division for BBE Engineering specialist in mine ventilation, refrigeration and energy optimisation BBE has established a new Automation Division to extend its services. The BBE Group’s Automation Division primarily supports the group’s consulting services and turnkey projects, but also provides automation and electrical services to mining and process plants in all commodities. The division, which has been running since November, comprises a team of experts skilled in medium- and low-voltage electrical systems, field instrumentation and equipment automation in mine ventilation, refrigeration and energy engineering. Other markets include mining process
plants, water and wastewater systems, and the manufacturing industry. “Automation has always been part of the BBE competency, particularly under our Projects umbrella. BBE Automation Division was a natural extension of our business and part of a growth strategy to develop an electrical and automation division, giving us focused expertise and greater capacity,” says Deon Nolan, business development manager, BBE Group. “Energy savings, smart control systems, cost-effective solutions that are the best available in the market, and automating plants in the dig data and internet of things era we live in are key services to our customers,” says Nolan.
Moving materials with a sustainable focus ”Products like low-friction bearings can extend the life of conveyors and lifts and help boost sustainability in the material handling sector,” says Jerome Pommereul, global business engineer, SKF. With industry companies aiming to implement environmental targets, addressing sustainability concerns – such as boosting energy efficiency, extending service life and lubricant disposal – has become a
priority. SKF has recently introduced a new range of small, sealed SKF Explorer spherical roller bearings that can prolong , or even eliminate, service intervals. Fitted in a gearless traction motor in a heavy-duty elevator, it lowers energy consumption by around 145 kWh per year – equating to a CO2 emission saving of 2 tonnes over the motor’s lifecycle. “These bearings can cut friction by as much as 20%, with
a subsequent 20°C reduction in working temperature, extending bearing life to match that of the lift system itself. This helps deliver the maintenance-free regime that is important to lift manufacturers,” says the company. The company noted the industry’s efforts to cut the use of grease in applications such as lifts, conveyor pulleys and cranes. “Companies are now opting to recycle lubrication grease instead of disposing of it. Less grease means fewer disposals, which ultimately means less pollution. “SKF has identified that using bearings that do not need re-lubrication is a possible option; while in bearings with solid oil, the lubricating oil leaves the oil-saturated polymer material on the bearing raceways. The part is then lubricated for life – which has the added advantage of cutting the need for maintenance operations.” According to the company, the bearing itself needs small quantities of grease to function. Furthermore, the bearing life is significantly improved because it is working in a protected and clean environment. “The sealed SKF Explorer spherical roller bearings form part of SKF’s Beyond Zero portfolio of products. We have designed them to impart real sustainable benefits in their applications.”
Low-friction bearings can extend the life of conveyors and help boost sustainability
In sid e M in in g 0 4 | 2017
35
MARKET news
from around the continent Foam mist system for rapid fire control Mining operations require a rapid response in the event of any fire emergency on-site to minimise potential damage and loss of life. For this reason, I-CAT Fire Solutions has developed the Blaze Buster, a rapid-response, self-contained foam mist system. Lourens Jansen van Rensburg, business development and marketing director, I-CAT. comments, “The system has a large cannon with a discharge range of about 40 m, in addition to a retractable mist hose reel. This is fitted with an additional gun that can be used in conjunction with the cannon, thus enabling two firefighters to work simultaneously, increasing the effectiveness of the system dramatically.”
Lourens Jansen van Rensburg, business development and marketing director, I-CAT
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The Blaze Buster consists of four 230 ℓ self-contained and pre-mixed foam cylinders. A total capacity of 600 ℓ of water with a continuous foam discharge duration of up to three minutes means its capacity is comparable to that of three commercial 8 500 ℓ fire engines. “The main advantage of the system is that no diesel engine, pumps, or any external water supply is required,” explains Jansen van Rensburg. “Another major benefit is that the foam unit does not require any start-up time, which means it is primed and ready for immediate deployment. At just under a tonne, the system is lightweight and, therefore, highly portable.” The Blaze Buster can be reinstated onsite rapidly by simply refilling the cylinders with the necessary quantity of water, using the measuring equipment that is included, and adding a 1% foam additive (also included). It is then repressurised within minutes with nitrogen.
Enhanced safety with virtual and augmented reality Global specialist in energy management and automation Schneider Electric has added advanced virtual reality (VR) and augmented reality (AR) technologies to its industrial software portfolio with the acquisition of MWPowerlab. MWPowerlab’s industry-leading 3D real-time technology gives customers the benefit of strengthened immersive simulation and training (IST) capabilities and advanced 3D visualisation, which increase safety standards, improve labour effectiveness and increase asset performance. VR and AR technologies will enhance Schneider Electric’s Enterprise Asset Performance Management offering. The two companies’ partnership is expected to grow through this acquisition, and the skills transfer of valuable domain
market news
expertise provided by MWPowerlab to Schneider will drive the continued innovation and digitisation of the entire value chain. “The sustained development into VR and AR has culminated in the technology becoming more accessible to diverse global markets, including South Africa,” says Marc Ramsay, vice–president: Industry Business, Schneider Electric South Africa. Maurizio Galardo, president, MWPowerlab, adds, “Our VR and AR technologies are now highly optimised for industrial applications, as a result of working with Schneider Electric over the past five years. Together, I believe we can unleash the power of 3D real-time technology across the simulation, asset management and HMI supervisory solutions that are part of the Schneider industrial software portfolio.”
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HEAD OFFICE: Tel: (011) 306-0700 Fax: (011) 918-7208 e-mail: Elb@elbquip.co.za Website: www.elbequipment.com
Branches and Dealers throughout Southern Africa
Food for thought
A two-sided approach The “Brutal Truth of the Day” award goes to the mining CEO who spelled out the primary motivation of all miners to a panel of assembled ministers and bureaucrats at a side event at Toronto’s Prospectors and Developers Association of Canada (PDAC) conference. By John Ffooks*
I
T CAME AS a sort of out-of-the-
to grasp that as you ask your question.”
blue response to a well-meaning
You could have heard a pin drop. How-
question from the polite and gently
ever, his point goes to the heart of the
spoken African minister of mines. At
disagreements we see across Africa
Governments and mining companies should work closer to understand each other’s challenges
the end of a long discussion about lo-
between governments and miners. Gov-
cal content, he asked how host
ernments employ bureaucrats who are,
required to spend a month living on a civ-
countries should phrase their carried
by nature, not risk takers. They are often
il service wage in the host country, shad-
interest in mining projects: should it be
bright, hard-working people motivated
owing a portfolio in a non-mining ministry
10%, 15% or 20%?
by a desire to make the lives of their
like health or education. The exposure to
fellow citizens better. However, they
the constant tensions and pressures on
are not risk takers.
limited budget may give some insight into
“How should it be valued? And how can we, the host government, work with you better?” he asked as a non-con-
This makes it very difficult for them to
frontational, softball question to end
understand risk takers when they meet,
the session. Then the CEO dropped this
for the simple reason that they don’t
It may be that a 10% (or greater) free
bombshell (and I quote): “When you
speak the same language. How can
carry is the easiest way to begin to share
start a project, you have nothing. You
you expect someone whose life is based
the spoils of success. It may be that our
have an idea. You raise money from
around a regular salary, a 40-hour work
CEO should be left alone to make his 50
week and a stable office environ-
times so that it can trickle down into the
people who could spend it on other things, like sweets or
ment to understand someone
the ball game. Then it succeeds and you make a lot of money and all of a sudden people descend on you like it was always meant to be – it wasn’t. “There was a 0.1%
who thinks that chasing
When you start a project, you have nothing – just an idea
chance it would succeed and people expect to take a share of it like it was a low-risk,
a 0.1% chance far in remote locations from
why the host government feels 10% of the upside is a reasonable price to ask.
rest of the economy. However, I think my modest proposal will go some way to helping both sides understand what the other is about.
home is a sensible thing? It just isn’t going
*John Ffooks is a senior partner at
to happen. If they
John W Ffooks & Co, a law firm
can’t speak the same
specialising in advice on the ground
language, how is the
in Francophone Africa.
disconnect ever going to get fixed? So I have, as
they say, a modest proposal – and readers are invited to suggest
high-return investment. If the host gov-
more: All bureaucrats involved with min-
ernment takes 10% of that, you lower
ing should be required to spend 90% of
the investors’ returns on their colossal
their monthly wage in a casino until such
risk. People don’t want to make twice
time they realise they should only play
their money investing in mining projects.
poker or blackjack and that these games
They want to make 50 times their mon-
aren’t gambling if you know what you’re
ey. And if they can’t, or if people want
doing. They’re about managing the odds
to stop them, then they will spend it
in your favour and playing the situation
on sweets, or going to the game, and
in front of you – not the one you wish you
not investing in mining in your country.
had. All board members and manage-
So, as a host government, you have
ment of mining companies should be
In sid e M in in g 0 4 | 2017
39
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