Inside Mining August 2013

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A AFRIC FRICA AN NU UPDATES P DAT ES ON TH THEE

ining GROU GROUND N D AAND ND U UNDERGROUND N DE RGRO U N D

HOT SEAT

Project director

Ken Dyamond

on Matomo’s latest triumph P8

PRESTIGIOUS PROJECTS IN AFRICA Tonkolili, Husab, Ghaghoo, Lubambe, Mayoko, Impala 17 Shaft and BTRP

OPENCAST MINING Banishing border barriers

MINERALS PROCESSING

Cat M-Series

graders deliver

The essence of evolution ISSN 1999-8872 • R40.00 (incl. VAT) • Vol. 6 • No. 8 • August 2013

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CONTENTS

A F R I C A N U P D AT E S O N T H E

ining

August 2013

GROUND AND UNDERGROUND

O ON THE COVER

P4

Selecting the right grader model S ffor o the application is a critical ffactor a in maintaining mine h haulages; precision control is p provided by the Cat M-Series, d distributed locally by

Barloworld Equipment B

12

EDITOR’S COMMENT

3

Travelling in Africa An experience well worth it

HOT SEAT

8

Matomo’s latest tailings triumph

IN THE SPOTLIGHT

12

Coal slurry, a hot commodity

PRESTIGIOUS PROJECTS IN AFRICA

22

14

Tonkolili Three projects in one

18

Husab Namibian mining will never be the same

22

Ghaghoo Lord of the rings

26

Lubambe Trackless tailoring

30

Mayoko ELB’s iron ore aptitude

32

Impala 17 Shaft World-class platinum sinking

36

BTRP There is gold in them tailings

OPENCAST MINING

40

40

Hard rock specialists with rock-hard ambitions

42

Cable caretaker

46

Diesel Power digests Africa

48

Powering massive electric shovels

MINERALS PROCESSING

50

BIOX and its bright future

54

Minimal maintenance for minerals processing

56

Roymec Technologies’ separation solutions

58

Revolutionary spiral concept for the coal industry

60

MIP Process Technology keeps it clean

MOTORS & GEARBOXES

50

62

Zesty growth aspirations

64

X Series gear units gain African market share

64

New and improved motors for Katanga

65

More gearboxes for Kusile

IN SID E M IN IN G 0 8 | 2013

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INS I DE MI NI NG 0 8 | 2 0 1 3

EDITOR’S COMMENT

Publisher Elizabeth Shorten Editor Laura Cornish Head of design Frédérick Danton Senior designer Hayley Mendelow Designer Kirsty Galloway Chief sub-editor Claire Nozaïc Sub-editor Patience Gumbo Marketing & online manager Martin Hiller Marketing & events coordinator Neo Sithole Production manager Antois-Leigh Botma Production coordinator Jacqueline Modise 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

Stacey Glad Tel: +27 (0)11 465 5452 Cell: +27 (0)83 567 0073 stacey@connect.co.za ___________________________________

MEDIA

No. 4 5th 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: R420.00 (incl VAT & postage) African countries: US$80 Foreign: US$100 E-mail: subs@3smedia.co.za ISSN 1999-8872 Inside Mining Copyright 2013. 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.

TRAVELLING ACROSS AFRICA

An experience well worth it!

I have spent the past month venturing across the African continent. I have travelled through the desert, waded through thick forests, felt the hottest heat and heaviest rainfall, all in the name of mining!

O

KAY, LET ME not be too misleading. While I may not physically have jourTOP On-site at Ghaghoo, neyed across Africa, this issue of Inside Mining features stories from Botswana around the continent. In the upcoming pages are a host of what I consider to be prestigious African projects, from Sierra Leone to the Republic of the Congo, from Namibia and Botswana to Zambia and, of course, right back to my starting point of South Africa.

The mining industry as a whole may be riding the bottom end of a cycle, but there are mining companies that are delivering the most amazing projects all over the continent.

Imagine for a moment what you would do if you stumbled across what is currently classified as the largest drilled magnetite iron ore deposit ever. You want to develop it, but there is no rail and the nearest port is decommissioned. If you are African Minerals, you develop your mine, build your rail and upgrade and expand your port – all while meeting production deadlines. Impressive.

Imagine if you owned what is said to be the third largest uranium deposit in the world. Swakop Uranium does and is making remarkable strides towards ensuring its mining vision becomes a reality – and with a deadline that in mining terms is right around the corner: 2015. If your mine is going to dramatically change the entire country’s economic status, you must be doing something right.

What about developing a decline through 80 m of soft Kalahari sand? Not a problem for Gem Diamonds, which invested in the design and development of a shield that has lined its Ghaghoo decline in Botswana with concrete ‘wedges’ for support and protection. The project has been successful and the final ring – number 750 – is complete.

Perhaps you are setting the benchmark for a brand new mining territory. Exxaro is doing so with its Mayoko iron ore venture in the Republic of the Congo. The company is developing a world-class mining project and is showcasing the country’s future mining potential – in the middle of nowhere. Talk about determination, miners like Exxaro have the lion’s share.

Closer to home, Impala 17 Shaft will represent a milestone in the platinum sector. Extending to a depth of just over 1 900 m, it will be the deepest platinum shaft development in history! It is so deep that it needs its own refrigeration shaft to ensure sufficient cool air is pumped down while underground development continues. South Africa may have one of the most mature mining industries, but it definitely remains on the top of innovative and evolutionary developments.

I don’t have the space to mention all the projects in the magazine, but I promise you every single one is outstanding in one way or another. And I may not have visited all of them personally, but the journey I have taken to learn and To our avid readers, be sure to sign up write about them makes me feel as if I have. But give me time, I and get the latest updates and inside scoop assure you I will get to all of them eventually. Hope I bump into from the mining industry. Check out what we you along the way. are talking about on our website, Facebook page or follow me on Twitter and have your say. @mining_news www.facebook.com/pages/Mining-News

IN SID E M IN IN G 0 8 | 2013

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COVER STORY

HAUL ROAD ECONOMICS

Driving down the Selecting the right grader model for the application is a critical factor in maintaining mine haulages, with precision control provided by the Cat M-Series.

INSET Cat 16M cabin layout The left and right seat-mounted joysticks incorporate the base 8 hydraulic functions, plus steering, transmission direction/ speed control, electronic throttle control and differential lock/ unlock control

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INS I DE MI NI NG 0 8 | 2 0 1 3

COVER STORY

cost per tonne T

HE SOUND OF GEARS constantly changing up and down as a mining truck tackles an incline out of the pit should send an immediate message to the listener. Because that’s the sound of lost productivity resulting from a poorly constructed and maintained haul road. And, unless those bumps and dips in the road are filled in and graded, over time, high rolling resistance will have a compound effect in lowering profitability.

As a general rule of thumb, if you can travel comfortably along a mine haul road in a light commercial vehicle at around 60 km/h (speed

limits permitting), then this is a good indication of a well-maintained riding surface.

However, as Johann Venter, head of Barloworld Equipment’s Product & Applications Group, explains, this is just one indication, and there are a host of other factors, such as gradients, drainage and road width, that need to be considered to ensure safe and cost-effective haulage. (Barloworld Equipment is the Cat dealer for Southern Africa.)

Each mine has its own unique features, such as multiple loading faces, different loading and hauling unit combinations, plus specific material densities. All these need to be taken into account in developing the ideal production model and fleet composition matches. Saving a few seconds during truck loading, for example, could translate into two to three more additional cycles per shift. Over a year, this could pass on huge savings.

“As a starting point, it’s important to note that haul roads begin at the loading face and end at the dump, and maintaining good floor conditions in both areas will definitely lower tyre wear (plus cuts and impact damage) and fuel burn costs,” Venter explains.

Taking care of tyres Tyres are a key expenditure item and need to be preserved for as long as possible. However, it is estimated that approximately 80% of earthmoving tyres fail well before their designed wear life due to poor road maintenance, as well as negative operating practices, such as overloading.

For off-highway trucks running radial-ply tyres, one would typically expect a minimum rolling resistance of around 1.2% for a hard, well-maintained haul road. “However, if this figure increases by just 5%, the impact becomes disproportionately greater, resulting in a decrease in production and an increase in working costs,” says Venter.

Size matters The size of motor grader required will depend primarily on the width of the haul road, but will also be influenced by the road’s condition: a neglected road will

MAIN PICTURE Available in seven different models, the M-Series starts with the 120M (operating weight: 14.5 t) and extends to the imposing 24M, shown here, with its operating weight of 62.5 t. The Cat 24M is currently the world’s largest grader in its class In each issue, Inside Mining offers advertisers the opportunity to promote their company’s products and services to the appropriate audience by booking the prime position of the front cover, which includes a two-page feature article. The magazine offers advertisers an ideal platform to ensure the maximum exposure of their brand. Please call +27(0)11 465 5452 to secure your booking.

INSID E M IN IN G 0 8 | 2013

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COVER STORY

require more intensive remedial action, and a larger grader to cut and grade final levels.

On the earthmoving front, Caterpillar’s previous generation G- and H-Series graders with conventional control steering have set the industry standard across the mining and construction sectors for many years, working alongside the current K-Series line-up (starting with the 12 t Cat 120K and ending with the 15.2 t Cat 160K).

The K-Series is complemented by the introduction of the revolutionary M-Series, which is making strong gains in Southern Africa following its global introduction some two years ago and sets the next benchmark for grading efficiencies.

saves fuel, while the machine’s electronically controlled power shift transmission ensures smooth shifting and maximum power to the ground. During all operations, on-board monitoring systems maintain a close watch on machine health.

“For reshaping haul roads, typical grader blade loads are about one-third to half of full capacity,” explains Venter. “However,

A wide range available Available in seven different models, the M-Series starts with the 120M (operating weight: 14.5 t) and extends to the imposing 24M (operating weight: 62.5 t), which is currently the world’s largest grader in its class. What distinguishes the M-Series from the K- and older Gand H-Series is the introduction of joystick controls that replace the conventional steering wheel and operating levers, which have been the norm for decades. Thanks to joystick technology, hand and wrist movements are reduced by as much as 78% during an average shift, with the M-Series easier to operate without sacrificing control.

The left and right seat-mounted joysticks, respectively, incorporate the base 8 hydraulic functions, plus steering, transmission direction/speed control, electronic throttle control, and differential lock/unlock control.

“This joystick control pattern is extremely intuitive and creates a direct relationship between the lean angle of the joystick and the turning angle of the steer tyres,” explains Venter. A brake tensioning system holds the joystick in position until the operator moves it. In addition, the steering control automatically reduces steering sensitivity at higher ground speeds for comfortable and predictable control.

All M-Series models come standard with the articulation return-to-centre feature.

This exclusive function automatically returns the machine to a straight frame position from any articulation angle with the touch of a single button.

Always in control On the go, better material control gets the job done faster, requires less power and

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INS I DE MI NI NG 0 8 | 2 0 1 3

A neglected road will require more intensive remedial action and a larger grader to cut and grade final levels where large hauling units travel on softer materials, heavier blade loads may be required in order to reshape the road surface.

Many mines are also located in mountainous areas, requiring haul roads with steep grades or where very precise roadway elevations and slopes are desired.”

The 120M through 24M models provide a broad range of extended blade positions, particularly beneficial in mid-range bank sloping, ditch cutting and ditch cleaning.

A long wheel base allows for an aggressive blade angle, permitting material to roll more freely, and reducing power requirements.

Servicing time on the M-Series has also been lowered. For example, topaccessible drawbar wear inserts and the shimless mouldboard retention system make DCM (drawbar, circle and moldboard) adjustments fast and simple, delivering more precise material control and smoother roadways, which in turn depend on regular dust suppression.

Diminishing dust Dust thrown up by continuous haulage can reduce visibility and mobility, posing a

safety hazard. Additionally, regular watering helps to maintain compaction.

“As a guideline, the size of the water tanker should match the size of the haul trucks,” Venter continues. “For example, if the mine is using Cat 777 90 t payload units, then these should be supported by Cat 777 water trucks. Tanker size will also depend on factors such as the length of the haul road and the number of fill points along the route.”

‘Spot’ watering also works well for areas with limited water supply; for safe travel, a ‘checkerboard’ or ‘spot’ intermittent pattern is recommended to reduce the slippage risk during retarding on grades.

Also consider the downside of overwatering: washing out the fines will lower the cohesion properties of the road, accelerating deterioration and causing potholes to form. Optimally, the slope of the road should adequately carry away stormwater run-off, with evidence of minimal water entry into the road sub-base.

“Remember to keep grades smooth and constant as this minimises transmission shifts, maintains a higher average speed and enables more constant braking effort,” stresses Venter. Grades less than 10% are recommended for maximum tyre life.

Road dimensions critical Computing the haul road width on horizontal curves is a specialist area.

For example, a wider road is required on curves to account for the overhang occurring at the front and rear of the machine, as well as the lateral clearance between passing trucks.

“On one-way straights and corners, a minimum of 2 to 2.5 widths is recommended,” explains Venter. “For two-way traffic, this would increase to a minimum of 3 to 3.5 truck widths on the straights, and a minimum of 3.5 to 4 truck widths in the corners.”

The sight distance for horizontal and vertical curves must be sufficient for a machine to stop before reaching a hazard or obstacle, and the distance from the operator’s eye must equal or exceed the required stopping distances.

“Each mine is different and an extra width allowance should be made, where needed, to accommodate difficult driving conditions,” concludes Venter.

HOT SEAT

B A R BER TON TA ILINGS R E TR E ATM E NT PL AN T

Matomo’s

latest triumph

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I NS IDE INS I DE MI NI NG 0 78 | 2 0 1 3

HOT SEAT

EPC-focused engineering and project management company Matomo has proved once again that its reputation for delivering projects on time and on budget is indisputable. Pan African’s Barberton Tailings Retreatment Plant (BTRP) is its latest showcase achievement, writes Laura Cornish.

I

N JUST 14 months, Matomo, a Basil Read Group company, successfully delivered a brand new, large-scale gold tailings retreatment plant for Pan African Resource’s Barberton mine on time and on budget. It is the company’s largest tailings project to date – more than double the capacity of any others in its portfolio.

In April 2012, bulk earthworks for the construction of the R305 million BTRP commenced. It is situated on the Barberton mine property adjacent to Fairview’s Bramber tailings dam. Now operational, it will ramp up over the next few months and, at nameplate capacity, increase the mine’s production to around 115 000 ozpa of gold (Barberton is currently delivering about 95 000 ozpa).

director, Ken Dyamond. “This again proves that with a well-defined scope, practical contracting principles in place to mitigate risk and good stakeholder management, the EPC method of executing projects provides a win-win for all parties involved.” For the EPC expert, delivering on its promises does not mean compromising on ‘softer’ project aspects, such as safety and quality. Not a single lost time injury has occurred onsite. “We worked together with the numerous subcontractors as a single team, with a common ‘no harm’ goal and a shared ‘zero tolerance’ vision.”

In addition to taking on a second phase of the work on the plant, Dyamond points out that the management of subcontractors was the company’s – and the project’s – biggest challenge. “So much so that once we recognised that we had a schedule risk, we changed certain subcontractors halfway through the project.” This makes the on-time achievement even more impressive.

The second phase of work Ken Dyamond (left), director of projects, included the addition of a with Victor McLoughlin, BTRP project briquette cyanide make-up manager, holding the first BTRP gold bar system, an oxygen storage circulation chamber (to As initially promised, commissioning of the improve recoveries) and a feed thickener.

100 000 tpm/1.2 Mtpa tailings retreatment Today, the plant is achieving average recovBTRP began in May 2013, and produced its eries of around 50%, the best average in the first gold in June. “The project’s success can tailings retreatment sector. be attributed to the excellent relationship Sound experience in between ourselves and Pan African Resourctailings technology es,” says MD Erik Bruggink. The companies “Most of our Matomo employees have dehave worked together before, when Matomo veloped sound metallurgical experience and seamlessly delivered Pan African’s first tailknowledge in this niche sector. We have ings plant platinum-from-chrome tailings completed many tailings recovery plants project – Phoenix. in the industry, from chrome and platinum “Despite encountering challenges along through to gold. Our plants are built for the way, we definitely consider the project flexibility and cater to current arisings and our latest triumph,” says Matomo’s projects historical tailings,” says Bruggink.

TOP The completed BTRP At present, the company remains on track to meet its contractual obligations on Impala LEFT BTRP under construction

“Despite encountering challenges along the way, we definitely consider the project our latest triumph.”

PV technology converts sunlight directly into energy INSET First Solar has achieved system availability of over 99% for the fleet of utility-scale PV plants

IN SID E M IN IN G 0 8 | 2013

9

HOT SEAT

Platinum and African Rainbow Minerals’ Two Rivers tertiary milling plant, but is hoping to improve on them “despite experiencing similar subcontractor challenges to those on the BTRP project,” Dyamond notes.

Late last year, the company was awarded the EPC contract for the construction of the tertiary milling plant. It is situated near Steelpoort on the southern part of the Eastern Limb of the Bushveld Igneous Complex. The 100 000 tpm plant will reprocess current arisings from the primary process plant.

The project pipeline is filled with promise and potential for Matomo.

Bruggink says the company is looking at another four tailings plant projects in the Steelpoort area – specifically for commodities chrome and platinum. “We are also doing a small upgrade on the dewatering circuit at the Dwarsrivier mine chrome project in the Steelpoort area,” Dyamond adds.

focus areas: energy efficiency, renewable energy, cogeneration and self-generation.

The company is currently executing its first renewable energy project, the 27 MW ABOVE The turbine blades for the Metrowind project are 55 m long BELOW TMP under construction

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Taking its skills to Africa Matomo is working towards growing its African footprint, both through minerals processing and energy. The company has a number of feasibility studies under way, most notably in Mozambique, Namibia and Zimbabwe, with a view to rolling them into execution in the short- to mid-term future. It has also been shortlisted for a wind energy project in Namibia.

Enterprise development

Renewable energy excellence “Moving into the energy sector (specifically renewable energy projects) has provided stability to the business.

In a time where most of the mining industry is retrenching, we are growing,” Bruggink declares.

The company’s energy division offers complete solutions for power generation, through understanding the complexities of the energy industry and realising the risks involved in managing power generation projects in remote locations. Its offering to the market is structured around four main

“We are in final negotiations for a solar photovoltaic (PV) project in Round 2 of the REIPPP and are bidding for numerous Round 3 projects, which include wind and solar plants,” Dyamond indicates.

Metrowind’s Van Stadens wind farm project in the Eastern Cape. Matomo was awarded the R475 million EPC contract for the construction of the wind farm in November 2012, as part of the first round of the Department of Energy’s Renewable Energy Independent Power Producer Procurement Programme (REIPPP). The scheduled commercial operation date is 1 February 2014.

The wind farm will feed 80 000 MWh/year of green electricity into the Nelson Mandela Bay Metro grid.

“Matomo decided to roll out its enterprise development programme in geographical areas where its projects are in execution. Due to the Van Stadens wind farm in the Eastern Cape, suitable companies were selected within the Port Elizabeth area,” Dyamond states. “Currently five 100% black-womenowned companies and one majority blackowned company form part of our Eastern Cape enterprise development programme, where we have provided assistance in terms of technical, business and project management skills as well as office and construction equipment.”

for Industrial Boilers A partnership between Budget Energy cc and The Black Diamond Coal Company (Pty) Ltd Operational plant producing pea sized briquettes Unique and patented shape provides combustion benefits Successful trials in industrial boilers Reducing slurry waste at coal mines

Marketing enquiries Budget Energy cc

The Black Diamond Coal Company (Pty) Ltd

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Joburg office: +27 11 022 5998

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andrew@icacoal.co.za

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IN THE SPOTLIGHT

C OAL SLU R R Y

It’s a

hot

commodity Coal slurry discard is generally a non-profitgenerating waste product, considered harmful to the environment and a nuisance to coal miners – but not anymore. A South African briquette technological breakthrough is turning unwanted waste into gold, writes Laura Cornish.

I

N CHINA, COAL waste is sold like any other commodity, and is considered highly valuable. It is used to generate power and steam for industrial boilers. Specialised power plants use slurry as a direct feed. In South Africa, it is just as its name suggests, waste, and nothing more.

Slurry is also damaging to the environment and a major problem for its owners as government increases its regulation and legislation in this area. There is a solution and it is ready for the market.

The technology

TOP AND ABOVE Budget Energy has a 1 500 tpm briquette manufacturing test plant in operation

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Established in South Africa in 2009, Budget Energy founding member Yafei Yi is introducing this Chinese concept – using coal slurry in alternative markets – to South Africa. He has developed a new briquette technology that solves coal mining waste dump problems while offering the opportunity to fuel the country’s industrial sector as it struggles to source value pea-sized coal fraction material. This offers massive advantages to the mining sector – entirely removing the environmental hazard associated with tailings management and acid mine drainage.

Since its inception in 2009, the company has made a remarkable revolution. It pioneered the production of briquettes using coal waste to manufacture large nut-sized, smokeless

IN THE SPOTLIGHT

briquettes for the low-income domestic household market.

Recognising the potential its briquette product could offer the country’s massive industrial market, Yi has developed a patented briquette manufacturing technology, in partnership with Chinese investors, specifically using South African coal slurry. “Following substantial research on South African coal and anthracite slurries, I have developed a briquette with highly efficient combustion rates. This is thanks to the incorporation of a ventilation hole through the briquette developed and patented in South Africa, increasing the surface area of the briquette, enabling it to burn equally from the inside and the outside. The result is that the briquette burns out more completely and the unburnt carbon is reduced significantly. In some product trials, the briquettes burn more efficiently that coal itself,” Yi explains.

The briquette binder comprises both local and imported ingredients, and due to specific additives, the briquettes are also waterproof.

The shape of the briquette, also patented, is equally important.

South African boilers differ from Chinese chain grate boilers in that the stoker length is much shorter. The calorific value (CV) of South African pea coal is also generally higher. This had to be taken into account when using the Chinese technology in South Africa. “This legal protection will underpin the investment, which will be required to reach full-scale production,” Yi notes.

With a facility in Chloorkop, Johannesburg, Budget Energy is already operating a 1 500 tpm briquetting plant, which it imported from China. Trials have already been conducted at two boiler sites west of Johannesburg and although they did not initially deliver satisfactory results, they have been performing well thanks to necessary refinements.

Coal-fired boiler specialist GH Boiler and Energy Services has subsequently conducted technical evaluations during the trials and reports comparative data on the coal and briquettes combustion. This was done by measuring and recording the boiler exhaust gases that reflect the boiler combustion conditions and combustion efficiencies of the coal versus briquettes.

Industrial Coal Africa and A1 Energy Consultants – to market the briquettes.

“We believe we are (possibly) the first to successfully conduct a trial in an industrial boiler using briquettes produced from coal slurry and have every confidence of the project’s success,” say directors Andrew Rayment and Andrew Snow.

The industrial market for peas is considerable with thousands of chain grate boilers in South Africa. “We are initially targeting a production capacity of 300 000 tpa and will import a plant capable of these volumes when we have sufficient interest from the industry,” Yi notes.

China uses coal slurry to produce electricity

The way forward Budget Energy has established a partnership alliance with The Black Diamond Coal Company – formed by coal traders, BELOW Boiler briquetting trial. From left: Andrew Snow (director of The Black Diamond Coal Company), Graham Haylett (GH Boiler and Energy Services), Andrew Rayment (director of The Black Diamond Coal Company), Liu Xiao Hong and Yafei Yi (Budget Energy)

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The next big step

Because coal slurry itself is deteriorating in terms of remaining suitable quality, Yi is already looking to introduce a flotation process, which would be used to ‘upgrade’ the quality of the slurry prior to briquetting.

“This technology is widely used in China and would allow for lowgrade slurry to be used. Low-grade slurry is plentiful in South Africa as this is a by-product when coal is beneficiated to improve the coal quality.

“Ultimately, our intention is to offer Eskom the technology necessary to produce power using coal fines. There are significant power generation opportunities in South Africa using slurry as a coal feed,” Rayment concludes.

PRESTIGIOUS PROJECTS IN AFRICA

TO NKOL ILI | SIE RRA LE ON E

Three projects in one MINE

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RAIL

PORT

PRESTIGIOUS PROJECTS IN AFRICA

With just a single asset, AIM-listed African Minerals may be considered a junior in the mining sector. Considering its major successes in bringing its Sierra Leonebased mine, Tonkolili, into production while overcoming massive infrastructure challenges, puts the company clearly in the major league, writes Laura Cornish.

T

HE AFRICAN MINERALS’ story is like a fairy tale. While evaluating numerous diamondiferous targets that were identified after a countrywide exploration programme eight years ago, the company stumbled upon what is currently classified as one of the largest defined magnetite iron ore deposits in the world. Realising the financial opportunities associated with such a lucrative asset, African Minerals changed strategic direction, and today is an iron ore focused player.

It took the company only three years, from discovery in 2008 to having “first ore on ship” in 2011. In that time, African Minerals produced its first iron ore from the mine at Tonkolili, built a 125-km railway and replaced an existing 74-km rail connecting the mine to the then defunct Port Pepel, and rehabilitated and upgraded the port to triple its original capacity. And last month the company announced it had ramped up to reach its 20 Mtpa iron export target.

“It is testament to the capability of the team at African Minerals that the practical demonstration of a sustainable run rate of 20 Mtpa has come so soon after the physical TOP Tonkolili’s strike length runs along four hills and covers 30 km LEFT Tonkolili has a 20 Mtpa run rate

installation of capacity. The No 2 Dumper at Pepel was commissioned, with first ore being offloaded on 29 April. Of equal importance is the fact that these operating accomplishments were achieved during the start of the rainy season in Sierra Leone, with 355 mm of rain falling at the port facilities since the beginning of May – an early demonstration of the success of our wet season shipping strategy in 2013,” says CEO Keith Calder, who joined the company in July 2012.

African Minerals is the largest employer in Sierra Leone and is set to become the largest contributor to the country’s GDP. Approximately 80% of the workforce (around 4 000 people) employed by the company are from Sierra Leone. During peak construction phase, there were approximately 11 000 people on-site.

The mine The US$1.5 billion (R15.01 billion) Tonkolili mine is a world-class asset, with a declared JORC-compliant resource of 12.8 billion tonnes – 11.6 billion tonnes of magnetite overlain by 1.2 billion tonnes of saprolitic hematite resource (representing 9% of the ore body) and a duricrust cap of 126.5 Mt of direct shipping ore (representing 1% of the ore body). Its strike length runs along four hills and covers 30 km, making it the

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same size as the entire greater London, explains Mike Jones, African Minerals’ head of external communications.

The ore body itself is a banded ironstone formation, but whereas in similar structures in Australia’s Pilbara region where the banded iron formation is subhorizontal and almost completely oxidised, here the formation is subvertical, and the magnetite is only oxidised to hematite right at the surface. The stripping ratio over the mine’s 60+ year life

is expected to be less than 1:1, meaning that for every tonne of iron ore mined, less than a tonne of waste has to be moved.

Tonkolili’s 20 Mtpa export is only the beginning as the company is currently exploiting the direct shipping ore (DSO) portion of the resource. As the deposit’s haematite material depletes and moves into the saprolite haematite stage, it will be expanded to produce 35 Mtpa (of concentrate) at 64% (high grade) iron. Between 90 and 120 Mtpa of mining and processing capacity will be required at the front end to deliver the target concentrate volume.

The US$1.5 billion (R15.01 billion) Tonkolili mine is a world-class asset Scoping level assessments have already revealed that expanding the necessary infrastructure is viable. “Our expansion goals are realistic. We will build our capacity up through modular, sequentially constructed process plants, the first to start producing in 2016. Each module will increase the capacity until it reaches the 35 Mtpa target in 2019,” Jones outlines. Early works on this expansion plan have already begun to refine project engineering design, and the company expects to be in a position to provide more detail on capital cost and scheduling in the latter part of H2, 2013.

African Minerals’ partners CRM – China Railways Materials (CRM) Commercial Corporation has invested almost US$300 million to attain a 12.5% interest in the company with associated agency and offtake agreements. In December 2012, African Minerals agreed to raise CRM’s restriction of share ownership to 15%, which demonstrated its strong support as a cornerstone shareholder.

SISG – African Minerals completed a deal with Shandong Iron and Steel Group (SISG) whereby SISG has contributed US$1.5 billion to the Tonkolili project level – a portion of which will initially fund the next phase of expansion – to acquire a 25% stake in the project, with associated offtake agreements.

“We currently have 10 MW of diesel generated power at the mine and another 10 MW at port. We need in the region of 150 MW of power for the Phase 2 expansion and we are pleased to note the progress that the government is making with various international construction groups and banks, which would support third-party long-term power offtake agreements. The most viable power option is hydroelectric power from the neighbouring Bumbuna and Yiben systems, close to the Tonkolili project.”

The rail Jones explains that the construction, rehabilitation and replacement of the full 200km+ railway line connecting the Tonkolili mine to Pepel port, coupled with the port rehabilitation, upgrade and expansion, equated to approximately three quarters of the entire project cash spend to date.

“The company has a 99-year exclusive lease on the rail, port and other infrastructure corridor areas. We completed the opening up of railway line in July 2011, which included upgrading a portion of it, and have subsequently completely replaced that upgraded section. Rail capacity for our next expansion will have to be increased by adding a double track for about 70% of the distance to accommodate the increased tonnages,” he says.

The port Considering Pepel port had been lying dormant since the 1970s, rehabilitation was essential. “We had to expand its export capacity threefold (from about 7 to 20 Mt).

Today, it has double ship-loading capability with stockyards that can hold about 1 Mt of material. The port will have to be further expanded for the new 35 Mtpa mine capacity – requiring some additional dredging and the construction of a second major ship-loading facility and wagon dumper.

Bucket wheel reclaimer in operation on-site

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H USA B | NA MIBIA

Uranium mining in Namibia Less than three years from now, Swakop Uranium’s Husab mine in Namibia will be operational, forever changing the face of mining in the country. It is set to be the world’s third largest uranium mine, writes Laura Cornish.

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T FULL PRODUCTION, Husab is expected to mine and produce 15 million pounds of uranium oxide (U3O8) every year. This is a substantial amount, considering the world’s largest uranium mine, McArthur River in Canada, produces up to 18 million pounds per annum.

At nameplate capacity, Husab will dwarf its operating competitors’ uranium

TOP At full production, Husab will produce 15 million pounds of U3O8 every year BELOW Construction work on the bridge over the Khan river is progressing well.

Stretching over 160 m, the bridge will be among the 20 longest in Namibia

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output, substantially. This includes next door neighbour Rössing, the longest running uranium opencast mine (about 4 million pounds a year) and Langer Heinrich (around 5 million pounds a year).

It has cemented its place as one of the largest resource drilling projects globally, with over 800 000 m of combined reverse circulation and diamond core drilling completed since April 2006.

The long-term uranium price outlook Despite the concern over the uranium price at present, Swakop Uranium’s Grant Marais, director of communications and stakeholder involvement, says that even though the uranium price will remain low in the

short term, the company believes that prices will increase substantially in the medium and long term.

“In fact, the World Nuclear Association 2011 Market Report reference scenario (post the Fukushima accident) shows a 48% increase in uranium demand from 2013 to 2023.” And the reason is simple, according to Marias: “About 435 reactors with a combined capacity of over 370 GWe require some 78 000 t of U308 concentrate, containing 66 000 t of uranium from mines, or the equivalent from stockpiles or secondary sources, each year. This includes initial cores for new reactors coming on line.”

Countries like China and India are expanding their nuclear capacity, while Japan

PRESTIGIOUS PROJECTS IN AFRICA

will never be the same is gradually restarting reactors that were shut down after the Fukushima accident.

China’s new built programme will give a five- to sixfold increase in nuclear capacity to at least 60 GWe by 2020 and a massive 400 GWe by 2050. The programme is seen as an alternative to the polluting, CO2 emitting coal-fired plants that supply 80% of the country’s electricity. India has a flourishing nuclear power programme and expects to have 14 600 MWe nuclear capacity on line by 2020. It aims to supply 25% of electricity from nuclear power by 2050.

“Bear in mind that each gigawatt electrical of increased new capacity will require about 150 tpa of extra uranium mine production routinely, and about 300 to 450 t of uranium for the first fuel load. Uranium mines worldwide currently supply some 68 800 t of U3O8 containing 58 344 t of uranium, about 86% of utilities’ annual requirements – a significant shortfall,” Marais explains.

Project stats and status Swakop Uranium’s promise to deliver on what it has confirmed as the highest grade granite-hosted uranium deposit in Namibia – and one of the world’s most significant discoveries in decades – is sound. Unlike many mining companies that over promise at feasibility stage, the Husab project is well into execution phase and is on track to meet its production start-up target – the end of 2015. “At the end of June, we have passed the first quarter construction mark,” Marais notes.

The project is on track to achieve the following milestones: • Q2, 2014: pre-stripping commences • Q2, 2015: 1 Mt ROM stockpile ready • Q3, 2015: permanent water supply available • Q3, 2015: cold commissioning of plant complete • Q4, 2015: uranium oxide production starts • Q4, 2016: sustainable production.

The mine itself is being developed as a conventional, large-scale load-and-haul opencast mine, feeding directly into a conventional agitated acid lead process, incorporating ion exchange and

solvent extraction circuits. Both are essential in extracting maximum uranium, upgrading the uranium concentration and preparing it for precipitation, while removing impurities.

The plant will process up to 15 Mtpa, producing approximately 15 million pounds of uranium oxide per annum, at an average 517 ppm grade for 20 years. There is also at least 280 Mt of reserves in the ground. The strip ratio is 6.2:1 – meaning just over 6 t of waste rock has to be removed to obtain 1 t of ore. For now, Husab will comprise two pits, each of which will be about 3 km

LEFT FROM TOP Scientists removing soil samples from around the base of the first Welwitschia plant that was excavated.

long, 1 km wide and 410 m deep after 20 years of mining.

Despite the project’s enormity, there remains opportunity to increase the reserve base, although this is not an immediate priority. “The focus is currently on the development of zones 1 and 2, while new defined resources will come from zones 3 to 5.” There is further exploration upside as well. 

At nameplate capacity, Husab will dwarf its operating competitors’ uranium output, substantially

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A three-dimensional image of the impressive bridge that forms part of the road design to Swakop Uranium’s Husab mine near Swakopmund. Construction of the bridge is on schedule for completion in April 2014

Boosting the Namibian economy

Water and power Water supply is essential both for the construction period and for the operation over the mine’s lifespan. Temporary water (during construction) will be sourced from the Rössing reservoir via a temporary pipeline. For this purpose, Swakop Uranium purchased a redundant pipeline from Areva (owner and developer of the Trekkopje uranium mine).

Permanent water will be desalinated, either from the large-scale Areva desalination

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plant or from a new desalination plant that will be built near Swakopmund.

In terms of electricity, rented diesel generators will be used for the first year of the project, after which NamPower will supply a temporary 66 kV supply. About 17 MvA provides sufficient power to operate the electrically powered shovels and drills as well as construction power needs. Towards month 30 of the project, NamPower will provide a permanent 220 kV powerline.

It is astounding to think that a single project can have such a dramatic impact on the economy, but in Africa it is possible.

The Husab project is expected to contribute between 5 and 6% of total government income. It will pay between N$1.1 billion and N$1.7 billion (R1.1 billion and R1.7 billion) per year in corporate tax and N$220 million per year in royalty payments. It will also contribute an additional N$7.3 billion, or 20%, to Namibian exports.

“Our mine will create 2 000 permanent employment opportunities (including contractors), resulting in at least another 8 000 jobs indirectly. Throughout the construction period, more than 6 000 jobs will be created,” states Marais. The number of people employed in the mining sector in Namibia will increase by 17%.

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G HAG H O O | BOTSWA N A

Lord of the rings A well-versed mining expert will tell you that no two mines are alike. A trip to Gem Diamonds’ Ghaghoo mining project in Botswana reveals this statement to be entirely true, writes Laura Cornish.

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LTHOUGH A traditional kimberlite deposit, theoretically speaking, Ghaghoo couldn’t be more different, or more ‘special’ – and it is still in development phase.

Acquired by Gem Diamonds in 2007, the intention was to inject massive capital into the project, develop a massive open-pit and mine large tonnages. As was the case with so many projects, however, 2008’s economic

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crash saw companies pull their purse strings tighter, Gem Diamonds included.

This meant the asset required a different approach to see it not only produced diamonds, but reach its full potential.

“A small underground mine was undeniably the way to go. Because the reserve is relatively shallow, approximately 80 m below surface, we chose a decline tunnel as the preferred access to the diamondiferous ore,” says Gem Diamonds’ COO Alan Ashworth. In Ghaghoo’s case, simpler in theory than in practice.

The pipe is located about 45 km within the south-eastern border of the Central Kalahari Game Reserve, a remote area recognised for

its beach sand-like qualities. And it is this exact sand that buries above the Ghaghoo ore body (for some 70 to 80 m).

“Developing a stable, strong and safe decline (at an eight degree angle) through 457 m of sand has been our greatest challenge, but we have overcome it due to our construction approach,” Ashworth points out. A hydraulically operated open-faced tunnel shield was specially designed and is used to support the tunnel development while it is lined with concrete segments – 10 segments constitute one ring supporting the 6 m diameter decline.

While such technology or methodology is not new (it was similar to that used to build London’s extensive underground system), it has never been used in a decline.

PRESTIGIOUS PROJECTS IN AFRICA

Ghaghoo’s grade Unusually, the mine’s reserve grade is higher than the resource grade because of the additional liberation expected from autogenous milling. Ashworth expects an average grade of 32 cpht in the VKSE phase of the pipe.

The ore body has been extensively explored and even comprises a defunct exploration shaft and tunnels. Resource data has been gathered from several different sampling campaigns conducted since the early 1980s.

To date, it has an indicated resource extending to 400 m below surface and an inferred resource to 524 m.

ABOVE The decline portal with a conveyor feeding out of the tunnel entrance OPPOSITE TOP The decline is lined with concrete segments for support and protection OPPOSITE BOTTOM Redpath Mining workers in the decline

Redpath Mining Botswana is responsible for the decline development, and despite encountering challenges associated with such unusual ground conditions, has performed remarkably well.

Construction for the decline portal commenced in July 2011 and the decline tunnel development commenced in January 2012 and now, two years later, the transition from sand to more stable basalt rock is under way. Geotechnical experts have been deployed to site to ensure the transition occurs smoothly and safely as the tunnel support structure changes from a cement ring lining to extensive roof bolt support.

The lined tunnel comprises 775 rings in total and demonstrates the integrity that any new decline tunnel should offer.

“We have tracked our progress closely and while we have not met our original project targets, we are now on track to reach our revised timeline, which should see us mine our first ore in June 2014,” Ashworth notes. Ghaghoo will be mined using the sub-level block caving method. The first horizontal mining level – 154 m below surface – enters the high grade ‘VKSE’ phase of the ore body (the pipe comprises three different facies). For now, it should take approximately one to one-and-a-half years to mine each new level in the VKSE. “It

would, however, be ideal if we could mine horizontally right across the pipe through all the phases,” Ashworth notes. “Perhaps in time we will.”

The DMS plant, designed to process around 720 000 tpa of run-of-mine (ROM) material,

future on the successes achieved in its first six months of diamond production.

Ultimately, we would like to expand the mine substantially.”

It is a large ore body and can accommodate a long lifespan. The plant has also been designed for expansion. “This is a new greenfields mine and our first full-scale development. It has been challenging, but there is nothing we have not been able to

“We are quietly confident that our diamond results will be better than our current expectations.”

Alan Ashworth, COO of Gem Diamonds is expected to recover approximately 230 000 carats per annum from, is complete and only waiting for commissioning. It was designed and built by diamond engineering specialist Consulmet on a turnkey basis. It incorporates an AG (autogenous) mill in order to achieve better liberation with greater fine diamonds recovery.

Once production starts While the primary objective is to retrieve the first set of diamonds and sell them, a mid- to long plan and strategy has already been devised.

“We are quietly confident that our diamond results will be better than our current expectations, but will plan Ghaghoo’s

overcome. We are excited about the potential of the resource and believe the kimberlite to be a good resource. It has also revealed some interesting coloured stones, including blues, pinks and oranges,” Ashworth surmises.

Infrastructure to accommodate a remote location Gem Diamonds has invested substantially into the necessary infrastructure to support the project, which includes a fully equipped tented campsite that accommodates up to 400 people. There is electricity, hot water, Wi-Fi, satellite television and even a games room for recreation. Heavy-duty multi-traction vehicles are also provided to transport workers, most of them citizens

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of Botswana, to and from site – 160 km of weathered, sandy road.

There is plenty of water – extracted from a 300 m deep aquifer via boreholes. Power is derived from a diesel generator plant, sufficient to run the mine once in production.

“We are, however, already investigating renewable energy potential sources,” Ashworth notes.

Uplifting safety Redpath Mining South Africa MD Ockert Douglas recently visited the Ghaghoo site as part of a roadshow campaign to promote the importance of safety in the workplace to more than 600 employees across its seven worksites.

“Safety is a core value of our business and our Fatality Prevention Programme contributes towards a sustainable future for the current and future employees of our business, and this initiative is fully endorsed by me and my management team,” he explains.

Douglas gave a presentation on the Redpath programme to more than 100 workers at Ghaghoo where he highlighted the main objectives of the programme, which includes commitment from leaders to implement the programme, to engage all employees in the process of fatality prevention and to ensure universal compliance with Redpath’s cardinal rules and fatal risk elimination protocols.

“The Fatality Prevention Programme is multifaceted and has been developed to work with and enhance existing safety systems,” says Douglas.

The Redpath Fatality Prevention Programme has developed the following

Redpth Mining MD Ockert Douglas presenting the company’s Fatality Prevention Programme to the Ghaghoo workforce

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protocol of 10 ‘cardinal rules’: • never move or operate machinery or equipment without the appropriate training and authorisation • never tamper with or make a safety device inoperable • always correctly isolate equipment from all energy sources before working on it • never remove another person’s personal underground access tag or personal lock • never enter an area that has access prohibiting barricades or signs without authorisation • never work or travel under unsupported ground or suspended loads • never work at height above the site’s prescribed distance or within the site’s prescribed distance from open holes without suitable fall protection • always comply with explosives, blasting and re-entry procedures • never operate heavy equipment within 10 m of any pedestrian without first establishing and then maintaining positive contact • always park equipment securely so that it cannot move in an uncontrolled way.

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LU BAMBE | ZA MBIA

Trackless tailoring In the wake of a successful decline sinking project completed last year at Lubambe copper mine in Zambia, Murray & Roberts Cementation has been awarded a new contract for trackless high-speed development at the mine, a project scheduled to extend to January 2014.

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PRESTIGIOUS PROJECTS IN AFRICA

T

HE ORIGINAL CONTRACT, which commenced in January 2011, comprised a twin decline system on the East Limb and ramps to access the ore body. This was completed in October 2012, ahead of schedule. The project is a joint venture between African Rainbow Minerals, Vale and Zambia Consolidated Copper Mines Investment Holdings “Our team achieved 14 190 m and we remained ahead of target against the mining schedule for the duration of the contract,” says Wyllie Pearson, Murray & Roberts Cementation senior project manager at Lubambe. “The support regime involved welded mesh with split sets being installed by the drill rig operators after every blast from grade line to grade line and extended to 0.5 m from the face.

“Additional work included in the first contract involved the installation of 75 m Level tips, 6.1 m in diameter by 18 m in length.

These tips were raisebored. Construction of the tip and box front infrastructure were subsequently also awarded to Murray & Roberts Cementation. Cover drilling, which was included in the contract to ensure safe and effective development, was undertaken using Kempe diamond drills that covered advance development.”

The latest contract involves all horizontal and inclined development for trackless OPPOSITE One of four ventilation shafts being sunk RIGHT Exploration drilling in progress BELOW Drill rig operator drills a development end for charging and blasting

“Although the new employees gained experience with the mechanised equipment being used on this project during our first contract, it was necessary to elevate the competency level for the latest project”

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RIGHT Development high-speed technology in ramps 3, 4 and shift boss checks the 5, situated in the mine’s Eastern Limb. explosive timing prior The Murray & Roberts Cementation to blasting team will continue the development of infrastructure for two conveyor belt systems and will maintain the owner’s fleet of equipment.

Pearson says his project team comprising South African, Australian, Filipino and Zambian personnel, is once again exceeding the development target.

The first sand zone, 30 m wide, has been successfully negotiated using Titan soil nails, Becker arch sets, 5.6 mm welded mesh and shotcrete as support mediums, and the second zone is currently being developed. Sand is excavated out of the face using a Hyundai mini excavator.

“Although the new employees gained experience with the mechanised equipment being used on this project during our first contract, it was necessary to elevate the competency level for the latest project,” he comments. “We’ve extended the training programme to include maintenance and rebuilding on both the mechanical and electrical sides, civil and steel fixing and the efficient supply of services, as well as the development logistics required to achieve 1 450 m/month.

Underground vehicle training has been accomplished with the assistance of the client’s simulators, supplied by Sandvik, and final assessments and passout were undertaken in underground conditions.”

The equipment purchased

by Lubambe for this contract was shipped to the Durban harbour and transported by truck to the Zambian Copperbelt. The machinery includes five Sandvik DD32026 split feed drill rigs, two Sandvik DD320-26 fixed feed drill rigs, two Sandvik LH514 and four Sandvik LH410 load haul dumper (LHD) units, nine Sandvik TH540 trucks, three Getman emulsion charge-up utility vehicles, one Getman scissor lift, one Fermel scissor lift, one Fermel grader, one Manitou and seven Toyota Land Cruisers. The drill rigs are currently developing approximately 1 450 m/ month while the LHDs and dump trucks are moving 63 500 t of ore and 32 500 t of waste – a total of 96 000 t of rock on a monthly basis, from the development ends to the internal silos and surface stockpiles.

All equipment for the contract is being maintained

by Murray & Roberts Cementation and is audited by the OEMs to ensure continued compliance with requirements. Murray & www.cementation.murrob.com Roberts Cementation has also established an on-site

MURRAY & ROBERTS CEMENTATION

SHAFT SINKING • RAISEBORING • DEVELOPMENT • CONTRACT MINING • MINE ENGINEERING

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Refurbishment of the workshop at the mine incorporating a main shaft in progress three-bay facility with a separate washing bay, two administration containers and three store containers. Maintenance services are carried out during the day shift and drill rigs are brought in for a 12-hour service every week.

“Safety is the cornerstone of all Murray & Roberts Cementation projects and our vision is to develop a business culture that supports and delivers injury-free projects,” Pearson says. “This is underpinned by the Murray & Roberts Group safety philosophy, ‘Stop.Think.

Act.24/7’, an approach that emphasises the importance of taking action to correct unsafe conditions and behaviour while recognising positive behaviour. The ‘24/7’ highlights the need to be safety-aware at all times, both at work and after hours.”

Murray and Roberts Cementation employees are taken through both Lubambe and Murray & Roberts Cementation safety inductions. The foreign supervision employees have also been through safety training at the company’s Bentley Park group training facility near Carletonville, South Africa, before being sent to Zambia. All employees undergo job specific safety training on-site, and to date, the team’s safety record is 162 809 fatality-free shifts and 1 884 814 fatality-free hours.

Although transport logistics has posed a challenge from time to time, Murray & Roberts Cementation has a depth of experience in African logistics and has an established track record, particularly in Zambia and the Democratic Republic of the Congo region.

IN SID E M IN IN G 0 8 | 2013 29

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MAYOKO | REPUBLIC OF THE CONGO

ELB’s iron ore aptitude Emerging iron ore company Exxaro has awarded the construction and supply of its first iron ore processing plant for its Mayoko project to ELB Engineering Services.

A

N INTERNATIONALLY recognised holistic solutions provider to the mining, power, port and construction sectors in the field of materials handling and process plants, ELB Engineering Services’ (ELB) contract covers the design, supply, building and commissioning of the 100 tph processing plant, which includes crushing, screening, desliming, classifying, dense media separation (DMS), thickening and product stacking.

The plant will be used for quality and materials handling characterisation of the various ore types present in the Mayoko deposits and also to produce final product,

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starting in 2013. The front end of the plant, which will receive run-of-mine ore from the opencast mine, includes primary jaw and secondary cone crushing. The DMS plant is being designed to produce sufficient stock levels to load a vessel for exporting of the products.

The final products will be stockpiled using two radial stackers on two final product blending beds, from where it will be exported.

All the major equipment for the processing plant will be sourced from ELB and its technology partners, with the mobile crushing and screening equipment being supplied

by ELB Equipment; the DMS plant by EPE, a partnership between ELB and PBA Projects; and the two 15 m diameter thickeners by MC Process.

“ELB’s successful completion of the project on time is of great importance to Exxaro,” says Peet Kotze, ELB business development executive. “For ELB, the project is an important extension of our process plant capability, which now includes iron ore processing, and highlights our ability to provide a full suite of world-class processing and related equipment through our international network of technology partners.”

TOP 100 tph process plant BELOW Bulk earthworks on site have started

How Mayoko came to be THE MAYOKO iron ore project was acquired in March 2012 as part of Exxaro’s acquisition of African Iron. The project already had a 121 Mt JORC-compliant mineral resource when Exxaro acquired it, consisting of a lumpy haematite cap of direct shipping ore (DSO) at 55% iron and beneficiable DSO ore at 41% iron.

Subsequent drilling across only 22% of the Mayoko project area confirmed a 685 Mt resource by January 2013, which excludes banded iron ore formation magnetite at depth, revealing the massive open-ended project characteristics. Exploration drilling is continuing and by now a JORC resource of at least 750 Mt has been proven.

It is situated near an existing underutilised railway line, passing within 2 km of the main prospect and terminating at the port of Pointe-Noire. Mayoko comprises 82 km of strike length, running parallel to the railway line. “Exxaro completed a lot of additional drilling last year and we believe that there could be as much as 2 billion tonnes in the regional geology,” says Ernst Venter, executive head: growth, technology and services at Exxaro.

The project is being developed in three phases. The first is to start production this year, the second is to produce 2 Mt of iron ore product in 2014 and the third is to expand the project significantly to 10 Mtpa by 2016/17. A feasibility study for this expansion is already under way.

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IMPALA 17 SHAFT | SOUTH AFRICA

World-class platinum

Impala Platinum’s 17 Shaft ore replacement project is a world-class development. Not only is it the biggest sinking contract ever awarded in the platinum sector, it celebrates first-time trial innovations as well, writes Laura Cornish.

T

HIS IS IMPALA Platinum’s deepest fourth-generation deep-level shaft. “Once complete, it will extend to 1 922 m below surface”, says Don Munro, WorleyParsonsTWP’s EPCM senior project manager of Impala 17 shaft and portfolio manager for Impala projects as well.

“The result of such a deep shaft sinking platinum project has necessitated distinctive design and extensive sinking requirements,” Munro continues. Due to thermal gradient and shaft depth, a stand-alone refrigeration shaft was required in addition to a main and ventilation shaft. In the platinum sector, this is a first.

TWP, now WorleyParsonsTWP following its acquisition by WorleyParsons earlier this year, was awarded the full EPCM contract for 17 Shaft, having completed the feasibility study in March 2007. Execution started four months later. First production is scheduled for 2017 – 10 years since project kick-off. “We remain on schedule to realise this, a remarkable achievement considering the duration of the project,” says Munro.

Project stats and status At full production, 17 Shaft will produce 180 000 ozpa. In order to achieve this, the mine must deliver 225 000 tpm of ore for processing and a further 35 000 tpm of waste. And while most platinum miners are seeing the volume of UG2 TOP Impala 17 Shaft at twilight TOP INSET Aerial view of Impala 17 Shaft LEFT 3D graphic showing underground development progress

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sinking Agile, Powerful, Prepared And Determined.

increase as their mines mature, this project’s ore ratios remain extremely attractive – 60% Merensky and 40% UG2.

Nearly 5 000 m of sinking has been completed to date, which equates to 97% of the sinking requirements. Each production level (eight in total) will comprise four ore passes, three in operation and the fourth, a spare. The mine has been designed to accommodate conventional mining methods.

While the labour force on-site has dropped from about 1 200 to just over 800 following completion of the underground scope of work on the refrigeration shaft (see below), the headcount is expected to go up to about 1 500 in the next two years as construction and development activities head towards peak phase. “The challenge going forward will be to complete all construction – including ore passes and horizontal construction – concurrently, with the main shaft sinking and equipping.”

The main shaft The main shaft (10 m in diameter and concrete lined) is currently at a depth of just over 1 763 m below collar being 27 Level – requiring only another 169 m to reach shaft bottom.

It will accommodate two 33 t skips, travelling at 18 m/s and a single double deck man cage. Each cage will carry 280 people per deck or 560 people in total. A service cage will also be in place.

The ventilation shaft The ventilation shaft (9 m in diameter and concrete lined) is just over 1 704 m below collar (26 level) and will reach a final depth of 1 763 m (27 Level) – just one level above main shaft’s last production level. 

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Our engineering skills are world-class and we have the people, systems and structures to make your project world-class too.

Call us, or visit www.twp.co.za TWP South Africa T 0861 TWP TWP (SA) / +27 11 218 3000 E twpinfo@twp.co.za

PRESTIGIOUS PROJECTS IN AFRICA

Innovation 17 Shaft’s exploration into and introduction of new methodologies and technical innovations will see this project emerge as an Impala Platinum flagship.

The shaft will be equipped with a loading facility on 27 Level, which will maximise the tonnage that the shaft can hoist during the reef development phase. “This will create opportunity to bring forward the development to reef, where an anticipated 1 200 tpd will be realised,” states Munro.

Main 17 Shaft bottom

The refrigeration shaft and plant Unique to 17 Shaft is its third shaft, designed for refrigeration purposes. The shaft has already been completed – to a depth of 1 438 m below collar. “We will strip out the shaft sinking services and dismantle and remove the headgear during August.”

The first phase of the associated refrigeration plant has already been commissioned, delivering chilled air to the downcast main shaft system, providing necessary chilled air for deeper level development and sinking operations. It was commissioned in October 2012. The ventilation reticulation is being supplemented by the refrigeration shaft that has been converted into a full-time upcast

“The result of such a deep shaft sinking platinum project has necessitated distinctive design and extensive sinking requirements” shaft for the sinking phase. This has been achieved by utilising the future refrigeration shaft spray chambers and force fans as an upcast ventilation system.

According to Munro, the design requirement for the ultimate longterm system includes a refrigeration machine duty of 42.5 MWR plus 16.1 MWR thermal store effect in the ice dam.

Impressive safety statistics focus “In terms of safety, our performance has improved substantially in the past year. This is an ongoing focus point and something we aim on improving even further. One of the key factors going forward to achieve this will be to mechanise as much of the work as possible,” Munro notes. The lost-time-injury (LTI) frequency rate for the project is 6.23 shifts lost per million man hours project-to-date. The 12-month moving average, however, is 3.9 and the three-month moving average is 2.0. This is impressive considering 15 million hours or 1.8 million shifts have been worked to date.

Supporting the sidewalls with mesh before the concrete lining is brought down and addressing the risk of pouring the concrete curb ring by not allowing people to work at shaft bottom during this process are some of the reasons attributable to the project’s safety successes.

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Mechanised development firsts The successful implementation of mechanised equipment is part of a strategy to remove the person from the blasted face area, thereby not exposing him to the dangers in this area.

Hydropower drill rigs Two possible options for a trackless drill rig are being pursued, namely a hydropower rail-bound UniRig mounted onto a UV base and a UniRig mounted onto a Crawler Carrier base.

With both options, when track-bound development commences at a later stage, the rig can be removed from the UV or Crawler Carrier base and put onto a track bound base. Impala Platinum will be trialling a rig on 27 Level at the main shaft. This rig will initially be transported using a load haul dumper bucket. The trial will take place between August and November 2013.

ABOVE LEFT UniRig mounted onto Crawler Carrier base ABOVE RIGHT UniRig mounted onto UV Base

Normet Minimec shotcreter The first to be delivered to South Africa, the Normet shotcreter is being trialled on 27 Level at the main shaft. This remotely controlled robotic machine has a 7 m reach. The size of end that can be sprayed is 8 m high x 6.4 m wide. A high-pressure water scaler to dress the face will be fitted to the shotcrete machine and will be powered using a hydropower pump.

For the ‘Station D’ development, the mechanised cycle will be as follows: • the Normet shotcreter will dress the blasted face area and thereafter shotcrete the face • LHDs will clean the blasted rock • the UniRig will drill the tendon support holes and assist with the tendon support installation and will also be used as a platform to charge the face with emulsion explosives.

Project innovations A provision for an impermeable layer under the waste dump will prevent the contamination of Normet Minimec Shotcreter

PRESTIGIOUS PROJECTS IN AFRICA

excellence the groundwater through leachates from the 3D image of station steelwork waste dump. All of the run-off will be contained in the pollution control dam and the dump will be rehabilitated during the life of mine. This is another industry first.

Rope load monitoring will be continuous in the service conveyance and kibble hoisting, mitigating the effect of slack and tightrope incidents that have caused serious problems in the hoisting environment for many years. Stage-to-service cage interface has also been installed on the main shaft. This system links the service cage, stage winder and the kibble winders, thereby preventing collisions between the service conveyance and the stage. This will become more relevant when the service cage becomes bigger and the speeds increase. A kibble loading system has been designed for the ventilation shaft bottom in order to maximise the tonnage that can be hoisted

Results Item 2-inch hoist poppet valve Hoist brake cylinder UZ12 slew motor UZ50 hoist motor Grab operating valve

Start (dB)

Finish (dB)

Attenuation (dB)

117.5

88.5

29.0

104.5

92.1

12.4

102.9

88.7

14.2

109.2

80.6

28.6

114.8

89.5

25.3

to optimise development opportunities. The system includes a temporary ore-pass system that will be commissioned from 21 Level to 27 Level, feeding onto a conveyor belt that tips into arrested kibbles.

The two ground-mounted six-rope permanent Koepe winders were modified to be used as single drum kibble winders for the sinking phase. This resulted in the more effective use of capital and in time will lead to the early establishment of permanent winding plant.

Making use of a friction winch and a clamping and lifting device allows for simultaneous installation of the six permanent Koepe winding ropes.

The pumping design has ensured that mine dewatering pumping will be done during the eight off-peak hours of the day.

Hearing conservation Lashing unit safety and NIHL mitigation initiatives started together with the OEM, Winder Controls, on a detailed review of the performance of lashing units, noise levels underground and the reduction of rope break incidents. Making use of OEM audits and spares has significantly reduced the plant downtime and has improved safety.

The installation of buffers and silencer packs reduced the attenuation levels attained on the ventilation shaft lashing unit in the region of 10 to 15 dB, making a significant contribution to the achievement of the 2013 NIHL requirements of the Department of Mineral Resources.

Key successes “From an EPCM perspective, we have had a very low turnover of staff, which has allowed continuity of design and construction. Good relationships have been established with all role players, which has allowed us to overcome challenges more effectively,” Munro proudly states. At the start of the project, a fourth shaft was developed down to competent ground – 42 m – where development access to the main shaft was pre-developed. Less sub-bank civils was required, which resulted in a two-month saving on the project timeline.

A design award was received for the main shaft multi-use headgear structure and covered all aspects from the design, fabrication and erection of the headgear.

Most recently, shaft sinking contractor Shaft Sinkers broke a project record with the most development blasted for the month of June.

Compiled by Don Munro

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A MEMBER OF THE RULMECA GROUP OF COMPANIES

PRESTIGIOUS PROJECTS PRESTIGIOUS PROJECTS IN | AFRICA AFRICA

B T R P | SOUTH AFRICA

Gold in them tailings

South Africa’s oldest gold mine Barberton, which first produced gold in 1886, recently celebrated a major milestone: increasing its output capability from 95 000 to 115 000 ozpa. This is due to the completion of a new Barberton Tailings Retreatment Project (BTRP), which has the sole purpose of producing gold from tailings reprocessing, writes Laura Cornish.

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PRESTIGIOUS PROJECTS IN AFRICA

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FRICAN PRECIOUS metals producer and owner of Barberton Gold Mining Operations, (which includes the Fairview, Consort and Sheba Mines) Pan African Resources understands tailings. It built its first tailings retreatment plant at Consort mine – the Segalla plant – and subsequently the Phoenix Platinum plant in the Mooinooi area, where it is processing chrome tailings for PGMs recovery. The company recently changed the processing streams into the plant at Phoenix, which has indicated positive results, further demonstrating its sound command of the tailings process.

Pan African’s announcement last year to build an equivalent gold tailings retreatment plant at its Barberton Gold Mining Operations operation, which includes Fairview, Consort and Sheba mines, could not have been better received, proving to the market that the company’s commitment to the old lady remains steadfast.

Instead of working the mine towards closure, it has invested in ‘upping’ its output at low production costs – for what could be a considerable period of time.

“Our aspiration for our Barberton operation has always been directed towards strong margins; however, with the underground infrastructure limiting the amount of tonnages hoisted, we started evaluating the tailings dams,” explains Pan African joint interim CEO Ron Holding. “With our strong management team at the mine, our OPPOSITE TOP BTRP increases Barberton's output by 20 000 ozpa BELOW CIL tanks and thickener

knowledge from past gold tailings experience and at the expected low production costs of US$800/oz (R7 935.76/oz), the BTRP will give us a very healthy margin.”

The Bramber dump (part of Fairview) drilling commenced in January 2011 and revealed a 3 Mt resource with an in-situ

0.52 g/t by Q2, 2014. It has a current life– of-mine of six years and should provide Pan African with an additional 20 000 ozpa of gold, increasing Barberton’s gold output by approximately 20%. “This BTRP equates to 10% of the company’s production or 20% of Barberton’s production.”

“This BTRP equates to 10% of the company’s production or 20% of Barberton’s production.” The capital expenditure budget for the project was R305 million grade of between 1.0 and 1.1 g/t. The adjacent Harper North and South dumps were identified and tested, with positive results and purchased to increase the resource to 6 Mt – providing sufficient tonnes to motivate the viability of building a plant to purely reprocess tailings material.

The new BTRP was commissioned on 28 June 2013 when it undertook its inaugural gold pour, 14 months from when construction commenced. It was completed on schedule and within budget.

Situated adjacent to Fairview mine’s Bramber tailings storage facility (TSF), the retreatment project is designed to retreat 100 000 tpm of gold tailings at an estimated average cash cost of US$800/oz. The plant utilises a carbon-in-leach process followed by electrowinning and smelting to produce a saleable gold product. The project will source about 12 000 tpm of current tailings via a pipeline from the Fairview concentrator and BIOX plant and some 88 000 tpm from the TSF. The BTRP is expected to ramp up to full capacity at an average recovered grade of

The total capital expenditure budget for the project was R305 million, of which approximately 90% has been invoiced to date. All of the construction capital requirements were funded via internal cash flows from Barberton.

Basil Read Matomo, which successfully constructed the Phoenix plant, designed and constructed the BTRP. The project is managed by an experienced team, including general manager Casper Strydom and metallurgy manager Jonathan Irons.

The BTRP has created an additional 86 direct employment opportunities in the Barberton area. During the construction phase, around 350 jobs were created. A total of 22 of the additional employees passed through Pan African’s Singobile life skills centre as part of Barberton’s CSI responsibilities.

“We are proud to have commissioned this project on schedule and within budget. The achievement reaffirms our ability to deliver on our development plans at our operations. It also demonstrates the potential for future success of our other

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PRESTIGIOUS PROJECTS PRESTIGIOUS PROJECTS IN | AFRICA AFRICA

FAR LEFT Ron Holding (centre right) and the BTRP team LEFT BTRP was commissioned on 28 June 2013 when it undertook its inaugural gold pour

organic growth projects at both Barberton and Evander.”

Despite the gold price, Holding says Barberton’s margins remain healthy and this will continue, thanks to the new tailings plant, which has a low production cost of US$800/oz.

While the project’s current lifespan is six years, Holding says the upside potential is significant. “Consort and Sheba mine dumps could contain as much as 12 Mt

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of tailings. We have already drilled at the Consort tailings dam and this resource will be added in our next resource statement.

We are also in the process of evaluating tailings situated at Sheba. These additional assets could increase the overall project’s lifespan to between 13 and 15 years.

Barberton mine Barberton’s remaining lifespan is 15 years, although Fairview’s high-grade 11 block

ore body alone will continue well past 15 years. It constitutes 50% of the gold produced from Fairview. Holding says the mine is currently 1 400 m below surface, but will extend further. “We have drilled down 160 m to confirm the extension of the 11 block ore body. We are drilling the pilot hole of the first raise bore hole of three ventilation raise bore holes required for ventilation and to improve the environmental conditions in the 11 block area, meaning that the requirement for refrigeration will be delayed by five years.”

Pan African is also looking at establishing access to known ore bodies, which will also take the mine beyond its current life model.

OPENCAST MINING

H A R D R O C K S P E C I A L IS T S

Rock-hard ambitions Hard rock opencast mining specialist Concor Opencast Mining is exploring various avenues to grow its business.

This includes geographic footprint expansion and diversifying its commodity focus, MD Chris Botha tells Laura Cornish.

H

AVING ESTABLISHED itself as a hard rock specialist in the platinum sector, with major contracts in place, Botha says that the current state of the platinum market has not impacted Concor Opencast Mining’s business. “Opencast platinum mining remains strong and continues to centre heavily on the mix of UG2 and Merensky reef,” he says.

production and performance expectations.” The project was awarded in November 2010.

The company also expects to see strategic coal supply agreements come to fruition as Eskom’s Medupi and Kusile power stations start operating.

“Our joint venture contract with Basil Read Mining at Assmang’s Beeshoek mine in the Commodity diversification Northern Cape has With its core business intact, Conseen us successfully cor Opencast Mining, a division of establish a presence Murray & Roberts Construction, in the region,” Botha is looking to establish a greater points out, adding presence in other strong performthat the award of ing commodity areas and open a second contract up new business opportunities as is imminent. well. It currently has the capacity Although not a comto move 3.5 million cubic metres modity, Concor OpenChris Botha, MD per month. “We are particularly cast Mining believes of Concor Opencast Mining keen on the coal and iron ore marnew business opporkets and can already boast of our tunities lie in mine successes in these industry sectors,” says Botha. rehabilitation, specifically waste handling. Environmental legislaThe company’s first coal mining contract with state-owned min- tion is becoming increasingly stringent and mines have to execute er African Exploration Mining & Finance Corporation contin- and finance rehabilitation activities to comply with regulation. “We ues to showcase its coal mining capabilities. “Our relationship already have our first contract under our belt, which entails using with the client is excellent and we have and continue to meet all waste to build a new tailings dam,” Botha explains.

“We are particularly keen on the coal and iron ore markets and can already boast of our successes in these industry sectors.”

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OPENCAST MINING

OPPOSITE In-pit tipping of level one blasted overburden material at Concor Opencast Mining’s Lonmin contract OPPOSITE INSET Excavator busy loading overburden at Concor Opencast Mining’s Lonmin contract

Moving into SADC Up until now, Concor Opencast Mining has focused its business primarily on projects in South Africa, which continues to support its order book substantially. “We are now exploring sub-Saharan Africa opportunities, primarily in Zambia, Botswana, Mozambique, Tanzania and Namibia, where we can enter into new territories while retaining our modus operandi. In the past 12 months, we have established a strong management team with good core competencies and experience that has helped deliver substantial growth for the business and will ensure our growth momentum continues.”

The company has already priced several contracts and could have its first African project under way in the next six months. Looking further north, Botha believes partnerships are key.

“We are already engaging with a few large international opencast contractors to establish partnerships and pick up new contracts.”

Remaining competitive While the mining industry at large remains depressed due to labour volatility, weak commodity prices and product oversupply, Botha believes there are still plenty of opportunities in Southern Africa, “especially compared to the construction market”.

The company has implemented a three-year business plan focusing on further enhancing its operational excellence. “We are spending a lot of management time simplifying, modifying and streamlining our systems and procedures, especially around our operational key performance indicators – productivity and cost measures. We are also looking to improve our Level 4 BEE rating as we grow.”

The company has also embarked on an aggressive training and development strategy for its operators, which it is doing through

the Murray & Roberts Cementation academy in Bentley Park. “We will invest in the necessary infrastructure, including simulators, to do the job properly.

“Ultimately, we have an experienced and motivated workforce and performed well in Deloitte’s ‘best company to work for’ survey. We hope to improve our score even further in the 2013 survey.”

Safety first and foremost Concor Opencast Mining’s entire business strategy is underpinned by a strong safety ethos. As part of the Murray & Roberts Group, we live by the zero harm policy ‘Stop.Think.Act.24/7’, and I am very happy to announce that we are a zero LTIFR (lost time injury frequency rates) business over a 12-month rolling period. We have faith and belief in our systems.”

OPENCAST MINING

P ROT E CTING ELEC TRICAL SU PPL I ES

Cable caretaker

Surface mines depend on electricity for critical operations at the mine face. This results in a plethora of cables snaking wherever power is required. A breakage in any one of these cables can be costly, causing losses in production for every second that machines lie idle.

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T PRESENT, moving of cables is time consuming and there are critical safety risks related to this – cables and associated equipment could be damaged, for example. Now, with the help of a team of local experts from Tega Industries South Africa, the problem has been resolved with the development of specialised technical solutions tailored specially for opencast mines.

Tega’s team of rubber specialists developed a range of cable protectors/bridges and stands TOP Tega’s cable protector can withstand the weight of 500 t trucks LEFT Cable damage is a major problem on opencast mines

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Tega offers value added consultancy services and solutions

in Mineral BeneďŹ ciation, Bulk Solids handling, Wear and Abrasion customised to suit speciďŹ c applications.

With focus on core engineering applications in the Mining and Mineral Processing Industry, Steel plants, Power, Port and Cement Industries.

Tega Industries (South Africa) Pty Ltd P.O Box 17260, Benoni West, 1503, South Africa, Phone: (011) 421 - 9916/ 7, 421 - 6714, 421 - 6761, Fax: (011) 845 1472, Email: info@tegaindustries.co.za, www.tegaindustries.com

TM

TOTAL : Solution

OPENCAST MINING

in response to calls from various customers.

This new system protects cables from being damaged while at the same time minimising the safety risks involved in the movement of the cables. A major advantage of this solution is the huge reduction in the time and effort involved in moving the cabling.

Technical solution

Getting it right Having studied the most successful techniques available worldwide, specialists at Tega succeeded in producing a unique system to satisfy mine requirements. This system includes an ingeniously designed elastomer cable protector/bridge with ramps on both sides and a specially formed channel in which the cable is placed.

In addition, Tega Industries has developed unique rubber cable stands that can be positioned to lift and support the cable joints from coming into contact with water. These cable stands, like the cable protectors/bridges, are made of durable material and can be easily moved by one or two people.

Dilemma of the past

According to Dean Harty of Tega IndusPrior to this new system all electrical tries’ industrial division, a team of polycables needed to be lifted clear of Cable protector mer scientists, engineers and technicians trucks. Tall heavy metal strucdesigned and developed this new system. tures were used to sus“Considering that trucks on some of pend the cables. These these mines can weigh up to 500 t, were cumbersome the task was not as easy as one and difficult to might think.” move safely.

He explains: “We Until now no needed a cable one has been able to protector/bridge provide run-over cable prowith the correct profile tectors/bridges that can withstand that would not hinder mine the onslaught of these 500 t plus mavehicles. At the same time the elaschines. “Our cable protectors/bridges tomer compound used had to have enough can. They are available in different compressive strength not to collapse unsizes to span different roads or tracks An insert covers the cable and further and allow for cables of up to 100 mm in der the sheer weight of these vehicles. They needed to be sufficiently light to be easily protects it from damage. These are the first diameter to be protected. In addition, our moved and durable enough to survive some cable protectors/bridges that can withstand rubber cable stands are illuminated and of the most hosare therefore clearly tile environments visible day and night,” on the planet in Harty continues. terms of mechanTega Industries worldical stress, heat wide specialises in engiand abrasion. neered rubber solutions Dean Harty, Tega Industries’ industrial division “In addition, we for a host of mining and needed to develop industrial applications. a system that could lift the cable out of harm’s damage from 500 t vehicles because they In mining and processing applications, its way in case surface water was encountered. are designed from special elastomer com- wear- and damage-resistant compounds are When used in conjunction with ‘ride-over’ pounds that make them strong, durable and being increasingly used to protect and improtectors/bridges and unique cable stands, comparatively light. They are able to resist prove the lifespan of equipment. Projects the new system has the potential to save a lot massive mechanical forces, as well as UV are also undertaken on behalf of companies of time and manpower. It would make mov- and chemical damage. They can be easily and to develop technical solutions for a wide safely moved with minimum effort. ing cables a cinch,” Harty says. range of applications.

“We needed a cable protector/ bridge with the correct profile that would not hinder mine vehicles.”

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Protecting Plants from Wear Since 1987

LINTEC ENGINEERING’S CORE FOCUS is to protect its customer’s plant from excessive wear.

Wear, problematic in bulk materials handling, causes high maintenance costs and unnecessary downtime, resulting in lost revenue. Lintec wear resistant applications will reduce maintenance costs and downtime, and increase plant performance.

Lintec selects the best lining materials for the application parameters and the client’s budget, thereby creating invaluable benefit for customers.

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OPENCAST MINING

T HE DIE SEL DRIVE

Digesting Africa

Step 1

D

IESEL POWER IS fully committed to the advancement of BBBEE in the mining sector. Transformation and partnering with appropriate BEE shareholders is critical to our ability to continue building our business and has become a fundamental requirement in order to conduct business in the industries that the company serves. With that in mind, our holding group has concluded a BEE transaction that sees us now compliant

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Opencast mining contractor Diesel Power Opencast Mining has taken major business steps forward this year, uplifting its industry status and ensuring its targets for growth are well within reach, writes Laura Cornish.

with South Africa’s codes of good practice and the mining charter requirements,” says Diesel Power’s executive chairman, Terry Bantock.

Strategically, the BEE transaction, coupled with significant progress made in all other transformation categories, provides Diesel Power with a new dimension, improving its rating from a Level 8 to Level 4.

As part of the deal, the company welcomed Jackie Mathebula to the company as executive director and shareholder. He brings a

wealth of industry relevant knowledge to the company, through his BEE consortium.

The combination of Diesel Power’s expertise and skill, coupled with its Level 4 BEE status, has strategically placed it in the best position possible to navigate through South Africa’s challenging economic climate with particular concerns relating to mining labour environment. The company TOP Diesel Power works with all the major coal blue chip mining companies

OPENCAST MINING

Invested in its fleet BANTOCK BELIEVES one of the reasons behind the company’s success is its commitment and investment in leading brand equipment, which it continues to grow annually. “The age of our fleet is equally as important. Over 50% of our fleet has been used for less than 10 000 hours and 98% has less than 20 000 hours,” Bantock states. “Looking after our assets is fundamental to our business – reliability and consistency – which leads to optimal production performance and ultimately sound customer service.”

ABOVE IMAGES On-site at Mayoko

has recently secured a five-year wage agreement with its recognised union in order to mitigate against labour unrest.

Step 2 DIESEL POWER Opencast Mining is well cemented in the South African coal industry and boasts an excellent safety track record. It has nine mining contracts at present and continues to work with all blue chip majors, including Exxaro, Anglo American Thermal Coal, Xstrata Coal South Africa, Sasol and HCI Khusela Coal.

“We are focusing on diversifying our portfolio outside of coal and outside of South Africa,” Bantock points out. According to Mining IQ, there are 440 surface mining projects in either grassroot or prefeasibility stages on the African continent – a good indication of the mid-to-long-term mining opportunities. Immediate, shortterm opportunities are up for the taking as well, however, and Diesel Power has proven this to be true.

Earlier this year, the company was awarded its first African opencast mining contract for Exxaro’s controlled DMC’s new

iron ore project – Mayoko – situathe Congo. Mathebula ed in the Republic of the believes the company’ss entrance into Africa is exciting, albeit in a tough operating environment. “We want to be a part volution and of Africa’s mining evolution development boom and feel chieve the best route to achieve this successfully is workwing ing with and following nto our current clients into s. new African territories.

“In essence, e, dlethis is a cradlervice, to-grave service, ces which reduces project risk ding while providing financial rewards.”

Jackie Mathebula, executive director and shareholder, Diesel Power

Working alongside Exxaro will ensure we operate at the highest standards, enabling us to develop a model or blueprint for operating in Africa, which we intend to perfect and replicate.

“Mayoko is a great project for us, and allows us to set a high standard from the start and move forward with a solid track record.

The first tranche of the Exxaro-owned fleet is already on-site and operating. Our operators have already undergone simulator training, and we have overcome regulatory logistical and language barriers,” Bantock continues.

Following its clients into Africa does not mean Diesel Power will restrict i existing clientbase. “We itself to its eva will evaluate companies already entren entrenched in their respective reg regions and we will also look at junior and mid-tier sized c companies with viable proje within our capital conects straints and risk framework” Bantock notes.

Step 3 The Diesel Power Group believes it can offer miniing clients a broader, more va value-add service in context of its entire service offering.

“In addition to mining, we have ssound experience in earthwork aand civils development as well as rehabilitation (which requires extensive e earthmoving). In essence, this is a cradle-to-grave service, which w reduces project risk while pro providing financial rewards,” Mathebul Mathebula outlines.

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OPENCAST MINING

GENEROUS GENERATOR

power. The Cummins PCC 3201 generator controller provides control and protection to the Cummins engine and the generator,” he explains.

Cummins South Africa’s project manager, Jan Maritz, says that the Martin trailer has heavy duty axles and a jumping beam suspension, which was specifically designed to accommodate the rough road and challenging conditions in the pit.

“The axles were also positioned in such a way that the trailer has a small turning radius to easily manoeuvre inside the opencast mine.”

Bester says: “The Bucyrus 495 rope shovel requires an electrical supply in order to tram from one point to the next, and the motivator provides this power while the shovel is being moved.”

According to Bester, the motivator has been designed with numerous protection features to safeguard the equipment, as well as the operating team. “A regeneration prevention feature is built into the motivator, as regenerative power occurs while the bucket is being lowered.

High volumes of this type of power can cause damage to the alternator, and it is therefore monitored to ensure that vital equipment is protected.”

He highlights the fact that the fire protection system is a dual system, with FM 200 gas in the switch gear section and dry powder in the generator section. “Additional infrared arc detection is installed within close proximity to the switch gear, which will dispense the fire suppression agent as soo soon as a flash is detected. What’s more, there are a number of easy accessie ble fire extinguishers mounted on the trailer ttoo,” he continues.

C The Cummins motivator also comes standar with an externally visible standard three-c three-colour alarm lighting system.

T his system sy This alerts operators of likely problems prob ly ranging from minor to major ffaults, in addition to potential fire hazards. haza fire

Powering massive electric shovels

Cummins South Africa, a diesel engine and related technology provider, is powering one of the largest scale electric rope shovels at Debswana’s Jwaneng diamond mine in Botswana.

C

UMMINS SOUTH AFRICA’S general manager for the projects division, Werner Bester, indicates that the Bucyrus 495 rope shovel is powered by a 2 MVA Cummins motivator, a containerised diesel generator that is genset-mounted onto

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MINERALS PROCESSING

B IOMIN’S BIOX BLO O M S

A technology with bright prospects

years ago, following uncompleted trials first undertaken by Gencor in the late-1990s.

Considering the increasing legislation and focus on green, environment-friendly mining practices and the need to recycle water, Aster looks set to increase in popularity. It works best in conjunction with BIOX, which is sensitive to cyanide. “Aster is a quick and easy way to detoxify cyanide- and thiocyanate-containing solutions,” says Van Niekerk.

Gold Fields’ executive vice president of technical services, Tim Rowland, comments: “Gold Fields is implementing major strategic change throughout the organisation and it was felt that the BIOX and Aster technologies would best be served under a focused and experienced management team.”

Current and future process plants

It has been five years since Gold Fields announced its intention to divest of gold ore refractory processing technology BIOX. Failing to sell it, the BIOX team have incorporated the technologies into a new company: Biomin South Africa, writes Laura Cornish.

A

LTHOUGH A NEW stand-alone company, Biomin South Africa is well past the original challenges typically associated with a new start-up company. Not only does it constitute the entire BIOX’s 11 staffed management team, but has an extensive and significant portfolio, with 10 installed, commissioned and operating BIOX plants across five continents.

In addition to supporting the proprietary technology BIOX, it will also take

50 INS I DE MI NI NG 0 8 | 2 0 1 3

over supporting technology Aster for all existing clients.

“This is an exciting new venture that is positioned to offer the same level of expertise and service to current BIOX and Aster technologies clients. Our team is geared to demonstrate these technologies to numerous other mining entities,” says Biomin South Africa’s MD, Jan van Niekerk.

While BIOX is a tried and tested technology (first commercialised in 1986), Aster was only reintroduced into the market about five

Pan African Resources’ Fairview plant owns and operates the oldest BIOX plant, processing 60 tpd of concentrate and incorporates Aster as well. Van Niekerk says that there are two BIOX plants installed in Ghana: one at AngloGold Ashanti’s Obuasi mine and the other at Golden Star Resources’ Bogosu operation. Outside of Africa, the Suzdal gold mine in Kazakhstan uses both BIOX and Aster.

Navoi Mining and Metallurgy uses the BIOX technology to treat the refractory gold concentrates at its Kokpatas mine near Uchkuduk in Uzbekistan. It is currently the largest plant in operation, processing 2 138 tph of concentrate following an expansion in 2010.

Van Niekerk is most excited about the construction of Biomin South Africa’s 11th BIOX plant, which is scheduled to produce its first gold towards the end of 2014. “The Runruno project belongs to Metals Exploration, a Philippines-focused exploration and development company. It will process 400 tpd of concentrate and represents the first new BIOX plant since 2010.

Considering BIOX caters to refractory ores, the question arises: How much opportunity exists for this technology? According to Van Niekerk, plenty. “We are busy with numerous early phase study and pilot plant test projects (including test work for Vantage Goldfields’ Barbrook project) and another one in Kazakhstan.”

Why BIOX? Although the gold price is unstable at present, currently sitting at around US$1 200/ oz (R11 922.27/oz), significantly down from a few months ago where it rose to about US$1 900/oz, Van Niekerk still believes the price is substantially higher than it used to

MINERALS PROCESSING

OPPOSITE BIOX technology is environment-friendly RIGHT BIOX technology was commercialised in 1986

be 10 years ago. This means a lot of unviable projects will be revaluated as viable And while there are BIOX-alternative technologies available on the market, specifically pressure oxidation (extremely complex and not well known in Africa) or roasting (not environment-friendly), Van Niekerk says BIOX is easy to operate, more suitable to a wider spread of applications and is, in fact, more cost competitive. “We also provide operator training during the commissioning phase. Flexibility is becoming key, as is the turndown capacity or ease of expansion of the technology, and this is precisely where BIOX offers significant advantages over roasting and pressure oxidation.”

further confident that a decision will be made on the Kazakshtan project in August.

These two projects will be our initial focus.”

Biomin’s long-term strategy Biomin’s short-term strategy “Our initial focus is ensuring the Runruno project develops as planned, and we are

Contradictory to common perception, Van Niekerk says that BIOX technology is not only suited to refractory gold deposits.

“We will look at opportunities for similar technology in the base metals and uranium sectors, which will likely be for niche applications. We have already completed test work on uranium concentrates, which have delivered good results.”

The company is further looking to expand its technology portfolio and is in the process

IN SID E M IN IN G 0 8 | 2013 51

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MINERALS PROCESSING

What is BIOX and Aster?

BIOX ADVANTAGES: • improved rates of gold recovery • significantly lower capital cost • low operating cost • robust technology that is suited to remote locations • low levels of skills required for operation • environment-friendly • ongoing process development and improvement • backed by over 25 years of operating knowledge by an experienced team that provides ongoing technical support.

ASTER offers competitive advantages to existing destruction processes, including: • efficient thiocyanate and cyanide removals • optimal microorganism performance to tailings feeds • simple metallurgical process with low capital cost • robust technology that is suited to remote locations • low levels of skill required for monitoring • low operating costs and is backed by an experienced team that provides ongoing technical support.

52 INS I DE MI NI NG 0 8 | 2 0 1 3

of acquiring the HiTeCC (high temperature caustic conditioning) technology, developed

by Fosterville Gold Mine – designed to strip gold from natural carbonaceous components in the ore before it is discarded as tails. Used in conjunction with BIOX, it could potentially increase recoveries further.

“The first BIOX plants constructed between 1990 and 1998 are first generation.

Those built between 2005 and 2010 are second generation, while current construction projects are considered third generation and focus primarily on ease of operation and maintenance.

Fourth-generation plants, on the horizon, will look at reducing capital and operation cost. The initial focus will be on decreasing the power consumption levels of the agitators and blowers – the big energy consumers.

“Certain initiatives to achieve this are already in place,” Van Niekerk notes. Importantly, older generation plants can also be upgraded.

Lastly, Biomin South Africa is also looking at the viability of supplying full turnkey plants (up to 25 tpd), as opposed to outsourcing it to engineering firms.

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MINERALS PROCESSING

T IP-TOP TRA NSFE R POI N TS

Minimal maintenance for minerals processing Poor design and implementation of transfer points can result in increased maintenance costs for minerals processing systems. This is made worse by a lack of proactive, scheduled maintenance and can result in excessive downtime and severely reduced profitability.

D

UE TO THE nature of their application, transfer points should be carefully considered as they can easily become an obstacle to efficient operation. The critical issue here is that the uncontrolled discharge of bulk materials through conventional chutes is associated with escalated maintenance and replacement costs,” says Faizal Mahomed, after-sales manager at M&J Engineering.

Mahomed points out that a common understanding in the industry is that the project is finished once the transfer points

and chutes have been installed and commissioned. “This is not the case, as once the chutes are in active operation problems can arise due to wear and a lack of maintenance. We are aware of the fact that inspections and maintenance are not the core business of the mines, which is why we recommend they invest in a maintenance contract that clearly outlines the after sales responsibilities of the supplier.”

Ironically, the reliable nature of the Weba Chute Systems means that routine maintenance is often not carried out on systems.

“However, normal wear and tear does occur and even a seemingly minor deflection, such as a slight spillage, can result in a significant loss of productivity over time,” Mahomed adds. “M&J Engineering thoroughly checks the condition of the chutes’ wear components to ensure that they operate within their engineered parameters. By timeously identifying issues, we are able to alleviate equipment failure.”

The company undertakes to continuously monitor its Weba Chute Systems from the date of installation. “This allows us to determine the wear rate and to ensure that the transfer point is performing optimally. A technician regularly inspects and monitors all transfer points. In instances where a mine has a large number of transfer points, this is extremely advantageous,” he explains.

After a routine check, a comprehensive report, including a detailed cost analysis, is compiled and issued to the customer. It includes information on the condition of the chute and identifies areas where maintenance is required, including the replacement of wear parts that have reached the end of their life.

TOP Locally manufactured Weba Chute Systems are designed according to the principle of conveyed material impacting on surfaces that already contain material LEFT Continuous monitoring of Weba Chute Systems from the date of installation allows company technicians to determine the wear rate and ensure that the transfer point is performing optimally

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MINERALS PROCESSING

S EPAR ATION SOLOUTION S

Packaged solutions for multinationals In response to the global mining industry’s need for integrated package solutions, higher levels of support and faster turnaround times, minerals processing specialist Roymec Technologies is consolidating its various business units under one roof, writes Laura Cornish.

T

HE MINING INDUSTRY comprises a large percentage of big multinational players, which, in today’s financially challenging economic climate, expect unparalleled service and support from their service providers and suppliers, regardless of their size or global footprint.

Accommodating multinational needs from multinational clients “To remain competitive, we need to provide the same level of service as any international competitor. In addition to support, this means carrying greater responsibility and

faster design cycles, drawing turnaround and fabrication times,” says Roymec Technologies process director, Mark Langton.

“Clients want package solutions, cutting out involvement with multiple suppliers, which in turn reduces risk,” technical director, Bruce Martinson adds.

In August this year, Roymec Technologies took occupancy of its new 6 000 m² business premises in Longmeadow, which has enabled it to consolidate its service offering under a single roof. This includes laboratories, a warehouse storage facility and offices for sales, engineering, contract management and administrative functions. Roymec will be expanding its pilot plant facilities to encompass testwork for a wide product range, including filter presses, vacuum

filters, pin bed clarifiers, thickeners and SX filtration.

“While we are already a quick and responsive organisation with high levels of skills, good staff retention and a well-developed depth of knowledge, our new facility will allow us to increase our speed and response time for testwork, concept development and internal process development,” says Martinson. “Because we foresee clients’ increasing preference for suppliers to take responsibility for spare parts and maintenance, our new premises will also cater to this need as we plan to increase our contingency spares and stockholding.”

Langton states : “At the end of the day, our decisions and actions are driven by the need to assist clients manage their costs. We have now positioned ourselves to grow further in size and in turnover, which will ultimately see us better our support capabilities.”

Taking remote service and support to new levels While Roymec Technologies is no stranger to working in Africa – the mining destination of choice into the foreseeable future – the company is keen to showcase its ability to work in any global mining area, regardless of logistical challenges or remote locations.

“We have largely been an Africa-focused copper business up until now, but we are Scrubber dust dewatering at ferrometals plant

56 INS I DE MI NI NG 0 8 | 2 0 1 3

MINERALS PROCESSING

working hard to expand our geographic footprint further and commodity focus to metals and minerals such as gold, uranium, and coal, etc. as well,” Martinson notes.

And the company is well on its way to achieving this. “Most recently, we successfully contracted to supply a paste thickening plant (including a 28 m diameter thickener with a deep sidewall) for a remote gold mine in Russia. In addition to overcoming logistical, legislative, language and time zone challenges, we also had to beat the Russian winter within a three-month window period,” Martinson outlines. The job was so successful that both Langton and Martinson believe Russia’s mining sector will become a substantial business generator into the future.

Positive outlook for paste thickening Process plants are being designed with a zero effluent discharge policy to preserve water as environmental legislation and preservation become increasingly regulated and stringent in the mining sector.

“As a result, the need for paste thickening is becoming increasingly popular as an effective method for recovering water from tailings,” Langton points out.

In line with the company’s predicted upturn in the demand for thickening, the company is investing significantly in thickener design methodologies. “Thickening technology may be mature, but there are

still a lot of unknown factors about the technology, including the importance of effective slurry distribution and flow, residence time, and factors affecting underflow,” Langton explains.

In order to better understand thickening, Roymec Technologies is developing a new generation sizing model for thickening, which will also incorporate paste thickening.

The future of ion exchange The company is also looking to establish itself as a leader in ion exchange – an area that has yet to become common place in the hydrometallurgical industry – despite the fact that it is more environmentally friendly.

TOP AND TOP INSET High-density tailings thickener at a gold plant in Kazakhstan ABOVE AND INSET NexGen high-rate clarifiers at AMD treatment plant

“In many instances, ion exchange could easily and viably displace solvent extraction technology. We believe in the technology and are investigating and developing new ion exchange processes aimed at making ion exchange more competitive. If successful, we will look to serve this niche industry for large-scale bulk metallurgical plants,” Langton concludes.

57

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MINERALS PROCESSING

THE S M AR T S PIR AL

Revolutionary coal concept The world is calling for cleaner coal. The coal mining sector is calling for greater yields and recoveries, and both are achievable, thanks to the traditional spiral and a few technical adjustments, writes Laura Cornish.

S

OUTHERN ILLINOIS University (SIU) has spent the past five years trialling work on a methodology that could drastically improve the coal sector’s environmental impacts, while simultaneously increasing recoveries.

The answer lies in the well-known and traditionally used spiral, which for the purposes of this particular trial was supplied by South Africa’s minerals processing supplier Multotec.

SIU has coined its technology the SIU smart spiral component (SSSC). And while it effectively delivers a cleaner coal (with less ash content), improved coal quality and yield is an additional advantage. For coal deficit countries such as South Africa, this is significant.

The basic principle behind a spiral is to separate ash (tailings) from coal. Incoming coal fed to a plant is a changing variable, which fluctuates constantly due to the change in run-of-mine characteristics.

Manual adjustment of the product splitter position is almost impossible, meaning installed spirals are never able to operate optimally. The result is that valuable coal ends up in the tailings stream while ash content in the coal stream is not optimally reduced.

This is set to change, however, due to the SSSC. Rikus Immink, MD of Multotec Process Equipment, explains the concept: “The smart spiral technology is, in fact, quite simple and will give operators more control. SIU and professor/inventor Dr Manoj Mohanty has created an automated splitter that can move/adjust constantly,

based on the coal quality produced by the spiral assembly or “stick” as it is called by the Australians.

This will ensure that the spiral is able to operate effectively at all times, finding the ideal position to reduce as much ash content from the feed as possible, which in turn delivers an improved coal quality and yield.”

How does it work?

Two sensors are used to establish a density gradient in the critical region across the spiral trough at the discharge end. Based on this continuously monitored density gradient, a microcontroller is programmed to send a signal to a DC geared motor that will move the splitter arm when sufficient variation in conductivity is detected.

“This allows you to extract the exact product you want to sell, and will ensure the highest product yield is constantly achieved.”

The SSSC has proved extremely successful to date at trial phase. The spiral was installed at coal mining company’s Knight Hawk’s Creek Paum mine in Illinois, which produces around 600 000 tpa of coal. According to Mohanty, the splitter is successfully moving at all times, due to the variability of the coal quality coming into the plant. Knight Hawk preparation manager Chris Stanley says the system, which has been running for a few months, has created a more “customisable and efficient TOP Inspection of the spiral splitter LEFT Multotec’s spiral manufacturing facility

58 INS I DE MI NI NG 0 8 | 2 0 1 3

MINERAL PROCESSING

process�. And one overriding factor remains present: coal with less ash content ‘burns cleaner’.

Immink explains that Multotec became involved in the project through its American distribution agent, PrepTech, and its founder Dr Barbara Arnold, who is also a past president of the American Coal Preparation Society. Arnold initiated the project with the university. “Mechanically, we know the concept works. The next stage is to ensure that the electronic components and sensitive drive units are properly housed to make the

product robust enough to operate without complications within typical rugged coal environments,� Immink notes.

The MD is hoping to bring the product to South Africa, where further test work can be performed on local coal samples. “This development is ideal for our coal, which generally has higher ash content. Even a minor reduction in the ash content can make a big difference to the final product outcome, because the coal industry is such a high-volume business.�

One question remains, however: why work on improving the traditional spiral when the more modern reflux classifier is starting to show its popularity? “I believe that the spiral works best when used in conjunction with an upflow-type classifier that Rikus Immink, MD of recovers coal fines initially, enabling the spiral to exMultotec Process Equipment tract best product from the

“Mechanically, we know the concept works.�

Skilled technical personnel are able to assess individual applications

remaining coal volumes, especially if incorporating the SSSC,� Immink explains.

While researchers continue to test the smart spiral at Creek Paum, it is expected to be commercialised within the near future.

IN SID E M IN IN G 0 8 | 2013 59

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MINERALS PROCESSING

D U S T DO -AWAY

Keeping it

clean

TOP Bag filter installation LEFT Wet scrubber

South African BEE level 2 company MIP Process Technologies has acquired the rights and technology for all Alliance Dust Control Services (ADCS) products – a perfect fit for the company’s extensive mining and minerals equipment range.

An Inside Mining exclusive.

A

DCS IS RENOWNED for providing dust and fume extraction solutions and has more than 30 years of industry experience.

“The acquisition of ADCS complements our current product range,” says MIP’s MD, Philip Hoff. “ADCS covers the complete range of air quality improvement systems used in industrial facilities to enhance breathable air quality and safety. This is accomplished by the removal of particulate matter from the air and environment by

60 INS I DE MI NI NG 0 8 | 2 0 1 3

using devices like bag filters, cyclones, and wet and dry scrubbers.”

The MIP/ADCS bag filters use a reverse pulse design. The self-cleaning feature of these units still makes it one of the most popular methods of dust collection today. It consists, primarily, of a series of cylindrical filter elements that are enclosed in a dustproof housing.

Dust-laden air enters the housing and clean air is withdrawn through the filter cylinders.

As dust particles accumulate on the filter elements, periodic cleaning is achieved by

the introduction of a momentary jet of compressed air through a specially designed venturi mounted above each filter cylinder. This primary compressed air jet pumps secondary air, by jet method, to produce a reverse flow sufficient to clean the filter cylinders.

Since only a small proportion of the total filter area is cleaned at one time, continuous flow through of the collector is maintained.

Diaphragm valves, activated by solenoid pilot valves and a solid-state timer, control the jets.

A further advantageous cost-saving benefit is an energy-minimising concept unit, designed by ADCS and MIP, where bags are only pulsed when a set pressure is reached thereby saving on bag life, compressed air and power.

Cyclones are sometimes used as pretreatment to remove larger particulates from flue gas. This increases the efficiencies of subsequent abatement processes. The MIP/ADCS cyclone range accommodates a variety of liner material to ensure compatibility with the nature of the gas to be treated. For higher flow rates, multi cyclones can be used.

The new portfolio of products includes scrubbers. Scrubbers use absorption as the primary mechanism to remove air pollutants. Scrubber systems can be divided into wet and dry scrubbers, depending on the usage of water.

“MIP offers the complete range of water reticulation, dust extraction and process equipment; it is your one-stop shop,” concludes Hoff.

The proudly South African company also offers customised and innovative process solutions for mining, minerals processing and related industries. It is recognised for its quality, reliability and is an established supplier of agitators, attrition scrubbers, clarifiers, flocculant plants, slurry samplers, thickeners and progressive cavity pumps.

MOTORS & GEARBOXES

C L I M BING THE LA DDE R OF S UC C E S S

Zesty growth

aspirations P

ARENT company WEG Group’s ambition to quadruple its business by 2020 is no small feat, especially in the wake of a troubled economic climate.

Nonetheless, the company is already proving its targets are well within reach, having achieved 19% growth in 2011 and in 2012.

Ultimately, its strategic 2020 plan aims to see it increase sales by at least 17% year on year for the next eight years, when it aims to arrive at a turnover of US$10 billion (about R98.73 billion).

Zest WEG Group is a leader in the supply of electric motors, thanks to its product line enhancements, industry upliftment through training and growth plans aimed at better servicing its clients writes Laura Cornish.

Organic and acquisitive growth The Southern Africa-focused subsidiary, Zest WEG Group, will contribute significantly to the 2020 plan. “We subscribe to it and are taking the necessary steps to ensure we deliver on our specific target growth initiatives,” says Gary Daines, Zest WEG Group’s sales and marketing director.

In line with this, the company has already occupied the facility adjacent to its warehouse and office premises in Linbro Park, which adds an additional 3 000 m² to its footprint. “Next to our people, our stock is our biggest asset, and we are not only expanding our holding capacity, but streamlining our processes as well. This includes the implementation of a new warehousing barcode

62 INS I DE MI NI NG 0 8 | 2 0 1 3

the nearby future.” The acquisition is evidence of WEG Group’s recognition that as a successful global business, it needs a global manufacturing base, which in addition to South Africa, includes Brazil, Argentina, Mexico, Portugal, China and the US.

Committed to clean energy production

system – also aimed at improving efficiency, stock management and customer service while reducing human error risk.” Following an analysis process for fast and slow moving items, an automatic positioning system will also be established to ensure product flow through.

The group’s expansion also includes the acquisition of Hawker Siddeley Electric Africa’s transformer facility in Wadeville. “This will enable us to increase our local component manufacturing capabilities, which in this case, is transformers up to 10 MVA. The deal is currently awaiting approval from the Competition Commission, but we expect access to the facility (which remains operational) from September. Our plan is to progressively introduce WEG technologies and methodologies to this new business arm in

Zest Energy, part of the Zest WEG Group, will soon celebrate the successful installation and operation of a 48 MW multi-extraction condensing steam turbine, whose purpose is to generate energy from additional high-pressure steam at Mondi’s Richards Bay mill.

Mondi has an independent power purchase agreement with Eskom and will sell the power into the national grid. The full project scope includes the design, manufacture, delivery, installation and commissioning of the turbine and associated equipment, including a 57 MVA alternator. The turbine is being manufactured by TGM Turbinas – Brazil’s number one manufacturer of steam turbines.

It is the largest turbine the company has ever manufactured and represents a major milestone in the alternate energy sector.

A contract accolade In March this year, Zest WEG Group renewed its low voltage motors supply

MOTORS & GEARBOXES

ABOVE Zest WEG Group has occupied the facility adjacent to its warehouse and office premises in Linbro Park ABOVE RIGHT Training forms a cornerstone of the Zest WEG Group operating philosophy RIGHT A WEG IE3 High Efficiency motor being prepared for delivery to Sasol OPPOSITE BOTTOM Zest WEG Group recently held a medium voltage seminar aimed at educating engineers and customers on the latest developments and technologies in the product range

contract with Sasol (South Africa). “We were first awarded this contract in 1997, making Sasol our longest standing customer, which has also standardised on our IE3 motors – the highest efficiency motor commercially available in South Africa. The contract has been renewed for another five years and is a real company accolade.”

service manager from Brazil who also presented. “When it comes to MV motors, it is essential that the application is understood in its entirety. Only then can we specify the best motor for the application, which in turn ensures our motor performs to the highest standard. Ultimately, this

Every aspect of the motor range was examined during the seminar, including noise, thermal aspects, mechanical design, vibration and magnetic circuit design. Daines says the seminar was well received and saw a total of 170 delegates present across the three days it ran for, in addition to 55 Zest WEG Group employees.

“We are a training-centric Training the company offering training industry – and on variable speed drives, its employees motors and transformers Zest WEG Group at our dedicated training Gary Daines, recently held a mefacilities around the counsales and marketing director, Zest WEG Group dium voltage (MV) try. Additionally we presseminar – aimed at ent focused seminars with educating engineers and customers on the leads to improved total cost of owner- the aim of upskilling the industry and prolatest developments and technologies in ship and the longest lifespan achievable,” vide value-add, driven through education the product range and earned each delegate Daines outlines. and product awareness.” a CBD point.

“The fact is we are still learning about New switchgear catalogue released electric motors every day, even though ZEST WEG GROUP has released its new switchgear catalogue, which it first launched four years ago. It outlines the complete switchgear range, their origination is 100 years old.” The semincorporating new products and developments. inar was attended by Carlos Grillo, WEG Included is a focus and development on small switchgear panels with quick R&D engineering manager who delivered a turnaround times. “Like the rest of our product range, it is designed at presentation, as well as Glauco Cisz, WEG simplifying the customers’ lives.”

“We are a training-centric company offering training on variable speed drives, motors and transformers.”

IN SID E M IN IN G 0 8 | 2013 63

MOTORS & GEARBOXES

X S ER IE S G E AR U N IT S

KUSILE POWER STATION

Gaining African market share

Gearing for more gearboxes

D

RIVE ENGINEERING company SEW Eurodrive has gained measurable market share in the Southern African conveying industry through its range of locally manufactured X Series helical and helical-bevel gear units.

Since entering the platinum sector in 2005, SEW Eurodrive’s general manager for sales and engineering, Conrad Pilger, notes that

for horizontal and vertical transportation of materials. They also run the travel and hoist drive on cranes.”

The X Series is an invertible gearbox, which means that the range can be used for left- and right-handed applications.

Pilger adds: “The gearbox can be flipped on its axis by 180 degrees and boasts sound thermal ratings and characteristics, due to the fact that the Southern African climate

ABOVE SEW Eurodrive X Series helical and helical bevel gear units on show LEFT The main area of application for the X Series is conveyor systems

the company has developed a reputation as an internationally recognised supplier of gear units for bulk handling applications.

“Having achieved significant success in smaller applications, we have successfully entered the mining sector and today are specified as a preferred solutions provider for end users and OEMs operating in the platinum and coal sectors across Southern Africa,” he says.

Pilger states that the robust range of X Series helical and helical-bevel gear units can be optimally adjusted to the task due to finely stepped torque ratings. “The universal modular system concept sets new standards with respect to availability and offers a broad range of options.”

The main area of application for the X Series is conveyor systems, says Pilger. “In this context, the gear units perform a reliable service in driving conveyor belts and bucket elevators

makes ambient temperatures critical in gear unit applications.”

According to Pilger, the SEW Eurodrive export business has grown by 33% in the past financial year. “While the South African market has remained stable and profitable for us over the years, we are seeing an increasing demand for our range of equipment across the African continent, where increased investment is prompting substantial infrastructural development.”

He points out that Mozambique is one of the company’s most rapidly developing markets. “Here, coal is a major industry for us.” SEW Eurodrive recently appointed a Portuguese-speaking export administrator to streamline the sales and support process, not only in Mozambique, but in Angola too.

“The mining industry in Angola is currently booming, and we are gaining a strong foothold in this market,” he concludes.

“Having achieved significant success in smaller applications, we have successfully entered the mining sector.”

Conrad Pilger, GM of sales and engineering, SEW Eurodrive

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H

ANSEN TRANSMISSIONS South Africa (HTSA) has secured a second order for the manufacture and supply of 384 M4 air-cooled condenser (ACC) industrial gearboxes for Kusile power station.

The order followed hot on the heels of the first order of 384 M4 ACCs for fan drives at Medupi power station.

HTSA’s MD, Fritz Fourie, believes the new order is a result of Hansen’s success at Medupi. “Medupi called for the delivery of the first fan drives in January 2009 and we have paid meticulous attention to service and delivery details to remain strictly on schedule,” says Fourie.

The Kusile ord der, received in A August 2009, s specifi ed del livery of the 3 384 M4 ACC d drives in batche of 16 over a es p period of three y years, comm mencing February 2010. “Delivery of the final batch was in October 2012,” confirms Fourie.

“Our highly skilled local HTSA engineering team developed the fan drives in close cooperation with major original equipment manufacturers of air-cooled condenser equipment to meet exacting operating conditions for air-cooled steam condensation plants commonly used in dry environments,” explains Fourie.

Fourie says that the special design criteria of the Hansen M4 ACC units dramatically reduce end-user operating costs for low total cost of ownership and feature optimised gear geometry to reach the perfect balance between strength, torque capacity, surface durability and low noise performance. According to Fourie, Hansen industrial gearboxes offer the lowest noise levels in the industry as they are carburised and ground to an AGMA level 11 finish.

MOTORS & GEARBOXES

KATANGA COPPER MINE

New and improved motor delivers

A

PURPOSE-MANUFACTURED 2 210 kW motor has been successfully installed and commissioned by Marthinusen & Coutts at Katanga mine in the Democratic Republic of the Congo. This is the third purpose-built motor manufactured by the company for installation at this mine.

“One of our major challenges was coping with the lack of information about the load that these motors drive,” says Henk de Swardt, engineering director at Marthinusen & Coutts. “Both motors were estimated to be more than 40 years old and were made in Belgium. A major concern was not having information about the load these motors could drive,” he explains.

According to De Swardt, the mine considered replacement essential because of high maintenance, frequent failures and associated repair costs. The interchangeability of parts was also a concern because of the age of the motors. There are currently six of these original motors installed. This 2 210 kW

motor is located 500 m underground. Technical personnel from Marthinusen & Coutts visited the mine in 2010 to undertake a full assessment of the installation and the machinery. The outcome was the design of a replacement motor that took all the original operating parameters into account. High levels of robustness and longevity were also incorporated into the motor.

“To allow this upgrade, the cooling circuit had to be modified from a water-cooled system to an open-air circuit due to water quality issues on-site. The open-air circuit offers greatly improved cooling, lower running temperatures and increased installation life.

We used a Class H insulation system instead of the original Class B to improve the longterm life of the stator and rotor windings.”

The use of modern design software allowed the rotor and stator design to be optimised to improve efficiency and torque, thus enhancing machine performance. “The full load temperature rise of the stator was 55.47°C and the rotor was 71.76°C, with full load efficiency at 96.3%. This reduces energy consumption costs and total cost of ownership.

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COMPANY PROFILE

GOL D ER AS S OC IATE S

Optimising risk management

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COMPANY PROFILE

in a turbulent sector Risk management is an increasingly essential tool in the mining industry, required to execute projects on time, to specification and on budget. Golder Associates’ business and regulatory division seamlessly integrates technical know-how with risk management to deliver the best solutions to clients.

Golder Associates’ business and regulatory division provides services across the entire mining value chain

G

OLDER MAY BE well-known for its environmental and engineering solutions, but the company’s service offering is in fact far broader. Aimed at growing its entire portfolio and better aligning itself with its global branches, the company’s dedicated business unit provides risk assessment and regulatory services to the mining sector – a speciality the company has been involved in for seven years.

“What we offer is fully integrated mining project studies, from conceptual stage through to pre-feasibility and full feasibility studies. We also offer trade-off studies, competent persons reports, mineral expert reports for compliance with stock exchange listings requirements, technical due diligence investigations for banks and investors, resource and reserve statements and mining right applications, and closure and rehabilitation analyses,” outlines Golder’s mining services business unit leader, Kerron Johnstone.

“We understand that a project needs a social licence to operate, in addition to a focus on financial modelling and regulatory compliance – today it has the power to determine a project’s feasibility, over and above the technical viability aspects,” says BRS manager Spencer Eckstein.

Because Golder has such a strong technical mining background and has a keen appreciation of the full mining value chain well embedded in the organisation, it is able to deliver on risk, legal and financial/economic issues in relation to specific technologies and different mining options. This integrated approach allows the team to successfully meet clients’ needs – integrating engineering studies, project management, risk assessment, legal and contractual assessment, and financial analysis.

“We function as a single global entity, which provides us with access to huge levels of international expertise. With our global footprint and skilled local practitioners who bring expertise and in-depth industry knowledge in core commodities

IN SID E M IN IN G 0 8 | 2013 67

COMPANY PROFILE

such as iron ore, copper and coal for any type of mining, we can deliver one solution, best suited to the client’s needs,” Eckstein continues.

And the sector will see numerous benefits from such a business unit moving forward. “Clients only have to deal with one entity managing their entire project, as opposed to numerous consultants. This promotes seamless integration between and across project phases and optimised service delivery. Because we are independent consultants, our motivations and instructions are entirely objective and are not biased in favour of a specific mine or engineering design,” Eckstein notes.

Golder believes that data-driven decisions minimise risk, optimise opportunities and improve project execution. The business and regulatory division offers the following core services:

throughout a project’s life and have to be managed on an ongoing basis. “What we do differently is integrate risk and financial analysis using trusted techniques to quantify the actual impact of risk on project schedule, cost and performance. We perform probabilistic modelling, sensitivity analyses and Monte Carlo simulations.

These data-driven tools and scenarios strengthen project execution.”

identifying areas for improvement and devising cost-saving initiatives.

Decision-making tools

Golder uses its decision-making tools to assist clients in choosing the best possible project direction against a number of criteria, which include technical feasibility of mining and processing methods, product and upgrade potential, and disposals. Environmental, social and legal considerations Financial analysis are also focused on.

Investment decisions are about returns The tools are based on the Analytical Hierand cashflow. Assuming all project fac- archy Process methodology, allowing Golder to compare project alternatives on a wide range of criteria to formulate an optimal range of solutions that can then be refined in further PIC MISSING study phases. These tools are therefore at their most useful at a prefeasibility stage.

Meet the Golder team

Optimisation processing An integrated approach combining technical and non-technical information within a regulatory framework and model places the client in a position to make datadriven decisions to minimise risk and optimise opportunities for maximum shareholder returns.

CLOCKWISE FROM TOP LEFT Kerron Johnstone mining services business unit leader, Spencer Eckstein, BRS manager

Regulatory compliance strategies

Golder develops strategies to ensure projects are legally and technically feasible in order to Willem Botha, operate. “Here we assist financial analyst clients to apply for minNirvishee Juggath, eral rights and obtain risk analyst environmental authorisation. It also extends to due diligences,” says Eckstein. “From a regulatory perspective we offer permitting solutions in parallel to technical Eckstein, BRS manager, Golder solutions, which shortens project life cycles.

We understand how regulators and ulti- tors have been dealt with, one overriding mately the shareholders and investors, question remains: Will this project make such as banking institutions, approach money? In addition to understanding the projects, which can assist clients by out- financial aspects of a project, Golder’s specialists integrate the non-financial and lining the best decision-making route.” technical aspects that will have a direct imRisk management pact on the financial viability of the proj“Our combination of risk management ect – grades, tonnages, technology choices, methodologies on mining projects allows currency fluctuations and environmental us to capture, identify and quantify the considerations such as water liabilities, to full spectrum of possible risks facing a name a few – into their analyses. This inproject,” outlines Johnstone. Risks live depth technical understanding helps with

Case study The business unit’s most recent project entailed the evaluation and feasibility study for a greenfields Spencer iron ore project. “Our study included permitting and regulatory requirements, geological modelling, mining rates, approaches to mining, site typography, logistics, etc.,” explains Johnstone.

“We looked at different options for plants, how to process the ore or whether to process it at all. The study also included all environmental aspects such as water, waste and tailings.

“In a nutshell, we took the project from concept phase to pre-feasibility phase, narrowing over 400 options down to 10 different possible mining configurations.”

“We function as a single global entity, which provides us with access to huge levels of international expertise.”

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“Not Just A Mining Show”

SKETCH5927/13

botswana 2013 *DERURQH )DLU *URXQGV 6HSWHPEHU

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COMPANY PROFILE

W E S T E RN E X

Exploration made easy The exploration industry holds the key to sustaining the mining sector’s future.

While drilling is considered the most critical activity during project conception phase, cutting, preparing, storing and protecting core samples is equally important.

E

STABLISHED OVER 25 years ago to supply Australia with mining, exploration and geological consumables, Westernex has now grown to become one of the largest suppliers in the world.

It specialises in a variety of products for the exploration market sector, including core trays, core sample cutters, storage bags and compasses. The company has established branches in Perth and Kalgoorlie, Australia; Cape Town, South Africa; and Accra, Ghana.

Core trays Westernex’s Africa manager, Rob Lees, believes the company is the market leader in global exploration and mining supply products. “Our Impala 1 and 2 plastic core trays, manufactured in Perth and distributed globally, are proving to be increasingly popular.

Demand for the product is on the rise as it

gains market acceptance as the preferred method for storing core samples.

“We have gained a wealth of technical expertise over the past 25 years and can now deliver a plastic tray that meets every possible core storage requirement. The trays have been designed to provide significant benefits over traditional metal core trays as they have no sharp edges, are non-magnetic and chemically inert, impervious to sulphides, have lifting handles and are non-corroding,” Lees outlines.

The Impala 2 core trays are made from a highly specified UV stabilised, talcreinforced polypropylene copolymer – the same material used in the Impala 1 tray that has had over 15 years’ proven performance in the field throughout the world.

The weights of the trays are indicative of the section (wall thickness), providing rigidity, with a design more robust than competitors’ trays.

They are available in a variety of sizes and come with a standard size aluminium identification tag in the pocket, one at each end of the tray, conveniently located between the lifting handles. They are available in highvisibility white or black for less glare. The trays come with a complete range of plastic core markers to complement them. “In fact, TOP Typical core cutting on the Almonte and repacking cut samples into the Impala core trays LEFT A core yard utilising the increasingly popular Impala core trays

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added value is what we aim to achieve in all aspects of core analysis,” Lees adds.

Although Westernex has focused on ensuring its core trays for warm environments can withstand the harshest weather conditions; it has recently introduced ‘cold spec trays’ for use in cold climates.

Core cutting Westernex is also the sole distributor for the easily recognisable heavy-duty Almonte Diamond core cutter, which, according to Lees, far outweighs any competitor product.

The continual core feed allows the operator to cut samples virtually hands free with ease and without fatigue. It increases productivity due to reduced operator physical stress, enabling faster results and higher turnaround time. It can handle variable core sizes, is self-flushing and boasts excellent blade efficiency. It also reduces noise levels and suits any global power supply outlet. Even more importantly, the Almonte core cutter offers a ‘quantum leap’ in operator safety and user-friendliness. Safety features include: • CE – The Almonte Core Saw passed all the vigorous tests to be awarded the safety mark “CE” from the European authorities • AS 4024.1501 – Plant Safety in the Mining Industry • Cat 4 – The Almonte core saw qualifies for a Category 4 rating. The Almonte Core saw complies and is recognised by the Australian Safety Standard and are quality controlled by a licensed electrical engineer • a fully enclosed blade guard

COMPANY PROFILE

• a limit switch to isolate power to the machine when the guard is raised • the drive feed activation is linked to blade operation; neither operates in isolation to the other • computer-controlled drives constantly monitor blade speed, pressure and feed chain speed • a reverse drive mode to enable safe, easy clearance of obstruction.

“The CE-certified Almonte has been around for a number of years and while others have attempted to replicate or improve on it, the saw cutter cannot be rivalled for its ability to cut all cores including the hardest economically, safely and quickly.”

Sample bags “We have gone through extensive research, trial and error to produce the highest quality calico bags for use in the mining/exploration industry. Our calico bags are double stitched for extra strength and are available either with a drawstring (made out of the same material as the bag-cotton) or a tape tie.” The company has a complete catalogue

of sample bags, ranging from geochem and hessian to paper and plastic (in a variety of sizes).

Compasses The Westernex range of compasses offer extreme accuracy, ease and speed of operation

Westernex has grown to become one of the largest suppliers of mining, exploration and geological consumables in the world and include the Breithaupt compass. This top-of-the-range stratum compass is excellent for geological, geophysical, mining tectonic and rock mechanical applications.

Unparalleled service Westernex’s service is unrivalled; unlike

basic procurement companies, it draws from 16 000 stock items from its new 6 000 m² warehouse in Perth or its 2 000 m² warehouse in west Kalgoorlie.

“We have a large dedicated export department at Westernex where we take care of requirements from anywhere in the world. Our in-house freight forwarding team already export to 109 countries out of 196 in the world.”

Choosing quality does not equate to excessive costs. The company has numerous global contacts who can deliver customised products and services. Administration costs are reduced thanks to one invoice including goods, packaging and freight charges. To reduce further administration costs, required inspections, customs clearance and packing insurance are also invoiced simultaneously.

“We supply quality products only, at competitive prices, and no matter how remote a location, Westernex provides a total procurement service from one carton to a full container anywhere in the world,” Lees concludes.

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COMPANY PROFILE

DS I S OUTH A FRICA

Committed to black economic empowerment DSI South Africa, a division of Dywidag Systems International, has concluded an empowerment transaction with black-owned company MIH Steel.

I

N LINE WITH THE provisions of ABOVE Gwen Mahuma with MD for DSI SA, Dr Schalk van der Merwe the mining charter, the local company is now a 26.1% BBBEE comproducts to the underground mining secpany. The deal was concluded in tor, including coal, gold, platinum and December 2012. diamond mines operated by companies This is an important step forward in the development of the company and recognises the importance attached by all shareholders and directors to black economic empowerment. Chairman of DSI South Africa, Nick Moses, comments: “We are very pleased to have completed this Nick Moses, chairman of DSI South Africa restructuring programme.”

DSI is a global market leader like Sasol Mining (Secunda), BHP Billiton in the development, production and appliand Anglo American. The company has a cation of mining products. Keeping in line 5 000 m² factory located in the centre of with its strategy ‘Local presence - Global the South African mining area. competence’, DSI has over 2 100 employMIH Steel is a 100% black-owned compaees worldwide, with operations across ny owned by Gwen Mahuma and her brothEurope, Middle East, Africa, Asia-Pacific, er Tebogo Mahuma. Gwen’s relationship North and South America. with DSI goes as far back as 2004 when DSI South Africa is South Africa’s leadshe owned 20% of DSI-Mandirk Strata ing manufacturer and supplier of mining

Support, a company that supplied shepherds crooks, Oslo straps, etc. to the gold and platinum mines as well as concrete lifting equipment. Gwen eventually sold her shares in 2009.

“We took some time to find the right business partner, and are now delighted to welcome Gwen to the company. We look forward to her contribution to the future success of the business,” Moses states.

Gwen is an avid supporter of women empowerment and her involvement in the infrastructure space includes shareholding and directorship in companies such as WSP Africa (a multidisciplinary engineering firm), 3Q Mahuma Concrete and Mahuma Investment Holdings.

“This is an important milestone in the development of our joint venture in South Africa. We remain optimistic and committed to the long-term future of mining in South Africa and the region,” comments Patrik Nolåker, DSI Group CEO.

“We took some time to find the right business partner, and are now delighted to welcome Gwen to the company.”

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Cable Bolts Rebar Rock Bolts Mechanical Rock Bolts Friction Stabilizers OMEGA-BOLT速 Trusses & Slings Chemicals Resins & Cement Cartridges Plates, Mesh, Straps Steel Arches & Props Utility Hangers Lattice Girders Drilling Fluids Equipment

THE UMBRELLA OF MINE SAFETY

Local Prese L Presence - Global Competence 30 North Reef Road Elandsfontein, Gauteng South Africa 1412

Phone +27-11-827 6721 E-Mail dsi@dywidag.co.za

www.dywidag-sa.com

ADVERTORIAL

S OF T WA RE STA NDA RD IS ATION

The key to sustainable growth in mining?

No! Yes! Well… it depends on what you mean by standardisation (and who you ask).

If what you mean is throwing out what you have and implementing one-size-fits-all solutions across the board, standardisation might very well be the key to failure.

M

any mining companies have fruitlessly attempted to standardise their way into optimisation, cycling through countless vendors and products to find a single standardised tool or provider that will get the job done everywhere, every time. But standardisation could never mean always doing things the same everywhere, simply because such a definition fails to capture the real value of either standardisation or deviation.

Nowhere has the dream of standardisation been more active than in the world of mining technical software solutions. Finding standardised ways of storing, exchanging and interpreting mining data has been suggested and rejected by many companies time and time again.

The value of deviation Mines and software providers have spent millions on developing optimised, purpose-fit algorithms, data structures and even hardware technologies that result in context-ideal solutions for a given mining type or mine. These optimised products are often simply the best tool for the job in the places they are used and replacing them might lead to decreasing performance instead of optimised outcomes. Specifically in the world of mining technical software such as mine planning and scheduling tools, non-standardised solutions are mostly the result of specified requirements and not of deviant purchasing.

The value of standardisation If you are reading this, then the chances are you have read a host of academic papers shouting from the rooftops the value of standardising – giving reasons such as simplified technology landscapes, vendor

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management, integrated reporting and much more.

I for one don’t challenge any of these, except to say that there are ways and means to achieve the desired outcome. At MineRP, we have invested heavily in the development of standards-based enterprise integration solutions. It might surprise you

We have invested heavily in the development of standards-based enterprise integration solutions then that this article seems to suggest that standardisation is not the answer. Well, what we’re suggesting is that the solution does not lie with implementing the same software everywhere, but rather with the implementation of a spatially aware, open standards-based translation and standardisation framework. This is exactly what MineRP developed with its MineRP

Crew efficiency with MineRP SpatialDash

Enterprise Integration framework for spatially related mining technical information. MineRP will allow your discipline specialists to continue using the software that works for them, yet with the ability to freely share, report and interoperate on data created in the various traditional silos.

Spatially relate, interoperate and optimise MineRP is much more than a traditional data warehouse that transforms data into a nice picture though. With specialised data convertors and connectors, mines implementing the MineRP framework are able to seamlessly share data at the operational as well as executive levels, finally delivering on the promise of mining technical integration and standardisation without the need to replace source systems across the organisation.

For more information about the MineRP Enterprise Integration solutions, please visit www.minerpsolutions.com or contact Empie Strydom estrydom@minerpsolutions.com

INDEX

INDEX TO ADVERTISERS 4th Annual Global Mining Technology Forum

55

Melco

35

AMEC

39

Metso Minerals

51

Aquadam

76

Micromine

59

Atlas Copco

52

MineRP

75

Bauma Africa 2013

61

Mintek

IFC

Babcock

OBC

Model Maker Systems

13

Barloworld Mining

OFC

MSA Africa

21 28

Budget Energy

11

Murray & Roberts Cementation

Dywidag Systems International (DSI SA)

73

Roymec Technologies

ELB Engineering

31

Sandvik Mining

Electra Mining Botswana

69

Scantech

20

Emerald Risk Transfer

25

SEW Eurodrive

49

Golder Associates

66

Tega Industries

43

Hansen Transmissions

65

Tenova Bateman Technologies

Lintec Engineering

45

Tenova Delkor

Loesche SA

57

Trollope Mining Services

44

M&J Engineering

29

TWP Projects

33

M3 Construction

38

Westernex

71

Zest WEG Group

53

Zimbabwe Mining & Infrastructure Indaba 2013

17

Matomo Marthinusen & Coutts

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8 41

2 7

24 IBC

IT PAYS TO TALK TO A SPECIALIST

Tenova Delkor is an industry specialist in solid / liquid separation and mineral processing applications for the minerals, chemical and industrial markets.

Offering comminution, flotation, sedimentation, filtration, screening, and gravity separation systems, Tenova Delkor services range from test work, process trade-offs and flowsheet design, to installation, commissioning and aftermarket support.

www.delkorglobal.com www.tenova.com TENOVA MINING & MINERALS is a total integrated technological solutions provider to the mining, bulk materials handling and minerals beneficiation industries.