Inside Mining December January 2018 by 3S Media

www.miningne.ws

AF R IC AN U PDATES ON TH E

DIAMOND PROCESSING The sticky end of diamond recovery

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

EXXARO COAL Powered by partnership

IRON ORE The price puzzle

ERWATventures into mining Holistic service excellence If you understand your market and have confidence in the future of your market, you will invest accordingly.” Thierry Pimi, MD, Cummins SA P8 ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 11 • No. 01 • December 2017 / January 2018

CONTENTS

A F R I C A N U P DAT E S O N T H E G RO U N D A N D

U N D E RGROUND

Telsmith’s Trac10 now in South Africa The growing demand for better, smarter, safer machines requires leveraging leading technology, such as remote crusher automation systems 12

REGULARS 3 Editor’s comment 5 African round-up COVER STORY 6 ERWAT ventures into mining

PIPES , PUMPS & VALVES 22 Dewatering a flooded mine

CEO TALKS 8 Holistic service excellence

ENERGY 26 Designing mines out of the energy squeeze

DEC/JAN

MINING MACHINERY 25 Remote upgrades enhance performance

LEADING INDUSTRY 10 Robust and reliable technology for Africa CASE STUDY | RENEWABLE ENERGY 28 The next step for miners COMMODITY | IRON ORE 12 The price puzzle MINING INDABA 31 Welcoming an inclusive Indaba DIAMOND PROCESSING 14 The sticky end of diamond recovery 32 Epiroc, united and inspired 34 Driving business growth COAL MINING 16 Powered by partnership 36 Complete mine-to-market solution INDUSTRY INSIGHT 18 Securing a prosperous future for

ON THE COVER p6 www.miningne.ws

AFR IC AN UPDATES ON THE

DIAMOND PROCESSING The sticky end of diamond recovery

MARKET NEWS 38 Mining industry news

surface mines

GROUND AND UNDERGROUND

EXXARO COAL Powered by partnership

IRON ORE The price puzzle

ERWATventures into mining

EVENT 40 More women in mining

LEGISLATION 20 Proposed regulatory overhaul

2017/2018

Holistic service excellence

If you understand your market and have confidence in the future of your market, you will invest accordingly.” Thierry Pimi, MD, Cummins SA P8

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 11 • No. 01 • December 2017 / January 2018

Wastewater treatment company ERWAT is venturing into the mining industry, offering wastewater and acid mine drainage solutions to the sector

Endorsed by 20

@mining_news

INS I DE MI N I N G D E C / JA N | 2 0 1 8

www.facebook.com/pages/ Mining-News

EDITOR'S COMMENT

Publisher Elizabeth Shorten Managing director Candice Landie Editor Mpinane Senkhane Journalist Phila Mzamo Head of design Beren Bauermeister Designer Frédérick Danton Chief sub-editor Tristan Snijders Sub-editor Morgan Carter Contributors Kirsty Kilner, Garyn Rapson, Tony Stone Client services & production manager Antois-Leigh Botma Financial manager Andrew Lobban Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham

Africa is open for investment

he Investing in African Mining Indaba is solely dedicated to the successful capitalisation and development of mining interests in Africa. Every year for more than 20 years now, investors, mining companies, governments and other stakeholders from around the

world come together to network and engage all towards the single goal of advancing mining on the continent. I will be attending the Investing in African Mining Indaba for the third

Printers United Litho Johannesburg

time in February, and I look forward to the event now more than ever.

Tel: +27 (0)11 402 0571 ___________________________________

technology development where it is, the environment is ideal for a platform

Advertising Sales

Jenny Miller Tel: +27 (0)11 467 6223 jennymiller@lantic.net ___________________________________ No. 9 3rd Avenue, Rivonia 2191 PO Box 92026, Norwood 2117

Our industry is at a turning point. With commodity prices recovering and like the Mining Indaba to really be conducive to industry growth. With the revised focus on the original concept of government, investment and operator, the Indaba is also focusing much more on the junior exploration industry and introducing this industry to the ever-important international mining investment community. It is encouraging to see the renewed effort to include junior miners in the proceedings and the associated cost-saving initiatives. In the December issue of Inside Mining, we feature wastewater treatment

Tel: +27 (0)11 233 2600

company Erwat’s MD, Tumelo Gopane, who offers insight into some exciting

Fax: +27 (0)11 234 7274/5

developments the company is pursuing in the mining industry in 2018.

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Thierry Pimi, MD of Cummins, is our CEO Talk guest, and he reflects on the successful year Cummins has enjoyed and the company’s future plans. The African mining industry is one of the world’s largest producers of

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metals, but what is the forecast for Africa’s

Foreign: US$50

commodity market next year?

Email: subs@3smedia.co.za

With the evolving and sometimes volatile

ISSN 1999-8872 Inside Mining

market conditions shaping the landscape

of the mining industry, it will be exciting to

All material in Inside Mining is copyright

Technological advances and innovations

see how the industry shapes up next year.

protected and may not be reproduced either

are likely to increase demand for battery

in whole or in part without the prior written

metals and will surely create opportunities

permission of the publisher. The views of

for the mining sector.

contributors do not necessarily reflect those of the publishers.

Where sustainability is concerned, this year, we have observed a call for collaborative action in order to ensure that the mining industry is responsive to the needs of the people it affects, allowing it to make a positive socio-economic impact and foster development across Africa. It is encouraging to see the consensus is that

To our avid readers, be sure to sign up and get the latest updates and inside scoops from the mining industry. Check out what we are talking about on our website and Facebook page, or follow us on Twitter and have your say.

this trajectory should be maintained into the new year. Enjoy this issue, and see you at the Indaba.

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

EDITOR

9th ANNUAL

WOMEN IN M INING

-Moving from the integration to the development of women in mining Date: 21, 22 & 23 February 2018

Venue: Indaba Hotel, Fourways, Johannesburg

CONFIRMED SPEAKERS INCLUDE: Seara Macheli-Mkhabela Executive Head: Corporate Affairs ANGLO AMERICAN PLATINUM

Gugu Mkhize Executive Manager: Corporate Services MINING QUALIFICATIONS AUTHORITY

Lindiwe Nakedi Managing Director GUBHANI EXPLORATION Chairperson WOMEN IN MINING SOUTH AFRICA (WIMSA)

Olebogeng Sentsho Head of Operations YEABO MINING

Izanne Goosen WIM Chairperson SASOL MINING

Boniswa Dladla Ore Processing Engineer DE BEERS GROUP

Kgomotso Tshaka Sustainability Executive WESIZWE PLATINUM

Vanisha Balgobind Executive Head: HR EXXARO

Tebogo Mdhluli-Segapo Senior Manager: Workforce Planning & Organisation Design ANGLO AMERICAN PLATINUM

Natasha Chengapar Chief Corporate Services Officer TSHIPI ENTLE MANGANESE MINE

Chantelle de Sousa Private Attorney

Asanda Benya Lecturer (Department of Sociology) UNIVERSITY OF CAPE TOWN

Linah Tshabalala Human Resource Manager ANGLO THERMAL

Noleen Pauls Principle Geoscientist REFLEX (EMEA REGION)

INTERNATIONAL PERSPECTIVE

Oshana Naidoo Chief Executive Officer TUSCAN MINING

Alice Murine Githiomi Geologist BASE TITANIUM- KENYA

Dr Gargi Mishra Founder MINING INNOVATION Member INTERNATIONAL WOMEN IN MINING (IWIM)

NEIGHBOURING PERSPECTIVE:

Dr Lilita Marques HRD Manager NAMDEB DIAMOND CORPORATION - NAMIBIA

Ndibo Matshameko Mine Geologist DEBSWANA

TWO PANEL DISCUSSIONS

Malebogo Marumoagae Director BELLE LARISSA- BOTSWANA

WORKSHOP / CASE STUDY TACKLING SEXUAL HARASSMENT IN THE WORKPLACE AND PROCEDURES Adv. Johan Raubenheimer Risk Management Consultant HOGAN LOVELLS

ADDRESSING HEALTH & SAFETY FOR WOMEN IN MINING WOMEN EMPOWERMENT FROM AN AFRICAN PERSPECTIVE

KEY STRATEGIES TO BE DISCUSSED • • • • • •

Looking at the current opportunities for SMME Supplier Development Beneficiation Forming “Regional Women in Mining Committees” for the upliftment of WIM Looking at a male perspective on the contribution made by women in mining Empowering women through successful public/private collaboration with financial institutions Opportunities for small scale artisanal women in mining groups (in Kenya) Addressing Health & Safety for women in mining

• • • • •

Holistic transformation as a woman in the mining industry Ensuring women play an imperative role in the drafting of your internal policies Sustainable organisation culture transformation of mining organisations: for an all - inclusive workplace Executing policies that cater to the special needs of pregnant women and maternity Empowering women in mining outside the workplace

CONFERENCE HIGHLIGHTS Register and pay by 1 December 2017 and receive a gift bag filled with great surprises

CELEBRITY SPEAKER Kabonina Qubeka Actress

Join ITC after day one for a 15 minute “time out” pamper massage

ITC IS ETDP & MICT SETA ACCREDITED & A LEVEL 1 B-BBEE COMPANY For easy registration contact Zakhele: +27 (0) 11 326 2501 or email bookings@intelligencetransferc.co.za or fax: +27 (0) 11 326 2960 or visit: www.intelligencetransferc.co.za

MINING NEWS

from around the continent

Minister of Petroleum and Mineral Resources Tarek El-Molla

EGYPT

Exxon eyes offshore oil and gas

“One hundred per cent of the value

A University of South Africa

of this diamond, of the auction sale is

graduate, Marcus has acted as

going to go to the government and

chairperson of a number of South

the people of Sierra Leone. Never

African regulatory and supervisory

before has this happened,” Rapaport

bodies, including the Financial Services

told reporters.

Board and the Standing Committee for

The gem was unearthed in March in Sierra Leone’s eastern Kono region by

Marcus was also the non-executive

a Christian pastor who gave it to the

chairperson of the Absa Group from

government to handle the sale. It was

2007 to 2009. She has also been a non-

the government’s second attempt to sell

executive director of Gold Fields Ltd

the diamond after it rejected the highest

and Bidvest, and governor of the South

bid of $7.8 million at an initial auction in

African Reserve Bank from November

the capital Freetown in May. Ahead of

2009 to November 2014.

the auction, the diamond was shown to

ExxonMobil is considering a foray into

some 70 potential buyers and received

Egypt’s offshore oil and gas, seeking to

seven bids, Rapaport said.

replicate rivals’ successes in the country

the Revision of the Banks Act.

ZAMBIA

Night driving ban lifted for truckers

“We showed the diamond

and boost its reserves, officials and

everywhere. We did whatever we could

Zambia has lifted a ban on night

industry sources have said.

and that’s the best price that we can

driving for truckers, imposed to improve

get from the market today,” he said.

road safety, after mining companies

According to Minister of Petroleum and Mineral Resources Tarek El-Molla,

in Africa’s number two copper

officials from the world’s largest listed oil

producer said the decision had hit

producer recently held talks with Egypt’s

SOUTH AFRICA

in oil and gas production, known as

Glencore appoints former Reserve Bank governor

upstream operations.

The board of natural resource

petroleum ministry to discuss investments

“We are exploring all opportunities for

commercial activity. Last year, the Southern African nation banned night driving for public service vehicles, including buses and trucks, in a bid to reduce the number of fatal road

commodities producer and

having more and further upstreamers in

trader Glencore has

Egypt,” Molla said on the sidelines of an

announced the

Minister of Transport and

OPEC meeting in Vienna.

appointment of

Communications Brian

“I would be happy to have them with

traffic accidents.

Gill Marcus as an

Mushimba said the ban

us,” he said, adding that no decision has

independent non-

would remain in force for

been made yet.

executive director

buses but trucks, which

of the company as

also transport copper, the

In 2016, Egypt had reserves of 3.5 billion barrels of oil and 1.8 trillion cubic metres of gas, according to BP’s Statistical Review of World Energy.

of 1 January 2018.

nation’s main export, would

Commenting on

be allowed to move at night.

chairman Tony Hayward

SIERRA LEONE

Diamond sells for US$6.5 million at auction

The Zambia Chamber of

the new appointment, said, “I am extremely

Former Reserve Bank governor Gill Marcus

pleased that Gill Marcus has accepted the board’s invitation to become a director of Glencore.

Mines (ZCM), which represents foreign mining companies operating in Zambia, welcomed

the lifting of the ban. “The mining sector is obviously

Sierra Leone sold one of the world’s

We believe that her long record of

relieved that the measures… have

largest uncut diamonds for $6.5 million

public service coupled with her finance

been amended to reflect the reality of

at a New York auction to raise funds for development projects in the West African country.

experience, geopolitical insights and non-executive board experience will be a great benefit to us.”

transporting essential industrial inputs and commodities on our roads,” Nathan Chishimba, president, ZCM, said.

The egg-sized gem – known as the Peace Diamond – was bought by British luxury jeweller Laurence Graff, said Martin

Night driving ban lifted for truckers in Zambia

Rapaport, chairman of Rapaport Group, a network of diamond companies that managed the auction.

IN SID E M IN IN G D E C/JA N | 2018

COVER STORY | ERWAT

he state-owned East Rand Water Care Company (ERWAT) developed its new strategy aimed at mining

soon after managing director Tumelo Gopane joined in 2016. The company will be exhibiting at the Investing in African Mining Indaba for the first time in February 2018 in aid of its goal of becoming the leading wastewater company on the continent. “There is a large amount of water that gets utilised in the mining process, and we know that most of it is directed to a tailings dam and very little, if any, of it is reused. So that is where ERWAT’s proposition to the mining industry comes from,” explains Gopane. He adds that the reuse of mining wastewater has already been adopted in a number of countries

ERWAT ventures into mining ERWAT provides bulk wastewater conveyance and a highly technical and proficient wastewater treatment service to some 2 000 industries and more than 3.5 million users. The company is now looking to venture into the mining industry, offering wastewater and acid mine drainage solutions.

globally, namely Singapore,

development of new ones. “We would like to see mining houses focus on getting the ore out of the ground, and allow us to focus on the water issues,” Gopane says. In explaining the proposition, Gopane shows that, as mines dewater, ERWAT will clean that water and restore it, making it available for reuse in processing and leave the raw water for potable use. “Currently, most mines abstract raw water from surrounding rivers, dams and lakes, which is essentially fresh water that would otherwise be reserved for human consumption. The ERWAT solution will alleviate a significant amount of pressure from the dams and rivers by eradicating the use of this water for mining,” Gopane explains.

Malaysia and Australia. miners, placing particular focus on the

The cost matrix

water to potable standards. In fact, you

necessity of correct water and waste

The cost of such a service is critically

can even go as far as treating water

management on mines.

linked to the adoption rate of this

“In Malaysia, they recycle 80% of their

to distilled water – which is so clean

Subsequently, miners spend a lot

method, given that cost cutting

that it is not encouraged for human

of time and money on R&D in water

has become a necessity in these

consumption,” he states.

and waste management. ERWAT’s

challenging economic times.

Essentially, where mining operations

proposition may solve this issue and

On average, a local miner pays

are using municipal water for most of

provide a more sophisticated way of

R3.50 per kilolitre for raw water, and

their processes – beyond water used

dealing with waste and water.

the assumption is that ERWAT (or any

in boilers – ERWAT can immediately

“We are saying to the

other company) would not be able to

alleviate that pressure and switch such

mining industry that it no

provide this service at the same cost

operations to treated wastewater,

longer needs tailings

or less. Gopane has a clear response

saving that municipal water for

dams; we can do

human use.

away with these going

Eradicate the need for tailings dams

eliminate the need for the

forward. Although we cannot do much about tailings dams that

The tailings dam has long been a part of

already exist,

the mining process. With the real threat

we can halt

that tailings dams pose to surrounding

their further

communities (as tragically shown by the

development,

1994 Merriespruit tailings dam disaster),

and

legislation has become tougher on

completely

INS I DE MI N I N G D E C / JA N | 2 0 1 8

to this.

“We would like to see mining houses focus on getting the ore out of the ground, and allow us to focus on the water issues.” Tumelo Gopane, MD, ERWAT

“During discussions with a major coal miner, the cost question came up. We then asked them whether they had examined the cost of treating their own water before using it, and to put a number to that. Through this, we estimated that the cost would probably come to an additional R3 to R4 per kilolitre. “What this means is that the cost of abstracting and treating water the way miners currently do is actually north of R6 or R7 per kilolitre – whereas reused water can cost around R5 per kilolitre. That would be a saving of R1 or R2 per kilolitre, which is a significant saving for miners,” Gopane adds.

Acid mine drainage The issue of water quality has become topical in the aftermath of the contamination in the Olifants River catchment in Mpumalanga over recent decades, as well the surfacing of acid mine drainage from old and abandoned mines around Gauteng in particular.

ERWAT has engaged with the Chamber of Mines, which has advised that the first order of business be to address the nine catchment areas in South Africa. With the Limpopo catchment being presumably the most stressed of the nine and mining activity in this area being extensive, ERWAT intends to approach miners in the area in a bid to build new partnerships. For more on ERWAT’s offering to the mining industry, visit stand 1120 at the Investing in African Mining Indaba between 5 and 8 February 2018.

“In South Africa, once a mine has closed down, nobody looks after the

and treat AMD to the extent where it will

plants. Depending on where the mines

shafts. What we are seeing in the

be suitable for use in mining processes.

are, we would set up pipes. Ultimately,

Ekurhuleni area is that some of these old

as a country, we need to have reservoirs

“We want to clean that water,

mines have been decommissioned for

build reservoirs and sell it to industry,”

and piping networks for process water,

about 40 years or more, which means

says Gopane.

especially in densely industrialised areas like Witbank, Rustenburg and

that we have neglected to keep track

In terms of infrastructure for this kind of

of what was happening in the cavities

activity, Gopane says plants of different

Middelburg. We would require regional

for decades, and this has now left us

sizes would be needed, depending

treatment plants, where we could store

with a serious AMD problem.

on the amount of water needed, to

the treated water in reservoirs and then

further clean the water – which he says

distribute to the areas concerned.”

“The reality is: if we don’t do

Gopane concludes, “We are ready

something quickly, AMD will likely

would not be particularly challenging

contaminate the entire underground

because South Africa has significantly

to approach the market with a new

potable water system, which would be

high compliance guidelines for the

offering and see the Investing in

catastrophic. This is an imminent threat,

discharge of wastewater.

African Mining Indaba as an ideal

and the reason why the Department of

“With our existing compliance levels,

Water and Sanitation (DWS) has made

to take that water to potable standards

the efforts it has on the eastern and

would be a small step,

central basins,” Gopane warns.

which would require

ERWAT is proposing to take the dewatering of the DWS to the next level

further treatment of the water at process

platform to engage with captains of industry.”

Watch our interview with ERWAT managing director Tumelo Gopane on www.miningne.ws

IN SID E M IN IN G D E C/JA N | 2018

CEO TALK

Holistic service excellence In a challenging economic climate, companies with effective, inspirational leaders are favourably positioned to weather the storm. Under managing director Thierry Pimi, Cummins SA has placed an unwavering focus on understanding its markets and pursuing service excellence to ensure continued positive growth.

orn in the Cameroon, edu-

construction sectors have been pretty

large industrial clients on the road, on-

cated in the UK and USA, a

much flat-lining for the last five years or

site and in the marine environment.

mechanical engineer with

more. But this does not diminish Pimi’s

From trucks and buses to specialty

an MBA in strategy and fi-

determination to pull Cummins SA

vehicles, equipment and machinery

through, and build on past successes.

belonging to brands such as MAN, Ko-

At the heart of the matter, Cummins

matsu, Hyundai and Hitachi – which, in

Southern Africa in 2016, during one of

designs, manufactures, sells and servic-

turn, equip the mining, civil engineering

the region’s most challenging times in

es diesel and alternative fuel engines

and construction industries, oil explora-

recent history.

from 2.8 ℓ to 95 ℓ, diesel and alterna-

tion, and commercial and leisure ma-

tive-fuel electrical generator sets from

rine applications – Cummins is a signifi-

engine, is struggling through

2.5 kW to 3 500 kW, as well as related

cant power that drives the world.

economic decline, in real terms

components and technology.

nance, and groomed to lead, Thierry Pimi took responsibility for Cummins

South Africa, SADC’s economic

(inflation removed), especially over the last seven years. The mining and

In essence, Cummins provides the power plants that drive OEMs and

According to financial media company CSIMarket, and comparing its results to the previous year, Cummins reported

“Service excellence – and looking after our customer’s customer – is the critical success factor, in any economic climate.” Thierry Pimi, MD, Cummins SA

INS I DE MI N I N G D E C / JA N | 2 0 1 8

CEO TALK future. It’s because we understand

Cummins SA service philosophy

this that we are confident, and will be

•P ersonalised service Cummins’ team of certified service professionals are friendly, thoroughly trained, knowledgeable and capable. They ensure the job is done right the first time, everywhere, every time

years to build a solid base in Southern

investing R300 million over the next 10

• Fast response and diagnosis No matter the location, at a Cummins’ branch or on-site, the same, high-quality diagnostic tools are used to ensure a fast and accurate diagnosis. If on-site, Cummins will strive to have a service vehicle on location within four hours of a service call

• Precise answers to your service needs Armed with the knowledge and understanding of the customer’s equipment and business needs, Cummins service professionals develop and communicate a service and repair plan specifically for the customer’s customer. Precise quotes are given in respect of costs and time required to complete a service or repair. The customer’s complete understanding of the entire service event is important

• High-quality repairs The key to a successful repair event is going beyond symptoms and understanding the root cause of a performance issue. Cummins trains and certifies its technicians on all Cummins products. This, together with years of experience and support from the Cummins factory, gives technicians a level of expertise that is unmatched in the industry

Africa to develop our expertise so that we may export this expertise to the rest of Africa,” says Pimi. “There are other ways we can invest in the market. Through constant analysis, we can devise appropriate responses to market forces, such as the current doldrums. We will look at creative ways of keeping our customers and our customers’ customers running efficiently. This will involve close collaboration and looking at practical ways to keep their operating costs down. It may also include rescheduling customer’s repayments or giving them preferential pricing options. But, most importantly, it means keeping them running 24/7 to ensure they remain productive and profitable. This means delivering service excellence.”

Service your market

• Ongoing communication Cummins will not keep you in the dark or ill-informed. Their service support team is dedicated to keeping the customer informed throughout the service event, simply because “every minute counts”

“We realised, given our business model, that service excellence – and looking after our customer’s customer – is the critical success fac-

a total global revenue increase in Q2

principles of best busi-

2017 of 12.15%, year-on-year – well be-

ness practices, there is a

yond inflation and GDP growth rates.

common thread through-

climate, but more so

out the demand side of our

in this difficult eco-

So, how does the company do it?

Understand your markets, and their needs

tor, in any economic

equation – uptime is critical to

nomic environment,” says

productivity and profitability. The longer a heavy hauler truck

Pimi. “We realised too that customer service isn’t just a

“We have taken the time to under-

stands idle, the less productive and

stand our markets,” Pimi says. “We

profitable it is. It’s

have segmented Africa into five

our responsibility to

clusters – the North, South, East, West

see that a heavy

and Central African clusters – each

haul truck is up

with their own unique challenges. The

and running in

Southern African cluster comprises all

the shortest time

you do or where

SADC countries except Angola, the

frame possible –

you operate, we

DRC, Tanzania and the Seychelles,”

even if it means

back up our prod-

he explains.

pulling out the

ucts with the ser-

old engine and

vice support you

“With the exception of South Africa,

department; it’s the entire com-

ABOVE The Cummins X15 engine BELOW The new Cummins generator

pany, from me down to the tea lady. It’s doing it and not just talking about it. “No matter what

none of the African clusters have the

putting in a

manufacturing capability to supply

new one, there

need it. That’s

Africa with power plants. Because of

and then. It’s

our commitment

this, and as a power supplier, our rela-

that simple.”

tions with foreign OEMs are absolutely

need, when you

to you,” he adds. Cummins’ excellent

critical. It’s also in understanding our

Invest in that market

financial performance in tough

customer’s customer and in looking af-

“If you understand your market and

times clearly shows its strategy is

ter them that we ensure our continued

have confidence in its future, you will

paying dividends, which means

success and sustainability,” says Pimi.

invest accordingly. We know, from

the company’s customers and

research, that the global market is

its customers’ customers are also

cyclical and will pick up again in the

benefiting. That’s the bottom line.

“Falling into the supply side of the equation and applying all the

IN SID E M IN IN G D E C/JA N | 2018

MINING EQUIPMENT

Robust and reliable technology Power and Energy

Multifaceted thyssenkrupp Industrial Solutions delivers end-to-end bulk materials handling, comminution, power and energy solutions, and has positioned itself as a leader in lab automation technology. In 2018, the focus remains on the provision of exceptional service and getting as close as possible to the client.

“The Power and Energy Business Unit’s key focus point is complete turnkey biomass and CFBC power plant solutions– and that’s really about the provision of robust and reliable technology for Africa,” says Arnold Webb, product manager: Power Plant Technologies. The Power and Energy BU focuses largely on new boiler installations at green- and brownfield sites. “The focus is on CFBC and biomass – complete power plants, specifically direct com-

he global diversified industrial

machines from a service perspective –

bustion thermal power plants – with the key

group boasts several business

and we highlight the importance of us

advantage being the robust and reliable

units and providing full turnkey

being close to our clients.

technology. It is proven high-efficiency tech-

“We have a massive footprint in sub-

solutions to clients across the

nology and, like the other technologies across

continent is a large part of thyssenk-

Saharan Africa, and that is the focus

the company, is focused on reducing plant

rupp’s value proposition and a key focus.

of the Mining Division of thyssenkrupp,”

life-cycle costs,” explains Webb.

he adds.

Wilfred Barkhuizen, GM: Minerals

With a massive global footprint, thyssenkrupp

thyssenkrupp Industrial Solutions further

Processing, thyssenkrupp, explains:

has leveraged its global expertise and applied

“Looking at the pit-to-port value

offers a complete pit-to-port bulk mate-

this to projects on the continent. Barkhuizen

chain, our focus remains on providing

rials handling and comminution solution

highlights this as one of the company’s unique

proven comminution technology.

that includes crushers, grinders, convey-

selling points. “We have global exposure to

thyssenkrupp’s equipment leads the

ors, stackers, travel cars, drum reclaimers,

projects all across the world, and we tend to

market and we really spend a lot of

as well as train and ship loading/unload-

take that experience and apply it to newer

time supporting and optimising our

ing equipment.

local projects. So, the way that projects are

TIMELINE 1969

1954

1844

Weserhütte is established.

1938

Polysius JHB (Poljob) supplies kiln plant to Cape Portland Cement, De Hoek works.

Uhde RSA designs & constructs chemical & industrial plants for RSA industry for over 40 yrs, working on a contract-tocontract basis from 1954 onwards.

1959

Registration as Krupp RSA (Pty) Ltd. Represented by Knut Hamelau who travelled out of Polysius Ascot (Polcot) to look after SSA clients. Only subsidiaries were Polcot & Polpar (France). Polysius HO in Beckum, Germany (Polbeck).

1962

First Uhde contract in RSA.

1967

Registration of Polysius (Pty) Ltd. Opens office cnr. Simmonds & Market Str. JHB CBD (1 Nov), close to all mining houses & 3 cement companies: Blue Circle Cement, Anglo Alpha Cement & Pretoria Portland Cement. Willi Boege, Konrad & Christa Kaminski – first Poljob employees.

INS I DE MI N I N G D E C / JA N | 2 0 1 8

1970

Moves to IMS Building, Loveday Str. Selby JHB CBD (1 May). Employment / transfer of Jochen Friedrich, GM Minerals industry & Dieter Luecke - Commercial Mngr. Polysius is market leader in cement technology. Known for reliability & service quality.

First contract: Supply pneumatic screening plant African Explosives, Modderfontein JHB (value R44 000); order for a similar plant from African Explosives for their works, Salisburg, Rhodesia (now Zimbabwe). New order from an iron ore reduction kiln plant for Dunswart Iron & Steel (DISO).

1969

1971

Uhde Germany establishes permanent branch office in RSA to build a team of engineers & related service personnel. Uhde starts operations in RSA with the establishment of a branch office.

Weserhütte supplies iron ore blending plant to ISCOR Sishen as first order in RSA.

1975

Joint venture with Polbeck (Beckum, Germany), Polpar & Polcot: Delivery of kiln to Sang Yong Cement, South Korea. Delivery of cement plant: Anglo Alpha & Blue Circle, RSA, as well as for Portland Holding & Circle Cement, Zimbabwe.

1979

ThyssenKrupp Materials Handling starts project with Sishen Iron Ore which became one of the largest concentration of Drum Reclaimers in the world (2017).

1981

Uhde establishes its local engineering company, Uhde (Pty) Ltd. This RSA subsidiary enables Uhde to utilise local engineering skills more effectively & successfully with tailor-made engineering systems.

1983

Polysius & Krupp Fördertechnik moves into Polysiusowned building, cnr. Bond & Surrey Str. Randburg (1 May). Joint Managing Directors: Dave Morcombe (Commercial) & Konny Kaminski (Technical).

MINING EQUIPMENT

for Africa put together, especially on an EPC basis, makes use of the latest technology, with the

particular, is looking into various low-energy-

The state-of-the-art Service Centre boasts

consumption technologies, and thyssenkrupp

capabilities that make it one of a kind in Afri-

designs machinery and equipment that

ca, given the in-house machinery, and repair

addresses precisely this challenge.

and manufacturing capabilities, based on

“Energy consumption is a critical area for

German engineering standards.

latest cost-saving methods, and the best

us; we have seen a lot of mines making use

combination of equipment based on the

of the high-pressure grinding rolls as an alter-

turing capabilities, but will always focus on

experience we have,” he explains.

native technology, which has a proven track

providing service to clients. The thyssenkrupp

record in hard rock mining over the last 35

success story bears testament to the compa-

years,” states Barkhuizen.

ny’s commitment to developing long-stand-

Increasingly complex value chain Barkhuizen explains how the orebodies that

The service centre has unique manufac-

ing partnerships with customers, and putting

are being exposed now in sub-Saharan Afri-

Service comes first

ca are often so complicated in mineralogy

With half of the thyssenkrupp Industrial Solu-

service at the heart of it all. By combining engineering expertise with

that the comminution circuit technology

tions Africa business dedicated to service, the

traditionally strong materials capabilities,

applied has become increasingly compli-

Service Centre at Chloorkop acts as a hub

thyssenkrupp aims to create value for

cated. In addition, lab analysis and product

for service activities throughout sub-Saharan

customers around the world and utilise

quality control thereafter have also become

Africa, with key resources based regionally

wide-ranging opportunities in the markets

more complicated.

in close proximity to customers. It is clear that

of the future. Together with its

“So, the whole process design is significantly

customers, it develops

service excellence is a key company tenet.

more complicated than it was before. To do

“The focus is on 360-degree service

competitive solutions

everything cost-effectively, one has to install

and what really sets thyssenkrupp apart

to future challenges

the latest technology and pour the latest

from others is our commitment to our

across numerous

knowledge into that process – thus making

customers’ success through the equipment

sectors.

the projects bankable. That is exactly what

life cycle. We have a dedicated

thyssenkrupp offers the market,” he asserts.

team, supported through a global

In Africa, the consumption and preservation

network, enabling us to provide

of energy is a major concern, and the onus

the extensive services required

lies with industry to adopt energy-efficient

by our customers,” says Ruben

ways of doing business. The mining industry, in

Lamprecht, GM: Service. Arnold Webb (left), product manager: Power Plant Technologies and Wilfred Barkhuizen, GM: Minerals Processing

2010

1997

1986

Polysius introduces Polycom High Pressure Grinding Roll (HPGR) technology to De Beers, for grinding of Kimberlite; leads to the delivery of some 15 HPGRs to De Beers group including Orapa & Jwaneng, Botswana. Poljob: First subsidiary to sell large diameter SAG mills.

1990

Joint controlling & personnel departments for Polysius & Krupp under Mr Morcombe. Total personnel: 47.

1996

Krupp Engineering acquires Uhde companies worldwide.

1997

Order for cement kiln extension: Collver, Zimbabwe. Polysius & Krupp, joint venture for the supply of raw material storage & slag grinding plant: Saldanha Steel (now Arcelor Mittal), W. Cape. Supply of reduction kiln & mill: Chrome Newcastle (joint venture with Bayer).

Uhde, Krupp & Polysius relocate to Sunninghill office. Building designed for some 200 employees. All engineering activities of Krupp Group in RSA consolidated into Krupp Engineering (Pty) Ltd. RSA trading name changes: ThyssenKrupp Engineering (Pty) Ltd., incorporating Uhde, Polysius & Krupp’s Materials Handling divisions (wholly owned subsidiary of Thyssen-Krupp Technologies AG GmbH), based in Sunninghill, RSA. KSA becomes: Krupp Engineering (Pty) Limited. Uhde joins ThyssenKrupp 2002 Materials Handling Krupp Engineering & Polysius as name change: a division of ThyssenKrupp the company. Engineering (Pty) Ltd.

1998

Collaboration between Uhde, Krupp & Polysius. Company name change..., a division of Krupp Engineering 3 Divisions consolidate their operations in the new Sunninghill offices developed specifically for the enlarged company.

2009

Official opening of Polysius Service Centre, 26 March.

ThyssenKrupp PDNA Engineering (Pty) Ltd. (TKPDNA), a Black Economic Empowered (BEE) Engineering & Projects company is established comprising of Uhde & ThyssenKrupp Materials Handling, divisions of ThyssenKrupp Engineering (Pty) Ltd. & PDNA. Industrial Projects (Pty) Ltd., a division of PD Naidoo & Associates (Pty) Ltd.

2010

Uhde RSA develops innovative approach to project management & engineering. Uhde offers turnkey solutions to all facets of project execution, maintaining a professional approach & integrity. Engineering background developed in RSA over the past 40 yrs, results in a diverse resource base comprised of experienced professionals. Financial yr 2010-2011 Planned turnover: R457m.

2011

As at 31 January:

Uhde workforce: 264 Permanent Employees: 152; Contracts: 112 Uhde executes several contracts for Sasol, largest petrochemicals company (RSA). Contract of R261m for extension of gas handling facilities at Temane, Mozambique. Project, March 2011.

2013

Executing contract for the water recovery growth project, Secunda, (RSA). Engineering services: New multiproduct pipeline project of Transnet through alliance of Arup & Worley Parsons. Provides engineering services to PDNAIP: Kusile (RSA) water project, Eskom.

2015

Uhde, Polysius & Materials Handling merge, now known as thyssenkrupp Industrial Solutions.

2017

We offer a full range of engineering, procurement & construction management services primarily to petrochemicals & chemical industries in the Sunninghill and Chloorkop offices.

IN SID E M IN IN G D E C/JA N | 2018

A bucket-wheel excavator processing iron ore (Picture: Citic)

iron ore rock from which metallic iron can be economically extracted is mined in many countries around the world. Of these,

South Africa is the 12th largest, with 770 Mt in reserve (2016). Australia leads the pack with a

The price puzzle

colossal 23 000 Mt. However, South Africa’s ore quality, at 64.2% iron content to crude ore, is better than Australia’s 44.2%.

Iron ore is usually found in the form of

For miners who have been working over the last 10 years, the constantly struggling iron ore price is frustrating. Given that the world population is growing, the demand should be there. So, why is the market so unstable? By Tony Stone

hematite (Fe2O3) or magnetite (Fe3O4), with roughly 98% of world iron ore pro-

duction used to make steel. Steel, in its various forms, is used in the manufacture of automobiles, locomotives, ships, beams used in buildings, train tracks, furniture, paper clips, tools, reinforcing rods for concrete, bicycles, and a whole range of products we need for modern life. In looking at the demand side of the equation, the world’s population of 7.6 billion, as at 2017, is currently growing at a rate of around 1.12% per year, down from 1.14% in 2016. The average population increase is estimated to be 83 million people per year, reaching 8.6 billion by 2030 and 9.8 billion by 2050. The United Nations predicts that, during this time, it’s expected that half of the world’s population growth will be concentrated in just nine countries: India, Nigeria, the Democratic Republic of the Congo, Pakistan, Ethiopia, the United Republic of Tanzania, the United States of America,

The iron ore spot price over five years

INS I DE MI N I N G D E C / JA N | 2 0 1 8

Uganda and Indonesia (ordered

COMMODITY | IRON ORE

770 Mt

98%

80 Mt

Number of countries with greater iron ore reserves than South Africa

Amount of reserves found in South Africa, of which a significant portion is found in hematite, which bears high-quality iron ore

Approximate percentage of the world’s iron ore used in steel production

South African production of iron ore per annum, ranking the country seventh among global producers

by their expected contribution to

developing world’s economies – e.g.

inflated by the 2008 to 2013 boom,

total growth), of which eight are

Africa – have not risen to the levels

normalised between 2013 and

developing economies. So, if the

required to offset the drop in demand

2015, with a slight over-correction.

demand is there, and is expected to

from the developed world. And,

Data analysis shows that iron ore

continue, why then is the iron ore

between January 1997 and December

prices should be aroundthe $80 to

price struggling? We know that

2006, the average price per tonne of

$85 mark, not the $62.50 it is now.

the world’s population growth has

iron ore was US$17.0975.

Hopefully, it will continue to selfcorrect and settle by end 2017 or

Since then, up until present day,

slowed, especially in the developed

early 2018. Time will tell.

the average is $95.8004, which,

world. Unfortunately though, the

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t 031 700 5460 I e support@wearcheck.co.za IN SID E M IN IN G D E C/JA N | 2018

DIAMOND PROCESSING

The sticky end of A grease table at Petra’s Williamson plant used for second recovery (Picture: Petra Diamonds)

characteristics of your diamonds and the material in which they are found. Kimberlite, which comprises a variety of ultramafic volcanic and sub-volcanic rock, along with a similar rock called lamproite, is important for delivering diamonds to the earth’s crust through magmatic intrusions that solidify into pipelike structures. Kimberlites contain high concentrations of magnetite (Mohs 5.5. to 6.5), an iron oxide with the

Understanding the physics of diamonds can be quite useful, especially when applying three of its principles to diamond recovery. By Tony Stone

(Mohs 5 to 6), and a black iron titanium oxide with the chemical FeTiO3, all of

which exhibit a weak magnetic field. Collectively, this is extremely important, because getting the diamonds out without damaging them

n speaking about diamond

of modern technology, you can

is crucial to retaining their value. A

recovery processes, Petra

increase productivity in your diamond

crack in a diamond diminishes its value

Diamonds adds one last step to

recovery process – if the beginning

and also determines the effectiveness

its process. From primary and

and the end are handled well.

of the intermediary processes, and the

secondary crushing, scrubbing and

chemical formula Fe3O4,and ilmenite

last step in our process. The jaw crusher,

screening, to dense media separation,

In the beginning

further screening and drying, followed

Diamonds have a Mohs hardness

for the lowest capital cost, with its 1:3

by magnetic separation and X-ray

Index of 10 (the maximum). Diamonds

reduction ratio, coupled with the cone

reparation, diamonds still get lost in

also show a variation in hardness with

crusher’s two-stage 1:3 reduction ratio,

the typical diamond recovery process.

the octahedral faces being harder

will reduce kimberlite to a miniscule

De Beers recovered 815 036 carats

than the cube faces. While this is less

level to maximise the extraction of

of diamonds from 6 133 799 tonnes

important in alluvial diggings than

large, small and very small diamonds.

of tailings. In understanding your

it is in kimberlite rock, it is important

Crushing kimberlite (Mohs 6 to 7) needs

subject matter, as well as the fallibility

to know and understand the

to be simultaneously hard and soft,

INS I DE MI N I N G D E C / JA N | 2 0 1 8

the most effective primary crusher

DIAMOND PROCESSING

Using a grease table or grease belt as the tail-end process will ensure a higher diamond recovery rate

and generally not exceed Mohs 8. The desire for maximum recovery must be there, at all times.

In the end

100°C) should be avoided, as must

It’s the knowledge that diamonds are

any contact with water or other

naturally hydrophobic, meaning a

fluids. The grease should always be

diamond’s surfaces repel water, which

stored in labelled containers and

is the key to the end process. This unique

away from strong oxidising agents or

feature allows the diamond recovery

combustible material.

process to utilise ‘grease’ technology

For the smaller mining operations,

at the tail end of the overall process.

grease tables are designed as

This technology comes in two forms

vibrating, downward-angled flat

– the vibrating grease table and

or stepped tables upon which thin

the automated grease belt. Both

layers of collector grease are hand-

methods apply the same principle but

spread. Water is sprayed on to the

are differentiated by the amount of

table through a number of sprayer bars positioned horizontally over the table, typically above each step. Concentrate is fed on to the table at the top end and transported downward by the water sprays. The hydrophobic diamonds stick to the grease while the hydrophilic materials, comprising garnets, ilmenites and other minerals commonly found in kimberlites, travel over the grease, down the table and into the waste stream. At a point, the process is stopped and the thin layers of diamond-bearing grease are scraped off and deposited into a boiler to separate the diamonds from the grease. The waste grease/water mix from the boiler is piped to a grease trap for further processing. For the larger mining operations, grease belts meet the processing

automation and proportional safety they offer, as well as the costs involved. Typically, the grease used in both technologies is Engen’s Collector DB grease or Sasol’s Diamond Grease 40 and 70. In both cases, it’s a lightcoloured compound used as a medium for separating diamonds from heavy concentrates. The diamonds’ hydrophobic nature means they adhere to the grease surface, which is also hydrophobic, thus separating the diamond from the water surface of the schist. The penetration (hardness or softness) of Collector DB may be adjusted to suit the diamond recovery operation through the use of Micro Wax 2528 or Tekniwax A. In handling and storing the grease, elevated temperatures (exceeding

A typical grease table (Picture: Gondwanaland Diamonds SA)

throughput demands in the same way as the grease tables but on an automated, continuous basis. At one end, the belt is coated with a thin layer of grease prior to it encountering the concentrate. A blade at the other end automatically scrapes clean the entire surface of the belt and deposits the grease and diamonds into a boiler below. The entire system is enclosed to provide a hands-off operation. This adds safety features to the process that cannot be overstated. Naturally, automated systems come at a price and are generally 20 to 30 times more expensive than an average vibrating grease table. However, this cost is relative to the rate of diamond recovery.

Benefits of multistage recovery Diamond recovery processes, be they DMS or X-ray, are not infallible, however. Using a grease table or grease belt as the tail-end process will ensure a higher diamond recovery rate. As has been found, the material that comes out of the grease process often comprises 50% or more of rough diamonds. If this does not make the idea of using grease as the tail-end diamond recovery process stick fast in your mind, then you may have missed something.

Scrapping the diamonds and grease off the table (Picture: Gondwanaland Diamonds SA)

IN SID E M IN IN G D E C/JA N | 2018

COAL MINING

Expansion GG6 at the Grootegeluk coal operation is under way

Unlocking Limpopo’s Waterberg coalfields is a process that began 10 years ago. Previously hindered by a lack of infrastructure, including unreliable water supply, the region’s coal operations will now benefit from a coal export transportation agreement between Exxaro and Transnet. By Phila Mzamo

Spatial Development

ore than 50% of South

rail infrastructure in

Framework

Africa’s remaining coal

the Waterberg area, which includes the

reserves lie in the Waterberg coalfields

– a 3 520 km2 expanse in Limpopo that stretches into Botswana, and hosts almost 76 billion tonnes of

Timing Logistics and water

KEY CHALLENGES

Outbound logistics

and help increase coal volumes from Waterberg to the Richards Bay Coal Terminal. The agreement will provide

the South African

Raw water supply Expedite increased supply

Environmental Stewardship Sustainable development and clean coal

economy and are playing our role in developing more rail capacity and unlocking the capacity of the Waterberg

region to domestic and export

markets,” says Gama.

the much needed rail infrastructure to

Gama explains that the signing of the

transport a total of 7.8 Mt of export coal once all the projects are ramped up.

rail capacity and expanding export rail

new agreement follows the completion

Some 3 Mt of this coal will come from

performance in the Waterberg area

of the first phase of 2016’s Waterberg

the Waterberg.

and across South Africa,” he explains.

Expansion Programme, which included

Mxolisi Mgojo, CEO, Exxaro, explains

“Exxaro is well positioned in the South

a 1.8 km passing loop, enabling

that 1 Mt of coal is worth nothing if it is

African coal market because we have

100-wagon trains to cross without

still in the ground. The value is created

the largest resource base – 87% of our

disrupting other rail operations on

when these resources are extracted

resources are situated in the Waterberg.

the line.

and moved.

By joining forces, we have made value

“We needed logistics; without it, the

Lephalale Line). “We are a key

The new 10-year agreement

agreement between the two entities,

Waterberg Link (the

enabler to growing

coal-bearing zones.

Freight Rail will override the existing

expansion of the

Aligning mine, line and port

in-situ inferred coal deposits, in 11

signed between Exxaro and Transnet

strengthening and

extraction a reality,” adds Mgojo.

“Phase 2 of the Waterberg Expansion Programme will row export rail

resources would be a stranded asset.

Siyabonga Gama, CEO, Transnet

Transnet was the obvious choice, as it

Freight Rail, says he welcomes the

upgrades of the existing rail networks

has a proven track record in building

partnership, adding that it will improve

and yards, using additional loops,

INS I DE MI N I N G D OE CC T / JA N OV N || 22001187

capacity to 6 Mt through incremental

COAL MINING while maintaining the existing

mine and domestic demands for the

GG7 and GG8 to advance to

axle load, electrical upgrades

area. “Phase 1 of the Mokolo and

Operating Level 2.

and improved train control systems.

Crocodile River West Augmentation

We plan to complete the second

Project (MCWAP) has been completed

of a series of milestones,” adds

phase of the project in March 2019,”

but has been insufficient to enable the

Gama. “We need to strengthen

adds Gama.

envisioned developments. Our team

the logistics backbone of South

of engineers believes that Exarro’s

Africa by supporting mining

requirements for immediate growth

companies. As Transnet, we had

Raw water augmentation is planned

have been catered for in MCWAP,”

to look at the partnership from a

to reconcile the poor water supply

says Mgojo.

logistics perspective; this partnership

Planned water supply

that entails the phased construction of

“The completion of Phase 2 of

two main bulk water transfer systems

MCWAP is expected by 2021/22, but

as well as infrastructure to meet the

we will expedite the process to enable

“We are celebrating the first

will definitely give Exxaro a competitive advantage.” Gama asserts, “We don’t want to be

other Waterberg developments.

partners with Exarro simply because

Investments approved for implementation

Alignment and collaboration are

we can. Through this partnership, we

imperative if we are to achieve these

are creating a Transnet that is agile.

economies of scale. We are working

We cannot have Transnet working

New rail loop and rapid load out station (R1.3 billion) will enable:

closely with the Department of Water

against industry.”

•M ovement of coal generated from Exxaro Waterberg growth strategy

will continue to search for

The agreement is a key contribution

cleaner power and ways to

to the Waterberg expansion

clean coal, in order to sustain

programme earmarked in the National

•E nable staging of 200-wagon trains as anticipated by TFR

the coal industry.

Development Plan as a strategic coal

•M aintain 200-wagon loading within four hours via two load-out stations (split trains)

Exxaro’s signing of the long-term

•E nables Thabametsi product via rail in the longer term

which requires rail capacity to the

•A cts as a catalyst for future non-Exxaro development in the Waterberg (designed for inclusion of other operations

and Sanitation in this regard.” Mgojo says the two entities

Expansion in the area

Developments for the area

mining area and national asset to growing the South African economy. Exxaro notes that it will be investing

agreement with Transnet will enable

50% of its R20 billion coal capex

the GG6 expansion of the Grootegeluk

programme over the next five years in

operation in the Waterberg area,

the Waterberg area.

Richards Bay Coal Terminal. Grootegeluk carries the bulk of the

“This agreement is an exciting milestone for Exxaro and a realisation of our vision of contributing to

operations, explains Johan Wepener,

unlocking the Waterberg – thus

GM, Grootegeluk. According to

creating jobs and powering economic

Wepener, GG6 will enable high-

development in South Africa. This

value export and semi-soft coking

agreement is testament to healthy

GG6 expansion

coal production of R4.8 billion.

public-private partnerships,”

•N ew mega processing plant to enable high-value export and SSCC production (R4.8 billion)

The expansion will also enable

concludes Mgojo.

• F lexible operation to serve market on demand •E nables GG7/8 to advance to Operating Level 2 Future prospects •U nlocks future reserves from the Waterberg, other than Exxaro For Exxaro •T urfvlakte – interim project to development of full-scale Thabametsi •T habametsi Multi-Product equal to Grootegeluk volumes – 30 Mtpa complex •E nables third-party players to participate

“We are a key enabler to growing the South African economy and are playing our role in developing more rail capacity.” Siyabonga Gama, CEO, Transnet IN SID E M IN IN G D E C/JA N | 2018

INDUSTRY INSIGHT

Securing a prosperous future for surface mines There is much to be said about industry associations, with their simultaneously loose and tight principles. They nurture synergy and achieve much through collaboration, despite their members’ competitiveness.

of issues facing

NP ASPASA was

number of companies that

this sector.

founded by

do not produce aggregates

the country’s

or sand yet seek the services

aggregate and

of the association. The

in the proactive

Sand Producers

guidance and

Association of Southern Africa

(ASPASA), the industry

a leading figure within the

management

What is ASPASA and why is it important?

he Aggregate and

local mining framework and attracted an increasing

association representing

In chatting to

Southern Africa’s quarries

ASPASA director

and surface mines,

Nico Pienaar (pictured

sand producers with the sole

decision to include other

has gained local and

above), the history and

purpose of self-regulating

surface mine types under

international stakeholder

purpose of ASPASA, and its

and representing the interests

the ASPASA umbrella now

recognition among the

future role, was explained

of their own industry. Since

gives those who have not

mining industry fraternity

through a series of questions

then, it has elevated the

previously been represented

and become a world leader

and answers.

quarrying industry to become

on formal mining structures

INS I DE MI N I N G D E C / JA N | 2 0 1 8

INDUSTRY INSIGHT What role does the ASPASA Technical Committee play?

and investment seriously? Social

members’ operations and

responsibility is a key focus

the supply of material or

an array of administrative,

The ASPASA Technical

for ASPASA members, and

services that could improve

technical, compliance and

Committee is a new focus

something we take very

their livelihoods.

skills development services.

area for the association.

seriously. By nature,

Technical and quality issues

worksites of the quarrying

are becoming more critical

industry, which we used

as new techniques and

to serve exclusively, are

Why should surface mines seek membership? The answer

methods drive the supply

usually set near communities

is easy: they pay a fee for a

ASPASA has been around

of better, more efficiently

and we have learned

very wide range of services.

since August 1990, and I

obtained materials. A

to work closely with

Just one consultation with

took on the directorship

quality standard has been

our neighbours. The

a legal firm might cost

back in January 1999. We

developed for members and

same applies for new

more than an entire year’s

successfully managed the

will be rolled out in 2018.

mining members from

membership; so, yes, it pays

other sectors and ASPASA

to become a member.

a strong and unequivocal voice. It also allows those with limited manpower access to

How long has the association been serving industry?

concrete readymix industry for a number of years until it was incorporated into

Do members take social responsibility

to assist communities with

encourages recruitment from the people living near

www.aspasa.co.za

the broader concrete industry last year. We now deal more exclusively with mining-related issues with the full support of all industry role players.

Can the industry function properly without ASPASA? This is a tricky question. To say the industry cannot function without us would be presumptuous or even arrogant, but our growing numbers suggest we are indeed doing good work for the industry. As needs change, so does our service offering. We constantly strive to survey members’ changing requirements in order to adapt and meet their everchanging needs.

Does ASPASA play a role in developing legislation? Yes, ASPASA does, and it has also been

Services offered by ASPASA • L egal compliance ASPASA shares relevant legal updates and information with members timeously. It also undertakes health, safety and environmental audits at member operations, which supports compliance as required by the Mining Charter • Technical/quality ASPASA has developed a quality document for its members to use. Work is also being done to standardise testing of materials, procedures and laboratory services •P ublic relations ASPASA actively markets the industry and its members. It has an active website, news bulletins and works closely with the industry’s media •G overnment liaison A committee has been established to deal with various relevant issues • Transport A specialist committee exists to handle issues relating to transport on-site, as well as on the roads. At present, the committee is busy formulating best practices for PDS and trackless mining equipment • I nternational liaison ASPASA is an active member of the Global Aggregates Information Network (GAIN), which represents similar organisations across the globe •S kills development The association offers a comprehensive range of accredited courses relating to all aspects of surface mining operations. These can be presented nationally, regionally or on a company level • L ocal liaison This is done with all the relevant industry bodies, including the Chamber of Mines, Sabita, TCI, SA Road Federation, Master Builders SA, etc. • Collaboration ASPASA also administers the SA Coal & Ash Association

involved in many issues that pertain to employers and employees. We serve on the Mine Health & Safety Council, the Mine Regulations Authority and various subcommittees. We also have a seat on the Chamber of Mines and a close relationship with bodies representing concrete, bitumen, roads and other infrastructure. We are constantly influencing and putting the industry’s views forward.

Getting down to the aggregate (Source: US Geological Survey)

IN SID E M IN IN G D E C/JA N | 2018

LEGISLATION

Proposed regulatory overhaul In November, the Minister of Environmental Affairs published the ‘Proposed Regulations Pertaining to the Financial Provision for Prospecting, Exploration, Mining or Production Operations’ (Draft FP Regulations) for comment. These seek to entirely replace the NEMA Financial Provisioning Regulations, published on 20 November 2015 (Financial Provisioning Regulations, 2015).

By Garyn Rapson and Kirsty Kilner* Fundamental changes proposed by the Draft FP Regulations Less financial provisioning to be made available: • Although the method to determine the full quantum of required financial provisioning – i.e. preparation of Annual Plan (Appendix 5), Final Plan (Appendix 6) and Risk Assessment Report (Appendix 7) – remains the same, less provisioning will actually need to be made available. • Provisioning will need to be made available for the sum of the costs to implement activities identified in the Final Plan and the Risk Assessment Report for three years looking forward, or one year (in the case of an applicant or holder of a mining permit). Note that this is reduced from 10 years under the Financial Provisioning Regulations, 2015 and the costs associated with the Annual Plan are no longer included (as these are paid for as part of opex). • Methodologies are now provided to calculate the quantum of provisioning to be made available for both new (Appendix 1) and existing (Appendix 2) developments. Changes to the use of financial vehicles for setting aside financial provisioning: • The restricted use of trust fund contributions

INS I DE MI N I N G D E C / JA N | 2 0 1 8

Power Powerto IMPRESS IMPRESS to

for residual environmental impacts

to be removed entirely and will not

only will be done away with – these

be formally regulated under the

funds can now also be used to

financial provisioning regulations.

implement measures set out in the Final Plan. Unfortunately, the

Extension of compliance timeframe

Draft FP Regulations continue to

for holders of offshore oil and gas

provide for a template trust deed

production rights:

(Appendix 4) and it appears as

• Holders of offshore oil and gas

though existing trust funds will need

production rights will have until 19

to be restructured to align with

February 2024 to comply with the

this template. •A new restriction is proposed for

Draft FP Regulations. • The Draft FP Regulations also

the use of financial guarantees for

distinguish between offshore oil and

residual environmental impacts.

gas exploration and production in

•C ontributions to ‘rehabilitation

terms of the content required to

companies’ have been recognised

be included in their Annual Plan

as a permissible financial vehicle,

(Appendix 8), Final Plan (Appendix

a development that promises to

9) and Risk Assessment Report

open up the rehabilitation market

(Appendix 10).

(NEMA will, however, need to be amended to ensure the lawfulness

Detailed transitional arrangements:

of such companies).

• Various transitional arrangements apply that now distinguish between

Section 11 and 102 applications

compliance with the old MPRDA

proposed to be brought into the fold:

system and work completed under

•A fundamental proposed change is

existing Financial Provisioning

that the Draft FP Regulations seek to expand the definition of applicant

Regulations, 2015.

to include applications for section 11

Conclusion

consent or section 102 amendments

While many of the changes currently

under the MPRDA.

proposed by the Draft FP Regulations

• S uch applicants are likely to be

are likely to be welcomed by the

required to amend or replace their

mining and petroleum industries,

financial provisioning in accordance

significant work will need to be

with the financial provisioning

done to ensure compliance by the

regulations before they can obtain

19 February 2019 deadline, except

section 11 consent or a section 102 amendment. •C are and Maintenance regulations are proposed

for holders of offshore oil and gas production rights. The public comment period closes on 10 December 2017. We urge the mining and petroleum industries to submit comments before the Draft FP Regulations are finalised. Don’t wait to have to challenge the rules of closure in the courts.

*Kirsty Kilner is a senior associate and Garyn Rapson a partner at law firm Webber Wentzel.

PIPES, PUMPS & VALVES This diver in a flooded mine gives an indication of what it will be like in the Prieska Copper Mine (Source: Global Underwater Explorers)

The storage challenge In accordance with directives from the DWS, a geomembrane-lined earth dam for bulk water storage capable

Dewatering a flooded mine

of storing the 7 million m3 of water will need to be built at surface level near the main shaft. Building just one dam will need the dimensions 1 000 m2 by 7 m deep, or variations thereof. No doubt it will be interesting to see what the engineers cook up. Even so, with dam design, earth and civil works requirements, including canals and silt traps, HDPE, LDPE, supported or unsupported PVC membranes

Price and politics closed the Prieska Copper Mine in January 1996. Today, it’s more than viable. But, it’s filled with water, from a depth of 1 024 m to 360 m below the surface, and must be dewatered. Tony Stone looks at the challenge.

ranging in thickness from 600 microns

This challenge was put to Dave

through to 2 mm, durable enough to last 20 years, dam cleaning solutions, pumps, filtration and pipe work requirements, it’s going to be a challenge.

The pump challenge Johnson of Mather+Platt. After some

he name of the old Prieska

The water challenge

Copper Mine is a bit of a

Since the closure of the mine,

the submersible motor pump is

misnomer. The mine is situated

7 million m3 of water (the equivalent

best suited to the task. It owes its

in the town of Copperton some

of 2 800 Olympic-sized swimming

development to the requirement

51 km from Prieska. In its heyday, the

pools) has filled the mine at a rate of

of a pumpset to be capable of

mine employed 4 000 people. But

just under 914 ℓ per day. Fortunately,

operating reliably in a fully submerged

today, all but 40 or so of the original 400

with all the limestone in and around

state, and consequently totally

residential houses, school, church and

Copperton, water sampling at 100

without maintenance.”

retail outlets lay flattened, demolished

m intervals to a depth of 600 m

to secure a mine closure certificate –

below surface confirmed the non-

titled ‘High Voltage Submersible Mine

one of perhaps a few.

acidic nature (pH 7.4) of the water.

Dewatering Pumps for Extremely High

But, despite this wonderful water

Lifts’, stated that submersible pumps

company, has acquired 73.3% of the

resource, and on instruction from the

rights to the Prieska (Copperton) and

Department of Water and Sanitation

better than the oil-filled motor or the

Marydale Volcanogenic Massive Sulfide

(DWS), Orion may not use this water

semi-wet submersible motor (canned

(VMS) orebodies.

and has to have potable water piped

motor). The water-filled motor is

68 km from the Orange River to

completely filled with water – i.e. the

the mine.

winding is immersed in water, and the

Orion Minerals, an Australian mining

Nonetheless, now that Orion has

thought, he says, “In this instance,

Schiele and Kuntz, in their paper

plain bearings are water-lubricated.

received regulatory permission

These water-lubricated bearings have

to access the underground

reached such an advanced stage of

workings at the historical Prieska

development that they offer complete

Copper Mine, access will allow

and absolute operational reliability and

for a detailed assessment of the

a very long service life, even under

current state of the shaft and other

heavy loadings.

underground infrastructure, as well

“The remarkable increase in output

as the commencement of drilling

ratings, and its proven reliability in

and extraction of samples for

service, point to the water-filled motor

metallurgical test work purposes,

being the pump of choice going

which means that the mine will have

forward. One feature of decisive

to be dewatered.

importance in this development has been the progress made in the field of waterproof and pressure-

Cross-section schematic of the Prieska Copper Mine showing the VMS orebody (Source: Orion Minerals)

INS I DE MI N I N G D E C / JA N | 2 0 1 8

tight plastic insulating materials for the winding wires. The quality of the plastic materials and the processing

PIPES, PUMPS & VALVES technology have improved continuously, with the result being that present-day winding wire insulations are capable of withstanding very high electrical, thermal and mechanical

A similar but appropriatesized lined earth dam such as this one will need to be constructed (Source: Aquatan)

loadings,” say Schiele and Kuntz. The Y(B)Q Series (explosiveproof) submerged motor pump for

of the water. The higher the pressure,

mines offers a range of head between

the better the secondary rubber seal

26 m and 1 440 m and a range of

will be.

quantity between 275 m3/h and

The Y(B)Q Series has as

1 450 m3/h. Since Prieska Copper Mine

standard features:

is 1 024 m deep, it would be a case of

• An axial-force self-balancing

motor guide bearing. • Diversified installation: These can be mounted in a vertical, horizontal, inclined way or at any angle. Besides the head and quantity

dropping the pump to the bottom of

structure: Two sets of impellers in

already mentioned, the pump’s

the shaft and letting it get on with it.

equal number in opposite directions

optimal working conditions include a

are arranged back to back to bring

voltage range of 380 V to 10 000 V, a

the axial force to zero.

medium temperature range of 10°C

High-pressure mine dewatering check valves intermittently located in the secured vertical pipe will be

• A water-filled motor: Water-filled

to 40°C, an ambient temperature

necessary. Dual’s Flo-Stop Valve has

motors are adopted so that the

maximum of +40°C, solid substance

a reinforced stainless steel ball. The

internal water circulation goes

content in water of ≤ 5% with a

unique design of the valve allows for

with the water flow in external

maximum solid particle size of ≤ 8

free movement of the ball, which lifts

environment to take away heat and

mm, and a pH value range of 4.0

out of the up-flowing water without

reduce motor temperature rise.

to 10.0.

• Water lubricated bearings: Water-

Regardless, in utilising this pump,

the ball falls back and positively

lubricated copper bearings and

or similar, on a 24/7 basis, it will take

locates in the stainless steel seat due

polymer composite FB102 are

close on seven months to dewater

to its own weight and back pressure

employed as thrust bearing and

the Prieska Copper Mine.

any interference. As the pump stops,

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MINING MACHINERY

Remote upgrades enhance performance area. Historical records and trending data provide additional troubleshooting tools, and may be used for predictive maintenance. The Telsmith Trac10 can be installed economically into any plant,” he notes. “As a

Due to the shortage of skilled machine operators and service technicians, and the increasing demand for safer operations, mines, quarries and plants around the world are striving to do more with less human interaction.

stand-alone crusher control system, it provides crusher operators with many of the advantages of automation without the expense of a complete rework of plant controls.”

Constant improvement Botha says that Osborn’s latest strategy

eading South African equipment

provides automated calibration and

reflects the company’s commitment to

manufacturer Osborn is

setting controls, and protects the crusher

continuous improvement. “Osborn has

responding to the skills deficit,

from overload, all to yield greater

been in business for almost 100 years,

and to the growing demand for

crushing performance and efficiency,”

but we will never rest on our laurels

better, smarter, safer machines, with

Botha explains.

when it comes to the quality and

a strategy that will leverage the latest

“Optimum crusher settings are

performance of our machines, or

state-of-the-art technology to advance and enhance

maintained via remote adjustment using the

its range of robust engineering products, which includes crushers, feeders and screens.

Remote control Osborn’s equipment upgrade and modernisation

Trac10. Your operator

“Osborn has been in business for almost 100 years, but we will never rest on our laurels.”

programme is set to include remote control systems that will enable the

can initiate an automated calibration process via the

to customer satisfaction. We have strived to investigate what is on offer internationally, what customers want from their equipment, and to ensure that Osborn’s offering is world-class and exceeds their expectations.” The company’s research has revealed

touchscreen

that there is a demand for machines

monitor, which

that are easier to operate, and simpler,

automatically

faster and safer to service, he states.

resets to the proper setting. Operators can also modify the

crusher settings at any time, even while crushing.”

To this end, Osborn’s upgrade strategy includes design enhancements for all of its machines, as well as remote control options. “We are building on the solid foundation of our reliable, robust

operation of its machines from tablets

Because Trac10 monitors crushing

and mobile phones, reveals marketing

operations, it helps to protect mines’

equipment that has made its mark in the

director Martin Botha. He says that

and quarries’ investment and lowers

world’s mining and quarrying industries

the company is taking its cue from

operating costs, Botha adds.

over many decades. We are taking our

USA-based Astec Industries' sister

“Trac10 includes sensors that

unrivalled, South African-manufactured

company Telsmith, which has launched

continuously monitor crusher lube,

machines, which are sought after

a remote crusher automation system

hydraulic and electrical systems,

around the globe, and refining them,

dubbed Trac10.

making adjustments and providing

to offer enhanced performance, ease

advanced warnings, even though

of operation and improved safety,”

the operator may be busy in another

he concludes.

“This stand-alone remote control system monitors crusher operations,

IN SID E M IN IN G D E C/JA N | 2018

ENERGY

Designing mines out of the energy squeeze Gone are the days when mines could design their energy systems based simply on peak requirements.

oddy McGeorge, principal

He says this requires a detailed

mining engineer, SRK

understanding of load requirements for

Consulting, believes that a

each production process on a mine,

completely new philosophy

so that management can estimate

is now required due to a number of

variability over time and incorporate

changing variables and conditions

these variations in its designs.

mines face today. “Today’s mine energy designs need to address higher risks, better

states. “A good example is in fuel

efficiencies and smarter applications,”

consumption in open-pit operations.

says McGeorge. “This means putting

About 70% of diesel consumed is used

energy decisions in the driving seat

in elevating waste material to be

of mine planning; this could include

dumped – so any design innovations

altering production plans to meet the

that reduce the amount or position of

needs of load balancing, exploring

waste can help cut the diesel bill.”

energy recovery systems, and installing more secure power sources on-site.”

INS I DE MI N I N G D E C / JA N | 2 0 1 8

“Savings can be valuably found where energy usage is highest,” he

McGeorge emphasises the need for innovative solutions, as most of the

ENERGY

15% in energy savings was achieved so far by South African mines, focused on lighter consumption areas, such as water heating and lighting

42% of cumulative energy per tonne hoisted was accounted to ventilation, well ahead of hoisting activities at 13%, and drilling at 9%

25% savings in energy usage shown by some mines by shifting loads away from areas of the workplace when not occupied by workers at that time

15% in energy savings so far achieved

contribute to balancing this network,”

current usage, best practice usage,

by South African mines (when Eskom

he says. “The strategy of load shifting

practical minimum usage, and

required the mining sector to limit

has shown substantial results, with

theoretical minimum usage.

its usage) was focused on lighter

some mines saving up to 25% of their

consumption areas, such as water

energy usage by shifting loads away

strong components of the modern

heating and lighting.

from areas of the workplace when not

design philosophy, allowing for real-

occupied by workers at that time.”

time monitoring and controlling of

The biggest culprets

A realistic goal for mines is to

“Technology and automation are

energy infrastructure. It should be

Research conducted in the US showed

halve energy consumption without

remembered, however, that

that most energy in open-pit mines was

impacting productivity, McGeorge

increased use of technology

consumed in mill and concentrator

notes – a challenge that could be met

will raise energy

operations, followed by waste rock

by using benchmarking and proper

consumption – so it must

removal and ore excavation. In

power management. The benchmark

be more productive.

a typical hard rock underground

approach considers possible energy

Also, applying new

mine, ventilation accounted for

savings in each mining process – from

technology to an

almost 42% of cumulative energy

extraction and materials handling to

old mine design is

per tonne hoisted, well ahead of

beneficiation and processing – and

possible, but is unlikely

hoisting activities, at 13%, and drilling,

across a range of mineral commodities.

to achieve optimal

at 9%. In deep mines with high rock

Consumption targets can then be

results,” McGeorge

temperatures, cooling is also a

compared between four categories:

concludes.

significant energy factor. “A new design philosophy must acknowledge that a mine is its own energy network, and all activities must be planned so that they

“A good example is in fuel consumption in open-pit operations. About 70% of diesel consumed is used in elevating waste material to be dumped.” Noddy McGeorge, principal mining engineer, SRK Consulting

RENEWABLE ENERGY

The next step for miners Alternative energy sources, such as solar or wind power, are deemed viable for consideration by mining companies and many methods guarantee continuous production. The cost of green energy has dropped dramatically in recent years, further strengthening miners’ renewable energy business case.

ccording to the World

(SAIIA), examines the extent to which

Energy Report 2016,

renewables can play a role in providing

the past 15 years have

energy for the mining sector in the

seen unprecedented

SADC region, with a particular focus on

change in the consumption of energy resources. Unexpected high growth

“Southern Africa’s energy production

in the renewables market, in terms of

is often unreliable and unable to meet

investment, new capacity and high

demand. In comparison, Belgium

growth rates in developing countries,

produces over 10 times more electricity

have changed the landscape for the

than the Democratic Republic of

energy sector.

the Congo, despite having 56 million

We have seen the growth of unconventional resources and

fewer people. “Renewable technologies are most

technological evolution for all forms

attractive to mining projects in remote

of energy resources, which has

regions with little or no access to

contributed to falling prices and the

established electric grids. The pressure of

increased decoupling of economic

inadequate supply has arguably shifted

growth and greenhouse gas emissions.

the dynamic of the mining industry’s

Many countries have achieved a

relationship with renewable energy, as

Renewable Energy Agency, the

more diversified energy mix, with a

firms increasingly turn to renewables as

cost of photovoltaic solar electricity

concomitant growth in community

one component of a basket of energy

decreased by 58% between 2010

ownership and evolution of micro grids.

options used to maintain stable power at

and 2015.

Alternative energy for mining Energy costs within the mining industry

mining sites,” SAIIA states.

Renewable energy technologies are well suited for mining projects in

can constitute a large portion of

The cost question

operating budgets. For this reason, the

Replacing or supplementing costly

access to established electrical grids.

possible implementation of alternative

generators with green energy is also

This is thanks to the fact that these

energy sources has become a real

attractive as it is estimated that solar

locations already have the necessary

option, given the benefits associated

and wind energy is roughly 70% cheaper

land required for small solar and wind

with renewables in particular. These

than electricity generated from diesel

turbine farms.

benefits include the fact that they

(even though the precise amount of

While many mines discard this

ensure continuous energy supply and

diesel fuel consumed by mines is not

option due to the large upfront

can reduce energy costs.

often disclosed).

expenditures attached, many

remote regions that have little to no

More and more miners are looking at

“Over the next decade, the price

renewable energy as the remedy to their

of coal-generated electricity in South

to invest through rental or power

power woes, as the subdued mineral

Africa is expected to rise to R6 0.78/

purchase agreements, allowing

price environment is incentivising firms to

kWh. In comparison, the third bidding

mines to pay for power over time.

reduce their reliance on more expensive

window of the South African Renewable

diesel or distant, unreliable electrical

Energy Independent Power Producer

The drawbacks

grid systems.

Programme has produced an average

Despite the advantages, the paper

tariff for wind-generated electricity

does illustrate some drawbacks.

The paper ‘Alternative Energy in

South Africa.

Mining’, published by the South

of R0.74/kWh,” the paper details.

African Institute of International Affairs

According to the International

INS I DE MI N I N G D E C / JA N | 2 0 1 8

green energy developers are willing

“While many advocates in the renewable energy sector see the

RENEWABLE ENERGY

82 gigawatts of energy was generated by wind power in the US by the end of 2016, making it the largest renewable generation capacity in the country. That’s enough to power over 20 million average American homes

174 petawatts is the amount of incoming solar radiation the earth gets in the upper atmosphere from the sun. About 30% is reflected back to space and the rest is absorbed by oceans, clouds and land masses.

of ‘bridging’ alternatives to coal, such as nuclear and shale gas, are being seriously considered,” states the report. There is also the consideration that renewable energy installations, especially solar power, do not benefit from the economics of scale available to large public projects. “Factors such as increased unit maintenance costs and lack of geographic diversity mean that the economics of private renewable energy development are much less certain than for public projects,” the paper continues. It’s safe to say renewable-energy projects in the mining industry will continue to supplement diesel and power sourced from the electricity reliance on diesel generators as making

developing sources like nuclear power

grid, but only to the extent that they

a clear case for a shift to renewables,

and shale gas through hydraulic fracking

remain more affordable. And even

this picture is incomplete. With mounting

in the Karoo basin.

then, increasing global environmental

energy concerns in Southern Africa,

“South Africa’s shale gas reserve is

awareness and government regulations

large-scale energy infrastructure

the fifth largest globally and would be

will provide increased incentives

development projects are under way

enough to drive more than half of the

for the use of cleaner power in the

across the region,” the paper reads.

country’s current electricity generation

mining industry.

Government is also considering other energy options, such as further

over a 20-year period. Although currently speculative, the vast potential

Read the full paper on www.saiia.org.za

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INVESTING IN

AFRICAN MINING

INDABA

5-8 Feb 2018 | Cape Town, South Africa

INSIGHTS. CONNECTIONS. OPPORTUNITIES. Meet

350+ 166+ 220+ INVESTORS

JUNIOR MINES

TOTAL MINING COMPANIES

More qualified, buyside investors than any other event.

No need for taxis around Cape Town, meet all the emerging projects from across Africa under one roof!

Connect with technical mining execs at Mining 2050, and hear from majors & mid-tiers in exciting new talks

Even more… • Focus on Sustainable Development. • Projects being pitched at the Investment Battlefield • Collaboration between governments at the Intergovernmental Summit

Don’t miss… • Brand new connections • The chance to raise your company profile • Opportunities to shape the future of the sector

MINING INDABA

Welcoming an inclusive Indaba Changes to the 2018 Investing in African Mining Indaba programme will bring back the emphasis on investment in African mining among government, mining investors and mining companies, says Alex Grose, managing director, Investing in African Mining Indaba.

e all affectionately

A poll by Mining Indaba on Twitter found that 40% of respondents were looking forward to the Junior Miners theme, while 17% were looking forward to the Technology Innovation theme. Sustainable Development and Government Policy were divided themes, at 23% and 20% respectively

know this event as the Mining Indaba but, really,

it’s called Investing in African Mining Indaba, and that’s really important. This is the world’s biggest mining investment event. It’s not competing with mining shows; it’s about investment. And to do that, we have to include junior miners, together with government, investment companies, and the

which will be ap-

much larger miners,” says Grose.

propriate for the

“We have decided to focus

products and ser-

more on junior minors because

vices they provide.

there seemed to be a lack of

“We have made

focus at the last few Indabas.

the exhibition hall

How can you have the biggest

more interactive,

mining event in Africa without

instead of just rows

including junior miners, who are

of exhibition stands.

the future of mining?”

A stand for a service

Grose anticipates that the Jun-

provider should not

ior Mining showcases will bring

be the same for

inclusivity to the 2018 Indaba,

machine manu-

and allow juniors their own area,

factures, so we’ve

which makes it much cheaper

opted to make the

for them to get involved. Here,

stands more inter-

they won’t be competing with

active, in order to

the big mining companies

boost engagement,”

for airtime.

Grose adds.

“We’re expecting 166 junior

Delegates will

miners,” says Grose.

now have the op-

Also on the 2018 Indaba pro-

portunity to walk around various

gramme will be the Intergovern-

stands and watch

mental Summit and Minister’s Symposium. The summit will be based on

we’ve moved sustainability to day one

collaboration and will create the plat-

of the event,” says Grose.

form for African mining heads to learn

“We have also included the Alternative

live presentations. One such interactive display on the exhibition floor will be Mining 2050, which

from each other and develop best-prac-

Mining Indaba, which we have previous-

will look at technology innovation and

tice models for the industry.

ly kept out of the Indaba proceedings.

the future of mining – a sustainable fu-

We realised that isolation is not the way

ture – and how we can create new jobs

to engage with people and now they’re

with this model.

The third biggest change for Indaba is looking at sustainability. “Sustainable development is big for us. Previously, we have put the sustainability talks on day four, but that’s not really putting it at the top of the agenda – so

part of our steering committee in the sustainability programme.” Lastly, the Mining Indaba team has tried to create value for exhibitors,

The Investing in African Mining Indaba will take place at the Cape Town Convention Centre on 5 to 8 February 2018.

IN SID E M IN IN G D E C/JA N | 2018

MINING INDABA

United and inspired

As a part of the global restructuring and reorganisation of the group, Atlas Copco has been separated into two separate entities – effective November 2016. The industrial part of the business remains with Atlas Copco, while the engineering and mining business has been cosigned to the new company, Epiroc.

customers, respectively. And Epiroc will be backed by Atlas Copco’s 144 years of experience and expertise. At a press conference held in Jet Park, Ekurhuleni, Sanjay Ahuja, regional GM, Epiroc, explained that the new company taking on the mining and civil engineering business will provide the best growth opportunities for both Eprioc and Atlas Copco. Epiroc is a Level 4 BBBEE contribu-

piroc means

Rock Excavation Technique Business

tor and, according to Ahuja, the new busi-

‘at rock’. This

have become part of Epiroc, which will

ness is completely devoted to supplying

is intended to

operate as an independent company

the market with products and services that

reflect the new

under its own brand name and logo.

enhance productivity, energy efficiency,

company’s focus on min-

As global leaders in their respec-

ing, rock excavation and

tive areas, the two separate

natural resources prox-

businesses will be ideally posi-

ergonomics and, most importantly, safety.

The details

imity to customers, as

tioned to deliver sustainable

Epiroc South Africa was formally estab-

well as a focus on

productivity solutions to their

lished and revealed on 1 November

the strength and importance of partnerships. Atlas Copco’s entire Construction Tools Division and Mining and

INS I DE MI N I N G D E C / JA N | 2 0 1 8

“Our intention is to focus exclusively on the mining and civil engineering sectors.” Sanjay Ahuja, regional GM, Epiroc

MINING INDABA

The Epiroc business Mining equipment and applications

Underground mining • Mechanical rock excavation • Face drill rigs/long-hole drill rigs • Underground loading and haulage • Ground support equipment • Ventilation systems • Rock drilling tools • Hydraulic drum cutters • Hydraulic breakers • Underground core drill rigs Surface mining • Blasthole drill rigs • Rock drilling tools • Hydraulic breakers • Hydraulic attachments Exploration • Surface core drill rigs • Reverse circulation drill rigs • Rock drilling tools Infrastructure equipment and applications Underground civil engineering • Face drill rigs/long-hole drill rigs • Underground loading and haulage • Ground support equipment • Ventilation systems • Rock drilling tools • Hydraulic drum cutters

• Hydraulic breakers • Underground core drill rigs Surface civil engineering and urban development • Surface drill rigs • Well drill rigs • Rock drilling tools • Hydraulic breakers • Drum cutters Quarrying • Surface drill rigs • Diamond wire cutting machines • Hydraulic dimensional stone drill rigs • Rotary blasthole rigs • Hydraulic breakers • Drum cutters Deconstruction and recycling • Hydraulic breakers • Cutters • Pulverisers • Grapples • Magnets • Compactors • Bucket crushers Natural resources equipment and applications • Geotechnical, well drilling, oil and gas • Water well drill rigs • Oil and gas drill rigs • Rock drilling tools • Hydraulic breakers

2017 and employs in excess of 1 000

board. Shareholding, however, will

“Our intention is to focus exclusively on

employees, most of whom were formally

remain unchanged.

the mining and civil engineering sectors

employed by Atlas Copco.

The new company’s service offering

and to evolve from the supply of mining

will include but not be limited to:

equipment to mining systems by auto-

for Southern African markets,

• surface and exploration drilling

mating and integrating equipment into

namely Mozambique, Namibia,

• underground hard rock excavation

the mining process. This will drive safety

Zimbabwe and Botswana. Ahuja was

• hydraulic attachment tools

and productivity improvements in the

appointed as regional GM and Per

• advanced drilling solutions

fields of loading, hauling and drilling,”

Lindberg is at the reins as president

• rock drilling tools

Ahuja said to media. Epiroc will be listed

and CEO, supported by a new

• Roctec.

on the stock exchange in 2018.

The company will be responsible

MINING INDABA

Driving business growth D

Babcock’s Equipment BU continues to see an increase in sales, with customer service excellence underpinning the sale of every piece of equipment.

espite the general down-

the local mining sector, we have also

gradient from a hurricane to a

turn in the mining industry,

experienced significant interest in the

mild breeze.

Babcock is ramping up

A60H articulated dump trucks (ADTs)

delivery of superior-quality

from mining companies operating

customers are seeking a more

construction equipment to new and

in regions outside Southern Africa,”

powerful alternative in tougher

existing customers.

says Vaughan.

conditions, which has put the A60H

David Vaughan, MD: Equipment,

He explains that one of the reasons

“We have noticed that Babcock

very much in the spotlight, without

Babcock, attributes the steady growth

for this is the wet, tropical climate in

relegating our smaller ADT range.

in part to the successful launch of the

some parts of Africa where steep,

In fact, the Volvo A40 still has a firm

Volvo A60H and EC950E earlier this

muddy inclines can create challenging

place in the mining space and remains

year, but also believes that unwavering

conditions for rigid dump trucks that

Babcock’s best seller,” comments

customer service, aftermarket support

use rear-wheel drive. Volvo ADTs,

Vaughan. According to recent figures,

and technical backup are key to

however, rise to the challenge with

Babcock is currently ranked one of the

growing market reach.

their automatic traction control and

market leaders in ADT sales and holds

slick climbing power, downgrading

in excess of 40% of the 40 t ADT market

the difficulties posed by a wet 20%

share in Southern Africa.

“Besides the attention that the new Volvo machines have garnered in

Customers come first Vaughan stresses that, while there has been an upturn in sales, Babcock remains true to its underlying commitment to looking after its customers, both new and existing. “Babcock has succeeded in offering solid service and support

INS I DE MI N I N G D E C / JA N | 2 0 1 8

MINING INDABA where and when it is needed most and, through this, we have built up a loyal customer base that we will always nurture,” he says. “For example, our sales teams meet with all prospective customers face-to-face right from the initial enquiry, while our technical support teams travel to remote regions to provide fast on-site backup and

The new Volvo A60H ADT in action

assistance throughout the duration of a work contract,” he explains.

“The A60H is ideal for hard rock mining,

and features a powerful 16 ℓ engine, a

“We have developed excellent

coal mining, general mining and big

new electrohydraulic control system,

relationships with customers who

quarry applications, and the EC950E

Volvo’s unique ECO mode and an

trust us to deliver, and we never

has been designed to load the massive

ergonomic design.”

take any business for granted.”

A60H, so they work hand in hand,”

Babcock has also been appointed

explains Vaughan. “Moreover, the

as an accredited service dealer for

Volvo A60H is designed to keep fuel

Allison transmissions, which form

The cost-effective 60 t Volvo A60H

consumption to a minimum while

part of the backbone of the A60H

ADT and 90 t EC950E crawler

the EC950E heavy-duty excavator

dump truck, providing a one-stop

excavator, the biggest ADT in the

delivers best-in-class fuel efficiency

shop for servicing and repairs.

Better together

world and the largest excavator Volvo has ever produced, respectively, were launched locally by Babcock in May. Babcock is the sole distributor of Volvo Construction Equipment in the region.

“We have developed excellent relationships with customers who trust us to deliver.” David Vaughan, MD: Equipment, Babcock

MICROMINE is a leading provider of innovative software solutions that span the breadth of the mining cycle from geological exploration and data management, to resource estimation, mine design, planning and production control. Customers use MICROMINE software to maximise their asset value, increase productivity and for decisions on which they know they can rely. Our software is renowned for its ease of use yet powerful capabilities. All products are available in numerous languages and supported by local experts. Founded 30 years ago, MICROMINE solutions are used at more than 2,000 sites in over 90 countries.

T: +61 (0)8 9423 9000 E: marketing@micromine.com www.micromine.com

MINING INDABA

Complete mine-to-market

solution

Through the establishment of various centres of excellence across the globe, WorleyParsons has centralised its specialised expertise in industry-specific locations in order to accomplish customer objectives of improving business efficiencies, enhancing tools and capabilities, and achieving performance targets.

exploration for and evaluation of mineral resources, mine planning, permitting and approvals management, mine and mining project development, materials handling and mineral processing, exist-

ith collective experience

established as the global project delivery

ing facility upgrades, and expansions or

of over 120 years in deep-

company’s Mining Centre of Excellence.

decommissioning across a whole range

level mining and process expertise, South Africa

Combining world-leading conceptto-completion expertise with design

of commodities. “We take a multidisciplinary approach,

is regarded as one of the world’s best

and major project delivery capabilities

with teams comprised of experts from

mining environments. Having managed

for the minerals and metals sector –

across the project life cycle, to identify

more deep-level-shaft projects in the

from bulk commodities to rare earths

challenges early and produce tailored

world than any other company, it stands

– WorleyParsons offers complete mine-

strategies that mitigate risks. We under-

to reason that WorleyParsons RSA was

to-market solutions, from inception to

stand the outcomes that our customers

rehabilitation. The company specialises in

want to achieve by using our services

new project developments and existing

and position our value chains according-

facility upgrades or expansions, across

ly,” says Dreyer. “We are also in a unique

the whole range of commodities.

position to be able to offer front-end

Mastering the entire value chain

end advisory consulting through Advisian – a WorleyParsons global business that

value through our extensive local expe-

provides management and strategic

Denver Dreyer, CEO, WorleyParsons RSA. “Our experts have a thorough understanding of the total

“We take a multidisciplinary approach to identify challenges early and produce tailored strategies that mitigate risks.” Denver Dreyer, CEO, WorleyParsons RSA INS I DE MI N I N G D OE CC T / JA N OV N || 22001187

technical specialist consulting and high-

“From strategy to operations, we realise rience and integrated solutions,” says

mining business value chain including the

advisory services coupled with technical consulting and deep domain expertise to address our customers’ business and asset challenges.”

Realising possibilities from mine to market. MINE CLOSURE

WorleyParsons’ service offering across the mining value chain: • Exploration and evaluation Mineral exploration is essential for the identification of value-creating mining projects. WorleyParsons is experienced in gathering, analysing and interpreting geological data from various ore bodies, on greenfield or brownfield sites. • Mine planning Utilising the latest mine planning and simulation software, the companycan identify ideal production profiles, mine work plans and development schedules to optimise project economics and investment decisions. • Mining and mine development The company’s expertise in mining and mine development ranges from conceptual determination through to the development, design and construction of mining infrastructure, as well as the operation, optimisation and troubleshooting of existing operations. • Materials handling WorleyParsons helps its customers achieve an optimised materials handling process by implementing innovative value-add solutions that drive productivity and efficiency. • Mineral processing The company has extensive experience across all facets of mineral processing for commodities such as base metals, precious metals, iron ore, rare earths, phosphates, alumina and mineral sands. • Tailings and waste management WorleyParsons has geotechnical expertise with significant tailings storage facilities design and management experience across a range of commodities. • Hydrometallurgy Expertise in hydrometallurgy ranges from conceptual flowsheet development, testing, design and construction, to complex plant commissioning, operation, optimisation and troubleshooting. • Pyrometallurgy For over 20 years, the company’s specialists have designed and delivered many of the world’s most complex pyrometallurgy facilities. •T ransport to market WorleyParsons’ integrated capabilities (road, rail, shipping, barging, intermodal transport and slurry pipelines) provide the best solution for customers’ unique challenges. •E nvironment and approvals Through its unique EcoNomics initiative, the company ensures sustainability issues are identified and delivered cost-effectively throughout all project phases. •N on-process infrastructure WorleyParsons understands the unique logistical challenges of remote and isolated mining projects and is able to efficiently deliver tailored non-process infrastructure solutions.

Resource Evaluation

Mine Planning

Mining & Mine Development

Materials Handling

Environment & Approvals

Mineral Processing

Tailings & Waste Management

Smelting & Refining

Transport to Market

Non-Process Infrastructure

WorleyParsons adds value through our full scope of services from pit to port including studies, mine planning, impact assessments, permitting and approvals, project management, construction management and global procurement. Our Mining Centre of Excellence in Johannesburg has niche expertise in underground and open cast mining and provides quality project development and engineering solutions for small to large projects across all areas of base metals, the coal supply chain, chemicals, ferrous metals, alumina, aluminium and iron ore. Supported by the WorleyParsons global group, we pride ourselves on customising solutions for local environments and committing to our customers’ goals.

www.worleyparsons.com

wprsainfo@worleyparsons.com

MARKET NEWS from around the continent BLT’s MDS trommels are designed and manufactured to exact specifications and vary in terms of dimensions of the trommel width, diameter and aperture of holes

BLT provides trammels for materials handling THE MINING SECTOR in Africa has shown particular interest in MDS trommel screens and apron feeders, designed especially for mineral processing and recycling applications. BLT Supplies has an extensive range of heavy-duty materials handling equipment in Africa, which includes trommel screens,

link conveyors, grab hoppers, surface feeders and radial boom stackers. “By using trommels to remove clay and wet, sticky material, crusher and vibratory screen blockages are prevented and this efficiency contributes to increased production,” says Ken Mouritzen, managing director, BLT. “Flexible MDS systems are

used to remove the small fraction (fines) from a waste stream, to make the remaining material easier to handle for the operatives or processing equipment. Heavy-duty MDS trommels are available as mobile and stationary units. They have output capacities of between 250 tph and 1 000 tph and can handle rock size up to 1.5 m. The most popular machine in the MDS range – the M515 track trommel, with a 30 t hopper capacity – has been supplied with fold-out stockpiling conveyors and is able to move around a mine and from one site to another. “This machine is capable of producing three products concurrently, at an output of over 400 tph,” concludes Mouritzen.

Hytec – accredited training provider The four learners currently undergoing training will be the first in South Africa to be certified fluid power fitters trained by a South African training provider. They are: Juan Hartzenberg, Daiyaan Naidoo, Innocent Mthanti and Sydney Scrooby, with Allen van Gent in the middle

THE HYTEC GROUP, a hydraulics, pneumatics and automation specialist company group, has become South Africa’s first company to receive full accreditation as a training provider to qualify fluid power fitters. The company received full accreditation with programme approval from Allen van Gent, training manager, Hytec Group (left), with John Wingrove, CEO, Hytec, pictured with the certificate recognising Hytec as fully accredited training provider for fluid power fitters

INS I DE MI N I N G D E C / JA N | 2 0 1 8

the industry sector education and training authority – merSETA – to provide theoretical and practical training for the National Certificate Mechanical Engineering: Fitting (Fluid Power) and the National Certificate Mechanical Engineering: Fitting (Manufacturing, Engineering and Related Industries), both at NQF level II. The importance of the certification cannot be underestimated, according to Allen van Gent, training manager, Hytec Group. “It is the formal recognition of the specific training that’s important,” he points out. “Essentially, the scope of training that we are accredited to provide encompasses every aspect that a fluid power fitter needs to know in order to conduct his day-to-day activities within the fluid power industry.” Currently, Hytec’s training facilities provide for the theoretical and practical learning of 36 learners. However, once housed in the new Hytec facility, due to open in 2018, three dedicated training rooms will be able to accommodate a combined capacity of 120 people.

Hyundai crawler built for tough conditions HPE AFRICA introduces the Hyundai 520LC-9S hydraulic crawler excavator, which is designed for high productivity, precision control and improved operator comfort in arduous mining and quarrying conditions. “The Hyundai R520LC-9S series also offers fuel efficiency, economic performance and low maintenance requirements,” says Alex Ackron, managing director, HPE Africa. “What’s notable is the newly designed operator cab, which is spacious, with clear visibility – an important safety feature on busy sites.” The redesigned hydraulic system and improved valve technology provide touchsensitive control for smooth operation and precise flow regulation for reduced fuel consumption. These excavators are

HPE Africa’s robust Hyundai 520LC-9S hydraulic crawler excavators are designed for high productivity, precision control and improved operator comfort in tough conditions

powered by six-cylinder, turbo-charged air-cooled Tier II engines, designed for high performance and reduced emissions. Variable operating modes are : P – power max mode, which maximises machine speed and power; S – standard mode, which provides a reduced, fixed rpm; and E – economy mode, which provides precise

hydraulic flow and engine power based on load demand. HPE Africa operates a country-wide network of well-equipped spares and workshop outlets. Repairs and services include minor and major component replacement, as well as rebuilding and refurbishment of units

Becker delivers pump solutions to mine

Becker Mining SA has recently supplied five pumps to a new furnace slag granulation process plant at a platinum mine in the Limpopo region. These robust HS pumps have been designed for optimum efficiency, low maintenance and extended service life in harsh operating conditions

BECKER MINING SA has recently supplied five HS pumps to a new furnace slag granulation process plant at a platinum mine in the Limpopo region. “This contract, for the manufacture of two 8x8-12 HS pumps with V-belt drives C/W 160 kW motors and three 6x6-18 HS pumps with V-belt drives C/W 90 kW motors, was delivered prior to the required delivery date,” says Rick Jacobs, head of sales at Becker Mining SA. “These robust pumps have been

designed for optimum efficiency, low maintenance and extended service life in harsh operating conditions.” Becker’s HS pump range includes four models – HS (horizontal type), VHS (vertical type), PVS (vertical type) and HTMS (submersible) pumps. These pumps are available in various sizes – from 50 mm to 203 mm units. The heavy-duty, hardened chrome iron construction (650 BHN) of the wet end in the HS series significantly increases

service life. These pumps have a recessed impeller that allows large, abrasive materials to pass through the pump without damaging the impeller, thereby extending the pump life and service intervals due to reduced wear. The hydro solids pump range offers flexible drive arrangements – from direct drives to various V-belt drives. The vertical spindle range of pumps is manufactured in different sizes with various shaft lengths to suit customer requirements.

IN SID E M IN IN G D E C/JA N | 2018

EVENT

More women in mining Through efforts to diversify the workplace and advances in technology, the number of women working in the mining sector has increased significantly.

ccording to the Chamber of Mines of South Africa, women now make up over 13% of people in the mining industry, a figure that represents an increase from 11 400 women in 2002 to around 57 800 in 2015. “Women in the South African mining industry face a range of challenges – some shared by their male counterparts and many more that only women working underground have to deal with. It is a priority for the Chamber of Mines and its member companies to ensure that women working in the industry have the same opportunities open to them as men – and that they are confident they are safe to pursue them,” the Chamber of Mines

In supporting this segment of miners, conferencing and training business Intelligence Transfer Centre (ITC) hosts an Annual Women in Mining Conference. In its ninth year, the conference is scheduled to take place on 21 to 23 February 2018 at the Indaba Hotel, Fourways. According to the wholly

black-owned conference company, female industry leaders will deliver key strategies on how to further develop women in mining while making the industry more inclusive, addressing the challenges they face. “The first day of the conference will include presentations from Tuscan Mining, Anglo American Platinum, Yeabo Mining, Sasol Mining, Wesizwe Platinum, Base Titanium-Kenya, and the Mining Qualifications Authority, to name a few,” ITC announced. “Day two will include presentations from Debswana, Women in Mining South Africa, Tshipi Entle Manganese Mine, Exxaro, Anglo Thermal, as well as a presentation from the De Beers Group.” South Africa has committed, through its policies, to working on rectifying the injustices of its past by helping those who have been historically disadvantaged. Over the last decade, one can certainly see there has been a rise in the number of women qualifying for technical roles in the industry, as opposed to just filling the ranks of more traditionally feminine roles, such as admin staff.

ERWAT OFC

Schneider Electric

Investing in African Mining Indaba

Tega Industries

recently published in its 2017 ‘Women in Mining Fact Sheet’. “As the mining industry – in South Africa and globally – moves into the future, it is increasingly clear that the work we and our members do will have to become more modernised. This will create significant opportunities for women in the industry,” it said.

Annual Women in Mining Conference

INDEX TO ADVERTISERS 9th Annual Women in Mining APE Pumps

4 23

IBC 27

Babcock OBC

MicroMine 35

ThyssenKrupp Gatefold

Dosetech 29

Osborn 24

Wearcheck 13

ELB Equipment

SBS Water Systems

WorleyParsons 37

INS I DE MI N I N G D E C / JA N | 2 0 1 8

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Driving operational efficiency • Connectivity for data that maximises asset utilisation • Resource-to-market integration for business efficiency • Enhanced safety and security

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Scan the QR code to download a FREE copy of the Mining, Metals & Minerals brochure & discover how you can get the most from your mine.

www.schneider-electric.co.za

Services

Babcock Branches Bartlett +27 (0)11 230 7300 Botswana +267 390 2869 Bloemfontein +27 (0)51 432 1226 Cape Town +27 (0)21 380 4700 Durban +27 (0)31 700 6009 East London +27 (0)43 703 0400 George +27 (0)44 878 1035 Kimberley +27 (0)53 832 3443 Kuruman +27 (0)53 712 0472 Middelburg +27 (0)13 001 1234 Mocambique +258 84 265 2397 Nelspruit +27 (0)13 001 1280 Port Elizabeth +27 (0)41 407 5900 Richards Bay +27 (0)35 751 1180 Rustenburg +27 (0)14 592 6150 Steelpoort +27 (0)13 230 9054 Swaziland +27 (0)11 230 7300 Wolmaransstad +27 (0)18 596 1514 Windhoek +264 61 305 560/3 Zambia Kitwe +260 212 216 200 Lusaka +260 211 127 2926/28 Zimbabwe +27 (0)11 230 7300 Independent Dealers Polokwane RGR Services +27 (0)15 297 6711 Tzaneen Swaarvoertuie +27 (0)15 307 5000

POWERING THROUGH YOUR WORKLOAD Demanding job sites are no problem for the EC480DL. With superior power this tough machine has first class productivity and reliability. Benefit from built in durability from the robust undercarriage, reinforced welding and thick protective plates - no application is too harsh. Increased engine power and enhanced hydraulics guarantee you more digging power and faster cycle times. Improved fuel efficiency ensures more material is moved per litre of diesel. Contact Babcock and discover the legendary performance for your self. Building Tomorrow.

Babcock International Group www.babcock.co.za Authorised dealer for Volvo Construction Equipment